John Deere 5080G 5090G 5090GH 5080GV 5090GV 5100GV 5080GF 5090GF 5100GF Tractor Repair Service Manual (TM402519) PDF - MJODTM402519.zip
A comprehensive factory service and repair guide covering John Deere Tractor models 5080G, 5090G, 5090GH, 5080GV, 5090GV, 5100GV, 5080GF, 5090GF, and 5100GF (Worldwide), packed with every technical detail you need to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
The workshop service repair manual for John Deere Tractors 5080G, 5090G, 5090GH, 5080GV, 5090GV, 5100GV, 5080GF, 5090GF, and 5100GF contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM402519 - John Deere Tractors 5080G, 5080GF, 5080GV, 5090GH, 5100GF, 5100GV, 5090G, 5090GV, 5090GF Technical Manual (Repair).PDF
Total Pages: 1,363 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Foreword
Safety
Safety Measures
General Information
Specifications
Tune-Up
Predelivery Inspection
Engine
Removal and Installation of Engine Components
Fuel and Air Intake Systems
Speed Control Linkage
Fuel System
Air Intake System
Electrical System
Battery, Starter Motor, and Alternator
Switches and Sensors
Transmission
Removal and Installation of Power Train Components
Clutch
Hi-Lo Clutch (24/24-Speed Transmission)
Transmission
24/12-Speed Transmission
Removal and Installation of Components - 24/12-Speed Transmission
Electro-Hydraulic Forward High/Low and Reverse Clutch - 24/12-Speed Transmission
Drive Systems
Component Removal and Installation
Front-Wheel Drive Clutch - Transmission
Differential
Final Drives
Power Take-Off
Transmission Housing - Sensors
Steering and Brake Systems
Steering System
Brake System
Hydraulic System
Hydraulic Pump and Filter
Hitch
Three-Point Hitch
Selective Control Valves
Miscellaneous
Removal and Installation of Components
Front Axle
Front and Rear Wheels
Trailer Mounting and Swinging Drawbar
Fenders
Operator's Cab and Open Operator's Station
Remove and Install Operator's Cab/Open Operator's Station
Controls and Instruments
Air-Conditioning System
Heating System
Operator's Cab
Open Operator's Station
Operator's Seat
Special Tools
Special Tools (Dealer-Fabricated)
Special Tools (Available as Spare Parts)
tm402519 - 5080G-5090G, 5090GH,5080GV-5100GV and5080GF-5100GF TractorsRepair
Table of Contents
Foreword
Section 05: Safety
Group 05: Safety Measures
Recognize Safety Information
Understand Signal Words
“Important” - Information
”Note” Information
Follow Safety Instructions
Handle Fluids Safely—Avoid Fires
Prevent Battery Explosions
Prepare for Emergencies
Prevent Acid Burns
Service Cooling System Safely
Avoid High-Pressure Fluids
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Keep ROPS Installed Properly
Service Tires Safely
Avoid Harmful Asbestos Dust
Avoid Heating Near Pressurized Fluid Lines
Remove Paint Before Welding or Heating
Use Proper Tools
Dispose of Waste Properly
Use Safety Lights and Devices
Practice Safe Maintenance
Service Front-Wheel Drive Tractor Safely
Live With Safety
Section 10: General Information
Group 05: Specifications
Summary of References - Specifications
Engine
Transmission
Front-Wheel Drive Clutch
Hydraulic System
Electrical System
Capacities
Sound Level
Fuel System
Brakes
Three-Point Hitch
Loads and Weights
Towable Loads
Shipping Weights
Maximum Permissible Axle Loads and Total Weights
Load Capacity of Tires
Load Capacity of Tires With Front Loader
Observe Rear Wheel Tread Width Limitations
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Diesel Fuel
Handling and Storing Diesel Fuel
Do Not Use Galvanized Containers
Fill Fuel Tank
Diesel Engine Break-In Oil
Diesel Engine Oil
Transmission and Hydraulic Oil
Front-Wheel Drive Axle and Rear Drop Axle Oil
Grease
Oil Filters
Lubricant Storage
Mixing of Lubricants
Diesel Engine Coolant
Operating in Warm Temperature Climates
Alternative and Synthetic Lubricants
Serial Number Plates
Product Identification Number Location
Engine Serial Number
Fuel Injection Pump Serial Number Location
Power Steering Valve Serial Number Location
Air-Conditioning Compressor Serial Number Location
Transmission Serial Number Location
Front Axle (2WD) Serial Number Location
Front-Wheel Drive Serial Number
Group 10: Tune-Up
Summary of References - Tune-Up
Using High-Pressure Washers
Preliminary engine test
Clean Radiator and Oil Cooler
Clean Air-Conditioning System Condenser
Check Hoses and Hose Clamps
Clean Engine Crankcase Vent Tube
Clean the Dust Unloading Valve
Engine Air Filter
Cleaning the Primary Filter Element
Cleaning a Dusty Element
Secondary (Safety) Element
Clean Cab Air Filters
Check Belt Wear and Tension
Check Engine Oil Level
Check Brake System Oil Level
Check Coolant Level
Check Transmission/Hydraulic System Oil Level
Check the Fuel Filter
Bleed Fuel System
Adjust Hand Throttle
Starting Motor
Battery - Checking Specific Gravity
Check Neutral Start System
Check Setting of Head Lights and Work Lights
Check Lights
Final Engine Check
Tractor Operation Check
Group 15: Predelivery Inspection
Predelivery Inspection
Section 20: Engine
Group 00: Removal and Installation of Engine Components
Summary of References - Remove and Install Engine Components
Engine Repair
Specifications
Remove Engine
Install Engine
Water Pump Repair
Remove and Inspect Radiator
Install Radiator
Remove, Inspect and Install Charge Air Cooler and Oil Cooler
Replace Thermostat
Section 30: Fuel and Air Intake Systems
Group 05: Speed Control Linkage
Summary of References - Speed Control Linkage
Adjust Hand Throttle Lever and Accelerator Pedal
Recondition Hand Throttle Lever and Accelerator Pedal
Group 10: Fuel System
Fuel System - Summary of References
Injection Pump, Nozzle and Governor Repair
Drain Fuel Tank
Remove, Inspect and Install Fuel Tank (Standard Tractors)
Remove, Inspect and Install Fuel Tank (F and V Tractors)
Remove, Inspect and Install Fuel Tank Protection
Replace Fuel Filter
Remove and Install Fuel Filter Assembly
Replace Fuel Transfer Pump
Bleed Fuel System
Group 15: Air Intake System
Summary of References - Air Intake System
Turbocharger Repair
Remove and Install the Air Cleaner Element
Remove and Install Air Intake Hoses
Section 40: Electrical System
Group 05: Battery, Starter Motor, and Alternator
Battery, Starter Motor and Alternator - Summary of References
Starting Motor Repair
Disconnect Battery
Connect Battery
Remove Battery
Install Battery
Remove and Install Battery (Standard Tractors)
Remove and Install Battery (F and V Tractors)
Remove and Install Starter Motor
Alternator/Regulator Repair
Replace Alternator/Regulator
Check Belt Wear and Tension
Group 10: Switches and Sensors
Summary of References - Switches and Sensors
Replace Air Filter Restriction Switch B02
Replace Fuel Level Sensor B03
Replace Engine Oil Pressure Switch B04
Replace Park Brake Switch B05
Replace Transmission Speed Sensor B06
Replace PTO Speed Selection Switch B07/A
Replace PTO Speed Selection Switch B07/B
Replace PTO Safety Switch B08
Replace Air-Conditioning Pressure Switch B15
Replace Neutral Start Switch B36
Replace Coolant Temperature Sensor B56
Replace Brake Oil Level Sensor B69
Replace Engine Speed Sensor B72
Replace Brake Pedal Switches B112
Replace Thermostat B150
Replace Resistor B151
Replace Position Sensor B200 (EHS II)
Replace Draft Sensor B201 (EHS II)
Replace Pressostat B304
Replace Main Switch S01
Replace Light/Horn Switch S09
Replace PTO Mode Switch S21/A (Independent PTO)
Replace PTO Mode Switch S21/B (Ground Drive PTO)
Replace Hazard Warning Light Switch S106
Replace Raise Limit Switch S200 (EHS II)
Replace Fuel Shut-Off Solenoid Valve Y13
Replace Dashboard
Replace Instrument Panel
Section 50: Transmission
Group 00: Removal and Installation of Power Train Components
Remove and Install Power Train Components - Summary of References
Remove and Install Power Train Components - Specifications
Separate Engine from Clutch Housing
Install Engine on Clutch Housing
Separate Clutch Housing from Transmission
Install Clutch Housing on Transmission
Separate Clutch Housing from Transmission - not for 24/12 Speed Transmission
Install Clutch Housing on Transmission - not for 24/12 Speed Transmission
Replace Clutch Housing Seal - 12/12 Speed Transmission
Replace Clutch Housing Seal - 24/24 Speed Transmission
Group 05: Clutch
Summary of References - Clutch
Specifications
Inspect and Repair Clutch Pedal and Linkage
Remove and Install Clutch Assembly
Disassemble and Inspect Clutch Assembly
Assemble Clutch Assembly
Traction Clutch Finger Adjustment
PTO Clutch Finger Adjustment
Remove and Inspect Clutch Release Mechanism
Install Clutch Release Mechanism
Group 10: Hi-Lo Clutch (24/24-Speed Transmission)
Summary of References - Hi-Lo Clutch (24/24-Speed Transmission)
Specifications
Remove and Inspect Mechanical Hi-Lo Drive
Install Mechanical Hi-Lo Drive
Disassemble, Inspect and Assemble Mechanical Hi-Lo Shift Shaft Assembly
Disassemble, Inspect and Assemble Mechanical Hi-Lo Synchronizer
Disassemble, Inspect and Assemble Mechanical Hi-Lo Drive Shaft
Disassemble, Inspect and Assemble Mechanical Hi-Lo Reduction Shaft
Inspect and Repair Mechanical Hi-Lo Shift Lever
Seal Ring Replacement of Hydraulic Hi-Lo Clutch Drive Shaft
Remove and Inspect Hydraulic Hi-Lo Clutch Assembly
Install Hydraulic Hi-Lo Clutch Assembly
Disassemble, Inspect and Assemble Hydraulic Hi-Lo Clutch
Disassemble, Inspect and Assemble Hydraulic Hi-Lo Drive Shaft
Group 20: Transmission
Transmission - Summary of References