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INSPECTION AND MAINTENANCE GUIDE
More than 40 years ago, the rst John Deere forage harvesting machine rolled off the assembly line in Ottumwa, Iowa. The Model 34 Pull-Type
Forage Harvester answered customer needs for simple, efcient and highly productive forage chopping.
Since then, John Deere has introduced renements and generations of new machines that have advanced the art and science of forage
harvesting. In 1992, forage harvesting production was moved to the John Deere Combine Works in Zweibrucken, Germany a move that put
John Deere engineering and manufacturing closer to its key European forage harvester markets.
47
To further strengthen the companys forage harvesting capabilities, John Deere acquired Kemper a foremost maker of grass pick-up and
maize headers.
Today, John Deere continues to provide growers and contractors with reliable, high performance and advanced machines such as our new
7050i Series machines. They offer HarvestLab real-time moisture sensing AutoLOC for optimal length of cut GreenStar HarvestMon and
HarvestDoc for GPS-based yield monitoring and documentation AutoTrac hands-free guidance the list goes on. Talk to your John Deere
dealer to learn how a history of harvesting excellence can pay off in your operation today.
8 11
Headers
12 13
Cutterhead Knives,
Installation and Adjustment
14 17
18 24
25 27
28 29
30 31
Drive sheaves
Having the last successful season still in mind, timely inspection and
preventative maintenance are critical to prevent down time and
costly in season repairs.
Dont forget downtime during harvest can have a measurable impact
on your bottom line.
Clean and inspect the area around the accelerator and accelerator band, as well as the area
over the ground drive transmission. Inspect the
right hand accelerator bearing supports. Replace
any of the bolts or braces that are damaged or
bent.
Kernel processor
A
During the season, crop residue can accumulate between the kernel processor and the cutterhead. John Deere recommends cleaning and inspecting this area frequently. Ensure this area is free of debris before sharpening
the knives.
The kernel processor on a John Deere Forage Harvester has earned a reputation for high capacity processing even in the toughest crops. It is
designed to provide a long period of dependable performance but there are special maintenance steps that you can take now to ensure reliable
performance for the upcoming season.
Cab maintenance
A clean cab can show your commitment to quality and your operations professionalism. It can also
preserve resale value so important
to todays top forage contractors.
Thats why it pays to clean your cab
completely before storing your
machine for the winter. Clean the
seats, wipe the console and corner
displays and for the nishing touch,
use John Deere window cleaner for
windows and mirrors. Your operators
and your customers will appreciate your attention to detail.
Unloading spout
After 300, 400 or even 500 hours of harvesting this past season, imagine
the tons of crop that have passed through the unloading spout. Good
reasons to give this area a careful winter clean and inspection. For better
inspection of rotation mechanism and transition chute remove the spout and
check for excessive play. Lubricate as indicated by the Operators Manual.
Check the wear plates and replace with John Deere parts as necessary.
Also, dont forget to clean and inspect the spout.
Inspect the cab air lter and housing. Use compressed air to clean the lter, as well as inside the
housing.
TORQ-GARD 15W40
209 l
20 l
5l
Container 1000 l
VC83070-200
VC83070-020
VC83070-005
VC83070-1000
209 l
20 l
5l
container 1000 l
Powerful, efcient John Deere engines and high capacity hydraulic system deliver the dependable power that helps you meet tight harvesting
schedules. Youll maintain that fast pace right from the start of next season when you make cleaning and inspection a top priority this winter.
And remember, when it comes to keeping your engine and powertrain components running in top shape, you cant do better than Genuine
John Deere parts.
VC81824-200
VC81824-020
VC81824-005
VC81824-1000
EXTREME-GARD 80W90
209 l
20 l
5l
Container 1000 l
VC82610X020
VC82610X005
VC82610X001
20 l
5l
1l
Grease
GREASE-GARD PREMIUM/PREMIUM PLUS
Cooling package
Grease-Gard Premium
Grease-Gard Premium
Grease-Gard Premium
Grease-Gard Premium Plus
Grease-Gard Premium Plus
Grease-Gard Premium Plus
VC65723-004
VC65723-005
VC65723-020
VC67009X004
VC67009X005
VC67009X020
400 g
5 kg
20 kg
400 g
5 kg
20 kg
Coolant
COOL-GARD
Blow out the cooling package the correct way by rst directing air
from the fan side, then from the rear of the machine. Also, remember to
clean the cooling package daily during the season. This ensures adequate engine cooling performance, thus improving engine efciency and
prolonging engine life.
Remove the engine air lter and clean thoroughly with compressed air.
Follow these steps: 1. Direct the air from inside out until as much dust
and dirt as possible has been removed. 2. Then, direct the air around
the outside of the lter until no more dust can be removed. 3. Repeat
this sequence until there is no visible dust being removed. If the air lter
maintenance interval requires, replace it with a John Deere lter.
EPH76215-200
EPH76215-020
EPH76215-005
200 l
20 l
5l
Cool-Gard will protect your engine and keep you mobile even in
cold winter weather. Designed specically for John Deere engine
cooling systems, this high performance anti-freeze minimises
deposits, prevents foaming and offers protection over a wide
temperature range. In addition, a wetting agent improves the
contact between Cool-Gard and the surfaces it touches providing highly efcient, full-time protection.
At John Deere, we do everything with your business in mind. The hybrid technology of our batteries ensures longer service life, extended storage life and a battery that is maintenance free. The robust intercell connectors and plate mountings ensure optimum resistance to vibration.
And of course they have been designed to deliver increased capacity and cyclic durability.
Remember to ask your dealer for original John Deere lters and batteries.
And when it comes to handling the wide range of weather conditions and the constant vibrations of off-road work, nothing beats an original
John Deere battery. Their special grid geometry, for example, delivers high starting performance even under the most extreme conditions.
Z62223
AH115836
AH168783
AH115833
Primary Filter
AZ101001
Secondary Filter
AL112936
Replace after the rst 100 hours, then every 250 hours and as required.
PMWF2075
PMWF2126
Batteries
SPFH 6650 6950, 6610 6910, 7200 7500
SPFH 7250 7850, 7700, 7800
SPFH 5420, 5440
10
88 Ah AL112404/405
174 Ah
AL119625
110 Ah
AZ27734
RE504493
R502778
RE532952
PMFS1007
AR86745
RE4205
AR86745
RE500186
RE506428
PMFS1000
RE523372
RE525523
RE507284
RE533910
PMFS1007
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Intake ngers
Inspect the intake ngers to ensure they
are positioned correctly, as shown in this
photo. Replace any worn or damaged
ngers.
LCA86063
Shift Collars
Maize headers
Maize header maintenance
Gathering drums
Grass pick-up
Youll want to thoroughly wash your
pick-up to remove the corrosive
effects of plant residue. Inspect the
auger, looking closely at the ighting
and auger ngers. Replace any ngers that are bent or worn.
Check and grease the outside auger
bearings.
Inspect blades
12
Replace scrapers
High-performance scrapers
Inspect scrapers
and replace any
that are damaged
or missing on the
rotor cleaning
drums. Sharp
scrapers ensure
proper performance of your maize
header. Also, check
to ensure the bolts
are tight.
New bolt-on
design lets you
use each side of
the scraper, reducing maintenance
costs.
LCA87284
Grass pick-ups
Pick-up drives
Pick-up
John Deere recommends disassembling the pick-up and careful
inspection of pick-up ngers - replace
any that are damaged. Be sure to
inspect the spacers on the pick-up
nger shaft. Inspect the chains and
drives and replace as necessary with
genuine John Deere parts.
Deck sheets
New deck sheets t
neatly under the auger
and improve crop ow
into the intake channel
on your forage harvester.
LCA106173 &
LCA106174 (630B)
LCA93949 (640B)
LCA100631 (645B)
13
Step 3
Install shearbar. Install the Teon strip, stationary knife and
Teon pads. When turning or changing the stationary knife,
always replace the Teon strip never reuse worn strips.
When installing bolts, use medium strength thread locker
(John Deere PM37418) and refer to the Operators Manual for
proper torque measurements.
Teon strip (1 Part) = p/n Z49449
Step 4
Install two reference knives. Install a reference knife on the
left and right hand sides of the cutterhead. Knives should be
adjusted to lightly touch the rod. When mounting angled corn
knives, rotate the drum manually and ensure that both ends
of the knife contact the rod.
14
Step 5
Prepare the sharpening stone. Use the sharpening stone for
precise adjustment. To move the stone manually over the
complete cutterhead, loosen the stone drive cable.
Important: Before loosening, be sure to mark the cable to
easily identify the end position (see photo). For 6050 machines (Serial Number 504992 and higher) and 7000 Series
forage harvesters, the side sharpening system is used but
please follow the same procedure specied here.
Step 1
Step 6
Step 2
Step 7
15
Step 8
Step 12
Shearbar
Step 9
Install remaining knives. Install remaining knives and
handtighten the bolts. Align the knives to the shearbar (see
Step 8). Grinding cycles will be reduced when the knives are
properly aligned.
Step 10
Stony Conditions
Sandy (abrasive)
Conditions
Normal Conditions
Maize
Changing Conditions
(whole crop; Alfa Alfa)
How to identify
Many scratches on
shearbar, frequently
displaced between the
crops
No signicant differences
DuraLine
Knife setup;
Drum diameter
standard
standard
Cutterdrum setup
1/2
full
full
Grinding procedure
per day
2 x 15 25 cycles
3 x 10 20 cycles
2 x 10 20 cycles
1 x 10 15 cycles
depends
Shearbar adjustment
3x
5x
3x
2x
3x
Step 11
Tighten all knife bolts according to the torque recommended
in the Operators Manual. Use an air wrench, with the torque
set below the nal torque required. The centre bolt torque can
be reduced by up 30 Nm (22 lb. Ft.). This prevents the knife
from pivoting around the centre bolt and contacting the stationary knife if a stone or other object is ingested.
16
Application:
Grass last cuts, Whole Crop,
Winter forage, Changing
conditions
Feature/Benet:
Short lengths of cut, Universal
solution
Application:
Grass rst cuts, Sugar cane
trash
Feature/Benet:
Long lengths of cut, Reduced
wear part cost
Application:
Grass all cuts
Feature/Benet:
Mixed lengths of cut, Reduced
shearbar wear
Application:
Corn (Maize)
Feature/Benet:
Constant cutting quality, Easy
adjustment
17
Cutting Section
Made to original equipment specications higher quality longer lasting and now more affordable
than you think!
So, take a closer look and learn about the vast differences between
John Deere original-equipment parts and all the others. Discover why
it pays to invest in Genuine John Deereparts. Real differences. Real
Value.
The Genuine John Deere saw-tooth kernel processor roll comes preassembled, so theres no need to manually install individual parts which
can lead to an unbalanced roll and premature wear. Unlike look-alike
rolls, the John Deere saw-tooth roll comes balanced, making installation
more convenient. Runout is true. Whats more, pre-assembled
John Deere rolls are resistant to moisture penetration that can lead to
an unbalanced roll.
Like many John Deere wear parts, the kernel processor roll is induction
hardened, rather than ame hardened like some look-alike parts suppliers. Induction hardening provides much more consistent hardening, for
longer life. The dark tooth proles in this illustration show the precise
zone hardening of the Genuine John Deere roll.
Triangle Milo
Unlike other forage harvester designs, the upper feedroll on the John Deere machine offers
replaceable wear bars. So if you damage a bar, you can replace individual bars rather than
replacing the entire roll. Plus, the wear bars can be reversed doubling the wear life. This can add
up to a signicant saving over the life of your machine. Plus, these bars are specically designed
for high wear conditions that you nd in high yield maize and sandy soils. Choose serrated or
smooth bars to match crop conditions.
Z73857 serrated bar for 72X0 75X0 SPFH
Z77329 serrated bar for 77X0 78X0 SPFH
Z74274 smooth bar for 72X0 75X0 SPFH
Z79099 smooth bar for 77X0 78X0 SPFH
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LOOK-ALIKE
Magnetised
60X0 75X0
AZ102631
107 teeth
77X0 78X0
AZ102632
118 teeth
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Look-alike
Now lets look at maize shearbars. We tested a John Deere maize shearbar against two look-alike shearbars on a customers John Deere forage
harvester. We ran all three bars in identical conditions and heres what we found:
B
C
A
E
D
F
There are higher demands on grass shearbars than on a maize shearbars. Since
grass is picked up from the ground, there is inevitable contamination by stones and
soil which are very abrasive to the cutting edge. Over time the edge-radius becomes
rounded. This larger radius requires more horsepower, increases fuel consumption
and reduces knife wear life. In fact, a large radius can increase fuel consumption
from 2 to 3 litres per hour. John Deere shearbars are designed to maintain a specic
radius, providing a good balance between useful service life, cutting performance
and fuel consumption.
Genuine John Deere Shearbar C: After 800 hectares the cutting edge is in excellent condition. The self-sharpening effect and coating
quality provided up to nearly ten times the life of
the look-alike shearbars.
John Deere offers nine different types of shearbars designed to meet your specic harvesting applications. So whether you need a at, raised, grass,
maize, universal, standard or heavy duty shearbar for your 6000 or 7000 Series, each is manufactured to meet the highest John Deere specications for
outstanding quality, performance and value.
53 hours Grass
The real difference
We welded a John Deere grass shearbar to a look-alike shearbar with a triangular inlay. We then installed the shearbar on a John Deere forage
harvester and ran it in very abrasive grass chopping conditions for a total of 53 hours. The result?
Check out the look-alike shearbar on the left. After only 53 hours, it has a 3 mm round radius. And since theres no self-sharping effect as on a
John Deere shearbar, the radius will continue to become even larger draining horsepower and fuel.
Now look at the John Deere grass shearbar on the right. The radius is only 1.25 mm! And thanks to the self-sharpening effect of the John Deere design
it will stay sharp!
20
New Grass
AZ103105 for 6010
AZ103112 for 6050; 7200 7500
AZ103113 for 7700 7800
Maize
AZ47614 for 6010
AZ53906 for 6050; 7200 7500
AZ64735 for 7700 7800
Do you know new John Deere Grass Shearbars last up to 30% longer?
Now you have even more reasons to choose John Deere shearbars. Three new grass shearbars feature an improved tungsten carbide inlay that provides
from 20 to 30 percent longer life than previous John Deere grass shearbars. You can see how the new larger inlay provides longer wear life and improved
cutting performance especially in tough, highly abrasive cutting conditions.
21
The cutterhead plays a critical role in the forage harvester performance. And thats why its so important to choose John Deere knives knives that t, perform and last. John Deere cutterhead knives meet
these requirements and are manufactured specically for your John Deere forage harvester.
Part Number
Description
Application
Z62076
Z62075
Z63136
Z69500
Z72500
Z81123
Z102741
Z103040
C
A
B
D
Look-alike
A Low particle content
B High porosity
C Irregular hardfacing
D Bonding failures
C
A
Look-alike parts suppliers often sell 12.9 zinc galvanized bolts that are not Dacromet coated. They
argue that harder is better. However, this is not the case.
During the galvanizing process, hydrogen penetrates the bolt and weakens it. The higher the property
class, the higher the effects of the hydrogen brittleness, increasing the likelihood of bolt shearing.
A Genuine John Deere Knife is 3/4 worn, but coating remains intact
B Look-alike Bonding failures cause coating to ake
C Look-alike Premature wear due to low carbide content
Although it might be considered a simple, uncomplicated part, a knife cover plate features special design characteristics that fulll specic functions.
It must hold the knife securely while chopping, while also allowing the controlled retraction of the knife in case of impact with stones or other foreign
objects.
Thats why John Deere plates are made to careful specications rened over years of eld tests. Because of the impact risk, they must provide high
strength to resist breaking. And because the cover plate functions much like a disc spring, all edges must clamp the knife when the attachment bolts are
torqued. This is why precise steel quality is so important.
Sharpening stones
Think all sharpening stones are the same? Think again.
Only the John Deere stone provides the properties that
meet original equipment specications for coarseness and
bonding.
Notice how improper steel rolling during manufacturing results in the grain running in the
wrong direction. This, along with lack of proper
sandblasting, enhances the risk of breakage.
22
23
Speed Changes
The conditions out in the eld may make demands to change the differential speed of the cutter drum, the accelerator and/or the kernel processor. Here
is a brief overview of the parts necessary to carry out the conversion for the 7250 7550 Series.
Chopping grass into consistently short lengths (< 2.5 cm) makes it easy
to compact. Good compaction is vital in the silage process, helping to
reduce the risk of mould, one of the biggest causes of lost silage. And
the short cut makes the silage easy to feed out. So when it comes to
planning your silage operation, count on your John Deere forage harvester to make your work easier and more protable by providing you
with the short, very precise silage material.
The new DuraLine knife and the standard knife together. The DuraLine
knife coating has been elongated by 5 mm.
Ideally, the knife is pulled out when it is half worn (after 10 mm wear on
coating). In this case repeat the set up instructions as described in the
operators manual and adjust with the help of the adjusting rod (A).
Z102741
Z103040
24
Recutter Spiral Floor: These quick change knives are easy to install,
even during the harvesting campaign. And with their tungsten carbide
coating, they have the resilience you need to easily get through the
harvesting season.
Parts List: BZ100221 for all 72X0 75X0 Series SPFH
BZ100222 for all 77X0 78X0 Series SPFH
25
Spout extension
A big help in difcult
harvesting conditions, this
spout extension provides
you with easier and more
precise trailer access.
BZ100002 for all 6000
and 7000 Series SPFH
with 250 mm spout
Xenon Lights
With up to 200% better illumination, these xenon lights will dramatically improve your night time
visibility, making harvesting at
night much less strenuous. Easy
to install, these lights emit less
heat and last up to ve times
longer than base equipment
halogen lights.
Ask your JD dealer for more information.
26
The new Labyrinth Sealing system features a special roll geometry (A), along with a rugged 3-lip
seal (B) installed in front of the heavy duty double-row bearing (C). This new design signicantly
improves sealing, preventing crop moisture from entering the bearing chamber. In addition, the double
ball bearing design provides more stability. Result? Less maintenance, lower costs.
Upgrade Kits:
BZ100186 for 7200 7500 SPFH
BZ100187 for 7700 7800 SPFH
When installing a new kernel processor, please also order the following drive parts (bundle
depends on blower speed)
BZ13528 at blower speed 1800 rpm for all 72X0 75X0 Series SPFH
BZ13529 at blower speed 2000 rpm for all 72X0 75X0 Series SPFH
BZ13659 at blower speed 1600 rpm for all 77X0 78X0 Series SPFH
27
ServiceAdvisor
All John Deere dealers are connected to a central, worldwide parts database. If the part you need is not in stock, your dealer can quickly query
other dealers using the JDPOINT online order system and have the part
delivered to your operation the very next day.
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The F.L.A.S.H. (Fast Locating And Special Handling) system lets dealers
access parts inventories in both Europe and North America.
If you manage a eet, JDLink helps you track all your SPFHs and
tractors. Review remotely the current rate of operation or ask your
dealer to review SPFH data while in operation all from the convenience of your ofce. JDLink can also provide you or your dealer visibility to live performance data, detailed service records and precise
vehicle location.
JDLink lets you minimise downtime and easily lets you manage your
eet more effectively.
You can order this upgrade kit via the John Deere AMS price list.
John Deere dealers work your hours. Most are open on weekends so
you can get the part or service you need as soon as possible. And
during the harvest season, dealers provide extended service hours. Its
all part of our long-term commitment to help keep your business
running strong.
29
Black Bodywarmer: Quilted comfortable bodywarmer with own reective security bands with
one zip pocket inside. Microbre outer. Polyester
lined.
Item No.: MCJ099199110 to 13.
Available in sizes M to XXL.
Reversible Safety Jacket: A sensible precaution for any pedestrian close to trafc or working
machines. Highly visible yellow jacket with
reective stripes on one side and black eece
jacket on the reverse side.
Item No: MCJ099806000 to 809000.
Available in sizes M to XXL.
500 ml
Penetrating Oil
MC430
Glass Cleaner
500 ml
MC449
MC406
500 ml
500 ml
500 ml
Multi-Purpose Lubricant
MC491
500 ml
500 ml
Green Spray JD
MCF809
Yellow Spray JD
400 ml
MCF808
700 ml
3l
VFLK0393
VFLK03093
Green Paint JD
VFLK0392
VFLK03092
30
400 ml
Yellow Paint JD
700 ml
3l
31
.JOHNDEERE COM
www.JohnDeere.co.uk
www.JDParts.JohnDeere.com
YY0944232E
11/08
John Deeres green and yellow colour scheme, the leaping deer symbol and JOHN DEERE are
trademarks of Deere & Company.
1/1/2
This literature has been compiled for worldwide circulation. While general information, pictures
and descriptions are provided, some illustrations and text may include finance, credit, insurance,
product options and accessories NOT AVAILABLE in all regions.
PLEASE CONTACT YOUR LOCAL DEALER FOR DETAILS. John Deere reserves the right to change
specification and design of products described in this literature without notice.