John Deere 540H and 548H Skidder (630436— ) Technical Manual with Electrical Wiring Diagrams (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnosis & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation.

TM11794 - John Deere 540H and 548H Skidder (630436— ) Technical Manual - Operation and Test.pdf
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Category: Operation and Test
Language: English Spanish French Russian
Published on 2018/09/13

TABLE OF CONTENTS
Section 9000: General Information...22
  Group 01: Safety...22
    Recognize Safety Information...25
    Follow Safety Instructions...26
    Operate Only If Qualified...27
    Wear Protective Equipment...28
    Avoid Unauthorized Machine Modifications...29
    Inspect Machine...30
    Stay Clear of Moving Parts...31
    Avoid High-Pressure Fluids...32
    Avoid High-Pressure Oils...33
    Do Not Use Starting Fluid...34
    Work In Ventilated Area...35
    Prevent Fires...36
    Prevent Battery Explosions...37
    Handle Chemical Products Safely...38
    Decommissioning — Proper Recycling and Disposal of Fluids and Components...39
    Prepare for Emergencies...40
    Clean Debris from Machine...41
    Use Steps and Handholds Correctly...42
    Start Only From Operator's Seat...43
    Use and Maintain Seat Belt...44
    Prevent Unintended Machine Movement...45
    Avoid Work Site Hazards...47
    Operate Machine Safely...48
    Keep Riders Off Machine...49
    Avoid Backover Accidents...50
    Avoid Machine Tip Over...51
    Operating on Slopes...53
    Operating or Traveling On Public Roads...54
    Inspect and Maintain ROPS...55
    Keep the Operator Protective Structure (OPS) in Place...56
    Add and Operate Attachments Safely...57
    Park and Prepare for Service Safely...58
    Service Tires Safely...60
    Service Cooling System Safely...61
    Service Accumulator Systems Safely...62
    Remove Paint Before Welding or Heating...63
    Make Welding Repairs Safely...64
    Drive Metal Pins Safely...65
Section 9001: Diagnostic Trouble Codes (DTC)...66
  Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes...75
    Engine Control Unit (ECU) Diagnostic Trouble Codes...75
    000091.09 - CAN Throttle Message Missing or Late...66
    000190.00 - Engine Overspeed Extreme...66
    000190.16 - Engine Overspeed Moderate...66
    000676.03 - Glow Plug Relay Out of Range High...66
    000676.05 - Glow Plug Relay Out of Range Low...66
    001075.05 - Low Pressure Fuel Pump Out of Range Low...66
    001075.06 - Low Pressure Fuel Pump Out of Range High...66
    002003.09 - TCU Communication Data Error...66
    002003.13 - TCU Communication Calibrate Error...66
    002017.09 - SDM Communication Data Error...66
    002017.13 - SDM Communication Calibrate Error...66
  Group 20: Transmission Control Unit (TCU) Diagnostic Trouble Codes...102
    Transmission Control Unit (TCU) Diagnostic Trouble Codes...102
    000158.03 - Switched Power Out of Range High...66
    000161.02 - Transmission Input Speed Sensor Erratic or Bad Data...66
    000177.00 - Transmission Oil Temperature High...66
    000177.03 - Transmission Oil Temperature Sensor Out of Range High...66
    000177.04 - Transmission Oil Temperature Sensor Out of Range Low...66
    000191.02 - Transmission Output Speed Data Invalid...66
    000525.02 - Shift Parameter Erratic or Bad Data...66
    000774.04 - Bump Up Shift Switch Short to Ground...66
    000775.04 - Bump Down Shift Switch Short to Ground...66
    000777.03 - Lockup Clutch Out of Range High...66
    000777.05 - Lockup Clutch Out of Range Low...66
    003509.04 - Sensor Supply #1 Out of Range Low...66
    003510.04 - Sensor Supply #2 Out of Range Low...66
    003511.04 - Sensor Supply #3 Out of Range Low...66
    003512.04 - Sensor Supply #4 Out of Range Low...66
    522002.31 - Upshift and Downshift Inputs Active...66
    522003.31 - Neutral, Forward, and Reverse Inputs Passive...66
    522004.04 - Park and Not Park Active Out of Range Low...67
    522005.03 - Park and Not Park Active Out of Range High...67
    522151.31 - Shifter Neutral and Forward Inputs Active...67
    522153.31 - Shifter Neutral and Reverse Inputs Active...67
    522169.04 - Gear Enable/Differential Lock Switch Out of Range...67
    522252.00 - Clutch #1 Hold Value Out of Range High...67
    522252.01 - Clutch #1 Hold Value Out of Range Low...67
    522253.00 - Clutch #2 Hold Value Out of Range High...67
    522253.01 - Clutch #2 Hold Value Out of Range Low...67
    522254.00 - Clutch #3 Hold Value Out of Range High...67
    522254.01 - Clutch #3 Hold Value Out of Range Low...67
    522255.00 - Clutch #4 Hold Value Out of Range High...67
    522255.01 - Clutch #4 Hold Value Out of Range Low...67
    522256.00 - Clutch A Hold Value Out of Range High...67
    522256.01 - Clutch A Hold Value Out of Range Low...67
    522257.00 - Clutch B Hold Value Out of Range High...67
    522257.01 - Clutch B Hold Value Out of Range Low...67
    522258.00 - Clutch C Hold Value Out of Range High...67
    522258.01 - Clutch C Hold Value Out of Range Low...67
    522259.00 - Clutch D Hold Value Out of Range High...67
    522259.01 - Clutch D Hold Value Out of Range Low...67
    522284.02 - Transmission Cylinder Speed Data Invalid...67
    522398.12 - Not Park and Park Pressure Inputs Active...67
    522414.03 - Clutch D Out of Range High...67
    522414.05 - Clutch D Out of Range Low...67
    522507.14 - Calibrate While Inching...67
    523655.03 - Forward and Reverse Inputs Active...67
    523689.04 - Differential Lock Short to Ground...67
    523697.04 - Inching Pedal Top of Clutch Switch Short to Ground...67
    523967.09 - Top of Clutch Input Passive Abnormal Data Rate...67
    523699.31 - Speed Clutch Slippage...67
    523700.16 - Inching Pedal Limit Exceeded...67
    523700.31 - Directional Clutch Slippage...67
    523708.02 - Inching Pedal Switch Module Data Invalid...68
    523708.04 - Inching Pedal Bottom of Clutch Switch Short to Ground...68
    523712.31 - Park Brake Not Set During Calibration...68
    523717.31 - Holding Clutch Unexpected Response...68
    523718.31 - Cylinder Speed Invalid During Calibration...68
    523720.00 - Clutch D Fill Out of Range High...68
    523720.01 - Clutch D Fill Out of Range Low...68
    523721.00 - Clutch C Fill Out of Range High...68
    523721.01 - Clutch C Fill Out of Range Low...68
    523722.00 - Clutch B Fill Out of Range High...68
    523722.01 - Clutch B Fill Out of Range Low...68
    523723.00 - Clutch A Fill Out of Range High...68
    523723.00 - Clutch A Fill Out of Range Low...68
    523724.00 - Clutch 4 Fill Out of Range High...68
    523724.01 - Clutch 4 Fill Out of Range Low...68
    523725.00 - Clutch 3 Fill Out of Range High...68
    523725.01 - Clutch 3 Fill Out of Range Low...68
    523726.00 - Clutch 2 Fill Out of Range High...68
    523726.01 - Clutch 2 Fill Out of Range Low...68
    523727.00 - Clutch 1 Fill Out of Range High...68
    523727.01 - Clutch 1 Fill Out of Range Low...68
    523728.31 - Unexpected Cylinder Speed REV Calibration...68
    523729.31 - Unexpected Cylinder Speed FWD Calibration...68
    523730.31 - No Cylinder Speed Calibration...68
    523731.31 - Output Speed During Calibration...68
    523732.31 - Engine Speed Too Low During Calibration...68
    523733.31 - Engine Speed Too High During Calibration...68
    523747.14 - Not Park and Park Pressure Inputs Passive...68
    523761.03 - Clutch 4 Out of Range High...68
    523761.05 - Clutch 4 Out of Range Low...68
    523762.03 - Clutch 3 Out of Range High...68
    523762.05 - Clutch 3 Out of Range Low...68
    523763.03 - Clutch 2 Out of Range High...68
    523763.05 - Clutch 2 Out of Range Low...69
    523764.03 - Clutch 1 Out of Range High...69
    523764.05 - Clutch 1 Out of Range Low...69
    523795.05 - Dual Mode Steering Solenoid Out of Range Low...69
    523795.06 - Dual Mode Steering Solenoid Out of Range High...69
    524029.00 - Inching Pedal Sensor Short to Power...69
    524029.01 - Inching Pedal Sensor Open or Short to Ground...69
    524127.04 - Declutch Pressure Switch Out of Range Low...69
    524271.03 - Clutch C Out of Range High...69
    524271.05 - Clutch C Out of Range Low...69
    524272.03 - Clutch B Out of Range High...69
    524272.05 - Clutch B Out of Range Low...69
    524273.03 - Clutch A Out of Range High...69
    524273.05 - Clutch A Out of Range Low...69
  Group 30: Standard Display Monitor (SDM) Diagnostic Trouble Codes...339
    Standard Display Monitor (SDM) Diagnostic Trouble Codes...339
    000096.03 - Fuel Level Sensor Out of Range High...69
    000096.04 - Fuel Level Sensor Out of Range Low...69
    000107.00 - Engine Air Filter Restriction Data Above Normal...69
    000126.00 - Transmission Oil Filter Restriction Data Above Normal...69
    000158.00 - System Voltage Data Above Normal...69
    000158.01 - System Voltage Data Below Normal...69
    001508.00 - Hydraulic Reservoir Oil Temperature Sensor Data Above Normal...69
    001508.03 - Hydraulic Reservoir Oil Temperature Sensor Out of Range High...69
    001508.04 - Hydraulic Reservoir Oil Temperature Sensor Out of Range Low...69
    001508.16 - Hydraulic Oil Temp Sensor Moderately High Value...69
    001713.00 - Hydraulic Oil Filter Restriction Data Above Normal...69
    002000.09 - ECU Communication Data Error...69
    002000.13 - ECU Communication Calibrate Error...69
    002003.09 - TCU Communication Data Error...69
  Group 40: Flex Load Controller (FLC) Diagnostic Trouble Codes...69
    000111.01 - Engine Coolant Level Low...69
    000589.01 - Alternator Speed Slow...69
    000746.05 - Differential Lock Open Circuit...70
    000746.06 - Differential Lock Short to Ground...70
    000977.05 - Reversing Fan Open Circuit...70
    000977.06 - Reversing Fan Short to Ground...70
    001071.03 - Proportional Fan Solenoid Short to Power...70
    001071.05 - Proportional Fan Solenoid Open Circuit or Short to Ground...70
    001550.05 - Air Conditioner Clutch Open Circuit...70
    001550.06 - Air Conditioner Clutch Short to Ground...70
    002000.09 - CAN Communication Lost for ECU...70
    002017.09 - CAN Communication Lost for SDM...70
    002141.09 - CAN Communication Lost for SSM...70
    522170.04 - Tong Squeeze Switch Short to Ground...70
    522171.04 - Tong Close Switch Short to Ground...70
    522172.04 - Tong Open Switch Short to Ground...70
    522174.04 - Grapple Rotate CCW Switch Short to Ground...70
    522175.04 - Grapple Rotate CW Switch Short to Ground...70
    522176.04 - Secondary Steering Pressure Switch Short to Ground...70
    522177.05 - Tong Close Solenoid Open Circuit...70
    522177.06 - Tong Close Solenoid Short to Ground...70
    522178.05 - Tong Open Solenoid Open Circuit...70
    522178.06 - Tong Open Solenoid Short to Ground...70
    522179.05 - Grapple Rotate CCW Solenoid Open Circuit...70
    522179.06 - Grapple Rotate CCW Solenoid Short to Ground...70
    522180.05 - Grapple Rotate CW Solenoid Open Circuit...70
    522180.06 - Grapple Rotate CW Solenoid Short to Ground...70
    522311.05 - Rear Washer Pump Open Circuit...70
    522311.06 - Rear Washer Pump Short to Ground...70
    522312.05 - Front Washer Pump Open Circuit...70
    522312.06 - Front Washer Pump Short to Ground...70
    522426.04 - Rear Wiper Park Short to Ground...70
    522427.04 - Front Wiper Park Short to Ground...70
    522433.05 - Rear Wiper Open Circuit...70
    522433.06 - Rear Wiper Short to Ground...70
    522434.05 - Front Wiper Low Speed Open Circuit...71
    522434.06 - Front Wiper Low Speed Short to Ground...71
    522435.05 - Front Wiper High Speed Open Circuit...71
    522435.06 - Front Wiper High Speed Short to Ground...71
    523577.05 - Secondary Steering Open Circuit...71
    523577.06 - Secondary Steering Short to Ground...71
    523795.05 - Dual Mode Steering Open Circuit...71
    523795.06 - Dual Mode Steering Short to Ground...71
    524097.03 - Accelerator Pedal Short to Power...71
    524097.04 - Accelerator Pedal Open or Short to Ground...71
  Group 50: Sealed Switch Module (SSM) Diagnostic Trouble Codes...509
    Sealed Switch Module (SSM) Diagnostic Trouble Codes...509
    002033.09 - SSM Lost Communications...71
    520752.04 - SSM Button 17 Stuck...71
    520752.09 - SSM Button 17 No CAN Message...71
    520753.04 - SSM Button 18 Stuck...71
    520753.09 - SSM Button 18 No CAN Message...71
    520754.04 - SSM Button 19 Stuck...71
    520754.09 - SSM Button 19 No CAN Message...71
    520755.04 - SSM Button 20 Stuck...71
    520755.09 - SSM Button 20 No CAN Message...71
    523335.04 - SSM Button 25 Stuck...71
    523335.09 - SSM Button 25 No CAN Message...71
    523336.04 - SSM Button 24 Stuck...71
    523336.09 - SSM Button 24 No CAN Message...71
    523338.04 - SSM Button 23 Stuck...71
    523338.09 - SSM Button 23 No CAN Message...71
    523339.04 - SSM Button 22 Stuck...71
    523339.09 - SSM Button 22 No CAN Message...71
    523340.04 - SSM Button 21 Stuck...71
    523340.09 - SSM Button 21 No CAN Message...71
    523849.04 - SSM Button 16 Stuck...71
    523849.09 - SSM Button 16 No CAN Message...71
    523850.04 - SSM Button 15 Stuck...72
    523850.09 - SSM Button 15 No CAN Message...72
    523852.04 - SSM Button 14 Stuck...72
    523852.09 - SSM Button 14 No CAN Message...72
    523854.04 - SSM Button 13 Stuck...72
    523854.09 - SSM Button 13 No CAN Message...72
    523855.04 - SSM Button 12 Stuck...72
    523855.09 - SSM Button 12 No CAN Message...72
    523856.04 - SSM Button 11 Stuck...72
    523856.09 - SSM Button 11 No CAN Message...72
    523857.04 - SSM Button 10 Stuck...72
    523857.09 - SSM Button 10 No CAN Message...72
    523858.04 - SSM Button 9 Stuck...72
    523858.09 - SSM Button 9 No CAN Message...72
    523860.04 - SSM Button 8 Stuck...72
    523860.09 - SSM Button 8 No CAN Message...72
    523861.04 - SSM Button 7 Stuck...72
    523861.09 - SSM Button 7 No CAN Message...72
    523862.04 - SSM Button 6 Stuck...72
    523862.09 - SSM Button 6 No CAN Message...72
    523863.04 - SSM Button 5 Stuck...72
    523863.09 - SSM Button 5 No CAN Message...72
    523864.04 - SSM Button 4 Stuck...72
    523864.09 - SSM Button 4 No CAN Message...72
    523865.04 - SSM Button 3 Stuck...72
    523865.09 - SSM Button 3 No CAN Message...72
    523867.04 - SSM Button 2 Stuck...72
    523867.09 - SSM Button 2 No CAN Message...72
    523868.04 - SSM Button 1 Stuck...72
    523868.09 - SSM Button 1 No CAN Message...72
  Group 60: Forward, Neutral, and Reverse (FNR) Shift Lever Controller Diagnostic Trouble Codes...72
    003651.03 - FNR Sensor Circuit Fault...72
    003651.04 - FNR Sensor Circuit Fault...73
    003651.13 - FNR Sensor Calibration Fault...73
    516205.02 - FNR Signal Data Erratic or Intermittent...73
    003654.03 - FNR Sensor Circuit Fault...73
    003654.04 - FNR Sensor Circuit Fault...73
    003654.13 - FNR Sensor Calibration Fault...73
Section 9005: Operational Checkout Procedure...612
  Group 10: Operational Checkout Procedure...612
    Operational Checkout...683
Section 9010: Engine...753
  Group 05: Theory of Operation...753
    PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Tier 3/Stage IIIA...787
    PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Stage II...788
    Engine Identification...757
    Coolant Heater Theory of Operation...763
    Engine Fuel System Component Location...765
    Engine Cooling System Component Location...766
    Engine Intake and Exhaust System Tier 3/Stage IIIA Component Location...767
    Engine Intake and Exhaust System Stage II Component Location...768
    Coolant Heater Component Location...769
    Engine Fluid Sample Port Locations...770
    Cold Weather Starting Aid...771
  Group 15: Diagnostic Information...753
    PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Tier 3/Stage IIIA...787
    PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Stage II...788
    Engine Will Not Crank...753
    Engine Coolant Temperature Above Normal...753
    Engine Coolant Temperature Below Normal...753
    Coolant Heater System Check—If Equipped...753
  Group 25: Tests...753
    PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Tier 3/Stage IIIA...787
    PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Stage II...788
    Fuel Line Leakage Test...789
    Air Intake System Leakage Test...790
    Air Filter Restriction Switch Test...793
    Intake Manifold Pressure Test—Turbocharger Boost—6.8L Stage II...796
    Engine Slow and Fast Idle Speed Check...798
Section 9015: Electrical System...799
  Group 05: System Information...799
    Electrical Diagram Information...808
  Group 10: System Diagrams...799
    Fuse Specifications...818
    System Functional Schematic, Wiring Diagrams, and Component Locations Legend...823
    System Functional Schematic and Section Legend...831
    Power and Ground Cables Component Location...841
    Load Center Harness (W10) Component Location...842
    Load Center Harness (W10) Wiring Diagram...844
    Engine Interface Harness (W11) Component Location...849
    Engine Interface Harness (W11) Wiring Diagram...850
    Engine Harness (W12) Component Location...851
    Engine Harness (W12) Wiring Diagram...854
    Transmission Harness (W13) Component Location...857
    Transmission Harness (W13) Wiring Diagram...858
    Hydraulic Reservoir Harness (W14) Component Location...859
    Hydraulic Reservoir Harness (W14) Wiring Diagram...861
    Fuel Sensor and Backup Alarm Harness (W15) Component Location...863
    Fuel Sensor and Backup Alarm Harness (W15) Wiring Diagram...864
    Cab Roof Harness (W16) Component Location...865
    Cab Roof Harness (W16) Wiring Diagram...867
    Radio Harness (W17) Component Location—If Equipped...870
    Radio Harness (W17) Wiring Diagram—If Equipped...871
    Secondary Steering Harness (W19) Component Location—If Equipped...872
    Secondary Steering Harness (W19) Wiring Diagram—If Equipped...874
    JDLink™ System Harnesses Component Location—MIG/GTT...875
    JDLink™ System Harnesses Component Location—MTG/SAT...877
    JDLink™ System Wiring Diagrams—MIG/GTT...879
    JDLink™ System Wiring Diagrams—MTG/SAT...880
    Pilot Control Harness (W24) Component Location...882
    Pilot Control Harness (W24) Wiring Diagram...883
    Diesel Fired Coolant Heater (DFCH) Harnesses (W25 and W26) Component Location—If Equipped...884
    Diesel Fired Coolant Heater (DFCH) Harnesses (W25 and W26) Wiring Diagram—If Equipped...886
    Forward, Neutral, and Reverse (FNR) Shift Lever Harness (W28) Component Location (S.N. 661906— )...888
    Forward, Neutral, and Reverse (FNR) Shift Lever Harness (W28) Wiring Diagram (S.N. 661906— )...889
  Group 15: Sub System Diagnostics...800
    Power and Charge Circuits Theory of Operation...895
    Start Circuit Theory of Operation...900
    Park Brake Circuit Theory of Operation...904
    Controller Area Network (CAN) Circuit Theory of Operation...908
    Engine Control Unit (ECU) Circuit Theory of Operation...910
    Standard Display Monitor (SDM) Circuit Theory of Operation...922
    Transmission Control Unit (TCU) Circuit Theory of Operation...926
    JDLink™ Circuit Theory of Operation—If Equipped...937
    Declutch Circuit Theory of Operation...939
    Differential Lock Circuit Theory of Operation...941
    Proportional Fan Speed and Reversing Fan Circuits Theory of Operation...944
    Grapple Control Circuit Theory of Operation...948
    Secondary Steering Circuit Theory of Operation...951
    Dual Mode Steer Circuit Theory of Operation...955
    Windshield Washer and Wiper Circuits Theory of Operation...957
    Heater, Air Conditioner, and Precleaner Circuits Theory of Operation...961
    Work Lights Circuits Theory of Operation...966
  Group 16: Monitor Operation...800
    Standard Display Monitor (SDM)—Service Mode...971
    Standard Display Monitor (SDM)—Clear Codes...973
    Standard Display Monitor (SDM)—Transmission Temperature...974
    Standard Display Monitor (SDM)—Transmission Calibration...975
    Standard Display Monitor (SDM)—Engine Temperatures...976
    Standard Display Monitor (SDM)—Engine Pressures...977
    Standard Display Monitor (SDM)—Engine Speeds...978
    Standard Display Monitor (SDM)—Engine Performance...979
    Standard Display Monitor (SDM)—Engine Live Values...980
    Standard Display Monitor (SDM)—Fan Diagnostics...981
    Standard Display Monitor (SDM)—Monitor Diagnostics...982
    Standard Display Monitor (SDM)—Software...983
    Standard Display Monitor (SDM)—Hide Menu...984
    Standard Display Monitor (SDM)—Restore Defaults...985
    Standard Display Monitor (SDM)—Reverse Fan Cycle...986
    Standard Display Monitor (SDM)—Machine Option...987
  Group 20: References...801
    Electrical Component Specifications...993
    JDLink™ System Identification...998
    JDLink™ Connection Procedure—If Equipped...1001
    Service ADVISOR™ Connection Procedure...1002
    Service ADVISOR™ Diagnostic Application...1005
    Reading Diagnostic Trouble Codes (DTCs) With Service ADVISOR™ Diagnostic Application...1006
    Intermittent Diagnostic Trouble Code (DTC) Diagnostics...1009
    Transmission Diagnostic Trouble Codes—Limp Home Mode and Inchless Power Shift...1010
    Controller Area Network (CAN) Circuit Test...1011
    Bump Shifter Test...1015
    Accelerator Pedal Sensor Test...1017
    Alternator Test...1019
    Relay Test...1021
    Diode Test...1024
    Battery Test Procedure...1025
    Transmission Control Unit (TCU) Calibration...1026
    Troubleshooting Transmission Gear Solenoid...1028
    Electronic Controllers Remove and Install...1029
    Connector Terminal Test...1031
    Disconnect Tab Retainer Connectors...1034
    Disconnecting Spring Wire Clip Connectors...1035
    Remove Connector Body from Blade Terminals...1036
    Replace Metri-Pack® (Pull Type) Connectors...1037
    Replace Metri-Pack® (Push Type) Connectors...1039
    Replace Metri-Pack® Connectors...1040
    Replace DEUTSCH® Circular Connectors...1042
    Replace DEUTSCH® Rectangular or Triangular Connectors...1044
    Install DEUTSCH® Contact...1046
    Replace WEATHER PACK® Connector...1048
    Install WEATHER PACK® Contact...1050
    Replace CINCH™ Connectors...1052
    Install CINCH™ Contact...1054
    Repair 32 and 48 Way CINCH™ Connectors...1056
Section 9020: Power Train...1060
  Group 05: Theory of Operation...1060
    Power Train Component Overview...1064
    DF180 Series Powershift Transmission...1065
    TEAMMATE™ Axles...1066
    Transmission Operation...1067
    Transmission Component Identification...1068
    Transmission Hydraulic System Operation...1225
    Transmission Charge Pump Operation...1073
    Transmission Filter Bypass Valve Operation...1075
    Transmission Control Valve Port Identification...1077
    Transmission Proportional Solenoid Valves Identification...1079
    Transmission Control Valve Operation...1080
    Transmission Pressure Regulator Valve Operation...1082
    Park Brake and Differential Lock Control Valve...1084
    Park Brake Control Circuit...1086
    Park Brake Manual Release Operation...1091
    Differential Lock Control Circuit...1092
  Group 15: Diagnostic Information...1060
    Transmission Overfills With Oil...1060
    Transmission Clutch Slippage...1060
    Transmission Shifts Too Slow...1060
    Transmission Shifts Too Fast...1060
    Park Brake Activates When Service Brakes Are Applied (No Load on Engine While in Gear)...1060
    Machine Will Not Move (Load on Engine or Engine Stalls When Shifted Into Gear)...1060
    Machine Creeps in Neutral (Load Put on Engine When Service Brakes Are Applied)...1060
    Transmission System Overheats...1060
    Lube Pressure Low, Transmission Charge Pressure Normal...1060
    Excessive Transmission Noise Under Load or No Load...1060
    Machine Makes Excessive Transmission Noise When Moving...1060
    Erratic Transmission Oil Pressure...1060
    Excessive Transmission Oil Pressure...1060
    Low Transmission Oil Pressure in All Gears...1060
    Low Transmission Oil Pressure in One Gear but Correct in Other Gears...1061
    Transmission Breather Oil Leakage...1061
    Filter or Filter Oil Lines Blow Out...1061
    Low Lube Pressure (Not All Gears)...1061
    Excessive Lube Pressure (Not All Gears)...1061
    Low Transmission Oil Cooler Inlet Pressure, Correct Lube Pressure...1061
    Low Transmission Oil Cooler Inlet Pressure and Lube Pressure...1061
    Transmission Oil Cooler Externally Leaking...1061
    Machine “Jumps” When Inching Pedal Engaged...1061
    Machine Lacks Power...1061
    Excessive Machine Vibration...1061
    Cold Weather Disconnect Slips...1061
    Disconnect Clutch Noisy or Chatters...1061
    Excessive Drive Line Vibration...1061
    Park Brake Comes On While Using a Hydraulic Function...1061
    Park Brake Engages While Machine Is Moving...1061
    Park Brake Will Not Release...1061
    No Differential Lock Operation...1061
    Differential Lock Slippage...1061
    Excessive Differential and/or Axle Noise...1061
    Oil Seepage From Outer Axle Seal...1061
    Power Train Component Location...1180
  Group 20: Adjustments...1061
    Inching Pedal Adjustment...1185
    Park Brake Manual Release Procedure...1188
    Cold Weather Disconnect Linkage Adjustment—If Equipped...1191
  Group 25: Tests...1061
    JT02156A Digital Pressure/Temperature Analyzer Installation...1195
    Transmission Oil Warmup Procedure...1196
    Transmission Pump Flow Test...1197
    Transmission System Pressure Test...1200
    Transmission Lube Circuit Pressure Test...1202
    Transmission Control Circuit Pressure Test...1205
    Transmission Cooler Relief Valve Pressure Test...1208
    Park Brake Pressure Test...1210
    Differential Lock Pressure Test...1214
Section 9025: Hydraulic System...1219
  Group 05: Theory of Operation...1219
    Hydraulic System Operation...1225
    Cooling Loop and Reversing Fan Circuit Operation...1227
    Service Brake Hydraulic Circuit Operation...1229
    Steering and Secondary Steering Hydraulic Circuit Operation...1231
    Dual Mode Steering Hydraulic Circuit Operation...1233
    Pilot Control Hydraulic Circuit Operation...1236
    Grapple Rotate Hydraulic Circuit Operation...1238
    Main Hydraulic Pump and Pressure Compensator Operation...1240
    Brake Accumulator Operation...1243
    Hydraulic Reservoir Operation...1244
    Hydraulic Oil Return Filter Operation...1246
    Hydraulic Fan Filter Operation...1248
    Brake Valve Operation...1249
    Priority Valve Operation...1251
    Steering Valve and System Operation...1255
    Secondary Steering Valve Operation...1257
    120 Series Cylinder Operation...1259
    Blade Valve Section Operation...1261
    Arch Valve Section Operation...1263
    System Relief Valve Operation...1264
    Circuit Relief Valve—Adjustable Operation...1266
    Circuit Relief Valve—Non-Adjustable Operation...1268
    Grapple Tong Valve Section Operation...1269
    Grapple Tong Flow Divider Operation...1271
    Pilot Controller Operation...1273
    Grapple Rotate Solenoid Valve Operation...1274
    Dual Mode Steering Solenoid Valve Operation...1276
    Rotary Manifold Operation...1278
    Fan Pump Operation...1279
    Fan Variable Speed and Reversing Control Valve Operation...1282
    Fan Motor Operation...1284
    Hydraulic Oil Cooler Operation...1285
    Cab Tilt Circuit Operation...1286
  Group 15: Diagnostic Information...1220
    Hydraulic System Overheating...1220
    Hydraulic Function Drifts Down...1220
    No Steering or Hydraulic Functions...1220
    Hydraulic Functions Slow...1220
    Individual Functions Slow (Cycle Time Slow)...1220
    No Hydraulic Functions (Steering Normal)...1220
    Low Hydraulic Power (Pressure)...1220
    Excessive Hydraulic Pump Noise...1220
    Function Powers Up or Down Without Moving Lever...1220
    Grapple Rotate Stalls...1220
    Grapple Rotates Too Fast...1220
    Grapple Rotates Slow...1220
    Tongs Do Not Close Evenly...1220
    Tongs Open or Close Slowly...1220
    Grapple Loses Logs During Skidding...1220
    Transmission Overfills With Oil...1220
    No Steering (Hydraulic Functions Normal)...1220
    Steering Valve Does Not Center...1220
    Steering Valve Locks Up...1220
    Frames Turn Wrong Direction...1220
    Steering Slow or Hard...1220
    Steering Erratic or Spongy...1220
    Machine Wanders...1220
    Quick Steer Mode Not Engaging...1220
    Quick Steer Mode Not Disengaging...1220
    Quick Steer Mode Engaging When Disengaged...1220
    Poor or No Brakes (Other Hydraulic Systems Normal)...1220
    Brakes Overly Aggressive...1220
    Brakes Drag...1220
    Brakes Chatter or Noisy...1220
    Delay in Braking...1221
    Fan Does Not Reach Full Speed (Both Directions)...1221
    Fan Does Not Reach Full Speed (Forward Direction Only)...1221
    Fan Does Not Reach Full Speed (Reverse Direction Only)...1221
    Fan Does Not Spin (Both Directions)...1221
    Fan Does Not Slow Down Before Reversing...1221
    High Fan Cooler Pressure or Pressure Spikes...1221
    High Return Pressure at Fan Reversing Control Valve Port T...1221
    High Flow From Fan Motor Case Drain...1221
    Fan Pump Is Cavitating...1221
    Hydraulic System Component Location...1364
    Hydraulic System Schematic...1367
  Group 20: Adjustments...1221
    Service Brake Pedal Adjustment...1372
    Service Brake Inspection and Adjustment...1373
    Service Brake Bleeding Procedure...1374
    Grapple Dampener Adjustment...1378
  Group 25: Test...1221
    D15032NU Vacuum Pump Installation...1383
    JT02156A Digital Pressure and Temperature Analyzer Kit Installation...1385
    JT07148 Digital Hydraulic Tester...1386
    Hydraulic Oil Warmup Procedure...1387
    Main Hydraulic Pump Standby Pressure Test...1388
    Main Hydraulic Pump Flow Test...1392
    Main Hydraulic Pump Leakage Test...1395
    Pressure Reducing Valve Pressure Test...1398
    Pilot Controller Pressure Test...1400
    Priority Valve and Relief Valve Pressure Test...1403
    Priority Valve Port LS Flow Test...1406
    Priority Valve and Relief Valve Leakage Test...1408
    System and Circuit Relief Valve Pressure Test...1410
    Hydraulic Component Leakage Test...1415
    Cylinder Leakage Test...1419
    Cylinder Drift Test...1421
    Dual Mode Steering Engagement Pressure Test...1423
    Grapple Rotate Motor Crossover Relief Valve Pressure Test...1426
    Grapple Rotate Solenoid Valve Neutral Leakage Test...1428
    Grapple Tong Flow Divider Relief Valve Test...1430
    Rotary Manifold Center Seal Leakage Test...1432
    Rotary Manifold Drain and Lower Seal Leakage Test...1434
    Service Brake Valve and Accumulator Pressure Test...1436
    Service Brake Valve Leakage Test...1439
    Steering Valve Neutral Leakage Test...1441
    Hydraulic Oil Filter Inspection Procedure...1443
    Cooling Fan Circuit Test...1444
    Fan Motor Case Drain Test...1449
    Secondary Steering Operation Test...1451
Section 9030: Winch...1452
  Group 05: Theory of Operation...1452
    John Deere 4000 Winch...1454
  Group 15: Diagnostic Information...1452
    Winch Control Lever Effort Excessive...1452
    Winch Clutch Slips...1452
    Winch Free Spool Effort Excessive...1452
    Winch Brake Will Not Hold...1452
    Winch Will Not Free Spool...1452
    Transmission Oil Level Varies Excessively...1452
    Winch Makes Grinding Noise When Going from FREE SPOOL to BRAKE OFF...1452
    Winch Component Location...1470
    Winch Hydraulic Schematic...1471
  Group 20: Adjustments...1452
    Winch Control Cable Adjustment Check...1473
    Brake Off Adjustment...1474
  Group 25: Test...1452
    Winch System Pressure Test...1483
    Winch Leakage Test...1487
    Winch Drum Rolling Drag Test...1491
Section 9031: Heating and Air Conditioning...1493
  Group 05: Theory of Operation...1493
    Air Conditioning System Cycle of Operation...1496
  Group 15: Diagnostic Information...1493
    Air Conditioning System Visual Checks...1502
    Blower Does Not Operate in Any Speed...1493
    Blower Does Not Operate in Low Speed...1493
    Blower Does Not Operate in Medium Speed...1493
    Blower Does Not Operate in High Speed...1493
    Blower Does Not Operate in Purge Speed...1493
    Air Conditioner Does Not Operate...1493
    Air Conditioner Does Not Cool Cab Interior...1493
    Air Conditioner Runs Constantly...1493
    Interior Windows Continuously Foggy...1493
    Heater Does Not Operate...1493
    Heater Does Not Warm Cab Interior...1493
    Heating and Air Conditioning System Component Location...1535
  Group 25: Tests...1493
    R134a Air Conditioning System Test...1540
    Air Conditioner Freeze Control Switch Test...1544
    Air Conditioning Compressor Clutch Test...1546
    Air Conditioning High/Low Pressure Switch Test...1547
    Air Conditioning Expansion Valve Test...1549
    Refrigerant Leak Test...1552

John Deere 540H and 548H Skidder (630436— ) Technical Manual - Operation and Test (TM11794)