John Deere 540G-III 548G-III 640G-III 648G-III & 748G-III Skidder Operator’s Manual – PDF DOWNLOAD
FILE DETAILS:
John Deere 540G-III 548G-III 640G-III 648G-III & 748G-III Skidder Operator’s Manual – PDF DOWNLOAD
P/N: OMT183331_SJ
Language: English
Division: Forestry
Product Lines: Skidders
Publication Type: Operator’s Manuals
Associated Models: 540GIII, 640GIII, 548GIII, 648GIII, 748GIII
Series: G SERIES III
Serial: 576603—604613
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
John Deere 540G-III 548G-III 640G-III 648G-III & 748G-III Skidder Operator’s Manual – PDF DOWNLOAD
Contents 7
Safety 11
John Deere Skidder Safety Features 11
Recognize Safety Information 12
Understand Signal Words 12
Follow Safety Instructions 12
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 13
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 14
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 15
Inspect Machine 15
Use Handholds and Steps 16
Prevent Machine Runaway 16
Use Seat Belt Properly 17
Maintain Seat Belt 17
Secondary Exits 18
Travel Safely 18
Operate Machine Safely 19
Avoid Power Lines 19
Work In Ventilated Area 19
Keep Riders Off Machine 20
Handle Fuel Safely—Avoid Fires 20
Prepare for Emergencies 20
Handle Starting Fluid Safely 21
Clean Trash from Machine 21
Protect Against Flying Debris 21
Wear Protective Clothing 22
Protect Against Noise 22
Handle Chemical Products Safely 22
Use Safety Lights and Devices 23
Keep ROPS Installed Properly 23
Keep the Operator Protective Structure (OPS) in Place 24
Lock Machine Frame 24
Warn Others of Service Work 25
Practice Safe Maintenance 26
Support Machine Properly 26
Remove Paint Before Welding or Heating 27
Avoid Heating Near Pressurized Fluid Lines 27
Avoid High-Pressure Fluids 28
Clean the Machine Regularly 28
Service Cooling System Safely 29
Store Attachments Safely 29
Dispose of Waste Properly 29
Safety Signs 30
Safety Signs 30
Operator’s Station 41
Monitor Panel Indicator Lights 41
Monitor Display Window 42
Engine Coolant Temperature Gauge 43
Fuel Level Gauge 43
Hydraulic Oil Temperature Indicator 43
Hydraulic Oil Filter Restriction Indicator 44
Transmission Oil Filter Restriction Indicator 44
Transmission Oil Temperature Indicator 44
Engine Air Cleaner Restriction Indicator 45
Engine Alternator Voltage Indicator 45
Engine Oil Pressure Indicator 45
Stop Indicator and Alarm 46
Service Required Indicator 47
Differential Lock Indicator 47
Check Service Code Indicator 48
Secondary Steering Indicator 48
Fasten Seat Belt Indicator 48
Park Brake Indicator 49
Steering Wheel Spinner Knob 49
Steering Wheel Tilt and Telescope Lever 49
Pedals 50
Levers 50
Differential Lock Button 51
Adjusting Seat 51
Adjusting Air Ride Suspension Seat—If Equipped 52
Seat Belt 53
Work Light Switch and Deluxe Work Light Switch—If Equipped 53
Removing Operator’s Station Door Window Screens 54
Opening Secondary Exit 54
Operator’s Manual Holder 54
Defrosting, Heating, and Air Conditioning Controls—If Equipped 55
Front Windshield Wiper and Washer 55
Rear Windshield Wiper and Washer—If Equipped 56
Windshield Washer Fluid Tank 56
Battery Disconnect 57
Fire Extinguisher 57
Dome Light—If Equipped 57
Pressurized Water System—If Equipped 58
Cold Weather Transmission Disconnect Handle—If Equipped 59
Pre-Start Inspection 60
Inspect Machine Daily Before Starting 60
Operating the Engine 61
Using Booster Batteries 61
Check Instruments Before Starting 63
Starting the Engine 64
Starting Fluid—If Equipped (Cold Weather Starting Aid) 67
Cold Weather Warm-Up 68
Engine Warm-Up 69
Check Instruments After Starting 69
Stopping the Engine 69
Driving the Machine 71
Driving on Public Roads 71
General Driving Precautions 71
Operating in Steep Conditions 71
Accelerator Pedal and Engine Speed Control Knob—If Equipped 72
Transmission Control and Park Brake Lever 73
Inching Pedal 73
Service Brake 74
Ground Speeds 74
Transporting Grapple—If Equipped 75
Park Brake 75
Parking the Machine 76
Lock All Compartments 77
Operating the Machine 78
Differential Lock Button 78
Blade Control Lever 79
Winch Control Lever—If Equipped 80
Fastening Cable to Winch Drum—4000 Series 81
Fastening Cable to Winch Drum—6000 Series 84
Winch Free Spool Drag Adjustment 85
Grapple and Arch Control Lever (Single Function)—If Equipped 86
Arch and Boom Control Lever and Grapple Control Lever (Dual Function)—If Equipped 87
Grapple Head 88
Grapple Damper 88
Grapple Shock 89
Transporting 90
Loading Machine on a Trailer 90
Towing Procedure 91
Fuels and Lubricants 96
Diesel Fuel 96
Low Sulfur Diesel Fuel Conditioner 96
Handling and Storing Diesel Fuel 97
Do Not Use Galvanized Containers 97
Fuel Tank 98
Diesel Engine Oil 99
Transmission and Hydraulic Oil 100
Grease 101
Oil Filters 101
Lubricant Storage 102
Alternative and Synthetic Lubricants 102
Mixing of Lubricants 102
Periodic Maintenance 103
Service Your Machine at Specified Intervals 103
Check the Hour Meter Regularly 103
Use Correct Fuels and Lubricants 103
Prepare Machine for Maintenance 104
Locking Machine Frames 105
Opening the Grille 105
Opening Engine Side Shields 106
Maintenance and Repair Record Keeping System 107
OILSCAN PLUS®, COOLSCAN PLUS®, and 3-Way Coolant Test Kit 108
Maintenance and Repair Record Keeping System 109
Maintenance—As Required 113
Clean Debris from Condenser and Oil Cooler—If Equipped, and Radiator 113
Inspect Serpentine Belt 114
Inspect Air Cleaner Elements 115
Clean Dusty Primary Element 116
Check Tire Pressure 117
Check Wheel Bolt Torque 118
Clean Fuel Tank Filler Screen 118
Fill and Charge Pressurized Water System—If Equipped 120
Check Fire Extinguisher Charge 121
Maintenance—Every 10 Hours or Daily 122
Check Recovery Tank Coolant Level 122
Check Engine Oil Level 123
Check and Drain Primary Fuel Filter (Water Separator) 124
Clean Air Cleaner Unloader Valve 124
Lubricate Frame Hinge Pivots 125
Lubricate Boom and Arch Cylinder Pins and Arch-to-Frame Pivot—If Equipped 126
Lubricate Damper, Yoke, and Crosshead Pins—If Equipped 127
Lubricate Tongs and Tong Cylinders—If Equipped 128
Lubricate Boom-to-Arch Pivot—If Equipped 128
Check Transmission Oil Level 129
Check Hydraulic System Oil Level 130
Maintenance—Every 100 Hours 131
Lubricate Front Axle Pivots and Front Steering Cylinder Pins 131
Lubricate Rear Steering Cylinder Pins 131
Lubricate Winch Fairlead Rollers—If Equipped 131
Lubricate Lower Drive Shaft Support Bearing 132
Lubricate Winch Telescoping Drive Shaft—If Equipped 132
Lubricate Lower Telescoping Drive Shaft 133
Lubricate Stacking Blade and Cylinder Pivots 133
Maintenance—Every 250 Hours 134
Change Engine Oil and Replace Filter 134
Maintenance—Every 500 Hours 137
Check Radiator Coolant Level 137
Replace Primary Fuel Filter (Water Separator)—540G-III, 548G-III, 640G-III, 648G-III 138
Replace Final Fuel Filter—540G-III, 548G-III, 640G-III, 648G-III 139
Replace Primary Fuel Filter (Water Separator)—748G-III 140
Replace Final Fuel Filter—748G-III 141
Check Brake Accumulator Action 142
Check Rear Differential Oil Level 142
Check Front Differential Oil Level 143
Replace Differential Lock Return Filter 144
Replace Transmission Oil Filter 145
Check Air Intake Hoses 146
Replace Hydraulic Oil Filter 147
Check Battery Electrolyte Level and Terminals 149
Maintenance—Every 1000 Hours 152
Replace Air Cleaner Elements 152
Replace Air Cleaner Unloader Valve 152
Change Front Differential Oil 153
Change Rear Differential Oil 156
Replace Transmission Breather Filter 157
Change Winch Oil—If Equipped 157
Lubricate Grapple Rotate Bearing—If Equipped 159
Replace Differential Lock Inlet Filter 159
Change Transmission Oil, Replace Filter, and Clean Suction Screen 159
Inspect Engine Torsional Damper 163
Change Hydraulic Oil 164
Replace Hydraulic Reservoir Breather Filter 166
Check Engine Idle Speeds 167
Adjust Engine Speed Control Linkage—540G-III, 548G-III, 640G-III, 648G-III 168
Adjust Engine Speed Control Linkage—748G-III 170
Check and Adjust Valve Lash—540G-III, 548G-III, 640G-III, 648G-III 172
Check and Adjust Valve Lash—748G-III 174
Maintenance 178
Replace Engine Torsional Damper 178
Clean Cab Recirculating Air Filter 179
Drain Final Fuel Filter—540G-III, 548G-III, 640G-III, 648G-III 179
Clean Crankcase Vent Tube 180
Add Coolant Conditioner to Radiator 180
Check Receiver-Dryer Moisture Indicator—If Equipped 182
Clean Fresh Air (Air Conditioning) Filter 183
Check Engine Air Cleaner 183
Hydraulic Cab Tilt Procedure 184
Servicing the Cooling System 189
Draining the Cooling System 189
Checking Coolant System 191
Diesel Engine Coolant 192
Filling the Cooling System 193
Testing the Coolant Level—Protection Level 194
Do Not Service Injection Nozzles 194
Do Not Adjust Injection Pump 195
Bleed Fuel System—540G-III, 548G-III, 640G-III, 648G-III 195
Bleed Fuel System—748G-III 197
Precautions for Alternator and Regulator 198
Handling Batteries Safely 199
Service Batteries Carefully 200
Checking Electrolyte Specific Gravity 202
Using Battery Charger 203
Replacing Batteries 204
Welding on Machine 204
Replacing Fuses 205
Changing Reverse Warning Alarm Volume 207
Checking Neutral Start System 208
Servicing Air Conditioning System—If Equipped 209
Checking Park Brake 210
External Service Brake Inspection 210
Winch BRAKE OFF Adjustment—If Equipped 212
Grapple Damper Adjustment—If Equipped 216
Replacing Grapple Shock—If Equipped 218
Brake Pedal Adjustment 218
Checking Windshield Regularly 219
Do Not Service Control Valves, Cylinders, Pumps or Motors 219
Adding Attachments/Accessories to Roll-Over Protective Structure (ROPS) 220
Hardware Torque Specifications 220
Keeping ROPS Installed Properly 221
Tighten Upper and Lower Frame Pivot Pin Cap Screws 222
Unified Inch Bolt and Cap Screw Torque Values 223
Metric Bolt and Cap Screw Torque Values 224
Additional Metric Cap Screw Torque Values 225
Check Oil Lines And Fittings 227
Service Recommendations for O-Ring Boss Fittings 228
Service Recommendations for Flat Face O-Ring Seal Fittings 230
Service Recommendations for Metric Series Four Bolt Flange Fitting 231
Service Recommendations For Inch Series Four Bolt Flange Fittings 232
Operational Checkout 233
Operational Checkout 233
Gauge, Indicators and Control Checks (Engine Off) 233
Gauge, Indicators, and Control Checks (Engine ON) 237
Brake System Checks 244
Steering System Checks 249
Transmission Cold Weather Disconnect Checks—If Equipped 254
Driving Checks 256
Hydraulic System Checks 258
Winch Checks 265
Accessory Check (Engine OFF) 269
ROPS and Cab Component Checks 272
Miscellaneous Checks 278
Troubleshooting 280
Using Troubleshooting Charts 280
Engine 281
Electrical System 288
Transmission 294
Park Brake 297
Axle Differential 298
Service Brakes 298
Hydraulic System 299
Steering System 299
Winch 300
Service Codes 300
Storage 301
Prepare Machine for Storage 301
Monthly Storage Procedure 302
Machine Numbers 304
Record Product Identification Number (PIN) 304
Record Engine Serial Number 304
Record Winch Serial Number 304
Record Transmission Serial Number 304
Specifications 305
540G-III Skidder Dimensions 305
540G-III Skidder Specifications 308
540G-III Skidder Drain and Refill Capacities 310
4000 Series Winch Specifications—540G-III 311
548G-III Grapple Skidder Dimensions 313
548G-III Grapple Skidder Specifications 316
548G-III Grapple Skidder 318
548G-III Grapple Skidder Drain and Refill Capacities 319
4000 Series Winch Specifications—548G-III 320
640G-III Skidder Dimensions 322
640G-III Skidder Specifications 325
640G-III Skidder Drain and Refill Capacities 327
4000 Series Winch Specifications—640G-III 328
6000 Series Winch Specifications—640G-III 330
648G-III Grapple Skidder Dimensions 331
648G-III Grapple Skidder Specifications 334
648G-III Grapple Skidder 336
648G-III Grapple Skidder Drain and Refill Capacities 337
4000 Series Winch Specifications—648G-III 338
748G-III Grapple Skidder Dimensions 340
748G-III Grapple Skidder Specifications 343
748G-III Grapple Skidder 345
748G-III Grapple Skidder Drain and Refill Capacities 346
6000 Series Winch Specifications—748G-III 347
Ground Speeds 348
Crime Prevention Tips 349
Help Prevent Crime 349
Record Identification Numbers 349
Keep Proof of Ownership 349
Park Indoors Out of Sight 349
When Parking Outdoors 350
Reduce Vandalism 350
Report Thefts Immediately 351
Checklists 361
Maintenance and Repair Record Keeping System 361
John Deere Service Literature Available 365
Technical Information 365
John Deere Service Keeps You On the Job 367
At Your Service when You Need It 367
Safety 11
John Deere Skidder Safety Features 11
Recognize Safety Information 12
Understand Signal Words 12
Follow Safety Instructions 12
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 13
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 14
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 15
Inspect Machine 15
Use Handholds and Steps 16
Prevent Machine Runaway 16
Use Seat Belt Properly 17
Maintain Seat Belt 17
Secondary Exits 18
Travel Safely 18
Operate Machine Safely 19
Avoid Power Lines 19
Work In Ventilated Area 19
Keep Riders Off Machine 20
Handle Fuel Safely—Avoid Fires 20
Prepare for Emergencies 20
Handle Starting Fluid Safely 21
Clean Trash from Machine 21
Protect Against Flying Debris 21
Wear Protective Clothing 22
Protect Against Noise 22
Handle Chemical Products Safely 22
Use Safety Lights and Devices 23
Keep ROPS Installed Properly 23
Keep the Operator Protective Structure (OPS) in Place 24
Lock Machine Frame 24
Warn Others of Service Work 25
Practice Safe Maintenance 26
Support Machine Properly 26
Remove Paint Before Welding or Heating 27
Avoid Heating Near Pressurized Fluid Lines 27
Avoid High-Pressure Fluids 28
Clean the Machine Regularly 28
Service Cooling System Safely 29
Store Attachments Safely 29
Dispose of Waste Properly 29
Safety Signs 30
Safety Signs 30
Operator’s Station 41
Monitor Panel Indicator Lights 41
Monitor Display Window 42
Engine Coolant Temperature Gauge 43
Fuel Level Gauge 43
Hydraulic Oil Temperature Indicator 43
Hydraulic Oil Filter Restriction Indicator 44
Transmission Oil Filter Restriction Indicator 44
Transmission Oil Temperature Indicator 44
Engine Air Cleaner Restriction Indicator 45
Engine Alternator Voltage Indicator 45
Engine Oil Pressure Indicator 45
Stop Indicator and Alarm 46
Service Required Indicator 47
Differential Lock Indicator 47
Check Service Code Indicator 48
Secondary Steering Indicator 48
Fasten Seat Belt Indicator 48
Park Brake Indicator 49
Steering Wheel Spinner Knob 49
Steering Wheel Tilt and Telescope Lever 49
Pedals 50
Levers 50
Differential Lock Button 51
Adjusting Seat 51
Adjusting Air Ride Suspension Seat—If Equipped 52
Seat Belt 53
Work Light Switch and Deluxe Work Light Switch—If Equipped 53
Removing Operator’s Station Door Window Screens 54
Opening Secondary Exit 54
Operator’s Manual Holder 54
Defrosting, Heating, and Air Conditioning Controls—If Equipped 55
Front Windshield Wiper and Washer 55
Rear Windshield Wiper and Washer—If Equipped 56
Windshield Washer Fluid Tank 56
Battery Disconnect 57
Fire Extinguisher 57
Dome Light—If Equipped 57
Pressurized Water System—If Equipped 58
Cold Weather Transmission Disconnect Handle—If Equipped 59
Pre-Start Inspection 60
Inspect Machine Daily Before Starting 60
Operating the Engine 61
Using Booster Batteries 61
Check Instruments Before Starting 63
Starting the Engine 64
Starting Fluid—If Equipped (Cold Weather Starting Aid) 67
Cold Weather Warm-Up 68
Engine Warm-Up 69
Check Instruments After Starting 69
Stopping the Engine 69
Driving the Machine 71
Driving on Public Roads 71
General Driving Precautions 71
Operating in Steep Conditions 71
Accelerator Pedal and Engine Speed Control Knob—If Equipped 72
Transmission Control and Park Brake Lever 73
Inching Pedal 73
Service Brake 74
Ground Speeds 74
Transporting Grapple—If Equipped 75
Park Brake 75
Parking the Machine 76
Lock All Compartments 77
Operating the Machine 78
Differential Lock Button 78
Blade Control Lever 79
Winch Control Lever—If Equipped 80
Fastening Cable to Winch Drum—4000 Series 81
Fastening Cable to Winch Drum—6000 Series 84
Winch Free Spool Drag Adjustment 85
Grapple and Arch Control Lever (Single Function)—If Equipped 86
Arch and Boom Control Lever and Grapple Control Lever (Dual Function)—If Equipped 87
Grapple Head 88
Grapple Damper 88
Grapple Shock 89
Transporting 90
Loading Machine on a Trailer 90
Towing Procedure 91
Fuels and Lubricants 96
Diesel Fuel 96
Low Sulfur Diesel Fuel Conditioner 96
Handling and Storing Diesel Fuel 97
Do Not Use Galvanized Containers 97
Fuel Tank 98
Diesel Engine Oil 99
Transmission and Hydraulic Oil 100
Grease 101
Oil Filters 101
Lubricant Storage 102
Alternative and Synthetic Lubricants 102
Mixing of Lubricants 102
Periodic Maintenance 103
Service Your Machine at Specified Intervals 103
Check the Hour Meter Regularly 103
Use Correct Fuels and Lubricants 103
Prepare Machine for Maintenance 104
Locking Machine Frames 105
Opening the Grille 105
Opening Engine Side Shields 106
Maintenance and Repair Record Keeping System 107
OILSCAN PLUS®, COOLSCAN PLUS®, and 3-Way Coolant Test Kit 108
Maintenance and Repair Record Keeping System 109
Maintenance—As Required 113
Clean Debris from Condenser and Oil Cooler—If Equipped, and Radiator 113
Inspect Serpentine Belt 114
Inspect Air Cleaner Elements 115
Clean Dusty Primary Element 116
Check Tire Pressure 117
Check Wheel Bolt Torque 118
Clean Fuel Tank Filler Screen 118
Fill and Charge Pressurized Water System—If Equipped 120
Check Fire Extinguisher Charge 121
Maintenance—Every 10 Hours or Daily 122
Check Recovery Tank Coolant Level 122
Check Engine Oil Level 123
Check and Drain Primary Fuel Filter (Water Separator) 124
Clean Air Cleaner Unloader Valve 124
Lubricate Frame Hinge Pivots 125
Lubricate Boom and Arch Cylinder Pins and Arch-to-Frame Pivot—If Equipped 126
Lubricate Damper, Yoke, and Crosshead Pins—If Equipped 127
Lubricate Tongs and Tong Cylinders—If Equipped 128
Lubricate Boom-to-Arch Pivot—If Equipped 128
Check Transmission Oil Level 129
Check Hydraulic System Oil Level 130
Maintenance—Every 100 Hours 131
Lubricate Front Axle Pivots and Front Steering Cylinder Pins 131
Lubricate Rear Steering Cylinder Pins 131
Lubricate Winch Fairlead Rollers—If Equipped 131
Lubricate Lower Drive Shaft Support Bearing 132
Lubricate Winch Telescoping Drive Shaft—If Equipped 132
Lubricate Lower Telescoping Drive Shaft 133
Lubricate Stacking Blade and Cylinder Pivots 133
Maintenance—Every 250 Hours 134
Change Engine Oil and Replace Filter 134
Maintenance—Every 500 Hours 137
Check Radiator Coolant Level 137
Replace Primary Fuel Filter (Water Separator)—540G-III, 548G-III, 640G-III, 648G-III 138
Replace Final Fuel Filter—540G-III, 548G-III, 640G-III, 648G-III 139
Replace Primary Fuel Filter (Water Separator)—748G-III 140
Replace Final Fuel Filter—748G-III 141
Check Brake Accumulator Action 142
Check Rear Differential Oil Level 142
Check Front Differential Oil Level 143
Replace Differential Lock Return Filter 144
Replace Transmission Oil Filter 145
Check Air Intake Hoses 146
Replace Hydraulic Oil Filter 147
Check Battery Electrolyte Level and Terminals 149
Maintenance—Every 1000 Hours 152
Replace Air Cleaner Elements 152
Replace Air Cleaner Unloader Valve 152
Change Front Differential Oil 153
Change Rear Differential Oil 156
Replace Transmission Breather Filter 157
Change Winch Oil—If Equipped 157
Lubricate Grapple Rotate Bearing—If Equipped 159
Replace Differential Lock Inlet Filter 159
Change Transmission Oil, Replace Filter, and Clean Suction Screen 159
Inspect Engine Torsional Damper 163
Change Hydraulic Oil 164
Replace Hydraulic Reservoir Breather Filter 166
Check Engine Idle Speeds 167
Adjust Engine Speed Control Linkage—540G-III, 548G-III, 640G-III, 648G-III 168
Adjust Engine Speed Control Linkage—748G-III 170
Check and Adjust Valve Lash—540G-III, 548G-III, 640G-III, 648G-III 172
Check and Adjust Valve Lash—748G-III 174
Maintenance 178
Replace Engine Torsional Damper 178
Clean Cab Recirculating Air Filter 179
Drain Final Fuel Filter—540G-III, 548G-III, 640G-III, 648G-III 179
Clean Crankcase Vent Tube 180
Add Coolant Conditioner to Radiator 180
Check Receiver-Dryer Moisture Indicator—If Equipped 182
Clean Fresh Air (Air Conditioning) Filter 183
Check Engine Air Cleaner 183
Hydraulic Cab Tilt Procedure 184
Servicing the Cooling System 189
Draining the Cooling System 189
Checking Coolant System 191
Diesel Engine Coolant 192
Filling the Cooling System 193
Testing the Coolant Level—Protection Level 194
Do Not Service Injection Nozzles 194
Do Not Adjust Injection Pump 195
Bleed Fuel System—540G-III, 548G-III, 640G-III, 648G-III 195
Bleed Fuel System—748G-III 197
Precautions for Alternator and Regulator 198
Handling Batteries Safely 199
Service Batteries Carefully 200
Checking Electrolyte Specific Gravity 202
Using Battery Charger 203
Replacing Batteries 204
Welding on Machine 204
Replacing Fuses 205
Changing Reverse Warning Alarm Volume 207
Checking Neutral Start System 208
Servicing Air Conditioning System—If Equipped 209
Checking Park Brake 210
External Service Brake Inspection 210
Winch BRAKE OFF Adjustment—If Equipped 212
Grapple Damper Adjustment—If Equipped 216
Replacing Grapple Shock—If Equipped 218
Brake Pedal Adjustment 218
Checking Windshield Regularly 219
Do Not Service Control Valves, Cylinders, Pumps or Motors 219
Adding Attachments/Accessories to Roll-Over Protective Structure (ROPS) 220
Hardware Torque Specifications 220
Keeping ROPS Installed Properly 221
Tighten Upper and Lower Frame Pivot Pin Cap Screws 222
Unified Inch Bolt and Cap Screw Torque Values 223
Metric Bolt and Cap Screw Torque Values 224
Additional Metric Cap Screw Torque Values 225
Check Oil Lines And Fittings 227
Service Recommendations for O-Ring Boss Fittings 228
Service Recommendations for Flat Face O-Ring Seal Fittings 230
Service Recommendations for Metric Series Four Bolt Flange Fitting 231
Service Recommendations For Inch Series Four Bolt Flange Fittings 232
Operational Checkout 233
Operational Checkout 233
Gauge, Indicators and Control Checks (Engine Off) 233
Gauge, Indicators, and Control Checks (Engine ON) 237
Brake System Checks 244
Steering System Checks 249
Transmission Cold Weather Disconnect Checks—If Equipped 254
Driving Checks 256
Hydraulic System Checks 258
Winch Checks 265
Accessory Check (Engine OFF) 269
ROPS and Cab Component Checks 272
Miscellaneous Checks 278
Troubleshooting 280
Using Troubleshooting Charts 280
Engine 281
Electrical System 288
Transmission 294
Park Brake 297
Axle Differential 298
Service Brakes 298
Hydraulic System 299
Steering System 299
Winch 300
Service Codes 300
Storage 301
Prepare Machine for Storage 301
Monthly Storage Procedure 302
Machine Numbers 304
Record Product Identification Number (PIN) 304
Record Engine Serial Number 304
Record Winch Serial Number 304
Record Transmission Serial Number 304
Specifications 305
540G-III Skidder Dimensions 305
540G-III Skidder Specifications 308
540G-III Skidder Drain and Refill Capacities 310
4000 Series Winch Specifications—540G-III 311
548G-III Grapple Skidder Dimensions 313
548G-III Grapple Skidder Specifications 316
548G-III Grapple Skidder 318
548G-III Grapple Skidder Drain and Refill Capacities 319
4000 Series Winch Specifications—548G-III 320
640G-III Skidder Dimensions 322
640G-III Skidder Specifications 325
640G-III Skidder Drain and Refill Capacities 327
4000 Series Winch Specifications—640G-III 328
6000 Series Winch Specifications—640G-III 330
648G-III Grapple Skidder Dimensions 331
648G-III Grapple Skidder Specifications 334
648G-III Grapple Skidder 336
648G-III Grapple Skidder Drain and Refill Capacities 337
4000 Series Winch Specifications—648G-III 338
748G-III Grapple Skidder Dimensions 340
748G-III Grapple Skidder Specifications 343
748G-III Grapple Skidder 345
748G-III Grapple Skidder Drain and Refill Capacities 346
6000 Series Winch Specifications—748G-III 347
Ground Speeds 348
Crime Prevention Tips 349
Help Prevent Crime 349
Record Identification Numbers 349
Keep Proof of Ownership 349
Park Indoors Out of Sight 349
When Parking Outdoors 350
Reduce Vandalism 350
Report Thefts Immediately 351
Checklists 361
Maintenance and Repair Record Keeping System 361
John Deere Service Literature Available 365
Technical Information 365
John Deere Service Keeps You On the Job 367
At Your Service when You Need It 367
S.V 03/24