John Deere DF180 Series Powershift Transmission G Series Grader Workshop Repair Manual CTM308 PDF - MJODCTM308.zip
Full service and repair guide with Electrical Wiring Diagrams covering the John Deere DF180 Series Powershift Transmission, containing every technical detail needed to service, troubleshoot, fix, and rebuild the unit just like a trained technician.
The John Deere DF180 Series Powershift Transmission workshop service and repair manual 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.
ctm308 - John Deere DF180 Series Powershift Transmission Repair Manual (Worldwide Edition) Component Technical Manual.pdf
Spanish
ctm595 - Manual de reparación de la servotransmisión serie DF180 -: (Edición mundial)
Published on 2019/06/07
English
ctm308 - DF180 Series Powershift Transmission Repair Manual -: (Worldwide Edition)
Published on 2019/05/17
French
ctm594 - Manuel de remise en état de la boîte PowerShift™ série DF180 -: (Édition mondiale)
Published on 2019/06/07
Portuguese
ctm596 - Manual de Reparação da Transmissão PowerShift Série DF180 -: (Edição Mundial)
Published on 2019/06/07
Russian
ctm597 - Руководство по ремонту трансмиссии PowerShift серии DF180 -: (Исполнение для всех стран)
Published on 2019/06/07
German
ctm730 - Reparaturhandbuch für PowerShift Getriebe der Serie DF180 -: (Weltweite Ausgabe)
Published on 2019/06/11
PRODUCT DETAILS:
Total Pages: 1,041 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English etc
TABLE OF CONTENTS................1
Section 01: General Information................17
Group 005: Safety................17
Recognize Safety Information................20
Handle Fluids Safely—Avoid Fires................21
Prevent Battery Explosions................22
Prepare for Emergencies................23
Prevent Acid Burns................24
Handle Chemical Products Safely................26
Avoid High-Pressure Fluids................27
Park Machine Safely................28
Support Machine Properly................29
Wear Protective Clothing................30
Work in Clean Area................31
Service Machines Safely................32
Work In Ventilated Area................33
Illuminate Work Area Safely................34
Replace Safety Signs................35
Use Proper Lifting Equipment................36
Avoid Heating Near Pressurized Fluid Lines................37
Remove Paint Before Welding or Heating................38
Use Proper Tools................39
Construct Dealer-Made Tools Safely................40
Decommissioning — Proper Recycling and Disposal of Fluids and Components................41
Live With Safety................42
Group 015: Transmission Identifications and General Procedures................17
Remote Mount Direct Drive Transmission Configuration................44
Remote Mount Converter Drive Transmission Configuration................45
Engine Mount Direct Drive Transmission Configuration................46
Transmission Specifications................47
Identification Plate................49
General Repair Procedures................50
Sealing Instructions................52
Anaerobic Sealant................53
Cold Weather Operation................54
Oil Temperature Warning Signal................55
Recommended Lubricants................56
Lubricant Storage................57
Mixing of Lubricants................58
Oil Analysis................59
Alternative and Synthetic Lubricants................60
Check and Service Transmission Regularly................61
Intervals For Changing Transmission Oil And Filters................62
Drain Transmission Oil................63
Fill The Transmission With Oil................64
Check Oil Lines and Fittings................65
Hydraulic Connections................66
Transmission Storage................67
Transmission Removal From Storage................68
Towing The Vehicle................69
Section 02: Repair and Adjustments - Transmission................70
Group 017: G Series Grader (S.N. 624392—678817)................70
Transmission Identification and Links — G Series Grader (S.N. 624392—678817)................81
Repair Stand — Install and Remove — G Series Grader (S.N. 624392—678817)................83
Driven Hub Yoke and Seal — Exploded View — G Series Grader (S.N. 624392—678817)................84
Front and Rear Housing — Exploded View — G Series Grader (S.N. 624392—678817)................125
Suction Screen Oil Line — Remove and Install — G Series Grader (S.N. 624392—678817)................87
Oil Pump — Exploded View — G Series Grader (S.N. 624392—678817)................90
Oil Pump — Remove and Install — G Series Grader (S.N. 624392—678817)................91
Speed Sensors — Remove and Install — G Series Grader (S.N. 624392—678817)................94
Hydraulic Tubes, Sensors, and Valve — Remove and Install — G Series Grader (S.N. 624392—678817)................97
Park Brake — Exploded View — G Series Grader (S.N. 624392—678817)................112
Control Valve — Exploded View — G Series Grader (S.N. 624392—678817)................114
Cap Screw — Exploded View — G Series Grader (S.N. 624392—678817)................115
Front and Rear Housing — Install — G Series Grader (S.N. 624392—678817)................116
Front Housing — Exploded View — G Series Grader (S.N. 624392—678817)................123
Rear Housing — Exploded View — G Series Grader (S.N. 624392—678817)................125
Gears Bearing and Shafts — Identification — G Series Grader (S.N. 624392—678817)................127
Gear Ratio Group — Remove — G Series Grader (S.N. 624392—678817)................128
Gear Ratio Group — Install — G Series Grader (S.N. 624392—678817)................131
First Stage Shaft — Exploded View — G Series Grader (S.N. 624392—678817)................134
Second Stage Shaft Assembly (Directional Clutch) — Exploded View — G Series Grader (S.N. 624392—678817)................135
Third Stage Shaft Assembly (Directional Clutch) — Exploded View — G Series Grader (S.N. 624392—678817)................138
Fourth Stage Shaft Assembly (Speed Clutch) — Exploded View — G Series Grader (S.N. 624392—678817)................141
Fifth Stage Shaft Assembly (Speed Clutch) — Exploded View — G Series Grader (S.N. 624392—678817)................144
Sixth Stage Shaft Assembly — G Series Grader (S.N. 624392—678817)................147
Output Shaft Assembly — Exploded View — G Series Grader (S.N. 624392—678817)................148
Adjustments — G Series Grader (S.N. 624392—678817)................149
Group 018: G Series Grader (S.N. 678818— )................70
Transmission Identification and Links — G Series Grader (S.N. 678818— )................151
Repair Stand — Install and Remove — G Series Grader (S.N. 678818— )................152
Driven Hub Yoke and Seal — Exploded View — G Series Grader (S.N. 678818— )................153
Front and Rear Housing — Exploded View — G Series Grader (S.N. 678818— )................198
Suction Screen Oil Line — Remove and Install — G Series Grader (S.N. 678818— )................156
Oil Pump — Exploded View — G Series Grader (S.N. 678818— )................159
Oil Pump — Remove and Install — G Series Grader (S.N. 678818— )................160
Sixth Stage Lube Line — Exploded View — G Series Grader (S.N. 678818— )................163
Speed Sensors — Remove and Install — G Series Grader (S.N. 678818— )................166
Park Brake Supply Line — Remove and Install — G Series Grader (S.N. 678818— )................168
Park Brake Pressure Sensor — Remove and Install — G Series Grader (S.N. 678818— )................170
Park Brake Valve — Remove and Install — G Series Grader (S.N. 678818— )................172
Park Brake Check Valve — Remove and Install — G Series Grader (S.N. 678818— )................174
Park Brake — Exploded View — G Series Grader (S.N. 678818— )................175
Park Brake — Assemble — G Series Grader (S.N. 678818— )................177
Park Brake — Disassemble — G Series Grader (S.N. 678818— )................183
Control Valve — Exploded View — G Series Grader (S.N. 678818— )................188
Front and Rear Housing — Assemble — G Series Grader (S.N. 678818— )................189
Front Housing — Exploded View — G Series Grader (S.N. 678818— )................196
Rear Housing — Exploded View — G Series Grader (S.N. 678818— )................198
Gears Bearing and Shafts — Identification — G Series Grader (S.N. 678818— )................199
Gear Ratio Group — Remove — G Series Grader (S.N. 678818— )................200
Gear Ratio Group — Install — G Series Grader (S.N. 678818— )................203
First Stage Shaft — Exploded View — G Series Grader (S.N. 678818— )................206
Second Stage Shaft (Directional Clutch) — Exploded View — G Series Grader (S.N. 678818— )................207
Third Stage Shaft (Directional Clutch) — Exploded View — G Series Grader (S.N. 678818— )................210
Fourth Stage Shaft (Speed Clutch) — Exploded View — G Series Grader (S.N. 678818— )................213
Fifth Stage Shaft (Speed Clutch) — Exploded View — G Series Grader (S.N. 678818— )................215
Sixth Stage Shaft Assembly — Exploded View — G Series Grader (S.N. 678818— )................218
Output Shaft Assembly — Exploded View — G Series Grader (S.N. 678818— )................219
Adjustments — G Series Grader (S.N. 678818— )................220
Group 019: H Series Remote Mount Transmission................71
Transmission Identification and Links — H Series Remote Mount Transmission................222
Repair Stand — H Series Remote Mount Transmission................223
Input Yoke Group — H Series Remote Mount Transmission................224
Remove and Install the DF180 Skidder Suction Tube Oil Line — H Series Remote Mount Transmission................226
Charge Pump, Idler, and Drive Gear Assembly — H Series Remote Mount Transmission................230
Speed Sensors — H Series Remote Mount Transmission................238
Main Housing Group — H Series Remote Mount Transmission................240
Park Brake — H Series Remote Mount Transmission................244
Control Valve — H Series Remote Mount Transmission................246
Winch Drive — H Series Remote Mount Transmission................248
Gear Ratio Group — H Series Remote Mount Transmission................250
First Stage Shaft Assembly — H Series Remote Mount Transmission................262
Second Stage Clutch Assembly — H Series Remote Mount Transmission................263
Third Stage Clutch Assembly — H Series Remote Mount Transmission................266
Fourth Stage Clutch Assembly — H Series Remote Mount Transmission................269
Fifth Stage Clutch Assembly — H Series Remote Mount Transmission................272
Sixth Stage Shaft Assembly — H Series Remote Mount Transmission................275
Seventh Stage Shaft Assembly — H Series Remote Mount Transmission................276
Group 020: Repair Procedures and Repair Stand................72
Transmission Repair Procedures................279
Transmission Lifting and Mounting on Repair Stand................281
Repair Stand Mounting — Remote Mount................284
Repair Stand Mounting — Engine Mount................287
Group 025: Winch Drive — Remote Mount................72
Winch Drive with 5C Yoke — Remote Mount................291
Winch Drive with Universal Joint Yoke — Remote Mount................293
Winch Drive without Gears — Remote Mount................295
Remove Winch Drive — Remote Mount................296
Install Winch Drive — Remote Mount................299
Group 030: Park Brake................72
Park Brake — Remote Mount Transmission................304
Park Brake — Engine Mount Transmission................305
Park Brake — Remove................307
Park Brake — Install................313
Group 035: Output Seals................73
Output Seals (Brake Side) — Remove and Install — Remote Mount Transmission................324
Output Seals (Opposite Brake Side) — Remove and Install — Remote Mount Transmission................328
Output Oil Seal and Yoke — Remove and Install — Engine Mount Transmission................331
Group 040: Suction Tube................73
Suction Tube — Remove and Install................340
Suction Screen Tube — Remove and Install — Torque Converter Drive................345
Group 045: Charge Pump and Idler Gears/Shaft — Remote Mount................73
Charge Pump and Auxiliary Pump Drive Train — Exploded View — Remote Mount Direct Drive................348
Charge Pump and Auxiliary Pump Gear Train — Cross-Section — Remote Mount Direct Drive................349
Charge Pump — Remove and Install — Remote Mount Direct Drive................351
Charge and Auxiliary Pump Gear Train — Remove and Install — Remote Mount Direct Drive................355
Pump Pad Covers and Idler Shaft — Exploded View — Remote Mount Converter Drive................361
Cover Plates to Front Housing — Remove and Install — Remote Mount Torque Converter Drive................362
Idler Shaft — Remove and Install — Remote Mount Torque Converter Drive................365
Group 050: Charge Pump and Idler Gears/Shaft — Engine Mount................73
Charge Pump — Exploded View — Engine Mount................370
Charge Pump — Remove and Install — Engine Mount................371
Charge Pump Drive Idler Gears, Bearings, and Shafts — Exploded View — Engine Mount................375
Charge Pump Drive — Cross-Section — Engine Mount................376
Charge Pump Output Gear — Remove and Disassemble — Engine Mount................377
Charge Pump Output Gear — Assemble and Install — Engine Mount................379
Charge Pump Idler Gear and Shaft — Remove and Disassemble — Engine Mount................381
Charge Pump Idler Gear and Shaft — Assemble and Install — Engine Mount................384
Auxiliary Pump Drive Idler Shaft — Exploded View — Engine Mount................387
Auxiliary Pump Drive Idler Gears, Bearings, and Shafts — Exploded View — Engine Mount................388
Auxiliary Pump Drive — Cross-Section — Engine Mount................389
Auxiliary Pump Output Gear — Remove and Disassemble — Engine Mount................391
Auxiliary Pump Output Gear — Assemble and Install — Engine Mount................394
Auxiliary Pump Idler Shaft and Gear — Remove and Disassemble — Engine Mount................397
Auxiliary Pump Idler Gear and Shaft — Assemble and Install — Engine Mount................400
Group 055: Control Valve................73
Control Valve — Exploded View — Direct Drive Transmission (8F - 8R)................405
Control Valve — Exploded View — Remote Mount Torque Converter Drive (6F - 6R)................406
Control Valve — Exploded View — Remote Mount Torque Converter Drive (6F - 3R)................407
Control Valve — Exploded View — Remote Mount Lockup Torque Converter Drive (6F - 3R)................408
Transmission Control Valve — Remove................409
Transmission Control Valve — Install................411
Proportional Solenoid Valve — Remove and Install................416
Cooler Relief Valve — Remove and Install................420
Main Pressure Regulator Valve — Remove and Install................422
Proportional Solenoid Plug — Remove and Install................424
Temperature Sensor — Remove and Install................426
Clutch Pressure Check Port Plug — Remove and Install................428
Group 060: Input Yoke — Remote Mount Transmission................74
Input Yoke Group — Exploded View — Remote Mount Transmission................430
Input Yoke — Remove and Install — Remote Mount Transmission................431
Group 065: Input Drive Hub — Engine Mount Transmission................74
Input Drive Hub — Exploded View — Engine Mount Transmission................435
Drive Hub — Remove — Engine Mount Transmission................436
Drive Hub — Install — Engine Mount Transmission................437
Group 070: Front and Rear Housing and Clutch Group................74
Front and Rear Housing Cap Screws — Exploded View — Remote Mount................440
Front and Rear Housing — Disassemble — Remote Mount................441
Sixth Stage Lube Line — Exploded View — Engine Mount................443
Sixth Stage Lube Line — Remove and Install................444
Front and Rear Housing Cap Screws — Exploded View — Engine Mount................446
Front and Rear Housing — Disassemble — Engine Mount................447
Front Housing Screen and Plugs — Exploded View................451
Front Housing Screen — Remove and Install — Engine Mount................452
Front Housing Plugs — Remove and Install................453
Gear Ratio Group — Identification — Engine Mount Direct Drive (8F - 8R)................454
Gear Ratio Group — Identification — Remote Mount Direct Drive (8F - 8R)................455
Gear Ratio Group — Identification — Remote Mount Torque Converter Drive (6F - 6R)................456
Gear Ratio Group — Identification — Remote Mount Torque Converter Drive (6F - 3R)................457
Gear Ratio Group — Remove — Remote Mount................458
Gear Ratio Group — Remove — Engine Mount................462
Gear Ratio Group — Install — Remote Mount................466
Gear Ratio Group — Install — Engine Mount................472
Seal Rings — Install................476
Front and Rear Housing — Assemble — Remote Mount................477
Front and Rear Housing — Assemble — Engine Mount................482
Housing Cap Screw — Tightening Sequence — Engine Mount................486
Sixth Stage Bearing Retainer — Remove — Engine Mount................487
Sixth Stage — Bearing Adjustment — Engine Mount................489
PTO Oil Seal — Remove and Install — Engine Mount................493
Front Housing — Exploded View — Remote Mount Direct Drive................494
Front Housing — Exploded View — Remote Mount Torque Converter Drive................496
Front Housing — Repair................499
Housing Bore Sleeves — Remove and Install................500
Front Housing Bearing Cup — Remove and Install................505
Lube Relief Valve — Remove and Install................506
Sump Drain Valve — Remove and Install — Remote Mount................508
Rear Housing — Exploded View — Remote Mount Direct Drive................509
Rear Housing — Exploded View — Remote Mount Torque Converter Drive................510
Rear Housing — Exploded View — Remote Mount................511
Speed Sensors — Exploded View — Engine Mount................512
Rear Housing — Exploded View — Engine Mount................513
Rear Housing — Repair — Engine Mount................515
Rear Housing Bearing Cup — Remove and Install................516
Magnetic Sensor Pickup — Remove and Install................518
Pluget Orifice — Install — Engine Mount................520
Identification Plate — Location................521
Group 075: Gears, Bearings, and Shafts................75
Clutch — Assemble — Direct Drive................535
Clutch — Disassemble — Direct Drive................548
Input Shaft (First Stage) and Sixth Stage (Idler Gear) — Remove and Install — Direct Drive................558
Seventh Stage (Output) Shaft — Disassemble and Assemble — Direct Drive................560
First Stage Shaft — Exploded View — Engine Mount Direct Drive (8F - 8R)................562
Second Stage (High / Low Forward) Clutch — Cross-Section — Engine Mount Direct Drive................563
Second Stage (High / Low Forward) Clutch — Exploded View — Engine Mount Direct Drive................565
Third Stage (High / Low Reverse) Clutch — Cross-Section — Engine Mount Direct Drive................567
Third Stage (High / Low Reverse) Clutch — Exploded View — Engine Mount Direct Drive................569
Fourth Stage (First / Third Speed) Clutch — Cross-Section — Engine Mount Direct Drive................571
Fourth Stage (First / Third Speed) Clutch — Exploded View — Engine Mount Direct Drive................573
Fifth Stage (Second / Fourth Speed) Clutch — Cross-Section — Engine Mount Direct Drive................575
Fifth Stage (Second / Fourth Speed) Clutch — Exploded View — Engine Mount Direct Drive................577
Sixth Stage — Exploded View — Engine Mount Direct Drive (8F - 8R)................579
Seventh Stage (Output) Shaft — Exploded View — Engine Mount Direct Drive................581
First Stage Shaft — Exploded View — Remote Mount Direct Drive (8F - 8R)................582
Second Stage (High / Low Forward) Clutch — Cross-Section — Remote Mount Direct Drive................583
Second Stage (High / Low Forward) Clutch — Exploded View — Remote Mount Direct Drive................585
Third Stage (High / Low Reverse) Clutch — Cross-Section — Remote Mount Direct Drive................586
Third Stage (High / Low Reverse) Clutch — Exploded View — Remote Mount Direct Drive................588
Fourth Stage (First / Third Speed) Clutch — Cross-Section — Remote Mount Direct Drive................590
Fourth Stage (First / Third Speed) Clutch — Exploded View — Remote Mount Direct Drive................592
Fifth Stage (Second / Fourth Speed) Clutch — Cross-Section — Remote Mount Direct Drive................594
Fifth Stage (Second / Fourth Speed) Clutch — Exploded View — Remote Mount Direct Drive................596
Sixth Stage — Exploded View — Remote Mount Direct Drive (8F - 8R)................598
Seventh Stage (Output) Shaft — Exploded View — Remote Mount Direct Drive................599
Clutch — Assemble — Torque Converter Drive................600
Clutch — Disassemble — Torque Converter Drive................613