John Deere Tractor 6215, 6415, 6615, 6715 Diagnostic Service Manual TM4648 PDF

John Deere Agriculture

6215, 6415, 6615, 6715 Tractors - Operation & Tests, Diagnosis

DIAGNOSIS AND TESTS SERVICE MANUAL 6415, 6615, 6715, 6215 (SN: 000000-398790, 398791- )

tm4648, May 2009

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Table of contents FOREWORD VERSION DATE Section 210 - GENERAL INFORMATION Group 05 - Safety Measures Group 15 - General References Section 211 - DIAGNOSTIC CODES Group BCU - BCU Diagnostic Trouble Codes Group ECU - ECU Diagnostic Trouble Codes Section 212 - OBSERVABLE SYMPTOMS Group 20 - Engine Group 40 - Electrical System Group 50 - SyncroPlus™ Transmission Group 51 - PowrReverser™ Transmission Group 55 - PowrQuad™ Transmission Group 60 - Steering and Brakes Group 90 - Operator′s Cab Section 213 - SYSTEM DIAGNOSTICS Group 45 - Electronics Section 220 - ENGINE Group 10 - Functional Tests Group 15 - Tests and Adjustments Section 230 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 240 - ELECTRICAL SYSTEM Group 10 - Sub-System Diagnostics (Cab) Group 10A - Sub-System Diagnostics (Open Operator′s Station) Group 15 - Component Testing Group 25 - Functional Schematics (Cab) Group 25A - Functional Schematics (Open Operator′s Station) Group 26 - Wiring Harnesses, Survey Group 26A - Wiring Harnesses Group 26B - Wiring Harnesses from Serial Number 398656 Section 245 - ELECTRONIC CONTROL UNITS Group 05 - Operation and General Information on Diagnostics Group 10 - Data BUS Systems, Diagnosis Group 20 - Data BUS Systems Group BCU - BCU - Basic Control Unit Group ECU - ECU - Engine control unit Section 250 - SYNCROPLUS™ TRANSMISSION Group 05 - Preliminary Checks Group 10 - Functional Tests Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 251 - POWRREVERSER™ TRANSMISSION Group 10 - Functional Tests Group 15 - Tests and Settings Group 20 - Theory of Operation <- Go to Global Table of contents

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Section 255 - POWRQUAD™ AND RANGE TRANSMISSION Group 10 - Functional Tests Group 15 - Tests and Settings Group 20 - Theory of Operation Section 256 - POWER TRAIN (WITHOUT TRANSMISSION) Group 10 - Functional Tests Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 260 - STEERING AND BRAKES Group 05 - Introductory Checks Group 10 - Operational Check-Out Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 270 - HYDRAVANTAGE™ HYDRAULIC SYSTEM Group 10 - Operational Check-Out Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 290 - OPERATOR′S CAB Group 10 - Operational Check-Out Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 299 - SPECIAL TOOLS Group 05 - Special Tools (Dealer-Fabricated) Group 10 - Special Tools and Test Equipment

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tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

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tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Foreword This “Operation and Tests and Diagnostics” manual applies to the following tractor types: 6215, 6415, 6615 and 6715 The manual is written for experienced technicians. 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.

This is the safety-alert symbol. When you see this symbol on your 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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tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

GENERAL INFORMATION

(g) by Belgreen

Version date 01 July 2006

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tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Section 210 - GENERAL INFORMATION Table of contents Group 05 - Safety Measures .................................................................................................... 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 Safety Measures on Electronic Control Units ........................................................................ 20 Group 15 - General References ............................................................................................. 22 Reference 210-15-001, General References - Summary ...................................................... 22 Reference 210-15-010, Unified Inch Bolt and Cap Screw Torque Values ............................. 23 Reference 210-15-015, Metric Bolt and Cap Screw Torque Values ...................................... 25 210-15-020, Hydraulic System Inch Fitting Torques ............................................................ 27 210-15-025, Hydraulic System Metric Fitting Torques ......................................................... 28 210-15-030, Component Identification Table ....................................................................... 29 Reference 210-15-035, How to Read a Functional Schematic .............................................. 30 210-15-040, How to Read a Diagnostic Schematic .............................................................. 30 210-15-042, Wire Numbers and Color Codes ....................................................................... 33 210-15-045, Schematic, Wiring and Harness Symbols ......................................................... 34 Reference 210-15-046, Troubleshooting Unsolved Problems ............................................... 36 210-15-050, Visual Check of the Electrical System .............................................................. 37 <- Go to Global Table of contents

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Types of fault ....................................................................................................................... 38 Reference 210-15-060, Seven Step Electrical Test Procedure ............................................. 43 210-15-065, Hydraulic System - Circuit Symbols ................................................................. 44

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tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety Measures

Group 05 - Safety Measures 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

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL INFORMATION

Group 05: Safety Measures

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

tm4648-DIAGNOSIS AND TESTS SERVICE MANUAL