JOHN DEERE 853J TRACKED FELLER BUNCHER TM10271 PDF MANUAL

853J, 903J, 953J Tracked Feller Buncher Repair

REPAIR TECHNICAL MANUAL Track models 853J, 903J, 953J TM10271 29 APR 15 (ENGLISH)

For complete service information also see: 853J, 903J, 953J Tracked Feller Buncher Diagnostic

TM10270

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OEM Engine Accessories

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CTM310

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120 Series Hydraulic Cylinders

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John Deere Construction and Forestry

Pinted by Belgreen

TM10271-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD Section 00 - GENERAL INFORMATION Group 0001 - Safety Information Group 0002 - General Specifications Group 0003 - Torque Values Group 0004 - Fuels and Lubricants Group 0005 - Inspection and Procedures Section 01 - TRACK DRIVE Group 0130 - Track System Group 0131 - Track Wear Limits and Replacement Section 04 - ENGINE Group 0400 - Removal and Installation Group 0407 - Oiling System Group 0420 - Fuel System Group 0422 - Starter Motor Group 0423 - Alternator Section 05 - ENGINE AUXILIARY SYSTEMS Group 0510 - Cooling System Group 0511 - Radiator and Fan Shroud Group 0520 - Air Intake System Group 0530 - Exhaust System Group 0540 - Engine Mounts Group 0564 - Fuel Tank Group 0574 - Engine Wiring Harness Section 17 - FRAMES Group 1740 - Frame Installation Group 1749 - Chassis Weights Group 1760 - Frame Hydraulics Section 18 - OPERATOR′S STATION Group 1810 - Cab Group 1830 - Heating and Air Conditioning Section 19 - SHEET METAL AND STYLING Group 1910 - Engine Enclosure Section 21 - MAIN HYDRAULIC SYSTEM Group 2100 - Remove and Install Group 2160 - Hydraulic System Group 2162 - Control Valves Group 2164 - Hydraulic Reservoir, Filters and Cooler Group 2165 - Cylinders Section 31 - BOOMS Group 3100 - Remove and Install Group 3165 - Hydraulic Cylinders Section 43 - SWING SYSTEM Group 4300 - Remove and Install Group 4350 - Swing Gearbox Group 4353 - Swing Bearing Section 99 - DEALER FABRICATED TOOLS Group 9900 - Dealer Fabricated Tools

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TM10271-REPAIR TECHNICAL MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.

<- Go to Global Table of contents

TM10271-REPAIR TECHNICAL MANUAL

GENERAL INFORMATION

(g) by Belgreen v2.0

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.

CAUTION:

: 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.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides 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.

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Section 00 page 1

TM10271-REPAIR TECHNICAL MANUAL

TM10271-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 00 - GENERAL INFORMATION Table of contents Group 0001 - Safety Information ........................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Replace Safety Signs ............................................................................................................................ 1 Follow Safe Procedures ......................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 2 Wear Protective Equipment .................................................................................................................. 3 Use Steps And Handholds Correctly ..................................................................................................... 3 Inspect Machine ................................................................................................................................... 3 Prevent Fires ........................................................................................................................................ 4 Handle Fluids Safely—Avoid Fires ......................................................................................................... 5 Clean Trash from Machine .................................................................................................................... 5 Handle Chemical Products Safely ......................................................................................................... 6 Dispose of Waste Properly .................................................................................................................... 6 Operate Only If Qualified ...................................................................................................................... 7 Control Pattern ..................................................................................................................................... 7 Use And Maintain Seat Belt .................................................................................................................. 7 Start Only From Operator′s Seat ........................................................................................................... 7 Operate Machine Safely ....................................................................................................................... 7 Avoid Power Lines ................................................................................................................................ 8 Avoid Tipping ........................................................................................................................................ 8 Keep Riders Off Machine .................................................................................................................... 10 Use Care When Swinging Machine ..................................................................................................... 10 Service Machines Safely ..................................................................................................................... 10 Practice Safe Maintenance ................................................................................................................. 12 Live With Safety ................................................................................................................................. 12 Park Machine Safely ........................................................................................................................... 13 Support Machine Properly .................................................................................................................. 13 Work in Clean Area ............................................................................................................................. 14 Work In Ventilated Area ...................................................................................................................... 14 Illuminate Work Area Safely ............................................................................................................... 14 Use Proper Tools ................................................................................................................................. 15 Use Proper Lifting Equipment ............................................................................................................. 15 Stay Clear Of Moving Parts ................................................................................................................. 16 Avoid High-Pressure Fluids ................................................................................................................. 16 Prevent Battery Explosions ................................................................................................................. 17 Prevent Acid Burns ............................................................................................................................. 18 Service Cooling System Safely ........................................................................................................... 18 Make Welding Repairs Safely ............................................................................................................. 19 Remove Paint Before Welding or Heating ........................................................................................... 19 Avoid Harmful Asbestos Dust ............................................................................................................. 20 Drive Metal Pins Safely ....................................................................................................................... 20 Avoid Unauthorized Machine Modifications ........................................................................................ 20 Add and Operate Attachments Safely ................................................................................................ 21 Group 0002 - General Specifications .................................................................................................. 22 853J, 903J, 953J Feller Buncher Machine Dimensions ......................................................................... 22 Group 0003 - Torque Values ................................................................................................................. 26 Torque Values — General ................................................................................................................... 26 Unified Inch Bolt and Screw Torque Values ........................................................................................ 27 Metric Bolt and Cap Screw Torque Values .......................................................................................... 28

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TM10271-REPAIR TECHNICAL MANUAL

TM10271-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Service Recommendations for O-Ring Boss Fittings ........................................................................... 29 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 31 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 32 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 33 Application of Adhesives — Through Holes ........................................................................................ 33 Application of Adhesives — Blind Holes .............................................................................................. 34 Application of Adhesives — Pre-Assembled Fasteners ....................................................................... 34 Application of Adhesives — Hydraulic Fittings .................................................................................... 35 Group 0004 - Fuels and Lubricants ..................................................................................................... 37 Fuels and Lubricants Specifications Table .......................................................................................... 37 Break-in Engine Oil ............................................................................................................................. 37 Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I ................................... 38 Track Drive and Swing Drive Oils ....................................................................................................... 40 Hydraulic System Oil .......................................................................................................................... 41 Diesel Fuel .......................................................................................................................................... 42 Low Sulfur Diesel Fuel Conditioner ..................................................................................................... 42 Diesel Fuel Storage ............................................................................................................................. 42 Handling and Storing Diesel Fuel ........................................................................................................ 43 Lubricity of Diesel Fuel ....................................................................................................................... 43 Grease ................................................................................................................................................ 44 Diesel Engine Coolant (engine with wet sleeve cylinder liners) .......................................................... 45 Supplemental Coolant Additives ......................................................................................................... 46 Operating in Warm Temperature Climates ......................................................................................... 46 Additional Information about Diesel Engine Coolants and Supplemental Coolant Additives .............. 47 Testing Diesel Engine Coolant ............................................................................................................ 48 Oil Filters ............................................................................................................................................ 48 Lubricant Storage ............................................................................................................................... 48 Alternative and Synthetic Lubricants .................................................................................................. 48 Mixing of Lubricants ........................................................................................................................... 48 Group 0005 - Inspection and Procedures ........................................................................................... 49 Troubleshooting Techniques ............................................................................................................... 49 Model and Serial Number Record ....................................................................................................... 50

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TM10271-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Group 0001 - Safety Information Recognize Safety Information

Safety Alert Symbols

Safety Alert Symbols This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury.

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

Follow Safety Instructions

Follow Safety Instructions Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently.

Be sure all operators of this machine understand every safety message. Replace operator′s manual and safety labels immediately if missing or damaged.

Replace Safety Signs <- Go to Section TOC

Section 00 page 1

TM10271-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Follow Safe Procedures

Follow Safe Procedures Unsafe work practices are dangerous. Understand service procedure before doing work; do not attempt shortcuts.

Prepare for Emergencies

First Aid Kit Be prepared if an emergency occurs or 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. <- Go to Section TOC

Section 00 page 2

TM10271-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Wear Protective Equipment

Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Use Steps And Handholds Correctly

Use Handholds And Steps Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

Inspect Machine

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Section 00 page 3

TM10271-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Inspect Machine Inspect machine carefully each day by walking around it before starting.

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

Inspect the boom and frame weldments for cracks.

Prevent Fires

Handle Fuel Safely

Clean Machine Regularly

Carry A Fire Extinguisher Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, <- Go to Section TOC

Section 00 page 4

TM10271-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

hydraulic lines and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.

Keep A Fire Extinguisher Available: Always keep a multi-purpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

Handle Fluids Safely—Avoid Fires

Handle Fuel Safely—Avoid Fires Handle fuel with care; it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.

Always stop engine before refueling machine. Fill fuel tank outdoors.

Handle Fluids Safely—Avoid Fires 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.

Clean Trash from Machine

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Section 00 page 5

TM10271-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Clean Trash From Machine Keep engine compartment, radiator, batteries, hydraulic lines, fuel tank, and operator′s station clean and free of debris.

Clean any oil spills or fuel spills on machine surfaces.

Temperature in engine compartment may go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.

Handle Chemical Products Safely

Handle Chemical Products Safely Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous.

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS). The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely.

Dispose of Waste Properly

Dispose Of Waste Properly Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly. <- Go to Section TOC

Section 00 page 6

TM10271-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Never pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your dealer for more information.

Operate Only If Qualified Do not operate this machine unless you have read the operator′s manual carefully and you have been qualified by supervised training and instruction.

Familiarize yourself with the job site and your surroundings before operating. Try all controls and machine functions with the machine in an open area before starting to work.

Know and observe all safety rules that may apply to your work situation and your work site.

Control Pattern Control pattern may be changed for attachment or operator preference. Try control pattern before operating. Be sure control pattern decals match machine operation.

Use And Maintain Seat Belt

Use and Maintain Seat Belt Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during other uses.

Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.

The complete seat belt assembly should be replaced every three years, regardless of appearance.

Start Only From Operator′s Seat

Operate Only From Operators Seat Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure all controls and working tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

Operate Machine Safely <- Go to Section TOC

Section 00 page 7

TM10271-REPAIR TECHNICAL MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.