PDF Operator Manual John Deere Timberjack 810D Forwarder - 954 KB
This operator's manual is the definitive guide for the John Deere Timberjack 810D Forwarder.
It contains vital information on safe operation, instrument panels, controls, and daily maintenance checks.
Familiarizing yourself with this manual is key to maximizing the productivity and safety of your forestry operations.
It's an essential resource for any operator to ensure the machine is used correctly and maintained properly.
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--- Page 1 ---
Timberjack 810D
Forwarder,)
(Serial No. WJ810D0001500--
OPERATOR’S MANUAL
810D
OMF066519 Issue 26.3.2004 (ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
The State of California requires the above two warnings.
Worldwide Construction
And Forestry Division
Printed in Finland
--- Page 3 ---
Warranty
Standard warranty clauses
The machine is covered by Timberjack’s guarantee in
compliance with the standard warranty clauses accepted
by the Timberjack group.
The manufacturer will not assume responsibility for the
machines delivered should the following conditions be
violated:
• The forwarder is exclusively operated and maintained
by experienced personnel who have been trained by
Timberjack or by a dealer authorized by Timberjack.
• The forwarder must be operated and maintained in
accordance with the instructions provided in this
manual.
• Only fuels and lubricants specified in this manual are
used.
• Only genuine spare parts are used
EL62757,000015D –19–19APR02–1/1
250, 1000 and 2000 Hours Service
The forwarder was checked and test driven before
delivery, and it can be put to use immediately. However,
to ensure good reliability it is very important to thoroughly
service the machine once it has been put to use.
THE WARRANTY GIVEN BY TIMBERJACK WILL BE
VALID PROVIDED THAT THE MACHINE IS HANDED
OVER FOR MAINTENANCE AT 250, 1000 AND 2000
RUNNING HOURS, THE SERVICE SHOP BEING ONE
AUTHORIZED BY TIMBERJACK.
Naturally the validity of warranty requires that during the
warranty period all the maintenance procedures have to
be performed according to the maintenance intervals
detailed in this manual.
EL62757,000015E –19–19APR02–1/1
2-1-1 032604
PN=7
--- Page 4 ---
Safety - Operating Precautions
Handle Starting Fluid Safely
CAUTION: Never use a liquid starting aid, if
engine is equipped with the pre-heat device.
The use with the pre-heat device will cause an
explosion in the intake manifold.
–UN–18MAR92
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
TS1356
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.
OUTJ003,000068F –19–14MAY01–1/1
Pay Attention to Bystanders
Keep windows clean and the cab floor free from loose
articles.
Keep the door closed when driving the machine. Do not
–UN–20DEC88
operate the machine with any of the safety covers or
protective devices removed.
Always keep the reverse warning alarm (if equipped) in
T6964AD
working condition.
Use a signal person when moving the machine in
congested areas (for example indoor service shop)
Coordinate hand signals before starting the machine.
The machine must not be operated by anyone under the
influence of alcohol or drugs.
Avoid using the machine when you are tired or ill, as there
is a greater risk of accident. Take sufficient breaks and
observe local regulations on working hours.
TX,05,FF3319 –19–08FEB93–1/1
3-3-4 032604
PN=17
--- Page 5 ---
Safety - Maintenance Precautions
Use Proper Tools
Use appropriate and correct size tools tools. Makeshift
tools and procedures can create safety hazards or cause
machine damages.
Illuminate your work area and service points adequately.
–UN–08NOV89
Secure that portable light has a bulb enclosed by a wire
cage. The hot filament of an accidentally broken bulb can
cause a risk of fire.
TS779
Use power tools only to loosen threaded parts and
fasteners. DO NOT use U.S. measurement tools on metric
fasteners.
Keep tools clean. Avoid bodily injury caused by slipping
wrenches.
Repair or replace worn or damaged tools, before initiating
repair work on your machine.
Use only service parts meeting manufacturer’s
specifications.
OUTJ003,00005AB –19–09MAY01–1/1
Support Machine Properly
Use 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. Make sure that
–UN–23AUG88
jack stands and lifting equipment are in good condition
and of adequate capacity.
Do not work under a machine that is supported solely by
a jack. If left in a raised position, hydraulically supported TS229
devices can settle or leak down.
AK12300,000004F –19–28FEB02–1/1
3-4-3 032604
PN=27
--- Page 6 ---
Operator’s Station
Start Key Positions
P—Vacuum pump (opt. eq.)
STOP—Engine turn-off
–UN–05MAR02
I—Power on
II— Empty
START—Starting.
T152192
In positions Start and II the load on the working
hydraulic pump is relieved making it easier for the
engine to run
EL62757,000016E –19–19APR02–1/1
Signal Lights
1—Turning signal
2—High beam
3—Work spot lights
4—Battery charging
5—Glow light
6—Parking brake
7—Brake system charge pressure
8—Supply pressure of driving hydraulics
–UN–30JAN03
T164093
EL62757,0000170 –19–19APR02–1/1
4-1-3 032604
PN=37
--- Page 7 ---
Operating the Machine, Control System
Alarms
The TMC control system is equipped with a
condition-monitoring system that greatly facilitates the use
and maintenance of the system. The alarms are recorded
in the alarm log.
The alarms are registered in ECU but they can bee
glanced only in TMC.
There are two kind of alarms: active and previous active
(see the TMC manual1 attached).
1
See alarms -section in TMC manual.
EL62757,000017B –19–21APR02–1/1
5-1-2 032604
PN=47
--- Page 8 ---
Starting and Turning Off the Engine
Before Starting the Engine for the First Time
in a Working Day
❒ Take an overall look at the machine (joints, hoses, etc.
• Check the engine oil level.
• Check the coolant level.
• Check the hydraulic oil level.
❒ Turn on the main switch (the switch is located on the
–UN–14APR03
left-hand side, under the cab).
❒ Check the fire extinguishing system. See separate
instructions by the manufacturer (optional equipment).
❒ Check the fuel level.
T189610
❒ Remove the lock pin of the emergency exit.
A—Main switch
EL62757,000018D –19–21APR02–1/1
5-3-1 032604
PN=57
--- Page 9 ---
Transportation of the Machine
Minilevers
For the transport minilevers are clamped to the extreme
position with rubber loops situated on outer side of control
panels.
EL62757,000018B –19–21APR02–1/1
Chains
Ensure that the machine or boom will not move during the
transport. The machine must be secured by at least two
chains (you can use a ratchet tensioner, for example). It is
good to utilize any support provided by, for instance, the
fenders of the truck or trailer if the tires of the machine
can be positioned against these. The chains secured to
the front frame and Rear frame must provide longitudinal
support for the machine both fore and aft, as well as
lateral support at suitable angles. Make sure that the
chains are not twisted after tightening to prevent the
tensioners from coming loose during the transport. In
addition, when securing the chains make sure that they
will not damage the forwarder. Finally, fit clearance lights
as stipulated by local laws.
NOTE: When travelling on public roads, all regulatory
requirements must be met in full.
EL62757,000018C –19–21APR02–1/1
5-5-2 032604
PN=67
--- Page 10 ---
Maintenance - Fluids and Lubricants
Diesel Fuel
Capacity Fuel tank 110 l (29 gal)
Recommended quality requirements for diesel fuel:
❒ Cetane number of 40 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20°C (-4 °F).
❒ When operating in cold circumstances use fuel that is
suitable for winter operation and has a cloud point
appearing at a lower level than the operating
temperatures.
❒ Sulfur content:
• Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
• The period for changing the engine oil must be
reduced by half if diesel fuel containing more than
0.5% sulphur is used.
• Do not use diesel fuel with sulfur content greater
than 1.0%.
NOTE: Do not use diesel fuel with sulfur content greater
than 1.0%.
IMPORTANT: Use only pure fuel. DO NOT mix used
engine oil or any other type of lubricant
with diesel fuel.
Bio-diesel fuels
Bio-diesel fuels may be used ONLY if the fuel properties
meet DIN 51606 or equivalent specification.
Continued on next page EL62757,0000151 –19–18APR02–1/3
6-1-3 032604
PN=77
--- Page 11 ---
Maintenance - General
Check all bolted joints
When the machine is new, check all bolted joints daily,
especially those between the boom and the frame and
those between the axles and the frame.
Keep tightening until the bolts maintain their tightness.
Check the hose joints, too. During ordinary operation, the
joints should be frequently checked in addition to
scheduled maintenance.
Bolt torque values
JOINT QUANTITY DIMENSION QUALITY TORQUE
Wheel bolts 8 M22x1,5 550 Nm
Cabine bolts 4 M16 100 Nm
Joints between axles and frame 4 M24 8.8 950 Nm
Horizontal bolts
Joints between axles and frame 8 M24 12.9 950 Nm
Vertical bolts
EL62757,0000221 –19–28NOV02–1/1
6-2-4 032604
PN=87
--- Page 12 ---
Maintenance - Every 10 hours or daily
Check the hydraulic oil level
1. Check the hydraulic oil level in the sight glass (1) of
the tank.
When you do this, the lift and jib cylinders have to be
in the innermost position.
2. If necessary add oil through the quick coupler (4) with
the hydraulic fill-up pump (3) (optional equipment).
• The quick coupler is mounted in a way that the new
oil enters the system through the filter.
• Also a manual pump can be used.
3. During the fill up, open venting screw (2). Do not forget
to close the screw.
–UN–09APR03
NOTE: Do not exceed the ’MAX’ mark. There always has
to be enough air space in the hydraulic oil tank,
because the fluid level goes up and down during
T189431
the operation.
See section 7-1, Vacuum pump (opt. equipment)
NOTE: Do not mix different type of oils.
Capacities Hydraulic tank min. 79 l (20.8 gal) /
max. 150 l (39.6 gal)
Mineral oil Summer oil SMRs norm SH 68
Winter oil SMRs norm SHS 32
Year-round oil SMRs norm SHS 46
If you use synthetic Neste Biohydrauli SE
biodegradeable oil: 46
–UN–11APR03
1—Oil level sight class
2—Venting screw
3—Switch, fill-up pump
4—Quick coupler - oil fill
T189555
EL62757,00000E8 –19–10APR02–1/1
6-4-1 032604
PN=97
--- Page 13 ---
Maintenance - Every 50 hours or Weekly
Grease the decking blade1
Grease the decking blade pins.
NOTE: There are six greasing points for the decking
blade. Four greasing points are external and two
–UN–13JUN01
are inside the frame. The belly pan must be
lowered to access the greasing points inside the
frame. Use a 1/2” wrench to lower the belly pan.
T142858
NOTE: Working in difficult circumstances, if necessary,
grease the decking blade daily.
1
Decking blade is an optional equipment.
EL62757,00000FE –19–10APR02–1/1
Check the battery electrolyte level.
Add purified water only into the battery.
EL62757,0000224 –19–28NOV02–1/1
Check the air conditioner
1. Check the amount of the refrigerant.
2. Check the service moisture indicator.
EL62757,00000FF –19–10APR02–1/1
Maintain the Boom
1. Check the boom slewing housing oil level
2. Check that the joint pins of the boom are secured
3. Check the sideways clearance of the extension booms.
4. Check the boom extension boom chains for tightness
5. Grease the rocker and cylinder bearings of the boom
and the slewing system bearing.
6. Lubricate the extension boom chains with oil
EL62757,0000101 –19–10APR02–1/1
6-5-2 032604
PN=107
--- Page 14 ---
Maintenance - Every 500 hours
IMPORTANT: Immediately after completing any oil
change, crank engine for 30 seconds
without permitting engine to start. This
will help insure adequate lubrication to
engine components before engine
starts.
9. Detach the connection (Y01) from the control unit of
the fuel pump and operate the engine by means of the
starter motor about 30 seconds. Reconnect the
connector again. Start engine and run to check for
possible leaks.
10. Stop engine and check oil level after 10 minutes. Oil
level reading should be within crosshatch of dipstick.
DPSG,OUOE003,8005 –19–18JUN99–2/2
6-7-2 032604
PN=117
--- Page 15 ---
Maintenance - Every 1000 hours
Replace the hydraulic return filter
CAUTION: Before working on the hydraulics,
park the machine on a level surface, lower the
decking blade, grapple to the ground, shut off
the engine.
IMPORTANT: When replacing the filter make sure that
no dirt enters the hydraulic system.
1. Open the vent screw (2) on top of the breather.
2. Remove the screws of cover (10)
–UN–09APR03
CAUTION: The filter cover is under spring
tension. Hold cover down while removing
screws
T189428
Clamp guarantees that the filter functions properly.
NOTE: Filter assembly consists of a filter element (7) and
a canister (6). Filter is in lock position inside the
canister.
IMPORTANT: The filter and the canister must be lifted
together from the tank to prevent the
contamination to flow into the tank.
3. Put the filter element and the canister into an oil
collecting sump
4. Unlock the filter element by twisting it counterclockwise
5. Remove the filter element and clean the canister
6. Replace the filter element and put it inside the canister.
2—Vent screw
3—Breather
4—Hydraulic oil tank
5—O-ring
6—Canister
–UN–09APR03
7—Filter element
8—Spring
9—O-ring
10—Cover
T189429
11—Screw
Continued on next page EL62757,000011C –19–10APR02–1/2
6-8-2 032604
PN=127
--- Page 16 ---
Maintenance - Every 2000 hours
Change Bogie Housings Oil
NOTE: Before changing the bogie housing oil, let the
machine stand for 30 minutes to allow impurities
to settle to the bottom.
–UN–13JUN01
1. Park the machine on a level surface. Engage the
parking brake. Install the frame lock.
2. Clean the area around the plugs.
T142919
3. Remove the filler plug to vent the bogie housing.
4. Remove the inspection plug. 1—Filler Plug
2—Inspection Plug
3—Drain Plug
5. Remove the drain plug and drain into a suitable
container.
If the oil is cloudy, replace all the oil in the bogie
housing.
NOTE: Dispose of waste properly. Do not dump oil on
ground or in sewers.
6. Install the drain plug. Add oil to the bogie housing
through the filler port until the oil level is up to the
inspection port.
7. Install the filler and inspection plugs.
NOTE: Any time plugs are removed, the O-ring seals
should be replaced.
8. Repeat the procedure at each bogie.
Bogie housing /each 52 l
Hypoid oil API GL-5 or MIL-L-2105 B or D
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90
OUTJ003,00006B8 –19–16MAY01–1/1
6-9-6 032604
PN=137
--- Page 17 ---
Hydraulic System: Hydraulic Oil Change
Filling the oil
IMPORTANT: Do not exceed the ’MAX’ mark.
There always has to be enough air
space in the hydraulic oil tank, because
the fluid level goes up and down during
the operation.
IMPORTANT: Do not mix different type of oils.
Add oil through the quick coupler (4) with the hydraulic
fill-up pump (3) (optional equipment). The quick coupler is
mounted in a way that the new oil enters the system
–UN–11APR03
through the filter.
NOTE: During the fill up, open the vent tap of the
hydraulic tank.
T189555
1. Clean the filling hose and remove the dust cap.
2. Place the hose into the canister containing new
hydraulic oil. 3—Switch for hydraulic fill-up pump
4—Quick coupler
3. Start the filling pump with switch (3).
4. Close the vent tap.
NOTE: Also a manual pump can be used.
EL62757,00000EC –19–10APR02–2/2
7-1-3 032604
PN=147
--- Page 19 ---
Hydrostatic System: Drive Motor adjusting
Checking and adjusting drive motors
pressure cut-off settings
The tools needed: 3-mm hex key and 10-mm wrench
1. Disconnect the parking brake solenoid Y41 from the
valve block. After this, the parking brake will stay
engaged.
2. Connect a pressure sensor to measuring point (216)
(...60 MPa) (0...8702 psi) and a pressure gauge to
measuring point (214) (...60 MPa) (0...8702 psi)
–UN–07APR03
3. Disconnect the connector of the motor steering (pos.
C)
4. Connect a 24 V tension with a separate cable from the
T189329
power outlet (2) next to the main switch (1)to the motor
steering (pos.C).
5. Start the engine
6. Engage high gear and rear wheel drive. Let the engine
idle.
7. Select the driving direction forward.
8. Set the adjustable speed range (snail) to 15 %
9. Press smoothly the drive pedal, the pressure will first
start to rise at measuring points (216) and (214).
–UN–07APR03
10. The engine rpm and the pressures are increasing, but
at a certain point the pressure of (216) stops to
increase and finally it starts to decrease.
T189330
C—Adjusting screw
(214)—Measure point, drive forward
(216)—Measure point, motor cut-off
(217)—Adjusting screw, motor cut-of
Continued on next page EL62757,00001A0 –19–21APR02–1/2
7-5-1 032604
PN=157
--- Page 20 ---
Brake System: Check and Adjust
Checking and Adjusting Parking Brake
Pressure
1. Start the engine
–UN–08APR03
2. Engage the working rpm and boom.
3. Use extension in movement or Y208 valve to raise the
pressure
T189379
4. Check the pressure at measuring point 114. The
pressure should be 3,0 MPa
5. If necessary, the pressure is adjusted fromadjusting
screw 112.
EL62757,00003C9 –22–10APR03–1/1
Checking the Work Brake
1. Connect a pressure sensor (0...30 MPa) (0...4351 psi)
to measuring points (305) and (304).
2. Start the engine
3. Disengage the parking brake. Symbol ’P’ on the TMC
–UN–13OCT02
display will be replaced by ’S’.
4. Make sure that the maximum pressure reading from
the pressure measuring points (305) and (304) are (6.5
... 7.0 MPa (943...1015 psi).
T152794
NOTE: The pressures cannot be adjusted.
EL62757,00001AB –19–21APR02–1/1
Checking the Drive Brake (Brake Pedal)
1. Connect a pressure sensor (0...30 MPa) (0...4351 psi)
to measuring points (305) and (304)
2. Start the engine and keep engaged the parking brake
3. Press the brake pedal and ensure that the pressure
–UN–13OCT02
reading from the (305) and (304) rises to 6.5 ... 7.0
MPa (943...1015 psi).
NOTE: The pressures cannot be adjusted.
T152794
EL62757,00001AC –19–21APR02–1/1
7-7-3 032604
PN=167
--- Page 21 ---
Electrical System
The RPM Sensor of the Drive Hydrostatics
Motor
The sensor (A4) is located on the left-hand side of the
drive hydrostatics motor. The sensor has an impact on the
function of the speedometer and odometer as well as on
the coupling of the work brake.
A—RPM Sensor
–UN–01OCT02
T159873
EL62757,00001B5 –19–21APR02–1/1
Hydraulic Tank Sensors
Hydraulic Oil Level Sensor
The sensor (5) trickers the alarm if the hydraulic oil levels
drops below the acceptable limit.
Hydraulic Oil Temperature Sensor
The sensor (6) sets off the alarm if the hydraulic oil
temperature exceeds the acceptable limit.
Hydraulic Oil Return Filter Sensor
The sensor (7) triggers the alarm if the hydraulic oil filter
has clogged.
5—Level Sensor
6—Temperature Sensor
7—Return Filter Sensor
–UN–15FEB03
T152795
EL62757,00001B6 –19–21APR02–1/1
8-1-9 032604
PN=177
--- Page 22 ---
Boom
Boom, Maintenance every 50 hours
Check the boom slewing housing oil level
The boom slew system and the lower bearing of the tower
are immersed in oil.
–UN–13JUN01
The oil level is checked in the measuring glass.
When the oil has flowed to the base after use, the oil level
T142875
must exceed the upper mark on the measuring glass. This
is to ensure that the slewing cylinder pipes will not
corrode. Boom slewing housing
1—Max oil level
As necessary fill in oil through the plug (1) 2—Min oillevel
Check that the joint pins of the boom are secured.
EL62757,00003C3 –22–06APR03–1/9
1. The joint pins must be well lubricated
2. Check that the joint pin are in good conditions.
3. Check that the pins are properly locked
Check the sideways clearance of the extension
booms.
–UN–13JUN01
T142876
Joint pins
Continued on next page EL62757,00003C3 –22–06APR03–2/9
10-1-7 032604
PN=187
--- Page 23 ---
Boom
Clean the Rotator Magnetic Plug
NOTE: The rotator is equipped with a magnetic plug to
collect metallic impurities from the oil. This plug
should be inspected and cleaned regularly.
–UN–13JUN01
To clean the magnetic plug:
1. Lower the grapple to the ground.
T142918
2. Remove and clean plug.
3. Install plug and tighten to specified torque. Grapple rotator magnetic plug
1—Magnetic lug
Specification
Rotator Magnetic Plug—Torque ........................................................ 60Nm
4. Rotate the grapple continuously in one direction
through ten complete rotations to circulate the oil from
the rotator to the tank.