JOHN DEERE 540G, 640G, 740G, SKIDDER AND 548G, 648G, 748G GRAPPLE SKIDDER SN 565684 TECHNICAL REPAIR

The John Deere 540G, 640G, 740G Skidder and 548G, 648G, 748G Grapple Skidder models are powerful, heavy-duty machines designed for demanding logging operations. To keep these machines in optimal working condition and extend their lifespan, regular maintenance and technical repairs are essential. This Technical Repair Manual (S.N. —565684) offers a comprehensive guide to diagnosing, repairing, and maintaining these machines, ensuring peak performance and reliability in the field.

DOWNLOAD NOW JOHN DEERE 540G, 640G, 740G, SKIDDER AND 548G, 648G, 748G GRAPPLE SKIDDER SN 565684 TECHNICAL REPAIR MANUAL (TM1600)

File Format: PDF

Size: 18.14 MB

No. of pages: 1078

Delivery Method: Instant Download – Access your file immediately after purchase.

Why This Manual is Essential:

Designed for both professional technicians and experienced operators, this manual offers comprehensive information with illustrations, schematics, and in-depth explanations. Proper maintenance and timely repairs can help prevent costly downtime and extend the life of your John Deere skidder or grapple skidder.

📑 Table of Contents:

- 540G, 640G, 740G, Skidder and 548G, 648G, 748G Grapple Skidder (S.N. —565684) Repair
- General Information
- Safety Information
- Handle Fluids Safely—Avoid Fires
- Prevent Battery Explosions
- Prepare for Emergencies
- Prevent Acid Burns
- Handle Chemical Products Safely
- Avoid High-Pressure Fluids
- Park Machine Safely
- Support Machine Properly
- Wear Protective Clothing
- Work in Clean Area
- Service Machines Safely
- Work in Ventilated Area
- Illuminate Work Area Safely
- Replace Safety Signs
- Use Proper Lifting Equipment
- Remove Paint Before Welding or Heating
- Avoid Heating Near Pressurized Fluid Lines
- Keep ROPS Installed Properly
- Service Tires Safely
- Avoid Harmful Asbestos Dust
- Practice Safe Maintenance
- Use Proper Tools
- Dispose of Waste Properly
- Live With Safety
- General Specifications
- 540G Skidder
- 540G Skidder Engine and System Specifications
- 540G Skidder Other Information
- Winch—4000 Series
- 540G Skidder Capacities
- 548G Grapple Skidder
- Single Function Grapple Specifications
- 548G Grapple Skidder Engine and System Specifications
- 548G Grapple Skidder Other Information
- Winch—4000 Series
- 548G Grapple Skidder Capacities
- 640G Skidder
- 640G Skidder Engine and System Specifications
- 640G Skidder Other Information
- Winch—4000 Series
- Winch—6000 Series
- 640G Skidder Capacities
- 648G Grapple Skidder
- Grapple Head Specifications
- 648G Grapple Skidder Engine and System Specifications
- 648G Grapple Skidder Other Information
- Winch—4000 Series
- 648G Grapple Skidder Capacities
- 740G Skidder
- 740G Skidder Engine and System Specifications
- 740G Skidder Other Information
- Winch—6000 Series
- 740G Skidder Capacities
- 748G Grapple Skidder
- Grapple Head Specifications
- 748G Grapple Skidder Engine and System Specifications
- 748G Grapple Skidder Other Information
- Winch—6000 Series
- 748G Grapple Skidder Capacities
- Torque Values
- Specifications
- Hardware Torque Specifications
- Keeping ROPS Installed Properly
- Tighten Upper Frame Pivot Pin
- Metric Bolt and Cap Screw Torque Values
- Unified Inch Bolt and Cap Screw Torque Values
- Additional Metric Cap Screw Torque Values
- Check Oil Lines and Fittings
- Service Recommendations for 37° Flare and 30° Cone Seat Connectors
- 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
- Fuels and Lubricants
- Specifications
- Diesel Fuel
- Low Sulfur Diesel Fuel Conditioner
- Handling and Storing Diesel Fuel
- Do Not Use Galvanized Containers
- Fuel Tank
- Diesel Engine Oil
- Transmission Hydraulic System, Park Brake, Differential, Hand Pump and Winch Oils
- Grease
- Lubricant Storage
- Alternative and Synthetic Lubricants
- Mixing of Lubricants
- Diesel Engine Coolant
- Wheels
- Powered Wheels and Fastenings
- Service Equipment and Tools
- Other Material
- Specifications
- Remove and Install Wheel
- Remove and Install Tire
- Axles and Suspension System
- Removal and Installation
- John Deere 1200 and 1400 TeamMate™ II Series Axles—Use CTM43
- Service Equipment and Tools
- Specifications
- Remove Front Axle and Differential
- Disassemble and Assemble Rear Oscillating Support
- Disassemble and Assemble Front Oscillating Support
- Install Front Axle and Differential
- Remove and Install Rear Axle and Differential Assembly
- Remove and Install Front Axle Guards
- Input Drive Shafts and U-Joints
- Specifications
- Remove and Install Front Differential Drive Shaft
- Remove and Install Rear Differential and Transmission Drive Shafts
- Universal Joint Installation and Lubrication
- Hydraulic System
- Specifications
- Differential Lock Solenoid Valve
- Remove and Install Differential Lock Solenoid Valve
- Differential Lock Relief Valve Cross Section
- Remove and Install Differential Lock Relief Valve
- Differential Lock Plumbing
- Front Differential Plumbing
- Rear Differential Plumbing
- Transmission
- Removal and Installation
- Service Equipment and Tools
- Other Material
- Specifications
- Remove Transmission
- Install Transmission
- Exploded View of Transmission Case
- Control Linkage
- Other Material
- Specifications
- Remove and Install Transmission Console Linkage (S.N. 535531— )
- Transmission Control and Park Brake Lever Adjustment
- Adjust Park Brake Switch
- Remove and Install Transmission Control Valve Linkage (S.N. 535531—)
- Transmission Control Valve Linkage Adjustment
- Remove and Install Clutch and Brake Valve Linkage
- Clutch Linkage Adjustment
- Brake Pedal Adjustment
- Input Drive Shafts and U-Joints
- Other Material
- Specifications
- Remove and Install Engine to Transmission Drive Shaft
- Gears, Shafts and Bearings
- Essential Tools
- Service Equipment And Tools
- Other Material
- Specifications
- Cross Section of C1 and C2 Clutch Pack Assembly
- Exploded View C1 and C2 Clutch Pack Assembly
- Exploded View of Oil Manifold Assembly
- Remove and Install Oil Manifold, C1 and C2 Clutch Pack Assembly
- Disassemble Oil Manifold, C1 and C2 Clutch Pack Assembly
- Remove and Install Transmission Front Cover
- Cross Section of C1 and C2 Clutch Pack Assembly and Oil Manifold
- Exploded View C1 and C2 Clutch Pack Assembly
- Exploded View Oil Manifold Assembly
- Assemble Oil Manifold, C1 and C2 Clutch Pack Assembly
- Disassemble and Assemble High and Low Range Clutch Shaft
- Complete Park Brake Assembly
- Cross Section Park Brake
- Remove and Install Park Brake
- Remove Reduction Gear and Shaft
- Inspect Reduction Gear and Shaft Assembly
- Cross Section Planetary Assembly
- Exploded View Planetary Assembly
- Remove and Disassemble Planetary Pack Assembly
- Assemble and Install Planetary Pack Assembly
- Remove and Install Idler and Winch Drive Gears
- Remove and Install Output Gear Assembly
- Exploded View of Pump Drive Gears
- Remove and Install Pump Idler Gear
- Remove and Install Small Hydraulic Pump Adapter
- Remove and Install Pump Drive Gear
- Install Planetary Assembly
- Hydraulic System
- Other Material
- Specifications
- Pressure Regulating Valve Oil Passage Identification
- Transmission Control Valve Oil Passage Identification
- C1 and C2 Clutch Pack and Front Cover Oil Passage Identification
- Remove Transmission Control Valve Assembly
- Disassemble Shift Valve
- Disassemble Control Valve Cover and Valves
- Disassemble B1-B2 and B3-B4-C3 Accumulators
- Assemble B1-B2 and B3-B4-C3 Accumulators
- Assemble Control Valve Cover and Valves
- Assemble Shift Valve
- Remove and Install Engagement Override Valve and Interrupter Valve
- Install Transmission Control Valve Assembly
- Remove Park Brake Sensor Valve
- Disassemble and Inspect Park Brake Sensor Valve
- Install Park Brake Sensor Valve
- Remove and Install Clutch Valve and Pressure Regulating Valve
- Disassemble and Assemble Pressure Regulating Valve
- Disassemble Transmission Clutch Valve
- Remove and Install Transmission Screen
- Remove Transmission Hydraulic Pump and Park Brake Pump
- Disassemble and Assemble Transmission Hydraulic Pump
- Install Transmission Hydraulic Pump and Park Brake Pump
- Remove and Install Park Brake Pump
- Disassemble and Assemble Transmission Oil Filter and Base
- Park Brake Sensor Valve Bleeding Procedure
- Engine
- Removal and Installation
- 4045, 6059 and 6068 John Deere Engine—Use CTM8
- 6076 John Deere Engine—Use CTM42
- John Deere PowerTech® 6.8 L Engine—Use CTM104
- John Deere PowerTech® 8.1 L Engine—Use CTM86
- Essential Tools
- Service Equipment and Tools
- Other Material
- Specifications
- Disconnect Turbocharger Oil Inlet Line
- Remove and Install Engine—540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Engine—740G, 748G (S.N. —559114)
- Remove and Install Engine—540G, 548G, 640G, 648G (S.N. 558325— ), 740G, 748G (S.N. 559115— )
- Remove and Install Oil Pan and Oil Pump
- Remove Oil Pan
- Remove Engine Oil Pump
- Install Engine Oil Pump
- Install Oil Pan
- Removing DB4 Fuel Injection Pump
- Installing DB4 Fuel Injection Pump
- JT07158 Time Trac® Installation
- Injection Pump Timing—540G, 548G, 640G, 648G (S.N. —558324) and 740G, 748G (S.N. —559114)
- Injection Pump Timing—540G, 548G (S.N. 558325—)
- Remove Fuel Injection Pump—740G, 748G (S.N. —559114)
- Install Fuel Injection Pump—740G, 748G (S.N. —559114)
- Remove Fuel Injection Pump—640G, 648G (S.N. 558325—)
- Install Fuel Injection Pump—640G, 648G (S.N. 558325— )
- Remove Fuel Injection Pump—740G, 748G (S.N. 559115— )
- Install Fuel Injection Pump—740G, 748G (S.N. 559115—)
- Bleed the Fuel System—540G, 548G, 640G, 648G (S.N. —558324)
- Bleed the Fuel System—540G, 548G, 640G, 648G (S.N. 558325—)
- Bleed Fuel System—740G, 748G (S.N. —559114)
- Bleed Fuel System—740G, 748G (S.N. 559115—)
- Remove Fuel Injection Nozzles—540G, 548G, 640G, 648G (S.N. —558324)
- Remove Fuel Injection Nozzles—540G, 548G, 640G, 648G (S.N. 558325—)
- Install Fuel Injection Lines and Nozzles—540G, 548G, 640G, 648G (S.N. —558324)
- Install Fuel Injection Nozzles—540G, 548G, 640G, 648G (S.N. 558325—)
- Remove Fuel Injection Nozzle—740G, 748G (S.N. —559114)
- Remove Fuel Injection Nozzle—740G, 748G (S.N. 559115— )
- Inspect and Clean Cylinder Head Nozzle Bore
- Install Fuel Injection Nozzle—740G, 748G (S.N. —559114)
- Install Fuel Injection Nozzle—740G, 748G (S.N. 559115—)
- Remove and Install Intake Manifold—540G, 548G, 640G, 648G
- Remove and Install Intake Manifold—740G, 748G (S.N. —559114)
- Remove and Install Intake Manifold—740G, 748G (S.N. 559115— )
- Remove and Install Turbocharger—540G, 548G, 640G, 648G
- Remove and Install Turbocharger—740G, 748G
- Remove and Install Water Pump—540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Water Pump—540G, 548G, 640G, 648G (S.N. 558325— )
- Remove and Install Water Pump—740G, 748G (S.N. —559114)
- Remove and Install Water Pump—740G, 748G (S.N. 559115— )
- Remove and Install Thermostats—540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Thermostat—540G, 548G, 640G, 648G (S.N. 558325— )
- Remove and Install Thermostat Housing—540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Thermostats—740G, 748G (S.N. —559114)
- Remove and Install Thermostats—740G, 748G (S.N. 559115— )
- Remove and Install Engine Oil Cooler—540G, 548G, 640G, 648G
- Remove and Install Oil Cooler—740G, 748G (S.N. —559114)
- Remove and Install Oil Cooler—740G, 748G (S.N. 559115— )
- Remove and Install Fuel Filter and Base—540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Fuel Filter and Base—540G, 548G, 640G, 648G (S.N. 558325— )
- Remove and Install Fuel Filter and Base—740G, 748G (S.N. —559114)
- Remove and Install Fuel Filter and Base—740G, 748G (S.N. 559115— )
- Remove and Install Fuel Transfer Pump—540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Fuel Transfer Pump—540G, 548G (S.N. 558325— )
- Remove and Install Fuel Transfer Pump—640G, 648G (S.N. 558325— )
- Remove and Install Fuel Transfer Pump—740G, 748G (S.N. —559114)
- Remove and Install Fuel Transfer Pump—740G, 748G (S.N. 559115— )
- Engine Auxiliary Systems
- Cold Weather Starting Aids
- Other Material
- Specifications
- Remove and Install Start Aid Solenoid and Nozzle—If Equipped
- Remove and Install Engine Coolant Heater
- Cooling Systems
- Essential Tools
- Specifications
- Remove and Install Fan Guards and Fan—540G, 548G, 640G, 648G (S.N. —558324); 740G, 748G (S.N. —552114)
- Remove and Install Fan Guards and Fan—540G, 548G, 640G, 648G (S.N. 558325— ); 740G, 748G (S.N. 559115— )
- Remove and Install Fan Belts —540G, 548G, 640G, 648G (S.N. —558324); 740G, 748G (S.N. —552114)
- Remove and Install Fan Belt —540G, 548G, 640G, 648G (S.N. —558324); 740G, 748G (S.N. —552114)
- Check and Adjust Fan Belt Tension —540G, 548G, 640G, 648G (S.N. —558324); 740G, 748G (S.N. —552114)
- Check Belt Tensioner Spring Tension —540G, 548G, 640G, 648G (S.N. 558325— ); 740G, 748G (S.N. 552115—)
- Remove and Install Automatic (Spring) Belt Tensioner —540G, 548G, 640G, 648G (S.N. 558325— ); 740G, 748G (S.N. 552115—)
- Remove and Install Fan Shroud—540G, 548G, 640G, 648G (S.N. —558324); 740G, 748G (S.N. —552114)
- Remove and Install Fan Shroud—540G, 548G, 640G, 648G (S.N. 558325— ); 740G, 748G (S.N. 552115—)
- Remove and Install Radiator—540G, 548G, 640G, 648G (S.N. —558324); 740G, 748G (S.N. —552114)
- Remove and Install Radiator—540G, 548G, 640G, 648G (S.N. 558325— ); 740G, 748G (S.N. 552115— )
- Speed Controls
- Other Material
- Specifications
- Remove and Install Speed Control Linkage—540G, 548G, 640G, 648G (S.N. —558205)
- Remove and Install Speed Control Linkage—540G, 548G, 640G, 648G (S.N. 558206— )
- Remove and Install Speed Control Linkage—740G, 748G (S.N. —558204)
- Remove and Install Speed Control Linkage—740G, 748G (S.N. 558205— )
- Remove and Install Engine Shut-Off Cable—740G, 748G (S.N. —559114)
- Engine Speed Control Linkage Adjustment—540G, 548G, 640G, 648G (S.N. —558205)
- Engine Speed Control Linkage Adjustment—540G, 548G, 640G, 648G (S.N. 558206— )
- Engine Speed Control Linkage Adjustment—740G, 748G (S.N. —558205)
- Engine Speed Control Linkage Adjustment—740G, 748G (S.N. 558206— )
- Fuel Shut-Off Cable Adjustment—740G and 748G
- Intake System
- Service Equipment and Tools
- Specifications
- Remove and Install Air Cleaner—540G, 548G, 640G, 648G
- Remove and Install Air Cleaner—740G, 748G
- Remove and Install Air Filter Elements
- Air Intake System Leakage Test
- External Exhaust System
- Remove and Install Muffler—540G, 548G, 640G, 648G (S.N. —555539)
- Remove and Install Muffler—540G, 548G, 640G, 648G (S.N. 555540— )
- Remove and Install Muffler—740G, 748G (S.N. —559114)
- Remove and Install Muffler—740G, 748G (S.N. 559115— )
- External Fuel Supply System
- Essential Tools
- Service Equipment and Tools
- Specifications
- Remove and Install Fuel Tank—540G, 548G, 640G
- Remove and Install Fuel Tank—648G, 740G and 748G
- Remove and Install Fuel Gauge Sender
- Remove Primary Fuel Filter (Water Separator)—540G, 548G, 640G, 648G (S.N. —558324); 740G, 748G (S.N. —552114)
- Disassemble, Clean and Assemble Water Separator—540G, 548G, 640G, 648G (S.N. —558324); 740G, 748G (S.N. —552114)
- Remove Primary Fuel Filter (Water Separator)—540G, 548G, 640G, 648G (S.N. 558325— ); 740G, 748G (S.N. 559115— )
- Disassemble, Clean and Assemble Water Separator—540G, 548G, 640G, 648G (S.N. 558325— ); 740G, 748G (S.N. 552115— )
- Damper Drive
- Elements
- Essential Tools
- Other Material
- Specifications
- Remove and Install Damper (Early Models)
- Remove and Install Damper (Later Models)
- Disassemble and Assemble Transmission Disconnect Linkage—If Equipped
- Transmission Disconnect Linkage Adjustment—If Equipped
- Remove and Disassemble Transmission Disconnect Linkage—If Equipped
- Assemble and Install Transmission Disconnect—If Equipped
- Steering System
- Secondary Steering
- Remove and Install Secondary Steering Pump
- Hydraulic System
- Other Material
- Specifications
- Remove Steering Valve
- Disassemble Steering Valve
- Cross Section of Steering Valve
- Assemble Steering Valve
- Install Steering Valve
- Remove and Install Priority Valve
- Disassemble and Assemble Steering Priority Valve
- Remove and Install Steering Cylinder
- Cross Section of Steering Cylinder
- Disassemble and Inspect Steering Cylinder
- Assemble Steering Cylinder
- Service Brakes
- Active Elements
- Brake Lining Inspection
- Controls Linkage
- Remove and Install Clutch Brake Valve Linkage
- Hydraulic System
- Specifications
- Remove and Install Brake Valve
- Disassemble and Assemble Brake Valve
- Service Brake Hydraulic Bleeding Procedure
- Brake Pedal Adjustment
- Remove and Install Accumulator
- Park Brake
- Active Elements
- Complete Park Brake Assembly
- Assembled Park Brake
- Hydraulic System
- Specifications
- Park Brake Solenoid
- Remove and Install Park Brake Solenoid
- Park Brake Relief Valve Cross Section
- Remove and Install Park Brake Relief Valve
- Park Brake Sensor Valve Bleeding Procedure
- Clean or Replace Park Brake/Differential Lock Valve Filter
- Electrical System
- Batteries, Support and Cables
- Essential Tools
- Specifications
- Service Batteries Carefully
- Check Battery Electrolyte Level and Terminals
- Using Battery Charger
- Procedure for Testing Batteries
- Using Booster Batteries—12 Volt System
- Remove and Install Batteries
- Alternator, Regulator and Charging System Wiring
- John Deere Alternator and Starting Motors Repair—Use CTM77
- Essential Tools
- Specifications
- Remove and Install Alternator—65 Amp Bosch (If Equipped)—540G, 548G, 640G, 648G
- Remove and Install Alternator—95 Amp Bosch (If Equipped)—540G, 548G, 640G, 648G (S.N. —558204)
- Remove and Install Alternator—95 Amp Bosch (If Equipped)—740G, 748G (S.N. —559114)
- Remove and Install Alternator—95 Amp Bosch (If Equipped)—540G, 548G, 640G, 648G (S.N. 558205— )
- Remove and Install Alternator—135 Amp Bosch (If Equipped)—540G, 548G, 640G, 648G (S.N. —558204)
- Remove and Install Alternator—135 Amp Bosch (S.N. 558205— )—For All Machines with A/C, 748G without A/C
- Fan and Alternator Belts Tension or Replacement
- Check Belt Tensioner Spring Tension—540G, 548G, 640G, 648G (S.N. 558325—), 740G, 748G (S.N. 559115—)
- Lighting System
- Remove and Install Lights
- Remove and Install Light Switch
- Replace Halogen Bulbs
- Wiring Harness and Switches
- Essential Tools
- Specifications
- Remove and Install Indicator Switches
- Replacing Relays, Fuses and Circuit Breakers
- Remove Blade Terminals from Fuse Block
- Remove and Install Start Relay and Accessory Relay
- Remove and Install Wiper Switch
- Remove and Install Neutral Start Switch and Reverse Warning Alarm Switch
- Remove and Install Horn Switch, Key Switch and Start Aid Switch
- Remove and Install Heater Fan Switch
- Remove and Install Secondary Steering Switch—If Equipped
- Remove and Install Light Switch
- Remove and Install Transmission Control and Park Brake Lever Switch
- Adjust Park Brake Lever Switch
- Remove and Install Battery Disconnect Switch
- Replace DEUTSCH™ Connectors
- Install DEUTSCH™ Contact
- Replace WEATHER PACK™ Connector
- Replace Sure-Seal™ Connector With WEATHER PACK™ Connector
- Install WEATHER PACK™ Contact
- Remove Connector Body from Blade Terminals
- Instruments and Indicators
- Other Material
- Specifications
- Remove and Install Engine Coolant Temperature Sender and Engine Oil Pressure Switch—540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Air Filter Restriction and Engine Coolant Temperature Switches—540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Engine Coolant Temperature Sender—540G, 548G, 640G, 648G (S.N. 558325— )
- Remove and Install Engine Oil Pressure Sending Unit—540G, 548G, 640G, 648G (S.N. 558325— )
- Remove and Install Air Filter Restriction and Engine Oil Pressure Switches—740G, 748G (S.N. —559114)
- Remove and Install Engine Coolant Temperature Sender and Engine Coolant Temperature Switch—740G, 748G (S.N. —559114)
- Remove and Install Engine Coolant Temperature Sender—740G, 748G (S.N. 559115—)
- Remove and Install Engine Oil Pressure Sending Unit—740G, 748G (S.N. 559115—)
- Remove and Install Air Filter Restriction Switch—540G, 548G, 640G, 648G (S.N. 558325— ), 740G, 748G (S.N. 559115—)
- Remove and Install Hydraulic Oil Filter Restriction and Hydraulic Oil Temperature Switches
- Remove and Install Differential Lock Switch
- Remove and Install Grapple Rotate Switch
- Remove and Install Transmission Oil Pressure, Temperature, and Filter Restriction Switches, and Park Brake Pressure Switch
- Remove and Install Service Brake Pressure Switch
- Indicator—Top Row Circuit Specifications
- Indicator—Middle Row Circuit Specifications
- Indicator—Bottom Row Circuit Specifications
- Remove and Install Hour Meter
- Remove and Install Engine Coolant Temperature Gauge and Fuel Gauge
- Remove and Install Fuel Level Sender
- Gauges and Hour Meter Circuit Specifications
- Display Module Connector Pin Location
- Remove and Install Monitor Lights
- Motors and Actuators
- John Deere Alternator and Starting Motors Repair—Use CTM77
- Specifications
- Remove and Install Starting Motor 540G, 548G, 640G, 648G (S.N. —558324)
- Remove and Install Starting Motor 740G, 748G (S.N. —559114)
- Remove and Install Starting Motor
- Frame, Chassis, or Supporting Structures
- Frame Installation
- Other Material
- Specifications
- Welding Repair of Major Structure
- Separate Engine and Equipment Frames
- Remove and Install Frame Pivot Pins (S.N. —564207)
- Remove and Install Frame Pivot Pins (S.N. 564208—)
- Remove and Install Lower Pivot Pin Seals (S.N. —564207)
- Remove and Install Lower Pivot Pin Seals (S.N. 564208— )
- Remove and Install Upper Pivot Bearing and Seals
- Remove Lower Pivot Pin Spherical Bushing
- Install Lower Pivot Pin Spherical Bushing
- Frame Bottom Guards
- Specifications
- Remove and Install Engine Frame Bottom Guards
- Remove and Install Equipment Frame Bottom Guard
- Operator's Station
- Removal and Installation
- Service Equipment and Tools
- Specifications
- Remove and Install Cab or Canopy
- Remove and Install Cab or Canopy Isolators
- Remove and Install Steering Column
- Operator Enclosure
- Special or Essential Tools
- Specifications
- Remove and Install Windowpane and Molding
- Clean Windows Regularly
- Remove and Install Cab Door and Adjust Latch
- Remove and Install Windshield Wiper and Washer
- Adjust Windshield Wiper and Washer
- Exploded View of Defrost Fan—If Equipped
- Seat and Seat Belt
- Disassemble and Assemble Suspension Seat
- Seat Belt
- Install Seat Belt Assembly (Right Side)
- Install Seat Belt Assembly (Left Side)
- Heating and Air Conditioning
- Essential Tools
- Other Material
- Specifications
- Proper Refrigerant Handling
- R134a Refrigerant Cautions
- Refrigerant Hoses and Tubing Inspection
- R134a Compressor Oil Charge Check
- R134a Component Oil Charge
- R134a Compressor Oil Removal
- R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure
- Recover R134a System
- Evacuate R134a System
- Charge R134a System
- Leak Testing
- Check and Adjust Compressor Belt Tension—540G, 548G, 640G, 648G (S.N. —558324), 740G, 748G (S.N. —559114)
- Check and Adjust Belt Tension—540G, 548G, 640G, 648G (S.N. 558325— ), 740G, 748G (S.N. 559115— )
- Remove and Install Compressor—540G, 548G, 640G, 648G (S.N. —558324), 740G, 748G (S.N. —559114)—If Equipped
- Remove and Install Compressor—540G, 548G, 640G, 648G (S.N. 558325—), 740G, 748G (S.N. 559115— )
- Disassemble and Inspect Compressor—540G, 548G, 640G, 648G (S.N. —558324), 740G, 748G (S.N. —559114)
- Clutch Pulley, Bearing and Hub Inspection—540G, 548G, 640G, 648G (S.N. —558324), 740G, 748G (S.N. —559114)
- Replace Clutch Pulley Bearing—540G, 548G, 640G, 648G (S.N. —558324), 740G, 748G (S.N. —559114)
- Replace Shaft Seal Seat—540G, 548G, 640G, 648G (S.N. —558324), 740G, 748G (S.N. —559114)
- Assemble Compressor—540G, 548G, 640G, 648G (S.N. —558324), 740G, 748G (S.N. —559114)
- Disassemble and Assemble Compressor Clutch—540G, 548G, 640G, 648G (S.N. 558325—), 740G, 748G (S.N. 559115—)
- Check Clutch Hub Clearance—540G, 548G, 640G, 648G (S.N. 558325—), 740G, 748G (S.N. 559115—)
- Inspect Compressor Manifold—540G, 548G, 640G, 648G (S.N. 558325—), 740G, 748G (S.N. 559115—)
- Disassemble, Inspect and Assemble Compressor—540G, 548G, 640G, 648G (S.N. 558325—), 740G, 748G (S.N. 559115—)
- Remove and Install Condenser
- Remove and Install Evaporator and Expansion Valve
- Remove and Install Receiver/Dryer
- Remove and Install Condenser Fan Motors
- Freeze Control Temperature Cycling Switch
- Disassemble and Assemble Blower Motor
- Remove and Install Heater—540G, 548G, 640G, 648G (S.N. —558324), 740G, 748G (S.N. —559114)—If Equipped
- Remove and Install Heater—540G, 548G, 640G, 648G (S.N. 558325—), 740G, 748G (S.N. 559115— )—If Equipped
- Remove and Install Heater Core
- Air Conditioning Component Location
- Sheet Metal and Styling
- Hood or Engine Enclosure
- Essential Tools
- Specifications
- Remove and Install Hood
- Grille and Grille Housing
- Specifications
- Remove and Install Grille and Grille Housing
- Safety, Convenience and Miscellaneous
- Fire Extinguisher
- Specifications
- Inspect Fire Extinguisher
- Disassemble and Assemble Pressurized Water System—If Equipped
- Fill and Charge Pressurized Water System—If Equipped
- Horn and Warning Devices
- Specifications
- Remove and Install Horn
- Remove and Install Reverse Warning Alarm
- Adjust Reverse Warning Alarm Volume—If Equipped
- Main Hydraulic System
- Hydraulic System
- Service Equipment and Tools
- Specifications
- Remove and Install Hydraulic Pump
- Hydraulic Pump Cross Section
- Disassemble and Inspect Hydraulic Pump
- Assemble Hydraulic Pump
- Remove and Install Priority Valve
- Disassemble and Assemble Steering Priority Valve
- Remove and Install Hydraulic Oil Filter
- Remove and Install Hydraulic Reservoir
- Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
- Winch
- Removal and Installation
- John Deere 4000 Series Winch Repair—Use CTM25
- John Deere 6000 Series Winch Repair—Use CTM41
- Specifications
- Remove Winch—4000 Series
- Install Winch—4000 Series
- Install Winch Drum Plug—4000 Series
- Fasten Cable to Winch Drum—4000 Series
- Winch Free Spool Drag Adjustment
- Remove Winch—6000 Series
- Install Winch—6000 Series
- Fasten Cable to Drum—6000 Series Winch
- Controls Linkage
- Other Material
- Specifications
- Remove and Install Winch Control Valve Linkage
- Remove and Install Winch Control Cable
- Input Drive Shafts and U-Joints
- Other Material
- Specifications
- Remove and Install Winch Drive Line
- Disassemble and Assemble Winch Drive Shaft
- Bulldozers (Stacking and Trailbuilding Blades)
- Blades
- Service Equipment and Tools
- Other Material
- Specifications
- Remove and Install Stacking Blade
- Remove Spherical Bushing
- Install Spherical Bushing
- Controls Linkage
- Other Material
- Remove and Install Control Linkage—Blade
- Remove and Install Blade Control Valve Support
- Hydraulic System
- Blade Control Valve
- Blade Cylinder
- Remove and Install Blade Lift Cylinder
- Arch or Boom
- Frames
- Service Equipment and Tools
- Specifications
- Remove and Install Log Arch
- Remove and Install Horizontal Roller
- Remove Side Roller
- Install Side Roller
- Remove and Install Roller Brackets
- Grapple
- Grapple Mechanism
- Service Equipment And Tools
- Specifications
- Remove and Install Grapple
- Disassemble and Assemble Grapple—8.0, 11.7 and 14.9 Sq. Ft. (548G, 648G, 748G)
- Disassemble and Assemble Grapple—10.4 Sq. Ft. (648G)
- Remove and Install Grapple Tong Cylinder
- Remove, Disassemble, Assemble and Install Grapple Damper
- Grapple Damper Adjustment
- Lubricate Damper, Yoke and Cross Head Pins
- Remove, Disassemble, Assemble and Install Grapple Rotate Yoke
- Control Linkage
- Other Material
- Single Function Grapple Control Linkage
- Remove and Install Dual Function Grapple Control Linkage
- Frames
- Essential Tools
- Other Material
- Specifications
- Remove and Install Single Function Grapple Cable Rollers
- Dual Function Grapple Cable Rollers
- Remove and Install Dual Function Grapple Cable Rollers
- Single Function Grapple Arch
- Remove and Install Single Function Grapple Arch
- Dual Function Grapple Arch
- Remove and Install Dual Function Grapple Arch
- Remove and Install Boom—Dual Function Grapple
- Remove Spherical Bushing
- Install Spherical Bushing
- Hydraulic System
- Service Equipment and Tools
- Other Material
- Specifications
- Remove and Install Boom Cylinder—Single Function Grapple
- Remove and Install Boom or Arch Cylinder—Dual Function Grapple
- Cross Section of Boom, Arch, Single Function, Dual Function and Blade Grapple Cylinders
- Disassemble and Inspect Boom, Arch, Blade, Single Function and Dual Function Grapple Cylinders
- Assemble Boom, Arch, Blade, and Single Function Grapple Cylinder
- Cross Section of 180 Series Grapple Cylinder
- Disassemble 180 Series Grapple Cylinder
- Assemble 180 Series Grapple Cylinder
- Remove and Install Grapple Tong Cylinder
- Remove Rotate Motor (S.N. —552976)
- Disassemble Rotate Motor (S.N. —552976)
- Assemble Rotate Motor (S.N. —552976)
- Install Rotate Motor (S.N. —552976)
- Remove Rotate Motor (S.N. 552977—)
- Disassemble Rotate Motor (S.N. 552977—)
- Assemble Rotate Motor (S.N. 552977—)
- Install Rotate Motor (S.N. 552977—)
- Remove and Install Rotate Motor Drive Gear
- Remove and Install Control Valve—Single Function Grapple
- Disassemble and Assemble Single Function Control Valve
- Remove and Install Control Valve—Dual Function Grapple
- Disassemble and Assemble Dual Function Control Valve
- Remove and Install Lift Check Poppets and Relief Valves
- Remove and Install Grapple Rotate Solenoid Valve
- Disassemble and Assemble Grapple Rotate Solenoid Valve
- Remove and Install Flow Divider
- Remove and Install Rotary Manifold
- Disassemble Rotary Manifold
- Dealer Fabricated Tools
- Dealer Fabricated Tools
- DF1055—Yoke Holding Tool (1200 and 1400 Series)
- DFT1099 Bushing Drivers
- DFT1104 Transmission Floor Stand
- DFT1105 Gear Alignment Tool
- DFT1106 Lift Handle
- DFRW20 Compressor Holding Fixture

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