JOHN DEERE 748L SKIDDER TM13136X19 PDF MANUAL

640L, 648L and 748L Skidders (SN. C666893—690813; D679126—690813) Repair

REPAIR TECHNICAL MANUAL models 640L (SN. C666893—690813; D679126—690813), 648L (SN. C666893—690813; D679126—690813), 748L (SN. C666893—690813) TM13136X19 05 OCT 15 (ENGLISH)

For complete service information also see: 640L, 648L, and 748L Skidders (SN. C666893—690813; D679126—690813) Diagnostic

TM13135X1

JDLink (MTG) Technical Manual

9 TM114519

60 and 6000 Winches

CTM41

PowerTech 4045, 6068 Diesel Engine Level 14 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR) Level 14 ECU

CTM320

40 and 4000 Winches

CTM25

TeamMate II 1400 Series Inboard Planetary Axles

CTM138619

TEAMMATE V 1700 Series Outboard Planetary Axles

CTM129419

V1400 and 1600 Series Inboard Planetary Axles

CTM129119

120 Series Hydraulic Cylinders

CTM120519

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

John Deere Construction and Forestry

Pinted by Belgreen

TM13136X19-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD MANUAL IDENTIFICATION—READ THIS FIRST! Section 00 - GENERAL INFORMATION Group 0001 - Safety Group 0003 - Torque Values Section 01 - WHEELS Group 0110 - Powered Wheels and Fastenings Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0200 - Removal and Installation Group 0225 - Input Drive Shafts and U-Joints Group 0260 - Hydraulic System Section 03 - TRANSMISSION Group 0300 - Removal and Installation Group 0315 - Controls Group 0325 - Input Drive Shafts and U-Joints Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEM Group 0505 - Cold Weather Starting Aids Group 0510 - Cooling Systems Group 0520 - Intake System Group 0530 - Exhaust Systems Group 0560 - External Fuel Supply Systems Section 07 - DAMPER DRIVE Group 0752 - Elements Section 09 - STEERING SYSTEM Group 0930 - Secondary Steering Group 0960 - Hydraulic System Section 10 - SERVICE BRAKES Group 1011 - Active Elements Group 1060 - Hydraulic System Section 11 - PARK BRAKE Group 1100 - Removal and Installation Group 1160 - Hydraulic System Section 16 - ELECTRICAL SYSTEM Group 1600 - Removal and Installation Section 17 - FRAME, CHASSIS, OR SUPPORTING STRUCTURES Group 1740 - Frame Installation Group 1746 - Frame Bottom Guards Section 18 - OPERATOR′S STATION Group 1800 - Removal and Installation Group 1810 - Operator Enclosure Group 1815 - Pedal Assembly Group 1821 - Seat and Seat Belt Group 1830 - Heating and Air Conditioning Section 19 - SHEET METAL AND STYLING Group 1910 - Hood or Engine Enclosure Section 20 - SAFETY AND CONVENIENCE Group 2003 - Pressurized Water System Section 21 - MAIN HYDRAULIC SYSTEM Group 2160 - Hydraulic System Section 30 - WINCH <- Go to Global Table of contents

TM13136X19-REPAIR TECHNICAL MANUAL

TM13136X19-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Group 3000 - Removal and Installation Group 3015 - Control Valve Group 3025 - Input Drive Shafts and U-Joints Group 3050 - Drive and Clutches Section 32 - STACKING BLADES Group 3201 - Blades Group 3260 - Hydraulic System Section 37 - ARCH OR BOOM Group 3740 - Frames Section 38 - GRAPPLE Group 3803 - Grapple Mechanism Group 3840 - Frames Group 3860 - Hydraulic System Section 99 - DEALER FABRICATED TOOLS Group 9900 - Dealer Fabricated Tools

<- Go to Global Table of contents

TM13136X19-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

TM13136X19-REPAIR TECHNICAL MANUAL

TM13136X19-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

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.

<- Go to Global Table of contents

TM13136X19-REPAIR TECHNICAL MANUAL

TM13136X19-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Manual Identification—READ THIS FIRST! IMPORTANT: Use only supporting manuals designated for your specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) when choosing the correct manual.

Choosing the Correct Supporting Manuals John Deere skidders are available in different machine configurations based on the various markets into which they are sold.

Different supporting manuals exist for different machine configurations.

When necessary, product identification numbers are listed on the front covers of skidder manuals. These numbers are used to identify the correct supporting manual for your machine.

Product Identification Number

Product Identification Number (PIN) Plate

Example of Product Identification Number (PIN) Plate LEGEND: 1Product Identification Number (PIN) Plate 217-Character PIN The product identification number (PIN) plate (1) is located on machine frame by articulation joint. Each machine has a 17character PIN (2) shown on PIN plate.

<- Go to Global Table of contents

TM13136X19-REPAIR TECHNICAL MANUAL

TM13136X19-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level, and machine serial number.

The following is an example for a machine that meets Tier 2 and Stage II emission levels: PIN Identification Table 17-Character PIN Examples 1234

5

6

7

8

9

10

11

12

13

14

15

16

17

1DW6

4

8

L

X

_

_

C

X

X

X

X

X

X

(1—3) World Code: Identifies location where machine is manufactured.

(1—3) World Code 1DW ..........

World Code (manufacturing location)

1DW ..........

Davenport Works

1T8 ..........

Thibodaux Works

1T0 ..........

Dubuque Works

(4—8) Machine Model Identifier: Identifies model number.

(4—8) Machine Model Identifier 648L ..........

Machine Model Identifier

→NOTE: Characters 7—8 identify series and major machine configuration options. These characters will change from one machine to another.

(7—8) Machine Option Code Machine Option Code

X ..........

X ..........

Base Machine

U ..........

Utility Skidder

(9) Check Letter: This is a random character assigned by the factory. This is not used in machine identification.

(9) Check Letter _ ..........

Check Letter (variable)

(10) Manufacturing Year Code: Identifies year of machine manufacture.

(10) Manufacturing Year Code Manufacturing Year Code (variable)

_ ..........

D ..........

2013

E ..........

2014

F ..........

2015

G ..........

2016

(11) Engine Emission Code: Represents engine emission certification.

(11) Engine Emission Code C ..........

Engine Emission Code

C ..........

Tier 2 and Stage II

D ..........

Tier 3 and Stage III A

E ..........

Interim Tier 4 and Stage III

F ..........

B Final Tier 4 and Stage IV

(12—17) Machine Serial Number: Identifies machine serial number. This character will change from one machine to another.

<- Go to Global Table of contents

TM13136X19-REPAIR TECHNICAL MANUAL

TM13136X19-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 00 - GENERAL INFORMATION Table of contents Group 0001 - Safety ................................................................................................................................. 1 Information for European Union Directives and Customs Union Technical Regulations Compliance ....................................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 3 Follow Safety Instructions ..................................................................................................................... 4 Operate Only If Qualified ...................................................................................................................... 5 Wear Protective Equipment .................................................................................................................. 6 Avoid Unauthorized Machine Modifications .......................................................................................... 6 Inspect Machine ................................................................................................................................... 6 Stay Clear of Moving Parts ................................................................................................................... 7 Avoid High-Pressure Fluids ................................................................................................................... 7 Avoid High-Pressure Oils ...................................................................................................................... 8 Do Not Use Starting Fluid—6.8L Engines Only ...................................................................................... 8 Work In Ventilated Area ........................................................................................................................ 9 Avoid Static Electricity Risk When Refueling ........................................................................................ 9 Prevent Fires ...................................................................................................................................... 10 In Case of Machine Fire ...................................................................................................................... 11 Prevent Battery Explosions ................................................................................................................. 11 Handle Chemical Products Safely ....................................................................................................... 12 Dispose of Waste Properly .................................................................................................................. 12 Exhaust Filter Ash Handling and Disposal .......................................................................................... 13 Prepare for Emergencies .................................................................................................................... 13 Clean Debris from Machine ................................................................................................................ 14 Use Steps and Handholds Correctly ................................................................................................... 14 Start Only From Operator′s Seat ......................................................................................................... 14 Use and Maintain Seat Belt ................................................................................................................ 15 Prevent Acid Burns ............................................................................................................................. 16 Add and Operate Attachments Safely ................................................................................................ 16 Prevent Unintended Machine Movement ............................................................................................ 18 Avoid Work Site Hazards .................................................................................................................... 18 Operate Machine Safely ..................................................................................................................... 19 Keep Riders Off Machine .................................................................................................................... 20 Avoid Backover Accidents .................................................................................................................. 20 Avoid Machine Tip Over ...................................................................................................................... 20 Operating on Slopes ........................................................................................................................... 22 Operating or Traveling On Public Roads ............................................................................................. 22 Use Special Care When Operating ...................................................................................................... 22 Inspect and Maintain ROPS ................................................................................................................. 22 Keep the Operator Protective Structure (OPS) in Place ...................................................................... 23 Travel Safely ....................................................................................................................................... 23 Avoid Power Lines .............................................................................................................................. 23 Park and Prepare for Service Safely ................................................................................................... 24 Follow Tire Recommendations ............................................................................................................ 25 Service Tires Safely ............................................................................................................................ 26 Service Cooling System Safely ........................................................................................................... 26 Service Accumulator Systems Safely .................................................................................................. 27 Clean Exhaust Filter Safely ................................................................................................................. 27 Remove Paint Before Welding or Heating ........................................................................................... 29 Make Welding Repairs Safely ............................................................................................................. 30 Drive Metal Pins Safely ....................................................................................................................... 30

<- Go to Global Table of contents

TM13136X19-REPAIR TECHNICAL MANUAL

TM13136X19-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Group 0003 - Torque Values ................................................................................................................. 32 Hardware Torque Specifications ......................................................................................................... 32 Metric Bolt and Cap Screw Torque Values .......................................................................................... 33 Additional Metric Cap Screw Torque Values ....................................................................................... 34 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 36 Check Oil Lines And Fittings ............................................................................................................... 36 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 38 Service Recommendations for O-Ring Boss Fittings ........................................................................... 39 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 41 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 42 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 43

<- Go to Global Table of contents

TM13136X19-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Group 0001 - Safety Information for European Union Directives and Customs Union Technical Regulations Compliance

Skidder

CE Mark

<- Go to Section TOC

Section 00 page 1

TM13136X19-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

PIN Plate

EAC Marking

EU Flex Label LEGEND: 1 2 <- Go to Section TOC

PIN Plate CE Mark (if required) Section 00 page 2

TM13136X19-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

3 4

To the Customer

Group 0001: Safety

EAC Marking (if required) EU Flex Label (if required)

Effective June, 2006, all machines sold in the European Union must comply with the machinery directive 2006/42/EC and any amendments. Each machine meeting these requirements must bear the conformity mark CE. In addition, each machine must be accompanied with a Declaration of Conformity by the machine manufacturer. This declaration must be kept with the machine at all times and does not declare conformity to national road regulations.

Effective February 15, 2013, all machines sold in the Customs Union must comply with the Technical Regulations of the Customs Union TR TS 010/2011. Each machine meeting these requirements must bear the EAC Marking.

→NOTE:

This machine may need country approval for travel on public roads in Europe as some European countries require special equipment and approvals.

Product Identification Number (PIN), CE Mark, EAC Marking, and EU Flex Label Locations The machine is identified by the PIN that is stamped on a serial number plate. The PIN plate (1), CE Mark or EAC Marking, and if required, EU flex label are located in the middle section of the machine

→NOTE:

If this machine was certified (homologated) to the requirements of the European Union, there will be a CE mark affixed in indicated area (2). If required this machine will also be affixed with an EU Flex label (4) beside the CE mark in the indicated area.

If this machine was certified (homologated) to the requirements of the Customs Union, there will be a EAC marking (3) affixed in the indicated area.

Sound and Vibration Specifications [1] - Sound levels: The operator sound pressure and exterior sound power levels are 71 dB(A) or less (*) with properly maintained machines equipped with an enclosed cabin. For machines equipped with an open canopy, the sound pressure and exterior sound power levels are 79 dB(A) or less (*) with properly maintained machines. Sound levels were obtained using the test method specified per ISO 6396:1999.

→NOTE: Factors affecting listed values include operator performance, machine age, the condition of window and door seals, the use of accessories, environment, and any machine movement. (*) Data acquisition system precision values with a 2% technical uncertainty.

[2] - Vibration levels: The operator vibration levels with properly maintained machines operating on a flat dirt area free of large objects such as trees and rocks are: • Whole Body: 1.99 m/s 2 or less (*) Vibration levels were obtained using the test method specified per ISO 2631-1:1997 or ISO TR 25398 where applicable.

The hand arm vibration levels do not exceed 2.5 m/s 2 on this machine.

→NOTE: Factors affecting listed values include operator performance, machine age, seat condition, the use of accessories, environment, and any machine movement. (*) Data acquisition system precision values with a 2% technical uncertainty.

Recognize Safety Information

<- Go to Section TOC

Section 00 page 3

TM13136X19-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

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. Use this operator’s manual for correct safety sign placement. Be sure that 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. <- Go to Section TOC

Section 00 page 4

TM13136X19-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or 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 the operator′s manual has been read carefully, and you have been qualified by supervised training and instruction.

Operator should be familiar with the job site and 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 every work situation and work site.

<- Go to Section TOC

Section 00 page 5

TM13136X19-REPAIR TECHNICAL MANUAL

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