John Deere TH6x4, TH6x4D, TE4x2 Gator Utility Manual TM2239 - PDF

Cover

2

Brakes

3

Electrical

52

Engine Diesel

505

Engine Gas (FE290D, FE350D)

688

Engine Gas (FH601D)

882

Engine Gas (FJ4000D)

1026

Miscelleneous

1165

Power Train

1217

Safety

1290

Specifications

1321

Steering

1365

TM2239 -Gator™ Utility Vehicle TS, TH 6X4,and TH 6X4 Diesel Brake Adjustment

Brake Adjustment Reason: To ensure service brake linkage and park brake linkage are adjusted properly.

NOTE: The brake rod needs to be adjusted before the brake cable.

Brake Rod Adjustment: 1.

NOTE: If this is a NEW transaxle or you have replaced the brake pack assembly, ONLY perform steps 1-6 and 8-10. New brake parts require a tighter linkage adjustment to account for initial break-in wear.

MXAL31228-UN: Brake Rod LEGEND: A -Nut B -Linkage C -Sleeves D -Contact Inside Spring Tighten nut (A) onto linkage (B) completely until the ends of sleeves (C) make contact inside spring (D). This sets a predetermined preload on the spring. Tighten brake rod nut to specification.

2.

3.

Item

Measurement

Specification

Brake Rod Nut

Torque

30 ±5 N•m (22 ±4 lb.-ft.)

Use jack stands or hoist to raise rear wheels at least 25 mm (1.0 in.) off ground.

NOTE: If brake cable is being replaced, DO NOT attach cable to brake pedal at this time. Attach cable only at mid-frame mounting and brake arm assembly.

MXAL31229-UN: Brake Arm LEGEND: E -Brake Arm Return Spring Disconnect brake arm return spring (E).

4.

MXAL31230-UN: Brake Rod LEGEND: F -Jam Nut G -Brake Rod Adjustment Nut H -Brake Rod I -Rear Brake Rod J -Spacer K -Washer L -Coupler Pin Loosen jam nut (F) and brake rod adjustment nut (G).

5.

NOTE: Check that brake cable is not tight or there is any movement in the brake pedal.

Hold brake rod (H) to rear and brake arm (I) forward to remove all play.

6.

7.

Turn adjustment nut (G) forward until it pushes spacer (J) and washer (K) forward until washer just contacts coupler pin (L).

Used Systems: Turn adjustment nut (G) complete 3 turns (eighteen flats of nut) away from pin (L).

Item

Measurement

Specification

Brake Rod Front Nut

Torque

30 ±5 N·m (22 ±4 lb.-ft.)

8.

Tighten jam nut (F).

9.

Install brake arm return spring.

10. NOTE: If no new parts have been installed, proceed to “Alternate Rear End Adjustment Procedure” below.

(DO NOT proceed if NEW parts have been installed).

Turn rear wheel, it should rotate with a slight drag and provide even braking on both sides.

Alternate Rear End Adjustment Procedure: (DO NOT use this procedure for NEW parts): NOTE: When using torque wrench, the torque wrench centerline should intersect the axle flange centerline!

For TS Gators: Using torque wrench, turn any lug of rear tire. Tire should rotate at less than maximum specifications.

Item

Measurement

Specification

Brakes –Alternate Rear End Adjustment (Ideal)

Drag

7 N·m (62 lb.-in.)

Item

Measurement

Specification

Brakes –Alternate Rear End Adjustment (Maximum)

Drag

11 N·m (8 lb.-ft.)

For TH Gators: Turn any lug of rear tire. Tire should rotate at less than specifications Item

Measurement

Specification

Brakes –Alternate Rear End Adjustment (Maximum)

Drag

20 N·m (15 lb.-ft.)

After repeating procedure for both sides, check both sides (left and right) for EVEN braking. If NOT EVEN, repeat entire procedure.

Brake Cable Adjustment: NOTE: This adjustment has no effect on park brake operation.

1 .

2

Before proceeding, ensure that transaxle brake rods are adjusted properly. See Brake Adjustment .

Remove hood from machine. See Hood Removal and Installation .

Place park brake in the fully off position.

.

3 4. .

NOTE: With the park brake lever in the fully off position, brake cable should have a slight amount of tension on it.

MXAL31231-UN: Brake Cable

LEGEND: A -Nuts Loosen nuts (A) securing front of brake cable.

5.

MXAL31232-UN: Brake Cable Adjust LEGEND: B -Cable Adjust brake cable until there is slight tension on cable (B) when checked near clevis at brake pivot arm. There should be no more freeplay in the brake pedal than the specifications.

Item

Measurement

Specification

Brake Pedal

Freeplay

0—4 mm (0—0.16 in.)

6

Tighten nuts securing front of brake cable.

.

Install all removed components.

7 .

KN52281,1001E01-19-20150427

TM2239 -Gator™ Utility Vehicle TS, TH 6X4,and TH 6X4 Diesel Brake and Brake Cable

Brake and Brake Cable

MXAL31223-UN: Brake Cables LEGEND: A - Bushing B - Snap Ring C - Brake Welded Assembly D - Brake Pedal Pad E - Brake Cable F - Park Brake Lever Assembly G - Park Brake Pawl H - Park Brake Pivot Pin I - Park Brake Actuator Rod J - Brake Welded Pivot Assembly K - Pivot Bracket L - Compression Spring M - Sleeve N - Brake Actuating Rod O - Transaxle Brake Lever P - Brake Rod Adjustment Nut Q - Washer R - Brake Rod Pins S - Spacer T - Brake Rod Lock Nut U - Stop Plate V - Brake Return Spring W - Drilled Pin X - Sleeve Y - Locking Nut Z - Brake Pedal Return Spring AA - Drilled Pin AB - Cotter Pin

KN52281,1001DF8-19-20120720

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

TM2239 -Gator™ Utility Vehicle TS, TH 6X4,and TH 6X4 Diesel Brake Cable Removal and Installation

Brake Cable Removal and Installation Removal: 1

Park machine safely. See Park Machine Safely .

.

Remove hood from machine. See Hood Removal and Installation .

2 .

3.

CAUTION: Brake pedal return spring is under high tension. Wear safety glasses and gloves when removing or installing spring from pedal.

MXAL31233-UN: Spring LEGEND: A - Brake Pedal Return Spring B - Brake Cable Adjustment Nuts Disconnect brake pedal return spring (A) from machine frame.

4.

5.

Loosen brake cable adjustment nuts (B) and slide cable from bracket.

MXAL31234-UN: Pin LEGEND: C - Cotter Pin D - Drilled Pin Remove cotter pin (C) from drilled pin (D) in brake cable clevis. Remove drilled pin and disconnect clevis from brake lever.

6.

MXAL31235-UN: Clip LEGEND: E - C-Clip F - Frame Guide Remove C-clip (E) and slide cable from frame guide (F).

7.

MXAL31236-UN: Pin LEGEND: G - Cotter Pin H - Brake Cable Clevis Remove cotter pin (G) from drilled pin in brake cable clevis (H). Remove drilled pin and disconnect clevis from brake lever.

8.

Remove cable from machine.

Installation: Installation is done in the reverse order of removal.

Adjust brake cable. See Brake Adjustment .

KN52281,1001E02-19-20120730

TM2239 -Gator™ Utility Vehicle TS, TH 6X4,and TH 6X4 Diesel Brake Disc Assembly Removal and Installation

Brake Disc Assembly Removal and Installation Removal: 1

Park machine safely. See Park Machine Safely .

.

Remove transaxle. See Transaxle Removal and Installation—TS .

2

Drain oil from transaxle.

.

Remove driven clutch if left hand brake assembly is to be serviced.

3

a.Remove drive belt.

.

4 .

b.

MXAL31245-UN: TS Gator shown.

MXAL31246-UN: TH Gator shown.

LEGEND: A -Driven Clutch Cap Screw and Washer Remove driven clutch cap screw and washer (A). Remove driven clutch.

5.

MXAL31247-UN: Brake Housing LEGEND: A -Ten Bolts B -Snap Ring C -Pry Tabs Remove ten bolts (A) from brake housing.

6.

Remove snap ring (B) from output shaft.

7.

8.

Separate housing from transaxle. A prybar may be used at the two indicated pry tabs (C).

MXAL31248-UN: Brake Plates LEGEND: D - Brake Plates E - Friction Discs Remove brake plates (D) and friction discs (E).

Inspection: 1.

NOTE: There are six steel balls between brake housing and actuator ring. They may fall out if assembly is not lying flat.

MXAL31249-UN: Housing LEGEND: F - Screws and Washers Remove two screws and washers (F) securing actuator ring to brake housing.

2.

MXAL31250-UN: Housing LEGEND: G - Steel Balls H - Snap Ring Inspect six steel balls (G) and their ramps in actuator ring for cracking, scoring, or wear. Replace as necessary.

3.

Remove snap ring (H) from brake arm. Remove brake arm from housing.

4.

MXAL31251-UN: Brake Arm O-Ring LEGEND: I - Brake Arm O-Ring Inspect brake arm O-ring (I). Replace as necessary.

5.

MXAL31252-UN: Friction Disc LEGEND: D -Friction Discs E -Plates Check brake friction discs (E) and plates (D) for wear or damage. Replace as necessary.

6.

MXAL31253-UN: Transaxle LEGEND: J -Transaxle Friction Surface Inspect transaxle friction surface (J) for wear or damage.

7.

Measure brake plate and friction disc thicknesses.

Item

Measurement

Specification

Brake Plate

Thickness

1.44—1.60 mm (0.057—0.063 in.)

Item

Measurement

Specification

Friction Disk

Thickness

4.60—4.80 mm (0.181—0.189 in.)

Installation: 1.

Remove any old gasket material from transaxle and brake housing.

2.

MXAL31254-UN: Brake Housing LEGEND: G -Six Steel Balls H -Snap Ring With brake housing lying flat, place the six steel balls (G) into cups.

3.

4.

Install brake arm and secure with snap ring (H).

MXAL31255-UN: Brake Housing LEGEND: K -Tab L -Screws and Washers Place actuator ring on top of brake housing, with tab (K) positioned as shown. Ensure that all six balls seat properly.

5.

6.

7.

Secure actuator ring with two screws and washers (L). Apply thread locking compound to cap screws and tighten to specification.

Item

Measurement

Specification

Brake Housing Cap Screws

Torque

17.8—11.8 N·m (69—104 lb.-in.)

Check operation of brake actuator.

MXAL31256-UN: Housing LEGEND: L -Tabs Install first brake plate, with tabs aligned as shown (L), into transaxle.

8.

MXAL31257-UN: Plates LEGEND: D -Brake Plates E -Friction Discs Install friction discs (E) and plates (D) in order as shown.

9.

10.

Apply a thin bead of RTV to one side of transaxle mating surface.

NOTE: The flat surface of the actuator ring tab and the flat surface of the brake arm (cam area) should be parallel when the brake housing is installed.

Install brake housing to transaxle with brake arms toward bottom of transaxle and secure with ten bolts.

Check operation of brake arms.

11

IMPORTANT:

.

Shaft seal must be installed squarely into the brake housing bore. Measure the install depth at several

12

locations to verify the proper install depth.

.

If removed, install a new axle shaft seal squarely into the brake housing to a depth of specification. See Axle Shaft Seal Removal and Installation .

Item

Measurement

Specification

Brake Shaft Seal Depth

Torque

5.5 mm (0.217 in.)

13

Install snap ring onto output shaft.

.

Install transaxle into machine frame. See Transaxle Removal and Installation—TS .

14 .

Item

Measurement

Specification

Brake Housing to Transaxle Case Cap Screws

Torque

28 N·m (20 lb.-ft.)

KN52281,1001E06-19-20120730

TM2239 -Gator™ Utility Vehicle TS, TH 6X4,and TH 6X4 Diesel Brake Function Test

Brake Function Test Check Park Brake: 1.

Place specified amount of ballast in cargo box.

Item

Measurement

Specification

Brake Function Test Ballast

Weight

180 kg (400 lbs)

2

Drive machine onto 30% (17°) slope. Lock park brake and turn off engine.

.

If machine does not move while you are sitting on the drivers seat, no adjustment is necessary. If machine does move, adjust brakes. See Brake Adjustment .

3

4. .

IMPORTANT: Over tightening brakes will cause damage to the transaxle.

Check for brake drag: a.Remove any items from cargo box. b.Move machine to smooth, level surface. c.Put machine in neutral with the park brake unlocked. d.Machine should roll 1 to 3 inches with less than the specified force.

Item

Measurement

Specification

Brake Function Test Applied

Force

90 N (20 pounds)

5

If more force is required, then the brakes are too tight. Adjust brake cable and/or brake rods.

.

Recheck for brake drag.

6 .

KN 5228 1,1 001D F F-1 9-201 20730

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