John Deere 540G-II 548G-II 640G-II 648G-II & 748G-II G-II Series Skidders Operator’s Manual – PDF DOWNLOAD
FILE DETAILS:
John Deere 540G-II 548G-II 640G-II 648G-II & 748G-II G-II Series Skidders Operator’s Manual – PDF DOWNLOAD
Division: Forestry
Product Lines: Skidders
Publication Type: Operator’s Manuals
Associated Models: 540GII, 548GII, 640GII, 648GII, 748GII
Series: G SERIES II
Serial: 565685–
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
John Deere 540G-II 548G-II 640G-II 648G-II & 748G-II G-II Series Skidders Operator’s Manual – PDF DOWNLOAD
Contents 5
Safety 9
John Deere Skidder Safety Features 9
Recognize Safety Information 10
Understand Signal Words 10
Follow Safety Instructions 10
Avoid Injury From Rollover Accidents Wear Your Seat Belt Do Not Attempt to Jump Clear of Tipping Machine—Serious or Fatal Crushing Injuries Will Result Machine Will Tip Over Faster Than You Can Jump Free 11
Avoid Injury From Backover Accidents Before Moving Machine, Be Sure All Persons Are Clear of Area Always Be Alert for Bystanders Moving Into the Work Area Use Horn or Other Signal to W 12
Avoid Injury From Rollaway Accidents To Prevent Rollaway, Always Make Sure Machine Is Properly Secured Before Leaving Operator’s Seat Death or Serious Injury May Result If You Attempt to Mount or Stop a Moving Machine 13
Inspect Machine 13
Use Handholds and Steps 14
Prevent Machine Runaway 14
Use Seat Belt Properly 14
Maintain Seat Belt 15
Secondary Exits 15
Travel Safely 16
Operate Machine Safely 16
Avoid Power Lines 17
Beware of Exhaust Fumes 17
Keep Riders Off Machine 17
Handle Fuel Safely—Avoid Fires 18
Prepare for Emergencies 18
Handle Starting Fluid Safely 18
Clean Trash from Machine 19
Protect Against Flying Debris 19
Wear Protective Clothing 19
Protect Against Noise 20
Handle Chemical Products Safely 20
Use Safety Lights and Devices 21
Keep ROPS Installed Properly 21
Keep the Operator Protective Structure (OPS) in Place 22
Lock Machine Frame 22
Warn Others of Service Work 23
Practice Safe Maintenance 24
Support Machine Properly 24
Remove Paint Before Welding or Heating 25
Avoid Heating Near Pressurized Fluid Lines 25
Avoid High Pressure Fluids 26
Clean the Machine Regularly 26
Service Cooling System Safely 27
Store Attachments Safely 27
Dispose of Waste Properly 27
Safety Signs 28
Safety Signs 28
Operator’s Station 41
Monitor Panel Indicator Lights 41
Monitor Display Window 42
Engine Coolant Temperature Gauge 43
Fuel Level Gauge 43
Transmission Oil Temperature Indicator 43
Hydraulic Oil Temperature Indicator 44
Check Service Code Indicator 44
Secondary Steering Indicator—If Equipped 45
Fasten Seat Belt Indicator 45
Engine Oil Pressure Indicator 46
Alternator Voltage Indicator 46
Engine Air Filter Indicator 46
Hydraulic Oil Filter Indicator 47
Transmission Oil Filter Indicator 47
Park Brake Indicator 47
Differential Lock Indicator 48
Stop Indicator and Alarm 48
Service Required Indicator 49
Pedals 49
Levers 50
Differential Lock Switch 50
Adjusting Seat 51
Adjusting Air Ride Suspension Seat—If Equipped 52
Seat Belt 53
Light Switch—If Equipped 53
Removing Operator’s Station Door Window Screens 54
Opening Secondary Exit 54
Operator’s Manual Holder 54
Heating and Air Conditioning Controls—If Equipped 55
Heater and Fan 55
Windshield Wiper and Washer—If Equipped 56
Battery Disconnect 56
Fire Extinguisher 56
Pressurized Water System 57
Cold Weather Transmission Disconnect Handle—If Equipped 58
Break In 59
Engine Break In Oil 59
Every 10 Hours or Daily 60
After the First 100 Hours 60
Pre Start Inspection 61
Inspect Machine Daily Before Starting 61
Operating the Engine 62
Using Booster Batteries 62
Check Instruments Before Starting 64
Starting the Engine 65
Starting Fluid—If Equipped (Cold Weather Starting Aid) 68
Cold Weather Warm Up 69
Engine Warm Up 70
Check Instruments After Starting 70
Stopping the Engine 70
Driving the Machine 72
Driving on Public Roads 72
General Driving Precautions 72
Operating in Steep Conditions 72
Engine Speed Control Knob—If Equipped, and Accelerator Pedal 73
Transmission Control and Park Brake Lever 74
Inching Pedal 74
Service Brake 75
Travel Speeds 76
Transporting Grapple 80
Park Brake 80
Parking the Machine 81
Lock All Compartments 82
Operating the Machine 83
Differential Lock Switch 83
Blade Control Lever 84
Winch Control Lever 85
Fasten Cable to Winch Drum—4000 Series 85
Fastening Cable to Winch Drum—6000 Series 89
Winch Free Spool Drag Adjustment 90
Grapple and Boom Control Lever (Single Function) 91
Grapple, Boom and Arch Control Levers (Dual Function) 92
Grapple Head 93
Grapple Damper 94
Grapple Shock 94
Transporting 95
Loading Machine on a Trailer 95
Towing Procedure 96
Fuels and Lubricants 99
Diesel Fuel 99
Low Sulfur Diesel Fuel Conditioner 99
Handling and Storing Diesel Fuel 100
Do Not Use Galvanized Containers 100
Fuel Tank 101
Diesel Engine Oil 102
Transmission Hydraulic System, Park Brake, Differential, Hand Pump Reservoir and Winch Oils 103
Grease 104
Oil Filters 104
Lubricant Storage 105
Alternative and Synthetic Lubricants 105
Mixing of Lubricants 105
Periodic Maintenance 106
Service Your Machine at Specified Intervals 106
Check the Hour Meter Regularly 106
Use Correct Fuels and Lubricants 107
Prepare Machine for Maintenance 107
Locking Machine Frames 109
Opening the Grille 110
Opening the Engine Side Shield 111
Maintenance and Repair Record Keeping System 112
Oilscan Plus®, Coolscan Plus® and 3 Way Coolant Test Kit 113
Maintenance and Repair Record Keeping System 114
Maintenance—As Required 118
Inspect Serpentine Belt 118
Inspect Element 119
Clean Dusty Primary Element 120
Check Tire Pressure 121
Check Wheel Bolts 122
Clean Fuel Tank Filler Screen 122
Fill and Charge Pressurized Water System—If Equipped 123
Check Fire Extinguisher Charge—If Equipped 124
Maintenance—Every 10 Hours or Daily 125
Check Recovery Tank Coolant Level 125
Check Engine Oil Level 125
Check Primary Fuel Filter (Water Separator) and Drain Water, If Necessary 126
Check Air Cleaner Unloader Valve 127
Lubricate Frame Hinge Pivots 127
Lubricate Boom and Arch Cylinder Pins and Arch to Frame Pivot 128
Lubricate Damper, Yoke and Cross Head Pins 129
Lubricate Tongs and Tong Cylinders 130
Lubricate Boom to Arch Pivot 130
Check Transmission Oil Level 131
Check Hydraulic System Oil Level 132
Maintenance—Every 100 Hours 133
Lubricate Front Axle Pivots and Front Steering Cylinder Pins 133
Lubricate Rear Steering Cylinder Pins 133
Drain Fuel Tank Sump Sediment 133
Lubricate Winch Fairlead Rollers 134
Lubricate Lower Drive Shaft Support Bearing 134
Lubricate Winch Telescoping Drive Shaft 135
Lubricate Lower Telescoping Drive Shaft 135
Lubricate Stacking Blade and Cylinder Pivots 136
Maintenance—Every 250 Hours 137
Change Engine Oil and Replace Filter 137
Maintenance—Every 500 Hours 139
Check Radiator Coolant Level 139
Replace Primary Fuel Filter (Water Separator)—540G II, 548G II, 640G II, 648G II 140
Replace Final Fuel Filter—540G II, 548G II, 640G II, 648G II 141
Replace Primary Fuel Filter (Water Separator)—748G II 142
Replace Final Fuel Filter—748G II 143
Check Brake Accumulator Action 143
Replace Differential Lock Return Filter 144
Replace Transmission Oil Filter 145
Check Air Intake Hoses 146
Replace Hydraulic Oil Filter 146
Check Battery Electrolyte Level and Terminals 148
Maintenance—Every 1000 Hours 151
Replace Air Cleaner Elements 151
Replace Unloader Valve 151
Change Front and Rear Differential Oil 152
Replace Transmission Breather Filter 155
Change Winch Oil 155
Lubricate Rotate Bearing 156
Replace Differential Lock Inlet Filter 157
Change Transmission Oil, Replace Filter and Clean Screen 157
Inspect Crankshaft Vibration Damper 160
Change Hydraulic Oil and Replace Filter 161
Replace Hydraulic Reservoir Breather Filter 164
Check Engine Speeds 164
Engine Speed Control Linkage Adjustment—540G II, 548G II, 640G II, 648G II 166
Engine Speed Control Linkage Adjustment—748G II 168
Check and Adjust Valve Clearance—540G II, 548G II, 640G II, 648G II 170
Check and Adjust Valve Clearance—748G II 173
Maintenance 176
Replace Crankshaft Vibration Damper 176
Check Cab Recirculating Air Filter 177
Drain Final Fuel Filter—540G II, 548G II, 640G II, 648G II 177
Clean Crankcase Vent Tube 178
Add Coolant Conditioner to Radiator 178
Check Receiver/Dryer Moisture Indicator—If Equipped 180
Clean Fresh Air (Air Conditioning) Filter—If Equipped 181
Check Engine Air Filter 181
Hydraulic Cab Tilt Procedure 182
Servicing the Cooling System 184
Draining the Cooling System 185
Checking Hoses 186
Diesel Engine Coolant 187
Filling the Cooling System 188
Testing the Coolant Level—Protection Level 189
Do Not Service Injection Nozzles 189
Do Not Adjust Injection Pump 190
Bleeding Fuel System 190
Precautions for Alternator and Regulator 192
Service Batteries Carefully 193
Checking Electrolyte Specific Gravity 195
Using Battery Charger 196
Replacing Batteries 197
Welding on Machine 197
Replacing Fuses 198
Changing Reverse Warning Alarm Volume 199
Checking Neutral Start System 200
Servicing Air Conditioning System—If Equipped 201
Checking Park Brake 202
Hydraulic Brake Bleeding Procedure 203
External Service Brake Inspection 204
Winch “Brake Off” Adjustment 206
Grapple Damper Adjustment 209
Brake Pedal Adjustment 210
Checking Windshield Regularly 211
Do Not Service Control Valves, Cylinders, Pumps or Motors 211
Adding Attachments/Accessories to Roll Over Protective Structure (ROPS) 212
Hardware Torque Specifications 212
Keeping ROPS Installed Properly 212
Tighten Upper Frame Pivot Pin 213
Metric Bolt and Cap Screw Torque Values 214
Unified Inch Bolt and Cap Screw Torque Values 215
Additional Metric Cap Screw Torque Values 216
Check Oil Lines and Fittings 217
Service Recommendations for O Ring Boss Fittings 218
Service Recommendations for Flat Face O Ring Seal Fittings 220
Service Recommendations for Metric Series Four Bolt Flange Fitting 221
Service Recommendations for Inch Series Four Bolt Flange Fittings 222
Operational Checkout 224
Operational Checkout 224
Gauge, Indicators and Control Checks (Engine Off) 224
Gauge, Indicators, and Control Checks (Engine On) 228
Transmission Cold Weather Disconnect Checks—If Equipped 242
Driving Checks 244
Hydraulic System Checks 246
Winch Checks 252
Accessory Check (Engine Off) 256
ROPS and Cab Component Checks 258
Miscellaneous Checks 262
Troubleshooting 264
Using Troubleshooting Charts 264
Engine 265
Electrical System 269
Transmission 273
Park Brake 275
Differential/Axle 276
Service Brakes 276
Hydraulic System 276
Steering System 277
Winch 278
Service Codes Quick Reference List 278
Storage 279
Prepare Machine for Storage 279
Monthly Storage Procedure 280
Machine Numbers 282
Record Product Identification Numbers (PIN) 282
Record Engine Serial Number 282
Record Winch Serial Number 282
Record Transmission Serial Number 282
Specifications 283
540G II Skidder Dimensions 283
540G II Skidder Specifications 286
540G II Skidder Drain and Refill Capacities 288
4000 Series Winch Specifications 289
548G II Grapple Skidder Dimensions 291
548G II Grapple Skidder Specifications 294
548G II Grapple Skidder 297
548G II Grapple Skidder Drain and Refill Capacities 298
4000 Series Winch Specifications 299
640G II Skidder Dimensions 301
640G II Skidder Specifications 305
640G II Skidder Drain and Refill Capacities 307
4000 Series Winch Specifications 308
6000 Series Winch Specifications 310
648G II Grapple Skidder Dimensions 311
648 II Grapple Skidder Specifications 314
648G II Grapple Skidder 317
648G II Grapple Skidder Drain and Refill Capacities 318
4000 Series Winch Specifications 319
748G II Grapple Skidder Dimensions 321
748 II Grapple Skidder Specifications 324
748G II Grapple Skidder 327
748G II Grapple Skidder Drain and Refill Capacities 328
6000 Series Winch Specifications 329
Crime Prevention Tips 330
Help Prevent Crime 330
Record Identification Numbers 330
Keep Proof Of Ownership 330
Park Indoors Out Of Sight 330
When Parking Outdoors 331
Reduce Vandalism 331
Report Thefts Immediately 332
Checklists 339
Maintenance and Repair Record Keeping System 339
John Deere Service Literature Available 343
Technical Information 343
John Deere Service Keeps You On the Job 345
At Your Service when You Need It 345
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