- Gallons
- 230,310
John Deere 540G-II 548G-II 640G-II 648G-II 748G-II Skidder Repair Technical Manual TM1694
- Download this document, you need 750 Gallons
John Deere 540G-II 548G-II 640G-II 648G-II 748G-II Skidder Repair Technical Manual TM1694
Size: 32.31 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Skidder
Type of Manual: Repair Technical Manual
Model: John Deere 540G-II 548G-II 640G-II 648G-II 748G-II Skidder
Serial Number: 565685-576252
Part Number: TM1694
Publication Date: 2005
Number of Pages: 902 Pages
Contents:
FOREWORD
Section 00 - GENERAL INFORMATION
Group 0001 - 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
Group 0002 - General Specifications
540G-II Skidder Dimensions
540G-II Skidder Specifications
540G-II Skidder Drain and Refill Capacities
4000 Series Winch Specifications
548G-II Skidder Dimensions
548G-II Skidder Specifications
548G-II Skidder
548G-II Skidder Drain and Refill Capacities
4000 Series Winch Specifications
640G-II Skidder Dimensions
640G-II Skidder Specifications
640G-II Skidder Drain and Refill Capacities
4000 Series Winch Specifications
6000 Series Winch Specifications
648G-II Skidder Dimensions
648G-II Skidder Specifications
648G-II Skidder
648G-II Skidder Drain and Refill Capacities
4000 Series Winch Specifications
748G-II Skidder Dimensions
748G-II Skidder Specifications
748G-II Skidder
748G-II Skidder Drain and Refill Capacities
6000 Series Winch Specifications
Group 0003 - Torque Values
Hardware Torque Specifications
ROPS Torque Specifications
Tighten Upper Frame Pivot Pin Nut
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Unified Inch Bolt and 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 Inch Series Four Bolt Flange Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Group 0004 - 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 Hydraulic System, Park Brake, Differential, Hand Pump Reservoir and Winch Oils
Grease
Oil Filters
Lubricant Storage
Alternative and Synthetic Lubricants
Mixing of Lubricants
Diesel Engine Coolant
Section 01 - WHEELS
Group 0110 - Powered Wheels and Fastenings
Service Equipment and Tools
Specifications
Remove and Install Wheel
Remove and Install Tire
Section 02 - AXLES AND SUSPENSION SYSTEM
Group 0200 - Removal and Installation
John Deere TeamMate TeamMate is a trademark of Deere & Company II 1200 and 1400 Series Axles-Use CTM43
Service Equipment and Tools
Other Material
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
Group 0225 - Input Drive Shafts and U-Joints
Other Material
Specifications
Remove and Install Front Differential Drive Shaft
Remove and Install Rear Differential and Transmission Drive Shafts
Universal Joint Installation and Lubrication
Group 0260 - Hydraulic System
Specifications
Remove and Install Differential Lock Solenoid Valve
Differential Lock Solenoid Valve
Remove and Install Differential Lock Relief Valve
Differential Lock Relief Valve Cross Section
Differential Lock and Axle Hose Routing
Group 0299 - Dealer Fabricated Tools
DFT1055-Yoke Holding Tool (1200 and 1400 Series Axles)
Section 03 - TRANSMISSION
Group 0300 - Removal and Installation
Service Equipment and Tools
Other Material
Specifications
Specifications-Continued
Transmission Component Location
Remove Transmission
Install Transmission
Group 0325 - Input Drive Shafts and U-Joints
Specifications
Remove and Install Engine to Transmission Drive Shaft
Group 0350 - Gears, Shafts and Bearings
Essential Tools
Service Equipment and Tools
Other Material
Specifications
General Repair Procedures
Use Proper Lifting Equipment
Lifting Transmission
Mounting Transmission on Repair Stand
Disassemble Winch PTO Gears-If Equipped
Exploded View of Winch PTO Gear Assembly
Exploded View of Winch PTO Cover-Without Winch
Assemble Winch PTO Gears-If Equipped
Disassemble Park Brake
Assemble Park Brake
Remove Charge Pump
Remove Charge Pump Idler Gear Assembly
Exploded View of Charge Pump Drive Assembly
Install Charge Pump Idler Gear Assembly
Install Charge Pump
Remove Transmission Control Valve
Disassemble Transmission Control Valve Assembly
Exploded View of Transmission Control Valve Assembly
Assemble Transmission Control Valve
Install Transmission Control Valve
Remove Input Yoke Assembly
Exploded View of Input Yoke Assembly
Install Input Yoke Assembly
Exploded View of Front Housing Assembly
Remove Front Housing
Repair Front Housing Assembly
Remove Transmission Clutch Packs and Gear Stage Assemblies
Install Transmission Clutch Packs and Gear Stage Assemblies
Exploded View of Input Shaft (First Stage) Assembly
Exploded View of Sixth Stage Gear (Idler Gear) Shaft Assembly
Disassemble Input (First Stage) and Idler (Sixth Stage) Gear Shaft Assemblies
Assemble Input (First Stage) and Idler (Sixth Stage) Gear Shaft Assemblies
Exploded View of Clutch Packs-High/Low Forward (Second Stage)
Exploded View of Direction Clutch Packs-High/Low Reverse (Third Stage)
Exploded View of First and Third Speed Clutch Packs (Fourth Stage)
Exploded View of Second and Fourth Speed Clutch Packs (Fifth Stage)
Disassemble Clutch Pack Assemblies
Assemble Clutch Pack Assemblies
Exploded View of Seventh Stage (Output Gear)
Disassemble Seventh Stage (Output) Shaft
Assemble Seventh Stage (Output) Shaft
Exploded View of Rear Housing
Repair Rear Transmission Housing
Assemble Front Housing to Rear Housing
Group 0360 - Hydraulic System
Specifications
Remove Transmission Charge Pump
Install Transmission Charge Pump
Remove Differential Lock Pump
Install Differential Lock Pump
Group 0399 - Dealer Fabricated Tools
DF1156 Transmission Housing Lifting Bracket
Section 04 - ENGINE
Group 0400 - Removal and Installation
PowerTechPowerTech is a registered trademark of Deere & Company 6.8L, 6068 John Deere Engine-Use CTM104
PowerTechPowerTech is a registered trademark of Deere & Company 8.1L, 6081 John Deere Engine-Use CTM86
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Disconnect Turbocharger Oil Inlet Line
Remove and Install Engine
Remove Oil Pan
Remove Engine Oil Pump-540G-II, 548G-II, 640G-II, 648G-II
Install Engine Oil Pump-540G-II, 548G-II, 640G-II, 648G-II
Remove Engine Oil Pump-748G-II
Install Engine Oil Pump-748G-II
Install Oil Pan
Remove Fuel Injection Pump-540G-II, 548G-II
Install Fuel Injection Pump-540G-II, 548G-II
JT07158 TIME TRAC TIME TRAC is a registered trademark of Deere & Company Installation
Injection Pump Timing-540G-II, 548G-II
Remove Fuel Injection Pump-640G-II, 648G-II
Install Fuel Injection Pump-640G-II, 648G-II
Remove Fuel Injection Pump-748G-II
Install Fuel Injection Pump-748G-II
Bleed Fuel System-540G-II, 548G-II, 640G-II, 648G-II
Bleed Fuel System-748G-II
Remove Fuel Injection Nozzles-540G-II, 548G-II, 640G-II, 648G-II
Install Fuel Injection Nozzles-540G-II, 548G-II, 640G-II, 648G-II
Remove Fuel Injection Nozzle-748G-II
Inspect and Clean Cylinder Head Nozzle Bore-748G-II
Install Fuel Injection Nozzle-748G-II
Remove and Install Intake Manifold-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Intake Manifold-748G-II
Remove and Install Turbocharger-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Turbocharger-748G-II
Remove and Install Water Pump-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Water Pump-748G-II
Remove and Install Thermostat-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Thermostats-748G-II
Remove and Install Engine Oil Cooler-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Oil Cooler-748G-II
Remove and Install Fuel Filter and Base-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Fuel Filter and Base-748G-II
Remove and Install Fuel Transfer Pump-540G-II, 548G-II
Remove and Install Fuel Transfer Pump-640G-II, 648G-II
Remove and Install Fuel Transfer Pump-748G-II
Section 05 - ENGINE AUXILIARY SYSTEMS
Group 0505 - Cold Weather Starting Aids
Other Material
Specifications
Remove and Install Starting Aid Solenoid and Nozzle-If Equipped
Remove and Install Engine Coolant Heater
Group 0510 - Cooling Systems
Specifications
Remove and Install Fan Guards and Fan
Remove and Install Fan Belt
Check Belt Tensioner Spring Tension
Remove and Install Automatic (Spring) Belt Tensioner
Remove and Install Fan Shroud
Remove and Install Radiator
Group 0515 - Speed Controls
Other Material
Specifications
Remove and Install Speed Control Linkage-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Speed Control Linkage-748G-II
Engine Speed Control Linkage Adjustment-540G-II, 548G-II, 640G-II, 648G-II
Engine Speed Control Linkage Adjustment-748G-II
Group 0520 - Intake System
Service Equipment and Tools
Specifications
Remove and Install Air Cleaner
Remove and Install Air Filter Elements
Air Intake System Leakage Test
Group 0530 - External Exhaust System
Specifications
Remove and Install Muffler-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Muffler-748G-II
Group 0560 - External Fuel Supply System
Essential Tools
Service Equipment and Tools
Specifications
Remove Fuel Tank-540G-II, 548G-II, 640G-II
Install Fuel Tank-540G-II, 548G-II, and 640G-II
Remove Fuel Tank-648G-II, 748G-II
Install Fuel Tank-648G-II, 748G-II
Remove and Install Fuel Gauge Sender
Replace Primary Fuel Filter (Water Separator)-540G-II, 548G-II, 640G-II, 648G-II
Replace Primary Fuel Filter (Water Separator)-748G-II
Replace Final Fuel Filter-748G-II
Section 07 - DAMPER DRIVE
Group 0752 - Elements
Other Material
Specifications
Remove and Install Damper
Disassemble and Assemble Transmission Disconnect Linkage-If Equipped (S.N. -573322)
Disassemble and Assemble Transmission Disconnect Linkage-If Equipped (640G-II, 648G-II, 748G-II S.N. 573323-)
Transmission Disconnect Linkage Adjustment-If Equipped
Remove and Disassemble Transmission Disconnect-If Equipped
Assemble and Install Transmission Disconnect-If Equipped
Section 09 - STEERING SYSTEM
Group 0930 - Secondary Steering
Remove and Install Secondary Steering Pump
Group 0960 - Hydraulic System
Service Equipment and Tools
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
Section 10 - SERVICE BRAKES
Group 1011 - Active Elements
Brake Lining Inspection
Group 1015 - Controls Linkage
Remove and Install Brake Pedal Assembly
Group 1060 - 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
Section 11 - PARK BRAKE
Group 1111 - Active Elements
Park Brake Assembly
Group 1160 - Hydraulic System
Specifications
Park Brake Solenoid
Remove and Install Park Brake Solenoid
Replace Park Brake/Differential Lock Valve Filter
Section 16 - ELECTRICAL SYSTEM
Group 1671 - Batteries, Support and Cables
Service Equipment and Tools
Other Material
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
Group 1672 - Alternator, Regulator and Charging System Wiring
John Deere Alternator and Starting Motors Repair-Use CTM77
Service Equipment and Tools
Specifications
Remove and Install Alternator-95 Amp Bosch
Remove and Install Alternator-135 Amp Bosch
Group 1673 - Lighting System
Remove and Install Lights
Remove and Install Light Switch
Replace Halogen Bulbs
Group 1674 - Wiring Harness and Switches
Essential Tools
Specifications
Remove and Install Indicator Switches
Replacing Fuses
Remove Blade Terminals from Fuse Block
Remove and Install Start Relay
Remove and Install Wiper Switch
Remove and Install Horn Switch, Key Switch and Start Aid Switch
Remove and Install Heater Fan Switch
Remove and Install Inching In/Out Switch
Remove and Install Input Shaft, Output Shaft and Cylinder Pick-Up Sensors
Remove and Install Secondary Steering Switch-If Equipped
Remove and Install Battery Disconnect Switch
Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Connectors
Install DEUTSCH DEUTSCH is a trademark of Deutsch Co. Contact
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector
Replace SURE-SEAL Connector with WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric Contact
Remove Connector Body from Blade Terminals
Group 1676 - Instruments and Indicators
Other Material
Specifications
Gauge, Switch and Sender Specifications
Remove and Install Engine Coolant Temperature Sender-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Engine Coolant Temperature Sender-748G-II
Remove and Install Engine Oil Pressure Sending Unit-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Engine Oil Pressure Sending Unit-748G-II
Remove and Install Air Filter Restriction Switch
Remove and Install Hydraulic Oil Filter Restriction and Hydraulic Oil Temperature Switches
Remove and Install Display Monitor
Remove and Install Display Monitor Bulbs
Remove and Install Transmission Controller
Remove and Install Forward and Reverse Switch
Remove and Install Park/Neutral/Gear Position Switch
Remove and Install Differential Lock Switch
Remove and Install Grapple Rotate Switch
Remove and Install Transmission Oil Filter Restriction Switch
Remove and Install Transmission Oil Temperature Switch and Transmission Control Valve Solenoids
Remove and Install Service Brake Pressure Switch
Remove and Install Fuel Level Sender
Group 1677 - Motors and Actuators
John Deere Alternator and Starting Motors Repair-Use CTM77
Specifications
Remove and Install Starting Motor
Section 17 - FRAME, CHASSIS, OR SUPPORTING STRUCTURES
Group 1740 - Frame Installation
Service Equipment and Tools
Other Material
Specifications
Welding Repair of Major Structure
Separate Engine and Equipment Frames (S.N. -575347 If Not Updated)
Remove and Install Frame Pivot Pins (S.N. -575347 If Not Updated)
Remove and Install Lower Pivot Pin and Pin Seals (S.N. -575347 If Not Updated)
Remove and Install Upper Pivot Pin (S.N. -575347 If Not Updated)
Remove and Install Upper Pivot Spherical Bushing (S.N. -575347 If Not Updated)
Remove and Install Lower Pivot Pin Spherical Bushing (S.N. -575347 If Not Updated)
Separate Engine And Equipment Frames (S.N. 575348- Or Older Version If Updated)
Install Articulation Joint Upper Pivot Pin (S.N. 575348- Or Older Version If Updated)
Install Lower Articulation Joint (S.N. 575348- Or Older Version If Updated)
Install Equipment Frame to Engine Frame (S.N. 575348- Or Older Version If Updated)
Group 1746 - Frame Bottom Guards
Specifications
Remove and Install Engine Frame Front Bottom Guard
Remove and Install Equipment Frame Bottom Guards
Group 1799 - Dealer Fabricated Tools
DFT1099 Bushing Drivers
Section 18 - OPERATOR′S STATION
Group 1800 - Removal and Installation
Specifications
Remove and Install Cab
Remove and Install Cab Isolators
Remove and Install Steering Column
Remove and Install Steering Universal Joint
Hydraulic Cab Tilt Procedure
Remove and Install Cab Tilt Hand Pump
Disassemble and Assemble Cab Tilt Hand Pump
Remove and Install Cab Tilt Cylinder
Bleed Cab Tilt Hand Pump Circuit
Group 1810 - Operator Enclosure
Essential Tools
Specifications
Remove and Install Window Frame 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
Group 1821 - Seat and Seat Belt
Specifications
Remove and Install Seat
Disassemble and Assemble Suspension Seat, Cushions and Armrest
Disassemble and Assemble Suspension Seat Base and Shock Absorber
Disassemble and Assemble Suspension Seat Base, Seat Slide and Control Lever
Disassemble and Assemble Air Suspension Seat
Seat Belt
Disassemble and Assemble Two-Inch Seat Belt Assembly
Disassemble and Assemble Anti-Cinch Seat Belt Assembly
Group 1830 - Heating and Air Conditioning
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Proper Refrigerant Handling
R134a Refrigerant Cautions
Refrigerant Hoses and Tubing Inspection
R134a Compressor Oil Charge Check
R134a Component Oil Charge
Add Refrigerant Oil to System-R134a
R134a Compressor Oil Removal
R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure
Recover R134a System
Evacuate R134a System
Charge R134a System
Leak Testing
Remove and Install Compressor Relief Valve-R134a
Remove and Install High and Low Pressure Switches
High Pressure Switch Test
Low Pressure Switch Test
Remove and Install Compressor
Disassemble and Assemble Compressor Clutch-R134a
Check Clutch Hub Clearance-R134a
Inspect Compressor Manifold-R134a
Disassemble, Inspect and Assemble Compressor-R134a
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-If Equipped
Remove and Install Heater Core
Air Conditioning Component Location
Group 1899 - Dealer Fabricated Tools
DFRW20 Compressor Holding Fixture
Section 19 - SHEET METAL AND STYLING
Group 1910 - Hood or Engine Enclosure
Essential Tools
Specifications
Remove and Install Hood
Group 1921 - Grille and Grille Housing
Specifications
Remove and Install Grille and Grille Housing
Section 20 - SAFETY, CONVENIENCE AND MISCELLANEOUS
Group 2003 - Fire Extinguisher
Specifications
Inspect Fire Extinguisher
Disassemble and Assemble Pressurized Water System
Fill and Charge Pressurized Water System-If Equipped
Group 2004 - Horn and Warning Devices
Specifications
Remove and Install Horn
Remove and Install Reverse Warning Alarm
Adjust Reverse Warning Alarm Volume-If Equipped
Section 21 - MAIN HYDRAULIC SYSTEM
Group 2160 - Hydraulic System
Service Equipment and Tools
Specifications
Remove and Install Hydraulic Pump Assembly
Hydraulic Pump Cross Section
Disassemble and Inspect Hydraulic Pump
Assemble Hydraulic Pump
Remove and Install Priority Valve
Disassemble and Assemble Priority Valve
Remove and Install Hydraulic Oil Filter
Remove and Install Hydraulic Reservoir
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Section 30 - WINCH
Group 3000 - Removal and Installation
John Deere 4000 Winch Repair-Use CTM25
John Deere 6000 Winch Repair-Use CTM41
Other Material
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 6000 Series Winch
Install 6000 Series Winch
Fasten Cable to Drum-6000 Series Winch
Group 3015 - Controls Linkage
Other Material
Specifications
Remove and Install Winch Control Valve Linkage
Remove and Install Winch Control Cable
Group 3025 - Input Drive Shafts and U-Joints
Other Material
Specifications
Remove and Install Winch Drive Line
Disassemble and Assemble Winch Drive Shaft
Group 3050 - Drive and Clutch
John Deere 4000 Winch Repair-Use CTM25
John Deere 6000 Winch Repair-Use CTM41
Section 32 - BULLDOZERS (STACKING & TRAILBUILDING BLADES)
Group 3201 - Blades
Service Equipment and Tools
Other Material
Specifications
Remove and Install Stacking Blade
Remove Spherical Bushing
Install Spherical Bushing
Group 3215 - Controls Linkage
Other Material
Remove and Install Control Linkage-Blade
Remove and Install Blade Control Valve Support
Group 3260 - Hydraulic System
Specifications
Blade Control Valve
Blade Cylinder
Remove and Install Blade Lift Cylinder
Group 3299 - Dealer Fabricated Tools
DFT1099 Bushing Drivers
Section 37 - ARCH OR BOOM
Group 3740 - 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
Section 38 - GRAPPLE
Group 3803 - Grapple Mechanism
Service Equipment and Tools
Specifications
Remove and Install Grapple
Disassemble and Assemble Grapple
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
Group 3815 - Control Linkage
Other Material
Single Function Grapple Control Linkage
Remove and Install Dual Function Grapple Control Linkage
Group 3840 - Frames
Service Equipment and Tools
Other Material
Specifications
Remove and Install Single Function Grapple Cable Rollers
Remove and Install Dual Function Grapple Cable Rollers
Remove and Install Single Function Grapple Arch
Remove and Install Dual Function Grapple Arch
Remove and Install Boom-Dual Function Grapple
Remove Spherical Bushing
Install Spherical Bushing
Group 3860 - Hydraulic System
Service Equipment and Tools
Other Material
Specifications
Remove and Install Arch Cylinder-Single Function Grapple
Remove and Install Boom Or Arch Cylinder-Dual Function Grapple
Cross Section of Blade, Boom, Arch, and Single Function Grapple Tong Cylinder
Disassemble and Inspect Blade, Boom, Arch and Single Function Grapple Tong Cylinder
Assemble Blade, Boom, Arch and Single Function Grapple Tong Cylinder
Cross Section of 180 Series Grapple Tong Cylinder
Disassemble 180 Series Grapple Tong Cylinder
Assemble 180 Series Grapple Tong Cylinder
Remove and Install Grapple Tong Cylinder
Remove Rotate Motor
Disassemble Rotate Motor
Assemble Rotate Motor
Install Rotate Motor
Remove and Install Rotate Motor Drive Gear
Remove and Install Control Valve-Single Function Grapple
Disassemble and Assemble Single Function Control Valve Sections
Remove and Install Control Valve-Dual Function Grapple
Disassemble and Assemble Dual Function Control Valve Sections
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 and Assemble Rotary Manifold
Group 3899 - Dealer Fabricated Tools
DFT1099 Bushing Drivers
Size: 32.31 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Skidder
Type of Manual: Repair Technical Manual
Model: John Deere 540G-II 548G-II 640G-II 648G-II 748G-II Skidder
Serial Number: 565685-576252
Part Number: TM1694
Publication Date: 2005
Number of Pages: 902 Pages
Contents:
FOREWORD
Section 00 - GENERAL INFORMATION
Group 0001 - 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
Group 0002 - General Specifications
540G-II Skidder Dimensions
540G-II Skidder Specifications
540G-II Skidder Drain and Refill Capacities
4000 Series Winch Specifications
548G-II Skidder Dimensions
548G-II Skidder Specifications
548G-II Skidder
548G-II Skidder Drain and Refill Capacities
4000 Series Winch Specifications
640G-II Skidder Dimensions
640G-II Skidder Specifications
640G-II Skidder Drain and Refill Capacities
4000 Series Winch Specifications
6000 Series Winch Specifications
648G-II Skidder Dimensions
648G-II Skidder Specifications
648G-II Skidder
648G-II Skidder Drain and Refill Capacities
4000 Series Winch Specifications
748G-II Skidder Dimensions
748G-II Skidder Specifications
748G-II Skidder
748G-II Skidder Drain and Refill Capacities
6000 Series Winch Specifications
Group 0003 - Torque Values
Hardware Torque Specifications
ROPS Torque Specifications
Tighten Upper Frame Pivot Pin Nut
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Unified Inch Bolt and 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 Inch Series Four Bolt Flange Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Group 0004 - 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 Hydraulic System, Park Brake, Differential, Hand Pump Reservoir and Winch Oils
Grease
Oil Filters
Lubricant Storage
Alternative and Synthetic Lubricants
Mixing of Lubricants
Diesel Engine Coolant
Section 01 - WHEELS
Group 0110 - Powered Wheels and Fastenings
Service Equipment and Tools
Specifications
Remove and Install Wheel
Remove and Install Tire
Section 02 - AXLES AND SUSPENSION SYSTEM
Group 0200 - Removal and Installation
John Deere TeamMate TeamMate is a trademark of Deere & Company II 1200 and 1400 Series Axles-Use CTM43
Service Equipment and Tools
Other Material
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
Group 0225 - Input Drive Shafts and U-Joints
Other Material
Specifications
Remove and Install Front Differential Drive Shaft
Remove and Install Rear Differential and Transmission Drive Shafts
Universal Joint Installation and Lubrication
Group 0260 - Hydraulic System
Specifications
Remove and Install Differential Lock Solenoid Valve
Differential Lock Solenoid Valve
Remove and Install Differential Lock Relief Valve
Differential Lock Relief Valve Cross Section
Differential Lock and Axle Hose Routing
Group 0299 - Dealer Fabricated Tools
DFT1055-Yoke Holding Tool (1200 and 1400 Series Axles)
Section 03 - TRANSMISSION
Group 0300 - Removal and Installation
Service Equipment and Tools
Other Material
Specifications
Specifications-Continued
Transmission Component Location
Remove Transmission
Install Transmission
Group 0325 - Input Drive Shafts and U-Joints
Specifications
Remove and Install Engine to Transmission Drive Shaft
Group 0350 - Gears, Shafts and Bearings
Essential Tools
Service Equipment and Tools
Other Material
Specifications
General Repair Procedures
Use Proper Lifting Equipment
Lifting Transmission
Mounting Transmission on Repair Stand
Disassemble Winch PTO Gears-If Equipped
Exploded View of Winch PTO Gear Assembly
Exploded View of Winch PTO Cover-Without Winch
Assemble Winch PTO Gears-If Equipped
Disassemble Park Brake
Assemble Park Brake
Remove Charge Pump
Remove Charge Pump Idler Gear Assembly
Exploded View of Charge Pump Drive Assembly
Install Charge Pump Idler Gear Assembly
Install Charge Pump
Remove Transmission Control Valve
Disassemble Transmission Control Valve Assembly
Exploded View of Transmission Control Valve Assembly
Assemble Transmission Control Valve
Install Transmission Control Valve
Remove Input Yoke Assembly
Exploded View of Input Yoke Assembly
Install Input Yoke Assembly
Exploded View of Front Housing Assembly
Remove Front Housing
Repair Front Housing Assembly
Remove Transmission Clutch Packs and Gear Stage Assemblies
Install Transmission Clutch Packs and Gear Stage Assemblies
Exploded View of Input Shaft (First Stage) Assembly
Exploded View of Sixth Stage Gear (Idler Gear) Shaft Assembly
Disassemble Input (First Stage) and Idler (Sixth Stage) Gear Shaft Assemblies
Assemble Input (First Stage) and Idler (Sixth Stage) Gear Shaft Assemblies
Exploded View of Clutch Packs-High/Low Forward (Second Stage)
Exploded View of Direction Clutch Packs-High/Low Reverse (Third Stage)
Exploded View of First and Third Speed Clutch Packs (Fourth Stage)
Exploded View of Second and Fourth Speed Clutch Packs (Fifth Stage)
Disassemble Clutch Pack Assemblies
Assemble Clutch Pack Assemblies
Exploded View of Seventh Stage (Output Gear)
Disassemble Seventh Stage (Output) Shaft
Assemble Seventh Stage (Output) Shaft
Exploded View of Rear Housing
Repair Rear Transmission Housing
Assemble Front Housing to Rear Housing
Group 0360 - Hydraulic System
Specifications
Remove Transmission Charge Pump
Install Transmission Charge Pump
Remove Differential Lock Pump
Install Differential Lock Pump
Group 0399 - Dealer Fabricated Tools
DF1156 Transmission Housing Lifting Bracket
Section 04 - ENGINE
Group 0400 - Removal and Installation
PowerTechPowerTech is a registered trademark of Deere & Company 6.8L, 6068 John Deere Engine-Use CTM104
PowerTechPowerTech is a registered trademark of Deere & Company 8.1L, 6081 John Deere Engine-Use CTM86
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Disconnect Turbocharger Oil Inlet Line
Remove and Install Engine
Remove Oil Pan
Remove Engine Oil Pump-540G-II, 548G-II, 640G-II, 648G-II
Install Engine Oil Pump-540G-II, 548G-II, 640G-II, 648G-II
Remove Engine Oil Pump-748G-II
Install Engine Oil Pump-748G-II
Install Oil Pan
Remove Fuel Injection Pump-540G-II, 548G-II
Install Fuel Injection Pump-540G-II, 548G-II
JT07158 TIME TRAC TIME TRAC is a registered trademark of Deere & Company Installation
Injection Pump Timing-540G-II, 548G-II
Remove Fuel Injection Pump-640G-II, 648G-II
Install Fuel Injection Pump-640G-II, 648G-II
Remove Fuel Injection Pump-748G-II
Install Fuel Injection Pump-748G-II
Bleed Fuel System-540G-II, 548G-II, 640G-II, 648G-II
Bleed Fuel System-748G-II
Remove Fuel Injection Nozzles-540G-II, 548G-II, 640G-II, 648G-II
Install Fuel Injection Nozzles-540G-II, 548G-II, 640G-II, 648G-II
Remove Fuel Injection Nozzle-748G-II
Inspect and Clean Cylinder Head Nozzle Bore-748G-II
Install Fuel Injection Nozzle-748G-II
Remove and Install Intake Manifold-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Intake Manifold-748G-II
Remove and Install Turbocharger-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Turbocharger-748G-II
Remove and Install Water Pump-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Water Pump-748G-II
Remove and Install Thermostat-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Thermostats-748G-II
Remove and Install Engine Oil Cooler-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Oil Cooler-748G-II
Remove and Install Fuel Filter and Base-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Fuel Filter and Base-748G-II
Remove and Install Fuel Transfer Pump-540G-II, 548G-II
Remove and Install Fuel Transfer Pump-640G-II, 648G-II
Remove and Install Fuel Transfer Pump-748G-II
Section 05 - ENGINE AUXILIARY SYSTEMS
Group 0505 - Cold Weather Starting Aids
Other Material
Specifications
Remove and Install Starting Aid Solenoid and Nozzle-If Equipped
Remove and Install Engine Coolant Heater
Group 0510 - Cooling Systems
Specifications
Remove and Install Fan Guards and Fan
Remove and Install Fan Belt
Check Belt Tensioner Spring Tension
Remove and Install Automatic (Spring) Belt Tensioner
Remove and Install Fan Shroud
Remove and Install Radiator
Group 0515 - Speed Controls
Other Material
Specifications
Remove and Install Speed Control Linkage-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Speed Control Linkage-748G-II
Engine Speed Control Linkage Adjustment-540G-II, 548G-II, 640G-II, 648G-II
Engine Speed Control Linkage Adjustment-748G-II
Group 0520 - Intake System
Service Equipment and Tools
Specifications
Remove and Install Air Cleaner
Remove and Install Air Filter Elements
Air Intake System Leakage Test
Group 0530 - External Exhaust System
Specifications
Remove and Install Muffler-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Muffler-748G-II
Group 0560 - External Fuel Supply System
Essential Tools
Service Equipment and Tools
Specifications
Remove Fuel Tank-540G-II, 548G-II, 640G-II
Install Fuel Tank-540G-II, 548G-II, and 640G-II
Remove Fuel Tank-648G-II, 748G-II
Install Fuel Tank-648G-II, 748G-II
Remove and Install Fuel Gauge Sender
Replace Primary Fuel Filter (Water Separator)-540G-II, 548G-II, 640G-II, 648G-II
Replace Primary Fuel Filter (Water Separator)-748G-II
Replace Final Fuel Filter-748G-II
Section 07 - DAMPER DRIVE
Group 0752 - Elements
Other Material
Specifications
Remove and Install Damper
Disassemble and Assemble Transmission Disconnect Linkage-If Equipped (S.N. -573322)
Disassemble and Assemble Transmission Disconnect Linkage-If Equipped (640G-II, 648G-II, 748G-II S.N. 573323-)
Transmission Disconnect Linkage Adjustment-If Equipped
Remove and Disassemble Transmission Disconnect-If Equipped
Assemble and Install Transmission Disconnect-If Equipped
Section 09 - STEERING SYSTEM
Group 0930 - Secondary Steering
Remove and Install Secondary Steering Pump
Group 0960 - Hydraulic System
Service Equipment and Tools
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
Section 10 - SERVICE BRAKES
Group 1011 - Active Elements
Brake Lining Inspection
Group 1015 - Controls Linkage
Remove and Install Brake Pedal Assembly
Group 1060 - 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
Section 11 - PARK BRAKE
Group 1111 - Active Elements
Park Brake Assembly
Group 1160 - Hydraulic System
Specifications
Park Brake Solenoid
Remove and Install Park Brake Solenoid
Replace Park Brake/Differential Lock Valve Filter
Section 16 - ELECTRICAL SYSTEM
Group 1671 - Batteries, Support and Cables
Service Equipment and Tools
Other Material
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
Group 1672 - Alternator, Regulator and Charging System Wiring
John Deere Alternator and Starting Motors Repair-Use CTM77
Service Equipment and Tools
Specifications
Remove and Install Alternator-95 Amp Bosch
Remove and Install Alternator-135 Amp Bosch
Group 1673 - Lighting System
Remove and Install Lights
Remove and Install Light Switch
Replace Halogen Bulbs
Group 1674 - Wiring Harness and Switches
Essential Tools
Specifications
Remove and Install Indicator Switches
Replacing Fuses
Remove Blade Terminals from Fuse Block
Remove and Install Start Relay
Remove and Install Wiper Switch
Remove and Install Horn Switch, Key Switch and Start Aid Switch
Remove and Install Heater Fan Switch
Remove and Install Inching In/Out Switch
Remove and Install Input Shaft, Output Shaft and Cylinder Pick-Up Sensors
Remove and Install Secondary Steering Switch-If Equipped
Remove and Install Battery Disconnect Switch
Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Connectors
Install DEUTSCH DEUTSCH is a trademark of Deutsch Co. Contact
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector
Replace SURE-SEAL Connector with WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric Contact
Remove Connector Body from Blade Terminals
Group 1676 - Instruments and Indicators
Other Material
Specifications
Gauge, Switch and Sender Specifications
Remove and Install Engine Coolant Temperature Sender-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Engine Coolant Temperature Sender-748G-II
Remove and Install Engine Oil Pressure Sending Unit-540G-II, 548G-II, 640G-II, 648G-II
Remove and Install Engine Oil Pressure Sending Unit-748G-II
Remove and Install Air Filter Restriction Switch
Remove and Install Hydraulic Oil Filter Restriction and Hydraulic Oil Temperature Switches
Remove and Install Display Monitor
Remove and Install Display Monitor Bulbs
Remove and Install Transmission Controller
Remove and Install Forward and Reverse Switch
Remove and Install Park/Neutral/Gear Position Switch
Remove and Install Differential Lock Switch
Remove and Install Grapple Rotate Switch
Remove and Install Transmission Oil Filter Restriction Switch
Remove and Install Transmission Oil Temperature Switch and Transmission Control Valve Solenoids
Remove and Install Service Brake Pressure Switch
Remove and Install Fuel Level Sender
Group 1677 - Motors and Actuators
John Deere Alternator and Starting Motors Repair-Use CTM77
Specifications
Remove and Install Starting Motor
Section 17 - FRAME, CHASSIS, OR SUPPORTING STRUCTURES
Group 1740 - Frame Installation
Service Equipment and Tools
Other Material
Specifications
Welding Repair of Major Structure
Separate Engine and Equipment Frames (S.N. -575347 If Not Updated)
Remove and Install Frame Pivot Pins (S.N. -575347 If Not Updated)
Remove and Install Lower Pivot Pin and Pin Seals (S.N. -575347 If Not Updated)
Remove and Install Upper Pivot Pin (S.N. -575347 If Not Updated)
Remove and Install Upper Pivot Spherical Bushing (S.N. -575347 If Not Updated)
Remove and Install Lower Pivot Pin Spherical Bushing (S.N. -575347 If Not Updated)
Separate Engine And Equipment Frames (S.N. 575348- Or Older Version If Updated)
Install Articulation Joint Upper Pivot Pin (S.N. 575348- Or Older Version If Updated)
Install Lower Articulation Joint (S.N. 575348- Or Older Version If Updated)
Install Equipment Frame to Engine Frame (S.N. 575348- Or Older Version If Updated)
Group 1746 - Frame Bottom Guards
Specifications
Remove and Install Engine Frame Front Bottom Guard
Remove and Install Equipment Frame Bottom Guards
Group 1799 - Dealer Fabricated Tools
DFT1099 Bushing Drivers
Section 18 - OPERATOR′S STATION
Group 1800 - Removal and Installation
Specifications
Remove and Install Cab
Remove and Install Cab Isolators
Remove and Install Steering Column
Remove and Install Steering Universal Joint
Hydraulic Cab Tilt Procedure
Remove and Install Cab Tilt Hand Pump
Disassemble and Assemble Cab Tilt Hand Pump
Remove and Install Cab Tilt Cylinder
Bleed Cab Tilt Hand Pump Circuit
Group 1810 - Operator Enclosure
Essential Tools
Specifications
Remove and Install Window Frame 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
Group 1821 - Seat and Seat Belt
Specifications
Remove and Install Seat
Disassemble and Assemble Suspension Seat, Cushions and Armrest
Disassemble and Assemble Suspension Seat Base and Shock Absorber
Disassemble and Assemble Suspension Seat Base, Seat Slide and Control Lever
Disassemble and Assemble Air Suspension Seat
Seat Belt
Disassemble and Assemble Two-Inch Seat Belt Assembly
Disassemble and Assemble Anti-Cinch Seat Belt Assembly
Group 1830 - Heating and Air Conditioning
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Proper Refrigerant Handling
R134a Refrigerant Cautions
Refrigerant Hoses and Tubing Inspection
R134a Compressor Oil Charge Check
R134a Component Oil Charge
Add Refrigerant Oil to System-R134a
R134a Compressor Oil Removal
R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure
Recover R134a System
Evacuate R134a System
Charge R134a System
Leak Testing
Remove and Install Compressor Relief Valve-R134a
Remove and Install High and Low Pressure Switches
High Pressure Switch Test
Low Pressure Switch Test
Remove and Install Compressor
Disassemble and Assemble Compressor Clutch-R134a
Check Clutch Hub Clearance-R134a
Inspect Compressor Manifold-R134a
Disassemble, Inspect and Assemble Compressor-R134a
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-If Equipped
Remove and Install Heater Core
Air Conditioning Component Location
Group 1899 - Dealer Fabricated Tools
DFRW20 Compressor Holding Fixture
Section 19 - SHEET METAL AND STYLING
Group 1910 - Hood or Engine Enclosure
Essential Tools
Specifications
Remove and Install Hood
Group 1921 - Grille and Grille Housing
Specifications
Remove and Install Grille and Grille Housing
Section 20 - SAFETY, CONVENIENCE AND MISCELLANEOUS
Group 2003 - Fire Extinguisher
Specifications
Inspect Fire Extinguisher
Disassemble and Assemble Pressurized Water System
Fill and Charge Pressurized Water System-If Equipped
Group 2004 - Horn and Warning Devices
Specifications
Remove and Install Horn
Remove and Install Reverse Warning Alarm
Adjust Reverse Warning Alarm Volume-If Equipped
Section 21 - MAIN HYDRAULIC SYSTEM
Group 2160 - Hydraulic System
Service Equipment and Tools
Specifications
Remove and Install Hydraulic Pump Assembly
Hydraulic Pump Cross Section
Disassemble and Inspect Hydraulic Pump
Assemble Hydraulic Pump
Remove and Install Priority Valve
Disassemble and Assemble Priority Valve
Remove and Install Hydraulic Oil Filter
Remove and Install Hydraulic Reservoir
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Section 30 - WINCH
Group 3000 - Removal and Installation
John Deere 4000 Winch Repair-Use CTM25
John Deere 6000 Winch Repair-Use CTM41
Other Material
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 6000 Series Winch
Install 6000 Series Winch
Fasten Cable to Drum-6000 Series Winch
Group 3015 - Controls Linkage
Other Material
Specifications
Remove and Install Winch Control Valve Linkage
Remove and Install Winch Control Cable
Group 3025 - Input Drive Shafts and U-Joints
Other Material
Specifications
Remove and Install Winch Drive Line
Disassemble and Assemble Winch Drive Shaft
Group 3050 - Drive and Clutch
John Deere 4000 Winch Repair-Use CTM25
John Deere 6000 Winch Repair-Use CTM41
Section 32 - BULLDOZERS (STACKING & TRAILBUILDING BLADES)
Group 3201 - Blades
Service Equipment and Tools
Other Material
Specifications
Remove and Install Stacking Blade
Remove Spherical Bushing
Install Spherical Bushing
Group 3215 - Controls Linkage
Other Material
Remove and Install Control Linkage-Blade
Remove and Install Blade Control Valve Support
Group 3260 - Hydraulic System
Specifications
Blade Control Valve
Blade Cylinder
Remove and Install Blade Lift Cylinder
Group 3299 - Dealer Fabricated Tools
DFT1099 Bushing Drivers
Section 37 - ARCH OR BOOM
Group 3740 - 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
Section 38 - GRAPPLE
Group 3803 - Grapple Mechanism
Service Equipment and Tools
Specifications
Remove and Install Grapple
Disassemble and Assemble Grapple
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
Group 3815 - Control Linkage
Other Material
Single Function Grapple Control Linkage
Remove and Install Dual Function Grapple Control Linkage
Group 3840 - Frames
Service Equipment and Tools
Other Material
Specifications
Remove and Install Single Function Grapple Cable Rollers
Remove and Install Dual Function Grapple Cable Rollers
Remove and Install Single Function Grapple Arch
Remove and Install Dual Function Grapple Arch
Remove and Install Boom-Dual Function Grapple
Remove Spherical Bushing
Install Spherical Bushing
Group 3860 - Hydraulic System
Service Equipment and Tools
Other Material
Specifications
Remove and Install Arch Cylinder-Single Function Grapple
Remove and Install Boom Or Arch Cylinder-Dual Function Grapple
Cross Section of Blade, Boom, Arch, and Single Function Grapple Tong Cylinder
Disassemble and Inspect Blade, Boom, Arch and Single Function Grapple Tong Cylinder
Assemble Blade, Boom, Arch and Single Function Grapple Tong Cylinder
Cross Section of 180 Series Grapple Tong Cylinder
Disassemble 180 Series Grapple Tong Cylinder
Assemble 180 Series Grapple Tong Cylinder
Remove and Install Grapple Tong Cylinder
Remove Rotate Motor
Disassemble Rotate Motor
Assemble Rotate Motor
Install Rotate Motor
Remove and Install Rotate Motor Drive Gear
Remove and Install Control Valve-Single Function Grapple
Disassemble and Assemble Single Function Control Valve Sections
Remove and Install Control Valve-Dual Function Grapple
Disassemble and Assemble Dual Function Control Valve Sections
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 and Assemble Rotary Manifold
Group 3899 - Dealer Fabricated Tools
DFT1099 Bushing Drivers
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