JOHN DEERE 335D KNUCKLEBOOM TM11720 MANUAL PDF

335D Knuckleboom Log Loader (PIN: 1T0335DX**C184061—) Repair

REPAIR TECHNICAL MANUAL Trailer Mount models 335D (PIN: 1T0335DX**C184061—) TM11720 12 JAN 15 (ENGLISH)

For complete service information also see: 335D Knuckleboom Log Loader (PIN: 1T0335DX**C184061—) DiagnosticTM11718 JDLink (MTG) Technical ManualTM114519 185 Series Hydraulic CylindersTM-H185A Alternators and Starting MotorsCTM77 PowerTech E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel System With Denso HPCRCTM502 120 Series Hydraulic CylindersCTM120519 185 Series Hydraulic CylindersCTM114919 125 Series Hydraulic CylindersCTM109319 PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)CTM104 JDLINK/ZXLINK Machine Monitoring SystemCTM10006

John Deere Construction and Forestry

Pinted by Belgreen

TM11720-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD Section 00 - GENERAL INFORMATION Group 0001 - Safety Information Group 0003 - Torque Values Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEMS Group 0510 - Cooling System Group 0520 - Air Intake System Group 0530 - Exhaust System Group 0560 - External Fuel Supply System Section 07 - DAMPER DRIVE Group 1710 - Elements Section 17 - FRAMES Group 1700 - Removal and Installation Group 1740 - Frame Installation Group 1765 - Frame Hydraulic Cylinders Section 18 - OPERATOR′S STATION Group 1810 - Cab Group 1821 - Seat Group 1830 - Heating and Air Conditioning Section 19 - SHEET METAL AND STYLING Group 1910 - Engine Enclosure Section 20 - SAFETY, CONVENIENCE AND MISCELLANEOUS Group 2001 - Radio Section 21 - MAIN HYDRAULIC SYSTEM Group 2100 - Removal and Installation Group 2160 - Hydraulic System Group 2161 - Hydraulic Pumps Group 2162 - Control Valves Group 2164 - Hydraulic Tank Section 31 - BOOMS Group 3100 - Booms Removal and Installation Group 3165 - Booms Hydraulic Cylinders Section 43 - SWING SYSTEM Group 4300 - Removal and Installation Group 4350 - Swing Gear Case Group 4367 - Swing Motor Group 4370 - Swivel Rotary Manifold Section 99 - DEALER FABRICATED TOOLS Group 9900 - Dealer Fabricated Tools

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TM11720-REPAIR TECHNICAL MANUAL

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

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TM11720-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

TM11720-REPAIR TECHNICAL MANUAL

TM11720-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 00 - GENERAL INFORMATION Table of contents Group 0001 - Safety Information ........................................................................................................... 1 Safety and Operator Convenience Features ......................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 2 Operate Only If Qualified ...................................................................................................................... 3 Wear Protective Equipment .................................................................................................................. 4 Avoid Unauthorized Machine Modifications .......................................................................................... 4 Inspect Machine ................................................................................................................................... 4 Stay Clear of Moving Parts ................................................................................................................... 5 Handle Starting Fluid Safely ................................................................................................................. 5 Avoid High-Pressure Oils ...................................................................................................................... 6 Avoid High-Pressure Fluids ................................................................................................................... 6 Work In Ventilated Area ........................................................................................................................ 7 Prevent Fires ........................................................................................................................................ 7 In Case of Machine Fire ........................................................................................................................ 8 Prevent Battery Explosions ................................................................................................................... 8 Handle Chemical Products Safely ......................................................................................................... 9 Dispose of Waste Properly .................................................................................................................... 9 Prepare for Emergencies .................................................................................................................... 10 Clean Debris from Machine ................................................................................................................ 10 Use Steps and Handholds Correctly ................................................................................................... 11 Start Only From Operator′s Seat ......................................................................................................... 11 Use and Maintain Seat Belt ................................................................................................................ 12 Prevent Unintended Machine Movement ............................................................................................ 12 Avoid Work Site Hazards .................................................................................................................... 12 Use Special Care When Operating Loader .......................................................................................... 13 Keep Riders Off Machine .................................................................................................................... 13 Avoid Machine Tip Over ...................................................................................................................... 14 Use Care When Swinging Machine ..................................................................................................... 14 Operate Hoist (Boom) With Care ........................................................................................................ 15 Avoid Power Lines .............................................................................................................................. 15 Add and Operate Attachments Safely ................................................................................................ 16 Inspect and Maintain FOPS/OFPS ........................................................................................................ 16 Park And Prepare For Service Safely .................................................................................................. 17 Service Machines Safely ..................................................................................................................... 17 Service Cooling System Safely ........................................................................................................... 18 Remove Paint Before Welding or Heating ........................................................................................... 18 Make Welding Repairs Safely ............................................................................................................. 19 Drive Metal Pins Safely ....................................................................................................................... 19 Group 0003 - Torque Values ................................................................................................................. 20 Metric Bolt and Cap Screw Torque Values .......................................................................................... 20 Additional Metric Cap Screw Torque Values ....................................................................................... 21 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 23 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 24 Service Recommendations for O-Ring Boss Fittings ........................................................................... 25 Service Recommendations For Flared Connections—Straight or Tapered Threads ............................ 27 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 29 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations ....................................................................................................................... 30 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service

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TM11720-REPAIR TECHNICAL MANUAL

TM11720-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Recommendations ....................................................................................................................... 32 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations ....................................................................................................................... 34 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 36 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 37 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations ............................ 38 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings ........................................ 39 Service Recommendations For O-Ring Boss Fittings With Shoulder ................................................... 41 Metric 24° O-Ring Seal DIN 20078 Service Recommendations ........................................................... 44

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TM11720-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Group 0001 - Safety Information Safety and Operator Convenience Features

Safety Features Please remember, the Operator is the key to reducing accidents.

1.Secondary Exit. The rear and right window provide a large exit path, if the cab door is blocked in an emergency.

Breakout hammer is provided behind the operator′s seat.

2.FOPS/OFPS. The cab includes falling object and operator protection guards to protect the operator. The cab can be locked to reduce vandalism.

3.Pressurized Cab with Heater, Defroster, and Air Conditioner. Ventilation system circulates both outside and inside air through filters for a clean working environment. Built in defroster vents direct air flow for effective window defogging/deicing. Air conditioner provides a comfortable, temperature-controlled working environment.

4.Seat Belt with Retractor. A seat belt is provided in the cab. The seat belt retractor helps keep the belts clean and convenient to use.

5.Engine Fan Guard. A secondary fan guard inside the engine compartment helps prevent contact with engine fan blades.

6.Bypass Start Protection. Shielding over starter solenoid helps prevent dangerous bypass starting.

7.Handholds. Large conveniently placed handholds make it easier to enter or exit the operator′s station.

8.Steps. Wide slip resistant steps make entry and exit easier and also provides a place to clean shoes.

9.Pilot Hydraulics. Pilot reset switch is provided to enable/disable pilot hydraulics. Hydraulics must be enabled after the engine is started or the hydraulics are disabled.

10.Fire Extinguisher. A fire extinguisher is provided in the cab as standard equipment.

Recognize Safety Information

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Section 00 page 1

TM11720-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: 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

Safety Messages Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.

Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or <- Go to Section TOC

Section 00 page 2

TM11720-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

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.

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Section 00 page 3

TM11720-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Wear Protective Equipment

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

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

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

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. Radio or music headphones are not suitable to use for hearing protection.

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or failures resulting from their use are not covered by any John Deere warranty.

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance.

Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

Inspect Machine

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Section 00 page 4

TM11720-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, stabilizer and frame weldments for cracks.

Stay Clear of Moving Parts

Stay Clear Of Moving Parts Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining any part of machine with moving parts.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

Handle Starting Fluid Safely

Store Safely Starting fluid is highly flammable. <- Go to Section TOC

Section 00 page 5

TM11720-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.

Avoid High-Pressure Oils

Avoid High Pressure Oils

Avoid High-Pressure Oils This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.

Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

Avoid High-Pressure Fluids

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Section 00 page 6

TM11720-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

High Pressure Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage.

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

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. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

Work In Ventilated Area

Engine exhaust fumes Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Prevent Fires

Handle Fuel Safely

Clean Machine Regularly <- Go to Section TOC

Section 00 page 7

TM11720-REPAIR TECHNICAL MANUAL

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