John Deere 6135J 6150J 6170J 6190J 6210J Repair Technical Manual TM804919

Description

File Details

• Manual type: Repair Technical Manual
• Brand / models: John Deere 6135J, 6150J, 6170J, 6190J, and 6210J tractors
• Document number / date: TM804919 23JAN17
• Publisher line: John Deere Montenegro; printed in Brazil
• Language: English (cover marked INGLÊS)
• Page count: 1108
• File format: PDF

What TM804919 Is Built For

The John Deere 6135J 6150J 6170J 6190J 6210J Repair Technical Manual TM804919 is written for an experienced technician. It is the repair half of John Deere technical-manual coverage: component removal, installation, reconditioning, wear limits, and torque values organized by machine group. Operation-and-tests diagnosis lives in a companion style of manual; this book is the shop-floor guide for taking assemblies apart and putting them back together correctly.

Each group opens with the essential tools, service equipment, other materials, service-part kits, specifications, wear tolerances, and torque values that apply to that job. That layout keeps a bench technician from hunting the whole book for a cap-screw spec while a PowrQuad module or rockshaft is on the stand.

Tractors and Engines Covered

All five J-series machines use a John Deere PowerTech PROCONVE MAR-I inline six-cylinder diesel, two valves per cylinder, turbocharged with charge-air cooler, 6.8 L displacement, 17:1 compression. Rated outputs printed in Section 10 are:

• 6135J — 100.66 kW (135 hp) at 2300 rpm; maximum torque 524 N·m (386.5 lb-ft) at 1500 rpm; engine maximum speed 2400 rpm; torque bulge 32%
• 6150J — 110 kW (150 hp) at 2100 rpm; 642 N·m (473.5 lb-ft) at 1550 rpm; maximum speed 2200 rpm; torque bulge 28%
• 6170J — 125 kW (170 hp) at 2100 rpm; 728 N·m (537 lb-ft) at 1550 rpm; maximum speed 2200 rpm; torque bulge 28%
• 6190J — 140 kW (190 hp) at 2100 rpm; 813 N·m (600 lb-ft) at 1550 rpm; maximum speed 2200 rpm
• 6210J — 155 kW (210 hp) at 2100 rpm; 878 N·m (647.5 lb-ft) at 1550 rpm; maximum speed 2200 rpm; torque bulge 25%

Engine performance figures were obtained according to SAE J 1995. Fuel delivery is High-Pressure Common Rail with an electric transfer pump and a two-stage filter that includes a water separator and water-in-fuel sensor. The electrical system is 12 V with a 90 A or 120 A alternator depending on lighting package, a sealed 12 V / 150 Ah battery, and a 3.8 kW starter.

IMAGES PREVIEW

Chapters Covered

• Section 05 — Safety: signal words, fluids and fires, batteries, agricultural chemicals, parking and supporting the machine, high-pressure fluids and fuel, accumulators, tires, ROPS, waste disposal
• Section 10 — General Information: specifications; fuels, lubricants, and coolant; serial numbers; adjustments, checks, and general service; metric and unified torque charts; hydraulic fitting torque
• Section 20 — Engine: remove and install components; monitoring systems
• Section 30 — Fuel, Air Intake, Cooling, and Exhaust: speed control, fuel system, air intake, cooling, exhaust, monitoring
• Section 40 — Electrical System: connectors; wiring harnesses; charging system; starter motor circuit; fuses, relays, and switches; electrical components
• Section 45 — Electronic Control Units: general information; remove and install components
• Section 50A — Drivetrain: model-specific remove/install (6135J, 6150J, and 6170J/6190J/6210J); universal joints, driveshafts, and torsional damper; front-wheel drive clutches by model; rear differentials by model; hydraulic pump drive; final drives; rear PTO; monitoring
• Section 50B — PowrQuad Transmission: remove/install PowrQuad module; transmission selectors control; PowrQuad module repair; remove/install range box; range box; monitoring
• Section 60A — Steering: hydrostatic steering; AutoTrac Integrated (6150J, 6170J, 6190J, 6210J); monitoring
• Section 60B — Brakes: brake valve; power-fill brake valve; rear wheel brakes
• Section 60C — Air Trailer Brake: air brake system (optional on 6170J, 6190J, 6210J)
• Section 70 — Hydraulic System Identification
• Section 70A — PC Hydraulic System, 6135J: rockshaft controls, hydraulic pump, valve block, rockshaft, SCVs and quick couplers
• Section 70B — PFC Hydraulic System, 6135J and 6150J: rockshaft controls, charge pump and hydraulic pump, valve block, rockshaft, SCVs
• Section 70C — PFC Hydraulic System, 6170J, 6190J, and 6210J: matching pump, valve-block, rockshaft, and coupler groups
• Section 80 — Miscellaneous: remove/install components; main frame; front and rear wheels and fenders; center link bracket and swinging drawbar
• Section 90 — Cab: remove/install; air-conditioning; heating; operator cab; monitoring
• Section 99 — Tools: dealer-fabricated special tools

Taken together, those sections give a shop the remove-and-install path for the engine package, the complete PowrQuad and range-box overhaul sequence, model-split final-drive and differential work, three hydraulic-architecture families, cab climate systems, and the harness and connector practice needed to put the tractor back on the CAN bus without creating new faults.

Transmission, Clutch, PTO, and Speeds

The John Deere 6135J 6150J 6170J 6190J 6210J Repair Technical Manual TM804919 documents a planetary, hydraulically shifted PowrQuad with 16 forward and 16 reverse gears and a mechanical/hydraulic clutch. The multi-disc oil-cooled clutch uses five 225 mm (8.85 in.) disks with auto-adjustable hydraulic actuation. Rear PTO is independent and electro-hydraulic, dual 540/1000 rpm. PTO power at engine rated speed is listed as 84 kW (112 hp) on the 6135J, 94 kW (126 hp) on the 6150J, 106 kW (142 hp) on the 6170J, 119 kW (159 hp) on the 6190J, and 131 kW (175 hp) on the 6210J. Engine speed at PTO rated speed is given model-by-model, including the 6135J reversible-shaft variants at 2143/2208 rpm.

Ground-speed charts calculate theoretical travel in every A–D range using the rated engine speed and a specified rear tire. A 6135J on 23.1-30 R1 tires at 2300 rpm is shown from 2.5 km/h in A1 to 30.6 km/h in D4 forward. The 6150J chart uses 24.5-32R1 tires at 2100 rpm; 6170J/6190J and 6210J charts use 20.8-38 rear tires. The manual reminds the reader that actual speed depends on rolling circumference, load, pressure, make, and grip.

Hydraulic Architectures and Hitch Data

Hydraulics are not one common circuit. The 6135J may be closed-center pressure-and-flow compensated (PFC) or open-center constant-flow pressure-compensated (PC). A gear pump at 65 L/min (17.2 gal/min) or a piston pump at 100 L/min (26.4 gal/min) is listed, both at 200 bar (2900 psi) maximum. The 6150J is PFC with a 100 L/min piston pump. The 6170J, 6190J, and 6210J are PFC with a 110 L/min (29 gal/min) piston pump. Hitch ratings differ: Category II ball or hook on the 6135J with 2550 kgf (5621 lbf) at 610 mm; Category III on the larger machines with lifting figures up to 5280 kgf (11 640 lbf) or 4800 kgf (10 582 lbf) depending on model and option. Selective control valves run from two basic SCVs to mixed deluxe/basic sets, with maximum SCV flow in the 96–110 L/min band.

Capacities, Axles, Weights, and Dimensions

Fuel tanks are 300 L (79.26 gal) on the 6135J, 6150J, and 6170J and 372 L (98.27 gal) on the 6190J and 6210J. Cooling system volume is 33.6 L (8.8 gal) on the 6135J and 39 L (10.3 gal) on the others. Engine oil is 21.3 L (5.62 gal) across the range. Transmission/hydraulic oil is 75.45 L (19.93 gal) on the 6135J and 6150J and 68 L (17.96 gal) on the 6170J, 6190J, and 6210J. Front-axle differential and final-drive fills change with Dana 750/163, Dana 750/202, ZF, and John Deere 3 Meters axles — the 3 Meters housing alone takes 22.4 L (5.91 gal) with 3.78 L (1 gal) per final drive. Capacities are approximate and can vary with hitch equipment or rice-region builds; oil-level checks require Park and level ground.

Maximum permissible weights run from 9500 kg (20 943 lb) on the 6135J to 12 300 kg (27 116 lb) on the 6170J and 6210J. Wheelbase is 2400 mm (94.5 in.) on the 6135J, 2650 mm (104.3 in.) on the 6150J, and 2688 mm (105.8 in.) standard on the 6170J–6210J family, stretching to 2807 mm (110.4 in.) with the 3 Meters front axle. Tire combination tables list forestry, dual, flanged, and rack-and-pinion pairings for every model.

Electrical, Control Units, and Identification

Section 40 walks connector families, ground points, and named harnesses from the cab power-link box through the engine, headlights, operator station, AutoTrac steering-input device, GreenStar display extensions, and CAN terminators. Section 45 covers electronic control-unit R&I and notes that programming uses the 17-digit vehicle serial number so the software file matches that tractor only. Serial-number group 15 shows plate locations for the machine (RH frame), 13-digit engine number (RH block), PowrQuad (LH front of the transmission), differential housing, Dana and ZF front-wheel drives, and the operator station. Manufacturer code BM is identified as John Deere Montenegro.

Routine Service Content Inside a Repair Book

Group 20 of Section 10 still carries the service jobs a shop repeats after a rebuild: air-filter replacement and cleaning, radiator and condenser cleaning, thermostat and coolant change, engine oil and filter, transmission/hydraulic oil and suction-screen service split by 6135J versus the larger four models, and front-axle differential and final-drive oil for ZF, Dana, John Deere 3 Meters, and standard housings. Neutral-start and park-system checks for the PowrQuad, lighting-circuit checks, and trailer-air-tank drain (if equipped) sit in the same group so a completed repair can be signed off against the printed procedure.

Get This Manual Working on the Bench

The John Deere 6135J 6150J 6170J 6190J 6210J Repair Technical Manual TM804919 supports engine package removal and installation, HPCR fuel and cooling work, charging and starter repair, ECU exchange, front-wheel-drive clutch and rear-differential overhaul by model, final-drive and PTO clutch/drive-train rebuilds, PowrQuad module and range-box disassembly with planetary and clutch exploded views, hydrostatic steering and AutoTrac hardware, oil-bath rear brakes and optional air trailer brakes, PC and PFC pump/valve-block/rockshaft/SCV work, main-frame and wheel service, and cab A/C and heater repair. Using the printed torque values, wear limits, and model-split procedures keeps a 6.8 L J-series tractor from being assembled to the wrong axle fill, the wrong hitch valve, or the wrong transmission oil volume. After payment the file is delivered instantly as a PDF — no shipping — ready to open on any device and print the group you need for the stand.