John Deere 6500 Self-Propelled Sprayers Service Repair Manual Instant Download (tm1511)

1
6100? 6500? 6600
Se?f-Prope??ed
Sprayers
For comp?ete service information a?so see 3029?
4039? 4045? 6059 and 6068 Engines . . . . . . . .
. . . . . . CTM8 A?ternators and Starting Motors
. . . . . . . . CTM77
John Deere Des Moines Works TM1511
(05DEC97) LITHO IN U.S.A. ENGL?SH
2
Introduction
FOREWORD This manual is written for an
experienced technician. Essential tools required
in performing certain service work are identified
in this manual and are recommended for use. Live
with safety Read the safety messages in the
introduction of this manual and the cautions
presented throughout the text of the manual. o
This is the safety-alert symbol. When you
see this symbol on the machine or in this
manual, be alert to the potential for personal
injury. Technical manuals are divided in two
parts repair and operation and tests. Repair
sections tell how to repair the components.
Operation and tests sections help you identify
the majority of routine failures quickly.
Information is organized in groups for the
various components requiring service instruction.
At the beginning of each group are summary
listings of all applicable essential tools,
service equipment and tools, other materials
needed to do the job, service parts kits,
specifications, wear tolerances, and torque
values. Technical Manuals are concise guides for
specific machines. They are on-the-job guides
containing only the vital information needed for
diagnosis, analysis, testing, and
repair. Fundamental service information is
available from other sources covering basic
theory of operation, fundamentals of
troubleshooting, general maintenance, and basic
type of failures and their causes.
DX,TMIFC -19-22MAY92 6100, 6500, 6600
Self-Propelled Sprayers
TM1511 (05DEC97)
051297 PN3
3
Contents
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 10
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 20
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 30
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 40
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 50
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 60
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 70
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 80
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 90
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company 220
SECTION 10GENERAL INFORMATION SECTION 70HYDRAULIC SYSTEM Group 05Safety Group 05Hydraulic Pump Group 10General Specifications Group 10Hydraulic Valves Group 15Fuels and Lubricants Group 15Hydraulic Cylinders Group 20Hydraulic Filter/Manifold Group 25Oil Cooler SECTION 20ENGINE REPAIR Group 30Hydraulic Reservoir Group 05Remove and Install Engine Group 10Cooling System SECTION 80SOLUTION SPRAY SYSTEM Group 05Nozzle Repair SECTION 30FUEL AND AIR SYSTEMS Group 10Solution Tank Group 05Air Intake and Exhaust Group 15Solution Pump Group 10Diesel Fuel System Group 20Solution Control Valves SECTION 90OPERATOR?S STATION REPAIR SECTION 40ELECTRICAL REPAIR Group 05R-12 Air Conditioning System Service Group 05Battery Group 06R134a Air Conditioning System Group 10Starting System Service Group 15Charging System Group 10R-12 Air Conditioning System Repair Group 20Engine Electrical Components Group 11R134a Air Conditioning System Repair Group 25Lights, Instruments, and Accessory Group 15Air Intake (Pressurizer) System Repair Circuit Repair Group 20Seat Repair Group 30Connector Repair Group 25Operator's Cab Group 35Machine Monitor System Group 30Controls Group 40Solution Control/Monitor System Group 35Cab Heater (If Equipped) Group 45Solution Pump Electric Clutch SECTION 220ENGINE OPERATION AND TESTS Group 50Retractable Ladder Group 10Diagnostic Information SECTION 50POWER TRAIN REPAIR SECTION 230FUEL/AIR OPERATION AND Group 05Remove and Install Hydrostatic TESTS Components Group 10Diagnostic Information Group 10Hydrostatic Drive Repair Group 15Power Wheel Repair SECTION 240ELECTRICAL SYSTEM OPERATION? TESTS AND SECTION 60STEERING AND BRAKES ADJUSTMENTS Group 05Remove and Install Steering Group 01Theory of Operation Components Group 02Electrical Diagrams Group 10Steering Column Repair Group 03Diagnostic Information Group 05Charging System Group 15Steering Valve Repair Group 10Starting System Group 20Steering MotorSingle Wheel Group 15Lights and Accessories Group 25Steering CylinderWide Axle Group 16Fuses and Relays Group 30Brake System Repair Group 35Front Wheel and Axle Continued on next page TM1511-19-05DEC97 COPYRIGHT 1997 DEERE COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION? Manual Previous Editions Copyright 1996, 1994, 1993, 1992 Deere Company
i
TM1511 (05DEC97)
6100, 6500, 6600 Self-Propelled Sprayers
051297 PN1044
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
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5
Group 20Machine Monitor System Group
24Agitation Solenoid Valve System6600 Group
25Solution Control System without (ERC) Group
26Electronic Rate Control (ERC)
Solution System Group 30Air Conditioning System
Group 31Pressurizer/Blower System Group 35Fuel
Control System Group 40Tread Adjust System (If
Equipped) Group 45Rear Fold Boom Control System
Group 46Front Fold Boom Control System Group
50Ground Speed Control System Group 55Auxiliary
Hydraulics System (If Equipped) Group
60Windshield Wiper System Group 65Retractable
Ladder System6500, 6600 Group 70Air Seat System
(If Equipped)
SECTION 281FOAM MARKER SYSTEM OPERATION? TESTS
AND ADJUSTMENTS Group 05System Operational
Checks Group 10Diagnostic Information Group
15Tests Group 25Theory of Operation
10
20
SECTION 290OPERATOR?S STATION OPERATION? TESTS
AND ADJUSTMENTS Group 05Operator's Station
Operational Checks Group 10Operator's Station
Diagnostic Information Group 15Operator's
Station Tests Group 20Adjustments Group
25Operator Station Theory of Operation Group
30Heater Theory of Operation
30
40
SECTION 299DEALER FABRICATED TOOLS Group
00Dealer Fabricated Tools
SECTION 250POWER TRAIN OPERATION AND TESTS Group
05System Operational Checks Group 10Diagnostic
Information Group 15System Tests Group 20System
Adjustments Group 25Theory of Operation
Index
50
60
SECTION 260STEERING/BRAKES OPERATION? TESTS AND
ADJUSTMENTS Group 05System Operational Checks
Group 10Diagnostic Information Group 15System
Tests Group 20Adjustments Group 25Theory of
Operation
70
SECTION 270HYDRAULIC SYSTEM OPERATION? TESTS AND
ADJUSTMENTS Group 05System Operational Checks
Group 10Diagnostic Information Group 15System
Tests Group 20System Adjustments Group 25Theory
of Operation
80
90
SECTION 280SOLUTION SYSTEM OPERATION? TESTS AND
ADJUSTMENTS Group 05System Operational Checks
Group 10Diagnostic Information Group
15Tests Group 20Adjustments Group 25Theory of
Operation
220
ii
6100, 6500, 6600 Self-Propelled
Sprayers 051297 PN1045
6
GENERAL INFORMATION 10
Section 10
Contents
Page
Group 05Safety . . . . . . . . . . . . . . . .
10-05-1
Group 10General Specifications Machine
Specifications 6100 . . . . . . . . . . . . . . .
. . . . . . . . . 10-10-1 6500 . . . . . . . . .
. . . . . . . . . . . . . . . 10-10-6 6600 . . .
. . . . . . . . . . . . . . . . . . . . .
10-10-11 Dimensions 6100 . . . . . . . . . . . .
. . . . . . . . . . . . 10-10-16 6500 Single
Wheel . . . . . . . . . . . . . . 10-10-18 6500
Wide Axle . . . . . . . . . . . . . . . .
10-10-20 6600 . . . . . . . . . . . . . . . . . .
. . . . . . 10-10-21 Metric Cap Screw Torque
Values . . . . . . 10-10-24 Unified Inch Cap
Screw Torque Values . . 10-10-25 Flat Face O-Ring
Seal Fitting Torque Chart . . . . . . . . . . .
. . . . . . . . . . . . 10-10-26 Identification
Numbers . . . . . . . . . . . . . . 10-10-27
Group 15Fuels and Lubricants Diesel Fuel . . . .
. . . . . . . . . . . . . . . . . Diesel Engine
Oil . . . . . . . . . . . . . . . . . Hydrostatic
and Hydraulic Oils . . . . . . . . Final Drives
. . . . . . . . . . . . . . . . . . . . Extreme
Pressure Grease . . . . . . . . . . . Hydraulic
Brake Fluid . . . . . . . . . . . . . . Lubricant
Storage . . . . . . . . . . . . . . . . .
Alternative and Synthetic Lubricants . . . .
Engine Coolant . . . . . . . . . . . . . . . . .
.
10-15-1 10-15-2 10-15-3 10-15-4 10-15-4 10-15-5 10
-15-5 10-15-5 10-15-6
10-1
6100, 6500, 6600 Self-Propelled
Sprayers 051297 PN1004
7
Group 05 Safety
RECOGNIZE SAFETY INFORMATION This is the
safety-alert symbol. When you see this symbol on
your machine or in this manual, be alert to the
potential for personal injury. Follow
recommended precautions and safe operating
practices.
10
05 1
DX,ALERT -19-03MAR93
UNDERSTAND SIGNAL WORDS A signal wordDANGER,
WARNING, or CAUTIONis used with the safety-alert
symbol. DANGER identifies the most serious
hazards. DANGER or WARNING safety signs are
located near specific hazards. General
precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages
in this manual. DX,SIGNAL -19-03MAR93
FOLLOW SAFETY INSTRUCTIONS Carefully read all
safety messages in this manual and on your
machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety
signs. Be sure new equipment components and
repair parts include the current safety signs.
Replacement safety signs are available from your
John Deere dealer. Learn how to operate the
machine and how to use controls properly. Do not
let anyone operate without instruction. Keep
your machine in proper working condition.
Unauthorized modifications to the machine may
impair the function and/or safety and affect
machine life. If you do not understand any part
of this manual and need assistance, contact your
John Deere dealer. DX,READ -19-03MAR93
10-05-1
6100, 6500, 6600 Self-Propelled
Sprayers 051297 PN4
8
HANDLE FLUIDS SAFELYAVOID FIRES When you work
around fuel, do not smoke or work near heaters or
other fire hazards. Store flammable fluids away
from fire hazards. Do not incinerate or puncture
pressurized containers. Make sure machine is
clean of trash, grease, and debris. Do not store
oily rags they can ignite and burn spontaneously.
10
05 2
DX,FLAME -19-04JUN90
PREVENT BATTERY EXPLOSIONS Keep sparks, lighted
matches, and open flame away from the top of
battery. Battery gas can explode. Never check
battery charge by placing a metal object across
the posts. Use a volt-meter or hydrometer. Do
not charge a frozen battery it may explode. Warm
battery to 16C (60F). DX,SPARKS -19-03MAR93
PREPARE FOR EMERGENCIES Be prepared if a fire
starts. Keep a first aid kit and fire
extinguisher handy. Keep emergency numbers for
doctors, ambulance service, hospital, and fire
department near your telephone. DX,FIRE2 -19-03
MAR93
10-05-2
6100, 6500, 6600 Self-Propelled
Sprayers 051297 PN5
9

• REMOVE AND INSTALL MAIN DRIVE BELT
• Remove wing nuts securing pump shield and lower
  shield to ground.
• Move solution tank back. (See procedure in
  Section 80, Group 10.)
• Remove solution pump drive belt. (See procedure
  in Section 80, Group 15.)
• Loosen nut (B) on idler sheave tension rod (A) to
  release main drive belt tension.
• Remove main drive belt.
• Inspect main drive belt for wear or damage.
  Replace as necessary.
• Install main drive belt.
• Adjust main drive belt. (See procedure in Section
  250, Group 20.)
• Install solution pump drive belt. (See procedure
  in Section 80, Group 15.)

50
05 2
NX1511,5005,C -19-21FEB94
50-05-2
6100, 6500, 6600 Self-Propelled
Sprayers 051297 PN149
10

• REMOVE HYDROSTATIC DRIVE PUMP
• 6500 (SN 6000) shown throughout. 6100, 6500 (SN
  6001 ) and 6600 procedures the same except
  where noted.
• Extend tread width to access components.
• Remove the solution tank. (See procedure in
  Section 80, Group 10.)
• Clean the hydrostatic drive pump and its line
  connections.

1. Drain the hydraulic reservoir.
2. Remove plug (I) to drain pump.

6. Remove line (A).
50
), 6600 A hose is used
For 6100, 6500 (SN 6001 in this location.
05 3
IMPORTANT Do not attempt to turn nut (D). Nut is
brazed to line. Loosen nut (E) to disconnect
lines (C) and (F).
AHydraulic Line 6500 (SN 6000) Hydraulic Hose
6100, 6500 (SN 6001 ), 6600 BHydraulic Hose
CHydraulic Line DFixed Nut EConnector Nut
FHydraulic Line GHydraulic Hose HRetainer (4
used) IDrain Plug
7. Remove retainers (H) and lines (C) and (F).
8. Disconnect hoses (B) and (G).
NX1511,5005,D -19-25JUN97
50-05-2
6100, 6500, 6600 Self-Propelled
Sprayers 051297 PN150
11

• Disconnect hose (A).
• Disconnect line (B).
• For 6100, 6500 (SN 6001 ), 6600 A hose is
• used in this location.

50 05 4
NX1511,5005,E -19-25JUN97

• Disconnect neutral switch wiring connector (A).
  (Located at top of pump.)
• Disconnect control cable (B).
• Disconnect pump-to-oil cooler hose (C).
• NX1511,5005,F -19-02NOV92

14. Loosen cap screws (A). NX1511,5005,
G -19-02NOV92
50-05-4
6100, 6500, 6600 Self-Propelled
Sprayers 051297 PN151
12

1. Remove three hydrostatic pump mounting cap screws
   and washers. Leave mounting cap screw (A) in
   place.
2. Install transmission jack under pump.
3. Remove remaining mounting cap screw (A) and
   washer.

18. Remove hydrostatic pump.
50 05 5
NX1511,5005,H -19-25JUN97

• INSTALL HYDROSTATIC DRIVE PUMP
• 6500 (SN 6000) shown throughout. Procedures for
  6100, 6500 (SN 6001 ), 6600 are the same except
  where noted.
• Coat splines of hydrostatic pump input shaft with
  John Deere NEVER-SEEZ? Lubricant, or equivalent.
• Use a transmission jack to install hydrostatic
  pump. (Pump input shaft must be connected to
  driveshaft yoke during p