540G,640G,740G, Skidderand 548G,648G,748G
GrappleSkidder (S.N.—565684)Repair
TECHNICALMANUAL
540G,640G,740G,Skidderand 548G,648G,748GGrappleSkidder (S.N.—565684)Repair
TM160003AUG98(ENGLISH)
Forcompleteserviceinformationalsosee:
540G,640G,740GSkidderand548G,648G, 748GGrappleSkidder(S.N.—565684)
OperationandTest
TM1599
4045,6059,6068Engine CTM8 6076Engine CTM42
StartingMotorsandAlternators .......... CTM77
JohnDeerePowerTech4.5Land6.8L Engine .............................. CTM104
JohnDeerePowerTech8.1LEngine ..... CTM86 4000SeriesWinch ..................... CTM25 6000SeriesWinch ..................... CTM41
TeamMateIIAxles ..................... CTM43
Introduction
Foreword
Thismanualiswrittenforanexperiencedtechnician. Essentialtoolsrequiredinperformingcertainservice workareidentifiedinthismanualandare recommendedforuse.
Livewithsafety:Readthesafetymessagesinthe introductionofthismanualandthecautionspresented throughoutthetextofthemanual.
Thisisthesafety-alertsymbol.Whenyouseethis symbolonthemachineorinthismanual,bealertto thepotentialforpersonalinjury.
Technicalmanualsaredividedintwoparts:repairand operationandtests.Repairsectionstellhowtorepair thecomponents.Operationandtestssectionshelpyou identifythemajorityofroutinefailuresquickly.
Informationisorganizedingroupsforthevarious componentsrequiringserviceinstruction.Atthe beginningofeachgrouparesummarylistingsofall applicableessentialtools,serviceequipmentandtools, othermaterialsneededtodothejob,servicepartskits, specifications,weartolerances,andtorquevalues.
TechnicalManualsareconciseguidesforspecific machines.Theyareon-the-jobguidescontainingonly thevitalinformationneededfordiagnosis,analysis, testing,andrepair.
Fundamentalserviceinformationisavailablefrom othersourcescoveringbasictheoryofoperation, fundamentalsoftroubleshooting,generalmaintenance, andbasictypeoffailuresandtheircauses.
DX,TMIFC–19–22MAY92–1/1
SECTION16—ElectricalSystem
SECTION00—GeneralInformationSECTION11—ParkBrake Group1111—ActiveElements Group0001—SafetyInformation Group0002—GeneralSpecificationsGroup1160—HydraulicSystem Group0003—TorqueValues Group0004—FuelsandLubricants
01 Group1671—Batteries,SupportandCables Group1672—Alternator,RegulatorandCharging
SECTION01—Wheels SystemWiring Group0110—PoweredWheelsandFastenings Group1673—LightingSystem Group1674—WiringHarnessandSwitches
SECTION02—AxlesandSuspensionSystem Group1676—InstrumentsandIndicators Group0200—RemovalandInstallation Group1677—MotorsandActuators Group0225—InputDriveShaftsandU-Joints Group0260—HydraulicSystem
SECTION17—Frame,Chassis,orSupporting Structures
SECTION03—Transmission Group1740—FrameInstallation
Group0300—RemovalandInstallation Group1746—FrameBottomGuards Group0315—ControlLinkage Group0325—InputDriveShaftsandU-Joints
SECTION18—Operator’sStation Group0350—Gears,ShaftsandBearings Group1800—RemovalandInstallation Group0360—HydraulicSystem Group1810—OperatorEnclosure Group1821—SeatandSeatBelt
SECTION04—Engine Group1830—HeatingandAirConditioning Group0400—RemovalandInstallation
SECTION19—SheetMetalandStyling
SECTION05—EngineAuxiliarySystems Group1910—HoodorEngineEnclosure
Group0505—ColdWeatherStartingAids Group1921—GrilleandGrilleHousing Group0510—CoolingSystems Group0515—SpeedControls
SECTION20—Safety,Convenienceand Group0520—IntakeSystem Miscellaneous Group0530—ExternalExhaustSystem Group2003—FireExtinguisher Group0560—ExternalFuelSupplySystem Group2004—HornandWarningDevices
SECTION07—DamperDrive
SECTION21—MainHydraulicSystem Group0752—Elements Group2160—HydraulicSystem
SECTION09—SteeringSystem
SECTION30—Winch
Group0930—SecondarySteering Group3000—RemovalandInstallation Group0960—HydraulicSystem Group3015—ControlsLinkage Group3025—InputDriveShaftsandU-Joints
SECTION10—ServiceBrakes Group1011—ActiveElements
SECTION32—Bulldozers(Stackingand Group1015—ControlsLinkage
Group1060—HydraulicSystem
Allinformation,illustrationsandspecificationsinthismanualarebasedon thelatestinformationavailableatthetimeofpublication.Therightis reservedtomakechangesatanytimewithoutnotice.
DisposeofWasteProperly 00-0001-10 Specifications
LiveWithSafety 00-0001-10
Group0002—GeneralSpecifications
540GSkidder 00-0002-2
HardwareTorqueSpecifications
00-0003-1
00-0003-1
KeepingROPSInstalledProperly ......... 00-0003-1
TightenUpperFramePivotPin 00-0003-2
540GSkidderEngineandSystem Values
MetricBoltandCapScrewTorque
00-0003-3 Specifications 00-0002-6
UnifiedInchBoltandCapScrewTorque
540GSkidderOtherInformation 00-0002-9 Values 00-0003-4 Winch—4000Series 00-0002-10
AdditionalMetricCapScrewTorque
540GSkidderCapacities 00-0002-12 Values 00-0003-5
548GGrappleSkidder
SingleFunctionGrappleSpecifications .... 00-0002-17
ServiceRecommendationsfor37° Flare
548GGrappleSkidderEngineandSystem and30° ConeSeatConnectors 00-0003-7 Specifications...................... 00-0002-18
Winch—4000Series 00-0002-23
ServiceRecommendationsforO-Ring
ServiceRecommendationsforFlatFace
548GGrappleSkidderCapacities 00-0002-25 O-RingSealFittings 00-0003-10
640GSkidder 00-0002-26
ServiceRecommendationsforMetric
640GSkidderEngineandSystem Specifications 00-0002-30SeriesFourBoltFlangeFitting 00-0003-11
640GSkidderOtherInformation 00-0002-33
Winch—4000Series .................. 00-0002-34 Continuedonnextpage
ServiceRecommendationsforInchSeries FourBoltFlangeFittings .............
Group0004—FuelsandLubricants
Specifications
DieselFuel
00-0003-12
00-0004-1
00-0004-1
LowSulfurDieselFuelConditioner 00-0004-2
HandlingandStoringDieselFuel 00-0004-2
DoNotUseGalvanizedContainers 00-0004-3
FuelTank 00-0004-3
DieselEngineOil
TransmissionHydraulicSystem,Park Brake,Differential,HandPumpandWinch
00-0004-4
Oils ..............................
00-0004-5
Grease 00-0004-6
LubricantStorage
00-0004-6
AlternativeandSyntheticLubricants 00-0004-7
MixingofLubricants
DieselEngineCoolant
00-0004-7
00-0004-8
HandleFluidsSafely—AvoidFires
Whenyouworkaroundfuel,donotsmokeorworknear heatersorotherfirehazards.
Storeflammablefluidsawayfromfirehazards.Donot incinerateorpuncturepressurizedcontainers.
Makesuremachineiscleanoftrash,grease,anddebris.
Donotstoreoilyrags;theycanigniteandburn spontaneously.
PreventBatteryExplosions
Keepsparks,lightedmatches,andopenflameawayfrom thetopofbattery.Batterygascanexplode.
Nevercheckbatterychargebyplacingametalobject acrosstheposts.Useavoltmeterorhydrometer.
Donotchargeafrozenbattery;itmayexplode.Warm batteryto16°C(60°F).
ChargeBattery—Minimum Temperature16
PrepareforEmergencies
Bepreparedifafirestarts. Keepafirstaidkitandfireextinguisherhandy.
Keepemergencynumbersfordoctors,ambulanceservice, hospital,andfiredepartmentnearyourtelephone.
PreventAcidBurns
Sulfuricacidinbatteryelectrolyteispoisonous.Itisstrong enoughtoburnskin,eatholesinclothing,andcause blindnessifsplashedintoeyes.
Avoidthehazardby:
1.Fillingbatteriesinawell-ventilatedarea.
2.Wearingeyeprotectionandrubbergloves.
3.Avoidingbreathingfumeswhenelectrolyteisadded.
4.Avoidingspillingordrippingelectrolyte.
5.Useproperjumpstartprocedure.
Ifyouspillacidonyourself:
1.Flushyourskinwithwater.
2.Applybakingsodaorlimetohelpneutralizetheacid.
3.Flushyoureyeswithwaterfor15—30minutes.Get medicalattentionimmediately.
Ifacidisswallowed:
1.Donotinducevomiting.
2.Drinklargeamountsofwaterormilk,butdonot exceed2L(2 quarts).
3.Getmedicalattentionimmediately.
DX,POISON–19–21APR93–1/1
SafetyInformation
HandleChemicalProductsSafely
Directexposuretohazardouschemicalscancause seriousinjury.Potentiallyhazardouschemicalsusedwith yourmachineincludesuchitemsaslubricants,coolants, paints,andadhesives.
AMaterialSafetyDataSheet(MSDS)providesspecific detailsonchemicalproducts:physicalandhealthhazards, safetyprocedures,andemergencyresponsetechniques.
ChecktheMSDSbeforeyoustartanyjobusinga hazardouschemical.Thatwayyouwillknowexactlywhat therisksareandhowtodothejobsafely.Thenfollow proceduresandrecommendedequipment.
SeeyourauthorizeddealerforMSDS’sonchemical productsusedwithyourmachine.
AvoidHigh-PressureFluids
Escapingfluidunderpressurecanpenetratetheskin causingseriousinjury.
Avoidthehazardbyrelievingpressurebefore disconnectinghydraulicorotherlines.Tightenall connectionsbeforeapplyingpressure.
Searchforleakswithapieceofcardboard.Protecthands andbodyfromhighpressurefluids.
Ifanaccidentoccurs,seeadoctorimmediately.Anyfluid injectedintotheskinmustbesurgicallyremovedwithina fewhoursorgangrenemayresult.Doctorsunfamiliarwith thistypeofinjuryshouldreferenceaknowledgeable medicalsource.SuchinformationisavailablefromDeere &CompanyMedicalDepartmentinMoline,Illinois,U.S.A.
ParkMachineSafely
Beforeworkingonthemachine:
• Lowerallequipmenttotheground.
• Stoptheengineandremovethekey.
• Disconnectthebatterygroundstrap.
SupportMachineProperly
Alwayslowertheattachmentorimplementtotheground beforeyouworkonthemachine.Ifyoumustworkona liftedmachineorattachment,securelysupportthe machineorattachment.
Donotsupportthemachineoncinderblocks,hollowtiles, orpropsthatmaycrumbleundercontinuousload.Donot workunderamachinethatissupportedsolelybyajack. Followrecommendedproceduresinthismanual.
• Hanga"DONOTOPERATE"taginoperatorstation. DX,LOWER–19–04JUN90–1/1
WearProtectiveClothing
Wearclosefittingclothingandsafetyequipment appropriatetothejob.
Prolongedexposuretoloudnoisecancauseimpairment orlossofhearing.
Wearasuitablehearingprotectivedevicesuchas earmuffsorearplugstoprotectagainstobjectionableor uncomfortableloudnoises.
Operatingequipmentsafelyrequiresthefullattentionof theoperator.Donotwearradioormusicheadphones whileoperatingmachine.
SafetyInformation
WorkinCleanArea
Beforestartingajob:
• Cleanworkareaandmachine.
• Makesureyouhaveallnecessarytoolstodoyourjob.
• Havetherightpartsonhand.
• Readallinstructionsthoroughly;donotattempt shortcuts.
ServiceMachinesSafely
Tielonghairbehindyourhead.Donotwearanecktie, scarf,looseclothing,ornecklacewhenyouworknear machinetoolsormovingparts.Iftheseitemsweretoget caught,severeinjurycouldresult.
Removeringsandotherjewelrytopreventelectrical shortsandentanglementinmovingparts.
WorkinVentilatedArea
Engineexhaustfumescancausesicknessordeath.Ifitis necessarytorunanengineinanenclosedarea,remove theexhaustfumesfromtheareawithanexhaustpipe extension.
Ifyoudonothaveanexhaustpipeextension,openthe doorsandgetoutsideairintothearea.
IlluminateWorkAreaSafely
Illuminateyourworkareaadequatelybutsafely.Usea portablesafetylightforworkinginsideorunderthe machine.Makesurethebulbisenclosedbyawirecage. Thehotfilamentofanaccidentallybrokenbulbcanignite spilledfueloroil.
ReplaceSafetySigns
Replacemissingordamagedsafetysigns.Seethe machineoperator’smanualforcorrectsafetysign placement.
UseProperLiftingEquipment
Liftingheavycomponentsincorrectlycancausesevere injuryormachinedamage.
Followrecommendedprocedureforremovaland installationofcomponentsinthemanual.
RemovePaintBeforeWeldingorHeating
Avoidpotentiallytoxicfumesanddust.
Hazardousfumescanbegeneratedwhenpaintisheated bywelding,soldering,orusingatorch.
Doallworkoutsideorinawellventilatedarea.Disposeof paintandsolventproperly.
Removepaintbeforeweldingorheating:
• Ifyousandorgrindpaint,avoidbreathingthedust. Wearanapprovedrespirator.
• Ifyouusesolventorpaintstripper,removestripperwith soapandwaterbeforewelding.Removesolventor paintstrippercontainersandotherflammablematerial fromarea.Allowfumestodisperseatleast15minutes beforeweldingorheating.
AvoidHeatingNearPressurizedFluidLines
KeepROPSInstalledProperly
Makecertainallpartsarereinstalledcorrectlyifthe roll-overprotectivestructure(ROPS)isloosenedor removedforanyreason.Tightenmountingboltstoproper torque.
TheprotectionofferedbyROPSwillbeimpairedifROPS issubjectedtostructuraldamage,isinvolvedinan overturnincident,orisinanywayalteredbywelding, bending,drilling,orcutting.AdamagedROPSshouldbe replaced,notreused.
Flammablespraycanbegeneratedbyheatingnear pressurizedfluidlines,resultinginsevereburnsto yourselfandbystanders.Donotheatbywelding, soldering,orusingatorchnearpressurizedfluidlinesor otherflammablematerials.Pressurizedlinescanbe accidentallycutwhenheatgoesbeyondtheimmediate flamearea. DX,ROPS3–19–03MAR93–1/1
ServiceTiresSafely
Explosiveseparationofatireandrimpartscancause seriousinjuryordeath.
Donotattempttomountatireunlessyouhavetheproper equipmentandexperiencetoperformthejob.
Alwaysmaintainthecorrecttirepressure.Donotinflate thetiresabovetherecommendedpressure.Neverweldor heatawheelandtireassembly.Theheatcancausean increaseinairpressureresultinginatireexplosion. Weldingcanstructurallyweakenordeformthewheel.
Wheninflatingtires,useaclip-onchuckandextension hoselongenoughtoallowyoutostandtoonesideand NOTinfrontoforoverthetireassembly.Useasafety cageifavailable.
Checkwheelsforlowpressure,cuts,bubbles,damaged rimsormissinglugboltsandnuts.
AvoidHarmfulAsbestosDust
Avoidbreathingdustthatmaybegeneratedwhen handlingcomponentscontainingasbestosfibers.Inhaled asbestosfibersmaycauselungcancer.
Componentsinproductsthatmaycontainasbestosfibers arebrakepads,brakebandandliningassemblies,clutch plates,andsomegaskets.Theasbestosusedinthese componentsisusuallyfoundinaresinorsealedinsome way.Normalhandlingisnothazardousaslongas airbornedustcontainingasbestosisnotgenerated.
Avoidcreatingdust.Neverusecompressedairfor cleaning.Avoidbrushingorgrindingmaterialcontaining asbestos.Whenservicing,wearanapprovedrespirator.A specialvacuumcleanerisrecommendedtoclean asbestos.Ifnotavailable,applyamistofoilorwateron thematerialcontainingasbestos.
Keepbystandersawayfromthearea.
SafetyInformation
PracticeSafeMaintenance
Understandserviceprocedurebeforedoingwork.Keep areacleananddry.
Neverlubricate,service,oradjustmachinewhileitis moving.Keephands,feet,andclothingfrom power-drivenparts.Disengageallpowerandoperate controlstorelievepressure.Lowerequipmenttothe ground.Stoptheengine.Removethekey.Allowmachine tocool.
Securelysupportanymachineelementsthatmustbe raisedforservicework.
Keepallpartsingoodconditionandproperlyinstalled.Fix damageimmediately.Replacewornorbrokenparts. Removeanybuildupofgrease,oil,ordebris.
Disconnectbatterygroundcable(—)beforemaking adjustmentsonelectricalsystemsorweldingonmachine.
DX,SERV–19–03MAR93–1/1
UseProperTools
Usetoolsappropriatetothework.Makeshifttoolsand procedurescancreatesafetyhazards.
Usepowertoolsonlytoloosenthreadedpartsand fasteners.
Forlooseningandtighteninghardware,usethecorrect sizetools.DONOTuseU.S.measurementtoolson metricfasteners.Avoidbodilyinjurycausedbyslipping wrenches.
UseonlyservicepartsmeetingJohnDeerespecifications.
DX,REPAIR–19–04JUN90–1/1
DisposeofWasteProperly
Improperlydisposingofwastecanthreatenthe environmentandecology.Potentiallyharmfulwasteused withyourmachineincludesuchitemsasoil,fuel,coolant, brakefluid,filters,andbatteries.
Useleakproofcontainerswhendrainingfluids.Donotuse foodorbeveragecontainersthatmaymisleadsomeone intodrinkingfromthem.
Donotpourwasteontotheground,downadrain,orinto anywatersource.
Airconditioningrefrigerantsescapingintotheaircan damagetheEarth’satmosphere.Governmentregulations mayrequireacertifiedairconditioningservicecenterto recoverandrecycleusedairconditioningrefrigerants.
Inquireontheproperwaytorecycleordisposeofwaste fromyourlocalenvironmentalorrecyclingcenter,orfrom yourauthorizeddealer.
LiveWithSafety
Beforereturningmachinetocustomer,makesure machineisfunctioningproperly,especiallythesafety systems.Installallguardsandshields.
TX,05,DH2502–19–26AUG92–1/1
GeneralSpecifications
NOTE:Specificationsanddesignsubjecttochange withoutnotice.Wheneverapplicable, specificationsareinaccordancewithSAE Standardsunlessotherwisenoted,these
specificationsarebasedonastandard machinewith23.1L—2610PRLS2tires, adjustablelogarch,fullfueltankand79kg (175lb)operator.
ItemMeasurementSpecification
A—OverallHeightHeight3010mm(9ft11in.)
A—OverallHeightwithFactoryHeight3229mm(10ft7in.)
InstalledAirConditioning
B—MainFairleadRollerHeightHeight2110mm(6ft11.1in.)
C—AuxiliaryPositionFairleadRollerHeight1925mm(6ft3.8in.)
Height
D—WheelbaseDistance2920mm(9ft7in.)
E—OverallLengthLength6084mm(19ft11.5in.)
F—FrontAxletoArticulationJointDistance1575mm(5ft2in.)
ItemMeasurementSpecification
G—FrontAxletoFrontofMachineDistance1507mm(4ft11in.)
H—FrontAxletoBladeCuttingEdgeDistance2112mm(6ft11.1in.)
Arc
I—MaximumBladeDigDepthBelowDepth288mm(11.3in.)
Ground
J—MaximumBladeLiftAboveDistance1220mm(3ft11.6in.)
Ground
Continuedonnextpage
CED,OUO1040,162–19–16JUN98–2/4
GeneralSpecifications
ItemMeasurementSpecification
TireSize:23.1—26
A—GroundClearanceClearance498mm(19.6in.)
B—WheelTreadDistance2.21m(7ft3in.)
C—OverallWidthWidth2.79m(9ft2in.)
TireSize:28L—26
A—GroundClearanceClearance514mm(20.2in.)
B—WheelTreadDistance2.29m(7ft6in.)
C—OverallWidthWidth3.0m(9ft10in.)
TireSize:23.1—26(NarrowGauge)
A—GroundClearanceClearance498mm(19.6in.)
B—WheelTreadDistance2.06m(6ft9in.)
ItemMeasurementSpecification
C—OverallWidthWidth2.64m(8ft8in.)
TireSize:28L—26(NarrowGauge)
A—GroundClearanceClearance514mm(20.2in.)
B—WheelTreadDistance2.18m(7ft2in.)
C—OverallWidthWidth2.9m(9ft6in.)
EngineSpecifications(S.N.—558324)
The5.9literengineisJohnDeereengineeredandmanufactured.Replaceablewettypecylinderlinersprovidesuperiorheatdissipation.High strengthalloycylinderheadshavereplaceablevalveseatinsertsforlongerservicelife.Castaluminumpistonsprovidegoodheattransfer whilepistonsaresprayedwithcoolingoilforlongerenginelife.Ahighefficiencyturbochargermaximizesengineperformance.
ItemMeasurementSpecification
Engine—JohnDeere6059Twith altitude-compensatingturbocharger (S.N.—558324)
RatedPower@2200rpmPower86kW(115nethp)
RatedPower@2200rpmPower90kW(120grosshp) CylindersQuantity6
FuelConsumption,TypicalUsage11.7—17.8L/h(3.1—4.7gal/hr)
MaximumNetEngineTorqueTorque30%@1400rpm465N•m(343 lb-ft)
ElectricalSystemVoltage12-volt
AlternatorAmperage95amps
BatteryCapacity180minutes,reserve Amps925coldcrankingamps
EngineSpecifications(S.N.558325—)
ThePowerTech 6.8literengineisJohnDeereengineeredandmanufactured.Replaceablewettypecylinderlinersprovidesuperiorheat dissipation.Highstrengthalloycylinderheadshavereplaceablevalveseatinsertsforlongerservicelife.Castaluminumpistonsprovidegood heattransferwhilepistonsaresprayedwithcoolingoilforlongerenginelife.Ahighefficiencyturbochargermaximizesengineperformance.
ItemMeasurementSpecification
Engine—JohnDeerePowerTech 6068Twithaltitude-compensating, spark-arrestingturbocharger(S.N. 558325—)
RatedPower@2200rpmPower89kW(119SAEnethp) PowerTechisaregisteredtrademarkofDeere&Company
ItemMeasurementSpecification
RatedPower@2200rpmPower95kW(127SAEgrosshp)
CylindersQuantity6
FuelConsumption,TypicalUsage14—21L/h(3.7—5.5gal/hr)
MaximumNetEngineTorqueTorque30%@1400rpm537N•m(398 lb-ft)
ElectricalSystemVoltage12-volt
AlternatorAmperage65amps
BatteryQuantityTwo12-Volt
540GSkidderForwardTravel Speeds1
Gear1Speed2.3km/h(1.4mph)
Gear2Speed3.2km/h(2.0mph)
Gear3Speed4.9km/h(3.0mph)
Gear4Speed6.4km/h(4.0mph)
Gear5Speed8.5km/h(5.3mph)
Gear6Speed11.1km/h(6.9mph)
Gear7Speed14.3km/h(8.9mph)
Gear8Speed24.8km/h(15.4mph)
540GSkidderReverseTravel Speeds
Gear1RSpeed3.1km/h(1.9mph)
Gear2RSpeed4.5km/h(2.8mph)
1At2200enginerpm,notireslipwith23.1—26tire.
ItemMeasurementSpecification
Gear3RSpeed6.8km/h(4.2mph)
Gear4RSpeed8.9km/h(5.5mph)
Hydraulics
Pump—@2200rpm,20684kPaFlowRate102L/min(27gpm) (3000psi)
CableArch HorizontalRollerDiameter152mm(6in.)
VerticalRollers(throughhardenedDiameter114mm(4.5in.) steel)
Weight OperatingWeightwithStandardWeight9980kg(22,000lb) Equipment
Steering
TurningRadiusOverTires(23.1—Distance5.47m(17ft11in.) 26tires)
TX,115,JC405–19–16JUN98–3/3
• Lubrication:
–Pressuresystemwithfull-flowfilter
• Transmission:
–Eightforward,fourreversespeeddirectdrive powershift
–Externallymountedchargepumpforeaseofservice
• Axles:
–1200SeriesTeamMate IIfrontandrearaxles
–Heavydutyinboardmountedplanetarytypegears thatdistributeshockloadsevenly
–Hydraulicallyapplieddifferentiallockinbothfrontand rearaxles
• Brakes:
–Hydraulicannularstylewetdiskbrakesareinboard mountedonfrontandrear
–Completelysealedrunninginacoolingoilbath
–Self-adjustingandself-equalizing
–Requirenoperiodicservice
–Spring-applied,hydraulically-released,wet multiple-discparkingbrakeistransmissionmounted
–Parkingbrakeautomaticallyappliedwhenengineis off
–Parkingbrakecanbemanuallyappliedbyplacingthe transmissioncontrolleverintheparkposition
• Steering:
–Aloadandspeedsensingpowersteeringsystem providesquickresponseandpowerforeasy maneuveringforwoodsoperations
–90° (45° eachdirection)offramearticulationprovides exceptionalmaneuverability
• Hydraulics:
–Axialpistonpressurecompensatedpumpformsthe heartofthequick,responsiveandpowerfulhydraulic system
–Closedcenterhydraulicsystemisseparatefrom transmissiontoenhanceoverallreliabilityofboth systems
GeneralSpecifications
Winch—4000Series
Winch: Thedirectdrive4000winchwithwetmultiplediscclutchandspringapplied,hydraulicallyreleasedbrakeisJohnDeereengineered andmanufactured.Lowfrictiondrumsealsandanadjustablefreespoolfeatureincreaseoperatingease.Itiscontrolledbyasingleleverthat hasbeenconvenientlylocatedfortheoperator.
CableCapacity: Calculatedwithnoallowancemadeforlooseorunevenspooling.
ItemMeasurementSpecification
4000SeriesWinch15.8mm(0.625 in.)Cable
8-in.DrumCapacity77.4m(254ft)
10-in.DrumCapacity60.6m(199ft)
4000SeriesWinch19.1mm(0.75 in.)Cable
8-in.DrumCapacity54.6m(179ft)
10-in.DrumCapacity43m(141ft)
4000SeriesWinch22.2mm(0.875 in.)Cable
8-in.DrumCapacity39.3m(129ft)
10-in.DrumCapacity30.8m(101ft)
4000SeriesWinch25.4mm(1.0in.)
Cable
8-in.DrumCapacity30.5m(100ft)
10-in.DrumCapacity23.8m(78ft)
4000SeriesWinch8-in.Drum StandardSpeed
BareDrumForce155kN(34,786lb)linepull@peak engineand15.8mm(0.625in.)
cable
GeneralSpecifications
ItemMeasurementSpecification
FullDrumForce95kN(21,437lb)linepull@peak engineand15.8mm(0.625in.)
cable
4000SeriesWinch8-in.DrumSlow Speed
BareDrumForce180kN(40,525lb)linepull@peak engineand15.8mm(0.625in.)
cable
FullDrumForce111kN(24,974lb)linepull@peak engineand15.8mm(0.625in.)
cable
4000SeriesWinch10-in.Drum
BareDrumForce147kN(32,985lb)linepull@peak engineand15.8mm(0.625in.)
cable
FullDrumForce111kN(24,974lb)linepull@peak engineand15.8mm(0.625in.)
cable
4000SeriesWinch8-in.Drum StandardSpeed
BareDrumSpeed44.5m/min(146fpm)linespeed@ 2200rpmand15.8mm(0.625in.)
cable
FullDrumSpeed73.8m/min(242fpm)linespeed@ 2200rpmand15.8mm(0.625in.)
cable
4000SeriesWinch8-in.DrumSlow Speed
BareDrumSpeed40.0m/min(131fpm)linespeed@ 2200rpmand15.8mm(0.625in.)
cable
ItemMeasurementSpecification
FullDrumSpeed66.4m/min(218fpm)linespeed@ 2200rpmand15.8mm(0.625in.)
cable
4000SeriesWinch10-in.Drum
BareDrumSpeed47.9m/min(157fpm)linespeed@ 2200rpmand15.8mm(0.625in.)
cable
FullDrumSpeed63.4m/min(208fpm)linespeed@ 2200rpmand15.8mm(0.625in.)
540GSkidderCapacities
ItemMeasurementSpecification
FuelTankCapacity157L(41.5gal)
CoolingSystemCapacity24.6L(26qt)
EngineLubrication(includingfilter)Capacity19L(5gal)
TransmissionCapacity29.3L(7.75gal)
FrontDifferential(1200SeriesAxle)Capacity17L(4.5gal)
RearDifferential(1200SeriesAxle)Capacity25L(6.5gal)
4000SeriesWinchCapacity35.2L(9.3gal)
HydraulicReservoirCapacity30.3L(8gal)
cable TX,115,JC410–19–17JUN98–1/1
CED,OUO1032,1139–19–10JUL98–3/3
548GGrappleSkidder
GeneralSpecifications
NOTE:Specificationsanddesignsubjecttochange withoutnotice.Wheneverapplicable, specificationsareinaccordancewithSAE Standardsunlessotherwisenoted,these
specificationsarebasedonastandard machinewith23.1L—2610PRLS2tires, adjustablelogarch,fullfueltankand79kg (175lb)operator.
ItemMeasurementSpecification
A—OverallHeightofBoomHeight2991mm(9ft10in.)
B—OverallLengthLength6330mm(20ft9in.)
C—OverallHeightHeight3010mm(9ft11in.)
D—MaximumBladeLiftAboveDistance1210mm(3ft11.6in.)
Ground
E—MaximumBladeDigBelowDepth288mm(11.3in.)
Ground
F—FrontAxletoFrontofMachineDistance1507mm(4ft11in.)
G—FrontAxletoBladeCuttingEdgeDistance2112mm(6ft11in.)
Arc
H—FrontAxletoArticulationJointDistance1575mm(5ft2in.)
ItemMeasurementSpecification
I—WheelbaseDistance2920mm(9ft7in.)
J—ReachofGrappleatGroundDistance1970mm(6ft5.6in.)
Level
K—HeightofGrapplefromGroundHeight864mm(2ft10in.)
Level
Continuedonnextpage
CED,OUO1032,1140–19–10JUL98–2/4
GeneralSpecifications
ItemMeasurementSpecification
TireSize:23.1—26
A—GroundClearanceClearance498mm(19.6in.)
B—WheelTreadDistance2.21m(7ft3in.)
C—OverallWidthWidth2.79m(9ft2in.)
TireSize:28L—26
A—GroundClearanceClearance514mm(20.2in.)
B—WheelTreadDistance2.29m(7ft6in.)
C—OverallWidthWidth3.0m(9ft10in.)
TireSize:23.1—26(NarrowGauge)
A—GroundClearanceClearance498mm(19.6in.)
B—WheelTreadDistance2.06m(6ft9in.)
C—OverallWidthWidth2.64m(8ft8in.)
TireSize:28L—26(NarrowGauge)
A—GroundClearanceClearance514mm(20.2in.)
ItemMeasurementSpecification
B—WheelTreadDistance2.18m(7ft2in.)
C—OverallWidthWidth2.9m(9ft6in.)
SingleFunctionGrappleSpecifications
CED,OUO1032,1140–19–10JUL98–4/4
ItemMeasurementSpecification
A—TongOpeningatTipsHeight2160mm(85in.)
B—MinimumDiameterofStemDiameter124mm(5in.)
C—EnclosureArea,TongsTip-to-TipArea0.75sqm(8sqft)
CED,OUO1032,1129–19–01JUL98–1/1
548GGrappleSkidderEngineandSystem Specifications
EngineSpecifications(S.N.—558324)
The5.9literengineisJohnDeereengineeredandmanufactured.Replaceablewettypecylinderlinersprovidesuperiorheatdissipation.High strengthalloycylinderheadshavereplaceablevalveseatinsertsforlongerservicelife.Castaluminumpistonsprovidegoodheattransfer whilepistonsaresprayedwithcoolingoilforlongerenginelife.Ahighefficiencyturbochargermaximizesengineperformance.
ItemMeasurementSpecification
Engine—JohnDeere6059Twith altitude-compensatingturbocharger (S.N.—558324)
RatedPower@2200rpmPower86kW(115nethp)
RatedPower@2200rpmPower90kW(120grosshp) CylindersQuantity6
FuelConsumption,TypicalUsage11.7—17.8L/h(3.1—4.7gal/hr)
MaximumNetEngineTorqueTorque30%@1400rpm465N•m(343 lb-ft)
ElectricalSystemVoltage12-volt
AlternatorAmperage65amps
BatteryCapacity180minutes,reserve Amps925coldcrankingamps
EngineSpecifications(S.N.558325—)
ThePowerTech 6.8literengineisJohnDeereengineeredandmanufactured.Replaceablewettypecylinderlinersprovidesuperiorheat dissipation.Highstrengthalloycylinderheadshavereplaceablevalveseatinsertsforlongerservicelife.Castaluminumpistonsprovidegood heattransferwhilepistonsaresprayedwithcoolingoilforlongerenginelife.Ahighefficiencyturbochargermaximizesengineperformance.
ItemMeasurementSpecification
Engine—JohnDeerePowerTech 6068Twithaltitude-compensating, spark-arrestingturbocharger(S.N. 558325—)
RatedPower@2200rpmPower89kW(119SAEnethp)
PowerTechisaregisteredtrademarkofDeere&Company
ItemMeasurementSpecification
RatedPower@2200rpmPower95kW(127SAEgrosshp)
CylindersQuantity6
FuelConsumption,TypicalUsage14—21L/h(3.7—5.5gal/hr)
MaximumNetEngineTorqueTorque30%@1400rpm537N•m(398 lb-ft)
ElectricalSystemVoltage12-volt
AlternatorAmperage65amps
548GGrappleSkidderForward TravelSpeeds1
Gear1Speed2.3km/h(1.4mph)
Gear2Speed3.3km/h(2.1mph)
Gear3Speed5.0km/h(3.1mph)
Gear4Speed6.5km/h(4.1mph)
Gear5Speed8.7km/h(5.4mph)
Gear6Speed11.3km/h(7.1mph)
Gear7Speed14.6km/h(9.1mph)
Gear8Speed25.3km/h(15.7mph)
548GGrappleSkidderReverse TravelSpeeds
Gear1RSpeed3.2km/h(2.0mph)
Gear2RSpeed4.6km/h(2.8mph)
1At2200enginerpm,notireslipwith28L—26tire.
ItemMeasurementSpecification
Gear3RSpeed6.9km/h(4.3mph)
Gear4RSpeed9.1km/h(5.6mph)
Hydraulics
Pump—@2200rpm,20684kPaFlowRate102L/min(27gpm) (3000psi)
Weight
OperatingWeightwithStandardWeight9861kg(21,740lb) Equipment
Steering
TurningRadiusOverTires(28L—Distance5.51m(18ft9in.) 26tires)
CED,OUO1032,1141–19–10JUL98–3/3
548GGrappleSkidderOtherInformation
• Lubrication:
–Pressuresystemwithfull-flowfilter(S.N.—558324)
–Pressuresystemwithoilcooler(S.N.558325—)
• Transmission:
–Eightforward,fourreversespeeddirectdrive powershift
–Externallymountedchargepumpforeaseofservice
• Axles:
–1200SeriesTeamMate IIfrontandrearaxles
–Heavydutyinboardmountedplanetarytypegears thatdistributeshockloadsevenly
–Hydraulicallyapplieddifferentiallockinbothfrontand rearaxles
• Brakes:
–Hydraulicannularstylewetdiskbrakesareinboard mountedonfrontandrear
–Completelysealedrunninginacoolingoilbath
–Self-adjustingandself-equalizing
–Requirenoperiodicservice
–Spring-applied,hydraulically-released,wet multiple-discparkingbrakeistransmissionmounted
–Parkingbrakeautomaticallyappliedwhenengineis off
–Parkingbrakecanbemanuallyappliedbyplacingthe transmissioncontrolleverintheparkposition
• Steering:
–Aloadandspeedsensingpowersteeringsystem providesquickresponseandpowerforeasy maneuveringforwoodsoperations
–90° (45° eachdirection)offramearticulationprovides exceptionalmaneuverability
• Hydraulics:
–Axialpistonpressurecompensatedpumpformsthe heartofthequick,responsiveandpowerfulhydraulic system
–Closedcenterhydraulicsystemisseparatefrom transmissiontoenhanceoverallreliabilityofboth systems
• Grapple:
–Engineeredtoprovidedurabilityandperformace
–Greaseadjustableoscillationdamperimproves componentlifeandreducesmaintenancerequirements
–Constantpressuretokeepgrappleclosedontheload isstandard
–Shapeandclampingforcehavebeenengineeredto maximizeloadretention
CED,OUO1032,1142–19–10JUL98–2/2
