John Deere Tractor 6010, 6110, 6210, 6310, 6410, 6510, 6610, 6810, 6910 Diagnostic Service Manual TM

John Deere Agriculture

6010, 6110, 6210, 6310, 6410, 6510, 6610, 6810, 6910, 6910S and SE Tractors

DIAGNOSIS AND TESTS SERVICE MANUAL 6210, 6410, 6510, 6610, 6810, 6910, 6010, 6110, 6310, SE6510, SE6610, SE6010, SE6110, SE6310, SE6410, 6910S

tm4552, March 2003

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Table of contents FOREWORD Section 210 - SAFETY Group 05 - Safety Section 211 - SERVICE CODE DIAGNOSTICS Group BCU - BCU Service Code Diagnostics Group BIF - BIF Service Code Diagnostics Group ECU (Level - ECU (Level 1 with LUCAS injection pump) Service Code Diagnostics Group ECU (Level - ECU (Level 4 with BOSCH VP44 injection pump) Service Code Diagnostics Group HCU - HCU Service Code Diagnostics Group PCU - PCU Service Code Diagnostics Group PEC - PEC Service Code Diagnostics Group PLC - PLC Service Code Diagnostics Group RCU - RCU Service Code Diagnostics Group SFA - SFA Service Code Diagnostics Group TCU - TCU Service Code Diagnostics Group UIC - UIC Service Code Diagnostics Section 212 - OBSERVABLE SYMPTOMS Group 40 - Electrical System Group 55 - PowrQuad, PowrQuad Plus and AutoQuad Transmissions Group 56 - Drive System (except transmission) Group 60 - Steering and Brakes Group 70 - Hydraulic System Section 220 - ENGINE Group 10 - Tests Section 230 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 10 - System Diagnosis Group 15 - Tests and Adjustments Group 20A - Fuel System Group 20B - Air Intake System Group 20C - Cooling System Group 20D - Cold-Weather Starting Aids Section 240 - ELECTRICAL SYSTEM Group 05 - General Group 10 - Functional Schematics and Wiring Diagrams (6010-6910S) Group 10A - Functional Schematics and Wiring Diagrams (SE Tractors) Group 10B - Functional Schematics and Wiring Diagrams (2-Post ROPS) Group 10C - Functional Schematics and Wiring Diagrams (AutoPowr) Group 15 - Circuit Testing (6010-6910S with Cab) Group 15A - Sub-System Diagnostics (SE Tractors) Group 15B - Sub-System Diagnostics (2-Post ROPS) Group 15C - Circuit Testing (AutoPowr Transmission) Group 16A - Data BUS Systems Group 16B - Data BUS Systems –– Diagnosis Group 20 - Adjustments Group 25 - Component Testing Section 245 - ELECTRONIC CONTROL UNITS Group 05 - Operation and General Information on Diagnostics Group BCU - BCU References <- Go to Global Table of contents

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Group BIF - BIF References Group ECU - ECU (Level 1) References Group HCU - HCU References Group PCU - PCU References Group PEC - PEC References Group PLC - PLC References Group RCU - RCU References Group SFA - SFA References Group TCU - TCU References Group UIC - UIC References Section 250 - SYNCROPLUS TRANSMISSION Group 05 - Operational Checkout Group 10 - Troubleshooting Group 15 - Tests and Adjustments Group 20 - SyncroPlus Transmission Operation Group 20A - Perma Clutch II Group 20B - Gear Transmission Group 20C - Creeper Transmission Group 20D - Range Transmission Section 251 - POWER REVERSER TRANSMISSION Group 05 - Operational Checkout Group 10 - Troubleshooting Group 15 - Test and Adjustments Group 20 - Power Reverser Operation Group 20A - Power Reverser Module Group 20B - Gear Transmission Section 252 - POWER SHIFT TRANSMISSION Group 05 - Operational Checkout Group 10 - Troubleshooting Group 15 - Adjustments Group 20 - Theory of Operation Section 253 - AUTOPOWR TRANSMISSION Group 10A - Diagnosis - UIC Group 10B - Diagnosis - TCU Group 10C - Diagnosis - PLC Group 15 - Tests and Adjustments Group 20 - Operation Section 255 - POWRQUAD, POWRQUAD PLUS AND AUTOQUAD II TRANSMISSIONS Group 05 - Operational Checkout Group 10A - POWRQUADPOWRQUAD is a trademark of Deere & Company.Transmission Check Group 10B - Troubleshooting on PowrQuad Plus and AutoQuad II Group 15 - Tests and Adjustments Group 20A - PowrQuad Transmission Operation Group 20B - PowrQuad Plus and AutoQuad II Transmission Operation Group 20C - Creeper Transmission Group 20D - Range Transmission Section 256 - DRIVE SYSTEMS Group 05 - Operational Checkout Group 10 - Troubleshooting <- Go to Global Table of contents

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Group 15 - Tests Group 20A - Front-Wheel Drive Clutch Group 20B - Differential Group 20C - Final Drives Group 20D - Rear PTO Options Group 20E - Front PTO Section 260 - STEERING AND BRAKES Group 05 - Operational Checkout Group 10 - Troubleshooting Group 15 - Tests and Adjustments Group 20A - Hydrostatic Steering Group 20B - Hydraulic Brakes Group 20C - Handbrake Group 20D - Hydraulic Trailer Brake Group 20E - Air Brake System Section 270 - HYDRAULIC SYSTEM Group 05 - Operational Checkout Group 10 - PFC Hydraulic System Troubleshooting Group 11 - PC Hydraulic System Troubleshooting Group 15 - Tests and Adjustments Group 20 - PFC Hydraulic System Group 20A - Charge Oil Pump Group 20B - Hydraulic Pumps Group 20C - Valves, Oil Cooler and Filter Group 20D - Rockshaft Group 20E - Selective Control Valves and Couplers Group 20F - Independent Control Valve (ICV) Group 21 - PC Hydraulic System and Components Section 280 - MISCELLANEOUS Group 05 - TLS Front Axle Operational Checkout Group 10 - TLS Front Axle Troubleshooting Group 15 - TLS Front Axle Tests and Adjustments Group 20 - TLS Front Axle Operation Section 290 - OPERATORS CAB Group 05 - Operational Checkout Group 10A - Air Conditioner Troubleshooting Group 10B - Ventilation and Heater Troubleshooting Group 10C - Operator′s Seat Troubleshooting Group 20A - Air Conditioner Operation Group 20B - Ventilation and Heating Operation Section 299 - SPECIAL TOOLS (DEALER-FABRICATED) Group 05 - Special Tools (Dealer-Fabricated)

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tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

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tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

SAFETY

(g) by Belgreen

Foreword This “Operation and Test” manual applies to the following types of tractor: 6010, 6110, 6210, 6310, 6410, 6510, 6610, 6810, 6910 and 6910S. SE tractors 6010, 6110, 6210, 6310, 6410, 6510 and 6610.

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.

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 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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tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Section 210 - SAFETY Table of contents Group 05 - Safety ...................................................................................................................... 1 Recognize Safety Information ................................................................................................ 1 ‘Important” - Information ....................................................................................................... 1 ‘Note” - Information ............................................................................................................... 1 Prevent Machine Runaway ..................................................................................................... 1 Handle Fluids Safely-Avoid Fires ............................................................................................ 2 Prevent Battery Explosions .................................................................................................... 3 Prepare for Emergencies ........................................................................................................ 3 Prevent Acid Burns ................................................................................................................. 4 Avoid High-Pressure Fluids ..................................................................................................... 5 Service Cooling System Safely ............................................................................................... 5 Remove Paint Before Welding or Heating .............................................................................. 6 Avoid Heating Near Pressurized Fluid Lines ........................................................................... 7 Work In Ventilated Area ......................................................................................................... 7 Wear Protective Clothing ....................................................................................................... 8 Practice Safe Maintenance ..................................................................................................... 9 Park Machine Safely ............................................................................................................. 10 Use Proper Lifting Equipment ............................................................................................... 10 Construct Dealer-Made Tools Safely .................................................................................... 11 Support Machine Properly .................................................................................................... 11 Work in Clean Area .............................................................................................................. 12 Illuminate Work Area Safely ................................................................................................. 13 Service Machines Safely ....................................................................................................... 13 Use Proper Tools .................................................................................................................. 14 Service Tires Safely .............................................................................................................. 14 Service Front-Wheel Drive Tractor Safely ............................................................................ 16 Safety Information - Air Brake System ................................................................................. 16 Avoid Eye Contact with Radar .............................................................................................. 17 Keep ROPS Installed Properly ............................................................................................... 18 Replace Safety Signs ............................................................................................................ 18 Dispose of Waste Properly ................................................................................................... 19 Live With Safety ................................................................................................................... 20

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tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - SAFETY

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.

“Important” - Information Information marked as IMPORTANT points out problems that may lead to machine damage.

By following the directions given, these problems can be avoided.

“Note” - Information When marked with NOTE the information given is more detailed or contains restrictions to directions given previously. On the other hand useful information may be given belonging to certain instructions without being directly connected to them.

Prevent Machine Runaway

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Section 210 page 1

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - SAFETY

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.

Handle Fluids Safely-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. <- Go to Section TOC

Section 210 page 2

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - SAFETY

Group 05: Safety

Do not store oily rags; they can ignite and burn spontaneously.

Prevent 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

Be prepared if a fire starts. <- Go to Section TOC

Section 210 page 3

tm4552-DIAGNOSIS AND TESTS SERVICE MANUAL