John Deere 994 Hay & Forage Rotary Platform Diagnostic Technical Manual TM2051 PDF

994 (4 and 4.5 Meter) Rotary Platform Diagnostic and Repair

TECHNICAL MANUAL 994 Rotary Platform 4 Meter and 4.5 Meter TM2051 23 MAR 14 (ENGLISH)

John Deere Agriculture Pinted by Belgreen

TM2051-TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD SERVICE TECHNICIAN RESPONSE Section 10 - GENERAL Group 05 - Safety Group 10 - Specifications Group 15 - General Information Group 20 - Lubrication Section 20 - PLATFORM DRIVES Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Driveline Repair Group 20 - Cutterbar-Conditioner Gear Case Group 25 - Roll Drive Gear Case (Roll Conditioner) Group 30 - Belt Drives Section 30 - CUTTING COMPONENTS Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Cutterbar Repair Group 20 - Disks and Knives Section 40 - PLATFORM Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Platform Repair Section 50 - CONDITIONER Group 05 - General Information Group 10 - Diagnosing Malfunctions Group 15 - Roll Arms and Bearings Group 20 - Rolls Group 25 - Impeller Section 60 - ELECTRICAL SYSTEM Group 05 - General Information Group 10 - Connector Repair Section 99 - DEALER FABRICATED TOOLS Group 05 - Dealer Fabricated Tools

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TM2051-TECHNICAL MANUAL

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TM2051-TECHNICAL MANUAL

TM2051-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.

The technical manual contains two types of information: diagnostics and repair. Diagnostic groups help you identify the majority of routine failures quickly. Repair groups tell how to repair the components.

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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TM2051-TECHNICAL MANUAL

GENERAL

(g) by Belgreen v2.0

Service Technician Response We need your help to continually improve our technical publications. Please FAX or mail your comments, ideas and improvements on this comment sheet.

Address John Deere Ottumwa Works 928 East Vine Street Ottumwa, Iowa 52501-4352 Dept. 77 Attn: Service Department

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Section 10 page 1

TM2051-TECHNICAL MANUAL

TM2051-TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 10 - GENERAL Table of contents Group 05 - Safety ..................................................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Understand Signal Words ..................................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Handle Fluids Safely—Avoid Fires ......................................................................................................... 2 Prepare for Emergencies ...................................................................................................................... 2 Handle Chemical Products Safely ......................................................................................................... 3 Avoid High-Pressure Fluids ................................................................................................................... 3 Park Machine Safely ............................................................................................................................. 4 Support Machine Properly .................................................................................................................... 4 Wear Protective Clothing ...................................................................................................................... 6 Work in Clean Area ............................................................................................................................... 6 Service Machines Safely ....................................................................................................................... 7 Work In Ventilated Area ........................................................................................................................ 7 Illuminate Work Area Safely ................................................................................................................. 7 Replace Safety Signs ............................................................................................................................ 8 Use Proper Lifting Equipment ............................................................................................................... 8 Stay Clear of Rotating Driveline ........................................................................................................... 8 Remove Paint Before Welding or Heating ............................................................................................. 9 Avoid Harmful Asbestos Dust ............................................................................................................... 9 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 11 Practice Safe Maintenance ................................................................................................................. 12 Practice Safe Service Procedures ....................................................................................................... 12 Use Proper Tools ................................................................................................................................. 13 Construct Dealer-Made Tools Safely ................................................................................................... 13 Dispose of Waste Properly .................................................................................................................. 14 Live With Safety ................................................................................................................................. 14 Group 10 - Specifications ..................................................................................................................... 16 994 Rotary Platform Specifications (Specifications and design subject to change without notice.) ..................................................................................................................................................... 16 Metric Bolt and Screw Torque Values ................................................................................................. 18 Unified Inch Bolt and Screw Torque Values ........................................................................................ 19 Group 15 - General Information ........................................................................................................... 20 Machine Description ........................................................................................................................... 20 Product Identification Numbers .......................................................................................................... 20 Platform Serial Number ...................................................................................................................... 21 Metric And Customary Design ............................................................................................................ 21 Repair Components ............................................................................................................................ 21 Unauthorized Modifications ................................................................................................................ 21 Platform Lift Lockout .......................................................................................................................... 21 Care Of V-Belts ................................................................................................................................... 22 Tighten Bearing Locking Collar ........................................................................................................... 22 Group 20 - Lubrication .......................................................................................................................... 24 Grease ................................................................................................................................................ 24 Cutterbar Oil ....................................................................................................................................... 25 Gear Case Oil ...................................................................................................................................... 26 Alternative and Synthetic Lubricants .................................................................................................. 26 Mixing of Lubricants ........................................................................................................................... 26 Lubricant Storage ............................................................................................................................... 26 Perform Lubrication and Maintenance ................................................................................................ 27 <- Go to Global Table of contents

TM2051-TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

Group 05 - Safety 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.

Follow Safety Instructions

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Section 10 page 1

TM2051-TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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

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

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

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

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

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

Handle Fluids Safely—Avoid Fires

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.

Prepare for Emergencies

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Section 10 page 2

TM2051-TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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.

Handle Chemical Products Safely

Material Safety Data Sheet Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment 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 John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Avoid High-Pressure Fluids

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Section 10 page 3

TM2051-TECHNICAL MANUAL

Section 10 - GENERAL

Group 05: Safety

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

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

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

Park Machine Safely

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

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Section 10 page 4

TM2051-TECHNICAL MANUAL