JOHN DEERE 608S FELLER BUNCHER MANUAL TMF387452 - PDF DOWNLOAD

753G/753GL/608S/608B/608L HARVESTER Tests

TECHNICAL MANUAL Track models 608B, 608L, 608S, 753G TMF387452 22 FEB 05 (ENGLISH)

For complete service information also see: 608B FELLER BUNCHER (S.N. 608BX005014-) Repair

TMF387520

608B FELLER BUNCHER Operation and Test (SN. WC608BX005014-) Diagnostic

TMF387519

753GL/608L TRACKED FELLER BUNCHER Repair

TMF387451

608L / 753GL FELLER BUNCHER Diagnostic

TMF387450

703G/753G/608S FELLER BUNCHER Repair

TMF387449

608S/703G/753G FELLER BUNCHER Diagnostic

TMF387448

PowerTech 8.1 L Diesel Engines Base Engine

CTM86

Alternators and Starting Motors

CTM77

PowerTech 8.1L Diesel Engines Level 9 Electronic Fuel System With Denso High Pressure Common Rail

CTM255

PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic Fuel Systems with Bosch In-Line Pump)

CTM134

John Deere Construction and Forestry

Pinted by Belgreen

tmf387452-TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD TECHNICAL INFORMATION FEEDBACK FORM Section 01 - GENERAL INFORMATION Group 0002 - General Specifications Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10 - Operational Checkout Procedure Section 9015 - ELECTRICAL SYSTEM Group 10 - System Diagrams Group 15 - Sub-System Diagnostics Section 9025 - HYDRAULIC SYSTEM Group 05 - Theory of Operation Group 10 - System Operational Checks Group 15 - Diagnostic Information Group 25 - Tests

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tmf387452-TECHNICAL MANUAL

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

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tmf387452-TECHNICAL MANUAL

tmf387452-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.

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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tmf387452-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:Timberjack 925 Devonshire Ave. Woodstock Ontario., Canada N4S 5S1 Attn: Supervisor Technical Manuals FAX NUMBER:519-537-2664 Ideas, Comments (Please State Page Number):

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Section 01 page 1

tmf387452-TECHNICAL MANUAL

tmf387452-TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 01 - GENERAL INFORMATION Table of contents Group 0002 - General Specifications .................................................................................................... 1 608B / 608S / 753G Harvester .............................................................................................................. 1 608L / 753GL Harvester ........................................................................................................................ 3 Drain and Refill Capacities .................................................................................................................... 4

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tmf387452-TECHNICAL MANUAL

Section 01 - GENERAL INFORMATION

Group 0002: General Specifications

Group 0002 - General Specifications 608B / 608S / 753G Harvester

608B / 608S / 753G Harvester LEGEND:

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A7823 mm (308 in) B4648 mm (183 in.)

C4354 mm (171 in.)

Section 01 page 1

tmf387452-TECHNICAL MANUAL

Section 01 - GENERAL INFORMATION

D E F G H I J K L

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Group 0002: General Specifications

2946 mm (116 in.)

1830 mm (72 in.)

3150 mm (124 in.)

3712 mm (146 in.)

3727 mm (147 in.)

3454 mm (136 in.)

3556 mm (132 in.)

4420 mm (174 in.)

9017 mm (355 in.)

Section 01 page 2

tmf387452-TECHNICAL MANUAL

Section 01 - GENERAL INFORMATION

Group 0002: General Specifications

608L / 753GL Harvester

608L Harvester LEGEND: A B C D E F G <- Go to Section TOC

7823 mm (308 in) 4648 mm (183 in.)

4354 mm (171 in.)

2946 mm (116 in.)

1830 mm (72 in.)

3150 mm (124 in.)

3712 mm (146 in.)

Section 01 page 3

tmf387452-TECHNICAL MANUAL

OPERATIONAL CHECKOUT PROCEDURE

H I J K L M

(g) by Belgreen v2.0

3727 mm (147 in.)

3454 mm (136 in.)

3556 mm (132 in.)

4420 mm (174 in.)

9017 mm (355 in.)

465 mm (18.3 in.)

Drain and Refill Capacities Drain and Refill Capacities Metric

English

Fuel tank

650 L

172 gal

Cooling system

52 L

13.7 gal

19.0 L

20 qt

filter Hydraulic tank

197 L

52 gal

Swing gear box

4.5 L

4.6 qt

Track drive gearbox (each)

4.8 L

5.0 qt

Engine

lubrication,

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including

Section 9005 page 4

tmf387452-TECHNICAL MANUAL

tmf387452-TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Table of contents Group 10 - Operational Checkout Procedure ....................................................................................... 1 Hydraulic System Checks ..................................................................................................................... 1

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tmf387452-TECHNICAL MANUAL

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Group 10: Operational Checkout Procedure

Group 10 - Operational Checkout Procedure Operational Checkout Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of machine operation while doing a walk around inspection and performing specific checks from the operator′s seat.

Should you experience a problem with the machine, you will find helpful diagnostic information in this checkout that will pinpoint the cause. This information may allow you to perform a simple adjustment to correct the problem. Use the table of contents to help find adjustment procedures.

The information you provide after completing the operational checkout will allow you or your authorized dealer to pinpoint a specific test or repair needed to restore the machine to design specifications.

A location will be required which is level and has adequate space to complete the checks. No tools or equipment are needed to perform the checkout.

Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) prior to doing the checkout. The machine must be at operating temperature for many of the checks.

Start at the top of the left column and read completely down column before performing check. Follow this sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to next check. If a problem is indicated, you will be referred to either a section in this manual or to your authorized dealer for repair.

Hydraulic System Checks ( 1 ) Hydraulic System Warm-Up Procedure

Action:

Left Joystick Function

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Section 9005 page 1

tmf387452-TECHNICAL MANUAL

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Group 10: Operational Checkout Procedure

Foot Pedal Functions

Right Joystick Functions CAUTION: Controls may be changed for attachment or operator preference. Try control pattern before operating.

Operate engine at slightly above slow idle speed.

Operate machine in clear area.

Cycle all hydraulic functions to warm oil in hydraulic system.

Repeat procedure until hydraulic oil is at operating temperature.

Is hydraulic oil temperature gauge indicating oil at operating temperature?

→NOTE:

If temperature is below 0 °C (32 °F), see cold weather warm-up procedure in Group 9025-20.

Result: YES:Go to next check. <- Go to Section TOC

Section 9005 page 2

tmf387452-TECHNICAL MANUAL

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Group 10: Operational Checkout Procedure

( 2 ) Check Left Joystick Rocker Switch Attachment Tilt Function

Action:

Left Joystick Rocker Switch Operate engine at fast idle.

Operate machine in clear area.

Move left arm rest down. Turn the pilot shut off switch to the ON position.

Raise attachment off ground.

Press the left joystick rocker switch up.

Does the attachment tilt up?

Press the left joystick rocker switch down.

Does the attachment tilt down?

Result: YES:Left Joystick Attachment Tilt Function is OK. NO:See tilt circuit relief valve specifications and corresponding notes in Circuit Relief Valve Test in Group 9025-25. ( 3 ) Left Joystick Telescoping Boom Function Check

Action:

Left Joystick Telescoping Boom Function Start engine.

Press the left button switch on the left joystick. sss: Telescoping boom should extend.

Press the right button switch on the left joystick. sss: Telescoping boom should retract. →NOTE: Hydraulic functions should operate promptly and smoothly and stop when the control is released.

→NOTE: After checks are completed, shut off the engine.

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Section 9005 page 3

tmf387452-TECHNICAL MANUAL

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Group 10: Operational Checkout Procedure

Result: YES:Telescoping boom extend/retract function is OK. NO:See telescoping boom circuit relief valve specifications and corresponding notes in Circuit Relief Valve Test in Group 9025-25. ( 4 ) Left Joystick Leveler Forward/Back Tilt Function Check

Action:

Joystick Leveler Back Tilt Function

Joystick Leveler Forward Function With machine on level ground, start engine.

Press the bottom right finger switch on the left joystick. sss: Leveler should tilt the cab back.

Press the bottom left finger switch on the left joystick. sss: Leveler should tilt the cab forward. →NOTE: Hydraulic functions should operate promptly and smoothly and stop when the control is released.

After checks are completed, shut the engine OFF.

Result: YES:Left Joystick Leveler Forward/Back Tilt Function is OK. NO:Contact authorized dealer for service.

OK:Go on to next check. ( 5 ) Right Joystick Harvesting Attachment Rotate Function Check

Action:

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Section 9005 page 4

tmf387452-TECHNICAL MANUAL

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Group 10: Operational Checkout Procedure

Right Joystick Harvesting Attachment Rotate Start engine.

Move the right joystick left towards the operator. sss: Attachment should rotate left.

Move the right joystick right away from the operator. sss: Attachment should rotate right.

→NOTE: Hydraulic functions should operate promptly and smoothly and stop when the control is released.

→NOTE: After checks are completed, shut off the engine.

Result: YES:Right joystick harvesting attachment rotate function is OK. NO:Contact authorized dealer for service.

OK:Go on to next check. ( 6 ) Right Joystick Rocker Switch Attachment Open/Close Function Check

Action:

Right Joystick Attachment Open/Close Function Start engine.

Press the right joystick rocker switch trigger up. sss: Attachment should OPEN. Press the right joystick rocker switch trigger down. sss: Attachment should CLOSE.

→NOTE: Hydraulic functions should operate promptly and smoothly and stop when the control is released.

→NOTE: After checks are completed, shut off the engine.

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Section 9005 page 5

tmf387452-TECHNICAL MANUAL

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Group 10: Operational Checkout Procedure

Result: YES:Right Joystick Attachment Open/Close Function is OK. NO:Contact authorized dealer for service.

OK:Go on to next check. ( 7 ) Right Joystick Leveler Left/Right Function Check

Action:

Leveler Right Tilt Function

Leveler Left Tilt Function With machine on level ground, start engine.

Press the bottom right finger switch on the right joystick. sss: Leveler should tilt the cab right.

Press the bottom left finger switch on the right joystick. sss: Leveler should tilt the cab left.

→NOTE: Hydraulic functions should operate promptly and smoothly and stop when the control is released.

After checks are completed, shut the engine OFF.

Result: YES:Right Joystick Leveler Left/Right Function is OK. NO:Contact authorized dealer for service.

OK:Go on to next check. ( 8 ) Cycle Time Check

Action: Run engine at fast idle.

For stick in and stick out cycle tests, start with attachment 101.6 mm (4 in.) off ground.

For all other cycle times use the full stroke of the cylinder. sss: Cycle times must be within the following specifications: <- Go to Section TOC

Section 9005 page 6

tmf387452-TECHNICAL MANUAL

ELECTRICAL SYSTEM

(g) by Belgreen v2.0

Cycle Times Oil Temperature

60 ± 5°C (140 ± 9°F)

Engine Speed

Fast Idle

Travel speed switch at fast speed. Propel forward or reverse 20 m (65 ft)

21.5-22.5 sec 43.5-

Travel speed switch at slow speed. Propel forward or reverse 20 m (65 ft)

44.5 sec 43.0-44.0

Propel forward or reverse slow speed 3 track revolutions

sec 23.0-25.0 sec

Propel forward or reverse fast speed 3 track revolutions

15-17 sec

Swing Right (2 revolutions)

15-17 sec

Swing Left (2 revolutions)

8.0-9.0 sec

Hoist Raise (FS20 Attachment)

3.0-4.0 sec

Hoist Lower (FS20 Attachment)

2.0-3.0 sec

Stick In (FS20 Attachment)

5.0-6.0 sec

Stick Out (FS20 Attachment)

3.0-3.5 sec

Head Tilt Backward

4.4-5.0 sec

Head Tilt Forward

0.8-1.0 sec

Harvesting Clamp Close (FS20)

[ Other attachments may have different cycle times. ]

Harvesting Clamp Open (FS20)

0.8-1.0 sec

Accum. Clamp Close (FS20)

0.8-1.0 sec

[ Other attachments may have different cycle times. ]

[ Other attachments may have different cycle times. ]

Accum. Clamp Open (FS20)

0.8-1.0 sec

[ Other attachments may have different cycle times. ]

Attachment Tilt Right (FS20)

2.5-3.0 sec

[ Other attachments may have different cycle times. ]

Attachment Tilt Left (FS20)

2.0-2.5 sec

[ Other attachments may have different cycle times. ]

Result: YES:Go to next check.

NO:See Cycle Times in Group 9025-25.

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Section 9015 page 7

tmf387452-TECHNICAL MANUAL

tmf387452-TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 9015 - ELECTRICAL SYSTEM Table of contents Group 10 - System Diagrams ................................................................................................................. 1 Electrical System Schematics ............................................................................................................... 1 Timbermatic 10 Schematics ................................................................................................................. 3 Electrical Box Harness .......................................................................................................................... 8 Timbermatic 10 Electrical Box ............................................................................................................ 10 Timbermatic 10 Electrical System ...................................................................................................... 12 CHAIR Module Connections ................................................................................................................ 14 HUB Module Connections ................................................................................................................... 18 Group 15 - Sub-System Diagnostics ................................................................................................... 20 Controls Circuits Operational Information .......................................................................................... 20 Controls Circuits Theory of Operation ................................................................................................. 21 Controls Circuits Schematics .............................................................................................................. 24 Controls Circuits Diagnostic Procedures ............................................................................................. 25 Control Modules Theory of Operation ................................................................................................. 29 Control Modules Schematic ................................................................................................................ 32 Control Modules Diagnostic Procedures ............................................................................................. 33

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tmf387452-TECHNICAL MANUAL

Section 9015 - ELECTRICAL SYSTEM

Group 10: System Diagrams

Group 10 - System Diagrams Electrical System Schematics

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Section 9015 page 1

tmf387452-TECHNICAL MANUAL

Section 9015 - ELECTRICAL SYSTEM

Group 10: System Diagrams

Electrical System Schematic-Sheet 1 of 1 Electrical System Schematic - Sheet 1of 1 ID

Schematic Location

Description

Machine Location

A04

1113S

Display Module

Cab, Front

A05

1111S

Printer (optional)

Cab, Right Rear Wall

A06

1106V

Programming Wheel

Cab, Front

A07

1110N

Hub Module

Cab, Electrical Box

F20

1101E

Fuse, Timbermatic 10

Cab, Lower Panel

S36

1107H

Head Close

Right Hand Joystick

S37

1108H

Button, Head Open

Right Hand Joystick

S38

1109H

Button, Urea

Right Hand Joystick

S43

1112G

Button, Feed Roller Open

Left Hand Joystick

S44

1114H

Button, Tilt Down

Left Hand Joystick

S46

1116H

Button, Teleboom Retract

Cab, Joystick

S47

1116G

Button, Teleboom Extend

Cab, Joystick

S48

1117H

Button,Top Knives Open

Left Hand Joystick

S49

1117G

Button, Top Knives Closed

Left Hand Joystick

S50

1118H

Button, Knives Open

Left Hand Joystick

S51

1118G

Button, Saw

Left Hand Joystick

S52

1100U

Button, Preselect 1

Preselection Keypad

S53

1100T

Button, Preselect 2

Preselection Keypad

S54

1101U

Button, Preselect 3

Preselection Keypad

S55

1101T

Button, Preselect 4

Preselection Keypad

S56

1102U

Button, Preselect 5

Preselection Keypad

S58

1103U

Button, Preselect 7

Preselection Keypad

S59

1103T

Button, Preselect 8

Preselection Keypad

S60

1103U

Button, Preselect 9

Preselection Keypad

S61

1104T

Button, Preselect 10

Preselection Keypad

S62

1102T

Button, Preselect 6

Preselection Keypad

S63

1115H

Button, Tilt Up

Left Hand Joystick

S64

1111H

Button, Feed Roller Close

Left Hand Joystick

S65

1111G

Button, Feed Reverse

Right Hand Joystick

S66

1110H

Button, Feed Forward

Right Hand Joystick

S67

1110G

Button, Multi-tree

Left Hand Joystick

T02

1109U

Converter, 24/12V

Cab, Right Rear Wall

X101-A

1106N

Teleboom Out (Rotate Left)

Electrical Enclosure

X101-B

1105N

Teleboom In (Rotate Right)

Electrical Enclosure

X101-C

1106N

+24V (Ground)

Electrical Enclosure

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Section 9015 page 2

tmf387452-TECHNICAL MANUAL

Section 9015 - ELECTRICAL SYSTEM

Group 10: System Diagrams

Timbermatic 10 Schematics

Timbermatic 10 Schematic-Sheet 1 of 2 Timbermatic 10 Schematic - Sheet 1 of 2 ID

Schematic Location

Description

Machine Location

A01

101Q

Hub Module Timbermatic 10

Electrical Box Cab

Q01

102E

10A Fuse

Electrical Box Enclosure

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Section 9015 page 3

tmf387452-TECHNICAL MANUAL

Group 10: System Diagrams

Section 9015 - ELECTRICAL SYSTEM H01 105G

Main Switch

Electrical Box Enclosure

K01 101H

Relay

Cab, Fuse Panel

K02 107G

Relay

Cab, Fuse Panel

110B

Pump 1

Harvester Unit

111B

Pump 2

Harvester Unit

112B

Proportional Pump

Harvester Unit

S24 103G

Main Switch

Electrical Enclosure

109C

Voltage Converter 12/12V

Cab

XH1 116N

Connector CANbus

Hub Module

XH2 102T

Connector CANbus

Hub Module

XH3 113N

Connector CANbus

Hub Module

XH4 101N

Connector CANbus

Hub Module

XH5 116T

Connector CANbus

Hub Module

113B

Urea Pump

Harvester Unit

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Section 9015 page 4

tmf387452-TECHNICAL MANUAL

Section 9015 - ELECTRICAL SYSTEM

Group 10: System Diagrams

Timbermatic 10 Schematic-Sheet 2 of 2 <- Go to Section TOC

Section 9015 page 5

tmf387452-TECHNICAL MANUAL

Section 9015 - ELECTRICAL SYSTEM

Group 10: System Diagrams

Timbermatic 10 Schematic - Sheet 2 of 2 ID

Schematic Location

Description

Machine Location

A02

202P

Chair Module Timbermatic 10

Electrical Box Cab

XM1

200M

Connector

Chair Module

XM1-15

200M

+24V

XM1-11

201M

Urea

Right

Hand

XM1-12

201M

Feed Reverse

Joystick

Right

XM1-13

202M

Feed Forward

Hand

Joystick

XM1-18

205M

+24V

Right

Hand

XM1-19

214M

+24V

Joystick

XM1-6

203R

Ground

XM1-5

208R

Ground

XM2

206M

Connector

Chair Module

XM2-19

203M

Feed Rollers Close

Left Hand Joystick

XM2-20

204M

Multi Tree Handling

Left Hand Joystick

XM2-21

205M

Feed Rollers Open

Left Hand Joystick

XM2-1

206M

Preselect 1

Preselection Keypad

XM2-2

207M

Preselect 2

Preselection Keypad

XM2-3

207M

Preselect 3

Preselection Keypad

XM2-4

208M

Preselect 4

Preselection Keypad

XM2-5

209M

Preselect 5

Preselection Keypad

XM2-6

210M

Preselect 6

Preselection Keypad

XM2-7

211M

Preselect 7

Preselection Keypad

XM2-8

211M

Preselect 8

Preselection Keypad

XM2-9

212M

Preselect 9

Preselection Keypad

XM2-10

213M

Preselect 10

Preselection Keypad

XM2-17

214M

Head Open

Right Hand Joystick

XM2-18

217M

Head Close

Right Hand Joystick

XM2-11

218M

Programming Wheel OK

Cab

XM2-12

218M

Programming Wheel Cancel

Cab

XM2-13

218M

Programming Wheel

Cab

XM2-14

219M

Programming Wheel

Cab

XM2-23

219M

Programming Wheel

Cab

XM3-16

215K

+12V

XM3-16

216K

+12V

XM3-9

200R

Ground

XM3-13

201R

Tilt Up

Left Hand Joystick

XM3-14

202R

Tilt Down

Left Hand Joystick

XM3-18

203R

Knives Open

Left Hand Joystick

XM3-10

204R

Rotator Right

Left Hand Joystick

XM3-11

205R

Rotator Left

Left Hand Joystick

XM3-12

205R

Saw Switch

Left Hand Joystick

XM3-5

206R

Upper Knives Open

Left Hand Joystick

XM3-7

208R

Upper Knives Close

Left Hand Joystick

XM4-1

216R

Ground

CAN

XM4-2

216R

CAN H

CAN

XM4-3

216R

CAN Ground

CAN

XM4-4

217R

CAN Batt

CAN

XM4-5

217R

+24V

CAN

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Section 9015 page 6

tmf387452-TECHNICAL MANUAL

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