JOHN DEERE TRACTORS 6140D TM605119 PDF

John Deere Agriculture

6100D, 6110D, 6115D, 6125D, 6130D, 6140D Tractors Diagnostic and Tests Technical Manual (November 2011)

DIAGNOSIS AND TESTS SERVICE MANUAL 6100D, 6110D, 6125D, 6130D, 6140D, 6115D

TM605119, November 2013

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Table of contents FOREWORD Section 210 - GENERAL Group 05 - Safety Group 10 - Tractor Specifications and Component Identification Group 15 - Serial Number Locations Group 20 - Diagnostic and Testing Procedures Group 40 - Electrical System Operational Checkout Group 50 - Power Train System Operational Checkout Group 55 - Mechanical Front Wheel Drive System Operational Checkout Group 60 - Brake System Operational Checkout Group 70 - Selective Control Valve System Operational Checkout Group 75 - Rockshaft System Operational Checkout Group 80 - Steering Operational Checkout Section 211 - DIAGNOSTIC TROUBLE CODES Group ECU - Engine Control Unit Diagnostic Trouble Codes Group CCU - Chassis Control Unit Diagnostic Trouble Codes Group PTR - Power Reverser Transmission Diagnostic Trouble Codes Group ICC - Instrument Cluster Controller Diagnostic Trouble Codes Section 212 - OBSERVABLE SYMPTOMS Group 220 - Engine Operation and Tests Group 230 - Fuel and Air Operation and Tests Group 240 - Electrical System Diagnosis and Tests Group 250 - Power Train Operation and Tests Group 255 - Mechanical Front Wheel Drive System Diagnosis and Tests Group 260 - Brake System Diagnosis and Tests Group 270 - Hydraulic System Diagnosis and Test Group 280 - Steering System Diagnosis and Tests Group 290 - Operator Station Diagnosis and Tests Section 220 - ENGINE SYSTEM DIAGNOSIS AND TESTS Group 05 - Engine Diagnostics General Information Group 10 - Test Procedures and Adjustments Group 15 - Cooling System Group 20 - Component Information Section 230 - FUEL/AIR OPERATION AND TESTS Group 05 - General Information Group 10 - Test Procedures and Adjustments Group 15A - Air Intake System Diagnostics Group 15B - Fuel System Diagnosis 4045 Group 20 - Component Information Section 240 - ELECTRICAL SYSTEM DIAGNOSTICS AND TESTS Group 05A - General Information Group 05B - Component Identification Group 10A - Accessing Diagnostic Codes and Addresses Group 10B - Calibration Procedures Group 10C - Diagnostic Trouble Codes Group 10D - Diagnostic Addresses Group 10E - PTR Component Tests Group 15A - Air Conditioning and Heater Diagnostics

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TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Group 15B - Air Filter Restriction Indicator Diagnostics Group 15C - Air Intake Heater Diagnostics Group 15D - Auxiliary Power Diagnostics Group 15E - Back-Up Alarm Diagnostics Group 15F - CAN Bus Diagnostics Group 15G - Charging System Diagnostics Group 15H - Control Unit Power Diagnostics - ECU Group 15I - Control Unit Power Diagnostics - EHC Group 15J - Dome Light Diagnostics Group 15K - Engine Coolant Temperature Diagnostics Group 15L - Engine Fuel Control Electrical Diagnostics Group 15M - Engine Oil Pressure Diagnostics Group 15N - Fuel Level Diagnostics Group 15O - Fuel Shut-Off Diagnostics (Rotary Injection Pump) Group 15P - Horn Diagnostics Group 15Q - Instrument Panel Diagnostics (Deluxe) Group 15R - Instrument Panel Diagnostics (Standard) Group 15S - Brake Light Diagnostics Group 15T - Road Lights Diagnostics Group 15U - Turn Signal Diagnostics Group 15V - Warning Lights Diagnostics Group 15W - Work Lights Diagnostics Group 15X - Power Distribution Diagnostics Group 15Y - Power Train - Reverser Electrical Diagnostics Group 15Z - Power Train - Wet Clutch Electrical Diagnostics Group 15AA - PTO Indicator Diagnostics Group 15AB - Radio Diagnostics Group 15AC - Starting System - Injection Pump Advance Timing Diagnostics Group 15AD - Starting System Diagnostics Group 15AE - Trailer Outlet (7-Pin) Diagnostics Group 15AF - Wiper Diagnostics Group 15AG - Secondary Brake Switch Diagnostics Group 20A - Circuit Code Listing Group 20B - Connector Information Section 250 - POWER TRAIN DIAGNOSIS AND TESTS Group 5 - General Information Group 10 - Test Procedures and Adjustments Group 15A - Dry Traction Clutch Diagnostics Group 15B - Wet Traction Clutch Diagnostics Group 15C - Power Reverser Diagnostics Group 15D - Power Reverser transmission Gearbox Diagnostics Group 15E - Collar Shift Transmission Diagnostics Group 15F - Top Shaft Synchronized (TSS) Transmission Diagnostics Group 20 - Component Information Section 255 - DRIVE SYSTEMS DIAGNOSIS AND TESTS Group 05 - General Information Group 15A - MFWD Diagnostics Group 15B - Power Take Off (PTO) Diagnostics Group 15C - Differential and Final Drive Diagnostics Group 20 - Component Information

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TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Section 260 - BRAKE SYSTEM DIAGNOSIS AND TEST Group 05 - General Information Group 10 - Test Procedures and Adjustments Group 15 - Brake System Diagnostics Group 20 - Component Identification Section 270 - HYDRAULIC SYSTEM DIAGNOSIS AND TESTS Group 05 - General Information Group 10 - Test Procedures and Adjustments Group 15A - Basic Hydraulic System Overall Diagnostics Group 15B - Rockshaft System Diagnostics Group 15C - Rear Mount Selective Control Valve System Diagnostics Group 15D - Mid Mount Selective Control Valve System Diagnostics Group 15E - Hydraulic Trailer Brake Valve System Diagnostics Group 20 - Component Information Section 280 - STEERING SYSTEM DIAGNOSIS AND TESTS Group 05 - General Information Group 10 - Test Procedures and Adjustments Group 15 - Steering System Diagnostics Group 20 - Component Information Section 290 - OPERATOR STATION DIAGNOSIS AND TESTS Group 05 - General Information Group 10 - Test and Adjustment Procedures Group 15A - Air Conditioning and Heating Diagnostics Group 15B - Seat Diagnostics Group 20 - Component Location Section 299 - SERVICE TOOLS Group 05 - Dealer Fabricated Tools Group 10 - Service Tools and Kits

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TM605119-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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TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

GENERAL

(g) by Belgreen

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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TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Section 210 - GENERAL Table of contents Group 05 - Safety ...................................................................................................................... 1 Recognize Safety Information ................................................................................................ 1 Understand Signal Words ....................................................................................................... 1 Follow Safety Instructions ...................................................................................................... 2 Prevent Machine Runaway ..................................................................................................... 2 Keep ROPS Installed Properly ................................................................................................. 3 Work In Ventilated Area ......................................................................................................... 4 Handle Fluids Safely—Avoid Fires .......................................................................................... 4 Prepare for Emergencies ........................................................................................................ 5 Wear Protective Clothing ....................................................................................................... 5 Handle Chemical Products Safely ........................................................................................... 6 Stay Clear of Rotating Drivelines ........................................................................................... 8 Practice Safe Maintenance ................................................................................................... 10 Park Machine Safely ............................................................................................................. 11 Support Machine Properly .................................................................................................... 11 Remove Paint Before Welding or Heating ............................................................................ 12 Avoid Heating Near Pressurized Fluid Lines ......................................................................... 13 Avoid High-Pressure Fluids ................................................................................................... 14 Service Cooling System Safely ............................................................................................. 14 Prevent Acid Burns ............................................................................................................... 16 Prevent Battery Explosions .................................................................................................. 17 Service Tires Safely .............................................................................................................. 17 Dispose of Waste Properly ................................................................................................... 19 Use Proper Lifting Equipment ............................................................................................... 19 Construct Dealer-Made Tools Safely .................................................................................... 20 Work in Clean Area .............................................................................................................. 20 Illuminate Work Area Safely ................................................................................................. 21 Service Machines Safely ....................................................................................................... 21 Use Proper Tools .................................................................................................................. 22 Wait Before Opening High-Pressure Fuel System ................................................................. 23 Handle Starting Fluid Safely ................................................................................................. 23 Protect Against High Pressure Spray .................................................................................... 24 Clean Vehicle of Hazardous Pesticides ................................................................................. 24 Live With Safety ................................................................................................................... 25 Group 10 - Tractor Specifications and Component Identification ................................... 26 General Specifications ......................................................................................................... 26 Overall Dimensions and Weights ......................................................................................... 31 Turning Radius—2WD Axle ................................................................................................... 32 Turning Radius—MFWD Axle ................................................................................................ 33 Ground Speeds—Collar Shift (CST) or Top Shaft Synchronized (TSS) Transmission ............. 34 Ground Speeds—PowrReverser™ Transmission (PRT) ......................................................... 35 Metric Bolt and Screw Torque Values ................................................................................... 37 Unified Inch Bolt and Screw Torque Values .......................................................................... 38 Sealants and Adhesives Cross-Reference Chart ................................................................... 40 How To Dispense/Apply/Assemble Gasket Sealants ............................................................. 40 Face Seal Fittings Assembly and Installation—All Pressure Applications .............................. 42

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TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Metric Face Seal Fitting Torque Chart—Standard Pressure Applications .............................. 43 SAE Face Seal Fitting Torque Chart—Standard Pressure Applications ................................. 45 Metric Face Seal Fitting Torque Chart—High Pressure Applications ..................................... 46 SAE Face Seal Fitting Torque Chart—High Pressure Applications ........................................ 48 Group 15 - Serial Number Locations .................................................................................... 49 Serial Numbers ..................................................................................................................... 49 Product Identification Number ............................................................................................. 49 Engine Serial Number Location ............................................................................................ 49 Fuel Injection Pump Serial Number Location ........................................................................ 50 Transaxle Serial Number Location ....................................................................................... 51 MFWD Serial Number Location (If Equipped) ....................................................................... 51 Cab Serial Number Location ................................................................................................. 52 Group 20 - Diagnostic and Testing Procedures .................................................................. 53 General Troubleshooting Information ................................................................................... 53 Group 40 - Electrical System Operational Checkout .......................................................... 55 Electrical System Operational Check ................................................................................... 55 Group 50 - Power Train System Operational Checkout ..................................................... 62 Power Train System Operational Check ............................................................................... 62 Group 55 - Mechanical Front Wheel Drive System Operational Checkout ..................... 65 Mechanical Front Wheel Drive System Operational Check ................................................... 65 Group 60 - Brake System Operational Checkout ................................................................ 67 Brake System Operational Check ......................................................................................... 67 Group 70 - Selective Control Valve System Operational Checkout ................................. 69 Selective Control Valve System Operational Check ............................................................. 69 Group 75 - Rockshaft System Operational Checkout ........................................................ 70 Rockshaft System Operational Check .................................................................................. 70 Group 80 - Steering Operational Checkout ......................................................................... 71 Steering Operational Check ................................................................................................. 71

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TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Group 05 - Safety Recognize Safety Information

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

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 <- Go to Section TOC

Section 210 page 1

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

manual.

Follow Safety Instructions

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.

Prevent Machine Runaway

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Section 210 page 2

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

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.

Keep ROPS Installed Properly

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.

The 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. <- Go to Section TOC

Section 210 page 3

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

The seat is part of the ROPS safety zone. Replace only with John Deere seat approved for your tractor.

Any alteration of the ROPS must be approved by the manufacturer.

Work In Ventilated Area

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.

Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards. <- Go to Section TOC

Section 210 page 4

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

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.

Prepare for Emergencies

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.

Wear Protective Clothing

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Section 210 page 5

TM605119-DIAGNOSIS AND TESTS SERVICE MANUAL

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