John Deere 7200, 7300, 7400, 7500, 7700, 7800 Forage Harvester Repair Technical Manual TM4668 PDF

7200, 7300, 7400,7500, 7700 and 7800 SelfPropelled Forage Harvesters Repair (Worldwide Edition)

REPAIR TECHNICAL MANUAL Harvest Lab models 7200, 7300, 7400, 7500, 7700, 7800 TM4668 29 DEC 13 (ENGLISH)

For complete service information also see: 7200, 7300, 7400, 7500, 7700 and 7800 Self-Propelled Forage Harvesters Diagnostic

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John Deere Agriculture Pinted by Belgreen

TM4668-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD VERSION DATE Section 05 - SAFETY Group 05 - Safety Information Section 10 - GENERAL INFORMATION Group 05 - Fuel, Lubricants and Coolant Group 10 - Torque Values Group 15 - Serial Numbers Group 20 - Dimensions Section 20 - ENGINE Group 05 - Engine Removal and Installation Section 30 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 05 - Fuel Tank Group 10 - Air Intake System Group 15 - Cooling System Section 40 - ELECTRICAL SYSTEM Group 05 - Harness and Connector Repair Group 10 - Electrical System Components Section 50 - POWER TRAIN Group 05 - Main Drive Belt Replacement Group 10 - Bevel Gear Drive Group 15 - Transmission and Differential (Three-Speed Transmission) Group 16 - Transmission and Differential (ProDrive Transmission) Group 20 - Final Drives Group 25 - Hydrostatic Drive, Variable Pump (Three-Speed Transmission) Group 26 - Hydrostatic Drive, Variable Pump (ProDrive Transmission) Group 30 - Hydrostatic Drive, Fixed-Displacement Motor (3-Speed Transm.)

Group 31 - Hydrostatic Drive, Variable-Displacement Motor (ProDrive) Group 40 - Rear Wheel Drive Axle—107 cc Motor Type Group 41 - Rear Wheel Drive Axle—140 cc Motor Type Group 45 - Rear Wheel Drive Axle, Variable-Displacement Motor Section 60 - BRAKES, STEERING AND REAR AXLE Group 05 - Brake Operation (Three-Speed Transmission) Group 06 - Brake Operation (ProDrive Transmission) Group 10 - Brakes (Three-Speed Transmission) Group 11 - Brakes (ProDrive Transmission) Group 15 - Hydrostatic Steering Group 16 - Row Guidance System (Gen. 1) Group 17 - Row Guidance System (Gen. 2) Group 20 - Rear Axle Section 70 - HYDRAULIC SYSTEM Group 05 - Hydraulic Pressure Accumulators Group 10 - Hydraulic Pumps Group 15 - Electromagnetic Control Valve Group 20 - Reverser Motor (Four-Speed LOC) Group 25 - Hydraulic Motor — Discharge Spout Group 30 - IV Length-of-Cut Transmission Motor Group 35 - IV Length-of-Cut Transmission Hydrostatic Pump Section 80 - MISCELLANEOUS Group 05 - Central Lubrication System Section 90 - OPERATOR′S CAB, AIR CONDITIONING SYSTEM Group 05 - Control Levers <- Go to Global Table of contents

TM4668-REPAIR TECHNICAL MANUAL

TM4668-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Group 10 - Cab Ventilation Group 15 - Operator′s Cab Group 20 - R134a Air Conditioning System Group 25 - Super Comfort Seat Section 99 - SPECIAL TOOLS Group 05 - Special Tools (Dealer Fabricated) Group 10 - Special Tools (Available as Spare Parts) Section 100 - HARVESTING UNITS Group 05 - Harvesting Unit Cross Drive Group 10 - Harvesting Units Section 110 - FEEDING SYSTEM Group 05 - Four Speed Length-Of-Cut Transmission Group 10 - IV Length-Of-Cut Transmission Group 15 - Reverser Motor and Clutch (4-Speed L.O.C) Group 20 - Electrical Clutch (4-Speed L.O.C) Group 25 - Feed Roll Channel Group 30 - Feed Roll Assembly Group 35 - Locking Pawl (4-Speed L.O.C) Section 120 - CUTTERHEAD ASSEMBLY Group 05 - Knife Sharpening Device Group 10 - Cutterhead Group 15 - Bottom and Outlet Bands Group 20 - Stationary Knife Removal and Installation Group 25 - Kernel Processor Group 30 - Power Chute Section 130 - DISCHARGE COMPONENTS Group 05 - Discharge Fan Group 10 - Blower Rotor and Rotor Bearings Group 15 - Discharge Spout

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TM4668-REPAIR TECHNICAL MANUAL

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TM4668-REPAIR TECHNICAL MANUAL

TM4668-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Foreword This repair manual is valid for the following self-propelled forage harvester models: 7200, 7300, 7400, 7500, 7700 and 7800 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 Manualsare service guidelines for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing and repair.

"Right-hand" and "left-hand" sides are determined by facing the direction of forward travel.

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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TM4668-REPAIR TECHNICAL MANUAL

SAFETY

(g) by Belgreen v2.0

Version Date 01 February 2011

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Section 05 page 1

TM4668-REPAIR TECHNICAL MANUAL

TM4668-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 05 - SAFETY Table of contents Group 05 - Safety Information ............................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 ‘Important” - Information ...................................................................................................................... 1 ‘Note” - Information .............................................................................................................................. 1 Prevent Machine Runaway ................................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 2 Prevent Acid Burns ............................................................................................................................... 3 Avoid High-Pressure Fluids ................................................................................................................... 3 Service Cooling System Safely ............................................................................................................. 4 Remove Paint Before Welding or Heating ............................................................................................. 4 Avoid Heating Near Pressurized Fluid Lines .......................................................................................... 6 Work In Ventilated Area ........................................................................................................................ 6 Wear Protective Clothing ...................................................................................................................... 7 Practice Safe Maintenance ................................................................................................................... 8 Park Machine Safely ............................................................................................................................. 8 Use Proper Lifting Equipment ............................................................................................................... 9 Construct Dealer-Made Tools Safely ..................................................................................................... 9 Support Machine Properly .................................................................................................................. 10 Work in Clean Area ............................................................................................................................. 10 Illuminate Work Area Safely ............................................................................................................... 10 Service Machines Safely ..................................................................................................................... 11 Use Proper Tools ................................................................................................................................. 11 Service Tires Safely ............................................................................................................................ 13 Avoid Eye Contact with Radar ............................................................................................................ 13 Replace Safety Signs .......................................................................................................................... 14 Dispose of Waste Properly .................................................................................................................. 14 Live With Safety ................................................................................................................................. 15 Safety Measures on Electronic Control Units ...................................................................................... 15 Service Accumulator Systems Safely .................................................................................................. 15

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TM4668-REPAIR TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Group 05 - Safety Information 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.

“Important” - Information Information marked as IMPORTANT points out problems that may lead to machine damage. By following the directions given, these problems can be avoided.

“Note” - Information When marked with NOTE the information given is more detailed or contains restrictions to directions given previously. On the other hand useful information may be given belonging to certain instruction without being directly connected to them.

Prevent Machine Runaway Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals. With normal circuitry bypassed, machine will start even if hydrostatic ground speed control lever is not in neutral position.

Start engine only from operator′s seat, with transmission in neutral or park.

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. <- Go to Section TOC

Section 05 page 1

TM4668-REPAIR TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

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

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

Prevent Battery Explosions

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 volt-meter or hydrometer.

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

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.

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Section 05 page 2

TM4668-REPAIR TECHNICAL MANUAL

Section 05 - SAFETY

Group 05: Safety Information

Prevent Acid Burns

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.

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.

Avoid High-Pressure Fluids

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Section 05 page 3

TM4668-REPAIR TECHNICAL MANUAL