Complete Repair Service Manual for John Deere 7250, 7350, 7450, 7550, 7750, 7850, 7950 Forage Harvesters (Worldwide Edition), with all the technical information to maintain, Repair, repair, service like professional mechanics.

John Deere Self-Propelled Forage Harvesters Models 7250, 7350, 7450, 7550, 7750, 7850, 7950 workshop repair service 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.

TM401419 - John Deere Self-Propelled Forage Harvesters Models 7250, 7350, 7450, 7550, 7750, 7850, 7950 Technical Manual (Repair).PDF
|TM401419 - John Deere Self-Propelled Forage Harvesters Models 7250, 7350, 7450, 7550, 7750, 7850, 7950 Technical Manual (Repair).epub

Total Pages: 2,550 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   Version Date
   Safety
      Safety Information
   General Information
      Fuel, Lubricants and Coolant
      Torque Values
      Serial Numbers
      Dimensions
   Engine
      Remove and Install Engine
   Fuel, Air Intake and Cooling Systems
      Fuel Tank
      Air Intake System
      Cooling System
   Electrical System
      Harness and Connector Repair
      Electrical System Components
   Power Train
      Main Drive Belt Replacement
      Bevel Gear Drive
      Transmission and Differential (Three-Speed Transmission)
      Transmission and Differential (ProDrive™ Transmission)
      Final Drives
      Hydrostatic Drive, Variable Pump (Three-Speed Transmission)
      Hydrostatic Drive, Variable Pump (ProDrive™ Transmission)
      Hydrostatic Drive, Fixed Displacement Motor (3-Speed Transm.)
      Hydrostatic Drive, Variable Displacement Motor (ProDrive™)
      Rear-Wheel Drive Axle
      Rear-Wheel Drive Axle, Variable Displacement Motor
   Brakes, Steering and Rear Axle
      Brake Operation (Three-Speed Transmission)
      Brake Operation (ProDrive™ Transmission)
      Brakes (Three-Speed Transmission)
      Brakes (ProDrive™ Transmission)
      Hydrostatic Steering
      Row Guidance System
      Rear Axle
   Hydraulic System
      Hydraulic Pressure Accumulators
      Hydraulic Pumps
      Electromagnetic Control Valve
      Reverser Motor (Four-Speed LOC)
      Hydraulic Motor - Discharge Spout
      Hydraulic Motor - Rotary Screen
      IVLOC Transmission Motor
      IVLOC Transmission Hydrostatic Pump
   Miscellaneous
      Central Lubrication System
   Operator`s Cab, Air-Conditioning System
      Control Levers
      Cab Ventilation
      Operator`s Cab
      R134a Air-Conditioning System
      Super Comfort Seat
   Special Tools
      Special Tools (Dealer Fabricated)
      Special Tools (Available as Spare Parts)
   Harvesting Units
      Harvesting Unit Cross Drive
      Harvesting Units
   Feeding System
      Four-Speed Length-Of-Cut Transmission
      IVLOC Transmission
      Reverser Motor and Clutch (4-Speed LOC Transmission)
      Electric Clutch (4-Speed LOC Transmission)
      Feed Roll Housing
      Feed Roll Assembly
      Locking Pawl (4-Speed LOC Transmission)
   Cutterhead Assembly
      Knife Sharpening Device
      Cutterhead
      Bottom and Outlet Bands
      Stationary Knife Removal and Installation
      Kernel Processor
      Power Chute
   Discharge Components
      Discharge Fan
      Blower Rotor and Rotor Bearings
      Discharge Spout

tm401419 - 7250, 7350, 7450,7550, 7750, 7850 and 7950Self-Propelled ForageHarvesters Repair -: (Worldwide Edition)

Table of Contents

Foreword

Version Date

Section 05: Safety

Group 05: Safety Information

Recognize Safety Information

“Important” - Information

“Note” - Information

Prevent Machine Runaway

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Avoid High-Pressure Fluids

Service Cooling System Safely

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Work In Ventilated Area

Wear Protective Clothing

Practice Safe Maintenance

Park Machine Safely

Use Proper Lifting Equipment

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 Proper Tools

Service Tires Safely

Avoid Eye Contact with Radar

Replace Safety Signs

Dispose of Waste Properly

Live With Safety

Safety Measures on Electronic Control Units

Service Accumulator Systems Safely

Section 10: General Information

Group 05: Fuel, Lubricants and Coolant

Diesel Fuel

Handle Fuel Safely—Avoid Fires

Handling and Storing Diesel Fuel

Lubricity of Diesel Fuel

Filling the Fuel Tank

Testing Diesel Fuel

Biodiesel Fuel

Biodiesel Fuel (7950 Only)

Minimizing the Effect of Cold Weather on Diesel Engines

Minimizing the Effect of Cold Weather on Diesel Engines (7950 Only)

Diesel Engine Break-In Oil

Diesel Engine Oil and Filter Service Intervals (7250-7750 With EGR Only)

Diesel Engine Oil and Filter Service Intervals (7250-7850 Without EGR Only)

Diesel Engine Oil (7950 Only)

Diesel Engine Oil and Filter Service Intervals (7950 Only)

Mixing of Lubricants

Oilscan™ and CoolScan™

Alternative and Synthetic Lubricants

Lubricant Storage

Oil Filters

Heavy Duty Diesel Engine Coolant

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

Cooling System Capacity

Transmission Oil

Use of Transmission Oil

Transmission and Hydraulic Oil

Use of Transmission and Hydraulic Oil

Brake Fluid for Brake System (Three-Speed Transmission)

Grease

Alternative and Synthetic Lubricants

Mixing of Lubricants

Lubricant Storage

Use Genuine John Deere Parts

Group 10: Torque Values

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Hydraulic System Inch Fitting Torque Values

Hydraulic System Metric Fitting Torques Values

Group 15: Serial Numbers

Serial Numbers

Forage Harvester Type Plate for Europe (Product Identification Up to SN 510523)

Forage HarvesterType Plate for Europe (Product Identification From SN 510524)

Forage Harvester Type Plate for North America (Product Identification Up to SN 510523)

Forage Harvester Type Plate for North America (Product Identification From SN 510524)

Product Identification Number (Europe)

Product Identification Number (North America)

Engine Serial Number — Engine Type 6090 (7250 Only)

Engine Serial Number — Engine Type 6135 (7350-7750)

Engine Serial Number — Cummins (7850 Only)

Engine Serial Number — Cummins (7950 Only)

Operator's Cab Serial Number

Four Wheel Drive Motor Serial Number

Kernel Processor Serial Number

Power Chute Serial Number

Three-Speed Transmission Serial Number

ProDrive Transmission Serial Number

Final Drive Serial Number

Angled Drive (Main Gearcase) Serial Number

Four-Speed Length-of-Cut Transmission Serial Number

IVLOC Transmission Serial Number

IVLOC Transmission Hydrostatic Pump Serial Number (Three-Speed Transmission)

IVLOC Transmission Hydrostatic Pump Serial Number (ProDrive Transmission)

IVLOC Transmission Motor Serial Number

Main Drive Hydrostatic Pump Serial Number (Three-Speed Transmission)

Main Drive Hydrostatic Pump Serial Number (ProDrive Transmission)

Main Drive Motor Serial Number (Three-Speed Transmission)

Main Drive Motor Serial Number (ProDrive Transmission)

Powered Rear Axle Serial Number

Heavy Duty Rear Axle Serial Number

Spout Serial Number

Group 20: Dimensions

Dimensions

Section 20: Engine

Group 05: Remove and Install Engine

Essential or Recommended Tools

Other Material

Specifications

Prepare Machine for Engine Removal

Removing and Installing Engine (7250)

Removing and Installing Engine (7350, 7450, 7550 and 7750)

Removing and Installing Engine (7850)

Removing and Installing Engine (7950)

Section 30: Fuel, Air Intake and Cooling Systems

Group 05: Fuel Tank

Specifications

Fuel System Components - 700 L (185 U.S. gal)

Fuel System Components - 1100 L (290 U.S. gal)

Fuel System Components (7950 Only)

Removing Fuel Tank

Removing Fuel Sending Unit

Group 10: Air Intake System

Specifications

Air Intake System (7250)

Air Intake System (7350)

Air Intake System (7450, 7550 and 7750)

Air Intake System (7850)

Air Intake System (7950)

Prepare Machine for Intercooler Removal

Removing and Installing Intercooler (7250)

Removing and Installing Intercooler (7350, 7450, 7550, 7750 and 7850)

Removing and Installing Intercooler (7950)

Group 15: Cooling System

Specifications

Cooling Package Location

Replacing Coolant Level Sending Unit

Prepare Machine for Radiator and Hydraulic Oil Cooler Removal

Removing and Installing Radiator (7250)

Removing and Installing Radiator (7350, 7450, 7550, 7750 and 7850)

Removing and Installing Radiator (7950)

Removing and Installing Hydraulic Oil Cooler (7250)

Removing and Installing Hydraulic Oil Cooler (7350, 7450, 7550, 7750 and 7850)

Removing and Installing Hydraulic Oil Cooler (7950)

Removing Fuel Cooler

Removing Air Conditioning Condenser

Removing IVLOC Cooler (7950 Only)

Replacing the Viscous Drive (7850 Only)

Checking Belt Tensioner Spring Tension and Belt Wear (7250—7750)

Checking Belt Tensioner Spring Tension and Belt Wear (7850 Only)

Checking Belt Tension and Belt Wear (7950 Only)

Rotary Screen

Removing Suction Blower (7950 Only)

Section 40: Electrical System

Group 05: Harness and Connector Repair

Essential or Recommended Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Connectors

Repair WEATHERPACK WEATHERPACK is a trademark of Packard Electric 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 Reel Reversing Valve Connector

Repair HD Series Deutsch Connectors

Repair CINCH Flex Box Connectors

Repair TYCO-AMP Standard Power Timer Connectors

TYCO-AMP Super Seal Connectors

Group 10: Electrical System Components

Essential or Recommended Tools

Specifications

Other Material

Electrical System — Specifications (7250-7850)

Electrical System — Specifications (7950)

Batteries

Battery Switch (7250-7850)

Battery Switch (7950)

Dangers When Handling Batteries

Battery Service

Checking Electrolyte Level

Checking Specific Gravity

Charging Batteries

Installing and Connecting Batteries

Servicing Electronic Control Units

Welding Near Electronic Control Units

Keep Electronic Control Unit Connectors Clean

Starting the Engine by Means of a Booster Battery (7250-7850)

Starting the Engine by Means of a Booster Battery (7950)

Alternator G4 (24 V - 7950 Only)

Alternator G5 (12 V)

Alternator G6 (12 V)

Starter Motor M1 (12 V — 7250-7850)

Starter Motor M1 (24 V — 7950)

Outlets

Replacing Terminating Resistors

Control Units

Fuse / Relay Tester

Spare Fuses

Fuse and Relay Boards A1, A2 and A3

Extra Fuses and Relays

Real Time Clock Battery (19 L Cummins Engine)

Engine Oil Pressure Sending Unit B1 / B45

Cutterhead Alarm, Front B2

Cutterhead Alarm, Back B3

Reverser Motor Pressure Switch B4

Lift Cylinder Pressure Transducer B5

Hydrostatic Oil Temperature Sending Unit B6

Hydraulic Oil Filter Sensor B7

Hydrostatic Charge Pressure Sending Unit B8

Air Cleaner Sending Unit B9

Cutterhead Speed Sending Unit B10 IVLOC

Cutterhead Speed Sending Unit B10 Four-Speed LOC

IVLOC Pressure Control Switch B11

Ground Speed Sending Unit B12 (Three-Speed Transmission)

IVLOC Hydraulic Pressure Switch B13

Front Wheel Speed Sending Units B14 / B68

Horn B15

Feedroll Speed Sending Unit B16 IVLOC

ATC Air Conditioning System Low Pressure Switch B17

ATC Air Conditioning System High Pressure Switch B18

Rear-Wheel Drive Pressure Sending Unit B22

Rear-Wheel Drive Speed Sending Unit B23

Metal Detector Sending Unit B24

Knock Sensors B26 and B27

Fuel Tank Sending Unit B28.1

Reverse Travel Alarm B30

Coolant Temperature Sending Unit B31 / B43

Intake Air Pressure Sending Unit B32

Fuel Temperature Sending Unit B33

Intake Air Temperature Sending Unit B34

Engine Camshaft Sending Unit B35 / B44

Engine Crankshaft Sending Unit B36 / B40

Fuel Pressure Sending Unit B37 / B39

Water-In-Fuel Sending Unit B38 / B46

Intake Manifold Pressure and Temperature Sending Unit B41 (15 L Cummins Engine)

Intake Manifold Pressure Sending Unit B41 (19 L Cummins Engine)

Ambient Air Pressure Sensor B42 (Cummins Engine)

Stationary Knife Motor-Impulse Sending Units B47 and B48 (Old Assembly)

Stationary Knife Motor-Impulse Sending Units B47 and B48 (New Assembly)

Inlet Temperature Sending Unit B49

Outlet Temperature Sending Unit B50

Cab Temperature Sending Unit B51

Evaporator Core Temperature Sending Unit B52

Kernel Processor Motor-Impulse Sending Unit B53 and B54 (Old Assembly)

Kernel Processor Motor-Impulse Sending Unit B53 and B54 (New Assembly)

Hydrostatic Pump Pressure Reverse Sending Unit B55

Feed Roll Distance Sending Unit B58

Hydrostatic Pump Pressure Forward Sending Unit B59

Hi/Lo Transmission Pressure Sending Unit B61

Hi/Lo Transmission Temperature Sending Unit B62

Front Motor Speed Sending Unit B63

Multi-Function Lever Position Sending unit B64

Parking Brake Sending Unit B65

Transmission Speed Sending Unit B66

Rear Wheel Sending Unit B67 (Row Guidance)

Row Guidance Steering Input Sending Unit B69

Automatic Spout Control Sending Units B70, B71 and B72

Exhaust Gas Recirculation (EGR) Exhaust Temperature Sending Unit B78

Exhaust Gas Recirculation (EGR) Fresh Air Temperature Sending Unit B79

Exhaust Gas Recirculation (EGR) Mixed Gas Temperature Sending Unit B80

Variable Geometry Turbocharger (VGT) Fan Speed Sending Unit B81

Fuel Rail Pressure Sending Unit B82

Low Pressure Pump Sending Unit B83

Fuel Pump Accumulator Pressure Sending Unit B86 (19 L Cummins Engine)

Turbocharger Speed Sending Unit B87 (19 L Cummins Engine)

Intake Manifold Temperature Sending Unit B88 (19 L Cummins Engine)

Fuel Temperature Sending Unit B89 (19 L Cummins Engine)

Condition Monitoring System Sending Units B90-B99

Alternators

Remove and Install Alternator

ATC Air Conditioning System Recirculating Blower Motor M3

Windshield Wiper Motor M4

Front Windshield Washer Pump M5

Spout Flap Motor M6

Kernel Processor Lift Motor M8

Variable Geometry Turbocharger (VGT) Actuator M9

Knife Sharpening Motor M10

Stationary knife Adjusting Motors M11 and M12 (Old Assembly)

Stationary knife Adjusting Motors M11 and M12 (New Assembly)

Kernel Processor Adjusting Motors M13 and M14 (Old Assembly)

Kernel Processor Adjusting Motors M13 and M14 (New Assembly)

Side Windshield Wiper Motors M15 and M16

Side Windshield Washer Pump M17

Sharpening Door Motor M18

ATC Air Conditioning System Pressurizer Blower Motor M20

Outside Mirror Motor M21 and M22

Exhaust Gas Recirculation (EGR) Torque Motor M23 and M24

Fuel Lift Pump M25 (7950 Only)

Fuel Transfer Pump A35 (John Deere Engine)

Stone Sweep Position Potentiometer R6

Sharpening Door Position Potentiometer R9

Header Angle Potentiometer R17 / B76

Transmission 3rd Gear Switch S21

Manual Sharpening Door Switch S26

Kernel Processor Electric Lift Switch S28

Header Safety Switch S30

LOC Neutral Position Switches S32 and S33

Stop Light Switch S35 / S35.1

Transmission Oil Pressure Switch S48 (ProDrive Transmission)

Battery Main Switch S51 (7250-7850)

Battery Main Switch S73 (7950 Only)

Accumulator Charge Pressure Switch S52

Manual Cutterhead Reverse Switch S53

Reverse Drive Switch S54 (Three-Speed Transmission)

Parking Brake Switch S56 (Three-Speed Transmission)

Coolant Level Switch S57

Reed Switch S60 (676/678 RHU)

Rotary Screen Speed Sending Unit S67

Ether Starting Aid Y1

Automatic Header Control Shut Off Valve Y2

IVLOC Quick Stop Pawl Solenoid Y3

IVLOC Solenoids

Proportional Valve Solenoids (Three-Speed Transmission)

Proportional Valve Solenoids (ProDrive Transmission)

Header Height Control (AHC) Solenoids

ProDrive Transmission Solenoids

ATC Air Conditioning Clutch Y11

Main Hydraulic System Solenoids (Four-Speed LOC Transmission)

Main Hydraulic System Solenoids (IVLOC Transmission)

IVLOC Proportional Valves Y18 and Y19

Gear Lock Solenoid Y20 (Three-Speed Transmission)

Wagon Dump High Flow Solenoids

Low Pressure Solenoid Valves (Old Assembly)

Low Pressure Solenoid Valves (Latest Assembly)

IVLOC Reversing Pawl Solenoid Y34

Four Speed LOC Reverser Motor Solenoid Y35

Four Speed LOC Electrical Clutch Y38

Four Speed LOC Pawl Solenoid Y39

Row Guidance Valve Block Y40

Rear Wheel Drive Proportional Valve Y41

Front Motor Proportional Valve Y45

Transmission Pump-Forward and Reverse Valves Y46 / Y47 (ProDrive Transmission)

Fuel Pump Control Solenoid Valve Y48 (9 L John Deere Engine)

Fuel Shut-Off Solenoid Valve Y50 (15 L Cummins Engine)

Wastegate Solenoid Valves Y61 and Y62 (15 L Cummins Engine)

Fuel Solenoids Y63, Y64, Y65 and Y66 (15 L Cummins Engine)

Fuel Pump Actuator (19 L Cummins Engine)

Safety Rules When Replacing Xenon Bulbs

Remove and Install High Intensity Discharge (Xenon) Lights (Optional)

Safety Rules When Replacing Halogen Bulbs

Replacing Bulbs

Cab Head Light Bulb Replacement and Adjustment

Turn Signal Indicator Light Bulb Replacement

Dome and Console Light Bulb Replacement

Automatic Function Control Panel Light Bulb Replacement

Moisture Sensor Adapter Glass Replacement

Observe Electrical Precautions

Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems

Section 50: Power Train

Group 05: Main Drive Belt Replacement

Specifications

Replace Main Drive Belt

Group 10: Bevel Gear Drive

Specifications

Other Material

Essential or Recommended Tools

Special Tool (Self-Manufactured)

Modify Assembly Fixture (KJD10350)

Other Material

Remove Bevel Gear Drive

Attaching Bevel Gear Drive to Assembly Fixture

Main Clutch Assembly

Check Main Clutch

Remove Clutch

Hub Components

Bevel Gear Drive Disassembly

Bevel Gear Drive Assembly

Determination of Adjusting Measure for Drive Pinion

Dimension “C”

Dimension “H”

Dimension “G”

Dimension “B”

Drive Shaft Reassembly

Determination of Adjusting Measure for Output Pinion

Dimension “D”

Dimension “F”

Dimension “E”

Dimension “A”

Output Shaft Reassembly

Output Shaft Adjustment

Install Output Shaft

Disk Clutch Reassembly

Install Clutch Oil Jet fitting

Install Bevel Gear Drive

Group 15: Transmission and Differential (Three-Speed Transmission)

Specifications

Other Material

Drain Oil

Remove and Repair Shifter Forks and Shifter Cam

Install Shifter Forks and Shifter Cam

Remove and Install Transmission Lube Pump

Remove and Install Suction Screen

Remove Transmission

Transmission Components

Transmission Recondition

Disassemble and Repair Transmission

Remove Pinion Shaft

Remove Differential

Disassemble Differential

Assemble Differential

Assemble Transmission

Install Transmission

Remove and Install Gearshift Lever and Linkage

Adjusting Gearshift Linkage

Group 16: Transmission and Differential (ProDrive™ Transmission)

Specifications

Essential or Recommended Tools

Special Tools—Dealer Fabricated

Other Material

Draining Oil

Remove and Install Shift Valve Housing

Remove and Repair Valves from Shift Valve Housing

Shift Valve Housing-Exploded View

Install Valves in the Shift Valve Housing

Remove Transmission

Transmission Components-Overview

Disassemble Transmission

Remove Brake Modules

Disassemble Brake Modules

Brake Modules-Exploded View

Assemble Brake Modules

Install Brake Modules

Remove Differential Module

Disassemble Differential Module (With Differential Lock)

Differential (With Differential Lock)-Exploded View

Assemble Differential Module (With Differential Lock)

Install Differential Module

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

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

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

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

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

Remove Countershaft

Repair Countershaft

Countershaft-Exploded View

Install Countershaft

Assemble Transmission

Install Transmission

Group 20: Final Drives

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

Final Drive Attaching Screws

Group 25: Hydrostatic Drive, Variable Pump (Three-Speed Transmission)

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Serial Number Plate

Clean Variable Pump

Flushing the Hydrostatic System

Remove Variable Pump

Remove Variable Pump (Machines with IVLOC)

Remove Variable Pump (Machines with Four- Speed LOC)

Disassemble Variable Pump

Assemble Variable Pump

Disassemble and Assemble End Cover

Repair Control Valve

Repair Charge Pump

Install Variable Pump

Remove and Install Hydrostatic Control Cable

Adjust Hydrostatic Neutral Linkage

Adjust Displacement Control Valve Neutral

Group 26: Hydrostatic Drive, Variable Pump (ProDrive™ Transmission)

Essential or Recommended Tools

Special Tool (Self-Manufactured)

Specifications

General View

Serial Number Plate

Clean Variable Pump

Remove Variable Pump

Sealing the Drive Shaft

Sealing the Boost Pump

Sealing the Control Piston Cover

Sealing The Boost Pressure Valve

Sealing the Pressure Cut Off Valve

Remove Control Unit

Disassembling the Pump

Disassembling Cylinder Assembly

Disassembling the Control Piston

Inspection Notes

Assembling the Pump

Installing the Rotary Group

Adjustment Instructions

Group 30: Hydrostatic Drive, Fixed Displacement Motor (3-Speed Transm.)

Essential or Recommended Tools

Other Material

Specifications

Clean Fixed-Displacement Motor

Remove Fixed-Displacement Motor

Disassemble Fixed-Displacement Motor

Inspect Parts

Lack of Lubrication

Abrasive Contamination

Cavitation

Over Speeding

Inspect Shaft Seal

Inspect Thrust Plate

Inspect Fixed Swashplate

Inspect Piston Slipper

Inspect Piston Retainer

Inspect Cylinder Block

Inspect Bearing Plate

Inspect Valve Plate

Inspect Bearing and Race

Inspect Servo Piston

Inspect Drive Shaft

Replace Cylinder Block Spring

Assemble Motor

Install Fixed-Displacement Motor

Remove and Install Motor Valve Block (Manifold)

Repair Motor Valve Block

Group 31: Hydrostatic Drive, Variable Displacement Motor (ProDrive™)

Specifications

Remove Variable-Displacement Motor

General View

Sealing the Cover Plate

Sealing of the Control Parts

Disassembling the Port Plate

Assembling the Port Plate

Group 40: Rear-Wheel Drive Axle

Specifications

Essential or Recommended Tools

Other Material

Changing Oil

Remove Axle Housing From Machine

Replacing Pivot Pin Bushings

Disassemble the Planetary Drive

Planetary Drive—Exploded View

Assembling the Planetary Drive

Disassemble the Swivel Housing

Swivel Housing—Exploded View

Assemble the Swivel Housing

Disassemble the Differential (Two Planet Gears)

Differential—Exploded View (Two Planet Gears)

Assemble the Differential (Two Planet Gears)

Disassemble the Differential (Four Planet Gears)

Differential—Exploded View (Four Planet Gears)

Assemble the Differential (Four Planet Gears)

Disassemble the Steering Cylinder

Steering Cylinder—Exploded View

Assemble the Steering Cylinder

Adjusting Tread

Fender and Fender Support Removal and Installation (ProDrive Transmission)

Group 45: Rear-Wheel Drive Axle, Variable Displacement Motor

Essential or Recommended Tools

Specifications

General View

Sealing the Cover Plate

Sealing of the Control Parts

Disassemble the Port Plate

Assembling the Port Plate

Disassembling the Rotary Group

Inspection Notes

Assembling the Rotary Group

Rotary Group Adjustment

Section 60: Brakes, Steering and Rear Axle

Group 05: Brake Operation (Three-Speed Transmission)

Essential or Recommended Tools

Other Material

Specifications

Remove and Install Master Cylinder

Disassemble and Assemble Master Cylinder (Double Bleed Screw)

Brake Fluid Reservoir

Adjusting Master Cylinder

Bleeding Brake System—Double Bleed Screw

Remove and Install Slave Cylinders

Disassemble and Assemble Slave Cylinders

Disassemble and Assemble Brake Pedals

Disassemble and Assemble Parking Brake Pedal

Adjust Park Brake Pedal

Group 06: Brake Operation (ProDrive™ Transmission)

Other Material

Specifications

Remove and Install Master Cylinder

Disassemble and Assemble Master Cylinder

Adjusting Master Cylinder

Bleed Service Brakes

Disassemble and Assemble Brake Pedals

Disassemble and Assemble Parking Brake Valve (Accumulator Charge)

Group 10: Brakes (Three-Speed Transmission)

Essential or Recommended Tools

Other Material

Specifications

Deglazing Brake Linings

Remove Brake Drum

Remove Brake Shoe

Repair Brakes

Brake Assembly

Group 11: Brakes (ProDrive™ Transmission)

Essential or Recommended Tools

Other Material

Specifications

Check Brake Disk Thickness

Repair Brake Disks

Group 15: Hydrostatic Steering

Essential or Recommended Tools

Other Material

Specifications

Steering Hydraulics (IVLOC - Three-Speed Transmission)

Steering Hydraulics (IVLOC - ProDrive Transmission)

Steering Hydraulics (Four-Speed LOC)

Removing the Steering Valve

Steering Valve Components

Disassembling the Steering Unit

Removing Safety Valves

Removing Check Valve

Removing Spool and Sleeve

Disassembling the Spool Assembly

Removing Leaf Springs

Removing Seal Ring

Removing the Safety Valves

Removing Pressure-Control Valve

Repairing the Steering Unit

Assembling the Steering Unit

Installing Pressure-Control Valve

Installing Safety Valves

Arranging the Leaf Springs

Installing the Leaf Springs

Assembling the Spool Assembly

Installing Retaining Ring and Cross Pin

Assembling the Thrust Bearing

Installing the Seal Ring

Installing O-Ring and Back-Up Ring

Installing Spool Assembly

Installing the Check Valve

Installing Safety Valves

Installing the O-Ring

Installing Distributor Plate and Drive Shaft

Installing Rotor and Stator

Installing Spacer Ring

Installing Metering Unit Cover

Safety Valve Test

Adjusting the Safety Valves

Pressure Control Valve Test

Adjusting the Pressure-Control Valve

Install Steering Valve

Bleeding the Hydrostatic Steering System

Steering Column Components

Disassemble And Assemble Steering Column

Replace Telescoping Shaft Bearings

Group 16: Row Guidance System

Specifications

Other Material

Row Guidance System Components

Checking Rotary Potentiometer

Removing and Installing Steering Valve Block and Steering Input Sending Unit

Calibrating Control Unit

Address RGC 100 Calibration — Sensitivity

Address RGC 101 Calibration — Feelers

Address RGC 102 Calibration — Wheel Angle Sensor/Steering Wheel Position Sensor

Address RGC 105 Calibration — Steering Valve Deadband

Address RGC 108 Calibration — Steering Test Mode

Address RGC 109 Calibration — Feeler Side Swap

Group 20: Rear Axle

Essential or Recommended Tools

Other Material

Rear Axle Pivot Bushing

Remove and Install Rear Axle Pivot Bushing

Section 70: Hydraulic System

Group 05: Hydraulic Pressure Accumulators

Specifications

Essential or Recommended Tools

General Repair Information

Accumulators

Harvesting Unit Float System (IVLOC - Three-Speed Transmission)

Harvesting Unit Float System (IVLOC - ProDrive Transmission)

Harvesting Unit Float System (Four-Speed LOC)

Main Clutch System (Old Assembly)

Main Clutch System (New Assembly)

Discharge Spout System

Discharge Spout System (IVLOC)

Checking Accumulators

Recharging Accumulators

Lowering Accumulator Pressure

Group 10: Hydraulic Pumps

Specifications

Other Material

General Repair Information

Draining Hydraulic Oil

Pressure And Temperature Sending Units At Hydraulic Oil Tank

Refilling Hydraulic Oil

Repair Information

Removing Hydraulic Pumps

Marking Hydraulic Pumps

Disassemble Hydraulic Pumps

Replace Shaft Seal

Installing Gasket and Support

Hydraulic Pumps, Exploded View

Assembling Hydraulic Pumps

Install Hydraulic Pumps

Group 15: Electromagnetic Control Valve

Specifications

Solenoid Valves - Main Block (Four-Speed LOC Transm.)

Solenoid Valves - Main Block (IV LOC Transmission)

Hydraulic Valve Assembly - Main Block (Four-Speed LOC Transm.)

Remove Solenoid Main Valve Block

Repair Unload Solenoid Valve (Y30)—Four-Speed LOC Transmission

Discharge Spout Rotation Solenoid Valves (Y12, Y13)—Four-Speed LOC Transmission

Solenoid Valves for Discharge Spout Raising/Lowering (Y15, Y14) & for Header Folding (Y23, Y24)—4-Speed LOC Transmission

Low Flow Solenoid Valves (Y25, Y26)—Four-Speed LOC Transmission

Trailer Solenoid Valves (Y31, Y32)—Four-Speed LOC Transmission

Repair Reverser Solenoid Valve (Y35)—Four-Speed LOC Transmission

Low Pressure Valve Block

Remove Low Pressure Valve Block

Repair Low Pressure Valve Block (New Assembly)

Proportional Valve Block (Three-Speed Transmission)

Proportional Valve Block (ProDrive Transmission)

Header Height Control (AHC) Valve Block—IVLOC

High Flow Wagon Dump Valve Block (Option)

Remove High Flow Wagon Dump Valve Block (Option)

Repair High-Flow Wagon Dump Valve Block (Option)

Group 20: Reverser Motor (Four-Speed LOC)

Removing Reverser Motor

Disassembling Reverser Motor

Repairing Reverser Motor

Group 25: Hydraulic Motor — Discharge Spout

Specifications

Removing Hydraulic Motor

Disassembling Hydraulic Motor — 7250-7550 and 7750-7950 up to SN 511705

Hydraulic Motor, Exploded View — 7250-7550 and 7750-7950 up to SN 511705

Repairing Hydraulic Motor — 7250-7550 and 7750-7950 up to SN 511705

Assembling Hydraulic Motor — 7250-7550 and 7750-7950 up to SN 511705

Group 26: Hydraulic Motor — Rotary Screen

Specifications

Removing and Installing Hydraulic Motor

Repairing Hydraulic Motor

Group 30: IVLOC Transmission Motor

Essential or Recommended Tools

Specifications

General Description

Remove/Install Motor

Replacing the Drive Shaft Seal

Remove the Connection Plate

Installing The Connection Plate

Disassemble the Flushing Valve

Assembling The Flushing Valve

Disassembling Motor

Inspecting Parts

Assemble the Motor

Adjusting Taper Roller Bearing Pre-Load

Group 35: IVLOC Transmission Hydrostatic Pump

Essential or Recommended Tools

Special Tool (Self-Manufactured)

Specifications

General Description

Sealing the Drive Shaft

Sealing the Boost Pump

Sealing the Control Piston Cover

Sealing the Valves

Sealing the Pressure Cut Off Valve

Remove the Control Unit

Disassembling the Pump

Inspection Notes

Assemble the Pump

Installing the Rotary Group

Installing the Control Plate

Adjustment instructions

Section 80: Miscellaneous

Group 05: Central Lubrication System

Specifications

Location of Primary and Secondary Distributors

Flow Schematic

Automatic Lubrication System (Option)

Operational Information

Adjusting Optional Pump Element for Flow Control

Quick Couplers for Kernel Processor and Harvesting Unit

Troubleshooting - Automatic Lubrication System

Section 90: Operator's Cab, Air-Conditioning System

Group 05: Control Levers

Multi-Function Lever (Three-Speed Transmission)

Multi-Function Lever (ProDrive Transmission)

Group 10: Cab Ventilation

Essential or Recommended Tools

Other Material

Specifications

Air Conditioning System With Precleaner (General Information)

Air Conditioning System Components

Recirculating Filter

Remove and Install Blower Motor

Remove and Install Recirculator Fan Motor Driver

Remove and Install Recirculator Motor

Remove and Install Temperature Control Door Actuator

Remove and Install Heater Core

Replace Evaporator

Replace Expansion Valve

Remove and Install Evaporator Temperature Sensor

Replace Low Pressure Switch

Replace High Pressure Switch

Remove and Install Receiver/Drier

Removing Air Conditioning Condenser

Repair Condenser

Replace Air Temperature Sensors

Group 15: Operator's Cab

Specifications

Remove and Install Cab Windshield

Remove and Install Cab Roof

Cab Door Latch Striker

Remove and Install Cab Door

Disassemble and Assemble Cab Door

Rear Window Installation

Right-Hand Cab Window

Remove Cab

Install Cab

Group 20: R134a Air-Conditioning System

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Service Parts Kits

Hose and Tubing O-Ring Connection Torques

Air-Conditioning - Important

Air-Conditioning System - Safety at Work

Handling Refrigerant

Storage of Refrigerant Containers

R134a Refrigerant

Service Work on Air-Conditioning System

Component Location

Test and Service Ports

Fill with Refrigerant Oil

Remove and Install Compressor

Checking Level in the Compressor

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Remove and Install Compressor Relief Valve

Compressor Oil Information

Group 25: Super Comfort Seat

Specifications

Remove and Install Operator’s Seat

Remove and Install Operator Presence Switch

Operator's Seat Exploded View

Operator's Seat Air Suspension Assembly—Exploded View

Disassemble and Assemble Operator's Seat Air Suspension Assembly

Section 99: Special Tools

Group 05: Special Tools (Dealer Fabricated)

Self-Manufactured Tool for Bevel Gear Drive Repair

Self-Manufactured Tool for ProDrive Transmission Repair

Self-Manufactured Tool for Hydrostatic Drive Pump Repair—ProDrive Transmission

Self-Manufactured Tool for Hydrostatic Drive Pump Repair—IVLOC Transmission

Group 10: Special Tools (Available as Spare Parts)

Essential or Recommended Tools

Essential Tools for Engine Repair

Essential Tools for Electrical System Repair

Essential Tools for Bevel Gear Drive Repair

Essential Tools for ProDrive Transmission Repair

Essential Tools for Final Drive Repair

Essential Tools for Hydrostatic Drive Pump Repair—Three-Speed Transmission

Essential Tools for Hydrostatic Drive Pump Repair—ProDrive Transmission

Essential Tools for Rear-Wheel Drive Axle Repair

Essential Tools for Rear Wheel Drive Motor Repair

Essential Tools for Brake System Repair—Three-Speed Transmission

Essential Tools for Brake System Repair—ProDrive Transmission

Essential Tools for Steering System Repair

Essential Tools for Rear Axle Repair

Essential Tools for Hydraulic Pressure Accumulator Repair

Essential Tools for IV Length-of-Cut Transmission Motor Repair

Essential Tools for IV Length-of-Cut Transmission Hydrostatic Pump Repair

Essential Tools for Air Conditioning System Repair

Essential Tools for IVLOC Transmission Repair

Essential Tools for Cutterhead Repair

Essential Tools for Blower Repair

Section 100: Harvesting Units

Group 05: Harvesting Unit Cross Drive

Specifications

Other Material

Harvesting Unit Cross Drive

Harvesting Unit Drive Exploded View—Four-Speed LOC Transmission

Harvesting Unit Drive Exploded View—IVLOC Transmission

Drive Assembly—Four-Speed LOC Transmission

Drive Assembly—IVLOC Transmission

Group 10: Harvesting Units

Harvesting Units

Section 110: Feeding System

Group 05: Four-Speed Length-Of-Cut Transmission

Specifications

Other Material

General Information

Remove Length-of-Cut Transmission From Machine

Disassemble Length-of-Cut Transmission

Transmission Case Shaft AZ Overview

Transmission Case Shaft BZ Overview

Transmission Case Shaft CZ Overview

Transmission Case Shaft DZ Overview

Transmission Case Shaft EZ Overview

Transmission Case Shaft FZ Overview

Transmission Case Shaft GZ Overview

Transmission Case Shaft HZ Overview

Assemble Length-Of-Cut Transmission

Chain Drive Exploded View

Installing Length-of-Cut Transmission

Group 10: IVLOC Transmission

Essential or Recommended Tools

Specifications

Other Material

General Information

Repair Multicoupler

Remove Cut Out Clutch Assembly

Disassemble/Assemble Cut Out Clutch

Install Cut Out Clutch Assembly

Remove/Disassemble Length-Of-Cut Transmission Brake With Transmission Case on Machine

Assemble/Install Length-Of-Cut Transmission Brake With Transmission Case on Machine

Remove/Disassemble Length-Of-Cut Transmission Feedroll Drive Gear Case With Transmission Case on Machine

Install/Assemble Length-Of-Cut Transmission Feedroll Drive Gear Case With Transmission Case on Machine

Remove Length-Of-Cut Transmission From Machine

Disassemble Length-Of-Cut Transmission

Disassemble/Assemble Length-Of-Cut Transmission Brake

Disassemble/Assemble Length-Of-Cut Transmission Main Clutch

Hydraulic Block Overview

Modulating Valve Overview

Shaft AZ Overview

Shaft CZ Overview

Shaft EZ Overview

Shaft FZ Overview

Shaft GZ Overview

Shaft GPL Overview—Part 1

Shaft GPL Overview—Part 2

Shaft HZ Overview—Part 1

Shaft HZ Overview—Part 2

Shaft HYZ Overview

Assemble Length-Of-Cut Transmission

Install Length-Of-Cut Transmission On Machine

Group 15: Reverser Motor and Clutch (4-Speed LOC Transmission)

Specifications

Other Material

Reverser Motor and Clutch Exploded View

Reverser Clutch Assembly

Install Reverser Motor with Clutch

Group 20: Electric Clutch (4-Speed LOC Transmission)

Specifications

Other Material

Electrical Clutch Exploded View

Electrical Clutch Assembly

Group 25: Feed Roll Housing

Open Feed Roll Housing

Close Feed Roll Housing

Feed Roll Housing Safety Switch (S30)

Group 30: Feed Roll Assembly

Specifications

Other Material

Disassemble/Assemble Feed Roll Gear Transmission

Disassemble/Assemble Feed Roll Assembly

Remove Rear Lower Feed Roll (Smooth Roll)

Install Rear Lower Feed Roll (Smooth Roll)

Replace Feed Roll Wear Plates and Stops

Lateral Guides for Upper Feed Rolls

Group 35: Locking Pawl (4-Speed LOC Transmission)

Specifications

Safety Measures

Adjusting Locking Pawl

Checking Adjustment

Section 120: Cutterhead Assembly

Group 05: Knife Sharpening Device

Specifications

Other Material

Knife Sharpening Device Removal

Knife Sharpening Device Repair

Knife Sharpening Device Cable Guide Exploded View

Sharpening Stone Block Cable Exploded View

Retensioning Guide Cable

Sharpening Stone Block Exploded View

Assemble Sharpening Stone Block

Sharpening Stone Replacement

Sharpening Stone Alignment

Group 10: Cutterhead

Essential or Recommended Tools

Specifications

Other Material

Cutterhead Type Identification

Replace Cutterhead and Knife Attaching Parts

Knife Screw Torque

Removing Cutterhead Assembly From Machine

Cutterhead Removal

Cutterhead—Exploded View - Type A

Cutterhead—Exploded View - Type B

R.H. Side Cutterhead Bearing—Repair - Type A

L.H. Side Cutterhead Bearing—Repair - Type A

R.H. Side Cutterhead Bearing—Repair - Type B

L.H. Side Cutterhead Bearing—Repair - Type B

Cutterhead Installation

Installing Cutterhead Assembly on Machine

Group 15: Bottom and Outlet Bands

Specifications

Recirculating Screens

Install/Change Recirculating Screen

Recirculating Screen Adjustment

Installing Spiral Floor

Installing Recutter Floor

Adjusting Spiral Floor

Adjusting the Recutter Floor

Replacing Recutter Floor Knives

Adjust the Discharge Chute

Group 20: Stationary Knife Removal and Installation

Specifications

Stationary Knife Removal

Remove Stationary Knife Adjusting Device

Install Stationary Knife

Torque at Stationary Knife Adjusting Device

Eliminate End Play of Adjusting Spindle

Group 25: Kernel Processor

Specifications

Essential or Recommended Tools

Other Material

Kernel Processor Main Drive Locking Device (Four-Speed LOC Only)

Replace Drive Belts of Lower Roll

Kernel Processor Removal (Drive Belt—Single Belts)

Kernel Processor Removal (Drive Belt - Multiple V-Belt)

Adjust the Feed Plate On the Kernel Processor

Kernel Processor Drive Exploded View (Old Assembly)

Kernel Processor Drive Exploded View (New Assembly)

Grooved Roll Removal—Standard Type Kernel Processor Only

Bevel Disk Roll Removal—KernelStar Type Kernel Processor Only

Kernel Processor Housing Exploded View

Standard Type Kernel Processor Rolls Exploded View

KernelStar Type Kernel Processor Rolls Exploded View

Manual Adjusting Device Exploded View

Electrical Adjusting Device Exploded View

Idler and Deflector Pulleys Exploded View

Idler Pulley Repair

Assemble Bevel Disk Rolls—KernelStar Type Kernel Processor Only

Kernel Processor Roll Installation

Adjust Kernel Processor Roll Clearance (Manual Adjustment)

Automatic Adjustment of Rolls

Adjust Scrapers

Pretension of Lower Roll Drive Belt

Group 30: Power Chute

Specifications

Power Chute Main Drive Locking Device (Four-Speed LOC Only)

Install the Power Chute on the Kernel Processor

Install the Power Chute on the Attaching Frame

Adjust the Feed Plate On the Power Chute

Power Chute Exploded View

Power Chute Repair

Power Chute Removal

Drive Belts

Section 130: Discharge Components

Group 05: Discharge Fan

Specifications

Discharge Fan Exploded View

Replace Wear Plate

Install Wear Plate

Replace and Adjust Blower Paddles - General

Adjust Blower Paddles

Adjust Deflecting Edges

Group 10: Blower Rotor and Rotor Bearings

Specifications

Essential or Recommended Tools

Remove/Install Blower Rotor Drive Pulley

Remove/Install Blower Rotor Self-Aligning Bearings—Up to SN 511705

Remove/Install Blower Rotor Self-Aligning Bearings—From SN 511706

Remove Blower Rotor—Up to SN 511705

Remove Blower Rotor—From SN 511706

Blower Rotor Exploded View—Up to SN 511705

Blower Rotor Exploded View—From SN 511706

Install Blower Rotor—Up to SN 511705

Install Blower Rotor—From SN 511706

Group 15: Discharge Spout

Specifications

Spout Turning Device Exploded View

Install Spout Turning Device

Install Spout Worm Gear — 7250-7550 and 7750-7950 up to SN 511705

Install Spout Motor Gear — 7750-7950 from SN 511706

Install Automatic Spout Control Sending Units

Spout Exploded View—High Arc

Spout Exploded View—Low Arc

John Deere Self-Propelled Forage Harvesters Models 7250, 7350, 7450, 7550, 7750, 7850, 7950 Repair Service Manual (TM401419)