Complete Repair Service Technical Manual for John Deere Tractors 6010, SE6010, 6110, SE6110, 6210, 6310, 6410, SE6410, 6510, SE6510, 6610, SE6610, with all the shop information to maintain, diagnose, repair, and service like professional mechanics.

John Deere Tractors 6010, 6110, 6210, 6310, 6410, 6510, 6610 and SE Models 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.

tm4559 - 6010, 6110, 6210, 6310, 6410, 6510, 6610 and se tractors Technical Manual.pdf
tm4559 - 6010, 6110, 6210, 6310, 6410, 6510, 6610 and se tractors Technical Manual.epub

Total Pages: 2,368 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
      Starting Motor Circuit
      Fuses, Relays and Switches
      Monitoring Systems
      Electrical Components
   SYNCROPLUS TRANSMISSION
      Removal and Installation of Transmission Components
      Transmission Shift Controls
      Perma Clutch II
      Gear Transmission
   POWER REVERSER
      Removal and Installation of Power Reverser Module
      Transmission Shift Controls
      Power Reverser Module
      Gear Transmission
   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 PowrQuad Module
      Transmission Shift Controls
      PowrQuad Module
      Creeper Transmission
      Option 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
      Steering Cylinders
      Brake Valve (Non-Power Brakes)
      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 Pump (PFC Hydraulic System)
      Hydraulic Pump (PC Hydraulic System)
      Valves
      Valves on PC Hydraulic System
      Rockshaft and Rockshaft Cylinder
      Three-Point Hitch
      Selective Control Valves and Couplers
      Independent Control Valve
   MISCELLANEOUS
      Removal and Installation of Components
      Main Frame
      Front Axle
      Front and Rear Wheels
      Trailer Hitch and Swinging Drawbar
      Triple Link Suspension (TLS) of FWD Axle
      Pick-Up Hitch
   OPERATOR'S CAB AND 2-POST ROPS
      Tilting, Removing and Installing the Operator's Cab
      Tilting, Removing and Installing the Operator's Cab (SE Tractors)
      Removing and Installing the Open Operator's Station
      Controls and Instruments
      Electronic Hitch Control Components
      Air Conditioning System
      Heating System (6010 to 6610)
      Heating System (SE 6010 to SE 6610)
      Operator's Cab
      Seats
      Radio
   SPECIAL TOOLS (DEALER-FABRICATED)

tm4559 - 6010, 6110, 6210, 6310, 6410, 6510, 6610 and se 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

SyncroPlus transmission

Power Reverser

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

Hydraulic system with gear-driven 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 and sub-assembly serial numbers

Engine serial number

Transmission serial number

Front wheel drive axle serial number

Operator's cab serial number

Sub-assembly serial numbers

Group 10: Tune-Up

Specifications

Using high-pressure washers

Preliminary engine test

Tractor Tune-Up

Remove and clean the primary air cleaner element

Check the air cleaner safety element

Check the 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

Clean battery, cables and battery box with a clean cloth

Neutral Start Circuit

Check operation of starter 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 or Essential Tools

Specifications

Removing the Engine (6010 to 6410)

Installing the Engine (6010 to 6410)

Preliminary Work, Replacing Engine Mountings (6010 to 6410)

Front Engine Mountings

Rear Engine Mountings

Removing the Engine (6510 and 6610)

Installing the Engine (6510 and 6610)

Preliminary Work, Replacing Engine Mountings (6510 and 6610)

Front Engine Mountings

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 On Tractors With Low Platform

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

Adjusting the Ball Joints With electronic speed control (“cruise control”)

Installing the Ball Joint Ball joint on sensor (on the left when viewed in direction of travel)

Changing the Sensor

Replacing the Accelerator Pedal Assembly (AutoPowr)

Removing the Foot Throttle Potentiometer

Removing the Hand Throttle Potentiometer

Group 10: Fuel System

General Information

Special Tool (Dealer-Fabricated)

Removing the Fuel Tank

Installing the Fuel Tank

Replacing the Fuel Gauge Sending Unit

Changing the Fuel Transfer Pump

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

Changing the 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

Exploded View of Air Cleaner

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

Relieving Tension on the Drive Belt

Replacing the 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

Exhaust to Top Right

Exhaust to Bottom Right

Section 40: ELECTRICAL SYSTEM

Group 05: Connectors

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

Changing terminals

Relay socket

Power distribution connectors

Load center

Group 10: Wiring Harnesses

Disconnecting Electrical Circuits

Ground Point Locations

Removing and Installing Engine Wiring Harness W3 (4-Cylinder Engine)

Removing and Installing Engine Wiring Harness W3 (Tractors with AutoPowr Transmission and 4-Cylinder Engine)

Removing and Installing Engine Wiring Harness W3 (6-Cylinder Engine)

Removing and Installing Engine Wiring Harness W3 (Tractors with AutoPowr Transmission and 6-Cylinder Engine)

Removing and Installing Engine Wiring Harness W3 (with Open Operator's Station)

Removing and Installing Starting Aid Wiring Harness W27

Removing and Installing Starting Aid Wiring Harness W27 (Tractors with AutoPowr Transmission)

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 AutoPowr Transmission)

Removing and Installing Cab Wiring Harness W4 (SE Tractors)

Removing and Installing Open Station Wiring Harness W4

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 Electronic Control Unit Wiring Harness W34

Removing and Installing Electronic Control Unit Wiring Harness W34 (Tractors with AutoPowr Transmission)

Removing and installing stepper motor driver wiring harness W35

Removing and Installing Cab Roof Wiring Harness W11

Removing and Installing Cab Roof Wiring Harness W11 (SE Tractors)

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 Air Conditioning and Fan Wiring Harness W8 (SE Tractors)

Removing and Installing Transmission Wiring Harness W13

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

Removing and Installing Transmission Wiring Harness W13 (SE Tractors)

Removing and Installing Transmission Wiring Harnesses W32 and W33 (with Open Operator's Station)

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

Group 15: Charging Circuit

Specifications

Repairing the Alternator

Disconnecting Electrical Circuits

Relieving the Drive Belt

Remove/Install the Alternator

Group 20: Starting Motor Circuit

Essential Tools

Specifications

Repairing the Starting Motor

Disconnecting Electrical Circuits

Removing and Installing the Starter Motor

Group 25: Fuses, Relays and Switches

Essential Tools

Specifications

Note

Disconnecting Electrical Circuits

Load Center (Tractors with Cab)

Load Center on Tractors with AutoPowr Transmission

Load Center on SE Tractors

Load Center on Tractors with Open Operator's Station

Replacing the Main Fuse

Replacing the electrical starting aid fuse

Replacing the Fuses for the Electrical Starting Aid (Tractors with AutoPowr Transmission)

Replacing the Fuse for the Injection Pump (Tractors with AutoPowr Transmission)

Replacing the Starting Motor Relay

Replacing the Electrical Starting Aid Relay

Replacing the Relay for the Front PTO

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

Replacing the Injection Pump Relay (Tractors with AutoPowr Transmission)

Replacing the Main (Key) Switch

Replacing the Brake Switches

Replacing the Light Switch and Low/High Beam Switch

Replacing the Light Switch

Replacing 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 Turn Signal Switch

Replacing the Horn Switch

Replacing the Dome Light Door Switch

Replacing Switches on Multi-Function Unit

Replacing the Windshield Wiper/Washer Switch

Replacing the Rear Window Wiper/Washer Switch

Replacing Windshield/Rear Window Switches

Replacing the Handbrake 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 Switches

Replacing the 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 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)

Replacing Flasher

Replacing the Basic Informator

Adjusting the Basic Informator

Group 40: Electrical Components

Note

Specifications

Disconnecting Electrical Circuits

Replacing the 7-terminal Power Outlet Socket

Replacing the 3-terminal Power Outlet Socket

Replacing Multiple Power-Outlet Socket Strip

Replacing the 2-terminal Power Outlet Socket

Removing the Wiper Motor

Adjusting the Headlights

Adjusting the Lights on the Cab Frame

Worklights with Xenon Bulbs

Section 50: SYNCROPLUS TRANSMISSION

Group 00: Removal and Installation of Transmission Components

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Removing the Clutch Housing

Installing the Clutch Housing

Removing the Gear Transmission

Installing the Gear Transmission

Group 05: Transmission Shift Controls

Specifications

Gear Shift Linkage, Exploded View and Assembly

Range Shift Linkage, Exploded View and Assembly

Adjusting the Shift Linkage and Parking Lock

Clutch Pedal Adjustment

Group 10: Perma Clutch II

Essential Tools

Specifications

Preliminary Work

Preliminary Work

Removing the Transmission Oil Pump

Transmission Oil Pump, Exploded View

Assembling the Transmission Oil Pump

Installing the Transmission Oil Pump

Disassembling the Clutch

Exploded View of Clutch

Assembling the Clutch

Installing the Clutch

Valves and other Hydraulic Components

Reconditioning the Engagement Override Valve

Reconditioning the Clutch Cooling Valve

Reconditioning the Cooling Pilot Valve

Reconditioning the Filter Relief Valve

Reconditioning the Pressure Regulating Valve

Reconditioning the Lube Relief Valve

Reconditioning the Cooler Relief Valve

Removing the Clutch Pedal Valve

Installing the Clutch Pedal Valve

Temperature and Pressure Sending Units

Test Ports

Group 15: Gear Transmission

Essential Tools

Specifications

Preliminary Work

Gear Transmission - Cross-Sectional View

Disassembling the Gear Shift Transmission

Exploded View of Gear Transmission

Exploded View of Shift Cover

Assembling the Drive Shaft

Installing Shafts

Final Assembly

Measuring the Gaps at the Connecting Ring

Final Assembly

Adjusting the Shift Linkage

Adjusting the Neutral Start Switch

Checking the Neutral Start Switch

Section 51: POWER REVERSER

Group 00: Removal and Installation of Power Reverser Module

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Removing the Power Reverser Module

Installing the Power Reverser Module

Removing and Installing the Gear Transmission

Group 05: Transmission Shift Controls

Specifications

Forward/Reverse Linkage, Exploded View and Assembly

Range Shift Linkage, Exploded View and Assembly

Gear Shift Linkage, Exploded View and Assembly

Adjusting the Forward/Reverse Linkage

Adjusting the Shift Linkage and Parking Lock

Adjusting the Reverse Drive Lever

Clutch Pedal Adjustment

Group 10: Power Reverser Module

Essential Tools

Specifications

Power Reverser Module - Sectional View

Components of Power Train

Preliminary Work

Repair Instructions

Removing the Disk Brake

Removing the Clutch and Planet Carrier

Removing the Transmission Oil Pump

Disassembling the Transmission Oil Pump

Exploded view of Transmission Oil Pump

Assembling the Transmission Oil Pump

Installing the Transmission Oil Pump

Disassembling the Clutch and Planet Carrier

Exploded View of Clutch and Planet Carrier

Assembling the Clutch and Planet carrier

Installing the Clutch and Planet Carrier

Exploded View of Disk Brake

Reconditioning and Installing the Disk Brake

Final Assembly

Valves and other Hydraulic Components

Repair Instructions

Replacing the Oil Filter

Reconditioning the Pressure Regulating Valve

Reconditioning the Cooling Pilot Valve

Reconditioning the Clutch Cooling Valve

Reconditioning the Engagement Override Valve

Reconditioning the Filter Relief Valve

Reconditioning the Cooler Relief Valve

Reconditioning the Lube Relief Valve

Reconditioning the Sump Valve

Reconditioning the Accumulator Piston

Reconditioning the Forward/Reverse Valve

Reconditioning the Fwd/Rev Cooling Control Valve

Reconditioning the Modulator Valve

Reconditioning the Connecting Valve

Reconditioning the Clutch Pedal Valve

Temperature and Pressure Sending Units

Replacing the Neutral Start Switch

Test Ports

Group 15: Gear Transmission

Essential Tools

Specifications

Preliminary Work

30 km/h (18.5 mph) Gear Transmission - Sectional View

40 km/h (25 mph) Gear Transmission - Sectional View

Disassembling the Gear Transmission

Exploded View of Gear Transmission

Exploded View of Shift Cover

Assembling the Drive Shaft

Installing Shafts

Final Assembly

Measuring the Gaps at the Connecting Ring

Adjusting the Shift Linkage

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

Repair 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 Oil Filter and System Pressure Control Block

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 the Park Lock Control Block

Repairing the Park Lock Control Block

Installing the 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 PowrQuad Module

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Removing the Module

Installing the PowrQuad Module

Removing Creeper or Option Transmission

Installing Creeper or Option Transmissions

Removing the Range Transmission

Installing the Range Transmission

Group 05: Transmission Shift Controls

Other Material

Specifications

Gear Shift Linkage without Forward/Reverse Interlock (Reverser Control on Shift Console)

Gear Shift Linkage with Forward/Reverse Interlock, from tractor ser. no. 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 ser. no. 260099, (Reverser Control on Shift Console)

Reverser Control on Steering Column

Gear Shift Linkage (Reverser Control on Steering Column)

Range Shift Linkage (Reverser Control on Steering Column)

Range Shift Linkage (PowrQuad Plus and AutoQuad Transmissions)

Adjusting the Reverser Control Linkage

Adjusting Shifter and Parking Lock - Reverser Control on Shift Console

Adjusting Shifter 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/Front Valve Housing

Removing the Front Valve Housing

Valves in Front Valve Housing

Valves in 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 Transmission Front Cover/Front Valve Housing

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

Specifications

Disassembling the Creeper Transmission

Assembling the Creeper Transmission

Shift Linkage (Locking Pins)-Sectional View

Installing the Shift Linkage

Reconditioning the Shift Cover

Final Assembly

Group 20: Option Transmission

Specifications

Disassembling the Option Transmission

Assembling the Countershaft

Installing Shafts

Final Assembly

Adjusting the Shift Linkage

Group 25: Range Transmission

Other Material

Specifications

Disassembling the Range Transmission

Exploded View - Drive Shaft and Parking Lock

Exploded View of Shift Linkage

Exploded View of Shift Cover

Assembling the Range Transmission

Section 56: DRIVE SYSTEMS

Group 00: Removal and Installation of Components

Special or Essential Tools

Self-Manufactured Tool

Specifications

Removing the FWD Clutch

Installing the Final Drives

Removing the Differential Housing

Installing the Differential Housing

Removing the Final Drives

Installing the Final Drives

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

Installing the Torsion Damper

Installing the U.j. Shaft (Engine)

Group 10: Front-Wheel Drive Clutch

Specifications

Other Material

Special Tool (Dealer-Manufactured)

Disassembling the Front-Wheel Drive Clutch

Assembling the Front-Wheel Drive Clutch

Group 15: Differential

Specifications

Removing the Differential

Disassembling the Differential

Assembling the Differential

Installing the Differential

Adjusting the Taper Roller Bearing

Adjusting Backlash

Final Assembly

Group 20: Hydraulic Pump Drive

Special or Essential Tools

Specifications

Removing Pump Drive

Installing the Pump Drive

Final Assembly

Adjusting the Pump Drive

Group 25: Final Drives

Special or Essential Tools

Specifications

Disassembling Final Drives

Assembling Final Drives

Adjusting Rear Axle Rolling Drag Torque

Final Assembly

Repairing Damaged or Worn Threads in the Flanged Axle (Repair Kit FKM10476)

Group 30: Rear PTO Options

Special or Essential Tools

Special Tools (Dealer Fabricated)

Other Material

Specifications

Replacing Output Shaft Seal Ring

Changing the O-Ring on Reversible PTO

Removing the PTO Clutch

Adjusting Play at Hub

Installing the PTO Clutch

Replacing the PTO Brake

Disassembling the PTO Drive Train

Repairing the Output Shaft (540/1000 rpm Reversible)

Repairing the Output Shaft (540/1000 rpm Shiftable)

Assembling the Output Shaft (540/1000 rpm Shiftable, 540/540E/1000 rpm)

Repairing the Countershaft (540/1000 rpm and 540/540E/1000 rpm)

Assembling the PTO Shifter (540/1000 rpm Shiftable and 540/540E/1000 rpm)

Assembling PTO Drive Train

Adjusting Taper Roller Bearing at Output Shaft

Adjusting Taper Roller Bearing of Countershaft

Installing the Support and Adjusting the Taper Roller Bearings

Installing the PTO Housing

Removing the PTO Modulating Valve

Repairing the PTO Modulating Valve

Installing the PTO Modulating Valve

Repairing the Solenoid Valve

Replacing PTO Speed Sending Unit If equipped

Changing and Adjusting the Bowden Cable

Group 35: Front PTO

Special or Essential Tools

Other Material

Specifications

General Repair Procedures

Repairing the 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/Installing the Valve Plate

Disassembling the Front PTO

Repairing the Oil Pump

Repairing the PTO Clutch

Repairing the PTO Brake

Installing the PTO Clutch and Brake

Repairing the Intermediate Gear Shaft (PTO Rotating Counterclockwise)

Repairing the Drive Shaft

Adjusting the Taper Roller Bearings at the Drive Shaft

Adjusting the Taper Roller Bearings at the Output Shaft

Adjusting the Taper Roller Bearings at the Intermediate Gear Shaft

Installing the Front PTO

Group 40: Front Implement Drive

Special or Essential Tools

Specifications

Removing/Installing the Front Implement Drive

Replacing the Damper

Section 60: STEERING AND BRAKES

Group 05: Hydrostatic Steering

Special or Essential Tools

Specifications

Preliminary Work

Removal - Tractors With Cab

Removal - SE Tractors and Tractors Without Cab

Disassembling the Steering Valve

Exploded View of Steering Valve

Assembling the Steering Valve

Adjusting the Double-Acting Shock Valves

Steering Wheel and Steering Column (With Cab)

Steering Wheel and Column (SE Tractors and Tractors Without Cab)

Repairing the Steering Column

Installation - Tractors With Cab

Installation - SE Tractors and Tractors Without Cab

Group 10: Steering Cylinders

General Information

Special or Essential Tools

Specifications

Removing the Steering Cylinder

Disassembling the Steering Cylinder

Assembling the Steering Cylinder

Installing the Steering Cylinder

Group 15A: Brake Valve (Non-Power Brakes)

Special or Essential Tools

Specifications

Checking Brake Piston Travel

Checking Control Valve Opening Pressure - Preliminary Work

Checking the Control Valve Opening Pressure

Repair Kit AL117240

Repairing the Control Valve (Repair Kit AL117240)

Checking Control Valve Opening Pressure

Adjusting the Brake Switches

Removing the Brake Valve

Disassembling the Brake Valve

Assembling the Brake Valve

Installing the Brake Valve

Adjusting the Brake Pedals

Checking Control Valve Opening Pressure - Preliminary Work

Checking Control Valve Opening Pressure

Adjusting the Brake Switches

Final Assembly

Group 15B: Brake Valve (Power Fill Brakes)

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 15C: Brake Valve (with MFWD and Disk Brake)

Special Tool (Dealer-Manufactured)

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 20: Rear Brakes

Special Tools

Specifications

Removing the Rear Brakes

Installing the Rear Brake

Checking Brake Pistons for Return Movement and Leakage

Final assembly

Bleeding the Brakes (Brake Valve, Non-Power Brakes)

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

Group 25: Handbrake

Specifications

Preliminary Work

Removing the Handbrake

Handbrake - Exploded View

Installing the Handbrake

Final Assembly

Handbrake Components

Replacing the Handbrake Cable

Handbrake Test

Adjusting the Handbrake

Group 30: Hydraulic Trailer Brake

Special Tools

Specifications

Repair Instructions

Changing the Trailer Brake Valve

Cleaning the Trailer Brake Valve

Cleaning the Screen

Replacing the Check Valve

Bleeding the Trailer Brake Valve

Checking the Trailer Brake Valve

Adjusting the Trailer Brake Valve

Group 35: Air Brakes

Special or Essential Tools

Specifications

Screw Union Installation

Changing the Compressor

Gaskets for the Compressor

Changing the Compressed Air Tank

Changing the Pressure Control Valve

Changing the Preload Valve

Changing the Trailer Control Valve

Exploded View of Trailer Control Valve

Exploded View of Trailer Control Valve (Tractors with MFWD and Disk Brake Only)

Changing the Trailer Control Valve

Exploded View of Trailer Control Valve

Changing the Coupling Ends

Changing the Pressure Gauge

Test Sequence

Checking the System for Leaks

Checking the “Supply” Coupling End

Checking Dual-Line Brakes

Checking Single-Line Brakes

Adjusting the Handbrake (With Air Brake System)

Section 70: HYDRAULIC SYSTEM

Group 05: Controls

General

Specifications

Replacing and Adjusting the SCV Actuating Elements

Installing the Multi-Function Lever

Adjusting the Multi-Function Lever

Group 10: Hydraulic Pump and Charge Pump (PFC Hydraulic System)

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

Adjusting the Swashplate Bearing Preload

Adjusting the Shaft Bearing Preload

Group 11: Hydraulic Pump (PC Hydraulic System)

Specifications

Repair Instructions

Removing the Hydraulic Pump

Exploded View

Reconditioning the Hydraulic Pump

Removing the Installation Plate

Changing the Lube Priority Valve

Installing the Installation Plate

Installing the Hydraulic Pump

Group 15: Valves

Special Tools

Dealer-Manufactured Special Tools

Specifications

Repair Instructions

Direct Control of Rockshaft

Removing the Rockshaft Valve

Repairing the Rockshaft Valve

Checking the Depth to which the Raising and Lowering Valves are screwed in

Changing the Stepper Motor

Centering the Stepper Motor

Installing the Rockshaft Valve

Shuttle Valves, Arrangement in PFC Hydraulic System

Removing the Main Block

Main Block - Exploded View

Repairing the Main Block

Installing the Main Block

Checking the 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 16: Valves on PC Hydraulic System

Note

Specifications

Repair Instructions

Shuttle Valves, Arrangement in PC Hydraulic System

Removing the Main Block

Main Block-Exploded View

Repairing the Main Block

Installing the Main Block

Checking the Filter By-Pass Valve and Oil Filter Head

Replacing the Lube Priority Valve

Group 20: Rockshaft and Rockshaft Cylinder

Specifications

Electronic Hitch Control Unit (HCU)

Removing the Position Sensor and Toothed Segment

Attaching the Toothed Segment

Exploded View

Installing the Position Sensor

Removing the Rockshaft

Assembling the Rockshaft

Removing the Rockshaft Cylinders

Repairing the Rockshaft Cylinder

Changing the Rockshaft Cylinder Gaskets

Assembling the Rockshaft Cylinders

Installing the Rockshaft Cylinder

Group 25: Three-Point Hitch

Special or Essential Tools

Self-Manufactured Special Tools

Specifications

Removing Draft-Sensing Pins or Draft Link Bearing Pins

Assembling the Draft-Sensing Pin(s)

Installing the Draft-Sensing Pin(s) or Bearing Pins

Checking and Adjusting the Draft Sensor

Group 30: Selective Control Valves and Couplers

Dealer-Manufactured Special Tools

Other Material

Specifications

Repair Instructions

SCV Identification

Removing Selective Control Valves

Series 100/101 Selective Control Valve - Exploded View

Reconditioning the Selective Control Valve - 100/101 Series

Series 200/201 Selective Control Valve - Exploded View

Series 300/301 Selective Control Valve - Exploded View

Replacing Control Knobs

Inspecting the Check Valves

Inspect Pressure Compensator Valve - 300/301 Series

Inspect Metering Valve - 300/301 Series

Inspect Metering Valve - 200/201 Series

Reconditioning the Valve Spool - 200/201 Series

Reconditioning the Valve Spool - 200/201 Series

Installing the SCV Unit

Shuttle Valves, Arrangement in PFC Hydraulic System

Shuttle Valves, Arrangement in PC Hydraulic System

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

Reconditioning 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 or Essential Tools

Dealer-Manufactured Special Tools

Self-Manufactured Tools

Specifications

Removing the Main Frame (6010 to 6410 Without FWD Axle With TLS)

Installing the Main Frame (6010 to 6410 Without FWD Axle With TLS)

Removing Main Frame (Tractors With TLS Front Wheel Drive Axle)

Installing the Front Wheel Drive Axle With TLS

Removing the Main Frame (6510 and 6610 Without FWD Axle With TLS)

Installing the Front Wheel Drive Axle With TLS

Removing the Front Axle

Installing the Front Axle

Removing the Front-Wheel Drive Axle

Installing the Front Wheel Drive Axle With TLS

Removing the Front Wheel Drive Axle With TLS

Installing the Front Wheel Drive Axle With TLS

Removing the Front Axle Support (6110 to 6610 With FWD Axle With TLS)

Installing the Front Axle Support (6110 to 6610 With FWD Axle With TLS)

Removing the Front Axle Support (6510 and 6610 Without FWD Axle With TLS)

Installing the Front Axle Support (6510 and 6610 Without FWD Axle With TLS)

Group 05: Main Frame

Specifications

Main Frame, 4-cyl. and 6-cyl. Tractors

Group 10: Front Axle

General Information

Specifications

Disassembling the Front Axle

Assembling the Front Axle

Assembling Axle Center Section

Installing the Front Axle

Installing the Tie Rod

Checking Front Wheel Toe-In

Adjusting Front Wheel Toe-In

Group 15: Front and Rear Wheels

Special or Essential Tools

Specifications

Removing a Wheel (Front or Rear)

Assembling the Rear Wheel (With Rack-and-Pinion Axle)

Attaching the Front Wheel

Attaching the Rear Wheel

Group 20: Trailer Hitch and Swinging Drawbar

Specifications

Installing Rigid Trailer Mounting

Installing the Guide Rails

Repairing the Automatic Trailer Hitch (Two-Lever Operation)

Repairing the Automatic Trailer Hitch (One-Lever Operation)

Remote Control for Automatic Trailer Hitch

Swinging Drawbar

Swinging Drawbar with Pick-Up Hitch

Adjusting the Retaining Strap

Group 25: Triple Link Suspension (TLS) of FWD Axle

General Information

Special or Essential Tools

Other Material

Specifications

Making the Hydraulic System Pressure-Free

Removing/Installing the Oscillation Limiter

Removing the Panhard Link

Installing the Panhard Link

Suspended Front Link (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/Installing the Accumulators

Repairing the Accumulator

Removing the Bearing Support

Installing the Bearing Support

Group 30: 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 AND 2-POST ROPS

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

Special or Essential Tools

Dealer-Manufactured 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 01: Tilting, Removing and Installing the Operator's Cab (SE Tractors)

Special or Essential Tools

Dealer-Manufactured Special Tools

Specifications

Tilting Flat-Floor Cabs on SE Tractors

Tilting the Operator's Cab Upward (SE Tractors)

Tilting the Operator's Cab Downward (SE Tractors)

Removing the Operator's Cab from SE Tractors

Installing the Operator's Cab on SE Tractors

Group 02: Removing and Installing the Open Operator's Station

Special or Essential Tools

Specifications

Removing the Open Operator's Station

Installing the Open Operator's Station

Group 05: Controls and Instruments

Replacing Bulbs on the Instrument Unit

Removing Control Unit

Removing Control Unit for the Lighting System

Replacing Electronic Control Unit (BCU)

Replacing Electronic Control Unit (RCU)If equipped

Replacing Electronic Control Unit (SFA)If equipped

Replacing Electronic Control Unit (ECU)If equipped

Replacing the Bus Resistors

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

Replacing the Electronic Control Unit (UIC/PLC)

Replacing the Electronic Control Unit (TCU)

Replacing the Performance Monitor (PRF)If equipped

Replacing Instrument Unit (BIF)

Group 10: Electronic Hitch Control Components

Disconnecting Electrical Circuits

Replacing the Hitch Control Unit (HCU)

Replacing the Operation Unit

Group 15: Air Conditioning System

Special or Essential 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 ValveNot on SE tractors

Replacing the Expansion Valve

Removing and Installing the Evaporator and Expansion Valve on SE Tractors

Install Condensation Water Drain Hoses Not on SE tractors

Arrangement of Condensation Water Drain Hoses on SE Tractors

Removing the Heater/Evaporator Housing From SE Tractors

Removing and Installing the Thermostat Switch

Adjusting the Thermostat Switch Bowden Cables Not on SE tractors

Removing and Installing the Thermostat Switch on SE tractors

Removing and Installing the High/Low Pressure Switch

Group 20: Heating System (6010 to 6610)

Ventilator and Heater-Exploded View

Removing and Installing Fan and Radiator

Removing and Installing the Heater Valve

Adjust Bowden Cables of Heater Valve

Removing the Cab Air Filter

Replacing Recirculating Air Filter

Group 21: Heating System (SE 6010 to SE 6610)

Ventilator and Heater-Exploded View

Removing the Cab Air Filter

Removing and Installing Fan and Radiator

Removing and Installing the Heater Valve

Removing the Heater/Evaporator Housing

Group 25: Operator's Cab

Specifications

Removing Cab Frame

Torques for Hardware on Platform Mountings (2-Post ROPS, Standard Version)

Torques for Hardware on Cab Mountings (6010-6410 and SE 6010 to SE 6410)

Torques for Hardware on Cab Mountings (6510, 6610, SE 6510 and SE 6610)

Removing the Outer Roof

Removing the Hatch

Removing and Installing the Windshield

Removing and Installing the Rear Window

Installing the 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

Exploded View of Comfort Seat MSG44-A1

Air Comfort Seat MSG95A-00, Lower Section

Passenger Seat, Exploded View

Group 35: Radio

Radio, Loudspeakers and Aerial, Exploded View

Section 99: SPECIAL TOOLS (DEALER-FABRICATED)

Group 05: Special Tools (Dealer-Fabricated)

Load-Positioning Device

Load-Positioning Device

Holding Device

Suspension Eyes for Operator's Cab

Holding Device

Holding Tool

Wooden Block

DFRW79 - Piston Holding Tool

Socket Wrench Insert

Seal Installer

Seal Installer

Assembly and Guide Mandrels

Turning Device

Installation tool

Tube

Bushing

Socket Wrench Insert

Special Key

Spannvorrichtung

John Deere Tractors 6010, SE6010, 6110, SE6110, 6210, 6310, 6410, SE6410, 6510, SE6510, 6610, SE6610 Repair Service Manual (TM4559)