John Deere 7200, 7300, 7400, 7500, 7700, 7800 Self Propelled Harvester Operating & Diagnostic Test M

7200, 7300, 7400, 7500, 7700 and 7800 SelfPropelled Forage Harvesters Diagnostic

OPERATION AND TEST MANUAL Self-Propelled Forage Harvester (SN. 508100-XXXXXX) models 7200, 7300, 7400, 7500, 7700, 7800 TM4670 04 FEB 14 (ENGLISH)

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

TM4668

Harvest Lab Stationary / Harvest Lab on 7x00, 7x50 and 7x80 Self-Propelled Forage Harvesters Technical Solutions Manual

TM132019

PowerTech 8.1 L Diesel Engines Base Engine

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Electronic Fuel Injection Systems

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Machine Connection Information

CTM441

PowerTech 8.1L Diesel Engines Level 9 Electronic Fuel System With Denso High Pressure Common Rail

CTM255

PowerTech 10.5 L & 12.5 L Diesel Engines, Level 6 Electronic Fuel Systems with Lucas EUIs

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PowerTech 10.5 L & 12.5 L Diesel Base Engine

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John Deere Agriculture Pinted by Belgreen

TM4670-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD VERSION DATE Section 210 - SAFETY AND GENERAL INFORMATION Group 05 - Safety Information Group 15 - General Information Section 211 - DIAGNOSTIC TROUBLE CODES Group AMS - AMS Diagnostic Trouble Codes Group ARC - ARC Diagnostic Trouble Codes Group ECUL9 - ECU Diagnostic Trouble Codes (6125 JD Control Unit Level 9) Group ECUL6 - ECU Diagnostic Trouble Codes (6125 JD Control Unit Level 6) Group ECU(Cummin - ECU Diagnostic Trouble Codes (Cummins Engine) Group JDL - JDL Diagnostic Trouble Codes Group OCP - OCP Diagnostic Trouble Codes Group PTP - PTP Diagnostic Trouble Codes Group RCP - RCP Diagnostic Trouble Codes Group RDC - RDC Diagnostic Trouble Codes Group RGC - RGC Diagnostic Trouble Codes Group SIG - SIG Diagnostic Trouble Codes Group SPF - SPF Diagnostic Trouble Codes Section 212 - OBSERVABLE SYMPTOMS Group 20 - Engine Group 40 - Electrical System Group 50 - ProDrive Group 70 - Hydraulic System Group 90 - Operator′s Station Section 213 - SYSTEM DIAGNOSTICS Group 40 - Electrical System Group 45 - Electronic System Section 220 - ENGINE Group 05 - Engine Specifications Group 10 - Operational Checks Group 15 - Tests and Adjustments Section 230 - FUEL, AIR INTAKE AND COOLING SYSTEMS Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 240 - ELECTRICAL SYSTEM (UP TO SERIAL NO. 508099) Group 10A - Power Distribution Group 10B - Lighting System Group 10C - Power Outlet Sockets Group 10D - Wipers Group 10E - Outside Mirrors Group 10F - Ether Starting Aid Group 10G - Horn Group 10H - Engine Start Group 10I - Air-Conditioning System Group 10J - Warning Devices and Monitors Group 10K - Area Counter Functions Group 10L - Electronically Controlled Lighting Functions Group 10M - Cutterhead Control Functions Group 10N - Engine Cooling Functions Group 10P - Engine Speed Control Functions Group 10Q - Feed Roll Control Functions <- Go to Global Table of contents

TM4670-OPERATION AND TEST MANUAL

TM4670-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Group 10R - Header Control Functions Group 10S - Kernel Processor Functions Group 10T - Knife Sharpening Functions Group 10U - Electronic Power Control Functions Group 10V - Lubrication Control Functions Group 10W - Metal Detector Functions Group 10X - Drive Train Control Functions Group 10Y - Row Guidance Functions Group 10Z - Stationary Knife Adjust Function Group 10AA - Spout Control Functions Group 10AB - Trailer Functions Group 10AC - System Interlock Functions Group 10AD - On-Board Diagnostic Functions Group 10AE - CAN Bus System Functions Group 15 - Wiring and Harness Diagrams Section 241 - ELECTRICAL SYSTEM (FROM SERIAL NO. 508100) Group 10A - Power Distribution Group 10B - Lighting System Group 10C - Sockets Group 10D - Wipers Group 10E - Outside Mirrors Group 10F - Ether Starting Aid Group 10G - Horn Group 10H - Engine Start Group 10I - Air-Conditioning System Group 10J - Warning Devices and Monitors Group 10K - Area Counter Functions Group 10L - Electronically Controlled Lighting Functions Group 10M - Cutterhead Control Functions Group 10N - Engine Cooling Functions Group 10P - Engine Speed Control Functions Group 10Q - Feed Roll Control Functions Group 10R - Header Control Functions Group 10S - Kernel Processor Functions Group 10T - Knife Sharpening Functions Group 10U - Electronic Power Control Functions Group 10V - Lubrication Control Functions Group 10W - Metal Detector Functions Group 10X - Drive Train Control Functions Group 10Y - Row Guidance Functions Group 10Z - Stationary Knife Adjust Function Group 10AA - Spout Control Functions Group 10AB - Trailer Functions Group 10AC - System Interlock Functions Group 10AD - On-Board Diagnostic Functions Group 10AE - CAN Bus System Functions Group 10AF - GreenStar Display/Moisture Sensor Group 10AG - AutoTrac Group 13 - Functional Schematics – Sections 1 to 41 Group 20 - Wiring and Harness Diagrams, Connectors and Components Group 21 - Wiring and Harness Diagrams (Splices) Group 25 - Location of Wiring Harnesses Section 245 - CONTROL UNITS <- Go to Global Table of contents

TM4670-OPERATION AND TEST MANUAL

TM4670-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Group 05 - Operation and General Information on Diagnostics Group 06 - Test Equipment Group 20 - CAN Bus System Group AMS - GreenStar Control Unit (AMS) Group ARC - Armrest Control Unit (ARC) Group ECU - Engine Control Unit (ECU) Group JDL - JDLink Control Unit (JDL) Group OCP - Overhead Control Panel Control Unit (OCP) Group PTP - ProDrive Control Unit (PTP) Group RCP - Cornerpost Control Unit (RCP) Group RDC - Rear Wheel Drive Control Unit (RDC) Group RGCI - Row Guidance I Control Unit (RGC I) Group RGCII - Row Guidance II Control Unit (RGC II) Group SIG - Metal Detector Control Unit (SIG) Group SPF - SPFH Main Control Unit (SPF) Group SSU - AutoTrac Control Unit (SSU) Section 250 - POWER TRAIN WITH 3-SPEED TRANSMISSION Group 10 - Operational Checks Group 15 - Tests and Adjustments for 3-Speed Transmission Group 20 - Theory of Operation of 3-Speed Transmission Section 251 - POWER TRAIN, PRODRIVE TRANSMISSION AND FOUR-WHEEL DRIVE Group 05 - Preliminary Checks Group 10 - Tests Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 260 - BRAKES, STEERING, REAR AXLE Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 261 - BRAKES, STEERING, ROW GUIDANCE II, REAR AXLE FOR MACHINES FROM SERIAL NUMBER 508100 Group 05 - Preliminary Checks Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 270 - HYDRAULIC SYSTEM Group 05 - General Information Group 10 - Hydraulic Circuit Diagrams Group 15 - Location of Hydraulic Components Group 20 - Hydraulic System Diagnostic Schematics Section 271 - HYDRAULIC SYSTEM (MACHINES WITH PRODRIVE TRANSMISSION) Group 05 - General Information Group 10 - Hydraulic Circuit Diagrams Group 15 - Location of Hydraulic Components Group 20 - Hydraulic System Diagnostic Schematics Section 290 - OPERATORS′S CAB Group 10 - Operational Checks Group 15 - Tests and Adjustments Group 20 - Theory of Operation Section 299 - SPECIAL TOOLS Group 10 - Special Tools and Test Equipment Section 310 - IVLOC TRANSMISSION Group 05 - General Information <- Go to Global Table of contents

TM4670-OPERATION AND TEST MANUAL

TM4670-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Group 10 - Operational Checks Group 15 - IVLOC Transmission Diagnostics Group 20 - Theory of Operation

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TM4670-OPERATION AND TEST MANUAL

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TM4670-OPERATION AND TEST MANUAL

TM4670-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Foreword This Diagnostics manual is valid for the following self-propelled forage harvester types: 7250, 7350, 7450, 7550, 7750, 7850 and 7950 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 Section 210 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 your machine or in this manual, be alert to the potential for personal injury.

This technical manual deals with Operation and Tests and provides safety, general and tool information. Repair specifications are supplied and operational checks are described. Information is organized in groups for the various components requiring service instructions. 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 service guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing and repair.

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

“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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TM4670-OPERATION AND TEST MANUAL

SAFETY AND GENERAL INFORMATION

(g) by Belgreen v2.0

Version Date February 01, 2011

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Section 210 page 1

TM4670-OPERATION AND TEST MANUAL

TM4670-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Section 210 - SAFETY AND GENERAL INFORMATION 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 Parking and Leaving the Forage Harvester ......................................................................................... 13 Avoid Eye Contact With Radar ............................................................................................................ 14 Keep ROPS Installed Properly ............................................................................................................. 14 Replace Safety Signs .......................................................................................................................... 15 Dispose of Waste Properly .................................................................................................................. 15 Live With Safety ................................................................................................................................. 16 Safety Measures on Electronic Control Units ...................................................................................... 16 Group 15 - General Information ........................................................................................................... 17 Reference 210-15-001, General References - Summary .................................................................... 17 Reference 210-15-005, Abbreviations ................................................................................................ 18 Reference 210-15-010, Unified Inch Bolt and Cap Screw Torque Values ............................................ 21 Reference 210-15-015, Metric Bolt and Cap Screw Torque Values ..................................................... 22 Reference 210-15-020, Hydraulic System Inch Fitting Torques .......................................................... 23 Reference 210-15-025, Hydraulic System Metric Fitting Torques ....................................................... 24 Reference 210-15-030, Serial Numbers .............................................................................................. 24 Forage Harvester Type Plate for Europe (Product Identification) ........................................................ 24 Forage Harvester Type Plate for North America (Product Identification) ............................................ 25 Product Identification Number (Europe) ............................................................................................. 26 Product Identification Number (North America) .................................................................................. 27 Engine Serial Number — Engine Type 6081 ....................................................................................... 27 Engine Serial Number — Engine Type 6125 ....................................................................................... 28 Engine Serial Number — Cummins ..................................................................................................... 28 Operator′s Cab Serial Number ............................................................................................................ 28 Four Wheel Drive Motor Serial Number .............................................................................................. 29 Kernel Processor Serial Number ......................................................................................................... 29 <- Go to Global Table of contents

TM4670-OPERATION AND TEST MANUAL

TM4670-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Power Chute Serial Number ................................................................................................................ 29 Three-Speed Transmission Serial Number .......................................................................................... 30 Final Drive Serial Number ................................................................................................................... 30 Angled Drive (Main Gearcase) Serial Number .................................................................................... 30 Length-of-Cut Transmission Serial Number ........................................................................................ 31 IV Length-of-Cut Transmission Serial Number .................................................................................... 31 IV Length-of-Cut Transmission Hydrostatic Pump Serial Number ....................................................... 31 IV Length-of-Cut Transmission Motor Serial Number .......................................................................... 32 Main Drive Hydrostatic Pump Serial Number ...................................................................................... 32 Main Drive Motor Serial Number (Harvesters without Four Wheel Drive) ........................................... 32 Rear Axle Serial Number .................................................................................................................... 32 Reference 210-15-035, Dimensions ................................................................................................... 34 Reference 210-15-040, Specifications ................................................................................................ 40 Reference 210-15-045, Drive Diagram ............................................................................................... 46 Reference 210-15-060, Component Identification Table .................................................................... 52 Reference 210-15-065, How to Read a Functional Schematic ............................................................ 53 Reference 210-15-070, How to Read a Wiring and Harness Diagram ................................................ 54 Reference 210-15-075, Schematic - Wiring and Harness Symbols ..................................................... 55 Schematic, Wiring and Harness Symbols ........................................................................................... 56 Schematic, Wiring and Harness Symbols ........................................................................................... 57 Schematic, Wiring and Harness Symbols ........................................................................................... 58 Reference 210-15-080, Visual Check of the Electrical System ........................................................... 58 Types of Fault ..................................................................................................................................... 60 Reference 210-15-090, Seven Step Electrical Test Procedure ............................................................ 63 Reference 210-15-095, Hydraulic System — Circuit Symbols ............................................................ 64

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TM4670-OPERATION AND TEST MANUAL