540G-III, 548G-III, 640G-III, 648G-III and 748G-III (S.N. 576253— ) Skidders

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

Introduction
HELP!! HELP!! HELP!! HELP!!

Section : 05 - Safety

John Deere Skidder Safety Features
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
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

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 Warn
Bystanders Before Moving Machine
---------------------------------
When Using a Signal Person, Keep
Person in View at All Times, Be Sure
Signal Person Is Clear Before
Backing Up

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

Inspect Machine
Use Handholds and Steps
Prevent Machine Runaway
Use Seat Belt Properly
Maintain Seat Belt
Secondary Exits
Travel Safely
Operate Machine Safely
Avoid Power Lines
Work In Ventilated Area
Keep Riders Off Machine
Handle Fuel Safely-Avoid Fires
Prepare for Emergencies
Handle Starting Fluid Safely
Clean Trash from Machine
Protect Against Flying Debris
Wear Protective Clothing
Protect Against Noise
Handle Chemical Products Safely
Use Safety Lights and Devices
Keep ROPS Installed Properly
Keep the Operator Protective Structure (OPS) in Place
Lock Machine Frame
Warn Others of Service Work
Practice Safe Maintenance
Support Machine Properly
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Avoid High-Pressure Fluids
Clean the Machine Regularly
Service Cooling System Safely
Store Attachments Safely
Dispose of Waste Properly

Section : 06 - Safety Signs

Safety Signs

Section : 10 - Operator's Station

Monitor Panel Indicator Lights
Monitor Display Window
Engine Coolant Temperature Gauge
Fuel Level Gauge
Hydraulic Oil Temperature Indicator
Hydraulic Oil Filter Restriction Indicator
Transmission Oil Filter Restriction Indicator
Transmission Oil Temperature Indicator
Engine Air Cleaner Restriction Indicator
Engine Alternator Voltage Indicator
Engine Oil Pressure Indicator
Stop Indicator and Alarm
Service Required Indicator
Differential Lock Indicator
Check Service Code Indicator
Secondary Steering Indicator
Fasten Seat Belt Indicator
Park Brake Indicator
Steering Wheel Spinner Knob
Steering Wheel Tilt and Telescope Lever
Pedals
Levers
Differential Lock Button
Adjusting Seat
Adjusting Air Ride Suspension Seat-If Equipped
Seat Belt
Work Light Switch and Deluxe Work Light Switch-If Equipped
Removing Operator's Station Door Window Screens
Opening Secondary Exit
Operator's Manual Holder
Defrosting, Heating, and Air Conditioning Controls-If Equipped
Front Windshield Wiper and Washer
Rear Windshield Wiper and Washer-If Equipped
Windshield Washer Fluid Tank
Battery Disconnect
Fire Extinguisher
Dome Light-If Equipped
Pressurized Water System-If Equipped
Cold Weather Transmission Disconnect Handle-If Equipped

Section : 20 - Pre-Start Inspection

Inspect Machine Daily Before Starting

Section : 25 - Operating the Engine

Using Booster Batteries
Check Instruments Before Starting
Starting the Engine
Starting Fluid-If Equipped (Cold Weather Starting Aid)
Cold Weather Warm-Up
Engine Warm-Up
Check Instruments After Starting
Stopping the Engine

Section : 30 - Driving the Machine

Driving on Public Roads
General Driving Precautions
Operating in Steep Conditions
Accelerator Pedal and Engine Speed Control Knob-If Equipped
Transmission Control and Park Brake Lever
Inching Pedal
Service Brake
Ground Speeds
Transporting Grapple-If Equipped
Park Brake
Parking the Machine
Lock All Compartments

Section : 35 - Operating the Machine

Differential Lock Button
Blade Control Lever
Winch Control Lever-If Equipped
Fastening Cable to Winch Drum-4000 Series
Fastening Cable to Winch Drum-6000 Series
Winch Free Spool Drag Adjustment
Grapple and Arch Control Lever (Single Function)-If Equipped
Arch and Boom Control Lever and Grapple Control Lever (Dual Function)-If Equipped
Grapple Head
Grapple Damper
Grapple Shock

Section : 40 - Transporting

Loading Machine on a Trailer
Towing Procedure

Section : 45 - Fuels and Lubricants

Diesel Fuel
Low Sulfur Diesel Fuel Conditioner
Handling and Storing Diesel Fuel
Do Not Use Galvanized Containers
Fuel Tank
Diesel Engine Oil
Transmission and Hydraulic Oil
Grease
Oil Filters
Lubricant Storage
Alternative and Synthetic Lubricants
Mixing of Lubricants

Section : 50 - Periodic Maintenance

Service Your Machine at Specified Intervals
Check the Hour Meter Regularly
Use Correct Fuels and Lubricants
Prepare Machine for Maintenance
Locking Machine Frames
Opening the Grille
Opening Engine Side Shields
Maintenance and Repair Record Keeping System
OILSCAN PLUS®, COOLSCAN PLUS®, and 3-Way Coolant Test Kit
Maintenance and Repair Record Keeping System

Section : 55 - Maintenance-As Required

Clean Debris from Condenser and Oil Cooler-If Equipped, and Radiator
Inspect Serpentine Belt
Inspect Air Cleaner Elements
Clean Dusty Primary Element
Check Tire Pressure
Check Wheel Bolt Torque
Clean Fuel Tank Filler Screen
Fill and Charge Pressurized Water System-If Equipped
Check Fire Extinguisher Charge

Section : 60 - Maintenance-Every 10 Hours or Daily

Check Recovery Tank Coolant Level
Check Engine Oil Level
Check and Drain Primary Fuel Filter (Water Separator)
Clean Air Cleaner Unloader Valve
Lubricate Frame Hinge Pivots
Lubricate Boom and Arch Cylinder Pins and Arch-to-Frame Pivot-If Equipped
Lubricate Damper, Yoke, and Crosshead Pins-If Equipped
Lubricate Tongs and Tong Cylinders-If Equipped
Lubricate Boom-to-Arch Pivot-If Equipped
Check Transmission Oil Level
Check Hydraulic System Oil Level

Section : 65 - Maintenance-Every 100 Hours

Lubricate Front Axle Pivots and Front Steering Cylinder Pins
Lubricate Rear Steering Cylinder Pins
Lubricate Winch Fairlead Rollers-If Equipped
Lubricate Lower Drive Shaft Support Bearing
Lubricate Winch Telescoping Drive Shaft-If Equipped
Lubricate Lower Telescoping Drive Shaft
Lubricate Stacking Blade and Cylinder Pivots

Section : 75 - Maintenance-Every 250 Hours

Change Engine Oil and Replace Filter

Section : 80 - Maintenance-Every 500 Hours

Check Radiator Coolant Level
Replace Primary Fuel Filter (Water Separator)-540G-III, 548G-III, 640G-III, 648G-III
Replace Final Fuel Filter-540G-III, 548G-III, 640G-III, 648G-III
Replace Primary Fuel Filter (Water Separator)-748G-III
Replace Final Fuel Filter-748G-III
Check Brake Accumulator Action
Check Rear Differential Oil Level
Check Front Differential Oil Level
Replace Differential Lock Return Filter
Replace Transmission Oil Filter
Check Air Intake Hoses
Replace Hydraulic Oil Filter
Check Battery Electrolyte Level and Terminals

Section : 85 - Maintenance-Every 1000 Hours

Replace Air Cleaner Elements
Replace Air Cleaner Unloader Valve
Change Front Differential Oil
Change Rear Differential Oil
Replace Transmission Breather Filter
Change Winch Oil-If Equipped
Lubricate Grapple Rotate Bearing-If Equipped
Replace Differential Lock Inlet Filter
Change Transmission Oil, Replace Filter, and Clean Suction Screen
Inspect Engine Torsional Damper
Change Hydraulic Oil
Replace Hydraulic Reservoir Breather Filter
Check Engine Idle Speeds
Adjust Engine Speed Control Linkage-540G-III, 548G-III, 640G-III, 648G-III
Adjust Engine Speed Control Linkage-748G-III
Check and Adjust Valve Lash-540G-III, 548G-III, 640G-III, 648G-III
Check and Adjust Valve Lash-748G-III

Section : 90 - Maintenance

Replace Engine Torsional Damper
Clean Cab Recirculating Air Filter
Drain Final Fuel Filter-540G-III, 548G-III, 640G-III, 648G-III
Clean Crankcase Vent Tube
Add Coolant Conditioner to Radiator
Check Receiver-Dryer Moisture Indicator-If Equipped
Clean Fresh Air (Air Conditioning) Filter
Check Engine Air Cleaner
Hydraulic Cab Tilt Procedure
Servicing the Cooling System
Draining the Cooling System
Checking Coolant System
Diesel Engine Coolant
Filling the Cooling System
Testing the Coolant Level-Protection Level
Do Not Service Injection Nozzles
Do Not Adjust Injection Pump
Bleed Fuel System-540G-III, 548G-III, 640G-III, 648G-III
Bleed Fuel System-748G-III
Precautions for Alternator and Regulator
Handling Batteries Safely
Service Batteries Carefully
Checking Electrolyte Specific Gravity
Using Battery Charger
Replacing Batteries
Welding on Machine
Replacing Fuses
Changing Reverse Warning Alarm Volume
Checking Neutral Start System
Servicing Air Conditioning System-If Equipped
Checking Park Brake
External Service Brake Inspection
Winch BRAKE OFF Adjustment-If Equipped
Grapple Damper Adjustment-If Equipped
Replacing Grapple Shock-If Equipped
Brake Pedal Adjustment
Checking Windshield Regularly
Do Not Service Control Valves, Cylinders, Pumps or Motors
Adding Attachments/Accessories to Roll-Over Protective Structure (ROPS)
Hardware Torque Specifications
Keeping ROPS Installed Properly
Tighten Upper and Lower Frame Pivot Pin Cap Screws
Unified Inch Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Check Oil Lines And Fittings
Service Recommendations for O-Ring Boss Fittings
Service Recommendations for Flat Face O-Ring Seal Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Inch Series Four Bolt Flange Fittings

Section : 95 - Operational Checkout

Operational Checkout

Section : 100 - Troubleshooting

Using Troubleshooting Charts
Engine
Electrical System
Transmission
Park Brake
Axle Differential
Service Brakes
Hydraulic System
Steering System
Winch
Service Codes

Section : 105 - Storage

Prepare Machine for Storage
Monthly Storage Procedure

Section : 110 - Machine Numbers

Record Product Identification Number (PIN)
Record Engine Serial Number
Record Winch Serial Number
Record Transmission Serial Number

Section : 115 - Specifications

540G-III Skidder Dimensions
540G-III Skidder Specifications
540G-III Skidder Drain and Refill Capacities
4000 Series Winch Specifications-540G-III
548G-III Grapple Skidder Dimensions
548G-III Grapple Skidder Specifications
548G-III Grapple Skidder
548G-III Grapple Skidder Drain and Refill Capacities
4000 Series Winch Specifications-548G-III
640G-III Skidder Dimensions
640G-III Skidder Specifications
640G-III Skidder Drain and Refill Capacities
4000 Series Winch Specifications-640G-III
6000 Series Winch Specifications-640G-III
648G-III Grapple Skidder Dimensions
648G-III Grapple Skidder Specifications
648G-III Grapple Skidder
648G-III Grapple Skidder Drain and Refill Capacities
4000 Series Winch Specifications-648G-III
748G-III Grapple Skidder Dimensions
748G-III Grapple Skidder Specifications
748G-III Grapple Skidder
748G-III Grapple Skidder Drain and Refill Capacities
6000 Series Winch Specifications-748G-III
Ground Speeds

Section : 120 - Crime Prevention Tips

Help Prevent Crime
Record Identification Numbers
Keep Proof of Ownership
Park Indoors Out of Sight
When Parking Outdoors
Reduce Vandalism
Report Thefts Immediately

Section : CLIS - Checklists

Maintenance and Repair Record Keeping System

Section : SLIT - John Deere Service Literature Available

Technical Information

Section : IBC - John Deere Service Keeps You On the Job

At Your Service when You Need It