John Deere 630, 635 Hay & Forage Mower-Conditioner All Inclusive Service Technical Manual (TM301219)
Complete Diagnosis and Repair Service manual with Electrical Wiring Diagrams for John Deere 630, 635 Hay & Forage Mower-Conditioner, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
John Deere Hay and Forage Mower Conditioners Models 630 and 635 workshop Diagnostic and 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.
TM301219 - John Deere 630, 635 Hay & Forage Mower-Conditioner Technical Manual (Diagnosis Operation Test Service Repair).PDF
tm301219 - 630 and 635 Mower-Conditioners - (European Edition) Technical Manual.epub
Total Pages: 646 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
General
Safety
General Information
Lubricants
Torques for Hardware
Electrical System: Repair
Electrical Repair: Connectors
Electrical Repair: Actuators
Power Train
Power Train: General Information
Driveline Repair
Tongue Drive Shaft
Drive Belts
Hitch and Tongue Gear Cases
Platform Gear Case
Roll Drive Gear Case (Roll Conditioner)
Hydraulics
Hydraulics: General Information
Lift Cylinders
Swing Cylinder
Windrow Forming Shield Cylinder
Cutting Height Adjustment Cylinder
Windrow Forming Shield Relief Valve
Windrow Forming Shield Diverter Valve
Miscellaneous
Wheels and Wheel Support Assembly
Carrier Frame and Tongue
Carrier Frame
Lift Arm
Limiting Chain
Tongue
Cutting Components
Cutting Components: General Information
Cutterbar Repair
Disks and Knives
Cutterbar Assembly
Conditioner
Conditioner: General Information
Roll Arms and Bearings
Rolls
Impeller
Platform
Platform: General Information
Platform Repair
Observable Symptom
Troubleshooting
Electrical System
Electrical System: General Information
Electric System: Road Light
Electrical System: Windrow Forming Shield Diverter Valve
Hydraulic Systems
Hydraulic Systems: Safety and General Information
Hydraulic Systems - Theory of Operation
Hydraulic System Component Information
Hydraulic Connections: Windrow Forming Shield
Hydraulic Component Information
Special Tools
Special Tools (Dealer-Fabricated)
Special Tools (Available as Spare Parts)
TABLE OF CONTENTS................1
Section 10: General................14
Group 05: Safety................14
Recognize Safety Information................17
Understand Signal Words................18
Follow Safety Instructions................19
Operate Mower-Conditioner Safely................20
Keep Riders Off Machine................21
Handle Fluids Safely—Avoid Fires................22
Prepare for Emergencies................23
Stay Clear of Rotating Drivelines................24
Avoid Injury From Thrown Objects................26
Use Safety Lights and Devices................27
Use a Safety Chain................28
Tow Loads Safely................29
Support Machine Properly................30
Wear Protective Clothing................31
Work in Clean Area................32
Service Machines Safely................33
Illuminate Work Area Safely................34
Replace Safety Signs................35
Use Proper Lifting Equipment................36
Remove Paint Before Welding or Heating................37
Avoid Heating Near Pressurized Fluid Lines................38
Service Tires Safely................39
Practice Safe Maintenance................40
Use Proper Tools................41
Construct Dealer-Made Tools Safely................42
Dispose of Waste Properly................43
Live With Safety................44
Group 10: General Information................14
General Information - Summary of References................46
630 and 635 Machine Description................47
Group 15: Lubricants................15
Lubricants - Summary of References................50
Grease................51
Cutterbar and Roll Drive Gear Case Oil................52
Swivel Gear Case Oil................53
Platform Gear Case Oil................54
Alternative and Synthetic Lubricants................55
Mixing of Lubricants................56
Lubricant Storage................57
Perform Lubrication and Maintenance................58
Group 20: Torques for Hardware................15
Metric Bolt and Screw Torque Values................61
Unified Inch Bolt and Screw Torque Values................63
Section 40: Electrical System: Repair................65
Group 10: Electrical Repair: Connectors................65
Electrical Repair: Connectors - Summary of References................67
Electrical Repair: Connectors - Special Tools................68
Electrical Connector Handling................69
Disconnect the Electrical Circuit................70
WEATHER PACK Connectors................71
Insulated and Non-Insulated Terminals................74
Individual Terminals................75
Harness Repair (Splice Broken or Cut Wire)................77
Harness Repair - Splice Connector................79
Group 15: Electrical Repair: Actuators................65
Electrical Repair: Actuators - Summary of References................81
Remove and Install Windrow Forming Shield Diverter Solenoid Y6................82
Section 50: Power Train................83
Group 05: Power Train: General Information................83
Power Train: General Information - Summary of References................86
Power Train Operation: With Impeller Conditioner................87
Power Train Operation: With Roll Conditioner................88
Group 15: Driveline Repair................83
Driveline Repair - Summary of References................91
Driveline Repair - Other Material................92
Driveline Repair - Specifications................93
Driveline Repair - Special Tools................94
Remove PTO Hookup Driveline................95
Disassemble and Assemble PTO Hookup Lock-Back Collar................97
Exploded View of PTO Hookup Driveline................99
Install PTO Hookup Driveline................100
Remove and Install Platform Driveline................102
Exploded View of Platform Driveline................107
Disassemble and Assemble Platform Driveline Slip Clutch (540 rpm only)................109
Adjust Platform Driveline Slip Clutch (540 rpm only)................111
Check Platform Driveline Slip Clutch (540 rpm only)................113
Adjust Gear Case Shield................115
Disassemble and Assemble PTO Hookup, Tongue Pivot and Platform Driveline................118
Disassemble and Assemble Cutterbar Driveline................123
Remove Roll Driveline (Roll Conditioner)................126
Disassemble and Assemble Upper Roll Driveline (Roll Conditioner)................128
Disassemble and Assemble Lower Roll Driveline (Roll Conditioner)................130
Install Roll Driveline (Roll Conditioner)................132
Group 20: Tongue Drive Shaft................83
Tongue Drive Shaft - Summary of References................135
Remove Tongue Drive Shaft................136
Exploded View of Tongue Drive Shaft................140
Install Tongue Drive Shaft................141
Group 30: Drive Belts................83
Drive Belts - Summary of References................145
Drive Belts - Other Material................146
Drive Belts - Specifications................147
Remove and Install Conditioner Drive Belt (Impeller Conditioner)................148
Adjust Conditioner Drive Belt Tension (Impeller Conditioner)................152
Disassemble and Assemble Conditioner Adjustable Idler Assembly (Impeller Conditioner)................153
Remove and Install Conditioner Drive Belt (Roll Conditioner)................155
Adjust Conditioner Drive Belt Tension (Roll Conditioner)................158
Disassemble and Assemble Conditioner Adjustable Idler Assembly (Roll Conditioner)................159
Group 40: Hitch and Tongue Gear Cases................84
Hitch and Tongue Gear Cases - Summary of References................163
Hitch and Tongue Gear Cases - Other Material................164
Hitch and Tongue Gear Cases - Specifications................165
Hitch and Tongue Gear Cases - Special Tools................166
Remove and Install Hitch and Tongue Gear Case Assembly................167
Disassemble Hitch and Tongue Drive Gear Cases................170
Inspect Hitch and Tongue Drive Gear Cases................178
Assemble Hitch and Tongue Drive Gear Cases................180
Group 45: Platform Gear Case................84
Platform Gear Case - Summary of References................197
Platform Gear Case - Other Material................198
Platform Gear Case - Specifications................199
Remove Platform Gear Case................200
Install Platform Gear Case................202
Group 49: Roll Drive Gear Case (Roll Conditioner)................84
Roll Drive Gear Case (Roll Conditioner) - Summary of References................205
Roll Drive Gear Case (Roll Conditioner) - Other Material................206
Roll Drive Gear Case (Roll Conditioner) - Specifications................207
Roll Drive Gear Case (Roll Conditioner) - Special Tools................208
Remove Roll Drive Gear Case (Roll Conditioner)................209
Disassemble and Assemble Roll Drive Gear Case (Roll Conditioner)................211
Install Roll Drive Gear Case (Roll Conditioner)................217
Section 70: Hydraulics................219
Group 05: Hydraulics: General Information................219
Hydraulics: General Information - Summary of References................222
Lift Cylinders Operation................223
Swing Cylinder Operation................224
Windrow Forming Shield Cylinder Operation................225
Cutting Height Adjustment Cylinder Operation................227
Group 15: Lift Cylinders................219
Lift Cylinders - Summary of References................229
Lift Cylinders - Other Material................230
Lift Cylinders - Specifications................231
Remove and Install Lift Cylinder................232
Disassemble and Assemble Right Lift Cylinder................235
Disassemble and Assemble Left Lift Cylinder................241
Phase Lift Cylinders................248
Group 20: Swing Cylinder................219
Swing Cylinder - Summary of References................250
Swing Cylinder - Other Material................251
Swing Cylinder - Specifications................252
Remove and Install Swing Cylinder................253
Disassemble and Assemble Swing Cylinder................256
Group 25: Windrow Forming Shield Cylinder................219
Windrow Forming Shield Cylinder - Summary of References................260
Windrow Forming Shield Cylinder - Other Material................261
Windrow Forming Shield Cylinder - Specifications................262
Remove Windrow Forming Shield Cylinder................263
Disassemble Windrow Forming Shield Cylinder................266
Assemble Windrow Forming Shield Cylinder................268
Install Windrow Forming Shield Cylinder................270
Group 30: Cutting Height Adjustment Cylinder................219
Cutting Height Adjustment Cylinder - Summary of References................273
Remove Cutting Height Adjustment Cylinder................274
Disassemble Cutting Height Adjustment Cylinder................278
Assemble Cutting Height Adjustment Cylinder................279
Install Cutting Height Adjustment Cylinder................280
Group 50: Windrow Forming Shield Relief Valve................620
Windrow Forming Shield Relief Valve - Summary of References................284
Windrow Forming Shield Relief Valve - Specifications................285
Remove Control Windrow Forming Shield Relief Valve................620
Disassemble Windrow Forming Shield Relief Valve................620
Assemble Windrow Forming Shield Relief Valve................620
Install Control Windrow Forming Shield Relief Valve................620
Group 55: Windrow Forming Shield Diverter Valve................616
Windrow Forming Shield Diverter Valve - Summary of References................294
Windrow Forming Shield Diverter Valve - Specifications................295
Disassemble Windrow Forming Shield Diverter Valve................616
Assemble Windrow Forming Shield Diverter Valve................616
Section 80: Miscellaneous................299
Group 05: Wheels and Wheel Support Assembly................299
Wheels and Wheel Support Assembly - Summary of References................301
Wheels and Wheel Support Assembly - Specifications................302
Remove and Install Wheel................303
Disassemble and Assemble Wheel Bearings................306
Disassemble and Assemble Wheel Support................308
Section 81: Carrier Frame and Tongue................311
Group 15: Carrier Frame................311
Carrier Frame - Summary of References................313
Adjust Carrier Frame Height................314
Group 20: Lift Arm................311
Lift Arm - Summary of References................318
Lift Arm - Specifications................319
Remove Left Lift Arm................320
Inspect Left Lift Arm................323
Install Left Lift Arm................324
Remove Right Lift Arm................326
Install Right Lift Arm................328
Group 25: Limiting Chain................311
Limiting Chain - Summary of References................330
Position Limiting Chain................331
Group 30: Tongue................311
Tongue - Summary of References................334
Tongue - Specifications................335
Remove and Install Tongue................336
Section 100: Cutting Components................340
Group 05: Cutting Components: General Information................340
Cutting Components: General Information - Summary of References................343
Cutterbar Description................344
Group 10: Cutterbar Repair................340
Cutterbar Repair - Summary of References................346
Cutterbar Repair - Other Material................347
Cutterbar Repair - Specifications................348
Cutterbar Repair - Special Tools................349
Drain Oil From Cutterbar................350
Remove and Install Cutterbar................352
Remove and Install Single Intermediate Module from Cutterbar................358
Remove and Install Converging Drums and Shields................367
Check Dented Module................378
Repair Dented Module................379
Disassemble and Assemble Cutterbar................381
Remove and Install Idler Gear Bearing From Idler Gear................388
Remove and Install Left End Quill Assembly................395
Remove and Install Right End or Intermediate Quill Assemblies................399
Cutterbar Quill and Pinion Gear Timing Detail (Disks Rotate Towards Cutterbar Center of Cutterbar)................404
Check Quill Bearing End Play................406
Inspect Idler Gear Bearing................408
Disassemble and Assemble Quill Assembly................410
Replace Left End Disk Driver................416
Replace Intermediate Disk Drivers................421
Replace Right End Disk Driver................426
Group 15: Disks and Knives................340
Disks and Knives - Summary of References................432
Disks and Knives - Specifications................433
Remove Disks................434
Install and Synchronize Disks................436
Check Knife Wear................438
Check Disk Wear................443
Remove and Install Knives................445
Replace Wear Cap On Knife Bolt................449
Replace Crop Accelerators (If Equipped)................451
Group 25: Cutterbar Assembly................341
Cutterbar Assembly - Summary of References................454
Cutterbar Assembly - Specifications................455
Remove and Install Cross Tube................456
Section 110: Conditioner................458
Group 05: Conditioner: General Information................458
Conditioner: General Information - Summary of References................461
Conditioner Description................462
Group 15: Roll Arms and Bearings................458
Roll Arms and Bearings - Summary of References................465
Roll Arms and Bearings - Other Material................466
Roll Arms and Bearings - Specifications................467
Remove Upper Roll Arm and Bearing (Left Side)................468
Install Upper Roll Arm and Bearing (Left Side)................472
Remove Upper Roll Arm and Bearing (Right Side)................476
Install Upper Roll Arm and Bearing (Right Side)................480
Replace Lower Roll Bearing (Left Side)................484
Replace Lower Roll Bearing (Right Side)................486
Group 20: Rolls................458
Rolls - Summary of References................489
Rolls - Other Material................490
Rolls - Specifications................491
Rolls - Special Tools................492
Remove and Install Lower Roll................493
Remove and Install Upper Roll................496
Adjust Roll Alignment................500
Adjust Roll Timing................503
Adjust Roll Pressure................507
Adjust Roll Spacing................509
Group 25: Impeller................458
Impeller - Summary of References................511
Impeller - Other Material................512
Impeller - Specifications................513
Remove Impeller................514
Install Impeller................516
Remove Impeller Bearing (Left Side)................517
Install Impeller Bearing (Left Side)................519
Remove Impeller Bearing (Right Side)................522
Install Impeller Bearing (Right Side)................525
Change Impeller Speed................528
Replace Rotor Tines................531
Section 120: Platform................533
Group 05: Platform: General Information................533
Platform: General Information - Summary of References................535
Platform Description................536
Group 10: Platform Repair................533
Platform Repair - Summary of References................538
Platform Repair - Other Material................539
Platform Repair - Specifications................540
Remove and Install Platform................541
Adjust Platform Float................545
Adjust Cutting Height - Manual Control................547
Adjust Cutting Height - Hydraulic Control................549
Remove and Install Gauge Shoes................551
Section 212: Observable Symptom................554
Group 10: Troubleshooting................554
Troubleshooting - Summary of References................556
Driveline Malfunctions................557
Telescoping Hook-Up Locking System................559
End Yokes................560
Inboard Yokes................561
Profile Tubes................562
Telescoping Hook-Up Guards................563
Diagnose Lift Circuit Malfunctions................564
Diagnose Swing Circuit Malfunctions................566
Diagnose Carrier Frame and Tongue Malfunctions................567
Diagnose Roll Conditioner Malfunctions................568
Diagnose Impeller Conditioner Malfunctions................570
Section 240: Electrical System................571
Group 05: Electrical System: General Information................571
Electrical System: General Information - Summary of References................573
Open Circuit................574
Grounded Circuit................575
Shorted Circuit................576
Symbols in System Diagrams................578
Component Identification Table................582
Electrical Circuit Malfunctions................584
Group 15: Electric System: Road Light................571
Electrical System: Road Light - Summary of References................586
Electrical System: Road Light - Wiring Harness List................587
Electrical System: Road Light - Component Identification................588
Electrical System: Road Light - Component Location................589
Electrical System: Road Light - Wiring Diagram................590
Group 20: Electrical System: Windrow Forming Shield Diverter Valve................616
Electrical System: Windrow Forming Shield Diverter Valve - Summary of References................592
Electrical System: Windrow Forming Shield Diverter Valve - Wiring Harness List................593
Electrical System: Windrow Forming Shield Diverter Valve - Component Identification................594
Electrical System: Windrow Forming Shield Diverter Valve - Component Location................595
Electrical System: Windrow Forming Shield Diverter Valve - Wiring Diagram................596
Section 270: Hydraulic Systems................597
Group 05: Hydraulic Systems: Safety and General Information................597
Hydraulic Systems: Safety and General Information - Summary of References................599
Avoid High-Pressure Fluids................600
Cleanliness................601
Testing Precautions................602
Hydraulic Symbols (As Defined by ISO 1219)................603
Group 20: Hydraulic Systems - Theory of Operation................597
Hydraulic Systems - Theory of Operation - Summary of References................606
Hydraulic Systems - Theory of Operation: Windrow Forming Shield Diverter Valve................616
Hydraulic Systems - Theory of Operation: Windrow Forming Shield Relief Valve................620
Section 279: Hydraulic System Component Information................609
Group 35: Hydraulic Connections: Windrow Forming Shield................612
Hydraulic Connections: Windrow Forming Shield - Summary of References................611
Hydraulic Connections: Windrow Forming Shield................612
Group 40: Hydraulic Component Information................609
Hydraulic Component Information - Summary of References................614
Hydraulic Component Information - Specifications................615
Windrow Forming Shield Diverter Valve................616
Check for Leaks at Windrow Forming Shield Diverter Valve................617
Windrow Forming Shield Relief Valve................620
Check Windrow Forming Shield Relief Valve Pressure................621
Section 399: Special Tools................623
Group 05: Special Tools (Dealer-Fabricated)................623
Special Tools (Dealer-Fabricated) - Summary of References................625
Gear Case Lifting Eye................626
DFEX1823A Backlash Measuring Strap................627
Group 10: Special Tools (Available as Spare Parts)................623
Special Tools (Available as Spare Parts) - Summary of References................629
D01044AA - Bushing, Bearing and Seal Driver Kit................630
D01218AA - Knife-Edge Puller................631
D01243AA - Knife-Edge Puller................632
D05304ST - Dial Indicator................633
D17507CI - Inside Micrometer................634
E83373 - Wrench................635
FKM10461 - Wiring Harness Repair Kit................636
FKM10467 - Crimping Pliers................637
FKM10468 - Crimping Pliers................638
JDG364 - Extraction Tool................639
JDG707 - Crimping Pliers................640
JDG783 - Crimping Pliers................641
JDT31 - Ball Loading Sleeve................642
KLM10019-1 - Crimping Pliers................643
John Deere 630, 635 Hay & Forage Mower-Conditioner All Inclusive Service Technical Manual (TM301219)
