John Deere 810D 1010D 1110D 1410D 1710D Wheeled Forwarder Diagnostic And Repair Manual TM2123

[Martin Welker]

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John Deere 810D 1010D 1110D 1410D 1710D Wheeled Forwarder Diagnostic And Repair Manual TM2123
Size: 59.87 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Wheeled Forwarder
Type of Manual: Diagnostic And Repair Manual
Model: John Deere Wheeled Forwarder
810D (SN: WJ810D001405–)
1010D (SN: WJ1010D003505–);
1110D (SN: WJ1110D001125–);
1410D (SN: WJ1410D000475–);
1710D (SN: WJ1710D000375–)
Part Number: TM2123
Publication Date: 2005
Number of Pages: 992 Pages

Contents:
FOREWORD
TIMBERJACK CONTACT INFORMATION
TECHNICAL INFORMATION FEEDBACK FORM
Section 00 - GENERAL INFORMATION
Group 0010 - Safety features
General
Decals and Signs
Forwarders Safety Features
Recognize Safety Information
Understand Signal Words
Replace Safety Signs
Maintain Safety Cabin
Park Machine Safely
Support Machine Properly
Use Proper Lifting Equipment
Remove Paint Before Welding or Heating
Welding Cautions
Attach Do not Operate Tag
Illuminate Work Area Safely
Using the Xenon Worklamp
Driving and Service
Use of Radio-transmitters
Prepare for Emergencies
Handle Fluids Safely-Avoid Fires
Handle Chemical Products Safely
Dispose of waste properly
Avoid High-Pressure Fluids
Wear Protective Clothing
Group 0020 - General Specifications
Timberjack Tools For Forwarders
Use Proper Tools
General Component Locator
Machine Dimensions
Power Unit Specifications
Power Train Specifications
Hydraulic System Specifications
Tires Specifications
Boom Specifications
Rotator GV12-2
Grapple Specifications
Group 0030 - Torque Values
Tightening Torque for Bolted Joints
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
Service Recommendations for O-Ring Boss Fittings
Service Recommendations for Flat Face O-Ring Seal Fittings
Service Recommendations For Inch Series Four Bolt Flange Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Metric Flanged Head
O-ring Fittings
SAE Code 61 and 62 Flanges
Tapered Pipe Treads (NPTF and NPT)
Flare Fittings
Group 0040 - Fluids and Lubricants
Recommended Lubricants and Fluids
Fluid and Lubricant Capacities
Diesel Fuel
Engine Oil
Coolant
Hydraulic oil
Gear oil
Brake fluid
Cab lift pump
Lubricant Storage
Grease
Group 0050 - Transporting and Towing
Transporting the Machine
Towing
Stowing a Disabled Boom
Group 0060 - Inspection and Procedures
Frames
Machine Condition and Cleanliness
Decals Condition
Parking Brake Start Prevent
Ignition Switch
Parking Brake Operation
Work Brake Operation
Service Brake Operation
Steering Operation
Low Gear Select
High Gear Select
Differential Locks
Rear Wheel Drive Engage
Drive Shafts
Wheel Rims
Wheel Nuts
Tire Pressure
Condition and Cleanliness
Door and Door Latch
Door Gas Cylinder
Operator′s Seat
Seat Belt
Windows
Service Decal
Dome Light
Windscreen Wiper/washers
Intermittent Windscreen Wiper Button
Horn
AC/Heater Blower Operation
Air Conditioner Operation
Heater Operation
Work Lights
Radio
Condition and Cleanliness
Frame Joint
Panels and Covers
Machine Condition and Cleanliness
Decals Condition
Parking Brake Start Prevent
Ignition Switch
Parking Brake Operation
Work Brake Operation
Service Brake Operation
Steering Operation
Low Gear Select
High Gear Select
Differential Locks
Rear Wheel Drive Engage
Drive Shafts
Wheel Rims
Wheel Nuts
Tire Pressure
Condition and Cleanliness
Door and Door Latch
Door Gas Cylinder
Operator′s Seat
Seat Belt
Windows
Service Decal
Dome Light
Windscreen Wiper/washers
Intermittent Windscreen Wiper Button
Horn
AC/Heater Blower Operation
Air Conditioner Operation
Heater Operation
Work Lights
Radio
Condition and Cleanliness
Frame Joint
Panels and Covers
Operational Checkout Record Sheet
Troubleshooting Techniques
Section 01 - WHEELS
Group 0110 - Wheels Service
Service Tires Safely
Service Equipment and Tools
Wheel Removal
Wheel Installation
Wheel Inspection
Tire Removal and Installation
Tire Pressure
Anti-Slip and Bogie Tracks Fitting
Section 02 - POWER TRAIN
Group 0210 - Theory of Operation
Power Train Overall Description
Drive Coupling
Prepare Machine for Maintenance
Group 0220 - Transfer case
Other Material
Transfer Case Operation
Operating Power Transmission
Transfer Case Removal and installation
Checking High / Low Gear Oil
Changing High / Low Gear Oil
Group 0230 - Drive shaft
Essential Tools
Other Material
Drive Shaft General
Bearing Drive Shafts
Diagnose Drive Lines
Universals
Group 0240 - Axles / Bogie
Essential Tools
Other Material
Bogie axle general
Bogie Axle Removal and Installation
Axle Removal and Installation
Bleeding the Differential Lock
Checking Differential Oil
Change Bogie Axle Differential Oil
Change Single Axle Differential Oil
Checking Bogie Housings Oil
Changing Bogie Housings Oil
Check Single Axle Wheel Ends ( Hub gear) Oil
Change Single Axle Wheel Ends Oil
Bogie Bearing Grease Points
Group 0250 - Brakes
Description
1010D Checking and Adjusting
Checking and Adjusting
Section 03 - HYDRAULIC SYSTEMS
Group 0310 - General
Essential Tools
Other Material
Drive Hydraulic System
Work Hydraulic System
Hydraulic Oil Cooling
Control of Transmission
Conversion Table for Pressures
Boom Control Valve
Thermostat valve
Hydraulic Pressure Filter
Service Accumulator Systems Safely
Group 0320 - Drive Hydraulics Service
General
Essential Tools
Service Equipment
Renew the pressure filter
Drive Motor Removal And Installation
Servicing Drive Motor
Drive Pump Removal and Installation
Servicing Drive Pump
Control Piston Zero Position Adjustment
Bleeding the Drive Hydraulics
Hydrostatic Pump and Motor Start-up Procedure
Group 0325 - Checking and Adjusting Drive Hydraulics
Checking and Adjusting 1010D
Charge pressure (810D supply pressure)
Pressure Cut-Off Valve Setting of The Drive Pump
Pressure Cut-Off Setting for the Drive Motor
1710D Checking and adjusting drive motors pressure cut-off settings
1410D and 1710D Checking the function of hydrostatic flushing valve
Group 0330 - Work Hydraulics
Work Pump Theory of operation
Work Pump Start-up Procedure
Valves General
1010D Bleeding Work Hydraulic System
810D,1110D and 1410D Bleeding Work Hydraulic System
1710D Bleeding Work Hydraulic System
Group 0335 - Work Hydraulics Service
Work Pump Removal and Installation
Work Pump Service
Auxiliary Valve Removal and Installation
Boom Control Valve Removal and Installation
Boom Control Valve Disassembly and Assembly
Thermostat valve Removal and Installation
Hydraulic Pressure Filter Replacement
Replace the hydraulic return filter
Hydraulic Tank Removal and installation
Grapple Cylinder Servicing - Supergrip SG 260/360
Grapple Cylinder Servicing - Loglift GF25/GF35
Group 0340 - Work Hydraulics Checking and Adjusting
Essential Tools
Adjusting 1010D Pressures
Adjustment of Pressure Difference
Adjusting the Maximum Pressure
Adjusting the Boom Pressure
Adjusting Auxiliary Functions
Adjusting Frame Brake
Adjusting Proportional Decking Blade
Hydraulic Function Cycle Times
Motor Start of Control Point Adjustment
Hose Inspection and Replacement
1010D Direction Selection Solenoids Inspection and Replacement
Group 0350 - Hydraulic Cylinders
Cylinder Service
Cylinder Internal Seal Leak Test
Group 0360 - Hydraulic Schematics
Content
Hydraulic Diagram Symbols
810D Hydraulic diagrams
1010D Hydraulic Diagrams
1110D Hydraulic Diagrams
1410D Hydraulic Diagrams
1710D Hydraulic Diagrams
Group 0370 - Diagnostic Information
Cab Tilt System
Hoses and Fittings
Hydraulic Tank and Filters
Work Pump
Cab Tilt System
Cab Tilt Cylinder and Hoses
Cab Tilt Safety Support
Hoses and Fittings
Hydraulic Tank and Filters
Work Pump
Cab Tilt System
Cab Tilt Cylinder and Hoses
Cab Tilt Safety Support
Diagnose Drive Hydraulics
Diagnose Hydraulic/ Hydrostatic Cooling System
Diagnose Cab Tilt Hydraulics
Diagnose Brake Hydraulics
Troubleshooting
Work Hydraulic Checkout Record Sheet
Hydrostatic System Checkout Record Sheet
Group 0380 - Appendix Manuals
Rexroth Drive Motors
Rexroth Drive Pumps
Rexroth Hydraulic Work Pumps
VOAC / Parker Boom Control Valves
Section 04 - ENGINE
Group 0410 - Engine mounting and dismounting
Engine Removal
Engine Installation
Group 0420 - Engine
See Deere Engine manuals for detailed information
Section 05 - ENGINE AUXILIARY SYSTEM
Group 0510 - Auxiliary Systems
Auxiliary System Manuals
Section 16 - ELECTRICAL-SYSTEM
Group 1610 - Main Electrical System
System Description
Main Switch
Batteries
Using Booster Battery
1010D Fuses and Relays
Fuses On The Left-Hand Side in the Engine Compartment
Instrument Box Fuses and Relays
Wiring Visual Inspection
ECU (Engine Control Unit)
Using a Digital Multimeter
Electrical Circuit Malfunction
Inspect Visually Electrical System
Seven Step Electrical Test Procedure
1010D Drive Pedal Adjustment
Group 1620 - Electrical Schematics
Electrical Schematic Information
Electrical Schematic Symbols
810D Wiring Diagrams
1010D Wiring Diagrams
1110D Wiring Diagrams
1410D Wiring Diagrams
1710D Wiring Diagrams
Group 1630 - Electrical Sensors
810D Location of ECU and engine sensors
1010D, 1110D and 1410D Location of ECU and engine sensors
1710D Engine Sensors
1010D Hydraulic Tank Sensors
810D, 1110D, 1410D and 1710D Hydraulic Tank Sensors
810D, 1110D and 1410D The RPM Sensor of the Drive Hydrostatics Motor
1710D The RPM Sensor of the Drive Hydrostatics Motor
Group 1640 - Control Systems
TMC Control System
Electronic Control System Terminology
Monitoring Engine Parameters
Measuring Temperature
Measuring Engine Speed
Water In Fuel (WIF) Sensor
Pump Control Valves (PCVs)
Electronic Injector (EI) Wiring Harness Connector
Alarms
Engine Control Unit (ECU)
Group 1650 - LCS- Loader Control System
Theory of Operation
LCS Service Display
Connecting the Service Display to the System
Using the Service Display
Display Diagram
Main Window
Alarm Windows
Boom Settings
Adjusting the Boom During Operation
Balance Window
Measurement Window
Transmission Measurement Window
Auxiliary Equipment Measurement Window
Module Outputs and Inputs
System Settings
Joystick Settings
Service Window
Group 1660 - Alternator
Alternator Removal
Alternator Installation
Group 1680 - Starter Motor
Starter Motor Removal
Starter Motor Installation
Section 17 - FRAMES
Group 1710 - Theory of operation
Overall description
Group 1720 - Frames
Essential Tools
Other Material
Frames, Covers and Panels
Frame Joint
Frame Joint Removal
Frame Joint Bearings Installation
Hinge Pin Installation
Frame Brake Removal
Frame Brake Unit Servicing
Group 1730 - Middle Joint
Overall description
Frame Brake Theory Of Operation
Friction Pad Changing
Frame Brake Pressure
Frame Joint
Frame Hinge Drive Shaft
Frame Joint Bearing Drive Shaft
Steering
Group 1740 - Operational Checks
Frames
Condition and Cleanliness
Frame Joint
Panels and Covers
Condition and Cleanliness
Frame Joint
Panels and Covers
Section 18 - CABIN
Group 1810 - Cabin Environment
About This Group
Overall Description
1010D Safety and alarms
1010D Cabin Component Locator
1010D Operator′s seat
1010D Controls
Emergency Stop Button
Warning Lamps and Buzzer
Preparedness for telephone
Cabin Component locator
Operator′s seat
1110D and 1410D Armrest Controls
1710D Armrest Controls
Dashboard
Group 1820 - Cabin Service
Other Material
Cabin Service
1010D Lifting and Lowering the Cab
How to Lift and Lowering the the Cab
1010D Cab Tilt Cylinder Replacement
1010D Cab Mount Replacement
1010D Cab Removal and installation
Section 19 - HEATING AND AIR CONDITIONING SYSTEM
Group 1910 - General
Theory of operation
AC/Heater Controls
Proper Refrigerant Handling
Risks and Counter-Measures
First Aid
Group 1920 - Air Conditioning / Heater Components
Introduction
AC Compressor
AC Condenser
AC Filter-dryer-receiver
AC Expansion Valve
AC Evaporator
Group 1930 - Diagnosing Air Conditioning / Heater System
Cab Heater System
Hoses and Fittings
AC Compressor Check
AC Compressor Belt Check
AC Condenser Check
AC Receiver Dryer Check
AC Evaporator Check
Outside Air Intake Filter Check
Inside Air Intake Filter Check
Exhaust Air Filter Check
Cab Door and Window Seals Check
Cab Air Recirculation Baffle
Heater Hoses and Fittings
Heater Water Shutoff Valve
Hoses and Fittings
AC Compressor Check
AC Compressor Belt Check
AC Condenser Check
AC Receiver Dryer Check
AC Evaporator Check
Outside Air Intake Filter Check
Inside Air Intake Filter Check
Exhaust Air Filter Check
Cab Door and Window Seals Check
Cab Air Recirculation Baffle
Heater Hoses and Fittings
Heater Water Shutoff Valve
AC Checkout Record Sheet
Diagnose Heater/Air Conditioner
Refrigerant Hoses and Tubing Inspection
Refrigerant Level Check
Leak Testing
Section 37 - BOOMS
Group 3710 - Forwarder Booms
Theory of Operation
Boom Slew System
Group 3720 - Boom Parts Removal and Installation
Other Material
Essential Tools
Assembly Instructions
Main Boom Cylinder
Slewing Cylinders Installation
Boom Slew Cylinders Service
1010D Outer Cylinder
CF572 Extension Cylinder
Group 3730 - Booms Removal and installation
Outer Boom Removal
Outer Boom Installation
Main Boom Removal
Main Boom Installation
Tower Removal
Tower Installation
Tower Service
Group 3740 - Diagnostic Information
Boom Operational Checkout Record Sheet
Diagnose Boom
Group 3750 - Boom overall maintenance
See Operator`s Manual F063390 for Detailed Service instructions
Section 38 - DECKING BLADE
Group 3810 - Theory of Operation
Decking Blade
Group 3820 - Service
Other Material
Decking Blade Cylinder Removal
Decking Blade
Decking Blade Hoses
Decking Blade
Decking Blade and Arms
Arm and Cylinder Pins
Hoses and Fittings
Cylinders Rod Seals
Decking Blade Up / Down
Decking Blade and Arms
Arm and Cylinder Pins
Hoses and Fittings
Cylinders Rod Seals
Decking Blade Up / Down
Section 40 - GRAPPLE
Group 4010 - Theory of Operation
Supergrip SG 260 / 360
Loglift GF25/35 Grapple
Group 4020 - Removal and Installation
Other Material
Supergrip SG 260/360 Grapple
Supergrip SG 260/360 Grapple Removal
Supergrip SG 260/360 Grapple Rotator Removal
Supergrip SG 260/360 Grapple Cylinder Removal
Supergrip SG 260/360 Grapple Cylinder Installation
Supergrip SG 260/360 Grapple Rotator Installation
Supergrip SG 260/360 Grapple Installation
Loglift GF25/GF35 Grapple
Loglift GF25/GF35 Grapple Removal
Loglift GF25/GF35 Grapple Rotator Removal
Loglift GF25/GF35 Grapple Cylinder Removal
Loglift GF25/GF35 Grapple Cylinder Installation
Loglift GF25/GF35 Grapple Rotator Installation
Loglift GF25/GF35 Grapple Installation
Group 4030 - Grapple Service
Supergrip SG 260/360 Grapple Bushings Replacement
Loglift GF25/GF35 Grapple Connecting Rod Bearings Replacement
Loglift GF25/GF35 Grapple Frame Bearings Replacement
Group 4040 - Grapple Rotator
Essential Tools
Grapple Rotator Servicing
Cleaning the Rotator Magnetic Plug
Group 4050 - Diagnostics
Grapple
Grapple Link
Grapple Frame and Arms
Grapple Arm and Cylinder Pins
Hoses and Fittings
Cylinder Rod Seals
Grapple Rotate Motor
Grapple Rotate
Grapple Open/Close
Grapple Link
Grapple Frame and Arms
Grapple Arm and Cylinder Pins
Hoses and Fittings
Cylinder Rod Seals
Grapple Rotate Motor
Grapple Rotate
Grapple Open/Close
Section 45 - TOOL DRAWINGS
Group 4510 - Dealer Fabricated Tools
TA0898 Frame Support
TA0899 Axle Support
TA0902 Frame Support
TA0904 Wrench Adapter, boom Bolts
TA0908 Nut Driver
TA0909#1 Driver, Drive Shaft Bearing Cups
TA0909#2 Driver, Drive Shaft Bearing Cone
TA0909#3 Driver, Drive Shaft Seals
TA0910 Bearing Driver
TA0911 Bearing Driver
TA0912 Bearing Driver
TA0913 Bearing/Pin Driver
TA0914 Pin Driver
TA0917 Nut Driver
TA0918 Lifting Bracket
TA0949 Cab Support Bar
479265-1 O-ring Seal Expander
479265-2 Seal Pusher
479266-1 Piston Installation Tool
F603762/F603764 Axle Mounting Bolt Installation Tool
Section 80 - OPTIONAL EQUIPMENTS
Group 8010 - Engine Preheater; EbenSpracher
Operation and maintenence
Group 8020 - 1410 and 1710D Decking Blade
Lowering the Decking Blade
Decking Blade′s Float
Group 8030 - Fire Extinguisher
General
Fire Alarm and Actions
After a fire
Control unit