Tài liệu Shop manual máy xúc + đào JOHN DEERE MODEL JD410 _ Phần 1

Phần 1 gồm:

MAINTENANCE MANUAL

Page

How To Use This Manual iii

CHAPTER 1 INTRODUCTION

Section I. General Information 1-1

Section II. Equipment Description and Data 1-2

Section III. Repair Parts; Special Tools; Test, Measurement,

and Diagnostic Equipment (TMDE); and Support Equipment . 1-3

Section IV. General Maintenance Instructions . 1-4

CHAPTER 2 TROUBLESHOOTING PROCEDURES . 2-1

CHAPTER 3 ENGINE ASSEMBLY MAINTENANCE

Section I. Engine Assembly Maintenance 3-1

Section II. Lubrication System Maintenance . 3-115

CHAPTER 4 CLUTCH ASSEMBLY MAINTENANCE . 4-1

CHAPTER 5 FUEL SYSTEM MAINTENANCE 5-1

CHAPTER 6 COOLING SYSTEM MAINTENANCE 6-1

CHAPTER 7 ELECTRICAL SYSTEM MAINTENANCE 7-1

CHAPTER 8 TRANSMISSION MAINTENANCE . 8-1

CHAPTER 9 AXLE MAINTENANCE

Section I. Front Axle Maintenance 9-1

Section II. Rear Axle Maintenance . 9-10

CHAPTER 10 BRAKE SYSTEM MAINTENANCE 10-1

CHAPTER 11 STEER!NG SYSTEM MAINTENANCE 11-1

CHAPTER 12 FRAME MAINTENANCE 12-1

CHAPTER 13 BODY AND ACCESSORIES MAINTENANCE . 13-1

CHAPTER 14 HYDRAULIC SYSTEM MAINTENANCE 14-1

CHAPTER 15 CRANES, SHOVELS, AND EARTHMOVING EQUIPMENT

COMPONENTS MAINTENANCE

Section I. Backhoe Assembly Maintenance 15-1

Section II. Loader Assembly Maintenance . 15-22

CHAPTER 16 PARTS PECULIAR MAINTENANCE 16-1

APPENDIX A REFERENCES A-1

APPENDIX B EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST . B-1

APPENDIX C ILLUSTRATED LIST OF MANUFACTURED ITEMS . C-1

APPENDIX D TORQUE LIMITS D-1

INDEX Index-1

ii

SPARE PART MANUAL

SECTION I. INTRODUCTION 1

SECTION II. REPAIR PARTS LIST 1-1

GROUP 01 ENGINE

0100 - ENGINE ASSEMBLY . 1-1

ENGINE ASSEMBLY . 1-1 1

0101 - CRANKCASE, BLOCK, CYLINDER HEAD . 2-1

CYLINDER BLOCK AND LINERS . 2-1 2

CYLINDER HEAD AND GASKET . 3-1 3

ENGINE FRONT PLATE . 4-1 4

0102 - CRANKSHAFT 5-1

CRANKSHAFT AND BEARING CAPS 5-1 5

0103 - FLYWHEEL ASSEMBLY . 6-1

FLYWHEEL . 6-1 6

FLYWHEEL HOUSING . 7-1 7

0104 - PISTONS AND CONNECTING RODS 8-1

PISTONS AND CONNECTING RODS 8-1 8

SECTION I. INTRODUCTION 1

SECTION II. REPAIR PARTS LIST 1-1

GROUP 01 ENGINE

0105 - VALVES, CAMSHAFTS, AND TIMING SYSTEM . 1-1

ROCKER ARM COVER 1-1 1

0106 - ENGINE LUBRICATION SYSTEM . 2-1

ENGINE OIL COOLER . 2-1 2

OIL FILLER INLET . 3-1 3

ENGINE OIL FILTER, DIPSTICK, AND VENTILATOR TUBE . 4-1 4

OIL PAN AND GASKET . 5-1 5

0108 - MANIFOLDS . 6-1

EXHAUST MANIFOLD . 6-1 6

GROUP 02 CLUTCH

0202 - CLUTCH RELEASE MECHANISM . 7-1

CLUTCH PEDAL SHAFT . 7-1 7

GROUP 03 FUEL SYSTEM

0301 - CARBURETOR. FUEL INJECTOR 8-1

FUEL INJECTION NOZZLE ASSEMBLY 8-1 8

0302 - FUEL PUMPS . . 9-1

FUEL INJECTION SYSTEM 9-1 9

FUEL PUMP ASSEMBLY 10-1 10

0304 AIR CLEANER 11-1

AIR INTAKE . 11-1 11

AIR CLEANER . 12-1 12

0306 - TANKS. LINES FITTINGS. HEADERS 13-1

FUEL TANK . . 13-1 13

0309 - FUEL FILTERS 14-1

DUAL STAGE FUEL FILTER ASSEMBLY 14-1 14

0311 - ENGINE STARTING AIDS . . 15-1

COLD WEATHER STARTING AID . 15-1 15

0312 - ACCELERATOR THROTTLE, OR CHOKE CONTROLS . 16-1

SPEED CONTROL LEVER AND CABLE 16-1 16

ACCELERATOR PEDAL AND SPEED CONTROL ROD . 17-1 17

GROUP 04 EXHAUST SYSTEM

0401 - MUFFLER AND PIPES 18-1

MUFFLER 18-1 18

GROUP 05 COOLING SYSTEM

0501 - RADIATOR, EVAPORATIVE COOLER, OR HEAT EXCHANGER . 19-1

ENGINE COOLANT HEATER AND HOSES . 19-1 19

RADIATOR AND RELATED PARTS . 20-1 20

0502 - COWLING, DEFLECTORS. AIR DUCTS. SHROUDS, ETC 21-1

FAN SHROUD ., 21-1 21

0503 - WATER MANIFOLD. HEADERS. THERMOSTATS. AND

HOUSING GASKET . 22-1

THERMOSTAT HOUSING ASSEMBLY 22-1 22

RADIATOR HOSES AND CLAMPS 23-1 23

0504 - WATER PUMP 24-1

WATER PUMP ASSEMBLY 24-1 24

0505 - FAN ASSEMBLY . 25-1

FAN, BELT, AND RELATED PARTS . 25-1 25

GROUP 06 ELECTRICAL SYSTEM

0601 - GENERATOR. ALTERNATOR . 26-1

GENERATOR ATTACHING PARTS . 26-1 26

GENERATOR ASSEMBLY. EXPLODED VIEW . 27-1 27

GENERATOR AND RELATED PARTS . 28-1 28

0602 - GENERATOR REGULATOR . 29-1

VOLTAGE REGULATOR 29-1 29

0603 - STARTING MOTOR 30-1

STARTING MOTOR, DRIVE, AND SWITCH ASSEMBLY . 30-1 30

0606 - ENGINE SAFETY CONTROLS . 31-1

PRESSURE AND STARTER SAFETY SWITCH 31-1 31

0607 - INSTRUMENT OR ENGINE CONTROL PANEL 32-1

PARKING BRAKE WARNING SWITCH AND WIRING . . 32-1 32

ENGINE ELECTRIC HOURMETER 33-1 33

GAGES, INDICATOR LIGHTS. AND WIRING HARNESS 34-1 34

IGNITION SWITCH . 35-1 35

INSTRUMENT PANEL COVER AND DASH . 36-1 36

LIGHT SWITCH AND TURN SIGNAL SWITCH . 37-1 37

FLUID STARTING AID WIRING . 38-1 38

0608 - MISCELLANEOUS ITEMS 39-1

CIGAR LIGHTER . 39-1 39

0609 - LIGHTS 40-1

TURNING LIGHT AND WARNING LIGHT 40-1 40

COMBINATION REAR LIGHT ASSEMBLY 41-1 41

COMBINATION REAR LIGHT AND RELATED PARTS . 42-1 42

FRONT LIGHT . 43-1 43

WARNING LIGHT FLASHER 44-1 44

0610 - SENDING UNITS AND WARNING SWITCHES 45-1

FUEL GAGE SENDING UNIT . 45-1 45

0611 - HORN, SIREN . 46-1

ELECTRIC HORN . 46-1 46

REVERSE WARNING ALARM 4 . 47-1 47

0612 - BATTERIES, STORAGE . 48-1

BATTERIES AND CABLES 48-1 48

BATTERY TRAY AND CLAMP 49-1 49

0613 - HULL OR CHASSIS WIRING HARNESS 50-1

REVERSE WARNING ALARM AND HORN HARNESS . 50-1 50

FRONT AND REAR LIGHT WARNING SYSTEM . 51-1 51

ELECTRICAL WIRING SYSTEM 52-1 52

GROUP 07 TRANSMISSION

0700 - TRANSMISSION ASSEMBLY 53-1

TRANSMISSION AND CASE . 53-1 53

0704 - TRANSMISSION TOP COVER ASSEMBLY 54-1

TRANSMISSION TOP COVER, USE ON SERIAL NUMBERS

235786 THRU 235999 . 54-1 54

TRANSMISSION TOP COVER, USE ON SERIAL NUMBERS

319995 THRU 342573 . 55-1 55

0705 - TRANSMISSION SHIFTING COMPONENTS 56-1

REVERSER CONTROL LEVER LINKAGE 56-1 56

REVERSER CONTROL LEVER . 57-1 57

0710 - TRANSMISSION ASSEMBLY AND ASSOCIATED PARTS 58-1

REVERSER CLUTCH HOUSING 58-1 58

0721 - COOLERS. PUMPS, MOTORS . 59-1

TRANSMISSION OIL FILTER 59-1 59

TRANSMISSION OIL COOLER . 60-1 60

TRANSMISSION FILTER SCREEN . 61-1 61

GROUP 10 FRONT AXLE

1000 - FRONT AXLE ASSEMBLY . 62-1

FRONT AXLE ASSEMBLY . 62-1 62

GROUP 11 REAR AXLE

1103 - PLANETARY OR FINAL DRIVE . 63-1

REAR AXLE HOUSING 63-1 63

GROUP 12 BRAKES

1201 - HANDBRAKES . 64-1

PARKING BRAKE LEVER AND LINKAGE 64-1 64

1204 - HVDRAULIC BRAKE SYSTEM 65-1

BRAKE VALVE AND OIL LINES 65-1 65

BRAKE VALVE HOUSING RELATED PARTS 66-1 66

1206 - MECHANICAL BRAKE SYSTEM . 67-1

BRAKE PEDALS . . 67-1 67

GROUP 13 WHEELS AND TRACKS

1311 - WHEEL ASSEMBLY . 68-1

FRONT WHEEL ASSEMBLY . 68-1 68

REAR WHEEL STEEL DISK 69-1 69

1313 - TIRES, TUBES. TIRE CHAINS . 70-1

TIRES, REAR AND FRONT . 70-1 70

GROUP 14 STEERING

1401 - MECHANICAL STEERING GEAR ASSEMBLY . 71-1

TIE-ROD ASSEMBLY 71-1 71

STEERING COLUMN AND RELATED PARTS . 72-1 72

1411 - HOSES. LINES, FITTINGS . 73-1

POWER STEERING CYLINDER HYDRAULIC HOSES, USE ON SERIAL

NUMBERS 235786 THRU 235999 73-1 73

POWER STEERING CYLINDER HYDRAULICS, USE ON SERIAL

NUMBERS 319995 THRU 342573 . 74-1 74

POWER STEERING CYLINDER OIL LINES, USE ON SERIAL

NUMBERS 235786 THRU 235999 75-1 75

POWER STEERING VALVE HYDRAULICS USE ON SERIAL

NUMBERS 319995 THRU 342573 . 76-1 76

POWER STEERING VALVE RETURN LINE AND ACCUMULATOR HOSE,

USE ON SERIAL NUMBERS 235786 THRU 235999 . 77-1 77

1412 - HYDRAULIC OR AIR CYLINDERS . 78-1

POWER STEERING CYLINDER AND PINS. USE ON SERIAL

NUMBERS 235786 THRU 235999 78-1 78

POWER STEERING CYLINDER AND PINS, USE ON SERIAL

NUMBERS 319995 THRU 342573 . 79-1 79

GROUP 15 FRAME TOWING ATTACHMENTS, DRAWBARS, AND ARTICULATION SYSTEMS

1501 - FRAME ASSEMBLY . 80-1

FRONT SUPPORT 80-1 80

1502 - COUNTERWEIGHTS 81-1

SINGLE COUNTERWEIGHT . 81-1 81

GROUP 18 BODY, CAB, HOOD, AND HULL

1801 - BODY, CAB, HOOD, AND HULL ASSEMBLIES 82-1

BACKHOE CONTROL GUARDS . 82-1 82

COWL . 83-1 83

HOOD AND RELATED PARTS 84-1 84

GRILLE HOUSING AND RELATED PARTS 85-1 85

1802 - FENDERS. RUNNING BOARDS WITH MOUNTING AND ATTACHING

PARTS, OUTRIGGERS. WINDSHIELD, GLASS, ETC 86-1

STEP 86-1 86

STABILIZER . 87-1 87

1805 - FLOORS, SUBFLOORS, AND RELATED COMPONENTS . 88-1

LEFT PLATFORM AND SUPPORT . 88-1 88

RIGHT PLATFORM AND RELATED PARTS 89-1 89

CENTER PLATFORM. REAR PLATFORMS, AND BATTERY COVER . 90-1 90

1806 - UPHOLSTERY, SEATS, AND CARPETS 91-1

SEAT LOWER SUPPORT AND SWIVEL 91-1 91

DELUXE SEAT SUPPORT . . 92-1 92

SEAT AND SEATBELT 93-1 93

1808 - STOWAGE RACKS, BOXES, STRAPS, CARRYING CASES,

CABLE REELS, HOSE REELS, ETC 94-1

BACKHOE VALVE BOX AND COVER . 94-1 94

TOOLBOX AND TRAY . 95-1 95

CONTROL BOX . 96-1 96

GROUP 22 BODY. CHASSIS, AND HULL ACCESSORY ITEMS

2202 - ACCESSORY ITEMS . . 97-1

REFLECTORS, USE ON SERIAL NUMBERS 319995 THRU 342573 97-1 97

2210 - DATA PLATES AND INSTRUCTION HOLDERS . 98-1

LOADER AND BACKHOE DECALS 98-1 98

TRACTOR DECALS . 99-1 99

TRACTOR LABELS 100-1 100

GROUP 24 HYDRAULIC AND FLUID SYSTEMS

2402 - MANIFOLD AND/OR CONTROL VALVES . 101-1

PRESSURE CONTROL VALVE . 101-1 101

HYDRAULIC RELIEF VALVE . 102-1 102

HYDRAULIC IMPACTOR VALVE AND MANIFOLD 103-1 103

JAW CONTROL VALVE . 104-1 104

LOADER VALVE MOUNTING BRACKET AND MANIFOLD BLOCK 106-1 106

2403 - HYDRAULIC CONTROLS AND/OR MANUAL CONTROLS 108-1

JAW VALVE LINKAGE . 108-1 108

BACKHOE CONTROL LEVERS AND LINKAGE, USE ON SERIAL

NUMBERS 235786 THRU 235999 109-1 109

BACKHOE CONTROL LEVERS AND LINKAGE, USE ON SERIAL

NUMBERS 319995 THRU 342573 110-1 110

LOADER CONTROL VALVE LINKAGE . 111-1 111

2406 - STRAINERS, FILTERS, LINES, AND FITTINGS, ETC 112-1

HYDRAULIC OIL LINE. PUMP TO COOLER . 112-1 112

HYDRAULIC OIL LINES TO PUMP, CLUTCH CONTROL VALVE.

FILTER RELIEF VALVES, AND RETURN 113-1 113

LOADER LEFT- AND RIGHT-HAND BOOM CYLINDER HOSES . 114-1 114

AUGER HYDRAULIC LINES AND FITTINGS, USE ON SERIAL

NUMBERS 319995 THRU 342573 115-1 115

JAW BUCKET HYDRAULIC HOSES. USE ON SERIAL NUMBERS

319995 THRU 342573 . 116-1 116

CROWD AND BUCKET CYLINDER HYDRAULICS, USE ON SERIAL

NUMBERS 319995 THRU 342573 . 117-1 117

CROWD CYLINDER LINES AND FITTINGS . 118-1 118

HYDRAULIC HOSES, USE ON SERIAL NUMBERS 235786 THRU . 119-1 119

235999

BACKHOE CONTROL TO MANIFOLD BLOCK OIL LINE

AND FITTINGS . 120-1 120

BACKHOE BOOM, CROWD AND BUCKET OIL LINES AND FITTINGS,

USE ON SERIAL NUMBERS 319995 THRU 342573 121-1 121

BACKHOE BOOM, CROWD AND BUCKET OIL LINES, USE ON SERIAL

NUMBERS 235786 THRU 235999 122-1 122

BACKHOE STABILIZER AND SWING CIRCUIT OIL LINES

AND FITTINGS 123-1 123

BACKHOE PRESSURE AND RETURN CIRCUIT OIL LINES AND

FITTINGS, USE ON SERIAL NUMBERS 319995 THRU 342573 . 124-1 124

BACKHOE PRESSURE AND RETURN CIRCUIT OIL LINES AND

FITTINGS, USE ON SERIAL NUMBERS 235786 THRU 235999 . 125-1 125

BACKHOE OIL LINES AND FITTINGS, USE ON SERIAL NUMBERS

319995 THRU 342573 126-1 126

LOADER LEFT AND RIGHT BUCKET CYLINDER CIRCUITS . . 127-1 127

LOADER PRESSURE AND RETURN CIRCUITS . 128-1 128

HYDRAULIC PUMP OIL PRESSURE LINES . 129-1 129

HYDRAULIC OIL FILTER . 130-1 130

JAW CYLINDER HOSES . 131-1 131

HYDRAULIC IMPACTOR HOSE 132-1 132

VALVE LINES AND FITTINGS . 133-1 133

2407 - HYDRAULIC CYLINDERS 134-1

LOADER BOOM ASSEMBLY . 134-1 134

JAW BUCKET CYLINDER . 135-1 135

BACKHOE BOOM CYLINDER . 136-1 136

BACKHOE SWING CYLINDER 137-1 137

BACKHOE BUCKET CYLINDER, USE ON SERIAL NUMBERS

235786 THRU 235999 . 138-1 138

BACKHOE CROWD CYLINDER 139-1 139

BACKHOE STABILIZER CYLINDER . 140-1 140

LOADER BUCKET CYLINDER 141-1 141

GROUP 47 GAGES (NONELECTRICAL), WEIGHING AND MEASURING DEVICES

4701 - INSTRUMENTS 142-1

TACHOMETER 142-1 142

4702 - GAGES, MOUNTINGS, LINES, AND FITTINGS . 143-1

AIR CLEANER RESTRICTION INDICATOR . 143-1 143

GROUP 74 CRANES, SHOVELS, AND EARTHMOVING EQUIPMENT COMPONENTS

7412 - BACKHOE ATTACHMENTS 144-1

JAW BUCKET 144-1 144

BACKHOE DIPPERSTICK . 145-1 145

BACKHOE BOOM, USE ON SERIAL NUMBERS 319995 THRU 342573 146-1 146

BACKHOE BOOM. USE ON SERIAL NUMBERS 235786 THRU 235999 . 147-1 147

BACKHOE SWING FRAME, USE ON SERIAL NUMBERS 319995

THRU 342573 148-1 148

BACKHOE SWING FRAME. USE ON SERIAL NUMBERS

235786 THRU 235999 . 149-1 149

BACKHOE MAIN FRAME AND TIE BARS, USE ON SERIAL NUMBERS

319995 THRU 342573 . 150-1 150

BACKHOE MAIN FRAME AND TIE BARS, USE ON SERIAL NUMBERS

235786 THRU 235999 . 151-1 151

7437 - LOADER BUCKET ASSEMBLY OR FORKLIFT. . 152-1

LOADER . 152-1 152

BUCKET . 153-1 153

LOADER SIDE FRAMES 154-1 154

BUCKET LEVEL INDICATOR 155-1 155

LOADER BUCKET LINKAGE . 156-1 156

GROUP 95 GENERAL USE STANDARDIZED PARTS

9501 - BULK MATERIEL .BULK-1

BULK MATERIEL BULK-1 BULK

GROUP 99 PARTS PECULIAR

9901 - MULTILISTED PARTS . 157-1

AUGER HYDRAULIC HOSES AND RELATED PARTS . 157-1 157

IMPACTOR LINES AND FITTINGS . 158-1 158

HYDRAULIC EARTH DRILL . 159-1 159

HYDRAULIC BACKHOE IMPACTOR 160-1 160

BACKHOE IMPACTOR WORKING TOOLS 161-1 161

HYDRAULIC BORING HEAD . 162-1 162

HYDRAULIC BORING HEAD MOTOR AND RELATED PARTS . 163-1 163

IMPACTOR ADAPTER . 164-1 164

SECTION III SPECIAL TOOLS LIST (NOT APPLICABLE)

SECTION IV CROSS-REFERENCE INDEXES

NATIONAL STOCK NUMBER INDEX I-1

PART NUMBER INDEX . I-17

FIGURE AND ITEM NUMBER INDEX I-50