John Deere Tractor 6403 and 6603 2WD or MFWD Repair Manual TM6024 PDF

John Deere Agriculture

6403 and 6603 Tractors Repai United StatesCanada

REPAIR MANUAL 6603, 6403 ( US & Canada)

tm6024, January 2008

tm6024-REPAIR MANUAL

(g) by Belgreen

Table of contents FOREWORD Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - Specifications Group 15 - Fuel and Lubricants Group 20 - Serial Number Locations Section 20 - ENGINE REPAIR Group 05 - Engine Group 10 - Cooling System Section 30 - FUEL AND AIR REPAIR Group 05 - Fuel System Group 10 - Speed Control Linkage Group 15 - Air Intake System Section 40 - ELECTRICAL REPAIR Group 05 - Battery, Starter and Alternator Group 10 - Harness and Connector Repair Group 15 - Wiring Harness Routing Group 20 - Electrical System Components Group 25 - Auxiliary Lighting Components Group 30 - Fuses And Relays Group 35 - Lighting Section 50 - POWER TRAIN Group 00 - Towing Group 05 - Component Removal Group 10 - PTO Group 15 - Clutch Group 20 - Clutch Housing Group 25 - Transaxle Group 30 - Differential Group 35 - Final Drives Group 40 - MFWD Drop Gearbox Section 60 - STEERING AND BRAKE REPAIR Group 05 - Steering Repair Group 10 - Front Axle—2WD Group 15 - Front Axle—MFWD (AS2035) Group 16 - Front Axle—MFWD (APL350) Group 16A - Technical Data and Adjustment Values for APL350 ZF Series Group 16B - Disassembly Group 16C - Assembling the differential Group 16D - Pinion depth Group 16E - Adjusting the play between the teeth Group 16F - Assembling the Housings Group 16G - Assembling the Universal Joint Group 16H - Planet Carrier Group 16I - Assembling the Hydraulic Cylinder Group 16J - Convergence Regulation Group 20 - Brake Repair Section 70 - HYDRAULIC REPAIR <- Go to Global Table of contents

tm6024-REPAIR MANUAL

tm6024-REPAIR MANUAL

(g) by Belgreen

Group 05 - Hydraulic Pump and Filter Group 10 - Rockshaft Group 15 - Lubrication System Group 20 - Selective Control Valve (SCV) Section 80 - MISCELLANEOUS REPAIR Group 05 - Hood and Shields Group 10 - 3-Point Hitch Group 15 - Wheels Group 20 - Front Support Section 90 - OPEN OPERATOR STATION REPAIR Group 05 - Seat and Support Group 10 - ROPS Group 15 - Operator Platform Section 95 - CAB OPERATOR STATION REPAIR Group 00 - Removal and Installation of Components Group 05 - Selective Control Valve Cable Adjustment Group 10 - Air Conditioning System Group 15 - Heating System Group 20 - Seat Section 96 - 6003 SERIES TOOL KIT (ESSENTIAL TOOL REFERENCE ONLY) Group 05 - 6003 SERIES TOOL KIT (ESSENTIAL TOOL Reference Only) Section 99 - SPECIAL TOOLS (DEALER-FABRICATED) Group 05 - DEALER-FABRICATED TOOLS

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tm6024-REPAIR MANUAL

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tm6024-REPAIR MANUAL

GENERAL INFORMATION

(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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tm6024-REPAIR MANUAL

tm6024-REPAIR MANUAL

(g) by Belgreen

Section 10 - GENERAL INFORMATION Table of contents Group 05 - Safety ...................................................................................................................... 1 Recognize Safety Information ................................................................................................ 1 Understand Signal Words ....................................................................................................... 1 Prevent Machine Runaway ..................................................................................................... 2 Handle Fluids Safely—Avoid Fires .......................................................................................... 2 Prevent Battery Explosions .................................................................................................... 3 Prepare for Emergencies ........................................................................................................ 3 Prevent Acid Burns ................................................................................................................. 5 Handle Chemical Products Safely ........................................................................................... 6 Avoid High-Pressure Fluids ..................................................................................................... 6 Park Machine Safely ............................................................................................................... 7 Support Machine Properly ...................................................................................................... 8 Wear Protective Clothing ....................................................................................................... 8 Work in Clean Area ................................................................................................................ 9 Service Machines Safely ....................................................................................................... 10 Work In Ventilated Area ....................................................................................................... 11 Illuminate Work Area Safely ................................................................................................. 11 Replace Safety Signs ............................................................................................................ 11 Use Proper Lifting Equipment ............................................................................................... 12 Construct Dealer-Made Tools Safely .................................................................................... 12 Remove Paint Before Welding or Heating ............................................................................ 13 Avoid Heating Near Pressurized Fluid Lines ......................................................................... 14 Keep ROPS Installed Properly ............................................................................................... 14 Service Tires Safely .............................................................................................................. 15 Avoid Harmful Asbestos Dust ............................................................................................... 17 Practice Safe Maintenance ................................................................................................... 17 Use Proper Tools .................................................................................................................. 19 Dispose of Waste Properly ................................................................................................... 19 Service Cooling System Safely ............................................................................................. 20 Live With Safety ................................................................................................................... 20 Group 10 - Specifications ....................................................................................................... 22 Machine Specifications and Capacities ................................................................................ 22 Machine Dimensions and Weights ....................................................................................... 25 Turning Radius for MFWD 6403 Tractors .............................................................................. 27 Turning Radius for MFWD 6603 Tractors .............................................................................. 28 Turning Radius for 2WD 6603 and 6403 Tractors ................................................................ 29 Ground Speeds Estimates .................................................................................................... 30 Metric Bolt and Screw Torque Values ................................................................................... 31 Unified Inch Bolt and Screw Torque Values .......................................................................... 33 Sealants and Adhesives Cross-Reference Chart ................................................................... 35 How To Dispense/Apply/Assemble Gasket Sealants ............................................................. 35 Face Seal Fittings Assembly and Installation—All Pressure Applications .............................. 37 Metric Face Seal Fitting Torque Chart—Standard Pressure Applications .............................. 38 SAE Face Seal Fitting Torque Chart—Standard Pressure Applications ................................. 40 Metric Face Seal Fitting Torque Chart—High Pressure Applications ..................................... 41 SAE Face Seal Fitting Torque Chart—High Pressure Applications ........................................ 43 <- Go to Global Table of contents

tm6024-REPAIR MANUAL

tm6024-REPAIR MANUAL

(g) by Belgreen

Prevent Hydraulic System Contamination ............................................................................ 43 Check Oil Lines and Fittings ................................................................................................. 45 Group 15 - Fuel and Lubricants ............................................................................................. 47 Diesel Fuel ........................................................................................................................... 47 Storing Fuel .......................................................................................................................... 48 Testing Diesel Fuel ............................................................................................................... 48 Diesel Engine Coolant .......................................................................................................... 49 Diesel Engine Oil .................................................................................................................. 51 Transmission and Hydraulic Oil ............................................................................................ 53 Fill The Transmission With Oil .............................................................................................. 54 Check And Service Transmission Regularly .......................................................................... 55 Transaxle—Assembly Lubrication ........................................................................................ 55 Cold Weather Operation ....................................................................................................... 56 MFWD Gear Oil ..................................................................................................................... 57 Lubricant Storage ................................................................................................................. 58 Alternative and Synthetic Lubricants ................................................................................... 58 Grease (Specific Application) ............................................................................................... 58 Grease .................................................................................................................................. 59 Group 20 - Serial Number Locations .................................................................................... 61 Serial Numbers ..................................................................................................................... 61 Product Identification Number Location ............................................................................... 61 Engine Serial Number Location ............................................................................................ 61 Fuel Injection Pump Serial Number Location ........................................................................ 62 Alternator Serial Number Location ....................................................................................... 62 Transaxle Serial Number Location ....................................................................................... 63 Mechanical Front Wheel Drive (MFWD) Serial Number Location .......................................... 63

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tm6024-REPAIR MANUAL

Section 10 - GENERAL INFORMATION

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

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tm6024-REPAIR MANUAL

Section 10 - GENERAL INFORMATION

Group 05: Safety

manual.

Prevent Machine Runaway

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. <- Go to Section TOC

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Section 10 - GENERAL INFORMATION

Group 05: Safety

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

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

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Section 10 page 3

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