John Deere 625, 630, 635, 830, 835 Conditioner Repair Manual TM101419 - PDF

625, 630, 635, 830 and 835 Mower-Conditioners Repair

REPAIR TECHNICAL MANUAL Mower Conditioners models 625, 630, 635, 830, 835 TM101419 15 JUL 13 (ENGLISH)

For complete service information also see: 100

Series

Hydraulic

TM-H100A

Cylinders

120

Series

CTM120519

Hydraulic

Cylinders

120

CTM114319

Series Hydraulic Cylinders

John Deere Agriculture Pinted by Belgreen

TM101419-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD SERVICE TECHNICIAN RESPONSE Section 10 - GENERAL Group 05 - Safety Group 10 - General Information Group 15 - Lubricants Group 20 - Torques for Hardware Section 40 - ELECTRICAL SYSTEM — REPAIR Group 10 - Connector Repair Section 50 - POWER TRAIN Group 05 - General Information Group 10 - Driveline Malfunctions Group 15 - Driveline Repair Group 20 - Tongue Drive Shaft Group 25 - Drive Belts Group 30 - Hitch, Tongue and Platform Gear Cases Group 35 - Main Drive Gear Case Repair—800 Series Group 40 - Main Drive Gear Case Repair—600 Series Group 45 - Roll Drive Gear Case (Roll Conditioner) Section 70 - HYDRAULICS Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Lift Cylinders Group 20 - Swing Cylinder Section 80 - MISCELLANEOUS Group 05 - Wheels and Wheel Support Assembly Section 81 - CARRIER FRAME AND TONGUE Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Carrier Frame Group 20 - Lift Arm Group 25 - Limiting Chain Group 30 - Tongue Section 100 - CUTTING COMPONENTS Group 05 - General Information Group 10 - Cutterbar Repair Group 15 - Disks and Knives Group 25 - Cutterbar Assembly Section 110 - CONDITIONER Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Roll Arms and Bearings Group 20 - Rolls Group 25 - Impeller Section 120 - PLATFORM Group 05 - General Information Group 10 - Platform Repair Section 240 - ELECTRICAL SYSTEM Group 05 - General Information Group 10 - Road Light Section 399 - SPECIAL TOOLS — DEALER-FABRICATED Group 05 - Manufacturing the Tools <- Go to Global Table of contents

TM101419-REPAIR TECHNICAL MANUAL

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TM101419-REPAIR TECHNICAL MANUAL

TM101419-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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TM101419-REPAIR TECHNICAL MANUAL

GENERAL

(g) by Belgreen v2.0

Service Technician Response We need your help to continually improve our technical publications. Please FAX or mail your comments, ideas and improvements on this comment sheet.

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John Deere Ottumwa Works 928 East Vine Street Ottumwa, Iowa 52501-4352 Dept. 77 Attn: Service Department

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Section 10 page 1

TM101419-REPAIR TECHNICAL MANUAL

TM101419-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 10 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Operate Mower-Conditioner Safely ....................................................................................................... 2 Keep Riders Off Machine ...................................................................................................................... 3 Handle Fluids Safely—Avoid Fires ......................................................................................................... 3 Prepare for Emergencies ...................................................................................................................... 3 Avoid High-Pressure Fluids ................................................................................................................... 4 Stay Clear of Rotating Drivelines .......................................................................................................... 4 Avoid Injury From Thrown Objects ........................................................................................................ 6 Use Safety Lights and Devices ............................................................................................................. 6 Use a Safety Chain ............................................................................................................................... 7 Tow Loads Safely .................................................................................................................................. 7 Support Machine Properly .................................................................................................................... 7 Wear Protective Clothing ...................................................................................................................... 9 Work in Clean Area ............................................................................................................................... 9 Service Machines Safely ..................................................................................................................... 10 Illuminate Work Area Safely ............................................................................................................... 10 Replace Safety Signs .......................................................................................................................... 10 Use Proper Lifting Equipment ............................................................................................................. 11 Remove Paint Before Welding or Heating ........................................................................................... 11 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 12 Service Tires Safely ............................................................................................................................ 12 Practice Safe Maintenance ................................................................................................................. 14 Use Proper Tools ................................................................................................................................. 14 Construct Dealer-Made Tools Safely ................................................................................................... 15 Dispose of Waste Properly .................................................................................................................. 15 Live With Safety ................................................................................................................................. 16 Group 10 - General Information ........................................................................................................... 17 625, 630 and 635 Side Pull Machine Description ................................................................................ 17 830 and 835 Machine Description ...................................................................................................... 17 Group 15 - Lubricants ............................................................................................................................ 19 Grease ................................................................................................................................................ 19 Cutterbar and Roll Drive Gear Case Oil .............................................................................................. 20 Swivel Gear Case Oil .......................................................................................................................... 21 Alternative and Synthetic Lubricants .................................................................................................. 21 Mixing of Lubricants ........................................................................................................................... 21 Lubricant Storage ............................................................................................................................... 21 Perform Lubrication and Maintenance ................................................................................................ 22 Group 20 - Torques for Hardware ....................................................................................................... 23 Metric Bolt and Screw Torque Values ................................................................................................. 23 Unified Inch Bolt and Screw Torque Values ........................................................................................ 24

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TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Group 05 - Safety Recognize Safety Information

Safety-alert symbol This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

Understand Signal Words

Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this manual.

Follow Safety Instructions

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Section 10 page 1

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Safety Messages Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.

Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

Operate Mower-Conditioner Safely

Safety Pinched or Cut Fingers

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Section 10 page 2

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Safety Pinched or Cut Feet Keep all shields in place.

Never hand feed material into machine.

Do not lean against, sit, or stand on cutterbar curtains or their supporting framework.

Do not operate mower-conditioner with cutterbar in raised position.

Regularly check that disks and knife bolts are tight.

Impeller conditioner: Make sure tines are securely fastened on rotor.

Always operate machine at rated speed.

Drive slowly over rough ground.

Keep Riders Off Machine

Safety Keep Riders off Machine Keep riders off.

Riders are subject to injury such as being struck by foreign objects and being thrown off of the machine. Riders also obstruct the operator′s view resulting in the machine being operated in an unsafe manner.

Handle Fluids Safely—Avoid Fires

Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

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Section 10 page 3

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Prepare for Emergencies

First Aid Kit Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Avoid High-Pressure Fluids

High Pressure Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

Stay Clear of Rotating Drivelines

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Section 10 page 4

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Rotating Drivelines

Drivelines Entanglement in rotating driveline can cause serious injury or death.

Keep tractor master shield and driveline shields in place at all times. Make sure rotating shields turn freely.

Wear close fitting clothing. Stop the engine and be sure that PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.

Do not install any adapter device between the tractor and the primary implement PTO drive shaft that will allow a 1000 rpm tractor shaft to power a 540 rpm implement at speeds higher than 540 rpm.

Do not install any adapter device that results in a portion of the rotating implement shaft, tractor shaft, or the adapter to be unguarded. The tractor master shield shall overlap the end of the splined shaft and the added adaptor device as outlined in the table. <- Go to Section TOC

Section 10 page 5

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Stay Clear of Rotating Drivelines PTO Type

Diameter

Splines

n ± 5 mm (0.20 in.)

1

35 mm (1.378 in.)

6

85 mm (3.35 in.)

2

35 mm (1.378 in.)

21

85 mm (3.35 in.)

3

45 mm (1.772 in.)

20

100 mm (4.00 in.)

Avoid Injury From Thrown Objects

Safety Objects Can Be Thrown Extreme care must be exercised to avoid injury from thrown objects. Do not, under any circumstances, operate the mowerconditioner when other people are in the vicinity. Stones and other objects can be thrown great distances by the rotating cutting blades.

The cutterbar curtains are very important to reduce the potential for thrown objects. Always keep these curtains down when operating the mower-conditioner. Replace the curtains if they should become worn or damaged.

For additional operator protection from thrown objects, it is required that this mower-conditioner be used with a tractor equipped with a complete operator enclosure.

Use Safety Lights and Devices

Use Safety Lights Prevent collisions between other road users, slow moving tractors with attachments or towed equipment, and self-propelled machines on public roads. Frequently check for traffic from the rear, especially in turns, and use hand signals or turn signal lights. <- Go to Section TOC

Section 10 page 6

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Use headlights, flashing warning lights, and turn signals day and night. Follow local regulations for equipment lighting and marking. Keep lighting and marking visible and in good working order. Replace or repair lighting and marking that has been damaged or lost.

Use a Safety Chain

Safety Use a Safety Chain A safety chain will help control drawn equipment should it accidentally separate from the drawbar.

Using the appropriate adapter parts, attach the chain to the tractor drawbar support or other specified anchor location.

See your John Deere dealer for a chain with a strength rating equal to or greater than the gross weight of the towed machine.

Do not use safety chain for towing.

Tow Loads Safely

Tow Loads Stopping distance increases with speed and weight of towed loads, and on slopes. Towed loads with or without brakes that are too heavy for the tractor or are towed too fast can cause loss of control. Consider the total weight of the equipment and its load.

Observe these recommended maximum road speeds, or local speed limits which may be lower: If towed equipment does not have brakes, do not travel more than 32 km/h (20 mph) and do not tow loads more than 1.5 times the tractor weight.

If towed equipment has brakes, do not travel more than 40 km/h (25 mph) and do not tow loads more than 4.5 times the tractor weight.

Ensure the load does not exceed the recommended weight ratio. Add ballast to recommended maximum for tractor, lighten the load, or get a heavier towing unit. The tractor must be heavy and powerful enough with adequate braking power for the towed load. Use additional caution when towing loads under adverse surface conditions, when turning, and on inclines.

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Section 10 page 7

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Support Machine Properly

Support Properly Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.

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Section 10 page 8

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Wear Protective Clothing

Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

Work in Clean Area

Clean Work Area Before starting a job: Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand. <- Go to Section TOC

Section 10 page 9

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Read all instructions thoroughly; do not attempt shortcuts.

Service Machines Safely

Moving Parts Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Illuminate Work Area Safely

Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Replace Safety Signs

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Section 10 page 10

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Use Proper Lifting Equipment

Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

Remove Paint Before Welding or Heating

Toxic Fumes Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating: Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

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Section 10 page 11

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

Service Tires Safely

Explosive Tire and Rim Parts Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. <- Go to Section TOC

Section 10 page 12

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

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Section 10 page 13

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Practice Safe Maintenance

Keep Area Clean Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts.

Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

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Section 10 page 14

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners.

Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

Construct Dealer-Made Tools Safely

Construct Dealer-Made Tools Safely Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.

Do not weld tools unless you have the proper equipment and experience to perform the job.

Dispose of Waste Properly

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Section 10 page 15

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 10: General Information

Recycle Waste Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Live With Safety

Safety Systems Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

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Section 10 page 16

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 10: General Information

Group 10 - General Information 625, 630 and 635 Side Pull Machine Description

630 Side-Pull Mower-Conditioner Shown The John Deere 625, 630 and 635 Mower-Conditioners are a side-pull design utilizing a mechanical PTO driveline. These machines are equipped with a rotary type cutterbar. They are available with either a roll type conditioner or impeller conditioner and an equal angle hitch or swivel hitch.

The machines consist of the following major assemblies: Carrier Frame Platform Rotary Cutterbar Conditioner Side-Pull Tongue Assembly Swivel Two-Point or Equal Angle Hitch Wheel Support Assemblies Windrow Forming Shields The carrier frame consists of a heavy steel tube that runs the full width of the machine. The carrier frame supports all the other major assemblies.

The platform contains the cutterbar, conditioner and related drive components. It connects to the carrier frame through a three-point suspension system.

The tongue is made of heavy gauge steel tubing. The tongue assembly attaches to the center of the carrier frame. The tongue can pivot on the carrier frame to allow the machine to be centered behind tractor for narrow transport width.

The wheel support assemblies utilize hydraulic lift cylinders controlled by tractor hydraulics to raise and lower the platform and machine.

Windrow forming shields consist of separate panels that can be adjusted to funnel freshly-cut crop into a windrow. The forming shields are installed directly on the platform. A swathboard is used to gain better crop control in sidehill conditions.

830 and 835 Machine Description

830 Mower-Conditioner The John Deere 830 and 835 Mower-Conditioners are a center-pivot design utilizing a mechanical PTO driveline. These machines are equipped with a rotary type cutterbar. They are available with either a roll type conditioner or impeller <- Go to Section TOC

Section 10 page 17

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 15: Lubricants

conditioner and an equal angle hitch or swivel hitch.

The machines consist of the following major assemblies: Carrier Frame Platform Rotary Cutterbar Conditioner Center-Pivot Tongue Assembly Swivel Two-Point or Equal Angle Hitch Wheel Support Assemblies Windrow Forming Shields The carrier frame consists of a heavy steel tube that runs the full width of the machine. The carrier frame supports all the other major assemblies.

The platform contains the cutterbar, conditioner and related drive components. It connects to the carrier frame through a three-point suspension system.

The tongue is made of heavy gauge steel tubing. The tongue assembly houses the PTO driveline and attaches to the center of the carrier frame. The tongue can pivot in relation to the carrier frame to allow the machine to cut crop on either side of the tractor.

The wheel support assemblies utilize hydraulic lift cylinders controlled by tractor hydraulics to raise and lower the platform and machine.

Windrow forming shields consist of separate panels that can be adjusted to funnel freshly-cut crop into a windrow. The forming shields are installed directly on the platform. A swathboard is used to gain better crop control in sidehill conditions.

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Section 10 page 18

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 15: Lubricants

Group 15 - Lubricants Grease

Greases for Air Temperature Ranges Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.

John Deere SD Polyurea Grease is preferred.

The following greases are also recommended: John Deere HD Lithium Complex Grease John Deere HD Water Resistant Grease John Deere GREASE-GARD ™ Other greases may be used if they meet the following: NLGI Performance Classification GC-LB IMPORTANT: Some types of grease thickeners are not compatible with others. Consult your grease supplier before mixing different types of grease.

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Section 10 page 19

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 15: Lubricants

Cutterbar and Roll Drive Gear Case Oil

Performance Classification Use oil viscosity based on the expected air temperature range during the period between oil changes.

John Deere HY-GARD ™ oil is recommended.

Other oils may be used if they meet the John Deere Standard JDM J20C. John Deere Low Viscosity HY-GARD ™ and BIO-HY-GARD ™ oils are NOT recommended.

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Section 10 page 20

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 15: Lubricants

Swivel Gear Case Oil

Oil Viscosity Use oil viscosity based on the expected air temperature range during the period between oil changes.

John Deere GL-5 GEAR LUBRICANT is recommended.

Other oils may be used if they meet API Service Classification GL-5.

Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location.

Consult your John Deere dealer to obtain information and recommendations.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic lubricants.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

Mixing of Lubricants In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

Consult your John Deere dealer to obtain specific information and recommendations.

Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used. Use clean containers to handle all lubricants. <- Go to Section TOC

Section 10 page 21

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 20: Torques for Hardware

Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination.

Store containers on their side to avoid water and dirt accumulation.

Make certain that all containers are properly marked to identify their contents.

Properly dispose of all old containers and any residual lubricant they may contain.

Perform Lubrication and Maintenance Clean lubrication fittings before using grease gun. Replace any lost or broken fittings immediately. If a new fitting fails to take grease, remove and check for failure of adjoining parts.

Extend swing cylinder fully and lower platform to the ground to allow access to all lubrication fittings.

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Section 10 page 22

TM101419-REPAIR TECHNICAL MANUAL

Section 10 - GENERAL

Group 20: Torques for Hardware

Group 20 - Torques for Hardware Metric Bolt and Screw Torque Values

Metric Bolt and Screw Metric Torque Values Class 4.8

Class 8.8 or 9.8

Class 10.9

Class 12.9

Lubricated

Lubricated

Lubricated

Lubricated

means coated withDry

means coated withDry

means coated withDry

means coated withDry

[ “Lubricated”

Bolt or Screw Size

M6

[ “Lubricated”

a lubricant such as[ “Dry” means engine oil,plain or zinc fasteners withplated without phosphate and oilany lubrication, or coatings, or M20M6 to M18 and largerfasteners with fasteners with JDMJDM F13B, F13E or F13C, F13F or F13JF13H zinc flake zinc flake coating.coating. ] ]

[ “Lubricated”

a lubricant such as[ “Dry” means engine oil,plain or zinc fasteners withplated without phosphate and oilany lubrication, or coatings, or M20M6 to M18 and largerfasteners with fasteners with JDMJDM F13B, F13E or F13C, F13F or F13JF13H zinc flake zinc flake coating.coating. ] ]

[ “Lubricated”

a lubricant such as[ “Dry” means engine oil,plain or zinc fasteners withplated without phosphate and oilany lubrication, or coatings, or M20M6 to M18 and largerfasteners with fasteners with JDMJDM F13B, F13E or F13C, F13F or F13JF13H zinc flake zinc flake coating.coating. ] ]

a lubricant such as[ “Dry” means engine oil,plain or zinc fasteners withplated without phosphate and oilany lubrication, or coatings, or M20M6 to M18 and largerfasteners with fasteners with JDMJDM F13B, F13E or F13C, F13F or F13JF13H zinc flake zinc flake coating.coating. ] ]

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

4.7

42

6

53

8.9

79

11.3

100

13

115

16.5

146

15.5

137

19.5

172

N˙m

lb.-ft.

N˙m

lb.-ft.

N˙m

lb.-ft.

N˙m

lb.-ft.

32

23.5

40

29.5

37

27.5

47

35

63

46

80

59

75

55

95

70

M8 11.5 102 14.5 128 22 194 27.5

243

N˙m lb.-ft. N˙m lb.-ft. N˙m

lb.-ft.

M10 23 204 29 21 43 32 55

40

N˙m lb.-ft.

M12 40 29.5 50 37 75 55 95

70 110 80 140 105 130 95 165 120

M14 63 46 80 59 120 88 150

110 175 130 220 165 205 150 260 190

M16 100 74 125 92 190 140 240

175 275 200 350 255 320 235 400 300

M18 135 100 170 125 265 195 330

245 375 275 475 350 440 325 560 410

M20 190 140 245 180 375 275 475

350 530 390 675 500 625 460 790 580

M22 265 195 330 245 510 375 650

480 725 535 920 680 850 625 1080 800

M24 330 245 425 315 650 480 820

600 920 680 1150 850 1080 800 1350 1000

M27 490 360 625 460 950 700 1200

885 1350 1000 1700 1250 1580 1160 2000 1475

M30 660 490 850 625 1290 950 1630

1200 1850 1350 2300 1700 2140 1580 2700 2000

M33 900 665 1150 850 1750 1300 2200

1625 2500 1850 3150 2325 2900 2150 3700 2730

M36 1150 850 1450 1075 2250 1650 2850

2100 3200 2350 4050 3000 3750 2770 4750 3500

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class.

If higher property class fasteners are used, tighten these to the strength of the original.

Make sure fastener threads are clean and that you properly start thread engagement.

When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

<- Go to Section TOC

Section 10 page 23

TM101419-REPAIR TECHNICAL MANUAL

ELECTRICAL SYSTEM — REPAIR

(g) by Belgreen v2.0

Unified Inch Bolt and Screw Torque Values

Unified Inch Bolt and Screw Unified Inch Bolt and Screw Torque Values SAE Grade 2 SAE Grade 1

Bolt or Screw Size

1/4

5/16

Lubricated

[ “Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. ]

[ Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length. ]

SAE Grade 5, 5.1 or 5.2

SAE Grade 8 or 8.2

Lubricated

Lubricated

Lubricated

[ “Lubricated”

[ “Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating. ]

[ “Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. ]

Dry

[ “Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. ]

Drymeans coated withDry

[ “Dry” meansa lubricant such as[ “Dry” means plain or zinc platedengine oil,plain or zinc without anyfasteners withplated without lubrication, or 1/4phosphate and oilany lubrication, or to 3/4 in. fastenerscoatings, or 7/8 in.1/4 to 3/4 in. with JDM F13B,and largerfasteners with F13E or F13H zincfasteners with JDMJDM F13B, F13E or flake coating. ]F13C, F13F or F13JF13H zinc flake zinc flake coating.coating. ] ]

Dry

[ “Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating. ]

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

N˙m

lb.-in.

3.7

33

4.7

42

6

53

7.5

66

9.5

84

12

106

13.5

120

17

150

N˙m

lb.-ft.

N˙m

lb.-ft.

28

20.5

35

26

7.7

68

9.8

86

3/8 13.5 120 17.5 155 22 194 27 240

12

106

15.5

137

19.5

172

25

221

N˙m

lb.-ft.

N˙m

lb.-ft.

35

26

44

32.5

49

36

63

46

56

41

70

52

80

59

100

74

N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.

7/16 22 194 28 20.5 35 26 44 32.5 N˙m lb.-ft.

1/2 34 25 42 31 53 39 67 49

85 63 110 80 120 88 155 115

9/16 48 35.5 60 45 76 56 95 70

125 92 155 115 175 130 220 165

5/8 67 49 85 63 105 77 135 100

170 125 215 160 240 175 305 225

3/4 120 88 150 110 190 140 240 175

300 220 380 280 425 315 540 400

7/8 190 140 240 175 190 140 240 175

490 360 615 455 690 510 870 640

1 285 210 360 265 285 210 360 265

730 540 920 680 1030 760 1300 960

1-1/8 400 300 510 375 400 300 510 375

910 670 1150 850 1450 1075 1850 1350

1-1/4 570 420 725 535 570 420 725 535

1280 945 1630 1200 2050 1500 2600 1920

1-3/8 750 550 950 700 750 550 950 700

1700 1250 2140 1580 2700 2000 3400 2500

1-1/2 990 730 1250 930 990 730 1250 930

2250 1650 2850 2100 3600 2650 4550 3350

Torque values listed are for general use only, based on the strength of the bolt or Replace fasteners with the same or higher grade. If higher grade fasteners screw. DO NOT use these values if a different torque value or tightening procedure is are used, tighten these to the strength of the original. Make sure fastener given for a specific application. For plastic insert or crimped steel type lock nuts, for threads are clean and that you properly start thread engagement. When stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel specific application. Shear bolts are designed to fail under predetermined loads. Alwaysbolts or wheel nuts, unless different instructions are given for the specific replace shear bolts with identical grade. application.

<- Go to Section TOC

Section 40 page 24

TM101419-REPAIR TECHNICAL MANUAL

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