John Deere JD540B Skidder and Grapple Skidder Repair Technical Manual (TM1139A)

John Deere JD540B Skidder and Grapple Skidder Repair Technical Manual (TM1139A)

Format: PDF (Printable Document)

File Language: English

File Pages: 772

File Size: 77.57 MB (Speed Download Link)

Brand: John Deere

Model: JD540B Skidder and Grapple Skidder

Book No: TM1139A

Type of Document: Repair Technical Manual

Categories: John Deere PDF, PDF

$ 40

John Deere JD540B Skidder and Grapple Skidder Repair Technical Manual (TM1139A)

Out in the bush or a muddy landing, the JD540B skidder earns its keep dragging wood all day, and this repair manual is what I’d pull when something stops that production. TM1139A helps you trace faults, strip components correctly, and put them back together so the machine will pull straight and clamp reliably again. For example, if the grapple won’t hold a load or the winch starts slipping under strain, this is the book I’d use to verify adjustments, inspect wear points, and confirm I’m reassembling everything to factory intent.

Applications & Use Cases

Diagnosing hydraulic issues when the boom, blade, or grapple moves slow, chatters, or won’t hold position.
Chasing drivetrain problems like weak pulling power, unusual noises, or vibration under load.
Guiding major teardown work on axles, winch, or steering so parts are removed, inspected, and reinstalled in the right order.
Verifying linkages and controls after replacing cables, valves, or cylinders to ensure full travel and proper response.
Identifying parts in assemblies so you order the correct seals, bearings, and hardware before a downtime repair.

FAQ

Q: Can I use this manual on a tablet in the field?

A: Yes, it’s practical to keep a digital copy on a tablet or laptop so you can zoom diagrams and search procedures right at the machine.

Q: Is it still worth printing pages from this manual?

A: Definitely—most techs print the few pages they need for a job so they can mark notes, take them under the machine, and not worry about getting them dirty.

Safety Note

Always lock out the machine, support it securely, and bleed off stored pressure before following any repair steps from this manual.

📘 Show Index

John Deere JD540B Skidder and Grapple Skidder Index:

Contents
Introduction
General Information
- General Specificatiions
- Predelivery, Delivery, And After-Sale Services
- Lubrication
Wheels
- Powered Wheels And Fastenings
  - General Inforamtion
  - Removal
  - Repair
  - Installation
- Weights
  - General Information
  - Removal
  - Repair
  - Installation
- Specifications And Special Tools
  - Specifications And Torque Values
    - Powered Wheels and Fastenings
    - Wheel Weights
  - Special Tools Powered Wheels and Fastenings
Axles And Suspension Systems
- Drive Axle Housing And Support
  - General Information
  - Removal
  - Repair
  - Installation
- Differential Or Bevel Drive
  - General Information
  - Removal
  - Repair
    - Differential Case
    - Differential Assembly
    - Differential Spiral Bevel Pinion Shaft
  - Adjustments
    - Cone Point
    - Pinion Shaft Rolling Torque
    - Differential Preload
    - Differential Backlash
    - Tooth Bearing Pattern
  - Testing
    - Leakage Pressure Test with Air
    - Leadage Test with Oil
  - Installation
  - Front Differential End Play Adjustment
  - Differential Lock Valve
    - General Information
    - Removal
    - Repair
    - Installation
- Input Drive Shafts And U-Joints
  - General Information
  - Removal
  - Repair
  - Installation
- Axle Shaft, Bearings, Reduction Gears
  - General Information
  - Removal
  - Repair
  - Assembly
  - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Drive Axle Housing And Support
    - Differential Or Bevel Drive
    - Input Drive Shafts And U-Joints
    - Axle Shaft, Bearings, Reduction Gears
  - Special Tools-Input Drive Shafts and U-Joints
Transmission
- Controls
  - Clutch Valve Linkage
  - Transmission Control Valve Shift Linkage
- Housings And Covers
  - General Information
  - Transfer Case
    - Removal
    - Repair
    - Installation
  - Clutch Housing And Transmission Case
    - Removal
    - Repair
    - Installation
- Gears, Shafts, Bearings And Power Shift Clutch
  - General Information
  - Removal
  - Repair
    - Auxiliary Drive Shaft and Transmission Drive Shaft
    - Clutch Pack Assembly
    - Low- and High-Range Drive Shafts
    - Planetary Pack Assembly
  - Installation
  - Transfer Drive
    - Removal
    - Repair
    - Installation
- Hydraulic System
  - Transmission Oil Pump
    - General Information
    - Removal
    - Disassembly
    - Inspection
    - Assembly
    - Installation
  - Transmission Oil Filter
    - General Information
    - Removal
    - Repair
    - Installation
  - Transmission Clutch Valve
    - General Information
    - Removal
    - Disassembly
    - Inspection
    - Assembly
    - Adjustment
    - Installation
  - Transmission Oil Pressure Regulating Valve
    - General Information
    - Removal
    - Repair
    - Installation
    - Adjustment
  - Transmission Control Valve Assembly
    - Transmission Control Valve
      - General Information
      - Removal
      - Disassembly
      - Inspection
      - Assembly
      - Installation
    - Transmission Shift Valve
      - General Information
      - Removal
      - Repair
      - Adjustment
      - Installation
- Clutch Disconnect And Controls
  - General Information
  - Clutch Controls
    - Removal
    - Repair
    - Installation
  - Clutch Elements
    - Removal
    - Repair
    - Installation
- Specifications And Special Tools
  - Specifications and torque Values
    - Housings And Covers
    - Gears, Shafts, Bearings And Powere Shift Clutch
    - Hydraulic System
    - Clutch Disconnect And Controls
  - Special Tools
    - Gears, Shafts, Bearings and Power Shift Clutch
    - Clutch Disconnect and Controls
Engine
- Engine Removal And Installation
  - Remove
  - Installation
- Crankshaft And Main Bearings
  - Crankshaft And Main Bearings
    - General Inforamtion
    - Removal
    - Repair
    - Installation
  - Crankshaft Rear Oil Seal and Wear Ring
    - Removal
    - Installation
- Camshaft And Valve Actuating Means
  - General Information
  - Valve Lift Check
  - Camshaft Removal
  - Repair
  - Installation
- Connecting Rods And Pistons
  - General Information
  - Removal
  - Repair
  - Installation
- Cylinder Block
  - General Information
  - Removal
  - Repair
  - Installation
- Oiling System
  - General Information
  - Oil Pump
    - Removal
    - Repair
    - Installation
  - Oil Pressure Regulating Valve
    - Removal
    - Disassembly
    - Assembly
    - Installation
  - Dipstick
- Ventilating System
  - General Information
  - Removal
  - Repair
  - Installation
- Cylinder Head And Valves
  - General Information
  - Removal
  - Repair
  - Assembly
  - Installation
- Exhaust Manifold
  - General Information
  - Removal
  - Repair
  - Installation
- Fuel Injection System
  - Fuel Injection Pump
    - General Information
    - Removal
    - Repair
    - Installation And Timing
    - Bleeding
  - Fuel Injection Nozzles
    - General Information
    - Removal
    - Repair
    - Installation
- Engine Balancer
  - General Information
  - Removal
  - Repair
  - Installation
- Turbocharger
  - General Information
  - Removal
  - Repair
  - Installation
- Water Pump
  - General Information
  - Removal
  - Repair
  - Installation
- Thermostats, Housings, And Water Piping
  - General Information
  - Removal
  - Repair
  - Installation
- Oil Cooler
  - General Information
  - Removal
  - Repair
  - Installation
- Fuel Filter
  - General Information
  - Removal
  - Repair
  - Installation
- Fuel Transfer Pump
  - General Information
  - Removal
  - Repair
  - Installation
- Starting Motor And Fastenings
  - Starting Motor
    - General Information
    - Removal
    - Testing and Diagnosis
    - Repair
    - Installation
- Flywheel, Housing and Fastenings
  - General Information
  - Removal
  - Repair
  - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Engine Break-In
    - Crankshaft And Main Bearings
    - Camshaft And Valve Actuating Means
    - Connecting Rods And Pistons
    - Cylinder Block
    - Oiling System
    - Cylinder Head And Valves
    - Exhaust Manifold
    - Fuel Injection System
    - Engine Balancer
    - Turbocharger
    - Water Pump
    - Thermostats, Housings And Water Piping
    - Oil Cooler
    - Starting Motor And Fastenings
    - Flywheel, Housing And Fastenings
  - Special Tools
    - Engine Removal And Installation
    - Crankshaft And Main Bearings
    - Camshaft And Valve Actuating Means
    - Connecting Rods And Pistons
    - Cylinder Block
    - Cylinder Head And Values
    - Fuel Injection System
    - Engine Balancer
    - Turbocharger
    - Water Pump
    - Starting Motor And Fastenings
Engine Auxiliary Systems
- Cold Weather Starting Aids
  - General Information
  - Skidders Without Cab
    - Removal
    - Repair
    - Installation
  - Skidders With Cab
    - Removal
    - Repair
    - Installation
  - All Skidders Engine Coolant Heater
    - Removal
    - Repair
    - Installation
- Cooling Systems
  - General Information
  - Removal
  - Repair
  - Installation
- Speed Controls
  - General Information
  - Removal
  - Repair
  - Installation
- Intake System
  - General Information
  - Removal
  - Repair
  - Installation
- External Exhaust Systems
  - General Information
  - Removal
  - Repair
  - Installation
- Mounting Frame
  - General Information
  - Removal
  - Repair
  - Installation
- External Fuel Supply Systems
  - General Information
  - Removal
  - Repair
  - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Cold Weather Starting Aids
    - Cooling Systems
    - Speed Controls
    - External Exhaust System
    - External Fuel Supply Systems
Steering System
- Emergency Steering
  - Emergency Steering Accumulator
    - General Information
    - Removal
    - Repair
    - Installation
  - Emergency Steering Low Pressure Warning Switch
    - General Information
    - Repair
- Hydraulic System
  - Steering Valve ( -400571)
    - General Information
    - Removal
    - Repair
    - Installation
  - Steering Valve(400572- )
    - Removal
    - Repair
    - Installation
  - Steering Cylinders
    - Removal
    - Repair
    - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Emergency Steering
    - Steering Valve ( -400571)
    - Steering Valve (400572- )
    - Steering Cylinder
  - Special Tools
    - Steering Valve
    - Emergency Steering Accumulator
Service Brakes
- Active Elements
  - General Information
  - Removal
  - Repair
  - Installation
- Controls Linkage
  - Removal
  - Repair
  - Assembly
  - Adjustment
  - Brake Pedal Test
- Hydraulic System
  - Brake Valve
    - General Information
    - Removal
    - Repair
    - Installation
    - Bleeding
  - Brake Accumulator
    - General Information
    - Removal
    - Repair
    - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Hydraulic System
  - Special Tools
    - Hydraulic system
Parking-Emergency Brakes
- Active Elements
  - General Information
  - Removal
  - Repair
  - Installation
- Controls Linkage
  - General Information
  - Removal
  - Repair
  - Installation
  - Adjustment
- Specifications And Special Tools
  - Specifications and Torque Values
    - Active Elements
    - Control Linkage
Electrical System
- Batteries, Supports And Cables
  - General Information
  - Removal
  - Inspection
  - Testing
  - Charging
  - Installation
- Alternator, Regulator And Charging System Wiring
  - General Information
  - Removal
  - Repair
  - Assembly
  - Tests After Assembly
  - Installation
- Lighting System
  - General Information
  - Removal
  - Repair
  - Installation
- Wiring Harnesses and Switches
  - Wiring Harness
    - General Information
  - Circuit Protectors
    - Main Circuit Breaker
      - General Information
      - Removal
      - Repair
      - Installation
    - Fuses
      - General Information
      - Repair
    - Start Circuit Relay
      - General Information
      - Removal
      - Repair
      - Installation
    - Switches
      - General Information
      - Removal
      - Repair
      - Installation
- Instruments And Indicators
  - General Information
  - Removal
  - Repair
  - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Batteries, Supports And Cables
    - Alternator, Regulator And Charging System Wiring
    - Lighting System
    - Wiring Harness And Switches
    - Instruments And Indicators
  - Special Tools
    - Batteries, Supports And Cables
    - Alternator, Regulator And Charging System Wiring
Frame, Chassis, Or Supporting Structure
- Frame Installation
  - Engine Frame
    - General Information
    - Separation
    - Repair
    - Joining
  - Equipment Frame
    - General Information
    - Separation
    - Repair
    - Joining
  - Frame Locking Bar
- Frame Bottom Guards
  - General Information
  - Removal
  - Repair
  - Installation
- Specifications And Special Tools
  - Frame Installation
  - Frame Bottom Guards
Operator’s Station
- Special Noise Control Items
  - ROPS Canopy with Windshield
  - ROPS Enclosed Cab
- Operator Enclosure
  - ROPS Canopy
    - General Informatioon
    - Removal
    - Repair
    - Installation
  - Platform
  - ROPS Enclosed Cab
  - ROPS Canopy with Windshield
- Seat
  - General Information
  - Removal
  - Repair
  - Installation
- Heating And Air Condtioning
  - General Information
  - Removal
  - Repair
  - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Operator Enclosure
    - Seat
Sheet Metal
- Hood Or Engine Enclosure
  - Engine side Shields
    - Removal
    - Repair
    - Installation
  - Hood
    - Removal
    - Repair
    - Installation
  - Cowl and Vandal Cover
    - Removal
    - Repair
    - Installation
- Grille And Grille Housing
  - Removal
  - Repair
  - Installation
Safety, Convenience And Miscellaneous
- Fire Extinguisher
  - Hand Held Fire Extinguisher
    - General Information
    - Repair
    - Installation
  - Fire Suppression System
    - General Information
    - Sensors
      - General Information
      - Removal
      - Repair
      - Installation
    - Tubes And Nozzles
      - Removal
      - Repair
      - Installation
    - System Recharging
    - System Testing
- Horn
  - General Information
  - Removal
  - Repair
  - Installation
- Cigar Lighter
  - General Information
  - Removal
  - Repair
  - Installation
Hydraulic System
- Hydraulic System
  - General Information
  - 3.00 In. (49 cm) Hydraulic Pump And Stroke Control Valve (Without Pump Serial Number Plate)
    - Removal
    - Repair
    - Assemble Pump Housing
    - Disassemble And Inspect Stroke Control Valve Assembly
    - Assemble Stroke Control Valve Assembly
    - Installation
  - 4.00 Cubic Inch (66 cm) Hydraulic Pump And Stroke Control Valve (Without Pump Serial Number Plate)
    - Removal
    - Repair
    - Assemble Pump Housing
    - Disassemble And Inspect Stroke Control Valve Assembly
    - Assembly Stroke Control Valve Assembly
    - Installation
  - (3 in.) 50cm Hydraulic Pump And Stroke Control Valve (with Pump Serial Number Plate)
    - Removal
    - Repair
    - Assemble Pump Housing
    - Disassemble And Inspect Control Valve Assembly
    - Assemble Stroke Control Valve Assembly
    - Installation
  - Pump Drive Assembly
    - Removal
    - Repair
    - Installation ( -267530)
    - Installation (267631- )
  - Hydraulic Manifold
    - Removal
    - Repair
    - Installation
  - Pressure Control Valve
    - General Information
    - Removal
    - Repair
    - Installation
  - Hydraulic System Filters
    - Removal
    - Repair
    - Installation
  - Oil Cooler
    - General Information
  - O-Ring Boss Fitting Service Recommendations
  - Tube and Hose fitting, 37° Flare and 30° Cone Seat connector Service Recommendations
  - SAE Four Bolt Flange Fitting Service Recommendations
- Specifications And Special Tools
  - Specifications and Torque Values
    - 3 in.³ (49 cm³) and 4 in.³ (66 cm³) Hydraulic Pump and Stroke Control Valve (Without Serial Number Plate)
    - 3 in.³ (50 cm³) Hydraulic Pump and Stroke control Valve (With Serial Number Plate)
    - Pump Drive Assembly
    - Hydraulic Manifold
    - Pressure Control Valve
    - Hydraulic Filters
  - Special Tools
    - Essential Tools
    - Convenience Tools
Winch
- Winch Housing And Mounting Structure
  - General Information
  - Winch Removal
  - Winch Drum
    - Removal
    - Repair
    - Installation
  - Winch Housing
    - Removal
    - Repair
    - Adjustment
  - Winch Installation
- Winch Drive And Clutches
  - General Information
  - Brake Band Assembly
    - Removal
    - Repair
    - Adjustment
      - Brake Band
      - Burnishing New Brake Facings
      - Brake Band Support Cap Screw
      - Free Spool
    - Installation
  - Brake And Clutch Assembly
    - Removal
    - Repair
    - Installation
  - Main Drive Shaft, Ring Gear and Pinion
    - General Information
    - Removal
    - Repair
    - Adjustment
      - Cone Point
      - Pinion Shaft Bearing Preload
      - Ring Gear and Pinion Backlash
    - Installation
  - Input And Idler Shafts
    - Removal
    - Repair
    - Adjustment
    - Installation
- Hydraulic System
  - General Information
  - Removal
  - Repair
  - Installation
  - Adjustment
- Specifications And Speciial Tools
  - Specifications and Torque Values
    - Winch Housing And Mounting Structure
    - Winch Drive And Clutches
    - Hydraulic System
  - Special tools
    - Winch Drive And Clutches
Bulldozers
- Blades
  - General Information
  - Removal
  - Repair
  - Installation
- Controls Linkage
  - General Information
  - Removal
  - Repair
  - Installation
  - Adjustment
- Hydraulic System
  - Blade Control Valve
    - General Information
    - Removal
    - Repair
    - Installation
  - Blade Lift Cylinder
    - General Information
    - Removal
    - Repair
    - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Hydraulic System
  - Special Tools
    - Hydraulic System
Arch Or Boom, Or Cranes
- Frames
  - Log Arch
    - General Information
    - Removal
    - Repair
    - Installation
- Specifications And Special Tools
  - Frames
Grapple
- Grapple Mechanism
  - General Information
  - Removal
  - Repair
  - Installation
  - Fairlead
- Control Linkage
  - General Information
  - Removal
  - Repair
  - Installation
  - Adjustment
- Frames
  - Grapple Boom ( -405039)
    - General Information
    - Removal
      - Boom Assembly
      - Rotate Shaft
    - Repair
      - Boom Assembly
      - Rotate Shaft
    - Installation
      - Boom Assembly
      - Rotate Shaft
  - Grapple Boom 405040- )
    - Removal
      - Boom Assembly
      - Rotate Shaft
    - Repair
      - Boom Assembly
      - Rotate Shaft
    - Installation
      - Boom Assembly
      - Rotate Shaft
  - Fairlead
    - Removal
    - Repair
    - Installation
- Hydraulic System
  - Grapple Control Valve
    - General Information
    - Removal
    - Disassembly
    - Inspection
    - Installation
  - Relief Valve
    - Removal
  - Rotate ( -266120) Ross Motor
    - General Information
    - Removal
    - Repair
    - Installation
  - Rotate Motor (266121- )
    - General Information
    - Removal
    - Testing
    - Repair
    - Installation
  - Crossover Relief Valve
    - General Information
    - Removal
    - Repair
    - Installation
  - Rotary Manifold
    - General Information
    - Removal
    - Repair
    - Installation
  - Grapple Cylinders
    - General Information
    - Removal
    - Repair
    - Installation
  - Boom Cylinders
    - General Information
    - Removal
    - Repair
    - Installation
- Specifications And Special Tools
  - Specifications and Torque Values
    - Frames
    - Hydraulic System
PTO Or Winch Drive
- Input Drive Shafts
  - Removal
  - Repair
  - Installation
- Gears, Shafts and Bearings
  - Removal
  - Repair
  - Installation
- Specifications and Special Tools
  - Specifications and Torque Values
    - Input Drive Shafts