John Deere 6145J 6165J 6180J 6205J Tractor Diagnostic & Tests Service Repair Manual (TM801419) PDF - MJODTM801419.zip

Full Diagnosis & Tests service guide, complete with electrical schematics, for John Deere Tractors 6145J, 6165J, 6180J, and 6205J — packed with everything needed to service, troubleshoot, and overhaul these machines the way professional technicians do.

This Diagnosis & Tests workshop manual for John Deere 2WD or MFWD Tractors 6145J, 6165J, 6180J & 6205J covers:

* 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 - 6145J, 6165J, 6180J, and 6205J Tractors —Diagnostic Technical Manual.pdf

tm801419 - 6145J, 6165J, 6180J, and 6205J Tractors —Diagnostic Technical Manual.epub

PRODUCT DETAILS:

Total Pages: 3,854 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

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