Day: December 19, 2024

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INSTANT DOWNLOAD

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Complete Repair Service Technical Manual for John Deere Tractors 6100J, 6115J, 6125J, 6135J, 6150J, 6170J, 6190J, 6210J, with all the workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere Tractors 6100J, 6115J, 6125J, 6135J, 6150J, 6170J, 6190J, 6210J workshop technical manual (repair) 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.
* 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.

TM808719 – 6J Tractors (600000 – )—Repair Technical Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,902 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English French Portuguese Spanish

TM808719 Repair Technical Manual 6J Tractors (600001 – )—Repair Technical Manual
Language: English
Equipment Model: 6100J, 6115J, 6125J, 6135J, 6150J, 6170J, 6190J, 6210J
Serial Number: 600000-
Edition: South America

TM808728 Repair Technical Manual 6J Tractors (600001 – )—Repair Technical Manual
Language: French

TM808754 Repair Technical Manual 6J Tractors (600001 – )—Repair Technical Manual
Language: Portuguese

TM808763 Repair Technical Manual 6J Tractors (600001 – )—Repair Technical Manual
Language: Spanish

TABLE OF CONTENTS
Section 05: Safety…32
Group 05: Safety…32
Recognize Safety Information…457
Understand Signal Words…36
Follow Safety Instructions…37
Practice Safe Maintenance…38
Live With Safety…39
Handle Fluids Safely—Avoid Fires…40
Prepare for Emergencies…41
Wear Protective Clothing…42
Work in Clean Area…43
Work In Ventilated Area…44
Illuminate Work Area Safely…45
Remove Paint Before Welding or Heating…46
Avoid Heating Near Pressurized Fluid Lines…47
Use Proper Tools…48
Construct Dealer-Made Tools Safely…49
In Case of Fire…50
Avoid Harmful Asbestos Dust…51
Decommissioning — Proper Recycling and Disposal of Fluids and Components…52
Precautions for Welding…53
Park Machine Safely…55
Support Machine Properly…56
Replace Safety Signs…57
Clean Vehicle of Hazardous Pesticides…58
Handle Agricultural Chemicals Safely…59
Service Machines Safely…61
Use Proper Lifting Equipment…62
Avoid High-Pressure Fluids…63
Service Accumulator Systems Safely…64
Wait Before Opening High-Pressure Fuel System…65
Keep ROPS Installed Properly…66
Service Tires Safely…67
Avoid Static Electricity Risk When Refueling…68
Prevent Acid Burns…70
Handling Batteries Safely…72
Prevent Battery Explosions…74
Section 10: General Information…225
Group 05: References for Technical Information…75
Sealants and Adhesives Cross-Reference Chart…79
Metric Bolt and Screw Torque Values…82
Unified Inch Bolt and Screw Torque Values…84
Face Seal Fittings Assembly and Installation—All Pressure Applications…87
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures…88
Metric Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications…90
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—Standard Pressures…92
SAE Face Seal and O-Ring Stud End Fitting Torque Chart—High Pressure Applications…94
Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications…96
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications…97
SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications…98
External Hexagon Port Plug Torque Chart…99
Prevent Hydraulic System Contamination…101
Identify Zinc-Flake Coated Fasteners…102
Use Torque Wrench Adapter…103
Servicing and Connecting Snap to Connect STC™ Fittings…105
Use Special Wrench…1930
Install Hydraulic Fittings…108
Section 20: Engine…110
Group 05: Remove and Install Components…110
John Deere Engine Component Information…192
Special Tools…1845
Specifications…1856
Remove and Install 4.5L Engine…116
Remove and Install 6.8L Engine…139
Engine Mountings—Exploded View…165
Replace Engine Mountings…166
Section 30: Fuel, Air Intake, Cooling, and Exhaust System…171
Group 05: Speed Control…171
General Information…225
Specifications…1856
Other Material…1855
Mechanical Hand Throttle Lever—Exploded View…177
Mechanical Speed Control Pedal—Exploded View…179
Mechanical Hand Throttle Lever and Speed Control Pedal Adjustment…184
Mechanical Speed Control Link Adjustment…183
Speed Control Pedal Adjustment…184
Remove and Install Hand Throttle Potentiometer…185
Remove and Install Speed Control Pedal Assembly…186
Remove and Install Speed Control Pedal Potentiometer…188
Group 10: Fuel System…171
John Deere Engine Component Information…192
General information…1857
Specifications…1856
Other Material…1855
Fuel System 4.5L Engine…196
Fuel System 6.8L Engine…198
Drain Fuel Filters…200
Drain Fuel Tank…202
Remove and Install Fuel Tank…204
Remove and Install Fuel Transfer Pump…209
Remove and Install Fuel Filters…213
Bleed Fuel System…217
Restarting an Engine Which Has Run Out of Fuel…220
Group 15: Air Intake System…171
General Information…225
Specifications…1856
Engine Air Cleaner—Exploded View…227
Remove and Install Engine Air Cleaner Housing…228
Group 20: Cooling System…172
General information…1857
Specifications…1856
Remove and Install Radiator…232
Remove and Install Expansion Tank…241
Remove and Install Engine Fan…245
Remove and Install Viscous Fan Drive Clutch…250
Remove and Install Oil Cooler/Air Conditioner Condenser…252
Remove and Install Ring-Shaped Oil Cooler…254
Remove and Install Charge Air Cooler…255
Releasing Drive Belt Tension…260
Replace Engine Fan Belt…261
Remove and Install Automatic Belt Tensioner…266
Remove and Install Fan Console…267
Disassemble, Repair, and Assemble Fan Console…270
Group 25: Exhaust System…172
General information…1857
Specifications…1856
Other Materials…1669
Remove and Install Muffler…276
Remove and Install Exhaust Pipe…278
Section 40: Electrical System…283
Group 05: Harness and Connectors Repair…283
Special Tools…1845
General…289
Use of High-Pressure Washers…290
Replace SURE-SEAL® Connectors…291
Install Weather Pack™ Contact…293
Service Parts Kits…295
Replace CPC™, Large Mate-N-Lok®, and Metrimate® Pin-Type Connectors…296
Replace CPC™ Blade Type Connectors…297
Replace Small Mate-N-Lok® Socket Connector…298
Replace Small Mate-N-Lok® Pin Connector…299
Replace DEUTSCH® Connectors…300
Replace Weather Pack™ Connector…302
Replace SURE-SEAL® Connector with Weather Pack™ Connector…304
Remove Connector Body from Blade Terminals…306
Install DEUTSCH® Contact…307
Installation of Repair Wire Assembly (RWA)…309
Group 15: Charging System…283
Special Tools…1845
Specifications…1856
Replacing Alternator…321
Disconnecting Electrical Circuits…460
Remove and Install Alternator…323
Remove and Install Alternator Pulley…325
Remove and Install the Battery…327
Group 20: Starter Motor Circuit…283
Special Tools…1845
Specifications…1856
Repairing Starter Motor…332
Disconnecting Electrical Circuits…460
Remove and Install Starter Motor…334
Group 25: Fuses, Relays, and Switches…284
Special Tools…1845
Specifications…1856
Disconnecting Electrical Circuits…460
Access to the Fuses and Relays…340
Main Fuses (If Equipped)…342
Fuse Box—Tractors with Open Operator’s Station…344
Fuse Box—Tractors with Cab…346
Power Link Box (If Equipped)…348
Power Link Box Components (If Equipped)…349
Remove and Install Starter Relay…350
Remove and Install Key Switch…353
Remove and Install Brake Switch…354
Remove and Install Light Switch…355
Remove and Install High-Beam and Low-Beam Headlights Switch…356
Remove and Install Worklights Switch…357
Remove and Install Hazard Warning Light Switch…358
Remove and Install Turn-Signal Switch…359
Remove and Install Horn Switch…360
Remove and Install Windshield Wiper and Windshield Washer Switch…361
Remove and Install Front-Wheel Drive Switch…362
Remove and Install Power Take-off Switch…363
Remove and Install Load Depth Control Potentiometer—Cab Tractors…364
Remove and Install Hitch Control Unit—Cab Tractors…365
Remove and Install FieldCruise™ Control Potentiometer…366
Remove and Install Fan Switch…368
Remove and Install Differential Lock Switch—Tractors with Open Operator’s Station…369
Remove and Install Differential Lock Switch—Tractors with Cab…370
Remove and Install Hydraulic Hitch Remote Control Switch—Tractors with Cab…371
Group 30: Electrical Components…284
Note…373
Special Tools…1845
Specifications…1856
Disconnecting Electrical Circuits…460
Lights with Halogen Bulbs…377
Remove and Install Instrument Panel…379
Remove and Install Trailer Socket…382
Remove and Install Service ADVISOR™ Socket…384
Remove and Install Windshield Wiper Motor…387
Removing Windshield Washer Pump…389
Handle Halogen Light Bulbs Safely…390
Replace High and Low Beam Headlights Bulbs…391
Replace Rear Worklight Bulb—Open Operator’s Station Tractors…393
Replace Front Turn-Signal Lights, Hazard Warning Lights, and Clearance Lights Bulbs—Open Operator’s Station Tractors…395
Replace Worklight Bulbs—Cab Tractors…397
Replace Front Turn-Signal Light, and Hazard Warning Lights Bulbs—Cab Tractors…399
Replace Rear Turn-Signal Light, Hazard Warning Light, and Brake Light Bulbs…400
Replace Backup Light Bulb…402
Replace License Plate Light Bulb…404
Group 35: Monitoring Systems…285
Replace Engine Speed Sensor (B001)…407
Replace Engine Air Cleaner Restriction Pressure Switch (B002)…408
Replace Fuel Level Sensor (B003)…409
Replace Engine Oil Pressure Switch (B004)…411
Replace Rear PTO Speed Sensor (B006)…413
Replace Transmission Oil Filter Restriction Switch (B007)…414
Replace Coolant Temperature Sensor (B008)…415
Replace Wheel Speed Sensor (B009)…417
Replace A/C Pressure Switch (B015)…418
Replace Draft Sensors (B019) and (B020)…419
Replace Rear Hitch Position Sensor (B021)…422
Replace Transmission Oil Pressure Switch (B031)…423
Replace Transmission Forward Pressure Switch (B032)…424
Replace Transmission Reward Pressure Switch (B033)…425
Replace Wheel Speed Sensor (B035)…426
Replace Neutral Start Switch (B036)…427
Replace Draft Sensor (B041)…428
Replace Coolant Temperature Sensor (B056)…430
Replace Manifold Air Temperature Sensor (B059)…431
Replace Hydraulic Oil Temperature Sensor (B066)…432
Replace Crankshaft Speed Sensor (B072)…433
Replace Event Sensor (B074)…434
Replace Fuel Temperature Sensor (B114)…435
Replace Water-in-Fuel Sensor (B121)…436
Replace Rail Pressure Sensor (B137)…438
Replace Steering Input Device (B138)…439
Replace Wheel Angle Sensor (B139)…440
Replace A/C Thermostat Switch (S070)…441
Section 45: Electronic Control Units…442
Group 05: General Information…225
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems…444
Servicing Electronic Control Units…445
Welding Near Electronic Control Units…446
Keep Electronic Control Unit Connectors Clean…447
Special Tools…1845
Control Unit Locations…449
Control Unit Functions…452
Group 10: Remove and Install Components…442
Safety Information…457
Instructions when Replacing a Control Unit…458
Instructions when Replacing a VIN Control Unit…459
Disconnecting Electrical Circuits…460
Specifications…1856
Remove and Install MHPC Control Unit (A064)…462
Remove and Install ECU Control Unit (A086)…465
Remove and Install MTG Control Unit (A155)…466
Remove and Install SBBC Control Unit (A132)…468
Replace Vehicle CAN Bus Active Terminator (A062)…470
Replace Vehicle CAN Bus Passive Terminator (A084)…471
Replace Implement CAN Bus Active Terminator (A083)…472
Replace Implement CAN Bus Passive Terminator (A063)…473
Section 50A: Drivetrain…474
Group 05: Remove and Install Components—6100J, 6115J, 6125J and 6135J Tractors…474
Special Tools…1845
Specifications…1856
Other Materials…1669
Remove and Install Front-Wheel Drive Clutch Housing…559
Remove and Install Drivetrain—Tractors with Open Operator’s Station…487
Remove and Install Drivetrain—Tractors with Cab…495
Remove and Install Final Drive—Tractors with Open Operator's Station…506
Remove and Install Final Drive—Tractors with Cab…511
Remove and Install Power Take-Off Housing—Tractors with Open Operator's Station…517
Remove and Install Power Take-Off Housing—Tractors with Cab…522
Group 06: Remove and Install Components—6150J Tractor…474
Special Tools…1845
Specifications…1856
Other Materials…1669
Remove and Install Front-Wheel Drive Clutch Housing…559
Remove and Install Drivetrain…562
Remove and Install Final Drive…574
Remove and Install Power Take-Off Housing…581
Group 07: Remove and Install Components—6170J, 6190J, and 6210J Tractor…474
Special Tools…1845
Specifications…1856
Other Materials…1669
Remove and Install Front-Wheel Drive Clutch Housing…559
Remove and Install Drivetrain…562
Remove and Install Final Drive…574
Remove and Install Power Take-Off Housing…581
Group 10: Universal Joints, Driveshafts, and Torsional Damper…474
Special Tools…1845
Specifications…1856
Front-Wheel Drive Driveshaft—Exploded View…588
Remove Front-Wheel Drive Driveshaft…589
Repairing MFWD Universal-Joint Drive Shaft…591
Install Front-Wheel Drive Driveshaft…595
Remove and Install Engine Driveshaft…597
Remove and Install Torsional Damper…599
Replace Torsional Damper Bearing…601
Group 15: Front-Wheel Drive Clutch—6100J, 6115J, 6125J and 6135J Tractors…475
Special Tools…1845
Specifications…1856
Other Material…1855
MFWD Clutch Repair Instructions…641
Front-Wheel Drive Clutch—Cross-Sectional View…607
Front-Wheel Drive Clutch — Exploded View…608
Disassemble, Inspect, and Assemble Front-Wheel Drive Clutch…610
Group 16: Front-Wheel Drive Clutch—6150J Tractor…475
Special Tools…1845
Specifications…1856
MFWD Clutch Repair Instructions…641
MFWD Clutch — Cross-Sectional View…642
Disassemble Front-Wheel Drive Clutch…646
Disassembling MFWD Clutch Assembly…649
Mounting MFWD Clutch Assembly…651
Mounting MFWD Clutch…655
Group 17: Front-Wheel Drive Clutch—6170J, 6190J, and 6210J Tractors…475
Special Tools…1845
Specifications…1856
MFWD Clutch Repair Instructions…641
MFWD Clutch — Cross-Sectional View…642
MFWD Clutch Exploded View…644
Disassemble Front-Wheel Drive Clutch…646
Disassembling MFWD Clutch Assembly…649
Mounting MFWD Clutch Assembly…651
Mounting MFWD Clutch…655
Group 20: Rear Differential—6100J, 6115J, 6125J, and 6135J Tractors…476
Specifications…1856
Other Materials…1669
Rear Differential Repair Instructions…712
Differential — Exploded View…665
Rear Differential—Cross-Sectional View…667
Remove Rear Differential…668
Disassemble Rear Differential…670
Assembling the differential…675
Install Rear Differential…681
Adjust Differential Bearings Preload…683
Adjust Rear Differential Backlash…733
Group 21: Rear Differential—6150J Tractor…476
Special Tools…1845
Specifications…1856
Rear Differential Repair Instructions…712
Rear Differential — Cross Sectional View…714
Rear Differential — Exploded View…716
Remove and Install Rear Differential…718
Disassembling Rear Differential…721
Assembling Rear Differential…725
Adjust Rear Differential Preload…731
Adjust Rear Differential Backlash…733
Group 22: Rear Differential—6170J, 6190J, and 6210J Tractors…476
Special Tools…1845
Specifications…1856
Rear Differential Repair Instructions…712
Rear Differential — Cross Sectional View…714
Rear Differential — Exploded View…716
Remove and Install Rear Differential…718
Disassembling Rear Differential…721
Assembling Rear Differential…725
Adjust Rear Differential Preload…731
Adjust Rear Differential Backlash…733
Group 25: Hydraulic Pump Drive…477
Special Tools…1845
Specifications…1856
Hydraulic Pump Drive—Cross-Sectional View…738
Remove and Disassemble Pump Drive Pinion…741
Remove and Disassemble Pump Drive Gear…745
Assemble and Install Pump Drive Gear…749
Assembling and Installing Pump Drive Pinion…755
Adjust Hydraulic Pump Drive…760
Group 30: Final Drives—6100J, 6115J, 6125J, and 6135J Tractors…477
Special Tools…1845
Specifications…1856
Final Drive Repair Instructions…783
Final Drive—Cross-Sectional View…767
Final Drive—Exploded View…768
Disassemble, Repair and Assemble Final Drives…770
Adjust Rear Axle Rolling Drag…778
Group 31: Final Drives—6150J, 6170J, 6190J, and 6210J Tractors…477
Special Tools…1845
Specifications…1856
Final Drive Repair Instructions…783
Final Drive Housing — Cross Sectional View…784
Final Drive Housing — Exploded View…785
Removing Planetary Carrier…787
Disassembling Planetary Carrier…789
Planetary Carrier — Exploded View…791
Assembling Planetary Carrier…792
Removing Final Drive Housing to Axle…794
Disassembling and Assembling Final Drive Housing…796
Disassembling and Assembling Axle…797
Installing Final Drive Housing to Axle…799
Installing Planetary Carrier…800
Measuring Rolling Drag…802
Checking Final Drive Shaft and Retainer…1926
Group 35: Rear Power Take—Off-6100J, 6115J, 6125J, and 6135J Tractors…478
Special Tools…1845
Specifications…1856
Other Material…1855
Replacing Output Shaft Retainer…1926
Replacing O-Ring of Reversible PTO…814
Rear Power Take-Off—Exploded View…815
Rear Power Take-Off—Cross-Sectional View…816
Remove and Install Power Take-Off Clutch…819
Repair Power Take-Off Clutch…820
Reconditioning PTO Brake…825
Power Take-Off Transmission—Cross-Sectional View…975
Disassemble Power Take-Off Transmission…828
Reconditioning Output Shaft (540/1000 RPM Reversible)…829
Mounting Output Shaft (540/1000 RPM)…832
Reconditioning Countershaft (540/1000 RPM)…834
Mounting PTO Transmission…835
Adjusting Output Shaft Cone Bearing…837
Adjusting Countershaft Cone Bearing…838
Installing Support and Adjusting Cone Bearings…840
Remove, Repair, and Install Rear Power Take-Off Solenoid Valve…886
Group 36: Rear Power Take-Off—6150J, 6170J, 6190J, and 6210J Tractors…478
Special Tools…1845
Specifications…1856
Replacing Output Shaft Seal Ring…846
Rear PTO Clutch – Cross Sectional View…847
Rear PTO Clutch – Exploded View…849
Remove Rear Power Take-Off Clutch…850
Disassemble, Repair, and Assemble Rear Power Take-Off Clutch…853
Repair Rear Power Take-Off Brake…862
Install Rear Power Take-Off Clutch…863
Rear PTO Drive Train – Cross Sectional View…866
Rear PTO Drive Train – Exploded View…867
Remove Rear Power Take-Off Drive Train…869
Disassemble, Repair, and Assemble Output Shaft…873
Disassemble, Repair, and Assemble Countershaft…878
Install Rear Power Take-Off Drive Train…880
Adjust Tapered Roller Bearing of Countershaft…881
Adjust Tapered Roller Bearing of Bearing Support…883
Remove, Repair, and Install Rear Power Take-Off Solenoid Valve…886
Section 50B: SyncroPlus™ Transmission…888
Group 05: Remove and Install Components…888
Special Tools…1845
Specifications…1856
Remove and Install Clutch Housing…894
Remove and Install SyncroPlus™ Housing…902
Group 10: Transmission Selectors Control…888
Specifications…1856
Other Materials…1669
Reconditioning Gearshift Mechanism…908
Reconditioning Range-Shift Lever Mechanism…912
Checking and Adjusting Shift Units…915
Adjusting the Clutch Pedal…920
Group 15: Clutch…888
Special Tools…1845
Specifications…1856
Other Materials…1669
Removing Clutch…927
Repairing Clutch…928
Installing Clutch…937
Transmission Oil Pump—Exploded View…939
Removing Transmission Oil Pump…1144
Repair Transmission Oil Pump…944
Install Transmission Oil Pump…947
Valves and Other Hydraulic Components…950
Repairing Engagement Override Valve (EOV)…952
Repairing Clutch Cooling Valve…953
Repairing Cooling Pilot Valve…954
Repairing Bypass Valve…955
Repairing Pressure Regulating Valve…956
Repairing Lube Relief Valve…957
Repairing Cooler Relief Valve…958
Repair Clutch Pedal Valve…959
Replacing Pressure and Temperature Sensor Units…968
Group 20: Gearbox…889
Special Tools…1845
Specifications…1856
Transmission—Exploded View…973
Transmission—Cross-Sectional View…975
Disassemble SyncroPlus™ Housing…977
Disassemble, Repair, and Assemble Drive Shaft…979
Disassemble, Repair, and Assemble Intermediate Shaft…986
Assemble SyncroPlus™ Housing…988
Preparing to Install Transmission…991
Repairing Shift Cover…996
Adjusting Gear Shift Actuating Mechanism…998
Adjusting Neutral Start Switch…999
Group 25: Creeper Transmission…889
Specifications…1856
Creeper Transmission—Cross-Sectional View…1003
Preparations…1005
Removing Creeper Transmission…1006
Disassembling Creeper Transmission…1008
Installing Creeper Transmission…1021
Shifting Mechanism — Cross-Sectional View…1015
Installing Gear Shift Elements…1017
Repairing Creeper Transmission Gearbox Cover…1018
Final Assembly…1019
Installing Creeper Transmission…1021
Group 30: Remove and Install Range Box…1222
Special Tools…1845
Specifications…1856
Other Material…1855
Remove and Install Range Box…1222
Group 35: Range Box…890
Special Tools…1845
Specifications…1856
Input Shaft—Exploded View…1231
Range box—Cross-Sectional View…1230
Remove and Install Input Shaft…1233
Adjust Input Shaft End Play…1236
Output Shaft—Exploded View…1239
Remove Output Shaft…1242
Disassemble and Assemble Output Shaft…1044
Install Output Shaft…1257
Range Box Cover—Exploded View…1267
Remove and Install Range Box Cover…1269
Shifting Mechanism—Exploded View…1272
Disassemble, Repair, and Assemble Shifting Mechanism…1274
Adjust Range Shift…1276
Park Lock—Exploded View…1278
Disassemble, Inspect, and Assemble Park Lock…1281
Disassemble, Inspect, and Assemble Park Lock Cam…1066
Adjust Park Lock Cam…1068
Section 50C: PowrQuad™ Transmission…1070
Group 05: Remove and Install PowrQuad™ Module…1070
Special Tools…1845
Specifications…1856
Remove and Install PowrQuad™ Housing…1076
Group 10: Transmission Selectors Control…1070
Specifications…1856
Other Materials…1669
Reconditioning of Gearshift, Park Brake, and Forward/Reverse Mechanism…1084
Reconditioning of Range-Shift Mechanism…1088
Adjust Gear-Shift and Range-Shift Cables…1091
Adjusting Forward/Reverse Cable…1093
Adjusting Cable and Stop Screw Park Break…1095
Adjust Clutch Pedal…1096
Group 15: PowrQuad™ Module…1070
Special Tools…1845
Specifications…1856
Other Materials…1669
Transmission Components…1105
Removing and Installing Oil Filter Base…1106
Replacing Oil Filter…1107
Removing and Installing Front Valve Housing…1108
Removing and Installing Front Valve Housing Valves (With Mechanically Actuated PowrQuad Module)…1111
Removing and Installing Transmission Front Cover…1124
Removing and Installing Transmission Front Cover Valves (With Mechanically Actuated PowrQuad Module)…1126
Removing Clutch Pedal Valve (Mechanically Actuated PowrQuad Module)…1131
Removing and Installing Shift Valve Housing (With Mechanically Actuated PowrQuad Module)…1137
Removing and Installing Shift Valve Housing Valves (With Mechanically Actuated PowrQuad Module)…1140
Removing Transmission Oil Pump…1144
Servicing Transmission Oil Pump…1145
Installing Transmission Oil Pump…1151
Removing Planetary Drive Gears…1152
Repairing Planetary Drive Gears…1154
Installing Planetary Drive Gears…1160
Removing B1 Brake Housing…1165
Reconditioning B1 Brake…1166
Installing B1 Brake Housing…1168
Removing B2-B3 Brake Housing…1169
Reconditioning B2 Brake…1170
Reconditioning B3 Brake…1172
Installing B2-B3 Brake Housing…1175
Removing C4 Clutch…1176
Reconditioning C4 Clutch…1177
Installing C4 Clutch…1188
Removing Reverse Brake…1189
Servicing Reverse Brake…1190
Installing Reverse Brake…1193
Removing Forward Clutch with Planetary Drive (Forward/Reverse)…1194
Servicing Forward Clutch with Planetary Drive (Forward/Reverse)…1195
Installing Forward Clutch with Planetary Drive (Forward/Reverse)…1209
Clutch Carriers for C4 Clutch and Forward Clutch—Exploded View…1211
Replace Clutch Carriers for C4 Clutch and Forward Clutch…1212
Replacing Output Shaft…1216
Group 20: Remove and Install Range Box…1222
Special Tools…1845
Specifications…1856
Other Material…1855
Remove and Install Range Box…1222
Group 25: Range Box…1071
Special Tools…1845
Specifications…1856
Range box—Cross-Sectional View…1230
Input Shaft—Exploded View…1231
Remove and Install Input Shaft…1233
Adjust Input Shaft End Play…1236
Output Shaft—Exploded View…1239
Remove Output Shaft…1242
Disassemble and Assemble Output Shaft (6100J—6135J Tractors)…1246
Install Output Shaft…1257
Adjust Output Shaft End Play (6150J—6210J Tractors)…1265
Range Box Cover—Exploded View…1267
Remove and Install Range Box Cover…1269
Shifting Mechanism—Exploded View…1272
Disassemble, Repair, and Assemble Shifting Mechanism…1274
Adjust Range Shift…1276
Park Lock—Exploded View…1278
Disassemble, Inspect, and Assemble Park Lock…1281
Disassemble, Inspect, and Assemble Park Lock Cam (6100J-6135J Tractors)…1286
Adjust Park Lock Cam (6100J-6135J Tractors)…1288
Section 60A: Steering…1290
Group 05: Hydrostatic Steering…1290
Special Tools…1845
Other Material…1855
Specifications…1856
Preliminary Tasks…1295
Disconnect and Connect the Steering or Brake Hoses…1296
Steering Wheel—Exploded View…1298
Remove and Install Steering Wheel…1301
Steering Column—Exploded View…1302
Remove and Install Steering Column—Tractors with Cab…1304
Remove and Install Steering Column—Tractors with Open Operator’s Station…1308
Exploded View of Steering Valve…1311
Remove and Install Steering Valve…1313
Disassembling Steering Valve…1314
Assembling Steering Valve…1318
Adjusting Shock Valves…1326
Group 10: AutoTrac™ Integrated Steering…1290
Specifications…1856
Preliminary Work…1330
Steering Column (with AutoTrac™ Integrated)—Exploded View…1331
AutoTrac™ Integrated—Components…1333
Remove and Install AutoTrac™ Integrated Steering Valve…1334
Replace Solenoid Valves…1337
Section 60B: Brakes…1339
Group 05: Brake Valve…1339
Special Tools…1845
Specifications…1856
Brake Valve Repair Instructions…1344
Remove and Install Brake Valve…1345
Disassembling Brake Valve…1347
Manual Dual Stage Brake Valve—Exploded View…1352
Remove and Install the Manual Dual Stage Brake Valve…1354
Adjusting Brake Pedals…1378
Adjusting Brake Switches…1379
Group 10: Power-Fill Brake Valve…1339
Special Tools…1845
Specifications…1856
Power-Fill Brake Valve—Exploded View…1361
Remove and Install the Power-Fill Brake Valve…1363
Disassemble, Repair, and Assemble the Power-Fill Brake Valve…1365
Adjusting Brake Pedals…1378
Adjusting Brake Switches…1379
Group 15: Rear Wheel Brakes—6100J, 6115J, 6125J, and 6135J Tractors…1339
Special Tools…1845
Other Materials…1669
Specifications…1856
Rear Wheel Brakes—Exploded View…1384
Remove the Rear Wheel Brakes…1385
Inspect and Repair Rear Wheel Brakes…1402
Install the Rear Wheel Brakes…1389
Check Brake Piston Return Movement and Leaks…1391
Bleeding Brakes without Air Brakes…1406
Group 16: Rear Wheel Brakes—6150J, 6170J, 6190J, and 6210J Tractors…1339
Special Tools…1845
Specifications…1856
Rear Wheel Brakes – Exploded View…1399
Remove Rear Wheel Brakes…1400
Inspect and Repair Rear Wheel Brakes…1402
Install Rear Wheel Brakes…1404
Bleeding Brakes without Air Brakes…1406
Bleeding Brakes with Air Brakes…1410
Section 60C: Air Trailer Brake…1412
Group 05: Air Brake System…1412
Special Tools…1845
Specifications…1856
Air Brake System Repair Instructions…1416
Screw Union Installation…1417
Remove and Install Air Trailer Brake Compressor…1419
Disassemble, Repair, and Assemble Trailer Brake Air Compressor…1421
Remove and Install Compressed-Air Tank…1423
Remove and Install Pressure Control Valve…1424
Remove and Install Trailer Control Valve (Dual-Line Brakes)…1425
Remove and Install Manual Control Valve…1427
Changing Coupling Ends…1429
Test Sequence…1430
Checking System for Leaks…1431
Check Dual-Line Brakes Pressure…1432
Section 70: Hydraulic System…1434
Group 05: Hydraulic System Identification…1434
Hydraulic System Identification of Type…1436
Section 70A: Hydraulic System—Gear-Driven Pump (OOS Tractors)…1437
Group 05: Rockshaft Controls…1437
Special Tools…1845
Remove, Install, and Adjust the Hitch Control Lever…1441
Remove, Install, and Adjust the Selective Control Valve Levers…1443
Group 10: Hydraulic Pump…1437
Special Tools…1845
Specifications…1856
Hydraulic System Repair Instructions…1644
Hydraulic Pump—Exploded View…1627
Remove Hydraulic Pump…1637
Remove Mounting Plate…1547
Replace Lube Oil Valve…1455
Install Mounting Plate…1550
Install Hydraulic Pump…1639
Group 15: Priority Valve, Hitch Valve, and Hydraulic Oil Filter…1437
Special Tools…1845
Specifications…1856
Other Materials…1669
Hydraulic System Repair Instructions…1644
Remove and Install the Priority Valve…1466
Hitch Valve—Exploded View…1468
Remove Hitch Valve…1646
Repair Hitch Valve…1471
Remove and Install the Control Lever Console…1477
Regulating Components—Exploded View…1479
Disassemble, Repair, and Assemble the Regulating Components…1481
Install Hitch Valve…1651
Recondition Hydraulic Oil Filter…1491
Group 20: Rockshaft…1437
Special Tools…1845
Specifications…1856
Other Materials…1669
Rockshaft—Exploded View…1675
Remove and Install Rockshaft…1679
Remove and Install Lift Cylinders…1684
Repair Lift Cylinders…1502
Remove and Install Draft Link Bearing Pins…1590
Group 25: Selective Control Valves and Quick Couplers…1438
Special Tools…1845
Other Material…1855
Specifications…1856
Remove the Selective Control Valves…1513
Repair Selective Control Valves Without Float Position…1515
Repair Selective Control Valves with Float Position…1517
Repair Inlet Plate…1519
Repair Outlet Plate…1521
Install the Selective Control Valves…1522
Quick Couplers—Exploded View…1524
Remove and Install Quick Couplers…1717
Disassemble, Repair, and Assemble Quick Couplers…1526
Section 70B: Hydraulic System—Gear-Driven Pump (Cab Tractors)…1528
Group 05: Rockshaft Controls…1528
Special Tools…1845
Specifications…1856
Selective Control Valves — Removing and Installing Actuating Elements…1616
Selective Control Valves — Adjusting Bowden Cable…1620
Group 10: Hydraulic Pump…1528
Special Tools…1845
Specifications…1856
Hydraulic System Repair Instructions…1644
Hydraulic Pump—Exploded View…1627
Remove Hydraulic Pump…1637
Remove Mounting Plate…1547
Replace Lube Priority Valve…1549
Install Mounting Plate…1550
Install Hydraulic Pump…1639
Group 15: Valve Block…1528
Special Tools…1845
Specifications…1856
Hydraulic System Repair Instructions…1644
Remove Hitch Valve…1646
Disassemble, Repair, and Assemble Hitch Valve…1648
Install Hitch Valve…1651
Remove and Install Stepper Motor…1653
Remove Priority Valves 1 and 3…1568
Disassemble, Repair, and Assemble Priority Valves 1 and 3…1570
Install Priority Valve 1 and 3…1574
Group 20: Rockshaft…1528
Special Tools…1845
Other Materials…1669
Specifications…1856
Position Sensor and Toothed Segment—Exploded View…1671
Remove and Install Position Sensor and Toothed Segment…1672
Rockshaft—Exploded View…1675
Remove and Install Rockshaft…1679
Remove and Install Lift Cylinders…1684
Remove and Install Draft Link Bearing Pins…1590
Group 25: Selective Control Valves and Quick Couplers…1529
Special Tools…1845
Specifications…1856
Repair Instructions for the Selective Control Valves (SCVs) and Couplers…1701
Remove Selective Control Valves (SCVs)…1703
Recondition the Mechanical Selective Control Valves (M-SCVs 200)…1705
Recondition the Selective Control Valves (M-SCVs 450)…1708
Install Selective Control Valves (SCVs)…1711
Remove and Install Quick Couplers…1717
Section 70C: Hydraulic System—Axial Piston Pump (Cab Tractors)…1611
Group 05: Rockshaft Controls…1611
Special Tools…1845
Specifications…1856
Selective Control Valves — Removing and Installing Actuating Elements…1616
Selective Control Valves — Adjusting Bowden Cable…1620
Group 10: Charge Pump and Hydraulic Pump…1611
Special Tools…1845
Specifications…1856
Charge Pump—Exploded View…1624
Remove and Install Charge Pump…1625
Hydraulic Pump—Exploded View…1627
Remove, Inspect, and Install Lube Oil Valve…1629
Hydraulic Oil Reservoir — Restrictor…1630
Pressure and Flow Regulator—Exploded View…1631
Remove, Inspect, and Install Pressure and Flow Regulator…1633
Repair Pressure and Flow Regulator…1635
Remove Hydraulic Pump…1637
Install Hydraulic Pump…1639
Group 15: Valve Block…1611
Special Tools…1845
Specifications…1856
Hydraulic System Repair Instructions…1644
Remove Hitch Valve…1646
Disassemble, Repair, and Assemble Hitch Valve…1648
Install Hitch Valve…1651
Remove and Install Stepper Motor…1653
Remove Priority Valve 1…1654
Disassemble, Repair, and Assemble Priority Valve 1…1655
Install Priority Valve 1…1657
Remove Priority Valves 2 and 3…1658
Disassemble, Repair, and Assemble Priority Valves 2 and 3…1661
Install Priority Valves 2 and 3…1665
Group 20: Rockshaft…1612
Special Tools…1845
Other Materials…1669
Specifications…1856
Position Sensor and Toothed Segment—Exploded View…1671
Remove and Install Position Sensor and Toothed Segment…1672
Rockshaft—Exploded View…1675
Remove and Install Rockshaft…1679
Remove and Install Rockshaft Support…1682
Remove and Install Lift Cylinders…1684
Draft Sensor and Draft Link Support—Exploded View…1686
Remove and Install Draft Link Support…1690
Group 25: Selective Control Valves and Quick Couplers…1612
Special Tools…1845
Specifications…1856
Repair Instructions for the Selective Control Valves (SCVs) and Couplers…1701
Remove Selective Control Valves (SCVs)…1703
Recondition the Mechanical Selective Control Valves (M-SCVs 200)…1705
Recondition the Selective Control Valves (M-SCVs 450)…1708
Install Selective Control Valves (SCVs)…1711
Remove and Install Quick Couplers…1717
Section 80: Miscellaneous…1719
Group 05: Remove and Install Components…1719
Special Tools…1845
Specifications…1856
Remove and Install Hood…1723
Remove and Install Main Frame—6100J, 6115J, 6125J, and 6135J Tractors…1725
Remove and Install Main Frame—6150J, 6170J, 6190J, and 6210J Tractors…1731
Remove and Install Front Axle—Standard Front Axle…1738
Remove and Install Front Axle—John Deere 3 Meters Front Axle…1742
Group 10: Main Frame…1719
Special Tools…1845
Specifications…1856
Repair Main Frame…1748
Group 15: Front Wheels, Rear Wheels and Fenders…1719
Special Tools…1845
Specifications…1856
Remove and Install Front Fenders…1756
Remove and Install Front and Rear Wheels…1763
Repair Front and Rear Wheels…1767
Service Heavy-Duty Wheel Clamps…1773
Group 20: Center Link Bracket and Swinging Drawbar…1719
Specifications…1856
Check Swinging Drawbar Wear…1781
Remove and Install Center Link Bracket…1782
Repair Swinging Drawbar—6100J, 6115J, 6125J, and 6135 Tractors…1784
Repair Swinging Drawbar—6150J, 6170J, 6190J, 6210J Tractors…1788
Repair Swinging Drawbar—6150J, 6170J, 6190J, 6210J Tractors…1788
Repair Drawbar with Ball Pin—6170J, 6190J, and 6210J Tractors…1790
Adjust Hammer Strap…1792
Section 90A: Open Operator's Station…1793
Group 05: Remove and Install Components…1793
Specifications…1856
Remove and Install Open Operator's Station…1796
Remove and Install Open Operator’s Station Console Cover…1804
Group 10: Open Operator's Station…1793
Specifications…1856
Remove and Install Open Operator’s Station Roof…1808
Section 90B: Cab…1810
Group 05: Remove and Install Components…1810
Special Tools…1845
Specifications…1856
Cab Mounts—Exploded View…1815
Swing Up Cab…1818
Swing Down Cab…1826
Remove and Install Cab…1830
Remove and Install Front Console Cover…1841
Group 10: Air-Conditioning System…1810
Special Tools…1845
Tightening Torque for Refrigerant Hoses…1846
Safety Regulations…1847
Handling Refrigerant…1848
Air Conditioning System – Safety at Work…1849
Storage of Refrigerant Containers…1851
Refrigerant R134a…1852
Air Conditioning System – Preventive Maintenance…1853
Important…1854
Other Material…1855
Specifications…1856
General information…1857
Air conditioning system – Instructions for starting up the DENSO air conditioning compressor…1858
Filling the Cylinder…1859
Charging Air Conditioning System (With Loading Cylinder)…1861
Charging Air Conditioning System (With Recovery/Recycling and Charging Station)…1863
Adding Oil to the Air Conditioning System…1864
Leak Test…1865
Evacuate Air Conditioning System…1866
Cleaning the Air Conditioning System…1868
Remove and Install Compressor…1869
Check Refrigerant Oil Level…1873
Disassemble and Assemble Magnetic Clutch of Air Conditioner Compressor…1874
Check Clutch Hub Clearance…1876
Remove and Install Condenser…1877
Replace Air Conditioner Receiver-Drier…1879
Replace Expansion Valve…1880
Remove and Install Evaporator and Expansion Valve…1881
Installing Condensation Water Drain Hoses…1883
Layout of Condensation Water Drain Hoses…1884
Vacuum Pump — General Information…1885
Group 15: Heating System…1811
Fan and Heater, Disassembling…1888
Replace Cab Air Filter…1890
Separating and Installing Fan…1892
Separating and Installing Heater Regulator…1893
Separating Heater/Evaporator Housing…1894
Group 20: Operator's Cab…1811
Removing Cab Frame…1897
Remove and Install Outer Roof…1898
Removing and Installing Windshield…1899
Remove and Install Rear Window…1900
Installing Door Lock…1902
Adjusting Window Contact Pressure…1904
Remove and Install Operator's Cab Door…1905
Removing and Installing Sun-Visor Roller…1907
Remove and Install Operator’s Seat…1908
Remove and Install Instructional Seat…1910
Section 99: Tools…1911
Group 05: Special Tools (Dealer-Fabricated)…1911
DFLX1 – Adapter Strut…1913
DFLX7 – Turning Device…1914
DFLX13 – Holding Device…1915
DFLX15 – Holding Device for Tractor Components…1916
DFLX29 – Support…1917
DFLX42 – Turning Device…1918
Lifting Device…1919
Suspension Device…1920
Suspension Eyes for Operator's Cab…1921
Holding Tool…1922
Wooden Block…1923
DFRW79 – Piston Retainer Tool…1924
Retainer Installer…1925
Retainer…1926
Socket Wrench Insert…1927
Seal Installer…1928
Assembling and Guide Drivers…1929
Special Wrench…1930
Bushing…1931
Quick Coupler Securing Support…1932
Lifting Tool…1933

John Deere Tractors 6100J, 6115J, 6125J, 6135J, 6150J, 6170J, 6190J, 6210J Repair Service Manual (TM808719)

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete Repair Service Technical Manual for John Deere 6M-1654, 6M-1854, 6M-2104 Tractors, with all the workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere 6M-1654, 6M-1854, 6M-2104 Tractors workshop technical manual (repair) 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.
* 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.

TM706419 – John Deere 6M-1654, 6M-1854, 6M-2104 Tractors Repair Technical Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,023 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

TM706414 Repair Technical Manual 6M-1654、6M-1854 和 6M-2104 拖拉机 维修手册
TM706419 Repair Technical Manual 6M-1654, 6M-1854, and 6M-2104 Tractors / (Repair Only) (Diagnostic manual with electrical wiring diagrams sold separately) (Asia, English)

TABLE OF CONTENTS
Section 05: Safety…21
Group 05: Safety Regulations…982
Recognize Safety Information…346
Understand Signal Words…25
Follow Safety Instructions…26
Prevent Machine Runaway…27
Operating the Tractor Safely…28
Use Safety Lights and Devices…30
Use Caution on Slopes, Uneven Terrain, and Rough Ground…31
Freeing a Mired Machine…32
Avoid Backover Accidents…33
Handle Fluids Safely—Avoid Fires…34
Handling Batteries Safely…35
Prepare for Emergencies…37
Avoid High-Pressure Fluids…38
Service Cooling System Safely…39
Remove Paint Before Welding or Heating…40
Avoid Heating Near Pressurized Fluid Lines…41
Work In Ventilated Area…42
Avoid Contact with Agricultural Chemicals…43
Handle Agricultural Chemicals Safely…44
Stay Clear of Rotating Drivelines…46
Wear Protective Clothing…48
Protect Against Noise…49
Practice Safe Maintenance…50
Avoid Hot Exhaust…51
Use Steps and Handholds Correctly…52
Use Seat Belt Properly…53
Park Machine Safely…54
Use Proper Lifting Equipment…55
Construct Dealer-Made Tools Safely…56
Support Machine Properly…57
Work in Clean Area…58
Illuminate Work Area Safely…59
Service Machines Safely…60
Service Accumulator Systems Safely…61
Service Tires Safely…62
Use Proper Tools…63
Service Front-Wheel Drive Tractor Safely…64
Avoid Eye Contact With Radar…65
Keep ROPS Installed Properly…66
Replace Safety Signs…67
Decommissioning — Proper Recycling and Disposal of Fluids and Components…68
Live With Safety…69
Safety Measures on Electronic Control Units…70
Servicing Electronic Control Units…71
Welding Near Electronic Control Units…72
Keep Electronic Control Unit Connectors Clean…73
Safety Instructions for Replacing a Halogen Bulb…74
Section 10: General Information…254
Group 05: Specifications…952
Engine…80
PTO…81
POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission…76
Clutch…83
Brakes…84
Hydraulic System…85
Wheel Configurations…86
Drawbar…87
Dimensions…88
Electrical System…91
Capacities…92
Diesel Fuel…93
Minimizing the Effect of Cold Weather on Diesel Engines…95
Biodiesel Fuel…97
Lubricity of Diesel Fuel…99
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III…100
Transmission and Hydraulic Oil…102
Front-Wheel Drive Axle Oil (Standard)…103
Diesel Engine Coolant (engine with wet sleeve cylinder liners)…105
Supplemental Coolant Additives…107
Multipurpose Extreme Pressure (EP) Grease…108
Oil Filters…109
Mixing of Lubricants…110
Lubricant Storage…111
Operating in Warm Temperature Climates…112
Alternative and Synthetic Lubricants…113
Metric Bolt and Screw Torque Values…114
Unified Inch Bolt and Screw Torque Values…116
Hydraulic system inch fitting torques…119
Hydraulic system metric fitting torques…120
Interpreting the Serial Number of Your Machine – 17 Digits PIN…121
Year of Production Table (Digit 5)…122
Transmission Type Table (Digit 6)…123
Identification Numbers…124
Product Identification Number…125
Engine Serial Number…126
Front-Wheel Drive Serial Number…127
Cab Serial Number…128
Group 10: Adjusting…77
Specifications…952
Using High-Pressure Washers…131
Preliminary Engine Test…132
Tractor Adjusting…133
Removing and Cleaning the Primary Air Cleaner Element…134
Checking the Air Cleaner Safety Element…135
Installing the Primary Filter Element…136
Checking Air Intake System Connections for Leaks…137
Checking Air Intake Hoses…138
Checking the Crankcase Vent Hose for Clogging…139
Cleaning Dirt from Radiator Screen…140
Adjust the Hood…141
Cleaning Radiator…143
Checking Expansion Tank Cap…144
Checking for Leaks in Radiator…145
Checking Engine Thermostat…146
Checking the Fuel Transfer Pump Operation…147
Cleaning Water Trap…148
Checking Fuel Filter…149
Bleed Fuel System…214
Check Transmission/Hydraulic System Oil Level…152
Cleaning Battery, Cables and Battery Box with a Clean Cloth…153
Checking Neutral Start Circuit…154
Checking Starter Motor…155
Checking Lighting Circuit…156
Final Engine Checks…157
Tractor Operation Check…158
Section 20: Engine…159
Group 00: Removing and Installing Engine…175
Special Tools…979
Specifications…952
Removing Engine…163
Installing Engine…175
Engine Mounting…182
Replace the Engine Mountings…184
Section 30: Fuel Systems, Air Intake, Cooling and Exhaust…188
Group 00: Removal and Installation of Components…188
Remove Engine Hood…192
Install Engine Hood…194
Remove Battery…196
Install Battery…197
Group 05: Speed Control…188
General Information…254
Specifications…952
Hand Throttle Lever and Accelerator Pedal Adjustment…201
Replace Accelerator Pedal Assembly…202
Remove Accelerator Pedal Potentiometer…203
Group 10: Fuel System…188
General Information…254
Removing the Fuel Tank…208
Installing the Fuel Tank…210
Replace Fuel Level Sensor…211
Replace the Fuel Transfer Pump…212
Changing the Fuel Filters…213
Bleed Fuel System…214
Group 15: Air Intake System…188
General Information…254
Air Filter – Exploded View…217
Replacing Air Filter Restriction Sensor…218
Group 20: Cooling System…188
General Information…254
Specifications…952
Removing Radiator…222
Installing Radiator…229
Replacing Fan…230
Remove and Install the Charge Air Cooler…231
Removing and Installing the Expansion Tank…233
Removing and Installing Thermostat…235
Fill Cooling System with Coolant…236
Releasing Drive Belt Tension…238
Replacing Engine Fan Belt…239
Replacing Drive Belt Tensioner…242
Remove and Install Fan Console…243
Group 30: Exhaust System…189
General Information…254
Specifications…952
Exhaust to Upper Right-Hand Side…247
Section 40: Electrical System…250
Group 05: Connectors…250
General Information…254
Fuse and Relay Boxes — Cab Tractors…255
Fuse and Relay Box — Open Station Tractors…258
Group 10: Wiring Harnesses…250
Disconnecting Electrical Circuits…343
Removing and Installing Wiring Harness W01 — Power Link Box…263
Removing and Installing Wiring Harness W02 — Engine Wiring Harness…264
Removing and Installing Wiring Harness W04 — Headlights…266
Removing and Installing Wiring Harness W08 — Cab Wiring Harness…267
Removing and Installing Wiring Harness W09 — Hood Harness…269
Removing and Installing Wiring Harness W19 — Cab Roof Harness…271
Removing and Installing Wiring Harness W26 — Fan and Air Conditioning…272
Removing and Installing Wiring Harness W28 — Front End of Transmission…273
Removing and Installing Wiring Harness W30 — Rear End of Transmission…275
Wiring Harness W31 — Power Take-Off for 7-Pin Socket…277
Wiring Harness W32 — Water in Fuel Sensor…278
Group 15: Charging Circuit…250
Special Tools…979
Specifications…952
Repairing the Alternator…282
Disconnecting Electrical Circuits…343
Relieve Drive Belt Tension…284
Removing/Installing Alternator…285
Removing/Installing Alternator Pulley…287
Group 20: Starter Motor Circuit…250
Specifications…952
Repairing the Starting Motor…291
Disconnecting Electrical Circuits…343
Removing and Installing Starter Motor…293
Group 25: Fuses, Relays and Switches…251
Note…329
Special Tools…979
Specifications…952
Removing Hood Covers…299
Disconnecting Electrical Circuits…343
Fuse and Relay Box…303
Fuses and relays (Power Link Box)…307
Power Link Box- Components…308
Replacing Starter Switch…309
Replacing Brake Switches…310
Replacing Light Switch…311
Replacing Full/Low Beam Switch…312
Replacing Work Light Switches…313
Replacing Hazard Warning Light Switch…314
Replacing Turn Signal Switch…315
Replacing Horn Switch…316
Replacing Windshield Wiper and Windshield Washer Switch…317
Replacing Front-Wheel Drive Switch…318
Replacing Fan Switch…319
Replacing Differential Lock Switch…320
Replacing Rockshaft Remote Control Switch…321
Group 30: Monitoring Systems…251
Note…329
Note…329
Disconnecting Electrical Circuits…343
Replacing Engine Oil Pressure Sensor Unit (B04)…326
Replacing Coolant Temperature Gauge Sensor Unit (B08)…327
Group 40: Electrical Components…251
Note…329
Special Tools…979
Specifications…952
Disconnecting Electrical Circuits…343
Replacing Socket of 7-Terminal Power Outlet…333
Replacing Service Socket…335
Removing Windshield Wiper Motor…337
Adjusting the Headlights…339
Section 45: Electronic Control Units…341
Group 05: Removal and Installation of Electronic Control Units…341
Disconnecting Electrical Circuits…343
Instructions when Replacing a VIN Control Unit…344
Instructions when Replacing a Control Unit…345
Safety Information…346
Replace BCU Control Unit…347
Replace ECU Control Unit…349
Group 10: Removal and Installation of Terminating Resistors…341
Terminating Resistors for the CAN Bus…352
Section 55: PowrQuad Transmission…354
Group 00: Removing and Installing PowrQuad Module…354
Special Tools…979
Special Tool (Own Fabrication)…361
Specifications…952
Removing PowrQuad Housing…363
Installing PowrQuad Housing…367
Removing Range Box…369
Installing Range Box…372
Final installation…374
Group 05: Transmission Selectors Control…354
Specifications…952
Reconditioning of Gear Shift, Park Brake and Forward/Reverse Mechanism…377
Reconditioning of Range Shift Mechanism…380
Adjust Gear-Shift and Range-Shift Cables…383
Adjusting Forward/Reverse Cable…385
Adjusting Cable and Stop Screw Park Brake…387
Adjusting Clutch Pedal…388
Group 10: PowrQuad Module…354
Special Tools…979
Other Material…989
Specifications…952
Transmission Components…397
Replacing Neutral Start Circuit (Mechanically Actuated PowrQuad Module)…398
Removing and Installing Oil Filter Base…399
Replacing Oil Filter…400
Removing and Installing Front Valve Housing…401
Removing and Installing Front Valve Housing Valves…404
Removing and Installing Transmission Front Cover…417
Removing and Installing Transmission Front Cover Valves…419
Removing Clutch Pedal Valve…424
Removing and Installing Shift Valve Housing…430
Removing and Installing Shift Valve Housing Valves…433
Removing Transmission Oil Pump…437
Servicing Transmission Oil Pump…438
Installing Transmission Oil Pump…444
Removing Planetary Drive Gears…445
Repairing Planetary Drive Gears…447
Installing Planetary Drive Gears…453
Removing B1 Brake Housing…458
Reconditioning B1 Brake…459
Installing B1 Brake Housing…461
Removing B2-B3 Brake Housing…462
Reconditioning B2 Brake…463
Reconditioning B3 Brake…465
Installing B2-B3 Brake Housing…468
Removing C4 Clutch…469
Reconditioning C4 Clutch…470
Installing C4 Clutch…481
Removing Reverse Brake…482
Servicing Reverse Brake…483
Installing Reverse Brake…486
Removing Forward Clutch with Planetary Drive (Forward/Reverse)…487
Servicing Forward Clutch with Planetary Drive (Forward/Reverse)…488
Installing Forward Clutch with Planetary Drive (Forward/Reverse)…502
Replacing Output Shaft…504
Group 20: Range Box…355
Special Tools…979
Other Material…989
Specifications…952
Cross-Sectional View—Input Drive Shaft…510
Remove Intermediate Shaft…511
Repair Intermediate Shaft…514
Remove Input Drive Shaft…516
Repair Input Drive Shaft…518
Install Input Drive Shaft…522
Adjust Input Drive Shaft End Play…524
Intermediate Shaft Installation and Cone Point Adjustment…526
Adjust Intermediate Shaft End Play…531
Remove, Repair, and Install Shift Cover…533
Repair Shifting Mechanism…535
Repair Park Lock…537
Adjust Range Shift…539
Replace Speed Sensor…540
Section 56: Drive Systems…542
Group 00: Removing and Installing Component…542
Special Tools…979
Special Tools (Dealer-Fabricated)…902
Specifications…952
Removing MFWD Clutch…554
Installing MFWD Clutch…557
Removing Differential Housing…558
Installing Differential Housing…566
Removing Final Drive…569
Installing Final Drive…574
Removing Rear PTO…577
Installing Rear PTO…580
Group 05: U-Jointed Shafts and Torsional Damper…542
Special Tools…979
Use of Special Tool KJD10426…584
Specifications…952
Removing MFWD Universal-Joint Drive Shaft…586
Repairing MFWD Universal-Joint Drive Shaft…587
Installing MFWD Universal-Joint Drive Shaft…591
Removing Engine Universal-Joint Drive Shaft…593
Removing Torsional Damper…594
Replacing Torsional Damper Bearings…595
Installing Torsional Damper…596
Installing Engine Universal-Joint Drive Shaft…598
Group 10: Front-Wheel Drive Clutch…83
Special Tools…979
Specifications…952
MFWD Clutch Repair Instructions…602
MFWD Clutch — Cross-Sectional View…603
Disassembling MFWD Clutch…605
Disassembling MFWD Clutch Assembly…607
MFWD Clutch Exploded View…609
Mounting MFWD Clutch Assembly…611
Mounting MFWD Clutch…615
Group 15: Rear Differential…543
Special Tools…979
Specifications…952
Rear Differential Repair Instructions…623
Removing Rear Differential…625
Rear Differential — Cross Sectional View…628
Disassembling Rear Differential…630
Rear Differential — Exploded View…634
Assembling Rear Differential…636
Adjust Rear Differential Preload…642
Adjust Rear Differential Backlash…644
Group 20: Hydraulic Pump Drive…543
Special Tools…979
Specifications…952
Removing and Disassembling Pump Drive Pinion…649
Removing and Disassembling Pump Drive Gear…652
Assembling and Installing Pump Drive Gear…654
Assembling and Installing Pump Drive Pinion…657
Checking and Adjusting Play of Pump Drive Pinion…660
Group 25: Final Drives…543
Special Tools…979
Specifications…952
Final Drive Repair Instructions…666
Checking Final Drive Shaft and Retainer…668
Final Drive Housing — Exploded View…669
Removing Planetary Carrier…671
Disassembling Planetary Carrier…673
Planetary Carrier — Exploded View…675
Assembling Planetary Carrier…676
Final Drive Housing — Cross Sectional View…678
Removing Final Drive Housing to Axle…679
Disassembling and Assembling Final Drive Housing…681
Disassembling and Assembling Axle…682
Installing Final Drive Housing to Axle…684
Installing Planetary Carrier…685
Measuring Rolling Drag…687
Final Assembly…692
Group 30: Rear PTO…81
Special Tools…979
Rear PTO – Specifications…952
Replacing Output Shaft Seal Ring…696
Rear PTO Clutch – Cross Sectional View…697
Rear PTO Clutch – Exploded View…699
Removing Rear PTO Clutch…700
Reconditioning Rear PTO Clutch…703
Reconditioning Rear PTO Brake…712
Installing Rear PTO Clutch…713
Rear PTO Drive Train – Cross Sectional View…716
Rear PTO Drive Train – Exploded View…717
Removing Rear PTO Drive Train…719
Reconditioning Output Shaft…722
Reconditioning Countershaft…727
Installing Rear PTO Drive Train…729
Adjust Taper Roller Bearing of Countershaft…730
Adjust Tapered Roller Bearing of Bearing Support…732
Reconditioning Rear PTO Solenoid Valve…735
Removing PTO Modulating Valve…737
Reconditioning PTO Modulating Valve…738
Installing PTO Modulating Valve…740
Replace B06 – Rear PTO Speed Sensor…741
Recondition the Oil Sight-Glass…742
Section 60: Steering and Brakes…745
Group 05: Hydrostatic Steering…745
Special Tools…979
Specifications…952
Preliminary Work…749
Disconnect/Connect Steering or Brake Hoses…750
Steering Valve – Removing…752
Steering Valve – Cross Sectional View…755
Adjusting Shock Valves…756
Steering – Exploded View…758
Steering Column – Exploded View…760
Installing Steering Valve…761
Group 15: Brake Valve…768
Special Tools…979
Specifications…952
Brake Valve Repair Instructions…767
Brake Valve…768
Group 20: Rear Wheel Brakes…84
Rear Brakes, Specifications…952
Rear Wheel Brakes – Exploded View…779
Removing Rear Brakes…780
Reconditioning Rear Brakes…782
Installing Rear Brakes…784
Replacing Retraction Pins on the Rear Wheel Brakes…786
Section 70: Hydraulic System…789
Group 05: Controls…789
Specifications…952
Selective Control Valves — Removing and Installing Actuating Elements…793
Selective Control Valves — Adjusting Bowden Cable…797
Group 10: Oil Filter, Charge Pump and Hydraulic Pump…789
Other Material…989
Specifications…952
Removing and Installing Hydraulic Oil Mesh Filter…801
Removing and Installing Hydraulic Oil Filter…804
Removing and Installing Charge Pump…806
Charge Pump – Checking the Lube Oil Valve…808
Hydraulic Oil Reservoir — Restrictor…809
Hydraulic Pump – Removing and Installing Pressure-and-Flow Controller…810
Hydraulic Pump – Reconditioning Pressure-and-Flow Controller…812
Removing and Installing Hydraulic Pump…814
Hydraulic Pump – Exploded View…817
Disassembling Hydraulic Pump…819
Assembling Hydraulic Pump…820
Group 15: Valves…789
Special Tools…979
Specifications…952
Hydraulic System Repair Instructions…830
Removing Priority 1 Control Block…832
Installing Priority 1 Control Block…833
Reconditioning Priority 1 Control Block…834
Removing Priority 3 Control Block…836
Installing Priority 3 Control Block…840
Recondition Priority 3 Control Block…844
Group 20: Hitch…789
Other Material…989
Specifications…952
Hitch Valve, Removing and Installing the Stepper Motor…849
Remove Hitch Valve…851
Recondition the Hitch Valve…853
Install the Hitch Valve…857
Rockshaft – Remove and Installing Position Sensor and Toothed Segment…860
Rockshaft – Removing and Installing Rockshaft…863
Rockshaft – Removing Rockshaft Cylinders…867
Rockshaft – Reconditioning Lift Cylinder…868
Rockshaft – Install Rockshaft Cylinders…871
Rockshaft – Removing and Installing Draft Load Potentiometer and Draft Link Support…872
Group 25: Selective Control Valves and Couplers…790
Specifications…952
Selective Control Valves (SCVs) and Couplers Repair Instructions…878
Remove the Selective Control Valves (SCVs)…880
Recondition the Selective Control Valves (M-SCVs 100)…882
Recondition the Selective Control Valves (M-SCVs 200)…886
Install the Selective Control Valves (SCVs)…889
Selective Control Valves (SCVs) – Reconditioning the Couplers…893
Section 80: Miscellaneous…895
Group 00: Removing and Installing Components…895
Special Tools…979
Special Tools (Dealer-Fabricated)…902
Specifications…952
Removing Main Chassis…904
Installing Main Chassis…909
Removing Front-Wheel Drive Axle…912
Installing Front-Wheel Drive Axle…915
Group 05: Main Chassis…895
Specifications…952
Reconditioning Main Chassis…919
Group 15: Wheels…895
Essential, Recommended and Fabricated Tools…921
Specifications…952
Service Heavy-Duty Wheel Clamps…923
Remove the Front and Rear Wheels…929
Recondition the Front and Rear Wheels…932
Install the Front and Rear Wheels…934
Group 20: Center Link Bracket and Swinging Drawbar…942
Specifications…952
Check Swinging Drawbar Wear…940
Installing Center Link Bracket…941
Swinging Drawbar…942
Adjust Hammer Strap…944
Section 90: Operator's Cab…945
Group 00: Removing and Installing Components…945
Special Tools…979
Dealer-Manufactured Special Tools…979
Specifications…952
Swinging up Operator's Cab…953
Swinging down Operator's Cab…962
Removing Operator's Cab…964
Installing Operator's Cab…972
Checking and Adjusting Gear Shift Units…976
Group 15: Air Conditioning System…945
Special Tools…979
Tightening Torque for Refrigerant Hoses…981
Safety Regulations…982
Handling Refrigerant…983
In the Event of an Emergency…984
Safety Equipment…985
Storage of Refrigerant Containers…986
Refrigerant R134a…987
Important…988
Other Material…989
Specification…990
Filling the Cylinder…991
Charging Air Conditioning System (With Loading Cylinder)…993
Charging Air Conditioning System (With Recovery/Recycling and Charging Station)…995
Adding Oil to the Air Conditioning System…996
Leak Test…998
Evacuate Air Conditioning System…999
Cleaning the Air Conditioning System…1001
Separating Compressor…1002
Checking Compressor Level…1003
Disassembling Compressor Clutch…1004
Checking Clutch Hub Separation…1007
Installing Compressor…1008
Separating and Installing Condenser…1009
Separating and Installing Drier…1010
Replacing Expansion Valve…1011
Separating and Installing Evaporator and Expansion Valve…1012
Installing Condensation Water Drain Hoses…1014
Layout of Condensation Water Drain Hoses…1015
Separating and Installing Thermostat…1016
Separating and Installing High/Low Pressure Switch…1017
Vacuum Pump — General Information…1018
Group 20: Heating System…946
Fan and Heater, Disassembling…1021
Removing Cab Air Filter…1023
Separating and Installing Fan…1025
Separating and Installing Heater Regulator…1026
Separating Heater/Evaporator Housing…1027
Group 25: Operator's Cab…946
Removing Cab Frame…1030
Cab Mounting Torques…1031
Removing and Installing Windshield…1033
Removing and Installing Rear Window…1034
Installing Door Lock…1036
Adjusting Window Contact Pressure…1038
Removing and Installing Operator's Cab Door…1039
Removing and Installing Sun-Visor Roller…1041
Section 99: Special Tools (Dealer-Fabricated)…1042
Group 05: Special Tools (Dealer-Fabricated)…902
DFLX1 – Adapter Strut…1044
DFLX6 – Bushing…1045
DFLX7 – Turning Device…1060
DFLX14 – Suspended MFWD Axle Housing Bracket…1047
DFLX29 – Support…1048
DFRW29 – Final Drive Adapter…1049
Lifting Device…1050
Holding Device…1051
Suspension Eyes for Operator's Cab…1052
Holding Tool…1053
Wooden Block…1054
DFRW79 – Piston Holding Tool…1055
Socket Wrench Insert…1062
Seal Installer…1061
Driver…1058
Assembly and Guide Mandrels…1059
Turning Device…1060
Seal Installer…1061
Socket Wrench Insert…1062
Special Wrench…1063
Quick Coupler Securing Support…1064
Lifting Tool…1065

John Deere 6M-1654, 6M-1854, 6M-2104 Tractors Repair Service Manual (TM706414)

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere 6M-1654, 6M-1854, and 6M-2104 Tractors, with workshop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 6M-1654, 6M-1854, and 6M-2104 Tractors workshop Diagnosis & Tests technical 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.

TM706319 – John Deere 6M-1654, 6M-1854, and 6M-2104 Tractors Diagnostics and Test Technical Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,543 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

TM706314 Diagnostic Technical Manual 6M-1654、6M-1854 和 6M-2104 拖拉机 诊断和检测
TM706319 Diagnostic Technical Manual 6M-1654, 6M-1854, and 6M-2104 Tractors / (Diagnostics) (Includes electrical wiring diagrams) (Repair manual sold separately) (Asia, English)

TABLE OF CONTENTS
Section 210: General Information…32
Group 05: Safety Information…1385
Recognize Safety Information…1385
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 – Wheel Speed Sensor, 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…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…421
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…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…624
Air Intake System – Theory of Operation…625
Group 20C: Cooling System…591
Cooling System – Summary of References…627
Coolant Circuit – Description…628
Cooling System Radiator – Description…630
Itercooler – Description…631
Ring-Shaped (Transmission Oil) Cooler – Description…632
Automatic Drive Belt Tensioner – Theory of Operation…634
Group 20D: Cold-Weather Starting Aids…591
Cold-Weather Starting Aids – Summary of References…636
Cold-Weather Starting Aids – General Information…637
Cold-Weather Starting Aids – Coolant Heater – Component Information…638
Cold-Weather Starting Aids – Transmission Oil Heater – Component Information…639
Cold-Weather Starting Aids – Charge Pump Preheater – Component Information…640
Section 240: Electrical System…641
Group 05A: Fuse Box…641
Fuse Box – Theory of Operation…651
Fuse Box – Electrical Diagram…652
Group 05B: Starting and Charging Circuit…641
Starting and Charging Circuit – Theory of Operation…655
Starting and Charging Circuit – Electrical Diagram…656
Circuit test for Starter motor checks (M01)…657
Circuit test for Alternator (G02)…660
Circuit test for Battery (G01)…665
Circuit test for K01 Starter relay…668
Group 05C: CAN BUS and Service Connector…641
CAN BUS System – Theory of Operation…670
CAN BUS System – Electrical Diagram…671
Group 05D: ECU – Power…641
ECU Power – Theory of Operation…673
ECU Power – Electrical Diagram…674
Group 05E: ECU – Throttle and Fuel System…641
ECU Throttle and Fuel System – Theory of Operation…676
ECU Throttle and Fuel System – Electrical Diagram…677
Circuit test for Foot throttle (B79)…678
Circuit test for Electrical hand throttle (B96)…681
Group 05F: ECU – Fuel Preheater and Aid Heater…641
ECU Fuel Preheater and Aid Heater – Theory of Operation…685
ECU Fuel Preheater and Aid Heater – Electrical Diagram…686
Circuit test for Fuel Pump (M31)…688
Circuit test for Heating Element of Fuel Preheater (R02)…690
Circuit test for Sender for Electrical starting aid heater (R15)…692
Group 05G: ECU – Sensors…641
ECU Sensors – Theory of Operation…695
ECU Sensors – Electrical Diagram…696
Circuit test for Engine Speed Sender (B72)…698
Group 05H: BCU – Electronic Hitch-Control…642
BCU – Electronic Hitch-Control – Theory of Operation…702
BCU – Electronic Hitch-Control – Electrical Diagram…703
Circuit test for Rockshaft Control Stepper Motor (M08)…704
Circuit test for Sensitivity Potentiometer (B26)…706
Circuit test for Depth-setting Potentiometer (R08)…709
Circuit test for Rate-of-Drop Potentiometer (R06)…712
Circuit test for Raise-Limit Potentiometer (R07)…715
Circuit test for Position Sensor (B21)…718
Circuit test for Draft Sensor (B41)…722
Circuit/harness test for Rapid Raise Switch (S24)…725
Circuit test for Left Remote Control Switch (S68)…728
Circuit test for Supply Voltage for 5-Volt BCU Components…731
Group 05I: BCU – Brakes…642
BCU – Brakes – Theory of Operation…735
BCU – Brakes – Electrical Diagram…736
Circuit test for Brake Pedal Sensor Unit (B88)…738
Group 05J: BCU – PTO…642
BCU – PTO – Theory of Operation…740
BCU – PTO – Electrical Diagram…741
Circuit test for PTO Switch (S21)…743
Circuit test for PTO Solenoid Valve (Y04)…746
Circuit test for Rear PTO Speed Sensor (B06)…749
Group 05K: BCU – Front-Wheel Drive…642
BCU – Front-Wheel Drive – Theory of Operation…753
BCU – Front-Wheel Drive – Electrical Diagram…754
Circuit test for Front-Wheel Drive Switch (S63)…756
Circuit test for Front-Wheel Drive Solenoid Valve (Y03)…759
Group 05L: BCU – Differential Lock…642
BCU – Differential Lock – Theory of Operation…763
BCU – Differential Lock – Electrical Diagram…764
Circuit test for Differential Lock Switch (S22)…766
Circuit test for Differential Lock Solenoid Valve (Y05)…769
Group 05M: BCU – Wheel Speed Sensor…643
BCU Wheel Speed Sensor – Theory of Operation…773
BCU Wheel Speed Sensor – Electrical Diagram…774
Circuit test for Wheel Speed Sensor (B09)…775
Group 05N: BCU – Turn Signal and Hazard Warning Lights…643
BCU – Turn Signal and Hazard Warning Lights – Theory of Operation…779
BCU – Turn Signal and Hazard Warning Lights – Electrical Diagram…780
Circuit test for hazard warning switch (S106)…782
Circuit test for Turn Signal Switch (S08)…786
Group 05O: Panel Warning Lights…643
Panel Warning Lights – Theory of Operation…791
Panel Warning Lights – Electrical Diagram…792
Circuit test for Sender for air cleaner restriction warning light (B02)…794
Circuit test for Fuel gauge sender (B03)…795
Circuit test for Engine oil pressure sender (B04)…796
Circuit test for Sender for the transmission oil filter sender (B07)…797
Circuit test for Coolant temperature sender (B08)…798
Circuit test for Transmission oil pressure sender (B31)…799
Circuit test for Transmission oil temperature sender (B29)…800
Group 05P: Lights, Tail Lights and License Plate…643
Lights and Tail Lights – Theory of Operation…802
Lights and Tail Lights – Electrical Diagram…803
Lighting Circuits…805
Group 05Q: Work Lights…643
Work Lights – Theory of Operation…810
Work Lights – Electrical Diagram…811
Work lights…812
Group 05R: Radio, Dome Light, Console Light and Beacon Light…643
Radio, Dome Light, Console Light and Beacon Light – Theory of Operation…815
Radio, Dome Light, Console Light and Beacon Light – Electrical Diagram…816
Circuit test for Radio (A60 – Radio Circuits)…817
Circuit test forDome Light (A08)…818
Circuit test for Beacon light (E27)…820
Group 05S: Horn and Accessories Socket…644
Horn and Accessories Socket – Theory of Operation…822
Horn and Accessories Socket – Electrical Diagram…823
Circuit test for Horn (H01)…824
Group 05T: Power Outlet…644
Power Outlet – Theory of Operation…827
Power Outlet – Electrical Diagram…828
Group 05U: Seat Compressor and Cigarette Lighter…644
Seat Compressor and Cigarette Lighter – Theory of Operation…830
Seat Compressor and Cigarette Lighter – Electrical Diagram…831
Seat and Cigarette lighter System…832
Group 05V: Fan and A/C…644
Fan and A/C – Theory of Operation…835
Fan and A/C – Electrical Diagram…836
Fan, Air Conditioning and Automatic A/C control…838
Group 05W: Front Windshield Wiper and Washer…644
Front Windshield Wiper and Washer – Theory of Operation…844
Front Windshield Wiper and Washer – Electrical Diagram…845
Front Windshield Wiper and Washer System…846
Group 05X: Rear Windshield Wiper and Washer…644
Rear Windshield Wiper and Washer – Theory of Operation…849
Rear Windshield Wiper and Washer – Electrical Diagram…850
Rear Windshield Wiper and Washer System…852
Group 05Y: Trailer Connector…644
Trailer Connector – Theory of Operation…855
Trailer Connector – Electrical Diagram…856
Group 10: Wiring Harnesses…644
Disconnecting Electrical Circuits…858
Location of Ground Points…859
Removing and Installing Wiring Harness W01 — Power link Box…861
Removing and Installing Wiring Harness W02 — Engine Wiring Harness…862
Removing and Installing Wiring Harness W04 — Headlights…864
Removing and Installing Wiring Harness W08 — Cab Wiring Harness…865
Removing and Installing Wiring Harness W09 — Hood…867
Removing and Installing Wiring Harness W19 — Cab Roof…869
Removing and Installing Wiring Harness W26 — Fan and Air Conditioning…870
Removing and Installing Wiring Harness W28 — Front End of Transmission…871
Removing and Installing Wiring Harness W30 — Rear End of Transmission…873
Wiring Harness W31 — Power Take-Off for 7-Pin Socket…875
Wiring Harness W32 — Sensor Wiring Harness…876
Group 15: Connectors…645
Connectors – Summary of References…879
A01 – Fuse and relay box…881
A02 – Fuse Box 2…884
A03 – Fuse Box 3…885
A04 – Fuse Box 4…886
A05 – Fuse Box 5…887
A06 – Power Link Box…888
A08 – Dome Light…889
A29 – Pneumatic operator's seat and rear wiper…890
A60 – Radio…891
A62 – Bus terminator…892
A84 – Bus terminator engine…893
B02 – Sender for air cleaner restriction warning light…894
B03 – Fuel gauge sensor unit…895
B04 – Sender for engine oil pressure indicator light…896
B06 – Rear PTO Speed Sensor…897
B07 – Transmission oil filter pressure sensor…898
B08 – Coolant temperature sensor…899
B09 – Wheel Speed Sensor…900
B14 – Compressor and thermostat switch…901
B15 – Air conditioning system pressure switch…902
B21 – Hitch-control position sensor…903
B26 – Sensitivity potentiometer…904
B27 – Feedback unit…905
B29 – Transmission oil temperature sensor…906
B30 – Hydrostatic oil temperature sensor…907
B31 – Transmission oil pressure sender…908
B36 – Neutral start switch…909
B37 – Interface handbrake…910
B41 – Draft potentiometer…911
B56 – Water temperature engine sensor…912
B59 – Manifold air temperature sensor…913
B72 – Crankshaft speed sensor…914
B74 – Event sensor…915
B79 – Foot throttle…916
B88 – Brake switch…917
B96 – Electrical hand throttle…918
B114 – Fuel temperature sensor…919
B121 – Water in fuel sensor…920
B137 – Fuel rail pressure sensor…922
E01 – Right-hand front light…923
E02 – Left-hand front light…924
E05 – Cigarette lighter…925
E09-R – Right-hand front working light…928
E09-L – Left-hand front working light…929
E11-1 – Right-hand rear working light…930
E11-2 – Left-hand rear working light…931
E12-2 – Console light…932
E27 – Beacon light…933
G01 – Battery…934
G02 – Alternator…935
H01 – Horn…936
H77 – Aid heater indicator light…937
K01 – Starter relay…938
M01 – Starter motor…939
M02 – Air conditioning compressor…940
M03 – Wiper motor…941
M04 – Wiper motor…942
M05 – Windshield washer pump…943
M06 – Windshield washer pump…944
M07 – Fan motor…945
M08 – Hitch-control stepper motor…946
M10 – Fan motor…947
M31 – Fuel pump…948
R02 – Fuel preheater…949
R03 – Resistors…950
R15 – Electrical starting aid heater…951
S01 – Starter switch…952
S04 – Horn switch…953
S08 – Turn signal switch…954
S09 – Light switch…955
S10 – Full/low beam light switch…956
S14 – Fan switch…957
S15 – Windshield wiper switch…958
S18 – Rear wiper switch…959
S20 – Windshield switch…960
S21 – Rear PTO switch…961
S22 – Differential lock switch…962
S36 – Beacon light switch…963
S63 – Front-wheel drive switch…964
S68 – External hitch-control switch…965
S92-2 – Rear work lights switch…966
S106 – Hazard warning lights switch…967
W25 – Radio antenna…968
X05 – Trailer connector…969
X25 – Instrument right panel connector…970
X26 – Instrument left panel connector…972
X37 – Accessories socket…974
X40 – Connector (W22 and W23)…975
X42 – Connector (W21 and W22)…976
X106 – Tail, brake and turn signal lights (right-hand)…977
X107 – Tail, brake and turn signal lights (left-hand)…978
X108 – Front right- hand turn signal light…979
X109 – Front left-hand turn signal light…980
X113 – License Light Connector…981
X182 – Connector (W08 and W26)…982
X234 – Connector (W30 and W31)…984
X239 – Outlet Socket Connector…985
X305 – Cooler grounding…986
X400 – Connector (W08 and W19)…987
X411 – Connector (W02 and W04)…990
X430 – Connector (W08 and W30)…992
X431 – Connector (W08 and W28)…995
X450 – Connector (W02 and W08)…998
X473 – Connector (W01 and W08)…1001
X504 – Connector (W08 and W09)…1003
X505 – Connector (W08 and W09)…1006
X547 – Connector (W01 and W02)…1008
X571 – Service connector (CAN Bus)…1009
X612 – Speaker connector…1010
X616-1 Basic control unit (BCU)…1011
X616-2 Basic control unit (BCU)…1013
X616-3 Basic control unit (BCU)…1016
X844-1 — Engine control unit (ECU)…1018
X844-2 — Engine control unit (ECU)…1020
XGND1 – Cab ground wire…1022
XGND2 – Cab ground wire…1023
XGND5 – Cab ground wire…1024
XGND6 – Rear Wiper Ground Wire…1025
XGND9 – Engine grounding…1027
XGND10 – Cab roof ground wire…1028
XGND14 – Cab roof ground wire…1029
XGND58 – Fan and A/C wiring harness grounding…1030
Y03 – Front-wheel drive solenoid valve…1031
Y04 – PTO Solenoid…1032
Y05 – Differential lock solenoid valve…1033
Y44 – Suction control valve…1034
Y47 – Injection valve…1035
Section 245: Electronic Control Units…1036
Group 05: Operation and General Information on Diagnostics…1036
Operation and General Information – Summary of References…1042
Eletronic Control Units – Special Tools…1043
Operation and General Information on Diagnostics – Abbreviations for Control Units…1044
Operation and General Information on Diagnostics – Instrument Unit Adjustment…1045
Operation and General Information on Diagnostics – Operation and Entering the Program Mode using the Performance Monitor…1051
Operation and General Information on Diagnostics – Procedure for Dealing with Diagnostic Trouble Codes…1058
Operation and General Information on Diagnostics – Accessing Addresses and Diagnostic Trouble Codes…1062
Operation and General Information on Diagnostics – Approved Software for Control Units…1073
Operation and General Information on Diagnostics – Locations and Allocations of Control Units…1074
Group 10A: Interactive Tests…1036
Interactive Tests – Summary of References…1076
Procedure in the Event of Problems with Interactive Tests…1077
BCU: Recording in Debug Mode…1078
BCU: Control Unit Information and Input Addresses – Summary…1079
BCU: BCU Test…1080
ECU: Cylinder Misfire Test…1081
ECU: Compression Test…1082
ECU: Cylinder Cut-Out Test…1083
ECU: Harness diagnostic mode test…1084
ECU: Internal Data Monitor (IDM)…1085
ECU: Communication Error Test…1086
ECU: Control Unit Information and Summary…1087
ECU: Engine Speed Change Test…1088
Group 10B: Interactive Calibrations…1036
Interactive Calibrations – Summary of References…1090
Procedure in the Event of Problems with Interactive Calibration…1091
BCU: Calibrate the Hitch Control…1092
ECU: Calibrate the Electronic Fuel Injectors (Move Injectors to Different Positions or Replace Injectors, and Display Progress of Calibration)…1096
Group 15: Information on How to Reprogram Control Units…1037
Information on How to Program Control Units – Summary of References…1098
General Information on How to Reprogram Control Units…1099
Check and Download Tractor-Specific Software Information…1100
Procedure When Replacing Control Units…1101
Important Notes on Programming…1102
Procedure When Programming Control Units…1103
Procedure in the Event of a Problem Programming Control Units Protected by VIN…1104
Procedure in the Event of a Programming Problem…1107
Group 20: Data BUS Systems, Operation…1037
Data BUS systems – Summary of References…1110
Data BUS Systems – CAN BUS Systems…1111
Data BUS Systems – CAN BUS Systems on Engines with Level 16 Control Unit (2-Valve HPCR Fuel System)…1113
Data BUS systems – Plug Layout…1114
Data BUS systems – Determining the Type of the CAN BUS Fault…1115
Group BCU: BCU – Basic Control Unit…1037
BCU – Summary of References…1118
BCU – Summary of Addresses…1119
BCU – Calibration and Input Addresses…1126
BCU – Summary of Operational Checks…1128
BCU – Theory of Operation (Basic Functions)…1129
BCU – Theory of Operation (Hitch Control)…1131
BCU – CAN BUS Information…1133
Address BCU020 – Input Address, Engine Speed Sensor/Pulses per Engine Revolution…1134
Address BCU021 – Input Address, Rear PTO Speed Sensor/Pulses per PTO Revolution…1135
Address BCU022 – Input Address, Front-Wheel Drive Control Function…1136
Address BCU023 – Vacant Input Address…1137
Address BCU024 – Input Address, Settings for Units of Measurement in Display and for Acoustic Indicator for Turn Signal…1138
Address BCU026 – Vacant Input Address…1139
Address BCU027 – Vacant Input Address…1140
Address BCU028 – Input Address, Rear PTO Present/Not Present…1141
Address BCU029 – Vacant Input Address…1142
Address BCU030 – Input Address, Sensor Diagnostics…1143
Address BCU031 – Vacant Input Address…1144
Address BCU034 – Input Address, Configuration of Instrument Unit and Self-Canceling Turn Signals…1145
Address BCU035 – Input Address, Service Interval Setting…1146
Address BCU041 – Vacant Input Address…1147
Address BCU042 – Vacant Input Address…1148
Address BCU043 – Vacant Input Address…1149
Address BCU045 – Vacant Input Address…1150
Address BCU046 – Input Address, Activate/De-activate Delayed Activation of Alternator…1151
Address BCU047 – Input Address, Delayed Activation of Alternator, Configuration…1152
Address BCU048 – Vacant Input Address…1153
Address BCU049 – Vacant Input Address…1154
Address BCU050 – Vacant Input Address…1155
Address BCU051 – Vacant Input Address…1156
Address BCU052 – Vacant Input Address…1157
Address BCU055 – Input Address, Configuration of Acoustic Alarm…1158
Address BCU056 – Input Address, Tire Configuration…1159
Address BCU058 – Input Address, Sensor for Wheel Speed / Transmission Pulses per Axle Revolution…1160
Address BCU060 – Vacant Input Address…1161
Address BCU063 – Vacant Input Address…1162
Address BCU065 – Vacant Input Address…1163
Address BCU071 – Vacant Input Address…1164
Address BCU073 – Vacant Input Address…1165
Address BCU074 – Vacant Input Address…1166
Address BCU075 – Vacant Input Address…1167
Address BCU077 – Vacant Input Address…1168
Address BCU078 – Vacant Input Address…1169
Address BCU088 – Vacant Input Address…1170
Address BCU089 – Vacant Input Address…1171
Address BCU090 – Vacant Input Address…1172
Address BCU091 – Vacant Input Address…1173
Address BCU092 – Vacant Input Address…1174
Address BCU093 – Vacant Input Address…1175
Address BCU094 – Vacant Input Address…1176
Address BCU097 – Input Address, Low Fuel Level Acoustic Alarm…1177
Address BCU099 – Input Address, Automatic Deletion of Diagnostic Trouble Codes…1178
Address BCU101 – Input Address, Leak-Off Function of Hitch Valve On or Off…1179
Address BCU118 – Input Address, Quick Withdrawal and Hitch Dampening On or Off…1180
Address BCU122 – Hitch Control Calibration…1181
Address BCU138 – Input Address, Leak-off Function of Hitch Valve (Adjusting Stepper Motor Steps)…1189
Address BCU145 – Input Address, Hitch Control On or Off…1190
Address BCU154 – Input Address, Leak-off Function of Hitch Valve (Time Setting)…1191
Address BCU162 – Input Address, Switching Off Hydraulic Oil Temperature Access (During Calibration)…1192
Address BCU165 – Input Address, Raise Rate Setting…1193
Address BCU167 – Input Address, Activate/De-activate Hitch Components…1194
Address BCU174 – Input Address, Index for Load Control…1195
Address BCU247 – Tractor Model Designation…1196
Address BCU248 – Tractor Serial Number…1197
B06 – Rear PTO Speed Sensor, Operational Check…1198
B09 – Wheel Speed Sensor, Operational Check…1199
B21 – Hitch Position Sensor, Operational Check…1200
B26 – Sensitivity Potentiometer, Operational Check…1201
B27 – Position Feedback Unit for Hitch Control, Operational Check…1202
B41 – Draft Sensor, Operational Check…1204
B88 – Brake Pedal Sensor Unit, Operational Check…1205
M08 – Stepper Motor for Hitch, Operational Check…1206
S08 – Turn Signal Switch, Operational Check…1207
S21 – Rear PTO Switch, Operational Check…1208
S22 – Differential Lock Switch, Operational Check…1209
S24 – Quick Withdrawal Switch, Operational Check…1210
S63 – Front-Wheel Drive Switch, Operational Check…1211
S68 – Switch for Hitch Remote Control (Left), Operational Check…1212
S106 – Hazard Warning Light Switch, Operational Check…1214
Supply Voltage for 5-volt BCU Components, Operational Check…1215
Group ECU: ECU Control Unit…1040
ECU – Summary of References…1217
ECU – Summary of Addresses (Level 16 ECU for 2-Valve Engine with HPCR)…1218
ECU – Calibration and Input Addresses (Level 16 ECU for 2-Valve Engine with HPCR)…1221
ECU – Theory of Operation (Level 16 ECU for 2-Valve Engine with HPCR)…1223
ECU – Summary of Operational Checks…1226
B02 – Air Cleaner Restriction Sensor, Operational Check…1227
B79 – Accelerator Pedal Potentiometer, Operational Check…1228
B96 – Hand Throttle Potentiometer, Operational Check…1230
R15 – Heating Element of Electrical Starting Aid (2-Valve Engine with HPCR), Operational Check…1232
Section 255: PowrQuad Transmissions…1234
Group 10: Operational Check…1234
PowrQuad Transmission—Operational Check…1243
Group 15: Tests and Adjustments…1234
PowrQuad Transmission—Summary of References…1251
PowrQuad Transmission— Special Tools…1252
PowrQuad Transmission—System Check…1253
PowrQuad Transmission—Test Ports…1261
PowrQuad Transmission—Checking Rate of Flow at Cooler…1263
PowrQuad Transmission—Checking the Cooler Relief Valve…1266
PowrQuad Transmission—System Pressure Check…1269
PowrQuad Transmission—Checking Lube Oil Pressure…1270
PowrQuad Transmission—Checking Cooling Oil Pressure (Forward Clutch)…1272
PowrQuad Transmission—Checking Cooling Oil Pressure (Reverse Brake)…1273
PowrQuad Transmission—Checking Pressure at Forward Clutch…1274
PowrQuad Transmission—Checking Pressure at Reverse Brake…1275
PowrQuad Transmission—Checking Pressure at Brake B1…1276
PowrQuad Transmission—Checking Pressure at Brake B2…1277
PowrQuad Transmission—Checking Pressure at Brake B3…1278
PowrQuad Transmission—Checking Pressure at Clutch C4…1279
PowrQuad Transmission—Adjusting System Pressure…1281
PowrQuad Transmission—Test Result Table…1283
PowrQuad Transmission—Adjusting Gear Shift…1286
PowrQuad Transmission—Adjusting Forward/Reverse Cable…1288
PowrQuad Transmission—Adjusting Park Lock…1290
Group 20: Operation…1234
PowrQuad Transmission — Summary of References…1292
PowrQuad Transmission—Layout…1293
PowrQuad Module—Layout…1294
PowrQuad Module—Cross-Sectional and 3D View…1296
PowrQuad Module—Location of Valves, Sensors and Switches…1298
PowrQuad Module—Element Engagement Chart…1301
PowrQuad Module—Pneumatic Pump…1302
PowrQuad Module—Transmission Oil Pump…1305
PowrQuad Module — Pressure-Regulating Valve and Filter Relief Valve…1307
PowrQuad Module—Overspeed Relief Valve and Anti-Cavitation Check Valve…1312
PowrQuad Module—Clutch Cooling Components…1314
PowrQuad Module —Clutch Cooling Valve (Forward/Reverse)…1315
PowrQuad Module—System 1 Oil and System 2 Oil…1316
PowrQuad Module—Hydraulic Schematic, Mechanically Actuated PowrQuad Module…1317
PowrQuad Module—Operation of Forward/Reverse Modulation, Mechanically Actuated PowrQuad Module…1319
PowrQuad Module—Neutral Start Circuit, Mechanically Actuated PowrQuad Module…1322
PowrQuad Module—Operation of Gear-to-Gear Modulation, Mechanically Actuated PowrQuad Module…1323
Group 30: Range Box…1235
Range Transmission — Cross-Sectional View…1328
Section 256: Drive Systems…1330
Group 10: Operational Check…1330
Power train – operational check…1334
Group 15: Tests and Adjustments…1330
Tests and Adjustments—Summary of References…1338
Tests and Adjustments—Special Tools…1339
Drive Systems—System Check…1340
Checking Pressure at the Front-Wheel Drive Clutch…1344
Checking Pressure at the Hydraulic Differential Lock…1345
Checking Pressure at the PTO…1346
Drive Systems—Test Result Table…1349
Group 20: Operation…1330
Drive Systems—Summary of References…1351
Front Wheel Drive Clutch—Cross-Sectional View…1352
Front Wheel Drive Clutch—Oil Flow and Power Flow…1354
Front Wheel Drive Clutch Disengaged—Oil Flow…1356
Differential—Cross-Sectional View…1358
Differential—Power Flows…1360
Differential—Oil Flows…1362
Final Drives—Operation and Cross-Sectional View…1365
PTO Options—Description…1366
PTO Options—PTO Modulating Valve and Solenoid Valve…1368
PTO Options—PTO brake and PTO clutch…1370
PTO Options—Power Flows…1372
Section 260: Steering and Brakes…1374
Group 05: Preliminary Checks…1374
Preliminary Checks—Summary of References…1377
Preliminary Checks – Steering System…1378
Preliminary Checks – Brake System…1382
Group 10: Operational Check…1374
Operational Checkout—Summary of References…1384
Safety Information…1385
Steering Check…1386
Checking Brakes…1387
Group 15: Tests and Adjustments…1374
Tests Tests Tests & Adjustments—Summary of References{pgNO}1374 Adjustments—Summary of References{pgNO}1389 Adjustments—Summary of References…1388
Steering and Brakes – Special Tools…1390
Steering and Brakes – Specifications…1392
Checking Steering Valve…1393
Checking Brake System…1396
Bleeding the Rear Brakes…1397
Adjusting Brake Pedals and Switches…1398
Group 20A: Hydrostatic Steering…1374
Description of Steering Valves, Operation…1406
Group 20B: Brakes…1374
Brakes—Summary of Reference…1414
Operation of Brake Piston, Plate and Disks…1415
Brake released…1417
Initial Braking…1419
Brake Engaged…1421
Rear Wheel Brakes, Operation…1423
Group 20C: Air brake system…1374
Steering and Brakes – Air Brakes, Summary of References…1425
Steering and Brakes – Air Brakes, Description…1426
Steering and Brakes – Air Brakes, Compressor…1428
Steering and Brakes – Air Brakes, Pressure Regulating Valve…1429
Steering and Brakes – Air Brakes, Compressed Air Tank…1430
Steering and Brakes – Air Brakes, Trailer Control Valve…1431
Steering and Brakes – Air Brakes, Coupling Ends…1432
Section 270: Hydraulic System…1433
Group 10: Operational Check…1433
Hydraulic System – Operational Check—Summary of References…1436
General Information – Transmission and Hydraulic System, Introductory Checks…1437
Hydraulic System – Load Check…1441
Hitch Control – Operational Check…1442
Hydraulic System – External Control of Hitch, Operational Check-Out…1444
Hydraulic System – Selective Control Valves (M-SCV), Operational Check-Out…1445
Group 15: Tests and Adjustments…1433
Tests and Adjustments – Summary of References…1449
Hydraulic System – Special Tools…1450
Hydraulic System – Safety Measures for Hydraulic Checks…1452
Warming Hydraulic System Oil…1454
PFC Hydraulic System – Worksheet for the Hydraulic System Diagnostics…1455
PFC Hydraulic System – Oil Pressure Test Ports…1458
PFC Hydraulic System – Checking and Adjusting the Maximum Load Sense Pressure…1459
PFC Hydraulic System – Check and Adjust System Oil Pressure…1461
PFC Hydraulic System – Check and Adjust Differential Pressure…1463
PFC Hydraulic System – Priority Circuit 1, Checking and Adjusting the Load Sense Oil Pressure for Steering…1465
PFC Hydraulic System – Priority Circuit 3, Checking the Oil Pressure…1467
PFC Hydraulic System – Hydraulic Pump, Checking the Delivery Rate…1469
PFC Hydraulic System – Check the Charge and Lube Oil Pressure…1471
Hydraulic System – Checking the Hitch Valve and the Stepper Motor…1472
Hydraulic System – Hitch Valve, Centering the Stepper Motor…1474
Hydraulic System – Hitch Valve, Rough Adjustment of the Raise and Lower Valves…1475
Hydraulic System – Hitch Valve, Checking the Position Sensor…1477
Hydraulic System – Hitch Valve, Checking and Adjusting the Draft Load Potentiometer…1478
Group 20: Theory of operation…1433
Hydraulic System Theory of Operation—Summary of References…1481
Hydraulic System – Summary of Abbreviations…1482
PFC Hydraulic System – Summary of Components…1483
PFC Hydraulic System — Symbolic Representation…1485
Group 20A: Oil Filter, Charge Pump and Hydraulic Pump…1434
Oil Filter, Charge Pump and Hydraulic Pump―Summary of References…1487
PFC Hydraulic System – Hydraulic Oil Filter, Operation…1488
PFC Hydraulic System – Charge Pump, Operation…1490
PFC Hydraulic System – Hydraulic Pump, Operation…1492
PFC Hydraulic System – Hydraulic Pump, Operating Modes…1496
PFC Hydraulic System – Hydraulic Oil Primary Filter, Component Information…1503
PFC Hydraulic System – Hydraulic Oil Filter, Component Information…1504
PFC Hydraulic System – Charge Pump, Component Information…1505
PFC Hydraulic System – Hydraulic Pump, Component Information…1507
Group 20B: Hitch…1434
Hitch – Summary of References…1509
Hitch – Summary of Components…1510
Hitch – Hitch Control, Operation…1512
Hitch – Hitch Valve, Operation…1514
Hitch – Position Sensor, Operation…1516
Hitch – Draft Sensor, Operation…1517
Hitch – Controls…1518
Hitch – Direct Control…1519
Group 20C: Selective control valves (SCV)…1434
Selective Control Valves (SCVs) – Summary of References…1521
Selective Control Valve (M-SCV 100) – Operation…1522
Selective Control Valve (M-SCV 200) – Operation…1530
Group 20D: Hydraulic block…1434
PFC Hydraulic System – Hydraulic Block, Summary of References…1542
PFC Hydraulic System – Hydraulic Block, Summary of Components…1543
PFC Hydraulic System – Priority 1 Control Block, Component Information…1545
PFC Hydraulic System – Priority 3 Control Block, Component Information…1547
Section 290: Operator's Cab…1549
Group 15: Tests and Adjustments…1549
Operational Checkout―Summary of References…1551
Safety in the Workplace…1552
Handling Refrigerant…1553
Safety Equipment…1554
In the Event of an Emergency…1555
Storage of Refrigerant Containers…1556
Refrigerant R134a…1557
Important…1558
Operator's Cab – Special Tools…1559
Specification…1560
Explanation Of Checks…1561
Pressure Deviations…1575
Group 20: Operation…1549
Air Condtioning System – Summary of References…1578
Air Condtioning System – R134A Refrigerant…1579
Air Condtioning System – Principle of Heat Exchange…1580
Refrigerant Circuit Layout…1581
Refrigerant Circuit Operation…1582
Component Description…1584
Air Condtioning System – Expansion Valve, Component Information…1588
Thermostat Switch…1590
Heating and Ventilation…1591
Section 299: Special Tools (Dealer-Fabricated)…1593
Group 05: Special Tools (Dealer-Fabricated)…1593
Special Tools (Dealer-Fabricated) — Summary…1595
Retainer Tool…1596
Adjustment Tool…1597
DFRW2—Needle Valve Test Hose Assembly…1598
DFLX10 and DFLX11—Test Harnesses…1599
DFLX12—Special Tool for 11-bit and 29-bit CAN BUS…1600
DFLX14—Solenoid Valve Test Harness…1601
Group 10: Special Tools (Available as Spare Parts)…1593
Special tool information…1603

John Deere 6M-1654, 6M-1854, and 6M-2104 Tractors Diagnosis and Test Service Technical Manual (TM706314)

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete Repair Service Technical Manual for John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J, with all the workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J workshop technical manual (repair) 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.
* 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.

TM135819 – John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J Repair Technical Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,102 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

TM135814 Repair Technical Manual 1654、1854、2054、2104、6165J、6185J、6205J 和 6210J 型修理手册
TM135819 Repair Technical Manual 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J Tractor Repair Manual

TABLE OF CONTENTS
Section 05: Safety….22
Group 05: Safety Regulations….1026
Recognize Safety Information….390
Understand Signal Words….26
Follow Safety Instructions….27
Prevent Machine Runaway….28
Operating the Tractor Safely….29
Use Safety Lights and Devices….31
Use Caution on Slopes, Uneven Terrain, and Rough Ground….32
Freeing a Mired Machine….33
Avoid Backover Accidents….34
Handle Fluids Safely—Avoid Fires….35
Handling Batteries Safely….36
Prepare for Emergencies….38
Avoid High-Pressure Fluids….39
Service Cooling System Safely….40
Remove Paint Before Welding or Heating….41
Avoid Heating Near Pressurized Fluid Lines….42
Work In Ventilated Area….43
Avoid Contact with Agricultural Chemicals….44
Handle Agricultural Chemicals Safely….45
Stay Clear of Rotating Drivelines….47
Wear Protective Clothing….49
Protect Against Noise….50
Practice Safe Maintenance….51
Avoid Hot Exhaust….52
Use Steps and Handholds Correctly….53
Use Seat Belt Properly….54
Park Machine Safely….55
Use Proper Lifting Equipment….56
Construct Dealer-Made Tools Safely….57
Support Machine Properly….58
Work in Clean Area….59
Illuminate Work Area Safely….60
Service Machines Safely….61
Service Accumulator Systems Safely….62
Service Tires Safely….63
Use Proper Tools….64
Service Front-Wheel Drive Tractor Safely….65
Avoid Eye Contact With Radar….66
Keep ROPS Installed Properly….67
Replace Safety Signs….68
Decommissioning — Proper Recycling and Disposal of Fluids and Components….69
Live With Safety….70
Safety Measures on Electronic Control Units….71
Servicing Electronic Control Units….72
Welding Near Electronic Control Units….73
Keep Electronic Control Unit Connectors Clean….74
Safety Instructions for Replacing a Halogen Bulb….75
Section 10: General Information….246
Group 05: Specifications….996
Engine….81
PTO….82
POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission….77
Clutch….84
Brakes….85
Hydraulic System….86
Wheel Configurations….87
Drawbar….88
Dimensions….89
Electrical System….92
Capacities….93
Diesel Fuel….94
Minimizing the Effect of Cold Weather on Diesel Engines….96
Biodiesel Fuel….98
Lubricity of Diesel Fuel….100
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III….101
Transmission and Hydraulic Oil….103
Front-Wheel Drive Axle Oil (Standard)….104
Diesel Engine Coolant (engine with wet sleeve cylinder liners)….106
Supplemental Coolant Additives….108
Multipurpose Extreme Pressure (EP) Grease….109
Oil Filters….110
Mixing of Lubricants….111
Lubricant Storage….112
Operating in Warm Temperature Climates….113
Alternative and Synthetic Lubricants….114
Metric Bolt and Screw Torque Values….115
Unified Inch Bolt and Screw Torque Values….117
Hydraulic system inch fitting torques….120
Hydraulic system metric fitting torques….121
Interpreting the Serial Number of Your Machine – 17 Digits PIN….122
Year of Production Table (Digit 5)….123
Transmission Type Table (Digit 6)….124
Identification Numbers….125
Product Identification Number….126
Engine Serial Number….127
Front-Wheel Drive Serial Number….128
Cab Serial Number….129
Group 10: Adjusting….78
Specifications….996
Using High-Pressure Washers….132
Preliminary Engine Test….133
Tractor Adjusting….134
Removing and Cleaning the Primary Air Cleaner Element….135
Checking the Air Cleaner Safety Element….136
Installing the Primary Filter Element….137
Checking Air Intake System Connections for Leaks….138
Checking Air Intake Hoses….139
Checking the Crankcase Vent Hose for Clogging….140
Cleaning Dirt from Radiator Screen….141
Adjust the Hood….142
Cleaning Radiator….144
Checking Expansion Tank Cap….145
Checking for Leaks in Radiator….146
Checking Engine Thermostat….147
Checking the Fuel Transfer Pump Operation….148
Cleaning Water Trap….149
Checking Fuel Filter….150
Bleed Fuel System….215
Check Transmission/Hydraulic System Oil Level….153
Cleaning Battery, Cables and Battery Box with a Clean Cloth….154
Checking Neutral Start Circuit….155
Checking Starter Motor….156
Checking Lighting Circuit….157
Final Engine Checks….158
Tractor Operation Check….159
Section 20: Engine….160
Group 00: Removing and Installing Engine….176
Special Tools….1023
Specifications….996
Removing Engine….164
Installing Engine….176
Engine Mounting….183
Replace the Engine Mountings….185
Section 30: Fuel Systems, Air Intake, Cooling and Exhaust….189
Group 00: Removal and Installation of Components….189
Remove Engine Hood….193
Install Engine Hood….195
Remove Battery….197
Install Battery….198
Group 05: Speed Control….189
General Information….246
Specifications….996
Hand Throttle Lever and Accelerator Pedal Adjustment….202
Replace Accelerator Pedal Assembly….203
Remove Accelerator Pedal Potentiometer….204
Group 10: Fuel System….189
General Information….246
Removing the Fuel Tank….209
Installing the Fuel Tank….211
Replace Fuel Level Sensor….212
Replace the Fuel Transfer Pump….213
Changing the Fuel Filters….214
Bleed Fuel System….215
Group 15: Air Intake System….189
General Information….246
Air Filter – Exploded View….218
Replacing Air Filter Restriction Sensor….219
Group 20: Cooling System….189
General Information….246
Specifications….996
Removing Radiator….223
Installing Radiator….230
Replacing Fan….231
Remove and Install the Charge Air Cooler….232
Removing and Installing the Expansion Tank….234
Removing and Installing Thermostat….236
Fill Cooling System with Coolant….237
Releasing Drive Belt Tension….239
Replacing Engine Fan Belt….240
Replacing Drive Belt Tensioner….243
Remove and Install Fan Console….244
Group 30: Exhaust System….190
General Information….246
Specifications….996
Exhaust to Upper Right-Hand Side….248
Section 40: Electrical System….251
Group 05: Connectors….284
Special Tools….1023
General….258
Using high-pressure washers….259
Disconnecting Electrical Circuits….387
Reconditioning Wire Ends….261
Installing a Terminal….262
WEATHER PACK Connectors….284
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Rear Terminal Lock….251
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Front Terminal Lock….251
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connectors….284
CAN BUS Terminating Resistor Connector….276
Electronic Control Unit Connectors….284
Connectors….284
CRIMP SNAP IN Connectors….289
KOSTAL Connectors….291
DEUTSCH Connectors….294
Individual Terminals….297
Fuse and Relay Boxes — Cab Tractors….299
Fuse and Relay Box — Open Station Tractors….302
Group 10: Wiring Harnesses….251
Disconnecting Electrical Circuits….387
Removing and Installing Wiring Harness W01 — Power Link Box….307
Removing and Installing Wiring Harness W02 — Engine Wiring Harness….308
Removing and Installing Wiring Harness W04 — Headlights….310
Removing and Installing Wiring Harness W08 — Cab Wiring Harness….311
Removing and Installing Wiring Harness W09 — Hood Harness….313
Removing and Installing Wiring Harness W19 — Cab Roof Harness….315
Removing and Installing Wiring Harness W26 — Fan and Air Conditioning….316
Removing and Installing Wiring Harness W28 — Front End of Transmission….317
Removing and Installing Wiring Harness W30 — Rear End of Transmission….319
Wiring Harness W31 — Power Take-Off for 7-Pin Socket….321
Wiring Harness W32 — Water in Fuel Sensor….322
Group 15: Charging Circuit….252
Special Tools….1023
Specifications….996
Repairing the Alternator….326
Disconnecting Electrical Circuits….387
Relieve Drive Belt Tension….328
Removing/Installing Alternator….329
Removing/Installing Alternator Pulley….331
Group 20: Starter Motor Circuit….252
Specifications….996
Repairing the Starting Motor….335
Disconnecting Electrical Circuits….387
Removing and Installing Starter Motor….337
Group 25: Fuses, Relays and Switches….252
Note….373
Special Tools….1023
Specifications….996
Removing Hood Covers….343
Disconnecting Electrical Circuits….387
Fuse and Relay Box….347
Fuses and relays (Power Link Box)….351
Power Link Box- Components….352
Replacing Starter Switch….353
Replacing Brake Switches….354
Replacing Light Switch….355
Replacing Full/Low Beam Switch….356
Replacing Work Light Switches….357
Replacing Hazard Warning Light Switch….358
Replacing Turn Signal Switch….359
Replacing Horn Switch….360
Replacing Windshield Wiper and Windshield Washer Switch….361
Replacing Front-Wheel Drive Switch….362
Replacing Fan Switch….363
Replacing Differential Lock Switch….364
Replacing Rockshaft Remote Control Switch….365
Group 30: Monitoring Systems….253
Note….373
Note….373
Disconnecting Electrical Circuits….387
Replacing Engine Oil Pressure Sensor Unit (B04)….370
Replacing Coolant Temperature Gauge Sensor Unit (B08)….371
Group 40: Electrical Components….253
Note….373
Special Tools….1023
Specifications….996
Disconnecting Electrical Circuits….387
Replacing Socket of 7-Terminal Power Outlet….377
Replacing Service Socket….379
Removing Windshield Wiper Motor….381
Adjusting the Headlights….383
Section 45: Electronic Control Units….385
Group 05: Removal and Installation of Electronic Control Units….385
Disconnecting Electrical Circuits….387
Instructions when Replacing a VIN Control Unit….388
Instructions when Replacing a Control Unit….389
Safety Information….390
Replace BCU Control Unit….391
Replace ECU Control Unit….393
Group 10: Removal and Installation of Terminating Resistors….385
Terminating Resistors for the CAN Bus….396
Section 55: PowrQuad Transmission….398
Group 00: Removing and Installing PowrQuad Module….398
Special Tools….1023
Special Tool (Own Fabrication)….405
Specifications….996
Removing PowrQuad Housing….407
Installing PowrQuad Housing….411
Removing Range Box….413
Installing Range Box….416
Final installation….418
Group 05: Transmission Selectors Control….398
Specifications….996
Reconditioning of Gear Shift, Park Brake and Forward/Reverse Mechanism….421
Reconditioning of Range Shift Mechanism….424
Adjust Gear-Shift and Range-Shift Cables….427
Adjusting Forward/Reverse Cable….429
Adjusting Cable and Stop Screw Park Brake….431
Adjusting Clutch Pedal….432
Group 10: PowrQuad Module….398
Special Tools….1023
Other Material….1033
Specifications….996
Transmission Components….441
Replacing Neutral Start Circuit (Mechanically Actuated PowrQuad Module)….442
Removing and Installing Oil Filter Base….443
Replacing Oil Filter….444
Removing and Installing Front Valve Housing….445
Removing and Installing Front Valve Housing Valves….448
Removing and Installing Transmission Front Cover….461
Removing and Installing Transmission Front Cover Valves….463
Removing Clutch Pedal Valve….468
Removing and Installing Shift Valve Housing….474
Removing and Installing Shift Valve Housing Valves….477
Removing Transmission Oil Pump….481
Servicing Transmission Oil Pump….482
Installing Transmission Oil Pump….488
Removing Planetary Drive Gears….489
Repairing Planetary Drive Gears….491
Installing Planetary Drive Gears….497
Removing B1 Brake Housing….502
Reconditioning B1 Brake….503
Installing B1 Brake Housing….505
Removing B2-B3 Brake Housing….506
Reconditioning B2 Brake….507
Reconditioning B3 Brake….509
Installing B2-B3 Brake Housing….512
Removing C4 Clutch….513
Reconditioning C4 Clutch….514
Installing C4 Clutch….525
Removing Reverse Brake….526
Servicing Reverse Brake….527
Installing Reverse Brake….530
Removing Forward Clutch with Planetary Drive (Forward/Reverse)….531
Servicing Forward Clutch with Planetary Drive (Forward/Reverse)….532
Installing Forward Clutch with Planetary Drive (Forward/Reverse)….546
Replacing Output Shaft….548
Group 20: Range Box….399
Special Tools….1023
Other Material….1033
Specifications….996
Cross-Sectional View—Input Drive Shaft….554
Remove Intermediate Shaft….555
Repair Intermediate Shaft….558
Remove Input Drive Shaft….560
Repair Input Drive Shaft….562
Install Input Drive Shaft….566
Adjust Input Drive Shaft End Play….568
Intermediate Shaft Installation and Cone Point Adjustment….570
Adjust Intermediate Shaft End Play….575
Remove, Repair, and Install Shift Cover….577
Repair Shifting Mechanism….579
Repair Park Lock….581
Adjust Range Shift….583
Replace Speed Sensor….584
Section 56: Drive Systems….586
Group 00: Removing and Installing Component….586
Special Tools….1023
Special Tools (Dealer-Fabricated)….946
Specifications….996
Removing MFWD Clutch….598
Installing MFWD Clutch….601
Removing Differential Housing….602
Installing Differential Housing….610
Removing Final Drive….613
Installing Final Drive….618
Removing Rear PTO….621
Installing Rear PTO….624
Group 05: U-Jointed Shafts and Torsional Damper….586
Special Tools….1023
Use of Special Tool KJD10426….628
Specifications….996
Removing MFWD Universal-Joint Drive Shaft….630
Repairing MFWD Universal-Joint Drive Shaft….631
Installing MFWD Universal-Joint Drive Shaft….635
Removing Engine Universal-Joint Drive Shaft….637
Removing Torsional Damper….638
Replacing Torsional Damper Bearings….639
Installing Torsional Damper….640
Installing Engine Universal-Joint Drive Shaft….642
Group 10: Front-Wheel Drive Clutch….84
Special Tools….1023
Specifications….996
MFWD Clutch Repair Instructions….646
MFWD Clutch — Cross-Sectional View….647
Disassembling MFWD Clutch….649
Disassembling MFWD Clutch Assembly….651
MFWD Clutch Exploded View….653
Mounting MFWD Clutch Assembly….655
Mounting MFWD Clutch….659
Group 15: Rear Differential….587
Special Tools….1023
Specifications….996
Rear Differential Repair Instructions….667
Removing Rear Differential….669
Rear Differential — Cross Sectional View….672
Disassembling Rear Differential….674
Rear Differential — Exploded View….678
Assembling Rear Differential….680
Adjust Rear Differential Preload….686
Adjust Rear Differential Backlash….688
Group 20: Hydraulic Pump Drive….587
Special Tools….1023
Specifications….996
Removing and Disassembling Pump Drive Pinion….693
Removing and Disassembling Pump Drive Gear….696
Assembling and Installing Pump Drive Gear….698
Assembling and Installing Pump Drive Pinion….701
Checking and Adjusting Play of Pump Drive Pinion….704
Group 25: Final Drives….587
Special Tools….1023
Specifications….996
Final Drive Repair Instructions….710
Checking Final Drive Shaft and Retainer….712
Final Drive Housing — Exploded View….713
Removing Planetary Carrier….715
Disassembling Planetary Carrier….717
Planetary Carrier — Exploded View….719
Assembling Planetary Carrier….720
Final Drive Housing — Cross Sectional View….722
Removing Final Drive Housing to Axle….723
Disassembling and Assembling Final Drive Housing….725
Disassembling and Assembling Axle….726
Installing Final Drive Housing to Axle….728
Installing Planetary Carrier….729
Measuring Rolling Drag….731
Final Assembly….736
Group 30: Rear PTO….82
Special Tools….1023
Rear PTO – Specifications….996
Replacing Output Shaft Seal Ring….740
Rear PTO Clutch – Cross Sectional View….741
Rear PTO Clutch – Exploded View….743
Removing Rear PTO Clutch….744
Reconditioning Rear PTO Clutch….747
Reconditioning Rear PTO Brake….756
Installing Rear PTO Clutch….757
Rear PTO Drive Train – Cross Sectional View….760
Rear PTO Drive Train – Exploded View….761
Removing Rear PTO Drive Train….763
Reconditioning Output Shaft….766
Reconditioning Countershaft….771
Installing Rear PTO Drive Train….773
Adjust Taper Roller Bearing of Countershaft….774
Adjust Tapered Roller Bearing of Bearing Support….776
Reconditioning Rear PTO Solenoid Valve….779
Removing PTO Modulating Valve….781
Reconditioning PTO Modulating Valve….782
Installing PTO Modulating Valve….784
Replace B06 – Rear PTO Speed Sensor….785
Recondition the Oil Sight-Glass….786
Section 60: Steering and Brakes….789
Group 05: Hydrostatic Steering….789
Special Tools….1023
Specifications….996
Preliminary Work….793
Disconnect/Connect Steering or Brake Hoses….794
Steering Valve – Removing….796
Steering Valve – Cross Sectional View….799
Adjusting Shock Valves….800
Steering – Exploded View….802
Steering Column – Exploded View….804
Installing Steering Valve….805
Group 15: Brake Valve….812
Special Tools….1023
Specifications….996
Brake Valve Repair Instructions….811
Brake Valve….812
Group 20: Rear Wheel Brakes….85
Rear Brakes, Specifications….996
Rear Wheel Brakes – Exploded View….823
Removing Rear Brakes….824
Reconditioning Rear Brakes….826
Installing Rear Brakes….828
Replacing Retraction Pins on the Rear Wheel Brakes….830
Section 70: Hydraulic System….833
Group 05: Controls….833
Specifications….996
Selective Control Valves — Removing and Installing Actuating Elements….837
Selective Control Valves — Adjusting Bowden Cable….841
Group 10: Oil Filter, Charge Pump and Hydraulic Pump….833
Other Material….1033
Specifications….996
Removing and Installing Hydraulic Oil Mesh Filter….845
Removing and Installing Hydraulic Oil Filter….848
Removing and Installing Charge Pump….850
Charge Pump – Checking the Lube Oil Valve….852
Hydraulic Oil Reservoir — Restrictor….853
Hydraulic Pump – Removing and Installing Pressure-and-Flow Controller….854
Hydraulic Pump – Reconditioning Pressure-and-Flow Controller….856
Removing and Installing Hydraulic Pump….858
Hydraulic Pump – Exploded View….861
Disassembling Hydraulic Pump….863
Assembling Hydraulic Pump….864
Group 15: Valves….833
Special Tools….1023
Specifications….996
Hydraulic System Repair Instructions….874
Removing Priority 1 Control Block….876
Installing Priority 1 Control Block….877
Reconditioning Priority 1 Control Block….878
Removing Priority 3 Control Block….880
Installing Priority 3 Control Block….884
Recondition Priority 3 Control Block….888
Group 20: Hitch….833
Other Material….1033
Specifications….996
Hitch Valve, Removing and Installing the Stepper Motor….893
Remove Hitch Valve….895
Recondition the Hitch Valve….897
Install the Hitch Valve….901
Rockshaft – Remove and Installing Position Sensor and Toothed Segment….904
Rockshaft – Removing and Installing Rockshaft….907
Rockshaft – Removing Rockshaft Cylinders….911
Rockshaft – Reconditioning Lift Cylinder….912
Rockshaft – Install Rockshaft Cylinders….915
Rockshaft – Removing and Installing Draft Load Potentiometer and Draft Link Support….916
Group 25: Selective Control Valves and Couplers….834
Specifications….996
Selective Control Valves (SCVs) and Couplers Repair Instructions….922
Remove the Selective Control Valves (SCVs)….924
Recondition the Selective Control Valves (M-SCVs 100)….926
Recondition the Selective Control Valves (M-SCVs 200)….930
Install the Selective Control Valves (SCVs)….933
Selective Control Valves (SCVs) – Reconditioning the Couplers….937
Section 80: Miscellaneous….939
Group 00: Removing and Installing Components….939
Special Tools….1023
Special Tools (Dealer-Fabricated)….946
Specifications….996
Removing Main Chassis….948
Installing Main Chassis….953
Removing Front-Wheel Drive Axle….956
Installing Front-Wheel Drive Axle….959
Group 05: Main Chassis….939
Specifications….996
Reconditioning Main Chassis….963
Group 15: Wheels….939
Essential, Recommended and Fabricated Tools….965
Specifications….996
Service Heavy-Duty Wheel Clamps….967
Remove the Front and Rear Wheels….973
Recondition the Front and Rear Wheels….976
Install the Front and Rear Wheels….978
Group 20: Center Link Bracket and Swinging Drawbar….986
Specifications….996
Check Swinging Drawbar Wear….984
Installing Center Link Bracket….985
Swinging Drawbar….986
Adjust Hammer Strap….988
Section 90: Operator's Cab….989
Group 00: Removing and Installing Components….989
Special Tools….1023
Dealer-Manufactured Special Tools….1023
Specifications….996
Swinging up Operator's Cab….997
Swinging down Operator's Cab….1006
Removing Operator's Cab….1008
Installing Operator's Cab….1016
Checking and Adjusting Gear Shift Units….1020
Group 15: Air Conditioning System….989
Special Tools….1023
Tightening Torque for Refrigerant Hoses….1025
Safety Regulations….1026
Handling Refrigerant….1027
In the Event of an Emergency….1028
Safety Equipment….1029
Storage of Refrigerant Containers….1030
Refrigerant R134a….1031
Important….1032
Other Material….1033
Specification….1034
Filling the Cylinder….1035
Charging Air Conditioning System (With Loading Cylinder)….1037
Charging Air Conditioning System (With Recovery/Recycling and Charging Station)….1039
Adding Oil to the Air Conditioning System….1040
Leak Test….1042
Evacuate Air Conditioning System….1043
Cleaning the Air Conditioning System….1045
Separating Compressor….1046
Checking Compressor Level….1047
Disassembling Compressor Clutch….1048
Checking Clutch Hub Separation….1051
Installing Compressor….1052
Separating and Installing Condenser….1053
Separating and Installing Drier….1054
Replacing Expansion Valve….1055
Separating and Installing Evaporator and Expansion Valve….1056
Installing Condensation Water Drain Hoses….1058
Layout of Condensation Water Drain Hoses….1059
Separating and Installing Thermostat….1060
Separating and Installing High/Low Pressure Switch….1061
Vacuum Pump — General Information….1062
Group 20: Heating System….990
Fan and Heater, Disassembling….1065
Removing Cab Air Filter….1067
Separating and Installing Fan….1069
Separating and Installing Heater Regulator….1070
Separating Heater/Evaporator Housing….1071
Group 25: Operator's Cab….990
Removing Cab Frame….1074
Cab Mounting Torques….1075
Removing and Installing Windshield….1077
Removing and Installing Rear Window….1078
Installing Door Lock….1080
Adjusting Window Contact Pressure….1082
Removing and Installing Operator's Cab Door….1083
Removing and Installing Sun-Visor Roller….1085
Section 99: Special Tools (Dealer-Fabricated)….1086
Group 05: Special Tools (Dealer-Fabricated)….946
DFLX1 – Adapter Strut….1088
DFLX6 – Bushing….1089
DFLX7 – Turning Device….1104
DFLX14 – Suspended MFWD Axle Housing Bracket….1091
DFLX29 – Support….1092
DFRW29 – Final Drive Adapter….1093
Lifting Device….1094
Holding Device….1095
Suspension Eyes for Operator's Cab….1096
Holding Tool….1097
Wooden Block….1098
DFRW79 – Piston Holding Tool….1099
Socket Wrench Insert….1106
Seal Installer….1105
Driver….1102
Assembly and Guide Mandrels….1103
Turning Device….1104
Seal Installer….1105
Socket Wrench Insert….1106
Special Wrench….1107
Quick Coupler Securing Support….1108
Lifting Tool….1109

John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J Repair Service Manual (TM135819)

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J Tractors, with workshop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J Tractors workshop Diagnosis & Tests technical 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.

TM135719 Diagnostic Technical Manual 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J Tractors / (Diagnostics) (Includes electrical wiring diagrams) (Repair manual sold separate).pdf
TM135714 Diagnostic Technical Manual 1654、1854、2054、2104、6165J、6185J、6205J 和 6210J 拖拉机诊断.pdf

PRODUCT DETAILS:
Total Pages: 1,601 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English Chinese

Also Available Now:
TM135814 Repair Technical Manual 1654、1854、2054、2104、6165J、6185J、6205J 和 6210J 型修理手册
TM135819 Repair Technical Manual 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J Tractor Repair Manual

TABLE OF CONTENTS
Section 210: General Information…32
Group 05: Safety Information…1385
Recognize Safety Information…1385
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 – Wheel Speed Sensor, 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…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…421
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…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…624
Air Intake System – Theory of Operation…625
Group 20C: Cooling System…591
Cooling System – Summary of References…627
Coolant Circuit – Description…628
Cooling System Radiator – Description…630
Itercooler – Description…631
Ring-Shaped (Transmission Oil) Cooler – Description…632
Automatic Drive Belt Tensioner – Theory of Operation…634
Group 20D: Cold-Weather Starting Aids…591
Cold-Weather Starting Aids – Summary of References…636
Cold-Weather Starting Aids – General Information…637
Cold-Weather Starting Aids – Coolant Heater – Component Information…638
Cold-Weather Starting Aids – Transmission Oil Heater – Component Information…639
Cold-Weather Starting Aids – Charge Pump Preheater – Component Information…640
Section 240: Electrical System…641
Group 05A: Fuse Box…641
Fuse Box – Theory of Operation…651
Fuse Box – Electrical Diagram…652
Group 05B: Starting and Charging Circuit…641
Starting and Charging Circuit – Theory of Operation…655
Starting and Charging Circuit – Electrical Diagram…656
Circuit test for Starter motor checks (M01)…657
Circuit test for Alternator (G02)…660
Circuit test for Battery (G01)…665
Circuit test for K01 Starter relay…668
Group 05C: CAN BUS and Service Connector…641
CAN BUS System – Theory of Operation…670
CAN BUS System – Electrical Diagram…671
Group 05D: ECU – Power…641
ECU Power – Theory of Operation…673
ECU Power – Electrical Diagram…674
Group 05E: ECU – Throttle and Fuel System…641
ECU Throttle and Fuel System – Theory of Operation…676
ECU Throttle and Fuel System – Electrical Diagram…677
Circuit test for Foot throttle (B79)…678
Circuit test for Electrical hand throttle (B96)…681
Group 05F: ECU – Fuel Preheater and Aid Heater…641
ECU Fuel Preheater and Aid Heater – Theory of Operation…685
ECU Fuel Preheater and Aid Heater – Electrical Diagram…686
Circuit test for Fuel Pump (M31)…688
Circuit test for Heating Element of Fuel Preheater (R02)…690
Circuit test for Sender for Electrical starting aid heater (R15)…692
Group 05G: ECU – Sensors…641
ECU Sensors – Theory of Operation…695
ECU Sensors – Electrical Diagram…696
Circuit test for Engine Speed Sender (B72)…698
Group 05H: BCU – Electronic Hitch-Control…642
BCU – Electronic Hitch-Control – Theory of Operation…702
BCU – Electronic Hitch-Control – Electrical Diagram…703
Circuit test for Rockshaft Control Stepper Motor (M08)…704
Circuit test for Sensitivity Potentiometer (B26)…706
Circuit test for Depth-setting Potentiometer (R08)…709
Circuit test for Rate-of-Drop Potentiometer (R06)…712
Circuit test for Raise-Limit Potentiometer (R07)…715
Circuit test for Position Sensor (B21)…718
Circuit test for Draft Sensor (B41)…722
Circuit/harness test for Rapid Raise Switch (S24)…725
Circuit test for Left Remote Control Switch (S68)…728
Circuit test for Supply Voltage for 5-Volt BCU Components…731
Group 05I: BCU – Brakes…642
BCU – Brakes – Theory of Operation…735
BCU – Brakes – Electrical Diagram…736
Circuit test for Brake Pedal Sensor Unit (B88)…738
Group 05J: BCU – PTO…642
BCU – PTO – Theory of Operation…740
BCU – PTO – Electrical Diagram…741
Circuit test for PTO Switch (S21)…743
Circuit test for PTO Solenoid Valve (Y04)…746
Circuit test for Rear PTO Speed Sensor (B06)…749
Group 05K: BCU – Front-Wheel Drive…642
BCU – Front-Wheel Drive – Theory of Operation…753
BCU – Front-Wheel Drive – Electrical Diagram…754
Circuit test for Front-Wheel Drive Switch (S63)…756
Circuit test for Front-Wheel Drive Solenoid Valve (Y03)…759
Group 05L: BCU – Differential Lock…642
BCU – Differential Lock – Theory of Operation…763
BCU – Differential Lock – Electrical Diagram…764
Circuit test for Differential Lock Switch (S22)…766
Circuit test for Differential Lock Solenoid Valve (Y05)…769
Group 05M: BCU – Wheel Speed Sensor…643
BCU Wheel Speed Sensor – Theory of Operation…773
BCU Wheel Speed Sensor – Electrical Diagram…774
Circuit test for Wheel Speed Sensor (B09)…775
Group 05N: BCU – Turn Signal and Hazard Warning Lights…643
BCU – Turn Signal and Hazard Warning Lights – Theory of Operation…779
BCU – Turn Signal and Hazard Warning Lights – Electrical Diagram…780
Circuit test for hazard warning switch (S106)…782
Circuit test for Turn Signal Switch (S08)…786
Group 05O: Panel Warning Lights…643
Panel Warning Lights – Theory of Operation…791
Panel Warning Lights – Electrical Diagram…792
Circuit test for Sender for air cleaner restriction warning light (B02)…794
Circuit test for Fuel gauge sender (B03)…795
Circuit test for Engine oil pressure sender (B04)…796
Circuit test for Sender for the transmission oil filter sender (B07)…797
Circuit test for Coolant temperature sender (B08)…798
Circuit test for Transmission oil pressure sender (B31)…799
Circuit test for Transmission oil temperature sender (B29)…800
Group 05P: Lights, Tail Lights and License Plate…643
Lights and Tail Lights – Theory of Operation…802
Lights and Tail Lights – Electrical Diagram…803
Lighting Circuits…805
Group 05Q: Work Lights…643
Work Lights – Theory of Operation…810
Work Lights – Electrical Diagram…811
Work lights…812
Group 05R: Radio, Dome Light, Console Light and Beacon Light…643
Radio, Dome Light, Console Light and Beacon Light – Theory of Operation…815
Radio, Dome Light, Console Light and Beacon Light – Electrical Diagram…816
Circuit test for Radio (A60 – Radio Circuits)…817
Circuit test forDome Light (A08)…818
Circuit test for Beacon light (E27)…820
Group 05S: Horn and Accessories Socket…644
Horn and Accessories Socket – Theory of Operation…822
Horn and Accessories Socket – Electrical Diagram…823
Circuit test for Horn (H01)…824
Group 05T: Power Outlet…644
Power Outlet – Theory of Operation…827
Power Outlet – Electrical Diagram…828
Group 05U: Seat Compressor and Cigarette Lighter…644
Seat Compressor and Cigarette Lighter – Theory of Operation…830
Seat Compressor and Cigarette Lighter – Electrical Diagram…831
Seat and Cigarette lighter System…832
Group 05V: Fan and A/C…644
Fan and A/C – Theory of Operation…835
Fan and A/C – Electrical Diagram…836
Fan, Air Conditioning and Automatic A/C control…838
Group 05W: Front Windshield Wiper and Washer…644
Front Windshield Wiper and Washer – Theory of Operation…844
Front Windshield Wiper and Washer – Electrical Diagram…845
Front Windshield Wiper and Washer System…846
Group 05X: Rear Windshield Wiper and Washer…644
Rear Windshield Wiper and Washer – Theory of Operation…849
Rear Windshield Wiper and Washer – Electrical Diagram…850
Rear Windshield Wiper and Washer System…852
Group 05Y: Trailer Connector…644
Trailer Connector – Theory of Operation…855
Trailer Connector – Electrical Diagram…856
Group 10: Wiring Harnesses…644
Disconnecting Electrical Circuits…858
Location of Ground Points…859
Removing and Installing Wiring Harness W01 — Power link Box…861
Removing and Installing Wiring Harness W02 — Engine Wiring Harness…862
Removing and Installing Wiring Harness W04 — Headlights…864
Removing and Installing Wiring Harness W08 — Cab Wiring Harness…865
Removing and Installing Wiring Harness W09 — Hood…867
Removing and Installing Wiring Harness W19 — Cab Roof…869
Removing and Installing Wiring Harness W26 — Fan and Air Conditioning…870
Removing and Installing Wiring Harness W28 — Front End of Transmission…871
Removing and Installing Wiring Harness W30 — Rear End of Transmission…873
Wiring Harness W31 — Power Take-Off for 7-Pin Socket…875
Wiring Harness W32 — Sensor Wiring Harness…876
Group 15: Connectors…645
Connectors – Summary of References…879
A01 – Fuse and relay box…881
A02 – Fuse Box 2…884
A03 – Fuse Box 3…885
A04 – Fuse Box 4…886
A05 – Fuse Box 5…887
A06 – Power Link Box…888
A08 – Dome Light…889
A29 – Pneumatic operator's seat and rear wiper…890
A60 – Radio…891
A62 – Bus terminator…892
A84 – Bus terminator engine…893
B02 – Sender for air cleaner restriction warning light…894
B03 – Fuel gauge sensor unit…895
B04 – Sender for engine oil pressure indicator light…896
B06 – Rear PTO Speed Sensor…897
B07 – Transmission oil filter pressure sensor…898
B08 – Coolant temperature sensor…899
B09 – Wheel Speed Sensor…900
B14 – Compressor and thermostat switch…901
B15 – Air conditioning system pressure switch…902
B21 – Hitch-control position sensor…903
B26 – Sensitivity potentiometer…904
B27 – Feedback unit…905
B29 – Transmission oil temperature sensor…906
B30 – Hydrostatic oil temperature sensor…907
B31 – Transmission oil pressure sender…908
B36 – Neutral start switch…909
B37 – Interface handbrake…910
B41 – Draft potentiometer…911
B56 – Water temperature engine sensor…912
B59 – Manifold air temperature sensor…913
B72 – Crankshaft speed sensor…914
B74 – Event sensor…915
B79 – Foot throttle…916
B88 – Brake switch…917
B96 – Electrical hand throttle…918
B114 – Fuel temperature sensor…919
B121 – Water in fuel sensor…920
B137 – Fuel rail pressure sensor…922
E01 – Right-hand front light…923
E02 – Left-hand front light…924
E05 – Cigarette lighter…925
E09-R – Right-hand front working light…928
E09-L – Left-hand front working light…929
E11-1 – Right-hand rear working light…930
E11-2 – Left-hand rear working light…931
E12-2 – Console light…932
E27 – Beacon light…933
G01 – Battery…934
G02 – Alternator…935
H01 – Horn…936
H77 – Aid heater indicator light…937
K01 – Starter relay…938
M01 – Starter motor…939
M02 – Air conditioning compressor…940
M03 – Wiper motor…941
M04 – Wiper motor…942
M05 – Windshield washer pump…943
M06 – Windshield washer pump…944
M07 – Fan motor…945
M08 – Hitch-control stepper motor…946
M10 – Fan motor…947
M31 – Fuel pump…948
R02 – Fuel preheater…949
R03 – Resistors…950
R15 – Electrical starting aid heater…951
S01 – Starter switch…952
S04 – Horn switch…953
S08 – Turn signal switch…954
S09 – Light switch…955
S10 – Full/low beam light switch…956
S14 – Fan switch…957
S15 – Windshield wiper switch…958
S18 – Rear wiper switch…959
S20 – Windshield switch…960
S21 – Rear PTO switch…961
S22 – Differential lock switch…962
S36 – Beacon light switch…963
S63 – Front-wheel drive switch…964
S68 – External hitch-control switch…965
S92-2 – Rear work lights switch…966
S106 – Hazard warning lights switch…967
W25 – Radio antenna…968
X05 – Trailer connector…969
X25 – Instrument right panel connector…970
X26 – Instrument left panel connector…972
X37 – Accessories socket…974
X40 – Connector (W22 and W23)…975
X42 – Connector (W21 and W22)…976
X106 – Tail, brake and turn signal lights (right-hand)…977
X107 – Tail, brake and turn signal lights (left-hand)…978
X108 – Front right- hand turn signal light…979
X109 – Front left-hand turn signal light…980
X113 – License Light Connector…981
X182 – Connector (W08 and W26)…982
X234 – Connector (W30 and W31)…984
X239 – Outlet Socket Connector…985
X305 – Cooler grounding…986
X400 – Connector (W08 and W19)…987
X411 – Connector (W02 and W04)…990
X430 – Connector (W08 and W30)…992
X431 – Connector (W08 and W28)…995
X450 – Connector (W02 and W08)…998
X473 – Connector (W01 and W08)…1001
X504 – Connector (W08 and W09)…1003
X505 – Connector (W08 and W09)…1006
X547 – Connector (W01 and W02)…1008
X571 – Service connector (CAN Bus)…1009
X612 – Speaker connector…1010
X616-1 Basic control unit (BCU)…1011
X616-2 Basic control unit (BCU)…1013
X616-3 Basic control unit (BCU)…1016
X844-1 — Engine control unit (ECU)…1018
X844-2 — Engine control unit (ECU)…1020
XGND1 – Cab ground wire…1022
XGND2 – Cab ground wire…1023
XGND5 – Cab ground wire…1024
XGND6 – Rear wiper ground wire…1025
XGND9 – Engine grounding…1026
XGND10 – Cab roof ground wire…1027
XGND14 – Cab roof ground wire…1028
XGND58 – Fan and A/C wiring harness grounding…1029
Y03 – Front-wheel drive solenoid valve…1030
Y04 – PTO Solenoid…1031
Y05 – Differential lock solenoid valve…1032
Y44 – Suction control valve…1033
Y47 – Injection valve…1034
Section 245: Electronic Control Units…1035
Group 05: Operation and General Information on Diagnostics…1035
Operation and General Information – Summary of References…1041
Eletronic Control Units – Special Tools…1042
Operation and General Information on Diagnostics – Abbreviations for Control Units…1043
Operation and General Information on Diagnostics – Instrument Unit Adjustment…1044
Operation and General Information on Diagnostics – Operation and Entering the Program Mode using the Performance Monitor…1050
Operation and General Information on Diagnostics – Procedure for Dealing with Diagnostic Trouble Codes…1057
Operation and General Information on Diagnostics – Accessing Addresses and Diagnostic Trouble Codes…1061
Operation and General Information on Diagnostics – Approved Software for Control Units…1072
Operation and General Information on Diagnostics – Locations and Allocations of Control Units…1073
Group 10A: Interactive Tests…1035
Interactive Tests – Summary of References…1075
Procedure in the Event of Problems with Interactive Tests…1076
BCU: Recording in Debug Mode…1077
BCU: Control Unit Information and Input Addresses – Summary…1078
BCU: BCU Test…1079
ECU: Cylinder Misfire Test…1080
ECU: Compression Test…1081
ECU: Cylinder Cut-Out Test…1082
ECU: Harness diagnostic mode test…1083
ECU: Internal Data Monitor (IDM)…1084
ECU: Communication Error Test…1085
ECU: Control Unit Information and Summary…1086
ECU: Engine Speed Change Test…1087
Group 10B: Interactive Calibrations…1035
Interactive Calibrations – Summary of References…1089
Procedure in the Event of Problems with Interactive Calibration…1090
BCU: Calibrate the Hitch Control…1091
ECU: Calibrate the Electronic Fuel Injectors (Move Injectors to Different Positions or Replace Injectors, and Display Progress of Calibration)…1095
Group 15: Information on How to Reprogram Control Units…1036
Information on How to Program Control Units – Summary of References…1097
General Information on How to Reprogram Control Units…1098
Check and Download Tractor-Specific Software Information…1099
Procedure When Replacing Control Units…1100
Important Notes on Programming…1101
Procedure When Programming Control Units…1102
Procedure in the Event of a Problem Programming Control Units Protected by VIN…1103
Procedure in the Event of a Programming Problem…1106
Group 20: Data BUS Systems, Operation…1036
Data BUS systems – Summary of References…1109
Data BUS Systems – CAN BUS Systems…1110
Data BUS Systems – CAN BUS Systems on Engines with Level 16 Control Unit (2-Valve HPCR Fuel System)…1112
Data BUS systems – Plug Layout…1113
Data BUS systems – Determining the Type of the CAN BUS Fault…1114
Group BCU: BCU – Basic Control Unit…1036
BCU – Summary of References…1117
BCU – Summary of Addresses…1118
BCU – Calibration and Input Addresses…1125
BCU – Summary of Operational Checks…1127
BCU – Theory of Operation (Basic Functions)…1128
BCU – Theory of Operation (Hitch Control)…1130
BCU – CAN BUS Information…1132
Address BCU020 – Input Address, Engine Speed Sensor/Pulses per Engine Revolution…1133
Address BCU021 – Input Address, Rear PTO Speed Sensor/Pulses per PTO Revolution…1134
Address BCU022 – Input Address, Front-Wheel Drive Control Function…1135
Address BCU023 – Vacant Input Address…1136
Address BCU024 – Input Address, Settings for Units of Measurement in Display and for Acoustic Indicator for Turn Signal…1137
Address BCU026 – Vacant Input Address…1138
Address BCU027 – Vacant Input Address…1139
Address BCU028 – Input Address, Rear PTO Present/Not Present…1140
Address BCU029 – Vacant Input Address…1141
Address BCU030 – Input Address, Sensor Diagnostics…1142
Address BCU031 – Vacant Input Address…1143
Address BCU034 – Input Address, Configuration of Instrument Unit and Self-Canceling Turn Signals…1144
Address BCU035 – Input Address, Service Interval Setting…1145
Address BCU041 – Vacant Input Address…1146
Address BCU042 – Vacant Input Address…1147
Address BCU043 – Vacant Input Address…1148
Address BCU045 – Vacant Input Address…1149
Address BCU046 – Input Address, Activate/De-activate Delayed Activation of Alternator…1150
Address BCU047 – Input Address, Delayed Activation of Alternator, Configuration…1151
Address BCU048 – Vacant Input Address…1152
Address BCU049 – Vacant Input Address…1153
Address BCU050 – Vacant Input Address…1154
Address BCU051 – Vacant Input Address…1155
Address BCU052 – Vacant Input Address…1156
Address BCU055 – Input Address, Configuration of Acoustic Alarm…1157
Address BCU056 – Input Address, Tire Configuration…1158
Address BCU058 – Input Address, Sensor for Wheel Speed / Transmission Pulses per Axle Revolution…1159
Address BCU060 – Vacant Input Address…1160
Address BCU063 – Vacant Input Address…1161
Address BCU065 – Vacant Input Address…1162
Address BCU071 – Vacant Input Address…1163
Address BCU073 – Vacant Input Address…1164
Address BCU074 – Vacant Input Address…1165
Address BCU075 – Vacant Input Address…1166
Address BCU077 – Vacant Input Address…1167
Address BCU078 – Vacant Input Address…1168
Address BCU088 – Vacant Input Address…1169
Address BCU089 – Vacant Input Address…1170
Address BCU090 – Vacant Input Address…1171
Address BCU091 – Vacant Input Address…1172
Address BCU092 – Vacant Input Address…1173
Address BCU093 – Vacant Input Address…1174
Address BCU094 – Vacant Input Address…1175
Address BCU097 – Input Address, Low Fuel Level Acoustic Alarm…1176
Address BCU099 – Input Address, Automatic Deletion of Diagnostic Trouble Codes…1177
Address BCU101 – Input Address, Leak-Off Function of Hitch Valve On or Off…1178
Address BCU118 – Input Address, Quick Withdrawal and Hitch Dampening On or Off…1179
Address BCU122 – Hitch Control Calibration…1180
Address BCU138 – Input Address, Leak-off Function of Hitch Valve (Adjusting Stepper Motor Steps)…1188
Address BCU145 – Input Address, Hitch Control On or Off…1189
Address BCU154 – Input Address, Leak-off Function of Hitch Valve (Time Setting)…1190
Address BCU162 – Input Address, Switching Off Hydraulic Oil Temperature Access (During Calibration)…1191
Address BCU165 – Input Address, Raise Rate Setting…1192
Address BCU167 – Input Address, Activate/De-activate Hitch Components…1193
Address BCU174 – Input Address, Index for Load Control…1194
Address BCU247 – Tractor Model Designation…1195
Address BCU248 – Tractor Serial Number…1196
B06 – Rear PTO Speed Sensor, Operational Check…1197
B09 – Wheel Speed Sensor, Operational Check…1198
B21 – Hitch Position Sensor, Operational Check…1199
B26 – Sensitivity Potentiometer, Operational Check…1200
B27 – Position Feedback Unit for Hitch Control, Operational Check…1201
B41 – Draft Sensor, Operational Check…1203
B88 – Brake Pedal Sensor Unit, Operational Check…1204
M08 – Stepper Motor for Hitch, Operational Check…1205
S08 – Turn Signal Switch, Operational Check…1206
S21 – Rear PTO Switch, Operational Check…1207
S22 – Differential Lock Switch, Operational Check…1208
S24 – Quick Withdrawal Switch, Operational Check…1209
S63 – Front-Wheel Drive Switch, Operational Check…1210
S68 – Switch for Hitch Remote Control (Left), Operational Check…1211
S106 – Hazard Warning Light Switch, Operational Check…1213
Supply Voltage for 5-volt BCU Components, Operational Check…1214
Group ECU: ECU Control Unit…1039
ECU – Summary of References…1216
ECU – Summary of Addresses (Level 16 ECU for 2-Valve Engine with HPCR)…1217
ECU – Calibration and Input Addresses (Level 16 ECU for 2-Valve Engine with HPCR)…1220
ECU – Theory of Operation (Level 16 ECU for 2-Valve Engine with HPCR)…1222
ECU – Summary of Operational Checks…1225
B02 – Air Cleaner Restriction Sensor, Operational Check…1226
B79 – Accelerator Pedal Potentiometer, Operational Check…1227
B96 – Hand Throttle Potentiometer, Operational Check…1229
R15 – Heating Element of Electrical Starting Aid (2-Valve Engine with HPCR), Operational Check…1231
Section 255: PowrQuad Transmissions…1233
Group 10: Operational Check…1233
PowrQuad Transmission—Operational Check…1242
Group 15: Tests and Adjustments…1233
PowrQuad Transmission—Summary of References…1250
PowrQuad Transmission— Special Tools…1251
PowrQuad Transmission—System Check…1252
PowrQuad Transmission—Test Ports…1261
PowrQuad Transmission—Checking Rate of Flow at Cooler…1263
PowrQuad Transmission—Checking the Cooler Relief Valve…1266
PowrQuad Transmission—System Pressure Check…1269
PowrQuad Transmission—Checking Lube Oil Pressure…1270
PowrQuad Transmission—Checking Cooling Oil Pressure (Forward Clutch)…1272
PowrQuad Transmission—Checking Cooling Oil Pressure (Reverse Brake)…1273
PowrQuad Transmission—Checking Pressure at Forward Clutch…1274
PowrQuad Transmission—Checking Pressure at Reverse Brake…1275
PowrQuad Transmission—Checking Pressure at Brake B1…1276
PowrQuad Transmission—Checking Pressure at Brake B2…1277
PowrQuad Transmission—Checking Pressure at Brake B3…1278
PowrQuad Transmission—Checking Pressure at Clutch C4…1279
PowrQuad Transmission—Adjusting System Pressure…1281
PowrQuad Transmission—Test Result Table…1283
PowrQuad Transmission—Adjusting Gear Shift…1286
PowrQuad Transmission—Adjusting Forward/Reverse Cable…1288
PowrQuad Transmission—Adjusting Park Lock…1290
Group 20: Operation…1233
PowrQuad Transmission — Summary of References…1292
PowrQuad Transmission—Layout…1293
PowrQuad Module—Layout…1294
PowrQuad Module—Cross-Sectional and 3D View…1296
PowrQuad Module—Location of Valves, Sensors and Switches…1298
PowrQuad Module—Element Engagement Chart…1301
PowrQuad Module—Pneumatic Pump…1302
PowrQuad Module—Transmission Oil Pump…1305
PowrQuad Module — Pressure-Regulating Valve and Filter Relief Valve…1307
PowrQuad Module—Overspeed Relief Valve and Anti-Cavitation Check Valve…1312
PowrQuad Module—Clutch Cooling Components…1314
PowrQuad Module —Clutch Cooling Valve (Forward/Reverse)…1315
PowrQuad Module—System 1 Oil and System 2 Oil…1316
PowrQuad Module—Hydraulic Schematic, Mechanically Actuated PowrQuad Module…1317
PowrQuad Module—Operation of Forward/Reverse Modulation, Mechanically Actuated PowrQuad Module…1319
PowrQuad Module—Neutral Start Circuit, Mechanically Actuated PowrQuad Module…1322
PowrQuad Module—Operation of Gear-to-Gear Modulation, Mechanically Actuated PowrQuad Module…1323
Group 30: Range Box…1234
Range Transmission — Cross-Sectional View…1328
Section 256: Drive Systems…1330
Group 10: Operational Check…1330
Power train – operational check…1334
Group 15: Tests and Adjustments…1330
Tests and Adjustments—Summary of References…1338
Tests and Adjustments—Special Tools…1339
Drive Systems—System Check…1340
Checking Pressure at the Front-Wheel Drive Clutch…1344
Checking Pressure at the Hydraulic Differential Lock…1345
Checking Pressure at the PTO…1346
Drive Systems—Test Result Table…1349
Group 20: Operation…1330
Drive Systems—Summary of References…1351
Front Wheel Drive Clutch—Cross-Sectional View…1352
Front Wheel Drive Clutch—Oil Flow and Power Flow…1354
Front Wheel Drive Clutch Disengaged—Oil Flow…1356
Differential—Cross-Sectional View…1358
Differential—Power Flows…1360
Differential—Oil Flows…1362
Final Drives—Operation and Cross-Sectional View…1365
PTO Options—Description…1366
PTO Options—PTO Modulating Valve and Solenoid Valve…1368
PTO Options—PTO brake and PTO clutch…1370
PTO Options—Power Flows…1372
Section 260: Steering and Brakes…1374
Group 05: Preliminary Checks…1374
Preliminary Checks—Summary of References…1377
Preliminary Checks – Steering System…1378
Preliminary Checks – Brake System…1382
Group 10: Operational Check…1374
Operational Checkout—Summary of References…1384
Safety Information…1385
Steering Check…1386
Checking Brakes…1387
Group 15: Tests and Adjustments…1374
Tests Tests Tests & Adjustments—Summary of References{pgNO}1374 Adjustments—Summary of References{pgNO}1389 Adjustments—Summary of References…1388
Steering and Brakes – Special Tools…1390
Steering and Brakes – Specifications…1392
Checking Steering Valve…1393
Checking Brake System…1396
Bleeding the Rear Brakes…1397
Adjusting Brake Pedals and Switches…1398
Group 20A: Hydrostatic Steering…1374
Description of Steering Valves, Operation…1406
Group 20B: Brakes…1374
Brakes—Summary of Reference…1414
Operation of Brake Piston, Plate and Disks…1415
Brake released…1417
Initial Braking…1419
Brake Engaged…1421
Rear Wheel Brakes, Operation…1423
Group 20C: Air brake system…1374
Steering and Brakes – Air Brakes, Summary of References…1425
Steering and Brakes – Air Brakes, Description…1426
Steering and Brakes – Air Brakes, Compressor…1428
Steering and Brakes – Air Brakes, Pressure Regulating Valve…1429
Steering and Brakes – Air Brakes, Compressed Air Tank…1430
Steering and Brakes – Air Brakes, Trailer Control Valve…1431
Steering and Brakes – Air Brakes, Coupling Ends…1432
Section 270: Hydraulic System…1433
Group 10: Operational Check…1433
Hydraulic System – Operational Check—Summary of References…1436
General Information – Transmission and Hydraulic System, Introductory Checks…1437
Hydraulic System – Load Check…1441
Hitch Control – Operational Check…1442
Hydraulic System – External Control of Hitch, Operational Check-Out…1444
Hydraulic System – Selective Control Valves (M-SCV), Operational Check-Out…1445
Group 15: Tests and Adjustments…1433
Tests and Adjustments – Summary of References…1449
Hydraulic System – Special Tools…1450
Hydraulic System – Safety Measures for Hydraulic Checks…1452
Warming Hydraulic System Oil…1454
PFC Hydraulic System – Worksheet for the Hydraulic System Diagnostics…1455
PFC Hydraulic System – Oil Pressure Test Ports…1458
PFC Hydraulic System – Checking and Adjusting the Maximum Load Sense Pressure…1459
PFC Hydraulic System – Check and Adjust System Oil Pressure…1461
PFC Hydraulic System – Check and Adjust Differential Pressure…1463
PFC Hydraulic System – Priority Circuit 1, Checking and Adjusting the Load Sense Oil Pressure for Steering…1465
PFC Hydraulic System – Priority Circuit 3, Checking the Oil Pressure…1467
PFC Hydraulic System – Hydraulic Pump, Checking the Delivery Rate…1469
PFC Hydraulic System – Check the Charge and Lube Oil Pressure…1471
Hydraulic System – Checking the Hitch Valve and the Stepper Motor…1472
Hydraulic System – Hitch Valve, Centering the Stepper Motor…1474
Hydraulic System – Hitch Valve, Rough Adjustment of the Raise and Lower Valves…1475
Hydraulic System – Hitch Valve, Checking the Position Sensor…1477
Hydraulic System – Hitch Valve, Checking and Adjusting the Draft Load Potentiometer…1478
Group 20: Theory of operation…1433
Hydraulic System Theory of Operation—Summary of References…1481
Hydraulic System – Summary of Abbreviations…1482
PFC Hydraulic System – Summary of Components…1483
PFC Hydraulic System — Symbolic Representation…1485
Group 20A: Oil Filter, Charge Pump and Hydraulic Pump…1434
Oil Filter, Charge Pump and Hydraulic Pump―Summary of References…1487
PFC Hydraulic System – Hydraulic Oil Filter, Operation…1488
PFC Hydraulic System – Charge Pump, Operation…1490
PFC Hydraulic System – Hydraulic Pump, Operation…1492
PFC Hydraulic System – Hydraulic Pump, Operating Modes…1496
PFC Hydraulic System – Hydraulic Oil Primary Filter, Component Information…1503
PFC Hydraulic System – Hydraulic Oil Filter, Component Information…1504
PFC Hydraulic System – Charge Pump, Component Information…1505
PFC Hydraulic System – Hydraulic Pump, Component Information…1507
Group 20B: Hitch…1434
Hitch – Summary of References…1509
Hitch – Summary of Components…1510
Hitch – Hitch Control, Operation…1512
Hitch – Hitch Valve, Operation…1514
Hitch – Position Sensor, Operation…1516
Hitch – Draft Sensor, Operation…1517
Hitch – Controls…1518
Hitch – Direct Control…1519
Group 20C: Selective control valves (SCV)…1434
Selective Control Valves (SCVs) – Summary of References…1521
Selective Control Valve (M-SCV 100) – Operation…1522
Selective Control Valve (M-SCV 200) – Operation…1530
Group 20D: Hydraulic block…1434
PFC Hydraulic System – Hydraulic Block, Summary of References…1542
PFC Hydraulic System – Hydraulic Block, Summary of Components…1543
PFC Hydraulic System – Priority 1 Control Block, Component Information…1545
PFC Hydraulic System – Priority 3 Control Block, Component Information…1547
Section 290: Operator's Cab…1549
Group 15: Tests and Adjustments…1549
Operational Checkout―Summary of References…1551
Safety in the Workplace…1552
Handling Refrigerant…1553
Safety Equipment…1554
In the Event of an Emergency…1555
Storage of Refrigerant Containers…1556
Refrigerant R134a…1557
Important…1558
Operator's Cab – Special Tools…1559
Specification…1560
Explanation Of Checks…1561
Pressure Deviations…1575
Group 20: Operation…1549
Air Condtioning System – Summary of References…1578
Air Condtioning System – R134A Refrigerant…1579
Air Condtioning System – Principle of Heat Exchange…1580
Refrigerant Circuit Layout…1581
Refrigerant Circuit Operation…1582
Component Description…1584
Air Condtioning System – Expansion Valve, Component Information…1588
Thermostat Switch…1590
Heating and Ventilation…1591
Section 299: Special Tools (Dealer-Fabricated)…1593
Group 05: Special Tools (Dealer-Fabricated)…1593
Special Tools (Dealer-Fabricated) — Summary…1595
Retainer Tool…1596
Adjustment Tool…1597
DFRW2—Needle Valve Test Hose Assembly…1598
DFLX10 and DFLX11—Test Harnesses…1599
DFLX12—Special Tool for 11-bit and 29-bit CAN BUS…1600
DFLX14—Solenoid Valve Test Harness…1601
Group 10: Special Tools (Available as Spare Parts)…1593
Special tool information…1603

John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, and 6210J Tractors Diagnosis and Test Service Technical Manual (TM135719)

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