John Deere 6200 6200L 6300 6300L 6400 6400L 6500 6500L Tractor Diagnosis & Tests Workshop Service Manual PDF (TM4524) - MJODTM4524.zip
A comprehensive Diagnosis & Tests technical guide, complete with electrical schematics, covering John Deere Tractors 6200, 6200L, 6300, 6300L, 6400, 6400L, 6500, and 6500L models. Inside, you'll find every piece of service data needed to maintain, troubleshoot, and repair these machines with the skill of a factory-trained technician.
This John Deere workshop manual for Diagnosis & Tests, covering tractor models 6200, 6200L, 6300, 6300L, 6400, 6400L, 6500, and 6500L, contains:
* 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.
tm4524 - 6200, 6200l, 6300, 6300l,6400, 6400l, 6500, 6500l tractors Technical Manual.pdf
tm4524 - 6200, 6200l, 6300, 6300l,6400, 6400l, 6500, 6500l tractors Technical Manual.epub
Total Pages: 1,504 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
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