John Deere 540G-III, 548G-III & 360D Skidder Operator’s Manual – PDF DOWNLOAD

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John Deere 540G-III, 548G-III & 360D Skidder Engine 6068TDW58 Operator’s Manual – PDF DOWNLOAD

FILE DETAILS:

John Deere 540G-III, 548G-III & 360D Skidder Engine 6068TDW58 Operator’s Manual – PDF DOWNLOAD

P/N: OMT229061_QT
Language: English
Division: Forestry
Product Lines: Skidders
Publication Type: Operator’s Manuals
Associated Models: 540GIII, 548GIII, 360D
Series: G SERIES III, D SERIES
Serial: (613179–630435) ENGINE 6068TDW58

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 540G-III, 548G-III & 360D Skidder Engine 6068TDW58 Operator’s Manual – PDF DOWNLOAD

Contents 11
Safety—Safety and Operator Conveniences 15
Safety and Operator Convenience Features 15
Safety—General Precautions 16
Information for European Union Directives Compliance 16
Recognize Safety Information 17
Follow Safety Instructions 17
Operate Only If Qualified 17
Wear Protective Equipment 17
Avoid Unauthorized Machine Modifications 18
Inspect Machine 18
Stay Clear of Moving Parts 18
Avoid High-Pressure Fluids 18
Avoid High-Pressure Oils 19
Work In Ventilated Area 19
Prevent Fires 20
Prevent Battery Explosions 20
Handle Chemical Products Safely 21
Dispose of Waste Properly 21
Prepare for Emergencies 21
Clean Debris from Machine 22
Safety—Operating Precautions 23
Use Steps and Handholds Correctly 23
Start Only From Operator’s Seat 23
Use and Maintain Seat Belt 23
Prevent Unintended Machine Movement 23
Avoid Work Site Hazards 24
Operate Machine Safely 24
Keep Riders Off Machine 25
Avoid Backover Accidents 25
Avoid Machine Tip Over 25
Operating on Slopes 26
Operating or Traveling On Public Roads 26
Inspect and Maintain ROPS 27
Keep the Operator Protective Structure (OPS) in Place 27
Add and Operate Attachments Safely 27
Safety—Maintenance Precautions 28
Park and Prepare for Service Safely 28
Service Tires Safely 28
Service Cooling System Safely 28
Remove Paint Before Welding or Heating 29
Make Welding Repairs Safely 29
Drive Metal Pins Safely 29
Safety—Safety Signs 31
Safety Signs 31
Operation—Operator’s Station 34
Adjusting Seat 34
Horn Button 34
Steering Wheel 34
Monitor Panel Functions 35
Pedals 37
Levers 37
Switches 38
Dome Light—If Equipped 39
Deluxe Work Lights—If Equipped 40
Defrosting, Heating, and Air Conditioning Controls—If Equipped 40
Windshield Wiper and Washer 41
Windshield Washer Fluid Tank 41
Removing Operator’s Station Door Window Screens 41
Opening Secondary Exit 41
Operator’s Manual Holder 41
Fire Extinguisher Mounting Location 42
Pressurized Water System—If Equipped 43
Operation—Operating the Machine 44
Inspect Machine Daily Before Starting 44
Engine Break-In Period 44
Starting the Engine 44
Check Monitor Panel 45
Engine Warm-Up 46
Cold Weather Transmission Disconnect Handle—If Equipped 46
Cold Weather Warm-Up 47
Blade Control Lever Operation 47
Winch Control Lever Operation 47
Single Function—Grapple and Arch Mechanical Control Lever Operation 48
Single Lever Pilot Control Operation 50
Differential Lock Switch 50
Engine Speed Control 50
Service Brake 51
Transmission Gear Selector 52
Inching Pedal Operation 53
De-clutch Function Operation—(S N 620843— ) 53
Parking the Machine 54
Lowering Hydraulic Equipment to Ground With Engine Off 55
Fastening Cable to Winch Drum—4000 Series 56
Winch Free Spool Drag Adjustment 59
Grapple Head 60
Grapple Dampener 60
Grapple Shock 60
Transporting Grapple—If Equipped 61
Loading Machine on a Trailer 61
Towing Procedure 61
Maintenance—Machine 66
Diesel Fuel 66
Lubricity of Diesel Fuel 66
Handling and Storing Diesel Fuel 66
Biodiesel Fuel 67
Testing Diesel Fuel 69
Minimizing the Effect of Cold Weather on Diesel Engines 69
Alternative and Synthetic Lubricants 70
Diesel Engine Oil 71
Engine Oil and Filter Service Intervals—Tier 2 and Stage II Engines 71
Hydraulic System Oil 72
Transmission, Park Brake, Differential, Cab Tilt Hydraulic Pump and Winch Oil 73
Grease 73
Heavy Duty Diesel Engine Coolant 74
Drain Intervals for Diesel Engine Coolant 75
John Deere COOL-GARD™ II Coolant Extender 75
Supplemental Coolant Additives 76
Operating in Warm Temperature Climates 76
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 77
Testing Diesel Engine Coolant 78
Maintenance—Periodic Maintenance 80
Service Your Machine at Specified Intervals 80
Check the Hour Meter Regularly 80
Fuel Tank 80
Battery Disconnect 80
Prepare Machine for Maintenance 81
Locking Machine Frames 81
Opening the Grille 82
Opening Engine Side Shields 82
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 82
Service Intervals 83
Required Parts 85
Maintenance—As Required 88
Clean Debris from Coolers 88
Inspect Serpentine Belt 88
Check and Clean Engine Air Cleaner Elements 88
Check Tire Pressure 89
Check Wheel Bolt Torque 91
Clean Fuel Tank Filler Screen 91
Fill and Charge Pressurized Water System—If Equipped 91
Check Fire Extinguisher Charge 93
Clean Hydraulic Tank Filler Screen 93
Clean Cab Recirculating Air Filter 94
Clean Fresh Air (Air Conditioning) Filter 95
Check Coolant 95
Maintenance—Every 10 Hours or Daily 97
Check Coolant Level 97
Check Engine Oil Level 97
Check and Drain Water Separator 98
Clean Air Cleaner Unloader Valve 99
Lubricate Frame Hinge Pivots 99
Lubricate Boom and Arch Cylinder Pins and Arch-to-Frame Pivot—If Equipped 100
Lubricate Dampener, Yoke, and Crosshead Pins—If Equipped 101
Lubricate Tongs and Tong Cylinders—If Equipped 102
Lubricate Boom-to-Arch Pivot—If Equipped 103
Check Transmission Oil Level 103
Check Hydraulic System Oil Level 105
Maintenance—Every 100 Hours 107
Lubricate Stacking Blade and Cylinder Pivots 107
Lubricate Front Axle Pivots and Front Steering Cylinder Pins 107
Lubricate Rear Steering Cylinder Pins 107
Lubricate Winch Fairlead Rollers 108
Lubricate Front Axle Drive Shaft U-Joints and Transmission Output Shaft Seal 108
Lubricate Rear Axle Drive Shaft U-Joints, Telescoping Splines, Support Bearing, and Transmission Output Shaft Seal 109
Lubricate Winch Drive Shaft U-Joints and Telescoping Splines 109
Lubricate Engine-to-Transmission Drive Shaft U-Joints and Telescoping Splines 110
Maintenance—Initial Service – 250 Hours 111
Change Engine Break-in Oil and Replace Filter 111
Replace Hydraulic Oil Filter 112
Replace Transmission Oil Filter 113
Change Front Axle Oil 114
Change Rear Axle Oil 115
Maintenance—Every 250 Hours 116
Take Engine Oil Sample 116
Maintenance—Every 500 Hours 117
Change Engine Oil and Replace Filter 117
Check Coolant System Radiator, Tubes, Connectors 118
Replace Primary Fuel Filter/Water Separator 119
Replace Final Fuel Filter 120
Check Brake Accumulator Action 121
Check Rear Axle Oil Level 121
Check Front Axle Oil Level 122
Check Coolant Level 123
Replace Transmission Oil Filter 123
Check Air Intake Hoses 124
Replace Hydraulic Oil Filter 124
Check Battery Electrolyte Level and Terminals 125
Take Fluid Samples 126
Maintenance—Every 1000 Hours 127
Replace Air Cleaner Elements 127
Replace Air Cleaner Unloader Valve 127
Change Front Axle Oil 128
Change Rear Axle Oil 130
Transmission Breather Filter—Replace 130
Change Winch Oil 130
Lubricate Grapple Rotate Bearing—If Equipped 131
Change Transmission Oil, Replace Filter, and Clean Suction Screen 131
Inspect Crankshaft Dampener 135
Change Hydraulic Oil 135
Replace Hydraulic Reservoir Breather Filter 137
Check and Adjust Valve Lash 138
Check Coolant 138
Maintenance—Every 4000 Hours 139
Replace Engine Crankshaft Dampener 139
Maintenance—Every 6000 Hours 140
Draining the Cooling System 140
Filling the Cooling System 141
Miscellaneous—Machine 144
Check Engine Idle Speeds 144
Drain Final Fuel Filter 144
Clean Crankcase Vent Tube 144
Check Receiver-Dryer Moisture Indicator—If Equipped 144
Hydraulic Cab Tilt Procedure 145
Checking Coolant System 150
Testing the Coolant Level—Protection Level 150
Do Not Service or Adjust Injection Nozzles or Injection Pump 151
Do Not Service Control Valves, Cylinders, Pumps or Motors 151
Bleed Fuel System 151
Precautions for Alternator and Regulator 154
Using Booster Batteries—24-Volt System 154
Handling, Checking and Servicing Batteries Carefully 156
Using Battery Charger 157
Replacing Batteries 157
Welding On Machine 157
Welding Near Electronic Control Units 158
Keep Electronic Control Unit Connectors Clean 158
Replacing Fuses 158
Checking Neutral Start System 160
Servicing Air Conditioning System—If Equipped 161
Checking Park Brake 162
Grapple Damper Adjustment—If Equipped 162
Grapple Shock Replace—If Equipped 164
Brake Pedal Adjustment 164
Checking Windshield Regularly 164
Keeping ROPS Installed Properly 165
Hardware Torque Specifications 165
Unified Inch Bolt and Screw Torque Values 165
Metric Bolt and Screw Torque Values 166
Check Oil Lines And Fittings 167
Dual Wheel Installation 168
Miscellaneous—Operational Checkout 169
Complete Machine Operational Checkout 169
Operational Checks—Key Switch ON, Engine Stopped 169
Operational Checks—Key Switch ON, Engine Running 180
Miscellaneous Checks 217
Miscellaneous—Troubleshooting 219
Troubleshooting Procedure 219
Engine Troubleshooting 219
Electrical System Troubleshooting 223
Transmission and Park Brake Troubleshooting 226
Axle Differential Troubleshooting 230
Service Brakes Troubleshooting 230
Hydraulic System Troubleshooting 231
Steering System Troubleshooting 232
Winch Troubleshooting 233
Air Conditioning System Troubleshooting 234
Heater System Troubleshooting 235
Miscellaneous—Storage 237
Prepare Machine for Storage 237
Monthly Storage Procedure 237
Miscellaneous—Machine Numbers 239
Keep Proof of Ownership 239
Keep Machines Secure 239
Record Product Identification Number (PIN) 239
Record Engine Serial Number 239
Record Winch Serial Number 240
Record Transmission Serial Number 240
Miscellaneous—Specifications 241
540G-III Cable Skidder—Machine Dimensions 241
540G-III Cable Skidder—Machine Specifications 242
540G-III Cable Skidder—Winch Specifications—4000 Series 244
540G-III Cable Skidder—Drain and Refill Capacities 246
548G-III Grapple Skidder—Machine Dimensions 246
548G-III Grapple Skidder—Grapple Dimensions 251
548G-III Grapple Skidder—Machine Specifications 251
548G-III Grapple Skidder—Winch Specifications—4000 Series 253
548G-III Grapple Skidder—Drain and Refill Capacities 255
Ground Speeds 255
EC Declaration of Conformity 256
Page Number 11
Section 1-1 15
Section 1-2 16
Section 1-3 23
Section 1-4 28
Section 1-5 31
Section 2-1 34
Section 2-2 44
Section 3-1 66
Section 3-2 80
Section 3-3 88
Section 3-4 97
Section 3-5 107
Section 3-6 111
Section 3-7 116
Section 3-8 117
Section 3-9 127
Section 3-10 139
Section 3-11 140
Section 4-1 144
Section 4-2 169
Section 4-3 219
Section 4-4 237
Section 4-5 239
Section 4-6 241

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