JOHN DEERE 843H BUNCHER SERVICE TECHNICAL MANUAL TM1845

643H and 843H FellerBuncher Repair

REPAIR TECHNICAL MANUAL Wheeled models 643H, 843H TM1845 22 FEB 05 (ENGLISH)

For complete service information also see: 643H (SN. 882120–), 843H (SN. 882128–), 740 (SN. 002154–), 840 (SN. 002154–) Feller-Buncher Diagnostic

TM2235

643H and 843H Feller-Buncher Diagnostic

TM1844

Alternators and Starting Motors

CTM77

Pump Drive Service Manual

CTM57

TeamMate II 1200, 1400,and 1600 Series Inboard Planetary Axles

CTM43

TeamMate II 1200, 1400, 1600 and 1800 Series Inboard Planetary Axles

CTM18

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

643H and 843H Feller-Buncher Repair

(g) by Belgreen v2.5

Table of contents FOREWORD TECHNICAL INFORMATION FEEDBACK FORM Section 00 - GENERAL INFORMATION Group 0001 - Safety Information Group 0002 - General Specifications Group 0003 - Torque Values Group 0004 - Fuels and Lubricants Section 01 - WHEELS Group 0110 - Powered Wheels and Fastenings Section 02 - AXLES AND SUSPENSION SYSTEM Group 0200 - Removal and Installation Group 0225 - Input Drive Shafts and U-Joints Section 03 - TRANSMISSION Group 0300 - Removal and Installation Group 0315 - Control Linkage Group 0350 - Gears, Shafts, Bearings, and Power Shift Clutch Group 0360 - Hydraulic System (Hydrostatic Transmission) Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEMS Group 0505 - Cold Weather Starting Aids Group 0510 - Cooling System Group 0515 - Speed Controls Group 0520 - Intake System Group 0530 - External Exhaust System Group 0560 - External Fuel Supply System Section 07 - DAMPENER DRIVE Group 0752 - Elements Section 08 - SPLITTER DRIVE (PUMP DRIVE GEARBOX) Group 0800 - Removal and Installation Group 0851 - Gears, Shafts and Bearings Section 09 - STEERING SYSTEM Group 0960 - Hydraulic System Section 10 - SERVICE BRAKES Group 1011 - Active Elements Group 1060 - Hydraulic System Section 11 - PARK BRAKE Group 1111 - Active Elements Section 16 - ELECTRICAL SYSTEM Group 1671 - Batteries, Support and Cables Group 1672 - Alternator, Regulator and Charging System Wiring Group 1674 - Wiring Harness and Switches Group 1676 - Instruments and Indicators Group 1677 - Motors and Actuators Section 17 - FRAME OR SUPPORTING STRUCTURE Group 1740 - Frame Installation Group 1746 - Frame Bottom Guards Section 18 - OPERATOR′S STATION Group 1800 - Removal and Installation Group 1810 - Operator′s Enclosure Group 1821 - Seat and Seat Belt Group 1830 - Heating and Air Conditioning <- Go to Global Table of contents

643H and 843H Feller-Buncher Repair

643H and 843H Feller-Buncher Repair

(g) by Belgreen v2.5

Section 20 - SAFETY, CONVENIENCE AND MISCELLANEOUS Group 2003 - Fire Extinguisher Group 2004 - Horn and Warning Devices Section 21 - MAIN HYDRAULIC SYSTEM Group 2160 - Hydraulic System Section 39 - SHEAR Group 3901 - Blades and Cutting Elements Group 3915 - Controls Linkage Group 3960 - Hydraulic System Section 99 - DEALER FABRICATED TOOLS Group 9900 - Dealer Fabricated Tools

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643H and 843H Feller-Buncher Repair

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643H and 843H Feller-Buncher Repair

643H and 843H Feller-Buncher Repair

(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.

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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643H and 843H Feller-Buncher Repair

643H and 843H Feller-Buncher Repair

(g) by Belgreen v2.5

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.

Technical Manual Fax SEND TO:

John Deere Dubuque Works P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, IA 52004-0538

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319-589-5800

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643H and 843H Feller-Buncher Repair

GENERAL INFORMATION

(g) by Belgreen v2.0

Dealer Acct. No.:

THANK YOU!

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Section 00 page 2

643H and 843H Feller-Buncher Repair

643H and 843H Feller-Buncher Repair

(g) by Belgreen v2.5

Section 00 - GENERAL INFORMATION Table of contents Group 0001 - Safety Information ........................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Handle Fluids Safely-Avoid Fires ........................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 2 Prevent Acid Burns ............................................................................................................................... 4 Handle Chemical Products Safely ......................................................................................................... 4 Avoid High-Pressure Fluids ................................................................................................................... 5 Park Machine Safely ............................................................................................................................. 5 Support Machine Properly .................................................................................................................... 6 Wear Protective Clothing ...................................................................................................................... 7 Work in Clean Area ............................................................................................................................... 7 Service Machines Safely ....................................................................................................................... 8 Beware of Exhaust Fumes .................................................................................................................... 8 Illuminate Work Area Safely ................................................................................................................. 8 Replace Safety Signs ............................................................................................................................ 9 Use Proper Lifting Equipment ............................................................................................................... 9 Remove Paint Before Welding or Heating ............................................................................................. 9 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 11 Service Tires Safely ............................................................................................................................ 12 Avoid Harmful Asbestos Dust ............................................................................................................. 12 Practice Safe Maintenance ................................................................................................................. 14 Use Proper Tools ................................................................................................................................. 14 Dispose of Waste Properly .................................................................................................................. 15 Use Handholds and Steps ................................................................................................................... 15 Travel Safely ....................................................................................................................................... 16 Service Cooling System Safely ........................................................................................................... 16 Handle Starting Fluid Safely ............................................................................................................... 17 Prevent Machine Runaway ................................................................................................................. 17 Group 0002 - General Specifications .................................................................................................. 19 643H (Shown with Continuous Saw) ................................................................................................... 19 643H Engine Specifications ................................................................................................................ 19 Hydrostatic Transmission and Axles ................................................................................................... 20 Shear Specifications ........................................................................................................................... 20 Tire Specifications .............................................................................................................................. 20 Other Information ............................................................................................................................... 20 Drain and Refill Capacities-643H ........................................................................................................ 21 843H (Shown with Continuous Saw) ................................................................................................... 22 843H Engine Specifications ................................................................................................................ 22 Hydrostatic Transmission and Axles ................................................................................................... 23 Saw Specifications .............................................................................................................................. 23 Tire Specifications .............................................................................................................................. 23 Other Information ............................................................................................................................... 23 Drain and Refill Capacities-843H ........................................................................................................ 23 Group 0003 - Torque Values ................................................................................................................. 25 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 25 Metric Bolt and Cap Screw Torque Values .......................................................................................... 26 Service Recommendations for O-Ring Boss Fittings ........................................................................... 27 Service Recommendations for Flat Face O-Ring Seal Fittings ............................................................ 29 <- Go to Global Table of contents

643H and 843H Feller-Buncher Repair

643H and 843H Feller-Buncher Repair

(g) by Belgreen v2.5

Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 30 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 31 Group 0004 - Fuels and Lubricants ..................................................................................................... 32 Diesel Fuel .......................................................................................................................................... 32 Low Sulfur Diesel Fuel Conditioner ..................................................................................................... 32 Diesel Fuel Storage ............................................................................................................................. 32 Fuel Tank ............................................................................................................................................ 33 Do Not Use Galvanized Containers ..................................................................................................... 33 Diesel Engine Oil ................................................................................................................................ 34 Hydraulic SystemThe hydraulic system tank also supplies the oil for the steering system, the service brake system and the hydrostatic system., Differential, Pump Drive Gearbox, Two-Speed Gearbox and Cab Tilt Pump Reservoir ....................................................................................................... 35 Grease ................................................................................................................................................ 36 Oil Filters ............................................................................................................................................ 36 Alternative and Synthetic Lubricants .................................................................................................. 36 Lubricant Storage ............................................................................................................................... 37 Mixing of Lubricants ........................................................................................................................... 37

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643H and 843H Feller-Buncher Repair

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Group 0001 - Safety Information Recognize Safety Information

Safety-alert symbol 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.

Understand Signal Words

Signal Words 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.

Handle Fluids Safely-Avoid Fires

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Section 00 page 1

643H and 843H Feller-Buncher Repair