60D Excavator *OMT244925* OPERATOR'S MANUAL OMT ISSUE A3 (ENGLISH) CALIFORNIA Proposition 65 Warning

Transcription

1 60D Excavator *OMT244925* OPERATOR'S MANUAL 60D Excavator OMT ISSUE A3 (ENGLISH) CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. If this product contains a gasoline engine: WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. The State of California requires the above two warnings. Additional Proposition 65 Warnings can be found in this manual. Worldwide Construction And Forestry Division LITHO IN U.S.A.

2 Introduction Foreword READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.) THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it. MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench. RIGHT-HAND AND LEFT-HAND sides are determined by facing in the direction of forward travel. WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the machine. WARRANTY is provided as part of John Deere's support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate or statement which you should have received from your dealer. This warranty provides you the assurance that John Deere will back its products where defects appear within the warranty period. In some circumstances, John Deere also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action. THE TIRE MANUFACTURER'S warranty supplied with your machine may not apply outside the U.S. If you are not the original owner of this machine, it is in your interest to contact your local John Deere dealer to inform them of this unit's serial number. This will help John Deere notify you of any issues or product improvements. DX,IFC APR09-1/1 PN=2

3 Introduction Emission Control Statement EMISSIONS CONTROL WARRANTY STATEMENT FOR NEW JOHN DEERE CONSTRUCTION EQUIPMENT (U.S. AND CANADA) To determine if the engine in your machine qualifies for the additional warranties set forth below, look for the "Engine Information" label located on your engine. If you reside in the United States and the engine label states: "Engine conforms to US EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control Warranty Statement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy duty non road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement." U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT Emissions control-related parts and components are warranted by John Deere for five years or 3000 hours of operation, whichever occurs first. John Deere further warrants that the engine covered by this warranty was designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards at the time of manufacture, and that it is free of defects in materials and workmanship which would cause it not to meet these standards within the period of five years or 3000 hours of operations, whichever occurs first. Warranties stated on this certificate refer only to emissions-related parts and components of your engine. The complete machine warranty, less emisions-related parts and components, is provided separately as "John Deere "Secure Warranty" For New Construction Products." CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and John Deere are pleased to explain the emission control system on your new engine. In California, new heavy-duty engines must be designed, built and equipped to meet the State's stringent anti-smog standards. John Deere must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, or improper maintenance of your machine. Your emissions control system includes: Fuel Metering System Fuel Injection System Air Induction System Intake Manifold Turbocharger System Charge Air Cooling System Miscellaneous Items used in Above Systems Where a warrantable condition exists, i.e. failure due to defect in John Deere-supplied material and/or workmanship, John Deere will repair your heavy-duty engine at no cost to you including diagnosis, parts and labor JOHN DEERE'S WARRANTY COVERAGE: The emission control system of your heavy-duty engine is warranted for five years or 3000 hours of operation, whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or replaced by John Deere. Warranties stated on this certificate refer only to emissions-related parts and components of your engine. The complete machine warranty, less emissions-related parts and components, is provided separately as the "John Deere "Secure Warranty" For New Construction Products." OWNER'S WARRANTY RESPONSIBILITIES: As the heavy-duty engine owner, you are responsible for the performance of the required maintenance as outlined in the Operator's Manual. John Deere recommends that you retain all receipts covering maintenance on your heavy-duty engine, but John Deere cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. However, as the heavy-duty engine owner, you should be aware that John Deere may deny you warranty coverage if your heavy- duty engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California's emissions requirements. You are responsible for initiating the warranty process. The CARB suggests that you present your machine to the nearest authorized John Deere dealer as soon as a problem is suspected. The warranty repairs should be completed by the service dealer as expeditiously as possible. If you have any questions regarding your warranty rights and responsibilities, you should contact John Deere at , or the State of California Air Resources Board, Mobile Source Operation Division, PO Box 8001, El Monte, CA The warranty period begins on the date the machine is delivered to an ultimate purchaser, or when otherwise put into service. John Deere warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board, and that it is free from defects in materials and workmanship which would cause the failure of a warranted part. Any warranted part which is scheduled for replacement as required maintenance by the operator's manual is warranted by John Deere for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement point, the part shall be repaired or replaced under warranty. Any such part repaired or replaced under warranty is warranted for the remainder of the period prior to the first scheduled replacement point for that part. Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of repairing or replacing as necessary, is warranted for the warranty period. Repair or replacement of a warranted part will be performed at no charge to you by an authorized John Deere dealer. You will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed by a John Deere dealer. John Deere is liable for damages to other engine components caused by failure under warranty of any warranted part. John Deere is NOT liable for travel or mileage on extended emissions warranty service calls. Any replacement part may be used in the performance of any maintenance or repairs, and such use will not reduce the warranty obligations of John Deere. However, the use of add-on or modified parts are grounds for disallowing a warranty claim. T JUN00 OUO1065,000006C JAN08-1/1 PN=3

4 Introduction Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO: John Deere Dubuque Works South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA USA FAX NUMBER: (USA) Publication Number: Page Number: Ideas, Comments: Name: Phone: Address: THANK YOU! TX,TM,FAX JUL01-1/1 PN=4

5 Contents Page Safety Safety and Operator Conveniences Safety and Operator Convenience Features Safety General Precautions Recognize Safety Information Follow Safety Instructions Operate Only If Qualified Wear Protective Equipment Avoid Unauthorized Machine Modifications Add Cab Guarding for Special Uses Inspect Machine Stay Clear of Moving Parts Avoid High-Pressure Fluids Avoid High-Pressure Oils Beware of Exhaust Fumes Prevent Fires Prevent Battery Explosions Handle Chemical Products Safely Dispose of Waste Properly Prepare for Emergencies Safety Operating Precautions Use Steps and Handholds Correctly Start Only From Operator's Seat Use and Maintain Seat Belt Prevent Unintended Machine Movement Avoid Work Site Hazards Keep Riders Off Machine Avoid Backover Accidents Avoid Machine Tip Over Use Special Care When Lifting Objects Add and Operate Attachments Safely Safety Maintenance Precautions Park and Prepare for Service Safely Service Cooling System Safely Remove Paint Before Welding or Heating Make Welding Repairs Safely Drive Metal Pins Safely Safety Safety Signs Safety Signs Operation Operator's Station Pedals, Levers, and Panels Monitor Panel and Functions (S.N ) Page Monitor Panel and Functions (S.N ) Switch Panel and Functions (S.N ) Switch Panel and Functions (S.N ) Key Switch Horn Engine Speed Control Knob Pilot Control Shutoff Lever Travel Alarm and Travel Alarm Cancel Switch (S.N ) Cab Heater and Air Conditioner Setting Trip Meters (S.N ) Operating AM/FM Radio Secondary Exit Tool Opening Front Upper (Secondary Exit) Window Removing Lower Front Window Opening Cab Window Door Release Lever Adjusting Operator's Seat Operation Operating the Machine Before Starting Work Operator's Daily Machine Check Before Starting Starting the Engine Cold Weather Warm-Up Travel Pedals and Levers Control Lever Pattern Operation Control Lever Pattern Conversion Operating Angle Blade If Equipped Operating Backfill Blade Operating Tips Backfill Blade Auxiliary Pedal If Equipped (S.N ) Auxiliary Function Lever Switch If Equipped (S.N ) Positioning Auxiliary Line Selector Valve Operating In Water and Mud Driving Up a Steep or Slippery Slope Lifting Lowering Boom With Engine Stopped Parking Machine Loading and Unloading for Transport Towing Machine Lifting Machine Continued on next page Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT 2013 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 2008, 2009, 2011, 2012 i PN=1

6 Contents Page Maintenance Machine Diesel Fuel Biodiesel Fuel Testing Diesel Fuel Handling and Storing Diesel Fuel Alternative and Synthetic Lubricants Diesel Engine Oil Diesel Engine Oil and Filter Service Intervals Hydraulic Oil Swing Gearbox and Travel Gearbox Oils Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease Heavy Duty Diesel Engine Coolant Drain Intervals for Diesel Engine Coolant John Deere COOL-GARD II Coolant Extender Supplemental Coolant Additives Operating in Warm Temperature Climates Additional Information About Diesel Engine Coolants and John Deere COOL-GARD II Coolant Extender Testing Diesel Engine Coolant Maintenance Periodic Maintenance Service Machine at Specified Intervals Check the Hour Meter Regularly Prepare Machine for Maintenance Opening Access Doors and Covers for Service Tilting the Operator Station Fuel Tank Checking Washer Fluid Level Hydraulic Breaker and Crusher Attachments Maintenance and Repair Record Keeping System Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit Service Intervals Required Parts Maintenance As Required Cleaning Air Cleaner Element Cleaning Radiator Core and Oil Cooler Check Coolant Maintenance Every 10 Hours or Daily Checking Engine Oil Level Checking Hydraulic Oil Tank Level Draining Fuel Tank Sump Draining Water Separator Checking Recovery Tank Coolant Level Checking Bucket Teeth Checking Track Sag Rubber Track Checking Track Sag Steel Track If Equipped Adjusting Track Sag Page Use and Maintain Seat Belt Maintenance Initial Service 50 Hours Lubricate Bucket and Link Pins Lubricate Front Joint Pins Check and Adjust Fan Belt Tension Maintenance Every 100 Hours Lubricate Bucket and Link Pins Lubricate Front Joint Pins Check and Adjust Fan Belt Tension Maintenance Initial Service 250 Hours Replacing Hydraulic Oil Tank Filter Maintenance Every 250 Hours Lubricate Swing Bearing Lubricate Tilt Mechanism Lubricate Angle Blade Bottom and Rod Pins If Equipped Checking Travel Gear Case Oil Level Draining Hydraulic Oil Tank Sump Take Engine Oil Sample Maintenance Every 500 Hours Changing Engine Oil and Replacing Filter Lubricate Front Joint Pins Lubricate Swing Bearing Gear Lubricate Control Lever Universal Joint Replacing Final Fuel Filter Lubricate Blade Pins Lubricate Center Pin If Equipped Replace Air Cleaner Elements and Dust Valve Take Fluid Samples Maintenance Every 1000 Hours Check Coolant Changing Travel Gearbox Oil Replacing Pilot System Oil Filter Checking and Adjusting Engine Valve Lash (Clearance) Checking Starter and Alternator Inspecting Crankcase Breather System Maintenance Every 2000 Hours Draining Cooling System Heavy Duty Diesel Engine Coolant Cooling System Fill and Deaeration Changing Hydraulic Tank Oil Miscellaneous Machine Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump Do Not Service Control Valves, Cylinders, Pumps, or Motors Continued on next page ii PN=2

7 Contents Page Cleaning Fuel Tank Inlet Screen Check Cab Fresh Air Filter Check Cab Recirculating Air Filter Check Air Intake Hoses Clean Air Cleaner Dust Valve Replace Water Separator Element Prime Fuel System Precautions for Alternator and Regulator Checking Starter and Alternator Check Battery Electrolyte Level and Terminals Handling, Checking, and Servicing Batteries Carefully Using Battery Charger Replacing the Battery Using Booster Batteries 12-Volt System Welding On Machine Clean Machine Regularly JDLink Machine Monitoring System (MMS) If Equipped JDLink Machine Monitoring System (MMS) Direct Laptop Connection If Equipped Replacing Fuses Replacing Bucket Teeth Replacing Bucket Tooth Tip Heavy-Duty Bucket Removing Bucket Track Sag General Information Checking Track Shoe Hardware Unified Inch Bolt and Screw Torque Values Metric Bolt and Screw Torque Values Bleed Hydraulic System Volt Auxiliary Power Outlet Cleaning Air Conditioning Condenser and Screens Installing Bucket With Quick Coupler Rubber Track Care Removing and Installing Rubber Track Converting the Track Page Miscellaneous Specifications Engine Specifications Drain and Refill Capacities Machine Specifications Working Ranges Lift Capacity Standard 1.50 m (4 ft 11 in.) Arm Lift Capacity Long 1.85 m (6 ft 1 in.) Arm Miscellaneous Operational Checkout Operational Checkout Miscellaneous Troubleshooting Using Troubleshooting Charts Engine Electrical System Hydraulic System Miscellaneous Storage Prepare Machine for Storage Monthly Storage Procedure Miscellaneous Serial Numbers Record Product Identification Number (PIN) Record Engine Serial Number Keep Proof of Ownership Keep Machines Secure iii PN=3

8 Contents iv PN=4

9 Safety Safety and Operator Conveniences Safety and Operator Convenience Features TX UN 13JUN08 Please remember that the operator is the key to preventing accidents. 1. Cab with Heater/Defroster/Air Conditioner. Circulates both outside and inside air through filters for a clean working environment. Built in defroster vents direct air flow for effective window defogging/deicing. 2. Seat Belt. A retractable seat belt is provided for the operator. 3. Pilot Control Shutoff. A lever near the cab exit reminds the operator to deactivate hydraulic functions before leaving the machine and prevents engine start-up unless lever is in locked position. 4. Handholds. Large, conveniently placed handholds make it easy to enter or exit the operator's station or service area. 5. Hydraulic Hose Protection. Covered hoses in swing area improve durability and protect the operator. 6. Swing Brake. Swing brake is engaged when the pilot control shutoff lever is raised. Helps secure upperstructure when transporting the machine. 7. Travel Alarm. Alerts bystanders of machine movement when travelling. 8. Fan Guard. A fan guard inside the engine compartment helps prevent contact with the fan blades. 9. Horn. Standard horn in useful when driving or signaling co-workers. 10. Frame Work Light. Light alerts bystanders that machine is running when lit. 11. Boom Work Light. Light provides additional illumination to work area. ER93822,000014A FEB12-1/ PN=9

10 Safety General Precautions Recognize Safety Information This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word DANGER, WARNING, or CAUTION is used with the safety alert symbol. DANGER identifies the most serious hazards. On the machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels. T UN 28AUG00 T AUG00 TX03679,00016CC JAN07-1/1 Follow Safety Instructions Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Be sure all operators of this machine understand every safety message. Replace operator's manual and safety labels immediately if missing or damaged. T UN 24AUG00 TX03679,00016F JAN07-1/1 Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruction. Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to every work situation and work site. TX03679,00016FA JAN07-1/ PN=10

11 Safety General Precautions Wear Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. TS206 UN 23AUG88 TX03679,00016D JAN07-1/1 Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or failures resulting from their use are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability. AM40430,00000A AUG09-1/1 Add Cab Guarding for Special Uses Special work situations or machine attachments may create an environment with falling or flying objects. Working near an overhead bank, doing demolition work, using a hydraulic hammer, or working in a wooded area, for example, may require added guarding to protect the operator. FOPS (falling object protective structures) and special screens or guarding should be installed when falling or flying objects may enter or damage the machine. Contact your authorized dealer for information on devices intended to provide protection in special work situations. TX14740,0001EF JAN07-1/1 Inspect Machine Inspect machine carefully each day by walking around it before starting. Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring. T6607AQ UN 18OCT88 TX03679, JAN07-1/ PN=11

12 Safety General Precautions Stay Clear of Moving Parts Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete. T UN 12SEP01 TX03679,00016D JAN07-1/1 Avoid High-Pressure Fluids Inspect hydraulic hoses periodically at least once per year for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts. 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 in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling or X9811 UN 23AUG88 DX,FLUID OCT11-1/1 Avoid High-Pressure Oils This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury. Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system. If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A. T UN 17MAR06 T UN 20SEP00 TX03679,00016D NOV08-1/ PN=12

13 Safety General Precautions Beware of Exhaust Fumes Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area. T UN 24AUG00 TX03679,00016D NOV08-1/1 Prevent Fires Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment. Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly. T UN 07SEP00 T UN 07SEP00 T UN 14SEP00 TX03679,00016F NOV08-1/1 Prevent Battery Explosions Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16 C (60 F). TS204 UN 23AUG88 TX03679,000174A NOV08-1/ PN=13

14 Safety General Precautions Handle Chemical Products Safely Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous. If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to internet website The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely. T UN 25AUG00 TX03679,00016D JAN07-1/1 Dispose of Waste Properly Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly. Never pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more information. T UN 25AUG00 TX03679, JAN07-1/1 Prepare for Emergencies Be prepared if an emergency occurs or 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. TS291 UN 23AUG88 TX03679,000174B JAN07-1/ PN=14

15 Safety Operating Precautions Use Steps and Handholds Correctly Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine. T UN 30AUG00 TX03679,00016F MAR07-1/1 Start Only From Operator's Seat Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals. T UN 07SEP00 TX03679, APR10-1/1 Use and Maintain Seat Belt Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly. The complete seat belt assembly should be replaced every 3 years, regardless of appearance. T SEP00 TX03679,00016DD NOV08-1/1 Prevent Unintended Machine Movement Be careful not to accidentally actuate control levers when co-workers are present. Pull pilot control shutoff lever (1) to locked position during work interruptions. Pull pilot control shutoff lever to locked position and stop engine before allowing anyone to approach machine. Always lower work equipment to the ground and pull pilot control shutoff lever to locked position before standing up or leaving the operator's seat. Stop engine before exiting. 1 Pilot Control Shutoff Lever 2 Console 3 Pilot Control Levers T UN 03DEC04 OUO1032,00015D JAN07-1/ PN=15

16 Safety Operating Precautions Avoid Work Site Hazards Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before you dig. Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires. Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position travel motors away from the hole. Reduce machine speed when operating tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seat belt. On units equipped with shoulder belts always wear both the seat and shoulder belt and do not lean forward while operating. T UN 01APR02 T UN 01APR02 T UN 01APR02 VD76477, FEB12-1/1 Keep Riders Off Machine Only allow operator on machine. Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator s view or impair his ability to operate machine safely. T UN 14APR99 TX14740,0001E7A MAR02-1/ PN=16

17 Safety Operating Precautions Avoid Backover Accidents Before moving machine, be sure all persons are clear of both travel and swing paths. Turn around and look directly for best visibility. Keep windows clean, adjusted, and in good repair. Be certain travel alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. T UN 14APR99 OUO1032,00015D JAN07-1/1 Avoid Machine Tip Over Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel. Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When traveling up or down slopes, keep the bucket on uphill side and just above ground level. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy load or swinging it over side of undercarriage may cause machine to tip. Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall. T SEP00 T UN 15SEP00 T UN 27SEP00 TX03679,00016DF JAN07-1/ PN=17

18 Safety Operating Precautions Use Special Care When Lifting Objects Never use this machine to lift people. Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free. Do not leave the seat when there is a raised load. Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over undercarriage side may cause machine to tip over. Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition. Use tether lines to guide loads and prearranged hand signals to communicate with co-workers. T UN 27SEP00 TX03679,00016E JAN07-1/1 Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability and may create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion. TX03679,00016F FEB07-1/ PN=18

19 Safety Maintenance Precautions Park and Prepare for Service Safely Warn others of service work. Always park and prepare your machine for service or repair properly. Park machine on a level surface and lower equipment and attachments to the ground. Place pilot shutoff lever in lock position. Stop engine and remove key. Attach a Do Not Operate tag in an obvious place in the operator's station. Securely support machine or attachment before working under it. Do not support machine with boom, arm, or other hydraulically actuated attachments. Do not support machine with cinder blocks or wooden pieces that may crumble or crush. Do not support machine with a single jack or other devices that may slip out of place. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work. T DEC01 TS229 UN 23AUG88 TX03679,00016E JAN07-1/1 Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. TS281 UN 23AUG88 DX,RCAP JUN90-1/ PN=19

20 Safety Maintenance Precautions Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. 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. Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly. TS220 UN 23AUG88 DX,PAINT JUL02-1/1 Make Welding Repairs Safely IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors. Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding. T UN 31AUG00 OUO1032,00015DD OCT09-1/1 Drive Metal Pins Safely Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping. T UN 14SEP00 TX03679, JAN07-1/ PN=20

21 Safety Safety Signs Safety Signs TX JUN08 Continued on next page ER93822,000014D JUN08-1/ PN=21

22 Safety Safety Signs TX JUN08 ER93822,000014D JUN08-2/ PN=22

23 Pedals, Levers, and Panels Operation Operator's Station TX UN 27MAY08 1 Left Control Lever 2 Pilot Control Shutoff Lever 3 Attachment Pedal (Optional) (S.N ) 4 Left Travel Pedal 5 Left Travel Lever 6 Right Travel Lever 7 Right Travel Pedal 8 Boom Swing Pedal 9 Monitor Panel 10 Right Control Lever / Horn Switch (Standard) 10 Right Control Lever / Horn Switch / Auxiliary Function Lever Switch (Optional) (S.N ) 11 Windshield Washer Fluid Container Lid 12 Blade Lever 13 Key Switch 14 Engine Control Dial 15 Switch Panel 16 Air Conditioner Control Panel 17 Cup Holder 18 Operator's Manual Box 19 Operator's Seat Continued on next page ER93822, FEB12-1/ PN=23

24 Operation Operator's Station TX UN 29MAY08 TX UN 29MAY08 Operator's Station Ground View Operator's Station Right Side 12 Blade Lever 15 Switch Panel 17 Cup Holder 20 Fuse Box 21 Tool Box 22 Door Lock Release Lever 23 Ash Tray 24 Radio (Optional) 25 Blade Angle Control Lever (Optional) TX UN 27FEB12 Blade Angle Control Lever (Optional) ER93822, FEB12-2/ PN=24

25 Operation Operator's Station Monitor Panel and Functions (S.N ) 1. Coolant Temperature Gauge: When the first three segments come ON, the coolant temperature is normal. NOTE: When the coolant temperature is lower than 20 C (68 F), the first segment flashes. 2. Fuel Gauge and Fuel Level Indicator: When the fuel level is low, the first segment flashes, indicating the fuel tank is almost empty. Add fuel before gauge reaches E. NOTE: When the key switch is OFF, continuously pressing display select switch (5) for more than 0.5 seconds displays the fuel level. 3. Monitor Display: Three modes are available: hour meter, trip meter 1, or trip meter 2. To change mode, press display select switch (5) until desired mode is displayed. Hour meter is the default display. The right-hand number on the hour meter indicates tenths of an hour (six minutes). 4. Set Switch: Used to set trip meters. 5. Display Select Switch: Used to change information shown in monitor display. 6. Auto Idle Indicator: Indicator lights when auto idle is engaged. 7. Auto Idle Switch: Press auto idle switch to engage auto idle. Auto idle indicator (6) lights. When auto idle is selected, the engine speed is reduced to the slow idle speed approximately four seconds after returning all control levers to neutral to reduce fuel consumption. 8. Fast Travel Mode Indicator: When fast travel mode is selected on travel speed control switch, fast travel mode indicator lights. 9. Engine Pre-Heat Indicator: Yellow indicator lights when key switch is held in the HEAT position. Indicator will go out after 15 seconds, indicating that pre-heating is completed. Start engine immediately after light goes out. 10. Alternator Voltage Indicator: Indicator lights with no or low alternator output. 11. Low Fuel Level Indicator: When the fuel level indicator flashes while machine is operating on level ground, fuel level is extremely low (approximately 6.5 L [1.7 gal]). Refuel as soon as possible. 12. Engine Coolant Temperature Gauge and Engine Coolant Temperature Indicator: Coolant temperature is normal when the gauge segments remain in the white range. 1 Coolant Temperature Gauge 2 Fuel Gauge 3 Monitor Display 4 Set Switch 5 Display Select Switch 6 Auto Idle Indicator 7 Auto Idle Switch Monitor Panel (S.N ) 8 Fast Travel Mode Indicator 9 Engine Pre-Heat Indicator 10 Alternator Voltage Indicator 11 Low Fuel Level Indicator 12 High Coolant Temperature Indicator 13 Engine Oil Pressure Indicator 14 System Failure Indicator The monitor alarm sounds and the gauge segments in the red range come ON when coolant temperature rises extremely high. Reduce load immediately and run engine at slow idle. Inspect for debris around radiator. Check for low coolant in the radiator recovery tank. 13. Engine Oil Pressure Indicator: IMPORTANT: Avoid engine damage. If engine oil pressure light comes on while operating, stop engine immediately. Indicator lights and alarm sounds when engine oil pressure is low. Stop engine immediately. NOTE: Cold oil, low oil level, or extreme off-level operation may cause indicator to light. 14. System Failure Indicator: The indicator displays ON or flash when an abnormality is found in the engine speed control system. Contact your authorized dealer as soon as possible. T UN 03DEC04 ER93822,000002F FEB12-1/ PN=25

26 Operation Operator's Station Monitor Panel and Functions (S.N ) 1. Coolant Temperature Gauge: When the first three segments are illuminated, the coolant temperature is normal. NOTE: When the coolant temperature is lower than 20 C (68 F), the first segment flashes. 2. Fuel Gauge: Position of segment illumination indicates fuel level. Add fuel before only the E segment of the gauge is illuminated and/or the Low Fuel Level Indicator (5) is illuminated. IMPORTANT: Avoid machine damage. If all segments of the fuel gauge are illuminated and flashing, immediately contact your authorized John Deere dealer. 3. Hour Meter: Numbers to the left of the decimal point indicate total accumulated operation hours since the machine began working. The number to the right of the decimal point indicates tenths of an hour (six minutes). 4. Overheat Indicator: If the temperature of the coolant is extremely hot, this indicator illuminates and a buzzer activates. Immediately stop machine operation and reduce engine speed to slow idle speed to reduce coolant temperature. 5. Low Fuel Level Indicator: If this indicator illuminates while on level ground, the amount of fuel remaining in the fuel tank is 10.0 L (2.6 gal) or less. Add fuel to the fuel tank as soon as safely possible. 6. Alternator Indicator: This indicator illuminates when little or no alternator output exists. If this indicator illuminates, examine components of the electrical system such as the alternator and/or battery. 7. Auto Idle Indicator: This indicator illuminates when the auto-idle switch on the switch panel is activated. 8. Fast Travel Mode Indicator: This indicator illuminates when the fast mode side (rabbit) of the travel mode switch has been pressed. 9. System Failure Indicator: This indicator will illuminate and/or flash when there is a strong possibility of an irregularity in the engine control system. 1 Coolant Temperature Gauge 2 Fuel Gauge 3 Hour Meter 4 Overheat Indicator 5 Low Fuel Level Indicator 6 Alternator Indicator Monitor Panel (S.N ) 7 Auto Idle Indicator 8 Fast Travel Mode Indicator 9 System Failure Indicator 10 Preheat Indicator 11 Engine Oil Pressure Indicator IMPORTANT: Avoid machine damage. If system failure indicator is illuminated, contact your authorized John Deere dealer immediately. 10. Preheat Indicator: This indicator illuminates when the machine determines that preheating is required. 11. Engine Oil Pressure Indicator: This indicator illuminates red when low engine oil pressure is present. The engine oil pressure warning buzzer activates simultaneously with indicator. IMPORTANT: Avoid machine damage. If engine oil pressure indicator is illuminated, stop the engine immediately. Examine the engine oil pressure system and engine oil level for the presence of irregularities. TX A UN 25AUG11 ER93822,000002A SEP11-1/ PN=26

27 Operation Operator's Station Switch Panel and Functions (S.N ) 1. Travel Mode Switch: Press the top half of travel mode switch to select the fast travel mode. When the travel load becomes heavy, machine automatically selects slow travel mode. Press the bottom half of travel mode switch to select the slow travel mode. 2. Work Light Switch: Press the top half of work light switch to illuminate lights on work lights located on boom and cab roof. Press the bottom half of switch to turn off lights. 3. Windshield Wiper/Washer Switch: The windshield wiper/washer switch has three positions: OFF, WIPER, WIPER/WASHER. OFF: Press bottom half of switch. Both windshield wiper and washer do not operate. WIPER: Toggle switch to center position. Windshield wiper operates. WIPER/WASHER: Press top half of switch. Both windshield wiper and washer operate. 4. Travel Alarm Cancel Switch: Press top half of travel alarm cancel switch to silence travel alarm after initial 13 second alarm. Switch is reset when travel motion stops. 5. Power Mode Switch: The power mode switch has two positions: P, E P mode: Press bottom half of switch. Use when general digging work is needed. Switch Panel (S.N ) 1 Travel Mode Switch 2 Work Light Switch 3 Windshield Wiper/Washer Switch 4 Travel Alarm Cancel Switch 5 Power Mode Switch 6 Auxiliary Flow Control Switch (if equipped) 7 Air Conditioner Control Panel E mode: Press top half of switch. Use to improve fuel efficiency and reduce noise level with a small difference in engine speed. 6. Auxiliary Flow Control Switch (if equipped): Press top half (LOW) of auxiliary flow control switch to place hydraulic attachment in reduced flow rate mode. Press bottom half (HIGH) of switch to place hydraulic attachment in high flow rate mode. TX UN 28MAY08 ER93822, SEP11-1/ PN=27

28 Operation Operator's Station Switch Panel and Functions (S.N ) 1. Travel Mode Switch: Press the top half of travel mode switch to select the fast travel mode. When the travel load becomes heavy, machine automatically selects slow travel mode. Press the bottom half of travel mode switch to select the slow travel mode. 2. Work Light Switch: Press the top half of work light switch to illuminate lights on work lights located on boom and cab roof. Press the bottom half of switch to turn off lights. 3. Windshield Wiper/Washer Switch: The windshield wiper/washer switch has three positions: OFF, WIPER, WIPER/WASHER. OFF: Press bottom half of switch. Both windshield wiper and washer do not operate. WIPER: Toggle switch to center position. Windshield wiper operates. WIPER/WASHER: Press top half of switch. Both windshield wiper and washer operate. 4. Auto-Idle Switch: Press the top half of auto-idle switch to activate auto-idle and illuminate auto-idle indicator on monitor panel. When auto-idle is activated, the engine speed will reduce to slow idle speed four seconds after releasing all control levers (neutral position). Using auto-idle reduces fuel consumption. Press the bottom half of the auto-idle switch to turn off auto-idle and auto-idle indicator. 5. Power Mode Switch: The power mode switch has two positions: P, E 1 Travel Mode Switch 2 Work Light Switch 3 Windshield Wiper/Washer Switch 4 Auto-Idle Switch Switch Panel (S.N ) 5 Power Mode Switch 6 Auxiliary Flow Control Switch (if equipped) 7 Air Conditioner Control Panel P mode: Press bottom half of switch. Use when general digging work is needed. E mode: Press top half of switch. Use to improve fuel efficiency and reduce noise level with a small difference in engine speed. 6. Auxiliary Flow Control Switch (if equipped): Press top half (LOW) of auxiliary flow control switch to place hydraulic attachment in reduced flow rate mode. Press bottom half (HIGH) of switch to place hydraulic attachment in high flow rate mode. TX UN 06OCT11 ER93822, SEP11-1/1 Key Switch Rotate key switch cover (1) counterclockwise to uncover key switch (3). To operate key switch, insert key (2) in key switch. Key is inserted and removed with switch in the OFF (4) position. Rotate key clockwise to Engine Preheat (5) position. Tractor accessories begin functioning with key in this position. Rotate key clockwise to START position (6). Key will return to Engine ON (7) when released. Engine begins functioning with key in this position. 1 Key Switch Cover 2 Key 3 Key Switch 4 OFF 5 Engine Preheat 6 START 7 Engine ON TX A UN 30MAY08 ER93822,000018E MAY08-1/ PN=28

29 Operation Operator's Station Horn Horn button (1) is located on right control lever. Press button to sound horn. 1 Horn Button TX A UN 27MAY08 Standard Lever TX UN 31AUG11 Auxiliary Function Lever (Optional) (S.N ) ER93822, AUG11-1/1 Engine Speed Control Knob Use the engine speed control knob (1) to adjust engine speed. Turn knob clockwise to increase speed. Turn knob counterclockwise to decrease speed. 1 Engine Speed Control Knob TX A UN 04JUN08 ER93822,00001A JUN08-1/ PN=29

30 Operation Operator's Station Pilot Control Shutoff Lever The pilot control shutoff lever (1) shuts off hydraulic pilot pressure to all pilot control valves. When pilot control shutoff lever is in locked (up) position, the machine will not move if a pilot control lever (3) or pedal is accidentally moved. IMPORTANT: Prevent possible console or control lever damage. Only use the pilot control shutoff lever to raise or lower console (2). Pilot control shutoff lever is linked to the console (2) latch mechanism. Raise and lower console using pilot control shutoff lever. Always pull pilot control shutoff lever up to locked position when you stop the engine or leave the operator s station. Engine will not start unless pilot control shutoff lever is in locked position. Slowly lower lever to unlocked position before starting operation. 1 Pilot Control Shutoff Lever 2 Console Locked Position Shown 3 Pilot Control Lever T UN 03DEC04 OUO1032, JAN07-1/1 Travel Alarm and Travel Alarm Cancel Switch (S.N ) IMPORTANT: If alarm is not operating during normal transport, or if alarm sounds when engine is running and machine is stationary see your authorized dealer. The travel alarm sounds when a travel pedal or lever is activated and will continue as long as the tracks are moving. After the initial 13 second alarm, the alarm can be silenced by depressing the top half of the travel alarm cancel switch (4). Travel alarm switch is reset when: travel motion stops or bottom half of travel alarm cancel switch is pressed. Switch Panel (S.N ) 1 Travel Mode Switch 2 Work Light Switch 3 Windshield Wiper/Washer Switch 4 Travel Alarm Cancel Switch 5 Power Mode Switch 6 Auxiliary Flow Control Switch (If Equipped) 7 Air Conditioner Control Panel TX UN 28MAY08 ER93822, SEP11-1/ PN=30

31 Operation Operator's Station Cab Heater and Air Conditioner TX UN 29MAY08 TX UN 29MAY08 1 Air Conditioner Control Panel 2 Right Rear Air Vent 3 Right Front Air Vent 4 Foot Air Vent 5 Right Front Air Vent Air conditioner control panel (1) is used to heat and cool air flow within the cab. Continued on next page ER93822,000018B JUN08-1/ PN=31

32 Operation Operator's Station TX UN 29MAY TX UN 28MAY08 Air Conditioner Panel Display Air Vent Modes CAUTION: Avoid personal injury and/or machine damage. Keep fire hazards away from the control panel. IMPORTANT: Avoid compressor damage. Do not suddenly increase engine speed. 1 Vent Mode Switch: Press the vent mode switch until desired mode (19-22) is displayed. 2 Circulation and Fresh Air Mode Switch: Press to select between recirculation and fresh air mode. Fresh air mode routes outside air into the cab. Circulation mode closes fresh air vent and circulates air already in cab. Circulation mode is also indicated on display when selected. 3 Right Air Vent Indicator 4 Cool Temperature Indicator 5 Warm Temperature Indicator 6 Recirculation Indicator 7 Blower Speed Increase Switch: Press to increase blower speed until desired speed is displayed. Blower speed can be set to one of four stages ranging from slow to fast. Speed will be indicated on air conditioner panel display. 8 Air Conditioner Switch: Press to turn on air conditioner. 9 Air Conditioner Power Switch: Press activate the air conditioner control panel. 10 Blower Speed Decrease Switch: Press to increase blower speed until desired speed is displayed. Blower speed can be set to one of four stages ranging from slow to fast. Speed will be indicated on air conditioner panel display. 11 A/C Indicator 12 Blower Speed Indicator 13 Blower Indicator 14 Temperature Increase Switch: Press to increase set temperature in cab. 15 Temperature Decrease Switch Press to decrease set temperature in cab. 16 Temperature Indicator 17 Vent Mode Indicator 18 Defroster Switch: Press to have air blow from all vents in cab. Heating Operation 1. Select desired vent mode (19-22). 22 is the mode usually used for the heating operation though any mode may be used. 2. Press the temperature decrease switch (15) to set the temperature indicator toward the right. 3. Adjust inside cab temperature using temperature control switches (14 and 15). 4. Adjust blower speed using blower control switches (7 and 10). 5. Operate circulation and fresh air mode switch to maintain the air vent in the fresh air circulation mode. When air conditioner switch (8) is activated during heating operation, air in the cab will be dehumidified. Cooling Operation 1. Select desired vent mode (19-22). 20 is the mode usually used for the cooling operation though any mode may be used. 2. Press the temperature increase switch (14) to set the temperature indicator toward the left. 3. Adjust inside cab temperature using temperature control switches (14 and 15). 4. Adjust blower speed using blower control switches (7 and 10). 5. Operate circulation and fresh air mode switch to maintain the air vent in the fresh air circulation mode. When air conditioner switch (8) is activated during cooling operation, cool air will blow out from all vents. Defroster Operation 1. Select the right front vents by operating vent mode switch (1). Vent mode (21) will be displayed in air conditioner control panel. 2. Adjust the louvers on right front vents as required. Continued on next page ER93822,000018B JUN08-2/ PN=32

33 Operation Operator's Station 3. Adjust blower speed using blower control switches (7 and 10). 4. Adjust inside cab temperature using temperature control switches (14 and 15). 5. If windows become clouded and/or dehumidifying is needed, turn air conditioner switch (8) on. ER93822,000018B JUN08-3/3 Setting Trip Meters (S.N ) NOTE: Trip meters are preset to 10,000 hours at the factory. Trip meters can be set to notify the operator that a certain number of operation hours have passed. There are two meters, TRIP 1 and TRIP 2, and each one is set individually. To Set Trip Meters 1. Turn key switch ON. 2. Press display select switch (1) to display either trip meter 1 (3) or trip meter 2 (4). 3. Press set switch (2) to select number of hours. The available hour settings are: Press display select switch (1) to set the trip meter hours. 5. When set hours reach zero, the trip meter display will flash. If trip meter is not reset at that time, the trip meter hours will continue to display the operation hours with a minus (-) sign until trip meter is reset. 1 Display Select Switch 2 Set Switch 3 TRIP 1 (trip meter 1) 4 TRIP 2 (trip meter 2) T UN 07DEC04 T UN 07DEC04 T UN 07DEC04 ER93822, SEP11-1/ PN=33

34 Operation Operator's Station Operating AM/FM Radio TX UN 28MAY08 Radio 9 Seek Button 10 Auto-Store/Scan Preset Button 11 Band Button 12 AM Frequency Indicator 1 Tone Control Knob 2 FM Stereo Frequency Indicator 3 Radio Frequency Display 4 Preset Display 5 Station Preset Buttons 6 Tuning Increase Button 7 Clock Button 8 Tuning Decrease Button 13 FM Frequency Indicator 14 Power Switch/Volume Control Knob Press power switch (1) to turn on radio, and repeatedly press one of tuning buttons (6 and 8) until desired station is reached. To preset a station, select the desired station using tuning buttons. Press and hold one of the station preset buttons (5) for more than 2 seconds until an electronic tone is heard. The frequency of the preset station is indicated on digital display (3). 1. Tone Control Knob Rotate clockwise to intensify treble. Rotate counterclockwise to reduce treble. 2. FM Stereo Frequency Indicator Illuminates when an FM stereo radio wave frequency is selected. 3. Radio Frequency Display Displays the radio frequency that is currently tuned. 4. Preset Display Displays the station preset button number assigned to the frequency that is currently tuned. 5. Station Preset Buttons Each button stores one preset AM (MW) and FM station. Press button assigned to desired station. 6. Tuning Increase Button Tap button to increase the frequency. Press and maintain pressure on button to continually increase radio frequency. Release button once desired radio frequency is displayed. 7. Clock Button Press button to display time. Press once more to display the current tuned frequency. 8. Tuning Decrease Button Tap button to decrease the frequency. Press and maintain pressure on button to continually decrease radio frequency. Release button once desired radio frequency is displayed. 9. Seek Button Press to locate the next receivable station. The seek function stops when a station has been located. 10. Auto-Store/Scan Preset Button Press to receive the preset frequency station for every 5 seconds sequentially. Once a desired station frequency has been found, press button again to interrupt the scan feature and maintain radio frequency. Press and hold button for 2 seconds to automatically store the station. 11. Band Button Press this button to select AM (MW) or FM band. 12. AM Frequency Indicator Illuminates when the AM (MW) band is selected. 13. FM Frequency Indicator Illuminates when the FM band is selected. 14. Power Switch/Volume Control Knob When rotating knob, a click indicates radio power has been turned on or off. Rotate knob clockwise to turn on radio and increase volume. Rotate knob counterclockwise to decrease volume and turn radio off. Radio Operation 1. Key switch must be in ON or START position. 2. If radio is not already powered on, rotate power switch/volume control knob clockwise until a click is heard. 3. Select station using: - tuning buttons; - station preset buttons; - auto-store/scan preset button; or - seek button 4. Rotate power switch/volume control knob to desired volume level. 5. Rotate tone control knob to preference. To turn radio off, rotate power switch/volume control knob counterclockwise until a click is heard. Continued on next page ER93822,000018A FEB12-1/ PN=34

35 Operation Operator's Station NOTE: If battery power to the radio is disconnected, radio frequencies assigned to the station preset buttons will be lost. Station Presetting Procedures Manually Setting Station Preset Buttons 1. Key switch must be in ON or START position. 2. If radio is not already powered on, rotate power switch/volume control knob clockwise until a click is heard. 3. Rotate power switch/volume control knob to desired volume level. 4. Select station using: - tuning buttons or - seek button 5. To assign radio frequency, continuously press a station preset buttons for 2 seconds. Each station preset button may be assigned one AM (MW) station and one FM station. The preset number is displayed when the frequency is assigned. After presetting has been completed, the preset frequency can be changed if a preset button is pressed and held for 2 seconds. Auto-Storing Procedure for Setting Station Preset Buttons NOTE: Using the auto-storing procedure overwrites any frequencies previously assigned to a station preset button. 1. Key switch must be in ON or START position. 2. If radio is not already powered on, rotate power switch/volume control knob clockwise until a click is heard. 3. Rotate power switch/volume control knob to desired volume level. 4. Press auto-store/scan preset button for more than two seconds. Radio automatically searches frequencies for receivable stations. The first six stations are assigned to the station preset buttons. Preset Scanning 1. Key switch must be in ON or START position. 2. If radio is not already powered on, rotate power switch/volume control knob clockwise until a click is heard. 3. Rotate power switch/volume control knob to desired volume level. 4. Press and release auto-store/scan preset button. Radio automatically searches preset frequencies for receivable stations for 5 seconds. Press and release auto-store/scan preset button a second time to resume normal radio operation. Setting the Clock 1. Key switch must be in ON or START position. 2. If radio is not already powered on, rotate power switch/volume control knob clockwise until a click is heard. 3. If necessary, press the clock button to display time. 4. While maintaining pressure on the clock button, press the tuning decrease button to change the hour display. Release buttons once desired hour is displayed. 5. While maintaining pressure on the clock button, press the tuning increase button to change the minute display. Release buttons once desired minute is displayed. ER93822,000018A FEB12-2/2 Secondary Exit Tool IMPORTANT: FOR SECONDARY EXIT. Use secondary exit tool (1) to break window. Always keep tool in machine. 1 Secondary Exit Tool TX A UN 02JUN08 ER93822, MAY08-1/ PN=35

36 Operation Operator's Station Opening Front Upper (Secondary Exit) Window Opening the Front Window 1. Disengage lock levers (1). 2. While holding the handles (2) on the window, pull window up and back until both lock levers are securely engaged. Switch (3) on front window prevents wiper from operating when front window is opened. Before closing front window, check that switch is OFF. Closing the Front Window CAUTION: Prevent possible injury from window closing. Front window comes down forcefully. Close window only when sitting in operator s seat. Guide window down slowly. 1. Sit in operator's seat. 2. Disengage lock levers (1). 3. Using the handles (2), slowly guide window down and forward until both lock levers are engaged. TX UN 28MAY08 TX UN 28MAY08 1 Lock lever (2 used) 2 Handle (2 used) 3 Switch TX UN 28MAY08 ER93822, JUN08-1/1 Removing Lower Front Window NOTE: Upper front window must be raised before lower front window can be removed. While pulling in on window, raise window to remove. NOTE: In cold weather, some operators may choose to work with the top glass open and the bottom glass in place. This provides excellent visibility and tends to hold the heat being circulated around the operator s feet. T UN 18DEC00 ER93822,000018C MAY08-1/ PN=36

37 Operation Operator's Station Opening Cab Window To open cab window, pull window bar (1) toward front of machine to release from latch. Continue pulling forward until window is opened desired amount. To close window, push window bar towards back of machine until window bar is latched. 1 Window bar TX A UN 30MAY08 ER93822, MAY08-1/1 Door Release Lever IMPORTANT: Prevent machine damage from swinging door. Ensure cab door is latched securely if operating with door open. The cab door can be locked in the open position. Open the door all the way until cab door striker (1) is secured in cab door latch (2). To release the door from locked position, push down on cab door release lever (3). 1 Cab Door Striker 2 Cab Door Latch 3 Cab Door Release Lever T UN 21DEC04 TX A UN 30MAY08 ER93822,000018D MAY08-1/1 Adjusting Operator's Seat Press seat fore-aft slide lever (1) upward to allow seat to slide forward or rearward. Release lever when seat is at desired position. 1 Fore-Aft Lever TX A UN 03JUN08 ER93822,000019F JUN08-1/ PN=37

38 Operation Operating the Machine Before Starting Work Review the operating precautions. See Safety-Operating Precautions. (Section 1-3.) Use seat belt when operating machine. Remember to fasten seat belt even during brief periods of use. T UN 24AUG00 Reading Operator's Manual TX03679, AUG12-1/1 Operator's Daily Machine Check Before Starting Safety and Protective Devices Checks Walk around machine to clear all persons from machine area before starting machine. Check condition of guards, shields, and covers Overall Machine Checks Check for worn or frayed electrical wires and loose or corroded connections. Check for bent, broken, loose, or missing boom, bucket, sheet metal, track parts. Check for loose or missing hardware Check for oil leaks, missing or loose hose clamps, kinked hoses, and lines or hoses that rub against each other or other parts. 1 Check Pedal and Lever Movement/Clean Out Cab Debris 2 Check Hydraulic Tank Oil Level. 3 Check Coolant Recovery Tank Level 4 Check/Clean Radiator and Oil Cooler Outer Fins 5 Check Engine Oil Level T UN 17AUG99 TX14740,0001E7F MAR02-1/ PN=38

39 Operation Operating the Machine Starting the Engine NOTE: Engine will not start unless pilot control shutoff lever is in locked (rearward) position. 1. Turn the key switch (1) to ON. See Key Switch. (Section 2-1.) 2. Turn engine control dial (2) to the low idle position. See Engine Control Dial. (Section 2-1.) 3. Sound horn to alert nearby people. IMPORTANT: Prevent starter damage. Never operate starter for more than 15 seconds at a time. If engine fails to start, return key switch to OFF. Wait for about 30 seconds, then try again. After a false start, do not turn key switch until engine stops. 4. Turn key switch to START. Release key; switch will return to ON position. See Key Switch. (Section 2-1.) 1 Key Switch 2 Engine Control Dial TX A UN 30MAY08 ER93822, MAY08-1/1 Cold Weather Warm-Up CAUTION: Prevent possible injury from unexpected machine movement. If hydraulic oil is cold, hydraulic functions move slowly. DO NOT attempt normal machine operation until hydraulic functions move at close-to-normal cycle times. In extremely cold conditions, an extended warm-up period will be necessary. Under such conditions, the radiator and oil cooler should be covered to maintain correct operating temperature. Avoid sudden operation of all functions until the engine and hydraulic oil are thoroughly warm. 1. Run engine at 1/2 speed for 5 minutes. Do not run at fast or slow idle. CAUTION: Prevent possible injury from unexpected machine movement. Clear the area of all persons before running your machine through the warm-up procedure. If machine is inside a building, warm the travel circuit first and move the machine to a clear area outside. Cold oil will cause machine functions to respond slowly. 2. Exercise travel and swing functions slowly, initially moving only short distances. 3. Operate boom, arm, and bucket functions by moving cylinders a short distance each direction for the first time. 4. Continue cycling cylinders by increasing cylinder extension until full stroke is obtained. IMPORTANT: Holding function actuated for more than 30 seconds can cause damage from hot spots in the control valve. 5. Actuate bucket curl function (cylinder extend) for 10 seconds and release for 5 seconds for a period of 2-1/2 minutes. 6. Repeat procedure with bucket dump function. 7. Operate all hydraulic functions to distribute warm oil in all cylinders, motors, and lines. 8. If hydraulic functions still move slowly, repeat steps 5 and 6. VD76477,000005C JUL06-1/ PN=39

40 Operation Operating the Machine Travel Pedals and Levers CAUTION: Prevent possible injury from unexpected machine movement. Keep bystanders clear of machine when traveling. The instructions below apply when the upperstructure is facing forward and travel motors are to the rear of the machine. If the upperstructure is rotated to the rear and the travel motors are to the front of the machine, the machine moves OPPOSITE to the direction described. NOTE: Unfold foot pedals before using. FORWARD TRAVEL: Push down on front (1) of both pedals or push both levers forward (1). REVERSE TRAVEL: Push down on rear (3) of both pedals or pull both levers rearward (3). NEUTRAL POSITION (2): Travel brakes will automatically stop and hold the machine. RIGHT TURN: Push down on front of left pedal or push left lever forward. LEFT TURN: Push down on front of right pedal or push right lever forward. SHORT TURN (COUNTERROTATE): Push down the front of one pedal and the rear of the other or push one lever forward and pull the other rearward. Levers T UN 07DEC04 1 Forward Travel 2 Neutral Position Pedals and Levers 3 Reverse Travel T UN 07DEC04 CAUTION: Prevent possible injury from machine tipping. Operate control pedals or levers slowly when traveling down a slope. TRAVELING DOWN A SLOPE: Operate control pedals or levers slowly when traveling down a slope. COLD WEATHER OPERATION: Travel pedal and lever dampers are provided for smooth control. In extremely cold weather, pedal or lever effort will increase. Operate pedals or levers several times with pilot control shutoff lever in locked position. OUO1032, DEC12-1/ PN=40

41 Operation Operating the Machine Control Lever Pattern Operation CAUTION: Never place any part of body beyond window frame to avoid serious crushing injury from boom. Boom could lower if the control lever is accidentally bumped or otherwise engaged. Immediately replace a missing or broken window. Never place any part of the body beyond the window frame. Replace missing or broken windows (if equipped) immediately. CAUTION: Prevent injury from unexpected control lever function. Be aware of the control lever pattern used on the machine before operating. A label showing each control lever pattern operation is provided on the operator's right. Check the pattern on the label and then carefully operate the machine to verify the selected pattern is correct. (See Control Lever Pattern Conversion in this section.) Control levers return to neutral when released. Functions will stop and remain positioned. The parking brake for swing and travel will also engage. Excavator Control Lever Pattern T UN 07DEC04 1 Arm Out 2 Arm In 3 Swing Left 4 Swing Right 5 Boom Down 6 Boom Up 7 Bucket Load 8 Bucket Dump T UN 07DEC04 Backhoe Control Lever Pattern T UN 07DEC04 Boom, Arm, Bucket Movement OUO1032, JUL06-1/ PN=41

42 Operation Operating the Machine Control Lever Pattern Conversion The machine pilot control levers can be changed from the standard Excavator control pattern to a Backhoe control pattern. To change control pattern: 1. Park machine on a level surface. 2. Run engine at slow idle speed without load for 3 minutes. 3. Turn key switch to OFF to stop engine. Remove key from switch. 4. Pull pilot shutoff lever up to the locked position. 5. Control pattern selector lever (1) is located under seat. Open panel (2) to access selector lever. 6. Rotate selector lever to desired control pattern position. (Lever must be aligned with arrow on selected control pattern and detented in order to function as expected.) 7. Close panel. 8. Verify selected pattern is visible through sight hole. 1 Control Pattern Selector Lever 2 Panel 3 Excavator Position 4 Backhoe Position TX A UN 02JUN08 TX A UN 02JUN08 ER93822, JUN08-1/ PN=42

43 Operation Operating the Machine Operating Angle Blade If Equipped Pull angle blade lever (3) rearward to raise angle blade (4). Push angle blade lever forward to lower angle blade (5). Push angle left turn switch (1) to angle blade left. Push angle right turn switch (2) to angle blade right. 1 Angle Left Turn Switch 2 Angle Right Turn Switch 3 Angle Blade Lever 4 Angle Blade Raise 5 Angle Blade Lower TX UN 17DEC08 TX UN 17DEC08 OU90V02, JAN09-1/ PN=43

44 Operation Operating the Machine Operating Backfill Blade Pull blade lever (1) rearward to raise blade (2). Push blade lever forward to lower blade (3). When the blade lever is released, it automatically returns to neutral, keeping the blade in position until the lever is moved again. 1 Blade Lever 2 Blade Raise 3 Blade Lower T UN 07DEC04 T UN 01DEC04 OUO1032,000157C NOV04-1/1 Operating Tips Backfill Blade Use blade only for moving loose material and for backfilling. Load the blade evenly. Do not use blade to dig. Do not run the machine into a load. Do not use the blade to stabilize machine. ER93822,00001A JUN08-1/ PN=44

45 Operation Operating the Machine Auxiliary Pedal If Equipped (S.N ) CAUTION: Avoid injury from unexpected machine movement. Keep pedal cover in locked position when not using auxiliary pedal. 1. Lift pedal cover (1) to unlock auxiliary pedal (2). 2. Push on the right or left side of the auxiliary pedal to operate the front-end attachment. (See Positioning Auxiliary Line Selector Valve below for single and double activation.) 3. Lower pedal cover to lock auxiliary pedal. T UN 07DEC04 1 Pedal Cover 2 Auxiliary Pedal ER93822,000002E AUG11-1/ PN=45

46 Operation Operating the Machine Auxiliary Function Lever Switch If Equipped (S.N ) CAUTION: Avoid personal injury or death. Never attempt to use this switch for purposes other than to operate the attachment installed on this machine. Do not attempt to modify the switch performance and/or shape. CAUTION: Avoid personal injury and/or machine damage. Before operating this switch, be sure to thoroughly read the attachment s operator manual and check the movement of each function in a safe location. CAUTION: Avoid personal injury and/or machine damage. Contact the attachment s manufacturer and sales company about requirements concerning the proper installation and operation of the attachment. 1. Move slide switch (2) of the right control lever (1) to either side to operate the installed attachment. 2. When pressure switch (3) is pressed, the installed attachment will operate as though the slide switch has been moved to the left side of the slide switch. If both slide switch and pressure switch are operated simultaneously, the pressure switch has priority. NOTE: The pressure switch operation is convenient when using a hydraulic breaker. Location of Auxiliary Function Lever Switch TX A UN 25AUG11 1 Right Control Lever 2 Slide Switch 3 Pressure Switch TX A UN 25AUG11 Auxiliary Function Lever Switches ER93822,000002B AUG11-1/ PN=46

47 Operation Operating the Machine Positioning Auxiliary Line Selector Valve IMPORTANT: Prevent possible machine damage. Stop the engine and move pilot control shutoff lever to locked (rearward) position before moving the selector valve. 1. Stop engine. 2. Remove plug (1) to access selector valve. Selector valve must be positioned according to the type of attachment to be operated: Position 2: Operating a breaker or other single actuating cylinder attachment requiring only ON/OFF operation. Position 3: Operating a crusher or other double actuating cylinder attachment requiring two actions such as OPEN/CLOSE operation. TX A UN 10JUN08 1 Selector Valve Plug 2 ON/OFF (for single actuating cylinder attachment) 3 OPEN/CLOSE (for double actuating cylinder attachment) TX A UN 10JUN08 ER93822,00001BA JUN08-1/1 Operating In Water and Mud Be careful not to operate the machine in water or mud above the upper track shoe surface (1), causing the swing bearing and rotary manifold to be submerged. Specification Upper Track Shoe Surface (Operable Water Depth) Distance mm 22 in. If the swing bearing and rotary manifold are submerged, remove cover from underneath center of machine. Remove drain plug to drain water and mud. Clean swing gear area. Install plug and cover. Grease swing bearing and grease swing bearing gear. (See Sections 3-6 and 3-7.) 1 Upper Track Shoe Surface T UN 08JUN99 ER93822, JUN08-1/ PN=47

48 Operation Operating the Machine Driving Up a Steep or Slippery Slope CAUTION: Prevent possible injury from machine rollover. Use this technique only on a short slope. Machine depends on support of boom/arm/bucket during entire procedure until machine reaches top of slope. Repositioning the bucket during this procedure is NOT recommended. DO NOT swing upperstructure during this procedure. DO NOT reposition bucket during this procedure. 1. Wear seat belt. 2. Position undercarriage so travel motors will be on uphill end of machine. 3. Push bucket into the ground. 4. When boom is on uphill end of machine: Pull machine using boom and arm cylinder to help travel motors. When boom is on downhill end of machine: Push machine using boom and arm cylinder to help travel motors. TX03679, JAN07-1/1 Lifting CAUTION: Prevent possible injury when lifting. Observe these rules when lifting with your machine: Never use machine to lift people Do not exceed lift capacity limits Keep everyone clear of raised loads Never attach sling or chain to bucket teeth Use tether lines to guide loads Use hand signals to communicate with others 1. Use proper rigging to attach and stabilize loads. 2. Without bucket loop: Curl bucket and retract arm. Fasten sling or chain to bucket pivot pin. With bucket loop: Curl bucket and retract arm. Fasten sling or chain to bucket loop. 3. Check stability by carefully doing a trial lift: Raise load just off of ground Swing load all the way to one side Move load slowly away from machine Lower load immediately if machine is not stable TX14740,0001EF JUL02-1/ PN=48

49 Operation Operating the Machine Lowering Boom With Engine Stopped When the engine stops during operation, the boom cannot be lowered using the pilot controller because there is no pilot pressure to move the boom valve spool. 1. Lift cab access to boom up circuit relief valve (1). 2. Make an alignment mark on the adjusting screw (2), nut (3), and relief valve body. 3. Loosen nut using a 14 mm wrench. CAUTION: Prevent possible injury from unexpected machine movement. Clear all persons from the area before lowering the boom. Loosening the boom up circuit relief valve adjusting screw more than two turns may result in the release of the pilot spring and oil from the circuit relief valve. 4. Slowly turn the adjusting screw out approximately 1-1/2 turns to lower the boom. 5. After bucket is on the ground, turn the adjusting screw in to its original setting. Hold the screw and tighten the nut. TX UN 05JUN08 T UN 17NOV04 1 Boom Up Circuit Relief Valve 2 Adjusting Screw 3 Nut ER93822,00001A FEB12-1/1 Parking Machine IMPORTANT: During freezing weather, prevent damage to undercarriage components from frozen mud and dirt. Machine must be parked on a solid level surface to prevent tracks freezing in the ground. 1. Park machine on a level surface. 2. Lower the bucket and blade to the ground. 3. Run engine at slow idle speed without load for 3 minutes. 4. Turn key switch to OFF. Remove key from switch. 5. Pull pilot control shutoff lever (1) to locked position. 6. Close windows and cab door. 7. Lock all access doors and compartments. 1 Pilot Control Shut-Off Lever 2 Console Lever in Locked Position 3 Pilot Control Levers T UN 03DEC04 ER93822, JUN08-1/ PN=49

50 Operation Operating the Machine Loading and Unloading for Transport CAUTION: Avoid possible injury from unexpected machine movement. Use extra care to prevent tip over or unexpected movement when loading and unloading machine for transport. Observe these rules when loading and unloading machine: Always wear seat belt. Locate trailer on a level and stable surface. Chock trailer wheels. Use loading ramps. Keep ramps at a low angle and firmly attached to trailer. 1. When loading machine, use bucket for support with angle of arm to boom at 90. IMPORTANT: Prevent machine or trailer damage. DO NOT allow machine or bucket to impact trailer. 2. Position machine on trailer (centerline of machine over centerline of trailer). 3. Lower boom until the bucket is at rest on trailer bed. 4. Stop engine. 5. Secure the bucket, blade and track frame to the trailer with chains or cables. Do not allow the chains or cables to come into contact with the rubber tracks, hydraulic hoses or hydraulic lines. 6. Verify the overall height of the load on the trailer. 7. When unloading machine, use bucket for support with angle of arm to boom at 90. T UN 21APR99 VD76477,000014E JUL06-1/1 Towing Machine CAUTION: Prevent possible injury from tow line breaking. Do not tow machine with damaged chains, frayed cables, slings, straps or wire tow lines. Always wear gloves when handling cables, straps or wire tow lines. Attach tow line to track frame of machine being towed, and of towing machine. Slowly tow machine. T UN 24JUN99 ER93822,000016B MAY08-1/ PN=50

51 Operation Operating the Machine Lifting Machine CAUTION: Prevent possible injury from unexpected machine movement when lifting the machine. Check lifting capacity of crane before lifting the excavator. Lift load only as high as necessary. Keep all people clear of raised load. 1. Swing the upperstructure so the blade is positioned to the rear. 2. Lower the blade to the ground. 3. Fully extend the boom, arm, and bucket cylinders. 4. Position the boom straight ahead of the upperstructure. 5. Turn key switch to OFF. Remove key from switch. 6. Pull the pilot control shutoff lever to the locked position. 7. Attach cables to the eye plates, one on the boom and two on the blade. 8. Slowly lift the machine. Specification Boom Eye Lifting Point to Branch Point Distance mm 67 in Blade Eye Lifting Point to Branch Point Distance mm 165 in For information concerning operating weights of machine, see Machine Specifications. (Sections 4-6.) 1 Distance from Boom Eye Lifting Point to Branch Point 2 Distance from Blade Eye Lifting Point to Branch Point T UN 20APR99 ER93822, FEB12-1/ PN=51

52 Maintenance Machine Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. Diesel fuels specified to EN 590 or ASTM D975 are recommended. Renewable diesel fuel produced by hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel. Renewable diesel that meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels. Required Fuel Properties In all cases, the fuel shall meet the following properties: Cetane number of 43 minimum. Cetane number greater than 47 is preferred, especially for temperatures below 20 C ( 4 F) or elevations above 1500 m (5000 ft.). Cold Filter Plugging Point (CFPP) should be at least 5 C (9 F) below the expected lowest temperature or Cloud Point below the expected lowest ambient temperature. Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO Diesel fuel quality and sulfur content must comply with all existing emissions regulations for the area in which the engine operates. DO NOT use diesel fuel with sulfur content greater than mg/kg ( ppm). Sulfur content for Interim Tier 4 and Stage III B engines Use ONLY ultra low sulfur diesel (ULSD) fuel with a maximum of 15 mg/kg (15 ppm) sulfur content. Sulfur Content for Tier 3 and Stage III A Engines Use of diesel fuel with sulfur content less than 1000 mg/kg (1000 ppm) is RECOMMENDED Use of diesel fuel with sulfur content mg/kg ( ppm) REDUCES oil and filter change intervals. BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John Deere dealer Sulfur Content for Tier 2 and Stage II Engines Use of diesel fuel with sulfur content less than 500 mg/kg (500 ppm) is RECOMMENDED. Use of diesel fuel with sulfur content mg/kg ( ppm) REDUCES the oil and filter change interval BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John Deere dealer Sulfur Content for Other Engines Use of diesel fuel with sulfur content less than 5000 mg/kg (5000 ppm) is recommended. Use of diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) REDUCES the oil and filter change intervals. IMPORTANT: Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel. IMPORTANT: Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines. DX,FUEL APR11-1/ PN=52

53 Maintenance Machine Biodiesel Fuel Biodiesel fuel is comprised of mono-alkyl esters of long chain fatty acids derived from vegetable oils or animal fats. Biodiesel blends are biodiesel mixed with petroleum diesel fuel on a volume basis. Before using fuel containing biodiesel, review the Biodiesel Use Requirements and Recommendations in this Operator s Manual. Environmental laws and regulations can encourage or prohibit the use of biofuels. Operators should consult with appropriate governmental authorities prior to using biofuels. All John Deere Engines with Exhaust Filter (Released 2011 and After) While 5% blends (B5) are preferred, biodiesel concentrations up to a 20% blend (B20) in petroleum diesel fuel can be used. Biodiesel blends up to B20 can be used ONLY if the biodiesel (100% biodiesel or B100) meets ASTM D6751, EN 14214, or equivalent specification. Expect a 2% reduction in power and a 3% reduction in fuel economy when using B20. Biodiesel concentrations above B20 can harm the engine s emission control systems and should not be used. Risks include, but are not limited to, more frequent stationary regeneration, soot accumulation, and increased intervals for ash removal. John Deere approved fuel conditioners, which contain detergent and dispersant additives, are required when using B20, and are recommended when using lower biodiesel blends. All John Deere Engines Excluding Exhaust Filter (Primarily Released Prior to 2012) While 5% blends (B5) are preferred, biodiesel concentrations up to a 20% blend (B20) in petroleum diesel fuel can be used. Biodiesel blends up to B20 can be used ONLY if the biodiesel (100% biodiesel or B100) meets ASTM D6751, EN 14214, or equivalent specification. Expect a 2% reduction in power and a 3% reduction in fuel economy when using B20. These John Deere engines can operate on biodiesel blends above B20 (up to 100% biodiesel). Operate at levels above B20 ONLY if the biodiesel is permitted by law and meets the EN specification (primarily available in Europe). Engines operating on biodiesel blends above B20 might not fully comply with or be permitted by all applicable emissions regulations. Expect up to a 12% reduction in power and an 18% reduction in fuel economy when using 100% biodiesel. John Deere approved fuel conditioners, which contain detergent and dispersant additives, are required when using B20, and are recommended when using lower biodiesel blends. Biodiesel Use Requirements and Recommendations The petroleum diesel portion of all biodiesel blends must meet the requirements of ASTM D975 (US) or EN 590 (EU) commercial standards. Biodiesel users in the U.S. are strongly encouraged to purchase biodiesel blends from a BQ-9000 Certified Marketer and sourced from a BQ-9000 Accredited Producer (as certified by the National Biodiesel Board). Certified Marketers and Accredited Producers can be found at the following website: Biodiesel contains residual ash. Ash levels exceeding the maximums allowed in either ASTM D6751 or EN14214 can result in more rapid ash loading and require more frequent cleaning of the Exhaust Filter (if present). The fuel filter can require more frequent replacement, when using biodiesel fuel, particularly if switching from diesel. Check engine oil level daily prior to starting engine. A rising oil level can indicate fuel dilution of the engine oil. Biodiesel blends up to B20 must be used within 90 days of the date of biodiesel manufacture. If used, biodiesel blends above B20 must be used within 45 days from the date of biodiesel manufacture. When using biodiesel blends up to B20, the following must be considered: Cold weather flow degradation Stability and storage issues (moisture absorption, microbial growth) Possible filter restriction and plugging (usually a problem when first switching to biodiesel on used engines.) Possible fuel leakage through seals and hoses (primarily an issue with older engines) Possible reduction of service life of engine components Request a certificate of analysis from your fuel distributor to ensure that the fuel is compliant with the specifications provided in this Operator s Manual. Consult your John Deere dealer for approved fuel conditioners to improve storage and performance with biodiesel fuels. The following must also be considered if using biodiesel blends above B20: Possible coking or blocked injector nozzles, resulting in power loss and engine misfire if John Deere approved fuel conditioners are not used Possible crankcase oil dilution (requiring more frequent oil changes) Possible lacquering or seizure of internal components Possible formation of sludge and sediments Possible thermal oxidation of fuel at elevated temperatures Possible compatibility issues with other materials (including copper, lead, zinc, tin, brass, and bronze) used in fuel handling equipment Possible reduction in water separator efficiency Possible damage to paint if exposed to biodiesel Continued on next page DX,FUEL AUG12-1/ PN=53

54 Maintenance Machine Possible corrosion of fuel injection equipment Possible elastomeric seal and gasket material degradation (primarily an issue with older engines) Possible high acid levels within fuel system Because biodiesel blends above B20 contain more ash, using blends above B20 can result in more rapid ash loading and require more frequent cleaning of the Exhaust Filter (if present) IMPORTANT: Raw pressed vegetable oils are NOT acceptable for use as fuel in any concentration in John Deere engines. Their use could cause engine failure. DX,FUEL AUG12-2/2 Testing Diesel Fuel A fuel analysis program can help to monitor the quality of diesel fuel. The fuel analysis can provide critical data such as cetane number, fuel type, sulfur content, water content, appearance, suitability for cold weather operations, bacteria, cloud point, acid number, particulate contamination, and whether the fuel meets specification. Contact your John Deere dealer for more information on diesel fuel analysis. DX,FUEL APR11-1/1 Handling and Storing Diesel Fuel CAUTION: Reduce the risk of fire. Handle fuel carefully. DO NOT fill the fuel tank when engine is running. DO NOT smoke while you fill the fuel tank or service the fuel system. Fill the fuel tank at the end of each day's operation to prevent water condensation and freezing during cold weather. Keep all storage tanks as full as practicable to minimize condensation. Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering. Monitor water content of the fuel regularly. When using biodiesel fuel, the fuel filter may require more frequent replacement due to premature plugging. Check engine oil level daily prior to starting engine. A rising oil level may indicate fuel dilution of the engine oil. IMPORTANT: The fuel tank is vented through the filler cap. If a new filler cap is required, always replace it with an original vented cap. When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel conditioner to stabilize the fuel and prevent water condensation. Contact your fuel supplier for recommendations. DX,FUEL APR11-1/ PN=54

55 Maintenance Machine Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location. Synthetic lubricants may be used if they meet the performance requirements as shown in this manual. The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils. Re-refined base stock products may be used if the finished lubricant meets the performance requirements. If alternative hydraulic oils are required the hydraulic system needs to be completely flushed. This may require large amounts of oil to properly drain previous product. NOTE: The following alternative oils could be used if factory fill has been completely flushed out. Texaco Rando 46 Texaco Rando 32 Mobil DTE25-46 Mobil DTE25-32 Shell Tellus 46 Shell Tellus 32 Consult your authorized dealer to obtain specific information and recommendations. IMPORTANT: Avoid mixing different brands or types of oils. Oil manufacturers blend base stock and additives to create their oils and to meet certain specifications and performance requirements. Mixing different oils can interfere with proper functioning of these formulations and degrade lubricant performance. This excavator is factory filled with 46HN extended life zinc-free hydraulic oil. Avoid servicing this excavator with products that do not meet this specification. If oils have been mixed or if alternate service oils are desired, the complete hydraulic system needs to be totally flushed by an authorized dealer. DW90712,00001C JUL06-1/1 Diesel Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. John Deere Plus-50 II oil is preferred. John Deere Plus-50 is also recommended. Other oils may be used if they meet one or more of the following: John Deere Torq-Gard API Service Category CJ-4 API Service Category CI-4 PLUS API Service Category CI-4 ACEA Oil Sequence E9 ACEA Oil Sequence E7 ACEA Oil Sequence E6 ACEA Oil Sequence E5 ACEA Oil Sequence E4 Multi-viscosity diesel engine oils are preferred. Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates. DO NOT use diesel fuel with sulfur content greater than mg/kg ( ppm). Plus-50 is a trademark of Deere & Company Torq-Gard is a trademark of Deere & Company SAE 15W-40 SAE 10W-40 SAE 10W o C 40 o C 30 o C 20 o C 10 o C o o 0 C 32 F -10 o C -20 o C -30 o C -40 o C 122 o F 104 o F 86 o F 68 o F 50 o F 14 o F -4 o F -22 o F -40 o F SAE 0W-40 SAE 5W-30 Oil Viscosities for Air Temperature Ranges TS1691 UN 18JUL07 DX,ENOIL APR11-1/ PN=55

56 Maintenance Machine Diesel Engine Oil and Filter Service Intervals The oil and filter service intervals in the following table should be used as guidelines. Actual service intervals also depend on operation and maintenance practices. It is suggested to use oil analysis to determine the actual useful life of the oil and to aid in selection of the proper oil and filter service interval. Oil and filter service intervals are based on a combination of oil pan capacity, type of engine oil and filter used, and sulfur content of the diesel fuel. Diesel fuel sulfur level will affect engine oil and filter service intervals. Higher fuel sulfur levels reduce oil and filter service intervals as shown in the table. Use of diesel fuel with sulfur content less than 0.10% (1000 mg/kg) is strongly recommended. Use of diesel fuel with sulfur content 0.10% (1000 mg/kg) to 0.50% (5000 mg/kg) may result in REDUCED oil and filter change intervals as shown in the table. BEFORE using diesel fuel with sulfur content greater than 0.50% (5000 mg/kg), contact your John Deere dealer. DO NOT use diesel fuel with sulfur content greater than 1.00% ( mg/kg). IMPORTANT: When using biodiesel blends greater than B20, reduce the oil and filter service interval by 50% or monitor engine oil based on test results from Oilscan. Oil types in the table include: John Deere Plus-50 II and John Deere Plus-50 Other Oils include John Deere Torq-Gard Supreme, API CJ-4, API CI-4 PLUS, API CI-4, ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils. Use of lower specification oils in Tier 3 engines may result in premature engine failure. NOTE: The 500 hour extended oil and filter change interval is only allowed if all the following conditions are met: Engine equipped with an extended drain interval oil pan Use of diesel fuel with sulfur content less than 0.50% (5000 mg/kg) Use of John Deere Plus-50 II or John Deere Plus-50 oil Use of an approved John Deere oil filter Oil pan capacity Greater than or equal to 0.10 U.S. Tier 3 and EU Stage III A - PowerTech Plus Oil Pan Size (L/kW) Greater than or equal to 0.12 Greater than or equal to 0.14 Greater than or equal to 0.22 U.S. Tier 3 and EU Stage III A - PowerTech Oil Pan Size (L/kW) Greater than or equal to 0.10 Greater than or equal to 0.12 Greater than or equal to 0.14 Fuel Sulfur Less than 0.10% (1000 mg/kg) Less than 0.10% (1000 mg/kg) Plus hours 500 hours 500 hours 500 hours 375 hours 500 hours 500 hours Other Oils 250 hours 250 hours 250 hours 250 hours 250 hours 250 hours 250 hours Fuel Sulfur % ( mg/kg) % ( mg/kg) Plus hours 300 hours 500 hours 500 hours 300 hours 400 hours 500 hours Other Oils 200 hours 200 hours 250 hours 250 hours 200 hours 200 hours 250 hours Fuel Sulfur % ( mg/kg) % ( mg/kg) Plus hours 250 hours 300 hours 500 hours 275 hours 350 hours 500 hours Other Oils 150 hours 150 hours 200 hours 250 hours 150 hours 175 hours 250 hours Fuel Sulfur % ( mg/kg) % ( mg/kg) Plus-50 Contact John Deere Dealer (dealer refers to DTAC solutions) 187 hours 250 hours 250 hours Other Oils Contact John Deere Dealer (dealer refers to DTAC solutions) 125 hours 125 hours 125 hours The service interval of Other Oils may be extended only if oil analysis is performed to determine the actual service life, to a maximum not to exceed that of Plus-50. Plus-50 is a trademark of Deere & Company Torq-Gard Supreme is a trademark of Deere & Company PowerTech Plus is a trademark of Deere & Company PowerTech is a trademark of Deere & Company DX,ENOIL AUG09-1/ PN=56

57 Maintenance Machine Hydraulic Oil IMPORTANT: Avoid mixing different brands or types of oils. Oil manufacturers engineer their oils to meet certain specifications and performance requirements. Mixing different oil types can degrade lubricant and machine performance. Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oil is preferred: 2000 hour change interval: Super EX 46HN Hitachi excavator oil from John Deere 1000 hour change interval: The following products can be used provided a complete hydraulic system flush has been performed. Contact your dealer for this procedure. Biodegradable Hydraulic Oil: Super EX 46HN Premium AW C 40 C 30 C 20 C 10 C 0 C -10 C -20 C -30 C -40 C 122 F 104 F 86 F 68 F 50 F 32 F 14 F -4 F -22 F -40 F Daphne Super Hydro A 32 Premium AW32 TX UN 24JUN10 Use only Exxon Mobil EAL Envirosyn 46H Synthetic Esther Oil when a biodegradable oil is required. (Contact your John Deere dealer for Registration and Routine Oil Analysis to meet warranty requirements.) DW90712, FEB12-1/1 Swing Gearbox and Travel Gearbox Oils Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oils are preferred: John Deere GL-5 GEAR LUBRICANT John Deere EXTREME-GARD Other oils may be used if they meet API Service Classification GL-5. TS1653 UN 14MAR96 EXTREME-GARD is a trademark of Deere & Company. ER93822,000016C MAY08-1/ PN=57

58 Maintenance Machine Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following greases are preferred: John Deere SD POLYUREA GREASE The following greases are also recommended: John Deere HD MOLY GREASE John Deere HD LITHIUM COMPLEX GREASE John Deere HD WATER RESISTANT GREASE John Deere GREASE-GARD Other greases may be used if they meet the following: NLGI Performance Classification GC-LB IMPORTANT: Some types of grease thickener are not compatible with others. TS1667 UN 30JUN99 CED,TX14740, DEC09-1/1 Heavy Duty Diesel Engine Coolant The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37 C (-34 F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations. The following engine coolants are preferred: John Deere COOL-GARD II Premix John Deere COOL-GARD II PG Premix Use John Deere COOL-GARD II PG Premix when a non-toxic coolant formulation is required. Additional Recommended Coolants The following engine coolant is also recommended: John Deere COOL-GARD II Concentrate in a 40 60% mixture of concentrate with quality water. John Deere COOL-GARD II Premix, COOL-GARD II PG Premix, and COOL-GARD II Concentrate coolants do not require use of supplemental coolant additives. Other Coolants John Deere COOL-GARD II and COOL-GARD II PG coolants might not be available in the geographical area where service is performed. If these coolants are unavailable, use a coolant concentrate or prediluted coolant intended for use with COOL-GARD is a trademark of Deere & Company heavy duty diesel engines and with a minimum of the following chemical and physical properties: Is formulated with a quality nitrite-free additive package. Provides cylinder liner cavitation protection according to either the John Deere Cavitation Test Method or a fleet study run at or above 60% load capacity Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion The additive package must be part of one of the following coolant mixtures: ethylene glycol or propylene glycol base prediluted (40 60%) heavy duty coolant ethylene glycol or propylene glycol base heavy duty coolant concentrate in a 40 60% mixture of concentrate with quality water Water Quality Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives. Do not mix ethylene glycol and propylene glycol base coolants. Do not use coolants that contain nitrites. DX,COOL APR11-1/ PN=58

59 Maintenance Machine Drain Intervals for Diesel Engine Coolant Drain and flush the cooling system and refill with fresh coolant at the indicated interval, which varies with the coolant used. John Deere COOL-GARD II Premix, COOL-GARD II PG Premix and COOL-GARD II Concentrate are maintenance free coolants for up to six years or 6000 hours of operation, provided that the cooling system is topped off using only John Deere COOL-GARD II Premix or COOL-GARD II PG Premix. Test the coolant condition annually with Coolant Test Strips designed for use with John Deere COOL-GARD II coolants. If the test strip chart indicates that additive is required, add John Deere COOL-GARD II Coolant Extender as directed. COOL-GARD is a trademark of Deere & Company If John Deere COOL-GARD II Premix, COOL-GARD II PG Premix, or COOL-GARD II Concentrate is used, but the coolant is not tested OR additives are not replenished by adding John Deere COOL-GARD II Coolant Extender, the drain interval is four years or 4000 hours of operation. This drain interval only applies to COOL-GARD II coolants that have been maintained within a 40 60% mixture of concentrate with quality water. If a coolant other than COOL-GARD II, or COOL-GARD II PG is used, reduce the drain interval to two years or 2000 hours of operation. DX,COOL APR11-1/1 John Deere COOL-GARD II Coolant Extender Some coolant additives will gradually deplete during engine operation. For John Deere COOL-GARD II Premix, COOL-GARD II PG Premix, and COOL-GARD II Concentrate, replenish coolant additives between drain intervals by adding John Deere COOL-GARD II Coolant Extender. John Deere COOL-GARD II Coolant Extender should not be added unless indicated by coolant testing. John Deere COOL-GARD II Coolant Extender is a chemically matched additive system for use with all John Deere COOL-GARD II coolants. John Deere COOL-GARD II Coolant Extender is not intended for use with nitrite-containing coolants. COOL-GARD is a trademark of Deere & Company IMPORTANT: Do not add a supplemental coolant additive when the cooling system is drained and refilled with any of the following: John Deere COOL-GARD II John Deere COOL-GARD II PG The use of non-recommended supplemental coolant additives may result in additive drop-out, gelation of the coolant, or corrosion of cooling system components. Add the recommended concentration of John Deere COOL-GARD II Coolant Extender. DO NOT add more than the recommended amount. DX,COOL APR11-1/ PN=59

60 Maintenance Machine Supplemental Coolant Additives Some coolant additives will gradually deplete during engine operation. For nitrite-containing coolants, replenish coolant additives between drain intervals by adding a supplemental coolant additive as determined necessary by coolant testing. John Deere Liquid Coolant Conditioner is recommended as a supplemental coolant additive for nitrite-containing coolants. John Deere Liquid Coolant Conditioner is not designed for use with John Deere COOL-GARD II Premix, COOL-GARD II PG Premix, or COOL-GARD II Concentrate. IMPORTANT: Do not add a supplemental coolant additive when the cooling system is drained and refilled with any of the following: COOL-GARD is a trademark of Deere & Company John Deere COOL-GARD II John Deere COOL-GARD II PG If other coolants are used, consult the coolant supplier and follow the manufacturer's recommendation for use of supplemental coolant additives. The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant. Add the manufacturer's recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount. DX,COOL APR11-1/1 Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants. Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required. John Deere COOL-GARD II Premix is available in a concentration of 50% ethylene glycol. However, there are situations in warm temperature climates where a coolant with lower glycol concentration (approximately 20% ethylene glycol) has been approved. In these cases, the low glycol formulation has been modified to provide the same level of corrosion inhibitor as John Deere COOL-GARD II Premix (50/50). COOL-GARD is a trademark of Deere & Company IMPORTANT: Water may be used as coolant in emergency situations only. Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added. Drain cooling system and refill with recommended glycol base engine coolant as soon as possible. DX,COOL NOV08-1/ PN=60

61 Maintenance Machine Additional Information About Diesel Engine Coolants and John Deere COOL-GARD II Coolant Extender Engine coolants are a combination of three chemical components: ethylene glycol (EG) or propylene glycol (PG) antifreeze, inhibiting coolant additives, and quality water. Coolant Specifications John Deere COOL-GARD II Premix either EG or PG, are fully formulated coolants that contain all three components in their correct concentrations. DO NOT add an initial charge of John Deere COOL-GARD II Coolant Extender to COOL-GARD II Premix. DO NOT add any other supplemental coolant additive or water to COOL-GARD II Premix. John Deere COOL-GARD II Concentrate contains both ethylene glycol and inhibiting coolant additives. Mix this product with quality water, but DO NOT add an initial charge of John Deere COOL-GARD II Coolant Extender or any other supplemental coolant additive. Replenish Coolant Additives Some coolant additives will gradually deplete during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL-GARD II Premix or COOL-GARD II Concentrate is used. Follow the recommendations in this manual for the use of John Deere COOL-GARD II Coolant Extender. Why use John Deere COOL-GARD II Coolant Extender? Operating without proper coolant additives will result in increased corrosion, cylinder liner erosion and pitting, and other damage to the engine and cooling system. A simple mixture of ethylene glycol or propylene glycol and water will not give adequate protection. John Deere COOL-GARD II Coolant Extender is a chemically matched additive system designed to fortify the proprietary additives used in John Deere COOL-GARD II Premix and COOL-GARD II Concentrate and to provide optimum protection for up to six years or 6000 hours of operation. COOL-GARD is a trademark of Deere & Company Avoid Automotive-type Coolants Never use automotive-type coolants (such as those meeting ASTM D3306). These coolants do not contain the correct additives to protect heavy-duty diesel engines. Do not treat an automotive engine coolant with supplemental coolant additives because the high concentration of additives can result in additive fallout. Water Quality Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.all water used in the cooling system should meet the following minimum specifications for quality: Chlorides <40 mg/l Sulfates <100 mg/l Total dissolved solids <340 mg/l Total hardness <170 mg/l ph 5.5 to 9.0 Freeze Protection The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit. Ethylene Glycol Freeze Protection Limit 40% -24 C (-12 F) 50% -37 C (-34 F) 60% -52 C (-62 F) Propylene Glycol Freeze Protection Limit 40% -21 C (-6 F) 50% -33 C (-27 F) 60% -49 C (-56 F) DO NOT use a coolant-water mixture greater than 60% ethylene glycol or 60% propylene glycol. DX,COOL APR11-1/ PN=61

62 Maintenance Machine Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting. Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating. Coolant Test Strips Coolant test strips are available from your John Deere dealer. These test strips provide a simple, effective method to check the freeze point and additive levels of your engine coolant. When Using John Deere COOL-GARD II John Deere COOL-GARD II Premix, COOL-GARD II PG Premix and COOL-GARD II Concentrate are maintenance free coolants for up to six years or 6000 hours of operation, provided that the cooling system is topped off using only John Deere COOL-GARD II Premix or COOL-GARD II PG premix. Test the coolant condition annually with coolant test strips designed for use with John Deere COOL-GARD II coolants. If the test strip chart indicates that additive is required, add John Deere COOL-GARD II Coolant Extender as directed. COOL-GARD is a trademark of Deere & Company Add only the recommended concentration of John Deere COOL-GARD II Coolant Extender. DO NOT add more than the recommended amount. When Using Nitrite-Containing Coolants Compare the test strip results to the supplemental coolant additive (SCA) chart to determine the amount of inhibiting additives in your coolant and whether more John Deere Liquid Coolant Conditioner should be added. Add only the recommended concentration of John Deere Liquid Coolant Conditioner. DO NOT add more than the recommended amount. Coolant Analysis For a more thorough evaluation of your coolant, perform a coolant analysis. The coolant analysis can provide critical data such as freezing point, antifreeze level, ph, alkalinity, nitrite content (cavitation control additive), molybdate content (rust inhibitor additive), silicate content, corrosion metals, and visual assessment. Contact your John Deere dealer for more information on coolant analysis. DX,COOL APR11-1/ PN=62

63 Maintenance Periodic Maintenance Service Machine at Specified Intervals Lubricate, make service checks, and make adjustments at intervals shown on the periodic maintenance chart and on the following pages. Perform service on items at multiples of the original requirement. For example, at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours, and 10 hours or daily. TX14740,0001C9F JUL07-1/1 Check the Hour Meter Regularly T UN 07DEC04 TX UN 27FEB12 Hour Meter (S.N ) Hour Meter (S.N ) 1 Hour Meter Check the hour meter (1) to determine when your machine needs periodic maintenance. Intervals on the periodic maintenance chart are for operating in normal conditions. If you operate your machine in difficult conditions, you should service it at shorter intervals. ER93822,00000FC FEB12-1/ PN=63

64 Maintenance Periodic Maintenance Prepare Machine for Maintenance 1. Park machine on a level surface, and lower bucket to the ground as shown. 2. Turn auto-idle switch to the OFF position. 3. Turn the engine speed dial (1) to slow idle. 4. Stop engine and remove key. 5. Pull the pilot shutoff lever (2) to the lock position. 1 Engine Speed Dial 2 Pilot Shutoff Lever TX UN 06JUN08 TX A UN 10JUN08 TX A UN 04JUN08 ER93822,00001A JUN08-1/ PN=64

65 Maintenance Periodic Maintenance Opening Access Doors and Covers for Service CAUTION: Prevent possible injury from door closing. Secure doors and covers in the OPEN position. TX A UN 05JUN08 TX A UN 05JUN08 Door Stopper Assembly (Right Door Shown) TX A UN 05JUN08 TX A UN 05JUN08 1 Right Access Door 2 Latch 3 Door Stopper 4 Door Stopper Holder 5 Access Door Lock Hole 6 Right Access Cover 7 Rod 8 Left Access Door 9 Cap Screw 10 Tank Cover 11 Tank Access Button To open right access door (1): 1. Pull latch (2) and guide right access door open. 2. Lift door stopper (3) out of door stopper holder (4). 3. Install stopper into access door lock hole (5). Right access door is secured in OPEN position. 4. Lift right access cover (6) until rod (7) is secured. Right access cover is secured in OPEN position. To open left access door (8): 1. Loosen cap screws (9). 2. Pull left access door open. 3. Lift door stopper (3) out of door stopper holder (4). 4. Install stopper into door lock hole (5). Door is secured in OPEN position. Continued on next page ER93822,00001A JUN08-1/ PN=65

66 Maintenance Periodic Maintenance TX A UN 05JUN08 TX A UN 05JUN08 TX A UN 05JUN08 10 Tank Cover 11 Tank Access Button 12 Wire 13 Cover Stopper 14 Cover Stopper Holder 15 Lock Hollow 16 Engine Access Door 17 Engine Access Latch 18 Engine Access Stopper To open tank cover (10): 1. Press tank access button (11). 2. Lift and guide tank cover toward the front of machine until wire (12) is extended. 3. Lift cover stopper (13) out of cover stopper holder (14). 4. Install stopper into lock hollow (15). 5. Lift cover gently until stopper is secured in lock hollow. Cover is secured in OPEN position. To open engine access door (16): 1. Lift engine access latch (17) to open engine access door. 2. Fully raise engine access door. 3. Engine access stopper (18) secures engine access door in OPEN position. To close engine access door, lift cover and push in top half of engine access stopper simultaneously to release engine access stopper. Slowly allow the engine access door to begin lowering. Release pressure on engine access stopper. Complete closing of engine access door by securely setting engine access latch. ER93822,00001A JUN08-2/ PN=66

67 Maintenance Periodic Maintenance Tilting the Operator Station IMPORTANT: Avoid machine damage. Do not use another method of tilting the operator station. Avoid damaging the tilt mechanism or operator station. Raise and lower the operator station slowly. Tilting Operator Station 1. Park machine on level surface with pilot shutoff lever in the locked position. 2. Close cab door, if equipped. 3. Move boom as far to the right as possible and retract all cylinders to avoid damaging machine. Tilting Boom Position T205706A UN 06DEC04 MD04263,000007D OCT12-1/3 4. Loosen panel cap screws (1) and raise panel (2). Tighten screws to hold panel in place. IMPORTANT: Avoid damaging operator station platform. Do not remove operator station platform cap screws (3). 5. Remove four operator station mounting cap screws (4) from rear of operator station. 1 Panel Cap Screw (2 used) 2 Panel 3 Operator Station Platform Cap Screw (2 used) 4 Operator Station Mounting Cap Screw (4 used) T UN 07DEC04 TX UN 23OCT12 Continued on next page MD04263,000007D OCT12-2/ PN=67

68 Maintenance Periodic Maintenance IMPORTANT: Avoid potential machine damage. Avoid contact between operator station and hoses, swing casting, or boom while tilting the operator station. 6. Turn tilt screw (1) clockwise until disk (2) is at end of tilt stop (3). 7. If access to the interior of the cab is required, open cab door and ensure both door latches are engaged. Lowering Operator Station IMPORTANT: Prevent damage to the cab door. Cab door must be closed before lowering operator station. 1. Turn tilt screw counterclockwise slowly until operator station is completely lowered. Do not over-tighten tilt screw. 2. Install operator station mounting cap screws in rear of operator station. Tighten to specification. Specification Operator Station Tilt Cap Screws Torque...90 N m 66 lb-ft 3. Loosen panel cap screws and lower panel. Tighten cap screws. 1 Tilt Screw 2 Disk Tilt Screw Assembly 3 Tilt Stop MD04263,000007D OCT12-3/3 TX UN 04DEC08 Fuel Tank CAUTION: Handle fuel carefully. DO NOT fill the fuel tank when engine is running. DO NOT smoke while you fill the fuel tank or service the fuel system. To avoid condensation, fill the fuel tank at the end of each day s operation. Specification 60D Fuel Tank Capacity L 32.0 gal ER93822,000019A JUN08-1/1 Checking Washer Fluid Level Check level in washer fluid reservoir (1). 1 Washer Fluid Reservoir T UN 29NOV04 OUO1032, NOV04-1/ PN=68

69 Maintenance Periodic Maintenance Hydraulic Breaker and Crusher Attachments IMPORTANT: Avoid mixing different brands or types of oils. Oil manufacturers engineer their oils to meet certain specifications and performance requirements. Mixing different oil types can degrade lubricant and machine performance. This excavator is factory filled with 46HN extended life zinc-free hydraulic oil. Avoid servicing this excavator with products that do not meet this specification. If oils have been mixed or if alternate service oils are desired, the complete hydraulic system needs to be totally flushed by an authorized dealer. Hydraulic breaker or crusher operation subjects the machine s hydraulic system to possible contamination and accelerated deterioration. The hydraulic return filter and hydraulic oil must be replaced more often to prevent damage to hydraulic pumps and other hydraulic components. Use of different attachments may shorten oil change interval. Use this table for reference. Bucket, Breaker, and Crusher Attachments Attachment Percentage of Operating Time Hydraulic Return Filter Change Interval Hydraulic Oil Change Interval Bucket 100% 500 hours 2000 hours Breaker or Crusher 100% 250 hours 1000 hours VD76477,00000C APR06-1/1 Maintenance and Repair Record Keeping System The checklist in this section summarizes scheduled maintenance, and parts and oil required at each maintenance interval. Use the checklist to: Remind you to perform machine maintenance at specified intervals to minimize downtime. Calculate cost of machine operation and ownership allowing you to make better job estimates. Place yourself in a stronger position at trade-in time. Satisfy your SECURE contract requirements. As maintenance is performed, check off each item on the list and record date and hour meter reading. Do not tear out or mark on checklist in this section; keep it to make extra copies. T7511CO UN 27JUN91 TX,50,FF NOV01-1/ PN=69

70 Maintenance Periodic Maintenance Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit Fluid Analysis Program Test Kits and the 3-Way Coolant Test Kit are John Deere fluid sampling products to help you monitor machine maintenance and system condition. The objective of a fluid sampling program is to ensure machine availability when you need it and to reduce repair costs by identifying potential problems before they become critical. Engine, hydraulic, power train, and coolant samples should be taken from each system on a periodic basis, usually prior to a filter and/or fluid change interval. Certain systems require more frequent sampling. Consult your authorized John Deere dealer on a maintenance program for your specific application. Your authorized John Deere dealer has the sampling products and expertise to assist you in lowering your overall operating costs through fluid sampling. Fluid Analysis Kits TX A UN 20FEB06 AM40430,00002FE OCT11-1/ PN=70

71 Maintenance Periodic Maintenance Service Intervals Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 2000 hours also service those items (if applicable) listed under 1000 hours, 500 hours, 250 hours, 50 hours, and 10 hours or daily. OIL SAMPLING Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form: 250, 500, 1000, and 2000 hours. Maintenance recommendations will be provided based upon the oil analysis and operating information you supply. Regular oil sampling will extend the operational life of your machine s systems. As Required Clean air cleaner element Clean radiator core Add coolant extender as indicated by COOL-GARD II test strips Check engine oil level Check hydraulic tank oil level Drain fuel tank sump Drain water separator Every 10 Hours or Daily Check coolant level at recovery tank Check bucket teeth Check track sag Check seat belt Initial Service 50 Hours 1 Grease bucket and link pins Check and adjust fan belt tension Grease front joint pins 1 Perform initial service once after the first 50 hours of operation. Grease bucket and link pins Grease front joint pins Every 100 Hours Check and adjust fan belt tension Initial Service 250 Hours 2 Replace hydraulic oil filter 2 Perform initial service once after the first 250 hours of operation. Take engine oil sample Check travel gearbox oil level Lubricate device tilting mechanism Lubricate angle blade rod pin if equipped Every 250 Hours Lubricate swing bearing Drain hydraulic oil tank sump Lubricate angle blade bottom pin if equipped Take engine coolant sample Take diesel fuel sample Replace air cleaner element Lubricate front joint pins Lubricate swing bearing gear Lubricate control lever universal joint Lubricate center pin if equipped Every 500 Hours Take travel gearbox oil sample Take hydraulic oil sample Replace hydraulic oil filter Replace fuel filter Change engine oil and replace filter Lubricate blade pins Drain and refill travel gearbox oil Replace pilot control oil filter Inspect crankcase breather system Every 1000 Hours Check and adjust valve clearance Check starter and alternator Check coolant Drain and refill hydraulic tank oil, clean suction screen Every 2000 Hours Every 6000 Hours Continued on next page ER93822,00000FE FEB12-1/ PN=71

72 Maintenance Periodic Maintenance Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 2000 hours also service those items (if applicable) listed under 1000 hours, 500 hours, 250 hours, 50 hours, and 10 hours or daily. Drain and refill engine coolant COOL-GARD is a trademark of Deere & Company ER93822,00000FE FEB12-2/2 Required Parts REQUIRED PARTS Ensure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated parts are also on hand, i.e., filter O-rings. Item Part Number Initial Service 250 Hours 1 Every 250 Hours Every 500 Hours Every 1000 Hours Every 2000 Hours Every 6000 Hours Hydraulic System Return Oil Filter AT O-Ring for AT Engine Oil Filter MIU Fuel Filter Element MIU Air Filter Primary RE Pilot Control Oil Filter O-Ring for Engine Rocker Arm Cover Gasket MIU Fuel and Water Separator Element MIU As Needed Cab Air Recirculation Filter As Needed Cab Fresh Air Filter As Needed John Deere Plus-50 II Oil TY L (3.0 gal.) API GL-5 Gear Oil (each travel TY gearbox) Hitachi SUPER EX 46HN Hydraulic Oil 11.2 L (3.0 gal.) 0.9 L (1.0 qt.) 11.2 L (3.0 gal.) 0.9 L (1.0 qt.) L (23.0 gal.) 11.2 L (3.0 gal.) 0.9 L (1.0 qt.) 87 L (23.0 gal.) COOL-GARD II Pre-mix TY L (2.0 gal.) Coolant Extender TY26603 As Needed Fluid Analysis Kits 3 Diesel Engine Oil AT Hydraulic Oil AT Travel Gearbox Oil AT Diesel Fuel AT Engine Coolant TY COOL-GARD II Test Strips TY Perform initial service once after the first 250 hours of operation. 2 For recommended oil types and oil viscosities based on operating temperatures, see Maintenance-Machine. (Section 3-1.) Plus-50 is a trademark of Deere & Company COOL-GARD is a trademark of Deere & Company 3 Based on fluid analysis results, intervals may need to be adjusted for your operating conditions. Consult your local John Deere dealer, ER93822,00000FD FEB12-1/ PN=72

73 Maintenance As Required Cleaning Air Cleaner Element 1. Loosen clamps (2) to remove cover (3). 2. Remove element (1). 3. Tap element with the palm of your hand, NOT ON A HARD SURFACE. CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kpa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kpa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. T UN 17AUG99 4. If this does not remove dust, use compressed air under 210 kpa (2.1 bar) (30 psi). 5. Direct air up and down from inside to outside. Be careful not to make a break in the element. 6. Install element. 7. Install cover with dust unloader valve (4) pointing down and tighten clamps. 8. Check air filter restriction indicator (5). If necessary, replace element. See Replacing Air Cleaner Element. (Section 3-7.) 1 Air Cleaner Element 2 Clamp (2 used) 3 Cover 4 Dust Unloader Valve 5 Air Filter Restriction Indicator TX A UN 05JUN08 ER93822, JUN08-1/1 Cleaning Radiator Core and Oil Cooler CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kpa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kpa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. Clean the radiator core and oil cooler with compressed air or water. Blow air straight through fins to avoid bending them. OUO1032,000159E NOV04-1/ PN=73

74 Maintenance As Required Check Coolant CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Remove radiator filler cap (1) only when engine is cold or when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely. IMPORTANT: John Deere COOL-GARD II Coolant Extender does not protect against freezing. Coolant extender prevents rust, scale, and liner cavitation. NOTE: Check coolant every 1000 hours or 1 year, or when replacing 1/3 or more of coolant. Add coolant extender as indicated by John Deere COOL-GARD II test strips. 1. Remove radiator filler cap (1) and test coolant solution. Use the following kit to check coolant: COOL-GARD II Test Strips Coolant test strips provide an effective method to check freeze point and additive levels of engine coolant. See your authorized dealer for COOL-GARD II test strips and follow instructions on kit. 2. Add John Deere COOL-GARD II Coolant Extender as necessary. Follow instructions on container for amount. For more information concerning cooling system capacity, see Drain and Refill Capacities. (Section 4-6.) COOL-GARD is a trademark of Deere & Company Recovery Tank 1 Radiator Filler Cap 2 Recovery Tank 3. Install radiator filler cap. ER93822, FEB12-1/1 T UN 01DEC04 TS281 UN 23AUG PN=74

75 Maintenance Every 10 Hours or Daily Checking Engine Oil Level IMPORTANT: Prevent engine damage. Do not run engine when oil level is below MIN. level on dipstick. The most accurate oil level reading is obtained when the engine is cold before starting the engine for the day s operation. 1. Make sure dipstick (1) is fully seated. 2. Remove dipstick to check oil level. BEFORE THE ENGINE IS STARTED: The engine is full when oil level is between MIN. and MAX levels on dipstick. AFTER THE ENGINE HAS BEEN RUN: Allow the oil to drain into the oil pan for 10 minutes before checking the oil level. Ten minutes after shutdown the engine oil level must be above the cross-hatch area. 1 Dipstick 2 Filler Cap 3. If necessary, remove filler cap (2) to add oil. (See Section 3-1.) TX A UN 30MAY08 ER93822, MAY08-1/ PN=75

76 Maintenance Every 10 Hours or Daily Checking Hydraulic Oil Tank Level IMPORTANT: Prevent damage to hydraulic system components. Do not run engine without oil in hydraulic tank. Avoid mixing different brands or types of oils. Oil manufacturers engineer their oils to meet certain specifications and performance requirements. Mixing different oil types can degrade lubricant and machine performance. This excavator is factory filled with 46HN extended life zinc-free hydraulic oil. Avoid servicing this excavator with products that do not meet this specification. If oils have been mixed or if alternate service oils are desired, the complete hydraulic system needs to be totally flushed by an authorized dealer. 1. Park machine on a level surface and position machine with cylinders fully retracted. 2. Stop engine. 3. Check hydraulic oil sight gauge (1) on hydraulic tank. Oil must be between marks on window. 4. If necessary, add oil. To add oil: 1. Open maintenance access cover. CAUTION: Avoid injury. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by SLOWLY loosening cap (2). 2. Slowly turn hydraulic oil filler cap (2) counterclockwise a few degrees to relieve pressure. Remove cap. 1 Hydraulic Oil Sight Gauge 2 Hydraulic Oil Filler Cap 3. Add oil. (See Section 3-1.) 4. Install filler cap. T UN 09DEC04 TX A UN 05JUN08 ER93822, JUN08-1/1 Draining Fuel Tank Sump NOTE: Fuel tank drain valve (1) is located under machine directly below fuel tank. 1. Open drain valve (1) for several seconds to drain water and sediment into a container. Dispose of waste properly. 2. Close drain valve. 1 Fuel Tank Drain Valve TX A UN 05JUN08 ER93822,00001A JUN08-1/ PN=76

77 Maintenance Every 10 Hours or Daily Draining Water Separator 1. Open right access door to access water separator (1). 2. Open drain valve (2) for several seconds to drain water and sediment into a container. Dispose of waste properly. 3. Close drain valve. 4. Close access door. 1 Water Separator 2 Drain Valve TX A UN 05JUN08 ER93822,00001AA JUN08-1/1 Checking Recovery Tank Coolant Level With the engine cold, coolant level must be between the FULL and LOW marks on the recovery tank (2). If coolant is below the LOW mark, add coolant to the recovery tank. CAUTION: Prevent possible injury from hot spraying water. DO NOT remove radiator filler cap (1) unless engine is cool. Then turn cap slowly to the stop. Release all pressure before you remove cap. IMPORTANT: Avoid mixing different brands or types of coolant. Coolant manufacturers engineer their coolants to meet certain specifications and performance requirements. Mixing different coolant types can degrade coolant and machine performance. If recovery tank is empty, check for leaks. Repair as required. Add coolant to the radiator then the recovery tank. Recovery Tank 1 Radiator Filler Cap 2 Recovery Tank NOTE: If recovery tank is full and radiator is low, check for leaks in radiator cap and hose connections between radiator and coolant recovery tank. Coolant level must be at bottom of the radiator filler neck. T UN 01DEC04 ER93822,00001AB JUN08-1/1 Checking Bucket Teeth Check bucket teeth for wear. Replace tooth if tooth wear is below 65 mm (2.6 in.) NOTE: Alternate buckets may use different tooth assemblies. CAUTION: Guard against injury from flying pieces of metal; wear goggles or safety glasses. CED,TX14740, JUL02-1/ PN=77

78 Maintenance Every 10 Hours or Daily Checking Track Sag Rubber Track 1. Rotate upperstructure so front of upperstructure is over travel motors (180 ). 2. Lower the bucket and blade to raise both tracks off ground. 3. Raise pilot control shutoff lever to locked position. CAUTION: Prevent possible injury from unexpected machine movement. Place blocks under machine frame to support machine while measuring track sag. 4. Place blocks under machine frame to support machine. 5. Lower pilot control shutoff lever to unlocked position. 6. Rotate track so track joint is positioned at the upper center of the track. 7. Stop engine. T UN 18JUN99 OUO1032,00015B JAN07-1/2 8. Measure distance (1) from bottom of center roller to inner ridge of rubber track. Specification Track Sag mm in. 9. If not to specification, adjust track sag. See Adjusting Track Sag. 10. Repeat check on other side of machine. 1 Track Sag Distance T UN 10JUN99 T UN 10JUN99 OUO1032,00015B JAN07-2/ PN=78

79 Maintenance Every 10 Hours or Daily Checking Track Sag Steel Track If Equipped 1. Rotate upperstructure 90 and lower bucket to raise track off ground. 2. Keep the angle (1) between boom and arm and position the bucket s round side on the ground. CAUTION: Prevent possible injury from unexpected machine movement. Place blocks under machine frame to support machine while measuring track sag. 3. Place blocks under machine frame to support machine. 4. Rotate track forward two full rotations and then in reverse two full rotations. 5. Stop engine. 6. Measure distance (2) at middle track roller from bottom of track frame to top surface of track shoe. Specification Track Sag mm in. 7. If not to specification, adjust track sag. See Adjusting Track Sag. (Section 3-4.) 8. Repeat check on other side of machine. 1 Boom-to-Arm Angle 2 Track Frame-to-Track Shoe Distance T UN 30NOV04 T UN 30NOV04 ER93822,00001A JUN08-1/ PN=79

80 Maintenance Every 10 Hours or Daily Adjusting Track Sag IMPORTANT: Prevent possible damage to track components. DO NOT use the grease fitting on the track adjusting cylinder for lubrication. Use this fitting ONLY for track adjustment. To tighten track, connect a grease gun to grease fitting (1) (located through access hole [4] in track frame). Add grease until sag is within recommended limits. CAUTION: Prevent possible serious injury from high-pressure grease penetrating your skin. Do not remove grease fitting (1) from valve (2). If grease does not escape immediately from the vent hole when check valve is loosened, slowly drive machine in forward and reverse direction until grease escapes. DO NOT disassemble parts until you know the correct procedure and have the correct tools. See your authorized John Deere dealer. If an accident occurs, see a doctor immediately. Any oil injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. To loosen, slowly turn valve (2) counterclockwise; grease will escape through the bleed hole (3). When amount of track sag is satisfactory, turn valve clockwise to tighten. 1 Grease Fitting 2 Valve Steel Track Shown 3 Bleed Hole 4 Access Hole T UN 30NOV04 T UN 10JUN99 OUO1032,000158B JUL06-1/1 Use and Maintain Seat Belt Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly. The complete seat belt assembly should be replaced every 3 years, regardless of appearance. T SEP00 TX03679,00016DD NOV08-1/ PN=80

81 Lubricate Bucket and Link Pins Maintenance Initial Service 50 Hours Lubricate bucket and link pins until grease escapes from joints. (See Section 3-1.) Lubricate every 10 hours when working in mud and water. T UN 07DEC04 Right Side Shown - 10 Points ER93822, FEB12-1/ PN=81

82 Maintenance Initial Service 50 Hours Lubricate Front Joint Pins T UN 30NOV04 T UN 30NOV04 One Point One Point T UN 30NOV04 T UN 30NOV04 One Point Two Points T UN 30NOV04 T UN 30NOV04 Two Points One Point T UN 30NOV04 One Point Continued on next page ER93822, FEB12-1/ PN=82

83 Maintenance Initial Service 50 Hours Add grease until grease escapes from joints. Lubricate every 10 hours when working in mud and water. See Grease. (Section 3-1.) ER93822, FEB12-2/2 Check and Adjust Fan Belt Tension 1. Check belts regularly for wear. Replace if necessary. 2. Check fan belt tension with belt deflection gauge at midway between fan pulley (5) and alternator (6). Fan Belt Specification Deflection Deflection mm in. Depressing Force Force...98 N 22 lb (force) 3. If deflection is not within specifications, loosen cap screws (7 9). 4. Move alternator until tension is correct. 5. Tighten cap screws. 1 Compressor Pulley 2 Tension Pulley 3 Crank Pulley 4 Bolt 5 Fan Pulley 6 Alternator 7 Cap Screw 8 Alternator Bracket Cap Screw 9 Adjusting Plate Cap Screw TX UN 27FEB08 TX UN 26FEB08 ER93822, FEB12-1/ PN=83

84 Lubricate Bucket and Link Pins Maintenance Every 100 Hours Lubricate bucket and link pins until grease escapes from joints. (See Section 3-1.) Lubricate every 10 hours when working in mud and water. T UN 07DEC04 Right Side Shown - 10 Points CED,TX14740, FEB12-1/ PN=84

85 Maintenance Every 100 Hours Lubricate Front Joint Pins T UN 30NOV04 T UN 30NOV04 One Point One Point T UN 30NOV04 T UN 30NOV04 One Point Two Points T UN 30NOV04 T UN 30NOV04 Two Points One Point T UN 30NOV04 One Point Continued on next page ER93822,000019B FEB12-1/ PN=85

86 Maintenance Every 100 Hours Add grease until grease escapes from joints. Lubricate every 10 hours when working in mud and water. See Grease. (Section 3-1.) ER93822,000019B FEB12-2/2 Check and Adjust Fan Belt Tension 1. Check belts regularly for wear. Replace if necessary. 2. Check fan belt tension with belt deflection gauge at midway between fan pulley (5) and alternator (6). Fan Belt Specification Deflection Deflection mm in. Depressing Force Force...98 N 22 lb (force) 3. If deflection is not within specifications, loosen cap screws (7 9). 4. Move alternator until tension is correct. 5. Tighten cap screws. 1 Compressor Pulley 2 Tension Pulley 3 Crank Pulley 4 Bolt 5 Fan Pulley 6 Alternator 7 Cap Screw 8 Alternator Bracket Cap Screw 9 Adjusting Plate Cap Screw TX UN 27FEB08 TX UN 26FEB08 ER93822,00001BC FEB12-1/ PN=86

87 Maintenance Initial Service 250 Hours Replacing Hydraulic Oil Tank Filter NOTE: Perform this service at the first 250 hours of operation and then at 500 hour intervals thereafter. 1. Park machine on a level surface with cylinders fully retracted. 2. Stop engine. CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Slowly loosen cap to release pressure. T UN 09DEC04 3. Slowly loosen hydraulic oil tank cap to release hydraulic pressure. Remove cap. 4. Hold down filter cover (2) against light spring load when removing cap screws (1). 5. Remove spring (4), valve (5) and filter element (6). NOTE: Remove element and inspect for metal particles and debris in bottom of filter can. Excessive amounts of brass and steel particles can indicate a hydraulic pump, motor, or valve malfunction, or a malfunction in process. Rubber-type material can indicate a cylinder packing problem. 6. Discard element and O-ring. 7. Fill new filter with oil. (See Section 3-1.) 8. Install new filter element, valve and spring. 9. Install cover and new O-ring. 10. Install cap screws. Specification Cap Screw Torque...49 N m 36 lb-ft IMPORTANT: Avoid hydraulic pump damage. Hydraulic system must be bled whenever the hydraulic oil filter is changed. 11. Bleed hydraulic system. See Bleeding Hydraulic System. (Section 4-1.) 1 Cap Screw (4 used) 2 Cover 3 O-Ring 4 Spring 5 Valve 6 Filter Element T UN 30NOV04 ER93822,000010B FEB12-1/ PN=87

88 Lubricate Swing Bearing Maintenance Every 250 Hours CAUTION: Prevent possible injury from unexpected machine movement if controls are moved by another person. Lubricating swing bearing gear and rotating the upperstructure must be done by one person. Each time you leave the cab: Lower the bucket to the ground Stop the engine Raise the pilot control shutoff lever to the locked position. T UN 30NOV04 1. Park machine on a level surface. 2. Turn key switch to OFF. Remove key from switch. 3. Lubricate swing bearing with 2 3 shots of grease at grease fitting. (See Section 3-1.) 4. Start engine. Raise bucket several inches off the ground and rotate upperstructure 90 degrees (1/4 turn). 5. Repeat steps 2 4 seven times. It is not necessary to start the engine the last time. NOTE: Lubricate the swing bearing gear at 500 hours. OUO1032, FEB12-1/1 Lubricate Tilt Mechanism 1. Park machine on a level surface. 2. Turn key switch to OFF. Remove key from switch. 3. Remove cap screws (1) from the tilt mechanism cover (2). 4. Remove tilt mechanism cover. 5. Coat entire length of bolt (3) with grease. See Grease. (Section 3-1.) 1 Cap Screw (2 used) 2 Tilt Mechanism Cover 3 Bolt TX A UN 06JUN08 TX A UN 06JUN08 ER93822,00001AE FEB12-1/ PN=88

89 Maintenance Every 250 Hours Lubricate Angle Blade Bottom and Rod Pins If Equipped Add grease until grease escapes from joints. See Grease. (Section 3-1.) TX UN 28FEB12 Rod Pin TX UN 28FEB12 Bottom Pin ER93822,000010D FEB12-1/1 Checking Travel Gear Case Oil Level 1. Park the machine on level ground rotating travel gear case until positioned as shown. 2. Lower bucket and blade to the ground. 3. Run engine at slow idle speed without load for 5 minutes. 4. Turn key switch to OFF. Remove key from switch. 5. Pull pilot control shutoff lever to locked position. CAUTION: High pressure release of oils from pressurized system can cause serious burns. Wait for travel gear case oil to cool. Keep body and face away from check plug. Gradually loosen check plug to release air to relieve pressure. 6. After travel gear case has cooled, slowly loosen fill plug (1) to release air to relieve pressure. 7. Remove check plug (2). Oil must be to bottom of hole. 8. If necessary, add oil until oil flows out of oil level check plug hole. (See Section 3-1.) 1 Fill Plug 2 Check Plug 9. Install plugs. 10. Check second travel gear case oil level. CED,TX14740, JUL11-1/1 T UN 22APR PN=89

90 Maintenance Every 250 Hours Draining Hydraulic Oil Tank Sump CAUTION: High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Slowly loosen cap to release pressure. 1. Slowly loosen hydraulic oil filler cap to release pressure. 2. Loosen hydraulic sump drain plug (1) for several seconds to drain water and sediment into a container. Do not remove plug completely. Dispose of waste properly. 3. Tighten drain plug. 1 Hydraulic Sump Drain Plug TX A UN 05JUN08 ER93822,00001AC JUN08-1/1 Take Engine Oil Sample See your authorized dealer. OUT4001,000039B MAR12-1/ PN=90

91 Maintenance Every 500 Hours Changing Engine Oil and Replacing Filter 1. Run engine to warm oil. 2. Park machine on a level surface and stop engine. 3. Remove drain plug (1) from engine oil pan. Allow oil to drain into a container. Dispose of waste oil properly. 4. Turn engine oil filter (2) counterclockwise to remove. Clean mounting surface on base. 5. Apply thin film of oil to rubber gasket of new filter. 6. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface. 7. Tighten filter 1-1/4 turn more. 8. Install drain plug. 9. Remove engine oil filler cap (3). Specification Oil Capacity with Filter Change Capacity L 3.0 gal 10. Fill engine with oil. (See Section 3-1.) 11. Install engine oil filler cap. 12. Start engine. Engine oil pressure indicator on monitor must go out immediately. If not, stop engine immediately and find the cause. 13. Stop engine. Check oil level on dipstick. 14. Check for any leakage at filter. Tighten filter just enough to stop leakage. 1 Drain Plug 2 Engine Oil Filter Oil Pan Oil Filter and Filler Cap 3 Engine Oil Filler Cap TX A UN 06JUN08 TX A UN 06JUN08 ER93822,00001AF FEB12-1/ PN=91

92 Maintenance Every 500 Hours Lubricate Front Joint Pins T UN 30NOV04 T UN 30NOV04 One Point One Point T UN 30NOV04 T UN 30NOV04 One Point Two Points T UN 30NOV04 T UN 30NOV04 Two Points One Point T UN 30NOV04 One Point Continued on next page ER93822,000019B FEB12-1/ PN=92

93 Maintenance Every 500 Hours Add grease until grease escapes from joints. Lubricate every 10 hours when working in mud and water. See Grease. (Section 3-1.) ER93822,000019B FEB12-2/2 Lubricate Swing Bearing Gear CAUTION: Prevent possible injury from unexpected machine movement if controls are moved by another person. Lubricating swing bearing gear and rotating the upperstructure must be done by one person. Each time you leave the cab: Lower the bucket to the ground Stop the engine Pull the pilot control shutoff lever to the locked position. 1. Apply grease to grease fitting. IMPORTANT: If water or mud is found in swing gear area, see Operating in Water and Mud. (Section 2-2.) 2. In order to apply grease evenly to the swing gear, raise the bucket approximately 200 mm (8 in.) off the ground, swing upperstructure four 90 intervals and apply grease at each interval. Add grease as required. (See Section 3-1.) T UN 30NOV04 OUO1032, FEB12-1/1 Lubricate Control Lever Universal Joint 1. Lift boot (1). Remove screws (2). 2. Remove bracket (3). 3. Lubricate points shown. 4. Install bracket and screws. 5. Install boot. 1 Boot 2 Screw (2 used) 3 Bracket T UN 30NOV04 T UN 30NOV04 Four Points OUO1032, FEB12-1/ PN=93

94 Maintenance Every 500 Hours Replacing Final Fuel Filter 1. Turn fuel shutoff valve (1) to OFF. 2. Remove fuel filter (2). Dispose of waste properly. 3. Clean mounting surface for fuel filter. 4. Add a small amount of fuel to new filter and install. 5. Turn fuel shutoff valve to ON. 6. Turn the key switch to ON for seconds to engage automatic bleeding. Do not start engine. 7. Start engine. Stop engine. Check for fuel leakage. TX A UN 06JUN08 TX A UN 06JUN08 ER93822,00001B JUN08-1/1 Lubricate Blade Pins Lubricate blade pins until grease escapes from joint. See Grease. (Section 3-1.) T UN 09DEC04 Four Points OUO1032, FEB12-1/1 Lubricate Center Pin If Equipped Lubricate pin until grease escapes from joint. See Grease. (Section 3-1.) TX UN 28FEB12 Center Pin ER93822,000010E FEB12-1/ PN=94

95 Maintenance Every 500 Hours Replace Air Cleaner Elements and Dust Valve 1. Shut off engine. 2. Open left access door. 3. Unlatch air cleaner cover (1) and remove. 4. Pull primary element (2) straight down to remove. The primary element makes a tight seal; there may be initial resistance when trying to remove it. To loosen from housing, grab the end of element and gently move element back and forth, and pull it out of housing. IMPORTANT: Failure to clean the housing properly may cause contaminants to be introduced to the seal area of the primary element during installation. This can cause a leak and shorter element life. 5. Clean the inside of filter canister. Use a soft rag to remove all dust and debris from the inside surface of housing. Be careful not to introduce contaminant into the outlet tube. NOTE: If the secondary element is not installed properly, it may attach itself to the primary element upon removal. TX A UN 06JUN08 TX A UN 06JUN08 6. Pull secondary element (if equipped) straight back to remove. 7. Before installing a new primary or secondary (if equipped) filter, inspect it carefully. Visually check for any voids, cuts, tears, or indentations in the urethane-sealing surface. If the check reveals damage, do NOT install the filter. 8. Install new secondary element (if equipped). Check to ensure secondary element is properly seated in the housing. It should fit snugly inside the outlet tube. Continue pushing filter into outlet tube until it stops. 9. Install new primary element. Apply pressure by hand at the outer rim of element, not the center, to seat element in housing. Sealing area will compress slightly and distribute the sealing pressure evenly. 1 Air Cleaner Cover 2 Primary Element NOTE: Do not use service cover latches to force the cover in position. Cover latches will prematurely fail if used to seat the cover. 10. Install air cleaner cover and fasten latches. The cover for the air cleaner fits only one way. When in the proper position, it will fit snugly against the housing. The cover should go on easily with no extra force. If cover does not seem to fit, filter is not properly seated in the housing. Continued on next page ER93822,00001B JUN08-1/ PN=95

96 Maintenance Every 500 Hours NOTE: A missing, damaged, or hardened dust valve will cause the air filter elements to be ineffective. 11. Replace dust valve (3). 3 Air Cleaner Dust Valve TX A UN 06JUN08 ER93822,00001B JUN08-2/2 Take Fluid Samples See your authorized dealer for taking the following fluid samples: Hydraulic Oil Travel Gear Case Coolant Diesel Fuel CS58540,000005C JUL11-1/ PN=96

97 Check Coolant See Check Coolant. (Section 3-3.) Maintenance Every 1000 Hours ER93822, FEB12-1/1 Changing Travel Gearbox Oil 1. Park the machine on level ground, rotating travel gearbox until positioned as shown. 2. Stop engine. CAUTION: High-pressure release of oils from pressurized system can cause serious burns. Wait for travel gearbox oil to cool. Keep body and face away from check plug. Gradually loosen fill plug to release pressure. 3. After travel gearbox has cooled, slowly loosen fill plug (1) to release pressure. 4. Remove drain plug (3). Allow oil to drain into a container. Dispose of waste oil properly. Install plug. 5. Remove oil fill plug (1). 6. Remove check plug (2). 7. Add oil to fill plug hole until oil flows out of oil level check plug hole. (See Section 3-1.) Specification Travel Gearbox Oil Capacity (Each) L 1.0 qt 1 Fill Plug 2 Check Plug 8. Clean and install plugs. Two Places 3 Drain Plug T UN 22APR99 ER93822,000019E JUN08-1/ PN=97

98 Maintenance Every 1000 Hours Replacing Pilot System Oil Filter 1. Open maintenance access cover. CAUTION: High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Slowly loosen cap to release pressure. 2. Slowly loosen hydraulic tank cap (1) to release pressure. NOTE: Pilot filter access panel (2) is under the left rear of machine. TX A UN 06JUN08 3. Remove screws (3) from pilot filter access panel. 1 Hydraulic Tank Cap 2 Pilot Filter Access Panel 3 Screw (3 used) T UN 30NOV04 T UN 30NOV04 Continued on next page ER93822,000019D JUN08-1/ PN=98

99 Maintenance Every 1000 Hours 4. Turn filter case (1) counterclockwise to remove from filter head (4). 5. Pull down on filter element (2) while moving it back and forth to remove. 6. Remove and discard O-ring (3). 7. Apply a thin film of clean oil to new O-ring and install in filter head. 8. Install new filter element by moving it back and forth while pushing it upward. 9. Install filter case. 10. Install hydraulic oil cap. IMPORTANT: Avoid hydraulic pump damage. Hydraulic system must be bled whenever the pilot oil filter is changed. 11. Bleed hydraulic system. See Bleeding Hydraulic System. (Section 4-1.) 1 Filter Case 2 Filter Element 12. Install pilot filter access cover. 3 O-Ring 4 Filter Head T UN 22JUN99 ER93822,000019D JUN08-2/2 Checking and Adjusting Engine Valve Lash (Clearance) See your authorized dealer for inspection and repair. CED,TX14740, JUN99-1/1 Checking Starter and Alternator See your authorized dealer for inspection and repair. CED,TX14740, MAY99-1/1 Inspecting Crankcase Breather System The EPA/ARB requires that the crankcase breather be inspected every 1000 hours. See your authorized John Deere dealer. ER93822,00001C JUN08-1/ PN=99

100 Maintenance Every 2000 Hours Draining Cooling System Drain and flush cooling system using commercial products. 1. Check coolant hoses for cracks and leaks. Replace if necessary. 2. Tighten clamps. 3. Check radiator and oil cooler for dirt, grease, leaks, and loose or broken mountings. Clean radiator and oil cooler fins. CAUTION: Prevent possible injury from hot spraying water. DO NOT remove radiator filler cap unless engine is cool. Then turn cap slowly to the stop. 4. Slowly turn radiator cap (1) to release pressure. Remove cap. 5. Turn radiator drain valve (2) counterclockwise to open valve. Allow coolant to drain into a container. Dispose of waste coolant properly. 6. Close drain valves. IMPORTANT: Avoid mixing different brands or types of coolant. Coolant manufacturers engineer their coolants to meet certain specifications and performance requirements. Mixing different coolant types can degrade coolant and machine performance. 7. Fill with proper coolant. (See Section 3-1.) Specification Cooling System Capacity L 2.0 gal 1 Radiator Cap 2 Drain Valve TX A UN 06JUN08 TX A UN 06JUN08 ER93822,00001A JUN08-1/ PN=100

101 Maintenance Every 2000 Hours Heavy Duty Diesel Engine Coolant The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37 C (-34 F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations. The following engine coolants are preferred: John Deere COOL-GARD II Premix John Deere COOL-GARD II PG Premix Use John Deere COOL-GARD II PG Premix when a non-toxic coolant formulation is required. Additional Recommended Coolants The following engine coolant is also recommended: John Deere COOL-GARD II Concentrate in a 40 60% mixture of concentrate with quality water. John Deere COOL-GARD II Premix, COOL-GARD II PG Premix, and COOL-GARD II Concentrate coolants do not require use of supplemental coolant additives. Other Coolants John Deere COOL-GARD II and COOL-GARD II PG coolants might not be available in the geographical area where service is performed. If these coolants are unavailable, use a coolant concentrate or prediluted coolant intended for use with heavy duty diesel engines and with a minimum of the following chemical and physical properties: Is formulated with a quality nitrite-free additive package. Provides cylinder liner cavitation protection according to either the John Deere Cavitation Test Method or a fleet study run at or above 60% load capacity Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion The additive package must be part of one of the following coolant mixtures: ethylene glycol or propylene glycol base prediluted (40 60%) heavy duty coolant ethylene glycol or propylene glycol base heavy duty coolant concentrate in a 40 60% mixture of concentrate with quality water Water Quality Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives. Do not mix ethylene glycol and propylene glycol base coolants. Do not use coolants that contain nitrites. COOL-GARD is a trademark of Deere & Company DX,COOL APR11-1/1 Cooling System Fill and Deaeration IMPORTANT: Use only permanent-type low silicate ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals. FREEZING TEMPERATURES: Fill with permanent-type, low silicate, ethylene glycol antifreeze (without stop-leak additive) and clean, soft water. Fill Fill radiator to the bottom of the radiator fill neck and fill recovery tank to the FULL mark. Deaeration The cooling system requires several warm-up and cool down cycles to deaerate. It will NOT deaerate during normal operation. Only during warm-up and cool down cycles will the system deaerate. 1. Start engine. Run engine until coolant reaches a warm temperature. 2. Stop engine. Allow coolant to cool. 3. Check coolant level at recovery tank. 4. Repeat Steps 1 3 until recovery tank coolant level is repeatedly at the same level (stabilized). NOTE: The level of the coolant in the cooling system MUST BE repeatedly checked after all drain and refill procedures to insure that all air is out of the system which allows the coolant level to stabilize. Check coolant level only when the engine is cold. 5. If necessary, fill recovery tank to FULL mark. 6. Install recovery tank and radiator caps. CED,TX14740, JUN99-1/ PN=101

102 Maintenance Every 2000 Hours Changing Hydraulic Tank Oil NOTE: Change original Hitachi factory fill hydraulic oil after first 2000 hours. Change every 1000 hours if using any of the other recommended hydraulic oils. IMPORTANT: Prevent damage to hydraulic system components. DO NOT run engine without oil in the tank. Avoid mixing different brands or types of oils. Oil manufacturers engineer their oils to meet certain specifications and performance requirements. Mixing different oil types can degrade lubricant and machine performance. This excavator is factory filled with 46HN extended life zinc-free hydraulic oil. Avoid servicing this excavator with products that do not meet this specification. If oils have been mixed or if alternate service oils are desired, the complete hydraulic system needs to be totally flushed by an authorized dealer. T UN 09DEC04 1. Park machine on surface with cylinders fully retracted. ER93822, JUN08-1/3 CAUTION: High-pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Slowly loosen cap to release pressure. 2. Slowly loosen hydraulic tank cap (1) to release pressure. Remove hydraulic tank cap. 3. Drain oil using a suction pump. 4. Remove drain plug (2). Allow remaining oil to drain into a container. Dispose of waste oil properly. 5. Install drain plug. TX A UN 06JUN08 1 Hydraulic Tank Cap 2 Drain Plug TX A UN 06JUN08 Continued on next page ER93822, JUN08-2/ PN=102

103 Maintenance Every 2000 Hours 6. Add oil until it is between marks on sight gauge (1). (See Section 3-1.) Specification Hydraulic Tank Oil Capacity L 23 gal. IMPORTANT: Avoid hydraulic pump damage. Hydraulic system must be bled whenever the hydraulic oil is changed. 7. Bleed hydraulic system. See Bleeding Hydraulic System. (Section 4-1.) T UN 29NOV04 1 Sight Gauge ER93822, JUN08-3/ PN=103

104 Miscellaneous Machine Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump If injection nozzles are not working correctly or are dirty, the engine will not run normally. (See your authorized dealer for service.) Changing the injection pump in any way not approved by the manufacturer will end the warranty. (See your copy of the John Deere warranty on this machine.) Do not service an injection pump that is not operating correctly. (See your authorized injection pump service center.) TX,90,FF SEP06-1/1 Do Not Service Control Valves, Cylinders, Pumps, or Motors Special tools and information are needed to service control valves, cylinders, pumps, or motors. If these parts need service, see your authorized dealer. TX,90,FF JAN07-1/1 Cleaning Fuel Tank Inlet Screen Clean screen (1) to remove any debris. Use solvent or diesel fuel. Replace screen if damaged. 1 Fuel Tank Inlet Screen T UN 06NOV00 TX14740,0001C FEB05-1/1 Check Cab Fresh Air Filter IMPORTANT: Replace filter every 6 cleanings. 1. Open left side access door. 2. Remove fresh air filter (1) from filter case. 3. Inspect filter. Clean or replace if necessary. 4. Clean filter in one of these ways: a. Tap filter on a flat surface with dirty side down. CAUTION: Prevent possible injury from flying chips. Reduce compressed air to less than 196 kpa (1.96 bar) (28.4 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. b. Use compressed air opposite to the normal air flow. c. Wash filter in warm, soapy water. Flush filter. Allow filter to dry before using heater, defroster, or air conditioner. 1 Fresh Air Filter 5. Install filter. 6. Close left side access door. TX A UN 09JUN08 ER93822,00001B JUN08-1/ PN=104

105 Miscellaneous Machine Check Cab Recirculating Air Filter IMPORTANT: Replace filter every 6 cleanings. 1. Remove screw (1) and remove access cover (2). 2. Remove air recirculation filter (3). 3. Inspect filter. Clean or replace if necessary. 4. Clean filter using one of these methods: a. Tap on a flat surface with dirty side down. CAUTION: Prevent possible injury from flying chips. Reduce compressed air to less than 196 kpa (1.96 bar) (28.4 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. b. Use compressed air opposite to the normal air flow. c. Wash filters in warm, soapy water. Flush filters. Allow filters to dry before using heater, defroster, or air conditioner. 5. Install filter. 6. Install cap screw. 1 Screw 2 Access Cover 3 Air Recirculation Filter TX A UN 09JUN08 TX A UN 09JUN08 ER93822,00001B JUN08-1/ PN=105

106 Miscellaneous Machine Check Air Intake Hoses 1. Open rear access door (1). 2. Remove bolts (2) to remove access cover (3). 3. Check hose (4) for cracks. Replace as necessary. 4. Tighten clamps. 1 Rear Access Door 2 Bolts (5 used) 3 Access Cover 4 Air Intake Hose TX A UN 12JUN08 TX A UN 12JUN08 TX A UN 12JUN08 ER93822,00001C JUN08-1/1 Clean Air Cleaner Dust Valve IMPORTANT: A missing, damaged, or hardened dust valve will make the dust cup precleaner ineffective, causing very short element life. Valve should suck closed above 1/3 engine speed. Open left rear access door. Squeeze dust valve (1) to remove dust from the air cleaner. If operating in high dust conditions, squeeze dust valve every couple of hours of operation to release dust. TX A UN 09JUN08 1 Air Cleaner Dust Valve ER93822,00001B JUN08-1/ PN=106

107 Miscellaneous Machine Replace Water Separator Element 1. Open right rear access door. 2. Close fuel shutoff valve (1) on top of water separator (2). 3. Turn water separator counterclockwise to remove. 4. Remove element and dispose 5. Install new element. Turn water separator clockwise by hand until O-ring touches mounting surface. 6. Open fuel shutoff valve. 7. Bleed fuel system. See Bleed Fuel System in Miscellaneous Machine. (Section 4-1.) 1 Fuel Shutoff Valve 2 Water Separator TX A UN 09JUN08 ER93822,00001B JUN08-1/1 Prime Fuel System CAUTION: Avoid personal injury and/or machine damage. Prime the fuel system using only the method described below. IMPORTANT: Avoid machine damage. Do not use the starter motor to crank the engine when priming the fuel system. Turn the key switch to the ON positon for 10 to 15 seconds. See Key Switch. (Section 2-1.) ER93822,00001C JUN08-1/1 Precautions for Alternator and Regulator When batteries are connected, follow these rules: 1. Disconnect negative (-) battery cable when you work on or near alternator or regulator. 2. Be sure alternator wires are correctly connected BEFORE you connect batteries. 3. Do not ground alternator output terminal. 4. Do not disconnect or connect any alternator or regulator wires while batteries are connected or while alternator is operating. 5. Connect batteries or a booster battery in the correct polarity (positive [+] to positive [+] and negative [-] to negative [-]). 6. Do not disconnect the batteries when engine is running and alternator is charging. 7. Disconnect battery cables before you connect battery charger to the batteries. T82,EXMA,I APR06-1/1 Checking Starter and Alternator See your authorized dealer for inspection and repair. CED,TX14740, MAY99-1/ PN=107

108 Miscellaneous Machine Check Battery Electrolyte Level and Terminals CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. NEVER check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. ALWAYS remove grounded (-) battery clamp first and replace it last. 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 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 1.9 L (2 quarts). 3. Get medical attention immediately. 1. Remove battery box cover. Continued on next page TS203 UN 23AUG88 DW90712,00003AA NOV06-1/ PN=108

109 Miscellaneous Machine IMPORTANT: If water is added to batteries during freezing weather, batteries must be charged after water is added to prevent batteries from freezing. Charge battery using a battery charger or by running the engine. 2. Fill each cell to within specified range with distilled water. DO NOT overfill. CAUTION: Prevent possible injury. ALWAYS remove grounded (-) battery clamp first and replace it last. 3. Disconnect battery clamps, grounded clamp first. T UN 25JAN01 1 Battery Post 2 Fill Tube 3 Electrolyte Level Range T UN 25JAN01 DW90712,00003AA NOV06-2/3 4. Clean battery terminals (1) and clamps with a stiff brush. 5. Apply lubricating grease (2) around battery terminal base only. 6. Install and tighten clamps, grounded clamp last. 1 Battery Terminal 2 Lubricating Grease T UN 25JAN01 DW90712,00003AA NOV06-3/ PN=109

110 Miscellaneous Machine Handling, Checking, and Servicing Batteries Carefully CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. 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 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 1.9 L (2 quarts). 3. Get medical attention immediately. WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in 4 L (1 gal) water. IMPORTANT: Do not overfill the battery cells. Check the specific gravity of electrolyte in each battery cell. Continued on next page TS204 UN 23AUG88 TS203 UN 23AUG88 TX03679, JAN07-1/ PN=110

111 Miscellaneous Machine See your authorized dealer for JT05460 SERVICEGARD battery and coolant tester. Follow directions included with the tester. A fully charged battery will have a corrected specific gravity reading of If the reading is below 1.200, charge the battery. T85402 UN 10NOV88 SERVICEGARD is a trademark of Deere & Company TX03679, JAN07-2/2 Using Battery Charger CAUTION: Prevent possible injury from exploding battery. Do not charge a battery if the battery is frozen or it may explode. Warm battery to 16 C (60 F) before charging. Turn off charger before connecting or disconnecting it. IMPORTANT: Do not use battery charger as a booster if a battery has a specific gravity reading or lower. Disconnect battery ground (-) clamp before you charge batteries in the machine to prevent damage to electrical components. TS204 UN 23AUG88 A battery charger may be used as a booster to start engine. Ventilate the area where batteries are being charged. Stop or cut back charging rate if battery case feels hot, or is venting electrolyte. Battery temperature must not exceed 52 C (125 F). N36890 UN 07OCT88 OUT4001, JUL07-1/1 Replacing the Battery Your machine has one 12-volt battery with negative (-) ground. Battery must meet one of the specifications below. Specification Battery Cold Cranking Amps At -18 C (0 F) amps Replace the failed battery with one of the same type. For example, replace a failed maintenance-free battery with a new maintenance-free battery. Different types of batteries may have different rates of charge. This difference could overload the battery and cause it to fail. ER93822,00001B JUN08-1/ PN=111

112 Miscellaneous Machine Using Booster Batteries 12-Volt System Before boost starting, machine must be properly shut down to prevent unexpected machine movement when engine starts. CAUTION: Prevent possible injury from exploding battery. An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Make sure the batteries are charged in a well ventilated area. IMPORTANT: The machine electrical system is a 12-volt negative (-) ground. Use only 12-volt booster batteries. 1. Connect one end of the positive cable to the positive terminal of the machine batteries and the other end to the positive terminal of the booster batteries. 2. Connect one end of the negative cable to the negative terminal of the booster batteries. Connect other end of the negative cable to the machine as far away from the machine batteries as possible. 3. Start engine. 4. Immediately after starting engine disconnect end of the negative cable from the machine. Then disconnect the other end of the negative cable from the negative terminal of the booster batteries. 5. Disconnect positive cable from booster batteries and machine batteries. TS204 UN 23AUG88 OUT4001,00000E JUL09-1/1 Welding On Machine IMPORTANT: Disconnect battery ground strap to prevent voltage spikes through alternator or monitor. Disable electrical power before welding. Disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors. Do not weld within 12 inches of electronic components. Remove electronic components if necessary. Connect welder ground clamp close to each weld area so electrical current does not arc inside any bearings. OUO1032,00015C DEC04-1/1 Clean Machine Regularly Remove any grease, oil, fuel, or debris build-up to avoid possible injury or machine damage. IMPORTANT: Directing pressurized water at electronic/electrical components or connectors, bearings and hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle. High pressure washing (greater than 1379 kpa (13.8 bar) (200 psi) can damage freshly painted finishes. Paint should be allowed to air dry for 30 days minimum after receipt of machine before cleaning with high pressure. Use low pressure wash operations until 30 days have elapsed. Do not spray oil cooler fins at an angle. Fins may bend. T6642EJ UN 18OCT88 TX03679,00017E DEC12-1/ PN=112

113 Miscellaneous Machine JDLink Machine Monitoring System (MMS) If Equipped JDLink is an equipment monitoring and information delivery system. JDLink automatically collects and manages information about where and how construction JDLink is a trademark of Deere & Company and forestry equipment is being used, as well as critical machine health data and service status. For more information, see your authorized dealer or visit (browse to Construction, Services and Support, JDLink ). VD76477, JUL12-1/1 JDLink Machine Monitoring System (MMS) Direct Laptop Connection If Equipped NOTE: (Location of control box behind the access door may vary depending on model.) Open left door (1) to access JDLink MMS. To download machine data using the JDLink MMS Direct: - Install the JDLink MMS Direct cable by inserting the Ethernet connector into the laptop. - Connect the JDLink MMS Direct cable to the vehicle 4-pin Deutsch connector (2). - Launch JDLink MMS Direct Software. Contact your authorized dealer to obtain the JDLink MMS Direct Kit (AT347680), which includes the JDLink MMS Direct cable (AT335476) and software. NOTE: On equipment using the JDLink Direct system, there is no nightly upload to a remote server and thus, the information is only stored in one location the controller. Without downloading the controller data on a regular basis, the data could be lost if the controller were to fail. To obtain the most detailed machine data on your laptop, you must perform a machine data download every 1000 hrs or less. 350DLC shown TX A UN 19JUN07 TX A UN 07MAR08 1 Left Access Door 2 4-pin Deutsch Connector JDLink is a trademark of Deere & Company OUT4001,00002F JUN07-1/ PN=113

114 Miscellaneous Machine Replacing Fuses The fuse block is located under the operator seat. Remove access cover (1) and fuse block cover (2) to access. 1 Access Cover 2 Fuse Block Cover TX A UN 09JUN08 TX A UN 09JUN08 Continued on next page ER93822,00000FF FEB12-1/ PN=114

115 Miscellaneous Machine IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Fuse (Blade-Type) Color Codes Amperage Rating Color 1 Black 3 Violet 4 Pink 5 Tan 7-1/2 Brown 10 Red 15 Light Blue 20 Yellow 25 Natural (white) 30 Light Green F1 Horn Relay 5 A Fuse (Marked HORN) F2 Monitor (Backup), Radio (Backup) 5 A Fuse (Marked RADIO/MONITOR) F3 Pilot Shut-Off Switch, Buzzer 5 A Fuse (Marked GATE LOCK BUZZER) F4 Angle Blade (Optional), Accessory Power Supply 10 A Fuse (Marked OUTLET) F5 Starter Relay, ECU (Start Signal) 5 A Fuse (Marked START) F6 Work Light Switch, Blower Motor Relay 25 A Fuse (Marked BLOWER ILLIMI.) F7 Radio, Wiper, Washer Switch 10 A Fuse (Marked RADIO/WIPER WASHER) F8 Monitor (Power Supply), Auto Idle (A/I) Controller, Starter Cut Relay, Fuel Transfer Pump, Alternator, Injection Pump Rack Module, ECU (Ignition Signal) 10 A Fuse (Marked ENGINE/MONITOR) F9 Cab Dome Light, Travel Speed Switch, Travel Alarm Controller, Travel Alarm 5 A Fuse (Marked TRAVEL AI/ ROOM LAMP) F10 Not Used F11 Work Light Relay 20 A Fuse (Marked WORK LIGHT) F12 Not Used F13 Not Used F14 Not Used F15 Not Used F16 Not Used F17 Not Used F18 Not Used F11 F13 F15 F17 F12 F14 F16 F18 Fuse Block Layout TX UN 28APR08 ER93822,00000FF FEB12-2/ PN=115

116 Miscellaneous Machine Replacing Bucket Teeth CAUTION: Guard against injury from flying pieces of metal; wear goggles or safety glasses. NOTE: Alternate buckets may use different tooth assemblies. 1. Position bucket to access locking pin (1). 2. Drive out locking pin. 3. Remove tooth (2). 4. Position bucket level, and place new tooth over tooth shank (3). 5. Drive locking pin back in to hole fully. NOTE: Check bucket teeth periodically so that wear does not extend to the bucket tooth shank. 1 Locking Pin 2 Tooth 3 Tooth Shank TX A UN 25FEB08 OUT4001, FEB08-1/1 Replacing Bucket Tooth Tip Heavy-Duty Bucket 1. Clean tooth (A) and tooth tip (B). 2. Insert lock removal tool under U-shaped pin (C). CAUTION: Avoid possible injury. Pin may fly after it is released from tooth tip. Keep a firm grip on pin to prevent injury. 3. Remove pin. 4. Turn tooth tip counterclockwise and pull it towards you to remove. 5. Clean tooth shank. 6. Replace U-shaped pin at same time you replace tooth tip. 7. Insert tooth tip on shank turning tip clockwise. 8. Install U-shaped pin. Side of pin marked "FRONT" (D) must face tooth tip. Make sure pin is firmly engaged over tooth tip. A Tooth B Tooth Tip C Pin D "Front" Mark Bucket Tooth Tip Heavy-Duty Bucket U-Shaped Pin Heavy-Duty Bucket T6879EE UN 06DEC88 T7527DO UN 27JUN91 04T,90,K AUG12-1/ PN=116

117 Miscellaneous Machine Removing Bucket 1. Lower bucket to the ground. 2. Remove cap screws (1). 3. Slide O-ring seals out of way. Remove bucket pins. 1 Cap Screw (2 used) TX A UN 25FEB08 OUT4001,000003C FEB08-1/1 Track Sag General Information To maximize undercarriage life, keep track sag within specification. Tracks may require adjustment several times during a working day due to changing soil type and moisture content. Adjust tracks in the actual operating conditions. TIGHT TRACK: Packing causes a tight track. If material packs in the undercarriage, adjust tracks with the material packed in the components. While the track spring will recoil and the machine can continue to operate with a tight track, continued operation will result in excessive pin and bushing wear, sprocket popping, tooth tip wear, and excessive loads on the entire undercarriage and travel drive system. Machine productivity and fuel consumption are also adversely affected because increased horsepower is needed to move the machine. LOOSE TRACK: A loose track has more side to side motion, increasing side wear on the links, rollers and front idler. An excessively loose track will slap at high ground speeds, resulting in high impact loads on the sprocket teeth, bushings, and carrier rollers. 04T,90,M JUL06-1/1 Checking Track Shoe Hardware Tracks shoes should be checked periodically for loose or missing cap screws and nuts. For shoes with missing or loose cap screws and nuts, remove shoes and clean the mating surface of shoes and links before tightening cap screws and nuts. The cap screws should be replaced because they have been stretched to yield previously. Operating a machine with loose shoes can cause the cap screws and holes in the shoes and links to wear making it difficult to keep the shoes tight. Loose shoes can also cause hardware failure and loss of shoes. 1. Clean the mating surface of shoe and links. Install shoes. 2. Apply a light coating of oil to cap screw threads before installing. 3. Install nuts with the rounded corners against milled surface of link and chamfered side is away from link. Check that nuts are square with the milled surface of link and there is full contact between nut and milled surface. As necessary, hold the nut so it does not turn. 4. Starting at any cap screw, tighten all cap screws in sequence to the torque specification, then 1/2 turn (180 ) more. TX14740,0001CFC JAN02-1/ PN=117

118 Miscellaneous Machine Unified Inch Bolt and Screw Torque Values TS1671 UN 01MAY03 Bolt or Screw SAE Grade 1 SAE Grade 2 a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2 Size Lubricated b Dry c Lubricated b Dry c Lubricated b Dry c Lubricated b Dry c N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. 1/ N m lb.-ft. N m lb.-ft. 5/ N m lb.-ft. N m lb.-ft. 3/ N m lb.-ft. N m lb.-ft. N m lb.-ft. 7/ N m lb.-ft. 1/ / / / / / / / / Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application. a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length. b Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. c Dry means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating. DX,TORQ JAN11-1/ PN=118

119 Miscellaneous Machine Metric Bolt and Screw Torque Values TS1670 UN 01MAY Bolt or Screw Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Size Lubricated a Dry b Lubricated a Dry b Lubricated a Dry b Lubricated a Dry b N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. N m lb.-in. M N m lb.-ft. N m lb.-ft. N m lb.-ft. N m lb.-ft. M N m lb.-ft. N m lb.-ft. N m lb.-ft. M N m lb.-ft. M M M M M M M M M M M Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application. a Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. b Dry means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating. DX,TORQ JAN11-1/ PN=119

120 Miscellaneous Machine Bleed Hydraulic System IMPORTANT: Avoid hydraulic pump damage. Perform the hydraulic system bleeding procedure every time you change the hydraulic filter, pilot system oil filter, or change hydraulic tank oil. Do not operate any hydraulic function, including unlocking pilot control shutoff lever, until you complete steps 1 5 in this procedure. 1. Turn engine speed control knob to slow idle position. 2. Start engine. Run for 5 10 seconds to ensure oil flow to hydraulic pump. Stop engine. 3. Check the hydraulic oil level at the sight gauge. Add hydraulic oil if necessary. (See Section 3-1.) 4. Start the engine again. Confirm oil level is above minimum point in hydraulic oil sight gauge. Run engine for approximately one minute to circulate oil through the system. 5. Stop engine and check hydraulic oil level. Add more oil if necessary. 6. Start engine again. Operate each cylinder and swing motor repeatedly for minutes to purge air from hydraulic system. 7. Park machine on a level surface and position machine with cylinders fully retracted. 8. Stop engine. Check hydraulic oil level. Add oil if necessary. T UN 09DEC04 OUO1032, APR06-1/1 12-Volt Auxiliary Power Outlet A 12-volt auxiliary power outlet (1) is provided for service and maintenance Volt Auxiliary Power Outlet T UN 10DEC04 OUO1032,000159A NOV04-1/ PN=120

121 Miscellaneous Machine Cleaning Air Conditioning Condenser and Screens 1. Open right access door. 2. Remove two wing screws (1). 3. Remove right condenser screen (2). 4. Remove left condenser screen (3). 5. Clean air conditioner condenser (4) with compressed air. Blow air straight through fins to avoid bending them. 6. Wipe off or rinse screens with warm water until clean. 7. Install air conditioning condenser 8. Install left condenser screen. 9. Install right condenser screen. 10. Install two wing screws. 11. Close right access door. TX A UN 12JUN08 ER93822,00001C JUN08-1/ PN=121

122 Miscellaneous Machine Installing Bucket With Quick Coupler 1. Position bucket and machine on a flat level surface. 2. Slowly lower boom and maneuver arm to insert arm pivot pin (1) into open end of bucket ears (2). 3. Extend bucket cylinder (3) until the square pin boss (4) rests on the flat surface of bucket ears (5). 1 Arm Pivot Pin 2 Bucket Ears 3 Bucket Cylinder 4 Square Pin Boss 5 Bucket Ears T123697B UN 19AUG99 Machine Shown with Optional Thumb Attachment T123698B UN 19AUG99 Continued on next page OUO1032,00015A NOV04-1/ PN=122

123 Miscellaneous Machine 4. Install bucket or attachment and wedge bar (1). Two lynch pins (2) are installed on rear of mechanical quick coupler. 5. Tighten cap screw (3) to specification. Specification Cap Screw Torque N m 100 lb-ft 1 Wedge Bar 2 Lynch Pins 3 Cap Screw T130378C UN 11JUL00 OUO1032,00015A NOV04-2/2 Rubber Track Care CAUTION: Prevent possible injury from unexpected machine movement. A machine with rubber track is less stable than a machine with steel shoes, as the edge of the rubber track may bend when bucket is loaded, especially when digging over the side. When you drive the machine: Do not operate on sharp, rocky, uneven surfaces. NOTE: The rubber track has a thin rubber film on its inner surface when it is new. It is normal for the film to come off when track rubs against rollers. Keep the rubber track free of oil, gasoline, etc. Avoid traveling on oil to reduce the chance of slipping. If machine is parked or stored for more than 90 days, park in an area out of direct sunlight. When transporting a machine with rubber tracks, always fasten the right and left track frames securely to the trailer. Do not allow tie down chains to come into direct contact with rubber track pads. TX,55,DH JAN07-1/1 Removing and Installing Rubber Track 1. Rotate upperstructure so front of upperstructure is over travel motors (180 ). 2. Lower the bucket and blade to raise both tracks off ground. CAUTION: Prevent possible injury from unexpected machine movement. Place blocks under machine frame to support machine while measuring track sag. 3. Place blocks under machine frame to support machine. Continued on next page T UN 30NOV04 OUO1032,000158C JUL06-1/ PN=123

124 Miscellaneous Machine CAUTION: Prevent possible injury from high-pressure grease. DO NOT remove grease fitting (1) from valve (2). 4. To loosen track, slowly turn valve (2) counterclockwise. Grease will escape through the bleed hole (3). CAUTION: Prevent potential injury from front idler. Do not stand in front of idler during removal of track. Front idler may come off unexpectedly. 5. Insert two or three steel pipes (4) into gaps among lower rollers, track frame, and rubber track. Rotate track slowly in reverse to lift track off idler. Pry track off idler. 6. Install the rubber track on the sprocket first. Position the other end of the rubber track on the front idler. 7. While rotating the sprocket in reverse, push on the rubber track to force it on the idler. 1 Grease Fitting 2 Valve 3 Bleed Hole 4 Steel Pipe T UN 30NOV04 T UN 30NOV04 OUO1032,000158C JUL06-2/3 8. Insert a steel pipe (4) into gaps among lower rollers, track frame, and rubber track and rotate slowly in reverse to force the rubber track onto the idler. 9. Check that the rubber track is correctly engaged with the sprocket and idler. 10. Adjust track sag. See Adjusting Track Sag. (Section 3-4.) 11. Lower the machine to the ground. 4 Steel Pipe T UN 30NOV04 OUO1032,000158C JUL06-3/3 Converting the Track The rubber track uses a different track adjuster than that used for the steel track. CAUTION: Prevent possible injury from high-pressure grease. DO NOT attempt to disassemble the track adjuster before converting the track. See your authorized dealer. Change the track adjuster whenever converting the track. See your authorized dealer for correct track adjuster. CED,TX14740, APR06-1/ PN=124

125 Miscellaneous Operational Checkout Operational Checkout This procedure is used to check operation of the machine. It is written so a technician can do a walk-around inspection, check machine operation, and perform specific checks from the operator s seat. If there is a problem with the machine, diagnostic information in this checkout will help determine the probable cause. This information can direct a technician to perform a simple adjustment to correct the problem. Use the table of contents to help find adjustment procedures. Machine is positioned so it is level and there is adequate space to complete the checks. No tools are needed to perform the checkout. Complete the usual necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring) prior to doing the checkout. The machine must be at operating temperature for many of the checks. Read each check completely before performing. Then perform check, and if no problem is found, you will be instructed to go to the next check. If a problem is indicated, you will be referred to either a section within this manual or to your authorized dealer for repair. ER93822,000010F SEP12-1/33 Ignition OFF, Engine OFF Checks ER93822,000010F SEP12-2/33 Horn Circuit Check 1 TX UN 30AUG11 Horn Button 1 Horn Button Key switch OFF. Push horn button on top of right control lever. LISTEN: Does horn activate? Continued on next page YES: Check complete. NO: Check fuse (F1) (marked HORN). See Fuse and Relay Specifications. (Section 4-1.) NO: Check switch, wiring, and connections. See your authorized dealer ER93822,000010F SEP12-3/ PN=125

126 Miscellaneous Operational Checkout Hour Meter and Fuel Gauge Check TX UN 23AUG11 Monitor Panel (S.N ) Shown 1 Hour Meter 2 Fuel Gauge 3 Display Select Button Push and hold display select button (3). LOOK: Does the hour meter (1) display machine hours? LOOK: Does fuel gauge (2) display a fuel level? Continued on next page YES: Check complete. NO: Check fuse (F2) (marked RADIO/MONITOR B). See Fuse and Relay Specifications. (Section 4-1.) NO: Check wiring and connections. See your authorized dealer. ER93822,000010F SEP12-4/ PN=126

127 Miscellaneous Operational Checkout Travel Lever and Pedal Neutral Check TX UN 22AUG11 Travel Levers and Pedals 1 Travel Forward 2 Travel Rearward 3 Pilot Shutoff Lever Push each travel lever forward, then release. Pull each travel lever rearward, then release. FEEL: Does each lever have equal effort to operate forward and reverse? FEEL/LOOK: Does each lever return to neutral at the same time when released? YES: Check complete. NO: Repair or replace pilot controller. See your authorized dealer. ER93822,000010F SEP12-5/33 Ignition ON, Engine OFF Checks ER93822,000010F SEP12-6/33 Monitor Indicators and Gauge Circuit Check NOTE: For identification of monitor indicators and gauges on machines (S.N ), see Monitor Panel and Functions (S.N ). (Section 2-1.) For identification of monitor indicators and gauges on machines (S.N ), see Monitor Panel and Functions (S.N ). (Section 2-1.) Monitor alarm is not checked during this procedure. Turn key switch to ON position. If engine coolant temperature is below 30 C (86 F), engine temperature gauge segment YES: Check complete. may not come on. Run engine a few minutes to warm coolant before check. LOOK: Do engine coolant temperature gauge and fuel gauge segments come on? NO: If any monitor light fails to come on, check and replace bulb. If all monitor lights fail to come on, check fuses (F2 and F8). See Fuse and Relay Specifications. (Section 4-1.) LOOK: Do all monitor lights come on and after 2 3 seconds only the alternator indicator and engine oil pressure indicator light remain on? NO: Check wiring. See your authorized dealer. Continued on next page ER93822,000010F SEP12-7/ PN=127

128 Miscellaneous Operational Checkout Engine Preheat Circuit Check Cold Weather Only NOTE: The preheat system is a timed system based on engine coolant temperature. The engine coolant temperature must be less than or equal to 0 C (32 F) for the preheat system to operate. Turn key switch to the ON position. Does the engine preheat indicator light come ON, then go OFF after the approximate amount of time elapses as indicated by the following table? Engine Coolant Temperature Continued on next page Preheat Time (approximate) 0 C (32 F) or higher 1.5 Seconds -7 C (19.4 F) 10 Seconds -10 C (14 F) 15 Seconds -15 C (5 F) 20 Seconds -20 C (-4 F) or lower 24 Seconds YES: Check complete. NO: Check engine coolant temperature sensor (B4), wires, and connections. See your authorized dealer. NO: If preheat indicator activates correctly but engine does not start or is hard to start in cold conditions, check fuses (F62 and F63). See Fuse and Relay Specifications. (Section 4-1.) If fuses OK, check intake air heater relay (K17), intake air preheater (R1 and R2), wires, and connections. See your authorized dealer. ER93822,000010F SEP12-8/ PN=128

129 Miscellaneous Operational Checkout Light Circuit Check TX UN 15AUG11 Switch Panel (S.N ) Shown 1 Key Switch 2 Engine Speed Dial 3 Travel Speed Switch 4 Work Light Switch 5 Windshield Wiper and Washer Switch 6 Travel Alarm Cancel Switch 7 Power Mode Switch NOTE: All accessories are powered from the fuse block. If any accessories do not function, check fuses in fuse block. Turn key switch (1) ON. Push work light switch (4) to ON position. LOOK: Are the work lights on the boom and left front corner of upperstructure ON? Push work light switch to OFF position. LOOK: Do all the lights go OFF? Continued on next page YES: Check complete. NO: Check fuse (F6) (marked WORK LIGHTS). See Fuse and Relay Specifications. (Section 4-1.) Check wiring and connections. See your authorized dealer. ER93822,000010F SEP12-9/ PN=129

130 Miscellaneous Operational Checkout Wiper Circuit Check TX UN 15AUG11 Windshield Wiper Switch 1 Key Switch 2 Engine Speed Dial 3 Travel Speed Switch 4 Work Light Switch 5 Windshield Wiper and Washer Switch 6 Travel Alarm Cancel Switch NOTE: Ensure upper front window is fully down and latched in place. Wiper interlock switch will prevent operation if window is not secured. Key switch (1) ON. Push wiper switch (5) to ON position. LOOK: Does wiper operate continuously? Push wiper switch to ON position. LOOK: Does wiper arm stop in park position at left side of window? Continued on next page YES: Check complete. NO: Check fuse (F7) (marked (RA- DIO/WIPER/WASHER). See Fuse and Relay Specifications. (Section 4-1.) Check wiring and connections. See your authorized dealer. ER93822,000010F SEP12-10/ PN=130

131 Miscellaneous Operational Checkout Washer Circuit Check TX UN 15AUG11 Windshield Wiper Switch 1 Key Switch 2 Engine Speed Dial 3 Travel Speed Switch 4 Work Light Switch 5 Windshield Wiper and Washer Switch 6 Travel Alarm Cancel Switch NOTE: Ensure upper front window is fully down and latched in place. Wiper interlock switch will prevent operation if window is not secured. Key switch (1) ON. Push wiper and washer switch (5) to the ON/WASHER position. LOOK: Does the washer motor and the wiper operate? YES: Check complete. NO: Check fuse (F7) (marked (RA- DIO/WIPER/WASHER). See Fuse and Relay Specifications. (Section 4-1.) Check wiring and connections. See your authorized dealer. ER93822,000010F SEP12-11/33 Ignition ON, Engine ON Checks Continued on next page ER93822,000010F SEP12-12/ PN=131

132 Miscellaneous Operational Checkout Monitor Indicators and Gauge Circuit Check IMPORTANT: Stop engine if any one of the following indicators are on: Engine oil indicator Alternator voltage indicator High coolant temperature indicator System failure indicator NOTE: For identification of monitor indicators and gauges on machines (S.N ), see Monitor Panel and Functions (S.N ). (Section 2-1.) For identification of monitor indicators and gauges on machines (S.N ), see Monitor Panel and Functions (S.N ). (Section 2-1.) Start engine. LOOK: Do alternator voltage and engine oil pressure indicators go OFF after engine starts? LOOK: Do all monitor indicators remain OFF after engine starts? NOTE: When the coolant temperature is lower than 20 C (68 F), the first segment will flash. LOOK: Are engine coolant temperature gauge segments in normal operating zone after a few minutes? Continued on next page YES: Check complete. NO: Check fluid levels (engine oil and coolant). If engine oil pressure indicator is on after engine starts, see your authorized dealer. NO: If alternator voltage indicator is on after engine starts, test alternator output. See Alternator Test. (Group ) Check belt tension. See Check and Adjust Fan Belt Tension. (Section 3-6.) ER93822,000010F SEP12-13/ PN=132

133 Miscellaneous Operational Checkout Pilot Control Shutoff Switch Check 1 TX UN 15AUG11 1 Pilot Shutoff Lever Pilot Shutoff Lever Locked CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate all machine functions. Run engine at slow idle. Move pilot shutoff lever (1) to LOCKED (raised) position. Slowly actuate dig and travel functions. LOOK: Do dig or travel functions operate? YES: Check pilot shutoff relay (K2), switches (S3 and S7), wiring, and connections. See your authorized dealer. NO: Go to next step in this check. 1 TX UN 15AUG11 Pilot Shutoff Lever Unlocked Move pilot control shutoff lever to UNLOCKED (lowered) position. Slowly actuate dig and travel functions. LOOK: Do dig and travel functions operate? Continued on next page YES: Check complete. NO: Check fuse (F3). See Fuse and Relay Specifications. (Section 4-1.) If fuse OK, check pilot shutoff relay (K2), switches (S3 and S7), pilot shutoff solenoid (Y10), wiring, and connections. See your authorized dealer. ER93822,000010F SEP12-14/ PN=133

134 Miscellaneous Operational Checkout Engine Speed Dial Check TX UN 15AUG11 Switch Panel (S.N ) Shown 8 9 TX UN 11AUG11 Monitor (S.N ) Shown 1 Key Switch 2 Engine Speed Dial 3 Travel Speed Switch 4 Work Light Switch 5 Windshield Wiper and Washer Switch 6 Travel Alarm Cancel Switch 8 Auto-Idle Indicator 9 Auto-Idle Switch Disengage auto-idle by pushing auto-idle switch (9) on monitor (S.N ) or the auto-idle switch located on right console (S.N ). Move pilot shutoff lever to the LOCKED (raised) position. Turn engine speed dial (2) clockwise to fast idle position. LISTEN: Does engine speed increase? Turn engine speed dial counterclockwise to slow idle position. LISTEN: Does engine speed decrease? Continued on next page YES: Go to next step in this check. NO: Check engine speed dial, wiring, and connections. See your authorized dealer. ER93822,000010F SEP12-15/ PN=134

135 Miscellaneous Operational Checkout E (Economy) Mode and P (Standard) Mode Check TX UN 15AUG11 Switch Panel (S.N ) Shown 8 9 TX UN 11AUG11 Monitor (S.N ) Shown 1 Key Switch 2 Engine Speed Dial 3 Travel Speed Switch 4 Work Light Switch 5 Windshield Wiper and Washer Switch 6 Travel Alarm Cancel Switch 7 Power Mode Switch 8 Auto-Idle Indicator 9 Auto-Idle Switch Push power mode switch (7) to P (standard) mode. Disengage auto-idle by pushing auto-idle switch (9) on monitor (S.N ) or the auto-idle switch located on right console (S.N ). Turn engine speed dial (2) clockwise to fast idle position. Push power mode switch to E (economy) mode. LISTEN: Does engine speed decrease? Push power mode switch to P (standard) mode. LISTEN: Does engine speed increase? Continued on next page YES: Check complete. NO: Check power mode switch, wiring, and connections. See your authorized dealer. ER93822,000010F SEP12-16/ PN=135

136 Miscellaneous Operational Checkout Auto-Idle Circuit Check TX UN 15AUG11 Switch Panel (S.N ) Shown 8 9 TX UN 11AUG11 Monitor (S.N ) Shown 1 Key Switch 2 Engine Speed Dial 3 Travel Speed Switch 4 Work Light Switch 5 Windshield Wiper and Washer Switch 6 Travel Alarm Cancel Switch 7 Power Mode Switch 8 Auto-Idle Indicator 9 Auto-Idle switch Turn engine speed dial (2) clockwise to (fast idle) position. Push power mode switch (7) to P (standard) mode. Move pilot shutoff lever to UNLOCKED (lowered) position. Engage auto-idle by pushing auto-idle switch (9) on monitor (S.N ) or the auto-idle switch located on right console (S.N ). LOOK: Does auto-idle indicator (8) come on? LOOK/LISTEN: Does engine speed decrease when no hydraulic functions are operated for at least 4 6 seconds? Slowly actuate dig function. YES: Check complete. LISTEN: Does engine speed return to fast idle. NO: See your authorized dealer. Continued on next page ER93822,000010F SEP12-17/ PN=136

137 Miscellaneous Operational Checkout Travel Alarm Circuit Check CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine TX UN 22AUG11 Operator's Station 1 Travel Forward 2 Travel Rearward 3 Pilot Shutoff Lever Move pilot shutoff lever (3) to the UNLOCKED (lowered) position. Slowly push travel levers or pedals forward (1). LISTEN: Does travel alarm activate? Slowly pull travel levers or push pedals rearward (2). LISTEN: Does travel alarm activate? Continued on next page YES: Check complete. NO: Check fuse (F8) (marked ENGINE/MONI- TOR). See Fuse and Relay Specifications. (Section 4-1.) Check travel alarm (H4), travel pressure sensor (B34), travel alarm controller (A8), wiring, and connections. See your authorized dealer. ER93822,000010F SEP12-18/ PN=137

138 Miscellaneous Operational Checkout Travel Alarm Cancel Switch Check TX UN 15AUG11 Switch Panel 1 Key Switch 2 Engine Speed Dial 3 Travel Speed Switch 4 Work Light Switch 5 Windshield Wiper and Washer Switch 6 Travel Alarm Cancel Switch CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. NOTE: Travel alarm must operate for this check. Push travel lever or pedals forward and allow travel alarm to operate for a minimum of 12 seconds. LISTEN: Does travel alarm activate? While continuing travel, push travel alarm cancel switch (6). LISTEN: Does travel alarm deactivate? Return travel levers or pedals to neutral and slowly pull travel levers or push pedals rearward. LISTEN: Does travel alarm activate again? Continued on next page YES: Check complete. NO: Check fuse (F8) (marked ENGINE/MONI- TOR). See Fuse and Relay Specifications. (Section 4-1.) NO: Check travel alarm cancel switch (S13), wiring, and connections. See your authorized dealer. ER93822,000010F SEP12-19/ PN=138

139 Miscellaneous Operational Checkout Hydraulic Oil Tank Pressurization Check 1 2 TX UN 06MAY08 1 Hydraulic Oil Tank 2 Hydraulic Oil Tank Cap Hydraulic Oil Tank Cap Engine running. Raise boom to full height, then lower boom to ground. Stop engine. Slowly loosen oil tank cap (2) on top of hydraulic tank cover. LISTEN: Is air heard escaping from under the cap? IMPORTANT: Avoid pump damage. The pressurized hydraulic oil tank creates pressure at the inlet to the hydraulic pumps. If the filler cap does not seal correctly, the hydraulic pumps could cavitate and damage the pumps. Continued on next page YES: Check complete. NO: Replace hydraulic oil tank cap. ER93822,000010F SEP12-20/ PN=139

140 Miscellaneous Operational Checkout Pilot Controller Pattern Check ISO Excavator Pattern TX A UN 15APR08 Pattern Selector Valve CAUTION Excavator Pattern FAMILIARIZE YOURSELF WITH THE PATTERN SELECTED BY OPERATING SLOWLY. Backhoe Pattern 4 5 TX UN 02AUG10 1 Pilot Control Pattern Lever Selector 2 Excavator Position 3 Backhoe Position 4 Excavator Pattern 5 Backhoe Pattern CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. Stop engine. Move pilot control pattern lever selector (1) to excavator position (2). Turn engine speed control dial counterclockwise to slow idle. Start engine. Push pilot shutoff lever to UNLOCKED position. Slowly move control levers to all excavator pattern (4) on decal. LOOK: Do bucket, boom, arm, and swing move as shown on decal? Continued on next page YES: Check complete. NO: Check pilot controller pattern conversion valve position. Check line connections. See your authorized dealer. ER93822,000010F SEP12-21/ PN=140

141 Miscellaneous Operational Checkout Pilot Controller Pattern Check SAE Backhoe Pattern TX A UN 15APR08 Pattern Selector Valve CAUTION Excavator Pattern FAMILIARIZE YOURSELF WITH THE PATTERN SELECTED BY OPERATING SLOWLY. Backhoe Pattern 4 5 TX UN 02AUG10 1 Pilot Control Pattern Lever Selector 2 Excavator Position 3 Backhoe Position 4 Excavator Pattern 5 Backhoe Pattern CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. Stop engine. Move pilot control pattern lever selector (1) to backhoe position (3). Turn engine speed control dial counterclockwise to slow idle. Start engine. Push pilot shutoff lever to UNLOCKED position. Slowly move control levers to all backhoe pattern (5) on decal. LOOK: Do bucket, boom, arm, and swing move as shown on decals? Continued on next page YES: Check complete. NO: Check pilot controller pattern conversion valve position. Check line connections. See your authorized dealer. ER93822,000010F SEP12-22/ PN=141

142 Miscellaneous Operational Checkout Swing Dynamic Braking Check TX UN 10AUG11 CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. Position upperstructure with boom in front. Move arm to extended position, bucket to the retracted (curl in) position, and bucket-to-arm pivot pin at the same height as boom-to-frame pivot pin. Turn engine speed dial clockwise to fast idle position. Push power mode switch to P (standard) mode position. Fully actuate swing function. Swing right 90 degrees (1/4 turn) and then release lever. LOOK: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever? Position upperstructure with boom to the front. Fully actuate swing function. Swing left 90 degrees and then release lever. LOOK: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasing lever? Continued on next page YES: Check complete. NO: Check swing motor. See your authorized dealer. NO: Check swing valve spool. See your authorized dealer. ER93822,000010F SEP12-23/ PN=142

143 Miscellaneous Operational Checkout Dig Function Drift Check TX UN 31AUG11 Dig Function Drift Test CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. Fill bucket with dirt. Position bucket at maximum reach with bucket pivot pin at the same height as boom pivot pin. Retract arm cylinder, then extend about 50 mm (2.00 in.). Extend bucket cylinder, then retract about 50 mm (2.00 in.). Retract blade cylinder, then extend about 50 mm (2.00 in.). Stop engine. Measure amount cylinders extend or retract in 5 minutes. Specification YES: Check complete. Boom Cylinder Drift... 5 mm 0.2 in. Arm Cylinder Drift mm 0.4 in. Bucket Cylinder Drift... 5 mm 0.2 in. Bottom of Bucket-To-Ground Drift mm 3.94 in. Blade Cylinder Drift... 5 mm 0.2 in. Bottom of Blade-To-Ground Drift mm 0.6 in. Boom Swing Cylinder Drift... 3 mm 0.12 in. LOOK: Is cylinder drift within specification? NO: See your authorized dealer. See your authorized dealer. Continued on next page ER93822,000010F SEP12-24/ PN=143

144 Miscellaneous Operational Checkout Control Valve Lift Check Test TX UN 09AUG11 Control Valve Lift CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. Turn engine speed control dial counterclockwise to slow idle position. Position machine as shown. Slowly actuate pilot controller to lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder). LOOK: Do functions move in opposite direction as control levers are moved, then change direction as levers are moved further? Continued on next page YES: See your authorized dealer. NO: Check complete. ER93822,000010F SEP12-25/ PN=144

145 Miscellaneous Operational Checkout Travel Speed Change Check TX UN 15AUG11 Switch Panel 1 Key Switch 2 Engine Speed Dial 3 Travel Speed Switch 4 Work Light Switch 5 Windshield Wiper and Washer Switch 6 Travel Alarm Cancel Switch CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. Turn engine speed dial (2) clockwise to fast idle position. Push travel speed switch (3) to slow speed (turtle) mode. Actuate travel function to full speed forward. Push travel speed switch to fast speed (rabbit) mode. FEEL/LOOK: Does machine travel speed increase? Actuate a dig function and then return to neutral. FEEL/LOOK: Does machine travel speed decrease and then increase as the dig function is actuated and released? Push travel speed switch to slow speed (turtle) mode. FEEL/LOOK: Does machine travel speed decrease? Continued on next page YES: Check complete. NO: Check travel speed solenoid. Check switch, wiring, and connections. See your authorized dealer. Check travel speed change valve. See your authorized dealer. ER93822,000010F SEP12-26/ PN=145

146 Miscellaneous Operational Checkout Travel System Tracking Check TX UN 12SEP12 Switch Panel (S.N ) Shown 1 Engine Speed Dial 2 Travel Speed Switch 3 Auto-idle switch 4 Power Mode Switch CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. Turn engine speed dial (1) clockwise to (fast idle) position. Turn auto-idle switch (3) OFF. Push power mode switch (4) to P (standard) mode. Push travel speed switch (2) to fast speed (rabbit) mode TX UN 17AUG12 Tracking Check 5 Distance of Mistrack 6 Acceleration and Deceleration Zone (approximately): 3 5 m (10 16 ft.) 7 Test Line (distance): 20 m (66 ft.) 8 Track Print Operate machine at full travel forward speed on a flat and level surface approximately 30 m (99 ft.). NOTE: When machine mistracks right, hydraulic pump 1 circuit oil flow may be less than specification. When machine mistracks left, hydraulic pump 2 circuit oil flow may be less than specification. Observe direction of mistrack. Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8). Continued on next page ER93822,000010F SEP12-27/ PN=146

147 Miscellaneous Operational Checkout Measure and record greatest distance of mistrack (5) between inside edge of track print and test line. Repeat procedure in reverse travel. LOOK: Does machine mistrack less than 200 mm (7.88 in.)? YES: Check complete. NO: Check travel motors. See your authorized dealer. Check main pump flow. See your authorized dealer. ER93822,000010F SEP12-28/33 Blade Function Check CAUTION: Machine will move during this check. Make sure area is clear and large enough to operate the machine. 1 TX UN 19SEP08 Blade Control Lever 1 Blade Control Lever Turn engine speed control dial counterclockwise to (slow idle) position. Pull blade control lever (1) rearward. LOOK: Does blade raise? Release lever. LOOK: Does lever return to neutral and the blade stop? Push lever forward. LOOK: Does blade lower? Release lever. LOOK/FEEL: Does lever return to neutral and the blade stop? Continued on next page YES: Check complete. NO: Check blade pilot controller. See your authorized dealer. Check blade valve spool. See your authorized dealer. ER93822,000010F SEP12-29/ PN=147

148 Miscellaneous Operational Checkout Angle Blade Function Check TX UN 28FEB12 Angle Blade Control Lever and Switches 168 Angle Blade Control Lever 170 Angle Blade Angle Left Switch 171 Angle Blade Angle Right Switch Pull angle blade control lever (168) rearward. Press angle blade angle left switch (170). LOOK: Does blade angle to the left? Release switch LOOK: Does blade stop? Press angle blade angle right switch (171). LOOK: Does blade angle to the right? Release switch. LOOK: Does blade stop? Continued on next page YES: Check complete. NO: Check angle blade angle left relay (K18) and angle blade angle right relay (K19). See your authorized dealer. Check angle blade angle left solenoid (Y27) and angle blade angle right solenoid (Y29). See your authorized dealer. ER93822,000010F SEP12-30/ PN=148

149 Miscellaneous Operational Checkout Cycle Times Check CAUTION: Make sure area is clear and large enough to operate all functions of machine. IMPORTANT: Warm hydraulic oil to operating temperature for this check. Turn engine speed dial clockwise to fast idle position. Record cycle time for each function. YES: Check complete. TX UN 31AUG11 Boom, Arm, Bucket, and Blade Cycle Times Specification Boom Raise (cylinder extend) Cycle Time sec. Boom Lower (cylinder retract) Cycle Time sec. Arm In (cylinder extend) Cycle Time sec. Arm Out (cylinder retract) Cycle Time sec. Bucket Load (cylinder extend) Cycle Time sec. Bucket Dump (cylinder retract) Cycle Time sec. Boom Swing Right (cylinder extend) Cycle Time sec. Boom Swing Left (cylinder retract) Cycle Time sec. Blade Raise Cycle Time sec. Blade Lower Cycle Time sec. Blade Angle Left Cycle Time sec. Blade Angle Right Cycle Time sec. Swing Function Specification Swing Left or Right, 3 Revolutions From a Running Start Cycle Time sec. Travel Function Specification Travel 20 m (66 ft.) From a Running Start (check in forward and reverse with travel speed switch in FAST position) Cycle Time sec. with rubber track sec. with steel track Travel 20 m (66 ft.) From a Running Start (check in forward and reverse with travel speed switch in SLOW position) Cycle Time sec. with rubber track sec. with steel track LOOK: Does machine perform within specifications? NO: See your authorized dealer. Continued on next page ER93822,000010F SEP12-31/ PN=149

150 Miscellaneous Operational Checkout Heater and Air Conditioner Circuit Check TX UN 11AUG11 Air Conditioner and Heater Control Panel TX UN 12AUG11 Air Conditioner and Heater Air Vents 1 A/C Switch 2 Air Conditioner/Heater Control Power Switch 3 Blower Speed Switch 4 A/C Indicator 5 Temperature Control Switch 6 Vent Mode Indicator 7 Defroster Switch 8 Vent Mode Switch 9 Circulation and Fresh Air Mode Switch 10 Air Conditioner/Heater LCD Display 11 Foot Air Vent 12 Lower Front Air Vent 13 Upper Front Air Vent 14 Rear Air Vent With engine running and at normal operating temperature. Push air conditioner/heater control power switch (2) ON. LOOK: Does air conditioning/heater LCD display (10) light up? Push the blower speed button (3) to increment through all four fan speeds. FEEL/LISTEN: Does blower motor have four speeds? Put blower speed to highest speed setting. Continued on next page ER93822,000010F SEP12-32/ PN=150

151 Miscellaneous Operational Checkout TX UN 11AUG11 Vent Mode Display 15 Upper Front Air Vent (13) 16 Upper Front and Rear Air Vent (13 and 14) 17 All Air Vents (11 14) 18 Foot and Lower Front Air Vent (11 and 12) Push vent mode switch (8) to display position (15). FEEL: Does air flow through the upper front vent? Push vent mode button again. FEEL: Does air flow through upper and rear vent? Push vent mode button again. FEEL: Does air flow through all vents (11 14)? Push vent mode button again. FEEL: Does air flow through lower and foot vent. Push temperature control switch (5) up arrow to for warm air. FEEL: Does warm air flow from vents? Push A/C ON button (1). LOOK: Does air conditioning indicator (4) come on? Push temperature control switch down arrow for cool air. FEEL: Does cool air flow from vents? YES: Check complete. NO: Check fuse (F6) (marked BLOWER/ILLUMI). See Fuse and Relay Specifications. (Section 4-1.) If fuse OK, check switches, relays, wiring, and connections. See your authorized dealer. ER93822,000010F SEP12-33/ PN=151

152 Using Troubleshooting Charts Miscellaneous Troubleshooting NOTE: Troubleshooting charts are arranged from the simplest to verify, to least likely, more difficult to verify. When diagnosing a problem, use all possible means to isolate the problem to a single component or system. Use the following steps to diagnose problems: Step 2. Troubleshooting charts. Step 3. Adjustments. Step 4. See your authorized dealer. Step 1. Operational Checkout Procedure. TX,FF, FEB02-1/ PN=152

153 Miscellaneous Troubleshooting Engine Symptom Problem Solution Engine Cranks But Will Not Start Or Hard To Start No fuel Incorrect fuel Add fuel. Use correct fuel. Fuel filter restricted Replace filter. Bleed air. Clean fuel tank inlet screen. Water separator restricted or not primed Water in fuel Inspect water separator. Inspect, drain fuel tank, and refill. Leaks in fuel system Inspect fuel system connections. See your authorized dealer. Contaminated fuel Drain fuel tank. Replace water separator and fuel filter. Add clean fuel. Bleed air. Air in fuel system Bleed air. Low battery power Charge or install new battery. Slow cranking speed (poor electrical connection) Clean and tighten battery and starter connections. Incorrect engine oil Use correct oil. Air filter restricted Inspect, clean, replace if necessary. Starter Repair or replace starter. Engine Knocks, Runs Irregularly, Or Stops Air filter restricted Fuel filter restricted Inspect, clean, replace if necessary. Replace filter. Bleed air. Clean fuel tank inlet screen. Water separator restricted Inspect water separator. Air in water separator Bleed air from fuel system. Engine oil level low Add correct oil proper level. Contaminated fuel Drain fuel tank. Replace water separator and fuel filter. Add clean fuel. Bleed air. Air in fuel system Bleed air from fuel system. Coolant temperature low Inspect for proper thermostat temperature and operation. Replace if necessary. Continued on next page MM16284, JUN08-1/ PN=153

154 Miscellaneous Troubleshooting Symptom Problem Solution Injection pump See your authorized dealer. Engine Starts But Will Not Continue To Run Air in fuel system No fuel flow to engine Bleed air from fuel system. Check and replace 10A fuse marked (ENGINE/MONITOR). Air filter restricted Inspect, clean, replace if necessary. Fuel filter restricted Replace filter. Bleed air. Clean fuel tank inlet screen. Engine Not Developing Full Power Air filters restricted Inspect, clean, replace if necessary. Fuel filter restricted Water separator Contaminated fuel Incorrect fuel Fuel line restricted Restricted vent in fuel tank cap Exhaust restriction Valve clearance Incorrect oil Replace filter. Bleed air. Clean fuel tank inlet screen. Inspect water separator. Drain fuel tank. Replace water separator and fuel filter. Add clean fuel. Bleed air. Use correct fuel. Repair or replace fuel line. Bleed air. Clean or install new cap. Install new muffler. Check and adjust valves. Use correct oil. Engine Overheats Coolant level low Add coolant to recovery tank. Remove cap when cool. Check coolant level in radiator. Radiator screen restricted Radiator core or oil cooler core restricted Air filter restricted Radiator cap Fan on backwards Cooling system passages restricted Fan system Remove and clean screen. Clean radiator and oil cooler. Inspect, clean, replace if necessary. Inspect and replace if necessary. Install fan correctly. Flush cooling system. See your authorized dealer. Continued on next page MM16284, JUN08-2/ PN=154

155 Miscellaneous Troubleshooting Symptom Problem Solution Low Engine Oil Pressure Oil level low Add correct oil to proper level. Oil filter restricted Incorrect oil Oil leaks Engine temperature too high Install new oil filter. Use correct oil. See your authorized dealer. Inspect cooling system. Engine Uses Too Much Oil Incorrect oil Use correct oil. Oil leaks Engine temperature too high Air cleaner restricted See your authorized dealer. Inspect cooling system. Inspect, clean, replace if necessary. Engine Uses Too Much Fuel Restricted or dirty air intake system Clean air intake system. Incorrect fuel Use correct fuel. Excessive Black Or Gray Exhaust Smoke Incorrect fuel Restricted or dirty air intake or exhaust system Cool engine Use correct fuel. Clean air intake and exhaust system. Inspect thermostat. Replace if necessary. Exhaust Smoke Is White Incorrect fuel Use correct fuel. Cold engine Cylinder head/head gasket leak Run engine until warm. See your authorized dealer. Exhaust Smoke Is Blue Engine oil level too high Drain oil to proper level. Excessive blowby See your authorized dealer. MM16284, JUN08-3/ PN=155

156 Miscellaneous Troubleshooting Electrical System Symptom Problem Solution Nothing Works Battery Recharge or replace. Fusible links Inspect fusible links. Replace if necessary. Batteries Undercharged Loose or corroded connections Clean and tighten connections or replace batteries. Batteries Will Not Take A Charge Loose or corroded connections Clean and tighten. Low battery power Replace batteries. Battery Uses Too Much Water Cracked battery case Replace battery. High ambient temperature Refill with water to proper level.. Cracked Battery Case No battery hold down clamp Replace battery and install hold down clamp. Loose battery hold down clamp Frozen battery Replace battery and install hold down clamp. Replace battery. Keep batteries fully charged in cold weather. Low Battery Output Low water level Add water to proper level. Dirty or wet battery top, causing discharge Corroded or loose battery cables Broken battery post Clean and wipe battery top dry. Clean and tighten battery cables. Wiggle battery post by hand. If post wiggles or turns, replace battery. Starter Will Not Turn Battery undercharged or dead Recharge or replace battery. Battery cables making poor connections Starter Clean connections. Repair or replace starter. Starter pinion jammed in flywheel gear Repair or replace starter or ring gear. Starter Turns But Will Not Crank Engine Engine Cranks Slowly Starter Battery cables damaged or broken internally Battery or starter cable connections loose or corroded Battery discharged or will not hold a charge Repair or replace starter. Inspect and replace cables. Clean and tighten connections. Recharge or replace battery. Continued on next page ER93822, FEB12-1/ PN=156

157 Miscellaneous Troubleshooting Symptom Problem Solution Starter Repair or replace starter. Low battery voltage Recharge or replace battery. Starter Continues To Run After Engine Starts Starter Key switch malfunction Repair or replace starter. Disconnect battery ground. See your authorized dealer. Charging Indicator Light On, Engine Running Loose or glazed alternator belt Excessive electrical load from added accessories Check belt. Replace if glazed. Remove accessories or install higher output alternator. Loose or corroded electrical connections on battery, ground strap, starter, or alternator Battery voltage low Inspect, clean, or tighten electrical connections. Charge or replace battery. Noisy Alternator Worn drive belt Replace belt. Worn pulleys Replace pulleys and belt. Pulley misaligned Adjust alternator mount. Alternator bearing Loosen alternator belts. Turn pulley by hand. If any roughness is felt, repair alternator. No Monitor Panel Indicators or Gauges Work Fuse Inspect and replace 10 A fuse marked (ENGINE/MONITOR). Individual Indicators Not Working Bulb Inspect and replace. In Monitor Panel No Switch Panel Switches Work Fuse Inspect and replace all fuses as necessary. Angle Blade Drift Too Great Angle blade moves when blade is not operated Check lever switches. Check relays and fuses. Check solenoids. Angle Blade Not Operating One side of angle blade does not work Check lever switches. Check relays and fuses. Check solenoids. Angle Blade Moves Slowly One side of angle blade does not work Check lever switches. ER93822, FEB12-2/ PN=157

158 Miscellaneous Troubleshooting Symptom Problem Solution Check relays and fuses. Check solenoids. ER93822, FEB12-3/ PN=158

159 Miscellaneous Troubleshooting Hydraulic System Symptom Problem Solution No Hydraulic Functions Low hydraulic oil level Add oil to proper level. Hydraulic Functions Are Slow or Have Little or No Power Restricted suction screen Low hydraulic oil level Cold oil Incorrect oil Suction screen restricted Engine speed too low Inspect and clean screen. Add oil to proper level. Perform hydraulic warm-up procedure. Use correct oil. Inspect and clean screen. Increase speed. Hydraulic Oil Overheats Incorrect oil Use correct oil. Restricted radiator or oil cooler Radiator screen restricted Restricted filters Low hydraulic oil level Contaminated oil Clean and straighten fins. Remove and clean. Install new filters. Add oil to proper level. Drain oil and refill to proper level. Oil Foams High or low oil level Correct oil level. Incorrect oil Water in oil Kinks or dents in oil lines Use correct oil. Inspect and replace oil. Inspect lines and replace as necessary. No Swing Function Pilot control hoses pinched or kinked Inspect and correct. Swing Function Is "Jerky" Lack of grease Fill with grease. Slow Travel Speed only Fuse Inspect and replace if necessary 10 A fuse marked (ENGINE/MONITOR). Pilot control line pinched or kinked Inspect and correct. Travel Is "Jerky" Track sag adjustment Adjust tension. Engine Stops When Travel Or Control Lever Moved Rocks or mud lodged in track frame Water separator restricted Remove and repair. Inspect water separator. Continued on next page ER93822, FEB12-1/ PN=159

160 Miscellaneous Troubleshooting Symptom Problem Solution Angle Blade Drift Too Great Angle blade moves when blade is not operated Check system relief and circuit relief valves. Angle Blade Not Operating One side of angle blade does not work Check hose routing. Check center joint. Angle Blade Moves Slowly One side of angle blade does not work Check hose routing. Check center joint. NOTE: If any other problems are encountered which require special tools or machine knowledge to correct, see your authorized dealer. ER93822, FEB12-2/ PN=160

161 Miscellaneous Storage Prepare Machine for Storage 1. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later. 2. Replace air cleaner elements. IMPORTANT: High pressure washing greater than 1379 kpa (13.8 bar) (200 psi) can damage freshly painted finishes. Paint should be allowed to air dry for 30 days minimum after receipt of machine before cleaning parts or machines with high pressure. Use low pressure wash operations until 30 days have elapsed. IMPORTANT: Avoid damage to hydraulic cylinder seals and rods. High pressure washing of cylinder seal areas can force moisture and debris past seals, causing damage to seals and rod. Use low pressure wash to clean cylinder seal areas. 3. Wash the machine. Use low pressure wash operations (less than 1379 kpa (13.8 bar) (200 psi) until 30 days after receipt of machine have elapsed. Paint areas to prevent rust. Replace decals, where needed. 4. Apply oil to track chains. Run machine back and forth several times. Park machine on a hard surface to prevent tracks from freezing to ground. 5. Store machine in a dry, protected place. If stored outside, cover with a waterproof material. IMPORTANT: LPS 3 Rust Inhibitor can destroy painted finish. DO NOT spray LPS 3 Rust Inhibitor on painted areas. 7. Place a DO NOT OPERATE tag on the right control lever. 8. Lubricate all grease points. NOTE: If the batteries are kept disconnected for more than one month or when the batteries are reconnected, contact your nearest Hitachi dealer. Resetting of the information controller (ICX) may be required. 9. Remove the batteries and store in a dry, protected place after charging fully. If not removed, disconnect the negative battery cable from the ( ) terminal. 10. Add a fuel stabilizer additive and top off fuel tank with fuel to prevent condensation. 11. Drain water separator. 12. Remove keys and lock all covers and doors. T5813AM UN 09FEB89 6. Retract all hydraulic cylinders, if possible. If not, coat exposed cylinder rods with LPS 3 Rust Inhibitor. LPS is a trademark of the Holt Lloyd Corporation. ER93822,000014C FEB12-1/1 Monthly Storage Procedure CAUTION: Prevent possible injury or death from asphyxiation. Engine exhaust fumes can cause sickness or death. Start engine ONLY in a well-ventilated area. 1. Drain water and sediment from fuel tank when air temperature is above freezing. 2. Remove LPS 3 Rust Inhibitor from cylinder rods with a cleaning solvent. T6191AA UN 18OCT88 LPS 3 Rust Inhibitor is a trademark of Illinois Tool Works. Continued on next page VD76477,00016A JUN11-1/ PN=161

162 Miscellaneous Storage IMPORTANT: Prevent possible engine damage. During cold temperatures, check fluidity of engine oil on dipstick. If the oil appears waxy and/or jelly-like rather than liquid, DO NOT attempt to start engine. Use external heat source to warm the crankcase until oil appears fluid. 3. Check all fluid levels. If low, check for leaks and add oil as required. 4. Check belts. 5. Check condition of all hoses and connections. 6. Check battery electrolyte level. Charge and install battery. 7. For machines with tires, check condition of tires and tire pressure. For machines with tracks, check condition of tracks and track sag. On crawler machines with non sealed-and-lubricated track chains, apply oil to the pin-to-bushing joints. Run machine back and forth several times. 8. Park machine on a hard surface to prevent tracks from freezing to ground. 9. Fill fuel tank. 10. Pre-lubricate turbocharger bearings, if equipped: a. Disconnect fuel shutoff fuse. b. Crank engine for 10 seconds. c. Connect fuel shutoff fuse. 11. Inspect engine compartment, and remove any foreign material that may have accumulated. Start engine and run until it reaches operating temperature. Run at 1/2 speed for five minutes. Do not run at fast or slow idle. If engine fails to start or runs poorly after starting, change fuel filter(s). Bleed fuel system. 12. Operate all controls, levers, seat adjustments, etc. CAUTION: Prevent possible injury from unexpected machine movement. Clear the area of all persons before running machine through the operation procedure. 13. Make sure the area is clear to allow for movement. Cycle all hydraulic functions several times. Check condition of all hoses and connections. 14. Park the machine with cylinder rods retracted, if possible. Turn key switch to OFF. 15. Apply LPS 3 Rust Inhibitor to exposed cylinder rod areas. T6181AU UN 18OCT88 VD76477,00016A JUN11-2/ PN=162

163 Miscellaneous Serial Numbers Record Product Identification Number (PIN) Purchase Date PIN NOTE: Record all 13 characters of the Product Identification Number. 1 Product Identification Number TX A UN 09JUN08 ER93822,00001B JUN08-1/1 Record Engine Serial Number Engine Serial Number (1) 1 Engine Serial Number TX A UN 09JUN08 ER93822,00001B JUN08-1/1 Keep Proof of Ownership 1. Maintain in a secure location an up-to-date inventory of all product and component serial numbers. 2. Regularly verify that identification plates have not been removed. Report any evidence of tampering to law enforcement agencies and order duplicate plates. 3. Other steps you can take: - Mark your machine with your own numbering system - Take color photographs from several angles of each machine TS1680 UN 09DEC03 DX,SECURE NOV03-1/ PN=163

164 Miscellaneous Serial Numbers Keep Machines Secure 1. Install vandal-proof devices. 2. When machine is in storage: - Lower equipment to the ground - Set wheels to widest position to make loading more difficult - Remove any keys and batteries 3. When parking indoors, put large equipment in front of exits and lock your storage buildings. 4. When parking outdoors, store in a well-lighted and fenced area. 5. Make note of suspicious activity and report any thefts immediately to law enforcement agencies. 6. Notify your John Deere dealer of any losses. TS230 UN 24MAY89 DX,SECURE NOV03-1/ PN=164