John Deere 7200 7300 7400 7500 7700 7800 7900 Forage Harvester Workshop Repair Service Manual PDF (TM4668) - MJODTM4668.zip

This is a full service and repair manual covering the John Deere 7200, 7300, 7400, 7500, 7700, 7800, and 7900 Forage Harvesters (Worldwide Edition). It contains the workshop-level detail needed to maintain, fix, and service these machines to the standard of a professional technician.

The workshop repair and service manual for the John Deere Self-Propelled Forage Harvesters — models 7200, 7300, 7400, 7500, 7700, 7800, and 7900 — provides the following:

* 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