Complete service repair manual with electrical wiring diagrams for John Deere Hay and Forage Mower Conditioners Models 525, 530, 535, 730, 735 , with workshop information to maintain, diagnose, repair, and service like professional mechanics.

John Deere Hay and Forage Mower Conditioners Models 525, 530, 535, 730, 735 workshop service & repair manual 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.

TM2324 - John Deere 525, 530, 535, 730, 735 Mower Conditioners Technical Manual - Repair.pdf
TM2324 - John Deere 525, 530, 535, 730, 735 Mower Conditioners Technical Manual - Repair.epub

Total Pages: 622 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle/iPad/iPhone/Android.
Language: English

MAIN SECTIONS
 Foreword
   Service Technician Response
   General
      Safety
      General Information
      Lubricants
      Torques for Hardware
   Electrical System - Repair
      Electrical Repair
   Power Train
      General Information
      Driveline Malfunctions
      Driveline Repair
      Tongue Drive Shaft
      Drive Belts
      Hitch, Tongue and Platform Gear Cases
      Main Drive Gear Case-500 Series
      Roll Drive Gear Case (Roll Conditioner)
   Hydraulics
      General Information
      Diagnosing Malfunctions
      Lift Cylinders
      Swing Cylinder
   Miscellaneous
      Wheels and Wheel Support Assembly
   Carrier Frame and Tongue
      General Information
      Diagnosing Malfunctions
      Carrier Frame
      Lift Arm
      Limiting Chain
      Tongue
   Cutting Components
      General Information
      Cutterbar Repair
      Disks and Knives
      Cutterbar Assembly
   Conditioner
      General Information
      Diagnosing Malfunctions
      Roll Arms and Bearings
      Rolls
      Impeller
   Platform
      General Information
      Platform Repair
   Electrical System
      General Information
      Road Light
   Special Tools - Dealer-Fabricated
      Manufacturing the Tools

tm2324 - 525, 530, 535, 730 and 735 Mower-Conditioners

Table of Contents

Foreword

Service Technician Response

Section 10: General

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Operate Mower-Conditioner Safely

Keep Riders Off Machine

Handle Fluids Safely—Avoid Fires

Prepare for Emergencies

Avoid High-Pressure Fluids

Stay Clear of Rotating Drivelines

Avoid Injury From Thrown Objects

Use Safety Lights and Devices

Use a Safety Chain

Tow Loads Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Service Tires Safely

Practice Safe Maintenance

Use Proper Tools

Construct Dealer-Made Tools Safely

Dispose of Waste Properly

Live With Safety

Group 10: General Information

525, 530 and 535 Side Pull Machine Description

730 and 735 Machine Description

Group 15: Lubricants

Grease

Cutterbar and Roll Drive Gear Case Oil

Swivel Gear Case Oil

Alternative and Synthetic Lubricants

Mixing of Lubricants

Lubricant Storage

Perform Lubrication and Maintenance

Group 20: Torques for Hardware

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Section 40: Electrical System — Repair

Group 10: Electrical Repair

Essential or Recommended Tools

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Male and Female Connectors

Section 50: Power Train

Group 05: General Information

Power Train Operation—525, 530 and 535 With Impeller Conditioner

Power Train Operation—525, 530 and 535 With Roll Conditioner

Power Train Operation—730 and 735 With Impeller Conditioner

Power Train Operation—730 and 735 With Roll Conditioner

Group 10: Driveline Malfunctions

Driveline Malfunctions

Telescoping Hook-Up Locking System

End Yokes

Inboard Yokes

Telescoping Hook-Up Guards

Group 15: Driveline Repair

Service Parts Kits

Essential or Recommended Tools

Other Material

Specifications

Removing and Installing Tongue Pivot Driveline (730 and 735 Only)

Removing and Installing Platform Driveline (730 and 735 Only)

PTO Hookup, Tongue Pivot and Platform Driveline—Exploded View (730 and 735 only)

Repairing PTO Hookup, Tongue Pivot and Platform Driveline

Repairing PTO Hookup Lock-Back Collar

Repairing Over-Running Coupler (730 and 735 Swivel Hitch Tongue Only)

Repairing Over-Running Coupler (730 and 735 Equal Angle Hitch Tongue Only)

Disassembling and Assembling Slip Clutch (730) (540 rpm only)

Repair PTO Hookup Driveline—500 & 700 Series Equal Angle Tongues

Repair PTO Driveline Hub—Slip Clutch Type—500 Series

Repair PTO Driveline Slip Clutch—500 Series (If Equipped)

Adjust PTO Driveline Slip Clutch—500 Series (If Equipped)

Slipping Seized PTO Driveline Slip Clutch—500 Series (If Equipped)

Constant Velocity Joint Driveline Exploded View—500 Series

Repair PTO Constant Velocity Joint—500 Series

Adjust Gear Case Shield

Repairing Cutterbar Driveline

Repairing Upper Roll Driveline (Roll Conditioner)

Repairing Lower Roll Driveline (Roll Conditioner)

Group 20: Tongue Drive Shaft

Other Material

Specifications

Removing Long Tongue Drive Shaft (700 Series)

Installing Long Tongue Drive Shaft (700 Series)

Removing Short Tongue Drive Shaft

Installing Short Tongue Drive Shaft

Group 25: Drive Belts

Other Material

Specifications

Removing Main Drive Belt (700 Series)

Installing Main Drive Belt

Adjusting Main Drive Belt Tension

Removing and Installing Fixed Idler

Repairing Adjustable Idler Assembly

Replacing Drive and Driven Sheave Bearing (700 Series)

Replacing Return Sheave Bearing

Replacing Conditioner Drive Belt—Impeller Conditioner

Adjusting Conditioner Drive Belt Tension—Impeller Conditioner

Replacing Conditioner Drive Belt—Roll Conditioner

Adjusting Conditioner Drive Belt Tension—Roll Conditioner

Repairing Conditioner Adjustable Idler Assembly

Group 30: Hitch, Tongue and Platform Gear Cases

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Removing and Installing Hitch and Tongue Gear Case Assembly—Two-Point Hitch

Disassembling Hitch and Tongue Drive Gear Cases

Inspecting Hitch and Tongue Drive Gear Cases

Assembling Hitch and Tongue Drive Gear Cases

Removing and Installing Cutterbar/Conditioner Gear Case

Exploded View Of Cutterbar/Conditioner Gear Case (700 Series)

Disassembling and Assembling Cutterbar/Conditioner Gear Case (700 Series)

Group 40: Main Drive Gear Case—500 Series

Essential and Recommended Tools

Service Equipment and Tools

Other Material

Specifications

540 RPM Gear Case—Cross Sectional View

1000 RPM Gear Case—Cross Sectional View

Disassemble Main Drive Gear Case

Assemble Main Drive Gear Case

Group 45: Roll Drive Gear Case (Roll Conditioner)

Essential or Recommended Tools

Other Material

Specifications

Disassembling and Assembling Roll Drive Gear Case

Section 70: Hydraulics

Group 05: General Information

Hydraulic Lift Cylinders Operation

Swing Cylinder Operation (700 Series)

Swing Cylinder Operation (500 Series)

Group 10: Diagnosing Malfunctions

Diagnose Lift Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Group 15: Lift Cylinders

Other Material

Specifications

Removing and Installing Lift Cylinder

Disassembling and Assembling Right Lift Cylinder

Disassembling and Assembling Left Lift Cylinder

Bleeding Platform Lift Circuit

Phasing Lift Cylinders

Group 20: Swing Cylinder

Other Material

Specifications

Removing and Installing Swing Cylinder (700 Series)

Removing and Installing Swing Cylinder (500 Series)

Disassembling and Assembling Swing Cylinder (700 Series)

Disassembling and Assembling Swing Cylinder (500 Series)

Section 80: Miscellaneous

Group 05: Wheels and Wheel Support Assembly

Specifications

Removing and Installing Wheel

Packing or Replacing Wheel Bearings

Repairing Wheel Support

Section 81: Carrier Frame and Tongue

Group 05: General Information

Tongue Description

Carrier Frame Description

Group 10: Diagnosing Malfunctions

Diagnosing Malfunctions

Group 15: Carrier Frame

Adjusting Carrier Frame Height

Group 20: Lift Arm

Specifications

Removing Left Lift Arm

Inspecting Left Lift Arm

Installing Left Lift Arm

Removing Right Lift Arm

Installing Right Lift Arm

Group 25: Limiting Chain

Positioning Limiting Chain

Group 30: Tongue

Essential or Recommended Tools

Specifications

Removing Tongue (700 Series)

Installing Tongue (700 Series)

Remove and Install Tongue (500 Series)

Section 100: Cutting Components

Group 05: General Information

Cutterbar Description

Group 10: Cutterbar Repair

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Specifications

Draining and Filling Cutterbar

Removing and Installing Cutterbar

Removing and Installing Single Intermediate Module from Cutterbar

Removing and Installing Converging Drums and Shields

Checking Dented Module

Repairing a Dented Module

Disassembling and Assembling Cutterbar

Removing and Installing Idler Gear Bearing From Idler Gear

Removing and Installing Left-Hand End Quill Assembly

Removing and Installing Right-Hand End or Intermediate Quill Assemblies

Cutterbar Quill and Pinion Gear Timing Detail—Disks Rotate Towards Cutterbar Center of Cutterbar

Checking Quill Bearing End Play

Inspecting Idler Gear Bearing

Disassembling and Assembling Quill Assembly

Replacing Left-Hand End Disk Driver

Replacing Intermediate Disk Drivers

Replacing Right-Hand End Disk Driver

Group 15: Disks and Knives

Specifications

Removing Disks

Installing and Synchronizing Disks

Checking Knife Wear

Checking Disk Wear

Removing and Installing Knives

Replacing Wear Cap On Knife Bolt

Replacing Crop Accelerators (If Equipped)

Group 25: Cutterbar Assembly

Removing and Installing Cross Tube

Section 110: Conditioner

Group 05: General Information

Conditioner Description

Group 10: Diagnosing Malfunctions

Diagnose Roll Conditioner Malfunctions

Diagnose Impeller Conditioner Malfunctions

Group 15: Roll Arms and Bearings

Essential and Recommended Tools

Other Material

Specifications

Removing Upper Roll Arm and Bearing—Left-Hand Side

Installing Upper Roll Arm and Bearing—Left-Hand Side

Removing Upper Roll Arm and Bearing—Right-Hand Side

Installing Upper Roll Arm and Bearing—Right-Hand Side

Replacing Lower Roll Bearing—Left-Hand Side

Replacing Lower Roll Bearing—Right-Hand Side

Group 20: Rolls

Essential or Recommended Tools

Other Material

Specifications

Removing and Installing Lower Roll

Removing and Installing Upper Roll

Adjusting Roll Alignment

Adjusting Roll Timing

Adjusting Roll Pressure

Adjusting Roll Spacing

Group 25: Impeller

Other Material

Specifications

Removing Impeller

Installing Impeller

Removing Impeller Bearing—Left-Hand Side

Installing Impeller Bearing—Left-Hand Side

Removing Impeller Bearing—Right-Hand Side

Installing Impeller Bearing—Right-Hand Side

Changing Impeller Rotor Speed

Section 120: Platform

Group 05: General Information

Platform Description

Group 10: Platform Repair

Other Material

Specifications

Adjusting Platform Float

Adjusting Cutting Height

Removing and Installing Gauge Shoes

Removing and Installing Platform

Section 240: Electrical System

Group 05: General Information

Electrical Circuit Malfunctions

Open Circuit

Grounded Circuit

Shorted Circuit

Symbols in System Diagrams

Component Identification Table

Group 10: Road Light

Tail/Warning Light Wiring Harness Diagram—Power Supply

Tail/Warning Light Main Wiring Harness Diagram

Section 399: Special Tools — Dealer-Fabricated

Group 05: Manufacturing the Tools

Gear Case Lifting Eye

Tongue Lifting Bracket (700 Series)

DFEX1823A Backlash Measuring Strap

John Deere 525, 530, 535, 730, 735 Mower Conditioners Repair Service Manual (TM2324)