JOHN DEERE 6135E TRACTORS TM608519 SERVICE MANUAL

tm608519 - 6105E, 6120E and 6135EFinal Tier IV Tractors, October 2015 Diagnostic Technical Manual(S.N. 000001 —) Technical Manual Table of Contents Foreword Section 210: General Information Group 05A: Safety Work In Ventilated Area Recognize Safety Information Avoid Backover Accidents Prevent Machine Runaway Avoid Contact with Agricultural Chemicals Clean Vehicle of Hazardous Pesticides Use a Safety Chain Work in Clean Area Decommissioning — Proper Recycling and Disposal of Fluids and Components Avoid Harmful Asbestos Dust Avoid Hot Exhaust Clean Exhaust Filter Safely Handle Fuel Safely—Avoid Fires Prepare for Emergencies Handle Fluids Safely—Avoid Fires Avoid High-Pressure Fluids Install All Guards Use Proper Lifting Equipment Illuminate Work Area Safely Live With Safety Service Machines Safely Support Machine Properly Remove Paint Before Welding or Heating Park Machine Safely Stay Clear of Rotating Drivelines

Follow Safety Instructions Use Proper Tools Service Tires Safely Keep ROPS Installed Properly Construct Dealer-Made Tools Safely Practice Safe Maintenance Understand Signal Words Replace Safety Signs Avoid Heating Near Pressurized Fluid Lines Wear Protective Clothing Service Accumulator Systems Safely Handling Batteries Safely Handle Agricultural Chemicals Safely Service Cooling System Safely Use Steps and Handholds Correctly Transport Tractor Safely

Group 05B: General References General Information - Summary of References How to Use This Manual General Troubleshooting Information Systematic Diagnostic Approach Overview Deliver Safely Glossary of Terms Information Available in Sections, Groups and Subgroups Trademarks

Group 05C: Technical Specific References Features and Accessories Metric Bolt and Screw Torque Values Unified Inch Bolt and Screw Torque Values

Section 211: Diagnostic Trouble Codes Group CCU: CCU Code Diagnostics CCU 000096.03 - Fuel Level Sensor Circuit Voltage High

CCU 000096.04 - Fuel Level Sensor Circuit Voltage Low CCU 000161.02 - Transmission Input Speed Sensor Conflict CCU 000237.02 - VIN Security Data Conflict CCU 000237.14 - VIN Security Not Enabled CCU 000237.31 - VIN Security Messages Missing CCU 000628.02 - CCU EOL Data Fault CCU 000629.12 - CCU Control Unit Fault CCU 000630.14 - Rear PTO Configuration Invalid CCU 001638.00 - Hydraulic Oil Temperature Very Hot CCU 001638.03 - Hydraulic Oil Temperature Sensor Circuit Voltage High CCU 001638.04 - Hydraulic Oil Temperature Sensor Circuit Voltage Low CCU 001638.16 - Hydraulic Oil Temperature High CCU 001883.00 - Rear PTO Overspeed CCU 001883.01 - Rear PTO Underspeed CCU 002818.31 - Operator Presence Switch Not Activated CCU 003509.03 - Sensor Supply Voltage Out of Range High CCU 003509.04 - Sensor Supply Voltage Out of Range Low CCU 521155.05 - PTO Lube Solenoid Current Low CCU 521155.06 - PTO Lube Solenoid Current High CCU 523316.04 - CCU Switched Supply Voltage Low CCU 523839.02 - Park Brake Switch Conflict CCU 523908.02 - Rear PTO External Switch Conflict CCU 524016.04 - Sensor Excitation Low CCU 524037.02 - MFWD Switch Circuit Fault CCU 524224.14 - PTO Switch Voltage Mismatch CCU 524235.05 - MFWD Solenoid Circuit Fault CCU 524252.05 - Rear PTO Solenoid Circuit Fault

Group ECU: ECU Code Diagnostics ECU - Non-Tractor ECU Codes ECU 000084.31 - ECU Calculated Vehicle Speed and CAN bus Vehicle Speed Mismatch ECU 000152.12 - Control Unit Fault ECU 000152.14 - Control Unit Fault ECU 000152.16 - Control Unit Fault

ECU 000237.02 - VIN Security Data Invalid ECU 000237.13 - VIN Option Code Security Data Conflict ECU 000237.31 - VIN Security Data Missing ECU 000647.03 - Engine Fan Circuit Current High ECU 000695.19 - Unapproved Engine Speed Request ECU 001110.31 - Engine Protection System Activated ECU 001550.05 - Air Conditioner Compressor Current Low ECU 001550.06 - Air Conditioner Compressor Current High ECU 003353.31 - Alternator Fault ECU 003695.03 - Diesel Particulate Filter Regeneration Inhibit Switch Shorted To Battery ECU 003695.04 - Diesel Particulate Filter Regeneration Inhibit Switch Shorted To Ground ECU 003695.05 - Diesel Particulate Filter Regeneration Inhibit Switch Circuit Open ECU 003695.13 - Diesel Particulate Filter Regeneration Inhibit Switch Out Of Calibration ECU 003695.14 - Diesel Particulate Filter Regeneration Special Instructions ECU 003696.03 - Diesel Particulate Filter Regeneration Force Switch Shorted To Battery ECU 003696.04 - Diesel Particulate Filter Regeneration Force Switch Shorted To Ground ECU 003696.05 - Diesel Particulate Filter Regeneration Force Switch Current Low ECU 523744.09 - Air Conditioner Compressor Clutch Status Message Missing ECU 524225.31 - Engine Start Protection Bypass Detected

Group EIC: EIC Code Diagnostics EIC 000628.02 - EOL Control Unit Fault EIC 000628.12 - EIC Programming Fault EIC 000630.13 - EIC Calibration Fault/Not Calibrated EIC 002000.09 - ECU Message Missing EIC 003695.14 - Diesel Particulate Filter Regeneration Fault EIC 003719.15 - Diesel Particulate Filter Regeneration Fault EIC 523702.14 - EIC Control Unit Fault EIC 523702.31 - EIC Control Unit Fault

Group ICC: ICC Code Diagnostics ICC 000107.00 - Air Filter Restricted ICC

000167.04

-

Alternator

Voltage

Below

Normal ICC 000237.02 - VIN Security Mismatch ICC 000237.14 - VIN Security Not Enabled

ICC 000237.31 - VIN Security Messages Missing ICC 000628.12 - ICC Programming Fault ICC 000630.02 - ICC Calibration Memory Fault ICC 000630.11 - Control Software Internal Fault ICC

000630.13

Calibrated

ICC

-

ICC

Calibration

000916.14

-

Vehicle

Fault/Not Service

Indication ICC 002000.09 - ECU Message Missing ICC 002003.09 - PTR Message Missing ICC 002007.09 - RPT Message Missing ICC 002047.09 - CCU Message Missing ICC 002145.06 - Control Unit Supply Circuit Fault ICC 002368.05 - Left Turn Signal Current Low ICC 002368.06 - Left Turn Signal Current High ICC 002370.05 - Right Turn Signal Current Low ICC 002370.06 - Right Turn Signal Current Low ICC 002876.02 - Turn-Signal Lever Malfunction ICC 003695.02 - Regeneration Switch Malfunction ICC 003696.02 Regeneration Switch Malfunction Group PTR: PTR- Code Diagnostics PTR 000070.14 - Park Brake Engaged During Movement PTR 000084.07 - Excessive Wheel Speed Detected During Calibration PTR 000158.01 - System Switched Voltage Low PTR 000190.18 - Engine Speed Missing During Shift PTR 000191.00 - Excessive Top Shaft Speed During Calibration PTR 000191.17 - Top Shaft Speed Too Low PTR 000598.02 - Clutch Switch Open With Pedal Up PTR 000598.03 - Clutch Switch Closed With Pedal Down PTR 000598.04 - Clutch Switch Signal Failed Low PTR 000628.02 - EOL Data Fault PTR 000629.12 - PTR Control Unit Fault PTR 000630.13 - Tractor Model Out of Range/Transmission Calibration Value High PTR 000630.14 - Tractor Model Out Of Range/Transmission Calibration Value High PTR 000752.03 - Power Shuttle Potentiometer Input Voltage High

PTR 000752.04 - Power Shuttle Potentiometer Input Voltage Low PTR 000761.00 - Excessive Pressure at Inactive Forward Clutch PTR 000761.03 - Forward Pressure Sensor Voltage High PTR 000761.04 - Forward Pressure Sensor Voltage Low PTR 000761.31 - Forward Pressure Sensor Out of Range Too Long PTR 000763.00 - Excessive Pressure at Inactive Reverse Clutch PTR 000763.03 - Reverse Pressure Sensor Voltage High PTR 000763.04 - Reverse Pressure Sensor Voltage Low PTR 000763.31 - Reverse Pressure Sensor Out of Range Too Long PTR 001504.10 - Seat Switch Closed Too Long PTR 002820.31 - Operator Not Present During Shift PTR 003509.03 - PTR Sensor Supply Voltage High PTR 003509.04 - PTR Sensor Supply Voltage Low PTR 521233.05 - High Valve Driver Fault PTR 521234.05 - Low Valve Driver Fault PTR 521235.05 - Reverse Valve Driver Fault PTR 521237.00 - Excessive Pressure at Inactive Forward Clutch PTR 521237.03 - Forward Pressure Sensor Voltage High PTR 521237.04 - Forward Pressure Sensor Voltage Low PTR 521237.31 - Forward Pressure Sensor Out of Range Too Long PTR 521238.00 - Transmission Forward Low Clutch Pressure High PTR 521238.03 - Transmission Forward Low Sensor Voltage High PTR 521238.04 - Transmission Forward Low Sensor Voltage Low PTR 521238.31 - Transmission Forward Low Pressure Circuit Fault PTR 523953.02 - Speed Control Lever Sensor Circuit Conflict PTR 523959.31 - No Wheel Speed While in Gear PTR 524020.31 - Reverser in Gear at Power-Up PTR 524021.31 - Directional Reverser Lever Switch Circuit Fault PTR 524160.02 - Not Valid Neutral/Not Neutral Switch PTR 524173.02 - Clutch Pedal Compare Error PTR 524173.15 - Clutch Pedal Voltage High PTR 524173.16 - Both Clutch Pedals Voltage High PTR 524173.17 - Clutch Pedal Voltage Low

PTR 524173.18 - Both Clutch Pedals Voltage Low PTR 524230.05 - Enable Valve Driver Fault PTR 524230.07 - Enable Valve Stuck PTR 524234.03 - Pressure Sensor Voltage High PTR 524234.04 - Pressure Sensor Voltage Low PTR 524254.03 - Transmission Enable Valve Power High PTR 524254.04 - Transmission Enable Valve Power Low

Section 212: Observable Symptoms and System Diagnostics Group 05B: General References Observable Symptoms and System Diagnostics - Summary of References

Group 20: Engine Diagnostics Engine System Problems

Group 30: Fuel, Air Intake, Exhaust and Cooling Diagnostics Fuel and Air System Problems

Group 40: Electrical Diagnostics Back-Up Alarm Problems Charging System Problems Door Switch and Dome Lamp Problems Electrical Connector Problems Horn Problems Lighting System Problems Power Outlet Problems Starting and Charging System Diagnosis Starting System Problems Trailer Connector and Junction Block Problems

Group 45: Electronic Control Unit Diagnostics CAN System Diagnosis Chassis Control Unit (CCU) Problems Codes After Adding / Removing Control Units Control Unit Problems Control Unit Programming Failed Control Unit System Diagnosis

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Engine Control Unit (ECU) Problems Instrument Cluster Control (ICC) Problems Power Train Reverser (PTR) Problems Programming Multiple Control Units

Group 50: Drive Systems and Transmission Diagnostics MFWD Problems MFWD System Diagnosis PR Transmission Problems PR Transmission System Diagnosis Rear Differential Lock Problems Rear Differential Lock System Diagnosis Rear PTO Problems Rear PTO System Diagnosis

Group 60: Steering and Brakes Diagnostics Brake Problems Brake System Diagnosis Steering Problems Steering System Diagnosis

Group 70: Hydraulic Diagnostics Mechanical Hitch Problems Mechanical Hitch System Diagnosis Mid-Mount SCV Problems Mid-Mount SCV System Diagnosis Rear SCV Problems Rear SCV System Diagnosis

Group 90: Cab/Open Operator’s Station Diagnostics HVAC Problems HVAC System Diagnosis Radio Problems Seat Problems Wiper Problems

Section 220: Engine

Group 05B: General References Engine - Summary of References Engine Information

Group 10AA: Engine Calibrations, Preliminary Checks and Operational Checks Engine Calibrations, Preliminary Checks and Operational Checks

Group 20AA: Engine Theory of Operation Engine Theory of Operation

Group 30AA: Engine Schematics Engine Schematics

Group 40AA: Engine Component and Connector Information Engine Components

Group 50AA: Engine Tests and Adjustments Engine Test Procedures and Adjustments Engine Performance Testing Engine Performance Variables

Section 230: Fuel, Air Intake, Exhaust and Cooling Group 05B: General References Fuel, Air Intake, Exhaust, and Cooling - Summary of References Fuel, Air Intake, Exhaust, and Cooling Information

Group 10AA: Fuel, Air Intake, Exhaust, and Cooling Theory of Operation Air Intake System Theory of Operation Cooling System Theory of Operation Fuel System Theory of Operation DEF Tank Header Theory of Operation Exhaust Aftertreatment System Theory of Operation

Section 240A: Electrical General and Theory of Operation Group 05B: General References Electrical General and Theory of Operation - Summary of References How to Use Electrical Information Circuit Malfunctions Circuit Types

Electrical Designators Electrical Procedure Electrical Schematic Symbols Reading Wiring Schematics and Diagrams Relay Circuit Types Troubleshooting Unresolved Electrical/Electronic Problems Using a Digital Multimeter Using a Probe Light Visually Inspect Electrical System Wiring Diagram and Schematic Information

Group 20AA: Theory of Operation CAN Communication System Theory Of Operation Chassis Control Unit (CCU) Theory of Operation Electrohydraulic Control Unit (EHC) Theory of Operation Engine Control Unit (ECU) Theory of Operation (4045 Engine) Fuel Level Sensor Theory of Operation Instrument Cluster Control (ICC) Theory of Operation Instrument Cluster Alarm Theory of Operation Power Train Reverser (PTR) Theory of Operation

Section 240B: Electrical Schematics Group 05B: General References Electrical Schematics - Summary of References How to Use Electrical Schematics Information

Group 30AA: Key Switch, Starter and Alternator Schematic (SE1) Key Switch, Starter and Alternator Schematic (SE1)

Group 30AD: Neutral Start Schematic (SE2C) Neutral Start Schematic (SE2C)

Group 30BA: Accessory Power Schematic (SE3) Accessory Power Schematic (SE3)

Group 30CA: Horn Schematic (SE4) Horn Schematic (SE4)

Group 30DA: Light Switch and Headlights Schematic (SE5A)

Light Switch and Headlights Schematic (SE5A)

Group 30DB: Cab Work Lighting Schematic (SE5B) Cab Work Lighting Schematic (SE5B)

Group 30DC: OOS Work Lighting Schematic (SE5C) OOS Work Lighting Schematic (SE5C)

Group 30DD: Lighting Schematic (SE6) Lighting Schematic (SE6)

Group 30ED: Loader Lights Schematic (SE8) Loader Lights Schematic (SE8)

Group 30FA: Power Source Schematic (SE9) Power Source Schematic (SE9)

Group 30GA: Trailer Connector Schematic (SE10) Trailer Connector Schematic (SE10)

Group 30GB: Trailer Connector Schematic (with Implement Flood Light Connector) (SE11) Trailer Connector Schematic (with Implement Flood Light Connector) (SE11)

Group 30HA: Back-Up Alarm Schematic (SE13A) Back-Up Alarm Schematic (SE13A)

Group 30HB: Beacon Light Schematic (SE13B) Beacon Light Schematic (SE13B)

Group 30IA: Mid-Mount SCV Schematic (SE14) Mid-Mount SCV Schematic (SE14)

Group 30JA: Power Outlets Schematic (with Square Terminals) (SE15A) Power Outlets Schematic (with Square Terminals) (SE15A)

Group 30JB: Power Outlets Schematic (with Round Terminals) (SE15B) Power Outlets Schematic (with Round Terminals) (SE15B)

Group 30KA: Heater Schematic (SE16) Heater Schematic (SE16)

Group 30KB: Air Conditioning Schematic (SE17) Air Conditioning Schematic (SE17)

Group 30LA: Front Windshield Wiper and Washer Schematic (SE19) Front Windshield Wiper and Washer Schematic (SE19)

Group 30LC: Rear Windshield Wiper and Washer Schematic (SE21) Rear Windshield Wiper and Washer Schematic (SE21)

Group 30MA: Dome Light, Door Switch and Radio Schematic (SE22) Dome Light, Door Switch and Radio Schematic (SE22)

Group 30NA: Air Seat Schematic (SE23) Air Seat Schematic (SE23)

Group 30OA: Instrument Cluster Control (ICC) Schematic (SE24) Instrument Cluster Control (ICC) Schematic (SE24)

Group 30PA: Seat Switch and Rear PTO Switch Schematic (SE25) Seat Switch and Rear PTO Switch Schematic (SE25)

Group 30QA: ELX Relay and Fuses Schematic (SE26) ELX Relay and Fuses Schematic (SE26)

Group 30RA: Mechanical Front-Wheel Drive (MFWD) Schematic (SE27) Mechanical Front-Wheel Drive (EH MFWD) Schematic (SE27)

Group 30SA: Brake Switch Schematic (SE28) EH MFWD Brake Switch Schematic (SE28)

Group 30TA: Electrohydraulic Control Unit (EHC) Schematic (SE29) Electrohydraulic Control Unit (EHC) Schematic (SE29)

Group 30UA: Engine Control Unit (ECU) Schematic (4045 Engine) (SE30) Engine Control Unit (ECU) Schematic (4045 Engine) (SE30)

Group 30VA: Controller Area Network Schematic (SE32) Controller Area Network Schematic (SE32)

Section 240C: Electrical Components and Connectors Group 05B: General References Electrical

Components

and

Connectors

-

Summary

of

References How to Use Electrical Component and Connector Information How 40AA: to Use Wire Harness Information Group Key Switch, Starter and Alternator Components and Connectors (SE1) F26 Fusible Link G01 Battery G02 Alternator

M01 Starter S01 Key Switch

Group 40AD: Neutral Start Components and Connectors (SE2C) K18 Neutral Start Relay

Group 40CA: Horn Components and Connectors (SE4) H01 Horn S05 Horn Switch

Group 40DA: Light Switch and Headlights Components and Connectors (SE5A) S42 Light Switch S45

Hi/Lo

Beam

Headlight

Switch X18 Headlight Extension

Group 40DB: Cab Work Lighting Components and Connectors (SE5B) E03 Left Front Work Light E04 Right Front Work Light E05 Left Rear Work Light E06 Right Rear Work Light E07 Left Front Work Light (Optional) E08 Right Front Work Light (Optional) E09 Right Rear Work Light (Optional) E10 Left Rear Work Light (Optional)

Group 40DC: OOS Work Lighting Components and Connectors (SE5C) E11 Left Rear Work Light E12 Right Rear Work Light E13 Right Front Work Light E14 Left Front Work Light K09 Worklight Relay (OOS, PR)

Group 40DD: Lighting Schematic (SE6) E01 Right Front High/Low Beam Headlight E02 Left Front High/Low Beam Headlight H02 Right Tail/Brake/Turn Light H03 Left Tail/Brake/Turn Light H04 Right Front Warning Light

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