JOHN DEERE 7810 2WD OR MFWD TRACTOR REPAIR TECHNICAL MANUAL TM1651 - PDF

7610, 7710, 7810 Tractors - Repair

REPAIR MANUAL 7610, 7710, 7810 (S.N. 000001-030000, 030001-050000, 050001-, 050001-090000, 090001-, 070001-) TM1651 25NOV10 (ENGLISH)

For complete service information also see: TM2030 - 7610, 7710 and 7810 Tractors Operation and TestTM2030 Alternators and Starting MotorsCTM77 OEM Engine AccessoriesCTM67 MFWD Axles 1100 and 1150 Series.CTM44 European 3029, 4039, 4045, 6059, 6068 Engines CTM3274 PowerTech 4.5 L and 6.8 L OEM Diesel -Engines Level 4 Electronic Fuel SystemsCTM170 With Bosch VP44 Pump PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic FuelCTM134 Systems with Bosch In-Line Pump) PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (BaseCTM104 Engine)

John Deere Agriculture

7610, 7710, 7810 Tractors - Repair

(g) by Belgreen v2.1

Table of contents FOREWORD NOTICE TO THE DEALER DEALER PREDELIVERY INFORMATION FORM QUICK REFERENCE SPECIFICATIONS Section 10 - GENERAL INFORMATION Group 05 - Safety Group 10 - General Information Section 20 - ENGINE Group 00 - Component Removal and Installation Group 05 - Engine Repair Section 30 - FUEL AND COOLING SYSTEMS Group 05 - Controls Group 10 - Diesel Fuel System Group 15 - Air Intake System Group 20 - Engine Cooling System Group 25 - Air Conditioning Condenser and Coolers—7610, 7710 and 7810 (S.N. -90000) Group 30 - Air Conditioning Condenser and Coolers—7710 and 7810 (S.N. 90001- ) Section 40 - ELECTRICAL Group 05 - Connectors Group 10 - Wiring Harness Routings Group 15 - Charging Circuit Group 20 - Starting Circuit Group 25 - Solenoids And Switches Group 30 - Monitoring System Group 40 - Auxiliary Lighting And Electrical Components Group 45 - Convenience And Accessory Components Section 50 - POWER SHIFT TRANSMISSION Group 00 - Component Removal and Installation Group 05 - Controls Group 10 - Transmission Group 15 - Reduction Gearbox Section 51 - AUTOPOWR/IVT TRANSMISSION Group 00 - Component Removal Group 05 - Controls Group 10 - Front Pump/Control Valve Assembly Group 15 - Transmission Front Housing Group 20 - Hydrostatic Module Group 25 - Shift Valve Assembly Group 30 - Transmission Rear Housing Group 35 - Differential Input Assembly Section 55 - POWRQUADPOWRQUAD IS A TRADEMARK OF DEERE & COMPANY TRANSMISSION Group 00 - Component Removal And Installation Group 05 - Control Linkages Group 10 - Transmission Group 15 - Creeper Transmission Group 20 - Range Box Section 56 - DRIVE SYSTEMS Group 00 - Component Removal And Installation Group 05 - Controls Group 10 - MFWD Clutch Group 15 - MFWD Axle Group 16 - Suspended MFWD Axle Components <- Go to Global Table of contents

7610, 7710, 7810 Tractors - Repair

7610, 7710, 7810 Tractors - Repair

(g) by Belgreen v2.1

Group 20 - Rear Differential Group 25 - Final Drive Group 30 - Rear PTO Group 35 - Drivelines Group 40 - Hydraulic Pump Drive Group 45 - Front PTO Section 60 - STEERING AND BRAKES Group 05 - Steering Column Group 10 - Hydrostatic Steering Group 15 - Steering Cylinders Group 20 - Brake Valve Group 25 - Brake Components Group 30 - Trailer Brakes Section 70 - HYDRAULICS Group 00 - Component Removal And Installation Group 05 - Hydraulic System Repair Group 10 - Hydraulic Pump And Charge Pump Group 15 - Hydraulic System Valves Group 20 - Selective Control Valves And Couplers Group 25 - Hitch Group 30 - Bleed Hydraulic System Section 80 - MISCELLANEOUS Group 00 - Component Removal And Installation Group 05 - Front Axle Group 10 - Hood Group 15 - Wagon And Pick-Up Hitch Section 90 - OPERATOR STATION Group 00 - Component Removal And Installation Group 05 - HVAC Group 10 - Air Conditioning System Group 20 - Seat Group 25 - ROPS and Cab Section 99 - DEALER FABRICATED TOOLS Group 05 - Fabricated Tools

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7610, 7710, 7810 Tractors - Repair

For the full PDF version of this manual, Please click on the above download PDF button.

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7610, 7710, 7810 Tractors - Repair

7610, 7710, 7810 Tractors - Repair

(g) by Belgreen v2.1

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.

Two technical manuals are used to provide service information. The Repair Technical Manual tells how to repair the components. The Operation and Test Technical Manual helps you quickly identify the majority of failures.

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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7610, 7710, 7810 Tractors - Repair

7610, 7710, 7810 Tractors - Repair

(g) by Belgreen v2.1

Notice To The Dealer This is a complete revision of TM1651 Repair Technical Manual for 7610, 7710, and 7810 Tractors.

Discard TM1651 dated 27FEB03

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7610, 7710, 7810 Tractors - Repair

7610, 7710, 7810 Tractors - Repair

(g) by Belgreen v2.1

Dealer Predelivery Information Form The John Deere Predelivery Form, when properly filled out and signed by dealer, verifies predelivery and delivery services were satisfactorily performed.

Because of the shipping factors involved, plus extra finishing touches necessary to promote customer satisfaction, there are certain predelivery services that must be performed by the dealer. These services are listed on the predelivery form with the tractor.

Perform all services listed and check each job off as it is completed. Fill form out completely and sign it.

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7610, 7710, 7810 Tractors - Repair

GENERAL INFORMATION

(g) by Belgreen v2.0

Quick Reference Specifications Miscellaneous Specifications Engine: Slow Idle .......... 800—900 rpm Fast Idle .......... 2225—2325 rpm Rated Engine Speed .......... 2100 rpm Valve Clearance: .. Intake: .... 7610 .......... 0.38 mm (0.015 in.) .... 7710 and 7810 .......... 0.51 mm (0.020 in.) .. Exhaust: .... 7610 .......... 0.45 mm (0.018 in.) .... 7710 and 7810 .......... 0.71 mm (0.028 in.)

Capacities: Fuel Tank: .. Open Station .......... 270 L (71.5 gal) .. 7610 Cab (Standard) .......... 246 L (65 gal) .. 7610 Cab (Optional) and 7710-7810 Cab .......... 344 L (91 gal) Cooling System: .. 7610 .......... 24 L (25 qt) .. 7710 and 7810 .......... 26 L (27.5 qt) Crankcase with Filter: .. 7610 .......... 19 L (20 qt) .. 7710 and 7810 .......... 24 L (25 qt) Transmission, Differential and Hydraulic System: .. PowrQuad ™ or AutoQuad II ™ .......... 87 L (23 gal) .. PowrQuad ™ or AutoQuad II ™ with MFWD .......... 98 L (26 gal) .. PowrQuad ™ with Creeper .......... 91 L (24 gal) .. PowrQuad ™ with MFWD and Creeper .......... 102 L (27 gal) .. Power Shift .......... 91 L (24 gal) .. Power Shift with MFWD .......... 102 L (27 gal) .. AutoPowr/IVT .......... 68 L (18 gal) .. AutoPowr/IVT with MFWD .......... 79.5 L (21 gal) MFWD: .. Axle Housing: .......... 8.5 L (9 qt) .. Wheel Hub .... Standard (Each) .......... 1.9 L (2 qt) .... High-Clearance (Each) .......... 3.8 L (4 qt) Torques: Front Axle Bolts (Tread Adjustment) .......... 600 N˙m (445 lb-ft) Front Wheel to Hub (2WD) .......... 310 N˙m (230 lb-ft) MFWD: .. Rim-to-Disk .......... 310 N˙m (230 lb-ft) .. Disk-to-Hub .......... 600 N˙m (445 lb-ft) Rear Wheel Retaining Bolts (Final Torque) .......... 600 N˙m (445 lb-ft) Rear Wheel-to-Rim .......... 600 N˙m (445 lb-ft) Cab Mounting Bolts .......... 204 N˙m (150 lb-ft)

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Section 10 page 1

7610, 7710, 7810 Tractors - Repair

7610, 7710, 7810 Tractors - Repair

(g) by Belgreen v2.1

Section 10 - GENERAL INFORMATION Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 1 Prepare for Emergencies ...................................................................................................................... 2 Prevent Acid Burns ............................................................................................................................... 3 Handle Chemical Products Safely ......................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 4 Park Machine Safely ............................................................................................................................. 5 Support Machine Properly .................................................................................................................... 5 Wear Protective Clothing ...................................................................................................................... 7 Work in Clean Area ............................................................................................................................... 7 Service Machines Safely ....................................................................................................................... 8 Work In Ventilated Area ........................................................................................................................ 8 Illuminate Work Area Safely ................................................................................................................. 8 Replace Safety Signs ............................................................................................................................ 9 Use Proper Lifting Equipment ............................................................................................................... 9 Service Tires Safely ............................................................................................................................ 11 Avoid Harmful Asbestos Dust ............................................................................................................. 11 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 13 Remove Paint Before Welding or Heating ........................................................................................... 13 Use Proper Tools ................................................................................................................................. 14 Construct Dealer-Made Tools Safely ................................................................................................... 14 Dispose of Waste Properly .................................................................................................................. 15 Live With Safety ................................................................................................................................. 15 Group 10 - General Information ........................................................................................................... 16 General Specifications ........................................................................................................................ 16 Sealants and Adhesives Cross-Reference Chart ................................................................................. 19 Metric Bolt and Cap Screw Torque Values .......................................................................................... 20 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 21 Glossary of Terms ............................................................................................................................... 22

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7610, 7710, 7810 Tractors - Repair

Section 10 - GENERAL INFORMATION

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.

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.

Prevent Battery Explosions

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Section 10 page 1

7610, 7710, 7810 Tractors - Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Item

Measurement

Specification

Battery

Temperature

16°C (60°F)

Prepare for Emergencies

Prepare for Emergencies 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.

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Section 10 page 2

7610, 7710, 7810 Tractors - Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

Prevent Acid Burns

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: [1] - Filling batteries in a well-ventilated area.

[2] - Wearing eye protection and rubber gloves.

[3] - Avoiding breathing fumes when electrolyte is added.

[4] - Avoiding spilling or dripping electrolyte.

[5] - Use proper jump start procedure.

If you spill acid on yourself: [1] - Flush your skin with water.

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Section 10 page 3

7610, 7710, 7810 Tractors - Repair

Section 10 - GENERAL INFORMATION

Group 05: Safety

[2] - Apply baking soda or lime to help neutralize the acid.

[3] - Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed: [1] - Do not induce vomiting.

[2] - Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

[3] - Get medical attention immediately.

Handle Chemical Products Safely

Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Avoid High-Pressure Fluids

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Section 10 page 4

7610, 7710, 7810 Tractors - Repair

For the full PDF version of this manual, Please click on the above download PDF button.