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Ultra-High Flow Wagon DumpJohn Deere 7050- and 7080-Series SPFH

Operator ManualParts Listing

Installation Instructions

Please retain this document for future reference.

RCI Engineering LLCRC076010 (08Nov12)

www.RCIengineering.com

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Table of Contents

1. Contents of Bundle……………….....…………………………………...… Pg. 31.1 Parts Listing………………………………………………..………….. Pg. 4

2. Service Information………………....……………………………..………. Pg. 53. Installation of Bundle…..…...………………………………………...…… Pg. 6

3.1 Install Hydraulic Reservoir…………………………………………… Pg. 63.2 Install Hydraulic Pump……………………………………………….. Pg. 73.3 Install Hydraulic Valve…………………………………...……………Pg. 83.4 Install Electrical……………………………………………………….. Pg. 11

4. Technical Information……..…………………………………….………….Pg. 16

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1. Contents of Bundle

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1.1 Parts ListingNote: For service parts, see your local dealer.

Key Part Number Description QTY

1 RC076011 Hose, Hydraulic 2

3 RC076012 Hose, Hydraulic 2

5 RC076013 Hose, Hydraulic 1

6 RC076015 Hose, Hydraulic 1

7 RC076014 Hose, Hydraulic 1

8 RC076016 Fitting, Adapter 1

9 RC042046 Tank, Hydraulic 1

10 RC042071 Fitting, Adapter 2

11 RC076023 Fitting, Adapter 2

12 RC076004 Fitting, Adapter 4

13 RC076022 Fitting, Adapter 2

14 RC076006 Fitting, Adapter 4

15 RC076005 Fitting, Adapter 4

16 RC076003 Fitting, Adapter 3

17 RC076008 Assembly, Hydraulic Manifold 1

18 RC076002 Pump, Gear 1

19 RC076007 Coupler, Hydraulic 2

22 RC052288 Harness, Power 1

23 RC076018 Adapter 1

24 RC042036 Ring, Snap 1

25 RC042035 Ring, Snap 1

26 RC042038 Ring, Snap 1

27 RC042040 Bearing, Tapered Roller 1

28 RC042037 Shim 5

29 RC076019 Gear 1

30 RC076009 Harness, Wiring 1

31 RC042052 Plug, Fitting 1

32 RC042051 Plug, Fitting 1

33 RC042059 Neck, Filler 1

34 RC042060 Clamp, Hose 1

35 RC042061 Hose, Hydraulic 1

36 RC042062 Line 1

- RC076021 Gasket, Paper 1

- RC076017 Strap, Cinch 2

- RC076024 Grommet 1

- 0161822 Screw, M8 x 20 Flange head cap 5

- 90701 Nut, M8 Flange 5

- 0161832 Screw, M10 x 25 Flange Head Cap 2

- 11115696 Screw, M12 x 40 Flange Head Cap 2

- 11127106 Screw, M10 x 20 Flange Head Cap 4

- 38631 Screw, M8 x 120 2

- 90701 Nut, M8 Flange 2

- RC076020 Clamp, P 3

- 63476 Band, Tie 15

- RC076010 Manual, Installation Instruction 1

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2. Service Information

Purpose of Bundle

This bundle allows for connection of two SCV functions for a dump wagon. Thetheoretical flow from this bundle is 30 gpm (113 lpm).

IMPORTANT:

1/ Follow all safety precautions as printed in the John Deere Operator Manual for theSelf-Propelled Forage Harvester.

2/ Follow all safety precautions as printed in the Operator Manual for the dump wagon.

3) The switches used in the control box of the bundle are latching. It is important to turnoff the individual functions when they are not moving so as to preventoverheating of oil and damage to components. Switches are lighted forconvenience but the circuits are not intended for continuous operation.

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3. Installation of Bundle

3.1 Install Hydraulic Reservoir

Drain and remove the hydraulic tank from the machine. Mark all hoses forinstallation in new tank upon completion of the change of tank

Note: Machines not equipped with the Pro Drive Transmission require theinstallation of a fill tube and return line from the filter to the tank. See partsdiagram for component location information regarding the fill tank. Also,depending on vintage of machine and options, a filter mount may need to bemoved slightly along the main frame of the machine to clear the new tank.

Note: Machines not equipped with the Pro Drive Transmission will require theinstallation of two plugs at the rear side of the tank. Plugs are included with thebundle. See Figure 1.

Reuse one hose clamp from production tank for installation of new fill neck onnon-Pro Drive machines.

Transfer all fittings from original tank to the new tank. Take care to remove allplugs and prevent trash from entering the new tank.

All tanks will have two additional ports to be used with the new pump. See Figure1 for one plug location. Other port is on fourth port from LH side of the machine,ORB Port of -20 size.

Install new hydraulic tank and all hydraulic lines. Inspect hose routings and adjustas necessary to prevent hoses rubbing on other components.

Figure 1. Tank InstallationKey 1 - Furthest port, plug installation

Key 2 - Plugs for Machines Without Pro-Drive Transmissions

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3.2 Install Hydraulic Pump

3.2.1 Assemble Adapter

Assemble auxiliary drive adapter. Refer to “SAE ‘B’ Rear Auxiliary Drive -Assemble Rear Auxiliary Drive Assembly” in the PowerTech Plus 6135 BaseEngine Repair Manual. Components needed are included in this bundle.

3.2.2 Assemble Hydraulic Pump to Adapter

Assemble gear pump to drive adapter using two M12 x 40 Flange Head CapScrews. Tighten hardware properly. Install SAE “B” pump gasket at pump face.Assemble the adapter to the engine per the instructions referenced above. Wheninstalling drive adapter to the engine, reuse the o-ring from the port cover on theadapter.

Install suction and pressure fittings at pump. Reference the parts page at thebeginning of this manual for proper component selection.

Note: Depending on vintage of forage harvester, it may be necessary to rerouteelectrical harnesses and/or coolant lines slightly to clear the new pump. Rerouteharnesses, hoses, and tubes as necessary. Do not permit existing lines to contactthe pump or adapter as vibration may cause damage over time.

Figure 2. Hydraulic Pump InstallationKey 1 – Adapter Key 2 – Pump

Key 3 – Pressure Port Key 4 – Suction Port

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3.3 Install Hydraulic Valve

3.3.1 Mark Location

Locate the inner body panel ahead of the right rear wheel fender.

At the top of the panel, locate and drill four holes at 7/16 in. (11 mm) diameter asshown in Figure 3 and Figure 4. Center the holes across the panel but keep asclose to the bend as possible. Set the manifold in the approximate mountinglocation to verify it clears all other components.

Figure 3. Valve Mounting LocationKey 1 – Hole Location

Figure 4. Hole Pattern for Valve Block

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3.3.2 Install Manifold and Quick Coupler

Install the main manifold as shown in Figure 5 using four (4) M10 x 20 Flange Bolts.Tighten hardware properly.

Figure 5. Manifold InstallationKey 1 – Manifold

Install the hydraulic fittings in the manifold. See parts page of this manual for portlocation and fitting identification.

Install the quick coupler at the left rear corner of the machine using two M8x200flange head bolts and M8 flange nuts. See Figure 6.

Install the hydraulic fittings in the quick couplers. See parts page of this manual forfitting identification.

Figure 6. Quick Coupler InstallationKey 1 – Coupler Key 2 – M8 Bolts

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3.3.3 Install Hydraulic Hoses

Install hydraulic hoses as indicated by the parts page of this manual. Installremaining fittings at the hydraulic tank in the remaining ports. Route hoses frommanifold along the fender, through the frame, to the quick couplers. Use cinch strapsto secure the hoses to the rear frame of the forage harvester.

Note: The manifold functions are in pairs, and side by side. Arrange the hoses fromthe manifold to the quick couplers as indicated in Figure 7 and Figure 8.

Note: The hoses are made from Bruiser™ material, to resist wear in sharp contactareas, but it is important to route the hoses through the frame as cleanly as possiblewithout rubbing on other hoses, sharp edges and overhangs.

Figure 7. Rear Hose RoutingKey 1 – Hoses Key 2 – Cinch Straps

Figure 8. Hose RoutingKey 1 – Manifold Key 2 – Fender Key 3 - Hoses

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3.4 Install Electrical

3.4.1 Install Harness at Rear

Note: It is permissible to route the harness out of the cab in two different manners.The first option is to route through the outer panel of the cab. The other is to routethe harness through the back of the cab at the same panel the other machine harnessespass through. The preferred location is the back of the cab but it may not be possibledepending on machine configuration.

If installing at the rear of the cab, drill a 7/8” (22mm) diameter hole in an area of thepanel away from other connectors. See Figure 9 for location.

Figure 9. Harness Location for Cab EntryKey 1 – Rear of Cab Key 2 – Side Panel of Cab

If installing at the side panel of the cab, remove the side panel from the right-rearcorner of the cab. Drill a 7/8” (22 mm) diameter hole as indicated in Figure 10.

Figure 10. Side Panel Entry to Cab

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Route the harness connectors for the manifold through the hole in the cab. Route theharness inside of the sheet metal for the fuel tank, along the rail. Use tie bands tosecure the harness to existing P-clamps along the rail.

Figure 11. Harness RoutingKey 1 – Harness Key 2 – Tie Band

Figure 12. Harness Routing to ManifoldKey 1 – Harness

Connections to the manifold are color-coded for wiring as follows:- Center coil – Brown- SCV 1A (closest to Cab) – Brown- SCV 1B (next to 1A) – Blue- SCV 2B (closest to radiator) – Pink- SCV 2A (next to 2B) – Purple

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3.4.2 Install Harness at Cab

Install the remaining harness inside the cab.

Install a grommet on the harness at the hole in the cab to seal the opening. Use high-temp RTV sealant around the grommet and harness to prevent moisture from entering thecab at the opening.

Route the harness along the other armrest harnesses and secure with tie bands as shownin Figure 13.

Figure 13. Harness Installation in CabKey 1 – Tie Band Key 2 – New Harness Key 3 – Existing Harness

There are three options for installation of the control box in the cab for the customer,depending on customer preference:

A) At side of armrestB) At windowC) At corner post

The preferred location is at the corner post due to accessibility and visibility. In any case,simply use the M8 Hardware to secure the control box in any of the locations. Take careto prevent damage any existing components or wiring during installation.

When preparing to mount the control box, it is recommended to drill two 3/8” (9 mm)diameter holes approximately 1-1/2” (40 mm) apart to secure the box to the mountinglocation. Remove the cover of the box prior to drilling holes to prevent damage to thewires.

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If installing on the corner post, remove the air vent to gain access to the inside of thecorner post to attach the hardware.

If installing on the side of the armrest, open the cover of the armrest to gain access to theinside of the armrest to attach the hardware.

If installing on the side of the cab, use the proper drill bit and tap to tap two holes for M8course thread bolts.

See Figures 14 through 16.

Figure 14. Preferred Mounting LocationKey 1 – Remove Air Vent Key 2 – Control Box

Figure 15. Alternate Mounting LocationKey 1 – Control Box

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Figure 16. Second Alternate Mounting LocationKey 1 – Armrest Key 2 – Control Box

Using the supplied connectors, connect the red power wire and black ground wire ofthe adapter harness to the matching wires of the main harness. Plug the adapter of theadapter harness into the power strip at the right side of the cab as shown in Figure 17.

Figure 17. Power Strip LocationKey 1 – Power Strip (under armrest, along side of cab)

Refill hydraulic system and check for leaks. Test function of all ports. If a functiondoes not operate correctly, first inspect wiring to the manifold.

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4. Technical Information

Hydraulic Schematic for Manifold

Figure 18. Manifold Functional Schematic

Figure 19. Electrical Functional Schematic