Complete Diagnosis and Tests technical manual with electrical wiring diagrams for John Deere Tractors 1654, JD1854, JD2054, JD2104, 6165J, 6185J, 6205J & 6210J 2WD / MFWD, with all the shop information to maintain, diagnose, rebuild like professional mechanics.
John Deere JD1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, 6210J Tractors workshop Operation and Tests manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM802219 TM – All Inclusive 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J & 6210J Tractors Diagnostic.pdf
TM802214 TM-All Inclusive 1654、1854、2054、2104、6165J、6185J、6205J 和 6210J拖拉机诊断.pdf
OMAL221436 Operator’s Manual JD1654, JD1854, JD2054, and JD2104 Tractors, (Asia, English).pdf
OMAL221437 Operator’s Manual 拖拉机 JD1654、JD1854、JD2054 和 JD2104.pdf
OMAL221438 Operator’s Manual Tractors JD1654, JD1854, JD2054&JD2104
PC4667 Parts Catalog 1654 Tractor \ China Edition.pdf
PC4667Z Parts Catalog 1654 Tractor \ China Edition.pdf
Total Pages: 1,511 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English Chinese
MAIN SECTIONS
Foreword
General Information
Safety Information
General References
Diagnostic Trouble Codes
BCU Diagnostic Trouble Codes
ECU Control Unit
Observable Symptoms
Electrical System
Electronic Control Units
PowrQuad Transmissions
Drive Systems
Steering and Brakes
Hydraulic System
Operator’s Cab
System Diagnosis
Electronics
Hydraulic System
Engine
General Information
Operational Checks
Tests and Adjustments
Fuel, Air Intake and Cooling Systems
Tests and Adjustments
Fuel System
Air Intake System
Cooling System
Cold-Weather Starting Aids
Electrical System
Fuse Box
Starting and Charging Circuit
CAN BUS and Service Connector
ECU – Power
ECU – Throttle and Fuel System
ECU – Fuel Preheater and Aid Heater
ECU – Sensors
BCU – Electronic Hitch-Control
BCU – Brakes
BCU – PTO
BCU – Front-Wheel Drive
BCU – Differential Lock
BCU – Hall Sending Unit Speedmeter
BCU – Turn Signal and Hazard Warning Lights
Panel Warning Lights
Lights, Tail Lights and License Plate
Work Lights
Radio, Dome Light, Console Light and Beacon Light
Horn and Accessories Socket
Power Outlet
Seat Compressor and Cigarette Lighter
Fan and A/C
Front Windshield Wiper and Washer
Rear Windshield Wiper and Washer
Trailer Connector
Wiring Harnesses
Connectors
Electronic Control Units
Operation and General Information on Diagnostics
Interactive Tests
Interactive Calibrations
Information on How to Reprogram Control Units
Data BUS Systems, Operation
BCU – Basic Control Unit
ECU Control Unit
PowrQuad Transmissions
Operational Check
Tests and Adjustments
Operation
Range Box
Drive Systems
Operational Check
Tests and Adjustments
Operation
Steering and Brakes
Preliminary Checks
Operational Check
Tests and Adjustments
Hydrostatic Steering
Brakes
Air brake system
Hydraulic System
Operational Check
Tests and Adjustments
Theory of operation
Oil Filter, Charge Pump and Hydraulic Pump
Hitch
Selective control valves (SCV)
Hydraulic block
Operator’s Cab
Tests and Adjustments
Operation
Special Tools (Dealer-Fabricated)
Special Tools (Dealer-Fabricated)
Special Tools (Available as Spare Parts)
TABLE OF CONTENTS
Section 210: General Information….32
Group 05: Safety Information….1379
Recognize Safety Information….1379
Follow Safety Instructions….36
Replace Safety Signs….37
Wear Protective Clothing….38
Prevent Battery Explosions….39
Service Tires Safely….40
Keep ROPS Installed Properly….41
Park Machine Safely….42
Handle Fluids Safely—Avoid Fires….43
Handle Fuel Safely—Avoid Fires….44
Prepare for Emergencies….45
Work in Clean Area….46
Prevent Machine Runaway….47
Work In Ventilated Area….48
Avoid High-Pressure Fluids….49
Use Proper Lifting Equipment….50
Illuminate Work Area Safely….51
Use Proper Tools….52
Live With Safety….53
Safety Measures on Electronic Control Units….54
Group 15: General References….32
General References—Summary of References….56
Unified Inch Bolt and Cap Screw Torque Values….57
Metric Bolt and Cap Screw Torque Values….59
Hydraulic System Unified Inch Fitting Torques….61
Hydraulic system metric fitting torques….62
Component Identification Table….63
How to use an Electrical Diagram….65
Electrical Diagram Symbols….68
Wire Numbers and Color Codes….70
Troubleshooting Unsolved Problems….71
Electrical System Visual Inspection….72
Circuit Malfunctions….73
Seven Steps Electrical Test Procedure….78
Hydraulic System — Circuit Symbols….80
Electrical System, Worksheet for Circuit/Harness Test….86
Section 211: Diagnostic Trouble Codes….88
Group BCU: BCU Diagnostic Trouble Codes….88
BCU 000084.02 – B09 – Hall Sending Unit Speedmeter, out of Valid Range….88
BCU 000168.03 – Control Unit, Supply Voltage Too High….88
BCU 000168.04 – Control Unit, Supply Voltage Too Low….88
BCU 000168.16 – Control Unit, Supply Voltage Too High (Engine Speed Above 500 rpm)….88
BCU 000168.17 – Control Unit, Supply Voltage Too Low (Engine Speed Above 1500 rpm)….88
BCU 000168.18 – Control Unit, Supply Voltage Too Low (Engine Speed Above 500 rpm)….88
BCU 000177.18 – Non-Existent Function Activated….88
BCU 000186.02 – B06 – Sensor for Rear PTO Speed, Open Circuit….88
BCU 000186.15 – B06 – Rear PTO Speed Sensor, Speed Present Despite Rear PTO Being Switched Off….88
BCU 000186.17 – B06 – Rear PTO Speed Sensor, Speed Not Present….88
BCU 000190.02 – Non-Existent Function Activated….88
BCU 000237.02 – VIN Information, Mismatch….88
BCU 000237.14 – VIN Information, System De-Activated….88
BCU 000237.31 – VIN Information, Incorrect….88
BCU 000629.12 – Control Unit Internal Fault….88
BCU 000639.12 – Vehicle CAN BUS, High Error Rate….88
BCU 000639.14 – Vehicle CAN BUS, Very High Error Rate….88
BCU 000746.31 – Y05 – Differential Lock Solenoid Valve, Fault….88
BCU 000980.07 – S21 – Rear PTO Switch, Fault….88
BCU 001058.18 – Non-Existent Function Activated….88
BCU 001079.03 – 5-volt Power Supply, Voltage Too High….88
BCU 001079.04 – 5-volt Power Supply, Voltage Too Low….88
BCU 001873.03 – B21 – Hitch Position Sensor, Voltage Too High….88
BCU 001873.04 – B21 – Hitch Position Sensor, Voltage Too Low….88
BCU 001873.15 – B21 – Hitch Position Sensor, Voltage Too High During Calibration….88
BCU 001873.17 – B21 – Hitch Position Sensor, Voltage Too Low During Calibration….88
BCU 001882.02 – Non-Existent Function Activated….88
BCU 001882.15 – Non-Existent Function Activated….88
BCU 001882.17 – Non-Existent Function Activated….88
BCU 001883.31 – Rear PTO Speed Too High….89
BCU 001890.03 – Non-Existent Function Activated….89
BCU 001890.04 – Non-Existent Function Activated….89
BCU 001890.31 – Non-Existent Function Activated….89
BCU 001893.07 – Non-Existent Function Activated….89
BCU 001894.31 – INFORMATION FOR OPERATOR: Rear PTO Switch was On When Engine was Started….89
BCU 002000.09 – Incorrect CAN BUS Message, Information from ECU….89
BCU 002392.31 – Non-Existent Function Activated….89
BCU 002818.31 – Non-Existent Function Activated….89
BCU 002876.07 – S08 – Turn signal switch, Fault (Turn Signal)….89
BCU 303053.03 – B26 – Sensitivity Potentiometer, Signal Voltage Too High During Calibration….89
BCU 303053.04 – B26 – Sensitivity Potentiometer, Signal Voltage Too Low During Calibration….89
BCU 303054.03 – B27 – Depth-Setting Potentiometer, Signal Voltage Too High During Calibration….89
BCU 303054.04 – B27 – Depth-Setting Potentiometer, Signal Voltage Too Low During Calibration….89
BCU 303056.03 – B27 – Raise-Limit Potentiometer, Signal Voltage Too High During Calibration….89
BCU 303056.04 – B27 – Raise-Limit Potentiometer, Signal Voltage Too Low During Calibration….89
BCU 303057.03 – B27 – Rate-of-Drop Potentiometer, Signal Voltage Too High During Calibration….89
BCU 303057.04 – B27 – Rate-of-Drop Potentiometer, Signal Voltage Too Low During Calibration….89
BCU 522451.03 – Non-Existent Function Activated….89
BCU 522451.04 – Non-Existent Function Activated….89
BCU 522451.14 – Non-Existent Function Activated….89
BCU 522507.31 – Control Unit Not Calibrated….89
BCU 523438.02 – Control Unit Internal Fault….89
BCU 523652.02 – Control Unit Connected to Wrong Harness Connector….89
BCU 523689.31 – S22 – Differential Lock Switch, Fault….89
BCU 523690.02 – S68 – Switches for Remote Control of Hitch (Left), Fault….89
BCU 523701.05 – M08 – Stepper Motor for Hitch (Coil 2), Open Circuit….89
BCU 523701.06 – M08 – Stepper Motor for Hitch (Coil 2), Current Too High….89
BCU 523702.14 – VIN Information, System De-Activated….89
BCU 523702.31 – VIN Information, Incorrect….89
BCU 523703.02 – B41 – Draft Sensor, Distorted Signal During Calibration….89
BCU 523703.03 – B41 – Draft Sensor, Voltage Too High During Calibration….89
BCU 523703.04 – B41 – Draft Sensor, Voltage Too Low During Calibration….90
BCU 523703.15 – B41 – Draft Sensor, Voltage Too High….90
BCU 523703.17 – B41 – Draft Sensor, Voltage Too Low….90
BCU 523704.02 – Non-Existent Function Activated….90
BCU 523704.03 – Non-Existent Function Activated….90
BCU 523704.04 – Non-Existent Function Activated….90
BCU 523704.15 – Non-Existent Function Activated….90
BCU 523704.17 – Non-Existent Function Activated….90
BCU 523751.05 – M08 – Stepper Motor for Hitch (Coil 1), Open Circuit….90
BCU 523751.06 – M08 – Stepper Motor for Hitch (Coil 1), Current Too High….90
BCU 523753.16 – M08 – Stepper Motor for Hitch, Raising Deadband Too High During Calibration….90
BCU 523753.18 – M08 – Stepper Motor for Hitch, Raising Deadband Too Low During Calibration….90
BCU 523756.16 – M08 – Stepper Motor for Hitch, Lowering Deadband Too High During Calibration….90
BCU 523756.18 – M08 – Stepper Motor for Hitch, Lowering Deadband Too Low During Calibration….90
BCU 523758.11 – Non-Existent Function Activated….90
BCU 523759.11 – Non-Existent Function Activated….90
BCU 523760.04 – Turn Signal/Hazard Flasher System, Supply Voltage Too Low….90
BCU 523760.31 – Turn Signal/Hazard Flasher System, Fault….90
BCU 523826.03 – Non-Existent Function Activated….90
BCU 523826.04 – Non-Existent Function Activated….90
BCU 523834.03 – B27 – Depth-Setting Potentiometer, Voltage Too High….90
BCU 523834.04 – B27 – Depth-Setting Potentiometer, Voltage Too Low….90
BCU 523839.31 – Non-Existent Function Activated….90
BCU 523843.02 – S24 – Quick Withdrawal Switch, Switch Status out of Valid Range….90
BCU 523843.03 – S24 – Quick Withdrawal Switch, Voltage Too High….90
BCU 523843.04 – S24 – Quick Withdrawal Switch, Voltage Too Low….90
BCU 523904.31 – Non-Existent Function Activated….90
BCU 523905.31 – Non-Existent Function Activated….90
BCU 523908.14 – Non-Existent Function Activated….90
BCU 523908.31 – Non-Existent Function Activated….90
BCU 524055.11 – Control Unit Internal Fault….90
BCU 524055.31 – Control Unit Not Calibrated….90
BCU 524216.14 – Non-Existent Function Activated….91
BCU 524216.31 – Non-Existent Function Activated….91
BCU 524224.14 – Non-Existent Function Activated….91
BCU 524224.31 – INFORMATION FOR OPERATOR: Rear PTO was Switched On When Engine Was Started….91
BCU 524235.02 – Non-Existent Function Activated….91
BCU 524235.31 – Y03 – Front-Wheel Drive Solenoid Valve, Fault….91
BCU 524252.31 – Y04 – Solenoid Valve for Rear PTO, Fault….91
Group ECU: ECU Control Unit….91
ECU 000029.03 – B96 – Hand Throttle Potentiometer, Voltage Too High….91
ECU 000029.04 – B96 – Hand Throttle Potentiometer, Voltage Too Low….91
ECU 000084.31 – Incorrect CAN BUS Message, Wheel Speed from BCU….91
ECU 000091.03 – B79 – Accelerator Pedal Potentiometer, Voltage Too High….91
ECU 000091.04 – B79 – Accelerator Pedal Potentiometer, Voltage Too Low….91
ECU 000097.03 – Water In Fuel Signal Out of Range….91
ECU 000097.04 – Water In Fuel Signal Out of Range Low….91
ECU 000097.16 – Water In Fuel Detected….91
ECU 000105.00 – Manifold Air Temperature Signal Extremely High….91
ECU 000105.03 – Manifold Air Temperature Signal Out of Range High….91
ECU 000105.04 – Manifold Air Temperature Signal Out of Range Low….91
ECU 000105.15 – Manifold Air Temperature Signal Slightly High….91
ECU 000105.16 – Manifold Air Temperature Signal Moderately High….91
ECU 000108.02 – Barometric Air Pressure Signal Invalid….91
ECU 000110.00 – Coolant Temperature Signal Extremely High….91
ECU 000110.03 – Coolant Temperature Signal Out of Range High….91
ECU 000110.04 – Coolant Temperature Signal Out of Range Low….91
ECU 000110.15 – Coolant Temperature Signal Slightly High….91
ECU 000110.16 – Engine Coolant Temperature Moderately High….91
ECU 000157.03 – Fuel Rail Pressure Signal Out of Range High….91
ECU 000157.04 – Fuel Rail Pressure Signal Out of Range Low….91
ECU 000157.10 – Fuel Rail Pressure Loss Detected….91
ECU 000157.17 – Fuel Rail Pressure Not Developed….91
ECU 000158.17 – ECU Power Down Error….91
ECU 000160.02 – Wheel Speed Signal Incorrect….92
ECU 000174.00 – Fuel Temperature Signal Extremely High….92
ECU 000174.03 – Fuel Temperature Signal Out of Range High….92
ECU 000174.04 – Fuel Temperature Signal Out of Range Low….92
ECU 000174.16 – Fuel Temperature Signal Moderately High….92
ECU 000189.00 – Engine Speed Derate Condition Exists….92
ECU 000190.00 – Engine Speed Extremely High….92
ECU 000190.16 – Engine Overspeed Moderate….92
ECU 000237.02 – VIN Information, Mismatch….92
ECU 000237.13 – VIN Option Code Invalid….92
ECU 000237.31 – VIN Information, Incorrect….92
ECU 000611.03 – Injector Shorted to Voltage Source….92
ECU 000611.04 – Injector Shorted to Ground….92
ECU 000627.01 – All Injector Circuits Have High Resistance….92
ECU 000629.12 – ECU EEPROM Error….92
ECU 000629.13 – ECU Boot Block Error….92
ECU 000636.02 – Camshaft Position Signal Invalid….92
ECU 000636.05 – Camshaft Position Circuit Has High Resistance….92
ECU 000636.06 – Camshaft Position Circuit Has Low Resistance….92
ECU 000636.08 – Camshaft Position Signal Missing….92
ECU 000636.10 – Camshaft Position Signal Rate of Change Abnormal….92
ECU 000637.02 – Crankshaft Position Signal Invalid….92
ECU 000637.05 – Crankshaft Position Circuit Has High Resistance….92
ECU 000637.06 – Crankshaft Position Circuit Has Low Resistance….92
ECU 000637.07 – Crankshaft and Camshaft Position Signals Out of Sync….92
ECU 000637.08 – Crankshaft Position Signal Missing….92
ECU 000637.10 – Crankshaft Position Signal Rate of Change Abnormal….92
ECU 000651.02 – Injector #1 Part Number Invalid….92
ECU 000651.05 – Injector #1 Circuit Has High Resistance….92
ECU 000651.06 – Injector #1 Circuit Has Low Resistance….92
ECU 000651.07 – Injector #1 Not Responding….92
ECU 000651.13 – Injector #1 Calibration Fault….92
ECU 000652.02 – Injector #2 Part Number Invalid….92
ECU 000652.05 – Injector #2 Circuit Has High Resistance….93
ECU 000652.06 – Injector #2 Circuit Has Low Resistance….93
ECU 000652.07 – Injector #2 Not Responding….93
ECU 000652.13 – Injector #2 Calibration Fault….93
ECU 000653.02 – Injector #3 Part Number Invalid….93
ECU 000653.05 – Injector #3 Circuit Has High Resistance….93
ECU 000653.06 – Injector #3 Circuit Has Low Resistance….93
ECU 000653.07 – Injector #3 Not Responding….93
ECU 000653.13 – Injector #3 Calibration Fault….93
ECU 000654.02 – Injector #4 Part Number Invalid….93
ECU 000654.05 – Injector #4 Circuit Has High Resistance….93
ECU 000654.06 – Injector #4 Circuit Has Low Resistance….93
ECU 000654.07 – Injector #4 Not Responding….93
ECU 000654.13 – Injector #4 Calibration Fault….93
ECU 000655.02 – Injector #5 Part Number Invalid….93
ECU 000655.05 – Injector #5 Circuit Has High Resistance….93
ECU 000655.06 – Injector #5 Circuit Has Low Resistance….93
ECU 000655.07 – Injector #5 Not Responding….93
ECU 000655.13 – Injector #5 Calibration Fault….93
ECU 000656.02 – Injector #6 Part # Data Invalid….93
ECU 000656.05 – Injector #6 Circuit Has High Resistance….93
ECU 000656.06 – Injector #6 Circuit Has Low Resistance….93
ECU 000656.07 – Injector #6 Not Responding….93
ECU 000656.13 – Injector #6 Calibration Fault….93
ECU 000676.03 – Glow Plug Relay Voltage Too High….93
ECU 000676.05 – Glow Plug Relay Voltage Too Low….93
ECU 001069.31 – Tire Size Error….93
ECU 001347.03 – Suction Control Valve Signal Out of Range High….93
ECU 001347.05 – Suction Control Valve Circuit Has High Resistance….93
ECU 001347.07 – Fuel Rail Pressure Actual to Desired Mismatch….93
ECU 001569.31 – Engine in Power Derate Condition….93
ECU 002033.09 – Incorrect CAN BUS Message, CAN Message from BCU….93
ECU 002033.14 – Communication Problem between ECU and BCU….93
ECU 002033.19 – Communication Problem between ECU and BCU….94
ECU 003509.03 – Sensor Supply #1 Voltage Out of Range High….94
ECU 003509.04 – Sensor Supply #1 Voltage Out of Range Low….94
ECU 003510.03 – Sensor Supply Voltage 2 Too High….94
ECU 003510.04 – Sensor Supply Voltage 2 Too Low….94
ECU 003511.03 – Sensor Supply Voltage 3 Too High….94
ECU 003511.04 – Sensor Supply Voltage 3 Too Low….94
Section 212: Observable Symptoms….421
Group 40: Electrical System….421
Control Unit(s) Not Displayed….421
Diagnostic Mode Cannot Be Entered or Connection Problems with Service ADVISOR (Cab Tractors)….421
Problems with the CAN-BUS Connection to Service ADVISOR….421
Problems with the Battery….421
Problems with the Starter Motor….421
Problems with the Fuel Preheater, Aid Heater and Fuel Pump….421
Problems with the Instrument Unit….421
Problems with the Horn….421
Problems with Cigarette Lighter (E05)….421
Problems with Seat with Compressor and Heater (A29)….421
Problems with the Parking Lights….421
Problems with Low-Beam Headlights….421
Problems with High-Beam Headlights….421
Problems with the Worklights on Front of Roof….421
Problems with the Worklights on Rear of Roof….421
Problems with the Radio….421
Problems with the Air-Conditioning System and/or with the Fan….421
Problems with the Front Windshield Wiper….421
Problems with the Front Windshield Washer….421
Problems with the Rear Windshield Wiper….421
Problems with the Rear Windshield Washer….421
Problems with the Beacon Light….421
Group 45: Electronic Control Units….421
Problems when Programming the BCU Control Unit….421
Problems when Programming the ECU Control Unit….421
Problem with the BCU Control Unit….421
Problem with the Instrument Unit (Adjustment)….421
Group 55: PowrQuad Transmissions….421
Problems with PowrQuad Transmission….421
Group 56: Drive Systems….422
Problems with the PTO….422
Group 60: Steering and Brakes….422
Problems with the Brakes….422
Problems with the Steering….422
Group 70: Hydraulic System….422
Problems with the Rockshaft….422
Problems with the Rockshaft's Remote Control….422
Group 90: Operator's Cab….422
Problems with the Air-Conditioning System….422
Section 213: System Diagnosis….527
Group 45: Electronics….527
29-bit CAN BUS – Check (Cab Tractors)….532
VIN Security Fault Diagnosis….536
Group 70: Hydraulic System….527
Check for PFC Hydraulic System….557
Section 220: Engine….576
Group 05: General Information….576
Information on Engine….578
Group 10: Operational Checks….576
Engine – Safety Measures….580
Engine – Preliminary Engine Tests….581
Group 15: Tests and Adjustments….576
Engine – Tune-Up, Summary of References….583
Engine – Measuring PTO Power Output….584
Engine – Engine Tests with Service ADVISOR….590
Section 230: Fuel, Air Intake and Cooling Systems….591
Group 15: Tests and Adjustments….591
Fuel, Air Intake and Cooling Systems – Tests and Adjustments, Summary of References….594
Fuel, Air Intake and Cooling Systems – General Information….595
Fuel, Air Intake and Cooling Systems – Explanation of Checks….596
Fuel, Air Intake and Cooling Systems – Safety Measures….597
Fuel, Air Intake and Cooling Systems – Special Tools, Summary of References….598
Fuel, Air Intake and Cooling Systems – Specifications….601
Air Intake System – System Check….602
Cooling System – Filling/Bleeding the System….603
Cooling System – Leak Test….604
Cooling System – Test Thermostat Opening Temperature….606
Cooling System – Flow Testing in the Low-Temperature Circuit….608
Cooling System – Check the Viscous Fan Drive….612
Fuel System – Check the Fuel Transfer Pump….614
Group 20A: Fuel System….591
Fuel System – Theory of Operation, Summary of References….617
Fuel System – Theory of Operation….618
Fuel System – Fuel Cooler, Component Information….620
Fuel System – Fuel Transfer Pump, Component Information….621
Group 20B: Air Intake System….591
Air Intake System – Theory of Operation, Summary of References….623
Air Intake System – Theory of Operation….624
Group 20C: Cooling System….591
Cooling System – Summary of References….626
Coolant Circuit – Description….627
Cooling System Radiator – Description….629
Itercooler – Description….630
Ring-Shaped (Transmission Oil) Cooler – Description….631
Automatic Drive Belt Tensioner – Theory of Operation….633
Group 20D: Cold-Weather Starting Aids….591
Cold-Weather Starting Aids – Summary of References….635
Cold-Weather Starting Aids – General Information….636
Cold-Weather Starting Aids – Coolant Heater – Component Information….637
Cold-Weather Starting Aids – Transmission Oil Heater – Component Information….638
Cold-Weather Starting Aids – Charge Pump Preheater – Component Information….639
Section 240: Electrical System….640
Group 05A: Fuse Box….640
Fuse Box – Theory of Operation….650
Fuse Box – Electrical Diagram….651
Group 05B: Starting and Charging Circuit….640
Starting and Charging Circuit – Theory of Operation….654
Starting and Charging Circuit – Electrical Diagram….655
Circuit test for Starter motor checks (M01)….656
Circuit test for Alternator (G02)….659
Circuit test for Battery (G01)….664
Circuit test for K01 Starter relay….667
Group 05C: CAN BUS and Service Connector….640
CAN BUS System – Theory of Operation….669
CAN BUS System – Electrical Diagram….670
Group 05D: ECU – Power….640
ECU Power – Theory of Operation….672
ECU Power – Electrical Diagram….673
Group 05E: ECU – Throttle and Fuel System….640
ECU Throttle and Fuel System – Theory of Operation….675
ECU Throttle and Fuel System – Electrical Diagram….676
Circuit test for Foot throttle (B79)….677
Circuit test for Electrical hand throttle (B96)….680
Group 05F: ECU – Fuel Preheater and Aid Heater….640
ECU Fuel Preheater and Aid Heater – Theory of Operation….684
ECU Fuel Preheater and Aid Heater – Electrical Diagram….685
Circuit test for Fuel Pump (M31)….687
Circuit test for Heating Element of Fuel Preheater (R02)….689
Circuit test for Sender for Electrical starting aid heater (R15)….691
Group 05G: ECU – Sensors….640
ECU Sensors – Theory of Operation….694
ECU Sensors – Electrical Diagram….695
Circuit test for Engine Speed Sender (B72)….696
Group 05H: BCU – Electronic Hitch-Control….641
BCU – Electronic Hitch-Control – Theory of Operation….700
BCU – Electronic Hitch-Control – Electrical Diagram….701
Circuit test for Rockshaft Control Stepper Motor (M08)….703
Circuit test for Sensitivity Potentiometer (B26)….705
Circuit test for Depth-setting Potentiometer (R08)….708
Circuit test for Rate-of-Drop Potentiometer (R06)….711
Circuit test for Raise-Limit Potentiometer (R07)….714
Circuit test for Position Sensor (B21)….717
Circuit test for Position Sensor (B41)….721
Circuit/harness test for Rapid Raise Switch (S24)….724
Circuit test for Left Remote Control Switch (S68)….727
Circuit test for Supply Voltage for 5-Volt BCU Components….730
Group 05I: BCU – Brakes….641
BCU – Brakes – Theory of Operation….734
BCU – Brakes – Electrical Diagram….735
Circuit test for Brake Pedal Sensor Unit (B88)….737
Group 05J: BCU – PTO….641
BCU – PTO – Theory of Operation….739
BCU – PTO – Electrical Diagram….740
Circuit test for PTO Switch (S21)….742
Circuit test for PTO Solenoid Valve (Y04)….745
Circuit test for Rear PTO Speed Sensor (B06)….748
Group 05K: BCU – Front-Wheel Drive….641
BCU – Front-Wheel Drive – Theory of Operation….752
BCU – Front-Wheel Drive – Electrical Diagram….753
Circuit test for Front-Wheel Drive Switch (S63)….755
Circuit test for Front-Wheel Drive Solenoid Valve (Y03)….758
Group 05L: BCU – Differential Lock….641
BCU – Differential Lock – Theory of Operation….762
BCU – Differential Lock – Electrical Diagram….763
Circuit test for Differential Lock Switch (S22)….765
Circuit test for Differential Lock Solenoid Valve (Y05)….768
Group 05M: BCU – Hall Sending Unit Speedmeter….642
BCU Hall Sending Unit Speedmeter – Theory of Operation….772
BCU Hall Sending Unit Speedmeter – Electrical Diagram….773
Circuit test for Hall Sending Unit Speedmeter (B09)….774
Group 05N: BCU – Turn Signal and Hazard Warning Lights….642
BCU – Turn Signal and Hazard Warning Lights – Theory of Operation….778
BCU – Turn Signal and Hazard Warning Lights – Electrical Diagram….779
Circuit test for hazard warning switch (S106)….781
Circuit test for Turn Signal Switch (S08)….785
Group 05O: Panel Warning Lights….642
Panel Warning Lights – Theory of Operation….790
Panel Warning Lights – Electrical Diagram….791
Circuit test for Sender for air cleaner restriction warning light (B02)….793
Circuit test for Fuel gauge sender (B03)….794
Circuit test for Engine oil pressure sender (B04)….795
Circuit test for Sender for the transmission oil filter sender (B07)….796
Circuit test for Coolant temperature sender (B08)….797
Circuit test for Transmission oil pressure sender (B31)….798
Circuit test for Transmission oil temperature sender (B29)….799
Group 05P: Lights, Tail Lights and License Plate….642
Lights and Tail Lights – Theory of Operation….801
Lights and Tail Lights – Electrical Diagram….802
Lighting Circuits….804
Group 05Q: Work Lights….642
Work Lights – Theory of Operation….809
Work Lights – Electrical Diagram….810
Work lights….811
Group 05R: Radio, Dome Light, Console Light and Beacon Light….642
Radio, Dome Light, Console Light and Beacon Light – Theory of Operation….814
Radio, Dome Light, Console Light and Beacon Light – Electrical Diagram….815
Circuit test for Radio (A60 – Radio Circuits)….816
Circuit test forDome Light (A08)….817
Circuit test for Beacon light (E27)….819
Group 05S: Horn and Accessories Socket….643
Horn and Accessories Socket – Theory of Operation….821
Horn and Accessories Socket – Electrical Diagram….822
Circuit test for Horn (H01)….823
Group 05T: Power Outlet….643
Power Outlet – Theory of Operation….826
Power Outlet – Electrical Diagram….827
Group 05U: Seat Compressor and Cigarette Lighter….643
Seat Compressor and Cigarette Lighter – Theory of Operation….829
Seat Compressor and Cigarette Lighter – Electrical Diagram….830
Seat and Cigarette lighter System….831
Group 05V: Fan and A/C….643
Fan and A/C – Theory of Operation….834
Fan and A/C – Electrical Diagram….835
Fan, Air Conditioning and Automatic A/C control….837
Group 05W: Front Windshield Wiper and Washer….643
Front Windshield Wiper and Washer – Theory of Operation….843
Front Windshield Wiper and Washer – Electrical Diagram….844
Front Windshield Wiper and Washer System….845
Group 05X: Rear Windshield Wiper and Washer….643
Rear Windshield Wiper and Washer – Theory of Operation….848
Rear Windshield Wiper and Washer – Electrical Diagram….849
Rear Windshield Wiper and Washer System….851
Group 05Y: Trailer Connector….643
Trailer Connector – Theory of Operation….854
Trailer Connector – Electrical Diagram….855
Group 10: Wiring Harnesses….643
Disconnecting Electrical Circuits….857
Location of Ground Points….858
Removing and Installing Wiring Harness W01 — Power link Box….860
Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Cab Tractors)….861
Removing and Installing Wiring Harness W04 — Headlights….863
Removing and Installing Wiring Harness W08 — (Cab Tractors)….864
Removing and Installing Wiring Harness W09 — Hood (Cab Tractors)….866
Removing and Installing Wiring Harness W19 — Cab Roof….868
Removing and Installing Wiring Harness W26 — Fan and Air Conditioning….869
Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors)….870
Removing and Installing Wiring Harness W30 — Rear End of Transmission (Cab Tractors)….872
Wiring Harness W31 — Power Take-Off for 7-Pin Socket….874
Group 15: Connectors….644
Connectors – Summary of References….877
A01 – Fuse and relay box….879
A02 – Fuse Box 2….882
A03 – Fuse Box 3….883
A04 – Fuse Box 4….884
A05 – Fuse Box 5….885
A06 – Power Link Box….886
A08 – Dome Light….887
A29 – Pneumatic operator's seat and rear wiper….888
A60 – Radio….889
A62 – Bus terminator….890
A84 – Bus terminator engine….891
B02 – Sender for air cleaner restriction warning light….892
B03 – Fuel gauge sensor unit….893
B04 – Sender for engine oil pressure indicator light….894
B06 – Rear PTO Speed Sensor….895
B07 – Transmission oil filter pressure sensor – Without AutoTrac™ Integrated….896
B08 – Coolant temperature sensor….897
B09 – Hall Sending Unit Speedmeter….898
B14 – Compressor and thermostat switch….899
B15 – Air conditioning system pressure switch….900
B21 – Hitch-control position sensor….901
B26 – Sensitivity potentiometer….902
B27 – Feedback unit….903
B29 – Transmission oil temperature sensor….904
B30 – Hydrostatic oil temperature sensor….905
B31 – Transmission oil pressure sender….906
B36 – Neutral start switch….907
B37 – Interface handbrake….908
B41 – Draft potentiometer….909
B56 – Water temperature engine sensor….910
B59 – Manifold air temperature sensor….911
B72 – Crankshaft speed sensor….912
B74 – Event sensor….913
B79 – Foot throttle….914
B88 – Brake switch….915
B96 – Electrical hand throttle….916
B114 – Fuel temperature sensor….917
B121 – Water in fuel sensor….918
B137 – Fuel rail pressure sensor….919
E01 – Right-hand front light….920
E02 – Left-hand front light….921
E05 – Cigarette lighter….922
E09-R – Right-hand front working light….923
E09-L – Left-hand front working light….924
E11-1 – Right-hand rear working light….925
E11-2 – Left-hand rear working light….926
E12-2 – Console light….927
E27 – Beacon light….928
G01 – Battery….929
G02 – Alternator….930
H01 – Horn….931
H77 – Aid heater indicator light….932
K01 – Starter relay….933
M01 – Starter motor….934
M02 – Air conditioning compressor….935
M03 – Wiper motor….936
M04 – Wiper motor….937
M05 – Windshield washer pump….938
M06 – Windshield washer pump….939
M07 – Fan motor….940
M08 – Hitch-control stepper motor….941
M10 – Fan motor….942
M31 – Fuel pump….943
R02 – Fuel preheater….944
R03 – Resistors….945
R15 – Electrical starting aid heater….946
S01 – Starter switch….947
S04 – Horn switch….948
S08 – Turn signal switch….949
S09 – Light switch….950
S10 – Full/low beam light switch….951
S14 – Fan switch….952
S15 – Windshield wiper switch….953
S18 – Rear wiper switch….954
S20 – Windshield switch….955
S21 – PTO switch….956
S22 – Differential lock switch….957
S36 – Beacon light switch….958
S63 – Front-wheel drive switch….959
S68 – External hitch-control switch….960
S92-2 – Rear work lights switch….961
S106 – Hazard warning lights switch….962
W25 – Radio antenna….963
X05 – Trailer connector….964
X25 – Instrument right panel connector….965
X26 – Instrument left panel connector….967
X37 – Accessories socket….969
X40 – Connector (W22 and W23)….970
X42 – Connector (W21 and W22)….971
X106 – Tail, brake and turn signal lights (right-hand)….972
X107 – Tail, brake and turn signal lights (left-hand)….973
X108 – Front right- hand turn signal light….974
X109 – Front left-hand turn signal light….975
X113 – License Light Connector….976
X182 – Connector (W08 and W26)….977
X234 – Connector (W30 and W31)….979
X239 – Outlet Socket Connector….980
X305 – Cooler grounding….981
X400 – Connector (W08 and W19)….982
X411 – Connector (W02 and W04)….985
X430 – Connector (W08 and W30)….987
X431 – Connector (W08 and W28)….990
X450 – Connector (W02 and W08)….993
X473 – Connector (W01 and W08)….996
X504 – Connector (W08 and W09)….998
X505 – Connector (W08 and W09)….1001
X547 – Connector (W02 and W03)….1003
X571 – Service connector (CAN Bus)….1004
X612 – Speaker connector….1005
X616-1 Basic control unit (BCU)….1006
X616-2 Basic control unit (BCU)….1008
X616-3 Basic control unit (BCU)….1011
X844-1 — Engine control unit (ECU)….1013
X844-2 — Engine control unit (ECU)….1015
XGND1 – Cab ground wire….1017
XGND2 – Cab ground wire….1018
XGND5 – Cab ground wire….1019
XGND6 – Rear wiper ground wire….1020
XGND9 – Engine grounding….1021
XGND10 – Cab roof ground wire….1022
XGND14 – Cab roof ground wire….1023
XGND58 – Fan and A/C wiring harness grounding….1024
Y03 – Front-wheel drive solenoid valve….1025
Y04 – PTO Solenoid….1026
Y05 – Differential lock solenoid valve….1027
Y44 – Suction control valve….1028
Y47 – Injection valve….1029
Section 245: Electronic Control Units….1030
Group 05: Operation and General Information on Diagnostics….1030
Operation and General Information – Summary of References….1036
Eletronic Control Units – Special Tools….1037
Operation and General Information on Diagnostics – Abbreviations for Control Units….1038
Operation and General Information on Diagnostics – Instrument Unit Adjustment….1039
Operation and General Information on Diagnostics – Operation and Entering the Program Mode using the Performance Monitor….1045
Operation and General Information on Diagnostics – Procedure for Dealing with Diagnostic Trouble Codes….1052
Operation and General Information on Diagnostics – Accessing Addresses and Diagnostic Trouble Codes….1056
Operation and General Information on Diagnostics – Approved Software for Control Units….1067
Operation and General Information on Diagnostics – Locations and Allocations of Control Units….1068
Group 10A: Interactive Tests….1030
Interactive Tests – Summary of References….1070
Procedure in the Event of Problems with Interactive Tests….1071
BCU: Recording in Debug Mode….1072
BCU: Control Unit Information and Input Addresses – Summary….1073
BCU: BCU Test….1074
ECU: Cylinder Misfire Test….1075
ECU: Compression Test….1076
ECU: Cylinder Cut-Out Test….1077
ECU: Harness diagnostic mode test….1078
ECU: Internal Data Monitor (IDM)….1079
ECU: Communication Error Test….1080
ECU: Control Unit Information and Summary….1081
ECU: Engine Speed Change Test….1082
Group 10B: Interactive Calibrations….1030
Interactive Calibrations – Summary of References….1084
Procedure in the Event of Problems with Interactive Calibration….1085
BCU: Calibrate the Hitch Control….1086
ECU: Calibrate the Electronic Fuel Injectors (Move Injectors to Different Positions or Replace Injectors, and Display Progress of Calibration)….1090
Group 15: Information on How to Reprogram Control Units….1031
Information on How to Program Control Units – Summary of References….1092
General Information on How to Reprogram Control Units….1093
Check and Download Tractor-Specific Software Information….1094
Procedure When Replacing Control Units….1095
Important Notes on Programming….1096
Procedure When Programming Control Units….1097
Procedure in the Event of a Problem Programming Control Units Protected by VIN….1098
Procedure in the Event of a Programming Problem….1101
Group 20: Data BUS Systems, Operation….1031
Data BUS systems – Summary of References….1104
Data BUS Systems – CAN BUS Systems….1105
Data BUS Systems – CAN BUS Systems on Engines with Level 16 Control Unit (2-Valve HPCR Fuel System)….1107
Data BUS systems – Plug Layout….1108
Data BUS systems – Determining the Type of the CAN BUS Fault….1109
Group BCU: BCU – Basic Control Unit….1031
BCU – Summary of References….1112
BCU – Summary of Addresses….1113
BCU – Calibration and Input Addresses….1120
BCU – Summary of Operational Checks….1122
BCU – Theory of Operation (Basic Functions)….1123
BCU – Theory of Operation (Hitch Control)….1125
BCU – CAN BUS Information….1127
Address BCU020 – Input Address, Engine Speed Sensor/Pulses per Engine Revolution….1128
Address BCU021 – Input Address, Rear PTO Speed Sensor/Pulses per PTO Revolution….1129
Address BCU022 – Input Address, Front-Wheel Drive Control Function….1130
Address BCU023 – Vacant Input Address….1131
Address BCU024 – Input Address, Settings for Units of Measurement in Display and for Acoustic Indicator for Turn Signal….1132
Address BCU026 – Vacant Input Address….1133
Address BCU027 – Vacant Input Address….1134
Address BCU028 – Input Address, Rear PTO Present/Not Present….1135
Address BCU029 – Vacant Input Address….1136
Address BCU030 – Input Address, Sensor Diagnostics….1137
Address BCU031 – Vacant Input Address….1138
Address BCU034 – Input Address, Configuration of Instrument Unit and Self-Canceling Turn Signals….1139
Address BCU035 – Input Address, Service Interval Setting….1140
Address BCU041 – Vacant Input Address….1141
Address BCU042 – Vacant Input Address….1142
Address BCU043 – Vacant Input Address….1143
Address BCU045 – Vacant Input Address….1144
Address BCU046 – Input Address, Activate/De-activate Delayed Activation of Alternator….1145
Address BCU047 – Input Address, Delayed Activation of Alternator, Configuration….1146
Address BCU048 – Vacant Input Address….1147
Address BCU049 – Vacant Input Address….1148
Address BCU050 – Vacant Input Address….1149
Address BCU051 – Vacant Input Address….1150
Address BCU052 – Vacant Input Address….1151
Address BCU055 – Input Address, Configuration of Acoustic Alarm….1152
Address BCU056 – Input Address, Tire Configuration….1153
Address BCU058 – Input Address, Sensor for Wheel Speed / Transmission Pulses per Axle Revolution….1154
Address BCU060 – Vacant Input Address….1155
Address BCU063 – Vacant Input Address….1156
Address BCU065 – Vacant Input Address….1157
Address BCU071 – Vacant Input Address….1158
Address BCU073 – Vacant Input Address….1159
Address BCU074 – Vacant Input Address….1160
Address BCU075 – Vacant Input Address….1161
Address BCU077 – Vacant Input Address….1162
Address BCU078 – Vacant Input Address….1163
Address BCU088 – Vacant Input Address….1164
Address BCU089 – Vacant Input Address….1165
Address BCU090 – Vacant Input Address….1166
Address BCU091 – Vacant Input Address….1167
Address BCU092 – Vacant Input Address….1168
Address BCU093 – Vacant Input Address….1169
Address BCU094 – Vacant Input Address….1170
Address BCU097 – Input Address, Low Fuel Level Acoustic Alarm….1171
Address BCU099 – Input Address, Automatic Deletion of Diagnostic Trouble Codes….1172
Address BCU101 – Input Address, Leak-Off Function of Hitch Valve On or Off….1173
Address BCU118 – Input Address, Quick Withdrawal and Hitch Dampening On or Off….1174
Address BCU122 – Hitch Control Calibration….1175
Address BCU138 – Input Address, Leak-off Function of Hitch Valve (Adjusting Stepper Motor Steps)….1183
Address BCU145 – Input Address, Hitch Control On or Off….1184
Address BCU154 – Input Address, Leak-off Function of Hitch Valve (Time Setting)….1185
Address BCU162 – Input Address, Switching Off Hydraulic Oil Temperature Access (During Calibration)….1186
Address BCU165 – Input Address, Raise Rate Setting….1187
Address BCU167 – Input Address, Activate/De-activate Hitch Components….1188
Address BCU174 – Input Address, Index for Load Control….1189
Address BCU247 – Tractor Model Designation….1190
Address BCU248 – Tractor Serial Number….1191
B06 – Rear PTO Speed Sensor, Operational Check….1192
B09 – Hall Sending Unit Speedmeter, Operational Check….1193
B21 – Hitch Position Sensor, Operational Check….1194
B26 – Sensitivity Potentiometer, Operational Check….1195
B27 – Position Feedback Unit for Hitch Control, Operational Check….1196
B41 – Draft Sensor, Operational Check….1198
B88 – Brake Pedal Sensor Unit, Operational Check….1199
M08 – Stepper Motor for Hitch, Operational Check….1200
S08 – Turn Signal Switch, Operational Check….1201
S21 – Rear PTO Switch, Operational Check….1202
S22 – Differential Lock Switch, Operational Check….1203
S24 – Quick Withdrawal Switch, Operational Check….1204
S63 – Front-Wheel Drive Switch, Operational Check….1205
S68 – Switch for Hitch Remote Control (Left), Operational Check….1206
S106 – Hazard Warning Light Switch, Operational Check….1208
Supply Voltage for 5-volt BCU Components, Operational Check….1209
Group ECU: ECU Control Unit….1034
ECU – Summary of References….1211
ECU – Summary of Addresses (Level 16 ECU for 2-Valve Engine with HPCR)….1212
ECU – Calibration and Input Addresses (Level 16 ECU for 2-Valve Engine with HPCR)….1215
ECU – Summary of Operational Checks….1217
ECU – Theory of Operation (Level 16 ECU for 2-Valve Engine with HPCR)….1218
B02 – Air Cleaner Restriction Sensor, Operational Check….1221
B96 – Hand Throttle Potentiometer, Operational Check….1222
B79 – Accelerator Pedal Potentiometer, Operational Check….1224
R15 – Heating Element of Electrical Starting Aid (2-Valve Engine with HPCR), Operational Check….1226
Section 255: PowrQuad Transmissions….1228
Group 10: Operational Check….1228
PowrQuad Transmission—Operational Check….1237
Group 15: Tests and Adjustments….1228
PowrQuad Transmission—Summary of References….1245
PowrQuad Transmission— Special Tools….1246
PowrQuad Transmission—System Check….1247
PowrQuad Transmission—Test Ports….1255
PowrQuad Transmission—Checking Rate of Flow at Cooler….1257
PowrQuad Transmission—Checking the Cooler Relief Valve….1260
PowrQuad Transmission—System Pressure Check….1263
PowrQuad Transmission—Checking Lube Oil Pressure….1264
PowrQuad Transmission—Checking Cooling Oil Pressure (Forward Clutch)….1266
PowrQuad Transmission—Checking Cooling Oil Pressure (Reverse Brake)….1267
PowrQuad Transmission—Checking Pressure at Forward Clutch….1268
PowrQuad Transmission—Checking Pressure at Reverse Brake….1269
PowrQuad Transmission—Checking Pressure at Brake B1….1270
PowrQuad Transmission—Checking Pressure at Brake B2….1271
PowrQuad Transmission—Checking Pressure at Brake B3….1272
PowrQuad Transmission—Checking Pressure at Clutch C4….1273
PowrQuad Transmission—Adjusting System Pressure….1275
PowrQuad Transmission—Test Result Table….1277
PowrQuad Transmission—Adjusting Gear Shift….1280
PowrQuad Transmission—Adjusting Forward/Reverse Cable….1282
PowrQuad Transmission—Adjusting Park Lock….1284
Group 20: Operation….1228
PowrQuad Transmission — Summary of References….1286
PowrQuad Transmission—Layout….1287
PowrQuad Module—Layout….1288
PowrQuad Module—Cross-Sectional and 3D View….1290
PowrQuad Module—Location of Valves, Sensors and Switches….1292
PowrQuad Module—Element Engagement Chart….1295
PowrQuad Module—Pneumatic Pump….1296
PowrQuad Module—Transmission Oil Pump….1299
PowrQuad Module — Pressure-Regulating Valve and Filter Relief Valve….1301
PowrQuad Module—Overspeed Relief Valve and Anti-Cavitation Check Valve….1306
PowrQuad Module—Clutch Cooling Components….1308
PowrQuad Module —Clutch Cooling Valve (Forward/Reverse)….1309
PowrQuad Module—System 1 Oil and System 2 Oil….1310
PowrQuad Module—Hydraulic Schematic, Mechanically Actuated PowrQuad Module….1311
PowrQuad Module—Operation of Forward/Reverse Modulation, Mechanically Actuated PowrQuad Module….1313
PowrQuad Module—Neutral Start Circuit, Mechanically Actuated PowrQuad Module….1316
PowrQuad Module—Operation of Gear-to-Gear Modulation, Mechanically Actuated PowrQuad Module….1317
Group 30: Range Box….1229
Range Transmission — Cross-Sectional View….1322
Section 256: Drive Systems….1324
Group 10: Operational Check….1324
Power train – operational check….1328
Group 15: Tests and Adjustments….1324
Tests and Adjustments—Summary of References….1443
Tests and Adjustments—Special Tools….1333
Drive Systems—System Check….1334
Checking Pressure at the Front-Wheel Drive Clutch….1338
Checking Pressure at the Hydraulic Differential Lock….1339
Checking Pressure at the PTO….1340
Drive Systems—Test Result Table….1343
Group 20: Operation….1324
Drive Systems—Summary of References….1345
Front Wheel Drive Clutch—Cross-Sectional View….1346
Front Wheel Drive Clutch—Oil Flow and Power Flow….1348
Front Wheel Drive Clutch Disengaged—Oil Flow….1350
Differential—Cross-Sectional View….1352
Differential—Power Flows….1354
Differential—Oil Flows….1356
Final Drives—Operation and Cross-Sectional View….1359
PTO Options—Description….1360
PTO Options—PTO Modulating Valve and Solenoid Valve….1362
PTO Options—PTO brake and PTO clutch….1364
PTO Options—Power Flows….1366
Section 260: Steering and Brakes….1368
Group 05: Preliminary Checks….1368
Preliminary Checks—Summary of References….1371
Preliminary Checks – Steering System….1372
Preliminary Checks – Brake System….1376
Group 10: Operational Check….1368
Operational Checkout—Summary of References….1378
Safety Information….1379
Steering Check….1380
Checking Brakes….1381
Group 15: Tests and Adjustments….1368
Tests Tests Tests & Adjustments—Summary of References{pgNO}1368 Adjustments—Summary of References{pgNO}1383 Adjustments—Summary of References….1382
Steering and Brakes – Special Tools….1384
Steering and Brakes – Specifications….1386
Checking Steering Valve….1387
Checking Brake System….1390
Bleeding the Rear Brakes….1391
Adjusting Brake Pedals and Switches….1392
Group 20A: Hydrostatic Steering….1368
Description of Steering Valves, Operation….1400
Group 20B: Brakes….1368
Brakes—Summary of Reference….1408
Operation of Brake Piston, Plate and Disks….1409
Brake released….1411
Initial Braking….1413
Brake Engaged….1415
Rear Wheel Brakes, Operation….1417
Group 20C: Air brake system….1368
Steering and Brakes – Air Brakes, Summary of References….1419
Steering and Brakes – Air Brakes, Description….1420
Steering and Brakes – Air Brakes, Compressor….1422
Steering and Brakes – Air Brakes, Pressure Regulating Valve….1423
Steering and Brakes – Air Brakes, Compressed Air Tank….1424
Steering and Brakes – Air Brakes, Trailer Control Valve….1425
Steering and Brakes – Air Brakes, Coupling Ends….1426
Section 270: Hydraulic System….1427
Group 10: Operational Check….1427
Hydraulic System – Operational Check—Summary of References….1430
General Information – Transmission and Hydraulic System, Introductory Checks….1431
Hydraulic System – Load Check….1435
Hitch Control – Operational Check….1436
Hydraulic System – External Control of Hitch, Operational Check-Out….1438
Hydraulic System – Selective Control Valves (M-SCV), Operational Check-Out….1439
Group 15: Tests and Adjustments….1427
Tests and Adjustments—Summary of References….1443
Hydraulic System – Special Tools….1444
Safety Measures for Hydraulic Checks….1446
PFC Hydraulic System – Worksheet for the Hydraulic System Diagnostics….1448
PFC Hydraulic System – Oil Pressure Test Ports….1451
PFC Hydraulic System – Checking and Adjusting the Maximum Load Sense Pressure….1452
PFC Hydraulic System – Check and Adjust System Oil Pressure….1454
PFC Hydraulic System – Check and Adjust Differential Pressure….1456
PFC Hydraulic System – Priority Circuit 1, Checking and Adjusting the Load Sense Oil Pressure for Steering….1458
PFC Hydraulic System – Priority Circuit 3, Checking the Oil Pressure….1460
PFC Hydraulic System – Hydraulic Pump, Checking the Delivery Rate….1462
Hydraulic System – Hitch Valve, Rough Adjustment of the Raise and Lower Valves….1464
Hydraulic System – Hitch Valve, Checking and Adjusting the Draft Potentiometer….1466
Group 20: Theory of operation….1427
Hydraulic System Theory of Operation—Summary of References….1469
Hydraulic System – Summary of Abbreviations….1470
PFC Hydraulic System – Summary of Components….1471
PFC Hydraulic System — Symbolic Representation….1473
Group 20A: Oil Filter, Charge Pump and Hydraulic Pump….1427
Oil Filter, Charge Pump and Hydraulic Pump―Summary of References….1475
PFC Hydraulic System – Hydraulic Oil Filter, Operation….1476
PFC Hydraulic System – Charge Pump, Operation….1478
PFC Hydraulic System – Hydraulic Pump, Operation….1480
PFC Hydraulic System – Hydraulic Pump, Operating Modes….1484
PFC Hydraulic System – Hydraulic Oil Primary Filter, Component Information….1491
PFC Hydraulic System – Hydraulic Oil Filter, Component Information….1492
PFC Hydraulic System – Charge Pump, Component Information….1493
PFC Hydraulic System – Hydraulic Pump, Component Information….1495
Group 20B: Hitch….1428
Hitch – Summary of References….1497
Hitch – Summary of Components….1498
Hitch – Hitch Control, Operation….1500
Hitch – Hitch Valve, Operation….1502
Hitch – Position Sensor, Operation….1504
Hitch – Draft Sensor, Operation….1505
Hitch – Controls….1506
Hitch – Direct Control….1507
Group 20C: Selective control valves (SCV)….1428
Selective Control Valves (SCVs) – Summary of References….1509
Selective Control Valve (M-SCV 100) – Operation….1510
Selective Control Valve (M-SCV 200) – Operation….1518
Group 20D: Hydraulic block….1428
PFC Hydraulic System – Hydraulic Block, Summary of References….1530
PFC Hydraulic System – Hydraulic Block, Summary of Components….1531
PFC Hydraulic System – Priority 1 Control Block, Component Information….1533
PFC Hydraulic System – Priority 3 Control Block, Component Information….1535
Section 290: Operator's Cab….1537
Group 15: Tests and Adjustments….1537
Operational Checkout―Summary of References….1539
Safety in the Workplace….1540
Handling Refrigerant….1541
Safety Equipment….1542
In the Event of an Emergency….1543
Storage of Refrigerant Containers….1544
Refrigerant R134a….1545
Important….1546
Operator's Cab – Special Tools….1547
Specification….1548
Explanation Of Checks….1549
Pressure Deviations….1563
Group 20: Operation….1537
Air Condtioning System – Summary of References….1566
Air Condtioning System – R134A Refrigerant….1567
Air Condtioning System – Principle of Heat Exchange….1568
Refrigerant Circuit Layout (Cab Tractors)….1569
Refrigerant Circuit Operation….1570
Component Description….1572
Air Condtioning System – Expansion Valve, Component Information….1576
Thermostat Switch….1578
Heating and Ventilation….1579
Section 299: Special Tools (Dealer-Fabricated)….1581
Group 05: Special Tools (Dealer-Fabricated)….1581
Special Tools (Dealer-Fabricated) — Summary….1583
Retainer Tool….1584
Adjustment Tool….1585
DFRW2—Needle Valve Test Hose Assembly….1586
DFLX10 and DFLX11—Test Harnesses….1587
DFLX12—Special Tool for 11-bit and 29-bit CAN BUS….1588
DFLX14—Solenoid Valve Test Harness….1589
Group 10: Special Tools (Available as Spare Parts)….1581
Special tool information….1591
John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, 6210J Tractors Diagnosis & Tests Service Manual (TM802219)
