John Deere 540G-II 548G-II 640G-II 648G-II 748G-II Skidder Service Manual TM1694

540G-II, 548G-II, 640G-II,
648G-II, 748G-II Skidders
(SN. 565685-576252)
Repair
REPAIR TECHNICAL MANUAL
Cable models 540G-II, 640G-II; Grapple models 548G-II, 648G-II, 748G-II (SN.
565685-576252)
For complete service information also see:
TM1694 22 FEB 05 (ENGLISH)
540G-II, 640G-II, 548G-II, 648G-II, 748G-II Skidder (SN. 565685-576252) DiagnosticTM1693
120 Series Hydraulic CylindersTM-H120A
PowerTech 8.1 L Diesel Engines Base EngineCTM86
Alternators and Starting MotorsCTM77
TeamMate II 1200, 1400,and 1600 Series Inboard Planetary AxlesCTM43
60 and 6000 WinchesCTM41
40 and 4000 WinchesCTM25
PowerTech 8.1L Diesel Engines Mechanical Fuel SystemsCTM243
PowerTech 6.8L and 8.1L, 6068 and 6081 Diesel Engines (Level 3 Electronic Fuel
Systems with Bosch In-Line Pump)CTM134
PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage
IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)CTM104
John Deere Construction and Forestry
Pinted by Belgreen

<- Go to Global Table of contents
tm1694-REPAIR TECHNICAL MANUAL
(g) by Belgreen v2.5
Table of contents
FOREWORD
HELP!! HELP!! HELP!! HELP!!
Section 00 - GENERAL INFORMATION
Group 0001 - Safety Information
Group 0002 - General Speciﬁcations
Group 0003 - Torque Values
Group 0004 - Fuels and Lubricants
Section 01 - WHEELS
Group 0110 - Powered Wheels and Fastenings
Section 02 - AXLES AND SUSPENSION SYSTEM
Group 0200 - Removal and Installation
Group 0225 - Input Drive Shafts and U-Joints
Group 0260 - Hydraulic System
Group 0299 - Dealer Fabricated Tools
Section 03 - TRANSMISSION
Group 0350 - Gears, Shafts and Bearings
Section 04 - ENGINE
Section 05 - ENGINE AUXILIARY SYSTEMS
Group 0505 - Cold Weather Starting Aids
Group 0510 - Cooling Systems
Group 0515 - Speed Controls
Group 0520 - Intake System
Group 0530 - External Exhaust System
Group 0560 - External Fuel Supply System
Section 07 - DAMPER DRIVE
Group 0752 - Elements
Section 09 - STEERING SYSTEM
Group 0930 - Secondary Steering
Section 10 - SERVICE BRAKES
Group 1011 - Active Elements
Group 1015 - Controls Linkage
Section 11 - PARK BRAKE
Group 1111 - Active Elements
Section 16 - ELECTRICAL SYSTEM
Group 1671 - Batteries, Support and Cables
Group 1672 - Alternator, Regulator and Charging System Wiring
Group 1673 - Lighting System
Group 1674 - Wiring Harness and Switches
Group 1676 - Instruments and Indicators
Group 1677 - Motors and Actuators
Section 17 - FRAME, CHASSIS, OR SUPPORTING STRUCTURES
Group 1740 - Frame Installation
Group 1746 - Frame Bottom Guards

Section 18 - OPERATOR′S STATION
Group 1810 - Operator Enclosure
Group 1821 - Seat and Seat Belt
Group 1830 - Heating and Air Conditioning
Section 19 - SHEET METAL AND STYLING
Group 1910 - Hood or Engine Enclosure
Group 1921 - Grille and Grille Housing
Section 20 - SAFETY, CONVENIENCE AND MISCELLANEOUS
Group 2003 - Fire Extinguisher
Group 2004 - Horn and Warning Devices
Section 21 - MAIN HYDRAULIC SYSTEM
Section 30 - WINCH
Group 3050 - Drive and Clutch
Section 32 - BULLDOZERS (STACKING & TRAILBUILDING BLADES)
Group 3201 - Blades
Section 37 - ARCH OR BOOM
Group 3740 - Frames
Section 38 - GRAPPLE
Group 3803 - Grapple Mechanism
Group 3815 - Control Linkage
Group 3840 - Frames

<- Go to Global Table of contents tm1694-REPAIR TECHNICAL MANUAL

Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified
in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text
of the manual.
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for
personal injury.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
Operation and tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are
summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service
parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of
troubleshooting, general maintenance, and basic type of failures and their causes.

Phone
FAX No.
Address
SEND TO:
Company Name
Ideas, Comments (Please State Page Number):
John Deere Dubuque Works
P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, Iowa 52004-0538
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FAX NUMBER: 319-589-5800
We need your help to continually improve our technical publications. Please FAX or mail your comments, ideas and
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<- Go to Section TOC
GENERAL INFORMATION
Dealer Acct. No.
Section 00 page 2
THANK YOU!

Table of contents
Group 0001 - Safety Information ........................................................................................................... 1
Handle Fluids Safely-Avoid Fires ........................................................................................................... 1
Prevent Battery Explosions ................................................................................................................... 1
Prepare for Emergencies ...................................................................................................................... 1
Prevent Acid Burns ............................................................................................................................... 3
Handle Chemical Products Safely ......................................................................................................... 3
Avoid High-Pressure Fluids ................................................................................................................... 4
Park Machine Safely ............................................................................................................................. 4
Support Machine Properly .................................................................................................................... 5
Wear Protective Clothing ...................................................................................................................... 6
Work in Clean Area ............................................................................................................................... 6
Service Machines Safely ....................................................................................................................... 6
Work In Ventilated Area ........................................................................................................................ 7
Illuminate Work Area Safely ................................................................................................................. 7
Replace Safety Signs ............................................................................................................................ 8
Use Proper Lifting Equipment ............................................................................................................... 8
Remove Paint Before Welding or Heating ............................................................................................. 8
Avoid Heating Near Pressurized Fluid Lines ........................................................................................ 10
Keep ROPS Installed Properly ............................................................................................................. 10
Service Tires Safely ............................................................................................................................ 11
Avoid Harmful Asbestos Dust ............................................................................................................. 11
Practice Safe Maintenance ................................................................................................................. 13
Use Proper Tools ................................................................................................................................. 13
Dispose of Waste Properly .................................................................................................................. 14
Live With Safety ................................................................................................................................. 14
Group 0002 - General Specifications .................................................................................................. 16
540G-II Skidder Dimensions ............................................................................................................... 16
540G-II Skidder Specifications ............................................................................................................ 18
540G-II Skidder Drain and Refill Capacities ........................................................................................ 19
4000 Series Winch Specifications ....................................................................................................... 19
548G-II Skidder ................................................................................................................................... 24
648G-II Skidder ................................................................................................................................... 35
748G-II Skidder ................................................................................................................................... 41

Group 0003 - Torque Values ................................................................................................................. 43
Hardware Torque Specifications ......................................................................................................... 43
ROPS Torque Specifications ................................................................................................................ 43
Tighten Upper Frame Pivot Pin Nut .................................................................................................... 43
Metric Bolt and Cap Screw Torque Values .......................................................................................... 44
Additional Metric Cap Screw Torque Values ....................................................................................... 45
Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 47
Check Oil Lines And Fittings ............................................................................................................... 47
Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 49
Service Recommendations for O-Ring Boss Fittings ........................................................................... 50
Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 52
Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 53
Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 54
Group 0004 - Fuels and Lubricants ..................................................................................................... 55
Diesel Fuel .......................................................................................................................................... 55
Low Sulfur Diesel Fuel Conditioner ..................................................................................................... 55
Handling and Storing Diesel Fuel ........................................................................................................ 55
Do Not Use Galvanized Containers ..................................................................................................... 55
Fuel Tank ............................................................................................................................................ 56
Diesel Engine Oil ................................................................................................................................ 57
Transmission Hydraulic System, Park Brake, Differential, Hand Pump Reservoir and Winch Oils ...... 58
Grease ................................................................................................................................................ 59
Oil Filters ............................................................................................................................................ 59
Lubricant Storage ............................................................................................................................... 59
Alternative and Synthetic Lubricants .................................................................................................. 60
Mixing of Lubricants ........................................................................................................................... 60
Diesel Engine Coolant ......................................................................................................................... 60

Section 00 - GENERAL INFORMATION Group 0001: Safety Information
Section 00 page 1
Group 0001 - Safety Information
Prepare for Emergencies
Prevent Battery Explosions
Handle Fluids Safely-Avoid Fires
Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Section 00 page 2
First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Section 00 page 3
Prevent Acid Burns
Handle Chemical Products Safely
Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1.Filling batteries in a well-ventilated area.
2.Wearing eye protection and rubber gloves.
3.Avoiding breathing fumes when electrolyte is added.
4.Avoiding spilling or dripping electrolyte.
5.Use proper jump start procedure.
If you spill acid on yourself:
1.Flush your skin with water.
2.Apply baking soda or lime to help neutralize the acid.
3.Flush your eyes with water for 15-30 minutes. Get medical attention immediately.
If acid is swallowed:
1.Do not induce vomiting.
2.Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3.Get medical attention immediately.

Section 00 page 4
Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere
equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and
how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
Park Machine Safely
Avoid High-Pressure Fluids

Section 00 page 5
Remove the Key
Before working on the machine:
Lower all equipment to the ground.
Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.
Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted
machine or attachment, securely support the machine or attachment. If left in a raised position, hydraulically supported
devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work
under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When implements or attachments are used with a tractor, always follow safety precautions listed in the implement operator′s
manual.
Support Machine Properly

Section 00 page 6
Work in Clean Area
Wear Protective Clothing
Clean Work Area
Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.
Protective Clothing
Wear close ﬁtting clothing and safety equipment appropriate to the job.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating
machine.

Section 00 page 7
Work In Ventilated Area
Service Machines Safely
Illuminate Work Area Safely
Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or
moving parts. If these items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust
fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area

Section 00 page 8
Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure
the bulb is enclosed by a wire cage. The hot ﬁlament of an accidentally broken bulb can ignite spilled fuel or oil.
Replace Safety Signs
Use Proper Lifting Equipment
Remove Paint Before Welding or Heating

Section 00 page 9
Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.
Remove paint before welding or heating:
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other ﬂammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.

Section 00 page 10
Keep ROPS Installed Properly
Avoid Heating Near Pressurized Fluid Lines
Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and
bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.
Roll-Over Protective Structure
Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any
reason. Tighten mounting bolts to proper torque.
The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident,
or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.

Section 00 page 11
Service Tires Safely
Avoid Harmful Asbestos Dust
Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inﬂate the tires above the recommended pressure. Never weld or heat a
wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally
weaken or deform the wheel.
When inﬂating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of
or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Section 00 page 12
Asbestos Dust
Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers
may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and
some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is
not hazardous as long as airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When
servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a
mist of oil or water on the material containing asbestos.
Keep bystanders away from the area.

Section 00 page 13
Use Proper Tools
Practice Safe Maintenance
Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts.
Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the
key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any
buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding
on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on
machine.

Section 00 page 14
Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners.
Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
Recycle Waste
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere
equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking
from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a
certified air conditioning service center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John
Deere dealer.
Live With Safety
Dispose of Waste Properly

Section 00 - GENERAL INFORMATION Group 0002: General Speciﬁcations
Section 00 page 15
Safety Systems
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all
guards and shields.

Item
A-Overall Height
A-Overall Height with Factory Installed Air Conditioning
B-Main Fairlead Roller Height
C-Auxiliary Position Fairlead Roller Height
D-Wheelbase
E-Overall Length
F-Front Axle to Articulation Joint
G-Front Axle to Front of Machine
H-Front Axle To Blade Cutting Edge Arc
I-Maximum Blade Dig Below Ground
J-Maximum Blade Lift Above Ground
Measurement
Height
Height
Height
Height
Length
Length
Distance
Distance
Distance
Depth
Height
Specification
3011 mm (9 ft 10.5 in.)
3229 mm (10 ft 7 in.)
2110 mm (6 ft 11.1 in.)
1925 mm (6 ft 3.8 in.)
2920 mm (9 ft 7 in.)
6330 mm (20 ft 9 in.)
1575 mm (5 ft 2 in.)
1507 mm (4 ft 11 in.)
2112 mm (6 ft 11.1 in.)
288 mm (11.3 in.)
1220 mm (3 ft 11.6 in.)
Group 0002: General Specifications
Section 00 page 16
Group 0002 - General Specifications
540G-II Skidder Dimensions
540G-II Skidder
→NOTE:
Specifications and design subject to change without notice. Whenever applicable, specifications are in
accordance with ICED and SAE standards. Except where otherwise noted, these specifications are based
on a unit with roll-over protective structure, full fuel tank, 80 kg (175 lb) operator, and standard
equipment.
→NOTE:
Sideview dimensions are for machine equipped with 28L-26 10 PR LS2 tires and adjustable log arch.

Tire-28L-26
Item
Tire-23.1-26
Tire-28L-26 (Narrow Gauge)
Tire-23.1-26 (Narrow Gauge)
Measurement
Ground Clearance
Wheel Tread
Overall Width
Ground Clearance
Wheel Tread
Overall Width
Ground Clearance
Wheel Tread
Overall Width
Ground Clearance
Wheel Tread
Overall Width
Speciﬁcation
498 mm (19.6 in.)
2.21 m (7 ft 3 in.)
2.79 m (9 ft 2 in.)
514 mm (20.2 in.)
2.28 m (7 ft 6 in.)
3 m (9 ft 10 in.)
498 mm (19.6 in.)
2.06 m (6 ft 9 in.)
2.64 m (8 ft 8 in.)
514 mm (20.2 in.)
2.18 m (7 ft 6 in.)
2.9 m (9 ft 6 in.)
Section 00 page 17
540G-II Skidder

Item
Forward Gear 1
Forward Gear 2
Forward Gear 3
Forward Gear 4
Forward Gear 5
Forward Gear 6
Forward Gear 7
With Standard Equipment
Rated Power @ 2200 rpm
Displacement
Cylinders
Fuel Consumption, Typical
Maximum Net Torque Rise
28L-26 Tire Size Turning Radius
Horizontal Roller
Vertical Rollers (Through Hardened Steel)
Without Air Conditioning
With Air Conditioning
With Air Conditioning and Special Work Lights
Battery
Hydraulic Pump Flow Rate @ 2200 rpm, 20 684 kPa (3,000 psi)
Spee
d
Spee
d
Spee
d
Spee
d
Spee
d
Measurement
Power
Weight
Amperage
Amperage
Amperage
Voltage
Volume
Quantity
Consumption
Torque
Radius
Diameter
Diameter
Flow Rate
Specification
2.3 km/h (1.4 mph)
3.1 km/h (1.9 mph)
4.1 km/h (2.5 mph)
5.4 km/h (3.4 mph)
7.3 km/h (4.5 mph)
9.6 km/h (6.0 mph)
14.3 km/h (8.9 mph)
65-amp alternator
95-amp alternator
135-amp alternator
Two 12-volt
9933 kg (21,990 lb)
89 kW (119 SAE net hp)
95 kW (127 SAE gross hp)
6.8 L (414 cu in.)
6
14-21 L/h (3.7-5.5 gal/hr)
39% @ 1400 rpm 537 N·m (398 lb-ft)
152 mm (6 in.)
114 mm (4.5 in.)
5.51 m (18 ft 1 in.)
102 L/min (27 gpm)
ENGINE: The PowerTech 6.8 liter engine is engineered and manufactured by John Deere. Replaceable wet-type cylinder liners provide superior heat dissipation. High
strength alloy cylinder heads have replaceable valve seat inserts for longer service life. Cast aluminum pistons provide good heat transfer while pistons are sprayed
with cooling oil for longer engine life. A high efficiency turbocharger maximizes engine performance.
Item Measurement Specification
TRANSMISSION: The eight forward and seven reverse speed direct drive powershift transmission is engineered and manufactured by John Deere specifically for
skidders. The transmission charge pump is externally mounted for ease of service.
AXLES: John Deere Team Mate II axles, 1200 Series, have heavy-duty inboard mounted planetary type gears that distribute shock loads evenly. Hydraulically applied
differential lock in both front and rear axles is standard.
BRAKES: Hydraulic annular style wet disk brakes are inboard mounted on both front and rear axles as standard equipment. Completely sealed running in a cooling oil
bath, they are self-adjusting, self-equalizing and require no periodic service. A spring applied hydraulically released wet multiple disk parking brake is transmission
mounted. It is automatically applied when the engine is off. It can be manually applied by placing the transmission control lever in the park position.
STEERING: A load and speed sensing power steering system provides quick response and power for easy maneuvering for woods operations. The 90° (45° each
direction) of frame articulation provides exceptional maneuverability.
HYDRAULICS: An axial piston pressure compensated pump forms the heart of the quick, responsive and powerful hydraulic system. The closed center hydraulic
system is separate from the transmission to enhance overall reliability of both systems.
Section 00 page 18
540G-II Skidder Specifications
Engine
Steering:
Hydraulics:
Cable Arch:
Electrical System:
Operating Weight:
Transmission, Axle and Brake
540G-II Skidder Travel Speeds
John Deere PowerTech ™ 6068T with Altitude-Compensating, Spark-Arresting Turbocharger
→NOTE:
Travel Speeds are at 2200 engine rpm, no tire slip, with 23.1-26 tire.

Item
Item
Fuel Tank
Cooling System
Engine Lubrication, Including Filter
Transmission
Differential (Front)
Differential (Rear)
Winch
Hydraulic Reservoir
Cab Tilt Pump System
Item
Forward Gear 8
Reverse Gear 1R
Reverse Gear 2R
Reverse Gear 3R
Reverse Gear 4R
Reverse Gear 5R
Reverse Gear 6R
Reverse Gear 7R
Bare Drum-4000 (8-in. Drum-Standard Speed)
Bare Drum-4000 (8-in Drum-Slow Speed)
Bare Drum-4000 (10-in Drum)
Full Drum-4000 (8-in. Drum-Standard Speed)
Full Drum-4000 (8-in. Drum-Slow Speed)
Full Drum-4000 (10-in. Drum)
Bare Drum-4000 (8-in. Drum-Standard Speed)
Bare Drum-4000 (8-in. Drum-Slow Speed)
Bare Drum-4000 (10-in. Drum)
Full Drum-4000 (8-in. Drum-Standard Speed)
Full Drum-4000 (8-in. Drum-Slow Speed)
Full Drum-4000 (10-in. Drum)
Measurement
Speed
Speed
Speed
Speed
Speed
Speed
Speed
Speed
Measurement
Capacity
Capacity
Capacity
Capacity
Capacity
Capacity
Capacity
Capacity
Capacity
Rate
Rate
Rate
Rate
Rate
Rate
Forc
e
Forc
e
Forc
e
Forc
e
Forc
e
Forc
e
Measurement
Specification
19.0 km/h (11.8 mph)
2.3 km/h (1.4 mph)
3.1 km/h (1.9 mph)
4.1 km/h (2.5 mph)
5.4 km/h (3.4 mph)
7.3 km/h (4.5 mph)
9.6 km/h (6.0 mph)
14.3 km/h (8.9 mph)
Specification
Specification
159 L (42 gal)
28.4 L (30 qt)
19 L (5 gal)
29.3 L (7.75 gal)
17.9 L (4.75 gal)
24.6 L (6.5 gal)
35.2 L (9.3 gal)
30.3 L (8 gal)
2 L (2 qt)
155 kN (34,786 lb)
180 kN (40,525 lb)
147 kN (32,985 lb)
95 kN (21,437 lb)
111 kN (24,974 lb)
111 kN (24,974 lb)
WINCH-4000 SERIES: The direct drive 4000 winch with wet multiple disc clutch and spring applied, hydraulically released brake is John Deere engineered and
manufactured. Low friction drum seals and an adjustable free spool feature increase operating ease. It is controlled by a single lever that has been conveniently
located for the operator.
8-in. Drum-15.8 mm (0.625 in.) CableCapacity77.4 m (254 ft)
8-in. Drum-25.4 mm (1 in.) CableCapacity30.5 m (100 ft)
10-in. Drum-19.1 mm (0.75 in.) CableCapacity43 m (141 ft)
10-in. Drum-25.4 mm (1 in.) CableCapacity23.8 m (78 ft)
44.5 m/min (146 fpm)
40.0 m/min (131 fpm)
47.9 m/min (157 fpm)
73.8 m/min (242 fpm)
66.4 m/min (218 fpm)
63.4 m/min (208 fpm)
Section 00 page 19
4000 Series Winch Specifications
540G-II Skidder Drain and Refill Capacities
→NOTE:
Cable capacity is calculated with no allowance made for loose or uneven spooling.
Line Speed @ 2,200 and 15.8 mm (0.625 in.) Cable
Linepull @ Peak Engine and 15.8 mm (0.625 in.) Cable

Item
A-Overall Boom Height
B-Overall Length
C-Overall Height
C-Overall Height with Factory Installed Air Conditioning
D-Maximum Blade Lift Above Ground
E-Maximum Blade Dig Below Ground
F-Front Axle to Front of Machine
G-Front Axle To Blade Cutting Edge Arc
H-Front Axle to Articulation Joint
I-Wheelbase
J-Reach of Grapple at Ground Level
K-Height of Grapple from Ground Level
Measurement
Height
Length
Height
Height
Height
Depth
Distance
Distance
Distance
Distance
Distance
Height
Specification
2991 mm (9 ft 10 in.)
6330 mm (20 ft 9 in.)
3010 mm (9 ft 10.5 in.)
3229 mm (10 ft 7.1 in.)
1210 mm (3 ft 11.6 in.)
288 mm (11.3 in.)
1507 mm (4 ft 11 in.)
2112 mm (6 ft 11.1 in.)
1575 mm (5 ft 2 in.)
2920 mm (9 ft 7 in.)
1970 mm (6 ft 5.6 in.)
864 mm (2 ft 10 in.)
Section 00 page 20
548G-II Skidder Dimensions
548G-II Grapple Skidder
→NOTE:
Specifications and design subject to change without notice. Whenever applicable, specifications are in
accordance with ICED and SAE standards. Except where otherwise noted, these specifications are based
on a unit with roll-over protective structure, full fuel tank, 80 kg (175 lb) operator, and standard
equipment.
→NOTE:
Sideview dimensions are for machine equipped with 28L-26 12 PR LS2 tires and adjustable log arch.

Tire-28L-26
Item
Tire-23.1-26
Tire-28L-26 (Narrow Gauge)
Tire-23.1-26 (Narrow Gauge)
Measurement
Ground Clearance
Wheel Tread
Overall Width
Ground Clearance
Wheel Tread
Overall Width
Ground Clearance
Wheel Tread
Overall Width
Ground Clearance
Wheel Tread
Overall Width
Speciﬁcation
498 mm (19.6 in.)
2.21 m (7 ft 3 in.)
2.79 m (9 ft 2 in.)
514 mm (20.2 in.)
2.29 m (7 ft 6 in.)
3 m (9 ft 10 in.)
498 mm (19.6 in.)
2.06 m (6 ft 9 in.)
2.64 m (8 ft 8 in.)
514 mm (20.2 in.)
2.18 m (7 ft 2 in.)
2.9 m (9 ft 6 in.)
Section 00 page 21
548G-II Grapple Skidder

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John Deere 540G-II 548G-II 640G-II 648G-II 748G-II Skidder Service Manual TM1694

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John Deere 540G-II 548G-II 640G-II 648G-II 748G-II Skidder Service Manual TM1694