John Deere 540G-III, 548G-III, 640G-III, 648G-III, 748G-III Operation,Diagnostic Test Service Manual

540G-III, 548G-III, 640G-III, 648G-III, 748G-III Skidders (SN.–586336) Diagnostic

OPERATION AND TEST MANUAL Cable models 540G-III, 548G-III, 640G-III; Grapple models 648G-III, 748G-III (SN.–586336) TM1870 30 JUN 15 (ENGLISH)

For complete service information also see: G-III Series Skidders 540GIII, 640GIII, 548GIII, 648GIII, 748GIII (SN. before 586336) TM1871 Repair JDLink (MTG) Technical Manual

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TMIV1200 - 1400 Series Inboard Planetary Axles

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TeamMate II 1200, 1400,and 1600 Series Inboard Planetary Axles

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60 and 6000 Winches

CTM41

Super Caddy Oil Cleanup Procedure

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DF180 Series Powershift Transmission Repair Manual

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40 and 4000 Winches

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John Deere Construction and Forestry Pinted by Belgreen

TM1870-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD TECHNICAL INFORMATION FEEDBACK FORM Section 9000 - GENERAL INFORMATION Group 01 - Safety Information Group 02 - General Specifications Group 03 - Torque Values Group 04 - Fuels and Lubricants Section 9005 - OPERATIONAL CHECKOUT Group 10 - Operational Checks Section 9010 - ENGINE Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests Section 9015 - ELECTRICAL SYSTEM Group 05 - System Information Group 10 - System Diagrams Group 15 - Sub-System Diagnostics Group 20 - References Section 9020 - POWER TRAIN Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests Section 9025 - HYDRAULIC SYSTEM Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests Section 9030 - MISCELLANEOUS COMPONENTS (WINCH) Group 05 - Theory Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests Section 9031 - HEATING AND AIR CONDITIONING Group 05 - Theory of Operation Group 10 - System Operational Checks Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests

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TM1870-OPERATION AND TEST MANUAL

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TM1870-OPERATION AND TEST MANUAL

TM1870-OPERATION AND TEST 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.

CAUTION: 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 listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service 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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TM1870-OPERATION AND TEST MANUAL

GENERAL INFORMATION

(g) by Belgreen v2.0

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.

Technical Manual Fax SEND TO:

John Deere Dubuque Works 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA

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Section 9000 page 1

TM1870-OPERATION AND TEST MANUAL

TM1870-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

Section 9000 - GENERAL INFORMATION Table of contents Group 01 - Safety Information ............................................................................................................... 1 Handle Starting Fluid Safely ................................................................................................................. 1 Clean Trash from Machine .................................................................................................................... 1 Protect Against Flying Debris ............................................................................................................... 1 Wear Protective Clothing ...................................................................................................................... 3 Protect Against Noise ........................................................................................................................... 3 Handle Chemical Products Safely ......................................................................................................... 3 Use Safety Lights and Devices ............................................................................................................. 4 Keep ROPS Installed Properly ............................................................................................................... 4 Keep the Operator Protective Structure (OPS) in Place ........................................................................ 5 Lock Machine Frame ............................................................................................................................. 5 Warn Others of Service Work ............................................................................................................... 6 Practice Safe Maintenance ................................................................................................................... 7 Support Machine Properly .................................................................................................................... 7 Remove Paint Before Welding or Heating ............................................................................................. 8 Avoid Heating Near Pressurized Fluid Lines .......................................................................................... 9 Avoid High-Pressure Fluids ................................................................................................................... 9 Clean the Machine Regularly .............................................................................................................. 10 Service Cooling System Safely ........................................................................................................... 10 Store Attachments Safely ................................................................................................................... 10 Dispose of Waste Properly .................................................................................................................. 11 Live With Safety ................................................................................................................................. 11 Group 02 - General Specifications ....................................................................................................... 13 540G-III Skidder Dimensions .............................................................................................................. 13 540G-III Skidder Specifications ........................................................................................................... 15 540G-III Skidder Drain and Refill Capacities ....................................................................................... 15 4000 Series Winch Specifications—540G-III ....................................................................................... 16 548G-III Grapple Skidder Dimensions ................................................................................................. 17 548G-III Grapple Skidder Specifications .............................................................................................. 19 548G-III Grapple Skidder .................................................................................................................... 20 548G-III Grapple Skidder Drain and Refill Capacities .......................................................................... 20 4000 Series Winch Specifications—548G-III ....................................................................................... 21 640G-III—Cable Skidder Dimensions .................................................................................................. 22 640G-III with Direct Drive—Cable Skidder Specifications ................................................................... 24 640G-III with Direct Drive—Winch Specifications—4000 Series .......................................................... 25 640G-III with Direct Drive—Winch Specifications—6000 Series .......................................................... 25 640G-III with Torque Converter—Cable Skidder Specifications ........................................................... 27 640G-III with Torque Converter—Winch Specifications—4000 Series ................................................. 28 640G-III with Torque Converter—Winch Specifications—6000 Series ................................................. 28 640G-III—Drain and Refill Capacities .................................................................................................. 29 648G-III—Grapple Skidder Dimensions ............................................................................................... 30 648G-III—Grapple Dimensions ............................................................................................................ 32 648G-III with Direct Drive—Grapple Skidder Specifications ................................................................ 33 648G-III with Direct Drive—Winch Specifications—4000 Series .......................................................... 34 648G-III with Torque Converter—Grapple Skidder Specifications ....................................................... 35 648G-III with Torque Converter—Winch Specifications—4000 Series ................................................. 36 648G-III—Drain and Refill Capacities .................................................................................................. 37 748G-III Grapple Skidder Dimensions ................................................................................................. 38 748G-III Grapple Skidder Specifications .............................................................................................. 40 748G-III Grapple Skidder .................................................................................................................... 41 <- Go to Global Table of contents

TM1870-OPERATION AND TEST MANUAL

TM1870-OPERATION AND TEST MANUAL

(g) by Belgreen v2.5

748G-III Grapple Skidder Drain and Refill Capacities .......................................................................... 41 6000 Series Winch Specifications—748G-III ....................................................................................... 42 Group 03 - Torque Values ..................................................................................................................... 43 Hardware Torque Specifications ......................................................................................................... 43 Keeping ROPS Installed Properly ........................................................................................................ 43 Metric Bolt and Screw Torque Values ................................................................................................. 44 Additional Metric Cap Screw Torque Values ....................................................................................... 45 Unified Inch Bolt and 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 Metric Series Four Bolt Flange Fitting ................................................. 53 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 54 Group 04 - Fuels and Lubricants ......................................................................................................... 55 Diesel Fuel .......................................................................................................................................... 55 Low Sulfur Diesel Fuel Conditioner ..................................................................................................... 55 Handling and Storing Diesel Fuel ........................................................................................................ 55 Do Not Use Galvanized Containers ..................................................................................................... 56 Fuel Tank ............................................................................................................................................ 56 Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I ................................... 58 Transmission, Hydraulic System, Park Brake, Differential, Cab Hydraulic Pump and Winch Oil ......... 60 Grease ................................................................................................................................................ 60 Oil Filters ............................................................................................................................................ 61 Lubricant Storage ............................................................................................................................... 61 Alternative and Synthetic Lubricants .................................................................................................. 61 Mixing of Lubricants ........................................................................................................................... 62

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TM1870-OPERATION AND TEST MANUAL

Section 9000 - GENERAL INFORMATION

Group 01: Safety Information

Group 01 - Safety Information Handle Starting Fluid Safely

Store Safely Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Do not use starting fluid on an engine equipped with glow plugs or an air intake heater.

Clean Trash from Machine

Clean Trash from Machine Keep engine compartment, radiator, batteries, hydraulic lines, fuel tank, and operator′s station clean.

Temperature in engine compartment may go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.

Protect Against Flying Debris

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Section 9000 page 1

TM1870-OPERATION AND TEST MANUAL

Section 9000 - GENERAL INFORMATION

Group 01: Safety Information

Protect Against Flying Debris When you drive connecting pins in or out, guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

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Section 9000 page 2

TM1870-OPERATION AND TEST MANUAL

Section 9000 - GENERAL INFORMATION

Group 01: 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.

Protect Against Noise

Noise Exposure Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Handle Chemical Products Safely

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Section 9000 page 3

TM1870-OPERATION AND TEST MANUAL