JOHN DEERE 643J FELLER BUNCHER REPAIR MANUAL TM2217 - PDF DOWNLOAD

643J and 843J FellerBuncher (SN.from 770001) Repair

REPAIR TECHNICAL MANUAL Wheeled models 643J (SN. 770001—), 843J (SN. 770001—) TM2217 08 APR 15 (ENGLISH)

For complete service information also see: 643J and 843J Wheeled Feller Buncher (SN. from 770001) Diagnostic

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John Deere Construction and Forestry

Pinted by Belgreen

TM2217-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD TECHNICAL INFORMATION FEEDBACK FORM Section 00 - GENERAL INFORMATION Group 01 - Safety Information Group 02 - General Specifications Group 03 - Torque Values Group 04 - 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 Group 0260 - Hydraulic System 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 0510 - Cooling System Group 0520 - Intake System Group 0530 - Exhaust System Group 0560 - 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 Section 20 - SAFETY, CONVENIENCE AND MISCELLANEOUS <- Go to Global Table of contents

TM2217-REPAIR TECHNICAL MANUAL

TM2217-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Group 2003 - Fire Extinguisher Group 2004 - Horn and Warning Devices Section 21 - MAIN HYDRAULIC SYSTEM Group 2160 - Hydraulic System Section 39 - BOOMS Group 3960 - Hydraulic System

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TM2217-REPAIR TECHNICAL MANUAL

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

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TM2217-REPAIR TECHNICAL MANUAL

TM2217-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.

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TM2217-REPAIR TECHNICAL MANUAL

GENERAL INFORMATION

(g) by Belgreen v2.0

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 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA

FAX NUMBER:

1-563-589-5800 (USA)

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

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THANK YOU!

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Section 00 page 1

TM2217-REPAIR TECHNICAL MANUAL

TM2217-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 00 - GENERAL INFORMATION Table of contents Group 01 - 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 Handle Engine Side Panels Safely ...................................................................................................... 18 Group 02 - General Specifications ....................................................................................................... 19 643J (Shown with Continuous Saw) .................................................................................................... 19 643J Engine Specifications .................................................................................................................. 19 643J Hydrostatic Transmission and Axles ........................................................................................... 20 643J Shear Specifications ................................................................................................................... 20 643J Tire Specifications ...................................................................................................................... 20 Other Information—643J ..................................................................................................................... 20 643J Drain and Refill Capacities .......................................................................................................... 21 843J (Shown with Continuous Saw) .................................................................................................... 22 843J Engine Specifications .................................................................................................................. 22 843J Hydrostatic Transmission and Axles ........................................................................................... 23 843J Saw Specifications ...................................................................................................................... 23 843J Tire Specifications ...................................................................................................................... 23 Other Information—843J ..................................................................................................................... 23 843J Drain and Refill Capacities .......................................................................................................... 23 Group 03 - Torque Values ..................................................................................................................... 25 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 25 Metric Bolt and Cap Screw Torque Values .......................................................................................... 26 Check Oil Lines and Fittings ............................................................................................................... 26

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TM2217-REPAIR TECHNICAL MANUAL

TM2217-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Service Recommendations for O-Ring Boss Fittings ........................................................................... 28 Service Recommendations for Flat Face O-Ring Seal Fittings ............................................................ 30 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 31 Service Recommendations For Flared Connections—Straight or Tapered Threads ............................ 32 Service Recommendations for Inch Series Four Bolt Flange Fittings .................................................. 34 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 35 Group 04 - Fuels and Lubricants ......................................................................................................... 36 Diesel Fuel .......................................................................................................................................... 36 Low Sulfur Diesel Fuel Conditioner ..................................................................................................... 36 Diesel Fuel Storage ............................................................................................................................. 36 Fuel Tank ............................................................................................................................................ 37 Do Not Use Galvanized Containers ..................................................................................................... 37 Diesel Engine Oil ................................................................................................................................ 38 Hydraulic System The hydraulic system tank 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 Reserv .................................................................................................................. 39 Recommended Hydraulic System Summer Oils ................................................................................. 40 Recommended Hydraulic System Winter Oils .................................................................................... 41 Grease ................................................................................................................................................ 41 Oil Filters ............................................................................................................................................ 42 Alternative and Synthetic Lubricants .................................................................................................. 42 Lubricant Storage ............................................................................................................................... 42 Mixing of Lubricants ........................................................................................................................... 42

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Group 01 - 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

TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

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.

Prevent Battery Explosions

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prepare for Emergencies

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

First Aid Kit 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.

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Prevent Acid Burns

Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: 1.Flush your skin with water.

2.Apply baking soda or lime to help neutralize the acid.

3.Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed: 1.Do not induce vomiting.

2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3.Get medical attention immediately.

Handle Chemical Products Safely

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Material Safety Data Sheet 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.

Avoid High-Pressure Fluids

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.

Park Machine Safely

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Remove the Key Before working on the machine: Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

Support Machine Properly

Support Properly Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. 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 implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Wear Protective Clothing

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

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

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

Work in Clean Area

Clean Work Area Before starting a job: Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand. <- Go to Section TOC

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Read all instructions thoroughly; do not attempt shortcuts.

Service Machines Safely

Moving Parts Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Beware of Exhaust Fumes

Beware of Exhaust Fumes Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

Illuminate Work Area Safely

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Section 00 page 8

TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Work Area Safely 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.

Replace Safety Signs

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

Use Proper Lifting Equipment

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.

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Section 00 page 9

TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Remove Paint Before Welding or Heating

Toxic Fumes Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating: Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

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 well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

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Section 00 page 10

TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Service Tires Safely

Explosive Tire and Rim Parts Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Avoid Harmful Asbestos Dust

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

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TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Practice Safe Maintenance

Keep Area Clean Understand service procedure before doing work. Keep area clean and dry.

Never lubricate or service machine while it is moving. Keep hands, feet, and clothing from power-driven parts.

Before servicing machine: Park the machine on a level surface.

Lower front-mounted equipment to ground.

Install frame locking pin before working in frame hinge pivot area.

Engage park brake.

Turn key switch OFF. Turn battery disconnect switch off.

Allow engine to cool.

If maintenance procedure must be performed with engine running, do not leave machine unattended.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

Turn battery disconnect switch to OFF before making adjustments on electrical systems or welding on machine.

Use Proper Tools

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Section 00 page 14

TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners.

Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting Timberjack specifications.

Dispose of Waste Properly

Recycle Waste Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Timberjack 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 Timberjack dealer.

Use Handholds and Steps

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Section 00 page 15

TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Use Handholds and Steps Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a three point contact with the steps and handrails, and face the machine. Do not use the steering wheel or any controls as handholds.

Never jump on or off the machine. Never mount or dismount a moving machine.

Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

Travel Safely

Travel Safely Know the location of bystanders before moving the machine.

Always keep the reverse warning alarm, if equipped, in working condition. It warns people when the machine starts to move in reverse.

Use a signal person when moving the machine in congested areas. Coordinate hand signals before starting the machine.

Service Cooling System Safely

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Section 00 page 16

TM2217-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 01: Safety Information

Cooling System Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Handle Starting Fluid Safely

Store Safely Starting fluid is highly flammable.

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.

Prevent Machine Runaway

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Section 00 page 17

TM2217-REPAIR TECHNICAL MANUAL

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