Complete Repair Service Manual for John Deere 7200, 7300, 7400, 7500, 7700, 7800, 7900 Forage Harvesters (Worldwide Edition), with workshop information to maintain, repair, and service like professional mechanics.

John Deere Self-Propelled Forage Harvesters Models 7200, 7300, 7400, 7500, 7700, 7800, 7900 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.

TM4668 - John Deere Self-Propelled Forage Harvesters Models 7200, 7300, 7400, 7500, 7700, 7800, 7900 Technical Manual (Repair).PDF
TM4668 - John Deere Self-Propelled Forage Harvesters Models 7200, 7300, 7400, 7500, 7700, 7800, 7900 Technical Manual (Repair).EPUB

Total Pages: 2,673 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
      Engine Removal and Installation
   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-107 cc Motor Type
      Rear Wheel Drive Axle-140 cc Motor Type
      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 (Gen. 1)
      Row Guidance System (Gen. 2)
      Rear Axle
   Hydraulic System
      Hydraulic Pressure Accumulators
      Hydraulic Pumps
      Electromagnetic Control Valve
      Reverser Motor (Four-Speed LOC)
      Hydraulic Motor - Discharge Spout
      IV Length-of-Cut Transmission Motor
      IV Length-of-Cut 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
      IV Length-Of-Cut Transmission
      Reverser Motor and Clutch (4-Speed L.O.C)
      Electrical Clutch (4-Speed L.O.C)
      Feed Roll Channel
      Feed Roll Assembly
      Locking Pawl (4-Speed L.O.C)
   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

tm4668 - 7200, 7300, 7400,7500, 7700 and 7800Self-Propelled ForageHarvestersRepair -: (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

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

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

Diesel Engine Coolant

Supplemental Coolant Additives

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)

Forage Harvester Type Plate for North America (Product Identification)

Product Identification Number (Europe)

Product Identification Number (North America)

Engine Serial Number — Engine Type 6081

Engine Serial Number — Engine Type 6125

Engine Serial Number — Cummins

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

IV Length-of-Cut Transmission Serial Number

IV Length-of-Cut Transmission Hydrostatic Pump Serial Number

IV Length-of-Cut 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—107 cc MotorType

Powered Rear Axle Serial Number—140 cc Motor Type

Heavy Duty Rear Axle Serial Number

Group 20: Dimensions

Dimensions

Section 20: Engine

Group 05: Engine Removal and Installation

Essential Tools

Other Material

Specifications

Prior to Removing Engine

Removing Panels

Removing and Installing Engine (7200)

Removing and Installing Engine (7300, 7400, 7500 and 7700)

Removing and Installing Engine (7800)

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)

Removing Fuel Tank

Removing Fuel Sending Units

Group 10: Air Intake System

Specifications

Air Intake System (7200)

Air Intake System (7300 - Up to SN 508099)

Air Intake System (7300 - From SN 508100 and 7400, 7500 and 7700)

Air Intake System (7800)

Removing Intercooler (7300 - Up to SN 508099 and 7200)

Removing Intercooler (7400, 7500, 7700 and 7800 - Up to SN 507478)

Removing Intercooler (7300 - From SN 508100 and 7400, 7500, 7700 and 7800 - From SN 507479)

Group 15: Cooling System

Specifications

Cooling Package Location

Replacing Coolant Level Sending Unit

Removing Radiator (7300 - Up to SN 508099 and 7200)

Removing Radiator (7400, 7500, 7700 and 7800) - Up to SN 507478

Removing Radiator (7300 - From SN 508100 and 7400, 7500, 7700 and 7800 - From SN 507479)

Removing Fuel Cooler (7400, 7500, 7700 and 7800)—Up to SN 507478

Removing Fuel Cooler (7800)—From SN 507479

Removing Hydraulic Oil Cooler (7300 - Up to SN 508099 and 7200)

Removing Hydraulic Oil Cooler (7400, 7500, 7700 and 7800)—Up to SN 507478

Removing Hydraulic Oil Cooler (7300 - From SN 508100 and 7400, 7500, 7700 and 7800 - From SN 507479)

Removing Transmission Oil Cooler (ProDrive Only)

Removing Air Conditioning Condenser (7300 - Up to SN 508099 and 7200)

Removing Air Conditioning Condenser (7400, 7500, 7700 and 7800)—Up to SN 507478

Removing Air Conditioning Condenser (7300 - From SN 508100 and 7400, 7500, 7700 and 7800 - From SN 507479)

Replacing the Viscous Drive

Checking Belt Tensioner Spring Tension and Belt Wear—Up to SN 507478

Checking Belt Tensioner Spring Tension and Belt Wear—From SN 507479

Rotary Screen

Section 40: Electrical System

Group 05: Harness and Connector Repair

Essential or Recommended Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Repair WEATHER PACK Connector

Remove Connector Body from Blade Terminals

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 DEUTSCH Connectors

Repair CINCH Connectors

Repair Relay Panel Connectors

Repair Reel Reversing Valve Connector

Group 10: Electrical System Components

Specifications

Electrical System — Specifications

Batteries

Battery Switch

Dangers When Handling Batteries

Battery Service

Checking Electrolyte Level

Checking Specific Gravity

Charging Batteries

Installing and Connecting Batteries

Alternators—Up to SN 507478

Alternator—From SN 507479

Starter Motor

Sockets

Replacing Terminating Resistors

Control Units

Fuse / Relay Tester

Spare Fuses

Fuse and Relay Boards A1, A2 and A3

Extra Fuses and Relays

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

Feedroll Speed Sensor B16 Four-Speed LOC - Up to SN 506846

ATC Air Conditioning System Low Pressure Switch B17

ATC Air Conditioning System High Pressure Switch B18

Solar Sending Unit B19—Up to SN 507478

Rear-Wheel Drive Pressure Sending Unit B22

Rear-Wheel Drive Speed Sending Unit B23

Metal Detector Sending Unit B24

Transmission Oil Temperature Sending Unit B25 - Up to SN 507478

Knock Sending Unit B26 and B27

Fuel Tank Sending Unit B28

Reverse Travel Alarm B30

Coolant Temperature Sending Unit B31 / B43

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 (Cummins Engine)

Ambient Air Pressure Sending Unit B42 (Cummins Engine)

Stationary Knife Motor-Impulse Sending Units B47 and B48

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

Hydrostatic Pump Pressure Reverse Sending Unit B55

Feedroll 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 Gen. 2)

Row Guidance Steering Input Sending Unit B69 (Row Guidance Gen. 2)

Alternators—Up to SN 507478

Alternator—From SN 507479

Remove and Install Alternators—Up to SN 507478

Remove and Install Alternator—From SN 507479

Rotary Radiator Screen Drive Motor M2

ATC Air Conditioning System Recirculating Blower Motor M3

Front Windshield Wiper Motor M4

Front Windshield Washer Pump M5

Spout Flap Motor M6

Kernel Processor Lift Motor M8

Knife Sharpening Motor M10

Stationary knife Adjusting Motors M11 and M12

Kernel Processor Adjusting Motors M13 and M14

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

Stone Sweep Position Potentiometer R6

Sharpening Door Position Potentiometer R9

Rear Wheel Potentiometer R12 (Row Guidance Gen. 1)

Header Angle Potentiometer R17

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

Row Guidance Pressure Switch S38 (Row Guidance Gen. 1)

Transmission Oil Pressure Switch S48

Battery Main Switch S51

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—Up to SN 507478

IVLOC Solenoids—From SN 507479

Proportional Valve Solenoids (Three-Speed Transmission)

Proportional Valve Solenoids (ProDrive Transmission)

ProDrive Transmission Solenoids

ATC Air Conditioning Clutch Y11

Main Hydraulic System Solenoids

IVLOC Proportional Valves Y18 and Y19

Gear Lock Solenoid Y20 (Three-Speed Transmission)

Wagon Dump High Flow Solenoids

Low Pressure Solenoids (Three-Speed Transmission)

Low Pressure Solenoids (ProDrive Transmission)

IVLOC Reversing Pawl Solenoid Y34

Four Speed LOC Reverser Motor Solenoid Y35

Row Guidance Solenoid Valves Y36 and Y37 (Row Guidance Gen. 1)

Four Speed LOC Electrical Clutch Y38

Four Speed LOC Pawl Solenoid Y39

Row Guidance Valve Block Y40 (Row Guidance Gen. 1)

Row Guidance Valve Block Y40 (Row Guidance Gen. 2)

Rear Wheel Drive Proportional Valve Y41

Fuel Pump Control Valves Y42 and Y43 (8.1L Engine)

Front Motor Proportional Valve Y45

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

Fuel Shutoff Solenoid Valve Y50 (Cummins Engine)

Wastegate Solenoids Y61 and Y62 (Cummins Engine)

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

Replacing Bulbs

Safety Rules When Replacing Halogen Bulbs

Safety Rules When Replacing Xenon Bulbs

Cab Head Light Bulb Replacement and Adjustment - Up to SN 508099

Cab Head Light Bulb Replacement and Adjustment - From SN 508100

HID-Xenon 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.)

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

Disassembling the Rotary Group

Inspection Notes

Assembling the Rotary Group

Rotary Group Adjustment

Group 40: Rear Wheel Drive Axle—107 cc Motor Type

Specifications

Essential Tools

Other Material

Remove Axle Housing From Machine

General Description

Sealing Compounds and Adhesives

Dimensions

Oil Change and Checks

Tightening Torques Overview

Disassembling the Steering Cylinder

Assembling the Steering Cylinder

Disassembling the Reduction Gear

Assembling the Reduction Gear

Disassembling the Wheel Hub

Assembling the Wheel Hub

Disassembling the Axle Housing

Assembling the Axle Housing

Disassembling the Differential Support

Assembling the Differential Support

Disassembling the Differential

Assembling the Differential

Disassembling the Pinion

Assembling the Pinion

Disassembling the Flange

Assembling the Flange

Toe-in Adjustment

Steering Angle Adjustment with Goniometer

Steering Angle Adjustment with Steering Stops

Testing after Assembling

Group 41: Rear Wheel Drive Axle—140 cc Motor Type

Specifications

Essential Tools

Other Material

Changing Oil

Remove Axle Housing From Machine

Replacing Pivot Pin Bushings

Disassemble the Planetary Drive

Planetary Drive—Exploded View

Assemble the Planetary Drive

Disassemble the Swivel Housing

Swivel Housing—Exploded View

Assemble the Swivel Housing

Disassemble the Differential

Differential—Exploded View

Assemble the Differential

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)

Service Equipment and 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

Hydraulic Lines to Steering Cylinders- Adjustable and Standard Rear Axle

Steering Cylinder With Ball Joints- Adjustable and Standard Rear Axle

Remove and Install Steering Cylinder- Adjustable and Standard Rear Axle

Repair Steering Cylinder- Adjustable and Standard Rear Axle

Tie Rod — Exploded View - Adjustable and Standard Rear Axle

Adjusting Toe-In - Adjustable and Standard Rear Axle

Checking Rear Wheel Toe-In - Adjustable and Standard Rear Axle

Group 16: Row Guidance System (Gen. 1)

Specifications

Row Guidance System Components

Checking and Adjusting Linear Potentiometer - Adjustable and Standard Rear Axle

Checking and Adjusting Rotary Potentiometer - Four Wheel Drive Rear Axle—107 cc Motor Type

Calibrating Control Unit

Address RGC 101 Calibration — Ratio Setting

Address RGC 102 Calibration — Filter Setting

Address RGC 106 Calibration — Feeler Rest Position

Address RGC 107 Calibration — Feeler Maximum Deflect Position

Address RGC 104 Calibration — Steering Offset

Address RGC 105 Calibration — Bias Calibration

Address RGC 108 Calibration — Steering Test Mode

Address RGC 109 Calibration — Feeler Side Swap

Group 17: Row Guidance System (Gen. 2)

Specifications

Other Material

Row Guidance System Components

Checking Rotary Potentiometer - Old Assembly

Checking Rotary Potentiometer - New Assembly

Removing and Installing Steering Valve Block and Steering Input Sending Unit

Calibrating Control Unit

Address RGC 100 Calibration — Sensitivity (GEN. 2)

Address RGC 101 Calibration — Feelers (GEN.2)

Address RGC 102 Calibration — Wheel Angle Sensor/Steering Wheel Position Sensor (GEN. 2)

Address RGC 105 Calibration — Steering Valve Deadband (GEN. 2)

Address RGC 108 Calibration — Steering Test Mode (GEN. 2)

Address RGC 109 Calibration — Feeler Side Swap

Group 20: Rear Axle

Essential or Recommended Tools

Other Material

Specifications

Rear Axle Spindle Components - Adjustable and Standard Rear Axle

Remove and Install Rear Spindle Assembly - Adjustable and Standard Rear Axle

Wheel Hub Exploded View

Adjusting Rear Axle Width

Rear Axle Pivot Bushing - Four Wheel Drive Rear Axle—107 and 140 cc Motor Type

Rear Axle Pivot Bushing - Adjustable and Standard Rear Axle

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 (Three-Speed Transmission)

Main Clutch System (ProDrive Transmission)

Discharge Spout System

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

Solenoid Valves - Main Block

Hydraulic Valve Assembly - Main Block

Remove Solenoid Main Valve Block

Repair Unload Valve (Y30)

Solenoid Valves, Discharge Spout Rotation (Y12 and Y13)

Solenoid Valves for Raising-Lowering Discharge Spout (Y15, Y14) and Header Folding (Y23, Y24)

Solenoid Valves, Low Flow (Y25 and Y26)

Solenoid Valves, Trailer (Y31 and Y32)

Repair Reverser Solenoid Valve (Y35), Four-Speed LOC

Solenoids, Low Pressure Valve Block

Remove Low Pressure Valve Block

Repair Low Pressure Valve Block (ProDrive Transmission)

Solenoids, Wagon Dump Valve Block

Remove Wagon Dump Valve Block

Repair Wagon Dump Valve Block

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

Hydraulic Motor, Exploded View

Repairing Hydraulic Motor

Assembling Hydraulic Motor

Group 30: IV Length-of-Cut 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: IV Length-of-Cut Transmission Hydrostatic Pump

Essential or Recommended Tools

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 - Up to SN 508099

Flow Schematic - From SN 508100

Central Lubrication System—Up to SN 506846

Operational Information—Up to SN 506846

Automatic Lubrication System—From SN 506847

Operational Information—From SN 506847

Adjust Pump Element for Flow Control

Quick Couplers for Kernel Processor and Harvesting Unit

Troubleshooting - Central/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

Specifications

Air Conditioning System With Precleaner (General Information)

Remove and Install Receiver/Drier

Replace Blower Motor

Replace Recirculator Motor Drive Module

Replace Heater Control Valve

Removing Air Conditioning Condenser (7300 - Up to SN 508099 and 7200)

Removing Air Conditioning Condenser (7400, 7500, 7700 and 7800)—Up to SN 507478

Removing Air Conditioning Condenser (7300 - From SN 508100 and 7400, 7500, 7700 and 7800 - From SN 507479)

Repair Condenser

Replace Evaporator

Remove and Install Evaporator Temperature Sensor

Replace Low Pressure Switch

Replace High Pressure Switch

Replace Air Temperature Sensors

Group 15: Operator's Cab

Specifications

Remove and Install Cab Windshield - Up to SN 508099

Remove and Install Cab Roof - Up to SN 508099

Remove and Install Cab Roof - From SN 508100

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

General Information

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Safety at Work

Handling Refrigerant

Refrigerant Splashes into Eyes

Safety Equipment

Storage of Refrigerant Containers

R134a Refrigerant

Test and Service Ports—Up to SN 507478

Test and Service Ports—From SN 507479

Discharge Air Conditioning Refrigerant

Remove and Install Compressor—Up to SN 507478

Remove and Install Compressor—From SN 507479

Test Volumetric Efficiency

Test Shaft Seal Leakage

Disassemble and Assemble Compressor Clutch

Check Clutch Hub Clearance

Inspect Compressor Manifold

Disassemble, Inspect, and Assemble Compressor

Remove and Install Compressor Relief Valve

System Information

Flush Air Conditioning System

Purge Air Conditioning System

Evacuate Air Conditioning System

Compressor Oil Information

Determine Correct Oil Charge

Check Refrigerant Oil Charge

Charge Air Conditioning System

Leak Testing Procedure

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

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—107 cc Motor Type

Essential Tools for Rear Wheel Drive Axle Repair—140 cc Motor Type

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 IV Length-of-Cut 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

Pickup Units

Row-Crop Units

Rotary Harvesting Units (Row-Independent)

Corn Heads

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: IV Length-Of-Cut Transmission

Essential Tools

Specifications

Other Material

General Information

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 on 7200, 7300, 7400 and 7500—Up to SN 507478

Hydraulic Block Overview on 7700, 7800 and Forage Harvesters 7200, 7300, 7400 and 7500—From SN 507479

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 L.O.C)

Specifications

Other Material

Reverser Motor and Clutch Exploded View

Reverser Clutch Assembly

Install Reverser Motor with Clutch

Group 20: Electrical Clutch (4-Speed L.O.C)

Specifications

Other Material

Electrical Clutch Exploded View

Electrical Clutch Assembly

Group 25: Feed Roll Channel

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 L.O.C)

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

Replace Cutterhead and Knife Attaching Parts

Knife Screw Torque

Removing Cutterhead Assembly From Machine

Cutterhead Removal

Cutterhead—Exploded View

R.H. Side Cutterhead Bearing—Repair

L.H. Side Cutterhead Bearing—Repair

Cutterhead Installation

Installing Cutterhead Assembly on Machine

Group 15: Bottom and Outlet Bands

Specifications

Cutterhead Bottom and Outlet Bands

Bottom Band Adjustment

Outlet Band Adjustment

Recirculating Screens

Install/Change Recirculating Screen

Recirculating Screen Adjustment

Bottom and Outlet Band Removal

Install Spiral/Recutter Floor

Spiral/Recutter Floor Adjustment

Adjust the Service Cover on the Transition 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

Other Material

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

Replace Drive Belts of Lower Roll

Kernel Processor Quick Removal

Adjust the Feed Plate On the Kernel Processor

Kernel Processor Drive Exploded View (Three-Speed Transmission)

Kernel Processor Drive Exploded View (ProDrive Transmission)

Grooved Roll Removal

Kernel Processor Housing Exploded View

Upper Grooved (Drive) Roll Exploded View—Up To SN 508668

Upper Grooved (Drive) Roll Exploded View—From SN 505669

Lower Grooved (Driven) Roll Exploded View—Up To SN 508668

Lower Grooved (Driven) Roll Exploded View—From SN 508669

Grooved Roll Adjusting Device, Exploded View

Electrical Adjusting Device, Exploded View

Idler and Deflector Pulleys, Exploded View

Idler Pulley Repair

Grooved Roll Installation—Up To SN 508668

Grooved Roll Installation—From SN 508669

Adjust Roll Clearance (Manual Adjustment)—Up To SN 507478

Adjust Roll Clearance (Manual Adjustment)—From SN 507479

Automatic Adjustment of Grooved 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

Remove Blower Rotor

Blower Rotor Exploded View

Install Blower Rotor

Group 15: Discharge Spout

Specifications

Spout Turning Device Exploded View

Install Spout Turning Device

Install Spout Worm Gear

Spout Exploded View—High Arc

Spout Exploded View—Low Arc

John Deere Self-Propelled Forage Harvesters Models 7200, 7300, 7400, 7500, 7700, 7800, 7900 Repair Service Manual (TM4668)