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

tm802319 - 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J,and 6210J Repair Manual Technical Manual.pdf

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.

Total Pages: 1,311 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)
      Special Tools (Dealer-Fabricated)
 

tm802319 - 1654, 1854, 2054, 2104, 6165J, 6185J, 6205J,and 6210J Repair Manual

Table of Contents

Foreword

Section 05: Safety

Group 05: Safety Regulations

Live With Safety

Recognize Safety Information

Follow Safety Instructions

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Handle Batteries Safely

Prepare for Emergencies

Remove Paint Before Welding or Heating

Avoid High-Pressure Fluids

Engine Coolant

Prevent Machine Runaway

Avoid Heating Near Pressurized Fluid Lines

Work In Ventilated Area

Wear Protective Clothing

Practice Safe Maintenance

Park Machine Safely

Use Proper Lifting Equipment

Support Machine Safely

Work in Clean Area

Illuminate Work Area Safely

Service Machines Safely

Use Proper Tools

Service Tires Safely

Safe Servicing of Front-Wheel Drive

Use Seat Belt Properly

Keep ROPS Installed Properly

Dispose of Waste Properly

Section 10: General Information

Group 05: Specifications

Engine

PTO

POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission

Clutch

Brakes

Hydraulic System

Wheel Configurations

Drawbar

Dimensions

Electrical System

Capacities

Transmission and Hydraulic Oil

Front-Wheel Drive Axle Oil (Standard)

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Hydraulic system inch fitting torques

Hydraulic system metric fitting torques

Interpreting the Serial Number of Your Machine - 13 digits PIN

Interpreting the Serial Number of Your Machine - 17 digits PIN

Year of Production Table (Digit 5)

Transmission Type Table (Digit 6)

Serial Number Plates

Product Identification Number

Engine Serial Number

POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Transmission Serial Number

Front-Wheel Drive Serial Number

POWRQUAD POWRQUAD is a registered trademark of the Deere & Company Differential Serial Number

Cab Serial Number

Group 10: Adjusting

Specifications

Using High-Pressure Washers

Preliminary Engine Test

Tractor Adjusting

Removing and Cleaning the Primary Air Cleaner Element

Checking the Air Cleaner Safety Element

Installing the Primary Filter Element

Checking Air Intake System Connections for Leaks

Checking Air Intake Hoses

Checking the Crankcase Vent Hose for Clogging

Cleaning Dirt from Radiator Screen

Adjust the Hood

Cleaning Radiator

Checking Expansion Tank Cap

Checking for Leaks in Radiator

Checking Engine Thermostat

Checking the Fuel Transfer Pump Operation

Cleaning Water Trap

Checking Fuel Filter

Bleed Fuel System

Check Transmission/Hydraulic System Oil Level

Cleaning Battery, Cables and Battery Box with a Clean Cloth

Checking Neutral Start Circuit

Checking Starter Motor

Checking Lighting Circuit

Final Engine Checks

Tractor Operation Check

Section 20: Engine

Group 00: Removing and Installing Engine

Special Tools

Specifications

Removing Engine

Installing Engine

Engine Mounting

Replace the Engine Mountings

Section 30: Fuel Systems, Air Intake, Cooling and Exhaust

Group 00: Removal and Installation of Components

Remove Engine Hood

Install Engine Hood

Remove Battery

Install Battery

Group 05: Speed Control

General Information

Specifications

Replace Accelerator Pedal Assembly

Remove Accelerator Pedal Potentiometer

Group 10: Fuel System

General Information

Removing the Fuel Tank

Installing the Fuel Tank

Replace Fuel Level Sensor

Replace the Fuel Transfer Pump

Changing the Fuel Filters

Bleed Fuel System

Group 15: Air Intake System

General Information

Air filter - Exploded view

Replacing Air Filter Restriction Sensor

Group 20: Cooling System

General Information

Specifications

Removing Radiator

Installing Radiator

Replacing Fan

Remove and Install the Charge Air Cooler

Removing and Installing the Expansion Tank

Removing and Installing Thermostat

Fill Cooling System with Coolant

Releasing Drive Belt Tension

Replacing Engine Fan Belt

Replacing Drive Belt Tensioner

Remove and Install Fan Console (with Mechanical Coolant Pump)

Group 30: Exhaust System

General Information

Specifications

Exhaust to Upper Right-Hand Side

Section 40: Electrical System

Group 05: Connectors

Special Tools

General

Using high-pressure washers

Disconnecting Electrical Circuits

Reconditioning Wire Ends

Installing a Terminal

WEATHER PACK Connectors

Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Rear Terminal Lock

Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connector with Front Terminal Lock

Metri-Pack Metri-Pack is a trademark of Delphi Connection Systems Connectors

CAN BUS Terminating Resistor Connector

Electronic Control Unit Connectors

Connectors

CRIMP SNAP IN Connectors

KOSTAL Connectors

DEUTSCH Connectors

Individual Terminals

Fuse and Relay Boxes — Cab Tractors

Fuse and Relay Box — Open Station Tractors

Group 10: Wiring Harnesses

Disconnecting Electrical Circuits

Removing and Installing Wiring Harness W01 — Power link Box

Removing and Installing Wiring Harness W02 — Engine Wiring Harness (Cab Tractors)

Removing and Installing Wiring Harness W04 — Headlights

Removing and Installing Wiring Harness W08 — (Cab Tractors)

Removing and Installing Wiring Harness W09 — Hood (Cab Tractors)

Removing and Installing Wiring Harness W19 — Cab Roof

Removing and Installing Wiring Harness W26 — Fan and Air Conditioning

Removing and Installing Wiring Harness W28 — Front End of Transmission (Cab Tractors)

Removing and Installing Wiring Harness W30 — Rear End of Transmission (Cab Tractors)

Wiring Harness W31 — Power Take-Off for 7-Pin Socket

Group 15: Charging Circuit

Special Tools

Specifications

Repairing the Alternator

Disconnecting Electrical Circuits

Relieve Drive Belt Tension

Removing/Installing Alternator

Removing/Installing Alternator Pulley

Group 20: Starter Motor Circuit

Specifications

Repairing the Starting Motor

Disconnecting Electrical Circuits

Removing and Installing Starter Motor

Group 25: Fuses, Relays and Switches

Note

Special Tools

Specifications

Removing Hood Covers

Disconnecting Electrical Circuits

Fuse and Relay Box - Cab Tractors

Fuses and relays (Power Link Box)

Power Link Box- Components

Replacing Starter Switch

Replacing Brake Switches

Replacing Light Switch

Replacing Full/Low Beam Switch

Replacing Work Light Switches

Replacing Hazard Warning Light Switch

Replacing Turn Signal Switch

Replacing Horn Switch

Replacing Windshield Wiper and Windshield Washer Switch

Replacing Front-Wheel Drive Switch

Replacing Fan Switch

Replacing Differential Lock Switch

Replacing Rockshaft Remote Control Switch

Group 30: Monitoring Systems

Note

Note

Disconnecting Electrical Circuits

Replacing Engine Oil Pressure Sensor Unit (B04)

Replacing Coolant Temperature Gauge Sensor Unit (B08)

Group 40: Electrical Components

Note

Special Tools

Specifications

Disconnecting Electrical Circuits

Replacing Socket of 7-Terminal Power Outlet

Replacing Service Socket

Removing Windshield Wiper Motor

Adjusting the Headlights

Section 45: Electronic Control Units

Group 05: Removal and Installation of Electronic Control Units

Disconnecting Electrical Circuits

Instructions when Replacing a VIN Control Unit

Instructions when Replacing a Control Unit

Safety Information

Replace BCU Control Unit

Replace ECU Control Unit

Group 10: Removal and Installation of Terminating Resistors

Terminating Resistors for the CAN BUS (Cab)

Section 55: PowrQuad Transmission

Group 00: Removing and Installing PowrQuad Module

Special Tools

Special Tool (Own Fabrication)

Specifications

Removing PowrQuad Housing

Installing PowrQuad Housing

Removing Range Box

Installing Range Box

Final installation

Group 05: Transmission Selectors Control

Specifications

Reconditioning Gear Shift Mechanism

Reconditioning of Range Shift Mechanism

Checking and Adjusting Gear Shift Units

Adjusting Clutch Pedal

Group 10: PowrQuad Module

Special Tools

Other Material

Specifications

Transmission Components

Replacing Neutral Start Circuit (Mechanically Actuated PowrQuad Module)

Removing and Installing Oil Filter Base

Replacing Oil Filter

Removing and Installing Front Valve Housing

Removing and Installing Front Valve Housing Valves (With Mechanically Actuated PowrQuad Module)

Removing and Installing Transmission Front Cover

Removing and Installing Transmission Front Cover Valves (With Mechanically Actuated PowrQuad Module)

Removing Clutch Pedal Valve (Mechanically Actuated PowrQuad Module)

Removing and Installing Shift Valve Housing (With Mechanically Actuated PowrQuad Module)

Removing and Installing Shift Valve Housing Valves (With Mechanically Actuated PowrQuad Module)

Removing Transmission Oil Pump

Servicing Transmission Oil Pump

Installing Transmission Oil Pump

Removing Planetary Drive Gears

Repairing Planetary Drive Gears

Installing Planetary Drive Gears

Removing B1 Brake Housing

Reconditioning B1 Brake

Installing B1 Brake Housing

Removing B2-B3 Brake Housing

Reconditioning B2 Brake

Reconditioning B3 Brake

Installing B2-B3 Brake Housing

Removing C4 Clutch

Reconditioning C4 Clutch

Installing C4 Clutch

Removing Reverse Brake

Servicing Reverse Brake

Installing Reverse Brake

Removing Forward Clutch with Planetary Drive (Forward/Reverse)

Servicing Forward Clutch with Planetary Drive (Forward/Reverse)

Installing Forward Clutch with Planetary Drive (Forward/Reverse)

Replacing Output Shaft

Group 20: Range Box

Special Tools

Other Material

Specifications

Cross-Sectional View—Input Drive Shaft

Remove Intermediate Shaft

Repair Intermediate Shaft

Remove Input Drive Shaft

Repair Input Drive Shaft

Install Input Drive Shaft

Adjust Input Drive Shaft End Play

Intermediate Shaft Installation And Cone Point Adjustment

Adjust Intermediate Shaft End Play

Remove, Repair, and Install Shift Cover

Repair Shifting Mechanism

Repair Park Lock

Adjust Range Shift

Replace Speed Sensor

Section 56: Drive Systems

Group 00: Removing and Installing Component

Special Tools

Special Tools (Dealer-Fabricated)

Specifications

Removing MFWD Clutch

Installing MFWD Clutch

Removing Differential Housing

Installing Differential Housing

Removing Final Drive

Installing Final Drive

Removing Rear PTO

Installing Rear PTO

Group 05: U-Jointed Shafts and Torsional Damper

Special Tools

Use of Special Tool KJD10426

Specifications

Removing MFWD Universal-Joint Drive Shaft

Repairing MFWD Universal-Joint Drive Shaft

Installing MFWD Universal-Joint Drive Shaft

Removing Engine Universal-Joint Drive Shaft

Removing Torsional Damper

Replacing Torsional Damper Bearings

Installing Torsional Damper

Installing Engine Universal-Joint Drive Shaft

Group 10: Front-Wheel Drive Clutch

Special Tools

Specifications

MFWD Clutch Repair Instructions

MFWD Clutch — Cross-Sectional View

Disassembling MFWD Clutch

Disassembling MFWD Clutch Assembly

MFWD Clutch Exploded View

Mounting MFWD Clutch Assembly

Mounting MFWD Clutch

Group 15: Rear Differential

Special Tools

Specifications

Rear Differential Repair Instructions

Removing Rear Differential

Rear Differential — Cross Sectional View

Disassembling Rear Differential

Rear Differential — Exploded View

Assembling Rear Differential

Adjust Rear Differential Preload

Adjust Rear Differential Backlash

Group 20: Hydraulic Pump Drive

Special tools

Specifications

Removing and Disassembling Pump Drive Pinion

Removing and Disassembling Pump Drive Gear

Assembling and Installing Pump Drive Gear

Assembling and Installing Pump Drive Pinion

Checking and Adjusting Play of Pump Drive Pinion

Group 25: Final Drives

Special Tools

Specifications

Final Drive Repair Instructions

Checking Final Drive Shaft and Retainer

Final Drive Housing — Exploded View

Removing Planetary Carrier

Disassembling Planetary Carrier

Planetary Carrier — Exploded View

Assembling Planetary Carrier

Final Drive Housing — Cross Sectional View

Removing Final Drive Housing to Axle

Disassembling and Assembling Final Drive Housing

Disassembling and Assembling Axle

Installing Final Drive Housing to Axle

Installing Planetary Carrier

Final Assembly

Group 30: Rear PTO

Special Tools

Rear PTO - Specifications

Replacing Output Shaft Seal Ring

Rear PTO Clutch - Cross Sectional View

Rear PTO Clutch - Exploded View

Removing Rear PTO Clutch

Reconditioning Rear PTO Clutch

Reconditioning Rear PTO Brake

Installing Rear PTO Clutch

Rear PTO Drive Train - Cross Sectional View

Rear PTO Drive Train - Exploded View

Removing Rear PTO Drive Train

Reconditioning Output Shaft

Reconditioning Countershaft

Installing Rear PTO Drive Train

Adjust Taper Roller Bearing of Countershaft

Adjust Tapered Roller Bearing of Bearing Support

Reconditioning Rear PTO Solenoid Valve

Removing PTO Modulating Valve

Reconditioning PTO Modulating Valve

Installing PTO Modulating Valve

Replace B06 - Rear PTO Speed Sensor

Recondition the Oil Sight-Glass

Section 60: Steering and Brakes

Group 05: Hydrostatic Steering

Special Tools

Specifications

Preliminary Work

Disconnect/Connect Steering or Brake Hoses

Steering Valve - Removing

Steering Valve - Cross Sectional View

Disassembling Steering Valve

Exploded View of Steering Valve

Mounting Steering Valve

Adjusting Shock Valves

Steering - Exploded View

Steering Column - Exploded View

Installing Steering Valve

Group 15: Brake Valve

Special Tools

Specifications

Brake Valve Repair Instructions

Brake Valve

Group 20: Rear Wheel Brakes

Rear Brakes, Specifications

Rear Wheel Brakes - Exploded View

Removing Rear Brakes

Reconditioning Rear Brakes

Installing Rear Brakes

Replacing Retraction Pins on the Rear Wheel Brakes

Section 70: Hydraulic System

Group 05: Controls

Specifications

Selective Control Valves — Removing and Installing Actuating Elements

Selective Control Valves — Adjusting Bowden Cable

Group 10: Oil Filter, Charge Pump and Hydraulic Pump

Other Material

Specifications

Removing and Installing Hydraulic Oil Mesh Filter

Removing and Installing Hydraulic Oil Filter

Removing and Installing Charge Pump

Charge Pump - Checking the Lube Oil Valve

Hydraulic Oil Reservoir — Restrictor

Hydraulic Pump - Removing and Installing Pressure-and-Flow Controller

Hydraulic Pump - Reconditioning Pressure-and-Flow Controller

Removing and Installing Hydraulic Pump

Hydraulic Pump - Exploded View

Disassembling Hydraulic Pump

Assembling Hydraulic Pump

Group 15: Valves

Special Tools

Specifications

Hydraulic System Repair Instructions

Removing Priority 1 Control Block

Installing Priority 1 Control Block

Reconditioning Priority 1 Control Block

Removing Priority 3 Control Block

Installing Priority 3 Control Block

Recondition Priority 3 Control Block

Group 20: Hitch

Other Material

Specifications

Rockshaft Valve, Removing and Installing the Stepper Motor

Remove Rockshaft Valve

Recondition the Rockshaft Valve

Install the Hitch Valve

Rockshaft - Removg and Installing Position Sensor and Toothed Segment

Rockshaft - Removing and Installing Rockshaft

Rockshaft - Removing Rockshaft Cylinders

Rockshaft - Reconditioning Lift Cylinder

Rockshaft - Install Rockshaft Cylinders

Rockshaft - Removing and Installing Draft Load Potentiometer and Draft Link Support

Group 25: Selective Control Valves and Couplers

Specifications

Selective Control Valves (SCVs) and Couplers Repair Instructions

Remove the Selective Control Valves (SCVs)

Recondition the Selective Control Valves (M-SCVs 100)

Recondition the Selective Control Valves (M-SCVs 200)

Install the Selective Control Valves (SCVs)

Selective Control Valves (SCVs) - Reconditioning the Couplers

Section 80: Miscellaneous

Group 00: Removing and Installing Components

Special Tools

Special Tools (Dealer-Fabricated)

Specifications

Removing Main Chassis

Installing Main Chassis

Removing Front-Wheel Drive Axle

Installing Front-Wheel Drive Axle

Group 05: Main Chassis

Specifications

Reconditioning Main Chassis

Group 15: Wheels

Essential, Recommended and Fabricated Tools

Specifications

Service Heavy-Duty Wheel Clamps

Group 20: Center Link Bracket and Swinging Drawbar

Specifications

Checking Swinging Drawbar Wear

Installing Center Link Bracket

Swinging Drawbar

Adjusting Retention Rod

Section 90: Operator's Cab

Group 00: Removing and Installing Components

Special Tools

Dealer-Manufactured Special Tools

Specifications

Swinging Up Operator's Cab

Swinging Down Operator's Cab

Removing Operator's Cab or Platform

Installing Operator's Cab or Platform

Checking and Adjusting Gear Shift Units

Group 15: Air Conditioning System

Special Tools

Tightening Torque for Refrigerant Hoses

Safety Regulations

Handling Refrigerant

In the Event of an Emergency

Safety Equipment

Storage of Refrigerant Containers

Refrigerant R134a

Important

Other Material

Specification

Filling the Cylinder

Charging Air Conditioning System (With Loading Cylinder)

Adding Oil to the Air Conditioning System

Leak Test

Evacuate Air Conditioning System

Cleaning the Air Conditioning System

Separating Compressor

Checking Compressor Level

Disassembling Compressor Clutch

Checking Clutch Hub Separation

Installing Compressor

Separating and Installing Condenser

Separating and Installing Drier

Replacing Expansion Valve

Separating and Installing Evaporator and Expansion Valve

Installing Condensation Water Drain Hoses

Layout of Condensation Water Drain Hoses

Separating and Installing Thermostat

Separating and Installing High/Low Pressure Switch

Vacuum Pump — General Information

Group 20: Heating System

Fan and Heater, Disassembling

Removing Cab Air Filter

Separating and Installing Fan

Separating and Installing Heater Regulator

Separating Heater/Evaporator Housing

Group 25: Operator's Cab

Removing Cab Frame

Cab Mounting Torques

Removing and Installing Windshield

Removing and Installing Rear Window

Installing Door Lock

Adjusting Window Contact Pressure

Removing and Installing Operator's Cab Door

Removing and Installing Sun-Visor Roller

Section 99: Special Tools (Dealer-Fabricated)

Group 05: Special Tools (Dealer-Fabricated)

DFLX1 - Adapter Strut

DFLX7 - Turning Device

DFLX14 – Suspended MFWD Axle Housing Bracket

DFLX29 - Support

Lifting Device

Holding Device

Suspension Eyes for Operator's Cab

Holding Tool

Wooden Block

DFRW79 - Piston Holding Tool

Socket Wrench Insert

Seal Installer

Driver

Assembly and Guide Mandrels

Turning Device

Seal Installer

Socket Wrench Insert

Special Wrench

Quick Coupler Securing Support

Lifting Tool