John Deere 7180 7280 7380 7480 7580 7780 7980 Forage Harvester Workshop Repair Service Manual PDF (TM404419) - MJODTM404419.zip
This complete service and repair manual covers John Deere Self-Propelled Forage Harvesters 7180, 7280, 7380, 7480, 7580, 7780 and 7980 (Worldwide Edition), providing every technical detail needed to service, fix, and rebuild these machines the way expert technicians do.
The workshop repair manual for John Deere Self-Propelled Forage Harvesters Models 7180, 7280, 7380, 7480, 7580, 7780 and 7980 contains:
* 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)