2WD or MFWD models 7610, 7710; 2WD or MFWD - PIN prefix RW - USA models 7810
TM2030 22APR10 (ENGLISH)
For complete service information also see: 7610 7710 and 7810 Tractors Repair
PowerTech 8.1 L Diesel Engines Base Engine
Alternators and Starting Motors
OEM Engine Accessories
MFWD Axles 1100 and 1150 Series.
PowerTech 8.1L Diesel Engines Level 9
Electronic Fuel System With Denso High Pressure Common Rail
PowerTech 8.1 L Diesel Engines Mechanical Fuel Systems
PowerTech 4.5L and 6.8L Diesel Engines Mechanical Fuel Systems
PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic Fuel Systems with Bosch In-Line Pump)
PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)
TM1651
CTM86
CTM77
CTM67
CTM44
CTM255
CTM243
CTM207
CTM104 John Deere Agriculture
CTM134
Table of contents
FOREWORD
Section 210 - GENERAL
Group 05 - Safety
Group 10 - General References
Group 15 - General References
Section 211 - SERVICE CODE DIAGNOSTICS
Group APC - APC Code Diagnostics
Group CCU - CCU Code Diagnostics
Group ECU - ECU Code Diagnostics
Group HCU - HCU Code Diagnostics
Group JdL - JdL Code Diagnostics
Group LHP - LHP Code Diagnostics
Group PCU - PCU Code Diagnostics
Group PEC - PEC Code Diagnostics
Group RCU - rcu Code Diagnostics
Group SFA - SFA Codes Diagnostics
Group UIC - UIC Code Diagnostics
Section 212 - OBSERVABLE SYMPTOMS
Group 05 - Axles
Group 10 - Brakes
Group 13 - Control Units
Group 15 - Electrical
Group 18 - Engine
Group 20 - Hitch
Group 25 - Heating, Ventilation, and Air Conditioning
Group 30 - Operators Station
Group 40 - Power Take-Off
Group 45 - Selective Control Valves
Group 46B - JdLink
Group 50 - Steering
Group 51 - AutoPowr / IVT Transmission
Group 55 - Powershift Transmission
Group 56 - PowerQuad Transmission
Group 57 - AutoQuad II Transmission
Group 70 - Hydraulics
Section 213 - COMPLETE SYSTEM DIAGNOSTICS
Group 40A - North American Lighting
Group 40B - European Lighting
Group 50 - Power Shift Transmission
Group 51 - AutoPowr / IVT Transmission
Group 54 - Autoquad II TransmissionAutoquad II Is A Trademark Of Deere & Company.
Group 55 - PowrQuad Transmission
Group 56 - Drive Systems
Group 56A - Differential Lock
Group 56B - MFWD
Group 56C - Front PTO
Group 56D - Rear PTO
Group 56E - SFA
Group 60A - Brakes
Group 60B - Steering
Group 70 - Hydraulic System
Group 90 - Air Conditioning System Diagnosis
Section 220 - ENGINES
Group 05 - General Information
Group 10 - Operational Checks
Group 15 - Test And References
Group 20 - Engine System Theory of Operation
Group 25 - Schematics and Diagrams
Section 230 - FUEL AND AIR
Group 15 - Tests and References
Group 20 - Fuel/Air/Cooling System Theory of Operation
Section 240 - ELECTRICAL
Group 05 - General Information
Group 15 - Tests and Adjustments
Group 20 - Theory of Operation
Group 25 - Functional Schematics
Group 35 - Sub-System Diagnostic Schematics
Section 245 - CONTROL UNITS
Group 05 - Codes And Addresses
Group APC - APC References
Group CCU - CCU References
Group ECU - ECU References
Group HCU - HCU References
Group LHP - LHP References
Group PCU - PCU References
Group PEC - PEC References
Group RCU - rcu References
Group SFA - SFA References
Group UIC - UIC References
Section 246B - AG MANAGEMENT SOLUTIONS (AMS)—JDLINK
Group 10A - Accessing Diagnostic Addresses and Codes
Group 10B - Diagnostic Trouble Codes
Group 10C - Diagnostic Addresses
Group 15A - JDLINK™ Machine Messenger Diagnostics
Section 250 - POWERSHIFT TRANSMISSION
Group 05 - General References
Group 10 - Operational Checks
Group 15 - Test And Procedure References
Group 20 - POWERSHIFT THEORY OF OPERATION
Group 25 - SCHEMATICS DIAGRAMS AND COMPONENT LOCATIONS
Section 251 - AUTOPOWR / IVTIVT IS A TRADEMARK OF DEERE & COMPANY TRANSMISSION
Group 05 - General References
Group 10 - Operational Checks
Group 15 - Test And Procedure References
Group 20 - AutoPowr / IVT Theory of Operation
Group 25 - Schematics Diagrams And Component Locations
Section 254 - AUTOQUAD II TRANSMISSION
Group 05 - General References
Group 10 - Operational And Preliminary Checks
Group 15 - Test And Adjustments
Group 20 - AutoQuad Theory Of Operation
Group 25 - SCHEMATICS DIAGRAMS AND COMPONENT LOCATIONS
Section 255 - POWRQUAD TRANSMISSION
Group 05 - General References
Group 10 - Operational Checks
Group 15 - Test And Adjustments
Group 20 - PowrQuad Theory Of Operation
Group 25 - SCHEMATICS DIAGRAMS AND COMPONENT LOCATIONS
Section 256 - DRIVE SYSTEMS
Group 10 - OPERATIONAL CHECKS
Group 15 - TEST REFERENCES
Group 20 - Theory Of Operation
Group 25 - SCHEMATICS DIAGRAMS AND COMPONENT LOCATIONS
Section 260 - STEERING AND BRAKES
Group 15 - Tests and Adjustments
Group 20 - STEERING AND BRAKES THEORY OF OPERATION
Group 25 - SCHEMATICS DIAGRAMS AND COMPONENT LOCATIONS
Section 270 - HYDRAULICS
Group 05 - GENERAL REFERENCES
Group 10 - OPERATIONAL AND PRELIMINARY CHECKS
Group 15 - TEST AND PROCEDURE REFERENCES
Group 20 - HYDRAULIC SYSTEM THEORY OF OPERATION
Group 25 - SCHEMATICS DIAGRAMS AND COMPONENT LOCATIONS
Section 290 - OPERATOR STATION
Group 10 - Operational Checks
Group 15 - Air Conditioning System References
Group 20 - Theory of Operation
Group 25 - Schematics, Diagrams and Component Locations
Section 299 - SERVICE TOOLS
Group 05 - Dealer Fabricated Tools
Group 10 - Service Test Kit Listing
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
Reference 210-15-010, Understanding Electrical VS. Electronic Circuits.....................................
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
Prevent Machine Runaway
Machinery Runaway
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed.
NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park. Handle Fluids Safely—Avoid Fires
Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Prevent Battery Explosions
Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Prepare for Emergencies
First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Handle Starting Fluid Safely
Store Safely
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.
To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.
Avoid hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15 30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.
Acid Burns
Service Cooling System Safely
Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
Handle Chemical Products Safely
Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
Avoid High-Pressure Fluids
High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
Park Machine Safely
Remove Key
Before working on machine:
Lower all equipment to the ground. Stop engine and remove key. Disconnect the battery ground strap. Hang a "DO NOT OPERATE" tag in operator station.
Stay Clear of Rotating Drivelines
Rotating Drivelines
Entanglement in rotating driveline can cause serious injury or death.
Keep tractor master shield and driveline shields in place at all times. Make sure rotating shields turn freely.
Wear close fitting clothing. Stop engine and be sure PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.
Support Machine Properly
Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When implements or attachments are used with a tractor, always follow safety precautions listed in the implement operator′s manual.
Wear
Clothing
Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
Operating equipment safely requires full attention of operator. Do not wear radio or music headphones while operating machine.
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
Work In Ventilated Area
Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area
Work in Clean Area
Clean Work Area
Before starting a job:
Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attempt shortcuts.
Remove Paint Before Welding or Heating
Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 76 mm (3 in.) from area to be affected by heating. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do all work in an area that is ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Avoid Heating Near Pressurized Fluid Lines
Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.
Illuminate Work Area Safely
Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
Replace Safety Signs
Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
Use Proper Lifting Equipment
Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
Roll-Over Protective Structure
Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque.
Protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.
Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. Heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Avoid Harmful Asbestos Dust
Asbestos Dust
Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.
Keep bystanders away from the area.
Protect Against High Pressure Spray
Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.
If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
High Pressure Spray
Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.
Use Proper Tools
Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
Dispose of Waste Properly
Recycle Waste
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.
Live With Safety
Safety Systems
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
Construct Dealer-Made Tools Safely
Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.
Do not weld tools unless you have the proper equipment and experience to perform the job.
Clean Vehicle of Hazardous Pesticides
CAUTION:
During application of hazardous pesticides, pesticide residue can build up on the inside or outside of the vehicle. Clean vehicle according to use instructions of hazardous pesticides.
When exposed to hazardous pesticides, clean exterior and interior of vehicle daily to keep free of the accumulation of visible dirt and contamination.
[1] - Sweep or vacuum the floor of cab.
[2] - Clean headliners and inside cowlings of cab.
[3] - Wash entire exterior of vehicle.
[4] - Dispose of any wash water with hazardous concentrations of active or non-active ingredients according to published regulations or directives.
Group 10 - General References
Reference 210-10-001, General Specifications
General Specifications
Machine Specifications
Cooling System:
Type .........69 kPa (0.7 bar) (10 psi) with Centrifugal Pump
Thermostats Two Heavy-Duty
Hydraulic System:
Type Closed-Center, Pressure/Flow Compensated Pump 9-Piston, Variable Displacement Axial
Pump Displacement 40 cm 3 (2.4 in. 3 )
Maximum Pressure.......... 20 000 kPa (200 bar) (2900 psi)
Steering System Hydrostatic
Available Flow at SCVs Ranges from 84 L/min (22 gpm) to 144 L/min (38 gpm)
Hitch Lift Capacity 7610:
2WD or MFWD Category 2 or 3N/2 3504 kg (7725 lb)
... 2WD Category 3N/2......... 4048 kg (8925 lb)
Optional (MFWD) Category 3N/2 4559 kg (10050 lb)
Hitch Lift Capacity 7710 and 7810:
2WD Category 3N/2 4048 kg (8925 lb)
MFWD Category 2 or 3N/2 4048 kg (8925 lb)
... Optional (MFWD) Category 3N/2 .........4559 kg (10050 lb)
Electrical System:
Type .........12 Volt, Negative Ground Alternator 140 amp
Batteries Two 12 Volt in Parallel Group 31
Cold Cranking Amps 1850
.. Capacity (approximate minutes)........... 190
Brakes:
Type .........Hydraulically Operated Wet Disk
Transmission:
Powershift:
Type Planetary Gears, Hydraulically Activated, Wet Disk Clutches, and Brakes
Gear Selections 19 Forward, 7 Reverse
Shifting Electro-Hydraulic, Full Power Shift On-the-Go, and Under Load
AutoPowr / IVT:
Type .........Planetary Gears, Hydro-Mechanical with Hydrostatic Module, Wet Disk Clutches and Brakes
Speed Selections Infinitely Variable
Shifting Automatic Shifting Under Load
PowrQuad:
Type Planetary Gears, Hydraulically Activated, Wet Disk Clutches, and Brakes
Gear Selections 16 or 20 Forward, 16 or 20 Reverse
Shifting Mechanical-Hydraulic, Full Power Shift On-the-Go, and Under Load in Each Range
AutoQuad II:
Type Planetary Gears, Hydraulically Activated, Wet Disk Clutches, and Brakes
Gear Selections 20 Forward, 20 Reverse
Shifting Mechanical, Electro-Hydraulic, Full Power Shift On-the-Go, and Under Load in Each Range
Power
Type Fully Independent
Speed:
540 rpm 2100 Engine rpm
1000 rpm 2100 Engine rpm
Size..........35 mm (1-3/8 in.)
Clutch Multiple Wet-Disk Hydraulically Operated
Weight:
Average Shipping Weight 2WD with Cab, PowrQuad, and 18.4-38 Rear and 11.00-16 Front Tires:
7610 5603 kg (12352 lb)
7710 and 7810 5838 kg (12871 lb)
Average Shipping Weight MFWD with Cab, PowrQuad, and 18.4-38 Rear and 14.9R28 Front Tires:
7610 6004 kg (13237 lb)
7710 and 7810 6415 kg (14142 lb)
Overall Dimensions (with Standard Tires):
Wheelbase:
... 2WD ..........2907 mm (114.4 in.)
MFWD 2800 mm (110.0 in.)
Length (Less Hitch and Drawbar):
2WD 4288 mm (168.8 in.)
MFWD 4395 mm (173.0 in.)
Rear Axle Diameter 92 mm (3.62 in.)
Width (Axle Length) 2438 mm (96.0) in.
Height:
..Top of ComfortGard 2962 mm (116.6 in.)
..Top of Steering Wheel 2929 mm (92.8 in.)
MFWD Turning Radius (with 14.9R28 Front Tires and 1930 mm (76 in.) Tread Setting:
MFWD Disengaged Without Brakes 5090 mm (200.4 in.)
2WD Turning Radius (with 11.00-16 Front Tires): 4602 mm (181.2 in.)
Ground Clearance (Front Axle, Crop Area):
.. 2WD.......... 657 mm (25.8 in.)
MFWD 566 mm (22.3 in.)
Reference 210-10-002, General Reference List
This is a list of additional references that may be of assistance to technicians during machine diagnosis.
SAFETY
Safety Information Section 210, Group 05.
GENERAL
General Specifications (See Reference 210-10-001 ).
Unified Inch Bolt and Cap Screw Torque Values (See Reference 210-10-004 ).
Metric Bolt and Cap Screw Torque Values (See Reference 210-10-005 ). Glossary of Terms (See Reference 210-10-003 ).
HYDRAULIC
Hydraulic Circuit Symbols (See Reference 210-15-013 ).
ELECTRICAL
Functional Schematics Listing (See Reference 240-25-001 )
Wiring Diagram Listing (See Reference 240-35-100 ).
Electronic device that controls AutoQuad II shifts
Warning sign on the rear of the tractor
SPEC Abbreviation
SW Abbreviation
Tach Device to measure rpm
TCU
Abbreviation
Temp Abbreviation
TL Abbreviation
Trans Abbreviation
Transient Voltage Protection TVP
User Interface Control Unit UIC
Voltage (Volts)
Electrical device used to protect a circuit from voltage surge
Computerized system to monitor operator inputs to AutoPowr / IVT
V Abbreviation
With W/ Abbreviation
Warning Lamp WL Abbreviation
Without W/O Abbreviation
Wide-Open Throttle WOT Abbreviation
Reference 210-10-004, Unified Inch Bolt and Cap Screw Torque Values
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Unified Inch Bolt and Cap Screw Torque Values, 1 of 2
a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length.
b "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c "Dry" means plain or zinc plated without any lubrication.
Unified Inch Bolt and Cap Screw Torque Values, 2 of 2
DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.
Reference 210-10-005, Metric Bolt and Cap Screw Torque Values
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Metric Bolt and Cap Screw Torque Values, 1 of 2
a "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b "Dry" means plain or zinc plated without any lubrication.
Metric Bolt and Cap Screw Torque Values, 2 of 2
DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.
Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.
Group 15 - General References
Service Equipment and Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.
Electronic Circuit Load Tester
DFRW51
DFRW51
Electrical Tests
Reference 210-15-001, Wiring Diagram
And Schematic Information
All vehicle wires are shown by a wire number which indicates the circuit number and wire color.
Example:
A wire with a number 226 would be used in an accessories circuit (22X), and it would be a light blue (XX6) wire.
Circuit
Color / Number Table
* Wire numbers may be machine specific.
Block Diagrams
Block diagrams are used for system overviews, and are usually found at the beginning of the theory of operation for a system or sub-system. They do not show pinouts or circuit numbers. They do show control units, and electrical interconnections between control units. See Reference 245-PEC-202 , CAN / CCD Theory of Operation for an example of a block diagram.
System Functional Schematic
System Functional Schematics will show individual circuits, wire numbers, and a schematic symbol for each component (electrical device). Each schematic symbol will have an identification letter (indicating the type of device) and number assigned to it. For example, the Key Switch is designated as S1. The “S” designates a switch, and the “1” designates the first switch to be assigned a number.
Electrical functional schematics (also referred to as “SE” drawings) show all circuits but not wiring harness connectors. These drawings are all found in Section 240, Group 25, and are divided into individual “SE” drawings depending on the system being represented. See Reference 240-25-101A ( 90,000) or 240-25-101B (90,001 ), SE1, SE2, and SE3 Power Supply, Starting and Charging Circuits; Wiper and Seat Control Circuits; Air Quality System for an example of a functional schematic.
System Wiring Diagram
System Wiring Diagrams show each individual wiring harness and all connectors in a system. Wiring Diagrams will show wire number, and a schematic symbol for each component. Each device will have the same number as on the Functional Schematic. Main connectors will have an identification letter/number assigned to it, (X1, X2, etc.).
System Wiring Diagrams also show graphical representation of connector, orientation, and terminal location. Pictorial representations of each connector also represent terminals, and their corresponding circuit for electrical / electronic testing.
Wiring diagrams do not represent any physical characteristics of size or physical location on the vehicle. See Reference 240-35-101A ( 90,000) or 240-35-101B (90,001 ) Power Supply, Starting, and Charging Circuit Wiring Diagram for an example of a system wiring diagram.
Harness Routing / Component Location Drawing
System Component Location Drawings are a pictorial view of all components and all connectors used on the machine by harness location. Each electrical device and connector will have the same identification number as the Functional Schematic
and Wiring Diagram. See Reference 240-25-300 Open Operator Station Harness Routing / Component Location Drawing for an example of a harness routing component location drawing.
Electrical Symbols
Electrical Symbols
Electrical Symbols
Reference 210-15-003, Reading Wiring Schematics And Drawings
Reading a System Functional Schematic
Functional Schematic
LEGEND:
A Main Power Leads
B Component Schematic Symbol
C Component Identification Code D Component Name E Ground Wires F Circuit Name
Section Number
System Functional Schematics are made up of sections which contain Subsystem Functional Schematics, arranged by a logical sequence of related functions. Each Subsystem is a major group of components like the wiper circuit or seat control circuit. Sections are named to reflect that group of components. System Functional Schematics are formatted with power supply wires shown across the top of the drawing and ground wires across the bottom. The diagram contains no harness or connector
information. Each electrical component is shown by a schematic symbol, the component name, and a component identification code. The same names and identification letter codes are used on all machine drawings the System Functional Schematic, System Wiring and Harness Diagram, and the System Component Location Drawing. Components and connectors can easily be cross-referenced from one drawing to another. See Reference 210-15-012 for Component Identification Codes.
Reading a Wiring Diagram
Reading a Wiring Diagram
LEGEND:
A Functional Schematic Symbol
B Connector Representation and Terminal Location
C Pin-Out / Corresponding Circuit
D Connector Identification Number
E Circuit Number
F Wire Harnesses
Wiring diagrams consist of individual or combinations of wiring harnesses (F). Larger harnesses may be divided into smaller partial drawings, as necessary, and involve multiple pages (foldout or non-foldout). The drawings do not represent any proportions of the actual harness but present circuit wire routing through connectors and interconnections. Wiring Diagrams also contain terminal identification, component identification and graphical representation of connectors, and terminals within connectors to aid in electrical / electronic testing.
Each component that is connected to a harness is shown by a schematic symbol (A). Each connector is represented by graphically displaying the connector (B), and it′s “X” connector number (D) as well as it′s orientation. Each connector will have pins / terminals clearly labeled (C), according to their corresponding circuit connections (E). The same names and identification numbers are used on all machine schematic and harness drawings. Components and connectors can easily be cross-referenced from one drawing to another.
Reference 210-15-004, Visually Inspect Electrical System
Visually inspect the electrical system prior to starting the tractor, after receiving customer complaint:
1. Look for bare wires that could ground a component or short across to another component.
2. Look for missing or worn conduit. This could indicate a wire problem.
3. Look for loose or broken connectors and wires.
4. Inspect batteries for:
Corroded terminals
Loose terminals or battery posts
Dirty condition
Damp condition
Cracked case
Proper electrolyte level.
5. Check alternator belt tension.
6. After machine has been shut down for five minutes inspect for overheated parts. Parts often will smell of burned insulation. Place hand on the alternator. heat in these parts when the unit has not been operated for some time is a sure clue to charging circuit problems.
7. If visual inspection does not indicate possible malfunction, but inspection does indicate that the machine can be run, turn the Key Switch to the IGN position. operate the accessory circuits, indicator lights, gauge lights, etc. How does each of these components work? Look for sparks or smoke which might indicate shorts.
8. Start machine. Check all gauges for good operation and check to see if system is charging or discharging.
→NOTE:
Many electrical failures cannot be detected even if the machine is started. Therefore a systematic and complete inspection of the electrical system is necessary.
DOWNLOAD DIAGNOSIS AND TESTS MANUAL
Reference 210-15-005, Seven Step Electrical Test Procedure
Seven Step Electrical Test Procedure
Seven Step Procedure
1 Switch "ON"
Check battery side of circuit breaker (A) for battery voltage.
2 Switch "OFF" Check load side of circuit breaker (B) for battery voltage.
3 Switch "OFF"
Check load side of circuit breaker (B) for continuity to ground. (Clip of tester at battery voltage (A).
4 Switch "OFF" Check load side of circuit breaker (B) for battery voltage.
5 Disconnect lead to component at (C). Check lead at "E" for battery voltage
Light No Light
Voltage. Normal - GO TO 2
- Repair high resistance
- Repair open circuit from battery
Voltage. Normal - GO TO 4
voltage - Replace circuit breaker
voltage - GO TO 3
to ground - Repair grounded circuit at or before switch
continuity to ground, replace circuit breaker
voltage. Normal - GO TO 6
voltage - Replace circuit breaker
voltage - GO TO 5
voltage - Repair component.
- Repair grounded circuit at or after switch
To verify a grounded circuit, place the tester clip at battery voltage. A light at "E" indicates the circuit is grounded. 6 Check lead to component at "C" for battery voltage
voltage. Normal - GO TO 7
voltage - Repair high resistance in circuit between circuit breaker and component
- Repair high resistance or open circuit breaker and component 7 Check ground lead of component at "D" for battery voltage
voltage - Good continuity to ground. Repair component.
- Poor continuity to ground. Repair high resistance circuit
voltage - Open ground circuit
Probe Light
The above example shows how to connect a probe light to check an electrical circuit for voltage. When checking a circuit for battery voltage, connect the probe light clip to ground as shown.
Probe Light
When checking a circuit for continuity to ground, connect the probe light to a known source of battery voltage as shown.
Controlling switches MUST BE “ON” and the circuit connected to the component to locate high resistance (0.5 to 5.0 Ohms) in the load circuit or ground circuit of a component.
The seven-step procedure is for use on ELECTRICAL circuits only. Review the description for electrical and electronic circuits in this group. The procedure can be used to locate opens, grounds, high resistance or faulty components with the use of the electrical wiring schematics. The simple circuit above can be used as a reference for each step, but you must refer to the wiring schematics for additional components that may be connected in parallel.
You may want to start at step “6” as your first step for diagnosing any malfunctioning electrical circuit where the component is easily accessible. If battery voltage is not present at step “6”, it will be necessary to go to step “1” to isolate the malfunction.
IMPORTANT:
This sequence CANNOT be used in electronic circuits.
→NOTE:
After any repair, always return to Operational Check, to be certain another circuit has not been affected during the repair.
DOWNLOAD DIAGNOSIS AND TESTS MANUAL
Reference 210-15-007, Circuit Types
Diagnosis in this section will be broken down into individual electrical circuits or subsystems (groups of individual circuits such as the overall lighting circuit) and into electronic circuits.
To understand what we are calling electrical circuits and electronic circuits, see the following circuit definitions.
Electrical Circuit
LEGEND:
A Source Voltage
B Source Voltage at Load
Electrical Circuit
IMPORTANT:
Complete electrical schematics are located in Section 240.
This circuit provides source voltage (A) to the load (B) and does not pass through electronic components. An electrical circuit is considered to end when the source voltage enters an electronic module or electronically controlled device. Heater-type, wire wound resistors are not considered electronic components, for example, blower motor speed resistor or ceramic-covered wire resistors are not electronic components.
Electronic Circuit
LEGEND:
A Source Voltage
B End of Electrical Circuit, Beginning of Electronic Circuit
C Electronic Module
D Load
Electronic Circuit
This circuit begins where the source voltage (A) of an electrical circuit enters an electronic module (B) or electronic control device (C). Usually source voltage has been changed with electronic components by decreasing the voltage and current flow to the load (D). Voltage can also be increased.
Secondary Electronic Circuit
LEGEND:
A Source Voltage
B End of Electrical Circuit, Beginning of Electronic Circuit
C Electronic Module
D Source of Voltage at Load
E Solenoid No. 1
F Solenoid No. 2
G Indicator Lamp ON, Solenoid No. 1 Disengaged
H Indicator Lamp ON, Solenoid No. 2 Engaged
Secondary Electronic Circuit
Even though electronic circuits use small amounts of current to operate electronic components, a secondary circuit of source voltage (D) to electrical components can pass through an electronically controlled relay inside a module. This secondary circuit is still considered to be part of the electronic circuit.
DOWNLOAD DIAGNOSIS AND TESTS MANUAL
Reference 210-15-008, Circuit Malfunctions
There are four major electrical circuit malfunctions:
1. High Resistance Circuit
2. Open Circuit 3. Grounded Circuit
4. Shorted Circuit
Each is explained separately below:
High Resistance Circuit
Battery
Fuse
Switch
Unwanted Resistance
Lamp (Load)
Ground
High Resistance Circuit
A high resistance circuit is a circuit having unwanted resistance (D) that causes a voltage drop and reduces current flow.
Open Circuit LEGEND:
Battery
Fuse
Switch
Open Circuit
Lamp (Load)
Ground
Open Circuit
An open circuit is a circuit having a break or separation (D) that prevents current from flowing in the circuit.
