John deere 6100 tractors service repair technical manual (tm4493).pdf

tm4493 - 6100 to 6600 Tractors
Cone Point Adjustment
Cone Point Adjustment
LX000789-UN: Cone Point Adjustment
LEGEND:
A - Spacer washer (use as required)
B - Bearing quill
C - Axial bearing
D - Needle bearing
E - Differential drive shaft face
1. Record dimension (a) stamped into bevel gear face. In most cases this dimension is exactly 172,0 mm (6.772 in.).
2. Measure dimension (b) from needle bearing to bearing quill.
3. Cone point dimension (c) of differential housing is always 219,5 mm (8.642 in.).
4. Calculate spacer washer thickness (d).
d = a + b - c
-: Spacer Washer Thickness
Example:
-: Calculation Example
 d = 172,0 mm + 48,1 mm - 219,5 mm
Thickness of Spacer Washers Available
0,2 mm (0.008 in.) 0,5 mm (0.020 in.)
0,3 mm (0.012 in.)
Dimension stamped into bevel gear face..............a=172,0 mm (6.772 in.)
Dimension from needle bearing to bearing quill, measured..............b=48,1 mm (1.894 in.)
Cone point dimension on differential housing as specified..............c=219,5 mm (8.642 in.)
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file:///C:/ProgramData/Service%20ADVISOR/Temp/tm4493_LXOUOE00392...

 d = 0,6 mm
 d = 6.772 in. + 1.894 in. - 8.642 in.
 d = 0.024 in.
In the example two 0,3 mm (0.012 in.) spacer washers have to be used.
LX000790-UN: Locking Latch and Taper Roller Bearing Cup
Press taper roller bearing cup (B) into bearing quill.
Install locking latch (A).
LX000791-UN: Tighten Screws and Bolt
Attach bearing quill.
Tighten screws (A and C) and bolt (B) to 55 N·m (40 lb-ft).
LX000792-UN: Install Shifter Shaft Housing
Install shifter shaft housing (A).
LX000793-UN: Install Spacer and Snap Ring
Install spacer [Older tractors only] (A).
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Install snap ring (B).
LX000794-UN: Front Wheel Drive Gear and Snap Ring
Install front wheel drive gear (A) and snap ring (B).
LX009123-UN: Check Axial Play
Check axial play of front wheel drive gear.
NOTE:
Front wheel drive gear axial play must be less than 0.1 mm (0.004 in.).
If axial play is not correct, use a different size snap ring to install the front wheel drive gear.
-: Snap Ring Thickness
LX000795-UN: Install Thrust Washer and Snap Ring
Install thrust washer and gear of range A (A).
Install snap ring (B).
Thickness of Snap Rings Available
2.0 mm (0.079 in.) 2.2 mm (0.087 in.)
2.1 mm (0.083 in.) 2.3 mm (0.091 in.)
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LX000796-UN: Install Synchronizer Unit and Snap Ring
Install synchronizer unit (B) and snap ring (A).
NOTE:
Axial play of synchronizer unit must be less than 0.1 mm (0.004 in.).
LX000797-UN: Check Gear Axial Play
Check axial play of gear for range A.
IMPORTANT:
When measuring axial play, use both hands to guide the gear onto the shaft. Make sure the gear is straight (i.e. not skewed).
NOTE:
Axial play of gear must be 0.15 to 0.6 mm (0.006 to 0.024 in.).
If axial play is not correct, use a different size thrust washer to install gear of range A.
-: Thrust Washer Thickness
LX000798-UN: Snap Ring, Thrust Washer and Gear
Install gear of range B (C) and thrust washer (B).
2.0 mm (0.079 in.) 2.2 mm (0.087 in.)
2.1 mm (0.083 in.) 2.3 mm (0.091 in.)
Thickness of Thrust Washers Available
3.65 mm (0.144 in.) 3.95 mm (0.156 in.)
3.80 mm (0.150 in.)
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Install snap ring (A).
IMPORTANT:
NOTE:
IMPORTANT:
Up to transmission serial no. 157465, snap ring (A) had a thickness of 2.0 mm (0.079 in.). When repairing, put additional washer L112108 on the outside
of the snap ring.
LX000799-UN: Install Snap Ring and Thrust Washer
Install thrust washer and gear of range C (B).
Install snap ring (A).
LX000800-UN: Install Synchronizer Unit & Snap Ring
Install synchronizer unit (B) and snap ring (A).
NOTE:
Axial play of synchronizer unit must be less than 0.1 mm (0.004 in.).
3.65 mm (0.144 in.) 3.95 mm (0.156 in.)
3.80 mm (0.150 in.)
2.0 mm (0.079 in.) 2.2 mm (0.087 in.)
2.1 mm (0.083 in.) 2.3 mm (0.091 in.)
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LX000801-UN: Check Gear Axial Play
Check axial play of gear for range C.
IMPORTANT:
NOTE:
If axial play is not correct, use a different size thrust washer to install gear of range C.
LX000802-UN: Install Gear, Thrust Washer & Snap Ring
Install gear of range D (C) with connecting ring.
Install thrust washer (B) and snap ring (A).
IMPORTANT:
NOTE:
3.65 mm (0.144 in.) 3.95 mm (0.156 in.)
3.80 mm (0.150 in.)
3.65 mm (0.144 in.) 3.95 mm (0.156 in.)
3.80 mm (0.150 in.)
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LX000803-UN: Range Transmission Assembly
LEGEND:
A - Ball
B - Shaft
C - Bushing
D - Cap screw (2 used)
E - Cap screw
F - Thrust washer
G - Double gear
H - Needle race
I - Thrust washer
J - Needle race
K - Spacer bushing
L - Double gear
M - Bolt
N - Idler gear housing
O - Shaft
Assemble idler gear housing [ 15- and 18-gear versions (SyncroPlus) or 20 and 24-gear versions (PowrQuad) ] .
LX000804-UN: Tighten Cap Screws
Install idler gear housing [ 15- and 18-gear versions (SyncroPlus) or 20 and 24-gear versions (PowrQuad) ] .
Tighten cap screws to 55 N·m (40 lb-ft).
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LX009122-UN: Shifter Shafts and Shifter Forks
LEGEND:
A - Shifter shaft (ranges A and B)
B - Shifter fork (ranges A and B)
C - Shifter fork (ranges C and D)
D - Shifter shaft (ranges C and D)
Install shifter shafts and shifter forks.
LX009124-UN: Taper Roller Bearing Cones
Press taper roller bearing cones (A) and (B) onto drive shaft.
LX009121-UN: Install Drive Shaft and Spring
Install drive shaft (B).
Connect spring (A) of parking lock.
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LX009359-UN: Install Parking Lock Shifter Cam
LEGEND:
A - Lever
B - Spring
C - Seal ring
D - Bushing (2 used)
E - Spring pin
F - Shifter cam
G - Spacer washer (thickness as required)
H - Axial bearing assy.
Install parking lock shifter cam in the transmission housing. Use a 1.6 mm (0.063 in.) spacer washer (G) (recommended average setting).
LX1016989-UN: Install Shifter Shaft & Stop Assy.
Referring to the exploded view, assemble and install the fwd/rev. shifter shaft (A) and stop assembly (B; if equipped).
LX009125-UN: Install Transmission Housing
Install transmission housing.
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Tighten cap screws.
LX009360-UN: Parking lock disengaged
LX009361-UN: Parking lock engaged, play
Check play of parking lock shifter cam as follows:
1. Engage parking lock. Turn shifter cam to end point, then back 10 degrees so that the cam is no longer touching.
2. Attach dial gauge to shifter cam. Use a suitable lever or screwdriver to press the locking latch against the teeth of front wheel drive gear and measure the play of
the shifter cam.
3. Play must be between 0.25 and 0.60 mm (0.010 and 0.024 in.).
4. If play is excessive, the transmission housing must removed once more and a larger spacer washer used (see “Install parking lock shifter cam”). If play is
insufficient, a smaller spacer washer must be used.
-: Space Washer Thickness
LX009126-UN: Install Taper Roller Bearing Cup
LEGEND:
A - Snap ring (thickness as required)
B - Taper roller bearing cup
Item Measurement Specification
Grade 8.8 Cap Screw Torque 90 N·m (65 lb-ft)
Grade 10.9 Cap Screw Torque 120 N·m (90 lb-ft)
Thickness of Spacer Washer Available
1.2 mm (0.047 in.) 1.7 mm (0.067 in.)
1.3 mm (0.051 in.) 1.8 mm (0.071 in.)
1.4 mm (0.055 in.) 1.9 mm (0.075 in.)
1.5 mm (0.059 in.) 2.0 mm (0.079 in.)
1.6 mm (0.063 in.)
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C - Needle bearing
D - Cap screw [ Later tractor series have 2 cap screws]
Install taper roller bearing cup (B) of drive shaft and needle bearing (C) of differential drive shaft.
LX009127-UN: Check Drive Shaft Axial Play
Check axial play of drive shaft.
NOTE:
Axial play of drive shaft must be less than 0.1 mm (0.004 in.).
If axial play is not correct, use a different size snap ring to install the taper roller bearing cup.
LX009128-UN: Tighten Cap Screw
Tighten cap screw to 30 N·m (22 lb-ft).
LX013472-UN: Countersunk Screw
Coat the thread on countersunk screw [ 12-gear version (SyncroPlus) and 16-gear version (Power Reverser or PowrQuad) only] (A) with LOCTITE® E 648 (L41860) and
tighten it to 25 N·m (18 lb-ft).
2.0 mm (0.079 in.) 2.2 mm (0.087 in.)
2.1 mm (0.083 in.) 2.3 mm (0.091 in.)
LOCTITE is a trademark of Loctite Corp. LX,5030 009469-19-1997/06/01
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Adjusting Shift Mechanism
Adjusting Shift Mechanism
1. Place shifter shafts in neutral position.
2.
LX000810-UN: Threaded Pins
Adjust shifter forks by means of threaded pins (A) until they are centered in relation to shift collars.
3. Move shifter forks to all positions.
NOTE:
Make sure that shifter forks do not rub laterally on shift collars in any shift position.
4. Tighten threaded pins to 40 N·m (30 lb-ft).
5. Recheck adjustment.
LX,RDTG 002138-19-1996/04/01
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Final Assembly
Final Assembly
1. Install front wheel drive clutch, see Section 56, Group 10.
2. If equipped, install option transmission or creeper transmission, see Group 00.
3. SyncroPlus™ : Install PERMA-CLUTCH 2™ and gear transmission. See Group 00.
PowrQuad™ : Install PowrQuad™ module. See Group 00.
Install forward/reverse linkage. See Section 55, Group 05.
4. Install differential, see Section 56, Group 15.
5. Install final drives, see Section 56, Group 00.
6. Install PTO, see Section 56, Group 00.
LX009129-UN: Tighten Cap Screws
Install shift cover.
Tighten cap screws to 30 N·m (22 lb-ft).
SyncroPlus is a trademark of Deere & Company.
PERMA-CLUTCH 2 is a trademark of Deere & Company.
PowrQuad is a trademark of Deere & Company. LX,RDTG 002139-19-1994/06/01
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Special or Essential Tools
Special or Essential Tools
NOTE:
Order tools according to information given in the U.S. SERVICEGARD™ Catalog or in the European
Microfiche Tool Catalog (MTC).
Tilting
device.......KJD10178
Tilting the cab up and
down
KJD10178-UN: KJD10178
Universal support stand
[ Additionally required:
1 commercial 12 ton
jack] .......JT05725
Supporting tractor during
rear wheel removal.
JT05725-UN: JT05725
Puller.......KJD10173
Removal and installation
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of PTO drive shaft and
pump drive shaft
KJD10173-UN: KJD10173
Lifting eye.......JD-244-1
of tractor components
LX002476-UN: JD-244-1
Lifting eye.......JD-244-2
of tractor components
LX002297-UN: JD-244-2
SERVICEGARD is a trademark of Deere & Company. LX,CRA50 002753-19-1993/10/01
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Dealer-Manufactured Special Tools
Dealer-Manufactured Special Tools
See also Section 99, Group 05.
LX1016738-UN: Lifting Device
Lifting device for clutch housing and PowrReverser™ module.
PowrReverser is a trademark of Deere & Company. LX,5100 012015-19-1997/06/01
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Specifications
Specifications
Item Measurement Specification
U.j. shaft to drive flange, corrugated-
head screws
Torque 135 N·m (100 lb-ft)
PowrReverser™ module to gear
transmission, cap screws
Clutch bowden cable support to
clutch housing, cap screws
Suction line of transmission oil pump
to clutch housing, hex. socket
screws
Torque 18 N·m (13.3 lb-ft)
Rear wheel to rear axle
Tractors with flanged axle, cap
screws
Transmission oil, 6100 - 6400
Tractors
Capacity 52 L (13.7 U.S.gal.) approx.
See Section 10, Group 05.
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Removing the PowrReverser™ Module
Removing the PowrReverser™ Module
LX1016498-UN: PowrReverser Module
LX002206-UN: Tilt Operator's Cab
For tilting the operator's cab, see Section 90, Groups 00 and 01.
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LX007211-UN: Remove Oil Drain Plugs
Pull out swinging drawbar to the rear.
Remove oil drain plugs (A) and (B). Drain transmission oil into a suitable container.
Capacity: oil and filter change approx. 52 L (13.7 U.S. gal.)
Refer to Section 10, Group 05 for the precise oil capacity.
LX002223-UN: Remove Plug
Remove plug (A).
LX002599-UN: PTO Drive Shaft and Puller
Pull PTO drive shaft (A) and then pump drive shaft out of housing by means of puller KJD10173 (B).
LX1016495-UN: Remove Bracket
Remove bracket (A).
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LX1015880-UN: Oil Cooler Hoses
Disconnect oil cooler hoses (A) and (B) where they meet the Power Reverser module.
LX007768-UN: Remove Cap Screws
Take out cap screws (A) and (B), and remove the u.j. shaft.
See also Section 56, Group 05.
LX1016742-UN: Disconnect Cables and Plugs
Disconnect cables and plugs (A) to (D).
LX1016736-UN: Remove Screws, Suction Line and Linkage
Take out screws (A) and pull suction line (B) out of the differential housing.
NOTE:
Trap the oil as it emerges from the suction line.
Disengage forward/reverse linkage (C).
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LX1016740-UN: Remove Return Hose
Remove return hose (A).
LX1016737-UN: Remove Pressure Line
Remove pressure line (A).
LX1016496-UN: Install Lifting Device and Cap Screw
Install lifting device (A) as shown, and secure it with cap screw (B). Attach lifting tackle.
LX1016739-UN: Remove Screws from Housing Flange
Take screws (A) out of the housing flange and remove the PowrReverser™ module.
NOTE:
Screw (B) remains in place.
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Installing the PowrReverser™ Module
Installing the PowrReverser™ Module
Clean the sealing surfaces thoroughly and install a new flange seal.
Attach the lifting device and tackle to the PowrReverser™ module.
LX1016741-UN: Install Cap Screws
Install the PowrReverser™ module. Install cap screws (A) and tighten them to 50 N·m (35 lb-ft).
LX1016736-UN: Suction Line, Screws and Linkage
Put new seals on the suction line (B), and install the suction line on the PowrReverser™ module and differential housing.
Tighten screws (A) to 18 N·m (13.3 lb-ft).
Adjust and install forward/reverse linkage (C). See Group 05 in this Section.
For installation of u.j. shaft, refer to Section 56, Group 05.
For further assembly, reverse disassembly procedure.
Install oil drain plugs, fill with transmission oil, and check the oil level.
Tilt down the operator's cab. See Section 90.
Check all the functions of the tractor. If necessary, rectify any faults as described in the Technical Manual.
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Removing and Installing the Gear Transmission
Removing and Installing the Gear Transmission
NOTE:
To remove or install the gear transmission, see Section 50, Group 00 ( SyncroPlus™ transmission).
NOTE:
See Group 15 in this Section for measuring the gaps at the connecting ring.
SyncroPlus is a trademark of Deere & Company. LX,5100 012068-19-1997/06/01
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John deere 6100 tractors service repair technical manual (tm4493).pdf

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John deere 6100 tractors service repair technical manual (tm4493).pdf