JD TM1500 Preview

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
Find manuals at https://best-manuals.com
TM1500 - 7600, 7700 and 7800 Tractors
Grp Description Page

Foreword 1
Dealer Predelivery Service 2
Quick Reference Specifications 3
05 Safety
05 Safety
Handle Fluids Safely-Avoid Fires 4
Prevent Battery Explosions 5
Prepare for Emergencies 6
Prevent Acid Burns 7
Handle Chemical Products Safely 8
Avoid High-Pressure Fluids 9
Park Machine Safely 10
Support Machine Properly 11
Wear Protective Clothing 12
Work in Clean Area 13
Service Machines Safely 14
Work in Ventilated Area 15
Illuminate Work Area Safely 16
Replace Safety Signs 17
Use Proper Lifting Equipment 18
Service Tires Safely 19
Avoid Harmful Asbestos Dust 20
Avoid Heating Near Pressurized Fluid Lines 21
Remove Paint Before Welding or Heating 22
Use Proper Tools 23
Dispose of Waste Properly 24
Live With Safety 25
10 General Information
05 General Information
General Specifications 26
Sealants and Adhesives Cross-Reference Chart 29
Glossary of Terms 30
Metric Bolt and Cap Screw Torque Values 32
Unified Inch Bolt and Cap Screw Torque Values 34
20 Engine
00 Component Removal and Installation
Special or Essential Tools 36
Service Equipment and Tools 37
Specifications 38
Repair Engine-Use CTM 39
Remove Engine 40
Install Engine in Repair Stand 45
Install Engine 46
05 Engine Repair
Access to Intake and Exhaust Valves 48
Access to Front Crankshaft Seal 49
Access to Rear Crankshaft Seal-PST or PQT W/Creeper 50
Access to Rear Crankshaft Seal-PQT W/O Creeper 51
Access to Camshaft 52
Access to Timing Gear Cover 53
Remove and Install Engine Valve Cover 54
Remove and Install Front Cooling Assembly 55
30 Fuel, Air Intake, and Cooling Systems
05 Throttle Controls
Specifications 57
Adjust Hand-Foot Throttle With Mechanical Linkage 59
10 Diesel Fuel System

Specifications 61
Fuel Tank System-Exploded View 62
Remove and Install Fuel Tank 63
15 Air Intake System
Inspect and Service the Air Intake 64
20 Engine Cooling System
Specifications 66
Test Radiator and Cap 67
Remove and Install Radiator 68
Remove and Install Viscous Fan Drive 69
Inspect Belt Tensioner 70
Replace Belt Tension Mechanism 71
Fan Belt Routing- 7600 72
Fan Belt Routing- 7700 and 7800 73
25 Air Conditioning Condenser and Coolers
Remove Fuel-Hydraulic Oil Cooler/Condenser 75
Leak Test Fuel-Hydraulic Oil Cooler/Condenser 77
Install Fuel-Hydraulic Oil Cooler/Condenser 78
40 Electrical
05 Connectors
Other Material 80
Using High-Pressure Washers 81
Replace Connector 82
Install Contact 83
Remove Connector Body from Blade Terminals 85
Replace (Pull Type) Connectors 86
Replace (Push Type) Connectors 87
Replace , Large and Pin Type Connectors 88
Replace Blade Type Connectors 89
Replace Small Socket Connector 90
Replace Small Pin Connector 91
Replace Connectors 92
Install Contact 94
Use Electrical Insulating Compound 96
10 Wiring Harness Routings
Ground Point Locations 97
Cab Harness Routing- Power Shift Transmission 99
Cab Harness Routing- Transmission 101
Cab Harness Routing- Power Shift and Transmission 103
Open Station Harness Routing and Component Identification 104
Harness Routing and Component Identification- Power Shift Transmission 106
Harness Routing and Component Identification-Transmission 107
PowrQuad
PowrQuad is a trademark of Deere & Company.
Engine Harness Routing and Component Identification- 6068 Engine (7600 Tractor) 108
15 Charging Circuit
Repair Alternator-Use CTM 111
Remove and Install Alternator 112
20 Starting Circuit
Specifications 114
Repair Starter-Use CTM 115
Remove and Install Starter Motor 116
Replace Starter Circuit Relay 117
Replace Fusible Link 118
Replace Neutral Start Switch-Transmission 119
Replace Neutral Start Switch- Power Shift Transmission 120
Replace Gear Encoder 121

Replace Switch Module 122
25 Switches, Relays, and Solenoids
Specifications 123
Replace Air Conditioning Relays and Switches 124
Replace Air Conditioning High and Low Pressure Switches 125
Replace MFWD Solenoid 126
Replace Hitch Return and Hitch Pressure Solenoids 127
Replace Differential Lock and Rear PTO Solenoids 128
Hitch-Position Feed-Back Sensor Location 129
Replace Hitch Position Potentiometer Assembly 130
Replace Hitch Control Potentiometer and Switch 132
Replace Fuel Shut-Off Solenoid 133
Replace Electric Fuel Pump- 7700 134
Remove Electrical Switches and Sensors-Transmission 135
Electrical Controls and Switches- Power Shift Transmission 136
Replace Sensors Front Valve Housing- Power Shift Transmission 137
Replace Brake Switch 138
Replace Ether Starting Aid Solenoid and Switch- 7700 and 7800 139
Replace PST Start-in-Gear Relays 140
Replace Load Center Fuses and Relays 141
Load Center Fuses, Relays, and Diodes- Cab (North American) 142
Load Center Fuses, Relays, and Diodes- Open Station (North American) 144
Load Center Fuses, Relays, and Diodes- (European) 145
30 Monitoring System
Other Material 148
Specifications 149
Replace Rear PTO Speed Sensor 150
Replace Hydraulic Oil Restriction Sensor 151
Replace Engine Oil Pressure Sensor 152
Replace Air Filter Restriction Indicator Sensor 153
Replace Engine Speed Sensor 154
Replace Engine Coolant Temperature Sensor 155
Replace Fuel Level Sensor 156
Replace Wheel Speed Sensor 157
Replace Radar Speed Sensor 158
Remove and Install Draft Link Sensor 159
Adjust Draft Link Sensor 160
Replace Power Shift Control Unit (PCU) 162
Replace Hitch Control Unit (HCU) And Central Control Unit (CCU) 163
Replace Transient Voltage Protector (TVP) 164
Remove and Install Display Module 165
Replace Display Module Bulbs 166
Replace Light Switch, Hazard Light Switch, and Audible Warning Alarm 167
Replace Multifunction or Washer Wiper Switch 168
Replace Multifunction Switch Wiring Harness 169
40 Auxiliary Lighting and Electrical Components
Replace Seven-Terminal Outlet Socket- North American Version 170
Replace Seven-Terminal Outlet Socket- European Version 171
45 Convenience and Accessory Components
Replace Pressurized Blower Motor 172
Replace Circulation Blower Motors 173
Replace Wiper Motor 174
Replace Thermo Starting Aid and Relay- 7600 175
Test Ground-Fault Interrupter- North American 176
Replace Transmission Cover Heater 177
Replace Hydraulic Charge Pump Heater 178
Row Guidance Component Identification 179
Replace Row Guidance Coupler Position Sensor 180
Remove and Install Row Guidance Probe Angle Position Sensor and Probe Rise/Lower 181
Remove Row Guidance Probe Motor 182
Wire Number and Color Codes 183

50 Power Shift Transmission
Other Material 186
Specifications 187
Sealing Instructions- Drive Train 188
Remove Drive Train 189
Install Drive Train 196
Remove Power Shift Transmission 197
Install Power Shift Transmission 198
Remove Reduction Gear Box 199
Install Reduction Gear Box 200
05 PST Controls
Shift Console Access 202
Transmission Shift Control and Park Linkage 203
Park Linkage Adjustments 204
Remove Shift Control Assembly 213
Disassemble and Assemble Shift Control Assembly 214
Replace Encoder 216
Replace Switch Module 217
Replace Power Shift Control Unit- (PCU) 218
Replace Relays 219
Recondition Park Lock Linkage 220
Recondition Tow Disconnect 221
Electrical Controls and Sensors 222
Wheel Speed Sensor 224
Remove and Install Thermal By-Pass Valve 225
10 PST Transmission
Other Material 229
Specifications 230
General Repair Procedures- Power Shift Transmission 232
Transmission Components 234
Prepare Transmission for Repair 235
Remove Transmission Front Cover/Front Valve Housing 236
Remove Front Valve Housing 237
Front Valve Housing Valves 238
Transmission Front Cover Valves 239
Replace Traction Clutch Valve Shifter Lever Shaft Seal 242
Transmission Pump-Cross-Sectional View 244
Repair Transmission Pump 245
Install Front Valve Housing 248
Install Transmission Front Cover/Valve Housing Assembly 249
Repair or Replace Electro-Hydraulic Valves 250
Remove Clutch Pack Assembly 251
Clutch Pack Assembly-Cross-Sectional View 252
Disassemble Clutch Pack Assembly 253
Assemble Clutch Pack Assembly 254
Install Clutch Pack Assembly 255
Remove and Disassemble C LO-B HI Pack 257
Assemble and Install C LO-B HI Pack 260
Remove and Disassemble Input Planetary Carrier Assembly 261
Assemble and Install Input Planetary Carrier Assembly 262
Disassemble Output Housing Module and Remove Output Planetary Carrier 264
Output Planetary Carrier Assembly-Cross-Sectional View 267
Planetary Carrier Assembly-Exploded View 269
Disassemble Output Planetary Carrier Assembly 270
Assemble Output Planetary Carrier Assembly 272
Remove and Disassemble B5 Pack 277
Assemble and Install B5 Pack 279

Install Output Planetary Carrier and Assemble Output Housing Module 280
15 PST Reduction Gear Box
Specifications 287
General Repair Procedures- Reduction Gear Box 288
Remove Differential Drive Shaft 290
Differential Drive Shaft-Cross-Sectional View 291
Determine Cone Point Shim Pack and Install Differential Drive Shaft 292
Reduction Gear Shaft-Cross-Sectional View 295
Remove and Install Reduction Gear Shaft 296
Repair Lube Manifold- Early Version 299
Repair Lube Manifold- Later Version 300
Remove and Install Tow Disconnect 301
Replace Transmission Lock Return Spring 303
Remove and Install Transmission Lock 304
55 Transmission
Other Material 310
Specifications 311
Sealing Instructions- Drive Train 312
Remove Drive Train 313
Install Drive Train 321
Remove Transmission 322
Install Transmission 323
Remove Creeper Transmission 324
Install Creeper Transmission 326
Remove Range Box 327
Install Range Box 329
05 PQT Controls
Shift Console Access 331
Shift and Park Linkage Assembly 332
PowrQuad
Shift and Park Linkage Symptom/Cause Chart 333
PowrQuad
Shift and Park Linkage Adjustment 334
PowrQuad
Shifter Cam Neutral Alignment 335
F-N-R Lower Linkage Inspection and Adjustment 340
F-N-R Upper Linkage Inspection and Adjustment 342
1-2-3-4 Speed Lower Linkage Inspection and Adjustment 344
1-2-3-4 Speed Upper Linkage Inspection and Adjustment 348
Park Rod Linkage Inspection and Adjustment 352
Range Shift Linkage Inspection and Adjustment 362
Shift and Park Linkage Final Checks and Adjustments 365
Remove Shift Control Assembly 369
Disassemble Shift Control Assembly 370
Repair Lower Shift Linkage 371
Repair Lower Park Lock Outer Linkage 372
Repair Lower Park Lock Inner Linkage 373
Creeper Control Lever 374
10 Transmission
Other Material 378
Specifications 379

General Repair Procedures- Transmission 382
Transmission Serial Number Information 384

Major Transmission Components 385
Install Transmission in Repair Stand 386
Remove Transmission Front Cover/Front Valve Housing 387
Remove Front Valve Housing 388
Front Valve Housing Valves 389
Transmission Front Cover Valves 391
Traction Clutch Valve 392
Replace Traction Clutch Valve Shifter Lever/Shaft Seal 393
Replace Traction Clutch Valve Inner Arm/Shaft 394
Transmission Pump-Cross-Sectional View 395
Repair Transmission Pump 396
Install Front Valve Housing 399
Install Transmission Front Cover/Front Valve Housing 400
Remove Shift Control Valve Housing 401
Replace Forward-Reverse/Speed Selector Shifter Levers/Shaft Seals 402
Replace Forward-Reverse/Speed Selector Shifter Shafts/Shifter Arms 403
Shift Control Valve Housing Valves Serial Number (-10891) 404
Shift Control Valve Housing Valves Serial Number (10892-) 405
Modulator Valve-Cross-Sectional View 406
Planetary Housing Valves 407
Forward/Reverse Control Valve-Cross-Sectional View Serial Number (-10891) 408
Forward/Reverse Control Valve-Cross-Sectional View Serial Number (10892-) 409
Speed Selector Valve-Cross-Sectional View Serial Number (-10891) 411
Speed Selector Valve-Cross-Sectional View Serial Number (10892-) 412
Assemble and Install Shift Valve Housing- Serial Number (-10891) 414
Assemble and Install Shift Valve Housing- Serial Number (10892-) 416
Disassemble Planetary/Reverse Brake Housing Assembly 417
Recondition Input Planetary Carrier 418
Input Planetary Assembly-Cross-Sectional View 419
Disassemble Reverse Brake Housing Components 420
Reverser Carrier/Traction Clutch Assembly-Cross-Sectional View 422
Recondition Reverser Carrier/Traction Clutch Assembly 423
Disassemble Planetary Housing Components 425
Direct Drive Clutch Assembly-Cross-Sectional View 428
Recondition Direct Drive Clutch Assembly 429
Assemble Planetary Housing Components 430
Assemble Reverse Brake Housing Components 433
Assemble Planetary/Reverse Brake Housing Assembly 435
15 Creeper Transmission
Other Material 439
Specifications 440
General Repair Procedures- Creeper Transmission 441
Recondition Creeper Transmission 443
Shifter Components-Cross-Sectional View 444
Remove and Install Shifter Components 445
Creeper Transmission-Cross-Sectional View 446
Remove Input/Output Drive Shaft Assembly 447
Disassemble and Assemble Drive Shaft/Snubber Brake 448
Remove and Install Countershaft 451
Install Input/Output Shaft Assembly 453
20 Range Box
Other Material 457
Specifications 458
30K and 40K Range Box 459
General Repair Procedures- Range Box 460
Remove and Disassemble Shifter Cover 462
Remove and Install Park Pawl 464

Reverse Interlock Shifter Shaft Components 465
Remove and Install Shifter Rails and Forks 466
Shifter Rails Interlock Components-Cross-Sectional View 467
Install Shifter Forks and Rails 468
Adjust Shifter Rails 469
Assemble and Install Shifter Cover 470
Remove Differential Drive Shaft 471
Differential Drive Shaft-Cross-Sectional View 472
Determine Cone Point Shim Pack and Install Differential Drive Shaft 474
Remove and Disassemble Input Shaft 476
Input Shaft-Cross-Sectional View 478
Assemble and Install Input Shaft 479
Adjust Input Shaft End Play 480
56 Drive Systems
Other Material 484
Specifications 485
Sealing Instructions 486
MFWD Axle Repair-Use CTM 487
Remove MFWD Clutch 488
Install MFWD Clutch 489
Remove MFWD Axle 490
Install MFWD Axle 491
Remove Rear PTO Assembly 492
Install Rear PTO Assembly 493
Remove Front PTO Assembly 494
Install Front PTO Assembly 495
Remove Final Drive 496
Install Final Drive 499
05 Controls
Specifications 500
MFWD Switch 501
MFWD Solenoid 502
Differential Lock Switch 503
Differential Lock Solenoid 504
Repair Lower Park Lock Inner Linkage 505
PTO Switches 506
PTO Shift Lever 507
PTO Clutch Solenoid 508
PTO Speed Sensor 509
10 MFWD Clutch
Specifications 512
General Repair Procedures- MFWD Clutch 513
Disassemble MFWD Clutch 515
MFWD Clutch-Cross-Sectional View With Secondary Brake 516
MFWD Clutch-Cross-Sectional View Less Secondary Brake 517
Disassemble MFWD Clutch Pack 520
Assemble MFWD Clutch Pack 522
Assemble MFWD Clutch 524
15 MFWD Axle
MFWD Axle Repair-Use CTM44 527
20 Rear Diff-7600(-07567), 7700(-09103), 7800(-14055)
Specifications 530
General Repair Procedures- Rear Differential 531
Remove Differential 533
Differential-Cross-Sectional View 534
Disassemble Differential 535

Assemble Differential 538
Adjust Differential Preload 542
Adjust Differential Backlash 543
21 Rear Diff-7600(07568-), 7700(09104-), 7800(14056-)
Specifications 545
General Repair Procedures- Rear Differential 546
Remove Differential 548
Differential-Component Identification 549
Differential-Cross-Sectional View 550
Disassemble Differential 551
Assemble Differential 554
Adjust Differential Preload 558
Adjust Differential Backlash 559
25 Final Drive
Other Material 562
Specifications 563
General Repair Procedures- Final Drive 564
Remove Planet Pinion Carrier 566
Planet Pinion Carrier-Cross-Sectional View 568
Disassemble Planet Pinion Carrier 569
Planet Pinion Carrier-Exploded View 571
Assemble Planet Pinion Carrier 572
Rear Axle Housing and Shaft-Cross-Sectional View 573
Remove Axle Housing 574
Disassemble and Assemble Axle Housing 575
Disassemble and Assemble Axle Shaft 576
Install Axle Housing 578
Install Planet Pinion Carrier and Check Rolling Drag Torque 579
30 PTO
Specifications 584
General Repair Procedures- PTO 585
Clutch 587
Repair PTO 588
PTO Clutch-Cross-Sectional View 589
Remove and Disassemble PTO Clutch 590
Assemble and Install PTO Clutch 592
Remove and Disassemble Countershaft 595
PTO Countershaft-Cross-Sectional View 596
Assemble and Install 597
Two-Speed PTO Output Shaft-Cross-Sectional View 599
Shiftable PTO Output Shaft-Cross-Sectional View 600
Remove and Disassemble Output Shaft 601
Assemble and Install PTO Output Shaft 604
Shiftable PTO Shifter-Exploded View 607
Remove PTO Shifter 608
Install PTO Shifter 610
Replace PTO Brake 612
Replace PTO Output Shaft Oil Seal 613
Remove Valve Housing 614
Disassemble and Assemble Valve Housing 615
Install Valve Housing 616
35 Drive Lines
Specifications 617
MFWD Drive Shaft 618
Engine Coupler Shaft 619
40 Hydraulic Pump Drive

Specifications 622
General Repair Procedures- Pump Drive 623
Hydraulic Pump Drive-Cross-Sectional View 624
Remove and Disassemble Pump Drive Pinion Gear 625
Remove and Disassemble Pump Drive Gear 627
Assemble and Install Pump Drive Gear 629
Assemble and Install Pump Drive Pinion 631
45 Front PTO
Other Material 635
Specifications 636
General Repair Procedures- PTO 637
Clutch 639
Remove PTO Clutch and Pump 640
Disassemble Pump 642
Disassemble PTO Clutch 644
Replace PTO Brake 646
Remove PTO Output Gear 647
Replace Idler Gear (Three Gear Clockwise Rotation PTO Only) 649
Remove Modulating Valve 650
Disassemble and Assemble Valve Housing 651
Install Modulating Valve 652
Install PTO Output Gear 653
Assemble PTO Clutch 654
Assemble Pump 655
Install PTO Clutch and Pump 656
Front PTO Driveline-Cross-Sectional View 658
Repair Front PTO Driveline 659
Repair Pressure and Lube Regulating Valves 660
60 Steering and Brakes
05 Hydrostatic Steering
Specifications 664
Remove and Install Steering Valve 665
Steering Valve-Exploded View 666
Disassemble, Inspect, and Assemble Steering Valve 667
Remove and Install Auxiliary Steering Pump 672
Disassemble, Inspect, and Assemble Auxiliary Steering Pump 673
10 Steering Cylinders
Specifications 675
Other Material 676
Service Parts Kits 677
Remove and Install Steering Cylinder 678
Cross-Sectional and Exploded View- Steering Cylinder Two-Wheel Drive 679
Cross-Sectional and Exploded View- Steering Cylinder MFWD 680
15 Brake Valve
Specifications 682
General Repair Procedures- Brake Valve 683
Remove and Install Brake Valve 684
Disassemble, Inspect, and Assemble Brake Valve 685
Bleed Brakes 691
Check Manual Brakes 692
20 Brake Components
Specifications 693
Remove, Inspect, and Install Brake Pistons, Plates, and Disks 694
Inspect and Adjust Secondary Brake 696
25 Trailer Brakes
Specifications 697
Remove and Install Hydraulic Trailer Brake Valve 698
Repair Hydraulic Trailer Brakes 699
Repair Air Trailer Brakes 700
70 Hydraulics
Essential or Recommended Tools 701
Specifications 702
Remove and Install Inlet-Priority Valve Assembly 703
Remove and Install Main Hydraulic Pump 705
Remove and Install Charge Pump 706
05 Controls
Remove, Install, and Adjust SCV Linkage 707
10 Hydraulic Pump and Charge Pump
Other Material 710
Specifications 712
General Repair Procedures- Hydraulic Pumps 713
Remove and Install Hydraulic Pump Controller 714
Hydraulic Pump Controller-Exploded View 716
Disassemble, Inspect, and Assemble Pump Controller 717
Hydraulic Pump-Exploded View 718
Disassemble, Inspect, and Assemble Hydraulic Pump 719
Adjust Yoke Bearing Preload 722
Adjust Shaft Bearing Preload 723
Inspect Hydraulic Charge Pump 725
15 Hydraulic System Valves
Specifications 728
General Repair Procedures- Hitch and Inlet-Priority Valves, and Filter Bypass 730
Remove, Inspect, and Install Hydraulic Filter Bypass 731
Disassemble, Inspect, and Assemble Inlet-Priority Valve 732
Remove and Install Hitch Valve 736
Disassemble, Inspect, and Assemble Hitch Valve 737
Adjust Hitch Valve 741
20 Selective Control Valves and Couplers
Other Material 743
Specifications 745
General Repair Procedures- Selective Control Valves and Couplers 746
SCV Identification 747
Remove, Inspect, and Install Selective Control Valves 748
Selective Control Valve-Exploded View- Three-Position 751
Selective Control Valve-Exploded View- Two-Position 752
Replace Control Knobs 753
Inspect Poppet Load-Check Valves 754
Inspect Pressure Compensator Valve- Three-Position SCV 755
Inspect Metering Valve- Three-Position SCV 756
Inspect Metering Valve- Two-Position SCV 757
Disassemble, Inspect, and Assemble Control Valve- Three-Position SCV 758
Disassemble, Inspect, and Assemble Control Valve- Two-Position SCV 764
Disassemble, Inspect, and Assemble Couplers 769
25 Hitch
Specifications 774
Remove and Install Lift Cylinders 775
Cross-Sectional and Exploded View- Lift Cylinder 776
Replace Rockshaft Housing Bushings 777
30 Row Guidance
Specifications 780
Remove and Install Probe Module 781
Repair Row Guidance Cylinder 783
Exploded View- Row Guidance Cylinder 784
35 Remote Cylinder
Specifications 786
Disassemble and Inspect Remote Cylinder 787
Assemble and Bleed Remote Cylinder 789
40 Bleed Hydraulic System
Bleed Hydraulic System 790
80 Miscellaneous
Specifications 794
Remove Front Axle 795
Install Front Axle 796
05 Front Axle
Other Material 797
Specifications 798
Replace Knee Bushings 799
10 Hood
Remove, Install, and Adjust Hood 801
15 Trailer and Pick-Up Hitch
Repair Trailer Hitch 802
Adjust Trailer Hitch Release 803
Repair Pick-Up Hitch 804
Adjust Pick-Up Hitch 805
90 Operator Station
Specifications 806
Remove Cab 807
Install Cab 811
05 Controls
Remove and Install Heater and Air Flow Control Cables 812
Adjust Heater and Air Flow Control Cables 813
10 Air Conditioning System
Other Material 817
Specifications 819
Hose and Tubing O-Ring Connection Torques 820
Discharge Air Conditioning System 821
Remove and Install Compressor 823
Test Volumetric Efficiency 825
Test Shaft Seal Leakage 827
Disassemble and Assemble Compressor Clutch 828
Disassemble, Inspect, and Assemble Compressor 830
Check Clutch Hub Clearance 833
Inspect Compressor Manifold 834
Remove and Install Compressor Relief Valve 835
Replace Receiver-Dryer 836
Remove Evaporator/Heater Core 837
Leak Test Evaporator/Heater Core 839
Install Evaporator/Heater Core 840
Service Expansion Valve 841
Expansion Valve Bench Test-Diagram 842
Expansion Valve Bench Test 843
Replace Thermo Switch 844
Remove, Clean, and Install Air Filters 845
Refrigerant Oil Information 846
Check Compressor Oil Charge 847
Determine Correct Refrigerant Oil Charge 848
Add Refrigerant Oil to System 850
System Information 851
Air Conditioning System-Diagram 852
Air Conditioning System Fitting-Reference Chart 853
Flush Air Conditioning System 854
Purge Air Conditioning System 856
Evacuate Air Conditioning System 857
Charge Air Conditioning System 859
15 Heating System
Remove Heater Control Valve 860
Leak Test Heater Control Valve 862
Install Heater Control Valve 863
20 Seat
Other Material 864
Remove Seat and Mechanical Suspension 865
Disassemble, Inspect, and Assemble Mechanical Suspension Assembly 866
Install Mechanical Suspension Assembly 868
Remove Seat and Air Suspension 869
Remove Seat From Suspension 870
Remove Swivel Plate 871
Disassemble, Inspect, and Assemble Air Suspension Assembly 872
Install Seat and Air Suspension 874
25 ROPS and Cab
Repair Cab Door Latch 875
Cab Door Adjustment- Step 1 876
Check ROPS 881
99 Dealer Fabricated Tools
05 Fabricated Tools
Fabricated Tools 882
DFRW20-Compressor Holding Fixture 883
DFRW29-Final Drive Housing Adapter 884
DFRW30-Axle Jacking Tool 885
DFRW60 - DFRW61 - DFRW62-Extension Harnesses 886
DFRW63-DFRW64-DFRW65-DFRW66-DFRW81-Tap-Out Harnesses 887
DFRW70-Holding Tool 889
DFRW77-Rear Tractor Access Platform 890
DFRW78-Seat Support Tray 891
DFRW79-Piston Holding Tool 892
DFRW80-Front PTO Lifting Brackets and Spacers 893
DFRW87-Pick-Up Hitch Adapter Plate 894
DFRW108-Park Rod Adjusting Nut Tool Tool may be purchased. Order JDG952 895
1 1
0001
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.
0001
2 2
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 0.35 mm (0.014 in.)
7700 and 7800
0.38 mm (0.015 in.)
Exhaust:
7600 0.45 mm (0.018 in.)
7700 and 7800
0.51 mm (0.020 in.)
Capacities
Fuel tank 344 L (91 gal)
Cooling system:
7600 24 L (25 qt)
7700 25 L (26.5 qt)
7800 26 L (27.5 qt)
Crankcase with Filter 18 L (19 qt)
Transmission, Differential and Hydraulic system:
Power Shift 91 L (24 gal)
Power Shift with MFWD 102.3 L (27 gal)
PowrQuad ™ 87 L (22.9 gal)
PowrQuad ™ with MFWD 98.3 L (25.9 gal)
PowrQuad ™ with Creeper
PowrQuad ™ with MFWD and Creeper 91 L (24 gal)
102.3 L (27 gal)
Mechanical Front Wheel Drive:
Axle Housing: 8.5 L (9 qt)
Wheel Hub 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 310 N·m (230 lb-ft)
Disk-to-Hub
600 N·m (445 lb-ft)
Rear Wheel Sleeve Retaining Bolts (Final Torque):
Cast Wheels 600 N·m (445 lb-ft)
Steel Wheels
Rear Wheel-to-Rim 500 N·m (370 lb-ft)
Rear Steel Wheel
Cab Mounting Bolts 600 N·m (445 lb-ft)
600 N·m (445 lb-ft)
204 N·m (150 lb-ft)
0003
4 4
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.
0004
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).
0005
6 6
0006
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.
0006
7 7
0007
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. 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.
0007
8 8
0008
tm1500 - 7600, 7700 and 7800 Tractors

Handle Chemical Products Safely
Handle Chemical Products Safely
TS1132-UN: Chemical Safety
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous
chemicals used with John Deere equipment include such items as lubricants, coolants, paints,
and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical
and health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely. Then follow procedures and
recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere
equipment.)
0008
9 9
0009
tm1500 - 7600, 7700 and 7800 Tractors

Avoid High-Pressure Fluids
Avoid High-Pressure Fluids
X9811-UN: High Pressure Fluid
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 from
Deere & Company Medical Department in Moline, Illinois, U.S.A.
0009
10 10
0010
tm1500 - 7600, 7700 and 7800 Tractors

Park Machine Safely
Park Machine Safely
TS230-UN: Park Machine
Before working on the machine:
l Lower all equipment to the ground.

l Stop the engine and remove the key.
l Disconnect the battery ground strap.
l Hang a “DO NOT OPERATE” tag in operator station.
0010
11 11
0011
tm1500 - 7600, 7700 and 7800 Tractors

Support Machine Properly
Support Machine Properly
TS229-UN: Support Machine
Always lower the attachment or implement to the ground before you work on the machine. If you
must work on a lifted machine or attachment, securely support the machine or attachment.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under
continuous load. Do not work under a machine that is supported solely by a jack. Follow
recommended procedures in this manual.
0011
12 12
0012
tm1500 - 7600, 7700 and 7800 Tractors

Wear Protective Clothing
Wear Protective Clothing
TS206-UN: Protective Wear
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or
music headphones while operating machine.
0012
13 13
0013
tm1500 - 7600, 7700 and 7800 Tractors

Work in Clean Area
Work in Clean Area
T6642EJ-UN: Clean Area
Before starting a job:
l Clean work area and machine.

l Make sure you have all necessary tools to do your job.
l Have the right parts on hand.
l Read all instructions thoroughly; do not attempt shortcuts.
0013
14 14
0014
tm1500 - 7600, 7700 and 7800 Tractors

Service Machines Safely
Service Machines Safely
TS228-UN: Service Safety
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when
you work near machine tools or moving parts. If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
0014
15 15
0015
tm1500 - 7600, 7700 and 7800 Tractors

Work in Ventilated Area
Work in Ventilated Area
TS220-UN: Ventilated Area
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an
enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
0015
16 16
0016
tm1500 - 7600, 7700 and 7800 Tractors

Illuminate Work Area Safely
Illuminate Work Area Safely
TS223-UN: Light Safety
Illuminate your work area adequately but safely. Use a portable safety light for working inside or
under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.
0016
17 17
0017
tm1500 - 7600, 7700 and 7800 Tractors

Replace Safety Signs
Replace Safety Signs
TS201-UN: Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct
safety sign placement.
0017
18 18
0018
tm1500 - 7600, 7700 and 7800 Tractors

Use Proper Lifting Equipment
Use Proper Lifting Equipment
TS226-UN: Lifting Safety
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
0018
19 19
0019
tm1500 - 7600, 7700 and 7800 Tractors

Service Tires Safely
Service Tires Safely
TS211-UN: Tire Safety
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform
the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended
pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air
pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand
to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
0019
20 20
0020
tm1500 - 7600, 7700 and 7800 Tractors

Avoid Harmful Asbestos Dust
Avoid Harmful Asbestos Dust
TS220-UN: Dust Safety
Avoid breathing dust that may be generated when handling components containing asbestos
fibers. Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and
lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is
usually found in a resin or sealed in some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material
containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If not available, apply a mist of oil or water on the material
containing asbestos.
Keep bystanders away from the area.
0020
21 21
0021
tm1500 - 7600, 7700 and 7800 Tractors

Avoid Heating Near Pressurized Fluid Lines
Avoid Heating Near Pressurized Fluid Lines
TS953-UN: Fluid Lines Safety
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut
when heat goes beyond the immediate flame area.
0021
22 22
0022
tm1500 - 7600, 7700 and 7800 Tractors

Remove Paint Before Welding or Heating
Remove Paint Before Welding or Heating
TS220-UN: Welding Preparation
Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a
torch.
Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.
Remove paint before welding or heating:
l If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
l If you use solvent or paint stripper, remove stripper with soap and water before welding.
Remove solvent or paint stripper containers and other flammable material from area.
Allow fumes to disperse at least 15 minutes before welding or heating.
0022
23 23
0023
tm1500 - 7600, 7700 and 7800 Tractors

Use Proper Tools
Use Proper Tools
TS779-UN: Proper Tool Use
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT useU.S.
measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
0023
24 24
0024
tm1500 - 7600, 7700 and 7800 Tractors

Dispose of Waste Properly
Dispose of Waste Properly
TS1133-UN: Waste Disposal
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid,
filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may
mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere.
Government regulations may require a certified air conditioning service center to recover and
recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or
recycling center, or from your John Deere dealer.
0024
25 25
0025
tm1500 - 7600, 7700 and 7800 Tractors

Live With Safety
Live With Safety
TS231-19: Safety Symbol
Before returning machine to customer, make sure machine is functioning properly, especially
the safety systems. Install all guards and shields.
0025
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Transmission Serial Number Information 384

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tm1500 - 7600, 7700 and 7800 Tractors

tm1500 - 7600, 7700 and 7800 Tractors

Dealer Predelivery Service

tm1500 - 7600, 7700 and 7800 Tractors

Quick Reference Specifications

-: Quick Reference Specifications

600 N·m (445 lb-ft)

204 N·m (150 lb-ft)

tm1500 - 7600, 7700 and 7800 Tractors

Handle Fluids Safely-Avoid Fires

TS227-UN: Fluid Fire

tm1500 - 7600, 7700 and 7800 Tractors

Prevent Battery Explosions

TS204-UN: Battery Explosion

tm1500 - 7600, 7700 and 7800 Tractors

Prepare for Emergencies

TS291-UN: Emergency Ready

Be prepared if a fire starts.

tm1500 - 7600, 7700 and 7800 Tractors

Prevent Acid Burns

TS203-UN: Acid Safety

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

tm1500 - 7600, 7700 and 7800 Tractors

Handle Chemical Products Safely

TS1132-UN: Chemical Safety

tm1500 - 7600, 7700 and 7800 Tractors

Avoid High-Pressure Fluids

X9811-UN: High Pressure Fluid

tm1500 - 7600, 7700 and 7800 Tractors

Park Machine Safely

TS230-UN: Park Machine

Before working on the machine:

l Lower all equipment to the ground.

tm1500 - 7600, 7700 and 7800 Tractors

Support Machine Properly

TS229-UN: Support Machine

tm1500 - 7600, 7700 and 7800 Tractors

Wear Protective Clothing

TS206-UN: Protective Wear

tm1500 - 7600, 7700 and 7800 Tractors

Work in Clean Area

T6642EJ-UN: Clean Area