John Deere 540H and 548H Skidder (S.N. 630436— ) 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.

TM11810 - John Deere 540H and 548H Skidder (S.N. 630436— ) Repair Technical Manual.pdf
tm11816 - John Deere Débardeurs 540H et 548H (630436— ).pdf
tm11821 - John Deere Remolcadores de troncos 540H y 548H (630436— ).pdf
tm12070 - John Deere трелевочных тракторов 540H и 548H (630436— ).pdf

Category: Repair
Language: English Spanish French Russian
Published on 2018/09/06

TABLE OF CONTENTS
Section 00: General Information...13
  Group 0001: Safety...13
    Recognize Safety Information...16
    Follow Safety Instructions...17
    Operate Only If Qualified...18
    Wear Protective Equipment...19
    Avoid Unauthorized Machine Modifications...20
    Inspect Machine...21
    Stay Clear of Moving Parts...22
    Avoid High-Pressure Fluids...23
    Avoid High-Pressure Oils...24
    Do Not Use Starting Fluid...25
    Work In Ventilated Area...26
    Prevent Fires...27
    Prevent Battery Explosions...28
    Handle Chemical Products Safely...29
    Decommissioning — Proper Recycling and Disposal of Fluids and Components...30
    Prepare for Emergencies...31
    Clean Debris from Machine...32
    Use Steps and Handholds Correctly...33
    Start Only From Operator's Seat...34
    Use and Maintain Seat Belt...35
    Prevent Unintended Machine Movement...36
    Avoid Work Site Hazards...38
    Operate Machine Safely...39
    Keep Riders Off Machine...40
    Avoid Backover Accidents...41
    Avoid Machine Tip Over...42
    Operating on Slopes...44
    Operating or Traveling On Public Roads...45
    Inspect and Maintain ROPS...46
    Keep the Operator Protective Structure (OPS) in Place...47
    Add and Operate Attachments Safely...48
    Park and Prepare for Service Safely...49
    Service Tires Safely...51
    Service Cooling System Safely...52
    Service Accumulator Systems Safely...53
    Remove Paint Before Welding or Heating...54
    Make Welding Repairs Safely...55
    Drive Metal Pins Safely...56
  Group 0003: Torque Values...14
    Hardware Torque Specifications...58
    Keeping ROPS Installed Properly...59
    Metric Bolt and Cap Screw Torque Values...61
    Additional Metric Cap Screw Torque Values...63
    Unified Inch Bolt and Cap Screw Torque Values...65
    Check Oil Lines And Fittings...67
    Service Recommendations for 37° Flare and 30° Cone Seat Connectors...68
    Service Recommendations for O-Ring Boss Fittings...70
    Service Recommendations For Flat Face O-Ring Seal Fittings...72
    Service Recommendations for Metric Series Four Bolt Flange Fitting...74
    Service Recommendations For Inch Series Four Bolt Flange Fittings...76
Section 01: Wheels...78
  Group 0110: Powered Wheels and Fastenings...78
    Wheel Remove and Install...81
    Tire Remove and Install...83
    Dual Wheel Installation...86
Section 02: Axles and Suspension Systems...87
  Group 0200: Removal and Installation...87
    TeamMate™ IV 1200 Series Inboard Planetary Axles...89
    Front Axle, Differential, and Oscillation Supports Remove and Install...90
    Rear Axle and Differential Remove and Install...97
    Front Axle Guards Remove and Install...102
    Oscillation Supports Repair...103
  Group 0225: Input Drive Shafts and U-Joints...87
    Front Axle Drive Shaft Remove and Install...106
    Rear Axle and Transmission Drive Shaft Remove and Install...108
  Group 0260: Hydraulic System...87
    Differential Lock Solenoid Valve Repair...115
Section 03: Transmission...118
  Group 0300: Removal and Installation...118
    Transmission Remove and Install...128
    Transmission Mount Remove and Install...137
  Group 0315: Controls...118
    Transmission Bump Shifter Remove and Install...144
  Group 0325: Input Drive Shafts and U-Joints...118
    Engine-to-Transmission Drive Shaft Remove and Install...150
  Group 0350: Gears, Shafts and Power Shift Clutches...118
    Transmission Repair Procedures...155
    Winch Drive Repair...156
    Input Yoke Remove and Install...163
  Group 0360: Hydraulic System...118
    Transmission Charge Pump Remove and Install...169
    Transmission Charge Pump Drive Repair...173
    Transmission Suction Tube Repair...178
    Transmission Control Valve Repair...180
Section 04: Engine...192
  Group 0400: Removal and Installation...192
    PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Tier 3/Stage IIIA...194
    PowerTech Plus™ 6.8L (6068) John Deere Engine—6.8L Stage II...195
    Engine Remove and Install...196
Section 05: Engine Auxiliary Systems...205
  Group 0505: Cold Weather Starting Aids...205
    Do Not Use Ether Start Aid...207
  Group 0510: Cooling System...205
    Air Baffle Enclosure Remove and Install...212
    Serpentine Belt Remove and Install...216
    Serpentine Belt Tensioner—Spring Tension Check...218
    Serpentine Belt Tensioner Remove and Install...220
    Aftercooler Remove and Install...222
    Radiator Remove and Install...227
    Transmission Oil Cooler Remove and Install...232
    Hydraulic Oil Cooler Remove and Install...237
    Fan Blade Remove and Install...242
    Fan Shroud Remove and Install...244
  Group 0520: Intake System...205
    Air Cleaner Remove and Install...247
  Group 0530: Exhaust System...205
    Muffler Remove and Install...251
  Group 0560: External Fuel Supply System...205
    Fuel Tank Remove and Install—Cable Skidder...258
    Fuel Tank Remove and Install—Grapple Skidder...263
Section 07: Dampener Drive...268
  Group 0752: Elements...268
    Dampener Remove and Install...271
    Transmission Cold Weather Disconnect Linkage Remove and Install—If Equipped...273
    Transmission Cold Weather Disconnect Repair—If Equipped...276
Section 09: Steering Systems...282
  Group 0930: Secondary Steering...282
    Secondary Steering Pump Remove and Install...286
  Group 0960: Hydraulic System...282
    Steering Valve Remove and Install...295
    Steering Valve Disassemble and Assemble...301
    Steering Cylinder Remove and Install...308
  Group 0962: Dual Mode Steering...282
    Dual Mode Steering Solenoid Valve Remove and Install...314
Section 10: Service Brakes...317
  Group 1015: Control Linkage...317
    Service Brake Pedal Remove and Install...319
  Group 1060: Hydraulic System...317
    Service Brake Valve Remove and Install...324
    Service Brake Valve Disassemble and Assemble...328
    Service Brake Accumulator Remove and Install...330
Section 11: Park Brake...333
  Group 1111: Active Elements...333
    Park Brake Remove and Install...337
  Group 1160: Hydraulic System...333
    Park Brake Solenoid Valve Repair...343
Section 17: Frame, Chassis, or Supporting Structures...346
  Group 1740: Frame Installation...346
    Welding Repair of Major Structure...349
    Engine and Equipment Frames—Separate...351
    Lower Pivot Pin Repair...358
    Upper Pivot Pin Repair...365
  Group 1746: Frame Bottom Guards...346
    Engine Frame Bottom Guard Remove and Install...374
    Equipment Frame Bottom Guard Remove and Install...376
Section 18: Operator's Station...378
  Group 1800: Removal and Installation...378
    Cab Remove and Install...392
    Cab Isolators Remove and Install...404
    Steering Column and Steering Wheel Remove and Install...407
    Steering Column and Steering Wheel Disassemble and Assemble...410
    Cab Tilt Hand Pump Remove and Install...412
    Cab Tilt Hand Pump Disassemble and Assemble...415
    Cab Tilt Hand Pump Bleeding Procedure...417
    Cab Tilt Cylinder Remove and Install...420
  Group 1810: Operator Enclosure...378
    Window Remove and Install...427
    Window Cleaning Procedure...431
    Cab Door Remove and Install...432
    Cab Door and Door Latch Disassemble and Assemble...434
    Front Windshield Wiper Remove and Install...437
    Rear Windshield Wiper Remove and Install...439
    Windshield Wiper Adjustment...442
  Group 1821: Seat and Seat Belt...378
    Seat Remove and Install...446
    Seat Disassemble and Assemble...448
    Seat Belt Remove and Install...452
  Group 1830: Heating and Air Conditioning...378
    R134a Refrigerant Cautions and Proper Handling...454
    Air Conditioning System Flush and Purge...455
    R134a Refrigerant Oil Information...459
    R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure...462
    R134a Refrigerant Recovery...464
    R134a System Evacuate...465
    R134a System Charge...467
    Compressor Relief Valve Remove and Install...468
    Air Conditioner Compressor Remove and Install...469
    Air Conditioner Compressor Clutch Remove and Install...471
    Air Conditioner Compressor Manifold Remove and Install...475
    Air Conditioner Condenser Remove and Install...477
    Blower Motor Remove and Install...479
    Precleaner Blower Assembly Remove and Install...481
    Refrigerant High/Low Pressure Switch Remove and Install...483
    Coolant Valve Remove and Install...485
    Freeze Control Switch Remove and Install...487
    Expansion Valve Remove and Install...489
    Heater Core Remove and Install...491
    Evaporator Remove and Install...493
    Receiver-Dryer Remove and Install...495
Section 19: Sheet Metal and Styling...497
  Group 1910: Hood or Engine Enclosure...497
    Hood Remove and Install...502
    Grille Guard Remove and Install...506
    Grille Housing Remove and Install...509
Section 20: Safety, Convenience and Miscellaneous...513
  Group 2003: Pressurized Water System...513
    Pressurized Water System—If Equipped...518
  Group 2004: Horn and Warning Devices...513
    Horn Remove and Install...523
    Reverse Warning Alarm Remove and Install...524
Section 21: Main Hydraulic System...525
  Group 2160: Hydraulic System...525
    General Oil Cleanup Procedure...530
    Hydraulic Component Failure Cleanup Procedure...534
    Hydraulic Pump Remove and Install...537
    Priority Valve Remove and Install...541
    Priority Valve Disassemble and Assemble...543
    Fan Variable Speed and Reversing Manifold Remove and Install...545
    Fan Variable Speed and Reversing Manifold Disassemble and Assemble...547
    Hydraulic Fan Motor Remove and Install...548
    Hydraulic Reservoir Remove and Install...550
    Hydraulic Fan and Cooling Loop Pump Remove and Install...556
Section 30: Winch...558
  Group 3000: Removal and Installation...558
    Winch 4000 Series Remove and Install...564
    Fastening Cable to Winch Drum—4000 Series...569
    Winch Free Spool Drag Adjustment...573
  Group 3015: Control Linkage...558
    Winch Control Valve Linkage Remove and Install...576
    Winch Control Cable Remove and Install...578
  Group 3025: Input Drive Shafts and U-Joints...558
    Winch Drive Shaft Remove and Install...584
    Winch Drive Shaft Disassemble and Assemble...586
  Group 3050: Drive and Clutch...558
    Winch 4000 Series Drive and Clutch Repair...588
Section 32: Stacking Blades...589
  Group 3201: Blades...589
    Stacking Blade Remove and Install...595
    Spherical Bushing Remove and Install...600
  Group 3215: Control Linkage...589
    Blade Control Linkage Remove and Install...604
    Blade Control Valve Remove and Install...606
  Group 3260: Hydraulic System...589
    Blade Lift Cylinder Remove and Install...610
Section 37: Arch or Boom...612
  Group 3740: Frames...612
    Arch Remove and Install...615
    Horizontal Roller Remove and Install...617
    Side Roller Remove and Install...619
    Roller Brackets Remove and Install...622
Section 38: Grapple...623
  Group 3803: Grapple Mechanism...623
    Grapple Remove and Install...627
    Grapple Disassemble and Assemble...629
    Grapple Dampener Disassemble and Assemble...631
    Grapple Dampener Adjustment...634
    Dampener, Yoke, and Crosshead Pins Lubricate...637
    Grapple Rotate Yoke Disassemble and Assemble...639
  Group 3815: Control Linkage...623
    Single Lever Pilot Controller Remove and Install...661
  Group 3840: Frames...623
    Single Function Grapple Cable Rollers Remove and Install...666
    Single Function Grapple Arch Remove and Install...668
  Group 3860: Hydraulic System...623
    Arch Cylinder Remove and Install—Single Function Grapple...674
    Grapple Tong Cylinder Remove and Install...676
    Grapple Rotate Motor Remove and Install...679
    Grapple Rotate Motor Disassemble...682
    Grapple Rotate Motor Assemble...691
    Rotate Motor Drive Gear Remove and Install...701
    Control Valve Options...702
    Pilot Operated Control Valve Remove and Install...703
    Single Function Pilot Operated Control Valve Disassemble and Assemble...707
    Control Valve Relief Valves Remove and Install...710
    Lift Check Valve Disassemble and Assemble...712
    Non-adjustable Circuit Relief Valve Disassemble and Assemble...713
    Adjustable Circuit Relief Valve Disassemble and Assemble...715
    Spool Valve Disassemble and Assemble...717
    Detent Disassemble and Assemble...719
    Pilot Operated Valve Remove and Install...721
    Solenoid Operated Valve Remove and Install...723
    Grapple Rotate Solenoid Valve Remove and Install...725
    Grapple Rotate Solenoid Valve Disassemble and Assemble...727
    Flow Divider Repair...729
    Rotary Manifold Remove and Install (S.N. —647783)...732
    Rotary Manifold Remove and Install (S.N. 647784— )...735
    Rotary Manifold Disassemble and Assemble (S.N. —647783)...738
    Rotary Manifold Disassemble and Assemble (S.N. 647784— )...742
Section 99: Dealer Fabricated Tools...750
  Group 9900: Dealer Fabricated Tools...750
    DFT1099 Bushing Drivers...753
    DFRW20 Compressor Holding Fixture...755

John Deere 540H and 548H Skidder (S.N. 630436— ) Repair Technical Manual (TM11810)