John Deere 7600, 7700, 7800 Tractors Repair Technical Manual (TM1500)

Technical manual John Deere 7600, 7700, 7800 Tractors Repair manual For complete service information also see: Diagnostic and testing manual 7600, TM1501 7700, 7800 tractors Series 400, 6076 diesel engine. Repair CTM42 manual Series 3029, 4039, 4045, 6059, 6068 CTM3274 diesel engine. Repair manual Operation manual 7600, 7700, 7800 OMAR112756 tractors

English TM1500

TM1500 - 7600, 7700 and 7800 Tractors Grp

05

Description Foreword Dealer Predelivery Service Quick Reference Specifications

Safety 05 Safety Handle Fluids Safely-Avoid Fires Prevent Battery Explosions Prepare for Emergencies Prevent Acid Burns Handle Chemical Products Safely Avoid High-Pressure Fluids Park Machine Safely Support Machine Properly Wear Protective Clothing Work in Clean Area Service Machines Safely Work in Ventilated Area Illuminate Work Area Safely Replace Safety Signs Use Proper Lifting Equipment Service Tires Safely Avoid Harmful Asbestos Dust Avoid Heating Near Pressurized Fluid Lines Remove Paint Before Welding or Heating Use Proper Tools Dispose of Waste Properly Live With Safety

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Engine 00 Component Removal and Installation Special or Essential Tools Service Equipment and Tools Specifications Repair Engine-Use CTM Remove Engine Install Engine in Repair Stand Install Engine 05 Engine Repair Repair Engine-Use CTM Access to Intake and Exhaust Valves Access to Front Crankshaft Seal Access to Rear Crankshaft Seal-PST or PQT W/Creeper Access to Rear Crankshaft Seal-PQT W/O Creeper Access to Camshaft Access to Timing Gear Cover Remove and Install Engine Valve Cover Remove and Install Front Cooling Assembly

30

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

General Information 05 General Information General Specifications Sealants and Adhesives Cross-Reference Chart Glossary of Terms Metric Bolt and Cap Screw Torque Values Unified Inch Bolt and Cap Screw Torque Values

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36 37 38 39 40 45 46 47 48 49 50 51 52 53 54 55

Fuel, Air Intake, and Cooling Systems 05 Throttle Controls Specifications Repair Engine-Use CTM Adjust Hand-Foot Throttle With Mechanical Linkage 10 Diesel Fuel System

57 58 59

Specifications Fuel Tank System-Exploded View Remove and Install Fuel Tank 15 Air Intake System Inspect and Service the Air Intake 20 Engine Cooling System Service Equipment and Tools Specifications Test Radiator and Cap Remove and Install Radiator Remove and Install Viscous Fan Drive Inspect Belt Tensioner Replace Belt Tension Mechanism Fan Belt Routing- 7600 Fan Belt Routing- 7700 and 7800 25 Air Conditioning Condenser and Coolers Service Equipment and Tools Remove Fuel-Hydraulic Oil Cooler/Condenser Leak Test Fuel-Hydraulic Oil Cooler/Condenser Install Fuel-Hydraulic Oil Cooler/Condenser

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Electrical 05 Connectors Service Equipment and Tools Other Material Using High-Pressure Washers Replace Connector Install Contact Remove Connector Body from Blade Terminals Replace (Pull Type) Connectors Replace (Push Type) Connectors Replace , Large and Pin Type Connectors Replace Blade Type Connectors Replace Small Socket Connector Replace Small Pin Connector Replace Connectors Install Contact Use Electrical Insulating Compound 10 Wiring Harness Routings Ground Point Locations Cab Harness Routing- Power Shift Transmission Cab Harness Routing- Transmission Cab Harness Routing- Power Shift and Transmission Open Station Harness Routing and Component Identification Harness Routing and Component Identification- Power Shift Transmission Harness Routing and Component Identification-Transmission PowrQuad PowrQuad is a trademark of Deere & Company.

Engine Harness Routing and Component Identification- 6068 Engine (7600 Tractor) Engine Harness Routing and Component Identification- 6076 Engine (7700 Tractor) Engine Harness Routing and Component Identification- 6076 Engine (7800 Tractor) 15 Charging Circuit Repair Alternator-Use CTM Remove and Install Alternator 20 Starting Circuit Special or Essential Tools Specifications Repair Starter-Use CTM Remove and Install Starter Motor Replace Starter Circuit Relay Replace Fusible Link Replace Neutral Start Switch-Transmission Replace Neutral Start Switch- Power Shift Transmission Replace Gear Encoder

79 80 81 82 83 85 86 87 88 89 90 91 92 94 96 97 99 101 103 104 106 107

108 109 110 111 112 113 114 115 116 117 118 119 120 121

Replace Switch Module 25 Switches, Relays, and Solenoids Specifications Replace Air Conditioning Relays and Switches Replace Air Conditioning High and Low Pressure Switches Replace MFWD Solenoid Replace Hitch Return and Hitch Pressure Solenoids Replace Differential Lock and Rear PTO Solenoids Hitch-Position Feed-Back Sensor Location Replace Hitch Position Potentiometer Assembly Replace Hitch Control Potentiometer and Switch Replace Fuel Shut-Off Solenoid Replace Electric Fuel Pump- 7700 Remove Electrical Switches and Sensors-Transmission Electrical Controls and Switches- Power Shift Transmission Replace Sensors Front Valve Housing- Power Shift Transmission Replace Brake Switch Replace Ether Starting Aid Solenoid and Switch- 7700 and 7800 Replace PST Start-in-Gear Relays Replace Load Center Fuses and Relays Load Center Fuses, Relays, and Diodes- Cab (North American) Load Center Fuses, Relays, and Diodes- Open Station (North American) Load Center Fuses, Relays, and Diodes- (European) 30 Monitoring System Service Equipment and Tools Other Material Specifications Replace Rear PTO Speed Sensor Replace Hydraulic Oil Restriction Sensor Replace Engine Oil Pressure Sensor Replace Air Filter Restriction Indicator Sensor Replace Engine Speed Sensor Replace Engine Coolant Temperature Sensor Replace Fuel Level Sensor Replace Wheel Speed Sensor Replace Radar Speed Sensor Remove and Install Draft Link Sensor Adjust Draft Link Sensor Replace Power Shift Control Unit (PCU) Replace Hitch Control Unit (HCU) And Central Control Unit (CCU) Replace Transient Voltage Protector (TVP) Remove and Install Display Module Replace Display Module Bulbs Replace Light Switch, Hazard Light Switch, and Audible Warning Alarm Replace Multifunction or Washer Wiper Switch Replace Multifunction Switch Wiring Harness 40 Auxiliary Lighting and Electrical Components Replace Seven-Terminal Outlet Socket- North American Version Replace Seven-Terminal Outlet Socket- European Version 45 Convenience and Accessory Components Replace Pressurized Blower Motor Replace Circulation Blower Motors Replace Wiper Motor Replace Thermo Starting Aid and Relay- 7600 Test Ground-Fault Interrupter- North American Replace Transmission Cover Heater Replace Hydraulic Charge Pump Heater Row Guidance Component Identification Replace Row Guidance Coupler Position Sensor Remove and Install Row Guidance Probe Angle Position Sensor and Probe Rise/Lower Remove Row Guidance Probe Motor Wire Number and Color Codes

122 123 124 125 126 127 128 129 130 132 133 134 135 136 137 138 139 140 141 142 144 145 147 148 149 150 151 152 153 154 155 156 157 158 159 160 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183

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Power Shift Transmission 00 Component Removal and Installation Special or Essential Tools Other Material Specifications Sealing Instructions- Drive Train Remove Drive Train Install Drive Train Remove Power Shift Transmission Install Power Shift Transmission Remove Reduction Gear Box Install Reduction Gear Box 05 PST Controls Special or Essential Tools Shift Console Access Transmission Shift Control and Park Linkage Park Linkage Adjustments Remove Shift Control Assembly Disassemble and Assemble Shift Control Assembly Replace Encoder Replace Switch Module Replace Power Shift Control Unit- (PCU) Replace Relays Recondition Park Lock Linkage Recondition Tow Disconnect Electrical Controls and Sensors Electrical Controls and Sensors Wheel Speed Sensor Remove and Install Thermal By-Pass Valve 10 PST Transmission Special or Essential Tools Service Equipment and Tools Other Material Specifications General Repair Procedures- Power Shift Transmission Transmission Components Prepare Transmission for Repair Remove Transmission Front Cover/Front Valve Housing Remove Front Valve Housing Front Valve Housing Valves Transmission Front Cover Valves Replace Traction Clutch Valve Shifter Lever Shaft Seal Transmission Pump-Cross-Sectional View Repair Transmission Pump Install Front Valve Housing Install Transmission Front Cover/Valve Housing Assembly Repair or Replace Electro-Hydraulic Valves Remove Clutch Pack Assembly Clutch Pack Assembly-Cross-Sectional View Disassemble Clutch Pack Assembly Assemble Clutch Pack Assembly Install Clutch Pack Assembly Remove and Disassemble C LO-B HI Pack Assemble and Install C LO-B HI Pack Remove and Disassemble Input Planetary Carrier Assembly Assemble and Install Input Planetary Carrier Assembly Disassemble Output Housing Module and Remove Output Planetary Carrier Output Planetary Carrier Assembly-Cross-Sectional View Planetary Carrier Assembly-Exploded View Disassemble Output Planetary Carrier Assembly Assemble Output Planetary Carrier Assembly Remove and Disassemble B5 Pack Assemble and Install B5 Pack

184 186 187 188 189 196 197 198 199 200 201 202 203 204 213 214 216 217 218 219 220 221 222 223 224 225 226 228 229 230 232 234 235 236 237 238 239 242 244 245 248 249 250 251 252 253 254 255 257 260 261 262 264 267 269 270 272 277 279

Install Output Planetary Carrier and Assemble Output Housing Module 15 PST Reduction Gear Box Special or Essential Tools Service Equipment and Tools Specifications General Repair Procedures- Reduction Gear Box Remove Differential Drive Shaft Differential Drive Shaft-Cross-Sectional View Determine Cone Point Shim Pack and Install Differential Drive Shaft Reduction Gear Shaft-Cross-Sectional View Remove and Install Reduction Gear Shaft Repair Lube Manifold- Early Version Repair Lube Manifold- Later Version Remove and Install Tow Disconnect Replace Transmission Lock Return Spring Remove and Install Transmission Lock

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Transmission 00 Component Removal and Installation Special or Essential Tools Service Equipment and Tools Other Material Specifications Sealing Instructions- Drive Train Remove Drive Train Install Drive Train Remove Transmission Install Transmission Remove Creeper Transmission Install Creeper Transmission Remove Range Box Install Range Box 05 PQT Controls Special or Essential Tools Shift Console Access Shift and Park Linkage Assembly PowrQuad PowrQuad is a trademark of Deere & Company.

Shift and Park Linkage Symptom/Cause Chart PowrQuad PowrQuad is a trademark of Deere & Company.

Shift and Park Linkage Adjustment PowrQuad PowrQuad is a trademark of Deere & Company.

Shifter Cam Neutral Alignment F-N-R Lower Linkage Inspection and Adjustment F-N-R Upper Linkage Inspection and Adjustment 1-2-3-4 Speed Lower Linkage Inspection and Adjustment 1-2-3-4 Speed Upper Linkage Inspection and Adjustment Park Rod Linkage Inspection and Adjustment Range Shift Linkage Inspection and Adjustment Shift and Park Linkage Final Checks and Adjustments Remove Shift Control Assembly Disassemble Shift Control Assembly Repair Lower Shift Linkage Repair Lower Park Lock Outer Linkage Repair Lower Park Lock Inner Linkage Creeper Control Lever Electrical Controls and Sensors 10 Transmission Special or Essential Tools Service Equipment and Tools Other Material Specifications

307 309 310 311 312 313 321 322 323 324 326 327 329 330 331 332

333

334

335 340 342 344 348 352 362 365 369 370 371 372 373 374 375 376 377 378 379

General Repair Procedures- Transmission Transmission Serial Number Information Major Transmission Components Install Transmission in Repair Stand Remove Transmission Front Cover/Front Valve Housing Remove Front Valve Housing Front Valve Housing Valves Transmission Front Cover Valves Traction Clutch Valve Replace Traction Clutch Valve Shifter Lever/Shaft Seal Replace Traction Clutch Valve Inner Arm/Shaft Transmission Pump-Cross-Sectional View Repair Transmission Pump Install Front Valve Housing Install Transmission Front Cover/Front Valve Housing Remove Shift Control Valve Housing Replace Forward-Reverse/Speed Selector Shifter Levers/Shaft Seals Replace Forward-Reverse/Speed Selector Shifter Shafts/Shifter Arms Shift Control Valve Housing Valves Serial Number (-10891) Shift Control Valve Housing Valves Serial Number (10892-) Modulator Valve-Cross-Sectional View Planetary Housing Valves Forward/Reverse Control Valve-Cross-Sectional View Serial Number (-10891) Forward/Reverse Control Valve-Cross-Sectional View Serial Number (10892-) Speed Selector Valve-Cross-Sectional View Serial Number (-10891) Speed Selector Valve-Cross-Sectional View Serial Number (10892-) Assemble and Install Shift Valve Housing- Serial Number (-10891) Assemble and Install Shift Valve Housing- Serial Number (10892-) Disassemble Planetary/Reverse Brake Housing Assembly Recondition Input Planetary Carrier Input Planetary Assembly-Cross-Sectional View Disassemble Reverse Brake Housing Components Reverser Carrier/Traction Clutch Assembly-Cross-Sectional View Recondition Reverser Carrier/Traction Clutch Assembly Disassemble Planetary Housing Components Direct Drive Clutch Assembly-Cross-Sectional View Recondition Direct Drive Clutch Assembly Assemble Planetary Housing Components Assemble Reverse Brake Housing Components Assemble Planetary/Reverse Brake Housing Assembly 15 Creeper Transmission Service Equipment and Tools Other Material Specifications General Repair Procedures- Creeper Transmission Recondition Creeper Transmission Shifter Components-Cross-Sectional View Remove and Install Shifter Components Creeper Transmission-Cross-Sectional View Remove Input/Output Drive Shaft Assembly Disassemble and Assemble Drive Shaft/Snubber Brake Remove and Install Countershaft Install Input/Output Shaft Assembly 20 Range Box Special or Essential Tools Service Equipment and Tools Other Material Specifications 30K and 40K Range Box General Repair Procedures- Range Box Remove and Disassemble Shifter Cover Remove and Install Park Pawl

382 384 385 386 387 388 389 391 392 393 394 395 396 399 400 401 402 403 404 405 406 407 408 409 411 412 414 416 417 418 419 420 422 423 425 428 429 430 433 435 438 439 440 441 443 444 445 446 447 448 451 453 455 456 457 458 459 460 462 464

Reverse Interlock Shifter Shaft Components Remove and Install Shifter Rails and Forks Shifter Rails Interlock Components-Cross-Sectional View Install Shifter Forks and Rails Adjust Shifter Rails Assemble and Install Shifter Cover Remove Differential Drive Shaft Differential Drive Shaft-Cross-Sectional View Determine Cone Point Shim Pack and Install Differential Drive Shaft Remove and Disassemble Input Shaft Input Shaft-Cross-Sectional View Assemble and Install Input Shaft Adjust Input Shaft End Play

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465 466 467 468 469 470 471 472 474 476 478 479 480

Drive Systems 00 Component Removal and Installation Special or Essential Tools Service Equipment and Tools Other Material Specifications Sealing Instructions MFWD Axle Repair-Use CTM Remove MFWD Clutch Install MFWD Clutch Remove MFWD Axle Install MFWD Axle Remove Rear PTO Assembly Install Rear PTO Assembly Remove Front PTO Assembly Install Front PTO Assembly Remove Final Drive Install Final Drive 05 Controls Specifications MFWD Switch MFWD Solenoid Differential Lock Switch Differential Lock Solenoid Repair Lower Park Lock Inner Linkage PTO Switches PTO Shift Lever PTO Clutch Solenoid PTO Speed Sensor 10 MFWD Clutch Special or Essential Tools Service Equipment and Tools Specifications General Repair Procedures- MFWD Clutch Disassemble MFWD Clutch MFWD Clutch-Cross-Sectional View With Secondary Brake MFWD Clutch-Cross-Sectional View Less Secondary Brake Disassemble MFWD Clutch Pack Assemble MFWD Clutch Pack Assemble MFWD Clutch 15 MFWD Axle MFWD Axle Repair-Use CTM44 20 Rear Diff-7600(-07567), 7700(-09103), 7800(-14055) Special or Essential Tools Service Equipment and Tools Specifications General Repair Procedures- Rear Differential Remove Differential Differential-Cross-Sectional View Disassemble Differential

481 483 484 485 486 487 488 489 490 491 492 493 494 495 496 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 515 516 517 520 522 524 527 528 529 530 531 533 534 535

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25

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35

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Assemble Differential Adjust Differential Preload Adjust Differential Backlash Rear Diff-7600(07568-), 7700(09104-), 7800(14056-) Service Equipment and Tools Specifications General Repair Procedures- Rear Differential Remove Differential Differential-Component Identification Differential-Cross-Sectional View Disassemble Differential Assemble Differential Adjust Differential Preload Adjust Differential Backlash Final Drive Special or Essential Tools Service Equipment and Tools Other Material Specifications General Repair Procedures- Final Drive Remove Planet Pinion Carrier Planet Pinion Carrier-Cross-Sectional View Disassemble Planet Pinion Carrier Planet Pinion Carrier-Exploded View Assemble Planet Pinion Carrier Rear Axle Housing and Shaft-Cross-Sectional View Remove Axle Housing Disassemble and Assemble Axle Housing Disassemble and Assemble Axle Shaft Install Axle Housing Install Planet Pinion Carrier and Check Rolling Drag Torque PTO Special or Essential Tools Service Equipment and Tools Specifications General Repair Procedures- PTO Clutch Repair PTO PTO Clutch-Cross-Sectional View Remove and Disassemble PTO Clutch Assemble and Install PTO Clutch Remove and Disassemble Countershaft PTO Countershaft-Cross-Sectional View Assemble and Install Two-Speed PTO Output Shaft-Cross-Sectional View Shiftable PTO Output Shaft-Cross-Sectional View Remove and Disassemble Output Shaft Assemble and Install PTO Output Shaft Shiftable PTO Shifter-Exploded View Remove PTO Shifter Install PTO Shifter Replace PTO Brake Replace PTO Output Shaft Oil Seal Remove Valve Housing Disassemble and Assemble Valve Housing Install Valve Housing Drive Lines Specifications MFWD Drive Shaft Engine Coupler Shaft Hydraulic Pump Drive Special or Essential Tools Service Equipment and Tools

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Specifications General Repair Procedures- Pump Drive Hydraulic Pump Drive-Cross-Sectional View Remove and Disassemble Pump Drive Pinion Gear Remove and Disassemble Pump Drive Gear Assemble and Install Pump Drive Gear Assemble and Install Pump Drive Pinion 45 Front PTO Special or Essential Tools Service Equipment and Tools Other Material Specifications General Repair Procedures- PTO Clutch Remove PTO Clutch and Pump Disassemble Pump Disassemble PTO Clutch Replace PTO Brake Remove PTO Output Gear Replace Idler Gear (Three Gear Clockwise Rotation PTO Only) Remove Modulating Valve Disassemble and Assemble Valve Housing Install Modulating Valve Install PTO Output Gear Assemble PTO Clutch Assemble Pump Install PTO Clutch and Pump Front PTO Driveline-Cross-Sectional View Repair Front PTO Driveline Repair Pressure and Lube Regulating Valves

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Steering and Brakes 05 Hydrostatic Steering Special or Essential Tools Service Equipment and Tools Specifications Remove and Install Steering Valve Steering Valve-Exploded View Disassemble, Inspect, and Assemble Steering Valve Remove and Install Auxiliary Steering Pump Disassemble, Inspect, and Assemble Auxiliary Steering Pump 10 Steering Cylinders Specifications Other Material Service Parts Kits Remove and Install Steering Cylinder Cross-Sectional and Exploded View- Steering Cylinder Two-Wheel Drive Cross-Sectional and Exploded View- Steering Cylinder MFWD 15 Brake Valve Service Parts Kits Specifications General Repair Procedures- Brake Valve Remove and Install Brake Valve Disassemble, Inspect, and Assemble Brake Valve Bleed Brakes Check Manual Brakes 20 Brake Components Specifications Remove, Inspect, and Install Brake Pistons, Plates, and Disks Inspect and Adjust Secondary Brake 25 Trailer Brakes Specifications Remove and Install Hydraulic Trailer Brake Valve Repair Hydraulic Trailer Brakes

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Repair Air Trailer Brakes

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Hydraulics 00 Component Removal and Installation

05 10

15

20

25

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Essential or Recommended Tools Specifications Remove and Install Inlet-Priority Valve Assembly Remove and Install Main Hydraulic Pump Remove and Install Charge Pump Controls Remove, Install, and Adjust SCV Linkage Hydraulic Pump and Charge Pump Essential or Recommended Tools Service Equipment and Tools Other Material Service Parts Kits Specifications General Repair Procedures- Hydraulic Pumps Remove and Install Hydraulic Pump Controller Hydraulic Pump Controller-Exploded View Disassemble, Inspect, and Assemble Pump Controller Hydraulic Pump-Exploded View Disassemble, Inspect, and Assemble Hydraulic Pump Adjust Yoke Bearing Preload Adjust Shaft Bearing Preload Inspect Hydraulic Charge Pump Hydraulic System Valves Essential or Recommended Tools Service Parts Kits Specifications General Repair Procedures- Hitch and Inlet-Priority Valves, and Filter Bypass Remove, Inspect, and Install Hydraulic Filter Bypass Disassemble, Inspect, and Assemble Inlet-Priority Valve Remove and Install Hitch Valve Disassemble, Inspect, and Assemble Hitch Valve Adjust Hitch Valve Selective Control Valves and Couplers Essential or Recommended Tools Other Material Service Parts Kits Specifications General Repair Procedures- Selective Control Valves and Couplers SCV Identification Remove, Inspect, and Install Selective Control Valves Selective Control Valve-Exploded View- Three-Position Selective Control Valve-Exploded View- Two-Position Replace Control Knobs Inspect Poppet Load-Check Valves Inspect Pressure Compensator Valve- Three-Position SCV Inspect Metering Valve- Three-Position SCV Inspect Metering Valve- Two-Position SCV Disassemble, Inspect, and Assemble Control Valve- Three-Position SCV Disassemble, Inspect, and Assemble Control Valve- Two-Position SCV Disassemble, Inspect, and Assemble Couplers Hitch Essential or Recommended Tools Specifications Remove and Install Lift Cylinders Cross-Sectional and Exploded View- Lift Cylinder Replace Rockshaft Housing Bushings Row Guidance Service Parts Kits Specifications Remove and Install Probe Module

701 702 703 705 706 707 708 709 710 711 712 713 714 716 717 718 719 722 723 725 726 727 728 730 731 732 736 737 741 742 743 744 745 746 747 748 751 752 753 754 755 756 757 758 764 769 773 774 775 776 777 779 780 781

Repair Row Guidance Cylinder Exploded View- Row Guidance Cylinder 35 Remote Cylinder Specifications Disassemble and Inspect Remote Cylinder Assemble and Bleed Remote Cylinder 40 Bleed Hydraulic System Bleed Hydraulic System

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Miscellaneous 00 Component Removal and Installation Special or Essential Tools Specifications Remove Front Axle Install Front Axle 05 Front Axle Other Material Specifications Replace Knee Bushings 10 Hood Remove, Install, and Adjust Hood 15 Trailer and Pick-Up Hitch Repair Trailer Hitch Adjust Trailer Hitch Release Repair Pick-Up Hitch Adjust Pick-Up Hitch

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793 794 795 796 797 798 799 801 802 803 804 805

Operator Station 00 Component Removal and Installation Specifications Remove Cab Install Cab 05 Controls Remove and Install Heater and Air Flow Control Cables Adjust Heater and Air Flow Control Cables 10 Air Conditioning System Special or Essential Tools Service Equipment and Tools Other Material Service Parts Kits Specifications Hose and Tubing O-Ring Connection Torques Discharge Air Conditioning System Remove and Install Compressor Test Volumetric Efficiency Test Shaft Seal Leakage Disassemble and Assemble Compressor Clutch Disassemble, Inspect, and Assemble Compressor Check Clutch Hub Clearance Inspect Compressor Manifold Remove and Install Compressor Relief Valve Replace Receiver-Dryer Remove Evaporator/Heater Core Leak Test Evaporator/Heater Core Install Evaporator/Heater Core Service Expansion Valve Expansion Valve Bench Test-Diagram Expansion Valve Bench Test Replace Thermo Switch Remove, Clean, and Install Air Filters Refrigerant Oil Information Check Compressor Oil Charge Determine Correct Refrigerant Oil Charge Add Refrigerant Oil to System System Information

806 807 811 812 813 814 816 817 818 819 820 821 823 825 827 828 830 833 834 835 836 837 839 840 841 842 843 844 845 846 847 848 850 851

Air Conditioning System-Diagram Air Conditioning System Fitting-Reference Chart Flush Air Conditioning System Purge Air Conditioning System Evacuate Air Conditioning System Charge Air Conditioning System 15 Heating System Remove Heater Control Valve Leak Test Heater Control Valve Install Heater Control Valve 20 Seat Other Material Remove Seat and Mechanical Suspension Disassemble, Inspect, and Assemble Mechanical Suspension Assembly Install Mechanical Suspension Assembly Remove Seat and Air Suspension Remove Seat From Suspension Remove Swivel Plate Disassemble, Inspect, and Assemble Air Suspension Assembly Install Seat and Air Suspension 25 ROPS and Cab Repair Cab Door Latch Cab Door Adjustment- Step 1 Cab Door Adjustment- Step 2 Cab Door Adjustment- Step 3 Cab Door Adjustment- Step 4 Cab Door Adjustment- Step 5 Check ROPS

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Dealer Fabricated Tools 05 Fabricated Tools Fabricated Tools DFRW20-Compressor Holding Fixture DFRW29-Final Drive Housing Adapter DFRW30-Axle Jacking Tool DFRW60 - DFRW61 - DFRW62-Extension Harnesses DFRW63-DFRW64-DFRW65-DFRW66-DFRW81-Tap-Out Harnesses DFRW70-Holding Tool DFRW77-Rear Tractor Access Platform DFRW78-Seat Support Tray DFRW79-Piston Holding Tool DFRW80-Front PTO Lifting Brackets and Spacers DFRW87-Pick-Up Hitch Adapter Plate DFRW108-Park Rod Adjusting Nut Tool Tool may be purchased. Order JDG952

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tm1500 - 7600, 7700 and 7800 Tractors Foreword 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.

T81389-UN:

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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0002

tm1500 - 7600, 7700 and 7800 Tractors Dealer Predelivery Service Dealer Predelivery Service The John Deere delivery receipt, when properly filled out and signed by the dealer and customer, verifies predelivery and delivery services were satisfactorily performed. When delivering the tractor, give the customer his copy of the delivery receipt and operators manual.

Be sure to explain their purposes to him.

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 in the first of two sections on the predelivery form which is attached to the tractor. The second section is a list of factory inspections that must be verified by the dealer.

Fill the form out completely and sign it. Send a copy to the factory and file the original with the shop order for the job. This will certify the proper delivery service has been completed.

Perform all services listed and check each job off as it is completed.

0002

3

3

0003

tm1500 - 7600, 7700 and 7800 Tractors Quick Reference Specifications Quick Reference Specifications -: Quick Reference Specifications Engine Slow Idle

800-900 rpm

Fast Idle

2225-2325 rpm

Rated Engine Speed 2100 rpm Valve Clearance: Intake: 7600 7700 and 7800

0.35 mm (0.014 in.)

0.38 mm (0.015 in.)

Exhaust: 7600 7700 and 7800

0.45 mm (0.018 in.)

0.51 mm (0.020 in.)

Capacities Fuel tank

344 L (91 gal)

Cooling system: 7600 7700 7800

24 L (25 qt) 25 L (26.5 qt) 26 L (27.5 qt)

Crankcase with Filter

18 L (19 qt)

Transmission, Differential and Hydraulic system: Power Shift Power Shift with MFWD PowrQuad ™ PowrQuad ™ with MFWD PowrQuad ™ with Creeper PowrQuad ™ with MFWD and Creeper

91 L (24 gal) 102.3 L (27 gal) 87 L (22.9 gal) 98.3 L (25.9 gal) 91 L (24 gal) 102.3 L (27 gal)

Mechanical Front Wheel Drive: Axle Housing: Wheel Hub

8.5 L (9 qt) 1.9 L (2 qt)

Torques: Front Axle Bolts

600 N·m (445 lb-ft)

Front Wheel to Hub Standard

136 N·m (100 lb-ft)

MFWD: Rim-to-Disk Disk-to-Hub

310 N·m (230 lb-ft) 600 N·m (445 lb-ft)

Rear Wheel Sleeve Retaining Bolts (Final Torque): Cast Wheels Steel Wheels Rear Wheel-to-Rim Rear Steel Wheel Cab Mounting Bolts

600 N·m (445 lb-ft) 500 N·m (370 lb-ft) 600 N·m (445 lb-ft) 600 N·m (445 lb-ft) 204 N·m (150 lb-ft)

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4

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0004

tm1500 - 7600, 7700 and 7800 Tractors Handle Fluids Safely-Avoid Fires Handle Fluids Safely-Avoid Fires

TS227-UN: Fluid Fire

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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5

5

0005

tm1500 - 7600, 7700 and 7800 Tractors Prevent Battery Explosions Prevent Battery Explosions

TS204-UN: Battery Explosion

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).

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tm1500 - 7600, 7700 and 7800 Tractors Prepare for Emergencies Prepare for Emergencies

TS291-UN: Emergency Ready

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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tm1500 - 7600, 7700 and 7800 Tractors Prevent Acid Burns Prevent Acid Burns

TS203-UN: Acid Safety

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.

2.

3.

4.

5.

Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

Avoiding spilling or dripping electrolyte.

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.

0007