John Deere Tractors 5415 Diagnostic Repair Service Manual.pdf

John Deere Agriculture
5215, 5315, 5415, 5515 and 5515 High Crop
Tractors
DIAGNOSIS AND TESTS SERVICE
MANUAL
5215, 5315, 5415, 5515
TM4856, August 2010

TM4856-DIAGNOSIS AND TESTS SERVICE MANUAL (g) by Belgreen
TM4856-DIAGNOSIS AND TESTS
SERVICE MANUAL
<- Go to Global Table of contents
Table of contents
FOREWORD
EDITION
Section 05 - SAFETY
Group 05 - Safety Measures
Section 10 - GENERAL INFORMATION
Group 05 - Specifications
Group 10 - Tune-Up
Group 15 - Predelivery Inspection
Section 20 - ENGINE — REPAIR
Group 00 - Removal and Installation of Engine Components
Section 30 - FUEL AND AIR INTAKE SYSTEMS — REPAIR
Group 05 - Speed Control Linkage
Group 10 - Fuel System
Group 15 - Air Intake System
Section 40 - ELECTRICAL SYSTEM — REPAIR
Group 05 - Battery, Starting Motor and Alternator
Group 10 - Switches and Sensors
Section 50 - TRANSMISSION — REPAIR
Group 00 - Removal and Installation of Power Train Components
Group 05 - Clutch
Group 10 - Hi-Lo Clutch (24/24-Speed Transmission)
Group 20 - Transmission
Section 51 - 24/12-SPEED TRANSMISSION — REPAIR
Group 00 - Removal and Installation of 24/12-Speed Transmission Components
Group 05 - Clutch - 24/12-Speed Transmission
Group 15 - El.-Hydr. High/Low/Reverse Clutch (24/12-Speed Transmission)
Section 56 - DRIVE SYSTEMS — REPAIR
Group 00 - Component Removal and Installation
Group 15 - Front-Wheel Drive Clutch — Transmission
Group 20 - Differential
Group 25 - Final Drives
Group 30 - Power Take-Off
Group 35 - Transmission Housing Sensors
Section 60 - STEERING AND BRAKE SYSTEMS — REPAIR
Group 05 - Steering System
Group 10 - Brake System
Section 70 - HYDRAULIC SYSTEM — REPAIR
Group 05 - Hydraulic Pump and Filter
Group 10 - Hitch
Group 15 - Three-Point Hitch
Group 20 - Selective Control Valves
Section 80 - MISCELLANEOUS — REPAIR
Group 00 - Removal and Installation of Components
Group 10 - Front Axle
Group 15 - Front and Rear Wheels
Group 20 - Trailer Mounting and Swinging Drawbar
Group 25 - Fenders
Section 90 - OPERATOR′S CAB AND OPEN OPERATOR′S STATION — REPAIR

SERVICE MANUAL
Group 00 - Removing and Installing Operator′s Cab/Open Operator′s Station
Group 05 - Controls and Instruments
Group 15 - Air Conditioning System
Group 20 - Heating System
Group 25 - Operator′s Cab
Group 30 - Open Operator′s Station
Group 35 - Operator′s Seat
Section 211 - DIAGNOSTIC TROUBLE CODES
Group EHM - Electro-Hydraulic Management
Group EHS - Electronic Hitch Sensing
Section 212 - OBSERVABLE SYMPTOMS
Group 30 - Fuel and Air Intake System
Group 40 - Electrical System
Group 50 - Power Train
Group 51 - PowrReverser Transmission
Group 60 - Steering and Brakes
Group 80 - Front-Wheel Drive
Section 220 - ENGINE — OPERATION AND TESTS
Group 10 - Operational Check-Out
Group 15 - Tests and Adjustments
Section 230 - FUEL, AIR INTAKE AND COOLING SYSTEMS
Group 15 - Tests and Adjustments
Group 20 - Theory of Operation
Section 240 - ELECTRICAL SYSTEM — OPERATION AND TESTS
Group S01 - SE01 - Motor Starting and Charging System
Group S02 - SE02 - Instrument Panel
Group S03 - SE03 - Horn
Group S06 - SE06 - Lighting System
Group S07 - SE07 - Work Lights
Group S09 - SE09 - Radio, Dome and Console Light
Group S10 - SE10 - Fan and Air-Conditioning System
Group S11 - SE11 - Wiper and Washer System
Group S13 - SE13 - Beacon Light
Group S14 - SE14 - Power Outlet
Group S15A - SE15A - Electronic Hitch Sensing (EHS)
Group S15B - SE15B - Electronic Hitch Sensing (EHS II)
Group S16A - SE16A - Hazard Warning and Turn Signal Lights
Group S16B - SE16B - PTO System
Group S16C - SE16C - Front-Wheel Drive, Differential Lock and Braking System
Group S21 - SE21 - Flow Divider Valve
Group S26A - SE26A - Electro-Hydraulic Management (EHM)
Group S26B - SE26B - Electro-Hydraulic Management (EHM II)
Group S27 - SE27 - Electro-Hydraulic Hi-Lo
Group 105 - Component Information - Connectors
Group 110 - Component Information - Wiring Harnesses
Group 115 - Component Information - Electrical Parts
Group 120 - Component Information - Ground Connection
Group 200 - Wiring Diagrams
Section 245 - ELECTRONIC CONTROL UNITS
Group 05 - Operation and General Information on Diagnostics

SERVICE MANUAL
Group 10 - Electro-Hydraulic Management
Group 20 - EHS - Electronic Hitch Sensing
Section 250 - POWER TRAIN — OPERATION AND TESTS
Group 05 - Component Location
Group 15 - Diagnosis, Tests and Adjustments
Section 251 - 24/12-SPEED TRANSMISSION — OPERATION AND TESTS
Section 260 - STEERING AND BRAKE SYSTEMS — OPERATION AND TESTS
Section 270 - HYDRAULIC SYSTEM — OPERATION AND TESTS
Group 15 - Diagnosis
Group 20 - Tests
Group 25 - Adjustments
Group 30 - Hydraulic System Schematics
Section 280 - MISCELLANEOUS
Group 10 - Operational Checks
Section 290 - AIR-CONDITIONING SYSTEM — OPERATION AND TESTS
Section 299 - SPECIAL TOOLS
Group 05 - Special Tools (Dealer-Fabricated)
Group 10 - Special Tools and Test Equipment

SERVICE MANUAL

SERVICE MANUAL
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.
CAUTION:
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.

SERVICE MANUAL
SAFETY (g) by Belgreen
Edition
TIR TM4856 01AUG2007

SERVICE MANUAL
Section 05 - SAFETY
Table of contents
Group 05 - Safety Measures ................................................................................1
Recognize Safety Information.............................................................................1
Understand Signal Words
‘Important” - Information
................................................................................1
. ...............................................................................2
”Note” Information..........................................................................................2
Follow Safety Instructions ..................................................................................2
Handle Fluids Safely—Avoid Fires ........................................................................3
Prevent Battery Explosions ................................................................................3
Prepare for Emergencies ....................................................................................4
Prevent Acid Burns..........................................................................................6
Service Cooling System Safely ............................................................................7
Avoid High-Pressure Fluids ................................................................................7
Park Machine Safely ........................................................................................8
Support Machine Properly
Wear Protective Clothing
. ..............................................................................9
. ...............................................................................9
Work in Clean Area ....................................................................................... 10
Service Machines Safely
Work In Ventilated Area
. .............................................................................. 11
................................................................................ 12
Illuminate Work Area Safely ............................................................................. 12
Replace Safety Signs...................................................................................... 13
Use Proper Lifting Equipment
Keep ROPS Installed Properly
. ........................................................................ 13
. ........................................................................ 14
Service Tires Safely ....................................................................................... 14
Avoid Harmful Asbestos Dust............................................................................ 16
Avoid Heating Near Pressurized Fluid Lines ........................................................... 16
Remove Paint Before Welding or Heating ............................................................. 17
Use Proper Tools .......................................................................................... 18
Dispose of Waste Properly .............................................................................. 19
Use Safety Lights and Devices .......................................................................... 19
Practice Safe Maintenance............................................................................... 20
Service Front-Wheel Drive Tractor Safely ............................................................. 22
Live With Safety........................................................................................... 22

Section 05 - SAFETY Group 05: Safety Measures
SERVICE MANUAL
Section 05 page 1
<- Go to Section TOC
Group 05 - Safety Measures
Recognize Safety Information
Safety-alert symbol
This is a 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.
Understand Signal Words
Signal Words

SERVICE MANUAL
Section 05 page 2
A signal word—DANGER, WARNING, or CAUTION—is 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.
“Important” - Information
Information marked as IMPORTANT points out problems that may lead to machine damage.
By following the directions given, these problems can be avoided.
”Note” Information
When marked with NOTE, the information given is more detailed or contains restrictions to
directions given previously. On the other hand, useful information may be given belonging to
certain instructions without being directly connected to these directions.
Follow Safety Instructions
Safety Messages
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.
There can be additional safety information contained on parts and components sourced from
suppliers that is not reproduced in this operator′s manual.

SERVICE MANUAL
Section 05 page 3
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.
Handle Fluids Safely—Avoid Fires
Avoid 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.
Prevent Battery Explosions

SERVICE MANUAL
Section 05 page 4
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 16°C (60°F).
Prepare for Emergencies
First Aid Kit
Be prepared if a fire starts.

SERVICE MANUAL
Section 05 page 5
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near
your telephone.

SERVICE MANUAL
Section 05 page 6
Prevent Acid Burns
Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.

SERVICE MANUAL
Section 05 page 7
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.
Service Cooling System Safely
Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure before removing completely.
Avoid High-Pressure Fluids

SERVICE MANUAL
Section 05 page 8
High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this
type of injury should reference a knowledgeable medical source. Such information is
available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by
calling 1-800-822-8262 or +1 309-748-5636.
Park Machine Safely

SERVICE MANUAL
Section 05 page 9
Remove Key
Before working on the machine:
Lower all equipment to the ground
Apply handbrake
Stop the engine and remove the key
Disconnect the battery ground strap
Hang a ”DO NOT OPERATE” tag in operator station
Support Machine Properly
Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If
the work requires that the machine or attachment be lifted, provide secure support for them.
If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under
continuous load. Do not work under a machine that is supported solely by a jack. Follow
recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions
listed in the implement or attachment operator′s manual.
Wear Protective Clothing

SERVICE MANUAL
Section 05 page 10
Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or
music headphones while operating machine.
Work in Clean Area

SERVICE MANUAL
Section 05 page 11
Clean Work Area
Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.
Service Machines Safely
Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when
you work near machine tools or moving parts. If these items were to get caught, severe injury

SERVICE MANUAL
Section 05 page 12
could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving
parts.
Work In Ventilated Area
Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an
enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the
area.
Illuminate Work Area Safely

SERVICE MANUAL
Section 05 page 13
Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside
or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.
Replace Safety Signs
Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct
safety sign placement.
Use Proper Lifting Equipment

SERVICE MANUAL
Section 05 page 14
Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
Keep ROPS Installed Properly
Roll-Over Protective Structure
Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is
loosened or removed for any reason. Tighten mounting bolts to proper torque.
The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way altered by welding, bending, drilling, or
cutting. A damaged ROPS should be replaced, not reused.
Service Tires Safely

SERVICE MANUAL
Section 05 page 15
Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to
perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended
pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in
air pressure resulting in a tire explosion. Welding can structurally weaken or deform the
wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to
stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

SERVICE MANUAL
Section 05 page 16
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Avoid Harmful Asbestos Dust
Asbestos Dust
Avoid breathing dust that may be generated when handling components containing asbestos
fibers. Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and
lining assemblies, clutch plates, and some gaskets. The asbestos used in these components
is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding
material containing asbestos. When servicing, wear an approved respirator. A special vacuum
cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the
material containing asbestos.
Keep bystanders away from the area.
Avoid Heating Near Pressurized Fluid Lines

SERVICE MANUAL
Section 05 page 17
Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in
severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally
burst when heat goes beyond the immediate flame area.
Remove Paint Before Welding or Heating
Toxic Fumes

SERVICE MANUAL
Section 05 page 18
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a
torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint
cannot be removed, wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before
welding. Remove solvent or paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Use Proper Tools
Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.

SERVICE MANUAL
Section 05 page 19
Dispose of Waste Properly
Recycle Waste
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid,
filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that
may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere.
Government regulations may require a certified air conditioning service center to recover and
recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or
recycling center, or from your John Deere dealer.
Use Safety Lights and Devices

SERVICE MANUAL
Section 05 page 20
Prevent Collisions
Prevent collisions between other road users, slow moving tractors with attachments or towed
equipment, and self-propelled machines on public roads. Frequently check for traffic from the
rear, especially in turns, and use turn signal lights.
Use headlights, flashing warning lights, and turn signals day and night. Follow local
regulations for equipment lighting and marking. Keep lighting and marking visible, clean, and
in good working order. Replace or repair lighting and marking that has been damaged or lost.
An implement safety lighting kit is available from your John Deere dealer.
Practice Safe Maintenance

SERVICE MANUAL
Section 05 page 21
Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing
from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower
equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace
worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments

SERVICE MANUAL
Section 05 page 22
on electrical systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical
system components or welding on machine.
Service Front-Wheel Drive Tractor Safely
Service Front-Wheel Drive Tractor Safely
When servicing front-wheel drive tractor with the rear wheels supported off the ground and
rotated by engine power, always support front wheels in a similar manner. Loss of electrical
power or transmission/hydraulic system pressure will engage the front driving wheels, pulling
the rear wheels off the support if front wheels are not raised. Under these conditions, front
drive wheels can engage even with switch in disengaged position.
Live With Safety

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