JOHN DEERE 7510 TRACTOR DIAGNOSIS & TESTS SERVICE MANUAL TM1654 - PDF

John Deere Agriculture

7210, 7410 and 7510 Tractors, Operation & Tests

DIAGNOSIS AND TESTS SERVICE MANUAL Covered models: 7210, 7410, 7510 (SN: 000001-050000, 050001-, 010001-050000)

tm1654, March 2003

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen v2.0

Table of contents FOREWORD Section 205 - SAFETY INFORMATION Group 05 - Safety Section 210 - GENERAL INFORMATION Group 05 - Operational Checkout Group 10 - General Reference Information Group 15 - Test Equipment Calibration Section 211 - DIAGNOSTIC TROUBLE CODES Group CCU - CCU Code Diagnostics Group HCU - HCU Code Diagnostics Group LHP - LHP Code Diagnostics Group RCU - RCU Code Diagnostics Section 212 - OBSERVABLE SYMPTOMS Group 10 - Brakes Group 30 - Operator Station Group 70 - Hydraulics Section 220 - ENGINE Group 05 - General Information Section 230 - FUEL, AIR INTAKE AND ENGINE COOLING SYSTEMS Group 25 - Fuel/Air/Cooling System Theory of Operation Section 240 - ELECTRICAL SYSTEM Group 04 - Diagnostic Codes and Addresses Group 05 - Electrical System Information Group 10 - System Diagrams Group 10A - System Diagram References Group 10B - System Functional Schematic (CAB) Group 10C - System Functional Schematic (OOS) Group 10D - Wiring Harnesses Group 15 - Sub-System Diagnostics Group 15A - Starting, Power and Charging Circuit Diagnostics Group 15B - Wiper and Seat Circuit Diagnosis Group 15C - Ground Fault Circuit Interrupter Diagnosis Group 15D - Air Quality System (AQS) Diagnosis Group 15E - Radio, Horn, Dome Lamp and Multi-Function Control Circuit Group 15F - Lighting Circuit Diagnosis Group 15G - Accessory Connector and Lighter Circuit Diagnosis Group 15H - Hitch Control Diagnosis Group 15J - CCU Diagnosis Group 15K - Differential Lock Circuit Group 15L - MFWD Circuit Group 15M - Rear PTO Circuit Group 15N - Wheel and Radar Speed Circuit Group 15P - Engine Speed Sensor Circuit Group 15Q - Fuel Level Sender Circuit Group 15R - System Voltage Circuit Group 15S - Engine Coolant Temperature Sensor Group 15T - Hydraulic Oil Temperature Circuit Group 15U - Engine Oil Pressure Sensor Circuit Group 15V - Transmission Oil Pressure Circuit Group 15W - Air Filter Restriction Sensor Circuit Group 15X - Transmission Oil Filter Restriction Sensor Circuit Group 15Y - Hydraulic Oil Filter Restriction Sensor Circuit <- Go to Global Table of contents

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen v2.0

Group 15Z - Sensor Excitation Power Circuit Group 15AA - Engine Hours and Engine Starts Group 15AB - Fuel Timing Advance Circuit Group 15AC - Display Modules Group 15AD - PowrQuad Control Circuit Group 15AE - ROW-TRAK Control Circuit Group 15AF - CCD Communication Group 20 - Calibration Group 20A - CCU Calibration Group 20B - Performance Monitor Calibration and Diagnostic Tool Group 20C - Battery References Section 250 - TRANSMISSIONS Group 05 - Operational Checks Group 10 - Transmission And Reverser Diagnosis Group 10A - PowrQuad PowrQuad is a trademark of Deere & Company. Diagnosis Group 10B - Reverser Control Unit (RCU) Group 10C - SyncroPlus SyncroPlus is a trademark of Deere & Company. Diagnosis Group 25 - Theory Of Operation Group 25A - PowrQuad PowrQuad is a trademark of Deere & Company. Theory of Operation Group 25B - Reverser Control Unit (RCU) Theory of Operation Group 25C - SyncroPlus SyncroPlus is a trademark of Deere & Company. Theory of Operation Section 256 - DRIVE SYSTEMS Group 05 - Operational Checks Group 10 - Drive System Diagnosis Group 20 - Adjustments Group 25 - Theory of Operation Section 260 - STEERING AND BRAKES Group 25 - Steering and Brakes Theory of Operation Section 270 - HYDRAULIC SYSTEM Group 05 - Operational Checks Group 10 - Hydraulic System Diagnosis Group 10A - Tools and Safety Group 10B - Diagnostic Guidelines Group 10C - Preliminary Checks Group 10D - Hydraulic Diagnosis Group 10E - Additional Troubleshooting Information Group 10F - Hitch Electrical Diagnosis Group 10G - HCU Additional Tests Group 10H - ROW-TRAKROW-TRAK is a trademark of Deere & Company Tests Group 20 - Calibrations and Adjustments Group 20A - Hitch Calibrations and Adjustments Group 20B - ROW-TRAK™ Calibrations and Adjustments Group 25 - Theory of Operation Group 25A - Hydraulic System Diagrams Group 25B - Hydraulic Control Circuit Group 25C - Steering Circuit Group 25D - Selective Control Valves (SCV) Group 25E - Hitch Group 25F - Electro-Hydraulic Depth Control Group 25G - Headland Management Systems (HMS) Group 25H - Hitch Dampening Section 290 - OPERATOR STATION Group 05 - Operational Checks

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tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen v2.0

Group 10 - Air Conditioning System Diagnosis Group 25 - Air Conditioning Theory of Operation Section 299 - DEALER FABRICATED TOOLS Group 05 - Dealer Fabricated Tools

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tm1654-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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tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

SAFETY INFORMATION

(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 205 page 1

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen v2.0

Section 205 - SAFETY INFORMATION Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Prevent Machine Runaway ................................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 2 Handle Starting Fluid Safely ................................................................................................................. 3 Prevent Acid Burns ............................................................................................................................... 4 Service Cooling System Safely ............................................................................................................. 4 Handle Chemical Products Safely ......................................................................................................... 5 Avoid High-Pressure Fluids ................................................................................................................... 5 Park Machine Safely ............................................................................................................................. 6 Support Machine Properly .................................................................................................................... 6 Wear Protective Clothing ...................................................................................................................... 8 Service Machines Safely ....................................................................................................................... 8 Work In Ventilated Area ........................................................................................................................ 9 Work in Clean Area ............................................................................................................................... 9 Remove Paint Before Welding or Heating ............................................................................................. 9 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 11 Illuminate Work Area Safely ............................................................................................................... 11 Replace Safety Signs .......................................................................................................................... 11 Use Proper Lifting Equipment ............................................................................................................. 12 Keep ROPS Installed Properly ............................................................................................................. 12 Service Tires Safely ............................................................................................................................ 14 Avoid Harmful Asbestos Dust ............................................................................................................. 14 Protect Against High Pressure Spray .................................................................................................. 15 Practice Safe Maintenance ................................................................................................................. 16 Use Proper Tools ................................................................................................................................. 16 Dispose of Waste Properly .................................................................................................................. 17 Live With Safety ................................................................................................................................. 17

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tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 205 - SAFETY INFORMATION

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.

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

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Section 205 page 1

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 205 - SAFETY INFORMATION

Group 05: Safety

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 volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prepare for Emergencies

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tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 205 - SAFETY INFORMATION

Group 05: Safety

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.

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Section 205 page 3

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 205 - SAFETY INFORMATION

Group 05: Safety

Prevent Acid Burns

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 the 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.

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Section 205 page 4

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 205 - SAFETY INFORMATION

Group 05: Safety

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

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tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 205 - SAFETY INFORMATION

Group 05: Safety

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 the Key Before working on the machine: Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

Support Machine Properly

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Section 205 page 6

tm1654-DIAGNOSIS AND TESTS SERVICE MANUAL

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