JOHN DEERE 7200R TRACTOR DIAGNOSIS MANUAL TM110019 PDF

John Deere Agriculture

7200R, 7215R, 7230R, 7260R and 7280R Tractors (Diagnostics) (Includes electrical wiring diagrams) (Repair manual sold separate)

DIAGNOSIS AND TESTS SERVICE MANUAL Covered models: 7200R, 7215R, 7230R, 7260R, 7280R (SN 000101-080000)

TM110019, September 2013

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

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Table of contents FOREWORD Section 210 - GENERAL Group 05 - Safety Group 10 - General References Section 211 - DIAGNOSTIC TROUBLE CODES Group AIC - Armrest Interface Control Unit (AIC) Group ASU - ActiveSeat™ Control Unit (ASU) Group ATC - Automatic Temperature Control Unit (ATC) Group CCU - Chassis Control Unit (CCU) Group CLC - Cab Load Center (CLC) Group CSC - Cab Suspension Control Unit (CSC) Group CSM - Cab Switch Module (CSM) Group ECU - Engine Control Unit (ECU) Group EIC - Engine Interface Control Unit (EIC) Group FCC - Front Console Control Unit (FCC) Group HCC - Hitch Control Unit (HCC) Group HV1 - Hitch Valve (HV1) Group JDL - JDLink™ (JDL) Group OIC - Operator Interface Control Unit (OIC) Group PDU - Primary Display Unit (PDU) Group PTF - Front PTO Control Unit (PTF) Group PTI - AutoPowr™ / IVT™ Transmission Control Unit (PTI) Group PTQ - PowrQuad™, AutoQuad™, and CommandQuad™ Transmission Control Unit (PTQ) Group RLC - Roof Lighting Control Unit (RLC) Group RPT - Rear PTO Control Unit (RPT) Group SCC - SCV Control Unit (SCC) Group SCO - Secondary Hydraulic Control Unit (SCO) Group SFA - Suspended Front Axle Control Unit (SFA) Group SMV - Sequence Control Unit (SMV) Group SV1 - SCV I Control Unit (SV1) Group SV2 - SCV II Control Unit (SV2) Group SV3 - SCV III Control Unit (SV3) Group SV4 - SCV IV Control Unit (SV4) Group SV5 - SCV V Control Unit (SV5) Group SV6 - SCV VI Control Unit (SV6) Group SVJ - Front Hitch SCV Control Unit (SVJ) Group SVK - Mid-Stack SCV 1 Control Unit (SVK) Group SVL - Mid-Stack SCV 2 Control Unit (SVL) Group SVM - Mid-Stack SCV 3 Control Unit (SVM) Group TEC/TEI - Tractor Equipment Control Unit (TEC/TEI) Group TII - AutoPowr™ / IVT™ Transmission Shift Control Unit (TII) Group TIQ - PowrQuad™, AutoQuad™, CommandQuad™ Transmission Shift Control Unit (TIQ) Group VLC - Vehicle Load Center Control Unit (VLC) Group VTI - Virtual Terminal Implement Control Unit (VTI) Group XMA - ActiveCommand Steering (ACS™) A-Box Main Control Unit (XMA) Group XMB - ActiveCommand Steering (ACS™) B-Box Main Control Unit (XMB) Group XMC - AutoTrac™ Main Control Unit (XMC) Group XSA - ActiveCommand Steering (ACS™) A-Box Supervisor Control Unit (XSA) Group XSB - ActiveCommand Steering (ACS™) B-Box Supervisor Control Unit (XSB) Group XSC - AutoTrac™ Supervisor Control Unit (XSC) Section 213 - SYSTEM DIAGNOSIS Group 40 - Electrical <- Go to Global Table of contents

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

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Group 45 - Control Units Group 50 - Transmission Group 55 - Drive Systems Group 60 - Brakes Group 65 - Steering Group 70 - Hydraulics Group 75 - Suspension Group 90 - Operator Station Section 220 - ENGINES Group 20 - Theory of Operation Group 50 - Test and Adjustments Section 230 - FUEL AND AIR Group 20 - Theory of Operation Section 240 - ELECTRICAL Group 05 - General Information Group 25 - Electrical System Schematics Group 50AA - Starting and Charging Group 50BA - Road Lighting Group 50BB - Field Lighting Group 50BC - Interior Lighting Group 50CA - ActiveSeat™ Group 50CB - Standard and Heated Seat Group 50DA - Audible Alerts Group 50DB - Windshield Wipers Group 50DC - Operator Displays Group 50DD - Cab Switch Module Group 50DE - Remote Mirrors Group 50DF - Radio Group 50EA - Accessory Power Connectors Group 50FA - PowrQuad-Plus™/AutoQuad-Plus™/CommandQuad™ Transmission Group 50FB - AutoPowr™ / IVT™ Transmission Group 50GA - Differential Lock Group 50GB - MFWD Group 50GC - PTO Group 50GD - Front PTO Group 50HA - Engines Group 50IA - GreenStar™ Group 50IB - JDLink™ Group 50JA - Rear SCV′s and Rear Hitch Group 50JB - Front Hitch and Midstack SCV′s Group 50KA - Suspended Front Axle Group 50KB - Cab Suspension Group 50LA - Air Trailer Brakes Group 50LB - Secondary Brakes Group 50LC - Front Brakes Group 50MA - HVAC (Manual) Group 50MB - HVAC (Automatic) Group 50NA - Steering Group 50OA - Controller Area Network (CAN) Section 245 - CONTROL UNITS Group 05 - General References Group 10 - Calibration Procedures Group 20 - Control Unit Theory of Operation

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TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

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Group 25 - Control Unit Schematics Group 50A - Armrest Control Unit Tests Group 50B - Automatic Temperature Control Unit Tests Group 50C - Cab Control Unit Tests Group 50D - Cab Switch Module Control Unit Tests Group 50E - CommandCenter™ Control Unit Tests Group 50F - Corner Post Display Control Unit Tests Group 50G - Engine Control Unit Tests Group 50H - Front Chassis Control Unit Tests Group 50I - Power Assisted PTO Control Unit Tests Group 50J - Rear Chassis Control Unit Tests Group 50K - Roof Control Unit Tests Group 50L - Steering Control Units Tests Group AIC - Armrest Interface Control Unit (AIC) Group ASU - ActiveSeat™ Control Unit (ASU) Group ATC - Automatic Temperature Control Unit (ATC) Group CCU - Chassis Control Unit (CCU) Group CLC - Cab Load Center (CLC) Group CSC - Cab Suspension Control Unit (CSC) Group CSM - Cab Switch Module (CSM) Group ECU - Engine Control Unit (ECU) Group EIC - Engine Interface Control Unit (EIC) Group FCC - Front Console Control Unit (FCC) Group HCC - Hitch Control Unit (HCC) Group HV1 - Hitch Valve (HV1) Group JDL - JDLink™ (JDL) Group OIC - Operator Interface Control Unit (OIC) Group PAP - Power Assisted PTO Control Unit (PAP) Group PDU - Primary Display Unit (PDU) Group PTF - Front PTO Control Unit (PTF) Group PTI - AutoPowr™ / IVT™ Transmission Control Unit (PTI) Group PTQ - PowrQuad™, AutoQuad™, and CommandQuad™ Transmission Control Unit (PTQ) Group RLC - Roof Lighting Control Unit (RLC) Group RPT - Rear PTO Control Unit (RPT) Group SCC - SCV Control Unit (SCC) Group SCO - Secondary Hydraulic Control Unit (SCO) Group SFA - Suspended Front Axle Control Unit (SFA) Group SMV - Sequence Control Unit (SMV) Group SV1 - SCV Control Unit (SV1) Group SV2 - SCV Control Unit (SV2) Group SV3 - SCV Control Unit (SV3) Group SV4 - SCV Control Unit (SV4) Group SV5 - SCV Control Unit (SV5) Group SV6 - SCV Control Unit (SV6) Group SVJ - Front Hitch SCV Control Unit (SVJ) Group SVK - Mid-Stack SCV 1 Control Unit (SVK) Group SVL - Mid-Stack SCV 2 Control Unit (SVL) Group SVM - Mid-Stack SCV 3 Control Unit (SVM) Group TEC/TEI - Tractor Equipment Control Unit (TEC/TEI) Group TII - AutoPowr™ / IVT™ Transmission Shift Control Unit (TII) Group TIQ - PowrQuad™, AutoQuad™, and CommandQuad™ Transmission Shift Control Unit (TIQ) Group VLC - Vehicle Load Center Control Unit (VLC) Group VTI - Virtual Terminal Implement Control Unit (VTI)

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TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

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Group XMA - ActiveCommand Steering (ACS™) A-Box Main Control Unit (XMA) Group XMB - ActiveCommand Steering (ACS™) B-Box Main Control Unit (XMB) Group XMC - AutoTrac™ Main Control Unit (XMC) Group XSA - ActiveCommand Steering (ACS™) A-Box Supervisor Control Unit (XSA) Group XSB - ActiveCommand Steering (ACS™) B-Box Supervisor Control Unit (XSB) Group XSC - AutoTrac™ Supervisor Control Unit (XSC) Section 249 - ELECTRICAL CONNECTORS, WIRING HARNESSES, AND COMPONENTS Group 40A - Assemblies Group 40B - Sensors Group 40E - Lights, Various Devices, and Equipment Group 40F - Fuses (Protection Devices) Group 40G - Power Supply and Generators Group 40H - Monitoring Devices, Reporting Devices, and Signaling Devices Group 40K - Relays Group 40M - Motors Group 40R - Resistors Group 40S - Switches Group 40V - Diodes Group 40W - Wiring Harnesses Group 40X - Interconnects and Ground Points Group 40Y - Electrically Actuated Mechanical Devices Section 250 - TRANSMISSIONS Group 10A - AutoPowr™ / IVT™ Preliminary and Operational Checks Group 20A - AutoPowr™ / IVT™ Theory of Operation Group 25A - AutoPowr™ / IVT™ Schematics and Diagrams Group 30A - AutoPowr™ / IVT™ Component Locations Group 50A - AutoPowr™ / IVT™ Tests and Adjustments Group 10B - PowrQuad Plus™ (PQ), AutoQuad Plus™ (AQ), and CommandQuad™ (CQ) PreliminaryOperational Checks Group 20B - PowrQuad Plus™ (PQ), AutoQuad Plus™ (AQ), and CommandQuad™ (CQ) Theory of Operation Group 25B - PowrQuad Plus™ (PQ), AutoQuad Plus™ (AQ), and CommandQuad™ (CQ) Schematics and Diagrams Group 30B - PowrQuad Plus™ (PQ), AutoQuad Plus™ (AQ), and CommandQuad™ (CQ) Component Locations Group 50B - PowrQuad Plus™ (PQ), AutoQuad Plus™ (AQ), and CommandQuad™ (CQ) Tests and Adjustments Section 255 - DRIVE SYSTEMS Group 05 - General References Group 10A - Axles and Differential Lock Preliminary and Operational Checks Group 20A - Axles and Differential Lock Theory of Operation Group 25A - Axles and Differential Lock Schematics and Diagrams Group 30A - Axles and Differential Lock Component Locations Group 50A - Axles and Differential Lock Test and Adjustments Group 10B - MFWD Preliminary and Operational Checks Group 20B - MFWD Theory of Operation Group 25B - MFWD Schematics and Diagrams Group 30B - MFWD Component Locations Group 50B - MFWD Tests and Adjustments Group 10C - PTO Preliminary and Operational Checks Group 20C - PTO Theory of Operation Group 25C - PTO Schematics and Diagrams Group 30C - PTO Component Locations

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TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

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Group 50C - PTO Tests and Adjustments Section 260 - BRAKES Group 05 - General References Group 10 - Preliminary and Operational Checks Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Group 30 - Components Group 50 - Tests and Adjustments Section 265 - STEERING Group 05 - General References Group 10 - Preliminary and Operational Checks Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Group 30 - Components Group 50 - Tests and Adjustments Section 270 - HYDRAULICS Group 10 - Preliminary and Operational Checks Group 20 - Theory of Operation Group 25 - Schematics and Diagrams Group 30 - Components Group 50 - Tests and Adjustments Section 275 - SUSPENSION SYSTEMS Group 05 - General References Group 10A - Suspended Front Axle Preliminary and Operational Checks Group 20A - Suspended Front Axle Theory of Operation Group 25A - Suspended Front Axle Schematics and Diagrams Group 30A - Suspended Front Axle Component Locations Group 50A - Suspended Front Axle Tests and Adjustments Group 10B - Cab Suspension Preliminary and Operational Checks Group 20B - Cab Suspension Theory of Operation Group 25B - Cab Suspension Schematics and Diagrams Group 30B - Cab Suspension Component Locations Group 50B - Cab Suspension Tests and Adjustments Section 290 - OPERATOR STATION Group 10A - HVAC Preliminary and Operational Checks Group 20A - HVAC Theory of Operation Group 30A - HVAC Component Locations Group 50A - HVAC Tests and Adjustments Group 10B - Seat Preliminary and Operational Checks Group 20B - Seat Theory of Operation Group 25B - Seat Schematics and Diagrams Group 30B - Seat Component Locations Group 50B - Seat Tests and Adjustments Section 299 - SERVICE TOOLS AND INSTALLING TEST EQUIPMENT Group 05 - Dealer Fabricated Tools Group 10 - Service Tools and Kits Group 50A - AutoPowr™ / IVT™ Transmission—Install Test Equipment Group 50B - PowrQuad Plus™ (PQ), AutoQuad Plus™ (AQ), and CommandQuad™ (CQ) Install Test Equipment Group 55 - Drive Systems—Install Test Equipment Group 60 - Brakes—Install Test Equipment Group 65 - Steering—Install Test Equipment Group 70 - Hydraulics—Install Test Equipment

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TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

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Group 75 - Suspension—Install Test Equipment Group 90A - Air Conditioning—Install Test Equipment Group 90B - Operator Seat—Install Test Equipment

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TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.

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TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

GENERAL

(g) by Belgreen v2.0

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.

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Section 210 page 1

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

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Section 210 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Wear Protective Clothing ...................................................................................................................... 3 Service Machines Safely ....................................................................................................................... 3 Stay Clear of Rotating Drivelines .......................................................................................................... 4 Handle Fluids Safely—Avoid Fires ......................................................................................................... 4 Prevent Battery Explosions ................................................................................................................... 4 Prepare for Emergencies ...................................................................................................................... 5 Remove Paint Before Welding or Heating ............................................................................................. 5 Avoid Heating Near Pressurized Fluid Lines .......................................................................................... 7 Handle Starting Fluid Safely ................................................................................................................. 7 Avoid Hot Exhaust ................................................................................................................................ 8 Clean Exhaust Filter Safely ................................................................................................................... 9 Prevent Acid Burns ............................................................................................................................. 11 Handle Agricultural Chemicals Safely ................................................................................................. 12 Clean Vehicle of Hazardous Pesticides ............................................................................................... 13 Handling Batteries Safely ................................................................................................................... 14 Avoid Harmful Asbestos Dust ............................................................................................................. 15 Dispose of Waste Properly .................................................................................................................. 15 Avoid High-Pressure Fluids ................................................................................................................. 16 Wait Before Opening High-Pressure Fuel System ............................................................................... 17 Service Accumulator Systems Safely .................................................................................................. 17 Protect Against High Pressure Spray .................................................................................................. 17 Service Cooling System Safely ........................................................................................................... 18 Prevent Machine Runaway ................................................................................................................. 18 Keep ROPS Installed Properly ............................................................................................................. 19 Avoid Backover Accidents .................................................................................................................. 19 Park Machine Safely ........................................................................................................................... 20 Support Machine Properly .................................................................................................................. 20 Work in Clean Area ............................................................................................................................. 21 Work In Ventilated Area ...................................................................................................................... 21 Illuminate Work Area Safely ............................................................................................................... 22 Use Proper Lifting Equipment ............................................................................................................. 22 Service Tires Safely ............................................................................................................................ 24 Instructional Seat ............................................................................................................................... 24 Service Front-Wheel Drive Tractor Safely ........................................................................................... 25 Use Steps and Handholds Correctly ................................................................................................... 25 Transport Tractor Safely ..................................................................................................................... 26 Practice Safe Maintenance ................................................................................................................. 27 Use Proper Tools ................................................................................................................................. 27 Construct Dealer-Made Tools Safely ................................................................................................... 28 Replace Safety Signs .......................................................................................................................... 28 Install All Guards ................................................................................................................................ 29 Live With Safety ................................................................................................................................. 29 Group 10 - General References ............................................................................................................ 31 General Reference List ....................................................................................................................... 31 Glossary of Terms ............................................................................................................................... 32 Trademarks ........................................................................................................................................ 35

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TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

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JIC Hydraulic Symbols ......................................................................................................................... 37 Wiring Diagram and Schematic Information ....................................................................................... 40 Electrical Schematic Symbols ............................................................................................................. 42 Reading Wiring Schematics and Diagrams ......................................................................................... 44 Visually Inspect Electrical System ...................................................................................................... 48 Seven Step Electrical Test Procedure ................................................................................................. 49 Circuit Types ....................................................................................................................................... 52 Circuit Malfunctions ............................................................................................................................ 54 Relay Circuit Types ............................................................................................................................. 56 Using a Digital Multimeter .................................................................................................................. 69 Troubleshooting Unresolved Electrical/Electronic Problems ............................................................... 71 Servicing Electronic Control Units ....................................................................................................... 71 Welding Near Electronic Control Units ................................................................................................ 73 Keep Electronic Control Unit Connectors Clean .................................................................................. 73

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TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Group 05 - Safety Recognize Safety Information

Safety-alert symbol 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.

Understand Signal Words

Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this manual.

Follow Safety Instructions

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Section 210 page 1

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Safety Messages Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.

Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

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Section 210 page 2

TM110019-DIAGNOSIS AND TESTS SERVICE MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.