John Deere 7425 7525 6140J 6155J 6155JH Tractor Diagnosis and Tests Technical Workshop Manual TM605919 PDF - MJODTM605919.zip

Technical Diagnostic & Testing Manual featuring electrical schematics for the John Deere 7425, 7525, 6140J, 6155J, and 6155JH Tractors, packed with every service detail needed to maintain, troubleshoot, and rebuild these machines the way professional technicians do.

The John Deere 7425, 7525, 6140J, 6155J, 6155JH Tractors Diagnosis & Tests workshop manual 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.

TM605919 - 7425, 7525, 6140J, 6155J, 6155JH Tractors Technical Manual - Diagnosis and Tests.pdf

TM605919 - 7425, 7525, 6140J, 6155J, 6155JH Tractors Technical Manual - Diagnosis and Tests.epub

Total Pages: 1,261 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

General References

Diagnostic Trouble Codes

BCU Diagnostic Trouble Codes

Observable Symptoms

Electrical System

Transmission

Drive Systems

Steering And Brakes

Hydraulic System

Engine

Function Test

Tests and Adjustments

Fuel, Air Intake and Cooling Systems

Tests and Adjustments

Descriptions

Electrical System

Sub-System Diagnostics (Cab Tractor)

Sub-System Diagnostics (Open Operator Station Tractor)

Component Tests

Functional schematics

Wiring Harnesses and Connectors

Electronic Control Units

Operation and General Information on Diagnostics

Data BUS Systems, Operation

BCU - Basic Control Unit

Forward/Reverse Module

Function Test

Tests and Adjustments

Operation

PowrQuad Transmissions

Preliminary Tests

Function Test

Tests and Adjustments

Operation

Drive Systems

Function Tests

Tests and Adjustments

Operation

Steering and Brakes

Function Test

Tests and Adjustments

Operation

Hydraulic System

Function Tests

Tests and Adjustments

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: Safety....21

Group 05: Safety Precautions....21

Recognize Safety Information....24

Information - "Important"....25

Information - "Note"....26

Prevent Machine Runaway....27

Handle Fluids Safely—Avoid Fires....28

Prevent Battery Explosions....29

Prepare for Emergencies....30

Prevent Acid Burns....31

Avoid High-Pressure Fluids....33

Service Cooling System Safely....34

Remove Paint Before Welding or Heating....35

Avoid Heating Near Pressurized Fluid Lines....36

Work In Ventilated Area....37

Wear Protective Clothing....38

Practice Safe Maintenance....39

Park Machine Safely....40

Use Proper Lifting Equipment....41

Construct Dealer-Made Tools Safely....42

Support Machine Properly....43

Work in Clean Area....44

Illuminate Work Area Safely....45

Service Machines Safely....46

Use Proper Tools....47

Service Tires Safely....48

Safe Maintenance of Mechanical Front-Wheel Drive (MFWD) System....49

Do Not Look Directly Into Radar Tube....50

Keep ROPS Installed Properly....51

Replace Safety Signs....52

Dispose of Waste Properly....53

Live With Safety....54

Safety Measures for Electronic Control Units....55

Group 15: General References....22

Ref. 210-15-001, General References—Summary....57

Ref. 210-15-010, Unified Non-Metric Bolt and Cap Screw Torque Values....58

Ref. 210-15-015, Unified Metric Bolt and Cap Screw Torque Values....60

Ref. 210-15-020, Hydraulic System Non-Metric Fitting Torque Values....61

Ref. 210-15-025, Hydraulic System Metric Fitting Torque Values....62

Ref. 210-15-030, Component ID Table....64

Ref. 210-15-035, Reading a Functional Schematic....66

Ref. 210-15-040, Reading a Diagnostic Schematic....67

Ref. 210-15-045, Wiring Schematics and Symbols....69

Ref. 210-15-050, Visually Inspect Electrical System....71

Ref. 210-15-055, Electrical Circuit Malfunctions....72

Ref. 210-15-060, Seven Step Electrical Test Procedure....77

Ref. 210-15-065, Hydraulic System — Hydraulic Circuit Symbols....79

Section 211: Diagnostic Trouble Codes....85

Group BCU: BCU Diagnostic Trouble Codes....85

BCU 000070.31 - Park Brake Fault....85

BCU 000084.02 - Wheel speed sensor circuit problem....85

BCU 000168.16 - Excessive System Voltage (Engine Running)....85

BCU 000168.17 - Insufficient System Voltage (Engine above 1500 rpm)....85

BCU 000168.18 - Insufficient System Voltage (Engine speed up to 1500 rpm)....85

BCU 000186.02 - Rear PTO Speed Sensor Circuit Fault....85

BCU 000186.17 - No rear PTO speed detected....85

BCU 000190.02 - Engine speed sensor circuit fault....85

BCU 000629.12 - Control Unit internal problem....85

BCU 000639.12 - Control Unit internal problem....85

BCU 000746.31 - Differential Lock Solenoid Circuit Fault....85

BCU 000980.07 - Rear PTO Switch Connector Defective....85

BCU 001676.31 - LTC Coolant Pump Relay Circuit Fault....85

BCU 299780.07 - Turn Signal Switch Fault....85

BCU 302073.31 - Rear PTO solenoid circuit fault....85

BCU 302080.31 - Differential lock switch fault....85

BCU 302085.31 - MFWD switch defective....85

BCU 302086.31 - MFWD clutch solenoid circuit fault....85

BCU 302106.31 - Control unit internal problem....85

BCU 302123.31 - Signal from forward/reverse switch does not match not-neutral switch signal....85

BCU 302124.31 - Alternator relay electrical circuit fault....85

BCU 302131.31 - Turn signal switch circuit fault....85

BCU 302132.31 - Turn signal fuses F03/04 and/or F03/07 failed....85

BCU 302133.31 - Rear PTO Selector Fault....85

BCU 302240.31 - Control unit plugged into wrong wiring harness....85

BCU 303027.31 - Incorrect hitch control unit calibration....85

BCU 303028.31 - Hitch control unit not calibrated....85

BCU 303037.03 - 5 V power supply too high....85

BCU 303037.04 - 5 V power supply too low....85

BCU 303041.02 - Stepper motor coil 1 circuit open....85

BCU 303042.02 - Stepper motor coil 2 circuit open....85

BCU 303043.02 - Defective stepper motor coil 1 electrical circuit....86

BCU 303044.02 - Defective stepper motor coil 2 electrical circuit....86

BCU 303045.04 - System voltage too low....86

BCU 303047.03 - System voltage too high....86

BCU 303049.03 - Quick raise/lower rocker switch voltage too high....86

BCU 303049.04 - Quick raise/lower rocker switch voltage too low....86

BCU 303052.03 - Right draft sensor signal voltage too high....86

BCU 303052.04 - Right draft sensor signal voltage too low....86

BCU 303053.03 - Sensitivity potentiometer signal voltage too high....86

BCU 303053.04 - Sensitivity potentiometer signal voltage too low....86

BCU 303054.03 - Depth potentiometer signal voltage too high....86

BCU 303054.04 - Depth potentiometer voltage too low....86

BCU 303055.03 - Position sensor signal voltage too high....86

BCU 303055.04 - Position sensor signal voltage too low....86

BCU 303056.03 - Raise limit potentiometer signal voltage too high....86

BCU 303056.04 - Raise limit potentiometer signal voltage too low....86

BCU 303057.03 - Rate-of-drop potentiometer signal voltage too high....86

BCU 303057.04 - Rate-of-drop potentiometer signal voltage too low....86

BCU 303060.02 - Stepper motor free step out of range....86

BCU 303177.18 - Hydraulic oil temperature low during calibration....86

BCU 303252.02 - Distorted right draft sensor signal during calibration....86

BCU 303252.03 - Right draft sensor voltage too high during calibration....86

BCU 303252.04 - Right draft sensor voltage too low during calibration....86

BCU 303255.03 - Position sensor signal voltage too high during calibration....86

BCU 303255.04 - Position sensor signal voltage too low during calibration....86

BCU 303260.16 - Stepper motor (raise) free step above upper threshold during calibration....86

BCU 303260.18 - Stepper motor (raise) free step below lower threshold during calibration....86

BCU 303261.16 - Stepper motor (lower) free step above upper threshold during calibration....86

BCU 303261.18 - Stepper motor (lower) free step below lower threshold during calibration....86

Section 212: Observable Symptoms....208

Group 40: Electrical System....208

Control Unit(s) Not Displayed....208

Diagnostic Mode Cannot Be Entered or Connection Problems with Service ADVISOR (Cab Tractors)....208

Diagnostic Mode Cannot Be Accessed or Connection Problems with Service ADVISOR (Open operator's station)....208

Problems with the Battery....208

Problem with starter motor....208

Horn problem....208

Group 55: Transmission....208

PowrQuad Transmission Problem....208

Group 56: Drive Systems....208

Rear PTO problem....208

Group 60: Steering And Brakes....335

Brake Problem....208

Steering problem....208

Park brake problem....208

Group 70: Hydraulic System....208

Hydraulic hitch problem....208

Section 220: Engine....255

Group 10: Function Test....255

Ref. 220-10-010, Safety....257

Ref. 220-10-020, Engine Preliminary Checks....258

Group 15: Tests and Adjustments....255

Ref. 220-15-010, Dynamometer Test....260

Section 230: Fuel, Air Intake and Cooling Systems....261

Group 15: Tests and Adjustments....261

Ref. 230-15-001, Tests and Adjustments—Summary of References....263

Ref. 230-15-010, General Information....264

Ref. 230-15-020, Explanation of Tests....265

Ref. 230-15-030, Safety....266

Ref. 230-15-040, Special Tools....1199

Ref. 230-15-050, Specifications....269

Ref. 230-15-060, Intake System Test....270

Ref. 230-15-070, Cooling System Leak Test....272

Ref. 230-15-080, Thermostat Opening Pressure Test....274

Ref. 230-15-090, Variable Speed Fan Drive Test....276

Fuel System - Check the Fuel Transfer Pump....277

Hand Throttle Lever and Accelerator Pedal Adjustment....279

Ref. 230-15-120, Adjust Accelerator Pedal....280

Group 20: Descriptions....261

Ref. 230-20-001, Description of Components - Summary of References....283

Ref. 230-20-010, Fuel Supply System Description....284

Ref. 230-20-020, Air Intake System Operation....285

Ref. 230-20-030, Coolant System Description....286

Ref. 230-20-040, Cooling System Radiator Description....288

Ref. 230-20-060, Annular Oil Cooler Description (Transmission Oil)....289

Ref. 230-20-070, Variable Speed Fan Drive Operation ( -XXXXXX)....291

Ref. 230-20-080, Fan Belt Tensioner Operation....293

Section 240: Electrical System....294

Group 10: Sub-System Diagnostics (Cab Tractor)....294

Sub-System Diagnostics (Cab) — Summary of References....300

Special Tools....1199

Starter Motor and Charging Circuit....378

Panel Warning Lights....347

Horn....306

Lights....347

Work lights....399

Radio, Digital Clock, Dome and Console Lights....347

Fan and Air Conditioning System....315

Windshield Wiper and Washer....317

Beacon light - Optional....410

Electronic Hitch Control....411

Front-Wheel Drive....355

Differential Lock....325

Hazard Warning Lights Unit....421

Speed Sensor and Radar....330

Service socket....331

BUS Terminator and Terminating Resistor....332

BCU power supply....333

PTO....415

Brakes....335

Group 10A: Sub-System Diagnostics (Open Operator Station Tractor)....294

Sub-System Diagnostics (Open Operator Station Tractor)—Summary of References....338

Special Tools....1199

Starter Motor and Charging Circuit....378

Panel Warning Lights....347

Horn - Optional....393

Lights....347

Work lights....399

Electronic Hitch Control....411

PTO....415

Front-Wheel Drive....355

Differential lock....419

Hazard Warning Lights Unit....421

Speed Sending Units....362

Power Feed....363

Brake System....423

Service Socket....366

BUS Terminating Resistor....367

Group 15: Component Tests....295

Starter Motor and Charging Circuit....378

Instrument Panel....388

Horn - Optional....393

Lighting Circuits....395

Work lights....399

Dome Light....401

Fan, Air Conditioning and Automatic A/C control....402

Windshield Wiper and Washer System....408

Beacon light - Optional....410

Electronic Hitch Control....411

PTO....415

BCU (FWD)....417

Differential lock....419

Hazard Warning Lights Unit....421

Brake System....423

Group 25C: Functional schematics....295

Functional Schematic and Wiring Harnesses (Cab Tractor) — Summary of References....425

Fuses and Relays....426

Fuse and Relay Box - Tractors with Open Operator Station....430

Group 26: Wiring Harnesses and Connectors....435

Wiring Harnesses and Connectors....435

Wiring Harness - Power Supply (Open Operator's Station)....437

Wiring Harness - Power Supply (Cab Tractors)....440

Engine Wiring Harness (Open Operator's Station)....443

Engine Wiring Harness (Cab Tractors)....453

Harness - Headlights....463