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

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

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

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John Deere 540G-III & 548G-III Skidder 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
Avoid Work Site Hazards 23
Prevent Unintended Machine Movement 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
Service Accumulator Systems Safely 29
Remove Paint Before Welding or Heating 29
Make Welding Repairs Safely 29
Drive Metal Pins Safely 30
Safety—Safety Signs 31
Replace Safety Signs 31
Safety Signs 31
Operation—Operator’s Station 35
Adjusting Seat 35
Steering Wheel 35
Horn Button 35
Sealed Switch Module (SSM) 36
Sealed Switch Module (SSM) Functions 37
Standard Display Monitor (SDM) 39
Pedals 42
Levers 42
Switches 44
Dome Light—If Equipped 45
Temperature and Blower Controls 46
Windshield Washer Fluid Tank 46
Removing Operator’s Station Door Window Screens 46
Opening Secondary Exit 47
Operator’s Manual Holder 47
Fire Extinguisher 47
Pressurized Water System—If Equipped 48
Radio—If Equipped 48
Operation—Operating the Machine 50
Inspect Machine Daily Before Starting 50
Engine Break-In Period 50
Starting the Engine 50
Check Standard Display Monitor (SDM) 51
Engine Warm-Up 52
Cold Weather Warm-Up 52
Blade Control Lever Operation 52
Winch Control Lever Operation—If Equipped 53
Single Lever Pilot Control Operation—If Equipped 54
Differential Lock Switch 56
Engine Speed Control 58
Service Brake 58
Operating on a Downhill Grade 58
Transmission Gear Selector 59
Inching Pedal Operation 63
Declutch Function Operation 64
Parking the Machine 65
Lowering Hydraulic Equipment to Ground With Engine Off 65
Fastening Cable to Winch Drum—4000 Series 67
Winch Free Spool Drag Adjustment 70
Grapple Head 71
Grapple Dampener 71
Grapple Shock 71
Transporting Grapple—If Equipped 72
Tiedown and Lift Points 72
Loading Machine on a Trailer 72
Towing Procedure 73
Lifting 76
Operation—Monitor Operation 77
Standard Display Monitor (SDM) Display 77
Standard Display Monitor (SDM) Main Menu 77
Standard Display Monitor (SDM) Main Menu—Codes 78
Standard Display Monitor (SDM) Main Menu—Codes—Active Codes 78
Standard Display Monitor (SDM) Main Menu—Codes—Stored Codes 78
Standard Display Monitor (SDM) Main Menu—Codes—Clear Codes 78
Standard Display Monitor (SDM) Main Menu—Diagnostics 78
Standard Display Monitor (SDM) Main Menu—Monitor 78
Standard Display Monitor (SDM) Main Menu—Monitor—Units 79
Standard Display Monitor (SDM) Main Menu—Monitor—Contrast 79
Standard Display Monitor (SDM) Main Menu—Monitor—Language 79
Standard Display Monitor (SDM) Main Menu—Monitor—Hide Menu 79
Standard Display Monitor (SDM) Main Menu—Monitor—Defaults 79
Standard Display Monitor (SDM) Main Menu—Configuration 79
Standard Display Monitor (SDM) Main Menu—Job Timer 80
Maintenance—Machine 81
Diesel Fuel 81
Lubricity of Diesel Fuel 81
Handling and Storing Diesel Fuel 81
BioDiesel Fuel 82
Testing Diesel Fuel 84
Minimizing the Effect of Cold Weather on Diesel Engines 84
Alternative and Synthetic Lubricants 85
Diesel Engine Break-In™ Oil 86
Diesel Engine Oil — Tier 2 and Stage II 86
Diesel Engine Oil and Filter Service Intervals 87
Hydraulic System Oil 88
Transmission, Park Brake, Differential, Cab Tilt Hydraulic Pump and Winch Oil 89
Grease 89
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 90
Drain Intervals for Diesel Engine Coolant 91
John Deere COOL-GARD™ II Coolant Extender 92
Supplemental Coolant Additives 92
Operating in Warm Temperature Climates 93
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 93
Testing Diesel Engine Coolant 94
Maintenance—Periodic Maintenance 96
Service Your Machine at Specified Intervals 96
Check the Hour Meter Regularly 96
Fuel Tank 96
Battery Disconnect 96
Prepare Machine for Maintenance 97
Locking Machine Frames 97
Opening the Grille 98
Opening Engine Side Shields 98
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 99
Service Intervals 99
Required Parts 101
Maintenance—As Required 104
Clean Debris from Coolers 104
Inspect Serpentine Belt 104
Inspecting and Cleaning Dusty Primary and Secondary Element 105
Check Tire Pressure 105
Check Wheel Bolt Torque 107
Clean Fuel Tank Filler Screen 107
Fill and Charge Pressurized Water System—If Equipped 107
Check Fire Extinguisher Charge 109
Clean Hydraulic Tank Filler Screen 109
Clean Cab Recirculating Air Filter 110
Clean Fresh Air (Air Conditioning) Filter 111
Check Coolant 112
Maintenance—Every 10 Hours or Daily 114
Check Coolant Level 114
Check Engine Oil Level 114
Check and Drain Primary Fuel Filter Water Separator 115
Clean Air Cleaner Unloader Valve 116
Lubricate Frame Hinge Pivots 116
Lubricate Boom and Arch Cylinder Pins and Arch-to-Frame Pivot—If Equipped 117
Lubricate Dampener, Yoke, and Crosshead Pins—If Equipped 118
Lubricate Tongs and Tong Cylinders—If Equipped 119
Lubricate Boom-to-Arch Pivot—If Equipped 120
Check Transmission Oil Level 120
Check Hydraulic System Oil Level 121
Maintenance—Every 100 Hours 123
Lubricate Stacking Blade and Cylinder Pivots 123
Lubricate Front Axle Pivots and Front Steering Cylinder Pins 123
Lubricate Rear Steering Cylinder Pins 123
Lubricate Winch Fairlead Rollers 124
Lubricate Front Axle Drive Shaft U-Joints and Transmission Output Shaft Seal 124
Lubricate Rear Axle Drive Shaft U-Joints, Telescoping Splines, Support Bearing, and Transmission Output Shaft Seal 125
Lubricate Winch Drive Shaft U-Joints and Telescoping Splines 125
Lubricate Engine-to-Transmission Drive Shaft U-Joints and Telescoping Splines 126
Maintenance—Initial Service – 250 Hours 127
Change Engine Break-In Oil and Replace Filter 127
Replace Hydraulic Oil Filter 128
Replace Transmission Oil Filter 130
Change Front Axle Oil 131
Change Rear Axle Oil 132
Maintenance—Every 250 Hours 133
Take Engine Oil Sample 133
Maintenance—Every 500 Hours 134
Change Engine Oil and Replace Filter 134
Check Coolant System Radiator, Tubes, Connectors 135
Replace Primary Fuel Filter/Water Separator 136
Replace Final Fuel Filter 137
Check Brake Accumulator Action 138
Check Rear Axle Oil Level 138
Check Front Axle Oil Level 139
Replace Transmission Oil Filter 139
Check Air Intake Hoses 139
Replace Hydraulic Oil Filter 139
Check Battery Electrolyte Level and Terminals 140
Take Fluid Samples 141
Maintenance—Every 1000 Hours 142
Replace Air Cleaner Elements 142
Replace Air Cleaner Unloader Valve 142
Change Front Axle Oil 143
Change Rear Axle Oil 143
Transmission Breather Filter—Replace 143
Change Winch Oil 143
Lubricate Grapple Rotate Bearing—If Equipped 144
Change Transmission Oil, Replace Filter, and Clean Suction Screen 144
Inspect Crankshaft Dampener 148
Change Hydraulic Oil 148
Replace Hydraulic Reservoir Breather Filter 150
Check and Adjust Valve Lash 151
Check Coolant 151
Maintenance—Every 4000 Hours 152
Replace Engine Crankshaft Dampener 152
Maintenance—Every 6000 Hours 153
Draining the Cooling System 153
Filling the Cooling System 153
Miscellaneous—Machine 156
Drain Final Fuel Filter 156
Clean Crankcase Vent Tube 156
Check Receiver-Dryer Moisture Indicator—If Equipped 156
Hydraulic Cab Tilt Procedure 157
Checking Coolant System 160
Testing the Coolant Level—Protection Level 160
Do Not Service or Adjust Injection Nozzles or Injection Pump 161
Do Not Service Control Valves, Cylinders, Pumps or Motors 161
Bleed Fuel System 161
Precautions for Alternator and Regulator 164
Using Booster Batteries—12-Volt System 164
Handling, Checking and Servicing Batteries Carefully 165
Using Battery Charger 167
Remove and Install Batteries 167
Replacing Batteries 168
Welding On Machine 168
Replacing Fuses 169
Checking Neutral Start System 172
Servicing Air Conditioning System—If Equipped 173
Checking Park Brake 175
Grapple Damper Adjustment—If Equipped 175
Grapple Shock Replace—If Equipped 178
Brake Pedal Adjustment 178
Inspect and Clean Windows 178
Keeping ROPS Installed Properly 179
JDLink™ Machine Monitoring System (MMS)—If Equipped 180
Hardware Torque Specifications 180
Unified Inch Bolt and Screw Torque Values 180
Metric Bolt and Screw Torque Values 181
Check Oil Lines And Fittings 182
Dual Wheel Installation 183
Miscellaneous—Operational Checkout 184
Complete Machine Operational Checkout 184
Diagnostic Trouble Code Check 184
Operational Checks—Key Switch OFF, Engine OFF Checks 184
Operational Checks—Key Switch ON, Engine OFF 185
Operational Checks—Key Switch ON, Engine ON 191
Miscellaneous Checks 221
Miscellaneous—Troubleshooting 223
Troubleshooting Procedure 223
Engine Troubleshooting 223
Electrical System Troubleshooting 227
Transmission and Park Brake Troubleshooting 230
Axle Differential Troubleshooting 234
Service Brakes Troubleshooting 234
Hydraulic System Troubleshooting 235
Steering System Troubleshooting 237
Winch Troubleshooting 237
Air Conditioning System Troubleshooting 238
Heater System Troubleshooting 239
Miscellaneous—Storage 241
Prepare Machine for Storage 241
Monthly Storage Procedure 241
Miscellaneous—Machine Numbers 243
Record Product Identification Number (PIN) 243
Record Engine Serial Number 243
Record Winch Serial Number 243
Record Transmission Serial Number 243
Record Rear Axle Housing Serial Number 244
Record Front Axle Housing Serial Number 244
Keep Proof of Ownership 244
Keep Machines Secure 245
Miscellaneous—Specifications 246
540G-III Cable Skidder—Machine Dimensions 246
540G-III Cable Skidder—Machine Specifications 247
540G-III Cable Skidder—Winch Specifications—4000 Series 248
540G-III Cable Skidder—Drain and Refill Capacities 250
548G-III Grapple Skidder—Machine Dimensions 250
548G-III Grapple Skidder—Grapple Dimensions 255
548G-III Grapple Skidder—Machine Specifications 255
548G-III Grapple Skidder—Winch Specifications—4000 Series 256
548G-III Grapple Skidder—Drain and Refill Capacities 258
Ground Speeds 258
EC Declaration of Conformity 259
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 35
Section 2-2 50
Section 2-3 77
Section 3-1 81
Section 3-2 96
Section 3-3 104
Section 3-4 114
Section 3-5 123
Section 3-6 127
Section 3-7 133
Section 3-8 134
Section 3-9 142
Section 3-10 152
Section 3-11 153
Section 4-1 156
Section 4-2 184
Section 4-3 223
Section 4-4 241
Section 4-5 243
Section 4-6 246

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