John Deere Tractors Service & Repair Manuals Collection

6120 to 6420 and 6120L to 6520L Tractors Repair TECHNICAL MANUAL 6120 to 6420 and 6120L to 6520L Tractors Repair TM4647 01DEC05 (ENGLISCH) For complete service information also see: 6120 to 6420 and 6120L to 6520L Tractors Operation and Tests ................... TM4646 6120 to 6420 and 6120L to 6520L Tractors Diagnostics .......................... TM4733 Front-Wheel Drive Axles - AS and MS Series ............................... CTM4687 Front-Wheel Drive Axles - 700 Series ..... CTM4820 POWERTECH Diesel Engines .......... CTM104 Mechanical Fuel Injection Systems ....... CTM207 Electronic Fuel Injection Systems (Level 4) .................................. CTM170 Electronic Fuel Injection Systems (Level 1) .................................. CTM284 Electronic Fuel Injection Systems (Level 11).................................. CTM220 Electronic Fuel Injection Systems (Level 12).................................. CTM331 Alternators and Starting Motors .......... CTM77 John Deere Werke Mannheim North American Version LITHO IN U.S.A.

Introduction LX24888,00004EE –19–01DEC02–1/1 Foreword This “Repair” manual is valid for the following tractor types: 6120, 6220, 6320 and 6420 6120L, 6220L, 6320L, 6420L, 6520L 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. This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to potential for personal injury. 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. LX18600,0000551 –19–02NOV05–1/1 Version Date 01 December 2005 TM4647 (01DEC05) 6120 to 6520L Tractors 022006 PN=2

Contents 05 SECTION 05—SAFETY Group 10—Input Housing Group 15—Output Housing Group 05—Safety Measures Group 20—Differential Drive Shaft Assembly SECTION 10—GENERAL INFORMATION SECTION 55—POWRQUAD, POWRQUAD PLUS Group 05—Specifications 10 AND AUTOQUAD TRANSMISSIONS Group 10—Tune-Up Group 00—Installing and Removing Components Group 15—Predelivery Inspection Group 05—Transmission Shift Controls Group 10—PowrQuad Module SECTION 20—ENGINE Group 15—Creeper Transmission Group 00—Installing and Removing Components Group 20—Option Transmission Group 25—Range Transmission SECTION 30—FUEL, AIR INTAKE, COOLING AND EXHAUST SYSTEMS SECTION 56—DRIVE SYSTEMS Group 05—Speed Control Group 00—Installing and Removing Components Group 10—Fuel System Group 05—U-Jointed Shafts and Torsion Damper 20 Group 15—Air Intake System Group 10—Front-Wheel Drive Clutch Group 20—Cooling System Group 15—Differential Group 25—Cold-Weather Starting Aid Group 20—Hydraulic Pump Drive Group 30—Exhaust System Group 25—Final Drives Group 30—Rear PTO SECTION 40—ELECTRICAL SYSTEM Group 35—Front PTO Group 05—Connectors Group 40—Front Implement Drive Group 10—Wiring Harnesses Group 15—Charging Circuit SECTION 60—STEERING AND BRAKES Group 20—Starter Motor Circuit Group 05—Hydrostatic Steering Group 25—Fuses, Relays and Switches Group 10—Steering Cylinder 30 Group 30—Monitoring Systems Group 15—Brake Valve Group 40—Electrical Components Group 20—Rear Brakes Group 40—AutoTrac SECTION 50—SYNCROPLUS TRANSMISSION Group 00—Installing and Removing Components SECTION 70—Hydraulic System Group 05—Transmission Shift Controls Group 05—Controls Group 10—Perma Clutch II Module Group 10—Hydraulic Pump and Charge Oil Pump Group 15—Gear Transmission Group 15—Valves Group 20—Rockshaft SECTION 51—POWER REVERSER TRANSMISSION Group 25—Selective Control Valves and Couplers Group 00—Installing and Removing Components Group 30—Independent Control Valve (ICV) 40 Group 05—Transmission Shift Controls Group 10—Power Reverser Module SECTION 80—MISCELLANEOUS Group 15—Gear Transmission Group 00—Installing and Removing Components Group 05—Main Frame Group 10—Front Axle SECTION 53—AUTOPOWR/IVT TRANSMISSION Group 00—Installing and Removing Components Continued on next page Group 05—Transmission Shift Controls All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. 50 COPYRIGHT  2005 DEERE & COMPANY European Office Mannheim All rights reserved A John Deere ILLUSTRUCTION  Manual Previous Editions Copyright  2004, 2003, 2002, 2001 51 53 55 56 TM4647 (01DEC05) i 6120 to 6520L Tractors 022006 PN=1

Contents 05 Group 15—Front Wheels, Rear Wheels and Fenders Group 20—Trailer Mounting and Swinging Drawbar Group 25—Triple Link Suspension (TLS) of Front-Wheel Drive Axle 10 SECTION 90—OPERATOR’S CAB Group 00—Installing and Removing Components Group 05—Controls and Instruments Group 10—Air Conditioning System Group 11—ClimaTrak Group 15—Heating System Group 20—Seats Group 25—Operator’s Cab Group 26—Low-Clearance Cab Group 30—Cab Suspension 20 SECTION 99—Special Tools (Dealer-Fabricated) Group 05—Special Tools (Dealer-Fabricated) Group 10—Special Tools (available from the dealer) 30 40 50 51 53 55 56 TM4647 (01DEC05) ii 6120 to 6520L Tractors 022006 PN=2

Contents 60 70 80 90 99 INDX TM4647 (01DEC05) iii 6120 to 6520L Tractors 022006 PN=3

Contents 60 70 80 90 99 INDX TM4647 (01DEC05) iv 6120 to 6520L Tractors 022006 PN=4

05 Section 05 SAFETY Contents Page Group 05—Safety Measures Recognize Safety Information .............. 05-05-1 ”Important” Information ...................05-05-1 ”Note” Information .......................05-05-1 Prevent Machine Runaway ................05-05-1 Handle Fluids Safely—Avoid Fires ..........05-05-2 Prevent Battery Explosions ................05-05-2 Prepare for Emergencies..................05-05-2 Prevent Acid Burns ......................05-05-3 Avoid High-Pressure Fluids ................05-05-4 Service Cooling System Safely .............05-05-4 Remove Paint Before Welding or Heating .....05-05-5 Avoid Heating Near Pressurized Fluid Lines . . .05-05-5 Work In Ventilated Area ..................05-05-6 Wear Protective Clothing ..................05-05-6 Practice Safe Maintenance ................05-05-7 Park Machine Safely .....................05-05-7 Use Proper Lifting Equipment ..............05-05-8 Construct Dealer-Made Tools Safely .........05-05-8 Support Machine Properly .................05-05-8 Work in Clean Area ......................05-05-9 Illuminate Work Area Safely ............... 05-05-9 Service Machines Safely ..................05-05-9 Use Proper Tools ...................... 05-05-10 Service Tires Safely .................... 05-05-10 Service Front-Wheel Drive Tractor Safely .... 05-05-11 Avoid Eye Contact With Radar ............ 05-05-11 Keep ROPS Installed Properly ............ 05-05-11 Replace Safety Signs ................... 05-05-12 Dispose of Waste Properly ............... 05-05-12 Live With Safety ....................... 05-05-12 Safety Measures on Electronic Control Units .............................. 05-05-13 TM4647 (01DEC05) 05-1 6120 to 6520L Tractors 022006 PN=1

Contents 05 TM4647 (01DEC05) 05-2 6120 to 6520L Tractors 022006 PN=2

Group 05 Safety Measures 05 05 1 DX,ALERT –19–29SEP98–1/1 Recognize Safety Information T81389 –UN–07DEC88 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. LX,CRA05 002885 –19–09APR92–1/1 ”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. LX,CRA05 002886 –19–09APR92–1/1 ”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 them. DX,BYPAS1 –19–29SEP98–1/1 Prevent Machine Runaway TS177 –UN–11JAN89 Avoid possible injury or death from machinery runaway. Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed. NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park. TM4647 (01DEC05) 05-05-1 6120 to 6520L Tractors 022006 PN=7

Safety Measures 05 05 2 DX,FLAME –19–29SEP98–1/1 Handle Fluids Safely—Avoid Fires TS227 –UN–23AUG88 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. DX,SPARKS –19–03MAR93–1/1 Prevent Battery Explosions TS204 –UN–23AUG88 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). DX,FIRE2 –19–03MAR93–1/1 Prepare for Emergencies TS291 –UN–23AUG88 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. TM4647 (01DEC05) 05-05-2 6120 to 6520L Tractors 022006 PN=8

John Deere Tractors Service & Repair Manuals Collection

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