John Deere Tractors 6200, 6200L, 6300, 6300L, 6400, 6400L, 6500, 6500L Diagnosis and Tests Service Technical Manual (TM4524)

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John Deere Tractors 6200, 6200L, 6300, 6300L, 6400, 6400L, 6500, 6500L Diagnosis and Tests Service Technical Manual (TM4524)

tm4524 - 6200, 6200l, 6300, 6300l,6400, 6400l, 6500, 6500l tractors Technical Manual.pdf

Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere Tractors 6200, 6200L, 6300, 6300L, 6400, 6400L, 6500, 6500L, with all the service information to maintain, diagnose, service like professional mechanics.

John Deere Tractors 6200, 6200L, 6300, 6300L, 6400, 6400L, 6500, 6500L workshop Diagnosis & Tests manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,513 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   Safety
      Safety Precautions
   Diagnostic Trouble Codes
      HCU Diagnostic Trouble Codes
      RCU Diagnostic Trouble Codes
   Engine
      Engine Tests
   Fuel, Air Intake and Cooling Systems
      System Diagnosis
      System Tests
      Fuel System
      Air Intake System
      Cooling System
      Cold Weather Starting Aids
   Electrical System
      System Information
      System Diagrams, Cab
      System Diagrams, 2-Post ROPS
      Sub-System Diagnostics, Cab
      Sub-System Diagnostics, 2-Post ROPS
      References
   Syncroplus Transmission
      Operational Checks
      System Diagnosis
      System Tests
      Theory of Operation - Syncroplus Transmission
      Theory of Operation - Perma Clutch II
      Theory of Operation - Gear Transmission
      Theory of Operation - Creeper Transmission
      Theory Of Operation - Range Transmission
   Powrquad Transmission
      Operational Checks
      System Diagnosis
      Adjustments
      Theory of Operation - Powrquad Transmission
   Drive Systems (Without Transmission)
      Operational Checks
      System Diagnosis
      System Tests
      Theory of Operation - Front-Wheel Drive Clutch
      Theory of Operation - Differential
      Theory of Operation - Final Drives
      Theory of Operation - Rear PTO Options
   Steering and Brakes
      Operational Checks
      System Diagnosis
      System Tests
      Theory of Operation (Complete System)
      Hydrostatic Steering
      Hydraulic Brakes
   Hydraulic System
      Operational Checks
      System Diagnosis
      System Tests
      Hydraulic System
      Charge Pump
      Hydraulic Pump
      Hydraulic System Valves
      Rockshaft and Lift Cylinders
      Selective Control Valves and Couplers
      Independent Control Valve
   Operator’s Station
      Operational Checks
      Air Conditioning - System Diagnosis
      Ventilation and Heater - System Diagnosis
      Operator’s Seat - System Diagnosis
      Air Conditioning System - Theory Of Operation
      Ventilation and Heater - Theory of Operation
   Special Tools (Dealer-Fabricated)

tm4524 - 6200, 6200l, 6300, 6300l,6400, 6400l, 6500, 6500l tractors

Table of Contents

Foreword

Section 210: Safety

Group 05: Safety Precautions

Recognize Safety Information

Prevent Machine Runaway

Handle Fluids Safely-Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Avoid High-Pressure Fluids

Service Cooling System Safely

Remove Paint Before Welding or Heating

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 Properly

Work in Clean Area

Illuminate Work Area Safely

Service Machines Safely

Use Proper Tools

Service Tires Safely

Service Front-Wheel Drive Tractor Safely

Keep ROPS Installed Properly

Replace Safety Signs

Dispose of Waste Properly

Live With Safety

Section 211: Diagnostic Trouble Codes

Group HCU: HCU Diagnostic Trouble Codes

HCU 022-System Voltage not in Specification

HCU 027-Calibration not Successful

HCU 028-Calibration Memory Failure

HCU 029-Calibration Memory Failure

HCU 030-Insignificant Fault that has no effect on Tractor Operation

HCU 041-Stepper Motor Circuit open

HCU 042-Stepper Motor Circuit open

HCU 043-Stepper Motor Circuit shorted

HCU 044-Stepper Motor Circuit shorted

HCU 045-Potentiometers and Position Sensor Supply Voltage Out of Range

HCU 046-Draft Sensor Supply voltage Out of Range

HCU 049-Raise/ Lower Rocker Switch Circuit

HCU 050-Stepper Motor Deadband out of range

HCU 051-Left Draft Sensor Circuit

HCU 052-Right Draft Sensor Circuit

HCU 053-Load/ Depth Control Potentiometer Circuit

HCU 054-Hitch Control Lever Potentiometer Circuit

HCU 055-Rockshaft Position Sensor Circuit

HCU 056-Raise Limit Control Potentiometer

HCU 057-Rate-of-Drop Control Potentiometer Circuit

HCU 058-Remote Control Switch Circuit

HCU 239-Circuit fault during Calibration

HCU 241-Hitch Position Sensor Circuit

HCU 242-Hitch Position Sensor Circuit

HCU 250-Right Draft Sensor Circuit

HCU 251-Right Draft Sensor Circuit

HCU 252-Right Draft Sensor Circuit

HCU 253-Left Draft Sensor Circuit

HCU 254-Left Draft Sensor Circuit

HCU 255-Left Draft Sensor Circuit

Group RCU: RCU Diagnostic Trouble Codes

RCU 015-Fault in Detent Solenoid Circuit

RCU 017-Insignificant Fault that has no Effect on Tractor Operation

RCU 025-Fault in Detent Solenoid Circuit

RCU 027-Enable Switch indicates no Pressure

RCU 029-Enable Pressure Switch indicates Pressure, but Pressure is actually zero

RCU 031-Fault in Enable Solenoid Circuit

RCU 032-Park Position, but its Valid Neutral Signal is missing

RCU 034-Reverser Drive Lever remains in Direction too long while Range Lever is in "Park" (Diagnostic Mode Only)

RCU 040-Forward and Reverse Switches open, but Not-Neutral Switch is closed

RCU 041-Forward and Reverse Switches both closed at same Time

RCU 042-Forward Switch closed, but Not-Neutral Switch open

RCU 043-Reverse Switch closed, but Not-Neutral Switch open

RCU 044-Not-Neutral Relay open, but Not-Neutral Switch closed

RCU 045-Direction of Travel is selected, but enable Solenoid is still closed

RCU 047-No Neutral Signal after Engine is started

RCU 048-System Voltage to low

RCU 051-Reverser Drive Lever in Direction, but Neutral Start Switch indicates neutral

RCU 053-Reverser Drive Lever in Neutral, but Neutral Start Switch indicates not neutral

RCU 055-Enable Solenoid stuck in closed Position

RCU 056-Reverser Drive Lever in forward or reverse when Engine is started

RCU 057-Transmission Enable Voltage to low during operation

RCU 058-Transmission Enable Voltage too low when Engine is started

RCU 064-Fault in Memory of RCU

RCU 065-Fault in RCU

RCU 067-Neutral Start Switch indicates Not-Neutral without cause

Section 220: Engine

Group 10: Engine Tests

Preliminary Engine Tests

Dynamometer Test

Section 230: Fuel, Air Intake and Cooling Systems

Group 10: System Diagnosis

Fuel System

Cooling System

Group 15: System Tests

Special or Essential Tools

Specifications

Testing the Air Intake System

Testing the Low-Pressure Switch in Air Intake System

Testing Cooling System for Leaks

Checking Expansion Tank Cap

Checking the Fuel Transfer Pump

Group 20A: Fuel System

General Information

Description

Fuel Transfer Pump - Theory of Operation

Fuel Filter - Theory of Operation

Group 20B: Air Intake System

Air Cleaner - Theory of Operation

Group 20C: Cooling System

General Information

Description of Radiator

Viscous Fan Drive - Theory of Operation

Automatic Drive Belt Tensioner - Theory of Operation

Group 20D: Cold Weather Starting Aids

General Information

Electrical Starting Aid - Theory of Operation

Fuel Preheater - Theory of Operation

Coolant Preheater - Theory of Operation

Transmission Oil Preheater - Theory of Operation

Section 240: Electrical System

Group 05: System Information

Special or Essential Tools

Using Electrical Section

Wiring Diagram and Schematic Information

Component Identification Table

How to Read a Functional Schematic

How to Read a Diagnostic Schematic

How to Read a Wiring and Harness Diagram

Symbols in Functional Schematic, Wiring and Harness Diagrams

Visually Inspect Electrical System

Electrical Circuit Malfunctions

High Resistance or Open Circuit

Grounded Circuit

Shorted Circuit

Seven Step Electrical Test Procedure

Group 10: System Diagrams, Cab

Fuses (Cab)

Part Designations in Functional Schematic, Wiring and Harness Diagrams (Cab)

Section Designations in Functional Schematic (Cab)

Harness Designation in Wiring Diagram (Cab)

Functional Schematic (Complete Tractor with Cab)

Engine Wiring Harness Diagram (W1, W2, W3) and Component Location up to Tractor Serial No. 116858 (Cab)

Engine Wiring Harness Diagram (W3, W14) and Component Location from Tractor Serial No. 116859 (Cab)

Cowl Wiring and Harness Diagram (W4, W5, W6, W7) and Component Location up to Tractor Serial No. 135238 (Cab)

Cowl Wiring and Harness Diagram (W4, W5, W6, W7) and Component Location from Tractor Serial No. 135239 (Cab)

Cab Roof Wiring and Harness Diagram ( W11) and Component Location up to Tractor Serial No. 135715

Transmission Wiring and Harness Diagram and Component Location up to Serial No. 178178 (AL70819, W13) (Cab)

Transmission Wiring and Harness Diagram and Component Location from Serial No. 178179 (AL111539, W13) (Cab)

Cowl Wiring and Harness Diagram (W4) with Electrical Reverser Control (Cab)

Transmission Wiring Harness (AL112509; W20) (Cab)

Back-Up Alarm Wiring Harness (AL81580; W25) (Cab)

Back-Up Alarm Wiring Harness (AL113003; W26) (Cab)

Cab Roof Wiring Harness (AL110051; W11) from serial No. 135716 - 183107

Cab Roof Wiring Harness (AL112968; W11) from serial No. 183108

Worklight Wiring Harness (AL83139; W18) (Cab)

Cab Lighting Wiring Harnesses (W21, W22), Low-clearance cab

Wiper Wiring Harnesses( W23, W24), Low-clearance cab

Circuit Board of Instrument Unit and Plug Arrangement (Without Digital Control) (Cab)

Circuit Board of Instrument Unit and Plug Arrangement (With Digital Control) (Cab)

Group 10A: System Diagrams, 2-Post ROPS

Fuses (ROPS)

Part Designations in Functional Schematic, Wiring and Harness Diagrams (ROPS)

Section Designations in Functional Schematic (ROPS)

Harness Designation in Wiring Diagram (ROPS)

Functional Schematic (Complete Tractor-ROPS)

Engine Wiring Harness Diagram (W3; W2; W1) and Component Location up to Tractor Serial No. 116858 (ROPS)

Engine Wiring Harness Diagram (W3; W14) and Component Location from Tractor Serial No. 116859 (ROPS)

Cowl Wiring and Harness Diagram (W4; W9) and Component Location, Standard Version (Rops)

Cowl Wiring and Harness Diagram (W4; W9) and Component Location, Low Profile Version (ROPS)

Transmission Wiring and Harness Diagram and Component Location up to Serial No. 178178 (AL70819, W13) (ROPS)

Transmission Wiring and Harness Diagram and Component Location from Serial No. 178179 (AL111539, W13) (ROPS)

Back-Up Alarm Wiring Harness (AL81580; W25) (ROPS)

Back-Up Alarm Wiring Harness (AL113003; W26) (ROPS)

Circuit Board of Instrument Unit and Plug Arrangement (Standard Version) (ROPS)

Group 15: Sub-System Diagnostics, Cab

Special or Essential Tools

Specifications

SE1-Starting Motor and Charging Circuit (Cab) - Functional and Diagnostic Schematic

SE1-Starting Motor and Charging Circuit (Cab) - Component Checks

SE2-Instrument Unit and Lighting (Cab) - Functional and Diagnostic Schematic

SE2-Instrument Unit and Lighting (Cab) - Voltage Checks

SE3-Display Unit (Cab) - Functional and Diagnostic Schematic

SE3-Display Unit (Cab) - Voltage Checks

SE5-Horn (Cab) - Functional and Diagnostic Schematic

SE5-Horn (Cab) - Voltage Checks

SE6-Cigarette Lighter and Operator’s Seat (Cab) - Functional and DiagnosticSchematic

SE6-Cigarette Lighter and Operator’s Seat (Cab) - Voltage Checks

SE8-Rear PTO (Cab) - Functional and Diagnostic Schematic

SE8-Rear PTO (Cab) - Voltage Checks

SE9-Front Wheel Drive (Cab) - Functional and Diagnostic Schematic

SE9-Front Wheel Drive (Cab) - Voltage Checks

SE10-Differential Lock (Cab) - Functional and Diagnostic Schematic

SE10-Differential Lock (Cab) - Voltage Checks

SE12-Hazard Warning Flasher and Turn Signal Lights (Cab) - Functional and Diagnostic Schematic

SE12-Hazard Warning Flasher and Turn Signal Lights (Cab) - Voltage Checks

SE13-Lights (Cab) - Functional and Diagnostic Schematic

SE13-Lights (Cab) - Voltage Checks

SE14-Work Lights (Cab) - Functional and Diagnostic Schematic

SE14-Work Lights (Cab) - Voltage Checks

SE15-3-Terminal, 7-Terminal and Front Loader Power Outlet Sockets (Cab) - Functional and Diagnostic Schematic

SE15- 3 Terminal, 7 Terminal and Front-Loader Power Outlet Sockets (Cab) - Voltage Checks

SE16-Radio, Dome and Console Lights (Cab) - Functional and Diagnostic Schematic

SE16-Radio, Dome and Console Lights (Cab) - Voltage Checks

SE17-Blower and Air Conditioning System (Cab) - Functional and Diagnostic Schematic

SE17-Blower and Air Conditioning System - Voltage Checks

SE18-Windshield Wipers and Washers (Cab) - Functional and Diagnostic Schematic

SE18-Windshield Wipers and Washer (Cab) - Voltage Checks

SE19-Clutch Cooling (Cab) - Functional and Diagnostic Schematic

SE19-Clutch Cooling (Cab) - Voltage Checks

SE20-Beacon Light (Cab) - Functional and Diagnostic Schematic

SE20-Beacon Light (Cab) - Voltage Checks

SE21-Electronic Rockshaft Control (Cab) - Functional and Diagnostic Schematic

SE24-Back-Up Alarm (Cab) - Functional and Diagnostic Schematic

SE24-Back-Up Alarm (Cab) - Voltage Checks

SE25-Electrical Reverser Control (Cab) - Functional and Diagnostic Schematic

Group 15A: Sub-System Diagnostics, 2-Post ROPS

Special or Essential Tools

Specifications

SE1-Starting Motor and Charging Circuit (Rops) - Functional and Diagnostic Schematic

SE1-Starting Motor and Charging Circuit (Rops) - Component Checks

SE2-Instrument Unit and Lighting (ROPS) - Functional and Diagnostic Schematic

SE2-Instrument Unit and Lighting (ROPS) - Voltage Checks

SE3-Display Unit (ROPS) - Functional and Diagnostic Schematic

SE3-Display Unit (ROPS) - Voltage Checks

SE5-Horn (ROPS) - Functional and Diagnostic Schematic

SE5-Horn (ROPS) - Voltage Checks

SE8-Rear PTO (ROPS) - Functional and Diagnostic Schematic

SE8-Rear PTO (ROPS) - Voltage Checks

SE9-Front Wheel Drive (ROPS) - Functional and Diagnostic Schematic

SE9-Front Wheel Drive (ROPS) - Voltage Checks

SE10-Differential Lock (ROPS) - Functional and Diagnostic Schematic

SE10-Differential Lock (ROPS) - Voltage Checks

SE12-Hazard Warning Flasher and Turn Signal Lights (ROPS) - Functional and Diagnostic Schematic - Low Profile Version

SE12-Hazard Warning Flasher and Turn Signal Lights - Voltage Checks

SE13-Lights (ROPS) - Functional and Diagnostic Schematic

SE13-Lights (ROPS) - Voltage Checks

SE14-Work Lights (ROPS) - Functional and Diagnostic Schematic

SE14-Work Lights (ROPS) - Voltage Checks

SE15- 3 Terminal, 7 Terminal and Front-Loader Power Outlet Sockets (ROPS) - Functional and Diagnostic Schematic

SE15- 3 Terminal, 7 Terminal and Front-Loader Power Outlet Sockets (ROPS) - Voltage Checks

SE19-Clutch Cooling (ROPS) - Functional and Diagnostic Schematic

SE19-Clutch Cooling (ROPS) - Voltage Checks

SE21-Electronic Rockshaft Control (ROPS), Functional and Diagnostic Schematic

SE24-Back-Up Alarm (ROPS) - Functional and Diagnostic Schematic

SE24-Back-Up Alarm (ROPS) - Voltage Checks

Group 20: References

Battery Specifications

Battery Operation

Check Battery Electrolyte Level and Terminals

Procedure for Testing Batteries

Diagnose Battery Malfunctions

Starting With a Booster Battery

Section 250: Syncroplus Transmission

Group 05: Operational Checks

Checking if Clutch Separates Properly

Checking Clutch for Slippage

Checking Slip Phase of Clutch

Checking the Transmission

Checking Neutral Start Switch

Group 10: System Diagnosis

Explanation of System Diagnosis

Safety Precautions

Special or Essential Tools

Specifications

Heating Up Hydraulic Oil

Connecting JT07115 Hydraulic Test Kit

Layout of Test Ports and Sending Units

Preliminary Checks

Checking Gear and Range Engagement

Checking Clutch Operation

Checking the Transmission Oil Filter

System (Engagement) Pressure Test

Adjusting System (Engagement) Pressure

Check Components Dependent on System (Engagement) Pressure

Checking the Filter Relief Valve

Testing the Engagement Override Valve and Clutch Pedal Valve

Checking the Modulation of the Clutch Pedal Valve

Checking the Lube Oil Pressure

Clutch Cooling System Test (Up to Tractor Serial No. 109779)

Clutch Cooling System Test (From Tractor Serial No. 109780)

Measuring the Flow Rate

Checking the Cooler Relief Valve

Group 15: System Tests

Special or Essential Tools

Specifications

Checking Gear and Range Engagement

Range Transmission Linkage Test

Adjusting Range Transmission Linkage

Gear Transmission Linkage Test

Adjusting Shift Linkage at Gear Transmission

Adjusting Neutral Start Switch

Checking Neutral Start Switch

Adjusting the Shift Linkage

Adjusting Parking Lock

Clutch Pedal Adjustment

Group 20: Theory of Operation - Syncroplus Transmission

Layout of 12-Speed Transmission

Layout of 12-Speed Transmission With Creeper

Lubrication System

Shift Operation

Synchronization

Transmission Circuit - Theory of Operation

Group 20A: Theory of Operation - Perma Clutch II

Components

Clutch Design

Power Flow, Clutch Pedal Depressed

Power Flow, Clutch Pedal Not Depressed

Transmission Oil Pump - Theory of Operation

Hydraulic Circuit Diagram

Description of Valves

Other Transmission Oil Circuit Components

Over-Speed Relief and Air-Suction Valves - Theory of Operation

Clutch Pedal Valve and Engagement Override Valve,Theory of Operation-EngineOn, Clutch Pedal Not Depressed Since Engine Has Been Started

Clutch Pedal Valve and Engagement Override Valve,Theory of Operation-Engine On, Clutch Pedal Depressed

Clutch Pedal Valve and Engagement Override Valve, Theory of Operation-Engine On, Clutch Pedal in Process of Being Released

Clutch Cooling, Theory of Operation-Engine On, Clutch Pedalin Process of Being Released

Clutch Cooling, Theory of Operation-Engine On, Clutch Almost Fully Engaged

Clutch Cooling, Theory of Operation -Engine On, Clutch Engaged

Clutch Cooling, Theory of Operation -Engine On, Clutch in Process of Disengagement

Clutch Cooling, Theory of Operation -Engine On, Clutch Disengaged

Clutch Cooling, Theory of Operation -Engine On, Clutch Only Briefly Disengaged

Pressure Regulating Valve and Filter Relief Valve,Theory of Operation-NormalOperation (Transmission Oil Filter Clean)

Pressure Regulating Valve and Filter Relief Valve, Theory of Operation-Transmission Oil Filter Clogged

Pressure Regulating Valve and Filter Relief Valve, Theory of Operation-Transmission Oil Filter Completely Clogged

Cooler Relief Valve - Theory of Operation

Lube Relief Valve - Theory of Operation

Group 20B: Theory of Operation - Gear Transmission

Gear Transmission Design

Power Flow in 1st Gear

Power Flow in 2nd Gear

Power Flow in 3rd Gear

Power Flow in Reverse Gear

Neutral Start Switch

Group 20C: Theory of Operation - Creeper Transmission

Layout of Creeper Transmission

Power Flow With Creeper Disengaged

Power Flow With Creeper Engaged

Group 20D: Theory Of Operation - Range Transmission

Layout

Power Flow, Range A

Power Flow, Range B

Power Flow, Range C

Power Flow, Range D

Parking Lock

Section 255: Powrquad Transmission

Group 05: Operational Checks

Operational Checks - Before You Start

Group 10: System Diagnosis

Use Step-By-Step Hydraulic Diagnostic Charts

Special or Essential Tools

Service Equipment and Tools

Other Material

Observe Safety Precautions

Avoid High-Pressure Fluids

Connecting the Performance Monitor

Operating the Performance Monitor

Diagnostic Program

List of Addresses

Diagnosis

1 Connecting the Performance Monitor

2 Commencing the Program

3 Calling Up and Cancelling Service Codes

4 Carrying Out a Test Drive

List of Service Codes

Description of Service Codes

Service Code RCU 015

Service Code RCU 017

Service Code RCU 025

Service Code RCU 027

Service Code RCU 029

Service Code RCU 031

Service Code RCU 032

Service Code RCU 034

Service Code RCU 040

Service Code RCU 041

Service Code RCU 042

Service Code RCU 043

Service Code RCU 044

Service Code RCU 045

Service Code RCU 047

Service Code RCU 048

Service Code RCU 051

Service Code RCU 053

Service Code RCU 055

Service Code RCU 056

Service Code RCU 057

Service Code RCU 058

Service Code RCU 064

Service Code RCU 065

Service Code RCU 067

5 Calling Up Diagnostic Addresses

List of Diagnostic Addresses

Performing Diagnosis

Address RCU 02

Address RCU 03

Address RCU 04

Address RCU 05

Address RCU 06

Address RCU 07

7 Calling Up RCU Calibration Addresses

8 Calling Up RCU Identification Addresses

Adjust for Correct Pressure and Temperature References

Shortened Diagnostic Procedure

Powrquad Transmission Test

Summary of Transmission Testing

Lube Relief Valve Stuck Open

Transmission Oil Pump Air Leak Check

Clutch and Brake Element Air Leak Check Using a Blow Gun

Transmission Control Valve Housing Gasket

Transmission Slippage

PTO Clutch Drag

Hydraulics Fluid Over-Heating

Other Malfunctions

Group 15: Adjustments

Adjusting the Forward/Reverse Linkage (With Mechanical Reverser Control)

Adjusting the Shift Linkage and Parking Lock (Previous Version)

Adjusting the Shift Linkage and Parking Lock (Latest Version), With Reverser Control on Switch Console

Adjusting the Shift Linkage and Parking Lock (Latest Version), With Reverser Control on Steering Column

Clutch Pedal Adjustment (Up to Tractor Serial No. 130420)

Clutch Pedal Adjustment (From Tractor Serial No. 130421)

Group 20: Theory of Operation - Powrquad Transmission

Components of Powrquad Transmission

Powrquad Housings

Planetary Operation

Air Pump

Transmission Oil Pump

Clutch Oil Manifold

Reverse Brake Housing

Forward/Reverse Controls

Hydraulic Circuit Diagram - Mechanical Reverser Control (Older Tractor Series)

Component Layout - Mechanical Reverser Control (Older Tractor Series)

Hydraulic Circuit Diagram - Mechanical Reverser Control (Latest Tractor Series)

Hydraulic Circuit Diagram - Electrical Reverser Control

Filter Relief Valve

Pressure Regulating Valve

Forward-Reverse Modulation

EOV Circuit (With Mechanical Reverser Control)

Theory Of Operation - Electrical Reverser Control

Reverse Drive Lever

Park Switch

Valve Housing on Powrquad Module

Relays

Reverser Control Unit (RCU)

Detail of Hydraulic Circuit Diagram (Simplified)

Speed Control Circuit

Speed Modulation

Clutch Cooling Components

Oil Cooler System

Low-Pressure Clutch Cooling Valve

High-Pressure Clutch Cooling Valve

FWD-REV Cooling Control Valve

Clutch Pedal Control of Cooling Flow:

Cooler and Lube Circuits

Module Lube

Module Lube Flow Paths

Clutch Cooling Circuit Operation

Oil Cooler

Test Ports and Sending Units - With Mechanical Reverser Control

Test Ports and Sending Units - With Electrical Reverser Control

Section 256: Drive Systems (Without Transmission)

Group 05: Operational Checks

Checking Rear PTO

Group 10: System Diagnosis

Front Wheel Drive

Differential

Hydraulic Pump Drive

Final Drives

Rear PTO

Group 15: System Tests

Safety Precautions

Special or Essential Tools

Specifications

Heating Up Hydraulic Oil

Testing Operating Pressure of Fwd Clutch

Testing Operating Pressure of Hydraulic Differential Lock

Testing Rear PTO

Testing Lube Pressure of Fwd Clutch, Differential Lock and PTO

Group 20A: Theory of Operation - Front-Wheel Drive Clutch

Layout (Up to Transmission Serial No. 114447)

Oil and Power Flows With Front Wheel Drive Engaged

Oil and Power Flows With Front Wheel Drive Disengaged

Layout (Transmission Serial No. 114448 to 161066)

Oil and Power Flows With Front Wheel Drive Engaged

Oil and Power Flows With Front Wheel Drive Disengaged

Layout (From Transmission Serial No. 161067)

Oil and Power Flows With Front-Wheel Drive Engaged

Oil and Power Flows With Front-Wheel Drive Disengaged

Group 20B: Theory of Operation - Differential

Layout

Power Flow When Moving Straight Ahead

Power Flow When Cornering

Oil Flow With Differential Lock Engaged

Oil Flow With Differential Lock Disengaged

Group 20C: Theory of Operation - Final Drives

Description

Group 20D: Theory of Operation - Rear PTO Options

Description of Rear PTO Options

PTO Modulating Valve and Solenoid Valve

Operation of PTO Clutch and Brake

PTO Power Flow (540 RPM)

PTO Power Flow (540/1000 RPM, Reversible)

Section 260: Steering and Brakes

Group 05: Operational Checks

Checking the Steering

Checking the Brakes

Group 10: System Diagnosis

Hydrostatic Steering

Hydraulic Brakes

Group 15: System Tests

Special or Essential Tools

Specifications

Testing Leaf Springs of Steering Valve

Checking Steering System for External Leakage

Checking Steering System for Internal Leakage

Checking Steering Unit

Steering Valve Hydraulic Connections

Testing and Adjusting Shock Valves

Checking Brake System

Checking Brakes for Air in the System

Checking Brakes for External Leakage

Checking Brake Valve for Internal Leakage

Adjusting Brake Pedals

Bleeding the Brakes

Checking Brake Piston Travel

Adjusting the Stop Light Switch

Checking Rear Brakes

Group 20: Theory of Operation (Complete System)

Description

Group 20A: Hydrostatic Steering

Description of Steering Valve

Operation of Metering Unit

Oil Flow in Steering System

Oil Flow - Neutral Position

Oil Flow - Emergency Steering

Group 20B: Hydraulic Brakes

Brake Valve Layout

Operation

Brake Valve - Sectional View

Hydraulic Circuit Diagram

Oil Flow During Brake Application

Rear Brake Operation

Section 270: Hydraulic System

Group 05: Operational Checks

Operational Checks

Operational Checks on Rockshaft Control

Group 10: System Diagnosis

Explanation of System Diagnosis

Safety Precautions

Special or Essential Tools

Connecting Testers to Test Ports

Heating Up Hydraulic Oil

Specifications

Test Sequence

Information on System Diagnosis

Hydraulic Test Record

Group 15: System Tests

Explanation of the Hydraulic Tests

Safety Precautions

Special or Essential Tools

Service Equipment and Tools

Heating Up Hydraulic Oil

Lube Oil Pressure of Charge Pump

Checking and Adjusting System Pressure of Hydraulic Pump

Adjusting the Load Sense Valve on the Hydraulic Pump

Checking Load Sense Pressure

Checking the Load Sense Valve

Pressure Difference (Dynamic)

Causes of Internal Leakage

Arrangement of Shuttle Valves

Hydraulic System Response to a Missing Shuttle Valve

Diagnosing Faults at the Selective Control Valves

Check for Leaks at Valve Spools

Diagnosing Faults at Independent Control Valves

Checking Pressure Relief Valve of Rockshaft

Adjusting the Power Beyond Application Valve

Adjusting the Power Beyond Application Valve

Hydraulic Pump

Charge Pump

Checking, Calibrating and Adjusting the Rockshaft Control

List of Diagnostic and Calibration Procedures

Hitch Troubleshooting Tips

Checking With the Performance Monitor

Checking on Tractors With Dual Gauge Plus Dash Not possible from tractor serial no. 126575 to 132999

Abbreviations Used in the Display

Identification of Hitch Controls

Test Sequence

Identification of Electronic Control Unit (HCU)

Address 03 (AL78061) System Voltage

Address 04 (AL78061) Raising Valve Command

Address 05 (AL78061) Lowering Valve Command

Address 06 (AL78061) Supply Voltage For Potentiometer And Position Sensor

Address 07 (AL78061) Supply Voltage For Draft Sensors

Address 08 (AL78061) LH Draft Sensor Output Voltage

Address 09 (AL78061) RH Draft Sensor Output Voltage

Address 10 (AL78061) Load/Depth Control Potentiometer Output Voltage

Address 11 (AL78061) Hitch Height Control Potentiometer Output Voltage

Address 12 (AL78061) Position Sensor output voltage

Address 13 (AL78061) Raise Limit Potentiometer Output Voltage

Address 14 (AL78061) Rate Of Drop Potentiometer Output Voltage

Address 15 (AL78061) Remote Control Switch Position

Address 16 (AL78061) Voltage of Raise/Lower Rocker Switch

Address 19 (AL78061) Stepper Motor Position

Address 03 (HCU AL81198, AL110388, AL112325 And AL116824) Voltage of Raise/Lower Rocker Switch

Address 04 (HCU AL81198, AL110388, AL112325 and AL116824) LH Draft Sensor Output Voltage

Address 05 (HCU AL81198, AL110388, AL112325 and AL116824) RH Draft Sensor Output Voltage

Address 06 (HCU AL81198, AL110388, AL112325 and AL116824) Load/Depth Control Potentiometer Output Voltage

Address 07 (HCU AL81198, AL110388, AL112325 and AL116824) Hitch Height Control Potentiometer Output Voltage

Address 08 (HCU AL81198, AL110388, AL112325 and AL116824) Position Sensor Output Voltage

Address 09 (HCU AL81198, AL110388, AL112325 and AL116824) Raise Limit Potentiometer Output Voltage

Address 10 (HCU AL81198, AL110388, AL112325 and AL116824) Rate Of Drop Potentiometer Output Voltage

Address 11 (HCU AL81198, AL110388, AL112325 and AL116824) Remote Control Switch In Raising Position

Address 12 (HCU AL81198, AL110388, AL112325 and AL116824) Remote Control Switch In Lowering Position

Address 13 (HCU AL81198, AL110388, AL112325 and AL116824) Supply Voltage For Potentiometer And Position Sensor

Address 14 (HCU AL81198, AL110388, AL112325 and AL116824) Supply Voltage For Draft Sensors

Address 16 (HCU AL81198, AL110388, AL112325 and AL116824) Stepper Motor Position

Address 17 (HCU AL81198, AL110388, AL112325 and AL116824) Raise/Lower Valve Command

Address 18 (HCU AL81198, AL110388, AL112325 and AL116824) System Voltage

Calibration Procedure with HCU AL78061

CalibrationWith performance monitor -Brief Instructions for HCU AL78061

Calibration Procedure with HCUs AL81198, AL110388 and AL112325

Calibration - Brief Instructions for Control Units AL81198, AL110388 and AL112325

Checking the Stepper Motor and Rockshaft Valve

Centering the Stepper Motor

Checking Depth to Which Raising and Lowering Valves are Screwed In

Checking and Adjusting the Position Sensor

Checking and Adjusting the Draft Sensor

Procedure With Service Code 050

Group 20: Hydraulic System

Hydraulic Symbols (ISO 1219)

Hydraulics - A Description

Hydraulic System - Theory of Operation

Symbolic Representation of Hydraulic System

Hydraulic System - Schematic View

Hydraulic System - Three-Dimensional View

Group 20A: Charge Pump

Charge Pump - Description and Theory of Operation

Group 20B: Hydraulic Pump

Description of Hydraulic Pump

Location of Oil Lines

Pump Operation

Operating Modes

Group 20C: Hydraulic System Valves

Hydraulic Oil Filter With Filter Relief Valve

Oil Cooler

Primary Filter

Description of Shuttle Valves

Shuttle Valves - Theory of Operation

Main Block With Inlet Priority Valve

Inlet Priority Valve - Theory of Operation

Power Beyond Valve

Group 20D: Rockshaft and Lift Cylinders

Description of Rockshaft

Rockshaft Control - Theory of Operation

Rockshaft Valve - Theory of Operation

Position Sensor

Draft Sensor

Operation Unit

Hitch Control Unit (HCU)

Direct Control of Rockshaft

Group 20E: Selective Control Valves and Couplers

Selective Control Valves

200 Series Selective Control Valve- Neutral

200 Series Selective Control Valve-Extend

200 Series Selective Control Valve- Retract

200 Series Selective Control Valve-Float

300 Series Selective Control Valve Operation- Neutral

300 Series Selective Control Valve - Extend

300 Series Selective Control Valve- Retract

300 Series Selective Control Valve- Float

Couplers

Group 20F: Independent Control Valve

Description

Independent Control Valve - Sectional View

Oil Flow Through the Independent Control Valve

Section 290: Operator’s Station

Group 05: Operational Checks

A/C System Operational Checks

Results of Operational Checks

Group 10A: Air Conditioning - System Diagnosis

Safety at Work

Handling Refrigerant

Safety Equipment

In an Emergency

Storage of Refrigerant Containers

R134A Refrigerant

Important Note

Service Equipment and Tools

Other Material

Specifications

A/C System Diagnosis

Group 10B: Ventilation and Heater - System Diagnosis

Diagnosing Faults at Ventilation and Heater

Group 10C: Operator’s Seat - System Diagnosis

Diagnosis, MSG95 Operator’s Seat

Group 20A: Air Conditioning System - Theory Of Operation

Principle of Heat Exchange

R134A Refrigerant

Layout of Refrigerant Circuit

Description of How Refrigerant Circuit Functions

Description of How Refrigerant Circuit Functions

Compressor

Condenser

Receiver-Drier

Expansion Valve

Thermostat Switch

Evaporator

Temperature Selection Knob and Compressor Switch

Group 20B: Ventilation and Heater - Theory of Operation

Ventilation and Heater

Section 299: Special Tools (Dealer-Fabricated)

Group 05: Special Tools (Dealer-Fabricated)

DFRW2-Needle Valve Test Hose Assembly

DFRW85-Reverse Brake Test Plate

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