John Deere Timberjack 810d (Tm2123) Forwarder Repair Manual
Technical manual
TECHNICAL MANUAL
Forwarders TM2123
tm2123 14AUG03 (ENGLISH)
For complete service information also see:
8100D operator‘s Manual
1010D operator‘s Manual
1110D operator‘s Manual
1410D operator‘s Manual
1710D operator‘s Manual
Deere engine 6081 HTJ 03 Manual
F064833
F064199
F064826
F064197
F063390
. CTM 86
Deere engine 6068 HTJ 76 Manual CTM 104
Deere engine 4045 HTJ 77 Manual CTM 104
Fuel system Manual for 4,5 and 6.8 l diesel engines
Fuel system Manual for 8,1l diesel engine
TMC Workshop
Booms
Timbermatic 700 / 900
LCS Technical manual
CTM 331
CTM 255
F064497
F062701
F065312
F061919
Introduction
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
This technical manual is concise guide for specific machine type. This is on-the-job guide containing only the vital information needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
Serial Numbers
This Manual covers the following range of Forwarders serial numbers:
• WJ810D0001405...
• WJ1010D003505...
• WJ1110D001125...
• WJ1410D000475...
• WJ1710D000375...
OUTJ003,0000344 –19–22JAN01–1/1
JK11466,0000003 –19–14AUG03–1/1
Timberjack Contact Information
Please, contact our web site: www.Timberjack.com.
EL62757,000015B –19–19APR02–1/1
Technical Information Feedback Form
We need your help to continually improve our Technical manuals please FAX or mail your comments, ideas and improvements on this comment sheet.
SEND TO: Timberjack Oy P.O. Box 474
FIN-33101 Tampere Finland
Attn: Publications Supervisor
FAX NUMBER: +358 205 84 6160
Ideas, Comments, (Please state Page Number): OVERALL, how would you
SECTION 00 General Information
Group 0010 Safety features
Group 0020 General Specifications
Group 0030 Torque Values
Group 0040 Fluids and Lubricants
Group 0050 Transporting and Towing
Group 0060 Inspection and Procedures
SECTION 01 Wheels
Group 0110 Wheels Service
SECTION 02 Power Train
Group 0210 Theory of Operation
Group 0220 Transfer case
Group 0230 Drive shaft
Group 0240 Axles / Bogie
Group 0250 Brakes
SECTION 03 Hydraulic systems
Group 0310 General
Group 0320 Drive Hydraulics Service
Group 0325 Checking and Adjusting Drive
Group 1650 LCS- Loader Control System
Group 1660 Alternator
Group 1680 Starter Motor
SECTION 17—Frames
Group 1710 Frame installation
Group 1720 Frame Hinge
Group 1740 Operational Checks
SECTION 18—Cabin
Group 1810 Cabin Environment
Group 1820 Cabin Service
SECTION 19 Heating and Air Conditioning System
Group 1910 General
Group 1920 Air Conditioning / Heater Components
Group 1930 Diagnosing Air Conditioning / Heater System
SECTION 37 Booms
Group 3710 Forwarder Booms
Group 3720 Boom Parts Removal and Installation
Group 3730 Booms Removal and installation Hydraulics
Group 0330 Work Hydraulics
Group 0335 Work Hydraulics Service
Group 0340 Work Hydraulics Checking and
Group 3740 Diagnostic Information
Group 3750 Boom overall maintenance
SECTION 38 Decking Blade Adjusting
Group 0350 Hydraulic Cylinders
Group 0360 Hydraulic Schematics
Group 0370 Diagnostic Information
Group 0380 Appendix Manuals
SECTION 04—Engine
Group 0410 Engine mounting and dismounting
Group 0420 Engine
SECTION 05 Engine Auxiliary system
Group 0510 Auxiliary Systems
SECTION 16 Electrical-System
Group 1610 Main Electrical System
Group 1620 Electrical Schematics
Group 1630 Electrical Sensors
Group 1640 Control Systems
Group 3810 Theory of Operation
Group 3820 Service
SECTION 40—Grapple
Group 4010 Theory of Operation
Group 4020 Removal and Installation
Group 4030 Grapple Service
Group 4040 Grapple Rotator
Group 4050 Diagnostics
SECTION 45 Tool Drawings
Group 4510 Dealer Fabricated Tools
SECTION 80 Optional Equipments
Group 8010 Engine Preheater; EbenSpra¨cher
Group 8020 1410 and 1710D Decking Blade
Continued on next page
All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
Group 0010—Safety features
General
Decals and Signs.
Forwarders Safety Features
Recognize Safety Information
.00-0010-1
.00-0010-2
Service Recommendations for O-Ring
Boss Fittings
Service Recommendations for Flat Face
.00-0010-7 O-Ring Seal Fittings
Understand Signal Words .00-0010-8
Replace Safety Signs
Maintain Safety Cabin .00-0010-9
Park Machine Safely
Service Recommendations For Inch
00-0030-8
00-0030-10
Series Four Bolt Flange Fittings 00-0030-11
Service Recommendations for Metric
Series Four Bolt Flange Fitting 00-0030-12
Support Machine Properly 00-0010-11 O-ring Fittings 00-0030-14
Securing the Service Position
.00-0010-12 SAE Code 61 and 62 Flanges 00-0030-15
Use Proper Lifting Equipment .00-0010-13
Remove Paint Before Welding or Flare Fittings.................................................
Welding Cautions .00-0010-14
Attach Do not Operate Tag
Use of Radio-transmitters
Group
0040 Fluids and Lubricants
Operational Checkout Record Sheet.............00-0060-27
Troubleshooting Techniques 00-0060-30
Comply with instructions in this manual and also your company’s regulations.
Should there be any information or instructions in this manual that are not in compliance with local laws and regulations in force in the country or region where this equipment is operated, the local laws and regulations must take precedence.
This machine should not be operated or maintained by personnel other than those who have been thoroughly trained.
As the maintainer ensure that you become familiar with all occupational safety regulations pertaining to forest machinery as well as all safety instructions pertaining to this equipment. Observe the instructions provided in this manual and on all hazard and information decals on the machine.
OUTJ003,00004A0 –19–15FEB01–1/1
Decals and Signs
810D Decals and Signs
A Punched serial number on the front frame, on the right side of the machine. Continued on next page
1010D Decals and Signs
A Pressed manufacturing number, on the front frame, on the right side of the machine (optional)
1110D Decals and Signs
A—Punched serial number on the front frame, on the right side of the machine.
Continued on next page
–19–22APR02–3/5
1410D Decals and Signs
A Serial number B Behind the front frame, on On the front frame, on the the left side right side of the machine (optional)
1710D Decals and signs
A Serial number On the front frame, on the right side of the machine (optional)
B—Behind the front frame, on the left side
EL62757,00001E5 –19–22APR02–5/5
1—Secondary exit. The 4—Seat safety switch. No 7—Frame brake. Locks the 9—Emergency stop Stops the right-hand cap window can function can be engaged horizontal hinge of the machine and engages the be used as a secondary before somebody sits on machine. parking brake. exit from the cab. the seat. 8 Hand-held fire 10 Stairs, anti-slips on the
2 ROPS. Integrated rollover 5 Safety signs. Warn and extinguishers and fire steps, handrails. Help to and operator protective give safety information for extinguisher system (opt.) climb into the machine. structures fully enclose the operator. and protect the operator 6 Back-up alarm (opt). Allerts
3 Central warning light and bystanders when machine alarms (+buzzer).Alarm is reversing. when malfunctions occur.
Please remember, the Operator is the key to preventing accidents.
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
A signal word DANGER, WARNING, or CAUTION is used with the safety-alert symbol. DANGER identifies the most serious hazards.
DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
Replace Safety Signs
Carefully study all of the safety messages that are in this manual and on the machine.
More specific measures are illustrated with pictographs which may also be attached to the machine in locations pertinent to their respective message.
Keep safety signs in good condition. Repair or replace damaged signs.
Maintain Safety Cabin
Cabin is safety tested according to international ROPS, FOPS and OPS standards.
Do not operate the machine with the door open or any of the safety covers or protective devices removed.
It is important to keep the operator protective structure in place (doors, screens, windows, windshield, etc.) to minimize hazards from whipping or intruding objects.
The protection offered by ROPS, FOPS and OPS will be impaired if cabin
• is subjected to structural damage
• is involved in an overturn incident
• is in any way altered by welding, bending, drilling, or cutting
To maintain ROPS, FOPS and OPS protection, replace damaged cabin parts immediately. A damaged structure should be replaced, not reused.
Do not attach any parts on the cabin by welding nor drill any holes on it because it is a safety cabin. It is forbidden to modify the window fastening.
Before working on the machine:
1. Park machine on a level surface.
2. Lower decking blade to the ground.
3. Secure boom and grapple in woodbunk.
CAUTION: Prevent unexpected machine movement and possible injury. Connect frame locking pin to both frames before working in frame hinge pivot area.
4. Install frame locking pin before working in frame hinge pivot area.
5. Engage park brake.
6. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger.
7. Turn key switch OFF. Remove key from switch. (If maintenance must be performed with engine running, DO NOT leave machine unattended.)
8. Attach a “Do Not Operate” tag to the key switch.
IMPORTANT: The mechanic, and foreman must be familiar with the safety rules and regulations provided in this technical manual and in the decals of the machine, as well as with those related to national road traffic and occupational safety.
All safety rules and regulations in effect pertaining to the machine and workplace must be obeyed.
Support Machine Properly
Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When working underneath raised equipment, always ensure that the equipment is supported on rigid blocks, jack stands or other stable support.
Do not use jacks, the dozer blade, grapple attachment, or boom to hold the machine in a raised position.
Install the frame lock to prevent accidental articulation of the machine.
Securing
Service Position
Before dismantling parts subjected to load, hydraulic cylinders, stays, wheels, etc., they must be supported and relieved so as to eliminate the risk of injury.
Having raised the cab to its full height, always lock the safety support in place. Do not use any middle position. Make sure that nobody comes close to the cab when raising or lowering it.
CAUTION: When lowering cab, its lowering speed may accelerate when the cab is appr. 5 centimeters from the fastening studs. Make sure that nobody comes too close to the cab when lowering it.
CAUTION: The use of engine hoods and belly pans may have been facilitated by means of lift supports. Should these supports become defective, the cover may unexpectedly come down. Do not go under these parts when lifting/lowering them or before they are properly secured in the uppermost position.
Before disconnecting any load-bearing parts, secure the vertical hinge of the machine.
Likewise, also secure the horizontal hinge, if necessary, as applicable under the circumstances.
If the machine breaks down in difficult terrain, and cannot be moved prior to being repaired, take extra care to fully immobilize the machine and all rotating or moving parts.
Install the frame lock (1) to prevent accidental articulation of the machine.
Read the manual carefully and follow the maintenance procedures provided.
NOTE: The operator and serviceman are responsible for safety on and around the machine.
Use Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.
Remove paint before welding or heating:
• If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is ventilated to carry toxic fumes and dust away.
Before you start arc welding the machine, do the following
Ensure that the area to be repaired is cleaned of debris and combustible material. Have a charged fire extinguisher available and know how to use it.
1. The first actions
a. turn the main switch off
b. disconnect the wire (1) between the battery and the frame.
c. disconnect central unit wires of the automatic fire extinguishing system (Not in model 1010D) (A) and the tripping of the extinguisher (F).
d. disconnect ECU’s cable
e. disconnect Hub’s cables (5 cables)
2. Grounding
a. Connect the ground wire as close to the welding point as possible.
b. The welding current must never pass through bearings, joints, electrical equipment, or hydraulic systems.
3. The parts that must never be welded:
• boom fastening bolts
• control valves
• hydraulic pipes
4. The parts that must not be welded without the manufacturer’s instructions:
• castings
• cylinder loops.
5. The points and components to which it is forbidden to attach other parts by welding:
• castings
• boom ends
• cylinder fastening lugs
• corners of box girders
6. Welding.
Disconnect battery cable
ECU cables Hub
Weld inside, if possible, in facilities reserved for this purpose where the temperature is at least 10 degrees centigrade. If welding in other places, pay attention to local regulations and to circumstances as well as to the environment before you start welding. The welder must possess adequate skills and the permits required.
7. Assessment of damage.
In case a component or structure has been damaged as a result of an accident, excessive load, or fatigue, it is first necessary to determine whether the structure requires reinforcements or is ordinary repair sufficient.
8. Instructions.
Before you start welding you can also contact the manufacturer who has detailed instructions for each case.
Possibility of major damage is reduced by regularly cleaning and checking the machine and the boom.
Attach Do not Operate Tag
If the machine becomes disabled, attach a warning tag to the armrest controls. If the machine should not be started, remove the ignition key and, as applicable, turn the main switch to ’OFF’.
Before undertaking any maintenance or repair work, obtain permission. DO NOT perform any maintenance work without authorization.
Consult the manufacturer’s instruction manual and follow recommended procedures.
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
Using the Xenon Worklamp
When using the lamp, please notice the following:
• Avoid looking directly into the intensive light
• The lens may occasionally be cleaned
• No aggressive or abrasive cleaners may be used
IMPORTANT: Do not wash the lens with liquid substances while switched on or while the lens is still warm, as the lens might crack.
Safety instructions for replacing the Xenon bulb
Please observe the following safety instructions when replacing the Xenon bulb:
• Always switch off the headlamp before exchanging bulbs and disconnect from the power supply.
• Never insert foreign objects of fingers into the bulb holder.
• The electrician connection between headlamp and lamp ballast is under high voltage and must not be disconnected.
• The ballast unit must never be operated without a bulb, as dangerous voltage spark-over, which leads to damage, may occur at the bulb holder.
• Allow the bulb cool off.
• Wear safety goggles and gloves when exchanging bulb.
CAUTION: The glass body of the Xenon bulb is filled with various gasses and metal gasses under pressure (danger of splintering).
• Never touch the glass bulb of the Xenon lamp, touch the bulb at its base only.
• Use a clean cloth and alcohol to remove any fingerprints from the glass bulb.
• The Xenon lamp has to be operated only in the closed work lamp.
IMPORTANT: If a Xenon bulb breaks in a closed room (workshop), the room is to be aired and everyone must leave the room for 20 minutes to exclude any danger to health due to escaped gas.
• Dispose of used Xenon bulbs as hazardous waste.
The machine may only be used or repaired by personnel who have received training that is approved by Timberjack.
IMPORTANT: Do not let an untrained person operate the machine.
• Carry no passengers. The vehicle is provided and approved with seating for the operator only.
• Use the handrails and steps provided when mounting and dismounting from the machine. Do not climb onto the machine in any other fashion.
• The machine must not be operated by anyone under the influence of alcohol or drugs.
• Avoid operating the machine if you are tired or ill, as there is a greater risk of accident. Take sufficient breaks and observe local regulations on working hours.
Use of Radio-transmitters
IMPORTANT: Any use of equipment containing a radio transmitter (e.g., telephone, communications radio) that has an antenna inside the cab is strictly prohibited.
Such equipment must be permanently installed in a proper manner with an antenna on a suitable grounded plate outside the cab.
Never mount an antenna inside the cabin because it may cause malfunction in electrical devices!
CAUTION: Never use a headset when there is thunder or lightening. Observe the danger of an outer antenna so that it does not come into contact with power lines.
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Handle Fluids Safely—Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Handle Chemical Products Safely
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.
See your authorized dealer for MSDS’s on chemical products used with your machine.
Dispose of waste properly
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. CED,TX14740,7088 –19–30JUN00–1/1
