John Deere 540H and 548H Skidder ( —630435) 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.

TM11330 - John Deere 540H and 548H Skidder ( —630435) Repair Technical Manual.pdf
tm11335 - John Deere Débardeurs 540H et 548H (SN —630435).pdf
tm11396 - John Deere Skidder 540H und 548H ( —630435).pdf

Category: Repair
Language: English French German
Published on 2018/08/24

TABLE OF CONTENTS
Section 00: General Information...12
  Group 0001: Safety Information...12
    Recognize Safety Information...15
    Follow Safety Instructions...16
    Operate Only If Qualified...17
    Wear Protective Equipment...18
    Avoid Unauthorized Machine Modifications...19
    Inspect Machine...20
    Stay Clear of Moving Parts...21
    Avoid High-Pressure Fluids...22
    Avoid High-Pressure Oils...23
    Do Not Use Starting Fluid...24
    Beware of Exhaust Fumes...25
    Prevent Fires...26
    Clean Debris from Machine...27
    Prevent Battery Explosions...28
    Handle Chemical Products Safely...29
    Dispose of Waste Properly...30
    Prepare for Emergencies...31
    Use Steps and Handholds Correctly...32
    Start Only From Operator's Seat...33
    Use and Maintain Seat Belt...34
    Prevent Unintended Machine Movement...35
    Avoid Work Site Hazards...36
    Operate Machine Safely...37
    Keep Riders Off Machine...38
    Avoid Backover Accidents...39
    Avoid Machine Tip Over...40
    Operating on Slopes...42
    Operating or Traveling On Public Roads...43
    Inspect and Maintain ROPS...44
    Keep the Operator Protective Structure (OPS) in Place...45
    Add and Operate Attachments Safely...46
    Park and Prepare for Service Safely...47
    Service Tires Safely...49
    Service Cooling System Safely...50
    Remove Paint Before Welding or Heating...51
    Make Welding Repairs Safely...52
    Drive Metal Pins Safely...53
  Group 0003: Torque Values...13
    Hardware Torque Specifications...55
    Keeping ROPS Installed Properly...56
    Metric Bolt and Cap Screw Torque Values...58
    Additional Metric Cap Screw Torque Values...60
    Unified Inch Bolt and Cap Screw Torque Values...62
    Check Oil Lines And Fittings...64
    Service Recommendations for 37° Flare and 30° Cone Seat Connectors...65
    Service Recommendations for O-Ring Boss Fittings...67
    Service Recommendations For Flat Face O-Ring Seal Fittings...69
    Service Recommendations for Metric Series Four Bolt Flange Fitting...71
    Service Recommendations For Inch Series Four Bolt Flange Fittings...73
Section 01: Wheels...75
  Group 0110: Powered Wheels and Fastenings...75
    Wheel Remove and Install...78
    Tire Remove and Install...80
    Dual Wheel Installation...83
Section 02: Axles and Suspension Systems...84
  Group 0200: Removal and Installation...84
    TeamMate™ IV 1200 Series Inboard Planetary Axles...86
    Front Axle, Differential, and Oscillation Supports Remove and Install...87
    Rear Axle and Differential Remove and Install...94
    Front Axle Guards Remove and Install...99
    Oscillation Supports Repair...100
  Group 0225: Input Drive Shafts and U-Joints...84
    Front Axle Drive Shaft Remove and Install...103
    Rear Axle and Transmission Drive Shaft Remove and Install...105
  Group 0260: Hydraulic System...84
    Differential Lock Solenoid Valve Repair...112
Section 03: Transmission...115
  Group 0300: Removal and Installation...115
    Transmission Remove and Install...130
    Transmission Mount Remove and Install...144
  Group 0315: Controls...115
    Transmission Bump Shifter Remove and Install...148
  Group 0325: Input Drive Shafts and U-Joints...115
    Engine-to-Transmission Drive Shaft Remove and Install...154
  Group 0350: Gears, Shafts and Power Shift Clutches...115
    Transmission Repair Procedures...159
    Winch Drive Repair...160
    Input Yoke Remove and Install...167
  Group 0360: Hydraulic System...115
    Transmission Charge Pump Remove and Install...175
    Transmission Charge Pump Drive Repair...181
    Transmission Suction Tube Repair...192
    Transmission Control Valve Repair...194
Section 04: Engine...206
  Group 0400: Removal and Installation...206
    PowerTech Plus™ 6.8 L (6068) John Deere Engines...208
    Engine Removal...209
    Engine Installation...219
Section 05: Engine Auxiliary Systems...223
  Group 0505: Cold Weather Starting Aids...223
    Do Not Use Ether Start Aid...225
  Group 0510: Cooling Systems...223
    Fan Guards Remove and Install...227
    Belt Remove and Install...228
    Belt Tensioner—Spring Tension Check...229
    Belt Tensioner Remove and Install...231
    Aftercooler Remove and Install...232
    Radiator Remove and Install...236
    Transmission Cooler Remove and Install...239
    Hydraulic Oil Cooler Remove and Install...242
    Fan Shroud Remove and Install...245
  Group 0520: Intake System...223
    Air Cleaner Remove and Install...249
  Group 0530: Exhaust System...223
    Muffler Remove and Install...252
  Group 0560: External Fuel Supply System...223
    Fuel Tank Remove and Install...257
Section 07: Dampener Drive...261
  Group 0752: Elements...261
    Dampener Remove and Install...264
    Transmission Cold Weather Disconnect Linkage Remove and Install...266
    Transmission Cold Weather Disconnect Repair...270
Section 09: Steering Systems...276
  Group 0930: Secondary Steering...276
    Secondary Steering Pump Remove and Install...280
  Group 0960: Hydraulic System...276
    Steering Valve Remove and Install...289
    Steering Valve Disassemble and Assemble...295
    Steering Cylinder Remove and Install...302
  Group 0962: Dual Mode Steering...276
    Dual Mode Steering Solenoid Valve Remove and Install...308
Section 10: Service Brakes...311
  Group 1015: Control Linkage...311
    Service Brake Pedal Remove and Install...313
  Group 1060: Hydraulic System...311
    Service Brake Valve Remove and Install...318
    Service Brake Valve Disassemble and Assemble...322
    Service Brake Accumulator Remove and Install...324
Section 11: Park Brake...328
  Group 1111: Active Elements...328
    Park Brake Remove and Install...333
  Group 1160: Hydraulic System...328
    Park Brake Solenoid Valve Repair...340
Section 17: Frame, Chassis, or Supporting Structures...343
  Group 1740: Frame Installation...343
    Welding Repair of Major Structure...346
    Engine and Equipment Frames—Separate...348
    Lower Pivot Pin Repair...353
    Upper Pivot Pin Repair...360
  Group 1746: Frame Bottom Guards...343
    Engine Frame Bottom Guard Remove and Install...369
    Equipment Frame Bottom Guard Remove and Install...371
Section 18: Operator's Station...373
  Group 1800: Removal and Installation...373
    Cab Remove and Install...393
    Cab Isolators Remove and Install...411
    Steering Column and Steering Wheel Remove and Install...414
    Steering Column and Steering Wheel Disassemble and Assemble...417
    Cab Tilt Hand Pump Remove and Install...419
    Cab Tilt Hand Pump Disassemble and Assemble...422
    Cab Tilt Hand Pump Bleeding Procedure...424
    Cab Tilt Cylinder Remove and Install...427
  Group 1810: Operator Enclosure...373
    Window Remove and Install...434
    Window Cleaning Procedure...438
    Cab Door Remove and Install...439
    Cab Door and Door Latch Disassemble and Assemble...441
    Front Windshield Wiper Remove and Install...444
    Rear Windshield Wiper Remove and Install...446
    Windshield Wiper Adjustment...449
  Group 1821: Seat and Seat Belt...373
    Seat Remove and Install...453
    Seat Disassemble and Assemble...455
    Seat Belt Remove and Install...459
  Group 1830: Heating and Air Conditioning...373
    Refrigerant Cautions and Proper Handling...461
    R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure...462
    R134a Refrigerant Oil Information...464
    Recover R134a Refrigerant...467
    Evacuate R134a System...468
    Charge R134a System...470
    Air Conditioning Compressor Remove and Install...471
    Air Conditioning Condenser Remove and Install...473
    Receiver Dryer Remove and Install...475
    Expansion Valve Remove and Install...477
    Air Conditioner and Heater Remove and Install...479
Section 19: Sheet Metal and Styling...481
  Group 1910: Hood or Engine Enclosure...481
    Hood Remove and Install...487
Section 20: Safety, Convenience and Miscellaneous...492
  Group 2003: Pressurized Water System...496
    Pressurized Water System...496
  Group 2004: Horn and Warning Devices...492
    Horn Remove and Install...500
    Reverse Warning Alarm Remove and Install...501
Section 21: Main Hydraulic System...502
  Group 2160: Hydraulic System...502
    Hydraulic Pump Remove and Install...511
    Hydraulic Pump Disassemble and Assemble...519
    Priority Valve Repair...534
    Cold Start Dump Valve Remove and Install (If Equipped)...537
    Fan Variable Speed and Reversing Manifold Remove and Install...539
    Fan Variable Speed and Reversing Manifold Disassemble and Assemble...541
    Hydraulic Fan Motor Remove and Install...542
    Hydraulic Reservoir Remove and Install...546
    Hydraulic Fan and Cooling Loop Pump Remove and Install...555
    Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy...558
Section 30: Winch...559
  Group 3000: Removal and Installation...559
    Winch 4000 Series Remove and Install...566
    Fastening Cable to Winch Drum—4000 Series...572
    Winch Free Spool Drag Adjustment...576
  Group 3015: Control Linkage...559
    Winch Control Valve Linkage Remove and Install...579
    Winch Control Cable Remove and Install...581
  Group 3025: Input Drive Shafts and U-Joints...559
    Winch Drive Shaft Remove and Install...587
    Winch 4000 Series Drive Shaft Disassemble and Assemble...589
  Group 3050: Drive and Clutch...559
    Winch 4000 Series Drive and Clutch Repair...591
Section 32: Stacking Blades...592
  Group 3201: Blades...592
    Stacking Blade Remove and Install...598
    Spherical Bushing Remove and Install...603
  Group 3215: Control Linkage...592
    Blade Control Linkage Remove and Install...607
    Blade Control Valve Remove and Install...609
  Group 3260: Hydraulic System...592
    Blade Lift Cylinder Remove and Install...613
Section 37: Arch or Boom...615
  Group 3740: Frames...615
    Arch Remove and Install...618
    Horizontal Roller Remove and Install...620
    Side Roller Remove and Install...622
    Roller Brackets Remove and Install...625
Section 38: Grapple...626
  Group 3803: Grapple Mechanism...626
    Grapple Remove and Install...631
    Grapple Disassemble and Assemble...634
    Grapple Dampener Repair...636
    Grapple Dampener Adjustment...639
    Dampener, Yoke, and Crosshead Pins Lubricate...642
    Grapple Rotate Yoke Repair...644
  Group 3815: Control Linkage...626
    Single Function Grapple Control Linkage Repair...664
    Single Lever Pilot Controller Remove and Install...666
  Group 3840: Frames...626
    Single Function Grapple Cable Rollers Remove and Install...671
    Single Function Grapple Arch Remove and Install...673
  Group 3860: Hydraulic System...626
    Arch Cylinder Remove and Install—Single Function Grapple...679
    Grapple Tong Cylinder Remove and Install...681
    Grapple Rotate Motor Remove and Install...684
    Grapple Rotate Motor Disassemble...687
    Grapple Rotate Motor Assembly...695
    Rotate Motor Drive Gear Remove and Install...704
    Control Valve Options...705
    Pilot Operated Control Valve Remove and Install...707
    Mechanical Linkage Control Valve Remove and Install...711
    Single Function Mechanical Linkage Control Valve Disassemble and Assemble...714
    Single Function Pilot Operated Control Valve Disassemble and Assemble...717
    Control Valve Relief Valves Remove and Install...720
    Lift Check Valve Disassemble and Assemble...722
    Non-adjustable Circuit Relief Valve Disassemble and Assemble...723
    Adjustable Circuit Relief Valve Disassemble and Assemble...725
    Spool Valve Disassemble and Assemble...727
    Detent Disassemble and Assemble...729
    Pilot Operated Valve Remove and Install...731
    Solenoid Operated Valve Remove and Install...733
    Grapple Rotate Solenoid Valve Remove and Install...735
    Grapple Rotate Solenoid Valve Disassemble and Assemble...738
    Flow Divider Repair...740
    Rotary Manifold Remove and Install...743
    Rotary Manifold Disassemble and Assemble...746
Section 99: Dealer Fabricated Tools...751
  Group 9900: Dealer Fabricated Tools...751
    DFT1099 Bushing Drivers...754
    DFT1216 Converter Housing Support...756
    DFRW20 Compressor Holding Fixture...758
    
John Deere 540H and 548H Skidder ( —630435) Repair Technical Manual (TM11330)