John Deere 6103 6203 6403 6603 Tractors Workshop Repair Service Manual TM6020 PDF - MJODTM6020.zip

Full service and repair workshop guide covering John Deere Tractor models 6103, 6203, 6403 and 6603 (built for Latin America, South Africa and Asia), packed with the dealer-level detail professional technicians rely on for maintenance, overhaul and servicing.

Inside the John Deere 6103, 6203, 6403 and 6603 technical repair manual you'll find:

* 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.

tm6020 - 6103, 6203, 6403 and 6603 Tractors Latin America, South Africa, Asia Technical Manual - Repair.pdf

tm6020 - 6103, 6203, 6403 and 6603 Tractors Latin America, South Africa, Asia Technical Manual - Repair.epub

Total Pages: 1,473 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

MAIN SECTIONS

Foreword

General Information

Safety

Specifications

Fuel and Lubricants

Serial Number Locations

Engine Repair

Engine

Cooling System

Fuel and Air Repair

Fuel System

Speed Control Linkage

Air Intake System

Electrical Repair

Battery, Starter and Alternator

Harness and Connector Repair

Wiring Harness Routing

Electrical System Components

Auxiliary Lighting Components

Fuses And Relays

Lighting

Power Train

Towing

Component Removal

PTO

Clutch

Clutch Housing (Until Transmission Serial Number - 001984)

Clutch Housing (From the Transmission Serial Number 001985 - )

Transaxle

Differential

Final Drives

MFWD Drop Gearbox

Steering and Brake Repair

Steering Repair

Front Axle-2WD

Front Axle-MFWD (AS2035)

Front Axle-MFWD (APL350)

Technical Data and Adjustment Values for APL350 ZF Series

Disassembly

Assembling the differential

Pinion depth

Adjusting the play between the teeth

Assembling the Housings

Assembling the Universal Joint

Planet Carrier

Assembling the Hydraulic Cylinder

Convergence Regulation

Brake Repair

Hydraulic Repair

Hydraulic Pump and Filter

Rockshaft

Lubrication System

Selective Control Valve (SCV)

Miscellaneous Repair

Hood and Shields

3-Point Hitch

Wheels

Front Support

Operator Station Repair

Seat and Support

ROPS

Operator Platform

Cab Operator Station Repair

Removal and Installation of Components

Selective Control Valve Cable Adjustment

Air Conditioning System

Heating System

Seat

6003 SERIES TOOL KIT (ESSENTIAL TOOL Reference Only)

6003 SERIES TOOL KIT (ESSENTIAL TOOL Reference Only)

SPECIAL TOOLS (Dealer-Fabricated)

tm6020 - 6103, 6203, 6403 and 6603 Tractors Latin America, South Africa, Asia

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Prevent Machine Runaway

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Construct Dealer-Made Tools Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Service Cooling System Safely

Live With Safety

Group 10: Specifications

Machine Specifications and Capacities

Machine Dimensions and Weights

Turning Radius for MFWD 6403 Tractors

Turning Radius for MFWD 6603 Tractors

Turning Radius for 2WD 6603 and 6403Tractors

Ground Speeds Estimates

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Sealants and Adhesives Cross-Reference Chart

How To Dispense/Apply/Assemble Gasket Sealants

Prevent Hydraulic System Contamination

Check Oil Lines and Fittings

Group 15: Fuel and Lubricants

Diesel Fuel

Storing Fuel

Testing Diesel Fuel

Heavy Duty Diesel Engine Coolant

Diesel Engine Oil

Transmission and Hydraulic Oil

Fill The Transmission With Oil

Check And Service Transmission Regularly

Cold Weather Operation

MFWD Gear Oil

Lubricant Storage

Alternative and Synthetic Lubricants

Grease (Specific Application)

Grease

Group 20: Serial Number Locations

Serial Numbers

Product Identification Number Location

Engine Serial Number Location

Fuel Injection Pump Serial Number Location

Alternator Serial Number Location

Transaxle Serial Number Location

Mechanical Front Wheel Drive (MFWD) Serial Number Location

Section 20: Engine Repair

Group 05: Engine

Essential or Recommended Tools

Other Material

Specifications

John Deere Engine Repair—Use CTM104

Remove and Install Engine

Remove Engine Oil Pan

Install Engine Oil Pan

Remove and Install Rocker Arm Cover

Access To Rear Crankshaft Seal

Access To Front Crankshaft Seal

Access To Front Timing Cover

Group 10: Cooling System

Other Material

Specifications

Engine Water Pump Repair—Use CTM104

Remove, Install and Adjust Fan Drive Belt

Remove, Inspect and Install Radiator

Remove and Install Cooling Package

Remove Water Pump

Install Water Pump

Remove Thermostat

Install Thermostat

Pressure Test Cooling System and Radiator Cap

Section 30: Fuel and Air Repair

Group 05: Fuel System

Specifications

Injection Pump, Nozzles and Governor Repair—Use CTM207

Remove and Install Fuel Tank

Replace Fuel Level Sender

Replace Final Fuel Filter and Primary Fuel Filter/Water Separator

Remove and Install Fuel Supply Pump

Bleed Fuel System

Group 10: Speed Control Linkage

Specifications

Inspect and Repair Speed Control Linkage

Adjust Throttle Lever Friction Nut

Adjust Throttle Linkage

Group 15: Air Intake System

Specifications

Replace Air Cleaner Elements/Housing

Inspect and Service Air Intake System

Remove Turbocharger

Install Turbocharger

Turbocharger Break-In

Section 40: Electrical Repair

Group 05: Battery, Starter and Alternator

Specifications

Prevent Battery Explosions

Handling Batteries Safely

Prevent Damage to Electrical Systems

Battery Replacement

Connecting Booster Battery

Charging Batteries

Connecting Battery Cables

Remove and Install Battery

Remove and Install Starter

Starter Repair—Use CTM77

Replace Alternator

Group 10: Harness and Connector Repair

Service Equipment and Tools

Electrical Tool Repair Kit

Wire Repair Pliers

Terminal Applicator

Service Parts Kits

Use Electrical Insulating Compound

Using High-Pressure Washers

Electrical Connector Handling

Connector Identification

Replace WEATHER PACK WEATHER PACK is a trademark of PACKARD ELECTRIC. Connector

Install WEATHER PACK WEATHER PACK is a trademark of PACKARD ELECTRIC. Contact

Remove Connector Body From Blade Terminals

Replace (Pull Type) METRI-PACK METRI-PACK is a trademark of Packard Electric. Connectors

Replace (Push Type) METRI-PACK METRI-PACK is a trademark of Packard Electric. Connectors

Harness Repair—Splice Connector

Wiring Harness Circuit Codes

Group 15: Wiring Harness Routing

Tractor Wiring Harness Replacement

Front Wiring Harness - Reference

Rear Wiring Harness - Reference

Replace Rear Electrical Harness—Cab Tractors

Replace Cab Roof Electrical Harness

HVAC/Wiper Relay Block Assembly

Group 20: Electrical System Components

Service Equipment and Tools

Other Material

Specifications

Replace Air Filter Restriction Switch

Replace Coolant Temperature Sensor

Replace Engine Speed Sensor

Replace Engine Oil Pressure Sensor

Replace Key Switch

Remove and Replace Light Switch

Replace Turn Signal Switch (Open Operator Station)

Replace Turn Signal Switch (Cab Tractors)

Replace Instrument Panel (Open Operator Station)

Replace Instrument Panel (Cab Tractors)

Replace Rear PTO Switch

Replace Neutral Start Switch

Replace Horn Switch (Open Operator Station)

Replace Horn Switch (Cab Tractors)

Replace Horn

Replace Operator Presence Switch

Replace PTO Warning Horn/Timer (OOS Shown)

Replace Starter Relay

Replace Manifold Heater and Relay (If Equipped)

Replace Fan Switch

Replace Switch of the Air-Conditioning System Compressor

Replace Speakers

Replace Antenna

Replace Wiper Control Switch

Replace Wiper Motor

Replace Blower Control Switch

Replace Air Conditioning ON/OFF Switch

Replace A/C Temperature Control Switch

Replace Dome Light

Replace Door Switch

Group 25: Auxiliary Lighting Components

Replace Seven Terminal Outlet Socket

Group 30: Fuses And Relays

Fuse Locations (OOS)

Fuse Location (Cab)

Fuse/Relay Block Assembly (Cab)

Electrical Load Center (Cab)

Relay Locations (OOS)

Fuse Identification

Relay Identification

Diode Block Locations

Group 35: Lighting

Safety Rules When Replacing Halogen Bulbs

Replace Headlight Bulbs

Replace Auxiliary Field Light Bulbs

Replace Warning/Tail Light Bulbs

Replace Dash Light Bulbs

Section 50: Power Train

Group 00: Towing

Towing Tractor

Adjust Range Shift Lever and Tow Lock

Group 05: Component Removal

Essential or Recommended Tools

Other Material

Specifications

Transaxle Separation

Transaxle Component Identification