JOHN DEERE TRACTORS 6403 (NORTH AMERICA) TM6025 PDF MANUAL

John Deere Agriculture

6403 & 6603 Tractors Diag & Test US & Canada

DIAGNOSIS AND TESTS SERVICE MANUAL 6603, 6403

tm6025, January 2008

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Table of contents FOREWORD Section 210 - GENERAL Group 05 - Safety Group 10 - Tractor Component Identification Group 15 - Specifications 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 212 - OBSERVABLE SYMPTOMS Group 220 - Engine Operation and Tests Group 230 - Fuel/Air Operation and Test 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 - Brakes System Diagnosis and Tests Group 270 - Hydraulic System Diagnosis and Test Group 280 - Steering System 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 15A - 4045 Engine Operation Group 15B - 6068 Engine Operation 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 15C - Fuel System Diagnosis 6068 Group 20 - Component Information Section 240 - ELECTRICAL SYSTEM DIAGNOSTICS AND TESTS Group 05 - General Information Group 15A - Air Filter Restrictor Indicator Diagnostics Group 15B - Alternator and Battery Diagnostics Group 15C - Engine Oil Pressure Diagnostics Group 15D - Engine Coolant Temperature Diagnostics Group 15E - Fuel Gauge Diagnostics Group 15F - Horn Diagnostics Group 15G - Hourmeter/Tachometer Diagnostics Group 15H - Instrument Panel Overall Diagnostics Group 15I - Lights - Canopy Lights Diagnostics Group 15J - Lights—Flood Light Diagnostics

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tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Group 15K - Lights—Headlight and Instrument Lighting Diagnostics Group 15O - Lights—Overall Light Diagnostics Group 15L - Lights—Tail Lights Diagnostics Group 15M - Lights—Turn Signal Diagnostics Group 15N - Lights—Warning Lights Diagnostics Group 15P - Manifold Heater Diagnostics Group 15Q - Power Distribution and Fuse Block Diagnostics Group 15R - PTO Indicator Diagnostics Group 15S - Starting System - Bypass Start Diagnostics Group 15T - Starting System - Injection Pump Advance Timing Diagnostics Group 15U - Starting System Normal Diagnostics Group 15V - 7-Pin Trailer Outlet Diagnostics Group 20A - Circuit Code Listing Group 20B - Connector Information Group 20C - Connector Repair Procedures Section 245 - ELECTRICAL SYSTEM OPERATION, TEST & ADJUST (CAB TRACTORS) Group 05 - Component Location Group 10 - Theory of Operation Group 15 - Diagnosis, Test and Adjust Group 20 - Wiring Schematics Section 250 - POWER TRAIN SYSTEM DIAGNOSIS AND TESTS Group 5 - General Information Group 10 - Test Procedures and Adjustments Group 15A - Power Train Overall Group 15B - Clutch Diagnostics Group 15C - Differential Diagnostics Group 15D - Differential Lock Diagnostics Group 15E - Final Drive Diagnostics Group 15F - Transmission Power Flow Diagnostics Group 15G - Top Shaft Synchronized Transmission Diagnostics Group 15H - Rear PTO Diagnostics Group 15I - Lube Circuit Group 15J - Clutch Interlock Group 20 - Component Information Section 255 - MECHANICAL FRONT WHEEL DRIVE SYSTEM DIAGNOSIS AND TESTS Group 05 - General Information Group 10 - MFWD Adjustments Group 15A - MFWD Overall Diagnostics Group 15B - Mechanical Front Wheel Drive Front Axle Diagnostics Group 15C - MFWD Drop Gear Box Group 20 - Component Information Section 260 - BRAKES 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

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tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Group 15B - Rockshaft System Diagnostics Group 15C - Selective Control 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 295 - OPERATOR′S CAB Group 10 - Operational Tests Group 15 - Tests and Adjustments Group 20 - Operation Section 299 - DEALER FABRICATED TOOLS Group 00 - Dealer Fabricated Tools

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tm6025-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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tm6025-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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tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

tm6025-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 Use Seat Belt and Foldable ROPS Properly—If Equipped ........................................................ 4 Keep ROPS Installed Properly ................................................................................................. 5 Operate Tractor Safely ........................................................................................................... 6 Use Caution on Hillsides ......................................................................................................... 6 Shift to Low Gear on Hills ....................................................................................................... 7 Avoid Tipping ......................................................................................................................... 8 Freeing a Mired Machine ...................................................................................................... 10 Work In Ventilated Area ....................................................................................................... 11 Park Tractor Safely ............................................................................................................... 11 Keep Riders Off Machine ...................................................................................................... 12 Handle Fuel Safely—Avoid Fires ........................................................................................... 12 Prepare for Emergencies ...................................................................................................... 13 Wear Protective Clothing ..................................................................................................... 13 Protect Against Noise ........................................................................................................... 14 Handle Chemical Products Safely ......................................................................................... 15 Stay Clear of Rotating Drivelines ......................................................................................... 16 Use Safety Lights and Devices ............................................................................................. 16 Use a Safety Chain ............................................................................................................... 17 Safely Transporting the Tractor ........................................................................................... 18 Tow Loads Safely ................................................................................................................. 19 Practice Safe Maintenance ................................................................................................... 19 Service Tractor Safely .......................................................................................................... 21 Support Machine Properly .................................................................................................... 21 Remove Paint Before Welding or Heating ............................................................................ 22 Avoid Heating Near Pressurized Fluid Lines ......................................................................... 22 Avoid High-Pressure Fluids ................................................................................................... 23 Service Cooling System Safely ............................................................................................. 24 Store Attachments Safely .................................................................................................... 24 Prevent Battery Explosions .................................................................................................. 25 Prevent Acid Burns ............................................................................................................... 26 Service Tires Safely .............................................................................................................. 27 Dispose of Waste Properly ................................................................................................... 28 Group 10 - Tractor Component Identification ..................................................................... 29 Identification Plates .............................................................................................................. 29 Record Tractor Serial Number .............................................................................................. 29 Record Front Axle Serial Number ......................................................................................... 29 Record Engine Serial Number .............................................................................................. 30 Record Transmission Serial Number .................................................................................... 31 Group 15 - Specifications ....................................................................................................... 32 Machine Specifications ......................................................................................................... 32 Machine Dimensions and Weights ....................................................................................... 35

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tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

(g) by Belgreen

Turning Radius for MFWD 6403 Tractors .............................................................................. 37 Turning Radius for MFWD 6603 Tractors .............................................................................. 38 Turning Radius for 2WD 6603 and 6403 Tractors ................................................................ 39 Ground Speeds, Collar Shift or TSS Transmission ................................................................ 40 Metric Bolt and Screw Torque Values ................................................................................... 41 Unified Inch Bolt and Screw Torque Values .......................................................................... 43 Group 20 - Diagnostic and Testing Procedures .................................................................. 45 General Troubleshooting Information ................................................................................... 45 Group 40 - Electrical System Operational Checkout .......................................................... 47 Electrical System Operational Check ................................................................................... 47 Group 50 - Power Train System Operational Checkout ..................................................... 54 Power Train System Operational Check ............................................................................... 54 Group 55 - Mechanical Front Wheel Drive System Operational Checkout ..................... 57 Mechanical Front Wheel Drive System Operational Check ................................................... 57 Group 60 - Brake System Operational Checkout ................................................................ 59 Brake System Operational Check ......................................................................................... 59 Group 70 - Selective Control Valve System Operational Checkout ................................. 61 Selective Control Valve System Operational Check ............................................................. 61 Group 75 - Rockshaft System Operational Checkout ........................................................ 62 Rockshaft System Operational Check .................................................................................. 62 Group 80 - Steering Operational Checkout ......................................................................... 63 Steering Operational Check ................................................................................................. 63

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tm6025-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

tm6025-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.

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

tm6025-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.

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Section 210 page 3

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Use Seat Belt and Foldable ROPS Properly—If Equipped

Foldable ROPS in Extended Position Shown

LEGEND: A <- Go to Section TOC

ROPS Section 210 page 4

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

BQuick-Lock Pins C Pins This tractor may be equipped with a foldable Roll-Over Protective Structure (ROPS). The ROPS (A) should be kept in the “up” or extended position (as pictured) with pins (C) retained with quick-lock pins (B), except when it is necessary to fold it for low clearance operations.

When the ROPS is in the “up” or extended position, ALWAYS use your seat belt to minimize chance of injury from an overturn accident.

Do not use seat belt when ROPS is folded down.

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 must be replaced, not reused.

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Section 210 page 5

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Operate Tractor Safely

Features designed into your tractor make operation safer and let it perform a wide variety of jobs. Use your tractor only for specified jobs it was designed to perform: implement carrier, load mover, remote power source, or transport unit—not a recreational vehicle.

Careless use or misuse can result in unnecessary accidents. Be alert to hazards of tractor operation. Understand causes of accidents and take every precaution to avoid them. Most common accidents are caused from: Tractor upsets Improper starting procedures Crushing and pinching during hitching Collisions with other motor vehicles Getting entangled in PTO shafts Falls from tractors Avoid accidents by taking the following precautions: Put transmission in neutral (N) and set brakes before dismounting. Leaving transmission in gear with engine stopped will NOT prevent the tractor from moving.

Be sure everyone is clear of tractor and attached equipment before starting engine.

Never try to get on or off a moving tractor.

When tractor is left unattended, place in neutral (N), set brakes, lower implements to the ground, stop the engine, and remove the key.

Use Caution on Hillsides

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Section 210 page 6

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

Section 210 - GENERAL

Group 05: Safety

Always wear seat belt with ROPS in upper position.

Avoid holes, ditches, and obstructions which cause the tractor to tip, especially on hillsides.

Avoid sharp, uphill turns.

Never drive near the edge of a gully or steep embankment -- it might cave in.

Driving forward out of a ditch or mired condition or up a steep slope could cause tractor to tip over rearward. Back out of these situations if possible.

Danger of overturn increases greatly with narrow tread setting, at high speed.

Hitch towed loads only to drawbar. When using a chain, take up the slack slowly.

Shift to Low Gear on Hills

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Section 210 page 7

tm6025-DIAGNOSIS AND TESTS SERVICE MANUAL

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