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 Cylinders
TM-H100A
120 Series Hydraulic Cylinders
CTM120519
120 Series Hydraulic Cylinders
CTM114319
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.
Address 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