Month: December 2024

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INSTANT DOWNLOAD

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Complete Parts Catalog for Articulated Haulers 861 Volvo BM.

Articulated Haulers 861 Volvo BM Parts Manual.pdf

PRODUCT DETAILS:
Total Pages: 582 pages
File Format: PDF (Windows & Mac & Linux)
Language: English

MAIN SECTIONS
2 – ENGINE WITH MOUNTING AND EQUIPMENT
3 – ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS
4 – POWER TRANSMISSION
5 – BRAKE
6 – STEERING
7 – FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 – MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 – HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS

2 – ENGINE WITH MOUNTING AND EQUIPMENT…….3
21 – ENGINE…….4
Engine with fitting parts…….5
Cylinder block…….8
Crankshaft and related parts…….10
Camshaft…….13
Timing gear casing;timinggears and engine-speed Indicator…….15
Cylinder head…….19
Lubricating oil system…….22
Oil pump…….24
Starting heater 98981 (6374)…….26
Starting heater 98981…….28
22 – LUBRICATING SYSTEM…….30
Cooling system…….31
Charge air cooling system 99006; 99719…….35
Radiator…….38
Water pump with fitting parts…….41
Water pump…….44
Belt transmission mo 38101-…….46
Oil cooler…….48
Engine heater 98982…….50
23 – FUEL SYSTEM…….52
Fuel system…….53
Fuel pipes; injectors…….56
Fuel tank tillv nr -59471…….59
Fuel tank tillv nr 59472-…….61
Fuel injection pump with fitting parts…….63
Injection pump…….65
Centrifugal governor-[3222]…….68
Centrifugal governor…….72
Centrifugal governor 99006 Mo 46982-…….76
Cold-starting device…….81
Smoke limiter…….83
Smoke limiter 99006 Mo 46982-…….85
Feed pump…….87
Injector…….89
Fuel filter…….92
Extra fuel filter 98980 (6355) Earlier Model…….94
Extra fuel filter 98980 Later Model…….96
24 – MISCELLANEOUS…….98
Inlet system…….99
Air filter-[2858]…….101
Pree cleaner; oilbath 98986 (6458)…….103
Air cleaner oil bath…….105
Exhaust system…….107
Exhaust system for underground version…….110
Exhaustheated trailerbody98995 (6417) 99522…….113
Exhaust cooling 99004; 99564…….116
Exhaust-heating 6 x 6 90224…….119
Exhaust cleaning 99004 Tillv Nr -58588…….121
Exhaust cleaning 99564 Tillv Nr 58589-…….123
Turbocharger with fitting parts…….125
Turbo charger…….127
Exhaust brake…….129
Baffle housing…….131
Pneumatic cylinder-[2513]…….133
25 – INLET & EXHAUST SYSTEM…….135
Regulator control…….136
3 – ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS…….138
31 – BATTERY…….139
Electrical system…….140
Electrical system;trailer6x6…….142
Battery with assembling details…….144
Alternator with assembling details…….146
Alternator tillv nr-58781…….149
Alternator tillv nr 58782-…….151
Alternator 99002…….153
Starter motor mo – 40921…….155
Starter motor mo 40922 -…….158
Electrical preheater 98981 (6374) 99823…….160
Headlight washer 98976 (6362)…….162
Lighting;tractor…….164
Windshield wiper and signal horn…….167
Lighting;trailer…….169
Tail light with bracket 6×6…….171
Headlamp…….173
Headlight 98987 (6463) 99824…….175
Headlight; left asy 98977…….177
Headlight guard 98978…….178
Signal lantern with revolving light 98974 (6310)…….180
Large-volume horn 98973 (6282)…….182
Electric components…….184
Electric components 99564…….187
Electric components 99824…….189
Instrument panel tillv nr – 59471…….191
Instrument panel tillv nr 59472 -…….195
Relay panel…….198
Emergency steering 90313-[1701]…….200
4 – POWER TRANSMISSION…….202
41 – CLUTCH; TORQUE CONVERTER…….203
Power transmission…….204
Torque converter tillv nr – 59407 6 X 4…….206
Torque converter tillv nr 59408 – 6 X 4…….209
Torque converter 6×6…….211
Housing;covers and boltings…….213
Clutches;gears and shafts…….216
Forward and reverse clutches…….219
Hydraulic lines and valve…….222
Gear selector valve…….226
Transmission pump…….228
Oil filter…….229
Range selector controls…….231
Pneumatic system for operation of controls Serial No. – 59471…….235
Pneumatic system for operation of controls Serial No. 59472 -…….239
Pneumatic system; trailer6x6…….243
Lock-up clutch tillv nr – 59407…….245
Controls for high and low ranges…….247
Pneumatic cylinder…….249
42 – TRANSMISSION; HYDRAULIC CONTROL…….251
Final gear with housing…….252
Drive axle shafts and drive axle tubes…….255
Pneumatic system for operation of Differential…….257
Controls for differential lock…….259
Power take-off with fitting parts and Controls…….261
Control cylinder…….263
Power take-off…….265
Wheel hub…….268
Wheel equipment; tractor-[0918]…….270
Wheel equipment 6×6…….272
Wheel equipment; tractor…….274
Wheel equipment…….276
43 – GEARBOX…….278
Propeller shafts with fitting parts…….279
Power shafts with fitting parts 6×6…….282
Propeller shaft; trailer 6×6…….284
Double joint…….286
Reduction gear…….287
Reduction gear 6×6…….290
Propeller shaft-[0626]…….293
Propeller shaft…….295
Controls for reduction gear…….297
44 – HYDROSTATIC DRIVE…….299
Drive axle tillv nr -59094…….300
Drive axle tillv nr 59095-…….303
Planet shaft AH 54 K 6×6…….306
Planet shaft ah 54d 6×6…….309
Drive axle gear tillv nr -59094…….312
Drive axle gear tillv nr 59095-…….315
Final drive 6×6-[0349]…….318
Final drive 6×6…….322
Final drive ev 80 6×6…….324
Differential lock tillv nr -59094…….327
Differential lock 6×6…….329
Differential lock tillv nr 59095-…….331
Wheel equipment; trailer SER NO – 59094-[0211]…….333
Wheel equipment; trailer SER NO – 59094…….335
Wheel equipment; trailer SER NO 59095 -…….337
Wheel equipment; trailer 6×6…….339
5 – BRAKE…….341
51 – WHEEL BRAKE…….342
Brake system…….344
Brake system;tractor units Tillv Nr – 59471…….346
Brake system; tractor units Tillv Nr 59472 -…….350
Brake system;tractor pipe lines Inlet And Feeding System…….353
Brake system;tractor pipe lines for Handbrake.tillv Nr -59471…….356
Brake system; tractor pipe lines for handbrake Tillv Nr 59472- ; 6×6…….359
Brake system;tractor pipe lines for Footbrake…….362
Hoses over hitch 6×6…….364
Hydraulic brake system Tractor…….367
Brake fluid system; trailer 6×6…….369
Brake system;trailer units 6 x 4…….371
Brake system; pipe work; trailer Tillv Nr – 58455…….374
Brake system; pipe work; trailer Tillv Nr 58456- 6 X 4…….377
Brake circuit 1; trailer 6×6…….380
Spring-brake 98998…….382
Universal joint brake 6×6…….384
Footbrake valve with mountings…….386
Air-compressor with fitting parts…….388
Air compressor…….390
Anti-freeze reservoir…….392
Air-pressure governor tillv nr -57290…….394
Footbrake valve…….396
Relay valve…….398
Brake unit…….400
Brake unit 6×6…….402
Spring-brake cylinder-[5416]…….404
Brake cylinder…….406
Spring-brake cylinder…….408
Parking brake valve…….411
Disc brake…….413
Disc brake 6×6-[5254]…….415
Drive wheel brake…….417
Bogie-wheel brake…….421
Disc brake 6×6…….424
Adjusting lever-[5147]…….426
Adjusting lever…….428
6 – STEERING…….430
61 – MISCELLANEOUS…….431
Steering system…….432
Emergency steering 90313…….436
Steering gear with fitting parts…….439
Steering gear…….441
Hydraulic pump…….445
Control valve…….447
Steering cylinder…….449
Pressure-regulating valve…….451
7 – FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT…….453
71 – FRAME…….454
Frame;tractor…….455
Engine mounting…….459
Guard plates tractor…….461
Guard plates tractor 98988;98999;(6423)…….463
Collision protector 98993; 98994…….466
Trailer frame and trailer body…….468
Frame; trailer 6×6…….472
Trailer and body 6×6…….475
Hitch…….477
Hitch 6×6…….480
Rear flap; mechanical 98491…….482
Extra flap 98492…….484
Extra flap 99616…….486
Draft hook…….488
72 – SUSPENSION…….490
Bogie suspension…….491
Bogie suspension trailing wheel axle…….494
Bogie-wheel axle with hub…….496
Front bogie axle suspension 6×6…….499
Rear bogie axle suspension 6×6…….502
8 – MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE…….504
81 – CAB; NAKED; CANOPY…….505
Engine hood…….506
82 – ENGINE HOOD; MUDGUARD; FOOT STEP…….509
Drivers cab…….510
Sun vizors and rear view mirrors…….513
Protective roof 99005…….516
Instrument panel and cover plates Tillv Nr -59471…….517
Instrument panel and cover plates Tillv Nr 59472 -…….519
Guards;mudguards and floor plates…….521
Door S_N – 59471…….524
Door S_N 59472 -…….526
Operator's seat-[4030]…….528
Operator's seat…….530
Drivers seat 98979 99820…….533
Drivers seat air norseman 98979 99820…….535
83 – DOORS; HATCH; COVER PLATE; (all)…….538
Heating system…….539
Heater and air control…….543
Cab fan 98972 (6347) 99821…….545
Cab ventilator 99003…….547
Air filter…….549
9 – HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS…….551
91 – WORKING HYDRAULIC; SERVO HYDRAULICS…….552
Hydraulic system…….553
Hydraulic system; trailer6x6…….555
Hydraulic oil tank…….557
Filter…….560
Controls for tipping cylinder…….562
Control duming pipe work 99019; 90365…….565
Hoist cylinder…….567
Hydraulic tipping cylinder 6×6…….569
Pneumatic cylinder tilt limiting…….571
93 – MISCELLANEOUS…….573
Tools 98975…….574
Tools 861 6 x 6 90262…….576
Sign plates and decals-[3435]…….579
Sign plates and decals…….582
Lgf-sign 99537; 6 x 4 99698; 6 X 6…….585

Articulated Haulers 861 Volvo BM Parts Manual

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service Parts manual for Volvo L50C Wheel Loaders.

L50C Volvo Parts Manual.pdf
L50C Volvo Service Repair Manual (bonus material).pdf

PRODUCT DETAILS:
Total Pages: 721 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
L50C Volvo Parts Manual
0 – Foreword..3
0 – GENERAL..4
03 – SPECIFICATIONS..5
Product identification plate..6
2 – ENGINE WITH MOUNTING AND EQUIPMENT..7
21 – ENGINE..8
Camshaft..9
Crankshaft and related parts TD 040 GA..11
Crankshaft and related parts TD 040 KAE; TD 40 GFE..13
Cylinder block TD 040 GA; TD 40 GFE..15
Cylinder block TD 040 KAE..18
Cylinder head..21
Cylinder liner and piston..24
Engine TD040GA; TD40KAE; TD40GFE..26
Engine mounting..28
Oil sump..30
Repair kits for engine..32
Timing gear casing..37
Valve mechanism..40
22 – LUBRICATING SYSTEM..42
Oil cooler..43
Oil pump..46
23 – FUEL SYSTEM..48
Centrifugal governor..49
Feed pump TD 040 KAE..53
Filter-[3056]..55
Fuel filter TD 040 GA; TD 40 GFE..57
Fuel injection pump Mounting TD040GA; TD40GFE..59
Fuel injection pump with fitting parts TD 040 KAE..61
Fuel lines Injectors TD 040 GA; TD 40 GFE..63
Fuel pump TD 040 GA; TD 40 GFE..66
Fuel system Fuel pump – fuel inject…68
Fuel system Fuel tank – fuel pump-[3214]..70
Fuel system Fuel tank – fuel pump..72
Fuel system; Fuel pump – fuel inject.-injector TD 040 KAE..74
Fuel tank..77
Injection pump TD 040 KAE..79
Injection pump TD040GA; TD40GFE..82
Injector TD 040 GA; TD 40 GFE..84
Regulator cover..86
25 – INLET & EXHAUST SYSTEM..88
Air filter-[2748]..89
Exhaust system..91
Inlet manifold TD 040 GA; TD 40 GFE..93
Inlet manifold TD 040 KAE..95
Inlet system..96
Oil bath filter 92572..98
Turbo charger Mounting TD040GA..100
Turbo charger TD 040 GA..102
Turbocharger with exhaustmanifold TD 040 KAE; TD 40 GFE..104
26 – COOLING SYSTEM..107
Coolant filter 92423..108
Cooling system TD 040 GA; TD 40 GFE..110
Cooling system TD 040 KAE..111
Cooling system-[2716]..113
Engine heater 92202; 92479..115
Extra water pump TD 040 KAE..117
Fan and fan housing..119
Radiator; fitting..121
Water pump TD 040 GA..123
Water pump TD 040 KAE; TD 40 GFE..125
27 – ENGINE CONTROL..128
Hand throttle 92459..129
Pedal..131
Regulator control..133
Stop control TD 040 KAE..135
3 – ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS..137
31 – BATTERY..138
Battery with fitting parts..139
32 – ALTERNATOR; CHARGE REGULATOR..141
Alternator Mounting TD040GA; TD40GFE..142
Alternator with assembling details TD040KAE..144
Alternator..146
33 – STARTING SYSTEM..148
Starter motor..149
Starter motor; mounting..151
35 – LIGHTING..152
License plate lamp 92457..153
Lighting; front..154
Lighting; rear..156
Work lights Front 92453..158
Work lights; front 80030..160
Work lights; front 80032..162
36 – OTHER ELECTRICAL EQUIPMENT..164
Back-up warning unit 93535..165
Compressor horn..166
Rotating beacon 92454..168
Windshield washer STD 92460..170
Windshield wiper; front..172
Windshield wiper; rear 92157..174
37 – CABLE; FUSE; RELAY..176
Cable harness Adjustableflow from hydraulic function 003. 94722..178
Cable harness Alternator..181
Cable harness Engine 33730..183
Cable harness Front 33730..186
Cable harness Starter relay TD 040 KAE..189
Cable harness Transmission 33730; 33747..191
Cable harness for Cdc-steering 94608..193
Cable harness for central lubrication 92752..195
Cable harness. 004th function. Pressure draining 94878..197
Cable harness; air-suspensioned seat. 94906; 94910..199
Cable harness; boom suspension system. 94616..201
Cable harness; engine 33730; 33747..203
Cable harness; front 33747..206
Cable harness; rear..208
Cable harness; secondary steering system. 93537..210
Cable harnesses; cab-[2000]..212
Cable harnesses; cab-[2016]..214
Cable harnesses; cab..216
Cable harnesses; gear lever carrier 33747..218
Cable terminal..220
Connectors..222
Electrical distribut.unit and cable harness 33748..225
Electrical distribut.unit and control unit 33731..227
Electrical distribut.unit and control unit 33748..230
Electrical system 005th and 6th fuction 94777..233
Electrical system Forward_reverse switch 92771..235
Electrical system Parking brake alarm 92158..237
Electrical system Secondary steering system 94454..239
Electrical system air conditioning 92161; 93674..241
Electrical system; extra forward and reverse switch 33748..244
Electrical system; parking brake alarm 93443..246
Electrical system;electric hydraulic parking brake 93444..248
Hose and manifold..250
Housings for timers and tabs..253
Humidity-proof connections..255
Insulator for spade terminal..257
Pin insulator..259
Pin..261
Single acting lifting system. Differential lock 92147; 94615; 94644..264
Spade terminal..266
Wires..269
38 – INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM..274
Display panel 92467..275
Instruments panel 33731..276
Instruments panel 33748..279
Relays; sensors and solenoid valves Reference list..281
Switch panel 33748..285
Switch panel..287
39 – MISCELLANEOUS..290
Electrical system Radio 92462..291
4 – POWER TRANSMISSION..293
42 – TRANSMISSION; HYDRAULIC CONTROL..294
Coupling-[1127]..295
Coupling..297
Gearbox mounting..299
Hydraulic transmission..301
Lubricating system Hydraulic transmission..304
Valve; circuit body and return valve..306
44 – HYDROSTATIC DRIVE..307
Filter..308
Hoses; Pump – hydraulic motor..309
Hydraulic motor..311
Pedal 92958..314
Pump..316
Pump; Mounting..319
Speed control 92958..321
Suction hose and filter..323
45 – PROPELLER SHAFT..325
Propeller shaft-[854]..326
Propeller shaft..327
Propeller shaft; mounting..329
46 – FRONT AXLE; REAR AXLE..331
Axle; front AWB 010 STD; 92147; 94644..332
Controls; differential lock 92147; 94644..335
Differential lock 92147; 94644 (23836)..337
Final drive 94644; 23820..339
Final drive STD; 92147; 94644..343
Planetary axle; mounting AWB 010..347
Planetaty shaft Rear Awb 010 AWB 10 STD; 94644..349
49 – MISCELLANEOUS..351
Cooling system..352
5 – BRAKE..354
51 – WHEEL BRAKE..355
Multi-disc brake SEE SB 510 WLO 25..356
52 – HYDRAULIC BRAKE SYSTEM..358
Brake system..359
Dual brake pedals 92461..361
Footbrake valve Mounting..363
Footbrake valve..365
Valve Accumulators..367
55 – PARKING BRAKE..369
Brake shoes..370
Brake system;electric hydraulic parking brake 93443..371
Hand brake 33730 33731..373
Hand brake 33748; 33747..375
6 – STEERING..377
64 – STEERING..378
Adjustable steering wheel 92465..379
Auxiliary steering system 93537..381
Auxiliary steering system 94454..384
Hydraulic cylinder-[4641]..387
Hydraulic cylinder; assembly..389
Sensor 94454 93537..391
Steering column assembly..393
Steering system..395
Steering unit..397
Valve housing-[4616]..399
66 – LEVEL STEERING..401
Comfort drive control 94608..402
Valve; circuit body and return valve 94608..404
7 – FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT..406
71 – FRAME..407
Frame..408
Lamp retainer..410
Protecting plates..412
Protection for lighting 92654; 92655; 92656..413
Rear hitch and counterweight..415
74 – FRAME LINK..417
Frame link..418
77 – WHEELS; TRACKS; TYRE; HUB; DRUM..420
Wheel 015;5-25_12; 15;5-R25..421
Wheel 017;5-R25..423
Wheel 017;5R25..425
Wheel 455_70 R24..427
Wheel 600-26;5_12 TWIN..428
8 – MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE..429
81 – CAB; NAKED; CANOPY..430
Cab body 33748..431
Cab body..432
Cab mounting block 33747..434
Operator's cab 33748..436
Operator's cab..438
82 – ENGINE HOOD; MUDGUARD; FOOT STEP..440
Engine cover..441
Fenders 92166..443
Fenders 92361..445
Foot step..447
Protecting plates Radiator casing..449
Radiator casing..451
Side hatches 94473; 92624..453
Side hatches..455
83 – DOORS; HATCH; COVER PLATE, (all)..458
Door mounting..459
Door..461
Hatches 33748..464
84 – TRIM PART; OUTSIDE; GLASS; SEALING MOULDING..466
Glass panes..467
Rear view mirror 33731..469
Rear view mirror 33748..472
Sliding window 92165; 94825..474
85 – CAB INTERIOR; UPHOLSTERY..476
Armrest 94608..477
Cdc-steering; armrest; mounting 94608..479
Driver's seat; air suspensioned Isri 94906-[3651]..481
Driver's seat; air suspensioned Isri 94906..483
Driver's seat; assembly..485
Instructor's seat 92464..487
Insulating matting 92705..489
Insulating matting..491
Interior components-[3839]..494
Interior components..496
Operator seat Isri 94900; 94904..497
Operator seat Isri 94902..499
Operator seat with fitting parts 33748..501
Operator's seat 33748..503
Operator's seat Be-ge 94908; 94910..505
86 – PROTECTIVE EQUIPMENT..507
Windshield guard for windshield 94989..508
87 – AIR CONDITIONING UNIT..510
Air compressor 92161; 93674..511
Air ducts..513
Air filter..515
Assembly hoses Evaparator; receiver drier; condenser. 92161; 93674..518
Compressor; assembly 92161..520
Compressor; assembly 93674..522
Condenser; assembly 92161; 93674..524
Evaporator; assembly 92161; 93674..526
Fan..529
Heating system..530
Radiator and control..531
88 – INTERIOR EQUIPMENT..533
Armrest 33748..534
Instrument panel 33748..536
Instrument panel..538
Radio bracket 92462..540
89 – MISCELLANEOUS..542
050 km_h Sign 92669..543
German version 92367..545
Sign plates and decals..547
Slow moving vehicle sign 99591..549
Tools 92360..551
Tools 92450; 92451..553
9 – HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS..555
91 – WORKING HYDRAULIC; SERVO HYDRAULICS..556
Boom lowering system STD..558
Boom suspension system; hydraulic hoses 94616..559
Boom suspension system; valves and nipples 94616..561
Control valve 94879; 93691..564
Feed lines; hydraulic power take off Gp 92660..566
Hydraulic oil tank..568
Hydraulic pump..570
Hydraulic system 003rd function 93691..572
Hydraulic system 003rd function 94879..574
Hydraulic system Feed lines and return lines..577
Hydraulic system Feed- and return line Hydraulic valve..579
Hydraulic system Lift function..581
Hydraulic system Tilt function..583
Hydraulic system; 004th function 94878..585
Hydraulic system; Feed line 005th and 6th funcion 94777..588
Hydraulic system; attachment bracket 93989 94702..590
Hydraulic system; feed- and return lines; 005th and 6th funcion 94777..593
Hydraulic system; tool bar 94942..596
Hydraulic valve..598
Oil filter..600
Servo hydraulic Control and valves 94722..602
Servo hydraulic Control lines Tilting..604
Servo hydraulic Feed line and return line..606
Servo hydraulic Fitting parts 33730..608
Servo hydraulic hydraulic lines 94722..610
Servo system Control lines Lifting..612
Servo valve 33747..614
Servo valve STD; 94879 ; 94850; 92163; 92164;93691..616
Servo valve with fitting parts 33747..619
Servo valve; assembly 33730..621
Single acting lifting function 94615..623
Suction and return lines;gp 92660..626
Valve body Assembly..629
Valve housing..631
Valve section 003rd function 94879; 93691..633
Valve section 94777-[2508]..635
Valve section 94777..637
Valve section Lift..639
Valve section Tilt..641
Valve section with assembly parts 94777..643
Valve; circuit body and return valve 94616..645
92 – MECHANICAL EQUIPMENT_ATTACHMENT..647
Attachment bracket 93642..648
Attachment bracket 94942; 80007..650
Hydraulic cylinder 94942;80007..652
Hydraulic cylinder..654
94 – UNIT; LOAD HANDLING..656
Assemble attachment bracket. 33739..657
Bucket positioner and boom kickout STD; 92163; 92164..659
Forward links with fitting parts 33739..661
Hydraulic cylinder; Lifting..663
Hydraulic cylinder; Tilting..665
Lifting frame work with assembly parts 33739..667
Lifting unit 33739..669
Lifting unit..671
Lifting- and tilt cylinder with assembly parts. 33739..674
Links with fitting parts..676
Rear links with assembly parts 33739..680
99 – MISCELLANEOUS..682
Central lubrication 92752..683
Central lubrication for tool bar. 92753..685
Distribution block; B001 92752..687
Distribution block; B002. 92752..689
Distribution block; B003. 92752..691
Pump 92752..693
L50C Volvo Service Repair Manual (bonus material)..695
0 – Foreword..696
0 – GENERAL..697
00 – DESCRIPTION; COMPLETE MACHINE..698
Description_037-06..699
Product identification plates..700
03 – SPECIFICATIONS..701
Brakes..702
Capacities and weights..704
Engine..705
Hydraulic system..709
Power transmission..710
Standard tightening torques..712
Steering..714
Tightening torques..715
07 – STANDARD TIME..717
Time Guide..718
08 – TOOL..727
E 1664 Lifting tool..728
E 1666 Spanner..729
E-tools..730
E1752 Lifting yoke..731
1 – STANDARD PARTS; SERVICE..732
17 – SERVICE..733
Cleanliness when working on hydraulic systems..734
Electric welding..735
Repairing hydraulic system..736
Towing..737
2 – ENGINE WITH MOUNTING AND EQUIPMENT..740
20 – GENERAL..741
Description_001-58..742
Specifications_001-27..746
21 – ENGINE..748
Engine; fitting..749
Engine; removing..752
Specifications_059-40..759
Valves; adjusting..760
Valves; adjusting_059-23..762
22 – LUBRICATING SYSTEM..764
Specifications_058-18..765
23 – FUEL SYSTEM..766
Checking speed with multimeter..767
Feed pump; checking feed pressure TD040KAE..769
Fuel system; air bleeding TD040 KAE; TD40 GFE..771
Fuel system; air bleeding TD040GA..773
Fuel tank and combined tank unit; changing..775
Fuel tank; specifications..778
Injection pump; fitting and adjusting injection timing; TD040KAE..779
Injection pump; fitting; TD040GFE..783
Injection pump; removing TD040GFE..788
Injection pump; removing; TD040KAE..792
Injection pump; specifications..795
Injection timing adjustment at low engine temp.; TD040GFE..796
Injection timing; checking and adjusting; TD040GA..798
Injection timing; checking and adjusting; TD040KAE..799
Injectors and delivery pipes; specifications..803
Low and high idling speed; checking and adjusting..804
Specifications_056-26..807
25 – INLET & EXHAUST SYSTEM..808
Air cleaner; specifications..809
Intercooler; specifications..810
Turbocharger; specifications..811
26 – COOLING SYSTEM..812
Specifications; coolant pump and thermostat..813
Specifications_049-22..814
27 – ENGINE CONTROL..815
Cold-starting control; specifications..816
3 – ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS..817
30 – GENERAL..818
General description..819
Special instructions when working on the electrical system..820
Specifications_039-23..821
31 – BATTERY..822
Battery; charging..823
Specifications_038-25..824
32 – ALTERNATOR; CHARGE REGULATOR..825
Specifications_037-39..826
33 – STARTING SYSTEM..827
Specifications_ ..828
35 – LIGHTING..829
Headlights; adjusting..830
Specifications ..831
37 – CABLE; FUSE; RELAY..832
Code key for diodes..835
Codes used in wiring diagrams..837
Electrical distribution box..847
Explanations of wiring diagrams;..851
List of circuits..853
Specifications..860
Wiring diag. 022D. 4th hydr. fctn.; 4th hydr. fctn.; actvt. thru. brake press. chg. attachm. locking brake press. chrg. and attachm. lock..861
Wiring diagram 001. Main diagram BCU..865
Wiring diagram 001B. Main diagram ECU..869
Wiring diagram 001C. Main diagram Limp-Home operation ECU..873
Wiring diagram 002. BCU..877
Wiring diagram 002B. ECU..881
Wiring diagram 002D. Intermittent wiper BCU..885
Wiring diagram 003. Gear shifting BCU..888
Wiring diagram 003B. Gear shifting ECU..892
Wiring diagram 003C. Limp-Home opn. ECU..896
Wiring diagram 004. Gear shift solenoids ECU..900
Wiring diagram 005. Engine TD40GA; TD40GFE..903
Wiring diagram 005D. Engine TD40KAE..906
Wiring diagram 005D. Preheating engine TD40KAE. W.e.fr. serial number 11233..910
Wiring diagram 006. Hydraulics..913
Wiring diagram 006B. Single lever ctrl. w. boom kick-out and bucket pos.; floating position and max. flow via 3rd hydr function..917
Wiring diagram 007B. Secondary steering ECU..921
Wiring diagram 007C. Secondary steering with ECU by-passed..924
Wiring diagram 008. Pressure draining; brake pressure charging;..927
Wiring diagram 008D. Brake pressure charging; attachment locking..931
Wiring diagram 009. Travel lights..934
Wiring diagram 010. Working lights; rotating warning beacon..938
Wiring diagram 011. Stop lights; direction indicators; hazard flashers..941
Wiring diagram 012. Radio; heated seat..945
Wiring diagram 013. Instruments; sensors BCU..949
Wiring diagram 013B. Instr; sensors ECU..954
Wiring diagram 013C. Instruments; sensors ECU during Limp-Home operation..959
Wiring diagram 014. Instr.; alternator BCU..963
Wiring diagram 014B. Instr.; alternator ECU..968
Wiring diagram 014C. Instruments; alternator ECU during Limp-Home operation..973
Wiring diagram 015. Dual control Forward_Reverse BCU..977
Wiring diagram 015B. Dual control Forward_Reverse ECU..980
Wiring diagram 015C. Dual control Forward_Reverse during Limp-Home operation ECU..984
Wiring diagram 015D. Single lever control..988
Wiring diagram 016. Air conditioning (AC)..991
Wiring diagram 017. Service display unit..994
Wiring diagram 018. Boom Susp. System (BSS)..999
Wiring diagram 019. Mechanical parking brake with Rider truck safety norm..1004
Wiring diagram 019D. Hydraulic parking brake..1009
Wiring diagram 020B. Lever steering (CDC) w. adjust. ramp gen. Up to and incl. s_n 10631..1012
Wiring diagram 020B. Lever steering (CDC) w. non-adjust ramp gen. W.e.fr. s_n 10632..1016
Wiring diagram 021. 4th hydraulic function; activation..1020
Wiring diagram 021D. 4th hydraulic function; activation..1023
Wiring diagram 022. 4th hydraulic function;..1026
Wiring diagram 023. 3rd hydraulic function..1029
Wiring diagram 025. 5th and 6th hydr. function..1033
Wiring diagram 026. Automatic greasing..1037
Wiring diagram 027. Automatic greasing with..1041
Wiring diagram 028. Mechanical and hydraulic..1045
Wiring diagram 028B. Mechanical and hydraulic parking brake with ECU..1049
38 – INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM..1053
Control unit BCU..1054
Control unit ECU..1056
Instruments and controls..1059
Limp-Home operation; by-passing control units..1061
Menu overview; service display unit..1063
Monitored functions ECU..1064
Other electrical functions controlled by the control unit; ECU..1067
Service display unit..1068
Units connected to control unit BCU..1076
Units connected to control unit ECU..1078
4 – POWER TRANSMISSION..1081
40 – GENERAL..1082
Description ..1083
42 – TRANSMISSION; HYDRAULIC CONTROL..1090
Gearbox; checking oil pressure..1091
Gearbox; installing..1094
Gearbox; removing..1101
Gearbox; sectional view..1110
44 – HYDROSTATIC DRIVE..1112
Hydrostatic pump; removing and fitting..1113
Hydrostatic system; checking oil pressure..1118
Hydrostatic system; neutral position..1123
Obligatory measures when repairing the hydrostatic system..1129
46 – FRONT AXLE; REAR AXLE..1132
Axle; installing..1133
Axle; removing..1135
49 – MISCELLANEOUS..1138
Clutch shaft; high-gear..1139
Clutch shaft; low-gear..1140
Differential carrier assembly; front axle..1141
Planetary gear..1142
Rear axle suspension..1143
5 – BRAKE..1144
50 – GENERAL..1145
Description of function..1146
Description_..1148
51 – WHEEL BRAKE..1150
Brake discs; checking wear (with built-in wear indicator)..1151
Brake discs; checking wear (without built-in wear indicator)..1154
52 – HYDRAULIC BRAKE SYSTEM..1156
Brake discs; replacing..1157
Brake system; checking and adjusting pressure in circuit..1166
Foot brake valve (removed); reconditioning..1169
Foot brake valve; description of function..1173
Functional check..1174
Hydraulic diagram; brake system..1179
Retardation; functional check..1182
55 – PARKING BRAKE..1184
Parking brake; adjusting..1185
6 – STEERING..1188
60 – GENERAL..1189
Description..1190
64 – STEERING..1191
Hydraulic diagram; steering system Basic Machine..1192
Hydraulic pump; description..1195
Steering cylinder; reconditioning..1198
Steering cylinder; replacing..1201
Steering cylinder; sectional view..1205
Steering pressure and stand-by pressure; checking and adjusting..1206
Steering valve; description..1209
Steering valve; reconditioning..1213
66 – LEVEL STEERING..1222
Hydraulic diagram; lever steering CDC Basic Machine..1223
7 – FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT..1225
70 – GENERAL..1226
General description..1227
74 – FRAME LINK..1228
Frame joint bearing; lower; sectional view..1229
Frame joint bearing; upper; sectional view..1230
Frame joint; replacing bearings..1231
75 – AXLE SUSPENSION..1254
Axle suspension; checking axial and radial clearance..1255
9 – HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS..1257
91 – WORKING HYDRAULIC; SERVO HYDRAULICS..1258
3rd function; flow control..1259
4th hydraulic function; description..1261
4th hydraulic function; wiring diagram..1262
5th_6th hydraulic functions and attachment..1264
5th_6th hydraulic functions; adjusting speed_flow..1266
5th_6th hydraulic functions; basic adjustment of speed_flow..1268
5th_6th hydraulic functions; description..1270
5th_6th hydraulic functions; draining the quick-action couplings..1272
5th_6th hydraulic functions; electrical functions…1273
5th_6th hydraulic functions; monitoring function; checking..1276
5th_6th hydraulic functions; wiring diagram..1279
Accumulator; Boom Suspension System;..1282
Attachment hydraulics GP; description..1285
Attachment hydraulics GP; wiring diagram..1287
Boom Suspension System; description..1288
Boom Suspension System; hydraulic diagram..1294
Boom Suspension System; safety valve; checking; adjusting..1297
Boom Suspension System; wiring diagram..1301
Control valve; description..1303
Hydraulic diagram basic machine; 3rd_4th;..1318
Hydraulic diagram; basic machine..1321
Hydraulic oil pump; removing and fitting..1324
Servo pressure; checking and adjusting..1326
Servo valve; description..1328
Shock valve; lifting function; checking and adjusting..1331
Shock valve; tilting function; checking and adjusting..1334
Stand-by pressure; checking and adjusting..1339
Working hydraulics; description..1341
Working pressure; checking and adjusting..1346
94 – UNIT; LOAD HANDLING..1348
Lifting arm; replacing bearings “A”..1349
Lifting cylinder; replacing..1353
Lifting cylinder; sectional view..1357
Lifting frame; replacing bearings “B”..1358
T link; upper; removed; replacing bearings “HIJ”..1364
T-link; lower; removed; replacing bearings “GH”..1371
Tilting arm; replacing bearings “GDF”..1376
Tilting cylinder; replacing..1382
Tilting cylinder; sectional view..1386

Volvo Construction L50C Wheel Loaders Parts Manual

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete Repair Service Technical Manual for John Deere 6145J, 6165J, 6180J & 6205J (Worldwide Edition), with all the shop information to maintain, repair, and rebuild like professional mechanics.

John Deere 2WD or MFWD Tractors 6145J, 6165J, 6180J & 6205J (Worldwide Edition) 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.

TM801519 Repair Technical Manual 6145J, 6165J, 6180J and 6205J Tractors / (Repair Only) (Diagnostic manual with electrical wiring diagrams sold separately)
TM801528 Repair Technical Manual Tracteurs 6145J, 6165J, 6180J et 6205J—Manuel technique de remise en état
TM801554 Repair Technical Manual Tratores 6145J, 6165J, 6180J e 6205J — Manual Técnico de Reparo
TM801563 Repair Technical Manual Tractores 6145J, 6165J, 6180J y 6205J — Manual técnico de reparación

PRODUCT DETAILS:
Total Pages: 1,311 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English etc.

MAIN SECTONS
Foreword
Safety
Safety Regulations
General Information
Specifications
Serial Numbers
Adjusting
Engine
Removing and Installing Engine
Removing and Installing Engine – 6205J Tractors
Fuel Systems, Air Intake, Cooling and Exhaust
Speed Control Link
Fuel System
Air Intake System
Cooling System
Exhaust System
Electrical System
Connectors
Wiring Harnesses
Charging Circuit
Starter Motor Circuit
Fuses, Relays and Switches
Monitoring Systems
Electrical Components
Electronic Control Units
General Information
Removal and Installation of Electronic Control Units
PowrQuad Transmission
Removing and Installing PowrQuad Module
Transmission Selectors Control
PowrQuad Module
Removing and Installing Range Box
Range Box
Drive Systems
Removing and Installing Component
U-Jointed Shafts and Torsional Damper
Front-Wheel Drive Clutch – 6145J Tractor
Front-Wheel Drive Clutch – 6165J, 6180J and 6205J Tractors
Rear Differential – 6145J Tractor
Rear Differential – 6165J, 6180J and 6205J Tractors
Hydraulic Pump Drive
Final Drives
Rear PTO
Steering and Brakes
Hydrostatic Steering
Steering – AutoTracAutoTrac is a trademark of Deere & Company
Brake Valve
Rear Wheel Brakes
Air Brake System
Hydraulic System
Controls
Oil Filters, Charge Pump and Hydraulic Pump
Valve Block – 6145J Tractor
Valve Block – 6165J, 6180J and 6205J Tractors
Rockshaft
Selective Control Valves and Couplers – 6145J Tractor
Selective Control Valves and Couplers – 6165J, 6180J and 6205J Tractors
Miscellaneous
Removing and Installing Components
Main Chassis
Front Wheels, Rear Wheels and Fenders
Center Link Bracket and Swinging Drawbar
Operator`s Cab
Removing and Installing Components
Air Conditioning System
Heating System
Operator`s Cab
Special Tools (Dealer-Fabricated)

TABLE OF CONTENTS
Section 05: Safety…25
Group 05: Safety Regulations…1286
Recognize Safety Information…468
Follow Safety Instructions…28
Replace Safety Signs…29
Wear Protective Clothing…30
Prevent Battery Explosions…31
Service Tires Safely…32
Keep ROPS Installed Properly…33
Park Machine Safely…34
Handle Fluids Safely—Avoid Fires…35
Handle Fuel Safely—Avoid Fires…36
Prepare for Emergencies…37
Work in Clean Area…38
Prevent Machine Runaway…39
Work In Ventilated Area…40
Avoid High-Pressure Fluids…41
Use Proper Lifting Equipment…42
Illuminate Work Area Safely…43
Use Proper Tools…44
Live With Safety…45
Safety Measures on Electronic Control Units…46
Section 10: General Information…253
Group 05: Specifications…1249
Engine…51
PTO…53
Clutch Specifications…1249
Transmission Specifications…1249
Brakes Specifications…1249
Hydraulic System…57
Electrical System…59
Tractor Weight in Standard Configuration…60
Capacities…62
Tire Combination Chart…64
Dimensions…66
Dimensions 6205J Tractor…68
Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I…70
Multipurpose Extreme Pressure (EP) Grease…72
Transmission and Hydraulic Oil…73
Front-Wheel Drive Axle Oil (Standard)…74
Front-Wheel Drive Oil (3 Meters)…76
Metric Bolt and Screw Torque Values…78
Unified Inch Bolt and Screw Torque Values…80
Hydraulic system inch fitting torques…82
Hydraulic system metric fitting torques…83
Group 10: Serial Numbers…47
Interpreting the Serial Number of Your Machine – 17 digits PIN…86
Year of Production Table (Digit 5)…87
Transmission Type Table (Digit 6)…88
Identification Numbers…89
Tractor Identification Number…90
Engine Serial Number…91
PowrQuad™ Transmission Serial Number…92
Differential Housing Serial Number…93
Rear Final Drives Serial Numbers…94
Front-Wheel Drive Serial Number—Dana…95
Sub-Assembly Serial Numbers…96
Group 15: Adjusting…48
General Specifications – 6205J Tractors…98
Using High-Pressure Washers…99
Preliminary Engine Test…100
Removing and Cleaning the Primary Air Cleaner Element…101
Checking the Air Cleaner Safety Element…102
Installing the Primary Filter Element…103
Checking Air Intake System Connections for Leaks…104
Checking the Crankcase Vent Hose for Clogging…106
Cleaning Radiator Screen…107
Checking Expansion Tank Cap…109
Checking for Leaks in Radiator…110
Checking Connections of Cooling System…111
Checking Engine Thermostat…113
Cleaning Water Separator…114
Checking Fuel Filter…115
Checking Fuel Injection Pump Adjustment…116
Checking the Fuel Transfer Pump Operation – 6205J Tractors…117
Cleaning Water Trap – 6205J Tractors…118
Checking Fuel Filter – 6205J Tractors…119
Bleed Fuel System – 6205J Tractors…208
Checking Engine Speed Control Link Adjustment…182
Cleaning Battery, Cables and Battery Box with a Clean Cloth…122
Checking Neutral Start Circuit…123
Checking Starter Motor…124
Checking Lighting Circuit…125
Final Engine Checks…126
Tractor Operation Check…127
Section 20: Engine…128
Group 00: Removing and Installing Engine…162
Special Tools…1284
Specifications…1249
Removing Engine…150
Installing Engine…162
Group 05: Removing and Installing Engine – 6205J Tractors…128
Specifications…1249
Removing Engine…150
Installing Engine…162
Engine Mounting…169
Replace the Engine Mountings…171
Section 30: Fuel Systems, Air Intake, Cooling and Exhaust…176
Group 05: Speed Control Link…176
Specifications…1249
Other Material…1293
Hand Throttle Lever and Accelerator Pedal Adjustment…188
Speed Control Link Adjustment…182
Hand Throttle Lever – Exploded View…183
Accelerator Pedal, with Mechanical Speed Control…185
Accelerator Pedal Adjustment…188
Replace Accelerator Pedal Assembly – 6205J Tractors…189
Remove Accelerator Pedal Potentiometer – 6205J Tractors…190
Group 10: Fuel System…176
General Information…253
Specifications…1249
Removing Fuel Tank…196
Installing Fuel Tank…198
Replacing Fuel Gauge Sensor Unit…199
Replacing Fuel Transfer Pump…200
Replacing Fuel Filter…201
Bleeding Fuel System…202
Fuel System – 6205J Tractor…204
Replace the Fuel Transfer Pump – 6205J Tractor…206
Changing the Fuel Filters – 6205J Tractors…207
Bleed Fuel System – 6205J Tractors…208
Group 15: Air Intake System…176
General Information…253
Air filter – Exploded view…211
Replacing Air Filter Restriction Sensor…212
Group 20: Cooling System…176
General Information…253
Specifications…1249
Removing Radiator…216
Installing Radiator…226
Replacing Fan…227
Removing and Installing the Expansion Tank…228
Removing and Installing Thermostat…231
Fill Cooling System with Coolant…232
Fill Cooling System with Coolant – 6205J Tractors…235
Remove and Install the Change Air Cooler…238
Remove and Install the Charge Air Cooler – 6205J Tractors…240
Releasing Drive Belt Tension…242
Replacing Engine Fan Belt…243
Replacing Drive Belt Tensioner…246
Repairing Fan Console…247
Remove and Install Fan Console (with Mechanical Coolant Pump)…249
Remove and Install Oil Cooler…250
Group 30: Exhaust System…177
General Information…253
Specifications…1249
Muffler and Exhaust Pipe…255
Section 40: Electrical System…260
Group 05: Connectors…294
Special Tools…1284
General…266
Using high-pressure washers…267
Disconnecting electrical circuits…432
Reconditioning Wire Ends…269
Installing a Terminal…270
WEATHER PACK Connectors…294
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Rear Terminal Lock…260
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Front Terminal Lock…260
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connectors…294
CAN BUS Terminating Resistor Connector…285
Electronic Control Unit Connectors…294
Connectors…294
CRIMP SNAP IN Connectors…299
KOSTAL Connectors…301
DEUTSCH Connectors…304
ITT Connector…308
Individual Terminals…312
Fuse and Relay Box — Open Station Tractors…314
Fuse and Relay Boxes — Cab Tractors…317
Group 10: Wiring Harnesses…260
Disconnecting Electrical Circuits…469
Wire Numbers and Color Codes…323
Location of Ground Points…324
Wiring Harness W01 — Power Supply…327
Removing and Installing Wiring Harness W01 — Power link Box (6205J Tractors)…328
Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Open Station Tractors)…329
Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Cab Tractors)…331
Removing and Installing Wiring Harness W02 — Engine Wiring Harness (6205J Tractors)…333
Wiring Harness W03 — Starter Relay…335
Wiring Harness W04 — Headlights…336
Wiring Harness W04 – Headlights – 6205J Tractors…337
Removing and Installing Wiring Harness W05 — Battery Cables (except 6205J)…338
Removing and Installing Wiring Harness W06 — Backup Alarm…340
W06 — Backup Alarm Wiring Harness…341
Removing and Installing Wiring Harness W08 — Open Station Tractors…342
Removing and Installing Wiring Harness W08 — (Cab Tractors without AutoTrac AutoTrac is a trademark of Deere & Company Integrated)…261
Removing and Installing Wiring Harness W08 — (Cab Tractors with AutoTrac AutoTrac is a trademark of Deere & Company Integrated)…261
Removing and Installing Wiring Harness W09 — Console…348
Removing and Installing Wiring Harness W09 — Console (6205J Tractors)…349
Removing and Installing Wiring Harness W18 — Sun Canopy…351
Removing and Installing Wiring Harness W19 — Cab Roof…352
Removing and Installing Wiring Harness W20 — Loudspeakers…354
W21 — Rear Wiper Switch Wiring Harness…355
W22 — Rear Wiper Wiring Harness…356
W23 — Rear Wiper Supply Wiring Harness…357
Removing and Installing Wiring Harness W26 — Fan and Air Conditioning…358
Removing and Installing Wiring Harness W28 — Front End of Transmission (Open Station Tractors)…359
Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors without AutoTrac AutoTrac is a trademark of Deere & Company Integrated)…261
Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors with AutoTrac AutoTrac is a trademark of Deere & Company Integrated…261
Removing and Installing Wiring Harness W30 — Rear End of Transmission (Open Station Tractors)…364
Removing and Installing Wiring Harness W30 — Rear End of Transmission (Cab Tractors)…365
Wiring Harness W31 — Power Take-Off for 7-Pin Socket…366
Removing and Installing Wiring Harness W43 — GreenStar™ Roof Wiring Harness…367
Removing and Installing Wiring Harness W44 — GreenStar™ Display Wiring Harness…368
Removing and Installing Wiring Harness W45 — AutoTrac™ SBBC Wiring Harness…369
Removing and Installing Wiring Harness W46 — Steering Wheel Position Wiring Harness…371
Removing and Installing Wiring Harness W47 — GreenStar™ Display Wiring Harness…372
Removing and Installing Wiring Harness W49 — Implement CAN Bus Wiring Harness…373
Removing and Installing Wiring Harness W94 — Wheel Angle Sensor Wiring Harness (Standard Front Axle)…374
Removing and Installing Wiring Harness W94 — Wheel Angle Sensor Wiring Harness (3 Meters Front Axle)…375
Group 15: Charging Circuit…262
Special Tools…1284
Specifications…1249
Repairing the Alternator…379
Disconnecting Electrical Circuits…469
Removing/Installing Alternator…381
Removing/Installing Alternator Pulley…383
Group 20: Starter Motor Circuit…262
Specifications…1249
Repairing the Starting Motor…387
Disconnecting Electrical Circuits…469
Removing and Installing Starter Motor…389
Group 25: Fuses, Relays and Switches…262
Note…437
Special Tools…1284
Specifications…1249
Removing Hood Covers…394
Disconnecting Electrical Circuits…469
Fuses—Junction Box…398
Fuse and Relay Box—Open Station Tractors…399
Fuse and Relay Box—Cab Tractors without AutoTrac AutoTrac is a trademark of Deere & Company Integrated…262
Fuse and Relay Box—Cab Tractors with AutoTrac AutoTrac is a trademark of Deere & Company Integrated…262
Fuses and relays (Power Link Box)…410
Power Link Box- Components…411
Replacing Starter Motor Relay…412
Replacing Starter Motor Relay – 6205J Tractors…414
Replacing Starter Switch…416
Replacing Brake Switches…417
Replacing Light Switch…418
Replacing Full/Low Beam Switch…419
Replacing Work Light Switches…420
Replacing Hazard Warning Light Switch…421
Replacing Turn Signal Switch…422
Replacing Horn Switch…423
Replacing Windshield Wiper and Windshield Washer Switch…424
Replacing Front-Wheel Drive Switch…425
Replacing Fan Switch…426
Replacing Differential Lock Switch…427
Replacing Rockshaft Remote Control Switch…428
Group 30: Monitoring Systems…263
Note…437
Note…437
Disconnecting electrical circuits…432
Replacing Engine Speed Sensor Unit (B01)…433
Replacing Engine Oil Pressure Sensor Unit (B04)…434
Replacing Coolant Temperature Gauge Sensor Unit (B08)…435
Group 40: Electrical Components…263
Note…437
Special Tools…1284
Specifications…1249
Disconnecting Electrical Circuits…469
Replacing Socket of 7-Terminal Power Outlet…441
Replacing Service Socket…443
Removing Windshield Wiper Motor…445
Removing Windshield Washer Pump…447
Adjusting the Headlights…448
Adjusting Cab Frame Lights…450
Lights with Halogen Bulbs…452
Section 45: Electronic Control Units…454
Group 05: General Information…253
Special Tools…1284
Control Unit Locations…457
Control Unit Functions…460
Group 10: Removal and Installation of Electronic Control Units…454
General Information on How to Reprogram Control Units…464
Check and Download Tractor-Specific Software Information…465
Instructions when Replacing a Control Unit…466
Instructions when Replacing a VIN Control Unit…467
Safety Information…468
Disconnecting Electrical Circuits…469
Replacing BCU Control Unit…470
Replacing TECU Control Unit…475
Replacing SBBC Control Unit…477
Replace ECU Control Unit…479
Terminating Resistors for the CAN BUS (Cab)…480
Section 55: PowrQuad Transmission…482
Group 00: Removing and Installing PowrQuad Module…482
Special Tools…1284
Specifications…1249
Removing PowrQuad Housing…488
Installing PowrQuad Housing…492
Group 05: Transmission Selectors Control…482
Specifications…1249
Reconditioning of Gearshift, Park Brake, and Forward/Reverse Mechanism…497
Reconditioning of Range-Shift Mechanism…501
Adjust Gear-Shift and Range-Shift Cables…504
Adjusting Forward/Reverse Cable…506
Adjusting Cable and Stop Screw Park Break…508
Adjusting Clutch Pedal…509
Group 10: PowrQuad Module…482
Special Tools…1284
Other Material…1293
Specifications…1249
Transmission Components…518
Replacing Neutral Start Circuit (Mechanically Actuated PowrQuad Module)…519
Removing and Installing Oil Filter Base…520
Replacing Oil Filter…521
Removing and Installing Front Valve Housing…522
Removing and Installing Front Valve Housing Valves (With Mechanically Actuated PowrQuad Module)…525
Removing and Installing Transmission Front Cover…539
Removing and Installing Transmission Front Cover Valves (With Mechanically Actuated PowrQuad Module)…541
Removing Clutch Pedal Valve (Mechanically Actuated PowrQuad Module)…546
Removing and Installing Shift Valve Housing (With Mechanically Actuated PowrQuad Module)…552
Removing and Installing Shift Valve Housing Valves (With Mechanically Actuated PowrQuad Module)…555
Removing Transmission Oil Pump…559
Servicing Transmission Oil Pump…561
Installing Transmission Oil Pump…568
Removing Planetary Drive Gears…569
Repairing Planetary Drive Gears…571
Installing Planetary Drive Gears…578
Removing B1 Brake Housing…584
Reconditioning B1 Brake…585
Installing B1 Brake Housing…587
Removing B2-B3 Brake Housing…588
Reconditioning B2 Brake…589
Reconditioning B3 Brake…591
Installing B2-B3 Brake Housing…594
Removing C4 Clutch…595
Reconditioning C4 Clutch…596
Installing C4 Clutch…607
Removing Reverse Brake…608
Servicing Reverse Brake…609
Installing Reverse Brake…612
Removing Forward Clutch with Planetary Drive (Forward/Reverse)…613
Servicing Forward Clutch with Planetary Drive (Forward/Reverse)…614
Installing Forward Clutch with Planetary Drive (Forward/Reverse)…628
Replacing Output Shaft…630
Group 15: Removing and Installing Range Box…638
Special Tools…1284
Specifications…1249
Removing Range Box…635
Installing Range Box…638
Final installation…640
Group 20: Range Box…483
Special Tools…1284
Other Material…1293
Specifications…1249
Cross-Sectional View—Range Box…645
Input Shaft—Exploded View…647
Remove Input Shaft…648
Repair Input Shaft…650
Install Input Shaft…654
Adjust Input Shaft End Play…656
Output Shaft—Exploded View…658
Remove Output Shaft…660
Output Shaft Installation and Pre-Charge Pinion Adjustment…664
Adjust Output Shaft End Play…670
Remove, Repair, and Install Shift Cover…672
Repair Shifting Mechanism…674
Repair Park Lock…676
Adjust Range Shift…678
Replace Ground Speed Sensor…679
Section 56: Drive Systems…681
Group 00: Removing and Installing Component…681
Special Tools…1284
Specifications…1249
Removing MFWD Clutch…688
Installing MFWD Clutch…691
Removing Differential Housing…692
Installing Differential Housing…700
Removing Final Drive…704
Installing Final Drive…709
Removing Rear PTO…712
Installing Rear PTO…715
Group 05: U-Jointed Shafts and Torsional Damper…681
Special Tools…1284
Use of Special Tool KJD10426…719
Specifications…1249
Removing MFWD Universal-Joint Drive Shaft…721
Repairing MFWD Universal-Joint Drive Shaft…722
Installing MFWD Universal-Joint Drive Shaft…726
Removing Engine Universal-Joint Drive Shaft…728
Removing Torsional Damper…729
Replacing Torsional Damper Bearings…730
Installing Torsional Damper…731
Installing Engine Universal-Joint Drive Shaft…733
Group 10: Front-Wheel Drive Clutch – 6145J Tractor…681
Special Tools…1284
Specifications…1249
MFWD Clutch Repair Instructions…754
MFWD Clutch — Cross-Sectional View…755
Disassembling MFWD Clutch…757
Disassembling MFWD Clutch Assembly…759
Mounting MFWD Clutch Assembly…763
Mounting MFWD Clutch…767
Group 11: Front-Wheel Drive Clutch – 6165J, 6180J and 6205J Tractors…682
Special Tools…1284
Specifications…1249
MFWD Clutch Repair Instructions…754
MFWD Clutch — Cross-Sectional View…755
Disassembling MFWD Clutch…757
Disassembling MFWD Clutch Assembly…759
MFWD Clutch Exploded View…761
Mounting MFWD Clutch Assembly…763
Mounting MFWD Clutch…767
Group 15: Rear Differential – 6145J Tractor…682
Special Tools…1284
Specifications…1249
Rear Differential Repair Instructions…799
Rear Differential — Cross Sectional View…801
Removing Rear Differential…803
Disassembling Rear Differential…806
Rear Differential — Exploded View…811
Assembling Rear Differential…813
Adjust Rear Differential Preload…819
Adjust Rear Differential Backlash…821
Installing Rear Differential…823
Group 16: Rear Differential – 6165J, 6180J and 6205J Tractors…682
Special Tools…1284
Specifications…1249
Rear Differential Repair Instructions…799
Rear Differential — Cross Sectional View…801
Removing Rear Differential…803
Disassembling Rear Differential…806
Rear Differential — Exploded View…811
Assembling Rear Differential…813
Adjust Rear Differential Preload…819
Adjust Rear Differential Backlash…821
Installing Rear Differential…823
Group 20: Hydraulic Pump Drive…683
Special Tools…1284
Specifications…1249
Removing and Disassembling Pump Drive Pinion…827
Removing and Disassembling Pump Drive Gear…830
Assembling and Installing Pump Drive Gear…832
Assembling and Installing Pump Drive Pinion…835
Checking and Adjusting Play of Pump Drive Pinion…838
Group 25: Final Drives…683
Special Tools…1284
Specifications…1249
Final Drive Repair Instructions…842
Final Drive Housing — Cross Sectional View…844
Final Drive Housing — Exploded View…845
Removing Planetary Carrier…847
Disassembling Planetary Carrier…849
Planetary Carrier — Exploded View…851
Assembling Planetary Carrier…852
Removing Final Drive Housing to Axle…854
Disassembling and Assembling Final Drive Housing…856
Disassembling and Assembling Axle…857
Installing Final Drive Housing to Axle…859
Installing Planetary Carrier…860
Measuring Rolling Drag…862
Checking Final Drive Shaft and Retainer…867
Final Assembly…967
Group 30: Rear PTO…53
Special Tools…1284
Specifications…1249
Replacing Output Shaft Seal Ring…873
Rear PTO Clutch – Cross Sectional View…874
Rear PTO Clutch – Exploded View…876
Removing Rear PTO Clutch…878
Reconditioning Rear PTO Clutch…881
Reconditioning Rear PTO Brake…890
Installing Rear PTO Clutch…891
Rear PTO Drive Train – Cross Sectional View…894
Rear PTO Drive Train – Exploded View…895
Removing Rear PTO Drive Train…898
Reconditioning Output Shaft…902
Reconditioning Countershaft…907
Installing Rear PTO Drive Train…909
Adjust Taper Roller Bearing of Countershaft…910
Adjust Tapered Roller Bearing of Bearing Support…912
Reconditioning Rear PTO Solenoid Valve…915
Reconditioning Rear PTO Modulating Valve…917
Replacing Rear PTO Speed Sensor…920
Reconditioning Oil Sight-Glass…921
Section 60: Steering and Brakes…924
Group 05: Hydrostatic Steering…924
Special Tools…1284
Preliminary Work…956
Disconnecting/Connecting Steering or Brake Hoses…929
Removing Steering Valve…931
Steering – Exploded View…934
Steering Column – Exploded View…936
Steering With AutoTrac AutoTrac is a trademark of Deere & Company Integrated…924
Installing Steering Valve…939
Group 10: Steering – AutoTracAutoTrac is a trademark of Deere & Company…924
Specifications…1249
AutoTrac™ Integrated—Components…944
Replacing the Steering Control…945
Replace Solenoid Valves…948
Replacing the Steering Wheel Position Sensor…950
Replacing the Wheel Angle Sensor…951
Group 15: Brake Valve…924
Special Tools…1284
Specifications…1249
Brake Valve Repair Instructions…955
Preliminary Work…956
Remove and Install Brake Valve…957
Disassembling Brake Valve…959
Installing Brake Valve…964
Adjusting Brake Pedals…965
Adjusting Brake Switches…966
Final Assembly…967
Group 20: Rear Wheel Brakes…924
Special Tools…1284
Specifications…1249
Rear Wheel Brakes – Exploded View…973
Removing Rear Brakes…974
Reconditioning Rear Brakes…976
Installing Rear Brakes…978
Replacing Retraction Pins on the Rear Wheel Brakes…980
Bleeding Brakes without Air Brakes…983
Bleeding Brakes with Air Brakes…985
Group 25: Air Brake System…925
Special Tools…1284
Specifications…1249
Air Brake System Repair Instructions…990
Screw Union Installation…991
Changing Compressor…993
Changing Compressor Gaskets…994
Changing Compressed Air Tank…996
Changing Pressure Control Valve…998
Changing Trailer Control Valve (Dual-Line Brakes)…999
Changing Coupling Ends…1000
Test Sequence…1001
Checking System for Leaks…1002
Checking Supply Coupling End…1003
Checking Dual-Line Brakes…1004
Adjusting Handbrake (Air Brake System)…1006
Section 70: Hydraulic System…1007
Group 05: Controls…1007
Specifications…1249
Selective Control Valves — Removing and Installing Actuating Elements…1012
Selective Control Valves — Adjusting Bowden Cable…1016
Group 10: Oil Filters, Charge Pump and Hydraulic Pump…1007
Specifications…1249
Removing and Installing Hydraulic Oil Mesh Filter…1019
Removing and Installing Hydraulic Oil Filter…1022
Charge Pump – Exploded View…1026
Removing and Installing Charge Pump…1029
Charge Pump – Checking the Lube Oil Valve…1033
Hydraulic Oil Reservoir — Restrictor…1034
Hydraulic Pump – Removing and Installing Pressure-and-Flow Controller…1035
Hydraulic Pump – Reconditioning Pressure-and-Flow Controller…1037
Removing and Installing Hydraulic Pump…1039
Hydraulic Pump – Exploded View…1044
Disassembling Hydraulic Pump…1046
Assembling Hydraulic Pump…1047
Group 15: Valve Block – 6145J Tractor…1007
Special Tools…1284
Specifications…1249
Hydraulic System Repair Instructions…1086
Rockshaft Direct Control…1060
Removing and Installing Rockshaft Valve Spacer…1061
Removing Rockshaft Valve…1088
Rocksaft Valve – Exploded View…1065
Repairing Rockshaft Valve…1067
Installing Rockshaft Valve…1070
Rockshaft Valve — Depth of Raising and Lowering Valves…1072
Rockshaft Valve — Removing and Installing Stepper Motor…1073
Rockshaft Valve — Centering Stepper Motor…1075
Removing Priority Valve…1076
Priority Valve – Exploded View…1078
Repairing Priority Valve…1080
Group 16: Valve Block – 6165J, 6180J and 6205J Tractors…1008
Special Tools…1284
Specifications…1249
Hydraulic System Repair Instructions…1086
Removing Rockshaft Valve…1088
Rockshaft Valve – Exploded View…1090
Reconditioning Rockshaft Valve…1092
Installing Rochshaft Valve…1095
Rockshaft Valve – Removing and Installing Stepper Motor…1098
Removing Priority 1 Control Block…1100
Install Priority 1 Control Block…1101
Reconditioning Priority 1 Control Block…1102
Removing Priority 3 Control Block…1105
Installing Priority 3 Control Block…1109
Recondition Priority 3 Control Block…1113
Group 20: Rockshaft…1008
Other Material…1293
Specifications…1249
Rockshaft – Removg and Installing Position Sensor and Toothed Segment…1119
Rockshaft – Removing and Installing Rockshaft…1123
Rockshaft – Removing and Installing Bearing Support…1128
Rockshaft – Removing Rockshaft Cylinders…1130
Rockshaft – Reconditioning Lift Cylinder…1131
Rockshaft – Installing Rockshaft Cylinders…1134
Rockshaft – Removing and Installing Draft Load Potentiometer and Draft Link Support…1135
Group 25: Selective Control Valves and Couplers – 6145J Tractor…1008
Special Tools…1284
Specifications…1249
Selective Control Valves (SCVs) and Couplers Repair Instructions…1174
Removing and Installing Shuttle Valves…1145
Removing Selective Control Valves…1146
Disassembling, Inspecting and Assembling 100 Series Selective Control Valve…1147
Disassembling, Inspecting and Assembling 300 Series Selective Control Valve…1153
Installing Selective Control Valves…1164
Adjusting Pressure with Selective Control Valves…1167
Quick Couplers — Service…1168
Mounting Quick Coupler…1170
Group 26: Selective Control Valves and Couplers – 6165J, 6180J and 6205J Tractors…1009
Special Tools…1284
Specifications…1249
Selective Control Valves (SCVs) and Couplers Repair Instructions…1174
Remove the Selective Control Valves (SCVs)…1176
Recondition the Selective Control Valves (M-SCVs 100)…1178
Recondition the Selective Control Valves (M-SCVs 300)…1182
Recondition the Selective Control Valves (M-SCVs 450)…1185
Install the Selective Control Valves (SCVs)…1188
Selective Control Valves (SCVs) – Reconditioning the Couplers…1193
Section 80: Miscellaneous…1195
Group 00: Removing and Installing Components…1195
Special Tools…1284
Specifications…1249
Removing Main Chassis…1199
Installing Main Chassis…1204
Removing Front-Wheel Drive Axle…1207
Installing Front-Wheel Drive Axle…1210
Group 05: Main Chassis…1195
Specifications…1249
Reconditioning Main Chassis…1214
Group 15: Front Wheels, Rear Wheels and Fenders…1195
Special Tools…1284
Specifications…1249
Installing Front Fenders…1218
Removing Front and Rear Wheels…1221
Reconditioning Front and Rear Wheels…1223
Install Front and Rear Wheels…1226
Service Heavy-Duty Wheel Clamps…1230
Group 20: Center Link Bracket and Swinging Drawbar…1241
Specifications…1249
Check Swinging Drawbar Wear…1238
Installing Center Link Bracket…1240
Swinging Drawbar…1241
Adjust Hammer Strap…1243
Drawbar With Ball Pin…1244
Section 90: Operator's Cab…1245
Group 00: Removing and Installing Components…1245
Special Tools…1284
Specifications…1249
Swinging Up Operator's Cab…1250
Swinging Down Operator's Cab…1267
Removing Operator's Cab or Platform…1270
Installing Operator's Cab or Platform…1278
Checking and Adjusting Gear Shift Units…1282
Group 15: Air Conditioning System…1245
Special Tools…1284
Tightening Torque for Refrigerant Hoses…1285
Safety Regulations…1286
Handling Refrigerant…1287
In the Event of an Emergency…1288
Safety Equipment…1289
Storage of Refrigerant Containers…1290
Refrigerant R134a…1291
Important…1292
Other Material…1293
Specification…1294
Filling the Cylinder…1295
Charging Air Conditioning System (With Loading Cylinder)…1297
Charging Air Conditioning System (With Recovery/Recycling and Charging Station)…1299
Adding Oil to the Air Conditioning System…1300
Leak Test…1302
Evacuate Air Conditioning System…1303
Cleaning the Air Conditioning System…1305
Separating Compressor…1306
Check Refrigerant Oil Level…1307
Disassembling Compressor Clutch…1308
Checking Clutch Hub Separation…1311
Install Compressor…1312
Separating and Installing Condenser…1313
Separating and Installing Drier…1314
Replacing Expansion Valve…1315
Separating and Installing Evaporator and Expansion Valve…1316
Installing Condensation Water Drain Hoses…1318
Layout of Condensation Water Drain Hoses…1319
Separating and Installing Thermostat…1320
Separating and Installing High/Low Pressure Switch…1321
Vacuum Pump — General Information…1322
Group 20: Heating System…1246
Fan and Heater, Disassembling…1325
Removing Cab Air Filter…1327
Separating and Installing Fan…1329
Separating and Installing Heater Regulator…1330
Separating Heater/Evaporator Housing…1331
Group 25: Operator's Cab…1246
Removing Cab Frame…1334
Cab Mounting Torques…1335
Removing and Installing Windshield…1337
Remove and Install Rear Window…1339
Installing Door Lock…1341
Adjusting Window Contact Pressure…1343
Removing and Installing Operator's Cab Door…1344
Removing and Installing Sun-Visor Roller…1346
Remove and Install Operator’s Seat…1347
Section 99: Special Tools (Dealer-Fabricated)…1349
Group 05: Special Tools (Dealer-Fabricated)…1349
DFLX1 – Adapter Strut…1351
DFLX7 – Turning Device…1366
DFLX14 – Suspended MFWD Axle Housing Bracket…1353
DFLX29 – Support…1354
DFLX42 – Turning Device…1366
Lifting Device…1356
Holding Device…1357
Suspension Eyes for Operator's Cab…1358
Holding Tool…1359
Wooden Block…1360
DFRW79 – Piston Holding Tool…1361
Socket Wrench Insert…1369
Seal Installer…1367
Driver…1364
Assembly and Guide Mandrels…1365
Turning Device…1366
Seal Installer…1367
JDG10198 Terminal Crimping Tool…1368
Socket Wrench Insert…1369
Special Wrench…1370
Electrical Repair Tool Kit…1371
Quick Coupler Securing Support…1372
Lifting Tool…1373

John Deere Tractors 6145J, 6165J, 6180J, 6205J Repair Technical Manual (TM801519)

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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 Tractors 6145J, 6165J, 6180J, 6205J, with all the technical information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 2WD or MFWD Tractors 6145J, 6165J, 6180J & 6205J 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.

TM801419 Diagnostic Technical Manual 6145J, 6165J, 6180J, and 6205J Tractors, Diagnostic Technical Manual.pdf
TM801428 Diagnostic Technical Manual Tracteurs 6145J, 6165J, 6180J et 6205J, Manuel technique de diagnostic.pdf
TM801454 Diagnostic Technical Manual Tratores 6145J, 6165J, 6180J e 6205J, Manual Técnico de Diagnósticos.pdf
TM801463 Diagnostic Technical Manual Tractores 6145J, 6165J, 6180J y 6205J, Manual técnico de diagnóstico.pdf

PRODUCT DETAILS:
Total Pages: 3,623 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English etc.

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MAIN SECTIONS
Foreword
General Information
Safety Information
General References
Diagnostic Trouble Codes
BCU – Basic Control Unit – Without AutoTrac™ Integrated
BCU – Basic Control Unit – With AutoTrac™ Integrated
TEC – Tractor Equipment Control Unit
TEI – Tractor Equipment Control Unit
XMC – AutoTrac™ Main Control Unit
XSC – AutoTrac™ Supervisor Control Unit
ECU – Engine Control Unit
Observable Symptoms
Electrical System
Electronic Control Units
PowrQuad Transmissions
Drive Systems
Steering and Brakes
Hydraulic System
Operator’s Cab
System Diagnosis
Electronics
Engine
Operational Checks
Tests and Adjustments
Fuel, Air Intake and Cooling Systems
Tests and Adjustments
Fuel System
Air Intake System
Cooling System
Electrical System – Cab Tractors – 6145J, 6165J and 6180J
Fuse Box – Without AutoTrac™ Integrated
Fuse Box – With AutoTrac™ Integrated
Starting and Charging Circuit
Panel Warning Lights without AutoTrac™ Integrated
Panel Warning Lights with AutoTrac™ Integrated
Lights, Tail Lights and License Plate
Work Lights
Radio, Dome Light, Console Light and Beacon Light
Horn and Accessories Socket
Power Outlet without AutoTrac™ Universal
Power Outlet with AutoTrac™ Universal
Fan and A/C
Reverse Light and Backup Alarm
Front Windshield Wiper and Washer
Rear Windshield Wiper and Washer
Trailer Connector
BCU – Turn Signal and Hazard Warning Lights
BCU – Electronic Hitch-Control
BCU – Brakes
BCU – PTO
BCU – Engine Speed Sensor
BCU – Front-Wheel Drive
BCU – Differential Lock
BCU – Ground Speed Sender
BCU – Transmission Enable Switches
BCU – Service Connector – Without AutoTrac™ Integrated
BCU – Seat Switch
BCU – AutoTrac™ Integrated Resume Switch
GreenStar™ without AutoTrac™ Integrated
GreenStar™ with AutoTrac™ Integrated
XMC and XSC – AutoTrac™ Integrated Steering Control Unit
TECU – AutoTrac™ Integrated Tractor Equipment Control Unit
AutoTrac™ Integrated Vehicle CAN Bus
Component Tests
Wiring Harnesses
Connectors
Electrical System – Cab Tractors – 6205J without AutoTrac™ Integrated
Fuse Box
Starting and Charging Circuit
Vehicle CAN Bus and Service Connector
ECU – Power
ECU – Throttle and Fuel System
ECU – Fuel Preheater and Aid Heater
ECU – Sensors
BCU – Electronic Hitch-Control
BCU – Brakes
BCU – PTO
BCU – Front-Wheel Drive
BCU – Differential Lock
BCU – Turn Signal and Hazard Warning Lights
Panel Warning Lights
Lights and Tail Lights
Work Lights
Radio, Dome Light and Console Light
Horn and Accessories Socket
Power Outlet – without AutoTrac™
Power Outlet – with AutoTrac™ Universal
Seat Compressor
Fan and Air Conditioning
Front Windshield Wiper and Washer
Rear Windshield Wiper and Washer – Theory of Operation
Trailer Connector
Backup Alarm
GreenStar™ Components
Wiring Harnesses
Connectors
Electrical System – Cab Tractors – 6205J with AutoTrac™ Integrated
Fuse Box
Starting and Charging Circuit
Vehicle CAN Bus and Service Connector
ECU – Power
ECU – Throttle and Fuel System
ECU – Fuel Preheater and Aid Heater
ECU – Sensors
BCU – Electronic Hitch-Control
BCU – Brakes
BCU – PTO
BCU – Front-Wheel Drive
BCU – Differential Lock
BCU – Wheel Speed Sensor
BCU – Turn Signal and Hazard Warning Lights
Panel Warning Lights
Lights and Tail Lights
Work Lights
Radio, Dome Light and Console Light
Horn and Accessories Socket
Power Outlet
Seat Compressor
Fan and Air Conditioning
Front Windshield Wiper and Washer
Rear Windshield Wiper and Washer – Theory of Operation
Trailer Connector
Backup Alarm
BCU – Transmission Enable Switches
BCU – Seat Switch
BCU – AutoTrac™ Integrated Resume Switch
GreenStar™ Components
XMC and XSC – AutoTrac™ Integrated Steering Control Unit
TECU – AutoTrac™ Integrated Tractor Equipment Control Unit
Wiring Harnesses
Connectors
Electrical System – Open Operator’s Station
Fuse Box
Starting and Charging Circuit
Panel Warning Lights
Lights and Tail Lights
Work Lights
Horn
Reverse Light and Backup Alarm
Trailer Connector
BCU – Turn Signal and Hazard Warning Lights
BCU – Electronic Hitch-Control
BCU – Brakes
BCU – Service Connector
BCU – PTO
BCU – Engine Speed Sensor
BCU – Front-Wheel Drive
BCU – Differential Lock
Component Tests
Wiring Harnesses
Connectors
Electronic Control Units
Operation and General Information on Diagnostics
Information on How to Reprogram Control Units
Data BUS Systems, Operation
Steering Control Units Tests
BCU – Basic Control Unit – Without AutoTrac™ Integrated
BCU – Basic Control Unit – With AutoTrac™ Integrated
TEC – Tractor Equipment Control Unit
TEI – Tractor Equipment Control Unit
XMC – AutoTrac™ Main Control Unit
XSC – AutoTrac™ Supervisor Control Unit
ECU – Engine Control Unit
PowrQuad™ Transmissions
Operational Check
Tests and Adjustments
Operation
Range Box
Drive Systems
Operational Check
Tests and Adjustments
Operation
Steering and Brakes
Preliminary Checks
Operational Check
Tests and Adjustments
Hydrostatic Steering
Brakes
Air brake system
Hydraulic System – 6145J
Operational Check
Tests and Adjustments
Operation
Hydraulic System – 6165J, 6180J and 6205J
Operational Check
Tests and Adjustments
Theory of operation
Oil Filter, Charge Pump and Hydraulic Pump
Hitch
Selective control valves (SCV)
Hydraulic block
Operator’s Cab
Tests and Adjustments
Operation
Special Tools (Dealer-Fabricated)
Special Tools (Dealer-Fabricated)

TABLE OF CONTENTS….1
Section 210: General Information….75
Group 05: Safety Information….3467
Recognize Safety Information….3467
Follow Safety Instructions….79
Replace Safety Signs….80
Wear Protective Clothing….81
Prevent Battery Explosions….82
Service Tires Safely….83
Keep ROPS Installed Properly….84
Park Machine Safely….85
Handle Fluids Safely—Avoid Fires….86
Handle Fuel Safely—Avoid Fires….87
Prepare for Emergencies….88
Work in Clean Area….89
Prevent Machine Runaway….90
Work In Ventilated Area….91
Avoid High-Pressure Fluids….92
Use Proper Lifting Equipment….93
Illuminate Work Area Safely….94
Use Proper Tools….95
Live With Safety….1066
Safety Measures on Electronic Control Units….97
Group 15: General References….75
General References—Summary of References….99
Unified Inch Bolt and Cap Screw Torque Values….100
Metric Bolt and Cap Screw Torque Values….102
Hydraulic System Unified Inch Fitting Torques….104
Hydraulic system metric fitting torques….105
Component Identification Table….107
How to use an Electrical Diagram….109
Electrical Diagram Symbols….112
Wire Numbers and Color Codes….114
Troubleshooting Unsolved Problems….115
Electrical System Visual Inspection….116
Circuit Malfunctions….117
Seven Steps Electrical Test Procedure….122
Hydraulic System — Circuit Symbols….124
Section 211: Diagnostic Trouble Codes….130
Group 1: BCU – Basic Control Unit – Without AutoTrac™ Integrated….130
BCU 000168.03 – Control Unit, Supply Voltage Too High….130
BCU 000168.04 – Control Unit, Supply Voltage Too Low….130
BCU 000168.16 – System Voltage Too High (Engine Running)….130
BCU 000168.17 – System Voltage Too Low (Engine Speed Over 1500 rpm)….130
BCU 000168.18 – System Voltage Too Low (Engine Speed Up to 1500 rpm)….130
BCU 000186.02 – B06 – Sensor for PTO Speed, Open Circuit….130
BCU 000186.15 – B06 – PTO Speed Sensor, Speed Present Despite PTO Being Switched Off….130
BCU 000186.17 – B06 – PTO Speed Sensor, Speed Not Present….130
BCU 000190.02 – Engine Speed Sender, Circuit Fault….130
BCU 000237.02 – VIN Information, Mismatch….130
BCU 000237.14 – VIN Information, System Deactivated….130
BCU 000237.31 – VIN Information, Incorrect….130
BCU 000629.12 – Control Unit, Internal Error….130
BCU 000639.12 – Control Unit, Internal Error….130
BCU 000639.13 – 29-bit CAN BUS, High Error Rate….130
BCU 000639.19 – 29-bit CAN BUS, Very High Error Rate….130
BCU 000746.31 – Differential Lock Solenoid Valve, Circuit Fault….130
BCU 000980.07 – PTO, Switch Error….130
BCU 001079.03 – B41 – Draft Potentiometer, Voltage Too High….130
BCU 001079.04 – B41 – Draft Potentiometer, Voltage Too Low….130
BCU 001873.03 – B21 – Hitch-control Position Sensor, Voltage Too High….130
BCU 001873.04 – B21 – Hitch-control Position Sensor, Voltage Too Low….130
BCU 001873.15 – B21 – Hitch-control Position Sensor, Voltage Too High During Calibration….130
BCU 001873.17 – B21 – Hitch-control Position Sensor, Voltage Too Low During Calibration….130
BCU 001894.31 – INFORMATION FOR OPERATOR: PTO Switch Was On When Engine Was Started….130
BCU 299780.07 – Malfunction at Turn Signal Switch….130
BCU 302001.31 – OPERATOR INFORMATION 250-Hour Service….130
BCU 302002.31 – OPERATOR INFORMATION 500-Hour Service….130
BCU 302003.31 – OPERATOR INFORMATION 750-Hour Service….130
BCU 302004.31 – OPERATOR INFORMATION 1500-Hour Service….130
BCU 302071.31 – OPERATOR INFORMATION Turn PTO switch OFF….131
BCU 302073.31 – PTO Solenoid, Circuit Fault….131
BCU 302080.31 – Differential Lock, Switch Error….131
BCU 302082.31 – OPERATOR INFORMATION Actuate Front-Wheel Drive Switch….131
BCU 302085.31 – Front Wheel Drive, Switch Error….131
BCU 302086.31 – Front-Wheel Drive Clutch Solenoid, Circuit Fault….131
BCU 302089.31 – OPERATOR INFORMATION Turn PTO switch OFF….131
BCU 302106.31 – Control Unit, Internal Error….131
BCU 302131.31 – Fault in Turn Signal Circuit….131
BCU 302132.31 – Defective Hazard Warning Light Fuse F113 and/or F114….131
BCU 302133.31 – PTO, Switch Error….131
BCU 302240.31 – Control Unit Connected to Wrong Wiring Harness Connector….131
BCU 303027.31 – Calibration of Hitch Control Unit Not Successful….131
BCU 303028.31 – Hitch Control Unit Not Calibrated….131
BCU 303037.03 – 5-Volt Supply Voltage Too High….131
BCU 303037.04 – 5-Volt Supply Voltage Too Low….131
BCU 303041.02 – Stepper Motor Coil 1, Open Lead….131
BCU 303042.02 – Stepper Motor Coil 2, Open Lead….131
BCU 303043.02 – Stepper Motor Coil 1, Circuit Fault….131
BCU 303044.02 – Stepper Motor Coil 2, Circuit Fault….131
BCU 303045.04 – System Voltage Too Low….131
BCU 303047.03 – System Voltage Too High….131
BCU 303049.02 – Conflicting Signals from Quick Raise/Lower Switch and Remote Switch….131
BCU 303049.03 – Rapid Raise/Lower Rocker Switch, Signal Voltage Too High….131
BCU 303049.04 – Rapid Raise/Lower Rocker Switch, Signal Voltage Too Low….131
BCU 303052.03 – Right Draft Sender, Signal Voltage Too High….131
BCU 303052.04 – Right Draft Sender, Signal Voltage Too Low….131
BCU 303053.03 – Sensitivity Potentiometer, Signal Voltage Too High….131
BCU 303053.04 – Sensitivity Potentiometer, Signal Voltage Too Low….131
BCU 303054.03 – Hitch Height Control Potentiometer, Signal Voltage Too High….131
BCU 303054.04 – Hitch Height Control Potentiometer, Signal Voltage Too Low….131
BCU 303055.03 – Position Sensor, Signal Voltage Too High….131
BCU 303055.04 – Position Sensor, Signal Voltage Too Low….131
BCU 303056.03 – Raise Limit Potentiometer, Signal Voltage Too High….132
BCU 303056.04 – Raise Limit Potentiometer, Signal Voltage Too Low….132
BCU 303057.03 – Rate-of-Drop Potentiometer, Signal Voltage Too High….132
BCU 303057.04 – Rate-of-Drop Potentiometer, Signal Voltage Too Low….132
BCU 303058.02 – Remote Control Switch, Erroneous Signal….132
BCU 303060.02 – Stepper Motor Deadband Out of Range….132
BCU 303252.02 – Right Draft Sender, Disrupted Signal During Calibration….132
BCU 303252.03 – Right Draft Sender, Signal Voltage Too High During Calibration….132
BCU 303252.04 – Right Draft Sender, Signal Voltage Too Low During Calibration….132
BCU 303255.03 – Position Sender, Signal Voltage Too High During Calibration….132
BCU 303255.04 – Position Sender, Signal Voltage Too Low During Calibration….132
BCU 303260.16 – Stepper Motor Raising Deadband Above Valid Range During Calibration….132
BCU 303260.18 – Stepper Motor Raising Deadband Below Valid Range During Calibration….132
BCU 303261.16 – Stepper Motor Lowering Deadband Above Valid Range During Calibration….132
BCU 303261.18 – Stepper Motor Lowering Deadband Below Valid Range During Calibration….132
BCU 522507.31 – Control Unit Not Calibrated….132
BCU 523438.02 – Control Unit Internal Fault….132
BCU 523652.02 – Controller Connected to Wrong Wiring Harness Connector….132
BCU 523689.31 – S22 – Differential Lock Switch, Fault….132
BCU 523690.02 – S68 – Switches for Remote Control of Rockshaft, Fault….132
BCU 523701.05 – M08 – Stepper Motor for Hitch (Coil 2), Open Circuit….132
BCU 523701.06 – M08 – Stepper Motor for Hitch (Coil 2), Current Too High….132
BCU 523702.14 – VIN Information, System Deactivated….132
BCU 523702.31 – VIN Information, Incorrect….132
BCU 523703.02 – B41 – Draft potentiometer, Distorted Signal During Calibration….132
BCU 523703.03 – B41 – Draft potentiometer, Voltage Too High During Calibration….132
BCU 523703.04 – B41 – Draft potentiometer, Voltage Too Low During Calibration….132
BCU 523703.15 – B41 – Draft potentiometer, Voltage Too High….132
BCU 523703.17 – B41 – Draft potentiometer, Voltage Too Low….132
BCU 523751.05 – M08 – Stepper Motor for Hitch (Coil 1), Open Circuit….132
BCU 523751.06 – M08 – Stepper Motor for Hitch (Coil 1), Current Too High….132
BCU 523753.16 – M08 – Stepper Motor for Hitch, Raising Deadband Too High During Calibration….132
BCU 523753.18 – M08 – Stepper Motor for Hitch, Raising Deadband Too Low During Calibration….132
BCU 523756.16 – M08 – Stepper Motor for Hitch, Lowering Deadband Too High During Calibration….133
BCU 523756.18 – M08 – Stepper Motor for Hitch, Lowering Deadband Too Low During Calibration….133
BCU 523760.04 – Turn Signal/Hazard Flasher System, Supply Voltage Too Low….133
BCU 523760.31 – Turn-Signal/Hazard Flasher System, Fault….133
BCU 523769.31 – Front-Wheel Drive Switch, Fault….133
BCU 523834.03 – B27 – Feedback Unit, Voltage Too High….133
BCU 523834.04 – B27 – Feedback Unit, Voltage Too Low….133
BCU 523843.02 – S24 – Quick Raise-Lower Switch, Switch Status Out of Valid Range….133
BCU 523843.03 – S24 – Quick Raise-Lower Switch, Voltage Too High….133
BCU 523843.04 – S24 – Quick Raise-Lower Switch, Voltage Too Low….133
BCU 524055.11 – Control Unit Internal Fault….133
BCU 524055.31 – Control Unit Not Calibrated….133
BCU 524224.02 – INFORMATION FOR OPERATOR: Switch Off the PTO Switch….133
BCU 524224.14 – INFORMATION FOR OPERATOR: Switch On Rear PTO Switch….133
BCU 524224.31 – INFORMATION FOR OPERATOR: PTO Was Switched On When Engine Was Started….133
BCU 524235.31 – Y03 – Front-Wheel Drive Solenoid Valve, Fault….133
BCU 524252.31 – Y04 – PTO Solenoid, Fault….133
Group 2: BCU – Basic Control Unit – With AutoTrac™ Integrated….133
BCU 000084.02 – B09 – Wheel Speed Sensor, out of Valid Range….133
BCU 000096.03 – B03 – Fuel Gauge Sensor Unit, Voltage Too High….133
BCU 000096.04 – B03 – Fuel Gauge Sensor Unit, Voltage Too Low….133
BCU 000096.17 – Fuel Level Too Low….133
BCU 000168.03 – Control Unit, Supply Voltage Too High….133
BCU 000168.04 – Control Unit, Supply Voltage Too Low….133
BCU 000168.16 – Control Unit, Supply Voltage Too High….133
BCU 000168.17 – Control Unit, Supply Voltage Too Low (Engine Speed Above 1500 rpm)….133
BCU 000168.18 – Control Unit, Supply Voltage Too Low (Engine Speed Above 500 rpm)….133
BCU 000177.18 – Transmission Oil Temperature Too Low During Calibration….133
BCU 000186.02 – B06 – Sensor for PTO Speed, Open Circuit….133
BCU 000186.15 – B06 – PTO Speed Sensor, Speed Present Despite PTO Being Switched Off….133
BCU 000186.17 – B06 – PTO Speed Sensor, Speed Not Present….133
BCU 000190.02 – B01 – Crankshaft Speed Sensor, Open Circuit….134
BCU 000237.02 – VIN Information, Mismatch….134
BCU 000237.14 – VIN Information, System Deactivated….134
BCU 000237.31 – VIN Information, Incorrect….134
BCU 000629.12 – Control Unit Internal Fault….134
BCU 000639.12 – Vehicle CAN Bus, High Error Rate….134
BCU 000746.31 – Y05 – Differential Lock Solenoid Valve, Fault….134
BCU 000980.07 – S21 – PTO Switch, Fault….134
BCU 001058.18 – INFORMATION FOR OPERATOR: Pressure Switch for Air-Brake System Is Not Activated (Pressure Too Low)….134
BCU 001079.03 – B41 – Draft Potentiometer, Voltage Too High….134
BCU 001079.04 – B41 – Draft Potentiometer, Voltage Too Low….134
BCU 001504.14 – INFORMATION FOR OPERATOR: Operator Presence Switch Not Activated While HMS Plus is Selected….134
BCU 001713.15 – Hydraulic Oil Filter Dirty….134
BCU 001873.03 – B21 – Hitch-control Position Sensor, Voltage Too High….134
BCU 001873.04 – B21 – Hitch-control Position Sensor, Voltage Too Low….134
BCU 001873.15 – B21 – Hitch-control Position Sensor, Voltage Too High During Calibration….134
BCU 001873.17 – B21 – Hitch-control Position Sensor, Voltage Too Low During Calibration….134
BCU 001883.31 – PTO Speed Too High….134
BCU 001894.13 – Solenoid Valve for PTO Not Calibrated….134
BCU 001894.31 – INFORMATION FOR OPERATOR: PTO Switch Was On When Engine Was Started….134
BCU 002240.09 – Incorrect CAN Bus Message, Information from TECU….134
BCU 002392.31 – H67 – Backup Alarm, Malfunction….134
BCU 002818.31 – INFORMATION FOR OPERATOR: Operator Presence Switch Not Activated….134
BCU 522507.31 – Control Unit Not Calibrated….134
BCU 523438.02 – Control Unit Internal Fault….134
BCU 523652.02 – Controller Connected to Wrong Wiring Harness Connector….134
BCU 523689.31 – S22 – Differential Lock Switch, Fault….134
BCU 523690.02 – S68 – Switches for Remote Control of Rockshaft, Fault….134
BCU 523701.05 – M08 – Stepper Motor for Hitch (Coil 2), Open Circuit….134
BCU 523701.06 – M08 – Stepper Motor for Hitch (Coil 2), Current Too High….134
BCU 523702.14 – VIN Information, System Deactivated….134
BCU 523702.31 – VIN Information, Incorrect….135
BCU 523703.02 – B41 – Draft potentiometer, Distorted Signal During Calibration….135
BCU 523703.03 – B41 – Draft potentiometer, Voltage Too High During Calibration….135
BCU 523703.04 – B41 – Draft potentiometer, Voltage Too Low During Calibration….135
BCU 523703.15 – B41 – Draft potentiometer, Voltage Too High….135
BCU 523703.17 – B41 – Draft potentiometer, Voltage Too Low….135
BCU 523751.05 – M08 – Stepper Motor for Hitch (Coil 1), Open Circuit….135
BCU 523751.06 – M08 – Stepper Motor for Hitch (Coil 1), Current Too High….135
BCU 523753.16 – M08 – Stepper Motor for Hitch, Raising Deadband Too High During Calibration….135
BCU 523753.18 – M08 – Stepper Motor for Hitch, Raising Deadband Too Low During Calibration….135
BCU 523756.16 – M08 – Stepper Motor for Hitch, Lowering Deadband Too High During Calibration….135
BCU 523756.18 – M08 – Stepper Motor for Hitch, Lowering Deadband Too Low During Calibration….135
BCU 523760.04 – Turn Signal/Hazard Flasher System, Supply Voltage Too Low….135
BCU 523760.31 – Turn-Signal/Hazard Flasher System, Fault….135
BCU 523769.31 – Front-Wheel Drive Switch, Fault….135
BCU 523834.03 – B27 – Feedback Unit, Voltage Too High….135
BCU 523834.04 – B27 – Feedback Unit, Voltage Too Low….135
BCU 523839.14 – INFORMATION FOR OPERATOR: Handbrake is Engaged and a Gear is Selected….135
BCU 523839.31 – INFORMATION FOR OPERATOR: Handbrake Activated While Wheel Speed is Recognized….135
BCU 523843.02 – S24 – Quick Raise-Lower Switch, Switch Status Out of Valid Range….135
BCU 523843.03 – S24 – Quick Raise-Lower Switch, Voltage Too High….135
BCU 523843.04 – S24 – Quick Raise-Lower Switch, Voltage Too Low….135
BCU 524055.11 – Control Unit Internal Fault….135
BCU 524055.31 – Control Unit Not Calibrated….135
BCU 524224.02 – INFORMATION FOR OPERATOR: Switch Off the PTO Switch….135
BCU 524224.14 – INFORMATION FOR OPERATOR: Switch On Rear PTO Switch….135
BCU 524224.31 – INFORMATION FOR OPERATOR: PTO Was Switched On When Engine Was Started….135
BCU 524235.31 – Y03 – Front-Wheel Drive Solenoid Valve, Fault….135
BCU 524252.31 – Y04 – PTO Solenoid, Fault….135
BCU 600006.31 – Diagnostic Trouble Code Not Known….135
Group 3: TEC – Tractor Equipment Control Unit….136
TEC 000628.12 – Control Unit Internal Fault….136
TEC 000629.12 – Control Unit Internal Fault….136
TEC 000630.02 – Control Unit Internal Fault….136
TEC 000639.12 – Implement CAN Bus, High Error Rate….136
TEC 000639.14 – Implement CAN Bus, Very High Error Rate….136
TEC 001231.12 – Vehicle CAN Bus, High Error Rate….136
TEC 001231.14 – Vehicle CAN Bus, Very High Error Rate….136
TEC 522550.14 – Implement Connected to Implement CAN Bus is Not Compatible with ISO….136
TEC 523652.02 – Controller Connected to Wrong Wiring Harness Connector….136
TEC 600006.31 – Diagnostic Trouble Code Not Known….136
Group 4: TEI – Tractor Equipment Control Unit….136
TEI 000628.12 – Control Unit Internal Fault….136
TEI 000629.12 – Control Unit Internal Fault….136
TEI 000630.02 – Control Unit Internal Fault….136
TEI 000639.12 – Implement CAN Bus, High Error Rate….136
TEI 000639.14 – Implement CAN Bus, Very High Error Rate….136
TEI 001231.12 – Vehicle CAN Bus, High Error Rate….136
TEI 001231.14 – Vehicle CAN Bus, Very High Error Rate….136
TEI 522550.14 – Implement Connected to Implement CAN Bus is Not Compatible with ISO….136
TEI 600006.31 – Diagnostic Trouble Code Not Known….136
Group 5: XMC – AutoTrac™ Main Control Unit….136
XMC 000110.00 – Engine Coolant Temperature Extremely High….136
XMC 000110.03 – Engine Coolant Temperature Sensor Input Voltage Too High….136
XMC 000110.04 – Engine Coolant Temperature Sensor Input Voltage Too Low….136
XMC 000168.01 – Steering System Control Unit Supply Voltage Low….136
XMC 000609.12 – Incorrect Software….136
XMC 000628.12 – Steering System Control Units Programming….136
XMC 000629.02 – Steering System Control Unit Fault….136
XMC 000629.12 – Steering System Control Unit Fault….136
XMC 000639.08 – Vehicle CAN Bus Fault….136
XMC 000701.02 – Incompatible Harness on Steering System Control Unit….136
XMC 000704.09 – System Start-up Checks Failed….136
XMC 000708.10 – Steering System Control Unit Fault….137
XMC 000708.16 – Steering System Control Unit Fault….137
XMC 000708.18 – Steering System Control Unit Fault….137
XMC 000708.20 – Steering System Control Unit Fault….137
XMC 000708.21 – Steering System Control Unit Fault….137
XMC 000709.10 – Steering System Control Unit Fault….137
XMC 000709.16 – Steering System Control Unit Fault….137
XMC 000709.18 – Steering System Control Unit Fault….137
XMC 000709.20 – Steering System Control Unit Fault….137
XMC 000709.21 – Steering System Control Unit Fault….137
XMC 001231.08 – Steering System Control Unit Fault….137
XMC 001231.12 – Steering System Control Unit Fault….137
XMC 001231.14 – Steering System Control Unit Fault….137
XMC 002000.09 – Engine Messages Missing….137
XMC 002003.09 – Transmission Messages Missing….137
XMC 002005.09 – BCU Messages Missing….137
XMC 002019.09 – Steering System Control Unit Fault….137
XMC 002049.09 – BCU Messages Missing….137
XMC 002071.09 – BCU Messages Missing….137
XMC 003841.00 – Steering System Control Unit Fault….137
XMC 003841.01 – Steering System Control Unit Fault….137
XMC 003841.02 – Steering System Control Unit Fault….137
XMC 003842.00 – Steering System Control Unit Fault….137
XMC 003842.01 – Steering System Control Unit Fault….137
XMC 522269.07 – Steer Right Valve Stuck Open….137
XMC 522270.07 – Steer Left Valve Stuck Open….137
XMC 522777.02 – Steering Wheel Sensors Disagree….137
XMC 522845.16 – Steer Right Solenoid Current High….137
XMC 522845.18 – Steer Right Solenoid Current Low….137
XMC 522846.03 – Steer Right Solenoid Short To Voltage Source….137
XMC 522846.05 – Steer Right Solenoid Open Circuit….137
XMC 522846.06 – Steer Right Solenoid Short To Ground….137
XMC 522846.16 – Steer Right Solenoid Current High….137
XMC 522846.18 – Steer Right Solenoid Current Low….138
XMC 522847.16 – Steer Left Solenoid Current High….138
XMC 522847.18 – Steer Left Solenoid Current Low….138
XMC 522848.03 – Steer Left Solenoid Short To Voltage Source….138
XMC 522848.05 – Steer Left Solenoid Open Circuit….138
XMC 522848.06 – Steer Left Solenoid Short To Ground….138
XMC 522848.16 – Steer Left Solenoid Current High….138
XMC 522848.18 – Steer Left Solenoid Current Low….138
XMC 522920.09 – XMC Timed Out Waiting for XSC….138
XMC 522976.12 – Steering System Control Unit Fault….138
XMC 523137.14 – Steering System Fault….138
XMC 523789.13 – Wheel Angle Sensor Not Calibrated….138
XMC 523795.13 – Steering Valve Not Calibrated….138
XMC 524055.02 – Steering System Control Unit Fault….138
XMC 524055.12 – Steering System Control Unit Fault….138
Group 6: XSC – AutoTrac™ Supervisor Control Unit….138
XSC 000609.12 – Incorrect Software….138
XSC 000611.09 – Start-up Checks Timed Out….138
XSC 000628.12 – Steering System Control Units Programming….138
XSC 000629.02 – Steering System Control Unit Fault….138
XSC 000629.12 – Steering System Control Unit Fault….138
XSC 000639.08 – Vehicle CAN Bus Fault….138
XSC 000701.02 – Incompatible Harness on Steering System Control Unit….138
XSC 000704.09 – System Start-up Checks Failed….138
XSC 000708.10 – Steering System Control Unit Fault….138
XSC 000708.16 – Steering System Control Unit Fault….138
XSC 000708.18 – Steering System Control Unit Fault….138
XSC 000708.20 – Steering System Control Unit Fault….138
XSC 000708.21 – Steering System Control Unit Fault….138
XSC 000709.08 – Steering System Control Unit Fault….138
XSC 000709.10 – Steering System Control Unit Fault….138
XSC 000709.16 – Steering System Control Unit Fault….138
XSC 000709.18 – Steering System Control Unit Fault….138
XSC 000709.20 – Steering System Control Unit Fault….139
XSC 000709.21 – Steering System Control Unit Fault….139
XSC 001231.08 – Steering System Control Unit Fault….139
XSC 001231.12 – Steering System Control Unit Fault….139
XSC 001231.14 – Steering System Control Unit Fault….139
XSC 001504.14 – Operator Out of Seat While AutoTrac™ is Active….139
XSC 001504.31 – Operator Out of Seat While AutoTrac™ Is Active….139
XSC 001807.10 – Steering Wheel Position Sensor 1 Delta High….139
XSC 001807.16 – Steering Wheel Position Sensor 1 Frequency High….139
XSC 001807.18 – Steering Wheel Position Sensor 1 Frequency Low….139
XSC 001807.20 – Steering Wheel Position Sensor 1 Duty Cycle High….139
XSC 001807.21 – Steering Wheel Position Sensor 1 Duty Cycle Low….139
XSC 001807.31 – Steering Wheel Motion Not Detected….139
XSC 002000.09 – Engine Messages Missing….139
XSC 002003.09 – Transmission Messages Missing….139
XSC 002005.09 – BCU Messages Missing….139
XSC 002028.09 – StarFire™ Receiver Messages Missing….139
XSC 002042.09 – GreenStar™ Display Messages Missing….139
XSC 002049.09 – BCU Messages Missing….139
XSC 002071.09 – BCU Messages Missing….139
XSC 002198.09 – Steering System Control Unit Fault….139
XSC 003511.03 – Sensor Supply 3 Voltage High….139
XSC 003511.04 – Sensor Supply 3 Voltage Low….139
XSC 003512.03 – Sensor Supply 4 Voltage High….139
XSC 003512.04 – Sensor Supply 4 Voltage Low….139
XSC 003841.00 – Steering System Control Unit Fault….139
XSC 003841.01 – Steering System Control Unit Fault….139
XSC 003841.02 – Steering System Control Unit Fault….139
XSC 003842.00 – Steering System Control Unit Fault….139
XSC 003842.01 – Steering System Control Unit Fault….139
XSC 522387.07 – No Movement Detected From Wheel Angle Sensor….139
XSC 522390.09 – Incorrect CAN Bus Message, Information from Implement….139
XSC 522390.11 – AutoTrac™ Stop Message Received….139
XSC 522451.00 – Wheel Angle Sensor (Secondary) Voltage High….140
XSC 522451.01 – Wheel Angle Sensor (Secondary) Voltage Low….140
XSC 522451.02 – Wheel Angle Sensors Disagree….140
XSC 522767.05 – Steering System Control Unit Valve Ground 2 Open Circuit….140
XSC 522768.05 – Steering System Control Unit Valve Ground 1 Open Circuit….140
XSC 522777.02 – Steering Wheel Sensors Disagree….140
XSC 522777.05 – Steering Wheel Sensor Disconnected….140
XSC 522920.09 – XSC Timed Out Waiting for XMC….140
XSC 522976.12 – Steering System Control Unit Fault….140
XSC 523137.14 – Steering System Fault….140
XSC 523218.04 – Steering System Control Unit Valve Power 2 Unswitched Voltage Low….140
XSC 523219.04 – Steering System Control Unit Valve Power 1 Unswitched Voltage Low….140
XSC 523789.05 – Wheel Angle Sensor Disconnected….140
XSC 523789.13 – Wheel Angle Sensors Not Calibrated….140
XSC 523795.07 – Steer Enable Valve Stuck Open….140
XSC 523795.13 – Steering Valve Not Calibrated….140
XSC 523815.03 – AutoTrac™ Steer Enable Solenoid Voltage High….140
XSC 523815.04 – AutoTrac™ Steer Enable Solenoid Voltage Low….140
XSC 523815.05 – AutoTrac™ Steer Enable Solenoid Current Low….140
XSC 523815.06 – AutoTrac™ Steer Enable Solenoid Current High….140
XSC 523821.02 – Incompatible Harness on Steering System Control Unit….140
XSC 523824.10 – Steering Wheel Position Sensor 2 Delta High….140
XSC 523824.16 – Steering Wheel Position Sensor 2 Frequency High….140
XSC 523824.18 – Steering Wheel Position Sensor 2 Frequency Low….140
XSC 523824.20 – Steering Wheel Position Sensor 2 Duty Cycle High….140
XSC 523824.21 – Steering Wheel Position Sensor 2 Duty Cycle Low….140
XSC 523826.00 – Wheel Angle Sensor (Primary) Voltage High….140
XSC 523826.01 – Wheel Angle Sensor (Primary) Voltage Low….140
XSC 523826.14 – Wheel Angle Sensor Movement Not Detected….140
XSC 523925.09 – Steering System Control Unit Fault….140
XSC 524055.02 – Steering System Control Unit Fault….140
XSC 524055.12 – Steering System Control Unit Fault….140
Group 7: ECU – Engine Control Unit….140
ECU 000029.03 – B96 – Electrical Hand Throttle, Voltage Too High….141
ECU 000029.04 – B96 – Electrical Hand Throttle, Voltage Too Low….141
ECU 000084.31 – Incorrect CAN Bus Message, Wheel Speed from BCU….141
ECU 000091.03 – B79 – Foot Throttle, Voltage Too High….141
ECU 000091.04 – B79 – Foot Throttle, Voltage Too Low….141
ECU 000097.03 – Water In Fuel Signal Out of Range….141
ECU 000097.04 – Water In Fuel Signal Out of Range Low….141
ECU 000097.16 – Water In Fuel Detected….141
ECU 000105.00 – Manifold Air Temperature Signal Extremely High….141
ECU 000105.03 – Manifold Air Temperature Signal Out of Range High….141
ECU 000105.04 – Manifold Air Temperature Signal Out of Range Low….141
ECU 000105.15 – Manifold Air Temperature Signal Slightly High….141
ECU 000105.16 – Manifold Air Temperature Signal Moderately High….141
ECU 000108.02 – Barometric Air Pressure Signal Invalid….141
ECU 000110.00 – Coolant Temperature Signal Extremely High….141
ECU 000110.03 – Coolant Temperature Signal Out of Range High….141
ECU 000110.04 – Coolant Temperature Signal Out of Range Low….141
ECU 000110.15 – Coolant Temperature Signal Slightly High….141
ECU 000110.16 – Engine Coolant Temperature Moderately High….141
ECU 000157.03 – Fuel Rail Pressure Signal Out of Range High….141
ECU 000157.04 – Fuel Rail Pressure Signal Out of Range Low….141
ECU 000157.10 – Fuel Rail Pressure Loss Detected….141
ECU 000157.17 – Fuel Rail Pressure Not Developed….141
ECU 000158.17 – ECU Power Down Error….141
ECU 000160.02 – Wheel Speed Signal Incorrect….141
ECU 000174.00 – Fuel Temperature Signal Extremely High….141
ECU 000174.03 – Fuel Temperature Signal Out of Range High….141
ECU 000174.04 – Fuel Temperature Signal Out of Range Low….141
ECU 000174.16 – Fuel Temperature Signal Moderately High….141
ECU 000189.00 – Engine Speed Derate Condition Exists….141
ECU 000190.00 – Engine Speed Extremely High….141
ECU 000190.16 – Engine Overspeed Moderate….141
ECU 000237.02 – VIN Information, Mismatch….141
ECU 000237.13 – VIN Option Code Invalid….142
ECU 000237.31 – VIN Information, Incorrect….142
ECU 000611.03 – Injector Shorted to Voltage Source….142
ECU 000611.04 – Injector Shorted to Ground….142
ECU 000627.01 – All Injector Circuits Have High Resistance….142
ECU 000629.12 – ECU EEPROM Error….142
ECU 000629.13 – ECU Boot Block Error….142
ECU 000636.02 – Camshaft Position Signal Invalid….142
ECU 000636.05 – Camshaft Position Circuit Has High Resistance….142
ECU 000636.06 – Camshaft Position Circuit Has Low Resistance….142
ECU 000636.08 – Camshaft Position Signal Missing….142
ECU 000636.10 – Camshaft Position Signal Rate of Change Abnormal….142
ECU 000637.02 – Crankshaft Position Signal Invalid….142
ECU 000637.05 – Crankshaft Position Circuit Has High Resistance….142
ECU 000637.06 – Crankshaft Position Circuit Has Low Resistance….142
ECU 000637.07 – Crankshaft and Camshaft Position Signals Out of Sync….142
ECU 000637.08 – Crankshaft Position Signal Missing….142
ECU 000637.10 – Crankshaft Position Signal Rate of Change Abnormal….142
ECU 000651.02 – Injector #1 Part Number Invalid….142
ECU 000651.05 – Injector #1 Circuit Has High Resistance….142
ECU 000651.06 – Injector #1 Circuit Has Low Resistance….142
ECU 000651.07 – Injector #1 Not Responding….142
ECU 000651.13 – Injector #1 Calibration Fault….142
ECU 000652.02 – Injector #2 Part Number Invalid….142
ECU 000652.05 – Injector #2 Circuit Has High Resistance….142
ECU 000652.06 – Injector #2 Circuit Has Low Resistance….142
ECU 000652.07 – Injector #2 Not Responding….142
ECU 000652.13 – Injector #2 Calibration Fault….142
ECU 000653.02 – Injector #3 Part Number Invalid….142
ECU 000653.05 – Injector #3 Circuit Has High Resistance….142
ECU 000653.06 – Injector #3 Circuit Has Low Resistance….142
ECU 000653.07 – Injector #3 Not Responding….142
ECU 000653.13 – Injector #3 Calibration Fault….142
ECU 000654.02 – Injector #4 Part Number Invalid….143
ECU 000654.05 – Injector #4 Circuit Has High Resistance….143
ECU 000654.06 – Injector #4 Circuit Has Low Resistance….143
ECU 000654.07 – Injector #4 Not Responding….143
ECU 000654.13 – Injector #4 Calibration Fault….143
ECU 000655.02 – Injector #5 Part Number Invalid….143
ECU 000655.05 – Injector #5 Circuit Has High Resistance….143
ECU 000655.06 – Injector #5 Circuit Has Low Resistance….143
ECU 000655.07 – Injector #5 Not Responding….143
ECU 000655.13 – Injector #5 Calibration Fault….143
ECU 000656.02 – Injector #6 Part # Data Invalid….143
ECU 000656.05 – Injector #6 Circuit Has High Resistance….143
ECU 000656.06 – Injector #6 Circuit Has Low Resistance….143
ECU 000656.07 – Injector #6 Not Responding….143
Section 212: Observable Symptoms….979
Group 40: Electrical System….979
Control Unit(s) Not Displayed….979
Diagnostic Mode Cannot Be Entered or Connection Problems with Service ADVISOR (Cab Tractors)….979
Diagnostic Mode Cannot Be Accessed or Connection Problems with Service ADVISOR (Open operator's station)….979
Problems During Reprogramming of Control Units….979
Problems with the Battery….979
Problems with the Starter Motor….979
Problems with the Horn….979
Problems with the Windshield Wiper….979
Problems with the Windshield Washer….979
Group 45: Electronic Control Units….979
Problems when Programming the Control Unit….979
Problems when Programming the BCU Control Unit….979
Problem with the BCU Control Unit….979
Problem with the TECU Control Unit….979
Group 55: PowrQuad Transmissions….979
Problems with PowrQuad Transmission….979
Group 56: Drive Systems….979
Problems with the PTO….2681
Group 60: Steering and Brakes….979
Problems with the Brakes….979
Problems with the Steering….979
Group 70: Hydraulic System….979
Problems with the Rockshaft….979
Problems with the Rockshaft's Remote Control….979
Group 90: Operator's Cab….979
Problems with the Air-Conditioning System….979
Section 213: System Diagnosis….1049
Group 45: Electronics….1049
Check for vehicle CAN bus….1054
Check for implement CAN bus….1058
VIN Security Fault Diagnosis….1062
Section 220: Engine….1064
Group 10: Operational Checks….1064
Safety….1066
Preliminary Engine Testing….1067
Group 15: Tests and Adjustments….1064
Dynamometer test….1069
Section 230: Fuel, Air Intake and Cooling Systems….1070
Group 15: Tests and Adjustments….1070
Fuel, Air Intake and Cooling Systems – Summary of References….1072
Fuel, Air Intake and Cooling Systems – General Information….1073
Fuel, Air Intake and Cooling Systems – Explanation of Checks….1074
Fuel, Air Intake and Cooling Systems – Safety Measures….1075
Special Tools….3826
Fuel, Air Intake, and Cooling Systems – Specifications….1077
Air Intake System – System Check….1078
Cooling System – Filling/Bleeding the System….1079
Cooling System – Leak Test….1081
Cooling System – Test Thermostat Opening Temperature….1083
Hand Throttle Lever and Accelerator Pedal Adjustment….1086
Accelerator Pedal Adjustment….1086
Cooling System – Flow Testing in the Low-Temperature Circuit (6205J Tractor)….1087
Cooling System – Check the Viscous Fan Drive (6205J Tractor)….1091
Fuel System – Check the Fuel Transfer Pump (6205J Tractor)….1094
Group 20A: Fuel System….1070
Fuel System – Theory of Operation (6145J, 6165J and 6180J Tractors)….1097
Fuel System – Theory of Operation (6205J Tractor)….1098
Fuel System – Fuel Cooler (6205J Tractor)….1100
Fuel System – Fuel Transfer Pump (6205J Tractor)….1101
Group 20B: Air Intake System….1070
Air Intake System – Theory of Operation….1104
Group 20C: Cooling System….1070
Coolant Circuit – Description (6145J, 6165J and 6180J Tractor)….1108
Coolant Circuit – Description (6205J Tractor)….1110
Cooling System Radiator – Description….1112
Intercooler – Description (6165J and 6180J Tractors)….1113
Ring-Shaped (Transmission Oil) Cooler – Description….1114
Automatic Drive Belt Tensioner – Theory of Operation….1116
Section 240A: Electrical System – Cab Tractors – 6145J, 6165J and 6180J….1117
Group 05: Fuse Box – Without AutoTrac™ Integrated….1117
Fuse Box – Theory of Operation….1133
Fuse Box – Electrical Diagram….1134
Group 05A: Fuse Box – With AutoTrac™ Integrated….1117
Fuse Box – Theory of Operation….1133
Fuse Box – Electrical Diagram….1134
Group 05B: Starting and Charging Circuit….1117
Starting and Charging Circuit – Theory of Operation….1137
Starting and Charging Circuit – Electrical Diagram….1138
Group 05C: Panel Warning Lights without AutoTrac™ Integrated….1117
Panel Warning Lights without AutoTrac™ Integrated – Theory of Operation….1141
Panel Warning Lights without AutoTrac™ Integrated – Electrical Diagram….1142
Group 05D: Panel Warning Lights with AutoTrac™ Integrated….1117
Panel Warning Lights with AutoTrac™ Integrated – Theory of Operation….1145
Panel Warning Lights with AutoTrac™ Integrated – Electrical Diagram….1146
Group 05E: Lights, Tail Lights and License Plate….1117
Lights and Tail Lights – Theory of Operation….1149
Lights and Tail Lights – Electrical Diagram….1150
Group 05F: Work Lights….1117
Work Lights – Theory of Operation….2216
Work Lights – Electrical Diagram….1154
Group 05G: Radio, Dome Light, Console Light and Beacon Light….1117
Radio, Dome Light, Console Light and Beacon Light – Theory of Operation….1157
Radio, Dome Light, Console Light and Beacon Light – Electrical Diagram….1158
Group 05H: Horn and Accessories Socket….1117
Horn and Accessories Socket – Theory of Operation….2227
Horn and Accessories Socket – Electrical Diagram….1161
Group 05I: Power Outlet without AutoTrac™ Universal….1117
Power Outlet without AutoTrac™ Universal – Theory of Operation….1164
Power Outlet without AutoTrac™ Universal – Electrical Diagram….1165
Group 05J: Power Outlet with AutoTrac™ Universal….1117
Power Outlet with AutoTrac™ Universal – Theory of Operation….1167
Power Outlet with AutoTrac™ Universal – Electrical Diagram….1168
Group 05K: Fan and A/C….1118
Fan and A/C – Theory of Operation….1170
Fan and A/C – Electrical Diagram….1171
Group 05L: Backup Alarm and Reverse Light….1118
Backup Alarm and Reverse Light – Theory of Operation….2264
Backup Alarm and Reverse Light – Electrical Diagram….1175
Group 05M: Front Windshield Wiper and Washer….1118
Front Windshield Wiper and Washer – Theory of Operation….1178
Front Windshield Wiper and Washer – Electrical Diagram….1179
Group 05N: Rear Windshield Wiper and Washer….1118
Rear Windshield Wiper and Washer – Theory of Operation….2254
Rear Windshield Wiper and Washer – Electrical Diagram….1182
Group 05O: Trailer Connector….1118
Trailer Connector – Theory of Operation….1184
Trailer Connector – Electrical Diagram….1185
Group 05P: BCU – Turn Signal and Hazard Warning Lights….1118
BCU – Turn Signal and Hazard Warning Lights – Theory of Operation….1188
BCU – Turn Signal and Hazard Warning Lights – Electrical Diagram….1189
Circuit test for Turn Signal Switch (S08)….1191
Circuit test for hazard warning switch (S62)….1195
Group 05Q: BCU – Electronic Hitch-Control….1118
BCU – Electronic Hitch-Control – Theory of Operation….1200
BCU – Electronic Hitch-Control – Electrical Diagram….1201
Circuit test for Rockshaft Control Stepper Motor (M08)….1227
Circuit test for Sensitivity Potentiometer (B26)….1205
Circuit test for Depth-setting Potentiometer (B27)….1208
Circuit test for Position Sensor (B21)….1211
Circuit test for Rate-of-Drop Potentiometer (B27)….1215
Circuit test for Raise-Limit Potentiometer (B27)….1218
Circuit/harness test for Rapid Raise Switch (S24)….1221
Circuit test for Left Remote Control Switch (S68)….1224
Circuit test for Rockshaft Control Stepper Motor (M08)….1227
Group 05R: BCU – Brakes….1119
BCU – Brakes – Theory of Operation….1230
BCU – Brakes – Electrical Diagram….1231
Group 05S: BCU – PTO….2681
BCU – PTO – Theory of Operation….1234
BCU – PTO – Electrical Diagram….1235
Circuit test for PTO Switch (S21)….1237
Circuit test for PTO Solenoid Valve (Y04)….1241
Group 05T: BCU – Engine Speed Sensor….1119
BCU – Engine Speed Sensor – Theory of Operation….1245
BCU – Engine Speed Sensor – Electrical Diagram….1246
Circuit test for Engine Speed Sender (B01)….1248
Group 05U: BCU – Front-Wheel Drive….1119
BCU – Front-Wheel Drive – Theory of Operation….1252
BCU – Front-Wheel Drive – Electrical Diagram….1253
Circuit test for Front-Wheel Drive Switch (S63)….1255
Circuit test for Front-Wheel Drive Solenoid Valve (Y03)….1258
Group 05V: BCU – Differential Lock….1119
BCU – Differential Lock – Theory of Operation….1262
BCU – Differential Lock – Electrical Diagram….1263
Circuit test for Differential Lock Switch (S22)….1265
Circuit test for Differential Lock Solenoid Valve (Y05)….1268
Group 05W: BCU – Ground Speed Sender….1119
BCU – Ground Speed Sender – Theory of Operation….1272
BCU – Ground Speed Sender – Electrical Diagram….1273
Group 05X: BCU – Transmission Enable Switches….1119
BCU – Transmission Enable Switches – Theory of Operation….2268
BCU – Transmission Enable Switches – Electrical Diagram….2269
Group 05Y: BCU – Service Connector – Without AutoTrac™ Integrated….1119
BCU – Service Connector – Theory of Operation….1280
BCU – Service Connector – Electrical Diagram….1281
Group 05Z: BCU – Seat Switch….1120
BCU – Seat Switch – Theory of Operation….2272
BCU – Seat Switch – Electrical Diagram….2273
Group 05AA: BCU – AutoTrac™ Integrated Resume Switch….1120
BCU – AutoTrac™ Resume Switch – Theory of Operation….2276
BCU – AutoTrac™ Resume Switch – Electrical Diagram….2277
Group 05AB: GreenStar™ without AutoTrac™ Integrated….1120
GreenStar™ Components without AutoTrac™ Integrated – Theory of Operation….1832
GreenStar™ Components without AutoTrac™ Integrated – Electrical Diagram….1833
Group 05AC: GreenStar™ with AutoTrac™ Integrated….1120
GreenStar™ Components – Theory of Operation….1296
GreenStar™ Components – Electrical Diagram….1297
Group 05AD: XMC and XSC – AutoTrac™ Integrated Steering Control Unit….1120
AutoTrac™ Control Unit – Theory of Operation….2283
AutoTrac™ Control Unit – Electrical Diagram….2284
Group 05AE: TECU – AutoTrac™ Integrated Tractor Equipment Control Unit….1120
Tractor Equipment Control Unit – Theory of Operation….2286
Tractor Equipment Control Unit – Electrical Diagram….2287
Group 05AF: AutoTrac™ Integrated Vehicle CAN Bus….1120
Vehicle CAN BUS – Theory of Operation….1307
Vehicle CAN BUS – Electrical Diagram….1308
Group 10: Component Tests….1120
Component Tests ― Summary of References….1310
Starting and Charging Circuit – Component Test….1311
Instrument Panel….2664
Circuit test for Horn (H01)….2230
Lighting Circuits….2671
Work lights….2675
Dome Light….1334
Fan, Air Conditioning and Automatic A/C control….1335
Windshield Wiper and Washer System….1341
Beacon light – Optional….1343
Electronic Hitch Control….2677
PTO….2681
BCU (FWD)….2683
Differential lock….2685
Hazard Warning Lights Unit….2687
Brake System….2689
Group 15: Wiring Harnesses….1121
Disconnecting Electrical Circuits….2691
Location of Ground Points….2692
W01 — Power Supply Wiring Harness….1362
W02 — Engine Wiring Harness….2292
W03 — Starter Relay Wiring Harness….1365
W04 — Headlights Wiring Harness….1366
W06 — Backup Alarm Wiring Harness….1367
W08 — Cab Wiring Harness without AutoTrac™ Integrated….1842
W08 — Cab Wiring Harness with AutoTrac™ Integrated….2296
W09 — Cowl Wiring Harness….2298
W19 — Cab Roof Wiring Harness….2300
W26 — Fan and Air Conditioning Wiring Harness….2304
W28 — Front End of Transmission Wiring Harness without AutoTrac™ Integrated….1851
W28 — Front End of Transmission Wiring Harness with AutoTrac™ Integrated….2305
W30 — Rear End of Transmission Wiring Harness….2307
W31 — Power Take-Off Wiring Harness for 7-Pin Socket….1381
W43 — GreenStar™ Roof Wiring Harness….2310
W44 — GreenStar™ Display Wiring Harness….2311
W45 — AutoTrac™ Integrated Steering Control Wiring Harness….2312
W46 — AutoTrac™ Integrated Steering Wheel Position Wiring Harness….2314
W47 — GreenStar™ Display Wiring Harness without AutoTrac™ Integrated….1858
W47 — GreenStar™ Display Wiring Harness with AutoTrac™ Integrated….2315
W49 — Implement CAN Bus Wiring Harness with AutoTrac™ Integrated….2316
W94 — Wheel Angle Sensor Wiring Harness (Standard Front Axle)….2317
W94 — Wheel Angle Sensor Wiring Harness (3 Meters Front Axle)….2318
Group 20: Connectors….1122
A01 – Fuse and relay box….1395
A02 – Fuse Box 2….1398
A03 – AutoTrac™ Not Integrated Fuse Box….1399
A03 – AutoTrac™ Integrated Fuse Box….1400
A04 – Fuse Box 3….1401
A05 – AutoTrac™ Integrated Fuse Box….1402
A08 – Dome Light….2332
A29 – Pneumatic operator's seat and rear wiper….1404
A52 – StarFire™ iTC Receiver….2336
A60 – Radio….1407
B01 – Engine speed sensor….1408
B02 – Sender for air cleaner restriction warning light….2341
B03 – Fuel gauge sensor unit – Without AutoTrac™ Integrated….1881
B03 – Fuel gauge sensor unit – With AutoTrac™ Integrated….2342
B04 – Sender for engine oil pressure indicator light….2343
B06 – PTO Speed Sensor….2719
B07 – Transmission oil filter pressure sensor – Without AutoTrac™ Integrated….1884
B07 – Transmission oil filter pressure sensor – With AutoTrac™ Integrated….2345
B08 – Coolant temperature sensor….2346
B09 – Wheel Speed Sensor….2347
B14 – Compressor and thermostat switch….2348
B15 – Air conditioning system pressure switch….1419
B21 – Hitch-control position sensor….2350
B26 – Sensitivity potentiometer….1421
B27 – Feedback unit….1422
B29 – Transmission oil temperature sensor….1891
B30 – Hydrostatic oil temperature sensor….2353
B31 – Transmission oil pressure sender….2354
B32 – Forward clutch pressure switch….2355
B33 – Reverse clutch pressure switch….2356
B36 – Neutral start switch….2357
B41 – Draft potentiometer….2359
B48 – Backup alarm switch….2360
B60 – Transmission oil temperature sensor….2364
B88 – Brake switch….1433
B138 – Steering wheel position sensor….2373
B139 – Wheel angle sensor (standard front axle)….2374
B139 – Wheel angle sensor (3 meters front axle)….2375
E01 – Right-hand front light….2376
E02 – Left-hand front light….2377
E09-R – Right-hand front working light….2378
E09-L – Left-hand front working light….2379
E10-R – Right-hand front working light – optional….1441
E10-L – Left-hand front working light – optional….1442
E11-1 – Right-hand rear working light….2380
E11-2 – Left-hand rear working light….2381
E12-2 – Console light….2382
E15-R – Right-hand rear working light – optional….1446
E15-L – Left-hand rear working light – optional….1447
E27 – Beacon light….1448
F13 – Main fuse….1449
F14 – Main fuse….1450
G01 – Battery….2386
G02 – Alternator….2387
H01 – Horn….2388
H34 – Front left-hand turn signal light….1454
H42 – Front right-hand turn signal light….1455
K01 – Starter relay….1456
K24 – Injection pump shut-off valve….1457
K28 – Backup alarm….1458
M01 – Starter motor….2392
M02 – Air conditioning compressor….2393
M03 – Wiper motor….2394
M04 – Wiper motor….2395
M05 – Windshield washer pump….1463
M06 – Windshield washer pump….2397
M07 – Fan motor….2398
M08 – Hitch-control stepper motor….2399
M10 – Fan motor….2400
P24-1 – Instrument panel….1468
P24-2 – Instrument panel….1469
P24-3 – Instrument panel….1470
R03 – Resistors….2403
S01 – Starter switch….2405
S04 – Horn switch….2406
S08 – Turn signal switch….2407
S09 – Light switch….2408
S10 – Full/low beam light switch….2409
S14 – Fan switch….2410
S15 – Windshield wiper switch….2411
S18 – Rear wiper switch….2412
Section 240B: Electrical System – Cab Tractors – 6205J without AutoTrac™ Integrated….1616
Group 05A: Fuse Box….1616
Fuse Box – Theory of Operation – without AutoTrac™ Integrated….1627
Fuse Box – Electrical Diagram – without AutoTrac™ Integrated….1628
Group 05B: Starting and Charging Circuit….1616
Starting and Charging Circuit – Theory of Operation – without AutoTrac™ Integrated….1631
Starting and Charging Circuit – Electrical Diagram – without AutoTrac™ Integrated….1632
Circuit test for Starter motor (M01)….2065
Circuit test for Alternator (G02)….2068
Circuit test for Battery (G01)….2073
Circuit test for K01 Starter relay….2076
Group 05C: Vehicle CAN Bus and Service Connector….1616
Vehicle CAN Bus and Service Connector – Theory of Operation – without AutoTrac™ Integrated….1646
Vehicle CAN Bus and Service Connector – Electrical Diagram – without AutoTrac™ Integrated….1647
Group 05D: ECU – Power….1616
ECU Power – Theory of Operation – without AutoTrac™ Integrated….1649
ECU Power – Electrical Diagram – without AutoTrac™ Integrated….1650
Group 05E: ECU – Throttle and Fuel System….1616
ECU Throttle and Fuel System – Theory of Operation – without AutoTrac™ Integrated….1652
ECU Throttle and Fuel System – Electrical Diagram – without AutoTrac™ Integrated….1653
Circuit test for foot throttle (B79) – without AutoTrac™ Integrated….1654
Circuit test for electrical hand throttle (B96) – without AutoTrac™ Integrated….1657
Group 05F: ECU – Fuel Preheater and Aid Heater….1616
ECU Fuel Preheater and Aid Heater – Theory of Operation – without AutoTrac™ Integrated….1661
ECU Fuel Preheater and Aid Heater – Electrical Diagram – without AutoTrac™ Integrated….1662
Circuit test for Fuel Pump (M31) – without AutoTrac™ Integrated….1664
Circuit test for Heating Element of Fuel Preheater (R02) – without AutoTrac™ Integrated….1666
Circuit test for Sender for Electrical starting aid heater (R15) – without AutoTrac™ Integrated….1668
Group 05G: ECU – Sensors….1616
ECU Sensors – Theory of Operation – without AutoTrac™ Integrated….1671
ECU Sensors – Electrical Diagram – without AutoTrac™ Integrated….1672
Circuit test for crankshaft speed sensor (B72) – without AutoTrac™ Integrated….1674
Group 05H: BCU – Electronic Hitch-Control….1617
BCU – Electronic Hitch-Control – Theory of Operation – without AutoTrac™ Integrated….1678
BCU – Electronic Hitch-Control – Electrical Diagram – without AutoTrac™ Integrated….1679
Circuit test for hitch-control stepper motor (M08) – without AutoTrac™ Integrated….1681
Circuit test for Sensitivity Potentiometer (B26) – without AutoTrac™ Integrated….1683
Circuit test for height potentiometer (R08) – without AutoTrac™ Integrated….1686
Circuit test for Rate-of-Drop Potentiometer (R06) – without AutoTrac™ Integrated….1689
Circuit test for Raise-Limit Potentiometer (R07) – without AutoTrac™ Integrated….1692
Circuit test for Position Sensor (B21) – without AutoTrac™ Integrated….1695
Circuit test for draft potentiometer (B41) – without AutoTrac™ Integrated….1698
Circuit-harness test for quick raise-lower switch (S24) – without AutoTrac™ Integrated….1701
Circuit test for external hitch-control switch (S68) – without AutoTrac™ Integrated….1704
Circuit test for Supply Voltage for 5-Volt BCU Components – without AutoTrac™ Integrated….1707
Group 05I: BCU – Brakes….1617
BCU – Brakes – Theory of Operation – without AutoTrac™ Integrated….1711
BCU – Brakes – Electrical Diagram – without AutoTrac™ Integrated….1712
Circuit test for Brake Pedal Sensor Unit (B88) – without AutoTrac™ Integrated….1714
Group 05J: BCU – PTO….2681
BCU – PTO – Theory of Operation – without AutoTrac™ Integrated….1716
BCU – PTO – Electrical Diagram – without AutoTrac™ Integrated….1717
Circuit test for PTO Switch (S21) – without AutoTrac™ Integrated….1719
Circuit test for PTO Solenoid (Y04) – without AutoTrac™ Integrated….1722
Circuit test for Rear PTO Speed Sensor (B06) – without AutoTrac™ Integrated….1725
Group 05K: BCU – Front-Wheel Drive….1617
BCU – Front-Wheel Drive – Theory of Operation – without AutoTrac™ Integrated….1729
BCU – Front-Wheel Drive – Electrical Diagram – without AutoTrac™ Integrated….1730
Circuit test for Front-Wheel Drive Switch (S63) – without AutoTrac™ Integrated….1732
Circuit test for Front-Wheel Drive Solenoid Valve (Y03) – without AutoTrac™ Integrated….1735
Group 05L: BCU – Differential Lock….1617
BCU – Differential Lock – Theory of Operation – without AutoTrac™ Integrated….1739
BCU – Differential Lock – Electrical Diagram – without AutoTrac™ Integrated….1740
Circuit test for Differential Lock Switch (S22) – without AutoTrac™ Integrated….1742
Circuit test for Differential Lock Solenoid Valve (Y05) – without AutoTrac™ Integrated….1745
Group 05N: BCU – Turn Signal and Hazard Warning Lights….1618
BCU – Turn Signal and Hazard Warning Lights – Theory of Operation – without AutoTrac™ Integrated….1749
BCU – Turn Signal and Hazard Warning Lights – Electrical Diagram – without AutoTrac™ Integrated….1750
Circuit test for hazard warning switch (S106) – without AutoTrac™ Integrated….1752
Circuit test for Turn Signal Switch (S08) – without AutoTrac™ Integrated….1755
Group 05O: Panel Warning Lights….1618
Panel Warning Lights – Theory of Operation – without AutoTrac™ Integrated….1759
Panel Warning Lights – Electrical Diagram – without AutoTrac™ Integrated….1760
Circuit test for Sender for air filter restriction warning light (B02)….2201
Circuit test for Fuel gauge sender (B03)….2202
Circuit test for Engine oil pressure sender (B04)….2203
Circuit test for Sender for the transmission oil filter (B07)….2204
Circuit test for Coolant temperature sender (B08)….2205
Circuit test for Transmission oil temperature sender (B29)….2206
Circuit test for Transmission oil pressure sender (B31)….2207
Group 05P: Lights and Tail Lights….1618
Lights and Tail Lights – Theory of Operation – without AutoTrac™ Integrated….1770
Lights and Tail Lights – Electrical Diagram – without AutoTrac™ Integrated….1771
Component Checks for Lighting Circuit – without AutoTrac™ Integrated….1773
Group 05Q: Work Lights….1618
Work Lights – Theory of Operation….2216
Work Lights – Electrical Diagram – without AutoTrac™ Integrated….1778
Component Checks for Work Lights….2218
Group 05R: Radio, Dome Light and Console Light….1618
Radio, Dome Light and Console Light – Theory of Operation….2221
Radio, Dome Light and Console Light – Electrical Diagram – without AutoTrac™ Integrated….1783
Circuit test for Radio (A60) – without AutoTrac™ Integrated….1784
Circuit test for Dome Light (A08) – without AutoTrac™ Integrated….1785
Group 05S: Horn and Accessories Socket….1618
Horn and Accessories Socket – Theory of Operation….2227
Horn and Accessories Socket – Electrical Diagram – without AutoTrac™ Integrated….1789
Circuit test for Horn (H01)….2230
Group 05T: Power Outlet – without AutoTrac™….1619
Power Outlet – Theory of Operation – without AutoTrac™….1794
Power Outlet – Electrical Diagram – without AutoTrac™….1795
Group 05U: Power Outlet – with AutoTrac™ Universal….1619
Power Outlet – Theory of Operation – with AutoTrac™ Universal….1797
Power Outlet – Electrical Diagram – with AutoTrac™ Universal….1798
Group 05V: Seat Compressor….1619
Seat Compressor – Theory of Operation….2236
Seat Compressor – Electrical Diagram – without AutoTrac™ Integrated….1801
Seat Compressor Component Check….1802
Group 05W: Fan and Air Conditioning….1619
Fan and Air Conditioning – Theory of Operation….2240
Fan and Air Conditioning – Electrical Diagram – without AutoTrac™ Integrated….1805
Fan and Air Conditioning Component Tests….2243
Group 05X: Front Windshield Wiper and Washer….1619
Front Windshield Wiper and Washer – Theory of Operation – without AutoTrac™ Integrated….1813
Front Windshield Wiper and Washer – Electrical Diagram – without AutoTrac™ Integrated….1814
Front Windshield Wiper and Washer System….2251
Group 05Y: Rear Windshield Wiper and Washer – Theory of Operation….2254
Rear Windshield Wiper and Washer – Theory of Operation….2254
Rear Windshield Wiper and Washer – Electrical Diagram – without AutoTrac™ Integrated….1819
Rear Windshield Wiper and Washer System….2257
Group 05Z: Trailer Connector….1619
Trailer Connector – Theory of Operation – without AutoTrac™ Integrated….1824
Trailer Connector – Electrical Diagram – without AutoTrac™ Integrated….1825
Group 05AA: Backup Alarm and Reverse Light….1619
Backup Alarm and Reverse Light – Theory of Operation….2264
Backup Alarm and Reverse Light – Electrical Diagram – without AutoTrac™ Integrated….1829
Group 05AB: GreenStar™ Components….1619
GreenStar™ Components without AutoTrac™ Integrated – Theory of Operation….1832
GreenStar™ Components without AutoTrac™ Integrated – Electrical Diagram….1833
Group 10: Wiring Harnesses….1620
Disconnecting Electrical Circuits….2691
W01 — Power link Box Wiring Harness….2291
W02 — Engine Wiring Harness….2292
W04 – Headlights Wiring Harness….2294
W05 — Backup Alarm Wiring Harness….2295
W08 — Cab Wiring Harness without AutoTrac™ Integrated….1842
W09 — Cowl Wiring Harness….2298
W17 — Power outlet harness….2299
W19 — Cab Roof Wiring Harness….2300
W21 — Rear Wiper Switch Wiring Harness….2301
W22 — Rear Wiper Wiring Harness….2302
W23 — Rear Wiper Supply Wiring Harness….2303
W26 — Fan and Air Conditioning Wiring Harness….2304
W28 — Front End of Transmission Wiring Harness without AutoTrac™ Integrated….1851
W30 — Rear End of Transmission Wiring Harness….2307
W31 — Trailer Connector Wiring Harness….2309
W43 — GreenStar™ Roof Wiring Harness….2310
W44 — GreenStar™ Display Wiring Harness….2311
W47 — GreenStar™ Display Wiring Harness without AutoTrac™ Integrated….1858
W97 — Reverse Light Wiring Harness….2319
Group 15: Connectors….1620
A01 – Fuse and relay box – Without AutoTrac™ Integrated….1863
A02 – Fuse Box 2 – Without AutoTrac™ Integrated….1866
A03 – Fuse Box 3 – Without AutoTrac™ Integrated….1867
A04 – Fuse Box 4 – Without AutoTrac™ Integrated….1868
A05 – Fuse Box 5 – Without AutoTrac™ Integrated….1869
A06 – Power Link Box….2330
A08 – Dome Light….2332
A09 – Fuse Box with AutoTrac™ Universal….1873
A29 – Pneumatic operator's seat and rear wiper – Without AutoTrac™ Integrated….1874
A52 – StarFire™ iTC Receiver….2336
A60 – Radio – Without AutoTrac™ Integrated….1877
A62 – Bus terminator – Without AutoTrac™ Integrated….1878
A84 – Bus terminator engine….2340
B02 – Sender for air cleaner restriction warning light….2341
B03 – Fuel gauge sensor unit – Without AutoTrac™ Integrated….1881
B04 – Sender for engine oil pressure indicator light….2343
B06 – Rear PTO Speed Sensor….2344
B07 – Transmission oil filter pressure sensor – Without AutoTrac™ Integrated….1884
B08 – Coolant temperature sensor….2346
B14 – Compressor and thermostat switch….2348
B15 – Air conditioning system pressure switch – Without AutoTrac™ Integrated….1887
B21 – Hitch-control position sensor….2350
B26 – Sensitivity potentiometer – Without AutoTrac™ Integrated….1889
B27 – Feedback unit – Without AutoTrac™ Integrated….1890
B29 – Transmission oil temperature sensor….1891
B30 – Hydrostatic oil temperature sensor….2353
B31 – Transmission oil pressure sender….2354
B36 – Neutral start switch….2357
B37 – Interface handbrake – Without AutoTrac™ Integrated….1895
B41 – Draft potentiometer….2359
B48 – Backup alarm switch….2360
B56 – Water temperature engine sensor….2362
B59 – Manifold air temperature sensor….2363
B72 – Crankshaft speed sensor….2365
B74 – Event sensor….2366
B79 – Foot throttle – Without AutoTrac™ Integrated….1903
B88 – Brake switch – Without AutoTrac™ Integrated….1904
B96 – Electrical hand throttle – Without AutoTrac™ Integrated….1905
B114 – Fuel temperature sensor….2370
B121 – Water in fuel sensor….2371
B137 – Fuel rail pressure sensor….2372
E01 – Right-hand front light….2376
E02 – Left-hand front light….2377
E09-R – Right-hand front working light….2378
E09-L – Left-hand front working light….2379
E11-1 – Right-hand rear working light….2380
E11-2 – Left-hand rear working light….2381
E12-2 – Console light….2382
E32 – Manometer light….2383
E67 – Reverse Light….2384
G01 – Battery….2386
G02 – Alternator….2387
H01 – Horn….2388
H67 – Backup alarm….2389
H77 – Aid heater indicator light….2390
K28 – Backup alarm relay….2391
M01 – Starter motor….2392
M02 – Air conditioning compressor….2393
M03 – Wiper motor….2394
M04 – Wiper motor….2395
M05 – Windshield washer pump – Without AutoTrac™ Integrated….1929
M06 – Windshield washer pump….2397
M07 – Fan motor….2398
M08 – Hitch-control stepper motor….2399
M10 – Fan motor….2400
M31 – Fuel pump….2401
R02 – Fuel preheater….2402
R03 – Resistors….2403
R15 – Electrical starting aid heater….2404
S01 – Starter switch….2405
S04 – Horn switch….2406
S08 – Turn signal switch….2407
S09 – Light switch….2408
S10 – Full/low beam light switch….2409
S14 – Fan switch….2410
S15 – Windshield wiper switch….2411
S18 – Rear wiper switch….2412
S20 – Windshield switch….2413
S21 – PTO switch – Without AutoTrac™ Integrated….1947
S22 – Differential lock switch – Without AutoTrac™ Integrated….1948
S63 – Front-wheel drive switch – Without AutoTrac™ Integrated….1949
S68 – External hitch-control switch – Without AutoTrac™ Integrated….1950
S92-2 – Rear work lights switch….2418
S106 – Hazard warning lights switch….2419
W25 – Radio Antenna – Without AutoTrac™ Integrated….1953
X05 – Trailer connector….2423
X25 – Instrument right panel connector….2424
X26 – Instrument left panel connector….2426
X37 – Accessories socket – Without AutoTrac™ Integrated….1959
X40 – Connector (W22 and W23)….2429
X42 – Connector (W21 and W22)….2430
X106 – Tail, brake and turn signal lights (right-hand) – Without AutoTrac™ Integrated….1962
X107 – Tail, brake and turn signal lights (left-hand) – Without AutoTrac™ Integrated….1963
X108 – Front right- hand turn signal light….2433
X109 – Front left-hand turn signal light….2434
X182 – Connector (W08 and W26) – Without AutoTrac™ Integrated….1966
X234 – Connector (W30 and W31) – With hitch….2437
X234 – Connector (W30 and W31) – Without hitch….2438
X239 – Outlet Socket Connector – Without AutoTrac™ Integrated….1970
X305 – Cooler grounding….2440
X400 – Connector (W08 and W19) – Without AutoTrac™ Integrated….1972
X411 – Connector (W02 and W04)….2444
X430 – Connector (W08 and W30) – Without AutoTrac™ Integrated – With hitch….1977
X430 – Connector (W08 and W30) – Without AutoTrac™ Integrated – Without hitch….1980
X431 – Connector (W08 and W28) – Without AutoTrac™ Integrated….1983
X450 – Connector (W02 and W08) – Without AutoTrac™ Integrated….1986
X473 – Connector (W01 and W08) – Without AutoTrac™ Integrated….1989
X504 – Connector (W08 and W09) – Without AutoTrac™ Integrated….1991
X505 – Connector (W08 and W09) – Without AutoTrac™ Integrated….1994
X535 – Connector (W18 and W43) – Without AutoTrac™ Integrated….1997
X547 – Connector (W01 and W02)….2470
X571 – Service connector (CAN Bus) – Without AutoTrac™ Integrated….1999
X612 – Speaker connector….2472
X616-1 Basic control unit (BCU) – Without AutoTrac™ Integrated….2001
X616-2 Basic control unit (BCU) – Without AutoTrac™ Integrated….2003
X616-3 Basic control unit (BCU) – Without AutoTrac™ Integrated….2006
X658 – Implement CAN Bus Terminator Connector – Without AutoTrac™ Integrated….2008
X731 – Connector (W43 and W44)….2483
X805 – CAN Bus Terminating Resistor….2484
X844-1 — Engine control unit (ECU)….2486
X844-2 — Engine control unit (ECU)….2488
X879-1 – Connector (W43 and W49)….2495
X879-2 – Connector (W43 and W49)….2496
X907 – Connector (W44 and W47) – Without AutoTrac™ Integrated….2018
X908 – Interface GreenStar™ Display Connector – Without AutoTrac™ Integrated….2020
X930 – Connector (W08 and W43)….2504
X1175 – Connector (W18 and W40)….2023
X1176 – Connector (W18 and W40)….2024
X1177 – Connector (W40 and W48)….2025
X1178 – Connector (W40 and W48)….2026
X1179 – AutoTrac™ Universal Steering Connector….2027
X1180 – Connector (W40 and W41)….2028
X1181-1 – Seat Switch Connector….2029
X1181-2 – Seat Switch Connector….2030
X1182-1 – Seat Switch Connector….2031
X1182-2 – Seat Switch Connector….2032
XGND1 – Cab ground wire – Without AutoTrac™ Integrated….2033
XGND2 – Cab ground wire – Without AutoTrac™ Integrated….2034
XGND5 – Cab ground wire – Without AutoTrac™ Integrated….2035
XGND6 – Rear wiper ground wire….2514
XGND7 – Rear wiper ground wire….2515
XGND9 – Engine grounding….2516
XGND10 – Cab roof ground wire….2517
XGND14 – Cab roof ground wire….2518
XGND58 – Fan and A/C wiring harness grounding….2519
Y03 – Front-wheel drive solenoid valve….2520
Y04 – PTO Solenoid….2521
Y05 – Differential lock solenoid valve….2522
Y44 – Suction control valve….2523
Y47 – Injection valve….2524
Section 240C: Electrical System – Cab Tractors – 6205J with AutoTrac™ Integrated….2047
Group 05A: Fuse Box….2047
Fuse Box – Theory of Operation – with AutoTrac™ Integrated….2059
Fuse Box – Electrical Diagram – with AutoTrac™ Integrated….2060
Group 05B: Starting and Charging Circuit….2047
Starting and Charging Circuit – Theory of Operation – with AutoTrac™ Integrated….2063
Starting and Charging Circuit – Electrical Diagram – with AutoTrac™ Integrated….2064
Circuit test for Starter motor (M01)….2065
Circuit test for Alternator (G02)….2068
Circuit test for Battery (G01)….2073
Circuit test for K01 Starter relay….2076
Group 05C: Vehicle CAN Bus and Service Connector….2047
Vehicle CAN Bus and Service Connector – Theory of Operation – with AutoTrac™ Integrated….2078
Vehicle CAN Bus and Service Connector – Electrical Diagram – with AutoTrac™ Integrated….2079
Group 05D: ECU – Power….2047
ECU Power – Theory of Operation – with AutoTrac™ Integrated….2082
ECU Power – Electrical Diagram – with AutoTrac™ Integrated….2083
Group 05E: ECU – Throttle and Fuel System….2047
ECU Throttle and Fuel System – Theory of Operation – with AutoTrac™ Integrated….2085
ECU Throttle and Fuel System – Electrical Diagram – with AutoTrac™ Integrated….2086
Circuit test for foot throttle (B79) – with AutoTrac™ Integrated….2087
Circuit test for electrical hand throttle (B96) – with AutoTrac™ Integrated….2090
Group 05F: ECU – Fuel Preheater and Aid Heater….2047
ECU Fuel Preheater and Aid Heater – Theory of Operation – with AutoTrac™ Integrated….2094
ECU Fuel Preheater and Aid Heater – Electrical Diagram – with AutoTrac™ Integrated….2095
Circuit test for Fuel Pump (M31) – with AutoTrac™ Integrated….2097
Circuit test for Heating Element of Fuel Preheater (R02) – with AutoTrac™ Integrated….2099
Circuit test for Sender for Electrical starting aid heater (R15) – with AutoTrac™ Integrated….2101
Group 05G: ECU – Sensors….2047
ECU Sensors – Theory of Operation – with AutoTrac™ Integrated….2104
ECU Sensors – Electrical Diagram – with AutoTrac™ Integrated….2105
Circuit test for crankshaft speed sensor (B72) – with AutoTrac™ Integrated….2107
Group 05H: BCU – Electronic Hitch-Control….2048
BCU – Electronic Hitch-Control – Theory of Operation – with AutoTrac™ Integrated….2111
BCU – Electronic Hitch-Control – Electrical Diagram – with AutoTrac™ Integrated….2112
Circuit test for hitch-control stepper motor (M08) – with AutoTrac™ Integrated….2114
Circuit test for Sensitivity Potentiometer (B26) – with AutoTrac™ Integrated….2116
Circuit test for height potentiometer (R08) – with AutoTrac™ Integrated….2119
Circuit test for Rate-of-Drop Potentiometer (R06) – with AutoTrac™ Integrated….2122
Circuit test for Raise-Limit Potentiometer (R07) – with AutoTrac™ Integrated….2125
Circuit test for Position Sensor (B21) – with AutoTrac™ Integrated….2128
Circuit test for draft potentiometer (B41) – with AutoTrac™ Integrated….2131
Circuit-harness test for quick raise-lower switch (S24) – with AutoTrac™ Integrated….2134
Circuit test for external hitch-control switch (S68) – with AutoTrac™ Integrated….2137
Circuit test for Supply Voltage for 5-Volt BCU Components – with AutoTrac™ Integrated….2140
Group 05I: BCU – Brakes….2048
BCU – Brakes – Theory of Operation – with AutoTrac™ Integrated….2144
BCU – Brakes – Electrical Diagram – with AutoTrac™ Integrated….2145
Circuit test for Brake Pedal Sensor Unit (B88) – with AutoTrac™ Integrated….2147
Group 05J: BCU – PTO….2681
BCU – PTO – Theory of Operation – with AutoTrac™ Integrated….2149
BCU – PTO – Electrical Diagram – with AutoTrac™ Integrated….2150
Circuit test for PTO Switch (S21) – with AutoTrac™ Integrated….2152
Circuit test for PTO Solenoid (Y04) – with AutoTrac™ Integrated….2155
Circuit test for Rear PTO Speed Sensor (B06) – with AutoTrac™ Integrated….2158
Group 05K: BCU – Front-Wheel Drive….2048
BCU – Front-Wheel Drive – Theory of Operation – with AutoTrac™ Integrated….2162
BCU – Front-Wheel Drive – Electrical Diagram – with AutoTrac™ Integrated….2163
Circuit test for Front-Wheel Drive Switch (S63) – with AutoTrac™ Integrated….2165
Circuit test for Front-Wheel Drive Solenoid Valve (Y03) – with AutoTrac™ Integrated….2168
Group 05L: BCU – Differential Lock….2048
BCU – Differential Lock – Theory of Operation – with AutoTrac™ Integrated….2172
BCU – Differential Lock – Electrical Diagram – with AutoTrac™ Integrated….2173
Circuit test for Differential Lock Switch (S22) – with AutoTrac™ Integrated….2175
Circuit test for Differential Lock Solenoid Valve (Y05) – with AutoTrac™ Integrated….2178
Group 05M: BCU – Wheel Speed Sensor….2049
BCU Wheel Speed Sensor – Theory of Operation….2182
BCU Wheel Speed Sensor – Electrical Diagram….2183
Circuit test for Wheel Speed Sensor (B09)….2184
Group 05N: BCU – Turn Signal and Hazard Warning Lights….2049
BCU – Turn Signal and Hazard Warning Lights – Theory of Operation – with AutoTrac™ Integrated….2188
BCU – Turn Signal and Hazard Warning Lights – Electrical Diagram – with AutoTrac™ Integrated….2189
Circuit test for hazard warning switch (S106) – with AutoTrac™ Integrated….2191
Circuit test for Turn Signal Switch (S08) – with AutoTrac™ Integrated….2194
Group 05O: Panel Warning Lights….2049
Panel Warning Lights – Theory of Operation – with AutoTrac™ Integrated….2198
Panel Warning Lights – Electrical Diagram – with AutoTrac™ Integrated….2199
Circuit test for Sender for air filter restriction warning light (B02)….2201
Circuit test for Fuel gauge sender (B03)….2202
Circuit test for Engine oil pressure sender (B04)….2203
Circuit test for Sender for the transmission oil filter (B07)….2204
Circuit test for Coolant temperature sender (B08)….2205
Circuit test for Transmission oil temperature sender (B29)….2206
Circuit test for Transmission oil pressure sender (B31)….2207
Group 05P: Lights and Tail Lights….2049
Lights and Tail Lights – Theory of Operation – with AutoTrac™ Integrated….2209
Lights and Tail Lights – Electrical Diagram – with AutoTrac™ Integrated….2210
Component Checks for Lighting Circuit – with AutoTrac™ Integrated….2212
Group 05Q: Work Lights….2049
Work Lights – Theory of Operation….2216
Work Lights – Electrical Diagram – with AutoTrac™ Integrated….2217
Component Checks for Work Lights….2218
Group 05R: Radio, Dome Light and Console Light….2049
Radio, Dome Light and Console Light – Theory of Operation….2221
Radio, Dome Light and Console Light – Electrical Diagram – with AutoTrac™ Integrated….2222
Circuit test for Radio (A60) – with AutoTrac™ Integrated….2223
Circuit test for Dome Light (A08) – with AutoTrac™ Integrated….2224
Group 05S: Horn and Accessories Socket….2050
Horn and Accessories Socket – Theory of Operation….2227
Horn and Accessories Socket – Electrical Diagram – with AutoTrac™ Integrated….2228
Circuit test for Horn (H01)….2230
Group 05T: Power Outlet….2050
Power Outlet – Theory of Operation – with AutoTrac™ Integrated….2233
Power Outlet – Electrical Diagram – with AutoTrac™ Integrated….2234
Group 05U: Seat Compressor….2050
Seat Compressor – Theory of Operation….2236
Seat Compressor – Electrical Diagram – with AutoTrac™ Integrated….2237
Seat Compressor Component Check – with AutoTrac™ Integrated….2238
Group 05V: Fan and Air Conditioning….2050
Fan and Air Conditioning – Theory of Operation….2240
Fan and Air Conditioning – Electrical Diagram – with AutoTrac™ Integrated….2241
Fan and Air Conditioning Component Tests….2243
Group 05W: Front Windshield Wiper and Washer….2050
Front Windshield Wiper and Washer – Theory of Operation – with AutoTrac™ Integrated….2249
Front Windshield Wiper and Washer – Electrical Diagram – with AutoTrac™ Integrated….2250
Front Windshield Wiper and Washer System….2251
Group 05X: Rear Windshield Wiper and Washer – Theory of Operation….2254
Rear Windshield Wiper and Washer – Theory of Operation….2254
Rear Windshield Wiper and Washer – Electrical Diagram – with AutoTrac™ Integrated….2255
Rear Windshield Wiper and Washer System….2257
Group 05Y: Trailer Connector….2050
Trailer Connector – Theory of Operation – with AutoTrac™ Integrated….2260
Trailer Connector – Electrical Diagram – with AutoTrac™ Integrated….2261
Group 05Z: Backup Alarm and Reverse Light….2050
Backup Alarm and Reverse Light – Theory of Operation….2264
Backup Alarm and Reverse Light – Electrical Diagram – with AutoTrac™ Integrated….2265
Group 05AA: BCU – Transmission Enable Switches….2050
BCU – Transmission Enable Switches – Theory of Operation….2268
BCU – Transmission Enable Switches – Electrical Diagram….2269
Group 05AB: BCU – Seat Switch….2051
BCU – Seat Switch – Theory of Operation….2272
BCU – Seat Switch – Electrical Diagram….2273
Group 05AC: BCU – AutoTrac™ Integrated Resume Switch….2051
BCU – AutoTrac™ Resume Switch – Theory of Operation….2276
BCU – AutoTrac™ Resume Switch – Electrical Diagram….2277
Group 05AD: GreenStar™ Components….2051
GreenStar™ Components – Theory of Operation – with AutoTrac™ Integrated….2279
GreenStar™ Components – Electrical Diagram – with AutoTrac™ Integrated….2280
Group 05AE: XMC and XSC – AutoTrac™ Integrated Steering Control Unit….2051
AutoTrac™ Control Unit – Theory of Operation….2283
AutoTrac™ Control Unit – Electrical Diagram….2284
Group 05AF: TECU – AutoTrac™ Integrated Tractor Equipment Control Unit….2051
Tractor Equipment Control Unit – Theory of Operation….2286
Tractor Equipment Control Unit – Electrical Diagram….2287
Group 10: Wiring Harnesses….2051
Disconnecting Electrical Circuits….2691
W01 — Power link Box Wiring Harness….2291
W02 — Engine Wiring Harness….2292
W04 – Headlights Wiring Harness….2294
W05 — Backup Alarm Wiring Harness….2295
W08 — Cab Wiring Harness with AutoTrac™ Integrated….2296
W09 — Cowl Wiring Harness….2298
W17 — Power outlet harness….2299
W19 — Cab Roof Wiring Harness….2300
W21 — Rear Wiper Switch Wiring Harness….2301
W22 — Rear Wiper Wiring Harness….2302
W23 — Rear Wiper Supply Wiring Harness….2303
W26 — Fan and Air Conditioning Wiring Harness….2304
W28 — Front End of Transmission Wiring Harness with AutoTrac™ Integrated….2305
W30 — Rear End of Transmission Wiring Harness….2307
W31 — Trailer Connector Wiring Harness….2309
W43 — GreenStar™ Roof Wiring Harness….2310
W44 — GreenStar™ Display Wiring Harness….2311
W45 — AutoTrac™ Integrated Steering Control Wiring Harness….2312
W46 — AutoTrac™ Integrated Steering Wheel Position Wiring Harness….2314
W47 — GreenStar™ Display Wiring Harness with AutoTrac™ Integrated….2315
W49 — Implement CAN Bus Wiring Harness with AutoTrac™ Integrated….2316
W94 — Wheel Angle Sensor Wiring Harness (Standard Front Axle)….2317
W94 — Wheel Angle Sensor Wiring Harness (3 Meters Front Axle)….2318
W97 — Reverse Light Wiring Harness….2319
Group 15: Connectors….2052
A01 – Fuse and relay box – With AutoTrac™ Integrated….2323
A02 – Fuse Box 2 – With AutoTrac™ Integrated….2326
A03 – Fuse Box 3 – With AutoTrac™ Integrated….2327
A04 – Fuse Box 4 – With AutoTrac™ Integrated….2328
A05 – Fuse Box 5 – With AutoTrac™ Integrated….2329
A06 – Power Link Box….2330
A08 – Dome Light….2332
A09 – Fuse Box with AutoTrac™ Integrated….2333
A29-1 – Pneumatic operator's seat and rear wiper – With AutoTrac™ Integrated….2334
A29-2 – Pneumatic operator's seat and rear wiper – With AutoTrac™ Integrated….2335
A52 – StarFire™ iTC Receiver….2336
A60 – Radio – With AutoTrac™ Integrated….2338
A62 – Bus terminator – With AutoTrac™ Integrated….2339
A84 – Bus terminator engine….2340
B02 – Sender for air cleaner restriction warning light….2341
B03 – Fuel gauge sensor unit – With AutoTrac™ Integrated….2342
B04 – Sender for engine oil pressure indicator light….2343
B06 – Rear PTO Speed Sensor….2344
B07 – Transmission oil filter pressure sensor – With AutoTrac™ Integrated….2345
B08 – Coolant temperature sensor….2346
B09 – Wheel Speed Sensor….2347
B14 – Compressor and thermostat switch….2348
B15 – Air conditioning system pressure switch – With AutoTrac™ Integrated….2349
B21 – Hitch-control position sensor….2350
B26 – Sensitivity potentiometer – With AutoTrac™ Integrated….2351
B27 – Feedback unit – With AutoTrac™ Integrated….2352
B30 – Hydrostatic oil temperature sensor….2353
B31 – Transmission oil pressure sender….2354
B32 – Forward clutch pressure switch….2355
B33 – Reverse clutch pressure switch….2356
B36 – Neutral start switch….2357
B37 – Interface handbrake – With AutoTrac™ Integrated….2358
B41 – Draft potentiometer….2359
B48 – Backup alarm switch….2360
B56 – Water temperature engine sensor….2362
B59 – Manifold air temperature sensor….2363
B60 – Transmission oil temperature sensor….2364
B72 – Crankshaft speed sensor….2365
B74 – Event sensor….2366
B79 – Foot throttle – With AutoTrac™ Integrated….2367
B88 – Brake switch – With AutoTrac™ Integrated….2368
B96 – Electrical hand throttle – With AutoTrac™ Integrated….2369
B114 – Fuel temperature sensor….2370
B121 – Water in fuel sensor….2371
B137 – Fuel rail pressure sensor….2372
B138 – Steering wheel position sensor….2373
B139 – Wheel angle sensor (standard front axle)….2374
B139 – Wheel angle sensor (3 meters front axle)….2375
E01 – Right-hand front light….2376
E02 – Left-hand front light….2377
E09-R – Right-hand front working light….2378
E09-L – Left-hand front working light….2379
E11-1 – Right-hand rear working light….2380
E11-2 – Left-hand rear working light….2381
E12-2 – Console light….2382
E32 – Manometer light….2383
E67 – Reverse Light….2384
G01 – Battery….2386
G02 – Alternator….2387
H01 – Horn….2388
H67 – Backup alarm….2389
H77 – Aid heater indicator light….2390
Section 241: Electrical System – Open Operator's Station….2528
Group 05: Fuse Box….2528
Fuse Box – Theory of Operation (OOS)….2535
Fuse Box – Electrical Diagram (OOS)….2536
Group 05A: Starting and Charging Circuit….2528
Starting and Charging Circuit – Theory of Operation (OOS)….2539
Starting and Charging Circuit – Electrical Diagram (OOS)….2540
Group 05B: Panel Warning Lights….2528
Panel Warning Lights – Theory of Operation (OOS)….2543
Panel Warning Lights – Electrical Diagram (OOS)….2544
Group 05C: Lights and Tail Lights….2528
Lights and Tail Lights – Theory of Operation (OOS)….2547
Lights and Tail Lights – Electrical Diagram (OOS)….2548
Group 05D: Work Lights….2528
Work Lights – Theory of Operation (OOS)….2551
Work Lights – Electrical Diagram (OOS)….2552
Group 05E: Horn….2528
Horn – Theory of Operation (OOS)….2554
Horn – Electrical Diagram (OOS)….2555
Group 05F: Reverse Light and Backup Alarm….2528
Reverse Light and Backup Alarm – Theory of Operation (OOS)….2557
Reverse Light and Backup Alarm – Electrical Diagram (OOS)….2558
Group 05G: Trailer Connector….2528
Trailer Connector – Theory of Operation (OOS)….2561
Trailer Connector – Electrical Diagram (OOS)….2562
Group 05H: BCU – Turn Signal and Hazard Warning Lights….2528
BCU – Turn Signal and Hazard Warning Lights – Theory of Operation (OOS)….2564
BCU – Turn Signal and Hazard Warning Lights – Electrical Diagram (OOS)….2565
Circuit test for Turn Signal Switch (S08) – Open operator's station….2567
Group 05J: BCU – Electronic Hitch-Control….2528
BCU – Electronic Hitch-Control – Theory of Operation (OOS)….2572
BCU – Electronic Hitch-Control – Electrical Diagram (OOS)….2573
Circuit test for Sensitivity Potentiometer (B26) – Open operator's station….2575
Circuit test for Depth-setting Potentiometer (B27) – Open operator's station….2578
Circuit test for Position Sensor (B21) – Open operator's station….2581
Circuit Test on Rate-of-Drop Potentiometer (B27) – Open Operator's Station….2584
Circuit test for Paise-Limit Potentiometer – Open operator's station….2587
Circuit test for Rockshaft Control Stepper Motor (M08) – Open operator's station….2590
Circuit/harness test for rapid raise switch (S24) — Open operator's station….2592
Circuit test for Left Remote Control Switch (S68) – Open Operator's Station….2595
Group 05K: BCU – Brakes….2529
BCU – Brakes – Theory of Operation (OOS)….2600
BCU – Brakes – Electrical Diagram (OOS)….2601
Group 05L: BCU – Service Connector….2529
BCU – Service Connector – Theory of Operation (OOS)….2604
BCU – Service Connector – Electrical Diagram (OOS)….2605
Group 05M: BCU – PTO….2681
BCU – PTO – Theory of Operation (OOS)….2608
BCU – PTO – Electrical Diagram (OOS)….2609
Circuit test for PTO Switch (S21) -Open Operator's Station….2611
Circuit test for PTO solenoid valve (Y04) – Open operator's station….2614
Group 05N: BCU – Engine Speed Sensor….2529
BCU – Engine Speed Sensor – Theory of Operation (OOS)….2618
BCU – Engine Speed Sensor – Electrical Diagram (OOS)….2619
Circuit test for Engine Speed Sender (B01) – Open operator's station….2621
Group 05O: BCU – Front-Wheel Drive….2529
BCU – Front-Wheel Drive – Theory of Operation (OOS)….2625
BCU – Front-Wheel Drive – Electrical Diagram (OOS)….2626
Circuit test for Front-Wheel Drive Switch (S63) – Open operator's station….2628
Circuit test for Front-Wheel Drive Solenoid Valve (Y03) – Open operator's station….2631
Group 05P: BCU – Differential Lock….2529
BCU – Differential Lock – Theory of Operation (OOS)….2635
BCU – Differential Lock – Electrical Diagram (OOS)….2636
Circuit test for Differential Lock Switch (S22) – Open operator's station….2638
Circuit test for Differential Lock Solenoid Valve (Y05) – Open operator's station….2641
Group 10: Component Tests….2530
Starter Motor and Charging Circuit….2654
Instrument Panel….2664
Horn – Optional….2669
Lighting Circuits….2671
Work lights….2675
Electronic Hitch Control….2677
PTO….2681
BCU (FWD)….2683
Differential lock….2685
Hazard Warning Lights Unit….2687
Brake System….2689
Group 15: Wiring Harnesses….2530
Disconnecting Electrical Circuits….2691
Location of Ground Points….2692
Wiring Harness W01 — Power Supply….2695
Wiring Harness W02 — Engine Wiring Harness (Open Station Tractor)….2696
Wiring Harness W03 — Starter Relay….2698
Wiring Harness W04 — Headlights….2699
Wiring Harness W06 — Backup Alarm….2700
Wiring Harness W08 — Open Operator's Station….2701
Wiring Harness W09 — Hood (Open Operator's Station)….2703
Wiring Harness W28 — Front End of Transmission (Open Operator's Station)….2705
Wiring Harness W30 — Rear End of Transmission (Open Operator's Station)….2706
Wiring Harness W31 — Power Take-Off for 7-Pin Socket….2707
Work Lights and Turn Signal Lights Harness (Open Operator's Station)….2708
Group 20: Connectors….2530
A01 – Fuse and relay box – OOS….2712
B01 – Engine speed sensor – OOS….2715
B02 – Sender for air cleaner restriction warning light – OOS….2716
B03 – Fuel gauge sensor unit – OOS….2717
B04 – Sender for engine oil pressure indicator light – OOS….2718
B06 – PTO Speed Sensor….2719
B07 – Transmission oil filter pressure sensor – OOS….2720
B08 – Coolant temperature sensor – OOS….2721
B21 – Hitch-control position sensor – OOS….2722
B27 – Feedback unit- OOS….2723
B26 – Sensitivity potentiometer – OOS….2724
B29 – Transmission oil temperature sensor – OOS….2725
B30 – Hydrostatic oil temperature sensor – OOS….2726
B31 – Transmission oil pressure sender – OOS….2727
B36 – Neutral start switch – OOS….2728
B41 – Draft potentiometer – OOS….2729
B48 – Backup alarm switch – OOS….2730
B88 – Brake switch – OOS….2732
E01 – Right-hand front light – OOS….2733
E02 – Left-hand front light – OOS….2734
E09-R – Right-hand front working light – OOS….2735
E09-L – Left-hand front working light – OOS….2736
E11-1 – Right-hand rear working light – OOS….2737
E11-2 – Left-hand rear working light – OOS….2738
F13 – Main fuse – OOS….2739
F14 – Main fuse – OOS….2740
G01 – Battery – OOS….2741
G02 – Alternator – OOS….2742
H01 – Horn – OOS….2743
H34 – Front left-hand turn signal light – OOS….2744
H42 – Front right-hand turn signal light – OOS….2745
K01 – Starter relay – OOS….2746
K24 – Injection pump shut-off valve – OOS….2747
K28 – Backup alarm – OOS….2748
M01 – Starter motor – OOS….2749
M08 – Hitch-control stepper motor – OOS….2750
P24-1 – Instrument panel – OOS….2751
P24-2 – Instrument panel – OOS….2752
P24-3 – Instrument panel – OOS….2753
S01 – Starter switch – OOS….2754
S04 – Horn switch – OOS….2755
S08 – Turn signal switch – OOS….2756
S09 – Light switch – OOS….2757
S10 – Full/low beam light switch – OOS….2758
S21 – PTO switch – OOS….2759
S22 – Differential lock switch – OOS….2760
S42 – Light switch – OOS….2761
S59 – Front lights switch – OOS….2762
S62 – Hazard warning lights switch – OOS….2763
S63 – Front-wheel drive switch – OOS….2764
S68 – External hitch-control switch – OOS….2765
S92-2 – Rear work lights switch – OOS….2766
X05 – Trailer connector – OOS….2767
X21 – Connector (W07 and W08) – OOS….2768
X37 – Connector (W05 and W07) – OOS….2770
X67 – Connector (W05 and W06) – OOS….2772
X106 – Tail, brake and turn signal lights (right-hand) – OOS….2773
X107 – Tail, brake and turn signal lights (left-hand) – OOS….2774
X234 – Connector (W08 and W31) – OOS….2775
X286 – Connector (W08 and W28) – OOS….2776
X287 – Connector (W30 and W31) – OOS….2778
X287 – Connector (W08 and W30) – Without Hitch – OOS….2779
X288 – Connector (W02 and W08) – OOS….2780
X289 – Connector (W02 and W08) – OOS….2781
X411 – Connector (W02 and W04) – OOS….2782
X473 – Connector (W01 and W08) – OOS….2784
X504 – Connector (W08 and W09) – OOS….2786
X505 – Connector (W08 and W09) – OOS….2789
X547 – Connector (W02 and W03) – OOS….2792
X571 – Service connector (CAN Bus) – OOS….2793
X616-1 Basic control unit (BCU) – OOS….2794
X616-2 Basic control unit (BCU) – OOS….2796
X616-3 Basic control unit (BCU) – OOS….2799
X811-1 – Connector (W08 and W20) – OOS….2801
X811-2 – Connector (W08 and W19) – OOS….2803
XGND1 – Platform ground wire – OOS….2805
XGND2 – Platform ground wire – OOS….2806
XGND9 – Engine grounding – OOS….2807
XGND26 – Grounding point – OOS….2808
Y03 – Front-wheel drive solenoid valve – OOS….2809
Y04 – PTO Solenoid – OOS….2810
Y05 – Differential lock solenoid valve – OOS….2811
Section 245: Electronic Control Units….2812
Group 05: Operation and General Information on Diagnostics….2812
Operation and General Information – Summary of References….2824
Eletronic Control Units – Special Tools….3826
Operation and General Information on Diagnostics – Instrument Unit Adjustment….2826
General Operation and Entering the Program Mode….2832
Calling up Addresses and Diagnostic Trouble Codes….2839
PRF — Performance monitor — Summary of Addresses….2851
Control Unit Locations and Identification….2853
Group 15: Information on How to Reprogram Control Units….2812
General Information on How to Reprogram Control Units….2856
Check and Download Tractor-Specific Software Information….2857
Procedure When Replacing Control Units….2858
Programming Control Units with Software Bundles….2859
Important Notes on Programming….2860
Procedure When Programming Control Units….2861
Procedure in the Event of a Problem Programming VIN Control Units….2862
Procedure in the Event of a Programming Problem….2865
Group 20: Data BUS Systems, Operation….2812
Data BUS systems….2868
CAN BUS Systems….2869
Determining the Type of the CAN Bus Fault….2872
Group 50: Steering Control Units Tests….2812
Steering System Control Unit Test (XMC, XSC)….2879
Group 55A: BCU – Basic Control Unit – Without AutoTrac™ Integrated….2812
BCU — Basic Control Unit — Summary of Addresses….2886
Hitch-Control Calibration and Input Addresses….2890
Test Procedure in the Case of Occasional BCU Circuit Problems….2905
BCU — Theory of Operation (Basic Functions)….2907
Theory of Operation (Hitch Control)….2910
Group 55B: BCU – Basic Control Unit – With AutoTrac™ Integrated….2812
BCU – Summary of Addresses….2920
BCU 020 – Engine Speed Sensor/Pulses per Engine Revolution….2928
BCU 021 – Rear PTO Speed Sensor/Pulses per PTO Revolution….2929
BCU 022 – Front-Wheel Drive Control Function….2930
BCU 024 – Settings for Units of Measurement in Display and for Acoustic Indicator for Turn Signal….2931
BCU 028 – PTO Present/Not Present….2932
BCU 029 – Backup Alarm Setup….2933
BCU 030 – Sensor Diagnostics….2934
BCU 034 – Configuration of Instrument Unit and Self-Canceling Turn Signals….2935
BCU 045 – Handbrake Control Function….2936
BCU 055 – Configuration of Acoustic Alarm….2937
BCU 056 – Tire Configuration….2938
BCU 058 – Sensor for Wheel Speed / Transmission Pulses per Axle Revolution….2941
BCU 060 – True Vehicle Speed Calibration Factor….2942
BCU 065 – Air Brake Pressure Enable….2943
BCU 075 – Activate/Deactivate Implement Switch….2944
BCU 089 – Configuration of Acoustic Alarm When Activating the BCU….2945
BCU 097 – Low Fuel Level Acoustic Alarm….2946
BCU 099 – Automatic Deletion of Diagnostic Trouble Codes….2947
BCU 118 – Quick Withdrawal and Hitch Dampening On or Off….2948
BCU 122 – Hitch Control Calibration….2949
BCU 145 – Hitch Control On or Off….2957
BCU 162 – Switching Off Hydraulic Oil Temperature Access (During Calibration)….2958
BCU 165 – Raise Rate Setting….2959
BCU 167 – Activate/Deactivate Hitch Components….2960
BCU 174 – Index for Load Control….2961
BCU 185 – Volume of Lift Cylinder….2962
BCU 225 – Configuration Data, Software Part Number….2963
BCU 226 – Configuration Data, Software Version Number….2964
BCU 227 – Bootblock Program, Part Number….2965
BCU 228 – Bootblock Program, Version Number….2966
BCU 229 – EOL Parameters, Part Number….2967
BCU 230 – EOL Parameters, Version Number….2968
BCU 231 – Operating System Software, Part Number….2969
BCU 232 – Operating System Software, Version Number….2970
BCU 233 – Software Part Number….2971
BCU 234 – Software Version Number….2972
BCU 235 – Control Unit, Part Number….2973
BCU 236 – Control Unit, Serial Number….2974
BCU 237 – Software Package, Part Number….2975
BCU 238 – Software Package, Version Number….2976
BCU 247 – Tractor Model Designation….2977
BCU 248 – Tractor Serial Number….2978
BCU 249 – Model Designation of Original Tractor….2979
BCU 250 – Serial Number of Original Tractor….2980
BCU 251 – John Deere Product Identification Number (PIN) of Current Vehicle….2981
Group 55C: TEC – Tractor Equipment Control Unit….2814
TEC – Summary of Addresses….2985
TEC 000 – Initial Address….2988
TEC 001 – TEC Control Unit Stored Codes….2989
TEC 002 – TEC System Beep Mode….2990
TEC 009 – Supply Voltage (BAT)….2991
TEC 015 – Input Signals, Status….2992
TEC 016 – Output Signals, Status….2993
TEC 031 – Vacant Input Address….2994
TEC 032 – Vacant Input Address….2995
TEC 033 – Vacant Input Address….2996
TEC 034 – Vacant Input Address….2997
TEC 040 – Display of Available Implements….2998
TEC 050 – AutoTrac Control, Status….2999
TEC 051 – E-SCV 1 Control, Status….3000
TEC 052 – E-SCV 2 Control, Status….3001
TEC 053 – E-SCV 3 Control, Status….3002
TEC 054 – E-SCV 4 Control, Status….3003
TEC 055 – E-SCV 5 Control, Status….3004
TEC 056 – E-SCV 6 Control, Status….3005
TEC 070 – Ground Speed Sensor (Radar) Present….3006
TEC 071 – Rear Hitch Present….3007
TEC 072 – Rear PTO Present….3008
TEC 073 – Front PTO Present….3009
TEC 074 – Direction of Travel Shown on GreenStar™ Display….3010
TEC 075 – Direction of Travel (Radar) Shown on GreenStar™ Display….3011
TEC 076 – Selective Control Valves (E-ICV/E-SCV) present / not present….3012
TEC 077 – Implement Lights, Configuration….3013
TEC 078 – Draft Sensor Present….3014
TEC 099 – Automatic Deletion of Diagnostic Trouble Codes….3015
TEC 100 – Number of E-SCVs Installed on the Tractor….3016
TEC 101 – Number of E-ICVs Installed on the Tractor….3017
TEC 102 – HMS Shown on GreenStar™ Display….3018
TEC 103 – Service Interval Shown on GreenStar™ Display….3019
TEC 104 – Fuel Tank Capacity….3020
TEC 105 – Gears Shown on GreenStar™ Display….3021
TEC 106 – Radar Calibration Using GreenStar™ Display….3022
TEC 107 – Oil Temperature Shown on GreenStar™ Display….3023
TEC 109 – Position of Hitch Shown on GreenStar™ Display….3024
TEC 110 – Status of E-SCVs Shown on GreenStar™ Display….3025
TEC 111 – Transmission Type….3026
TEC 112 – GPS Speed Shown….3027
TEC 113 – Selection of Creeper Mode….3028
TEC 114 – Precondition for Distance Counter….3029
TEC 115 – Monitoring of Steering Control Valve….3030
TEC 116 – Vacant Input Address….3031
TEC 117 – Vacant Input Address….3032
TEC 225 – Configuration Data, Software Part Number….3033
TEC 226 – Configuration Data, Software Version Number….3034
TEC 227 – Bootblock Program, Part Number….3035
TEC 228 – Bootblock Program, Version Number….3036
TEC 231 – Operating System Software, Part Number….3037
TEC 232 – Operating System Software, Version Number….3038
TEC 233 – Software Part Number….3039
TEC 234 – Software Version Number….3040
TEC 235 – Control Unit, Part Number….3041
TEC 236 – Control Unit, Serial Number….3042
TEC 237 – Software Package, Part Number….3043
TEC 238 – Software Package, Version Number….3044
TEC 247 – Tractor Model Designation….3045
TEC 248 – Tractor Serial Number….3046
TEC 249 – Model Designation of Original Tractor….3047
TEC 250 – Serial Number of Original Tractor….3048
TEC 251 – John Deere Product Identification Number (PIN) of Current Vehicle….3049
Group 55D: TEI – Tractor Equipment Control Unit….2816
TEI – Summary of Addresses….3053
TEI 000 – Initial Address….3056
TEI 001 – TEI Control Unit Stored Codes….3057
TEI 002 – TEI System Beep Mode….3058
TEI 009 – Supply Voltage (BAT)….3059
TEI 015 – Input Signals, Status….3060
TEI 016 – Output Signals, Status….3061
TEI 031 – Vacant Input Address….3062
TEI 032 – Vacant Input Address….3063
TEI 033 – Vacant Input Address….3064
TEI 034 – Vacant Input Address….3065
TEI 040 – Display of Available Implements….3066
TEI 050 – AutoTrac Control, Status….3067
TEI 051 – E-SCV 1 Control, Status….3068
TEI 052 – E-SCV 2 Control, Status….3069
TEI 053 – E-SCV 3 Control, Status….3070
TEI 054 – E-SCV 4 Control, Status….3071
TEI 055 – E-SCV 5 Control, Status….3072
TEI 056 – E-SCV 6 Control, Status….3073
TEI 070 – Ground Speed Sensor (Radar) Present….3074
TEI 071 – Rear Hitch Present….3075
TEI 072 – Rear PTO Present….3076
TEI 073 – Front PTO Present….3077
TEI 074 – Direction of Travel Shown on GreenStar™ Display….3078
TEI 075 – Direction of Travel (Radar) Shown on GreenStar™ Display….3079
TEI 076 – Selective Control Valves (E-ICV/E-SCV) present / not present….3080
TEI 077 – Implement Lights, Configuration….3081
TEI 078 – Draft Sensor Present….3082
TEI 099 – Automatic Deletion of Diagnostic Trouble Codes….3083
TEI 100 – Number of E-SCVs Installed on the Tractor….3084
TEI 101 – Number of E-ICVs Installed on the Tractor….3085
TEI 102 – HMS Shown on GreenStar™ Display….3086
TEI 103 – Service Interval Shown on GreenStar™ Display….3087
TEI 104 – Fuel Tank Capacity….3088
TEI 105 – Gears Shown on GreenStar™ Display….3089
TEI 106 – Radar Calibration Using GreenStar™ Display….3090
TEI 107 – Oil Temperature Shown on GreenStar™ Display….3091
TEI 109 – Position of Hitch Shown on GreenStar™ Display….3092
TEI 110 – Status of E-SCVs Shown on GreenStar™ Display….3093
TEI 111 – Transmission Type….3094
TEI 112 – GPS Speed Shown….3095
TEI 113 – Selection of Creeper Mode….3096
TEI 114 – Precondition for Distance Counter….3097
TEI 115 – Monitoring of Steering Control Valve….3098
TEI 116 – Vacant Input Address….3099
TEI 117 – Vacant Input Address….3100
TEI 219 – Configuration Data of Control Unit Bootblock Program, Part Number….3101
TEI 220 – Configuration Data of Control Unit Bootblock Program, Version Number….3102
TEI 225 – Configuration Data, Software Part Number….3103
TEI 226 – Configuration Data, Software Version Number….3104
TEI 227 – Bootblock Program, Part Number….3105
TEI 228 – Bootblock Program, Version Number….3106
TEI 231 – Operating System Software, Part Number….3107
TEI 232 – Operating System Software, Version Number….3108
TEI 233 – Software Part Number….3109
TEI 234 – Software Version Number….3110
TEI 235 – Control Unit, Part Number….3111
TEI 236 – Control Unit, Serial Number….3112
TEI 237 – Software Package, Part Number….3113
TEI 238 – Software Package, Version Number….3114
TEI 247 – Tractor Model Designation….3115
TEI 248 – Tractor Serial Number….3116
TEI 249 – Model Designation of Original Tractor….3117
TEI 250 – Serial Number of Original Tractor….3118
TEI 251 – John Deere Product Identification Number (PIN) of Current Vehicle….3119
Group 55E: XMC – AutoTrac™ Main Control Unit….2818
XMC Control Software – Summary of Addresses….3123
XMC 000 – Initial Address….3126
XMC 001 – XMC Control Unit Stored Codes….3127
XMC 002 – XMC System Beep Mode….3128
XMC 003 – Control Unit Unswitched Supply Voltage Status….3129
XMC 004 – Control Unit Switched Supply Voltage Status….3130
XMC 007 – Sensor Supply 3 Voltage Status….3131
XMC 008 – Sensor Supply 4 Voltage Status….3132
XMC 009 – Watchdog 5V Regulator Voltage Status….3133
XMC 010 – Valve Power 1 Supply Voltage Status….3134
XMC 011 – Valve Power 2 Supply Voltage Status….3135
XMC 014 – Steering CAN Bus High Voltage Status….3136
XMC 015 – Steering CAN Bus Low Voltage Status….3137
XMC 030 – Steering Wheel Position Address Display Format….3138
XMC 031 – Steering Wheel Position Sensor 1 Status….3139
XMC 032 – Steering Wheel Position Sensor 2 Status….3141
XMC 035 – Steering Wheel Position and Status….3143
XMC 036 – Wheel Angle Address Display Format….3144
XMC 037 – Wheel Angle Sensor (Primary) Status….3145
XMC 038 – Wheel Angle Sensor (Secondary) Status….3147
XMC 041 – Wheel Angle Steering Stops….3149
XMC 042 – Wheel Angle and Status….3150
XMC 150 – Control Unit Configuration….3151
XMC 155 – ELX2 Status….3152
XMC 156 – Engine Information….3153
XMC 157 – Harness ID Status….3154
XMC 158 – Operator Presence Status….3155
XMC 159 – Steering Oil Temperature….3156
XMC 160 – Transmission Information….3157
XMC 161 – GPS-based Vehicle Speed….3158
XMC 162 – Buffered Wheel Speed….3159
XMC 163 – Wheel-based Vehicle Speed….3160
XMC 164 – Vehicle Stopped State….3161
XMC 167 – GreenStar™ Yaw Rate….3162
XMC 168 – Steering Control Mode….3163
XMC 172 – Auxiliary Steering Exit Code….3165
XMC 185 – GreenStar™ Lateral Error….3167
XMC 186 – GreenStar™ Heading Error….3168
XMC 187 – GreenStar™ Curvature….3169
XMC 188 – AutoTrac™ Lateral Integrator….3170
XMC 189 – AutoTrac™ Information….3171
XMC 190 – AutoTrac™ Exit Code….3173
XMC 191 – AutoTrac™ Hours….3175
XMC 192 – GPS-based Wheel Slip….3176
XMC 219 – Configuration Data of Control Unit Bootblock Program, Part Number….3177
XMC 220 – Configuration Data of Control Unit Bootblock Program, Version Number….3178
XMC 225 – Configuration Data, Software Part Number….3179
XMC 226 – Configuration Data, Software Version Number….3180
XMC 227 – Bootblock Program, Part Number….3181
XMC 228 – Bootblock Program, Version Number….3182
XMC 229 – EOL Parameters, Part Number….3183
XMC 230 – EOL Parameters, Version Number….3184
XMC 231 – Operating System Software, Part Number….3185
XMC 232 – Operating System Software, Version Number….3186
XMC 233 – Software Part Number….3187
XMC 234 – Software Version Number….3188
XMC 235 – Control Unit, Part Number….3189
XMC 236 – Control Unit, Serial Number….3190
XMC 237 – Software Package, Part Number….3191
XMC 238 – Software Package, Version Number….3192
XMC 245 – Number of CAN BUS Off Retries, Configuration….3193
XMC 246 – CAN BUS Off Intervals, Configuration….3194
XMC 251 – John Deere Product Identification Number (PIN) of Current Vehicle….3195
Group 55F: XSC – AutoTrac™ Supervisor Control Unit….2820
XSC Control Software – Summary of Addresses….3199
XSC 000 – Initial Address….3202
XSC 001 – XSC Control Unit Stored Codes….3203
XSC 002 – XSC System Beep Mode….3204
XSC 003 – Control Unit Unswitched Supply Voltage Status….3205
XSC 004 – Control Unit Switched Supply Voltage Status….3206
XSC 007 – Sensor Supply 3 Voltage Status….3207
XSC 008 – Sensor Supply 4 Voltage Status….3208
XSC 009 – Watchdog 5V Regulator Voltage Status….3209
XSC 010 – Valve Power 1 Supply Voltage Status….3210
XSC 011 – Valve Power 2 Supply Voltage Status….3211
XSC 014 – Steering CAN Bus High Voltage Status….3212
XSC 015 – Steering CAN Bus Low Voltage Status….3213
XSC 022 – Wheel Angle Sensor, Calibration….3214
XSC 023 – Steering Control Valve, Calibration….3216
XSC 030 – Steering Wheel Position Address Display Format….3219
XSC 031 – Steering Wheel Position Sensor 1 Status….3220
XSC 032 – Steering Wheel Position Sensor 2 Status….3222
XSC 035 – Steering Wheel Position and Status….3224
XSC 036 – Wheel Angle Address Display Format….3225
XSC 037 – Wheel Angle Sensor (Primary) Status….3226
XSC 038 – Wheel Angle Sensor (Secondary) Status….3228
XSC 041 – Wheel Angle Steering Stops….3230
XSC 042 – Wheel Angle and Status….3231
XSC 043 – Enable Solenoid Valve Address Display Format….3232
XSC 046 – Enable Solenoid Valve Status….3233
XSC 150 – Control Unit Configuration….3235
XSC 155 – ELX2 Status….3236
XSC 156 – Engine Information….3237
XSC 157 – Harness ID Status….3238
XSC 158 – Operator Presence Status….3239
XSC 159 – Steering Oil Temperature….3240
XSC 160 – Transmission Information….3241
XSC 161 – GPS-based Vehicle Speed….3242
XSC 162 – Buffered Wheel Speed….3243
XSC 163 – Wheel-based Vehicle Speed….3244
XSC 164 – Vehicle Stopped State….3245
XSC 167 – GreenStar™ Yaw Rate….3246
XSC 168 – Steering Control Mode….3247
XSC 172 – Auxiliary Steering Exit Code….3249
XSC 178 – AutoTrac™ Valve Deadband Offset….3251
XSC 179 – AutoTrac™ Settings Display Format….3252
XSC 180 – AutoTrac™ Faster Speed Threshold….3253
XSC 181 – AutoTrac™ Slower Speed Threshold….3254
XSC 185 – GreenStar™ Lateral Error….3255
XSC 186 – GreenStar™ Heading Error….3256
XSC 187 – GreenStar™ Curvature….3257
XSC 188 – AutoTrac™ Lateral Integrator….3258
XSC 189 – AutoTrac™ Information….3259
XSC 190 – AutoTrac™ Exit Code….3261
XSC 191 – AutoTrac™ Hours….3263
XSC 192 – GPS-based Wheel Slip….3264
XSC 193 – AutoTrac™ Sensitivity….3265
XSC 194 – AutoTrac™ Heading Lead….3266
XSC 195 – AutoTrac™ Heading Gain….3267
XSC 196 – AutoTrac™ Curve Sensitivity….3268
XSC 197 – AutoTrac™ Acquisition Sensitivity….3269
XSC 198 – AutoTrac™ Lateral Gain….3270
XSC 199 – AutoTrac™ Inner Loop Scale Factor….3271
XSC 219 – Configuration Data of Control Unit Bootblock Program, Part Number….3272
XSC 220 – Configuration Data of Control Unit Bootblock Program, Version Number….3273
XSC 225 – Configuration Data, Software Part Number….3274
XSC 226 – Configuration Data, Software Version Number….3275
XSC 227 – Bootblock Program, Part Number….3276
XSC 228 – Bootblock Program, Version Number….3277
XSC 229 – EOL Parameters, Part Number….3278
XSC 230 – EOL Parameters, Version Number….3279
XSC 231 – Operating System Software, Part Number….3280
XSC 232 – Operating System Software, Version Number….3281
Section 255: PowrQuad™ Transmissions….3309
Group 10: Operational Check….3309
Introductory Checks for Transmission and Hydraulic Diagnosis….3316
PowrQuad Transmission—Operational Check….3321
Group 15: Tests and Adjustments….3309
PowrQuad™ Transmission—Summary of References….3329
Special Tools….3826
PowrQuad™ Transmission—System Check….3331
PowrQuad Transmission—Test Ports….3340
PowrQuad™ Transmission—Checking Rate of Flow at Cooler….3342
PowrQuad™ Transmission—Checking the Cooler Relief Valve….3345
PowrQuad™ Transmission—System Pressure Check….3348
PowrQuad™ Transmission—Checking Lube Oil Pressure….3349
PowrQuad™ Transmission—Checking Cooling Oil Pressure (Forward Clutch)….3351
PowrQuad™ Transmission—Checking Cooling Oil Pressure (Reverse Brake)….3352
PowrQuad™ Transmission—Checking Pressure at Forward Clutch….3353
PowrQuad™ Transmission—Checking Pressure at Reverse Brake….3354
PowrQuad™ Transmission—Checking Pressure at Brake B1….3355
PowrQuad™ Transmission—Checking Pressure at Brake B2….3356
PowrQuad™ Transmission—Checking Pressure at Brake B3….3357
PowrQuad™ Transmission—Checking Pressure at Clutch C4….3358
PowrQuad™ Transmission—Adjusting System Pressure….3360
PowrQuad™ Transmission—Test Result Table….3362
PowrQuad Transmission—Adjusting Gear Shift….3365
PowrQuad Transmission—Adjusting Forward/Reverse Cable….3367
PowrQuad Transmission—Adjusting Park Lock….3369
Group 20: Operation….3309
PowrQuad Transmission — Summary of References….3371
PowrQuad Transmission—Layout….3372
PowrQuad Module—Layout….3373
PowrQuad Module—Cross-Sectional and 3D View….3375
PowrQuad Module—Location of Valves, Sensors and Switches….3378
PowrQuad Module—Element Engagement Chart….3381
PowrQuad Module—Pneumatic Pump….3382
PowrQuad Module—Transmission Oil Pump….3384
PowrQuad™ Module — Pressure-Regulating Valve and Filter Relief Valve….3386
PowrQuad Module—Overspeed Relief Valve and Anti-Cavitation Check Valve….3391
PowrQuad Module—Clutch Cooling Components….3393
PowrQuad Module —Clutch Cooling Valve (Forward/Reverse)….3394
PowrQuad™ Module—System 1 Oil and System 2 Oil….3395
PowrQuad Module—Hydraulic Schematic, Mechanically Actuated PowrQuad Module….3396
PowrQuad Module—Operation of Forward/Reverse Modulation, Mechanically Actuated PowrQuad Module….3398
PowrQuad Module—Neutral Start Circuit, Mechanically Actuated PowrQuad Module….3402
PowrQuad Module—Operation of Gear-to-Gear Modulation, Mechanically Actuated PowrQuad Module….3403
Group 30: Range Box….3310
Range Transmission — Cross-Sectional View….3408
Section 256: Drive Systems….3410
Group 10: Operational Check….3410
Power train – operational check….3414
Group 15: Tests and Adjustments….3410
Tests and Adjustments—Summary of References….3682
Special Tools….3826
Safety Measures for Hydraulic Checks….3684
Drive Systems—System Check….3422
Checking Pressure at the Front-Wheel Drive Clutch….3426
Checking Pressure at the Hydraulic Differential Lock….3427
Checking Pressure at the PTO….3428
Drive Systems—Test Result Table….3431
Group 20: Operation….3410
Drive Systems—Summary of References….3433
Front Wheel Drive Clutch—Cross-Sectional View….3434
Front Wheel Drive Clutch—Oil Flow and Power Flow….3436
Front Wheel Drive Clutch Disengaged—Oil Flow….3438
Differential—Cross-Sectional View….3440
Differential—Power Flows….3442
Differential—Oil Flows….3444
Final Drives—Operation and Cross-Sectional View….3447
PTO Options—Description….3448
PTO Options—PTO Modulating Valve and Solenoid Valve….3450
PTO Options—PTO brake and PTO clutch….3452
PTO Options—Power Flows….3454
Section 260: Steering and Brakes….3456
Group 05: Preliminary Checks….3456
Preliminary Checks—Summary of References….3459
Preliminary Checks – Steering System….3460
Preliminary Checks – Brake System….3464
Group 10: Operational Check….3456
Operational Checkout—Summary of References….3466
Safety Information….3467
Steering Check….3468
Checking Brakes….3469
Group 15: Tests and Adjustments….3456
Special Tools….3826
Steering and Brakes – Specifications….3472
Checking Steering Valve….3473
Checking Brake System….3476
Bleeding the Rear Brakes….3477
Adjusting Brake Pedals and Switches….3478
Group 20A: Hydrostatic Steering….3456
Description of Steering Valves, Operation….3486
AutoTrac™, Theory of Operation….3493
Group 20B: Brakes….3456
Brakes—Summary of Reference….3498
Rear Brake Without Power-fill Theory of Operation….3499
Rear Brake With Power-fill Theory of Operation….3501
Rear Brake Without Power-fill Schematic….3515
Rear Brake With Power-fill Schematic….3517
Group 20C: Air brake system….3456
Steering and Brakes – Air Brakes, Summary of References….3520
Steering and Brakes – Air Brakes, Description….3521
Steering and Brakes – Air Brakes, Compressor….3523
Steering and Brakes – Air Brakes, Pressure Regulating Valve….3524
Steering and Brakes – Air Brakes, Compressed Air Tank….3525
Steering and Brakes – Air Brakes, Trailer Control Valve….3526
Steering and Brakes – Air Brakes, Coupling Ends….3527
Section 270A: Hydraulic System — 6145J….3528
Group 10: Operational Check….3528
Checking Hydraulic System Load….3531
Hitch Control – Operational Check….3532
External Control of Hitch – Operational Check….3534
Selective Control Valves – Operational Check….3535
Group 15: Tests and Adjustments….3528
Tests and Adjustments — Summary of References….3538
Safety Measures for Hydraulic Checks….3684
Warming Hydraulic System Oil….3686
Hydraulic System — Oil Pressure Test Ports….3542
PFC Hydraulic System Check….3545
PFC Hydraulic System — Test Result Table….3558
Charge Pump—Checking Lube Oil Pressure….3559
Hydraulic Pump — Testing and Adjusting the System Pressure (PFC Hydraulic System)….3561
Charge Pump — Checking Flow Rate (PFC Hydraulic System)….3563
Hydraulic Pump — Pressure-and-Flow Regulator Check….3565
Checking the Pressure Differential Dynamically (PFC Hydraulic System Only)….3568
Checking the LS (Load-Sense) Pressure….3570
Selective Control Valves — Check for Leaks at Valve Spools (PFC Hydraulic System Only)….3572
Selective Control Valves (SCV) — Checking for Leaks in Couplers….3574
300 and 301 Series Selective Control Valves— Adjust Detent Kickout Relief Valve Parts….3575
Selective Control Valves—Adjusting Left-Hand Endplate With Additional LS Port For External Consumers….3577
Selective Control Valves—Adjusting Right-Hand Endplate With Additional Ports For External Consumers….3579
Checking Stepper Motor and Rockshaft Valve….3581
Rockshaft Valve — Checking for Leaks….3583
Rockshaft Valve — Checking the Pressure-Relief Valve….3584
Rockshaft Valve — Checking Depth to Which Pressure and Discharge Valves are Screwed In….3586
Rockshaft Valve — Checking the Position Sensor….3587
Rockshaft — Testing and Adjusting the Draft Potentiometer (6145J)….3588
Adjusting the Power Beyond Valve….3590
Group 20: Operation….3528
PFC Hydraulic System — Summary of References….3594
PFC Hydraulic System — Description….3595
PFC Hydraulic System — Operation….3596
PFC Hydraulic System — Symbolic Representation….3597
PFC Hydraulic System — Schematic View….3605
PFC Hydraulic System — Three-Dimensional View….3607
PFC Hydraulic System — Hydraulic Pump Description….3609
PFC Hydraulic System — Oil Lines of Hydraulic Pump….3610
PFC Hydraulic System — Hydraulic Pump Operation….3611
PFC Hydraulic System — Hydraulic Pump Operating Modes….3615
Primary Hydraulic Oil Filter — Description….3623
Hydraulic System — Description of Hydraulic Oil Filter….3624
PFC Hydraulic System — Description and Arrangement of Shuttle Valves….3625
PFC Hydraulic System — Operation of Shuttle Valves….3627
PFC Hydraulic System — Description of Main Block with Priority Valve….3629
PFC Hydraulic System — Operation of Priority Valve in Main Block….3631
Power Beyond Valve — Operation….3636
Rockshaft — Description….3638
Rockshaft — Operation of Rockshaft Control….3640
Rockshaft — Operation of Rockshaft Valve….3642
Rockshaft — Operation of Position Sensor….3644
Rockshaft — Operation of Draft Sensor….3645
Rockshaft — Description of Controls….3646
Rockshaft — Direct Drive….3647
100 and 300 Series Selective Control Valves (Mechanically Actuated) — Description….3648
100 Series Selective Control Valve (Mechanically Actuated) — Operation….3649
300 Series Selective Control Valve (Mechanically Actuated) — Operation….3658
Couplers — Description….3667
Selective Control Valve End Plate — Summary….3668
Section 270B: Hydraulic System — 6165J, 6180J and 6205J….3670
Group 10: Operational Check….3670
Hydraulic System – Operational Check—Summary of References….3673
Hydraulic System—Load Check….3674
Hitch Control Operational Check….3675
Hydraulic System – External Control of Hitch, Operational Check-Out….3677
Selective Control Valves Operational Check….3678
Group 15: Tests and Adjustments….3670
Tests and Adjustments—Summary of References….3682
Special Tools….3826
Safety Measures for Hydraulic Checks….3684
Warming Hydraulic System Oil….3686
PFC Hydraulic System – Worksheet for the Hydraulic System Diagnostics….3687
PFC Hydraulic System – Test Ports for Oil Pressure….3690
PFC Hydraulic System – Checking and Adjusting the Maximum Load Sense Pressure….3692
PFC Hydraulic System – Check and Adjust System Oil Pressure….3694
PFC Hydraulic System – Priority Circuit 1, Checking and Adjusting the Load Sense Oil Pressure for Steering….3696
PFC Hydraulic System – Priority Circuit 3, Checking the Oil Pressure….3698
PFC Hydraulic System – Hydraulic Pump, Checking the Delivery Rate….3700
PFC Hydraulic System – Charge Pump, Check the Delivery Rate….3702
PFC Hydraulic System – Check the Charge and Lube Oil Pressure….3704
Hydraulic System – Selective Control Valves (SCV 300 and 450), Adjust the Automatic Release of Detent….3705
Hydraulic System – Selective Control Valves (SCV), Checking the Couplers for Leaks….3707
Hydraulic System – Checking the Hitch Valve and the Stepper Motor….3708
Hydraulic System – Hitch Valve, Centering the Stepper Motor….3710
Hydraulic System – Hitch Valve, Checking for Leaks….3711
Hydraulic System – Hitch Valve, Rough Adjustment of the Raise and Lower Valves….3712
Hydraulic System – Hitch Valve, Checking the Position Sensor….3714
Hydraulic System – Hitch Valve, Checking and Adjusting the Draft Potentiometer….3715
Group 20: Theory of operation….3670
Hydraulic System Theory of Operation—Summary of References….3718
Hydraulic System – Summary of Abbreviations….3719
PFC Hydraulic System – Summary of Components….3720
PFC Hydraulic System — 6165J and 6180J Tractors Symbolic Representation….3722
PFC Hydraulic System — 6205J Tractors Symbolic Representation….3724
Group 20A: Oil Filter, Charge Pump and Hydraulic Pump….3671
Oil Filter, Charge Pump and Hydraulic Pump―Summary of References….3727
PFC Hydraulic System – Hydraulic Oil Filter, Operation….3728
PFC Hydraulic System – Charge Pump, Operation….3730
PFC Hydraulic System – Hydraulic Pump, Operation….3732
PFC Hydraulic System – Hydraulic Pump, Operating Modes….3736
PFC Hydraulic System – Hydraulic Oil Primary Filter, Component Information….3744
PFC Hydraulic System – Hydraulic Oil Filter, Component Information….3745
PFC Hydraulic System – Charge Pump, Component Information….3746
PFC Hydraulic System – Hydraulic Pump, Component Information….3748
Group 20B: Hitch….3671
Hitch – Summary of References….3750
Hitch – Summary of Components….3751
Hitch – Hitch Control, Operation….3753
Hitch – Hitch Valve, Operation….3755
Hitch – Position Sensor, Operation….3757
Hitch – Draft Sensor, Operation….3758
Hitch – Controls….3759
Hitch – Direct Control….3761
Group 20C: Selective control valves (SCV)….3671
Selective Control Valves (SCVs) – Summary of References….3763
Selective Control Valve (M-SCV 100) – Operation….3764
Selective Control Valve (M-SCV 300) – Operation….3772
Selective Control Valve (M-SCV 450) – Theory of Operation….3784
Group 20D: Hydraulic block….3671
PFC Hydraulic System – Hydraulic Block, Summary of References….3801
PFC Hydraulic System – Hydraulic Block, Summary of Components….3802
PFC Hydraulic System – Priority 1 Control Block, Component Information….3804
PFC Hydraulic System – Priority 3 Control Block, Component Information….3806
Section 290: Operator's Cab….3808
Group 10: Operational and Preliminary Checks….3808
Air-Conditioning and Heater System Operational Check….3813
Group 15: Tests and Adjustments….3808
Operational Checkout―Summary of References….3818
Safety in the Workplace….3819
Handling Refrigerant….3820
Safety Equipment….3821
In the Event of an Emergency….3822
Storage of Refrigerant Containers….3823
Refrigerant R134a….3847
Important….3825
Special Tools….3826
Specification….3827
Air Conditioning System Checks….3828
Pressure Deviations….3842
Group 20: Operation….3808
Operation of Air Conditioning/Heating/Ventilation—Summary of References….3845
Principle of Heat Exchange….3846
Refrigerant R134a….3847
Refrigerant Circuit Layout (Cab Tractors)….3848
Refrigerant Circuit Operation….3849
Component Description….3852
Expansion Valve….3856
Thermostat Switch….3858
Heating and Ventilation….3859
Section 299: Special Tools (Dealer-Fabricated)….3861
Group 05: Special Tools (Dealer-Fabricated)….3861
Special Tools (Dealer-Fabricated) — Summary….3863
Retainer Tool….3864
Adjustment Tool….3865
DFRW2—Needle Valve Test Hose Assembly….3866
DFLX10 and DFLX11—Test Harnesses….3867
DFLX12—Special Tool for 11-bit and 29-bit CAN BUS….3869
DFLX14—Solenoid Valve Test Harness….3870

John Deere Tractors 6145J, 6165J, 6180J, 6205J Diagnostics Technical Manual (TM801419)

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair technical manual for John Deere Tractors JD1654, JD1854, JD2054, JD2104, 6165J, 6185J, 6205J & 6210J (Asian Edition) 2WD / MFWD, with all the technical information to maintain, repair, rebuild like professional mechanics.

John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, 6210J Tractors workshop service repair 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.
* 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.

tm802319 – 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J,and 6210J Repair Manual Technical Manual.pdf
TM802314 Repair Technical Manual 1654、1854、2054、2104、6165J、6185J、6205J 和 6210J型修理手册
TM802319 Repair Technical Manual 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J & 6210J Tractors (Asian Edition)

OMAL221436 Operator’s Manual JD1654, JD1854, JD2054, and JD2104 Tractors, (Asia, English)
OMAL221437 Operator’s Manual 拖拉机 JD1654、JD1854、JD2054 和 JD2104
OMAL221438 Operator’s Manual Tractors JD1654, JD1854, JD2054&JD2104
PC4667 Parts Catalog 1654 Tractor \ China Edition
PC4667Z Parts Catalog 1654 Tractor \ China Edition

Total Pages: 1,121 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
Safety
Safety Regulations
General Information
Specifications
Adjusting
Engine
Removing and Installing Engine
Fuel Systems, Air Intake, Cooling and Exhaust
Removal and Installation of Components
Speed Control
Fuel System
Air Intake System
Cooling System
Exhaust System
Electrical System
Connectors
Wiring Harnesses
Charging Circuit
Starter Motor Circuit
Fuses, Relays and Switches
Monitoring Systems
Electrical Components
Electronic Control Units
Removal and Installation of Electronic Control Units
Removal and Installation of Terminating Resistors
PowrQuad Transmission
Removing and Installing PowrQuad Module
Transmission Selectors Control
PowrQuad Module
Range Box
Drive Systems
Removing and Installing Component
U-Jointed Shafts and Torsional Damper
Front-Wheel Drive Clutch
Rear Differential
Hydraulic Pump Drive
Final Drives
Rear PTO
Steering and Brakes
Hydrostatic Steering
Brake Valve
Rear Wheel Brakes
Hydraulic System
Controls
Oil Filter, Charge Pump and Hydraulic Pump
Valves
Hitch
Selective Control Valves and Couplers
Miscellaneous
Removing and Installing Components
Main Chassis
Wheels
Center Link Bracket and Swinging Drawbar
Operator’s Cab
Removing and Installing Components
Air Conditioning System
Heating System
Operator’s Cab
Special Tools (Dealer-Fabricated)

TABLE OF CONTENTS
Section 05: Safety….21
Group 05: Safety Regulations….989
Live With Safety….23
Recognize Safety Information….346
Follow Safety Instructions….25
Handle Fluids Safely—Avoid Fires….26
Prevent Battery Explosions….27
Handle Batteries Safely….28
Prepare for Emergencies….29
Remove Paint Before Welding or Heating….30
Avoid High-Pressure Fluids….31
Engine Coolant….32
Prevent Machine Runaway….33
Avoid Heating Near Pressurized Fluid Lines….34
Work In Ventilated Area….35
Wear Protective Clothing….36
Practice Safe Maintenance….37
Park Machine Safely….38
Use Proper Lifting Equipment….39
Support Machine Safely….40
Work in Clean Area….41
Illuminate Work Area Safely….42
Service Machines Safely….43
Use Proper Tools….44
Service Tires Safely….45
Safe Servicing of Front-Wheel Drive….46
Use Seat Belt Properly….47
Keep ROPS Installed Properly….48
Dispose of Waste Properly….49
Section 10: General Information….203
Group 05: Specifications….959
Engine….53
PTO….54
POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission….50
Clutch….56
Brakes….57
Hydraulic System….58
Wheel Configurations….59
Drawbar….60
Dimensions….61
Electrical System….64
Capacities….65
Transmission and Hydraulic Oil….66
Front-Wheel Drive Axle Oil (Standard)….67
Metric Bolt and Screw Torque Values….69
Unified Inch Bolt and Screw Torque Values….71
Hydraulic system inch fitting torques….74
Hydraulic system metric fitting torques….75
Interpreting the Serial Number of Your Machine – 13 digits PIN….76
Interpreting the Serial Number of Your Machine – 17 digits PIN….77
Year of Production Table (Digit 5)….78
Transmission Type Table (Digit 6)….79
Serial Number Plates….80
Product Identification Number….81
Engine Serial Number….82
POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission Serial Number….50
Front-Wheel Drive Serial Number….84
POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Differential Serial Number….50
Cab Serial Number….86
Group 10: Adjusting….50
Specifications….959
Using High-Pressure Washers….89
Preliminary Engine Test….90
Tractor Adjusting….91
Removing and Cleaning the Primary Air Cleaner Element….93
Checking the Air Cleaner Safety Element….94
Installing the Primary Filter Element….95
Checking Air Intake System Connections for Leaks….96
Checking Air Intake Hoses….97
Checking the Crankcase Vent Hose for Clogging….98
Cleaning Dirt from Radiator Screen….99
Adjust the Hood….100
Cleaning Radiator….102
Checking Expansion Tank Cap….103
Checking for Leaks in Radiator….104
Checking Engine Thermostat….105
Checking the Fuel Transfer Pump Operation….106
Cleaning Water Trap….107
Checking Fuel Filter….108
Bleed Fuel System….171
Check Transmission/Hydraulic System Oil Level….110
Cleaning Battery, Cables and Battery Box with a Clean Cloth….111
Checking Neutral Start Circuit….112
Checking Starter Motor….113
Checking Lighting Circuit….114
Final Engine Checks….115
Tractor Operation Check….116
Section 20: Engine….117
Group 00: Removing and Installing Engine….133
Special Tools….986
Specifications….959
Removing Engine….121
Installing Engine….133
Engine Mounting….140
Replace the Engine Mountings….142
Section 30: Fuel Systems, Air Intake, Cooling and Exhaust….146
Group 00: Removal and Installation of Components….146
Remove Engine Hood….150
Install Engine Hood….152
Remove Battery….154
Install Battery….155
Group 05: Speed Control….146
General Information….203
Specifications….959
Replace Accelerator Pedal Assembly….159
Remove Accelerator Pedal Potentiometer….160
Group 10: Fuel System….146
General Information….203
Removing the Fuel Tank….165
Installing the Fuel Tank….167
Replace Fuel Level Sensor….168
Replace the Fuel Transfer Pump….169
Changing the Fuel Filters….170
Bleed Fuel System….171
Group 15: Air Intake System….146
General Information….203
Air filter – Exploded view….174
Replacing Air Filter Restriction Sensor….175
Group 20: Cooling System….146
General Information….203
Specifications….959
Removing Radiator….179
Installing Radiator….186
Replacing Fan….187
Remove and Install the Charge Air Cooler….188
Removing and Installing the Expansion Tank….190
Removing and Installing Thermostat….193
Fill Cooling System with Coolant….194
Releasing Drive Belt Tension….196
Replacing Engine Fan Belt….197
Replacing Drive Belt Tensioner….200
Remove and Install Fan Console (with Mechanical Coolant Pump)….201
Group 30: Exhaust System….147
General Information….203
Specifications….959
Exhaust to Upper Right-Hand Side….205
Section 40: Electrical System….208
Group 05: Connectors….241
Special Tools….986
General….215
Using high-pressure washers….216
Disconnecting Electrical Circuits….343
Reconditioning Wire Ends….218
Installing a Terminal….219
WEATHER PACK Connectors….241
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Rear Terminal Lock….208
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Front Terminal Lock….208
Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connectors….241
CAN BUS Terminating Resistor Connector….233
Electronic Control Unit Connectors….241
Connectors….241
CRIMP SNAP IN Connectors….246
KOSTAL Connectors….248
DEUTSCH Connectors….251
Individual Terminals….254
Fuse and Relay Boxes — Cab Tractors….256
Fuse and Relay Box — Open Station Tractors….259
Group 10: Wiring Harnesses….208
Disconnecting Electrical Circuits….343
Removing and Installing Wiring Harness W01 — Power link Box….264
Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Cab Tractors)….265
Removing and Installing Wiring Harness W04 — Headlights….267
Removing and Installing Wiring Harness W08 — (Cab Tractors)….268
Removing and Installing Wiring Harness W09 — Hood (Cab Tractors)….270
Removing and Installing Wiring Harness W19 — Cab Roof….272
Removing and Installing Wiring Harness W26 — Fan and Air Conditioning….273
Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors)….274
Removing and Installing Wiring Harness W30 — Rear End of Transmission (Cab Tractors)….276
Wiring Harness W31 — Power Take-Off for 7-Pin Socket….278
Group 15: Charging Circuit….209
Special Tools….986
Specifications….959
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….209
Specifications….959
Repairing the Starting Motor….291
Disconnecting Electrical Circuits….343
Removing and Installing Starter Motor….293
Group 25: Fuses, Relays and Switches….209
Note….329
Special Tools….986
Specifications….959
Removing Hood Covers….299
Disconnecting Electrical Circuits….343
Fuse and Relay Box – Cab Tractors….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….210
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….210
Note….329
Special Tools….986
Specifications….959
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 (Cab)….352
Section 55: PowrQuad Transmission….354
Group 00: Removing and Installing PowrQuad Module….354
Special Tools….986
Special Tool (Own Fabrication)….361
Specifications….959
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….959
Reconditioning Gear Shift Mechanism….377
Reconditioning of Range Shift Mechanism….380
Checking and Adjusting Gear Shift Units….983
Adjusting Clutch Pedal….388
Group 10: PowrQuad Module….354
Special Tools….986
Other Material….996
Specifications….959
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 (With Mechanically Actuated PowrQuad Module)….404
Removing and Installing Transmission Front Cover….417
Removing and Installing Transmission Front Cover Valves (With Mechanically Actuated PowrQuad Module)….419
Removing Clutch Pedal Valve (Mechanically Actuated PowrQuad Module)….424
Removing and Installing Shift Valve Housing (With Mechanically Actuated PowrQuad Module)….430
Removing and Installing Shift Valve Housing Valves (With Mechanically Actuated PowrQuad Module)….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….986
Other Material….996
Specifications….959
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….986
Special Tools (Dealer-Fabricated)….918
Specifications….959
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….986
Use of Special Tool KJD10426….584
Specifications….959
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….56
Special Tools….986
Specifications….959
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….986
Specifications….959
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….647
Specifications….959
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….986
Specifications….959
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
Final Assembly….687
Group 30: Rear PTO….54
Special Tools….986
Rear PTO – Specifications….959
Replacing Output Shaft Seal Ring….691
Rear PTO Clutch – Cross Sectional View….692
Rear PTO Clutch – Exploded View….694
Removing Rear PTO Clutch….695
Reconditioning Rear PTO Clutch….698
Reconditioning Rear PTO Brake….707
Installing Rear PTO Clutch….708
Rear PTO Drive Train – Cross Sectional View….711
Rear PTO Drive Train – Exploded View….712
Removing Rear PTO Drive Train….714
Reconditioning Output Shaft….717
Reconditioning Countershaft….722
Installing Rear PTO Drive Train….724
Adjust Taper Roller Bearing of Countershaft….725
Adjust Tapered Roller Bearing of Bearing Support….727
Reconditioning Rear PTO Solenoid Valve….730
Removing PTO Modulating Valve….732
Reconditioning PTO Modulating Valve….733
Installing PTO Modulating Valve….735
Replace B06 – Rear PTO Speed Sensor….736
Recondition the Oil Sight-Glass….737
Section 60: Steering and Brakes….740
Group 05: Hydrostatic Steering….740
Special Tools….986
Specifications….959
Preliminary Work….744
Disconnect/Connect Steering or Brake Hoses….745
Steering Valve – Removing….747
Steering Valve – Cross Sectional View….750
Disassembling Steering Valve….751
Exploded View of Steering Valve….755
Mounting Steering Valve….757
Adjusting Shock Valves….765
Steering – Exploded View….767
Steering Column – Exploded View….769
Installing Steering Valve….770
Group 15: Brake Valve….777
Special Tools….986
Specifications….959
Brake Valve Repair Instructions….776
Brake Valve….777
Group 20: Rear Wheel Brakes….57
Rear Brakes, Specifications….959
Rear Wheel Brakes – Exploded View….788
Removing Rear Brakes….789
Reconditioning Rear Brakes….791
Installing Rear Brakes….793
Replacing Retraction Pins on the Rear Wheel Brakes….795
Section 70: Hydraulic System….798
Group 05: Controls….798
Specifications….959
Selective Control Valves — Removing and Installing Actuating Elements….802
Selective Control Valves — Adjusting Bowden Cable….806
Group 10: Oil Filter, Charge Pump and Hydraulic Pump….798
Other Material….996
Specifications….959
Removing and Installing Hydraulic Oil Mesh Filter….810
Removing and Installing Hydraulic Oil Filter….813
Removing and Installing Charge Pump….817
Charge Pump – Checking the Lube Oil Valve….821
Hydraulic Oil Reservoir — Restrictor….822
Hydraulic Pump – Removing and Installing Pressure-and-Flow Controller….823
Hydraulic Pump – Reconditioning Pressure-and-Flow Controller….825
Removing and Installing Hydraulic Pump….827
Hydraulic Pump – Exploded View….832
Disassembling Hydraulic Pump….834
Assembling Hydraulic Pump….835
Group 15: Valves….798
Special Tools….986
Specifications….959
Hydraulic System Repair Instructions….845
Removing Priority 1 Control Block….847
Installing Priority 1 Control Block….848
Reconditioning Priority 1 Control Block….849
Removing Priority 3 Control Block….851
Installing Priority 3 Control Block….855
Recondition Priority 3 Control Block….859
Group 20: Hitch….798
Other Material….996
Specifications….959
Rockshaft Valve, Removing and Installing the Stepper Motor….864
Remove Rockshaft Valve….866
Recondition the Rockshaft Valve….868
Install the Hitch Valve….872
Rockshaft – Removg and Installing Position Sensor and Toothed Segment….875
Rockshaft – Removing and Installing Rockshaft….878
Rockshaft – Removing Rockshaft Cylinders….882
Rockshaft – Reconditioning Lift Cylinder….883
Rockshaft – Install Rockshaft Cylinders….886
Rockshaft – Removing and Installing Draft Load Potentiometer and Draft Link Support….887
Group 25: Selective Control Valves and Couplers….799
Specifications….959
Selective Control Valves (SCVs) and Couplers Repair Instructions….893
Remove the Selective Control Valves (SCVs)….895
Recondition the Selective Control Valves (M-SCVs 100)….897
Recondition the Selective Control Valves (M-SCVs 200)….901
Install the Selective Control Valves (SCVs)….904
Selective Control Valves (SCVs) – Reconditioning the Couplers….909
Section 80: Miscellaneous….911
Group 00: Removing and Installing Components….911
Special Tools….986
Special Tools (Dealer-Fabricated)….918
Specifications….959
Removing Main Chassis….920
Installing Main Chassis….925
Removing Front-Wheel Drive Axle….928
Installing Front-Wheel Drive Axle….931
Group 05: Main Chassis….911
Specifications….959
Reconditioning Main Chassis….935
Group 15: Wheels….911
Essential, Recommended and Fabricated Tools….937
Specifications….959
Service Heavy-Duty Wheel Clamps….939
Group 20: Center Link Bracket and Swinging Drawbar….949
Specifications….959
Checking Swinging Drawbar Wear….947
Installing Center Link Bracket….948
Swinging Drawbar….949
Adjusting Retention Rod….951
Section 90: Operator's Cab….952
Group 00: Removing and Installing Components….952
Special Tools….986
Dealer-Manufactured Special Tools….986
Specifications….959
Swinging Up Operator's Cab….960
Swinging Down Operator's Cab….969
Removing Operator's Cab or Platform….971
Installing Operator's Cab or Platform….979
Checking and Adjusting Gear Shift Units….983
Group 15: Air Conditioning System….952
Special Tools….986
Tightening Torque for Refrigerant Hoses….988
Safety Regulations….989
Handling Refrigerant….990
In the Event of an Emergency….991
Safety Equipment….992
Storage of Refrigerant Containers….993
Refrigerant R134a….994
Important….995
Other Material….996
Specification….997
Filling the Cylinder….998
Charging Air Conditioning System (With Loading Cylinder)….1000
Adding Oil to the Air Conditioning System….1002
Leak Test….1003
Evacuate Air Conditioning System….1004
Cleaning the Air Conditioning System….1006
Separating Compressor….1007
Checking Compressor Level….1008
Disassembling Compressor Clutch….1009
Checking Clutch Hub Separation….1012
Installing Compressor….1013
Separating and Installing Condenser….1014
Separating and Installing Drier….1015
Replacing Expansion Valve….1016
Separating and Installing Evaporator and Expansion Valve….1017
Installing Condensation Water Drain Hoses….1019
Layout of Condensation Water Drain Hoses….1020
Separating and Installing Thermostat….1021
Separating and Installing High/Low Pressure Switch….1022
Vacuum Pump — General Information….1023
Group 20: Heating System….953
Fan and Heater, Disassembling….1026
Removing Cab Air Filter….1028
Separating and Installing Fan….1030
Separating and Installing Heater Regulator….1031
Separating Heater/Evaporator Housing….1032
Group 25: Operator's Cab….953
Removing Cab Frame….1035
Cab Mounting Torques….1036
Removing and Installing Windshield….1038
Removing and Installing Rear Window….1039
Installing Door Lock….1041
Adjusting Window Contact Pressure….1043
Removing and Installing Operator's Cab Door….1044
Removing and Installing Sun-Visor Roller….1046
Section 99: Special Tools (Dealer-Fabricated)….1047
Group 05: Special Tools (Dealer-Fabricated)….918
DFLX1 – Adapter Strut….1049
DFLX7 – Turning Device….1063
DFLX14 – Suspended MFWD Axle Housing Bracket….1051
DFLX29 – Support….1052
Lifting Device….1053
Holding Device….1054
Suspension Eyes for Operator's Cab….1055
Holding Tool….1056
Wooden Block….1057
DFRW79 – Piston Holding Tool….1058
Socket Wrench Insert….1065
Seal Installer….1064
Driver….1061
Assembly and Guide Mandrels….1062
Turning Device….1063
Seal Installer….1064
Socket Wrench Insert….1065
Special Wrench….1066
Quick Coupler Securing Support….1067
Lifting Tool….1068

John Deere 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J, 6210J Tractors Repair Service Manual (TM802319)

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