Operator’s Manual for John Deere Timberjack 1010D Forwarder PDF

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John Deere Timberjack 1010D Forwarder Operator’s Manual – PDF DOWNLOAD

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John Deere Timberjack 1010D Forwarder Operator’s Manual – PDF DOWNLOAD

• P/N: F067058_NK
• Language: English
• Division: Forestry
• Product Lines: Forwarders
• Publication Type: Operator’s Manuals
• Associated Models: 1010D
• Series: D SERIES
• Serial: WJ1010D003747 – 3799

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere Timberjack 1010D Forwarder Operator’s Manual – PDF DOWNLOAD

Contents 2
Introduction 8
Operator’s manual for Timberjack Forwarder 8
Foreword 10
Timberjack Contact Information 11
Technical Information Feedback Form 11
Warranty 12
Standard warranty clauses 12
Timberjack Standard Warranty 12
Machines with Extended Coverage (For specified machines only!) 12
Periodic Maintenance 13
Safety – Safety Features 14
1010D Forwarder Safety Features 14
Safety – General Precautions 15
General 15
Recognize Safety Information 15
Understand Signal Words 15
Prepare for Emergencies 16
Wear Protective Clothing 16
Handle Fluids Safely—Avoid Fires 17
Handle Chemical Products Safely 17
Replace Safety Signs 18
Maintain Safety Cabin 18
Use of Radio-transmitters 19
Safety – Operating Precautions 20
Inspect machine 20
Attach Do not Operate Tag 20
Prevent Machine Runaway 21
Use Handholds and Steps 21
Secondary exit 22
Handle Starting Fluid Safely 22
Pay Attention to Bystanders 23
Carry no passangers 23
Use Seat Belts 24
Avoid Risks under Difficult Conditions 24
Stop Working if Machine Gives an Alarm 24
Loading the Machine 25
Keep Danger Zone Clear 25
Avoid Crush Points 25
Power Cables 26
Driving/Transporting on Public Roads 27
Ensure Safety before Driving on Frozen Water 27
Fire Prevention 28
What To Do If the Machine Catches Fire 29
Safety – Maintenance Precautions 30
General 30
Securing the Service Position 31
Use Proper Clothing 31
Use Proper Tools 32
Support Machine Properly 32
Shut Down Engine, Disconnect Battery Cable 33
Service Cooling System Safely 33
Prevent Battery Explosions 33
Prevent Acid Burns 34
Replacing the Xenon Worklamp 35
Start Only from Operator’s Seat 35
Beware of Exhaust Fumes 36
Avoid High Pressure Fluids 36
Avoid Heating near Pressurized Fluid Lines 37
Make Welding Repairs Safely 37
Service Tires Safely 38
Refueling and Servicing Fuel System 38
Dispose of Waste Properly 39
Operator’s Station 40
Cab Component Locator 40
Dashboard Component Locator 41
Warning lights and alarms 42
Left Armrest Controls 47
Right Armrest Controls 47
Window Washers and Wipers 48
Boom Control Lever, Left 49
Boom Control Lever, Right 50
Radio 51
AC/Heater Controls 51
Overhead Panel Switches 54
Instrument Box 55
Cab Air Filters 56
Main Switch 56
Seat 57
Lifting and Lowering the Cab 59
Lifting the Cab 59
Lowering the Cab 60
Starting and Driving: Controls 62
Seat Safety Switch 62
Cab Steps Safety Switch 63
Emergency Stop Button 64
Secondary Exit 64
Working RPMs with a Manual Throttle 65
Using the Boom 66
Brakes 67
Frame Brake 68
Drive Direction Select 68
Steering 69
High/ Low Gear Select 69
Differential Locks 70
Decking Blade 71
Starting the Machine 72
Before Starting the Engine for the First Time in a Working Day 72
Normal Starting 73
Starting a cold engine 75
After starting 76
Using Booster Batteries 77
Turning off the Engine 77
Driving the Machine 78
Travel Speeds 78
Off-Road Driving 78
Driving on Road 80
Transporting the Machine 81
Towing the Machine 82
Stowing a Disabled Boom 86
Maintenance – Fluids and Lubricants 88
Recommended Lubricants and Fluids 88
Capacities 89
Diesel Fuel 90
Engine Oil 93
Coolant 94
Hydraulic oil 95
Gear oil 96
Brake fluid 96
Cab lift pump 97
Grease 97
Maintenance – General 98
Service, General 98
Use Correct Fuels and Lubricants 98
Prepare Machine for Maintenance 99
Machine Frame, Locking and Unlocking 100
Check all bolted joints 101
Cleaning the Cab Windows 102
Tires 103
Changing Wheels 104
Anti slips 105
Fitting bogie tracks 106
Maintenance Intervals and Service Parts 108
Maintenance intervals and Service Parts 108
Maintenance – Every 10 hours or daily 112
Check Hydraulic Oil Level 112
Check Engine Oil Level 113
Remove Sediment and Water from the Primary Fuel Filter 114
Check the coolant and the windshield washer fluid level 115
Check the radiator grille cleanness 116
Check the driving brake oil level 116
Check the air filter 117
Check the tires for air pressure and overall shape 117
Fill up the fuel tank 118
The following service and checks are to be made at the end of each workday 118
Maintain the Boom 118
Maintenance – Every 50 hours or Weekly 119
Grease the center hinge bearings and steering cylinder bearings 119
Grease the decking blade1 120
Check the battery electrolyte level 120
Check the air conditioner 120
Maintain the Boom 120
Maintenance — Every 250 Hours 121
Clean the machine 121
Check Transfer Case Oil Level 122
Check Differential Oil Level 123
Check Single Axle Wheel Ends Oil Level 124
Check Bogie Housings Oil Level 125
Grease Bogie Bearings 126
Check Wheel Nut Torque 126
Check Cab Air Filters 127
Maintain the boom 128
Check the air conditioner 129
Maintenance – Every 500 hours 130
Change engine oil and replace oil filter 130
Change the fuel filters 132
Clean crankcase vent tube 133
Check the air intake system 133
Check belt tensioner spring tension and belt wear 133
Check cooling system 135
Remove sediment and water from the fuel tanks 136
Check the batteries for charge 137
Grease the driveshafts 138
Maintenance — Every 1000 Hours 139
Change Hydraulic Oil 139
Change Hydraulic Oil Return Filter 140
Check Hydraulic Tank Breather 142
Change Transfer Case Oil 143
Renew the pressure filter of the drive hydraulic system 145
Change the Brake Pedal Circuit Oil 145
Check Wheel Rims and Wheel Nut Torque 146
Maintain the boom 146
Check the air conditioner 146
Maintenance — Every 2000 Hours 147
Check Valve Clearance 147
Change Engine Coolant 149
Change Bogie Axle Differential Oil 152
Change Bogie Housings Oil 153
Change Single Axle Differential Oil 154
Change Single Axle Wheel Ends Oil 155
Maintenance – Calendar Periods 156
Have the fire extinguisher maintained 156
Have the pressure accumulators of the boom damper checked 156
Change AC Receiver/Dryer 156
Maintenance – As required 157
When Necessary, Service and Adjust the Following 157
Bleed Fuel System 158
Clean the Fuel Tank Filler Filter 160
Adjusting the Seat Turntable Brake 160
Maintain the Boom 161
Hydraulic System – General 162
Hydrostatic System 162
Working Hydraulic System 162
Brake System 163
Hydraulic System – Bleeding 164
General 164
Bleeding Air from the Hydrostatic System 164
Bleeding Air from the Working Hydraulic System 166
Bleeding Air from Brake System 167
Hydrostatic System – Pressure Control 171
Checking and Adjusting the Charge Pressure 171
Checking the Hydrostatics Pilot Pressure 172
Checking and Adjusting the Drive Pressure 173
Checking and Adjusting the Function of DA Cartridge Valve 174
Checking and Adjusting the Motor Control Starting Point 175
Checking and Adjusting Pressure Cut-Off Setting for the Drive Motor 176
Working Hydraulic System – Pressure Control 177
Adjusting the Maximum Pressure 177
Adjusting the Pressure Difference 177
Checking the Boom Valve Pilot Control Pressure 178
Measuring the pressures for each function 179
Checking and Adjusting Auxiliary Function Pressure 180
Checking and Adjusting Frame Brake Pressure 181
Checking Pressures of Optional Equipment 181
Brake System- Checking and Adjusting 182
4 Wheel Long Forwarder: Check and Adjust Parking Brake Pressure 182
Checking the Service Brake (pedal brake) pressure 183
Checking the Work Brake Pressure 184
Checking the Brake Charging Pressure 185
Mechanical Adjustment of Brakes 186
Electrical System 188
Main Switch 188
Location of ECU and engine sensors 188
Hydraulic Tank Sensors 189
1010D Drive Pedal Adjustment 190
Batteries 191
Welding 192
Fuses in Instrument Box 194
Fuses and Relays Under the Cab 195
Realys in Instrument box / Circuit board 195
Transmission 196
Operating Power Transmission 196
High/Low Gear 196
Hydrostatic System 197
Boom, General 198
A General Description of the Boom 198
Operating Safety Precautions 199
General Operating Instructions 201
Boom Maintenance, General 202
Assembly Instructions 202
Welding Instruction 202
Bleeding the Hydraulic System 202
Maintenance Schedule 203
Boom, Maintenance every 10 hours 204
Check boom structures 204
The following service and checks are to be made at the end of each workday 204
Boom, Maintenance every 50 hours 205
Check Boom Slew Housing Oil Level 205
Check Boom Pins Condition 205
Check Extension Boom Side Play 205
Check the clearance of the 2nd extension slide bearing piece1 206
Check Extension Boom Chains 207
Check Grapple 207
Grease the Boom 209
Boom, Maintenance every 250 hours 211
Clean the Loader 211
Check Boom Structures 211
Check Boom Fastener Torques 212
Check Extension Boom Vertical Play 213
Grease the grapple and link 214
Boom, Maintenance every 1000 hours 215
Change Boom Slew Housing Oil 215
Clean the Rotator Magnetic Plug 215
Clean the boom extension boom chains (depending on the model) 216
Boom, Maintenance as required 217
Adjust rotator link brakes 217
Boom, Technical Data 218
Boom CF5 218
Rotator and Grapple 218
Equipment, Air Conditioner 222
Introduction 222
Risks and Counter-Measures 223
First Aid 224
Main Parts of Air Conditioning System 224
Maintenance – Weekly: Check the refrigerant level 226
Maintenance – Weekly: Check the service moisture indicator of the dryer 229
Maintenance – Weekly: Check the condensation water outlets 229
Maintenance – every 1000 hours: Service the compressor 229
Maintenance – every 1000 hours: Service the evaporator element 230
Maintenance – every 1000 hours: Service the condenser element 230
Maintenance – every 1000 hours: Service the hoses and connectors 231
Maintenance – every 24 months: Replace the Dryer 231
Equipment, Engine Preheater 232
Operation and maintenence 232
Troubleshooting 240
Engine Troubleshooting 240
Diagnose Drive Lines 245
Diagnose Brake Hydraulics 246
Diagnose Cab Tilt Hydraulics 246
Diagnose Hydraulic/Hydrostatic Cooling System 247
Diagnose Hydrostatic Drive System 248
Diagnose Hydrostatic Drive Pump 250
Diagnose Hydrostatic Drive Motor 253
Diagnose Boom 254
Diagnose Heater/Air Conditioner 258
Storage 260
Prepare Machine for Storage 260
Monthly Storage Procedure 262
Hydraulic Diagrams 264
Boom Hydraulics 264
Drive hydraulics 268
Brake hydraulics 270
Extra Equipment 272
Options 274
Wiring Diagrams 276
General 276
1/13 278
2/13 280
3/13 282
4/13 284
5/13 286
6/13 288
7/13 290
8/13 292
9/13 294
10/13 296
11/13 298
12/13 300
13/13 302
1010D Specifications 304
Decals and Manufacturing numbers 304
Dimensions 305
Load area 307
Axles 307
Transmission 308
Engine 309
Steering 309
Brakes 310
Hydraulic system 310
Electrical System 310
Boom 311
Cab 311

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