John Deere Self-Propelled Forage Harvesters Models 7180, 7280, 7380, 7480, 7580, 7780, 7980 Repair Service Manual (TM404419)
Catalog:
Price: US$ 79.00
Complete Repair Service Manual for John Deere Self-Propelled Forage Harvesters Models 7180, 7280, 7380, 7480, 7580, 7780 & 7980 (Worldwide Edition), with all the technical information to maintain, repair, rebuild like professional mechanics.
John Deere Self-Propelled Forage Harvesters Models 7180, 7280, 7380, 7480, 7580, 7780, 7980 workshop Repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM404419 - John Deere Self-Propelled Forage Harvesters Models 7180, 7280, 7380, 7480, 7580, 7780, 7980 Technical Manual (Repair).PDF
Total Pages: 2,516 pages
File Format: PDF (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
Version Date
Safety
Safety Information
General Information
Fuel, Lubricants, Hydraulic Oil and Coolant
Torque Values
Serial Numbers
Dimensions
Engine
Remove and Install Engine
Fuel, Air Intake and Cooling Systems
Fuel Tank
Air Intake System
Cooling System
Electrical System
Harness and Connector Repair
Electrical System Components
Power Train
Main Drive Belt Replacement
Bevel Gear Drive
Transmission and Differential (3-Speed Transmission)
Transmission and Differential (ProDrive™ Transmission)
Final Drives
Hydrostatic Drive, Variable Pump (3-Speed Transmission)
Hydrostatic Drive, Variable Pump (ProDrive™ Transmission)
Hydrostatic Drive, Fixed-Displacement Motor (3-Speed Transmission)
Hydrostatic Drive, Variable Displacement Motor (ProDrive™)
Rear-Wheel Drive Axle
Rear-Wheel Drive Axle, Variable Displacement Motor
Brakes, Steering and Rear Axle
Brake Operation (3-Speed Transmission)
Brake Operation (ProDrive™ Transmission)
Brakes (3-Speed Transmission)
Brakes (ProDrive™ Transmission)
Hydrostatic Steering
Row Guidance System
Rear Axle
Hydraulic System
Hydraulic Pressure Accumulators
Hydraulic Pumps
Electromagnetic Control Valve
Hydraulic Motor - Discharge Spout
Hydraulic Motor - Rotary Screen
Length-Of-Cut Transmission Motor
Length-Of-Cut Transmission Hydrostatic Pump
Miscellaneous
Central Lubrication System
Operator`s Cab, Air-Conditioning System
Control Levers
Cab Ventilation
Operator`s Cab
R134a Air-Conditioning System
Super Comfort Seat
Special Tools
Special Tools (Dealer Fabricated)
Special Tools (Available as Spare Parts)
Harvesting Units
Harvesting Unit Cross Drive
Harvesting Units
Feeding System
Length-Of-Cut Transmission
Feed Roll Housing
Feed Roll Assembly
Cutterhead Assembly
Knife Sharpening Device
Cutterhead
Bottom and Outlet Bands
Stationary Knife Removal and Installation
Kernel Processor
Discharge Components
Discharge Fan
Blower Rotor and Rotor Bearings
Discharge Spout
tm404419 - 7180,7280,7380,7480,7580, 7780 and 7980 Self-Propelled ForageHarvesters Repair -: (Worldwide Edition)
Table of Contents
Foreword
Version Date
Section 05: Safety
Group 05: Safety Information
Recognize Safety Information
Understand Signal Words
Prevent Machine Runaway
Handle Fluids Safely—Avoid Fires
Handling Batteries Safely
Prepare for Emergencies
Avoid High-Pressure Fluids
Service Cooling System Safely
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Avoid Hot Exhaust
Clean Exhaust Filter Safely
Exhaust Filter Cleaning
Use Steps and Handholds Correctly
Work In Ventilated Area
Wear Protective Clothing
Practice Safe Maintenance
Park Machine Safely
Use Proper Lifting Equipment
Construct Dealer-Made Tools Safely
Support Machine Properly
Work in Clean Area
Illuminate Work Area Safely
Service Machines Safely
Handle Electronic Components and Brackets Safely
Use Proper Tools
Service Tires Safely
Avoid Eye Contact with Radar
Replace Safety Signs
Dispose of Waste Properly
Live With Safety
Service Accumulator Systems Safely
Safety Measures on Electronic Control Units
Servicing Electronic Control Units
Welding Near Electronic Control Units
Keep Electronic Control Unit Connectors Clean
Section 10: General Information
Group 05: Fuel, Lubricants, Hydraulic Oil and Coolant
Diesel Fuel
Handle Fuel Safely—Avoid Fires
Handling and Storing Diesel Fuel
Lubricity of Diesel Fuel
Filling the Fuel Tank
Testing Diesel Fuel
Biodiesel Fuel (7180-7780)
Biodiesel Fuel (7980 Only)
Minimizing the Effect of Cold Weather on Diesel Engines
Cold Weather Operation of Diesel Engines (7980 Only)
John Deere Break-In™ Engine Oil (7180 and 7280-7780 Tier 3 Only)
John Deere Break-In Plus™ Engine Oil (7280-7780 Interim Tier 4/Stage III B)
Diesel Engine Oil and Filter Service Intervals (7180 Only)
Diesel Engine Oil and Filter Service Intervals (7280-7780 Interim Tier 4/Stage III B Only)
Diesel Engine Oil and Filter Service Intervals (7280-7780 Tier 3 Only)
Diesel Engine Oil and Filter Service Intervals (7180-7780 Without EGR Only)
Diesel Engine Oil (7980 Only)
Diesel Engine Oil and Filter Service Intervals (7980 Only)
Mixing of Lubricants
Oilscan™ and CoolScan™
Alternative and Synthetic Lubricants
Lubricant Storage
Oil Filters
Heavy Duty Diesel Engine Coolant
Supplemental Coolant Additives
Drain Intervals for Diesel Engine Coolant
Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER
Testing Diesel Engine Coolant
Operating in Warm Temperature Climates
Cooling System Capacity
Transmission Oil
Hydraulic Oil
Brake Fluid for Brake System (3-Speed Transmission Only)
Grease
Alternative and Synthetic Lubricants
Mixing of Lubricants
Lubricant Storage
Use Genuine John Deere Parts
Group 10: Torque Values
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Hydraulic System Inch Fitting Torque Values
Hydraulic System Metric Fitting Torques Values
Group 15: Serial Numbers
Serial Numbers
Forage Harvester Serial Number Plate (Product Identification) for Europe
Forage Harvester Serial Number Plate (Product Identification) for North America
Product Identification Number (Europe)
Product Identification Number (North America)
Engine Serial Number — Engine Type 6090 (7180 Only)
Engine Serial Number - Engine Type 6135 (7280—7780)
Engine Serial Number — Cummins (7980 Only)
Operator's Cab Serial Number
Four Wheel Drive Motor Serial Number
Kernel Processor Serial Number
3-Speed Transmission Serial Number
ProDrive™ Transmission Serial Number
Final Drive Serial Number
Angled Drive (Main Gearcase) Serial Number
Lengh-of-Cut Transmission Serial Number
Serial Number of Hydrostatic Pump for Lengh-of-Cut Transmission
Hydrostatic Pump Serial Number (3-Speed Transmission)
Hydrostatic Pump Serial Number (ProDrive™ Transmission)
Main Drive Motor Serial Number (3-Speed Transmission)
Main Drive Motor Serial Number (ProDrive™ Transmission)
Serial Number of Hydrostatic Motor for Lengh-of-Cut Transmission
Powered Rear Axle Serial Number
Heavy Duty Rear Axle Serial Number
Spout Serial Number
Group 20: Dimensions
Dimensions
Section 20: Engine
Group 05: Remove and Install Engine
Essential or Recommended Tools
Other Material
Specifications
Exhaust Filter / Diesel Particulate Filter Ash Handling and Disposal (7280-7780 Interim Tier 4-Stage III B)
Emission Control System, Important Instructions (7280-7780 Interim Tier 4/Stage III B)
Prepare Machine for Engine Removal
Exhaust Filter (7280-7780 Interim Tier 4/Stage III B)
Remove and Install Engine (7180)
Remove and Install Engine (7280-7780 Tier 3, Non EGR)
Remove and Install Engine (7280-7780 Interim Tier 4/Stage III B)
Remove and Install Engine (7980)
Section 30: Fuel, Air Intake and Cooling Systems
Group 05: Fuel Tank
Specifications
Fuel System Components (7180-7780)
Fuel System Components (7980)
Remove Fuel Tank
Remove Fuel Sending Unit
Group 10: Air Intake System
Essential or Recommended Tools
Specifications
Air Intake System (7180)
Air Intake System (7280, 7380)
Air Intake System (7480, 7580 and 7780)
Air Intake System (7980)
Prepare Machine for Intercooler Removal
Remove and Install Intercooler (7180)
Removing and Installing Intercooler (7280-7780 Tier 3, Non EGR)
Removing and Installing Intercooler (7280-7780 Interim Tier 4/Stage III B)
Removing and Installing Intercooler (7980)
Group 15: Cooling System
Essential or Recommended Tools
Specifications
Cooling Package Location
Replacing Coolant Level Sending Unit
Prepare Machine for Radiator and Hydraulic Oil Cooler Removal
Remove and Install Radiator and Hydraulic Oil Cooler (7180)
Remove and Install Radiator and Hydraulic Oil Cooler (7280-7780 Tier 3, Non EGR)
Remove and Install Radiator and Hydraulic Oil Cooler (7280-7780 Interim Tier 4/Stage III B)
Remove and Install Radiator and Hydraulic Oil Cooler (7980)
Remove Fuel Cooler
Removing Air Conditioning Condenser
Remove Length-Of-Cut Transmission Cooler (7980 Only)
Check Fan Drive Belt Tensioner Spring Tension and Belt Wear (7180 Only)
Check Fan Drive Belt Tensioner Spring Tension and Belt Wear (7280-7780 Tier 3 Only)
Check Fan Drive Belt Tension and Belt Wear (7980 Only)
Rotary Screen
Remove Suction Blower (7980 Only)
Section 40: Electrical System
Group 05: Harness and Connector Repair
Essential or Recommended Tools
Other Material
Use Electrical Insulating Compound
Using High-Pressure Washers
Connectors
Repair WEATHERPACK WEATHERPACK is a trademark of Packard Electric Connector
Remove Blade Terminals from Connector Body
Repair (Pull Type) METRI-PACK METRI-PACK is a trademark of Delphi Packard Electric Systems Connectors
Repair (Push Type) METRI-PACK Connectors
Repair CPC CPC is a trademark of AMP Inc. , Large MATE-N-LOC MATE-N-LOC is a trademark of AMP Inc. and METRIMATE METRIMATE is a trademark of AMP Inc. Pin Type Connectors
Repair CPC Blade Type Connectors
Repair Small MATE-N-LOC Socket Connector
Repair Small MATE-N-LOC Pin Connector
Repair CINCH Connectors
Repair Relay Panel Connectors
Repair Reel Reversing Valve Connector
Repair HD Series Deutsch Connectors
Repair CINCH Flex Box Connectors
Repair TYCO-AMP Standard Power Timer Connectors
TYCO-AMP Super Seal Connectors
Group 10: Electrical System Components
Essential or Recommended Tools
Specifications
Other Material
Electrical System - Specifications (7180 and 7280-7780 Tier 3)
Electrical System - Specifications (7280-7780 Interim Tier 4/Stage III B)
Electrical System - Specifications (7980)
Batteries
Battery Switch (7180-7780)
Battery Switch (7980)
Dangers When Handling Batteries
Battery Service
Checking Electrolyte Level
Checking Specific Gravity
Charging Batteries
Installing and Connecting Batteries
Servicing Electronic Control Units
Welding Near Electronic Control Units
Keep Electronic Control Unit Connectors Clean
Starting the Engine by Means of a Booster Battery (7180-7780)
Starting the Engine by Means of a Booster Battery (7980)
Alternator G4 (24 V - 7980 Only)
Alternator G5 (12 V - 7180 and 7280-7780 Tier 3 Only)
Alternator G6 (12 V - 7980 Only)
Alternator G7 (12 V - 7280-7780 Interim Tier 4/Stage III B Only)
Starter Motor M1 (12 V - 7180 and 7280-7780 Tier 3)
Starter Motor M1 (12 V - 7280-7780 Interim Tier 4/Stage III B)
Starter Motor M1 (24 V - 7980)
Outlets
Replacing Terminating Resistors
Control Units
Fuse / Relay Tester
Spare Fuses
Fuse and Relay Boards A1, A2 and A3
Extra Fuses and Relays
Real Time Clock Battery (7980)
Engine Oil Pressure Sending Unit B1 / B45 / B112
Cutterhead Alarm, Front B2
Cutterhead Alarm, Back B3
Lift Cylinder Pressure Transducer B5
Hydrostatic Oil Temperature Sending Unit B6
Hydraulic Oil Filter Sensor B7
Hydrostatic Charge Pressure Sending Unit B8
Air Cleaner Sending Unit B9
Cutterhead Speed Sending Unit B10 (Length-Of-Cut Transmission)
Length-Of-Cut Transmission Pressure Control Switch B11
Ground Speed Sending Unit B12 (3-Speed Transmission)
Length-Of-Cut Transmission Hydraulic Pressure Switch B13
Front Wheel Speed Sending Units B14 / B68
Horn B15
Feedroll Speed Sending Unit B16 (Length-Of-Cut Transmission)
ATC Air Conditioning System Low Pressure Switch B17
ATC Air Conditioning System High Pressure Switch B18
Rear-Wheel Drive Pressure Sending Unit B22
Rear-Wheel Drive Speed Sending Unit B23
Metal Detector Sending Unit B24
Knock Sensors B26 and B27
Fuel Tank Sending Unit B28.1
Reverse Travel Alarm B30
Coolant Temperature Sending Unit B31 / B43 / B108
Intake Air Pressure Sending Unit B32 (7180 and 7280-7780 Tier 3)
Fuel Temperature Sending Unit B33 / B109
Intake Air Temperature Sending Unit B34 / B114
Engine Camshaft Sending Unit B35 / B44 / B102
Engine Crankshaft Sending Unit B36 / B40 / B103
Fuel Pressure Sending Unit B37 / B39
High Fuel Pressure Sending Unit B110 (7280-7780 Interim Tier4/Stage III B)
Water-In-Fuel Sending Unit B38 / B46 / B107
Intake Manifold Pressure Sending Unit B41 (7980)
Ambient Air Pressure Sending Unit B42 (7980)
Stationary Knife Motor-Impulse Sending Units B47 and B48
Inlet Temperature Sending Unit B49
Outlet Temperature Sending Unit B50
Cab Temperature Sending Unit B51
Evaporator Core Temperature Sending Unit B52
Kernel Processor Motor-Impulse Sending Unit B53 and B54
Hydrostatic Pump Pressure Reverse Sending Unit B55
Feed Roll Distance Sending Unit B58
Hydrostatic Pump Pressure Forward Sending Unit B59
Hi/Lo Transmission Pressure Sending Unit B61
Hi/Lo Transmission Temperature Sending Unit B62
Front Motor Speed Sending Unit B63
Multi-Function Lever Position Sending unit B64
Park Brake Sending Unit B65
Transmission Speed Sending Unit B66
Rear Wheel Sending Unit B67 (Row Guidance)
Row Guidance Steering Input Sending Unit B69
Automatic Spout Control Sending Units B70, B71 and B72
Exhaust Gas Recirculation (EGR) - Exhaust Temperature Sending Unit B78 (7180 and 7280-7780 Tier 3)
Exhaust Gas Recirculation (EGR) - Fresh Air Temperature Sending Unit B79 (7180 and 7280-7780 Tier 3)
Exhaust Gas Recirculation (EGR) - Mixed Gas Temperature Sending Unit B80 (7180 and 7280-7780 Tier 3)
Variable Geometry Turbocharger (VGT) - Fan Speed Sending Unit B81 (7180 and 7280-7780 Tier 3)
Fuel Rail Pressure Sending Unit B82 (7180)
Low Pressure Pump Sending Unit B83 (7280-7780 Tier 3)
Low Fuel Pressure Sending Unit B126 (7280-7780 Interim Tier 4/Stage III B)
Fuel Pump Accumulator Pressure Sending Unit B86 (7980)
Turbocharger Speed Sending Unit B87 (7980)
Intake Manifold Temperature Sending Unit B88 (7980)
Fuel Temperature Sending Unit B89 (7980)
Condition Monitoring System Sending Units B90-B99
EGR Exhaust Temperature Sending Unit B104 (7280-7780 Interim Tier 4/Stage III B)
EGR Fresh Air Temperature Sending Unit B105 ( 7280-7780 Interim Tier 4/Stage III B)
EGR Mixed Air Temperature Sending Unit B106 (7280-7780 Interim Tier 4/Stage III B)
Exhaust Pressure Sending Unit B111 (7280-7780 Interim Tier 4/Stage III B)
EGR Delta Pressure Sending Unit B113 ( 7280-7780 Interim Tier 4/Stage III B)
Humidity/Pressure/Temperature Sending Unit B114 at Compressor Inlet (7280-7780 Interim Tier 4/Stage III B)
Dual Turbos Temperature Sending Unit B118 (7280-7780 Interim Tier 4/Stage III B)
Aftertreatment Engine Temperature Sending Unit B119 (7280-7780 Interim Tier4-Stage III B)
DPF Differential Pressure Sending Unit B120 (7280-7780 Interim Tier 4/Stage III B)
Fan Speed Sending Unit B121 (7280-7780 Interim Tier 4/Stage III B)
Coolant Level Warning Sending Unit B122 (7280-7780 Interim Tier 4/Stage III B)
Manifold Air Pressure (MAP) Sending Unit B123 (7280-7780 Interim Tier 4/Stage III B)
Downstream HCI Fuel Pressure Sending Unit B124 (7280-7780 Interim Tier 4/Stage III B)
Upstream HCI Fuel Pressure Sending unit B125 (7280-7780 Interim Tier 4/Stage III B)
Coolant Loss Sending Unit B127 (7280-7780 Interim Tier 4/Stage III B)
Coolant Condition Sending Unit B130 (7280-7780 Interim Tier 4/Stage III B)
Alternators
Remove and Install Alternator
ATC Air Conditioning System Recirculating Blower Motor M3
Windshield Wiper Motor M4
Windshield Washer Pump M5
Spout Flap Motor M6
Kernel Processor Lift Motor M8
Variable Geometry Turbocharger (VGT) Actuator M9
Knife Sharpening Motor M10
Stationary Knife Adjusting Motors M11 and M12
Kernel Processor Adjusting Motors M13 and M14
Side Windshield Wiper Motors M15 and M16
Side Window Washer Pump M17
Sharpening Door Motor M18
ATC Air Conditioning System Pressurizer Blower Motor M20
Outside Mirror Motor M21 and M22
Exhaust Gas Recirculation (EGR) Torque Motors M23 and M24 (7180-7780 Tier 3)
Fuel Lift Pump M25 (7980)
Exhaust Gas Recirculation (EGR) Torque Motor M26 (7280-7780 Interim Tier 4/Stage III B)
Intake Air Throttle M27 (7280-7780 Interim Tier 4/Stage III B)
Variable Geometry Turbocharger (VGT) Actuator M28 (7280-7780 Interim Tier 4/Stage III B)
Fuel Transfer Pump A35 (7180-7780 Tier 3)
Fuel Dosing Pump A49 (7280-7780 Interim Tier 4/Stage III B)
Low Pressure Fuel Pump A50 (7280-7780 Interim Tier 4/Stage III B)
Stone Sweep Position Potentiometer R6
Sharpening Door Position Potentiometer R9
Header Angle Potentiometer B76
Transmission 3rd Gear Switch S21
Manual Sharpening Door Switch S26
Kernel Processor Electric Lift Switch S28
Header Safety Switch S30
Stop Light Switch S35 / S35.1
Transmission Oil Pressure Switch S48 (ProDrive™ Transmission)
Battery Main Switch S51 (7180-7780)
Battery Main Switch S73 (7980)
Accumulator Charge Pressure Switch S52
Manual Cutterhead Reverse Switch S53
Reverse Drive Switch S54 (3-Speed Transmission)
Park Brake Switch S56 (3-Speed Transmission)
Coolant Level Switch S57 (7180-7780 Tier 3 and 7980)
Reed Switch S60 (676/678 RHU)
Rotary Screen Speed Sending Unit S67
Ether Starting Aid Y1
Automatic Header Control Shut Off Valve Y2
Length-Of-Cut Transmission Quick Stop Pawl Solenoid Valve Y3
Length-Of-Cut Transmission Solenoid Valves
Proportional Valve Solenoids
Header Height Control (AHC) Solenoids
ProDrive™ Transmission Solenoid Valves
ATC Air Conditioning Clutch Y11
Main Hydraulic System Solenoid Valves
Length-Of-Cut Transmission Proportional Valves Y18 and Y19
Gear Lock Solenoid Valve Y20 (3-Speed Transmission)
Wagon Dump High Flow Solenoid Valves
Low Pressure Solenoid Valves
Length-Of-Cut Transmission Reversing Pawl Solenoid Valve Y34
Row Guidance Valve Block Y40
Rear Wheel Drive Proportional Valve Y41
Front Motor Proportional Valve Y45
Transmission Pump-Forward and Reverse Valves Y46 / Y47 (ProDrive™ Transmission)
Fuel Pump Control Solenoid Valve Y48 (7180 only)
HCI Fuel Shut-Off Valve Y76 (7280-7780 Interim Tier 4/Stage III B)
HCI Fuel Dosing Valve Y77 (7280-7780 Interim Tier 4/Stage III B)
Variable Speed Fan Valve Block Y78/Y79 (7280-7780 Interim Tier 4/Stage III B)
Fuel Pump Actuator (7980)
Safety Rules When Replacing Xenon Bulbs
Remove and Install High Intensity Discharge (Xenon) Lights (Optional)
Safety Rules When Replacing Halogen Bulbs
Replacing Bulbs
Cab Head Light Bulb Replacement and Adjustment
Turn Signal Indicator Light Bulb Replacement
Dome and Console Light Bulb Replacement
Automatic Function Control Panel Light Bulb Replacement
Moisture Sensor Adapter Glass Replacement
Observe Electrical Precautions
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems
Section 50: Power Train
Group 05: Main Drive Belt Replacement
Specifications
Replace Main Drive Belt
Group 10: Bevel Gear Drive
Specifications
Other Material
Essential or Recommended Tools
Special Tool (Self-Manufactured)
Modify Assembly Fixture (KJD10350)
Other Material
Remove Bevel Gear Drive
Attaching Bevel Gear Drive to Assembly Fixture
Main Clutch Assembly
Check Main Clutch
Remove Clutch
Hub Components
Bevel Gear Drive Disassembly
Bevel Gear Drive Assembly
Determination of Adjusting Measure for Drive Pinion
Dimension “C”
Dimension “H”
Dimension “G”
Dimension “B”
Drive Shaft Reassembly
Determination of Adjusting Measure for Output Pinion
Dimension “D”
Dimension “F”
Dimension “E”
Dimension “A”
Output Shaft Reassembly
Output Shaft Adjustment
Install Output Shaft
Disk Clutch Reassembly
Install Clutch Oil Jet fitting
Install Bevel Gear Drive
Group 15: Transmission and Differential (3-Speed Transmission)
Specifications
Other Material
Drain Oil
Remove and Repair Shifter Forks and Shifter Cam
Install Shifter Forks and Shifter Cam
Remove and Install Transmission Lube Pump
Remove and Install Suction Screen
Remove Transmission
Transmission Components
Transmission Recondition
Disassemble and Repair Transmission
Remove Pinion Shaft
Remove Differential
Disassemble Differential
Assemble Differential
Assemble Transmission
Install Transmission
Remove and Install Gearshift Lever and Linkage
Adjusting Gearshift Linkage
Group 16: Transmission and Differential (ProDrive™ Transmission)
Specifications
Essential or Recommended Tools
Special Tools—Dealer Fabricated
Other Material
Draining Oil
Remove and Install Shift Valve Housing
Remove and Repair Valves from Shift Valve Housing
Shift Valve Housing-Exploded View
Install Valves in the Shift Valve Housing
Remove Transmission
Transmission Components-Overview
Disassemble Transmission
Remove Brake Modules
Disassemble Brake Modules
Brake Modules - Exploded View
Assemble Brake Modules
Install Brake Modules
Remove Differential Module
Disassemble Differential Module (With Differential Lock)
Differential (With Differential Lock) - Exploded View
Assemble Differential Module (With Differential Lock)
Install Differential Module
Remove Gear-Shift Planetary Drive With Clutch (Forward/Reverse)
Disassemble Gear-Shift Planetary Drive With Clutch (Forward/Reverse)
Gear-Shift Planetary Drive With Clutch (Forward/Reverse) - Exploded View
Assemble Gear-Shift Planetary Drive With Clutch (Forward/Reverse)
Install Gear-Shift Planetary Drive With Clutch (Forward/Reverse)
Remove Countershaft
Repair Countershaft
Countershaft - Exploded View
Install Countershaft
Assemble Transmission
Install Transmission
Group 20: Final Drives
Specifications
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Remove Final Drive
Disassemble and Assemble Final Drive
Adjust Spindle Bearing (Preferred Method)
Adjust Spindle Bearing (Alternative Method)
Install Final Drive
Final Drive Attaching Screws
Group 25: Hydrostatic Drive, Variable Pump (3-Speed Transmission)
Specifications
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Serial Number Plate
Clean Variable Pump
Flushing the Hydrostatic System
Remove Variable Pump
Remove Variable Pump (Machines with Length-Of-Cut Transmission)
Disassemble Variable Pump
Assemble Variable Pump
Disassemble and Assemble End Cover
Repair Control Valve
Repair Charge Pump
Install Variable Pump
Remove and Install Hydrostatic Control Cable
Adjust Hydrostatic Neutral Linkage
Adjust Displacement Control Valve Neutral
Group 26: Hydrostatic Drive, Variable Pump (ProDrive™ Transmission)
Essential or Recommended Tools
Special Tool (Self-Manufactured)
Specifications
General View
Serial Number Plate
Clean Variable Pump
Remove Variable Pump
Sealing the Drive Shaft
Sealing the Boost Pump
Sealing the Control Piston Cover
Sealing The Boost Pressure Valve
Sealing the Pressure Cut Off Valve
Remove Control Unit
Disassembling the Pump
Disassembling Cylinder Assembly
Disassembling the Control Piston
Inspection Notes
Assembling the Pump
Installing the Rotary Group
Adjustment Instructions
Group 30: Hydrostatic Drive, Fixed-Displacement Motor (3-Speed Transmission)
Essential or Recommended Tools
Other Material
Specifications
Clean Fixed-Displacement Motor
Remove Fixed-Displacement Motor
Disassemble Fixed-Displacement Motor
Inspect Parts
Lack of Lubrication
Abrasive Contamination
Cavitation
Over Speeding
Inspect Shaft Seal
Inspect Thrust Plate
Inspect Fixed Swashplate
Inspect Piston Slipper
Inspect Piston Retainer
Inspect Cylinder Block
Inspect Bearing Plate
Inspect Valve Plate
Inspect Bearing and Race
Inspect Servo Piston
Inspect Drive Shaft
Replace Cylinder Block Spring
Assemble Motor
Install Fixed-Displacement Motor
Remove and Install Motor Valve Block (Manifold)
Repair Motor Valve Block
Group 31: Hydrostatic Drive, Variable Displacement Motor (ProDrive™)
Specifications
Essential or Recommended Tools
Remove Variable-Displacement Motor
General View
Sealing the Cover Plate
Sealing of the Control Parts
Disassembling the Port Plate
Assembling the Port Plate
Group 40: Rear-Wheel Drive Axle
Specifications
Essential or Recommended Tools
Other Material
Changing Oil
Remove Axle Housing From Machine
Replacing Pivot Pin Bushings
Disassemble the Planetary Drive
Planetary Drive—Exploded View
Assembling the Planetary Drive
Disassemble the Swivel Housing
Swivel Housing—Exploded View
Assemble the Swivel Housing
Disassemble the Differential (Two Planet Gears)
Differential—Exploded View (Two Planet Gears)
Assemble the Differential (Two Planet Gears)
Disassemble the Differential (Four Planet Gears)
Differential—Exploded View (Four Planet Gears)
Assemble the Differential (Four Planet Gears)
Disassemble the Steering Cylinder
Steering Cylinder—Exploded View
Assemble the Steering Cylinder
Adjusting Tread
Remove and Install Fender and Fender Support (ProDrive™ Transmission)
Group 45: Rear-Wheel Drive Axle, Variable Displacement Motor
Essential or Recommended Tools
Specifications
General View
Sealing the Cover Plate
Sealing of the Control Parts
Disassemble the Port Plate
Assembling the Port Plate
Section 60: Brakes, Steering and Rear Axle
Group 05: Brake Operation (3-Speed Transmission)
Essential or Recommended Tools
Other Material
Specifications
Remove and Install Master Cylinder
Disassemble and Assemble Master Cylinder (Double Bleed Screw)
Brake Fluid Reservoir
Adjusting Master Cylinder
Bleeding Brake System—Double Bleed Screw
Remove and Install Slave Cylinders
Disassemble and Assemble Slave Cylinders
Disassemble and Assemble Brake Pedals
Disassemble and Assemble Parking Brake Pedal
Adjust Park Brake Pedal
Group 06: Brake Operation (ProDrive™ Transmission)
Other Material
Specifications
Remove and Install Master Cylinder
Disassemble and Assemble Master Cylinder
Adjust Master Cylinder
Bleed Service Brakes
Disassemble and Assemble Brake Pedals
Disassemble and Assemble Park Brake Valve (Accumulator Charge)
Group 10: Brakes (3-Speed Transmission)
Essential or Recommended Tools
Other Material
Specifications
Deglazing Brake Linings
Remove Brake Drum
Remove Brake Shoe
Repair Brakes
Brake Assembly
Group 11: Brakes (ProDrive™ Transmission)
Essential or Recommended Tools
Other Material
Specifications
Check Brake Disk Thickness
Repair Brake Disks
Group 15: Hydrostatic Steering
Essential or Recommended Tools
Other Material
Specifications
Steering Hydraulics (Length-Of-Cut Transmission - 3-Speed Transmission)
Steering Hydraulics (Length-Of-Cut Transmission - ProDrive™ Transmission)
Removing the Steering Valve
Steering Valve Components
Disassembling the Steering Unit
Removing Safety Valves
Removing Check Valve
Removing Spool and Sleeve
Disassembling the Spool Assembly
Removing Leaf Springs
Removing Seal Ring
Remove the Safety Valves
Remove Pressure-Control Valve
Repairing the Steering Unit
Assembling the Steering Unit
Installing Pressure-Control Valve
Installing Safety Valves
Arranging the Leaf Springs
Installing the Leaf Springs
Assembling the Spool Assembly
Installing Retaining Ring and Cross Pin
Assembling the Thrust Bearing
Installing the Seal Ring
Installing O-Ring and Back-Up Ring
Installing Spool Assembly
Installing the Check Valve
Installing Safety Valves
Installing the O-Ring
Installing Distributor Plate and Drive Shaft
Installing Rotor and Stator
Installing Spacer Ring
Installing Metering Unit Cover
Safety Valve Test
Adjusting the Safety Valves
Pressure Control Valve Test
Adjusting the Pressure-Control Valve
Install Steering Valve
Bleeding the Hydrostatic Steering System
Steering Column Components
Disassemble And Assemble Steering Column
Replace Telescoping Shaft Bearings
Group 16: Row Guidance System
Specifications
Other Material
Row Guidance System Components
Checking Rotary Potentiometer
Removing and Installing Steering Valve Block and Steering Input Sending Unit
Calibrating Control Unit
Address RGC 100 Calibration — Sensitivity
Address RGC 101 Calibration - Feelers
Address RGC 102 Calibration — Wheel Angle Sensor/Steering Wheel Position Sensor
Address RGC 105 Calibration — Steering Valve Deadband
Address RGC 108 Calibration — Steering Test Mode
Address RGC 109 Calibration — Feeler Side Swap
Group 20: Rear Axle
Essential or Recommended Tools
Other Material
Rear Axle Pivot Bushing
Remove and Install Rear Axle Pivot Bushing
Section 70: Hydraulic System
Group 05: Hydraulic Pressure Accumulators
Specifications
Essential or Recommended Tools
General Repair Information
Accumulators
Harvesting Unit Float System (3-Speed Transmission)
Harvesting Unit Float System (ProDrive™ Transmission)
Main Clutch System
Discharge Spout System
Checking Accumulators
Recharging Accumulators
Lowering Accumulator Pressure
Group 10: Hydraulic Pumps
Specifications
Other Material
General Repair Information
Draining Hydraulic Oil
Pressure and Temperature Sending Units At Hydraulic Oil Reservoir
Refilling Hydraulic Oil
Repair Information
Removing Hydraulic Pumps
Marking Hydraulic Pumps
Disassemble Hydraulic Pumps
Replace Shaft Seal
Installing Gasket and Support
Assembling Hydraulic Pumps
Install Hydraulic Pumps
Group 15: Electromagnetic Control Valve
Specifications
Solenoid Valves - Main Block
Remove Solenoid Main Valve Block
Low Pressure Valve Block
Remove Low Pressure Valve Block
Repair Low Pressure Valve Block
Proportional Valve Block
Header Height Control (AHC) Valve Block
High Flow Wagon Dump Valve Block (Option)
Remove High Flow Wagon Dump Valve Block (Option)
Repair High-Flow Wagon Dump Valve Block (Option)
Variable Speed Fan Valve Block (Interim Tier4/Stage III B)
Remove Variable Speed Fan Valve Block (Interim Tier4/Stage III B)
Group 25: Hydraulic Motor — Discharge Spout
Specifications
Remove Hydraulic Motor
Disassemble Hydraulic Motor - 7180-7580
Hydraulic Motor, Exploded View - 7180-7580
Repair Hydraulic Motor - 7180-7580
Assemble Hydraulic Motor - 7180-7580
Group 26: Hydraulic Motor — Rotary Screen
Specifications
Removing and Installing Hydraulic Motor
Repairing Hydraulic Motor
Group 30: Length-Of-Cut Transmission Motor
Essential or Recommended Tools
Specifications
General Description
Remove and Install Motor
Replacing the Drive Shaft Seal
Remove the Connection Plate
Installing The Connection Plate
Disassemble the Flushing Valve
Assembling The Flushing Valve
Disassembling Motor
Inspecting Parts
Assemble the Motor
Adjusting Taper Roller Bearing Pre-Load
Group 35: Length-Of-Cut Transmission Hydrostatic Pump
Essential or Recommended Tools
Special Tool (Self-Manufactured)
Specifications
General Description
Sealing the Drive Shaft
Sealing the Boost Pump
Sealing the Control Piston Cover
Sealing the Valves
Sealing the Pressure Cut Off Valve
Remove the Control Unit
Disassembling the Pump
Inspection Notes
Assemble the Pump
Installing the Rotary Group
Installing the Control Plate
Adjustment instructions
Section 80: Miscellaneous
Group 05: Central Lubrication System
Specifications
Location of Primary and Secondary Distributors
Flow Schematic
Automatic Lubrication System (Option)
Operational Information
Adjusting Optional Pump Element for Flow Control
Quick Couplers for Kernel Processor and Harvesting Unit
Troubleshooting - Automatic Lubrication System
Section 90: Operator's Cab, Air-Conditioning System
Group 05: Control Levers
Multi-Function Lever (3-Speed Transmission)
Multi-Function Lever (ProDrive™ Transmission)
Group 10: Cab Ventilation
Essential or Recommended Tools
Other Material
Specifications
Air Conditioning System With Precleaner (General Information)
Air Conditioning System Components
Recirculating Filter
Remove and Install Blower Motor
Remove and Install Recirculator Fan Motor Driver
Remove and Install Recirculator Motor
Remove and Install Temperature Control Door Actuator
Remove and Install Heater Core
Replace Evaporator
Replace Expansion Valve
Remove and Install Evaporator Temperature Sensor
Replace Low Pressure Switch
Replace High Pressure Switch
Remove and Install Receiver/Drier
Removing Air Conditioning Condenser
Repair Condenser
Replace Air Temperature Sensors
Group 15: Operator's Cab
Specifications
Remove and Install Cab Windshield
Remove and Install Cab Roof
Cab Door Latch Striker
Remove and Install Cab Door
Disassemble and Assemble Cab Door
Rear Window Installation
Right-Hand Cab Window
Remove Cab
Install Cab
Group 20: R134a Air-Conditioning System
Specifications
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Service Parts Kits
Hose and Tubing O-Ring Connection Torques
Air-Conditioning - Important
Air-Conditioning System - Safety at Work
Handling Refrigerant
Storage of Refrigerant Containers
R134a Refrigerant
Service Work on Air-Conditioning System
Component Location (7180-7780 Tier 3 Non EGR and 7980)
Component Location (7280-7780 Interim Tier 4/Stage III B)
Test and Service Ports
Fill with Refrigerant Oil
Remove and Install Compressor
Checking Level in the Compressor
Disassemble and Assemble Compressor Clutch (7180-7780 Tier 3 Non EGR and 7980)
Check Clutch Hub Clearance (7180-7780 Tier 3 Non EGR and 7980)
Inspect Compressor Manifold (7180-7780 Tier 3 Non EGR and 7980)
Remove and Install Compressor Relief Valve (7180-7780 Tier 3 Non EGR and 7980)
Compressor Oil Information
Group 25: Super Comfort Seat
Specifications
Remove and Install Operator’s Seat
Remove and Install Operator Presence Switch
Operator's Seat Exploded View
Operator's Seat Air Suspension Assembly—Exploded View
Disassemble and Assemble Operator's Seat Air Suspension Assembly
Section 99: Special Tools
Group 05: Special Tools (Dealer Fabricated)
Self-Manufactured Tool for Bevel Gear Drive Repair
Self-Manufactured Tool for ProDrive™ Transmission Repair
Self-Manufactured Tool for Hydrostatic Drive Pump Repair - ProDrive™ Transmission
Self-Manufactured Tool for Hydrostatic Drive Pump Repair - Length-Of-Cut Transmission
Group 10: Special Tools (Available as Spare Parts)
Essential or Recommended Tools
Essential Tools for Engine Repair
Essential Tools for Engine Cooling System
Essential Tool for Exhaust Filter Repair
Essential Tools for Electrical System Repair
Essential Tools for Bevel Gear Drive Repair
Essential Tools for ProDrive™ Transmission Repair
Essential Tools for Final Drive Repair
Essential Tools for Hydrostatic Drive Pump Repair - 3-Speed Transmission
Essential Tools for Hydrostatic Drive Pump Repair - ProDrive™ Transmission
Essential Tools for Rear-Wheel Drive Axle Repair
Essential Tools for Rear Wheel Drive Motor Repair
Essential Tools for Brake System Repair - 3-Speed Transmission
Essential Tools for Brake System Repair - ProDrive™ Transmission
Essential Tools for Steering System Repair
Essential Tools for Rear Axle Repair
Essential Tools for Hydraulic Pressure Accumulator Repair
Essential Tools for Length-of-Cut Transmission Motor Repair
Essential Tools for Length-of-Cut Transmission Hydrostatic Pump Repair
Essential Tools for Air Conditioning System Repair
Essential Tools for Length-of-Cut Transmission Repair
Essential Tools for Cutterhead Repair
Essential Tools for Blower Repair
Essential Tools for KernelStar Type Kernel Processor Repair
Section 100: Harvesting Units
Group 05: Harvesting Unit Cross Drive
Specifications
Other Material
Harvesting Unit Cross Drive
Harvesting Unit Drive, Exploded View - Length-Of-Cut Transmission
Drive Assembly - Length-Of-Cut Transmission
Group 10: Harvesting Units
Harvesting Units
Section 110: Feeding System
Group 10: Length-Of-Cut Transmission
Essential or Recommended Tools
Specifications
Other Material
General Information
Repair Multicoupler
Remove Cut Out Clutch Assembly
Disassemble/Assemble Cut Out Clutch
Install Cut Out Clutch Assembly
Remove/Disassemble Length-Of-Cut Transmission Brake With Transmission Case on Machine
Assemble/Install Length-Of-Cut Transmission Brake With Transmission Case on Machine
Remove/Disassemble Length-Of-Cut Transmission Feedroll Drive Gear Case With Transmission Case on Machine
Assemble/Install Length-Of-Cut Transmission Feedroll Drive Gear Case With Transmission Case on Machine
Remove Length-Of-Cut Transmission From Machine
Disassemble Length-Of-Cut Transmission
Disassemble/Assemble Length-Of-Cut Transmission Brake
Disassemble/Assemble Length-Of-Cut Transmission Main Clutch
Hydraulic Block Overview
Modulating Valve Overview
Shaft AZ Overview
Shaft CZ Overview
Shaft EZ Overview
Shaft FZ Overview
Shaft GZ Overview
Shaft GPL Overview—Part 1
Shaft GPL Overview—Part 2
Shaft HZ Overview—Part 1
Shaft HZ Overview—Part 2
Shaft HYZ Overview
Assemble Length-Of-Cut Transmission
Install Length-Of-Cut Transmission On Machine
Group 25: Feed Roll Housing
Open Feed Roll Housing
Close Feed Roll Housing
Feed Roll Housing Safety Switch (S30)
Group 30: Feed Roll Assembly
Specifications
Other Material
Disassemble/Assemble Feed Roll Gear Transmission
Disassemble/Assemble Feed Roll Assembly
Remove Rear Lower Feed Roll (Smooth Roll)
Install Rear Lower Feed Roll (Smooth Roll)
Replace Feed Roll Wear Plates and Stops
Lateral Guides for Upper Feed Rolls
Section 120: Cutterhead Assembly
Group 05: Knife Sharpening Device
Specifications
Other Material
Knife Sharpening Device Removal
Knife Sharpening Device Repair
Knife Sharpening Device Cable Guide Exploded View
Sharpening Stone Block Cable Exploded View
Retensioning Guide Cable
Sharpening Stone Block Exploded View
Assemble Sharpening Stone Block
Sharpening Stone Replacement
Sharpening Stone Alignment
Group 10: Cutterhead
Essential or Recommended Tools
Specifications
Other Material
Cutterhead Type Identification
Replace Cutterhead and Knife Attaching Parts
Knife Screw Torque
Removing Cutterhead Assembly From Machine
Cutterhead Removal
Cutterhead—Exploded View - Type A
Cutterhead—Exploded View - Type B
R.H. Side Cutterhead Bearing—Repair - Type A
L.H. Side Cutterhead Bearing—Repair - Type A
R.H. Side Cutterhead Bearing—Repair - Type B
L.H. Side Cutterhead Bearing—Repair - Type B
Cutterhead Installation
Installing Cutterhead Assembly on Machine
Group 15: Bottom and Outlet Bands
Specifications
Recirculating Screens
Install/Change Recirculating Screen
Recirculating Screen Adjustment
Installing Spiral Floor
Installing Recutter Floor
Adjusting Spiral Floor
Adjusting the Recutter Floor
Replacing Recutter Floor Knives
Adjust the Discharge Chute
Group 20: Stationary Knife Removal and Installation
Specifications
Stationary Knife Removal
Remove Stationary Knife Adjusting Device
Install Stationary Knife
Torque at Stationary Knife Adjusting Device
Eliminate End Play of Adjusting Spindle
Group 25: Kernel Processor
Specifications
Essential or Recommended Tools
Other Material
Replace Drive Belts of Lower Roll
Kernel Processor Removal
Adjust the Feed Plate On the Kernel Processor
Kernel Processor Drive Exploded View
Grooved Roll Removal—Standard Type Kernel Processor Only
Bevel Disk Roll Removal—KernelStar Type Kernel Processor Only
Kernel Processor Housing Exploded View
Standard Type Kernel Processor Rolls Exploded View
KernelStar Type Kernel Processor Rolls Exploded View
Manual Adjusting Device Exploded View
Electrical Adjusting Device Exploded View
Idler and Deflector Pulleys Exploded View
Idler Pulley Repair
Assemble Bevel Disk Rolls—KernelStar Type Kernel Processor Only
Kernel Processor Roll Installation
Adjust Kernel Processor Roll Clearance (Manual Adjustment)
Automatic Adjustment of Rolls
Adjust Scrapers
Pretension of Lower Roll Drive Belt
Section 130: Discharge Components
Group 05: Discharge Fan
Specifications
Discharge Fan Exploded View
Replace Wear Plate
Install Wear Plate
Replace and Adjust Blower Paddles - General
Adjust Blower Paddles
Adjust Deflecting Edges
Group 10: Blower Rotor and Rotor Bearings
Specifications
Essential or Recommended Tools
Remove/Install Blower Rotor Drive Pulley
Remove/Install Blower Rotor Self-Aligning Bearings
Remove Blower Rotor
Blower Rotor Exploded View
Install Blower Rotor
Group 15: Discharge Spout
Specifications
Spout Turning Device Exploded View
Install Spout Turning Device
Install Spout Worm Gear (7180-7580)
Install Spout Motor Gear (7780 and 7980)
Install Automatic Spout Control Sending Units
Spout Exploded View—High Arc
Spout Exploded View—Low Arc
John Deere Self-Propelled Forage Harvesters Models 7180, 7280, 7380, 7480, 7580, 7780, 7980 Repair Service Manual (TM404419)
