John Deere Self-Propelled Forage Harvesters Models 8100, 8200, 8300, 8400, 8500, 8600, 8700, 8800 (Worldwide Edition) Service Repair Technical Manual (TM407119)

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Price: US$ 149.00

Complete service repair manual for John Deere 8100, 8200, 8300, 8400, 8500, 8600, 8700, 8800 Forage Harvester (Worldwide Edition), with workshop information to maintain, service, and repair like professional mechanics.

John Deere Self-Propelled Forage Harvesters Models 8100, 8200, 8300, 8400, 8500, 8600, 8700 & 8800 workshop 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.
* 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.

TM407119 - John Deere Self-Propelled Forage Harvesters Models 8100, 8200, 8300, 8400, 8500, 8600, 8700, 8800 (Worldwide Edition) Technical Manual (Repair).PDF
TM407119 - John Deere Self-Propelled Forage Harvesters Models 8100, 8200, 8300, 8400, 8500, 8600, 8700, 8800 (Worldwide Edition) Technical Manual (Repair).EPUB

Total Pages: 2,813 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   Version Date
   General
      Safety Information
      General Information
      Specifications
   Engine
      Engine
   Fuel, Air Intake, Cooling and Exhaust Systems
      Fuel System
      Air Intake System
      Cooling System
      Exhaust System
   Electrical System
      Harness and Connectors
      Batteries
      Alternator
      Starter Motor
      Fuse and Relay
      Lights and HarvestLab™ Sensor Adapter Glass
      Electrical System Components
   ProDrive™ Transmission
      Transmission and Differential
      Hydrostatic Drive Variable Pump
      Variable Displacement Front Motor
   Push Button Shift Transmission (PBST)
      Transmission and Differential
      Hydrostatic Drive Variable Pump
      Fixed Displacement Front Motor
   Header Drive
      Header Drive Gearbox
      Header Drive Gearbox Telescoping Driveline
      Header Drive Hydrostatic Pump
      Header Drive Hydrostatic Motor
   Right Feedroll Drive
      Right Feedroll Gearbox
      Feedroll Hydrostatic Pump
      Feedroll Motor
   Left Feedroll Drive
      Left Feedroll Gearbox
      Feedroll Telescopic Driveline
   Power Distribution Gear
      Power Distribution Gear
   Final Drives
      Final Drive Transmission
   Main Clutch
      Main Clutch
   Steering System
      Hydrostatic Steering
      Autotrac™ Steering
   Brake System
      Brakes-Prodrive™ Transmission
      Brakes-PBST Transmission
   Rear Axle
      Rear-Wheel Drive Axle
      Rear-Wheel Drive Axle Hydraulic Motor
   Hydraulic System
      Spout Turn
      Spout Raise/Lower
      Spout Fold/Unfold
      Header Lateral Tilt
      Wagon Dump
      Header Raise/Lower
      Auxiliary Drive
      Filters
      Load Sensing Pump
      Knife Sharpening
      Rotary Screen Motor
      Main Drive Belt Tension Cylinder
      Hydraulic Oil Reservoir
      Power Distribution Gear Oil Reservoir
      Electromagnetic Control Valve
      Accumulators
   Machine Specific System
      Central Lubrication System
      Air Compressor System
      Additive Dosing System
   Operator’s Station
      Air Conditioning System (R134a)
      Air Seat
      Cab
   Special Tools
      Special Tools (Available as Spare Parts)
   Feeding System
      Feedroll Housing
      Feedroll Assembly
   Cutterhead Assembly
      Cutterhead
      Knife Sharpening Device
      Bottom and Transition Chutes
      Stationary Knife
      Kernel Processor
      Kernel Star
   Discharge System
      Discharge fan
      Blower Rotor
      Discharge Spout

tm407119 - 8100—8800Self-Propelled ForageHarvesters Repair -: (Worldwide Edition)

Table of Contents

Foreword

Version Date

Trademarks

Section 10: General

Group 05: Safety Information

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Prevent Machine Runaway

Handle Fluids Safely—Avoid Fires

Handling Batteries Safely

Prevent Battery Explosions

Prevent Acid Burns

Prepare for Emergencies

Handle Starting Fluid Safely

In Case of Fire

Avoid High-Pressure Fluids

Service Cooling System Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Precautions for Welding

Make Welding Repairs Safely

Welding On Machine

Avoid Hot Exhaust

Avoid Harmful Asbestos Dust

Exhaust Filter Cleaning

Clean Exhaust Filter Safely

Use Steps and Handholds Correctly

Work In Ventilated Area

Wear Protective Clothing

Protect Against Noise

Practice Safe Maintenance

Park Machine Safely

Use Proper Lifting Equipment

Install All Guards

Construct Dealer-Made Tools Safely

Support Machine Properly

Work in Clean Area

Illuminate Work Area Safely

Service Machines Safely

Handle Electronic Components and Brackets Safely

Use Electronic Display Properly

Operate Guidance Systems Safely

Read The Guidance Manual

Use Proper Tools

Service Tires Safely

Follow Tire Recommendations

Avoid Eye Contact with Radar

Replace Safety Signs

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Service Accumulator Systems Safely

Safety Measures on Electronic Control Units

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Installation of Repair Wire Assembly (RWA)

Group 10: General Information

General Information-Summary of References

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Hydraulic System Inch Fitting Torque Values

Hydraulic System Metric Fitting Torque Values

Group 15: Specifications

Specifications—Summary of References

Serial Numbers

Forage Harvester Type Plate (Europe)

Forage Harvester Type Plate (North America)

Product Identification Number

Operator’s Cab Serial Number

Engine Serial Number—Engine Type 6090

Engine Serial Number—Engine Type 6135

Engine Serial Number—Engine Type QSK19

Power Distribution Gear Serial Number

Load Sensing Pump Serial Number

Exhaust Filter System Serial Number (Final Tier 4/Stage IV Engine Only)

SCR (Selective Catalytic Reduction) Module Serial Number (Final Tier 4/Stage IV Engine Only)

Push Button Shift Transmission Serial Number

Hydrostatic Pump Serial Number (Push Button Shift Transmission)

Main Drive Motor Serial Number (Push Button Shift Transmission)

ProDrive™ Transmission Serial Number

Hydrostatic Pump Serial Number (ProDrive™ Transmission)

Main Drive Motor Serial Number (ProDrive™ Transmission)

Final Drive Serial Number

Rear Axle Serial Number

Rear Wheel Drive Motor Serial Number

Header Drive Gear Case Hydrostatic Pump Serial Number

Header Drive Gear Case Motor Serial Number

Header Drive Gear Case Serial Number

Right Feed Roll Gear Case Hydrostatic Pump Serial Number

Right Feed Roll Gear Case Hydrostatic Motor Serial Number

Right Feed Roll Gear Case Serial Number

Left Feed Roll Gear Case Serial Number

Kernel Processor Serial Number

Spout Serial Number

Dimensions

Diesel Fuel

Handle Fuel Safely—Avoid Fires

Handling and Storing Diesel Fuel

Lubricity of Diesel Fuel

Avoid Static Electricity Risk When Refueling

Filling the Fuel Tank

Testing Diesel Fuel

Biodiesel Fuel (8100—8600 Only)

Biodiesel Fuel (8700 and 8800 Only)

Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines

Storing Diesel Exhaust Fluid (DEF)

Testing Diesel Exhaust Fluid (DEF)

Disposal of Diesel Exhaust Fluid (DEF)

Fill the Diesel Exhaust Fluid (DEF) Tank

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere Break-In™ Plus Engine Oil (8100—8600 Final Tier 4/Stage IV Engine Only)

John Deere Break-In™ Engine Oil (8100—8600 Tier 2/Stage II Engine Only)

John Deere Break-In™ Engine Oil (8100—8600 Tier 3/Stage III A Engine Only)

Diesel Engine Oil (8100—8600 Final Tier 4/Stage IV Engine Only)

Diesel Engine Oil (8100—8600 Tier 2/Stage II Engine Only)

Diesel Engine Oil (8100—8600 Tier 3/Stage III A Engine Only)

Diesel Engine Oil (8700 and 8800 Only)

Engine Oil and Filter Service Intervals (8100—8600 Final Tier 4/Stage IV Engine Only)

Engine Oil and Filter Service Intervals (8100—8600 Tier 2/Stage II Engine Only)

Engine Oil and Filter Service Intervals (8100—8600 Tier 3/Stage III A Engine Only)

Engine Oil and Filter Service Intervals (8700 and 8800 Only)

Oilscan™ and CoolScan™

Oil Filters

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Supplemental Coolant Additives

Drain Intervals for Diesel Engine Coolant

Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER

Testing Diesel Engine Coolant

Operating in Warm Temperature Climates

Transmission Oil

Hydraulic Oil

Brake Fluid (Push Button Shift Transmission Only)

Multipurpose Extreme Pressure Grease

General Multipurpose Grease

Grease for Automated Lubrication Systems

Capacities

Alternative and Synthetic Lubricants

Mixing of Lubricants

Lubricant Storage

Use Genuine John Deere Parts

Section 20: Engine

Group 05: Engine

Engine, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Prepare Machine for Engine Removal (8100—8600)

Prepare Machine for Engine Removal (8700, 8800)

Remove/Install 9.0 L Final Tier 4/Stage IV Engine

Remove/Install 9.0 L Tier 3/Stage III A Engine

Remove/Install 9.0 L Tier 2/Stage II Engine

Remove/Install 13.5 L Final Tier 4/Stage IV Engine

Remove/Install 13.5 L Tier 3/Stage III A Engine

Remove/Install 13.5 L Tier 2/Stage II Engine

Remove/Install QSK19 Engine (8700, 8800)

Section 30: Fuel, Air Intake, Cooling and Exhaust Systems

Group 05: Fuel System

Fuel System, Summary of References

Specifications

Fuel System Components - 9.0 L Final Tier 4/Stage IV Engine

Fuel System Components - 9.0 L Tier 3/Stage III A Engine

Fuel System Components - 9.0 L Tier 2/Stage II Engine

Fuel System Components - 13.5 L Final Tier 4/Stage IV Engine

Fuel System Components - 13.5 L Tier 3/Stage III A Engine

Fuel System Components - 13.5 L Tier 2/Stage II Engine

Fuel System Components - QSK19 Engine (8700, 8800)

Remove/Install Fuel Tank

Remove/Install Fuel Level Sensor

Group 10: Air Intake System

Air Intake System, Summary of References

Essential or Recommended Tools

Air Intake System Components

Remove/Install Charge Air Cooler

Group 15: Cooling System

Cooling System, Summary of References

Specifications

Other Material

Essential or Recommended Tools

Remove/Install Fuel Cooler

Remove/Install Air Conditioner Condenser

Remove/Install Distribution Gear Oil Cooler

Preliminary Operation

Remove/Install Radiator

Remove/Install Hydraulic Oil Cooler

Remove/Install Prodrive™ Transmission Oil Cooler

Remove/Install Cooling Package

Remove/Install Fan System

Group 20: Exhaust System

Exhaust System, Summary of References

Specifications

Selective Catalytic Reduction (SCR) System Overview

Restored Operation Option

Cleaning Diesel Exhaust Fluid (DEF) Tank

Remove/Install Diesel Exhaust Fluid Tank (DEF)

Remove/Install Diesel Exhaust Fluid (DEF) Header Assembly

Remove/Install Diesel Exhaust Fluid (DEF) Tank Header Suction Filter

Changing Diesel Exhaust Fluid (DEF) Dosing Unit Filter

Remove/Install Diesel Exhaust Fluid (DEF) Dosing Unit Filter and Equalizing Element

Remove/Install Diesel Exhaust Fluid (DEF) Tank Vent Filter

Remove/Install Diesel Particulate Filter

Remove/Install Diesel Exhaust Fluid Dosing Injector

Remove/Install Exhaust Filter

Section 40: Electrical System

Group 05: Harness and Connectors

Harness and Connectors, Summary of References

Essential or Recommended Tools

Other Material

Installation of Repair Wire Assembly (RWA)

Use Electrical Insulating Compound

Keep Electronic Control Unit Connectors Clean

Using High-Pressure Washers

Connectors

Strip Wire Ends

Install a Terminal

Installation of the Repair Cable Kit (Smoke and Heat Exhaust System)

Repair WEATHERPACK Connector

Remove Blade Terminals from Connector Body

Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors

Repair (Push Type) METRI-PACK Connectors

Repair CPC CPC is a trademark of AMP Inc. , Large MATE-N-LOC MATE-N-LOC is a trademark of AMP Inc. and METRIMATE METRIMATE is a trademark of AMP Inc. Pin Type Connectors

Repair CPC Blade Type Connectors

Repair Small MATE-N-LOC Socket Connector

Repair Small MATE-N-LOC Pin Connector

Repair CINCH Connectors

Repair Relay Panel Connectors

Repair HD Series DEUTSCH Connectors

Repair CINCH Flex Box Connectors

Repair TYCO-AMP Standard Power Timer Connectors

TYCO-AMP Super Seal Connectors

Repair AMPSEAL 16™ Connectors

Bosch™ Connectors

Connectors for Electronic Control Units

Group 10: Batteries

Batteries, Summary of References

Dangers When Handling Batteries

Battery Service

Checking Electrolyte Level

Checking Specific Gravity

Charging Batteries

Installing and Connecting Batteries

Disconnect the Battery on Machine With Final Tier 4/Stage IV Engine

Starting the Engine by Means of a Booster Battery (8100—8600)

Start the Engine With a Battery Booster or Charger (8700, 8800)

Observe Electrical Precautions

Remove/Install Batteries

Group 15: Alternator

Alternator, Summary of References

Specifications

Essential or Recommended Tools

Remove/Install Alternator Motor Engine (8100—8600)

Remove/Install 12 V Alternator Motor Engine (8700, 8800)

Check 12 V Alternator/Compressor Drive Belt Wear (8700, 8800)

Remove/Install 24 V Alternator Motor Engine (8700, 8800)

Check 24 V Alternator Drive Belt Wear (8700, 8800)

Group 20: Starter Motor

Starter Motor, Summary of References

Remove/Install Starter Motor Engine (8100—8600)

Remove/Install Starter Motor Engine (8700, 8800)

Group 25: Fuse and Relay

Fuse and Relay, Summary of References

Fuse Center Cover

Fuse Center

Inline Fuses

Master Fuses

Engine Control Unit (ECU) Fuses (8700, 8800)

Cab Fuse (Diode Module Fuse)

Engine Start Relay

Starter Relay (8700, 8800)

Switched Power Relay (8700, 8800)

Group 30: Lights and HarvestLab™ Sensor Adapter Glass

Lights and HarvestLab™ Sensor Adapter Glass, Summary of References

Safety Rules When Replacing Halogen Bulb

Replace Cab Headlight Bulb

Adjust Cab Headlights

Replace Cab Halogen Light Bulb

Adjust Cab Halogen Lights

Replace Fascia or Side Finder Light Bulb (If Equipped)

Replace Lower Driving or Lower Work Light Bulb (If Equipped)

Adjust Lower Driving or Lower Work Lights (If Equipped)

Safety Rules When Replacing High Intensity Discharge (HID) Xenon Light

Replace High Intensity Discharge (Xenon) Light Bulb (If Equipped)

Adjust High Intensity Discharge (Xenon) Lights (If Equipped)

Replace Beacon Light Bulb

Replace Work Lights (If Equipped)

Replace Service Lights

Replace Tail, Stop, or Turn Lights

Replace Cab Interior Light

Replace Map Light

Replace HarvestLab™ Sensor Version 1.4 Adapter Glass

Replace HarvestLab™ 3000 Sensor Adapter Glass

Group 35: Electrical System Components

Electrical System Components, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Accessing Diagnostic Addresses Menu

Cutterhead Angle Sensor B009

Spout Rotation Angle Sensor B011

Spout Tilt Position Sensor B012 and Spout Flap Position Sensor B013

Cutterhead Speed Sensor B019

Sharpening Stone Position Sensor B020

Sharpening Door Position Sensor B021

Kernel Processor Gap Motor Speed Sensor B030 and Gap Adjustment Motor M009

Mass Flow Sensor (Right Feed Rolls) B061 and Mass Flow Sensor (Left Feed Rolls) B062

ProCut Sensor B108 (Left-Hand Side) and B109 (Right-Hand Side)

Header Lateral Tilt Sensor B135

Cutterhead Assembly Safety Switch S012

Section 50A: ProDrive™ Transmission

Group 05: Transmission and Differential

Transmission and Differential, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install ProDrive™ Transmission Valve Block

ProDrive™ Transmission Valve Block—Exploded View

Remove Transmission

Remove Brake Assemblies

Disassemble Brake Assemblies

Assemble Brake Assemblies

Install Brake Assemblies

Remove/Install Park Brake Housing

Disassemble/Assemble Park Brake

Remove Gear-Shift Planetary Drive With Clutch (Forward/Reverse)

Disassemble/Assemble Gear-Shift Planetary Drive With Clutch (Forward/Reverse)

Install Gear-Shift Planetary Drive With Clutch (Forward/Reverse)

Remove/Install Differential Module

Disassemble Differential Module (With Differential Lock)

Assemble Differential Module (With Differential Lock)

Remove/Install Countershaft

Repair Countershaft

Countershaft—Exploded View

Assemble Transmission

Install Transmission

Group 10: Hydrostatic Drive Variable Pump

Hydrostatic Drive Variable Pump, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Hydrostatic Drive Variable Pump

Repair Hydrostatic Drive Variable Pump

Group 15: Variable Displacement Front Motor

Variable Displacement Front Motor, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Variable Displacement Front Motor

Repair Variable Displacement Front Motor

Section 50B: Push Button Shift Transmission (PBST)

Group 05: Transmission and Differential

Transmission and Differential, Summary of References

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Remove PBST Transmission

Remove/Repair Shifter Forks

Install Shifter Forks

Remove/Install Transmission Lube Pump

Disassemble/Repair PBST Transmission

Assemble PBST Transmission

Remove/Install Park Brake Actuator

Disassemble/Assemble Park Brake Actuator

Valve Block Shifter Exploded View

Remove/Install Transmission Shift Valve

Disassemble/Assemble Transmission Shift Valve

Install PBST Transmission

Group 10: Hydrostatic Drive Variable Pump

Hydrostatic Drive Variable Pump, Summary of References

Specifications

Service Equipment and Tools

Other Material

Clean Variable Pump

Flushing the Hydrostatic System

Remove Hydrostatic Drive Variable Pump

Install Hydrostatic Drive Variable Pump

Start-Up Procedure After Hydrostatic System Repair

Group 15: Fixed Displacement Front Motor

Fixed Displacement Front Motor, Summary of References

Specifications

Clean Fixed-Displacement Motor

Remove Fixed-Displacement Motor

Install Fixed-Displacement Motor

Section 50C: Header Drive

Group 05: Header Drive Gear Case

Header Drive Gear Case, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Header Drive Gear Case

Disassemble Header Gear Case or Heavy-Duty Header Gear Case

Header Gear Case—Exploded View

Assemble Header Gear Case

Assemble Heavy-Duty Header Gear Case

Group 10: Header Drive Gear Case Telescoping Driveline

Header Drive Gear Case Telescoping Driveline, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Header Drive Gear Case Telescoping Driveline

Repair Header Drive Gear Case Intermediate Bearing Hub

Group 15: Header Drive Hydrostatic Pump

Header Drive Hydrostatic Pump, Summary of References

Specifications

Essential or Recommended Tools

Special Tool (Self-Manufactured)

Other Material

Remove/Install Header Drive Hydrostatic Pump

Repair Header Drive Hydrostatic Pump

Group 20: Header Drive Hydrostatic Motor

Header Drive Hydrostatic Motor, Summary of References

Specifications

Remove/Install Header Drive Hydrostatic Motor

Repair Header Drive Hydrostatic Motor

Section 50D: Right Feed Roll Drive

Group 05: Right Feed Roll Gear Case

Right Feed Roll Gear Case, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Right Feed Roll Gear Case

Disassemble Right Feed Roll Gear Case

Right Feed Roll Gear Case—Exploded View

Assemble Right Feed Roll Gear Case

Group 10: Feed Roll Hydrostatic Pump

Feed Roll Hydrostatic Pump, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Feed Roll Hydrostatic Pump

Repair Feed Roll Hydrostatic Pump

Group 15: Feed Roll Motor

Feed Roll Motor, Summary of References

Specifications

Essential or Recommended Tools

Remove/Install Feed Roll Motor

Repair Feed Roll Motor

Section 50E: Left Feed Roll Drive

Group 05: Left Feed Roll Gear Case

Left Feed Roll Gear Case, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Left Feed Roll Gear Case

Disassemble Left Feed Roll Gear Case

Left Feed Roll Gear Case—Exploded View

Assemble Left Feed Roll Gear Case

Group 10: Feed Roll Telescopic Driveline

Feed Roll Telescopic Driveline, Summary of References

Remove/Install Feed Roll Telescopic Driveline

Section 50F: Power Distribution Gear

Group 05: Power Distribution Gear

Power Distribution Gear, Summary of References

Specifications

Essential or Recommended Tools

Other Material

General Repair Information

Prepare Machine for Power Distribution Gear Removal

Remove/Install Power Distribution Gear

Driveshaft Housing Disassembly

Driveshaft Housing Assembly

Driveshaft and Gear Train Disassembly

Driveshaft and Gear Train Assembly

Section 50G: Final Drives

Group 05: Final Drive Transmission

Final Drive Transmission, Summary of References

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Remove Final Drive

Disassemble and Assemble Final Drive

Adjust Spindle Bearing (Preferred Method)

Adjust Spindle Bearing (Alternative Method)

Install Final Drive

Section 50H: Main Clutch

Group 05: Main Clutch

Main Clutch, Summary of References

Specifications

Other Material

Remove/Install Main Clutch

Remove/Install Main Drive Pulley

Section 60A: Steering System

Group 05: Hydrostatic Steering

Hydrostatic Steering, Summary of References

Specifications

Other Material

Remove/Install Manual Steering Valve

Steering Column Exploded View

Remove/Install Steering Wheel

Remove/Install Steering Column Covers

Remove/Install Steering Column

Remove/Install Steering Column Harness

Remove/Install Steering Column Tilt Struts

Remove/Install Steering Column Pivots

Remove/Install Steering Column Link Shaft

Remove/Install Tilt Adjust Pedal and Linkage

Group 10: Autotrac™ Steering

Autotrac™ Steering, Summary of References

Remove/Install Steering Column Sensor—Without Subfloor Cab

Remove/Install Steering Column Sensor—With Subfloor Cab

Remove/Install AutoTrac™ Valve Block—Up to S.N. 515999

Remove/Install AutoTrac™ Valve Block—From S.N. 516000

Section 60B: Brake System

Group 05: Brakes—Prodrive™ Transmission

Brakes—Prodrive™ Transmission, Summary of References

Essential or Recommended Tools

Park Brake Release

Bleed Service Brakes

Disassemble/Assemble Brake Pedals

Service Brake Repair

Group 10: Brakes—PBST Transmission

Brakes—PBST Transmission, Summary of References

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Deglazing Brake Linings

Park Brake Release

Remove/Install Brake Drum

Remove Brakes

Repair Brakes

Assemble Brakes

Remove/Install Master Cylinder

Adjusting Master Cylinder

Brake Fluid Reservoir

Bleeding Brake System

Remove/Install Slave Cylinders

Disassemble/Assemble Slave Cylinder

Disassemble/Assemble Brake Pedals

Section 60C: Rear Axle

Group 05: Rear-Wheel Drive Axle

Rear-Wheel Drive Axle, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Change Rear Axle Oil

Remove/Install Rear Axle

Replacing Pivot Pin Bushings

Disassemble the Planetary Drive

Planetary Drive—Exploded View

Assembling the Planetary Drive

Disassemble the Swivel Housing—8.5 Tons Axle Type

Disassemble the Swivel Housing—11.5 Tons Axle Type

Swivel Housing 8.5 Tons Axle Type—Exploded View

Swivel Housing 11.5 Tons Axle Type—Exploded View

Assemble the Swivel Housing—8.5 Tons Axle Type

Assemble the Swivel Housing—11.5 Tons Axle Type

Disassemble the Differential

Differential—Exploded View

Assemble the Differential

Disassemble the Steering Cylinder

Steering Cylinder—Exploded View

Assemble the Steering Cylinder

Adjusting Tread

Remove/Install Rear Axle Hub

Group 10: Rear-Wheel Drive Axle Hydraulic Motor

Rear-Wheel Drive Axle Hydraulic Motor, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Variable Displacement Rear Motor

Repair Variable Displacement Rear Motor

Group 15: Two Wheel Drive Axle

Two Wheel Drive Axle, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Change Rear Axle Oil

Remove/Install Rear Axle

Replacing Pivot Pin Bushings

Disassemble the Planetary Drive

Planetary Drive—Exploded View

Assemble the Planetary Drive

Disassemble the Swivel Housing—8.5 Tons Axle Type

Disassemble the Swivel Housing—11.5 Tons Axle Type

Swivel Housing 8.5 Tons Axle Type—Exploded View

Swivel Housing 11.5 Tons Axle Type—Exploded View

Assemble the Swivel Housing—8.5 Tons Axle Type

Assemble the Swivel Housing—11.5 Tons Axle Type

Disassemble the Steering Cylinder

Steering Cylinder—Exploded View

Assemble the Steering Cylinder

Adjusting Tread

Remove/Install Rear Axle Hub

Section 70: Hydraulic System

Group 05: Spout Turn

Spout Turn, Summary of References

General Repair Information

Remove/Install Spout Motor

Group 10: Spout Raise/Lower

Spout Raise/Lower, Summary of References

General Repair Information

Change Spout Raise/Lower Solenoid Valve

Change Spout Raise Cylinder

Group 15: Spout Fold/Unfold

Spout Fold/Unfold, Summary of References

General Repair Information

Change Spout Fold/Unfold Solenoid Valve

Change Spout Fold/Unfold Cylinders

Group 20: Header Lateral Tilt

Header Lateral Tilt, Summary of References

General Repair Information

Change Header Lateral Tilt Solenoid Valves

Change Header Lateral Tilt Cylinder

Group 25: Wagon Dump

Wagon Dump, Summary of References

General Repair Information

Change Wagon Dump Solenoid Valves

Change Wagon Dump Solenoid Valves (Fast Dump)

Group 30: Header Raise/Lower

Header Raise/Lower, Summary of References

General Repair Information

Change Header Raise/Lower Solenoid Valves

Change Header Raise/Lower Cylinders

Group 35: Auxiliary Drive

Auxiliary Drive, Summary of References

Other Material

General Repair Information

Remove/Install Hydraulic Pumps

Repair Hydraulic Pumps

Remove/Install Suction Fan Motor

Group 40: Filters

Filters, Summary of References

General Repair Information

Replace Power Distribution Gear Oil Filter

Replace Hydraulic System Reservoir Filter

Replace ProDrive™ Transmission Hydraulic Oil Filter

Group 45: Load Sensing Pump

Load Sensing Pump, Summary of References

Specifications

Other Material

General Repair Information

Remove/Install Load Sensing Pump

Repair Load Sensing Pump

Group 50: Knife Sharpening

Knife Sharpening, Summary of References

General Repair Information

Remove/Install Knife Sharpening Motor

Remove/Install Knife Sharpening Door Cylinder

Remove/Install Knife Sharpening Hydraulic Block

Group 55: Rotary Screen Motor

Rotary Screen Motor, Summary of References

General Repair Information

Remove/Install Rotary Screen Motor

Group 60: Main Drive Belt Tension Cylinder

Main Drive Belt Tension Cylinder, Summary of References

General Repair Information

Change Main Drive Belt Tension Cylinder

Group 65: Hydraulic Oil Reservoir

Hydraulic Oil Reservoir, Summary of References

General Repair Information

Drain/Refill Hydraulic Oil Reservoir

Remove/Install Hydraulic Oil Reservoir

Group 70: Power Distribution Gear Oil Reservoir

Power Distribution Gear Oil Reservoir, Summary of References

General Repair Information

Drain/Refill Power Distribution Gear Oil Reservoir (8100—8600)

Drain/Refill Power Distribution Gear Oil Reservoir (8700 and 8800)

Remove/Install Power Distribution Gear Oil Reservoir

Group 80: Electromagnetic Control Valve

Electromagnetic Control Valve, Summary of References

Specifications

Essential or Recommended Tools

Other Material

General Repair Information

Main Valve Block

Low-Pressure Hydraulic Valve Block

Feed Roll Quick-Stop Valve Block

Header Height Valve Block

Wagon Dump Valve Block (Fast Dump)

Dual Header Drive Valve Block (DHD)

Wagon Dump Valve Block

Header Tilt Valve Block

Spout Fold/Unfold Valve Block

Change Valve

Multicoupler Check Valves General View

Disassemble/Assemble Multicoupler

Group 85: Accumulators

Accumulators, Summary of References

Specifications

Essential or Recommended Tools

General Repair Information

Accumulators

Check Accumulator

Recharge Accumulators

Lower Accumulator Pressure

Section 80: Machine Specific System

Group 05: Central Lubrication System

Summary of references, Central Lubrication System

Location of Distributors

Important Lubrication Instructions

Automatic Lubrication System

Quick Couplers

Group 10: Air Compressor System

Air Compressor System, Summary of References

Remove/Install Air Compressor System on 9 L Engine

Remove/Install Air Compressor System on 13.5 L Engine

Remove/Install Air Compressor System on QSK19 Engine (8700, 8800)

Group 15: Additive Dosing System

Additive Dosing System, Summary of References

Specifications

Change Additive Dosing System Nozzle

Additive Dosing System Cabinet

Check Filters

Remove/Install Tanks

Section 90: Operator’s Station

Group 05: Air Conditioner System (R-134a)

Air Conditioner System (R-134a), Summary of References

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Air Conditioner - Important

Air Conditioner System - Safety at Work

Handling Refrigerant

Storage of Refrigerant Containers

R-134a Refrigerant

Service Work on Air Conditioner System

Test and Service Ports

Fill with Refrigerant Oil

Remove/Install Compressor

Charge Air Conditioner System

Group 10: Air Seat

Air Seat, Summary of References

Specifications

Essential or Recommended Tools

Remove/Install Operator Seat

Remove/Install Armrest Control Pivot

Remove/Install Operator Presence Switch

Remove/Install Seat Cushions

Remove/Install Lap Belt

Remove/Install Left-Hand Armrest

Operator Seat Exploded View

Remove/Install Operator Air Seat Suspension

Seat Suspension Component Overview

Remove/Install Seat Suspension Bellows

Remove/Install Vertical Shock Absorber Control Cable Handle

Remove/Install Vertical Shock Absorber Control Cable

Remove/Install Vertical Shock Absorber

Remove/Install Horizontal Shock Absorber

Remove/Install Fore/Aft Isolator Assembly

Remove/Install Fore/Aft Isolator Handle

Remove/Install Fore/Aft Isolator Locking Mechanism

Remove/Install Seat Suspension Compressor

Remove/Install Seat Level Indicator

Remove/Install Seat Suspension Air Spring

Remove/Install Seat Air Reservoir

Remove/Install Seat Height Control

Remove/Install Upper Seat Suspension Frame

Remove/Install Lower Seat Suspension Frame

Group 15: Cab

Cab, Summary of References

Specifications

Essential or Recommended Tools

Heating, Ventilating, and Air Conditioner System—HVAC (General Information)

Remove/Install Receiver/Dryer

Remove/Install Pressurizer Blower Motor

Remove/Install Recirculation Fan Motor

Remove/Install Recirculation Fan Motor Driver

Remove/Install Actuator Valves

Remove/Install Climate Control Unit

Remove/Install Evaporator

Remove/Install Heater Core

Replace Expansion Valve

Replace Air Conditioner High/Low-Pressure Switch

Remove Cab

Install Cab

Remove/Install Cab Windshield

Remove/Install Rear Window

Remove/Install Lower Cab Fascia

Remove/Install Front Portion of Cab Roof

Remove/Install Rear Portion of Cab Roof

Remove/Install Cab Inner Roof

Remove/Install Cab Headliner

Remove/Install Left-Hand Side Cab Door

Disassemble/Assemble Left-Hand Side Cab Door

Remove/Install Right-Hand Side Cab Door

Disassemble/Assemble Right-Hand Side Cab Door

Cab Door Latch Striker

Remove/Install Refrigerator

Remove/Install Refrigerator Doors

Remove/Install Refrigerator Control Unit

Remove/Install Refrigerator Thermostat

Section 99: Special Tools

Group 05: Special Tools (Available as Spare Parts)

Special Tools, Summary of References

Essential Tools for Engine

Essential Tools for Fuel, Air Intake, Cooling and Exhaust Systems

Essential Tools for Electrical System

Essential Tools for ProDrive™ Transmission

Essential Tools for Push Button Shift Transmission (PBST)

Essential Tools for Header Drive

Essential Tools for Right Feed Roll Drive

Essential Tools for Left Feed Roll Drive

Essential Tools for Power Distribution Gear

Essential Tools for Final Drives

Essential Tools for Brakes System

Essential Tools for Rear Axle

Essential Tools for Hydraulic System

Essential Tools for Operator’s Station

Essential Tools for Feeding System

Essential Tools for Cutterhead Assembly

Essential Tools for Discharge System

Section 110: Feeding System

Group 05: Feed Roll Housing

Feed Roll Housing, Summary of References

Specifications

Remove/Install Feed Roll Housing

Remove/Install Pivoting System

Remove/Install Feed Roll Housing Rollers

Group 10: Feed Roll Assembly

Feed Roll Assembly, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Feed Roll Wear Plates

Remove/Install Scraper

Remove/Install Feed Roll

Repair Front Feed Rolls

Repair Rear Feed Rolls

Section 120: Cutterhead Assembly

Group 05: Cutterhead

Cutterhead, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Open/Close Feed Roll Housing

Replace Cutterhead Knives

Remove/Install Cutterhead Assembly

Disassemble Cutterhead

Left-Hand Side Cutterhead Bearing—Repair

Right-Hand Side Cutterhead Bearing—Repair

Group 10: Knife Sharpening Device

Knife Sharpening Device, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Knife Sharpening Sensor Repair

Knife Sharpening Door Repair

Knife Sharpening Device Repair

Adjust Knife Sharpening Device Position

Grinding Tool Exploded View

Grinding Tool Repair

Replace Sharpening Stone

Sharpening Stone Control

Group 15: Bottom and Transition Chutes

Bottom and Transition Chutes, Summary of References

Specifications

Essential or Recommended Tools

Remove/Install Spiral Floor

Remove/Install Recutter Floor

Remove/Install Deflectors

Remove/Install Discharge Chute Panels

Remove/Install Grass Chute Cover

Install Discharge Chute

Group 20: Stationary Knife

Stationary Knife, Summary of References

Specifications

Other Material

Remove/Install Stationary Knife

Remove/Install Stationary Knife Support Diffuser

Remove/Install Stationary Knife Arms

Group 25: Kernel Processor

Summary of references, Kernel Processor

Specifications

Essential or Recommended Tools

Other Material

Operate the Kernel Processor—Type A

Operate the Kernel Processor—Type B

Remove/Install Pulleys

Remove/Install Gap Control Structure

Repair Kernel Processor

Group 30: KernelStar™ Processor

Summary of references, KernelStar™ Processor

Specifications

Essential or Recommended Tools

Other Material

Operate the Kernel Processor—Type A

Operate the Kernel Processor—Type B

Remove/Install Pulleys

Remove/Install Gap Control Structure

Repair KernelStar™

Assemble Bevel Disk Rolls

Section 130: Discharge System

Group 05: Discharge fan

Discharge fan, Summary of references

Specifications

Essential or Recommended Tools

Remove/Install Blower Wear Plates

Remove/Install Discharge Tower Wear Plates

Remove/Install Blower Side Wear Plates

Remove/Install Blower Scrapers

Replace and Adjust Blower Paddles

Group 10: Blower Rotor

Blower Rotor, Summary of References

Specifications

Essential or Recommended Tools

Other Material

Remove/Install Blower Rotor Drive Pulley

Remove/Install Kernel Processor Drive Pulley

Remove/Install Blower Rotor Self-Aligning Bearing on Right-Hand Side

Remove/Install Blower Rotor Self-Aligning Bearing on Left-Hand Side

Remove/Install Blower Rotor

Group 15: Discharge Spout

Discharge Spout, Summary of References

Specifications

Other Material

Remove/Install Discharge Spout Motor Gear

Adjust Discharge Spout Motor Gear

Remove/Install Discharge Spout

Remove/Install Discharge Spout Turning Device

Remove/Install HarvestLab™ Sensor Version 1.4 (Option)

Remove/Install HarvestLab™ 3000 Sensor (Option)

Discharge Spout Service Opening and Wear Plates

John Deere Self-Propelled Forage Harvesters Models 8100, 8200, 8300, 8400, 8500, 8600, 8700, 8800 (Worldwide Edition) Service Repair Technical Manual (TM407119)

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