JOHN DEERE 748G-II SKIDDER TM1694 REPAIR MANUAL

540G-II, 548G-II, 640G-II, 648G-II, 748G-II Skidders (SN. 565685-576252) Repair

REPAIR TECHNICAL MANUAL Cable models 540G-II, 640G-II; Grapple models 548G-II, 648G-II, 748G-II (SN. 565685-576252) TM1694 22 FEB 05 (ENGLISH)

For complete service information also see: 540G-II,

640G-II,

548G-II,

648G-II,

748G-II

Skidder

(SN.

565685-576252)

DiagnosticTM1693 120 Series Hydraulic CylindersTM-H120A PowerTech 8.1 L Diesel Engines Base EngineCTM86 Alternators and Starting MotorsCTM77 TeamMate II 1200, 1400,and 1600 Series Inboard Planetary AxlesCTM43 60 and 6000 WinchesCTM41 40 and 4000 WinchesCTM25 PowerTech 8.1L Diesel Engines Mechanical Fuel SystemsCTM243 PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic Fuel Systems with Bosch In-Line Pump)CTM134 PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)CTM104

John Deere Construction and Forestry

Pinted by Belgreen

tm1694-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD HELP!! HELP!! HELP!! HELP!!

Section 00 - GENERAL INFORMATION Group 0001 - Safety Information Group 0002 - General Specifications Group 0003 - Torque Values Group 0004 - Fuels and Lubricants Section 01 - WHEELS Group 0110 - Powered Wheels and Fastenings Section 02 - AXLES AND SUSPENSION SYSTEM Group 0200 - Removal and Installation Group 0225 - Input Drive Shafts and U-Joints Group 0260 - Hydraulic System Group 0299 - Dealer Fabricated Tools Section 03 - TRANSMISSION Group 0300 - Removal and Installation Group 0325 - Input Drive Shafts and U-Joints Group 0350 - Gears, Shafts and Bearings Group 0360 - Hydraulic System Group 0399 - Dealer Fabricated Tools Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEMS Group 0505 - Cold Weather Starting Aids Group 0510 - Cooling Systems Group 0515 - Speed Controls Group 0520 - Intake System Group 0530 - External Exhaust System Group 0560 - External Fuel Supply System Section 07 - DAMPER DRIVE Group 0752 - Elements Section 09 - STEERING SYSTEM Group 0930 - Secondary Steering Group 0960 - Hydraulic System Section 10 - SERVICE BRAKES Group 1011 - Active Elements Group 1015 - Controls Linkage Group 1060 - Hydraulic System Section 11 - PARK BRAKE Group 1111 - Active Elements Group 1160 - Hydraulic System Section 16 - ELECTRICAL SYSTEM Group 1671 - Batteries, Support and Cables Group 1672 - Alternator, Regulator and Charging System Wiring Group 1673 - Lighting System Group 1674 - Wiring Harness and Switches Group 1676 - Instruments and Indicators Group 1677 - Motors and Actuators Section 17 - FRAME, CHASSIS, OR SUPPORTING STRUCTURES Group 1740 - Frame Installation Group 1746 - Frame Bottom Guards Group 1799 - Dealer Fabricated Tools

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tm1694-REPAIR TECHNICAL MANUAL

tm1694-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 18 - OPERATOR′S STATION Group 1800 - Removal and Installation Group 1810 - Operator Enclosure Group 1821 - Seat and Seat Belt Group 1830 - Heating and Air Conditioning Group 1899 - Dealer Fabricated Tools Section 19 - SHEET METAL AND STYLING Group 1910 - Hood or Engine Enclosure Group 1921 - Grille and Grille Housing Section 20 - SAFETY, CONVENIENCE AND MISCELLANEOUS Group 2003 - Fire Extinguisher Group 2004 - Horn and Warning Devices Section 21 - MAIN HYDRAULIC SYSTEM Group 2160 - Hydraulic System Section 30 - WINCH Group 3000 - Removal and Installation Group 3015 - Controls Linkage Group 3025 - Input Drive Shafts and U-Joints Group 3050 - Drive and Clutch Section 32 - BULLDOZERS (STACKING & TRAILBUILDING BLADES) Group 3201 - Blades Group 3215 - Controls Linkage Group 3260 - Hydraulic System Group 3299 - Dealer Fabricated Tools Section 37 - ARCH OR BOOM Group 3740 - Frames Section 38 - GRAPPLE Group 3803 - Grapple Mechanism Group 3815 - Control Linkage Group 3840 - Frames Group 3860 - Hydraulic System Group 3899 - Dealer Fabricated Tools

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tm1694-REPAIR TECHNICAL MANUAL

tm1694-REPAIR 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.

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.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary service listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, 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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tm1694-REPAIR TECHNICAL MANUAL

tm1694-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

HELP!! HELP!! HELP!! HELP!!

We need your help to continually improve our technical publications. Please FAX or mail your comments, ideas and improvements.

Send To Address SEND TO:

John Deere Dubuque Works P.O. Box 538 Attn: Publications Supervisor, Dept.

303 Dubuque, Iowa 52004-0538

FAX NUMBER: 319-589-5800

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tm1694-REPAIR TECHNICAL MANUAL

tm1694-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 00 - GENERAL INFORMATION Table of contents

Group 0001 - Safety Information ........................................................................................................... 1 Handle Fluids Safely-Avoid Fires ........................................................................................................... 1 Prevent Battery Explosions ................................................................................................................... 1 Prepare for Emergencies ...................................................................................................................... 1 Prevent Acid Burns ............................................................................................................................... 3 Handle Chemical Products Safely ......................................................................................................... 3 Avoid High-Pressure Fluids ................................................................................................................... 4 Park Machine Safely ............................................................................................................................. 4 Support Machine Properly .................................................................................................................... 5 Wear Protective Clothing ...................................................................................................................... 6 Work in Clean Area ............................................................................................................................... 6 Service Machines Safely ....................................................................................................................... 6 Work In Ventilated Area ........................................................................................................................ 7 Illuminate Work Area Safely ................................................................................................................. 7 Replace Safety Signs ............................................................................................................................ 8 Use Proper Lifting Equipment ............................................................................................................... 8 Remove Paint Before Welding or Heating ............................................................................................. 8 Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 10 Keep ROPS Installed Properly ............................................................................................................. 10 Service Tires Safely ............................................................................................................................ 11 Avoid Harmful Asbestos Dust ............................................................................................................. 11 Practice Safe Maintenance ................................................................................................................. 13 Use Proper Tools ................................................................................................................................. 13 Dispose of Waste Properly .................................................................................................................. 14 Live With Safety ................................................................................................................................. 14 Group 0002 - General Specifications .................................................................................................. 16 540G-II Skidder Dimensions ............................................................................................................... 16 540G-II Skidder Specifications ............................................................................................................ 18 540G-II Skidder Drain and Refill Capacities ........................................................................................ 19 4000 Series Winch Specifications ....................................................................................................... 19 548G-II Skidder Dimensions ............................................................................................................... 20 548G-II Skidder Specifications ............................................................................................................ 22 548G-II Skidder ................................................................................................................................... 24 548G-II Skidder Drain and Refill Capacities ........................................................................................ 24 4000 Series Winch Specifications ....................................................................................................... 24 640G-II Skidder Dimensions ............................................................................................................... 26 640G-II Skidder Specifications ............................................................................................................ 28 640G-II Skidder Drain and Refill Capacities ........................................................................................ 29 4000 Series Winch Specifications ....................................................................................................... 29 6000 Series Winch Specifications ....................................................................................................... 30 648G-II Skidder Dimensions ............................................................................................................... 31 648G-II Skidder Specifications ............................................................................................................ 33 648G-II Skidder ................................................................................................................................... 35 648G-II Skidder Drain and Refill Capacities ........................................................................................ 35 4000 Series Winch Specifications ....................................................................................................... 35 748G-II Skidder Dimensions ............................................................................................................... 37 748G-II Skidder Specifications ............................................................................................................ 39 748G-II Skidder ................................................................................................................................... 41 748G-II Skidder Drain and Refill Capacities ........................................................................................ 41 6000 Series Winch Specifications ....................................................................................................... 41

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tm1694-REPAIR TECHNICAL MANUAL

tm1694-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Group 0003 - Torque Values ................................................................................................................. 43 Hardware Torque Specifications ......................................................................................................... 43 ROPS Torque Specifications ................................................................................................................ 43 Tighten Upper Frame Pivot Pin Nut .................................................................................................... 43 Metric Bolt and Cap Screw Torque Values .......................................................................................... 44 Additional Metric Cap Screw Torque Values ....................................................................................... 45 Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 47 Check Oil Lines And Fittings ............................................................................................................... 47 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 49 Service Recommendations for O-Ring Boss Fittings ........................................................................... 50 Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 52 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 53 Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 54 Group 0004 - Fuels and Lubricants ..................................................................................................... 55 Diesel Fuel .......................................................................................................................................... 55 Low Sulfur Diesel Fuel Conditioner ..................................................................................................... 55 Handling and Storing Diesel Fuel ........................................................................................................ 55 Do Not Use Galvanized Containers ..................................................................................................... 55 Fuel Tank ............................................................................................................................................ 56 Diesel Engine Oil ................................................................................................................................ 57 Transmission Hydraulic System, Park Brake, Differential, Hand Pump Reservoir and Winch Oils ...... 58 Grease ................................................................................................................................................ 59 Oil Filters ............................................................................................................................................ 59 Lubricant Storage ............................................................................................................................... 59 Alternative and Synthetic Lubricants .................................................................................................. 60 Mixing of Lubricants ........................................................................................................................... 60 Diesel Engine Coolant ......................................................................................................................... 60

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tm1694-REPAIR TECHNICAL MANUAL

For the full PDF version of this manual, Please click on the above download PDF button.

JOHN DEERE 2255 TRACTOR DIAGNOSTIC & REPAIR TECHNICAL MANUAL TM4401 - PDF

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Group 0001 - Safety Information 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.

Prevent Battery Explosions

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prepare for Emergencies

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Section 00 page 1

tm1694-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Prevent Acid Burns

Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

4.Avoiding spilling or dripping electrolyte.

5.Use proper jump start procedure.

If you spill acid on yourself: 1.Flush your skin with water.

2.Apply baking soda or lime to help neutralize the acid.

3.Flush your eyes with water for 15-30 minutes. Get medical attention immediately.

If acid is swallowed: 1.Do not induce vomiting.

2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3.Get medical attention immediately.

Handle Chemical Products Safely

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

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

High-Pressure Fluids 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 from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Park Machine Safely

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tm1694-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

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

Support Properly Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

When implements or attachments are used with a tractor, always follow safety precautions listed in the implement operator′s manual.

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Wear Protective Clothing

Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

Work in Clean Area

Clean Work Area Before starting a job: Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Service Machines Safely

Moving Parts Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Work In Ventilated Area

Engine exhaust fumes Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area

Illuminate Work Area Safely

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Replace Safety Signs

Safety Signs Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Use Proper Lifting Equipment

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.

Remove Paint Before Welding or Heating

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Toxic Fumes Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.

Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

Keep ROPS Installed Properly

Roll-Over Protective Structure Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque.

The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Service Tires Safely

Explosive Tire and Rim Parts Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Avoid Harmful Asbestos Dust

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Practice Safe Maintenance

Keep Area Clean Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts.

Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

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Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners.

Avoid bodily injury caused by slipping wrenches.

Use only service parts meeting John Deere specifications.

Dispose of Waste Properly

Recycle Waste Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Live With Safety

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Section 00 - GENERAL INFORMATION

Group 0002: General Specifications

Group 0002 - General Specifications 540G-II Skidder Dimensions

540G-II Skidder →NOTE: Specifications and design subject to change without notice. Whenever applicable, specifications are in accordance with ICED and SAE standards. Except where otherwise noted, these specifications are based on a unit with roll-over protective structure, full fuel tank, 80 kg (175 lb) operator, and standard equipment. →NOTE: Sideview dimensions are for machine equipped with 28L-26 10 PR LS2 tires and adjustable log arch.

Item

Measurement

Specification

A-Overall Height

Height

3011 mm (9 ft 10.5 in.)

A-Overall Height with Factory Installed Air Conditioning

Height

3229 mm (10 ft 7 in.)

B-Main Fairlead Roller Height

Height

2110 mm (6 ft 11.1 in.)

C-Auxiliary Position Fairlead Roller Height

Height

1925 mm (6 ft 3.8 in.)

D-Wheelbase

Length

2920 mm (9 ft 7 in.)

E-Overall Length

Length

6330 mm (20 ft 9 in.)

F-Front Axle to Articulation Joint

Distance

1575 mm (5 ft 2 in.)

G-Front Axle to Front of Machine

Distance

1507 mm (4 ft 11 in.)

H-Front Axle To Blade Cutting Edge Arc

Distance

2112 mm (6 ft 11.1 in.)

I-Maximum Blade Dig Below Ground

Depth

288 mm (11.3 in.)

J-Maximum Blade Lift Above Ground

Height

1220 mm (3 ft 11.6 in.)

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Section 00 - GENERAL INFORMATION

Group 0002: General Specifications

540G-II Skidder Item

Measurement

Specification

Tire-23.1-26

Ground Clearance

498 mm (19.6 in.)

Wheel Tread

2.21 m (7 ft 3 in.)

Overall Width

2.79 m (9 ft 2 in.)

Ground Clearance

514 mm (20.2 in.)

Wheel Tread

2.28 m (7 ft 6 in.)

Overall Width

3 m (9 ft 10 in.)

Ground Clearance

498 mm (19.6 in.)

Wheel Tread

2.06 m (6 ft 9 in.)

Overall Width

2.64 m (8 ft 8 in.)

Ground Clearance

514 mm (20.2 in.)

Wheel Tread

2.18 m (7 ft 6 in.)

Overall Width

2.9 m (9 ft 6 in.)

Tire-28L-26

Tire-23.1-26 (Narrow Gauge)

Tire-28L-26 (Narrow Gauge)

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Section 00 - GENERAL INFORMATION

Group 0002: General Specifications

540G-II Skidder Specifications Engine ENGINE: The PowerTech 6.8 liter engine is engineered and manufactured by John Deere. Replaceable wet-type cylinder liners provide superior heat dissipation. High strength alloy cylinder heads have replaceable valve seat inserts for longer service life. Cast aluminum pistons provide good heat transfer while pistons are sprayed with cooling oil for longer engine life. A high efficiency turbocharger maximizes engine performance.

Item Measurement Specification

John Deere PowerTech ™ 6068T with Altitude-Compensating, Spark-Arresting Turbocharger Rated Power @ 2200 rpm

89 kW (119 SAE net hp)

Power

95 kW (127 SAE gross hp) Displacement

Volume

6.8 L (414 cu in.)

Cylinders

Quantity

6

Fuel Consumption, Typical

Consumption

14-21 L/h (3.7-5.5 gal/hr)

Maximum Net Torque Rise

Torque

39% @ 1400 rpm 537 N·m (398 lb-ft)

Without Air Conditioning

Amperag

65-amp alternator

With Air Conditioning

e

95-amp alternator

With Air Conditioning and Special Work Lights

Amperag

135-amp alternator

Battery

e

Two 12-volt

Electrical System:

Amperag

Operating Weight:

e Voltage Weight

With Standard Equipment

9933 kg (21,990 lb)

Transmission, Axle and Brake TRANSMISSION: The eight forward and seven reverse speed direct drive powershift transmission is engineered and manufactured by John Deere specifically for skidders. The transmission charge pump is externally mounted for ease of service.

AXLES: John Deere Team Mate II axles, 1200 Series, have heavy-duty inboard mounted planetary type gears that distribute shock loads evenly. Hydraulically applied differential lock in both front and rear axles is standard.

BRAKES: Hydraulic annular style wet disk brakes are inboard mounted on both front and rear axles as standard equipment. Completely sealed running in a cooling oil bath, they are self-adjusting, self-equalizing and require no periodic service. A spring applied hydraulically released wet multiple disk parking brake is transmission mounted. It is automatically applied when the engine is off. It can be manually applied by placing the transmission control lever in the park position.

STEERING: A load and speed sensing power steering system provides quick response and power for easy maneuvering for woods operations. The 90° (45° each direction) of frame articulation provides exceptional maneuverability.

HYDRAULICS: An axial piston pressure compensated pump forms the heart of the quick, responsive and powerful hydraulic system. The closed center hydraulic system is separate from the transmission to enhance overall reliability of both systems.

Item Measurement Specification

Steering: 28L-26 Tire Size Turning Radius

Radius

5.51 m (18 ft 1 in.)

Flow Rate

102 L/min (27 gpm)

Horizontal Roller

Diamete

152 mm (6 in.)

Vertical Rollers (Through Hardened Steel)

r

114 mm (4.5 in.)

Hydraulics: Hydraulic Pump Flow Rate @ 2200 rpm, 20 684 kPa (3,000 psi)

Cable Arch:

Diamete

→NOTE:

r

Travel Speeds are at 2200 engine rpm, no tire slip, with 23.1-26 tire.

Item

Measurement

Specification

Spee

2.3 km/h (1.4 mph)

d

3.1 km/h (1.9 mph)

Spee

4.1 km/h (2.5 mph)

d

5.4 km/h (3.4 mph)

Spee

7.3 km/h (4.5 mph)

d

9.6 km/h (6.0 mph)

Spee

14.3 km/h (8.9 mph)

540G-II Skidder Travel Speeds Forward 1 Gear

2

Forward 3

Gear

Forward

Gear

4

Forward 5

Gear

Forward

Gear

Forward

Gear 6 <- Go to Section TOC Forward Gear

d Spee d

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Section 00 - GENERAL INFORMATION

Group 0002: General Specifications

Item

Measurement

Specification

Forward Gear 8

Speed

19.0 km/h (11.8 mph)

Reverse Gear 1R

Speed

2.3 km/h (1.4 mph)

Reverse Gear 2R

Speed

3.1 km/h (1.9 mph)

Reverse Gear 3R

Speed

4.1 km/h (2.5 mph)

Reverse Gear 4R

Speed

5.4 km/h (3.4 mph)

Reverse Gear 5R

Speed

7.3 km/h (4.5 mph)

Reverse Gear 6R

Speed

9.6 km/h (6.0 mph)

Reverse Gear 7R

Speed

14.3 km/h (8.9 mph)

540G-II Skidder Drain and Refill Capacities Item

Measurement

Specification

Fuel Tank

Capacity

159 L (42 gal)

Cooling System

Capacity

28.4 L (30 qt)

Engine Lubrication, Including Filter

Capacity

19 L (5 gal)

Transmission

Capacity

29.3 L (7.75 gal)

Differential (Front)

Capacity

17.9 L (4.75 gal)

Differential (Rear)

Capacity

24.6 L (6.5 gal)

Winch

Capacity

35.2 L (9.3 gal)

Hydraulic Reservoir

Capacity

30.3 L (8 gal)

Cab Tilt Pump System

Capacity

2 L (2 qt)

4000 Series Winch Specifications WINCH-4000 SERIES: The direct drive 4000 winch with wet multiple disc clutch and spring applied, hydraulically released brake is John Deere engineered and manufactured. Low friction drum seals and an adjustable free spool feature increase operating ease. It is controlled by a single lever that has been conveniently located for the operator.

Item Measurement Specification 8-in. Drum-15.8 mm (0.625 in.) CableCapacity77.4 m (254 ft) 8-in. Drum-19.1 mm (0.75 in.) CableCapacity54.6 m (179 ft) 8-in. Drum-22.2 mm (0.875 in.) CableCapacity39.3 m (129 ft) 8-in. Drum-25.4 mm (1 in.) CableCapacity30.5 m (100 ft) 10-in. Drum-15.8 mm (0.625 in.) CableCapacity60.6 m (199 ft) 10-in. Drum-19.1 mm (0.75 in.) CableCapacity43 m (141 ft) 10-in. Drum-22.2 mm (0.875 in.) CableCapacity30.8 m (101 ft) 10-in. Drum-25.4 mm (1 in.) CableCapacity23.8 m (78 ft)

→NOTE: Cable capacity is calculated with no allowance made for loose or uneven spooling.

Item

Measurement

Specification

Linepull @ Peak Engine and 15.8 mm (0.625 in.) Cable Forc

155 kN (34,786 lb)

Speed) Bare Drum-4000 (8-in Drum-Slow

e

180 kN (40,525 lb)

Speed)

Forc

147 kN (32,985 lb)

Bare Drum-4000 (10-in Drum)

e

95 kN (21,437 lb)

Full Drum-4000 (8-in. Drum-Standard Speed)

Forc

111 kN (24,974 lb)

Full Drum-4000 (8-in. Drum-Slow Speed)

e

111 kN (24,974 lb)

Full Drum-4000 (10-in. Drum)

Forc

Bare

Drum-4000

(8-in.

Drum-Standard

Line Speed @ 2,200 and 15.8 mm (0.625 in.) Cable Bare

Drum-4000

(8-in.

Drum-Standard

Speed) Bare Drum-4000 (8-in. Drum-Slow Speed) Bare Drum-4000 (10-in. Drum) Full Drum-4000 (8-in. Drum-Standard Speed) Full Drum-4000 (8-in. Drum-Slow Speed) Full Drum-4000 (10-in. Drum) <- Go to Section TOC

Reate RFoartce Reate RFoartce Reate Rate

Section 00 page 19

44.5 m/min (146 fpm) 40.0 m/min (131 fpm) 47.9 m/min (157 fpm) 73.8 m/min (242 fpm) 66.4 m/min (218 fpm) 63.4 m/min (208 fpm) tm1694-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0002: General Specifications

548G-II Skidder Dimensions

548G-II Grapple Skidder →NOTE: Specifications and design subject to change without notice. Whenever applicable, specifications are in accordance with ICED and SAE standards. Except where otherwise noted, these specifications are based on a unit with roll-over protective structure, full fuel tank, 80 kg (175 lb) operator, and standard equipment. →NOTE: Sideview dimensions are for machine equipped with 28L-26 12 PR LS2 tires and adjustable log arch.

Item

Measurement

Specification

A-Overall Boom Height

Height

2991 mm (9 ft 10 in.)

B-Overall Length

Length

6330 mm (20 ft 9 in.)

Height

3010 mm (9 ft 10.5 in.)

Height

3229 mm (10 ft 7.1 in.)

Conditioning D-Maximum Blade Lift Above Ground

Height

1210 mm (3 ft 11.6 in.)

E-Maximum Blade Dig Below Ground

Depth

288 mm (11.3 in.)

F-Front Axle to Front of Machine

Distance

1507 mm (4 ft 11 in.)

G-Front Axle To Blade Cutting Edge Arc

Distance

2112 mm (6 ft 11.1 in.)

H-Front Axle to Articulation Joint

Distance

1575 mm (5 ft 2 in.)

I-Wheelbase

Distance

2920 mm (9 ft 7 in.)

J-Reach of Grapple at Ground Level

Distance

1970 mm (6 ft 5.6 in.)

K-Height of Grapple from Ground Level

Height

864 mm (2 ft 10 in.)

C-Overall Height C-Overall

Height

<- Go to Section TOC

with

Factory

Installed

Air

Section 00 page 20

tm1694-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0002: General Specifications

548G-II Grapple Skidder Item

Measurement

Specification

Tire-23.1-26

Ground Clearance

498 mm (19.6 in.)

Wheel Tread

2.21 m (7 ft 3 in.)

Overall Width

2.79 m (9 ft 2 in.)

Ground Clearance

514 mm (20.2 in.)

Wheel Tread

2.29 m (7 ft 6 in.)

Overall Width

3 m (9 ft 10 in.)

Ground Clearance

498 mm (19.6 in.)

Wheel Tread

2.06 m (6 ft 9 in.)

Overall Width

2.64 m (8 ft 8 in.)

Ground Clearance

514 mm (20.2 in.)

Wheel Tread

2.18 m (7 ft 2 in.)

Overall Width

2.9 m (9 ft 6 in.)

Tire-28L-26

Tire-23.1-26 (Narrow Gauge)

Tire-28L-26 (Narrow Gauge)

<- Go to Section TOC

Section 00 page 21

tm1694-REPAIR TECHNICAL MANUAL

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