John Deere Tractors 6810, 6910, 6910S Repair Service Manual (TM4566)

tm4566 - 6810, 6910 and 6910s tractors Technical Manual - Repair.pdf

Complete Repair Service Technical Manual for John Deere Tractors 6810, 6910, 6910S, with all the shop information to maintain, repair, service like professional mechanics.

John Deere Tractors 6810, 6910, and 6910S workshop technical manual (repair) includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 1,997 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   SAFETY
      Safety Measures
   GENERAL INFORMATION
      Specifications
      Tune-Up
      Predelivery Inspection
   ENGINE
      Engine Removal and Installation
   FUEL, AIR INTAKE, COOLING AND EXHAUST SYSTEMS
      Speed Control Linkage
      Fuel System
      Air Intake System
      Cooling System
      Cold Weather Starting Aids
      Exhaust System
   ELECTRICAL SYSTEM
      Connectors
      Wiring Harnesses
      Charging Circuit
      Starter Motor Circuit
      Fuses, Relays and Switches
      Monitoring Systems
      Electrical Components
   POWER SHIFT TRANSMISSION
      Removing and Installing the Power Shift Transmission
      Shift Controls
      Power Shift Transmission
      Reduction Gearbox
   AUTOPOWR TRANSMISSION
      Removing and Installing the AutoPowr Transmission
      Transmission Shift Controls
      Input Housing
      Output Housing
      Assembling the Differential Drive Shaft
   POWRQUAD, POWRQUAD PLUS AND AUTOQUAD TRANSMISSIONS
      Removal and Installation of Transmission Components
      Transmission Shift Controls
      PowrQuad Module
      Creeper Transmission
      Range Transmission
   DRIVE SYSTEMS
      Removal and Installation of Components
      U-Jointed Shafts and Torsion Damper
      Front-Wheel Drive Clutch
      Differential
      Hydraulic Pump Drive
      Final Drives
      Rear PTO Options
      Front PTO
      Front Implement Drive
   STEERING AND BRAKES
      Hydrostatic Steering
      Brake Valve (Power Fill Brakes)
      Brake Valve (with MFWD and Disk Brake)
      Rear Brakes
      Handbrake
      Hydraulic Trailer Brake
      Air Brakes
   HYDRAULIC SYSTEM
      Controls
      Hydraulic Pump and Charge Oil Pump
      Valves
      Rockshaft and Rockshaft Cylinder (up to Tractor Serial No. 260141)
      Rockshaft and Rockshaft Cylinder (from Tractor Serial No. 260142)
      Three-Point Hitch
      Selective Control Valves and Couplers
      Independent Control Valve
   MISCELLANEOUS
      Removal and Installation of Components
      Main Frame
      Front and Rear Wheels
      Trailer Hitch and Swinging Drawbar
      Triple Link Suspension (TLS) of FWD Axle
      Pick-Up Hitch
   OPERATOR'S CAB
      Tilting, Removing and Installing the Operator's Cab
      Controls and Instruments
      Electonic Hitch Control Components
      Air Conditioning System
      Heating System
      Operator's Cab
      Seats
      Components for Radio Installation
   SPECIAL TOOLS (DEALER-FABRICATED)

tm4566 - 6810, 6910 and 6910s tractors

Table of Contents

Foreword

Section 05: SAFETY

Group 05: Safety Measures

Recognize Safety Information

Prevent Machine Runaway

Handle Fluids Safely-Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Avoid High-Pressure Fluids

Service Cooling System Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Work In Ventilated Area

Wear Protective Clothing

Practice Safe Maintenance

Park Machine Safely

Use Proper Lifting Equipment

Construct Dealer-Made Tools Safely

Support Machine Properly

Work in Clean Area

Illuminate Work Area Safely

Service Machines Safely

Use Proper Tools

Service Tires Safely

Service Front-Wheel Drive Tractor Safely

Safety Information - Air Brake System

Avoid Eye Contact With Radar

Keep ROPS Installed Properly

Replace Safety Signs

Dispose of Waste Properly

Live With Safety

Section 10: GENERAL INFORMATION

Group 05: Specifications

Engine

Cooling System

Injection pump (Lucas)

Injection pump (Bosch VP44)

Air Intake System

Electrical System

Hydrostatic Steering System

Clutch

AutoPowr transmission

PowrQuad and PowrQuad Plus transmissions

AutoQuad and AutoQuad II transmissions

Power Shift Transmission

Creeper Transmission*

Rear PTO

Front PTO

Differential

Differential Lock

Final Drives

Front Wheel Drive

FWD Axle with TLS

Hydraulic Brakes

Handbrake

Parking Lock

Hydraulic System with Axial Piston Pump

Rockshaft

Front Hitch

Ground Speeds

Front and Rear Wheels

Dimensions and Weights

Capacities

Handling and Storing Diesel Fuel

Diesel Fuel

Lubricity of Diesel Fuel

Diesel Engine Break-In Oil

Diesel Engine Oil

Transmission and Hydraulic Oil

Front Wheel Drive Axle Oil

Diesel Engine Coolant

Supplemental Coolant Additives

Grease

Oil Filters

Mixing of Lubricants

Lubricant Storage

Operating in Warm Temperature Climates

Alternative and Synthetic Lubricants

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

Torques for Inch Fittings Used in the Hydraulic System

Torques for Metric Fittings Used in the Hydraulic System

Installing Oil Hoses

Product Identification Number

Group 10: Tune-Up

Specifications

Using High-Pressure Washers

Preliminary Engine Test

Tractor Tune-Up

Remove and clean the primary air cleaner element

Checking the Air Cleaner Safety Element

Check dust unloading valve and dust trap If equipped

Check air intake system connections for leaks

Check crankcase vent hose for clogging

Clean radiator grille screen

Clean the radiator and oil cooler (or condenser)

Check caps on expansion tank

Check the radiator for leaks

Check engine thermostat

Check operation of fuel transfer pump

Checking the fuel filter

Bleeding the fuel system

Checking the fuel filter (with Bosch VP44 injection pump)

Bleeding the fuel system (with Bosch VP44 injection pump)

Clean the water trap

Run the engine until it is warm, and check engine speeds

Check setting of fuel injection pump

Check setting of speed control linkage

Cleaning the Battery, Cables and Battery Box with a Clean Cloth

Neutral Start Circuit

Check operation of starting motor

Check operation of lighting system

Final Engine Check

Tractor Operation Check

Group 15: Predelivery Inspection

Predelivery Inspection

Section 20: ENGINE

Group 00: Engine Removal and Installation

Special Tools

Specifications

Removing the Engine

Installing the Engine

Preparations for Replacing the Engine Mountings

Replacing Front Engine Mountings

Replacing Rear Engine Mountings

Section 30: FUEL, AIR INTAKE, COOLING AND EXHAUST SYSTEMS

Group 05: Speed Control Linkage

General Information

Specifications

Adjust Hand Throttle Lever and Accelerator Pedal

Adjusting Speed Control Linkage

Hand Throttle Lever-Exploded View

Accelerator Pedal-Exploded View

Accelerator Pedal, With Electronic Speed Control (“Cruise Control”)

Adjusting the Ball Joints

Installing the Ball Joint

Changing the Foot Throttle Potentiometer

Replacing the Accelerator Pedal Assembly (AutoPowr)

Removing the Foot Throttle Potentiometer

Removing the Hand Throttle Potentiometer

Group 10: Fuel System

General Information

Removing the Fuel Tank

Installing the Fuel Tank

Replacing the Fuel Level Sending Unit

Changing the Fuel Transfer Pump

Changing the Fuel Transfer Pump (with Bosch VP44 Injection Pump)

Changing Fuel Filter

Bleeding the Fuel System

Bleeding Air from the Fuel System (with Bosch VP44 Injection Pump)

Installing Check Valve in Fuel System

Group 15: Air Intake System

General Information

Air Cleaner-Exploded View

Air Intake System

Group 20: Cooling System

General Information

Specifications

Removing the Radiator

Changing the Fan or the Viscous Fan Drive

Installing Radiator

Oil Cooler for Front PTO

Installing Oil Hoses

Relieve Drive Belt Tension

Replacing Drive Belt

Replacing the Drive Belt Tensioner

Repairing the Fan Console

Group 25: Cold Weather Starting Aids

Fuel Preheater

Electrical Starting Aid

Coolant Heater

Group 30: Exhaust System

General Information

Specifications

Exhaust to Top Left-Install Muffler

Installing the Muffler Pipe

Installing the Exhaust Pipe

Exhaust to Top Right - Installing the Muffler

Installing the Exhaust Pipe and Muffler Pipe

Section 40: ELECTRICAL SYSTEM

Group 05: Connectors

Special or Essential Tools

General

Using high-pressure washers

Disconnecting electrical circuits

Stripping wire ends

Installing a terminal

WEATHER PACK connector

METRI PACK connector with terminal lock at the rear

METRI PACK connector with terminal lock at the front

METRI PACK connector

Connectors for electronic control units

Connector for injection pump

Connector at CAN bus terminating resistor

CRIMP SNAP IN connectors

Connectors

CPC connectors

KOSTAL connectors

DEUTSCH Connectors

Changing terminals

Relay socket

Power distribution connectors

Load center

Load center

Group 10: Wiring Harnesses

Disconnecting electrical circuits

Ground Point Locations

Removing and Installing Engine Wiring Harness W3

Removing and Installing Engine Wiring Harness W3 (Tractors with AutoPowr Transmission or Tractor 6910S)

Removing and Installing Starting Aid Wiring Harness W27

Removing and Installing Starting Aid Wiring Harness W27 (Tractors with AutoPowr Transmission or Tractor 6910S)

Removing and installing worklight wiring harness W14 (front corner)

Removing and Installing FWD Axle Wiring Harness W36 (with TLS)

Removing and Installing Front PTO Wiring Harness W39

Removing and Installing Cab Wiring Harness W4

Removing and Installing Cab Wiring Harness W4 (Tractors with Power Shift Transmission)

Removing and Installing Cab Wiring Harness W4 (Tractor 6910S)

Removing and Installing Cab Wiring Harness W4 (Tractors with AutoPowr Transmission)

Removing and installing harness for 7-terminal power socket W29

Removing and installing harness for 3-terminal power socket W31

Removing and installing multi-function unit wiring harnesses W5, W6

Removing and Installing Air Brake Wiring Harness W54 (50 km/h Tractors)

Removing and installing the shift console wiring harness (Power Shift transmission) W45

Removing and Installing Electronic Control Unit Wiring Harness W34

Removing and Installing Electronic Control Unit Wiring Harness W34 (Tractors with AutoPowr Transmission or Tractor 6910S)

Removing and installing stepper motor driver wiring harness W35

Removing and Installing Cab Roof Wiring Harness W11

Removing and Installing Worklight Wiring Harness W18 (Cab)

Removing and installing wiper wiring harnesses W7, W10 and W38

Removing and installing air conditioning and fan wiring harness W8

Removing and Installing Transmission Wiring Harness W13

Removing and Installing Transmission Wiring Harness W13 (Tractors with AutoPowr Transmission)

Removing and Installing Transmission Wiring Harness W20 (Tractors with Electrical Reverser Control)

Removing and Installing Transmission Wiring Harness W44 (Tractors with Power Shift Transmission)

Group 15: Charging Circuit

Specifications

Repairing the Alternator

Disconnecting Electrical Circuit

Relieve Drive Belt Tension

Remove/Install the Alternator

Group 20: Starter Motor Circuit

Special or Essential Tools

Specifications

Repairing the Starting Motor

Disconnecting electrical circuits

Removing and Installing Starter Motor

Group 25: Fuses, Relays and Switches

Special or Essential Tools

Specifications

Note

Disconnecting electrical circuits

Load Center

Load Center on Tractors with AutoPowr Transmission

Replacing the Main Fuse

Replacing the Electrical Starting Aid Fuse

Replacing the Fuses (Electrical Starting Aid) on Tractors with AutoPowr Transmission or 6910S Tractors

Replacing the Fuse for the Injection Pump (Tractors with AutoPowr Transmission) or Tractor 6910S

Replacing the starting motor relay

Replacing the Starting Motor Relay on Tractor with AutoPowr Transmission or Tractor 6910S

Replacing the electrical starting aid relay

Replacing the Relay for Electrical Starting Aid on Tractor with AutoPowr Transmission or Tractor 6910S

Replacing the relays for Power Shift transmission

Replacing front PTO relay

Replacing the Air Brake Relay (on 50km/h Tractors)

Replacing the Relay for the Injection Pump (Tractors with AutoPowr Transmission) or Tractor 6910S

Replacing the main switch

Replacing Brake Switches

Replacing Brake Switches (on 50km/h Tractors)

Replacing the Braking Switches (Tractors with AutoPowr Transmission)

Replacing the light switch

Replacing the worklight switches

Replacing the switch for lights on cab frame

Replacing the switch for the beacon light

Replacing the hazard warning light switch

Replacing the handbrake switch

Replacing Switches on Multi-Function Unit

Replacing the Rear Window Wiper/Washer Switch

Replacing the windshield/rear window switches

Replacing the dome light door switch

Replacing the Park Lock Switch (Tractors with Electrical Reverser Control)

Replacing the Switch for Reverse Range Lockout (Tractors with Electrical Reverser Control)

Replacing the front wheel drive switch

Replacing the headland management (HMS) switch

Replacing the rear PTO preselector switch

Replacing the switch for AutoQuad transmission

Replacing the switch for AutoQuad II transmission

Replacing the Gear Selector Switch on PowrQuad Plus, AutoQuad and AutoQuad II Transmissions

Replacing the blower switch

Replacing switch of air conditioning system compressor

Replacing the differential lock switch

Replacing the PTO switch

Replacing switch for remote control of PTO

Replacing the Rockshaft Control Switch

Replacing the Cruise Control Potentiometer

Replacing the Cruise Control Potentiometer

Rockshaft control

Electrical actuation of the independent control valves

Group 30: Monitoring Systems

Note

Note

Disconnecting electrical circuits

Replacing the Sending Unit for Air Cleaner Restriction

Replacing the Engine Speed Sending Unit

Replacing the Sending Unit for Engine Oil Pressure

Replacing Coolant Temperature Sending Unit

Replacing Manifold Pressure Sending Unit (Power Shift transmission)

Replacing the Ground Speed Sending Unit

Replacing Acoustic Warning Signal Sending Unit

Replacing the Sending Unit for the Park Lock's Acoustic Alarm (Tractors with AutoPowr Transmission)

Group 40: Electrical Components

Note

Specifications

Disconnecting electrical circuits

Replacing the 7-Terminal Power Outlet Socket

Replacing the 3-terminal power outlet socket

Replacing the multiple power-outlet socket strip

Removing the wiper motor

Adjusting the headlights

Adjusting the lights on the cab frame

Worklights with xenon bulbs

Section 52: POWER SHIFT TRANSMISSION

Group 00: Removing and Installing the Power Shift Transmission

Special Tools

Dealer-Manufactured Special Tools

Specifications

Removing the Power Shift Transmission

Installing the Power Shift Transmission

Group 05: Shift Controls

Removing and Installing the Shift Control Assembly

Disassemble and Assemble Shift Control Assembly

Replace Encoder

Replace Switch Module

Adjusting the Parking Lock

Group 10: Power Shift Transmission

Special Tools

Service Equipment and Tools

Other Material

Specifications

General Repair Procedures

Transmission Components

Removing the Power Shift Transmission

Remove Transmission Front Cover/Front Valve Housing

Remove Front Valve Housing

Valves in Front Valve Housing

Valves in Transmission Front Cover

Remove Clutch Pedal Valve

Replace Shaft Seal of Traction Clutch Valve Shifter Lever

Repair Transmission Oil Pump

Install Front Valve Housing

Install Transmission Front Cover

Repair or Replace Electro-Hydraulic Valves

Remove Clutch Pack Assembly

Disassemble Clutch Pack

Assemble Clutch Pack

Install Clutch Pack Assembly

Remove and Disassemble CLO-BHI Pack

Assemble and Install CLO-BHI Pack

Remove and Disassemble Input Planetary Carrier Assembly

Assemble and Install Input Planetary Carrier Assembly

Disassemble Output Housing Module and Remove Output Planetary Carrier

Disassemble Output Planetary Carrier Assembly

Assemble Output Planetary Carrier Assembly

Remove and disassemble B5 Brake Pack

Assemble and Install B5 Brake Pack

Install Output Planetary Carrier and Assemble Output Housing Module

Group 15: Reduction Gearbox

Special Tools

Service Equipment and Tools

Specifications

General Repair Procedures

Remove Differential Drive Shaft

Install Differential Drive Shaft and Adjust Cone Point

Remove and Install Reduction Gear Shaft

Repair Lube Manifold

Remove and Install Tow Disconnect

Replace Transmission Lock Return Spring

Remove and Install Parking Lock

Section 53: AUTOPOWR TRANSMISSION

Group 00: Removing and Installing the AutoPowr Transmission

Special or Essential Tools

Specifications

Removing the AutoPowr Transmission

Installing the AutoPowr Transmission

Group 05: Transmission Shift Controls

Repairing the Speed Control Lever

Repairing the Reverser Control

Repairing the Clutch Actuation Mechanism

Repairing the Manual Park Lock Release Mechanism

Releasing the Park Lock Manually

Group 10: Input Housing

Special or Essential Tools

Specifications

Removing the Clutch Control Block

Removing the System Pressure Control Block and Oil Filter

Removing the Transmission Oil Pump

Repairing the Transmission Oil Pump

Installing the Transmission Oil Pump

Repairing the System Pressure Control Block

Installing the System Pressure Control Block and Oil Filter

Repairing the Clutch Control Block

Installing the Clutch Control Block

Replacing the Hydrostatic Speed Sending Unit

Group 15: Output Housing

Special or Essential Tools

Specifications

Removing Park Lock Control Block

Removing Locking Pawl of Park Lock

Installing Locking Pawl of Park Lock

Repairing the Park Lock Control Block

Installing Park Lock Control Block

Replacing the Transmission Speed Sending Unit

Replacing the Transmission Input Speed Sending Unit

Group 20: Assembling the Differential Drive Shaft

Specifications

Preliminary Work

Differential Drive Shaft - Cross-Sectional View

Removing the Differential Drive Shaft

Repairing the Differential Drive Shaft

Final Assembly

Section 55: POWRQUAD, POWRQUAD PLUS AND AUTOQUAD TRANSMISSIONS

Group 00: Removal and Installation of Transmission Components

Special Tools

Dealer-Manufactured Special Tools

Specifications

Removing the PowrQuad Module

Installing the PowrQuad Module

Removing the Creeper Transmission

Installing the Creeper Transmission

Removing the Range Transmission

Installing the Range Transmission

Group 05: Transmission Shift Controls

Specifications

Gear shift linkage without forward/reverse interlock (reverser control on shift console)

Gear shift linkage with forward/reverse interlock, from tractor serial number 260099, (reverser control on shift console)

Range shift linkage without forward/reverse interlock (reverser control on shift console)

Range shift linkage with forward/reverse interlock, from tractor serial number 260099, (reverser control on shift console)

Gear shift linkage (reverser control on steering column)

Range shift linkage (reverser control on steering column)

Range shift linkage (PowrQuad Plus and AutoQuad transmissions)

Installing transmission bowden cables

Reverser control linkage adjustment

Adjusting shift linkage and parking lock - reverser control on shift console

Adjusting the shift linkage and parking lock - reverser control on steering column

Adjusting the shift linkage and parking lock - PowrQuad Plus and AutoQuad transmissions

Clutch pedal adjustment

Group 10: PowrQuad Module

Special or Essential Tools

Service Equipment and Tools

Other Material

Specifications

Transmission components

Installing transmission in repair stand

Removing the transmission front cover

Removing the front valve housing from the transmission cover

Valves in front valve housing

Valves in the front transmission cover

Removing the clutch pedal valve

Installing the clutch pedal valve

Transmission pump - cross-sectional view

Repairing the transmission pump

Installing the front valve housing

Installing the front transmission cover

Removing the shift valve housing

Replacing the shaft seals and shifter levers

Replacing the shifter shafts and arms

Valves in the shift valve housing

Speed modulator valve - cross-sectional view

Planetary housing valves

Forward/reverse valve - cross-sectional view (mechanical reverser control)

Forward/reverse valve - cross-sectional view (electrical reverser control)

Speed valve - cross-sectional view

Assembling and installing the shift valve housing

Disassembling the planetary gear

Reconditioning the input planetary carrier

Disassembling the input planetary assembly

Disassembling the disk brake housing

Planetary carrier/tractor clutch - cross-sectional view

Reconditioning the planetary carrier/tractor clutch

Disassembling the planetary housing components

Reconditioning the direct drive clutch

Assembling the planetary housing components

Assembling the disk brake housing

Assembling the planetary carrier

Assembling the planetary gear/disk brake housing

Removing the stepper motor

Installing the stepper motor

Adjusting the stepper motor

Group 15: Creeper Transmission

Service Equipment and Tools

Other Material

Specifications

Preliminary Work

Removing Shifter Components

Repair Input/Output Drive Shaft

Remove and Install Countershaft

Install Input/Output Shaft Assembly

Final Assembly

Group 20: Range Transmission

Special Tools

Service Equipment and Tools

Other Material

Specifications

Repair Instructions

Preliminary Work

Range Transmission-Sectional View

Shifting Mechanism-Cross-Sectional View

Removing Differential Drive Shaft

Removing Drive Shaft

Differential Drive Shaft - Exploded View

Drive Shaft (30 KM/H; 18.5 MPH Version) - Exploded View

Drive Shaft (40 KM/H; 25 MPH Version) - Exploded View

Shifting Mechanism - Exploded View

Parking Lock - Exploded View

Repairing the Drive Shaft

Installing Drive Shaft

Adjusting Drive Shaft End Play

Install Differential Drive Shaft and Adjust Cone Point

Adjusting End Play of Differential Drive Shaft

Adjusting Shifting Mechanism

Repairing and Installing Shift Cover

Final Assembly

Section 56: DRIVE SYSTEMS

Group 00: Removal and Installation of Components

Essential Tools

Self-manufactured tools

Specifications

Removing the differential housing

Installling the differential housing

Removing the final drives

Installing the final drives

Removing the FWD clutch

Installing the FWD clutch

Removing the rear PTO

Installing the rear PTO

Removing the front PTO

Installing the front PTO

Group 05: U-Jointed Shafts and Torsion Damper

Specifications

Removing the U.j. Shaft (FWD)

Reconditioning the U.j. Shaft (FWD)

Installing the U.j. Shaft (FWD)

Removing the U.j. Shaft (Engine)

Removing the Torsion Damper

Changing the Torsion Damper Bearings

Installing the Torsion Damper

Installing the U.j. Shaft (Engine)

Group 10: Front-Wheel Drive Clutch

Special Tools

Service Equipment and Tools

Specifications

Repair Instructions

Preliminary Work

Removing Clutch

Disassemble Clutch

Assembling Clutch

Installing Clutch

Adjust End Play

Adjusting the Brake Band

Final Assembly

Group 15: Differential

Special Tools

Service Equipment and Tools

Specifications

Repair Instructions

Preliminary Work

Removing the Differential

Disassembling the Differential

Assembling the Differential

Installing the Differential

Adjusting Differential Preload

Adjusting Backlash

Final Assembly

Group 20: Hydraulic Pump Drive

Special Tools

Service Equipment and Tools

Specifications

Remove and Disassemble Pump Drive Pinion Gear

Remove and Disassemble Pump Drive Gear

Assemble and Install Pump Drive Gear

Assemble and Install Pump Drive Pinion

Group 25: Final Drives

Special Tools

Service Equipment and Tools

Other Material

Specifications

Repair Instructions

Preliminary Work

Remove Planet Pinion Carrier

Disassemble Planet Pinion Carrier

Assemble Planet Pinion Carrier

Remove Axle Housing

Disassemble and Assemble Axle Housing

Disassemble and Assemble Axle Shaft

Install Axle Housing

Install Planet Pinion Carrier and Check Rolling Drag Torque

Final Assembly

Group 30: Rear PTO Options

Special Tools

Service Equipment and Tools

Specifications

Repair Instructions

Repair Rear PTO

Remove and Disassemble Countershaft

Assemble and Install Countershaft

Remove and Disassemble Output Shaft

Assemble and Install PTO Output Shaft

Remove PTO Shifter

Install PTO Shifter

Replacing Oil Seal on PTO Output Shaft

Remove Modulating Valve

Disassemble and Assemble Modulating Valve

Install Modulating Valve

Changing and Adjusting the Bowden Cable

Adjusting the Indicator Light Switch

Group 35: Front PTO

Service Equipment and Tools

Other Material

Specifications

General Repair Procedures

Front PTO-Cross-Sectional View

Repairing Solenoid Valve

Removing the Modulating Valve

Repairing the Modulating Valve

Installing the Modulating Valve

Replacing PTO Speed Sending Unit

Changing/Washing the Filter

Checking the Pressure Regulating Valve

Checking the Check Valves

Removing the Valve Plate

Disassembling Front PTO

Removing the Output Shaft Assembly

Repair Oil Pump

Assemble Oil Pump

Repairing the PTO Clutch

Repairing the PTO Brake

Installing Clutch and Brake

Repairing Intermediate Gear Shaft (PTO Rotating Counterclockwise)

Repairing the Drive Shaft

Assemble Drive Shaft, Shift Device and Front PTO

Adjusting Taper Roller Bearing of Drive Shaft

Adjusting Taper Roller Bearing of Output Shaft

Adjusting Taper Roller Bearing of Intermediate Gear Shaft

Installing Front PTO

Group 40: Front Implement Drive

Special Tools

Specifications

Front PTO Drive, Replace Damper

Section 60: STEERING AND BRAKES

Group 05: Hydrostatic Steering

Special Tools

Specifications

Preliminary Work

Removal

Disassembling the Steering Valve

Exploded View of Steering Valve

Assembling the Steering Valve

Adjusting the Double-Acting Shock Valves

Steering Wheel and Column-Exploded View

Repairing the Steering Column

Installation

Group 10: Brake Valve (Power Fill Brakes)

Special Tool (Dealer-Fabricated)

Specifications

Preliminary Work

Removing the Brake Valve

Brake Valve, Disassembly

Exploded View

Assembling the Brake Valve

Installing the Brake Valve

Adjusting the Brake Pedals

Adjust Brake Switches

Final Assembly

Bleeding the Brakes

Group 10A: Brake Valve (with MFWD and Disk Brake)

Special Tool (Dealer-Fabricated)

Specifications

Preliminary Work

Removing the Brake Valve

Disassembling the Brake Valve

Exploded View

Assembling the Brake Valve

Installing the Brake Valve

Adjusting the Brake Pedals

Adjusting the Brake Switches

Final Assembly

Bleeding the Brakes

Group 15: Rear Brakes

Specifications

Preliminary Work

Removing the Rear Brakes

Rear Brakes-Exploded View

Repairing the Rear Brakes

Installing the Rear Brakes

Final Assembly

Bleeding the Brakes (Brake Valve, Power-Fill Brakes and MFWD and Disk Brake)

Group 20: Handbrake

Specifications

Preliminary Work

Removing the Handbrake

Exploded View of Handbrake - 6810 Tractor

Exploded View of Handbrake - 6910 Tractor

Installing the Handbrake

Adjusting the Brake Band

Final Assembly

Handbrake Components

Replacing the Handbrake Cable

Adjusting the Handbrake

Group 25: Hydraulic Trailer Brake

Special Tools

Specifications

Repair Instructions

Replacing Trailer Brake Valve

Cleaning Trailer Brake Valve

Cleaning the Screen

Replacing the Check Valve

Bleeding Trailer Brake Valve

Checking Trailer Brake Valve

Adjusting Trailer Brake Valve

Group 30: Air Brakes

Special Tools

Specifications

General Information

Screw Union Installation

Changing the Compressor

Gaskets for the Compressor

Change Compressed Air Tank

Changing the Pressure Control Valve

Changing the Preload Valve

Changing the Trailer Control Valve

Change Pressure Gauge

Changing the Coupling Ends

Visual and Operational Checks

Test sequence

Checking the System for Leaks

Check Handbrake (Dual-Line Brakes)

Check Handbrake (Single-Line Brakes)

Adjusting the Handbrake

Checking the “Supply” Coupling End

Section 70: HYDRAULIC SYSTEM

Group 05: Controls

General Information

Specifications

Replacing and Adjusting the SCV Actuating Elements

Install Multi-Function Lever

Adjusting the Multi-Function Lever

Group 10: Hydraulic Pump and Charge Oil Pump

Service Equipment and Tools

Other Material

Specifications

Repair Instructions

Removing the Charge Pump

Disassembling the Charge Pump

Assembling the Charge Pump

Installing the Charge Pump

Checking the Lube Oil Valve

Restrictor in Oil Tank

Check Valve in Oil Leak-Off Line

Changing the Hydraulic Pump Controller

Hydraulic Pump Controller - Exploded View

Adjusting the Controller

Removing the Hydraulic Pump

Installing the Hydraulic Pump

40 cm3 (2.4 cu.in.) Hydraulic Pump - Exploded View

25 cm3 (1.5 cu.in.) Hydraulic Pump - Exploded View

Disassemble, Inspect and Assemble Hydraulic Pump

Adjust Swashplate Bearing Preload

Adjust Shaft Bearing Preload

Group 15: Valves

Special Tools

Special Tools (Dealer Fabricated)

Specifications

Repair Instructions

Direct Control of Rockshaft

Removing the Rockshaft Valve

Repairing the Rockshaft Valve

Depth to Which Raising and Lowering Valves Are Screwed In

Changing the Stepper Motor

Centering the Stepper Motor

Installing the Rockshaft Valve

Installing the Shuttle Valves

Removing the Main Block

Main Block-Exploded View

Repairing the Main Block

Installing the Main Block

Checking Oil Filter Head

Power Beyond Application Valve-Exploded View

Connecting the Power Beyond Application Valve

Adjusting the Power Beyond Application Valve

Converting the Power Beyond Application Valve

Connecting the Power Beyond Application Valve

Adjusting the Power Beyond Application Valve

Group 20: Rockshaft and Rockshaft Cylinder (up to Tractor Serial No. 260141)

Special Tools

Specifications

Electronic Hitch Control Unit (HCU)

Changing the Position Sensor

Cross-Section and Exploded View - Lift Cylinder

Removing and Installing the Lift Cylinders

Rockshaft - Exploded View

Replacing the Bushings on the Rockshaft Housing

Group 20A: Rockshaft and Rockshaft Cylinder (from Tractor Serial No. 260142)

Specifications

Electronic Hitch Control Unit (HCU)

Removing the Position Sensor and Toothed Segment

Attaching the Toothed Segment

Position Sensor - Exploded View

Installing the Position Sensor

Removing the Rockshaft Cylinders

Repairing the Rockshaft Cylinders

Installing the Rockshaft Cylinders

Rockshaft - Exploded View

Removing the Rockshaft

Installing the Rockshaft

Group 25: Three-Point Hitch

Other Material

Draft Sensor and Draft Link Support - Exploded View

Changing the Draft Sensor and Draft Link Support

Group 30: Selective Control Valves and Couplers

Special Tools (Dealer Fabricated)

Other Material

Specifications

Repair Instructions

SCV Identification

Removing Selective Control Valves

100 Series Selective Control Valve-Exploded View

Repairing 100 Series Selective Control Valve

200 Series Selective Control Valve-Exploded View

300 Series Selective Control Valve-Exploded View

Replacing Control Knobs

Inspect the Check Valves - 200 and 300 Series

Inspect Pressure Compensator Valve-300 Series

Inspect Metering Valve-300 Series

Inspect Metering Valve-200 Series

Repairing 300 Series Selective Control Valve Spool

Repairing 200 Series Selective Control Valve Spool

Installing Selective Control Valves

Install Shuttle Valves at the SCV

Installing the Left-Hand Endplate

Installing the Right-Hand Endplate

Adjusting LS Relief - L.H. Endplate with extra LS Connector for External Consumers

Adjusting LS Relief - R.H. Endplate with Extra Connectors for External Consumers

Adjusting the Kickout Relief Valve Detent - 300 Series SCV

Changing Couplers

DeLuxe Coupler - Exploded View

Repairing the Deluxe Coupler

Checking Couplers for Leaks

Group 35: Independent Control Valve

Other Material

Specifications

Repair Instructions

Removing the Independent Control Valve

Repairing the Control Valves (Mechanical Actuation)

Repairing the Control Valves (Electrical Actuation)

Inlet Plate with Pressure-Limiting Valve

Assembling the Control Valve

Installing the Control Valve

Section 80: MISCELLANEOUS

Group 00: Removal and Installation of Components

Special Tools

Dealer Fabricated Tools

Specifications

Removing the Main Frame (Tractors Without TLS Front Axle)

Installing the Main Frame (Tractors Without TLS Front Axle)

Removing Main Frame (Tractors With TLS Front Axle)

Installing Main Frame (Tractors With TLS Front Axle)

Removing the Front Wheel Drive Axle

Installing the Front-Wheel Drive Axle

Removing the Front Wheel Drive Axle With TLS

Installing the Front Wheel Drive Axle With TLS

Removing the Front Axle Support (Tractors Without TLS Front Axle)

Installing the Front Axle Support (Tractors Without TLS Front Axle)

Removing the Front Axle Support (Tractors With TLS Front Axle)

Installing the Front Axle Support (Tractors With TLS Front Axle)

Group 05: Main Frame

Specifications

Removing and Installing the Main Frame

Group 10: Front and Rear Wheels

Special Tools

Specifications

Removing a Wheel (Front or Rear)

Attaching Front Wheel

Attaching Rear Wheel

Group 15: Trailer Hitch and Swinging Drawbar

Specifications

Installing the Trailer Mounting for Center Link

Installing Guide Rails (with Height-Adjustable Trailer Hitch)

Height-Adjustable Trailer Hitch - Exploded View

Repairing Automatic Trailer Hitch (Two-Lever Operation)

Repairing Automatic Trailer Hitch (One-Lever Operation)

Remote Control for Automatic Trailer Hitch

Swinging Drawbar - Exploded View

Swinging Drawbar (with Pick-Up Hitch)

Group 20: Triple Link Suspension (TLS) of FWD Axle

General Information

Special Tools

Service Equipment and Tools

Other Material

Specifications

Relieving Pressure in the Hydraulic System

Removing/Installing the Oscillation Limiter

Removing the Panhard Link

Installing the Panhard Link

Suspended Front Axle (SFA) Controller

Removing the Position Sensor

Repairing the Position Sensor

Installing the Position Sensor

Adjusting the Sensor Rod

Removing the Hydraulic Cylinder

Repairing the Hydraulic Cylinder

Installing the Hydraulic Cylinder

Removing the Control Valve Block

Installing the Control Valve Block

Repairing the Solenoid Valves

Repairing the Pressure-Regulating Valve

Repairing the Pressure-Relief Valve

Repairing the Electro-Hydraulic Control Valve Plugs

Repairing the Bleed Valves

Repairing the Distributor Block

Removing and Installing the Accumulator

Repairing the Accumulator

Removing the Bearing Support

Installing the Bearing Support

Group 25: Pick-Up Hitch

Specifications

Other Material

Installing the Upper Frame

Frame Assembly - Exploded View

Operating Lever and Lift Links - Exploded View

Hydraulic Parts

Repairing the Retainer Spring

Repairing the Latch Housing

Repairing the Hydraulic Cylinder

Adjusting the Lift Links

Adjusting the Guide Stop

Adjusting the Locking Pin

Operational Check

Section 90: OPERATOR'S CAB

Group 00: Tilting, Removing and Installing the Operator's Cab

Special Tools

Specifications

Tilting the Operator's Cab Upward

Tilting the Operator's Cab Downward

Removing the Operator's Cab

Installing the Operator's Cab

Group 05: Controls and Instruments

Replacing Bulbs on the Instrument Unit

Removing Control Unit

Removing Control Unit for the Lighting System

Important Instructions

Replacing Electronic Control Unit (BCU)

Replacing Electronic Control Unit (RCU)

Replacing Electronic Control Unit (SFA)

Replacing Electronic Control Unit (ECU)

Replacing the Bus Resistors

Replacing Transmission Control Unit (PST)

Replacing the PPST/E-ICV Control Unit (PEC)

Replacing the Electronic Control Unit (UIC/PLC)

Replacing the Electronic Control Unit (TCU)

Replacing the Performance Monitor (PRF)

Replacing Instrument Unit (BIF)

Group 10: Electonic Hitch Control Components

Disconnecting Electrical Circuit

Replacing the Hitch Control Unit (HCU)

Replacing the Operation Unit

Group 15: Air Conditioning System

Special Tools

Specifications

Torques for Tightening Refrigerant Hoses

Safety At Work

Handling Refrigerant

In an Emergency

Safety Equipment

Storage of Refrigerant Containers

R134A Refrigerant

Important Note

Discharging the System

Evacuating the System

Filling with Refrigerant Oil

Instructions for Starting Up the DENSO Air-Conditioning Compressor

Filling the System

Topping Up a Partly Discharged System

Leak Test

Removing the Compressor

Checking Level in the Compressor

Disassembling the Compressor Clutch

Checking Clutch Hub Clearance

Checking the Compressor Manifold

Installing the Compressor

Routing the Air-Conditioning Hoses

Removing and Installing the Condenser

Removing and Installing the Receiver-Drier

Removing and Installing the Evaporator and Expansion Valve

Replacing the Expansion Valve

Installing Condensation Water Drain Hoses

Removing and Installing the Thermostat Switch

Adjusting Thermostat Switch Bowden Cables

Removing and Installing the High/Low Pressure Switch

Group 20: Heating System

Ventilation and Heater-Exploded View

Removing and Installing Fan and Radiator

Removing and Installing the Heater Valve

Adjusting Heater Valve Bowden Cables

Removing the Cab Air Filter

Replacing Recirculating Air Filter

Group 25: Operator's Cab

Specifications

Removing Cab Frame

Cab Mounting Torques

Removing Outer Roof

Removing Hatch

Installing Windshield

Installing Rear Window

Installing Door Lock

Replacing Handrail or Rear View Mirror

Adjusting Window Contact Pressure

Removing the Cab Door

Installing the Cab Door

Removing Inner Roof Trim

Group 30: Seats

Specifications

Comfort Seat MSG85

Air Comfort Seat MSG95A-00, Lower Section

Passenger Seat, Exploded View

Group 35: Components for Radio Installation

Radio, Loudspeakers and Aerial, Exploded View

Section 99: SPECIAL TOOLS (DEALER-FABRICATED)

Group 05: Special Tools (Dealer-Fabricated)

Lifting Device

Lifting Device

Adapter

Holding Device

Suspension Eyes for Operator's Cab

Holding Tool

DFRW79 - Piston Holding Tool

Socket Wrench Insert

Driver

DFRW29-Final Drive Housing Adapter

DFRW30-Axle Jacking Tool

Socket Wrench Insert

Special Key

Installation tool

Tube

Unlocking Device

Suspension Device