624H Loader and TC62H Tool Carrier

Transcription

1 624H Loader and TC62H Tool Carrier OPERATOR S MANUAL 624H Loader and TC62H Tool Carrier OMT Issue B3 (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. Worldwide Construction And Forestry Division (This manual replaces OMT G0) 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 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. DX,IFC NOV01 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 heavyduty 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 HG31779, APR02 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 P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, IA FAX NUMBER: Ideas, Comments (Please State Page Number): OVERALL, how would you rate the quality of this publication? (Check one) Poor Fair Good Very Good Excellent Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU! TX,II,FAX 19 10JUL01 1/ PN=4

5 Contents Page Page Safety Safety Features Operation Operator s Station Safety Features Levers Pedals Safety General Precautions Deluxe Monitor Panel (Earlier Machines) Recognize Safety Information Deluxe Monitor Panel Functions (Earlier Follow Safety Instructions Machines) Operate Only If Qualified Deluxe Monitor Panel (Later Machines) Wear Protective Equipment Deluxe Monitor Panel Functions (Later Avoid Unauthorized Machine Modifications Machines) Add Cab Guarding For Special Uses Console Switches and Accessories Inspect Machine (Later Machines Single Lever Design) Stay Clear Of Moving Parts Console Switch and Accessory Avoid High-Pressure Fluids Functions (Later Machines Single Lever Beware Of Exhaust Fumes Design) Prevent Fires Console Switches and Accessories Prevent Battery Explosions (Later Machines Two Lever Design) Handle Chemical Products Safely Console Switch and Accessory Dispose of Waste Properly Functions (Later Machines Two Lever Prepare for Emergencies Design) Safety Operating Precautions Monitor Display Unit Use Steps And Handholds Correctly Monitor Display Unit Accessory Menu Start Only From Operator s Seat Normal Display Use And Maintain Seat Belt Clutch Cut-Off (A 01) Prevent Unintended Machine Movement Quick Shift Mode (A 02) Avoid Work Site Hazards Auto Mode to First (A 03) Use Special Care When Operating Loader Job Timer Mode (A 04) Keep Riders Off Machine Stop Watch Mode (A 05) Avoid Backover Accidents Hour Meter Mode (A 06) Avoid Machine Tip Over Metric Units Mode (A 07) Operating on Slopes Monitor Display Unit User Diagnostics Operating Or Traveling On Public Roads Menu Inspect and Maintain ROPS Service Codes (d 01) Add And Operate Attachments Safely Continuity Check (d 02) Battery Monitor (d 03) Safety Maintenance Precautions Engine Sensors (d 04) Park And Prepare For Service Safely Transmission Sensors (d 05) Service Cooling System Safely Hydraulic Sensors (d 06) Remove Paint Before Welding or Heating Fuel Sensor (d 07) Make Welding Repairs Safely (d08)-not Used Drive Metal Pins Safely Machine I.D. Mode (d 10) Horn Button Safety Safety Signs Safety Signs Continued on next page 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 2003 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 1997, 1998, 2000, 2001, 2002 i PN=1

6 Contents Page Page Turn Signals Transmission, Hydraulic System, Park Air Conditioning Controls Brake, and Differential Oil Air Flow Knob Grease Adjusting Steering Wheel Tilt Diesel Engine Coolant Opening and Securing Side Door Opening Side Window/Secondary Exit Maintenance Periodic Maintenance Opening Rear Side Window Service Your Machine at Specified Intervals Adjusting Seat Check the Monitor Display Unit Regularly Seat Belt Opening Engine Side Shields and Service Doors Operation Operating the Machine Locking Machine Frame Inspect Machine Daily Before Starting Boom Lock Check Instruments Before Starting Opening Grille Door Starting the Engine Fuel Tank Starting Fluid If Equipped (Cold Weather Check Windshield Washer Fluid Level Starting Aid) Maintenance and Repair Record Battery Keeping System Using Booster Batteries 24 Volt System OILSCAN PLUS, COOLSCAN PLUS, Engine Air Heater If Equipped and 3-Way Coolant Test Kit Using Coolant Heater If Equipped Service Intervals Warm-Up Cold Weather Warm-Up Maintenance As Required Neutral Lock Check Tire Pressure Shifting the Transmission Tire Pressures Park Brake Switch Tighten Wheel Retainer Cap Screws Boom and Bucket Control Lever One Check Fire Extinguisher If Equipped Lever Design Clean or Replace Air Cleaner Elements Boom and Bucket Control Lever Check Air Inlet Cover Two Lever Design Inspect Serpentine Belt Quick Shift Switch Drain Fuel Tank Sediment Ride Control Switch Earlier Machines (If Drain and Clean Primary Fuel Filter Equipped) Ride Control Later Machines (If Equipped) Secondary Steering If Equipped Maintenance Every 10 Hours or Daily Differential Lock Switch Check Recovery Tank Coolant Level Boom Height Kickout Adjustment Clean Air Cleaner Dust Unloader Valve Return-to-Carry Kickout Adjustment Check Engine Oil Level Return-To-Dig Adjustment (S.N ) Check Hydraulic Oil Level Return-To-Dig Adjustment (S.N ) Check Transmission Oil Level Fork Attachment Parking the Machine Maintenance After First 100 Hours Loading Machine on a Trailer Change Engine Break-In Oil and Towing Procedure Replace Filter Lifting the Machine Change Transmission Oil Replace Transmission Oil Filter Maintenance Machine Diesel Fuel Maintenance Every 100 Hours Low Sulfur Diesel Fuel Conditioner Grease Loader Linkage and Cylinder Pivots Dieselscan Fuel Analysis Grease Front Steering Cylinder Pivots Handling and Storing Diesel Fuel Grease Oscillating Rear Axle and Rear Alternative And Synthetic Lubricants Steering Cylinder Pivots Diesel Engine Break-In Oil Diesel Engine Oil Continued on next page ii PN=2

7 Contents Page Page Check Cab Fresh Air Filter If Equipped Precautions for Alternator and Regulator With Cab Handling, Checking And Servicing Batteries Check Cab Recirculating Air Filter If Carefully Equipped With Cab Replacing Batteries Removing Batteries Maintenance Every 250 Hours Replacing Fuses Grease Front Driveline Sliding Joint Fuse (Blade-Type) Color Codes Check Receiver Dryer Moisture Indicator Replacing Halogen Bulbs Check Radiator Coolant Level Engine Speeds Change Engine Oil and Replace Filter Checking Neutral Start System Servicing Air Conditioning System Maintenance Every 500 Hours Welding on Machine Lubricate Upper and Lower Drive Line External Service Brake Inspection Sliding Joints Checking Brake Accumulators Check Air Intake Hoses Checking Ride Control Accumulator If Check Battery Electrolyte Level and Equipped Terminals Transmission Oil Cooler, Hydraulic Oil Replace Primary Fuel Filter Cooler, Air-to-Air Aftercooler, and Replace Final Fuel Filter Service Recommendations For STC 1 Replace Hydraulic System Return Filter Fittings Grease Rear Oscillating Support Cover Do Not Service Control Valves, Replace Hydraulic Reservoir Breather Filter Cylinders, Pumps or Motors Replace Transmission Oil Filter Hardware Torque Specifications Check Park Brake Oil Level Keep ROPS Installed Properly Check Front and Rear Differential Oil Level Metric Bolt and Cap Screw Torque Values Unified Inch Bolt and Cap Screw Torque Maintenance Every 1000 Hours Clean Engine Crankcase Vent Tube Values Replace Air Cleaner Dust Unloader Valve Miscellaneous Operational Checkout Replace Air Cleaner Elements Operational Checkout Check Coolant Checking and Clearing Diagnostic Check Radiator Hoses Change Transmission Oil Trouble Codes From Monitor Grease Frame Hinge Pivots Engine Off Checks Check Park Brake Engine Running Checks Change Park Brake Oil Maintenance Every 2000 Hours Miscellaneous Troubleshooting Troubleshooting Procedure Adjust Engine Valve Lash (Clearance) Diagnostic Trouble Codes Quick Reference List Maintenance Every 3000 Hours Engine Change Hydraulic System Oil Diagnose Clean Hydraulic System Strainer Transmission System Malfunctions Change Front and Rear Differential Oil Differential And Axle Malfunctions Clean Axle Differential Recirculation Screen Service Brake Malfunctions Drive Line Malfunctions Miscellaneous Machine Park Brake Malfunctions Draining the Cooling System Loader Hydraulic System Malfunctions Filling the Cooling System Steering Malfunctions Replacing Engine Vibration Damper Air Conditioning System Adjusting Pilot Controller Tower Heater System Checking Fuel Tank Vent Hose Bleeding Fuel System Continued on next page iii PN=3

8 Contents Page Miscellaneous Storage Prepare Machine For Storage Miscellaneous Machine Numbers Record Product Identification Number (PIN) Record Engine Serial Number Record Transmission Serial Number Record Hydraulic Pump Serial Number Record Axle Serial Number Miscellaneous Specifications 624H/TC62H Specifications H High Lift Specifications Drain and Refill Capacities 624H/TC62H Miscellaneous Crime Prevention Tips Help Prevent Crime Record Identification Numbers Keep Proof of Ownership Park Indoors Out of Sight When Parking Outdoors Reduce Vandalism Report Thefts Immediately iv PN=4

9 Safety Safety Features Safety Features T T UN 01JUN01 Please remember, the operator is the key to preventing accidents. 1. ROPS, FOPS, and OPS. Structures designed to help protect the operator are certified to ISO, SAE, and OSHA. Enclosures also deflect sun and rain. 2. Pressurized Cab with Heater/Defroster. Positive pressure ventilation system 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. 3. Mirrors. Large exterior mirrors on both sides and an inside mirror offers operator a broad view of area behind machine. 4. Large Windshield Wiper with Washer. Extra long wiper cleans large windshield area. 5. Loader Boom Service Lock. Loader includes a mechanical lock for securing boom in the raised position before work is started on or around the machine. 6. Halogen Lights and Turn Signals. High intensity halogen drive/work lights and high-visibility turn signals are standard equipment. 7. Articulation Locking Bar. A self-storing mechanical lock is provided for transport or service. 8. Handholds. Large, conveniently placed handholds make it easy to enter or exit the operator s station or service area. 9. Horn. Standard horn is useful when driving or signaling co-workers. 10. Independent Parking Brake. Electronically controlled and engages whenever the engine is stopped. 11. Seat Belt Retractors. Seat belt retractors help keep belts clean and convenient to use. 12. Bypass Start Protection. Shielding over the starter terminals helps prevent dangerous bypass starting. 13. Engine Fan Guard. A secondary fan guard inside the engine compartment helps prevent contact with the rotating fan blades. 14. Back Up Alarm. Alerts bystanders when reverse travel direction is selected by operator. 15. Stop and Signal Lights. Highly visible stop lights are standard equipment. TX03679,00016FD 19 14JUN01 1/ PN=7

10 Safety General Precautions Recognize Safety Information This is the safety alert symbol. When you see this symbol on your 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 your 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 19 21AUG00 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 MAR01 1/1 Operate Only If Qualified Do not operate this machine unless you have read the operator s manual carefully and you have been qualified by supervised training and instruction. Familiarize yourself with the job site and your 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 your work situation and your work site. TX03679,00016FA 19 30OCT00 1/ PN=8

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 OCT00 1/1 Avoid Unauthorized Machine Modifications 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. 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. TX03679,00016B OCT00 1/1 Add Cab Guarding For Special Uses Special work situations or machine attachments may create an environment with falling or flying objects. Loading logs, using fork attachments, or operating in waste management applications requires special work tools. Added cab guarding to protect the operator may also be required. Use load-clamping grapples to keep bulky loads from falling and add special screens or guarding when objects may be directed toward the cab. Contact your authorized dealer for information on devices intended to protect the operator from falling or flying objects in special work situations. T UN 04MAY01 TX03679,00017C JUN01 1/ PN=9

12 Safety General Precautions 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, SEP00 1/1 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 OCT00 1/1 Avoid High-Pressure Fluids This machine uses a high-pressure hydraulic system. Escaping fluid 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 fluid. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system. If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid 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 31OCT00 T UN 20SEP00 TX03679,00016D OCT00 1/ PN=10

13 Safety General Precautions Beware Of Exhaust Fumes Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, 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 SEP00 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 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 multi-purpose fire extinguisher on or near the machine. Know how to use extinguisher properly. T UN 14SEP00 T UN 07SEP00 T UN 07SEP00 TX03679,00016F SEP00 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 19 14SEP00 1/ PN=11

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 AUG02 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. T UN 25AUG00 If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your dealer for more information. TX03679, SEP00 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 19 14SEP00 1/ PN=12

15 Safety Operating Precautions Use Steps And Handholds Correctly Prevent falls by facing the machine when you get 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 SEP00 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, MAY01 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. T SEP00 The complete seat belt assembly should be replaced every three years, regardless of appearance. TX03679,00016DD 19 17OCT00 1/ PN=13

16 Safety Operating Precautions Prevent Unintended Machine Movement When co-workers are present, disable hydraulics. Lower all equipment to the ground during work interruptions. Lock transmission control in neutral, engage park brake and stop engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator s seat, or exiting the machine. T UN 15MAY01 TX03679,00017C OCT02 1/1 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 starting work. 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 attachment 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. 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. T UN 15JUN01 T UN 24APR01 Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations. Avoid working under over-hanging embankments or stockpiles that could collapse on machine. T UN 04MAY01 TX03679,000179A 19 02MAY01 1/ PN=14

17 Safety Operating Precautions Use Special Care When Operating Loader Never use the loader to lift people. Do not allow anyone to ride in the bucket or use the bucket as a work platform. Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes or an unstable surface. Drive and turn slowly with a raised load. Ensure that objects in the bucket are secure. Do not attempt to lift or carry objects that are too big or too long to fit inside the bucket unless secured with an adequate chain or other device. Keep bystanders away from raised loads. Be careful when lifting objects. Never attempt to lift objects too heavy for your machine. Assure machine stability and hydraulic capability with a test lift before attempting other maneuvers. Use an adequate chain or sling and proper rigging techniques to attach and stabilize loads. Never lift an object above or near another person. T UN 15MAY01 T UN 07MAY01 TX03768,0000B MAY01 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 04MAY01 TX03679,000179B 19 20APR01 1/ PN=15

18 Safety Operating Precautions Avoid Backover Accidents Before moving machine, be sure all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning 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 04MAY01 TX03679,000179C 19 20APR01 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. Be careful on slopes. Avoid sharp turns. Balance loads so weight is evenly distributed and load is stable. Carry tools and loads close to the ground to aid visibility and lower center of gravity. Use extra care on soft, rocky or frozen ground. Know the capacity of the machine. Do not overload. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Ensure solid footing. Use extra care in soft ground conditions that may not uniformly support the wheels, especially when raising the boom. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall. T SEP00 T UN 04MAY01 T UN 04MAY01 TX03679,000179D 19 02MAY01 1/ PN=16

19 Safety Operating Precautions Operating on Slopes Avoid side slope travel whenever possible. Drive up steep slope in forward and down in reverse. Select low gear speed before starting down slope. The grade of the slope will be limited by ground condition and load being handled. Use service brakes to control speed. Sudden brake application with a loaded bucket on downhill side could cause machine to tip forward. T UN 30APR01 TX03679,000179E 19 14MAY01 1/1 Operating Or Traveling On Public Roads Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers. Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition. T UN 22MAY01 TX03679,00017C JUN01 1/ PN=17

20 Safety Operating Precautions Inspect and Maintain ROPS A damaged roll-over protective structure (ROPS) should be replaced, not reused. The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. To maintain the ROPS: Replace missing hardware using correct grade hardware. Check hardware torque. Check isolation mounts for damage, looseness or wear; replace them if necessary. Check ROPS for cracks or physical damage. TX03679,000179F 19 20APR01 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 SEP00 1/ PN=18

21 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 to the ground. Engage park brake. Stop engine and remove key. Install frame locking bar. Attach a Do Not Operate tag in an obvious place in the operator s station. T DEC01 Securely support machine or attachment before working under it. Do not support machine with boom, bucket, or other hydraulically actuated equipment. 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. TS229 UN 23AUG88 TX03679,00017A SEP01 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 19 04JUN90 1/ PN=19

22 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 101 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. TS220 UN 23AUG88 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. DX,PAINT 19 24JUL02 1/1 Make Welding Repairs Safely NOTE: 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. T UN 31AUG00 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. TX03679,00016D OCT00 1/ PN=20

23 Safety Maintenance Precautions 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, SEP00 1/ PN=21

24 Safety Safety Signs Safety Signs Left Side Shown Continued on next page TX03679,00017F AUG01 1/2 T OCT PN=22

25 Safety Safety Signs Right Side Shown T OCT02 TX03679,00017F AUG01 2/ PN=23

26 Operation Operator s Station Levers Single Lever (Joystick) Design T UN 10SEP98 Two Lever Design T156903B UN 01JUL02 Single Lever (Joystick) with Auxiliary Control Design T UN 10SEP98 Two Lever with Auxiliary Control Design T160584B UN 17OCT02 HG31779, OCT02 1/2 A Transmission Control Lever B Turn Signal T UN 12FEB98 HG31779, OCT02 2/ PN=24

27 Operation Operator s Station Pedals A Accelerator B Brake/Clutch Cut-Off Pedal C Brake/Clutch Cut-Off Pedal D Differential Lock Foot Switch If equipped TX,10,JC1191 T UN 10SEP JUN96 1/ PN=25

28 Operation Operator s Station Deluxe Monitor Panel (Earlier Machines) T UN 25FEB97 A Coolant Level Indicator H Service Required Indicator P Hydraulic Oil Temperature V Engine Coolant B Engine Air Filter I Right Turn Indicator Indicator Temperature Gauge Restriction Indicator J Park Brake Indicator Q Message Display (Deluxe W Hydraulic Oil Temperature C Engine Oil Pressure K Brake Oil Pressure Monitor only) Gauge (Deluxe Monitor Indicator Indicator R Transmission Service only) D Engine Preheat Indicator L Secondary Steering Indicator X Transmission Oil If Equipped Warning Indicator If S Transmission Filter Temperature Gauge E Left Turn Indicator Equipped Indicator Y Fuel Gauge F STOP Indicator M Work Lights Indicator T Battery Voltage Indicator Z Basic Display Window G High Beams ON Indicator N Fasten Seat Belt Indicator U Engine Oil Pressure Gauge (not used) O Hydraulic Oil Filter (Deluxe Monitor only) Restriction Indicator MENU provides initial entry into the accessories and diagnostics system. Each time MENU is pressed, display will cycle to the next menu. Once a main menu has been selected, pressing MENU again will return to the Normal Display Menu. BACK will back out of a menu, one item each time the key is pressed. NEXT will move to the next selection within a menu or mode. SELECT switches between volts/kilometers/hours during normal operation. During accessories or diagnostics modes, SELECT will activate the currently chosen menu. TX,10,JC AUG98 1/ PN=26

29 Operation Operator s Station Deluxe Monitor Panel Functions (Earlier Machines) A Check Engine Indicator: Indicator will light when excessive water is present in primary fuel filter (water separator). STOP indicator will light, alarm will sound and engine will derate to 50% of full power until water is drained. When water is drained, indicators and alarm will go off and the engine will return to full power. B Engine Air Filter Restriction Indicator: Indicator will light and service required indicator will light when air elements are restricted. Clean or change elements. C Engine Oil Pressure Indicator: IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. Indicator will light, STOP indicator will flash, and alarm will sound when engine oil pressure is low. Stop machine. STOP ENGINE IMMEDIATELY. NOTE: Cold oil or extreme off level operation may cause indicator to light. D Engine Preheat Indicator If Equipped:Indicator will light when key switch is turned clockwise to the ON position. Light will turn off approximately seconds depending on engine temperature, indicating that preheating is completed. Light will turn off while cranking engine. E Left Turn Indicator: Indicator will light when left turn signal switch is engaged. F STOP Indicator: CAUTION: Prevent possible injury or machine damage. If STOP indicator light flashes and alarm sounds, stop immediately and investigate cause of problem. The STOP indicator light flashes and alarm sounds when: Engine oil pressure is low. Engine coolant temperature is excessively high. Transmission oil temperature is excessively high. Transmission is shifted into gear with park brake engaged. Push park brake switch to OFF. Brake pressure is low. Steering system pressure is low, and secondary steering is activated. G High Beams ON Indicator : Not used. H Service Required Indicator (Yellow): Indicator will light when a problem is developing. It is not necessary to stop the engine immediately, but the cause should be investigated as soon as possible. The service required indicator lights when: Alternator voltage is low. Transmission filter is restricted. Engine air filter is restricted. Hydraulic oil temperature is too high. Hydraulic oil filter is restricted. NOTE: Cold oil may cause hydraulic and transmission oil filter restriction indicators to light temporarily. It is not necessary to stop the engine immediately but the cause should be investigated as soon as possible. I Right Turn Indicator: Indicator will light when right turn signal switch is engaged. J Park Brake Indicator: Indicator light will when park brake is engaged and transmission control lever is in neutral N. If park brake is engaged and transmission control lever is in forward F or reverse R, the STOP indicator light will flash and alarm will sound. Push park brake switch to OFF. Continued on next page HG31779,000005F 19 29APR02 1/ PN=27

30 Operation Operator s Station K Brake Oil Pressure Indicator: CAUTION: Prevent possible injury or machine damage. If brake pressure indicator light comes on while operating, stop machine immediately. Indicator will light, STOP indicator will flash, and alarm will sound when brake oil pressure is low, or brake accumulator has lost its charge. Stop machine immediately and push park brake switch to ON. L Secondary Steering Warning Indicator If Equipped: IMPORTANT: Prevent possible damage to secondary steering system. Stop machine immediately if secondary steering indicator light and alarm come on while operating. THE SECONDARY STEERING SYSTEM IS NOT INTENDED FOR CONTINUOUS USE. Indicator will light, STOP indicator will flash and alarm will sound when secondary steering system is activated. Stop machine immediately and take corrective action. The secondary steering system is not intended for continuous use. M Work Lights Indicator: Indicator will light when work lights switch is on. N Fasten Seat Belt Indicator: Indicator will light for the first five seconds after the engine is started to warn the operator to fasten seat belt. O Hydraulic Oil Filter Restriction Indicator: IMPORTANT: Prevent possible hydraulic pump damage. Change hydraulic oil filter as soon as possible when a problem occurs. Indicator will light and service required indicator will light when hydraulic filter element is restricted. NOTE: Cold oil may cause hydraulic oil filter restriction indicator light to light until oil is warm. P Fuel Filter Restriction Indicator: NOTE: Indicator may come on during cold startups or when machine is under heavy loads. A flickering light is an early warning that fuel filter needs to be changed. Indicator will light when fuel pressure drops below 300 kpa (43.5 psi). If pressure drops below 200 kpa (29 psi), indicator will remain on. SERVICE REQUIRED indicator will come on and engine will derate to 50% of full power. Replace primary fuel filter (water separator) element and primary fuel filter strainer. Q Message Display: Displays a 12 character alpha-numeric message that provides a text description of the currently displayed mode. This message display supplements the information that is shown on the basic display window. R Transmission Service Indicator: Indicator will light and stay on when a transmission clutch slippage service code has been detected. The transmission will shift to neutral and then machine can only be moved in limp home mode. A service code will be logged in Monitor Display Unit. This code can be read by accessing the Monitor Diagnostic Mode (d). The indicator light will go off when key switch has been turned to OFF. Every time clutch slippage occurs, the light will go on and will remain on until key switch is turned to OFF. See your authorized dealer for servicing. S Transmission Filter Indicator: Indicator will light and the service required indicator will light when the transmission filter is restricted. Continued on next page HG31779,000005F 19 29APR02 2/ PN=28

31 Operation Operator s Station T Battery Voltage Indicator: Indicator will light and service required indicator will light when alternator output is low. Check battery charge by selecting battery voltage on digital display. U Engine Oil Pressure Gauge: IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. Indicator will light, STOP indicator will flash, and alarm will sound when engine oil pressure gauge indicates low pressure. Stop machine. STOP ENGINE IMMEDIATELY. If pointer deflects to the far right side of the scale, electronic communication is lost or a sensor error is active. NOTE: Extreme off level operation may cause indicator to light. V Engine Coolant Temperature Gauge: STOP indicator light will flash, and audible alarm will sound when pointer is in red zone. Stop machine and allow engine to cool. Shut off engine and take corrective action. If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active. indicator points to red zone, hydraulic oil temperature is too high. Stop work cycle and cycle loader functions without load to lower indicator reading. If indicator still stays in red zone, stop machine and see your authorized dealer. If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active. X Transmission Oil Temperature Gauge: If indicator is in red zone, STOP indicator light will flash, and audible alarm will sound indicating that the temperature is to high. Stop machine and allow transmission to cool. Shut off engine and take corrective action. If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active. Y Fuel Gauge: Indicator will reflect fuel level in tank. Always fill tank at the end of the day to eliminate condensation in fuel tank. Z Basic Display Window: The display window has six display: Gear FNR Auto Tachometer Hour Meter Voltmeter/Odometer W Hydraulic Oil Temperature Gauge: Normal operating temperature is in green zone. If gauge HG31779,000005F 19 29APR02 3/ PN=29

32 Operation Operator s Station Deluxe Monitor Panel (Later Machines) T155127B UN 24MAY02 1 Check Engine Indicator 8 Service Required Indicator 15 Hydraulic Oil Filter 21 Engine Oil Pressure 2 Engine Air Filter Restriction 9 Right Turn Indicator Restriction Indicator Gauge Indicator 10 Park Brake Indicator 16 Fuel Filter Restriction 22 Engine Coolant 3 Engine Oil Pressure 11 Brake Oil Pressure Indicator Temperature Gauge Indicator Indicator 17 Message Display 23 Hydraulic Oil Temperature 4 Engine Preheat Indicator 12 Secondary Steering 18 Transmission Service Gauge If Equipped Warning Indicator If Indicator 24 Transmission Oil 5 Left Turn Indicator Equipped 19 Transmission Filter Temperature Gauge 6 STOP Indicator 13 Pin Disconnect Indicator Indicator 25 Fuel Gauge 7 High Beams ON Indicator 14 Fasten Seat Belt Indicator 20 Battery Voltage Indicator 26 Basic Display Window (not used) MENU provides initial entry into the accessories and diagnostics system. Each time MENU is pressed, display will cycle to the next menu. Once a main menu has been selected, pressing MENU again will return to the Normal Display Menu. BACK will back out of a menu, one item each time the key is pressed. NEXT will move to the next selection within a menu or mode. SELECT switches between volts/kilometers/hours during normal operation. During accessories or diagnostics modes, SELECT will activate the currently chosen menu. HG31779, APR02 1/ PN=30

33 Operation Operator s Station Deluxe Monitor Panel Functions (Later Machines) 1 Check Engine Indicator: Indicator will light when excessive water is present in final fuel filter. STOP indicator will light, alarm will sound, and engine will derate to 50% of full power until water is drained. When water is drained, indicators and alarm will turn off and the engine will return to full power. 2 Engine Air Filter Restriction Indicator: Indicator will light and service required indicator will light when air elements are restricted. 3 Engine Oil Pressure Indicator: IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. Indicator will light, STOP indicator will flash, and alarm will sound when engine oil pressure is low. Stop machine. STOP ENGINE IMMEDIATELY. NOTE: Cold oil or extreme off level operation may cause indicator to light. 4 Engine Preheat Indicator If Equipped: Indicator will light when key switch is turned clockwise to the On position. Light will turn off approximately seconds depending on engine temperature, indicating that preheating is completed. Light will turn off while cranking engine. Indicator will also light for approximately seconds after engine is running, indicating post heat. 5 Left Turn Indicator: Indicator will light when left turn signal switch is engaged. 6 STOP Indicator: CAUTION: Prevent possible injury or machine damage. If STOP indicator light flashes and alarm sounds, stop immediately and investigate cause of problem. The STOP indicator light flashes and alarm sounds when: Engine oil pressure is low. Engine coolant temperature is excessively high. Transmission oil temperature is excessively high. Transmission is shifted into gear with park brake engaged. Brake pressure is low. Steering system pressure is low, and secondary steering is activated. 7 High Beams ON Indicator : Not used. 8 Service Required Indicator (Yellow): Indicator will light when a problem is developing. It is not necessary to stop the engine immediately, but the cause should be investigated as soon as possible. The service required indicator lights when: Alternator voltage is low. Transmission filter is restricted. Engine air filter is restricted. Hydraulic oil temperature is too high. Hydraulic oil filter is restricted. Fuel filter is restricted. Transmission fault indication. NOTE: Cold oil may cause hydraulic and transmission oil filter restriction indicators to light temporarily. It is not necessary to stop the engine immediately but the cause should be investigated as soon as possible. 9 Right Turn Indicator: Indicator will light when right turn signal switch is engaged. 10 Park Brake Indicator: Indicator will light when park brake is engaged and transmission control lever is in N Neutral. Continued on next page HG31779,000005F 19 29APR02 1/ PN=31

34 Operation Operator s Station If park brake is engaged and transmission control lever is in F Forward or R Reverse, the STOP indicator will flash and alarm will sound. Push park brake switch to OFF. 11 Brake Oil Pressure Indicator: CAUTION: Prevent possible injury or machine damage. If brake pressure indicator light comes on while operating, stop machine immediately. Indicator will light, STOP indicator will flash, and alarm will sound when brake oil pressure is low or brake accumulator has lost its charge. Stop machine immediately and push park brake switch to ON. 12 Secondary Steering Warning Indicator If Equipped: IMPORTANT: Prevent possible damage to secondary steering system. Stop machine immediately if secondary steering indicator light and alarm come on while operating. THE SECONDARY STEERING SYSTEM IS NOT INTENDED FOR CONTINUOUS USE. Indicator will light, STOP indicator will flash, and alarm will sound when secondary steering system is activated. Stop machine immediately and take corrective action. The secondary steering system is not intended for continuous use. 13 Pin Disconnect Indicator: Indicator will light when pin disconnect switch is activated to retract cylinders for removal of attachments. 14 Fasten Seat Belt Indicator: Indicator will light for the first 5 seconds after the engine is started to warn the operator to fasten seat belt. 15 Hydraulic Oil Filter Restriction Indicator: as soon as possible when a problem occurs. Indicator will light and service required indicator will light when hydraulic filter element is restricted. NOTE: Cold oil may cause hydraulic oil filter restriction indicator light to light until oil is warm. 16 Fuel Filter Restriction Indicator: NOTE: Indicator may come on during cold startups or when machine is under heavy loads. A flickering light is an early warning that fuel filter needs to be changed. Indicator will light when fuel pressure drops below 300 kpa (43.5 psi). If pressure drops below 200 kpa (29 psi), indicator will remain on. Service required indicator will light and engine will derate to 50% of full power. 17 Message Display: Displays a 12 character alpha-numeric message that provides a text description of the currently displayed mode. This message display supplements the information that is shown on the basic display window. 18 Transmission Service Indicator: Transmission service indicator and service required indicator will light and stay on when a transmission clutch slippage service code has been detected. The transmission will shift to Neutral and then machine can only be moved in limp home mode. A service code will be logged in Monitor Display Unit. This code can be read by accessing the Monitor Diagnostic Mode (d). The indicator light will turn off when key switch has been turned off. Every time clutch slippage occurs, the transmission service indicator and service required indicator will light and will remain on until key switch is turned off. IMPORTANT: Prevent possible hydraulic pump damage. Change hydraulic oil filter Continued on next page HG31779,000005F 19 29APR02 2/ PN=32

35 Operation Operator s Station 19 Transmission Filter Indicator: Indicator will light and the service required indicator will light when the transmission filter is restricted. 20 Battery Voltage Indicator: Indicator will light and service required indicator will light when alternator output is low. Check battery charge by selecting battery voltage on digital display. 21 Engine Oil Pressure Gauge: IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. Indicator will light, STOP indicator will flash, and alarm will sound when engine oil pressure gauge indicates low pressure. Stop machine. STOP ENGINE IMMEDIATELY. If pointer deflects to the far right side of the scale, electronic communication is lost or a sensor error is active. NOTE: Extreme off level operation may cause indicator to light. 22 Engine Coolant Temperature Gauge: STOP indicator will flash and audible alarm will sound when pointer is in red zone. Stop machine and allow engine to cool. Shut off engine and take corrective action. If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active. 23 Hydraulic Oil Temperature Gauge: Normal operating temperature is in green zone. If gauge indicator points to red zone, hydraulic oil temperature is too high. Stop work cycle and cycle loader functions without load to lower indicator reading. If indicator still stays in red zone, stop machine and see your authorized dealer. If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active. 24 Transmission Oil Temperature Gauge: If indicator is in red zone, STOP indicator will flash and audible alarm will sound indicating that the temperature is too high. Stop machine and allow transmission to cool. Shut off engine and take corrective action. If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active. 25 Fuel Gauge: Indicator will reflect fuel level in tank. Always fill tank at the end of the day to eliminate condensation in fuel tank. 26 Basic Display Window: The display window has six displays: Gear FNR Auto Tachometer Hour Meter Voltmeter/Odometer HG31779,000005F 19 29APR02 3/ PN=33

36 Operation Operator s Station Console Switches and Accessories (Later Machines Single Lever Design) T159422C UN 28OCT02 1 Pilot Enable/Boom Down 7 Not Used 14 Beacon Switch If 18 Ride Control Switch If Switch 8 Front Wiper Knob Equipped Equipped 2 Drive, Tail and Marker 9 Rear Wiper Knob 15 Pin Disconnect Switch If 19 Return-to-Carry Switch If Switch 10 Temperature Control Knob Equipped Equipped 3 Cab Work Light Switch If 11 Blower Speed Knob 16 Spin Control Mode 20 Boom Height Kickout Equipped 12 Air Conditioning Switch Knob If Equipped Switch If Equipped 4 4-Way Flasher Switch If Equipped 17 Spin Control Switch If 5 Clutch Cut-Off Switch 13 Axle Disconnect Switch Equipped 6 Automatic Transmission If Equipped Switch HG31779, SEP02 1/ PN=34

37 Operation Operator s Station Console Switch and Accessory Functions (Later Machines Single Lever Design) 1 Pilot Enable/Boom Down Switch: The switch has three positions: Push upper half to lower boom with engine off Push to middle position to unlock pilot controllers; normal operation Push lower half to lock pilot controllers; locks hydraulic controls 2 Drive, Tail and Marker Switch: The switch has three positions: Push upper half to turn on headlights, tail lights/brake lights and turn signal/4-way lights Push switch to middle position to turn on tail lights/brake lights and turn signal/4-way lights Push lower half of switch to turn lights off 3 Cab Work Light Switch If Equipped: Push upper half of switch to turn front and rear work lights on. Push lower half of switch to turn work lights off. 4 4-Way Flasher Switch: Push upper half of switch and front and rear amber lights will flash. 5 Clutch Cut-Off Switch: CAUTION: Prevent possible injury from unexpected machine movement. When stopping on inclines, push the lower half of the clutch cut-off switch to engage clutch cut-off before releasing left service brake. This will prevent the machine from rolling downhill during transmission re-engagement cycle. Push upper half of switch to disengage clutch before either brake pedal can be used to disengage transmission clutches. Use the switch in situations such as truck loading where machine positioning and maximum hydraulics are needed. NOTE: The park brake will also disengage the transmission clutches. Release park brake before operating. 6 Automatic Transmission Switch: Push upper half of switch to the Auto position. Move transmission lever to 3 or 4. Transmission will start in 2nd gear. As speed increases, transmission will automatically shift to 3rd and 4th gear. As load increases or speed decreases, transmission will automatically shift to 3rd and 2nd gear. 7 Not Used 8 Front Wiper Knob: The knob has four positions: First position is Off Second position is intermittent wiper operation Third position is low speed Fourth position is high speed Push wiper/washer knob in to wash front window. 9 Rear Wiper Knob: The knob has four positions: First position is Off Second position is intermittent wiper operation Third position is low speed Fourth position is high speed Push wiper/washer knob in to wash rear window. 10 Temperature Control Knob: Turn knob to adjust air temperature. Turn knob clockwise to increase temperature. Turn counterclockwise to decrease temperature. 11 Blower Speed Knob: Turn knob clockwise to increase blower speed or counterclockwise to reduce blower speed. Blower knob has four speed settings. Continued on next page HG31779, SEP02 1/ PN=35

38 Operation Operator s Station 12 Air Conditioning Switch If Equipped: Push upper half of switch to turn air conditioning on. Push lower half of switch to turn air conditioning off. 13 Axle Disconnect Switch: Push upper half of switch to disconnect front axle. 14 Beacon Switch: Push upper half of switch to turn beacon light on. Push lower half of switch to turn beacon light off. 15 Pin Disconnect Switch If Equipped: Push switch in then lift switch up to retract cylinders for removal of attachments. 16 Spin Control Mode Knob If Equipped: Turn knob to a setting that minimizes wheel spin while filling the bucket. NOTE: Spin control reduces engine rpm to minimize wheel spin and prolong tire life. The five different settings allow the operator to customize the machine to differing tractive conditions. Spin control only works in first gear. 17 Spin Control Switch If Equipped: Push upper half of switch to turn spin control on. Push lower half of switch to turn spin control off. NOTE: If maximum power to wheels is needed, turn spin control switch off. Push upper half to turn ride control on Push to middle Auto position that functions the same as the On position with one exception. The ride control is turned off when ground speed is approximately 6 km/h (3 1/2 mph) or less Push lower half to turn ride control off 19 Return-to-Carry Switch If Equipped: The switch has three positions: Push upper half to set return-to-carry height Push to middle position to activate return-to-carry. Push boom lever to float position. Boom will kick-out of float position when it reaches a preset distance from ground. Push lower half to deactivate return-to-carry NOTE: Boom float will not work once the boom is below preset distance from ground. Push switch to Off position to activate boom float. 20 Boom Height Kickout Switch: The switch has three positions: Push upper half to set boom height Push to middle position to activate boom height kickout. Pull lever to raise detent position. Boom will kick-out of detent position when it reaches a preset height from ground. Push lower half to deactivate boom height kickout 18 Ride Control Switch: The switch has three positions: HG31779, SEP02 2/ PN=36

39 Operation Operator s Station Console Switches and Accessories (Later Machines Two Lever Design) T156392B UN 24JUN02 1 Ride Control Switch If 6 Pilot Enable/Boom Down 11 4-Way Flasher Switch 17 Air Conditioning Switch Equipped Switch 12 Spin Control Mode If Equipped 2 Reverse Fan Switch If 7 Pin Disconnect Switch If Knob If Equipped 18 Blower Speed Knob Equipped Equipped 13 Spin Control Switch If 19 Temperature Control Knob 3 Axle Disconnect Switch If 8 Beacon Switch If Equipped 20 Front Wiper Knob Equipped Equipped 14 Not Used 21 Rear Wiper Knob 4 Boom Height Kickout 9 Cab Work Light Switch If 15 Clutch Cut-Off Switch Switch If Equipped Equipped 16 Automatic Transmission 5 Return-to-Carry Switch If 10 Drive, Tail and Marker Switch Equipped Switch HG31779, JUN02 1/ PN=37

40 Operation Operator s Station Console Switch and Accessory Functions (Later Machines Two Lever Design) 1 Ride Control Switch: The switch has three positions: Push right half to turn ride control on Push to middle Auto position that functions the same as the On position with one exception. The ride control is turned off when ground speed is approximately 6 km/h (3 1/2 mph) or less Push left half to turn ride control off 2 Reverse Fan Switch If Equipped: Push upper half of switch to manually reverse the cooling fan. 3 Axle Disconnect Switch: Push upper half of switch to disconnect front axle. 4 Boom Height Kickout Switch: The switch has three positions: Push upper half to set boom height Push to middle position to activate boom height kickout. Pull lever to raise detent position. Boom will kick-out of detent position when it reaches a preset height from ground. Push lower half to deactivate boom height kickout 5 Return-to-Carry Switch If Equipped: The switch has three positions: Push upper half to set return-to-carry height Push to middle position to activate return-to-carry. Push boom lever to float position. Boom will kick-out of float position when it reaches a preset distance from ground. Push lower half to deactivate return-to-carry NOTE: Boom float will not work once the boom is below preset distance from ground. Push switch to Off position to activate boom float. 6 Pilot Enable/Boom Down Switch: The switch has three positions: Push upper half to lower boom with engine off Push to middle position to unlock pilot controllers; normal operation Push lower half to lock pilot controllers; locks hydraulic controls 7 Pin Disconnect Switch If Equipped: Push switch in then lift switch up to retract cylinders for removal of attachments. 8 Beacon Switch: Push upper half of switch to turn beacon light on. Push lower half of switch to turn beacon light off. 9 Cab Work Light Switch If Equipped: Push upper half of switch to turn front and rear work lights on. Push lower half of switch to turn work lights off. 10 Drive, Tail and Marker Switch: The switch has three positions: Push upper half to turn on headlights, tail lights/brake lights and turn signal/4-way lights Push switch to middle position to turn on tail lights/brake lights and turn signal/4-way lights Push lower half of switch to turn lights off 11 4-Way Flasher Switch: Push upper half of switch and front and rear amber lights will flash. 12 Spin Control Mode Knob If Equipped: Turn knob to a setting that minimizes wheel spin while filling the bucket. NOTE: Spin control reduces engine rpm to minimize wheel spin and prolong tire life. The five different settings allow the operator to customize the machine to differing tractive conditions. Spin control only works in first gear. 13 Spin Control Switch If Equipped: Push upper half of switch to turn spin control on. Push lower half of switch to turn spin control off. Continued on next page HG31779, APR02 1/ PN=38

41 Operation Operator s Station NOTE: If maximum power to wheels is needed, turn spin control switch off. 14 Not Used 15 Clutch Cut-Off Switch: CAUTION: Prevent possible injury from unexpected machine movement. When stopping on inclines, push the lower half of the clutch cut-off switch to engage clutch cut-off before releasing left service brake. This will prevent the machine from rolling downhill during transmission re-engagement cycle. Push upper half of the clutch cut-off switch to disengage clutch before either brake pedal can be used to disengage transmission clutches. Use the switch in situations such as truck loading where machine positioning and maximum hydraulics are needed. NOTE: The park brake will also disengage the transmission clutches. Release park brake before operating. 16 Automatic Transmission Switch: Push upper half of switch to the Auto position. Move transmission lever to 3 or 4. Transmission will start in 2nd gear. As speed increases, transmission will automatically shift to 3rd and 4th gear. As load increases or speed decreases, transmission will automatically shift to 3rd and 2nd gear. 17 Air Conditioning Switch If Equipped: Push lower half of switch to turn air conditioning on. Push upper half of switch to turn air conditioning off. 18 Blower Speed Knob: Turn knob clockwise to increase blower speed or counterclockwise to reduce blower speed. Blower knob has four speed settings. 19 Temperature Control Knob: Turn knob to adjust air temperature. Turn knob clockwise to increase temperature. Turn counterclockwise to decrease temperature. 20 Front Wiper Knob: The knob has four positions: First position is Off Second position is intermittent wiper operation Third position is low speed Fourth position is high speed Push wiper/washer knob in to wash front window. 21 Rear Wiper Knob: The knob has four positions: First position is Off Second position is intermittent wiper operation Third position is low speed Fourth position is high speed Push wiper/washer knob in to wash rear window. HG31779, APR02 2/ PN=39

42 Operation Operator s Station Monitor Display Unit The monitor display unit has a basic digital LCD display window. On machines equipped with the deluxe monitor display unit there is also a 12 character alpha-numeric message display that provides a text description of the currently displayed mode. This message display supplements the information that is shown on the basic display window. The four main menus are: Normal menu is displayed when the machine is first turned on, and no special functions are selected. Accessory menu allows the operator to make changes to various operating characteristics of the machine. Diagnostics menu provides a limited set of tools, and is intended to be used by service personnel and machine operator s for diagnostic and troubleshooting functions. Service menu is for service personnel and requires a special procedure to gain access. This mode provides an additional and more sophisticated set of tools for diagnostics and troubleshooting. T UN 11MAR97 The monitor display unit keypad is used to navigate through the different menus and modes of operation. Key names and general functions are as follows: MENU provides initial entry into the accessories and diagnostics system. Each time MENU is pressed, display will cycle to the next menu. Once a main menu has been selected, pressing MENU again will return to the Normal Display Menu. BACK will back out of a menu, one item each time the key is pressed. NEXT will move to the next selection within a menu or mode. SELECT switches between volts/kilometers, hours during normal operation. During accessories or diagnostics modes, SELECT will activate the currently chosen menu in Basic Display Window. TX,10,JC SEP02 1/ PN=40

43 Operation Operator s Station Monitor Display Unit Normal Display When key switch is turned on, all lights on display monitor will come on, alarm will sound and stop and caution lights will flash. The basic display window will show the bulb check mode. The window will contain numerical digit 8 s and will be shown for approximately 5 seconds. Then the machine model number will show in the basic display window. T UN 22OCT97 Continued on next page TX,10,JC SEP98 1/ PN=41

44 Operation Operator s Station Approximately five seconds later, the Normal display will be shown. NOTE: Press SELECT to alternate between Odometer and System Voltage display. When the machine is in neutral, the gear display (A) shows the gear position of the shift lever. When the machine is not in neutral, it displays the gear that the transmission has engaged. When the transmission controller service code F 1655 occurs, a "---" is shown in this part of the display window because there is a CAN transmittal failure. The FNR Display (B) shows the forward, neutral, reverse status. When a transmission controller unit failure occurs, this display is blank. The Auto Display (C) shows whether the transmission "Auto" mode is On or Off. When a transmission controller unit failure occurs, this display is blank. A Gear Display B FNR Display C Auto Display D Tachometer Display E Hour Meter Display F Voltmeter/Odometer Display G Basic Display Window H Message Display Window (If Equipped) T UN 22OCT97 The Tachometer Display (D) shows the torque converter input shaft rpm to the nearest 5 rpms. When a transmission controller unit malfunction occurs, a "---" is displayed and the icon is turned off. The Hour Meter Display (E) shows the machine hours in whole hour increments. The hour meter accumulates hours only when the engine is on; and the icon flashes once per second. The engine is considered on when the tachometer is greater than 300 rpm or engine oil pressure is greater than 89.6 kpa (0.9 bar) (13 psi). The hour meter displays up to 99,999 hours. The Voltmeter/Odometer Display (F) shows either the voltmeter or odometer reading. Press SELECT to toggle between these readings. On U.S. and Hitachi export machines, the display rotates from volts to miles to kilometers. On Hitachi domestic machines, the display rotates from kilometers to volts only. Continued on next page TX,10,JC SEP98 2/ PN=42

45 Operation Operator s Station The voltmeter displays battery voltage when the machine is off and system voltage to the nearest tenth when the machine is on. The odometer is capable of displaying up to 99,999.9 total miles (or 999,999 if the decimal point is disregarded). From 0 to 62,111.7 miles (0 to 99,937.7 km), the odometer displays both miles and kilometers in tenths. From 62,111.8 to 99,999.9 miles (99,937.8 to 160,889.8 km) miles are displayed in tenths and kilometers in ones. From 100,000 miles (160,900 km) on, both miles and kilometers are displayed in ones. The odometer runs only when the engine is on. When the 0.1 Hour Meter Mode is turned On in the Accessory Menu (A 06), machine hours will be displayed in tenths of hours in the volts/miles/km display. Press SELECT to toggle between hours and the volts/miles/km display. TX,10,JC SEP98 3/3 Monitor Display Unit Accessory Menu Clutch Cut-Off (A 01) At Normal Mode display, press MENU once. Display window will show A, indicated Accessory Mode. Press SELECT again; display window shows A 01, indicating Clutch Cut-Off Mode. T UN 22OCT97 Continued on next page CED,OUOE035, NOV98 1/ PN=43

46 Operation Operator s Station In the Clutch Cut-Off Mode of operation, there are three different functions to choose from: Level Ground Small Slope Steep Slope On the Level Ground setting, clutch releases with low brake pedal pressure. On the Small Slope setting, clutch releases with medium brake pedal pressure. T UN 22OCT97 On Steep Slope setting, clutch releases with high brake pedal pressure. By turning one of these functions On, the other two are automatically turned Off. Press SELECT again. Display shows A 011 Level Ground Setting, If setting shows Off, press SELECT again and it will be On, disabling the other two positions. Press NEXT to move to A 012 Small Slope Setting, and NEXT again to A 013 Steep Slope Setting. Press SELECT to choose a setting and disable the other two settings. Level Ground (A 011): When the Level Ground function is turned On in the monitor display unit, the clutch cut-off switch turned On, and the brake pedal pressed down, the clutch cut-off sensor (B33), which is a rotary potentiometer, will sense the position of the brake pedal linkage by the voltage reading. When it senses voltage higher than the low voltage set point, the transmission will disengage (release clutch) and modulate to neutral. In this position the machine will still roll slightly. In Auto mode the transmission will re-engage and modulate into the appropriate gear (based on ground speed) if the pressure at the clutch cut-off sensor reaches the engagement pressure set point. This pressure is lower than the clutch cut-off set point. The transmission will also re-engage if the clutch cut-off switch is turned to the Off position. Continued on next page CED,OUOE035, NOV98 2/ PN=44

47 Operation Operator s Station Small Slope (A 012): When the Small Slope function is turned On in the monitor display unit, the clutch cut-off switch turned On, and the brake pedal is pressed down, the clutch cut-off sensor will sense the hydraulic brake pressure. When it senses pressure higher than the medium pressure set point, the transmission will disengage and modulate to neutral. In Auto mode the transmission will re-engage and modulate into the appropriate gear (based on ground speed) if the pressure at the clutch cut-off sensor reaches the engagement pressure set point. This pressure is lower than the clutch cut-off pressure set point. The transmission will also re-engage if the clutch cut-off switch is turned to the Off position. Steep Slope (A 013): When the Steep Slope is turned On in the monitor display unit, the clutch cut-off switch turned On, and the brake pedal is pressed down, the clutch cut-off sensor will sense the hydraulic brake pressure. When it senses pressure higher than the high pressure set point, the transmission will disengage and modulate to neutral. In Auto mode the transmission will re-engage and modulate into the appropriate gear (based on ground speed) if the pressure at the clutch cut-off sensor reaches the engagement pressure set point. This pressure is lower than the clutch cut-off pressure set point. The transmission will also re-engage if the clutch cut-off switch is turned to the Off position. CED,OUOE035, NOV98 3/ PN=45

48 Operation Operator s Station Monitor Display Unit Accessory Menu Quick Shift Mode (A 02) The Quick Shift mode allows the operator to choose between Down/Up and Down Only shift functions when the transmission is in manual or automatic operation. Down/Up: When this function is turned On, the transmission will down shift one gear when the Quick Shift Switch (at top of pilot controller handle) is pressed down once. It is not possible to down shift more than one gear. When the quick shift switch is pressed down again, the transmission will electronically shift up one gear again. T UN 22OCT97 Down Only Transmission in Manual Operation: When this function is turned On, each time the quick shift switch (at top of pilot controller handle) is pressed down, the transmission will shift down one gear (regardless of selected gear). If the operator presses down on the quick shift switch while no shift is taking place, the controller will cause the transmission to shift down one gear (regardless of selected gear). Once a down shift is made by pressing the quick shift switch, the transmission will not shift up again unless a direction or gear change is made. Down Only Transmission in Automatic Operation: If the operator presses the quick shift switch when the transmission is in automatic operation, the transmission will down shift to one gear below the gear displayed in basic display window. This change is made independent from shifter switch selection. Down Only works basically the same in automatic as in manual, except it will shift Up or Down from the highest gear downshifted to. If the operator presses down on the quick shift switch while an up shift is taking place, the transmission controller will cause the transmission to shift down to the previous gear. Continued on next page TX,10,JC AUG97 1/ PN=46

49 Operation Operator s Station In Auto mode, if the operator presses down on the quick shift switch while a down shift is taking place, the transmission controller will ignore the request for the down shift. Transmission will automatically shift up or down from the gear displayed in basic display window until shifter switch is moved to Neutral. This will cancel down shift mode and transmission will go back to fully automatic mode. TX,10,JC AUG97 2/5 Press SELECT at the A 02 display. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC AUG97 3/5 If the A 021 display shows OFF, press SELECT to turn Down/Up shift function On and disable the Down Only function. To choose the Down Only shift function, press NEXT. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC AUG97 4/ PN=47

50 Operation Operator s Station At A 022 display, press SELECT to turn Down Only shift function On and to disable Down/Up function. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC AUG97 5/5 Monitor Display Unit Accessory Menu Auto Mode to First (A 03) In Auto Mode to First, the transmission will shift to first gear if a high load is sensed while the transmission is actually in second gear. This shift change is made independent from shifter switch selection. A direction change during normal conditions will not cause the transmission to shift down into first gear. If a direction change is made during high transmission load conditions, the transmission will shift down into first gear. Press SELECT at the A 03 display. Deluxe Monitor Display Unit Shown T UN 22OCT97 Press SELECT again to either turn this option On or Off. TX,10,JC AUG97 1/ PN=48

51 Operation Operator s Station Monitor Display Unit Accessory Menu Job Timer Mode (A 04) The job timer is a resetable hour meter that can be used to time tasks to the nearest tenth of an hour. At the A 04 display, press SELECT. Then press SELECT again to turn the timer On or Off. When the timer is Off, press NEXT to reset the timer. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC AUG97 1/1 Monitor Display Unit Accessory Menu Stop Watch Mode (A 05) The stop watch is a resetable timer that is used to measure time in seconds and tenths of seconds. At the A 05 display, press SELECT. Then press SELECT again to turn the timer On or Off. When the timer is Off, press NEXT to reset the timer. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC AUG97 1/ PN=49

52 Operation Operator s Station Monitor Display Unit Accessory Menu 0.1 Hour Meter Mode (A 06) At the A 06 display, press SELECT. Then press SELECT again to turn the 0.1 Hour Meter Mode On or Off. When the 0.1 Hour Meter Mode is turned On, the hour meter reading can be accessed during normal machine operation by pressing SELECT. The odometer reading will switch to the voltmeter reading, and then to the hour meter reading (A) in hours and tenths of hour as SELECT is pressed. Deluxe Monitor Display Unit Shown T UN 22OCT97 When the 0.1 Hour Meter Mode is turned Off, only the odometer reading and voltmeter are available, by pressing SELECT. The 0.1 Hour Meter Mode On or Off position stays set after machine shut down. A Hour Meter Reading Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 1/1 Monitor Display Unit Accessory Menu Metric Units Mode (A 07) This mode allows the technician to choose between metric and English unit displays. At the A 07 display, press SELECT. Press SELECT to turn Metric Units display On or Off. When Metric Units mode is On, all values will be shown in metric. When Metric Units mode is Off, all values will be shown in English units. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,TEST,HH SEP96 1/ PN=50

53 Operation Operator s Station Monitor Display Unit User Diagnostics Menu Service Codes (d 01) This mode displays the eight highest priority service codes which have occurred on the machine. At the d 01 display, press SELECT. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC NOV98 1/6 An F is shown in the display window to indicate service code mode. The first fault code number is shown. To move to the second service code, press NEXT. To obtain additional information about the first service code, press SELECT again. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC NOV98 2/ PN=51

54 Operation Operator s Station The display window will show the hour meter reading at first occurrence of the service. To obtain additional information about the service code, press NEXT. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC NOV98 3/6 The display window will show the hour meter reading at last occurrence of the fault and the total number of occurrences. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC NOV98 4/ PN=52

55 Operation Operator s Station To move to the second service code, press BACK until the Fxxxx display is shown. This example: F Then press NEXT. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC NOV98 5/6 Continue to scroll through service codes using this sequence until END is shown in the display window. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC NOV98 6/6 Monitor Display Unit User Diagnostics Menu Continuity Check (d 02) In this diagnostic mode, sensors and circuits connected to the chassis computer unit (CCU) are monitored for a state of change. Examples of state of change are switches going from open to closed or closed to open, circuit shorts and opens, high rate of change from analog sensors, and changes in digital speed sensor outputs. Continued on next page TX,10,JC SEP98 1/ PN=53

56 Operation Operator s Station At the d 02 display, press SELECT. Two different continuity check modes are provided. Press SELECT to choose the mode wanted. With Speed Sensors (d 021) mode monitors all circuits and sensors. This mode is useful when the machine is parked with the engine off. Without Speed Sensors (d 022) monitors everything except the digital speed sensors. This mode is useful when the engine is running and/or the machine is rolling, when the engine, transmission and wheel speed sensors are pulsing continuously. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 2/4 After one of the continuity check modes is selected, the display window will be in a waiting position until a state of change is detected. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 3/ PN=54

57 Operation Operator s Station Whenever a change of state is detected, the warning horn will beep to inform the technician of the change. The circuit device component number and section number as it appears on the system functional schematic will show on the basic display window. Press SELECT to display sensor data and units in the message display window. Press SELECT again or BACK to remove the information from the message window. Press NEXT to move to the next sensor display. The audible alarm can be used to verify that a switch is changing state when it is activated (or isn t changing state when it should be, if there is no beep.) Also, by moving a potentiometer type control slowly through its operating range, a break or bad spot can be detected. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 4/4 Monitor Display Unit User Diagnostics Menu Battery Monitor (d 03) This mode allows the technician to view the current voltage of the left and right batteries. At the d 03 display, press SELECT. Battery voltage will be displayed in basic display window. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP97 1/ PN=55

58 Operation Operator s Station On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle the reading in and out of the alpha-numeric window. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP97 2/2 Monitor Display Unit User Diagnostics Menu Engine Sensors (d 04) This mode allows the technician to monitor all engine sensors that are accessible to the computer system. TX,10,JC SEP98 1/7 Press SELECT at the d 04 display. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 2/ PN=56

59 Operation Operator s Station The d 041 display for Engine Coolant Temperature will be shown. Temperature will be displayed in C or F (depending on setting selected in A 07 model) and sensor voltage will be displayed. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 3/7 On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle reading in and out of the alpha-numeric window. Press NEXT. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 4/ PN=57

60 Operation Operator s Station The d 042 display for Engine Oil Pressure will be shown. Pressure will be displayed in kpa or psi and sensor voltage will be displayed. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 5/7 On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle reading in and out of the alpha-numeric window. Press NEXT. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 6/ PN=58

61 Operation Operator s Station The d 043 display for Throttle sensor voltage will be shown. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 7/7 Monitor Display Unit User Diagnostics Menu Transmission Sensors (d 05) This mode allows the technician to monitor all transmission sensors that are accessible to the computer system. TX,10,JC SEP98 1/4 Press SELECT at the d 05 display. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 2/ PN=59

62 Operation Operator s Station The d 051 Oil Temperature Sensor display will show the oil temperature in C or F (depending on setting selected in A 07 mode) and sensor voltage. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 3/ PN=60

63 Operation Operator s Station On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle reading in and out of the alpha-numeric window. Press NEXT. The d 052 Clutch cut-off Sensor display will show the Clutch Cutoff Sensor pressure (early units) or voltage (later units). Press NEXT. The d 053 Torque Input Speed Sensor display will show the speed in rpm. Deluxe Monitor Display Unit Shown T UN 22OCT97 Press NEXT. The d 054 Torque Output Speed Sensor display will show the speed in rpm. Press NEXT. The d 055 Internal Clutch Speed Sensor display will show the speed in rpm. Press NEXT. The d 056 Output Shaft Speed Sensor display will show the speed in rpm. TX,10,JC SEP98 4/4 Monitor Display Unit User Diagnostics Menu Hydraulic Sensors (d 06) This mode allows the technician to monitor all hydraulic sensors that are accessible to the computer system. Continued on next page TX,10,JC SEP98 1/ PN=61

64 Operation Operator s Station Press SELECT at the d 06 display. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 2/4 The d 061 Oil Temperature Sensor display will show the temperature in C or F (depending on setting selected in A 07 mode) and sensor voltage. Press NEXT. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 3/ PN=62

65 Operation Operator s Station The d 062 Pump Output Pressure Sensor display will show the pump pressure in kpa or psi (depending on the setting selected in A 07 mode) and sensor voltage (This is only available on machines with Load Performance Management installed). Deluxe Monitor Display Unit Shown T UN 08JUN98 TX,10,JC SEP98 4/4 Monitor Display Unit User Diagnostics Menu Fuel Sensor (d 07) This mode allows the fuel level sensor to be monitored. Press SELECT at the d 07 Fuel Sensor display. The Fuel Sensor display will show fuel level in gal or L (depending on setting selected in A 07 mode) and sensor voltage. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP97 1/ PN=63

66 Operation Operator s Station On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle reading in and out of the alpha-numeric window. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP97 2/2 Monitor Display Unit User Diagnostics Menu (d 08) Not Used TX,9015,MM APR98 1/1 Monitor Display Unit User Diagnostics Menu Machine I.D. Mode (d 10) This mode provides the technician with machine identification information for hour meter readings, part numbers and serial numbers of the monitor display unit and chassis controller unit. Continued on next page TX,10,JC SEP98 1/ PN=64

67 Operation Operator s Station Press SELECT at the d 10 display. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 2/10 The d 101 MDU Original display will show the monitor display unit hour meter reading and the original monitor display unit serial number. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 3/ PN=65

68 Operation Operator s Station Press NEXT. The d 102 CCU Original display will show the chassis controller unit hour meter reading and the original chassis controller serial number. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 4/10 Press NEXT. The d 103 MDU Part Number display will show the monitor display unit part number and serial number. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 5/ PN=66

69 Operation Operator s Station Press NEXT. The d 104 CCU Part Number display will show the chassis controller unit part number and serial number. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 6/10 Press NEXT. The d 105 MDU Software Number display will show the monitor display unit software number. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 7/ PN=67

70 Operation Operator s Station Press NEXT. The d 106 CCU Software Number display will show the chassis controller unit software number. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 8/10 Press NEXT. The d 107 TCU Serial Number display will show the transmission controller unit serial number. Deluxe Monitor Display Unit Shown T UN 22OCT97 Continued on next page TX,10,JC SEP98 9/ PN=68

71 Operation Operator s Station Press NEXT. The d 108 TCU Software Number display will show the transmission controller unit software number. Deluxe Monitor Display Unit Shown T UN 22OCT97 TX,10,JC SEP98 10/ PN=69

72 Operation Operator s Station Horn Button A Horn Button Horn Button T UN 12FEB98 TX,10,JC OCT98 1/1 Turn Signals Push turn signal lever (A) forward to signal a left turn. Pull turn signal lever rearward to signal a right turn. A Signal Lever T UN 13FEB98 CED,OUO1021, MAR98 1/ PN=70

73 Operation Operator s Station Air Conditioning Controls NOTE: Open valve (D) before operating heater. Turn temperature control knob (A) clockwise to increase temperature. Turn blower knob (B) clockwise to increase blower speed. (Knob also turns on heater blower.) Blower has four speeds. IMPORTANT: Before you start air conditioner first time in the season, check filters and condenser. Clean them if necessary. Check refrigerant level. Earlier Machines T UN 10SEP98 To operate air conditioning, press air conditioning switch (C). A Temperature Control Knob B Blower Knob C Air Conditioning Switch D Heater Valve Later Machines Two Lever Design T111213B UN 27AUG97 T156775D UN 10OCT02 TX,10,JC OCT02 1/ PN=71

74 Operation Operator s Station Air Flow Knob Air flow knob (1) has four air flow positions. The first position is for total defrost. Turn knob clockwise to the second position for more defrost than vent air flow. Turn knob clockwise to the third position for more vent air flow and less defrost. Turn the knob clockwise to the fourth position for total vent air flow. T159630B UN 20SEP02 1 Air Flow Knob HG31779,000012E 19 20SEP02 1/1 Adjusting Steering Wheel Tilt Lift lever (A) to adjust steering column to desired tilt. Release lever. A Lever T UN 12FEB98 CED,OUO1021, MAR98 1/1 Opening and Securing Side Door To open left side cab door from inside, push forward on lever (A). A Lever T131654B UN 13JUN00 Continued on next page CED,OUOE035, JUN00 1/ PN=72

75 Operation Operator s Station Open door until outside latch (A) fastens into notch (B). Door must be secure against bumper (C). Adjust rubber bumper as necessary to maintain proper tension. To release secured open door from inside the cab or on the ground, pull up on lever (D) located to the left of the operator s seat. Door will latch when closed. A Outside Latch B Notch C Bumper D Release Lever T160585B UN 17OCT02 T UN 02NOV98 CED,OUOE035, JUN00 2/ PN=73

76 Operation Operator s Station Opening Side Window/Secondary Exit NOTE: The cab right side window can be used as a secondary exit. Push up on lever (1) to open window. Position outer notch (2) over catch to hold window open. To release secured window, push down on lever (3) located behind cab seat. 1 Lever 2 Outer Notch 3 Lever T160250B UN 07OCT02 T160249B UN 07OCT02 HG31779,000014D 19 07OCT02 1/1 Opening Rear Side Window Pull on latch tab (A) to release window lock. A Latch Tab T131655B UN 19JUN00 TX,10,JC JUN00 1/ PN=74

77 Operation Operator s Station Adjusting Seat CAUTION: You can lose control of machine and be injured if seat is loose. Be sure seat is properly locked in position before operating the machine. Use flip-out lever to turn weight adjustment knob (F). Turn knob clockwise for firm ride and counterclockwise for soft ride. Lift fore-aft adjustment lever (H) to move seat forward and rearward. Release handle at one of several positions. Remove your weight from seat. Lift seat height adjustment lever (E) and move seat to desired height. Move seat to mid-to-aft position. While sitting in seat, turn weight adjustment knob (F) to support weight. Check weight indicator (G) for appropriate weight setting and continue to turn until yellow pointer inside tube is flush with tube opening. While sitting in seat, lift backrest tilt adjustment knob (D) and allow cushion to angle forward or lean backward into desired position and release handle. T103679B UN 22NOV96 While sitting in seat, rotate armrest adjustment knob (C) to tilt to desired armrest position. To raise or lower armrest height, loosen two nuts on armrest height adjustment bracket (B) and adjust to desired position. Tighten nuts to secure. While sitting in seat, rotate lumbar support lever (A) to increase or decrease support to lower back. On air ride equipped seats, to lower seat height or decrease firmness in ride, pull out on height/firmness adjustment knob (I). To raise seat or increase firmness in ride, turn key to On and push in on height/firmness adjustment knob. A Lumbar Support Lever B Armrest Height Adjustment Bracket C Armrest Adjustment Knob D Backrest Tilt Adjustment Knob E Seat Height Adjustment Lever F Weight Adjustment Knob G Weight Indicator H Fore-Aft Adjustment Lever I Height/Firmness Adjustment Knob (Air Ride Seat only) T UN 26NOV96 CED,OUO1021, MAR98 1/ PN=75

78 Operation Operator s Station Seat Belt T UN 01MAR00 Seat belt and mounting hardware must be inspected for wear or damage before operating the machine. Replace the belt or mounting hardware if worn or damaged. Replace the complete seat belt assembly every three years regardless of appearance. A date label, to determine the age of the belt, is attached to each belt. TX,10,JC JUN00 1/ PN=76

79 Operation Operating the Machine Inspect Machine Daily Before Starting Do periodic service checks. A Check wheels (front and rear) for loose or missing hardware. B Clean operator s station. C Check air inlet cover. D Clean radiator. E Check fuel level on monitor. F Check tires (front and rear). ELECTRICAL SYSTEM: Check for worn or frayed wires and loose or corroded connections. BOOM, BUCKET, SHEET METAL: Check for bent, broken, loose, or missing parts. HARDWARE: Check for loose or missing parts. PARK BRAKE: Check for correct operation. T UN 18SEP96 HYDRAULIC SYSTEM: Check for leaks, missing or loose clamps, kinked hoses, and lines or hoses that rub against each other or other parts. LUBRICATION: Check lubrication points shown on Periodic Maintenance Chart. A Wheels (Front and Rear) B Operator s Station C Air Inlet Cover D Radiator E Fuel Level (Monitor) F Tires PROTECTIVE DEVICES: Check guards, shields, ROPS, covers, seat belt. SAFETY: Walk around machine to clear all persons from machine area. TX,20,JC JUL02 1/ PN=77

80 Operation Operating the Machine Check Instruments Before Starting Turn key switch clockwise to On position. All indicators must light. If any indicator fails to light, the bulb may be burned out. If bulb is not burned out, but indicator light still fails to light, see your authorized dealer. T DEC98 HG31779,00000B JUL02 1/1 Starting the Engine CAUTION: Avoid possible injury or death from a runaway machine. DO NOT start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed. NEVER start engine while standing on ground. Start engine only from operator s seat, with transmission control lever in Neutral. Engage park brake. TS177 UN 11JAN89 Use of seat belt with roll-over protective structure (ROPS) is recommended under all operating conditions. 1. Fasten seat belt. Continued on next page TX,25,JC JUL02 1/ PN=78

81 Operation Operating the Machine 2. Move transmission control lever (A) to N. Engage neutral lock (B). 3. Turn key switch to On position. Push horn button to sound horn to alert bystanders that machine will be started. IMPORTANT: Never operate starter motor for more than 20 seconds at a time. If engine fails to start after two or three tries, return key switch to Off position. Wait for about 2 minutes, then try again. T UN 13FEB98 After a false start, DO NOT turn key switch until engine stops or starter may be damaged. A Transmission Control Lever B Neutral Lock Engine will not start by towing or pushing. Permanent damage to transmission will result. 4. Turn key switch to Start position. DO NOT crank engine more than 20 seconds. Wait 2 minutes before trying again. Release key when engine starts. IMPORTANT: If STOP indicator light does not go out within 10 seconds after starting engine, STOP THE ENGINE. Find and correct the cause. 5. Operate machine at less than normal loads and at slow idle speed until engine warms up. IMPORTANT: If engine stops when operating under load, remove load. Restart engine immediately. Run 30 seconds at 1/2 speed before adding load. TX,25,JC JUL02 2/ PN=79

82 Operation Operating the Machine Starting Fluid If Equipped (Cold Weather Starting Aid) USE STARTING FLUID CAUTION: Prevent possible injury from exploding container. Starting fluid is highly flammable. Keep container away from heat, sparks, and open flame. Contents are pressurized. DO NOT puncture or incinerate container. Remove container from machine if engine does not need starting fluid. TS281 UN 23AUG88 IMPORTANT: Prevent damage to engine. Use starting aid when temperatures are below 4 C (40 F) and only when engine is COLD. 1. Turn key switch clockwise to Start position. Continued on next page CED,OUO1021, JUL02 1/ PN=80

83 Operation Operating the Machine IMPORTANT: Excess starting fluid could damage engine; press start aid button only when engine is cold and cranking. Starting aid fluid is being injected into engine as long as you press button. 2. After one or two revolutions of engine crankshaft, press starting aid button (A) until engine starts. Crank engine for 20 seconds maximum, then allow 2 minutes between cranking periods. REPLACING START AID CONTAINER T UN 13FEB98 1. Loosen hose clamp (B). 2. Turn start aid container (C) counterclockwise to remove. 3. Remove safety cap from new container. 4. Turn container clockwise in starting aid base to install. 5. Tighten hose clamp. OPERATING MACHINE WITHOUT START AID CONTAINER INSTALLED IMPORTANT: Protect starting aid components from possible damage. Install starting aid plug in starting aid base. A Starting Aid Button B Hose Clamp C Start Aid Container D Plug T UN 15SEP98 Remove container and install plug (D) in base. CED,OUO1021, JUL02 2/ PN=81

84 Operation Operating the Machine Using Booster Batteries 24 Volt System Before boost starting, machine must be properly shut down and secured to prevent unexpected machine movement when engine starts. CAUTION: 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. TS204 UN 23AUG88 IMPORTANT: The machine electrical system is a 24-volt negative (-) ground. Connect two 12-volt booster batteries together in series as shown for 24 volts. 1. Connect one end of the positive cable to the positive terminal of machine batteries (A) and the other end to the positive terminal of booster batteries (B). 2. Connect one end of the negative cable to the negative terminal of booster batteries. Then connect the other end of negative cable to the machine frame as far away from the machine batteries as possible. 3. Start the engine. A Machine Batteries B Booster Batteries T7233JN UN 21MAY90 4. Immediately after starting the engine, disconnect the end of negative cable from the machine frame first. Then disconnect the other end of negative cable from the negative terminal of booster batteries. 5. Disconnect the positive cable from the booster batteries and machine batteries. CED,TX14795, SEP00 1/ PN=82

85 Operation Operating the Machine Engine Air Heater If Equipped IMPORTANT: DO NOT USE ETHER WITH THIS SYSTEM. Damage to your engine may occur. NOTE: As long as monitor light remains on, air heater will be operating. 1. Turn key switch to On. If engine temperature is below 10 C (50 F), engine preheat indicator (A) will light and stay on 0 30 seconds, depending on initial engine temperature. Light will turn off, indicating that preheating is completed. A Engine Preheat Indicator T UN 22OCT97 2. Turn key to Start. Light will turn off while cranking or if battery voltage drops below 20 volts. 3. If engine temperature is 20 C (68 F) or lower, preheat indicator will light and will remain on for approximately 30 seconds depending on current engine temperature. IMPORTANT: Warm up at 1/2 speed and DO NOT accelerate rapidly during warm-up. NOTE: Battery voltage light may come on during post heat and may remain on for a short period of time. CED,OUO1021, OCT02 1/1 Using Coolant Heater If Equipped CAUTION: Prevent possible injury from fire from an overheated electrical cord. Use a heavy-duty, grounded cord to connect heater to electrical power. Connect the coolant heater to 115-volt electrical power 10 hours before you start the engine. T82,25,C DEC91 1/ PN=83

86 Operation Operating the Machine Warm-Up Operate machine at less-than-normal loads and speeds for first few minutes until temperatures and pressures reach normal operating range. TX,25,JC NOV94 1/1 Cold Weather Warm-Up IMPORTANT: If hydraulic oil and transmission oil are cold, functions move slowly. Do not attempt normal machine operations until hydraulic and transmission functions move at close-to-normal cycle times. 1. Start engine. Run engine at minimum speed for 5 minutes. 2. Cycle boom with bucket stalled in rollback position until bucket functions move at normal speed. 3. Check transmission oil level with engine at low idle. Prepare machine to shift transmission as follows: Machine stopped Engine slightly above low idle Bucket off the ground and empty Brakes apply right or left brake pedal with clutch cut-off disengaged Parking brake released Cycle transmission 10 times by shifting: Neutral-F1 R1 F1 R1 F1 Neutral. Each cycle should be approximately 5 seconds. 4. Shift from F1-R1 without braking until transmission operates normally. TX,25,JC SEP98 1/1 Neutral Lock CAUTION: Prevent possible injury from unexpected machine movement. Always move transmission control lever to N Neutral, and engage neutral lock before starting or dismounting. Move neutral lock (A) to the locked position to engage neutral lock. Move lock to the unlocked position to disengage neutral lock. T UN 12FEB98 A Neutral Lock CED,OUO1021, JUL02 1/ PN=84

87 Operation Operating the Machine Shifting the Transmission Unlock neutral lock. Release park brake. Change direction of machine by moving transmission control lever (A) to F Forward" or R Reverse". Change speed of machine by moving transmission control lever to desired gear. Machine has four forward gears and three reverse gears. Shifting to 4th gear reverse will give same travel speed as 3rd gear reverse. Select a gear suitable to operating and road conditions. T UN 13FEB98 When automatic transmission switch (B) is on, transmission will shift up or down as required to highest gear selected. In automatic transmission mode, transmission starts out in 2nd gear. A Transmission Control Lever B Automatic Transmission Switch Later Machines One Lever Design T159423M UN 19SEP02 Later Machines Two Lever Design T156774C UN 27JUN02 HG31779,000014E 19 07OCT02 1/ PN=85

88 Operation Operating the Machine Park Brake Switch CAUTION: Prevent possible injury or death from machine runaway. Before disengaging park brake, be sure engine is running and service brakes are operational. NOTE: Transmission clutches are disengaged when park brake is applied. The park brake switch (A) has three positions: T UN 11MAY98 Park brake ON Neutral, center detented position Park brake release, momentary position A Park Brake Switch To engage park brake, move switch from the neutral, center detented position to the park brake ON, detented position. To release park brake, move switch to the neutral, center detented position, then the park brake release momentary position. NOTE: If park brake is engaged when engine is running and transmission control lever is in Neutral, park brake indicator will light. If park brake is engaged when engine is running and transmission control lever is moved to F or R, park brake indicator will light, STOP indicator will light, and alarm will sound. Basic Display will read N. F or R will not appear until park brake is released. If engine is stopped with park brake switch OFF, park brake is automatically applied. Press park brake switch to ON and then back to momentary position to release park brake after starting engine. Park brake will come on if transmission pressure drops below 150 psi. CED,OUO1021, SEP02 1/ PN=86

89 Operation Operating the Machine Boom and Bucket Control Lever One Lever Design Move control lever forward (A) to lower boom, or rearward (D) to raise boom. NOTE: Pilot enable/boom down switch must be pushed while moving control lever forward to lower boom with engine stopped. Move control lever left (F) to roll back bucket, or right (C) to dump bucket. Return-to-Carry (I) If Equipped: With Return-to-Carry switch on, push boom down lever to Float position (lever in full forward detent position [B]). The boom will stop at a pre-set height and lever will return to neutral position automatically. NOTE: Return-to-carry (I) will override float position. Return-to-carry must be off for float detent to operate. NOTE: Boom float will not work once the boom is below preset distance from ground. Push switch to Off position to activate boom float. Earlier Machines A Lower Boom B Float C Dump Bucket D Raise Boom E Boom Height Kickout F Rollback Bucket G Return-to-Dig H Fast Bucket Dump I Pilot Enable/Boom Down Switch J Return-to-Carry Switch If Equipped T UN 10SEP98 Float (lever in full forward detent position [B]): This position allows oil to flow in and out both ends of cylinders so the bucket can follow the contour of the ground. Manually release lever from this position. Return-to-Dig (lever in full left detent position [G]): Bucket will return to set dig position. Boom Height Kickout (lever in full rear detent position [E]): Lever will remain in this position until boom is at a pre-set height, then will return to neutral automatically. Boom and bucket functions can be operated simultaneously by moving lever between positions. For example, to raise boom and roll back bucket, move lever between positions (D) and (F). HG31779,00000B JUL02 1/ PN=87

90 Operation Operating the Machine Boom and Bucket Control Lever Two Lever Design Move left control lever forward (A) to dump bucket, or rearward (B) to roll back bucket. Return-to-Carry (I) If Equipped: With Return-to-Carry switch on, push boom down lever to Float position (lever in full forward detent position [D]). The boom will stop at a pre-set height and lever will return to neutral position automatically. T156928B UN 10JUL02 NOTE: Pilot enable/boom down switch must be pushed while moving control lever forward to lower boom with engine stopped. Move right control lever forward (E) to lower boom or rearward (F) to raise boom. NOTE: Return-to-carry (I) will override float position. Return-to-carry must be off for float detent to operate. NOTE: Boom float will not work once the boom is below preset distance from ground. Push switch to Off position to activate boom float. Float (right lever in full forward detent position [D]): This position allows oil to flow in and out both ends of cylinders so the bucket can follow the contour of the ground. Manually release lever from this position. Return-to-Dig (left lever in full rearward detent position [C]): Bucket will return to set dig position. Later Machines A Dump Bucket B Rollback Bucket C Return-to-Dig D Float E Lower Boom F Raise Boom G Boom Height Kickout H Fast Bucket Dump I Return-to-Carry Switch If Equipped T156774D UN 27JUN02 Boom Height Kickout (right lever in full rearward detent position [G]): Lever will remain in this position until boom is at a pre-set height, then will return to neutral automatically. HG31779,00000B JUL02 1/ PN=88

91 Operation Operating the Machine Quick Shift Switch Down/Up Press switch (A) to down shift from selected gear to next lower gear when transmission control lever is positioned in gears 2 4. Press again to return to original gear. NOTE: Machine can be programmed with Monitor Accessory Mode 02 for down/up 021 or Down only 022. Down Only Earlier Machines T UN 10SEP98 This mode will allow transmission to down shift one gear for each pressing of button. Once a down shift is made by pressing the quick shift switch, the transmission will not shift up again unless a direction or gear change is made. A Switch Later Machines Two Lever Design T156926B UN 01JUL02 HG31779, SEP02 1/ PN=89

92 Operation Operating the Machine Ride Control Switch Earlier Machines (If Equipped) CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with Ride Control. Ride control accumulator energy must be discharged when working on hydraulic components. Turn ignition switch to ON position, cycle the ride control switch from OFF to ON (center position). Boom will jump up if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. Side Console Cab Units Shown A Ride Control Switch T UN 25SEP98 ON Position Turn ride control switch (A) ON to improve machine ride and reduce tire flexing when traveling over rough terrain at a high speed with loaded bucket. If engine is stopped with ride control switch in ON position, ride control is automatically turned off. Start the engine. Press ride control switch to the Off position and then back to the On or Auto position to turn ride control on. To discharge the energy in the ride control accumulator, do the following: 1. Make sure area around bucket is clear. 2. Turn ride control OFF. 3. Lower boom and bucket to ground position and stop engine. NOTE: Return-to-carry must be off for float detent to operate. 4. Turn key switch on without starting the engine and cycle ride control switch to the ON position (middle switch position). Continued on next page TX,30,JC JUN00 1/ PN=90

93 Operation Operating the Machine 5. Press and hold the pilot enable/boom down switch while holding the boom control in the float position for five seconds. TX,30,JC JUN00 2/3 Auto Position With the ride control switch (A) in the Auto position, the ride control functions the same as the On position with one exception. When ground speed is approximately 6 km/h (3 1/2 mph) or less, the ride control is turned off. When the ground speed is greater than 6 km/h (3 1/2 mph), the operation will be the same as the On position. A Ride Control Switch Side Console Cab Units Shown T UN 25SEP98 TX,30,JC JUN00 3/ PN=91

94 Operation Operating the Machine Ride Control Later Machines (If Equipped) CAUTION: Prevent possible injury from unexpected boom. The bucket may jump up when ride control switch is turned ON. Clear all bystanders from area. Ride control will improve machine ride and reduce tire flexing when traveling through rough terrain at a high speed with loaded bucket. On Position Later Machines One Lever Design T159423D UN 17SEP02 With the ride control switch (1) in the On position, ride control will remain on as long as engine is running. If engine is stopped with ride control switch in On position, ride control is automatically turned off. Auto Position With the ride control switch in the Auto position, ride control will remain on as long as engine is running and ground speed is at least 6 km/h (3 1/2 mph). Off Position Ride control is turned off. Operating Ride Control Later Machines Two Lever Design 1 Ride Control Switch T156774K UN 18JUL02 1. Make sure area around bucket is clear. 2. Start the engine. 3. If ride control switch is in the Off position, push switch to On or Auto mode. If switch is already in On or Auto position, ride control will automatically reactivate as soon as a ground speed greater than 6 km/h (3.5 mph) is reached and will operate until engine is stopped or switch is turned Off. Discharging Ride Control Accumulator 1. Make sure area around bucket is clear. 2. Turn ride control off. 3. Lower boom and bucket to ground and stop engine. Continued on next page HG31779, SEP02 1/ PN=92

95 Operation Operating the Machine NOTE: Return-to-carry must be off for boom float to operate. 4. Turn key switch to On without starting the engine and cycle ride control switch to the On position (middle switch position). 5. Press and hold the pilot enable/boom down switch while holding the boom control in the float position for 5 seconds. HG31779, SEP02 2/2 Secondary Steering If Equipped IMPORTANT: Prevent possible damage to secondary steering system. Stop machine immediately if steering pressure indicator light and audible alarm come on while operating. THE SECONDARY STEERING SYSTEM IS NOT INTENDED FOR CONTINUOUS USE. Steering pressure indicator light (B) will light, STOP indicator light (A) will flash, and audible alarm will sound when secondary steering system is activated. The light indicates low hydraulic pressure resulting from mechanical malfunction, such as loss of engine power. An electrically driven pump will actuate to provide steering A STOP Indicator Light B Steering Pressure Indicator Light T UN 25SEP98 The secondary steering system will function only when key switch is on. NOTE: Secondary steering is activated if the engine dies with key on. The secondary steering motor will stop when the key is turned off. TX,35,JC SEP98 1/ PN=93

96 Operation Operating the Machine Differential Lock Switch Hold switch (A) down to lock front differential or front and rear differential, if equipped. Release switch to unlock differential. NOTE: Use differential lock only when conditions require traction. Avoid using differential lock when steering. A Switch T UN 13FEB98 TX,35,JC SEP98 1/1 Boom Height Kickout Adjustment 1. Move loader control lever to boom raise detent position and release. 2. After loader control lever returns to neutral, make a mark on the adjustable plate and loader frame for the tool carrier. For the loader, make a mark on plate edge and mounting block. 3. Position the boom in the desired boom height kickout position. Stop engine. 4. Loosen cap screws (A) and adjust plate to align marks on plate and loader frame or mounting block. Loader T106999B UN 06FEB97 5. Inspect air gap between switch (B) and adjustable plate (C). Specification Boom Height Kickout Switch-to-Adjustable Plate Gap mm ( in.) 6. If air gap is out of specifications, loosen hex nuts and adjust switch (B) to get correct air gap. 7. Start engine and check boom height kickout for correct adjustment. Readjust as required. A Cap Screw (2 used) B Switch C Adjustable Plate Tool Carrier T107042B UN 07FEB97 TX,20,SS AUG96 1/ PN=94

97 Operation Operating the Machine Return-to-Carry Kickout Adjustment 1. Move Return-to-Carry switch on side dash to ON position. Raise boom to maximum height. 2. Put boom lever in Float detent position and observe at what position boom stops lowering and control lever releases from detent. 3. Stop engine. Make a mark on the adjustable plate and loader frame for the tool carrier. For the loader, make a mark on plate edge and mounting block. Loader T107043B UN 07FEB97 4. Start engine and position boom in desired Return-to-Carry position. 5. Stop engine. Loosen cap screws (A) and adjust plate (B) to align marks on plate and loader frame or mounting block. 6. Inspect air gap between switch (B) and adjustable plate (C). Specification Boom Height Kickout Switch-to-Adjustable Plate Gap mm ( in.) 7. If air gap is out of specifications, loosen hex nuts on switch and adjust switch (B) to get correct air gap. 8. Start engine and check boom Return-to-Carry kickout for correct adjustment. Readjust as required. A Cap Screw (2 used) B Switch C Adjustable Plate Tool Carrier T107041B UN 06FEB97 NOTE: The boom Float position detent will not operate at ground level with Return-to-Carry switch ON. Turn Return-to-Carry switch off to activate normal Float function of boom. TX,20,SS AUG96 1/ PN=95

98 Operation Operating the Machine Return-To-Dig Adjustment (S.N ) SPECIFICATIONS Air Gap Between Switch and Bar Distance 5 8 mm ( in.) Cap Screw Torque 121 Nm (89 lbft) OTHER MATERIAL T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE Products TY9473 Canadian Thread Lock and Sealer (Medium Strength)LOCTITE Products T UN 16AUG Thread Lock and Sealer (Medium Strength)LOCTITE Products T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE Products TY9473 Canadian Thread Lock and Sealer (Medium Strength)LOCTITE Products 242 Thread Lock and Sealer (Medium Strength)LOCTITE Products A Air Gap Switch-To-Bar B Adjustable Bar C Cap Screws D Alignment Marks E Adjusting Nuts (2) F Switch TY6305 U.S. Clean And Cure PrimerLOCTITE Products TY9485 Canadian Clean And Cure PrimerLOCTITE Products 764 Clean And Cure PrimerLOCTITE Products 1. Raise boom approximately 300 mm (12 in.) above ground. Move bucket from full rollback to dump. 2. Move loader control lever to return-to-dig detent position and release. 3. After control lever returns to neutral, scribe a mark (D) on the switch bracket and adjustable bar (B) to align with each other. 4. Position the boom and bucket in the desired return-to-dig position. Stop engine. 5. Remove cap screws (C), one at a time and remove old thread lock and sealer using Clean and Cure Primer. Apply medium strength thread lock and sealer to cap screws. 6. Install cap screws (C) but do not tighten. Adjust bar to align marks on switch bracket and end of bar. Torque cap screws to 121 Nm (89 lbft). Specification Cap Screw Torque Nm (89 lbft) LOCTITE is a trademark of Loctite Corp. Continued on next page PN=96 TX,20,SS JUN00 1/2

99 Operation Operating the Machine 7. Loosen adjusting nuts to switch (F). Adjust air gap (A) between switch and adjustable bar (B) to 5 8 mm ( in.). Retighten adjusting nuts. Specification Air Gap Between Switch and Bar Distance mm ( in.) 8. Raise boom. Cycle bucket from full rollback to dump. Adjust as required to get desired position. TX,20,SS JUN00 2/ PN=97

100 Operation Operating the Machine Return-To-Dig Adjustment (S.N ) T UN 26JUN00 A Air Gap Switch-To-Bar C Cap Screws E Hex Nuts F Switch B Adjustable Bar D Alignment Marks SPECIFICATIONS Cap Screw Torque 121 Nm (89 lbft) Air Gap Between Switch and 5 8 mm ( in.) Bar Distance Hex Nut Torque 75 N m (55 lbft) OTHER MATERIAL T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE Products TY9473 Canadian Thread Lock and Sealer (Medium Strength)LOCTITE Products 242 Thread Lock and Sealer (Medium Strength)LOCTITE Products T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE Products TY9473 Canadian Thread Lock and Sealer (Medium Strength)LOCTITE Products 242 Thread Lock and Sealer (Medium Strength)LOCTITE Products TY6305 U.S. Clean And Cure PrimerLOCTITE Products TY9485 Canadian Clean And Cure PrimerLOCTITE Products 764 Clean And Cure PrimerLOCTITE Products 1. Raise boom approximately 300 mm (12 in.) above ground. Move bucket from full rollback to dump. 2. Move loader control lever to return-to-dig detent position and release. 3. After control lever returns to neutral, scribe a mark (D) on the switch bracket and adjustable bar (B) to align with each other. 4. Position the boom and bucket in the desired return-to-dig position. Stop engine. 5. Remove cap screws (C), one at a time and remove old thread lock and sealer using Clean and Cure Primer. Apply medium strength thread lock and sealer to cap screws. 6. Install cap screws (C) but do not tighten. Adjust bar to align marks on switch bracket and end of bar. Torque cap screws to 121 Nm (89 lbft). LOCTITE is a trademark of Loctite Corp. Continued on next page PN=98 CED,TX18076, JUN00 1/2

101 Operation Operating the Machine Specification Cap Screw Torque Nm (89 lbft) 7. Loosen hex nuts (E) to switch bracket. Adjust air gap (A) between switch and adjustable bar (B) to 5 8 mm ( in.). Torque hex nuts to 75 Nm (55 lbft). Specification Air Gap Between Switch and Bar Distance mm ( in.) Hex Screw Torque Nm (55 lbft) CED,TX18076, JUN00 2/ PN=99

102 Operation Operating the Machine Fork Attachment T UN 06AUG97 LOADING Center forks and carriage before lifting. Inspect load to ensure stability when lifted. Never attempt to lift load with one fork. Approach load slowly and squarely with fork tips level. Move forks slowly under load with load positioned equally on forks. Continue to drive forward until load is against backrest of forks. UNLOADING Always use a signal person if you cannot see the placement area for the load. Make certain area is clear of all objects. Lower load to ground and tilt forks to a level position. Back away carefully to disengage forks. ELEVATED LOADS Slowly raise load with a slight back tilt to cradle load. Never tilt load forward unless load is over landing area and ready to be set down. If there is any indication of load instability during the lift such as movement, leaning, or swaying, stop lifting immediately. Lower load and restock. As load approaches desired height, slow the lift speed to a minimum. Continue the lift until load is slightly higher than the landing point. After load is securely in place, retract forks clear of load and lower forks to traveling height before moving. DRIVING ON A SLOPE CAUTION: Prevent possible injury from machine rollover, do not turn on slopes. Do not drive across slopes under any circumstances. Driving up or down slope WITH load on forks: Lower load near to ground. Keep mast tilted back to retain load. Slowly drive straight up or back straight down slope. Driving up or down slope WITHOUT load on forks: Lower forks near to ground. Keep mast tilted back. Slowly drive straight down or back straight up slope. LIFTING CAPACITY To maintain stability, only lift loads equal to or less than mast capacity or rated operating capacity of machine, whichever is less. (See Specifications section for machine lifting capacities.) TRAVELING Operate machine controls from operator seat only. While driving, carry load low for good visibility and machine stability. Continued on next page CED,TX03679, NOV99 1/ PN=100

103 Operation Operating the Machine Downshift with care. A sudden deceleration could shift or topple load. A sudden reversal of travel direction could tip load or over turn the machine. Come to a gradual stop before reversing directions. Slow travel speed when making turns to avoid an overturn. Use low gear for hillside or ramp operation. Never coast downhill with transmission in neutral. The machine could go out of control and tip over. Reduce speed when driving over rough terrain, carrying a heavy load, or working in a congested area. Avoid rocks, curbs, and ditches. OPERATING TIPS Never use the fork attachment as a working platform. Know locations of bystanders in the working area at all times. DO NOT touch, lean on, or reach through the mast, boom or lift mechanism or permit others to do so. Never climb on the mast, boom, or attachments. NEVER allow anyone to stand or pass under the raised forks, mast, carriage, boom, or attachments. Reduce speed and sound horn at blind intersections, exits, and when approaching pedestrians. FORK INSPECTION The forks are the main load bearing components of the mast. Forks must be maintained and checked periodically to assure safe operation. Inspect forks daily. If any of the following conditions exist, replace forks before operating machine. Check for visibly bent forks and abrasions. If forks are bent more than 3, replace forks. (Tapered forks are 90 nominal and standard forks are 87 nominal.) If a flat spot is clearly evident from abrasive wear, replace forks. Inspect forks for cracks along the inside radius of heel. Inspect hanger block welds for visible cracks. Check to see that the spring loaded keeper, with washer, is in position in the upper hanger block and that the keeper is functioning properly. (Spring in keeper must pull pin down into hanger block when pin is pulled out and released.) Inspect hanger blocks for any sign of deformation, cracks, and wear. Bent forks are not always detectable by sight. Remove forks and measure the interior angle of each fork to detect a bent fork. Tapered tip forks have an interior angle of 90. Standard square tip forks have an interior angle of 87. If angle is bent more than 3, replace fork. FORK ADJUSTMENT To change fork position: CAUTION: To prevent injury, never stand under forks or any part of lift mechanism. 1. Lower forks to approximately 25 mm (1 in.) above ground. CAUTION: To prevent injury when sliding forks, keep hands and fingers out of fork adjustment path. 2. Lift pin and slide fork to desired position. Slide fork by placing a foot on tine and palm of other hand on top of fork. Alternately push fork with hand (top) and foot (lower) in a rocking motion until fork reaches desired position. 3. Release pin and check that fork is engaged in notch. 4. Check that mast backing plate pins are in place at each end. Measure backing plate pins for wear. Pins should be equal in length on both sides of plate. Replace pins if worn or damaged. CED,TX03679, NOV99 2/ PN=101

104 Operation Operating the Machine Parking the Machine 1. Park machine on a level surface. 2. Lower bucket to ground. 3. Move transmission control lever (A) to N. Engage neutral lock (B). CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine. A Transmission Control Lever B Neutral Lock T UN 13FEB98 4. Push park brake switch to ON. IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 5. Run engine at 1/2 speed without load for 2 minutes before stopping, to avoid damage to turbocharger. Release accelerator pedal to slow idle. 6. Turn key switch to Off. 7. Turn battery disconnect switch OFF, if equipped. CED,OUO1021, JUL02 1/ PN=102

105 Operation Operating the Machine Loading Machine on a Trailer 1. Keep the trailer bed clean. Put chock blocks against trailer wheels. 2. Use a ramp or loading dock. Ramps must be strong enough, have a low angle, and correct height. 3. Fasten seat belt before starting engine. CAUTION: Position the machine so that its centerline is over the centerline of the truck bed. NEVER steer the machine while on the ramp. If changing direction is required on the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again. A Transmission Control Lever B Neutral Lock T UN 13FEB98 4. Drive the machine onto the ramp slowly. The centerline of the machine should be over the centerline of the trailer. 5. Lower all equipment onto blocks or trailer bed. 6. Move transmission control lever (A) to N. Engage neutral lock (B). CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn off engine or push park brake switch to ON to hold machine. 7. Push park brake switch to ON. 8. Connect frame locking bar. 9. Turn key switch to Off. 10. Turn battery disconnect switch OFF, if equipped. 11. Cover exhaust opening to prevent entry of debris and water. Continued on next page CED,OUO1021, JUL02 1/ PN=103

106 Operation Operating the Machine 12. Fasten each corner of the machine to the trailer with a chain or cable with appropriate load binder. 13. Place blocks in front of and behind tires. CED,OUO1021, JUL02 2/ PN=104

107 Operation Operating the Machine Towing Procedure T UN 20MAR01 1 Front Driveshaft 3 Park Brake Hose 4 Telescoping Driveshaft 5 Rear Driveshaft 2 Park Brake Fitting Plug CAUTION: Do not allow an operator on the machine being towed unless the operator can control the steering and brakes. IMPORTANT: Engine cannot be started by towing. Tow the machine off-road to the nearest location where repair work can be done. Haul the machine if it must be moved further than 460 m (500 yd). Never tow machine faster than 3.2 km/hr (2 mph) to avoid transmission damage. If the engine or the transmission hydraulic system are non-functional, the park brake is ON. CAUTION: Prevent possible injury from unexpected machine movement. Place blocks at front and rear of tires to prevent machine from rolling. 1. Place blocks at front and rear of tires. 2. Connect the towed and towing machines together. NOTE: Frame locking bar is installed to prevent weaving as machine is towed. 3. Start engine if possible, and install frame locking bar. 4. Move transmission control lever to Neutral position. Engage neutral lock. Continued on next page OUOE003,000009E 19 18JUL02 1/ PN=105

108 Operation Operating the Machine 5. If park brake indicator does not come on, the park brake is OFF. Go to Step 11. If park brake indicator is on, the park brake is ON. Go to Step Stop engine. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar. 7. Disconnect park brake hose (3) from park brake fitting (2). Plug hose. 8. Connect a hose from a hand operated hydraulic pump to the fitting on park brake. NOTE: Keep hydraulic hand operated pump filled with oil. CAUTION: Prevent possible injury from unexpected machine movement. Sit in operator s seat when pumping the hydraulic pump. When towing the machine, maintain at least 1379 kpa (13.8 bar) (200 psi). If pressure is below 1379 (13.8 bar) (200 psi), park brake may engage. 9. Place hydraulic hand pump on left side of operator s station floor. IMPORTANT: Do not pump pressure up to more than 2068 kpa (20.7 bar) (300 psi) to avoid damage to the park brake. 10. Pump handle until gauge needle indicates 1379 kpa (13.8 bar) (200 psi) which will be required to disengage park brake. To engage the park brake, open the valve in the hand-operated pump to relieve pressure. CAUTION: Prevent possible injury from unexpected machine movement. Never attempt to remove driveshafts without blocking front and rear tires. 11. Remove driveshafts if a hand operated pump is not available to release the park brake. Disconnect driveshafts (1 and 4) at differential and transmission and remove from machine. CAUTION: Prevent possible injury from unexpected machine movement. Place blocks at front and rear of tires to prevent machine from rolling. NOTE: Limit tow to 460 m (500 yd) maximum. 12. Tow the machine slowly. 13. Place blocks at front and at rear of tires. 14. Reapply park brake or reinstall driveshaft if it was removed. See your authorized dealer for installation information. OUOE003,000009E 19 18JUL02 2/ PN=106

109 Operation Operating the Machine Lifting the Machine CAUTION: Prevent possible injury from unexpected machine movement. Clear all bystanders from lifting area. Select correct lifting cable strength for weight of machine. Test lift by raising machine 0.3 m (1 ft) off the ground. Specification 624H Loader Weight... TC62H Tool Carrier Weight kg (25,873 lb) kg (30,532 lb) 1. Install machine frame locking bar. 2. Attach cables (A) to machine so cables do not rub machine. 3. Attach a tether cable to machine to control machine as it is lifted. 4. Test lift by raising machine 0.3 m (1 ft) off the ground. 5. Lift machine and swing to unloading area. A Cables T7477AV UN 19MAR91 CED,OUOE002, SEP98 1/ PN=107

110 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. In all cases, the fuel shall meet the following properties: Cetane number of 40 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20 C (-4 F) or elevations above 1500 m (5000 ft). Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5 C (9 F) below the expected low temperature. Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test. Sulfur content: Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred. If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for engine oil and filter by 50%. DO NOT use diesel fuel with sulfur content greater than 1.0%. Bio-diesel fuels may be used ONLY if the fuel properties meet DIN or equivalent specification. DO NOT mix used engine oil or any other type of lubricant with diesel fuel. DX,FUEL FEB99 1/1 Low Sulfur Diesel Fuel Conditioner When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulfur diesel fuels. If the local fuel distributor will supply only low sulfur fuel, order and use John Deere PREMIUM DIESEL FUEL CONDITIONER. It provides lubricating properties along with other useful benefits, such as cetane improver, anti-oxidant, fuel stabilizer, corrosion inhibitor and others. John Deere PREMIUM DIESEL FUEL CONDITIONER is specifically for use with low sulfur fuels. Nearly all other diesel fuel conditioners only improve cold weather flow and stabilize long-term fuel storage. They do not contain the lubrication additives needed by rotary fuel injection pumps. TX,45,JC AUG97 1/ PN=108

111 Maintenance Machine Dieselscan Fuel Analysis DIESELSCAN is a John Deere fuel sampling program to help you monitor the quality of your fuel source. It verifies fuel type, cleanliness, water content, suitability for cold weather operation, and if fuel is within ASTM specifications. Check with your John Deere dealer for availability of DIESELSCAN kits. DIESELSCAN is a trademark of Deere & Company DX,FUEL DEC00 1/1 Handling and Storing Diesel Fuel 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. Fill the fuel tank at the end of each day s operation to prevent condensation and freezing during cold weather. 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 MAR96 1/1 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. In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. Consult your authorized dealer to obtain specific information and recommendations. Re-refined base stock products may be used if the finished lubricant meets the performance requirements. TX14740,0001C OCT00 1/ PN=109

112 Maintenance Machine Diesel Engine Break-In Oil New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level. Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine. After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL. If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation: ACEA Specification E1 After the break-in period, use John Deere PLUS-50 or other diesel engine oil as recommended in this manual. IMPORTANT: Do not use PLUS-50 oil or engine oils meeting API CH-4, API CG4, API CF4, ACEA E3, or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly. API Service Classification CE PLUS-50 is a registered trademark of Deere & Company. DX,ENOIL JAN00 1/ PN=110

113 Maintenance Machine Diesel Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. 50 C 122 F The following oil is preferred: 40 C 104 F John Deere PLUS-50 The following oil is also recommended: John Deere TORQ-GARD SUPREME Other oils may be used if they meet one or more of the following: API Service Classification CH-4 API Service Classification CG-4 API Service Classification CF-4 ACEA Specification E3 ACEA Specification E2 Multi-viscosity diesel engine oils are preferred. If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by 50%. SAE 15W-40 SAE 10W-40 SAE 5W-30 SAE 5W C 20 C 10 C 0 C -10 C -20 C -30 C -40 C 86 F 68 F 50 F 32 F 14 F -4 F -22 F -40 F SAE 30 TS1668 UN 05OCT01 Extended service intervals may apply when John Deere preferred engine oils are used. Consult your John Deere dealer for more information. PLUS-50 is a registered trademark of Deere & Company. TORQ-GARD SUPREME is a registered trademark of Deere & Company DX,ENOIL 19 05OCT01 1/ PN=111

114 Maintenance Machine Transmission, Hydraulic System, Park Brake, and Differential Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oils are preferred: John Deere HY-GARD John Deere Low Viscosity HY-GARD Other oils may be used if they meet one of the following: John Deere Standard JDM J20C John Deere Standard JDM J20D Use John Deere BIO-HY-GARD 1 oil when a biodegradable fluid is required. TS1660 UN 10OCT97 HY-GARD is a registered trademark of Deere & Company BIO-HY-GARD is a trademark of Deere & Company 1 BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD should not be mixed with mineral oils because this reduces the biodegradability and makes proper oil recycling impossible. CED,TX03679, JUN00 1/ PN=112

115 Maintenance Machine 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. Consult your grease supplier before mixing different types of grease. TS1667 UN 30JUN99 DX,GREA JAN00 1/ PN=113

116 Maintenance Machine 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). John Deere COOL-GARD The following engine coolant is preferred for service: John Deere COOL-GARD Prediluted Coolant The following engine coolant is also recommended: John Deere COOL-GARD Coolant Concentrate in a 40 to 60% mixture of concentrate with quality water. John Deere COOL-GARD coolants do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval. Ethylene glycol base coolants Other fully formulated low silicate ethylene or propylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications: ASTM D6210 prediluted coolant ASTM D6210 coolant concentrate in a 40 to 60% mixture of concentrate with quality water Coolants meeting ASTM D6210 do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval. Other low silicate ethylene glycol base coolants for heavy-duty engines may also be used if they meet one of the following specifications: ASTM D5345 prediluted coolant ASTM D4985 coolant concentrate in a 40 to 60% mixture of concentrate with quality water Coolants meeting ASTM D5345 or ASTM D4985 require an initial charge of supplemental coolant additives, formulated for protection of heavy duty diesel engines against corrosion and cylinder liner erosion and pitting. They also require periodic replenishment of additives during the drain interval. Propylene glycol base coolants Fully formulated low silicate propylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications: ASTM D6211 prediluted coolant ASTM D6211 coolant concentrate in a 40 to 60% mixture of concentrate with quality water Coolants meeting ASTM D6211 do not require use of supplemental coolant additives, except for periodic replenishment during the drain interval. Freeze protection A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37 C (-34 F). A 50% mixture of propylene glycol engine coolant in water provides freeze protection to -33 C (-27 F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations. 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. IMPORTANT: Do not mix ethylene glycol and propylene glycol base coolants. DX,COOL OCT01 1/ PN=114

117 Maintenance Periodic Maintenance Service Your Machine at Specified Intervals Lubricate, make service checks and adjustments at intervals shown on the periodic maintenance chart (A) and on the following pages. Service 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. A Maintenance Chart T111207B UN 27AUG97 TX,50,JC SEP97 1/1 Check the Monitor Display Unit Regularly At the A 06 display, press SELECT. Then press SELECT again to turn the 0.1 Hour Meter Mode On or Off. T UN 22OCT97 TX,50,JC SEP97 1/2 When the 0.1 Hour Meter Mode is turned On, the hour meter reading (A) can be accessed during normal machine operation by pressing SELECT. The odometer reading will switch to the voltmeter reading, and then to the hour meter reading in hours and tenths of hour. Intervals on the periodic maintenance chart are for operating in normal conditions. If you operate your machine in severe conditions, you should service it at SHORTER INTERVALS. A Hour Meter Reading T UN 22OCT97 TX,50,JC SEP97 2/ PN=115

118 Maintenance Periodic Maintenance Opening Engine Side Shields and Service Doors CAUTION: Prevent possible injury from engine service door closing. Always keep service door in the open locked position when servicing the engine area. 1. Pull out on latch (A) to open lower engine service door. A Latch T106380B UN 24JAN97 TX,50,JC JUN00 1/2 2. Open service door to full extent. Gas cylinder (A) will lock door in place. A Cylinder T131518B UN 07JUN00 TX,50,JC JUN00 2/ PN=116

119 Maintenance Periodic Maintenance Locking Machine Frame CAUTION: Prevent possible injury from unexpected machine movement. Connect frame locking bar to both frames before you work in frame pivot area. 1. Align machine frames. 2. Remove quick lock ring (1) and pull locking pin (2) from hole. T161062B UN 29OCT02 3. Rotate locking bar (3) to align with hole in machine frame. 4. Install locking pin through hole in loader frame and end of locking bar. Install quick lock ring to secure locking bar in place. 1 Quick Lock Ring 2 Locking Pin 3 Locking Bar T161061B UN 29OCT02 HG31779, OCT02 1/ PN=117

120 Maintenance Periodic Maintenance Boom Lock CAUTION: Always install boom lock before working on or around this machine with the boom raised. Empty bucket and place in dump position before installing boom lock. 1. Raise boom. Empty bucket and place in dump position before installing boom lock (1). T161064B UN 29OCT02 2. Loosen hand bolt (2) and remove boom lock from side of machine. 3. Install lock on boom cylinder and lock lever facing to outside of machine and lower boom onto lock. 4. Tighten hand bolt. 5. Before removing boom lock from cylinder, raise boom slightly to relieve pressure. Return boom lock to storage position on side of machine and tighten hand hold. T161065B UN 29OCT02 1 Boom Lock 2 Hand Bolt HG31779, OCT02 1/ PN=118

121 Maintenance Periodic Maintenance Opening Grille Door Press down on release lever (1) to open grille door fully. Door will automatically lock open. Rotate stop (2) to release door lock. 1 Release Lever 2 Stop T146005B UN 26SEP01 T139740C UN 10AUG01 CED,OUOE002, SEP01 1/1 Fuel Tank CAUTION: Handle fuel carefully. If the engine is hot or running, DO NOT fill the fuel tank. DO NOT smoke while you fill fuel tank or work on fuel system. To avoid condensation, fill the fuel tank at the end of each day s operation. Shut off engine before filling. Specification Fuel Tank Capacity L (70 gal) CED,OUOE002, SEP98 1/1 Check Windshield Washer Fluid Level Open left engine side shield. Check fluid in windshield washer bottle (A). During winter season, use all season windshield washer fluid which will not freeze. A Windshield Washer Bottle T111207C UN 27AUG97 TX,50,JC SEP97 1/ PN=119

122 Maintenance Periodic Maintenance Maintenance and Repair Record Keeping System The checklist on the following page 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. Use the second copy of this form (immediately preceding the Service Literature page inside the back cover). Do not tear out or mark on Checklist in the Periodic Maintenance chapter; keep it to make extra copies. T7511CO UN 27JUN91 TX,50,RB JUN00 1/ PN=120

123 Maintenance Periodic Maintenance OILSCAN PLUS, COOLSCAN PLUS, and 3-Way Coolant Test Kit Oilscan Plus T UN 16SEP97 3-Way Coolant Test Kit T UN 16SEP97 Oilscan Plus, Coolscan Plus and 3-Way Coolant Test Kit are John Deere fluid sampling products to help you monitor machine performance 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. and/or fluid change interval. Certain systems require more frequent sampling. Consult your John Deere dealer on a maintenance program for your specific application. Your dealer has the sampling products and expertise to assist you in lowering your overall operating costs through fluid sampling. Oil and coolant samples should be taken from each system on a periodic basis, usually prior to a filter OILSCAN PLUS is a trademark of Deere & Company COOLSCAN PLUS is a trademark of Deere & Company CED,OUO1040, JUN98 1/ PN=121

124 Maintenance Periodic Maintenance Service Intervals 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 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily. Inspect tires and check pressure Check wheel retainer cap screws Clean or replace air cleaner elements Check and clean air inlet cover Check recovery tank coolant level Clean air cleaner dust unloader valve Check engine oil level Change engine break-in oil and replace filter Grease loader linkage and cylinder pivots Grease front steering cylinder pivots Grease oscillating rear axle Model: 624H PIN/Serial Number: As Required Inspect belts Drain water from fuel tank Drain and clean primary fuel filter Every 10 Hours or Daily Check hydraulic system oil level Check transmission oil level After First 100 Hours Change transmission oil and replace filter Every 100 Hours Grease rear steering cylinder pivots Check and clean cab fresh air filter Check and clean cab recirculating air filter Customer: Delivery Date: Oil Sampling Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form. Maintenance recommendations supplied by OILSCAN 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. Grease drive line sliding joints Check receiver dryer moisture indicator Check radiator coolant level Comments: Every 250 Hours Drain and refill engine oil Replace engine oil filter Date: Hour Meter Reading: Maintenance Performed By: Grease drive line sliding joints, upper and lower Check air intake hoses Check battery water level Check coolant conditioner Replace final fuel filter Replace primary fuel filter Comments: Every 500 Hours Replace hydraulic system return filter Grease rear oscillating support cover Replace hydraulic reservoir breather filter Replace transmission oil filter Check park brake oil level Check front and rear differential oil level Date: Hour Meter Reading: Maintenance Performed By: OILSCAN is a trademark of Deere & Company. Continued on next page PN=122 CED,OUOE002, DEC01 1/2

125 Maintenance Periodic Maintenance Remove and clean engine crankcase vent tube Replace air cleaner dust unloader valve Replace air cleaner elements Check radiator coolant and hoses Comments: Every 1000 Hours Drain and refill transmission oil Grease frame hinge pivots Drain and refill park brake oil Date: Hour Meter Reading: Maintenance Performed By: Every 2000 Hours Check and adjust engine valve lash Comments: Date: Hour Meter Reading: Maintenance Performed By: Drain, flush and refill hydraulic system oil Clean hydraulic system fill strainer Comments Every 3000 Hours Drain and refill front and rear differential oil Clean axle differential recirculating screen Date: Hour Meter Reading: Maintenance Performed By: REQUIRED PARTS Insure 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. Part Number ASI 250 HOURS 500 HOURS 1000 HOURS 3000 HOURS Engine Oil Filter RE Primary Fuel Filter RE Final Fuel Filter RE Transmission Filter AT (S.N ) AT (S.N ) Hydraulic System Return AT Filter Air Filter Primary AT Air Filter Secondary AT Hydraulic Reservoir AM Breather Filter John Deere PLUS-50 Oil (S.N ) 20 L (21 qt) 20 L (21 qt) 20 L (21 qt) 20 L (21 qt) 20 L (21 qt) (S.N ) 21 L (22 qt) 21 L (22 qt) 21 L (22 qt) 21 L (22 qt) 21 L (22 qt) HY-GARD Transmission and Hydraulic Oil 72 L (76 qts) 28 L (30 qts) 189 L (50 gal) Coolant Conditioner (as TY16004 needed) OILSCAN PLUS Kit: (10 samples per kit) Diesel Engine Oil AT Transmission Oil AT Axle Oil AT Hydraulic Oil AT COOLSCAN PLUS Kit AT PLUS-50 is a trademark of Deere & Company. HY-GARD is a trademark of Deere & Company. OILSCAN PLUS is a trademark of Deere & Company. COOLSCAN PLUS is a trademark of Deere & Company. CED,OUOE002, DEC01 2/ PN=123

126 Maintenance As Required Check Tire Pressure CAUTION: Explosive separation of a tire and rim parts can cause serious injury or death. Always maintain the correct tire pressure. DO NOT inflate tires above the recommended pressure. Inspect tires and wheels daily. DO NOT operate with low pressure, cuts, bubbles, damaged rims, or missing lug bolts. Carefully inspect any tire and rim assembly that has been run flat or severely underinflated before reinflating the tire. Damage to the rim and tire may have developed. Call your authorized dealer or a qualified repair service to inspect the rim and tire assembly and make necessary repairs. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. NEVER cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion. Do not attempt to mount a tire if you do not have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service. Check tire pressure with an accurate gauge having 7.0 kpa (0.07 bar) (1 psi) graduations. TS211 UN 23AUG88 T108057B UN 12MAR97 1. Remove pipe cap (A). 2. Shut off air supply to hose. 3. Move gauge hand to correct pressure. 4. Lock air chuck on tire valve. T87502 UN 21OCT88 A Pipe Cap Continued on next page TX,55,JC MAR97 1/ PN=124

127 Maintenance As Required 5. Turn on air supply. Stand to front or rear of tire when you add air to tire. 6. After tire is at correct pressure, shut off air supply. Release chuck. (See following Tire Pressure chart.) 7. Inspect tire for damage. TX,55,JC MAR97 2/2 Tire Pressures Item Measurement Specification Tire Pressures Bias Shipping Pressure Front Pressure 379 kpa (3.79 bar) (55 psi) Rear Pressure 310 kpa (3.10 bar) (45 psi) 17.5 R25 Radial Shipping Front Pressure 414 kpa (4.14 bar) (60 psi) Pressure Rear Pressure 276 kpa (2.75 bar) (40 psi) Bias Shipping Pressure Front Pressure 310 kpa (3.10 bar) (45 psi) Rear Pressure 241 kpa (2.41 bar) (35 psi) 20.5 R25 Radial Shipping Front Pressure 310 kpa (3.10 bar) (45 psi) Pressure Rear Pressure 207 kpa (2.06 bar) (30 psi) 1 Tire shipping pressure may not be the same as tire operating pressure. You may change tire pressures to suit working condition according to tire manufacturer s recommendations. TX,55,JC SEP97 1/1 Tighten Wheel Retainer Cap Screws NOTE: Tighten cap screws after first 10 hours, then again after first 50 hours of loaded operation. After that, tighten as required. Tighten wheel cap screws. Tighten Wheel Retainer Cap Screws Specification Wheel Retainer Cap Screws Dry Torque N m (400 lb-ft) TX,55,JC AUG02 1/ PN=125

128 Maintenance As Required Check Fire Extinguisher If Equipped IMPORTANT: Dry powder has a tendency to pack in the bottom of an extinguisher. Before using extinguisher (A), turn it upside down and shake it until you feel the powder move. Check gauge. If fire extinguisher is not fully charged, charge or replace it. NOTE: The fire extinguisher must be charged or replaced after any use. A Fire Extinguisher T UN 17FEB98 CED,OUO1021, MAR98 1/ PN=126

129 Maintenance As Required Clean or Replace Air Cleaner Elements 1. Open left service door. 2. Remove air cleaner cover by releasing clips (A). 3. Remove primary element (B). 4. Remove secondary element (C). A Clips (3 used) B Primary Element C Secondary Element T111212B UN 27AUG97 T111216B UN 27AUG97 T111211B UN 27AUG97 TX,55,JC SEP97 1/1 Check Air Inlet Cover 1. Open left engine side shield. 2. Check cover (A) for debris. Remove debris if necessary. 3. Close side shield. A Inlet Cover T111239B UN 27AUG97 TX,55,JC SEP97 1/ PN=127

130 Maintenance As Required Inspect Serpentine Belt With Air Conditioning T111242B UN 27AUG97 T UN 30SEP98 1. Check belt (A) regularly for wear, especially for cracks at the bottom of grooves and for frayed edges. IMPORTANT: If belt is stretched to the point that the belt tensioner is against its stop, belt must be replaced. 2. If necessary, replace belt. 3. Hold tension adjuster assembly away from belt while removing old belt and installing new belt. A Belt T UN 30SEP98 TX,55,JC SEP97 1/ PN=128

131 Maintenance As Required Drain Fuel Tank Sediment NOTE: Petcock is located at left front of machine frame bottom guard (A). 1. Loosen petcock (B). 2. Drain water and sediment into a container. 3. Tighten petcock. 4. Dispose of waste properly. A Bottom Guard B Petcock T UN 19MAR98 T103144C UN 12DEC96 CED,OUOE002, SEP98 1/ PN=129

132 Maintenance As Required Drain and Clean Primary Fuel Filter 1. Open left engine side shield to access primary fuel filter. 2. Put container under drain valves (B and C). 3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base. 4. Remove hand primer (A) from fuel filter base. Disassemble hand primer assembly and clean out any debris. T111238D UN 27AUG97 A Hand Primer B Drain Valve (Primary Fuel Filter) C Drain Valve (Final Fuel Filter) T8387AE UN 17DEC94 TX,55,JC SEP97 1/2 5. Remove fuel inlet line (A) and fuel drain plug (C). 6. Flush any debris from filter base (B). 7. Install fuel inlet drain plug and fuel inlet line. 8. Assemble primer assembly and install onto fuel filter base. 9. Install filter element to fuel filter base. 10. Bleed fuel system. T8387AD UN 17DEC Close side shield. 12. Dispose of waste properly. A Fuel Inlet line B Filter Base C Fuel Drain Plug TX,55,JC SEP97 2/ PN=130

133 Maintenance Every 10 Hours or Daily Check Recovery Tank Coolant Level With the engine cold, coolant level must be between FULL and ADD marks on the recovery tank. If coolant is below the ADD mark, add coolant to the recovery tank. CAUTION: Prevent possible injury from hot spraying coolant. DO NOT remove radiator filler cap unless engine is cool. Then turn cap slowly to the stop. Release all pressure before you remove cap. T111210B UN 27AUG97 If recovery tank is empty, check for leaks. Repair as required. Add coolant to the radiator and the 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 filler neck. A Coolant Recovery Tank Radiator Cap T6274AQ UN 18OCT88 TX,60,JC SEP97 1/1 Clean Air Cleaner Dust Unloader Valve IMPORTANT: A missing, damaged, or hardened dust unloader valve will make the dust cup precleaner ineffective, causing very short element life. Valve should suck closed above 1/3 engine speed. Squeeze dust valve (A) 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. T111210C UN 27AUG97 A Dust Valve TX,60,JC SEP97 1/ PN=131

134 Maintenance Every 10 Hours or Daily Check Engine Oil Level IMPORTANT: If oil level is low, the engine can be damaged. DO NOT operate the engine when oil level is below the ADD mark. The most accurate oil level reading is obtained when the engine is cold, before starting the engine for the day s operation. 1. Park machine on a level surface. 2. Push park brake switch to ON. 3. Make sure dipstick (A) is fully seated. A Dipstick B Filler Cap T111215B UN 27AUG97 4. BEFORE THE ENGINE IS STARTED: The engine is full when oil level is in the cross hatched area. It is acceptable to run the engine when the oil level is above the ADD mark. 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 ADD mark. 5. If necessary, remove filler cap (B) to add oil. See Diesel Engine Oil. (Section 3-1.) TX,60,JC SEP97 1/ PN=132

135 Maintenance Every 10 Hours or Daily Check Hydraulic Oil Level IMPORTANT: Prevent possible hydraulic pump damage. DO NOT operate engine without oil in the hydraulic reservoir. 1. Park machine on a level surface. 2. Lower equipment to the ground. 3. When oil is cold, oil level must be in FULL range on sight glass (B). 4. If necessary, remove filler cap (A) and add oil. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.) 5. Install filler cap. A Filler Cap B Sight Glass T UN 19FEB97 CED,OUO1021, MAR98 1/ PN=133

136 Maintenance Every 10 Hours or Daily Check Transmission Oil Level IMPORTANT: Prevent possible transmission damage. DO NOT operate engine when transmission oil level is low. 1. Before starting engine, check oil level on dipstick (A). If oil is to lower mark when oil is cold, there is sufficient oil to start the engine. 2. If necessary, add oil at filler tube. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.) T106381B UN 24JAN97 3. Install dipstick. 4. Start engine. 5. Engage service brakes. Move clutch cut-off switch to disengaged position. 6. Move auto transmission switch to Off position. Release park brake. 7. Move transmission control lever to 3rd speed forward "3F" position. A Dipstick T UN 23OCT96 Operate engine at fast idle for 30 seconds. Reduce engine speed to slow idle and place transmission control lever in neutral N for 15 seconds. Repeat this step until transmission oil reaches normal operating temperature (approximately (80 C) (175 F). 8. Move transmission control lever to neutral N and engage neutral lock. Lower all equipment to ground. 9. Push park brake switch to ON. 10. Release service brakes. 11. Check oil level with engine at slow idle. With oil at normal operating temperature, oil level should be between HOT marks on dipstick. TX,60,JC AUG96 1/ PN=134

137 Maintenance After First 100 Hours Change Engine Break-In Oil and Replace Filter IMPORTANT: If fuel sulphur content exceeds 0.5 percent, change engine oil at 1/2 the normal interval. 1. Run engine to warm oil. 2. Park machine on a level surface. 3. Lower equipment to ground. T108430B UN 08APR97 4. Move transmission control lever to neutral "N". Engage neutral lock. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine. T106389B UN 24JAN97 5. Push park brake switch to ON. A Drain Valve 6. Turn key switch to Off. 7. Attach hose to drain valve (A). Allow oil to drain into a container. Dispose of waste oil properly. Continued on next page TX,75,JC DEC01 1/ PN=135

138 Maintenance After First 100 Hours 8. Turn filter (B) counterclockwise to remove. 9. Clean mounting surface. Apply thin film of oil to gasket of new filter. NOTE: Before installing filter, to assure proper lubrication at start-up, fill the engine oil filter with engine oil. 10. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface. 11. Tighten 1/2 1 turn more. T111215C UN 27AUG Tighten drain valve. 13. Remove filler cap (A). A Filler Cap B Filter 14. Fill engine with oil. (See Fuels and Lubricants chapter.) Engine Oil With Filter Specification (S.N ) Capacity... (S.N ) Capacity L (21 qt) 21 L (22 qt) 15. Install filler cap. 16. Start engine and run at slow idle. 17. Check that engine oil pressure light on monitor goes out and audible alarm stops immediately. If not, stop engine immediately and find cause. 18. Stop the engine. Check oil level. The engine is full when oil level is in the cross hatched area on the dipstick. 19. Check for any leakage at filter. Tighten filter only enough to stop leakage. TX,75,JC DEC01 2/ PN=136

139 Maintenance After First 100 Hours Change Transmission Oil NOTE: Change after first 100 hours and then every 1000 hours. 1. Operate machine under load until transmission oil reaches normal operating temperature. 2. Park machine on a level surface. 3. Lower bucket to ground. 4. Move transmission control lever to neutral "N". Engage neutral lock. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine. 5. Push park brake switch to ON. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing oil. 6. Install frame locking bar. IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 7. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger. Release accelerator pedal to slow idle. 8. Turn key switch to Off. Let machine sit for approximately 10 minutes. Continued on next page CED,OUOE002, OCT02 1/ PN=137

140 Maintenance After First 100 Hours NOTE: Drain plug is magnetic. If an excessive amount of metal particles appear on plug, see your John Deere dealer. 9. Remove bottom guard, if equipped. Remove plug (A), located inside hole in bottom guard, to drain oil. Allow oil to drain into a container. Dispose of waste oil properly. 10. Install drain plug. A Drain Plug T106393C UN 24JAN97 CED,OUOE002, OCT02 2/3 11. Remove transmission dipstick (A). 12. Fill transmission with oil. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.) Specification Transmission Case and Filter Oil Capacity L (29 qt) 13. Start engine and run for 2 minutes. 14. Move transmission control lever to neutral "N", and engage neutral lock. A Dipstick T106381B UN 24JAN Check oil level with oil at operating temperature. Oil must be between marks on dipstick. CED,OUOE002, OCT02 3/ PN=138

141 Maintenance After First 100 Hours Replace Transmission Oil Filter 1. Operate machine under load until transmission oil reaches normal operating temperature. 2. Park machine on a level surface. 3. Lower bucket to ground. 4. Move transmission control lever to neutral "N". Engage neutral lock. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine. 5. Push park brake switch to ON. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing oil filter. 6. Install frame locking bar. IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 7. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger. Release accelerator pedal to slow idle. 8. Turn key switch to Off. Continued on next page TX,80,JC OCT02 1/ PN=139

142 Maintenance After First 100 Hours 9. Turn filter (A) counterclockwise to remove. 10. Clean mounting surface. Apply thin film of oil to gasket of new filter. 11. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface. 12. Tighten 3/4 of a full turn more. 13. Start engine and run for 2 minutes. 14. Move transmission control lever to neutral "N", and engage neutral lock. A Transmission Oil Filter T131555C UN 14JUN00 TX,80,JC OCT02 2/3 15. Check oil level. Oil must be between marks on dipstick (A). Add oil if necessary. 16. Check for leaks around the filter base. Tighten filter only enough to stop leaks. A Dipstick T106381B UN 24JAN97 TX,80,JC OCT02 3/ PN=140

143 Maintenance Every 100 Hours Grease Loader Linkage and Cylinder Pivots Six Points T160586B UN 17OCT02 Three Points, Right Side Shown T106375B UN 24JAN97 CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. 624H Loader Lubricating Points Lower bucket flat on ground. Lubricate following 13 points until grease escapes around seals. See Grease. (Section 3-1.) Lubricate every 10 hours when operating in severe conditions such as deep mud, water, or snow. Four Points, Right Side Shown T106379C UN 10APR97 Continued on next page TX,70,JC SEP97 1/ PN=141

144 Maintenance Every 100 Hours 12 Points, Right Side Shown T106376D UN 03SEP97 2 Points, Left Side Shown T106377B UN 24JAN97 TC62H Lubricating points Lower bucket flat on ground. Lubricate following 26 points until grease escapes around seals. See Grease. (Section 3-1.) Lubricate every 10 hours when operating in severe conditions such as deep mud, water, or snow. 12 Points, Right Side Shown T106378C UN 04MAR97 TX,70,JC SEP97 2/ PN=142

145 Maintenance Every 100 Hours Grease Front Steering Cylinder Pivots CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. Lubricate each point with three shots of grease. See Grease. (Section 3-1.) Grease daily when operating in severe conditions such as deep mud, water or snow. Two Points, Right Side Shown T106372B UN 28JAN97 TX,70,JC OCT02 1/1 Grease Oscillating Rear Axle and Rear Steering Cylinder Pivots CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. Lubricate oscillating rear axle with 10 shots of grease and rear steering cylinder pivots with three shots of grease. See Grease. (Section 3-1.) Grease daily when operating in severe conditions such as deep mud, water, or snow. Four Points T106381C UN 24JAN97 TX,70,JC OCT02 1/1 Check Cab Fresh Air Filter If Equipped With Cab 1. Open cab fresh air filter door by pulling up on lever (A) to the left of the operator s seat. A Lever T105479B UN 12DEC96 Continued on next page TX,70,JC SEP98 1/ PN=143

146 Maintenance Every 100 Hours 2. Remove filter assembly by turning knob (A). A Knob T UN 10SEP98 Continued on next page TX,70,JC SEP98 2/ PN=144

147 Maintenance Every 100 Hours NOTE: If operating in dusty conditions, cab fresh air filter should be checked and cleaned as necessary. 3. Release clips (B). 4. Remove filter (C). Replace if damaged. 5. Clean filter in one of these ways: 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. Tap filter on a flat surface with the dirty side down. Use compressed air opposite to the normal air flow. Wash the filter in warm, soapy water. Flush the filter. Let it dry before using the heater, defroster, or air conditioner. 6. Remove dust from filter housing. 7. Install filter and filter duct work. T105493B UN 12DEC96 8. Install filter assembly. Close cab fresh air filter door. B Clips C Filter T105494B UN 12DEC96 TX,70,JC SEP98 3/ PN=145

148 Maintenance Every 100 Hours Check Cab Recirculating Air Filter If Equipped With Cab NOTE: The cab recirculating air filter is located next to the seat. 1. Loosen wing bolt (1) holding grille. Remove grille. 2. Remove filter. 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. 1 Wing Bolt T159520B UN 18SEP02 3. Clean filter in one of these ways: Tap it on a flat surface with the dirty side down. Use compressed air opposite to the normal air flow. 4. Install filter. 5. Install grille. HG31779, SEP02 1/ PN=146

149 Maintenance Every 250 Hours Grease Front Driveline Sliding Joint CAUTION: Prevent possible injury from unexpected machine movement. Turn engine off and lower bucket to ground before lubricating. NOTE: To prevent plug loss, lubricate the machine when it is fully articulated or half articulated and NOT in the straight position. Install frame lock bar using hole (1) for articulated position. T161066B UN 29OCT02 1 Frame Locking Bar TX,75,JC OCT02 1/2 T UN 02NOV98 Lubricate until grease escapes around vent holes in drive shaft end. See Grease. (Section 3-1.) NOTE: Grease daily when operating in deep mud, water, or snow. TX,75,JC OCT02 2/ PN=147

150 Maintenance Every 250 Hours Check Receiver Dryer Moisture Indicator IMPORTANT: Prevent possible compressor damage. If receiver dryer moisture eye color indicates "WET" (pink) dryer is saturated and should be changed within the next 100 machine hours to prevent further buildup of moisture in the refrigerant. 1. Open right side engine side panel. 2. Check sight glass (A) to determine if color indicates dryer is dry (blue) or wet (pink). A Sight Glass T111214D UN 27AUG97 3. If wet (pink), see your authorized dealer within the next 100 machine hours to service the receiver dryer. 4. Close engine side panel. TX,75,JC SEP97 1/1 Check Radiator Coolant Level CAUTION: Prevent possible injury from hot spraying coolant. DO NOT remove radiator filler cap unless engine is cool. Then turn cap slowly to the stop. Release air to relieve all pressure before you remove cap. 1. Slowly remove cap. Coolant level must be at bottom of the filler neck. NOTE: If radiator coolant level is low, check for leaks on radiator cap, and hose connections between radiator and coolant recovery tank. T6642EK UN 01NOV88 2. Add coolant, if necessary. 3. Install filler cap. TX,75,JC OCT02 1/ PN=148

151 Maintenance Every 250 Hours Change Engine Oil and Replace Filter IMPORTANT: If fuel sulphur content exceeds 0.5 percent, change engine oil at 1/2 the normal interval. NOTE: If engine has not run 250 hours before the season changes, change oil. 1. Run engine to warm oil. 2. Park machine on a level surface. T108430B UN 08APR97 3. Lower equipment to ground. 4. Move transmission control lever to neutral "N". Engage neutral lock. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine. A Drain Valve T106389B UN 24JAN97 5. Push park brake switch to ON. 6. Turn key switch to Off. 7. Attach hose to drain valve (A). Allow oil to drain into a container. Dispose of waste oil properly. Continued on next page TX,75,JC DEC01 1/ PN=149

152 Maintenance Every 250 Hours 8. Turn filter (B) counterclockwise to remove. 9. Clean mounting surface. Apply thin film of oil to gasket of new filter. NOTE: Before installing filter, to assure proper lubrication at start-up, fill the engine oil filter with engine oil. 10. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface. 11. Tighten 1/2 1 turn more. T111215C UN 27AUG Tighten drain valve. 13. Remove filler cap (A). A Filler Cap B Filter 14. Fill engine with oil. See Diesel Engine Oil. (Section 3-1.) Engine Oil With Filter Specification (S.N ) Capacity... (S.N ) Capacity L (21 qt) 21 L (22 qt) 15. Install filler cap. 16. Start engine and run at slow idle. 17. Check that engine oil pressure light on monitor goes out and audible alarm stops immediately. If not, stop engine immediately and find cause. 18. Stop the engine. Check oil level. The engine is full when oil level is in the cross hatched area on the dipstick. 19. Check for any leakage at filter. Tighten filter only enough to stop leakage. TX,75,JC DEC01 2/ PN=150

153 Maintenance Every 500 Hours Grease Upper and Lower Drive Line Sliding Joints CAUTION: Prevent possible injury from unexpected machine movement. Turn engine off and lower bucket to ground before lubricating. Install frame lock bar using hole (1) for articulated position. 1 Frame Locking Bar T161066B UN 29OCT02 TX,80,JC OCT02 1/2 T UN 04NOV98 Lubricate until grease escapes around vent holes in drive shaft end. See Grease. (Section 3-1.) NOTE: Grease daily when operating in deep mud, water, or snow. TX,80,JC OCT02 2/ PN=151

154 Maintenance Every 500 Hours Check Air Intake Hoses Check hoses (A) for cracks. Check hose clamps for tightness. A Hose T111237B UN 27AUG97 TX,80,JC SEP97 1/ PN=152

155 Maintenance Every 500 Hours 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. TS203 UN 23AUG88 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 TX,75,DH APR93 1/ PN=153

156 Maintenance Every 500 Hours 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. T6996DB UN 09SEP03 3. Disconnect battery clamps, grounded clamp first. A Battery Post B Fill Tube C Electrolyte Level Range T6996DA UN 09SEP03 TX,75,DH APR93 2/3 4. Clean battery terminals (A) and clamps with a stiff brush. 5. Apply lubricating grease (B) around battery terminal base only. 6. Install and tighten clamps, grounded clamp last. A Battery Terminal B Lubricating Grease T6758AA UN 21OCT88 TX,75,DH APR93 3/ PN=154

157 Maintenance Every 500 Hours Replace Primary Fuel Filter 1. Turn filter locking ring (A) counterclockwise to remove filter. Allow sediment to drain into a container. Dispose of waste properly. 2. Turn sediment bowl (B) counterclockwise to remove from filter assembly. 3. Clean filter base. 4. Install new filter. (Follow instructions on filter.) T111238C UN 27AUG97 5. Install sediment bowl. 6. Bleed fuel system. See Bleeding Fuel System. (Section 3-1.) A Filter Locking Ring B Sediment Bowl TX,80,JC OCT02 1/1 Replace Final Fuel Filter 1. Turn filter locking ring (A) counterclockwise to remove filter. Allow sediment to drain into a container. Dispose of waste properly. 2. Clean filter base. 3. Install new filter. (Follow instructions on filter.) 4. Bleed fuel system T111238B UN 27AUG97 A Filter Locking Ring TX,80,JC SEP97 1/ PN=155

158 Maintenance Every 500 Hours Replace Hydraulic System Return Filter CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing filter. 1. Turn filter (A) counterclockwise to remove. 2. Clean mounting surface. Apply thin film of oil to gasket of new filter. 3. Install new filter. Tighten filter 3/4 of a full turn after seal contacts mounting base. 4. Fully loosen filter element. Repeat step 3. Cover removed for clarity of photograph A Hydraulic System Return Filter T131555B UN 08JUN00 5. Start engine. Check for leaks around filter base. Tighten filter only enough to stop leaks. 6. Stop engine. Check oil level. TX,80,JC JUN00 1/1 Grease Rear Oscillating Support Cover CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. Lubricate point (A) with three shots of grease. See Grease (Section 3-1.) Grease daily when operating in severe conditions such as deep mud, water or snow. T106389C UN 31JAN97 A Lubrication Fitting TX,70,JC FEB97 1/ PN=156

159 Maintenance Every 500 Hours Replace Hydraulic Reservoir Breather Filter Hydraulic reservoir breather filter is located on back side of reservoir under the hood. 1. Turn filter (A) counterclockwise to remove. 2. Install new filter and tighten until snug. A Filter T UN 02NOV98 CED,OUOE035, NOV98 1/ PN=157

160 Maintenance Every 500 Hours Replace Transmission Oil Filter 1. Operate machine under load until transmission oil reaches normal operating temperature. 2. Park machine on a level surface. 3. Lower bucket to ground. 4. Move transmission control lever to neutral "N". Engage neutral lock. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine. 5. Push park brake switch to ON. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing oil filter. 6. Install frame locking bar. IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 7. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger. Release accelerator pedal to slow idle. 8. Turn key switch to Off. Continued on next page TX,80,JC OCT02 1/ PN=158

161 Maintenance Every 500 Hours 9. Turn filter (A) counterclockwise to remove. 10. Clean mounting surface. Apply thin film of oil to gasket of new filter. 11. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface. 12. Tighten 3/4 of a full turn more. 13. Start engine and run for 2 minutes. 14. Move transmission control lever to neutral "N", and engage neutral lock. A Transmission Oil Filter T131555C UN 14JUN00 TX,80,JC OCT02 2/3 15. Check oil level. Oil must be between marks on dipstick (A). Add oil if necessary. 16. Check for leaks around the filter base. Tighten filter only enough to stop leaks. A Dipstick T106381B UN 24JAN97 TX,80,JC OCT02 3/ PN=159

162 Maintenance Every 500 Hours Check Park Brake Oil Level 1. Remove plug (A). Check oil level. IMPORTANT: Oil level must be at bottom of check plug on the side of the park brake. Too much oil can cause overheating. Too little oil can cause bearing failure. 2. Add oil if necessary. Allow 2 minutes for oil to settle to bottom of level plug. 3. Check oil level and install plug. T UN 14APR98 A Plug T OCT02 CED,OUOE002, OCT02 1/ PN=160

163 Maintenance Every 500 Hours Check Front and Rear Differential Oil Level NOTE: Dipsticks are located on left front and left rear axle housing. 1. Clean area around dipstick IMPORTANT: To properly check oil level, do not thread dipstick into dipstick port. 2. Remove dipstick (A). 3. Oil must be to FULL level on dipstick. Left Front Differential Shown T106373B UN 29JAN97 IMPORTANT: Each differential housing has three separate components. Allow 10 minutes for oil to stabilize in each sump before checking. A Dipstick 4. If necessary, add oil. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.) NOTE: If axle is hot and dipstick too warm to hold with bare hands, the oil will expand and it is normal for it to be up to 25 mm (1 in.) above FULL mark. Do not adjust level. If oil level is above FULL mark, drain oil and check oil level. 5. Install dipstick. TX,80,JC SEP98 1/ PN=161

164 Maintenance Every 1000 Hours Clean Engine Crankcase Vent Tube Remove clamp at valve cover. IMPORTANT: Do not pull on hose. Connector damage may occur. Remove crankcase vent tube (A) and clean. A Crankcase Vent Tube T111240B UN 27AUG97 TX,85,JC SEP98 1/1 Replace Air Cleaner Dust Unloader Valve NOTE: A missing, damaged, or hardened dust valve will cause the air filter elements to be ineffective. Replace dust unloader valve (A). A Dust Unloader Valve T111210C UN 27AUG97 TX,85,JC SEP98 1/1 Replace Air Cleaner Elements 1. Remove cover. 2. Remove primary element (A). 3. Remove secondary element (B). 4. Clean air cleaner canister. 5. Install new elements making sure secondary element is centered in canister. T UN 16SEP98 6. Install cover. A Primary Element B Secondary Element T UN 16SEP98 TX,85,JC SEP98 1/ PN=162

165 Maintenance Every 1000 Hours Check Coolant CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Only remove filler cap when engine is cold or when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. IMPORTANT: John Deere Liquid Coolant Conditioner does not protect against freezing. Coolant conditioner prevents rust, scale, and liner cavitation. TS281 UN 23AUG88 NOTE: Check coolant every 500 hours or 6 months, or when replacing 1/3 or more of coolant. Add coolant conditioner as necessary. 1. Remove radiator cap (A) and test coolant solution. Use one of the following kits to check coolant. 3-WAY Heavy Duty Coolant Test Kit (TY16175) Coolant test strips provide an effective method to check freeze point and additive levels of engine coolant. See your authorized dealer for 3-WAY Heavy Duty Coolant Test Kit and follow instructions on kit. T UN 20FEB98 CoolScan Plus For a more thorough evaluation of coolant, perform CoolScan Plus analysis, where available. See your authorized dealer for information about CoolScan Plus. 2. Add TY16004 John Deere Coolant Conditioner or equivalent non-chromatic conditioner/rust inhibitor as necessary. Follow instructions on container for amount. 3-Way Test Kit T UN 13AUG97 Specification Cooling System Capacity L (23 qt) approximate 3. Install cap. CoolScan Plus T UN 13AUG97 CoolScan Plus is a trademark of Deere & Company. CED,OUOE002, SEP98 1/ PN=163

166 Maintenance Every 1000 Hours Check Radiator Hoses 1. Check upper (A) and lower radiator hoses for cracks and leaks. Replace if necessary. 2. Tighten clamps. Upper Radiator Hose Shown T111237C UN 27AUG97 CED,TX03679, JUN00 1/ PN=164

167 Maintenance Every 1000 Hours Change Transmission Oil NOTE: Change after first 100 hours and then every 1000 hours. 1. Operate machine under load until transmission oil reaches normal operating temperature. 2. Park machine on a level surface. 3. Lower bucket to ground. 4. Move transmission control lever to neutral "N". Engage neutral lock. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine. 5. Push park brake switch to ON. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing oil. 6. Install frame locking bar. IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 7. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger. Release accelerator pedal to slow idle. 8. Turn key switch to Off. Let machine sit for approximately 10 minutes. Continued on next page CED,OUOE002, OCT02 1/ PN=165

168 Maintenance Every 1000 Hours NOTE: Drain plug is magnetic. If an excessive amount of metal particles appear on plug, see your John Deere dealer. 9. Remove bottom guard, if equipped. Remove plug (A), located inside hole in bottom guard, to drain oil. Allow oil to drain into a container. Dispose of waste oil properly. 10. Install drain plug. A Drain Plug T106393C UN 24JAN97 CED,OUOE002, OCT02 2/3 11. Remove transmission dipstick (A). 12. Fill transmission with oil. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.) Specification Transmission Case and Filter Oil Capacity L (29 qt) 13. Start engine and run for 2 minutes. 14. Move transmission control lever to neutral "N", and engage neutral lock. A Dipstick T106381B UN 24JAN Check oil level with oil at operating temperature. Oil must be between marks on dipstick. CED,OUOE002, OCT02 3/ PN=166

169 Maintenance Every 1000 Hours Grease Frame Hinge Pivots CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. Lubricate each point with a minimum of three shots of grease and until grease escapes around the seals. See Grease. (Section 3-1.) Two Points T106386C UN 10MAR97 TX,85,JC JUN00 1/ PN=167

170 Maintenance Every 1000 Hours Check Park Brake 1. Start engine. CAUTION: Prevent possible injury from sudden machine stop. Fasten seat belt for this check. 2. Fasten seat belt. 3. Move park brake switch (A) to OFF, and move transmission control lever to 1st gear forward. T UN 13FEB98 4. Drive machine at 3 mph and move park brake switch to ON. Machine must stop within 2 m(6 ft), and transmission must shift to neutral. A Park Brake Switch 5. If repair is necessary, see your authorized dealer. TX,85,JC SEP98 1/ PN=168

171 Maintenance Every 1000 Hours Change Park Brake Oil CAUTION: Prevent possible injury from unexpected machine movement. Always install frame locking bar. IMPORTANT: Oil must be at bottom of the check plug on the side of the park brake. Too much oil can cause overheating; too little can cause bearing failure. Park Brake Oil Specification Park Brake Oil Capacity ml (10 oz) T UN 14APR98 1. Remove plug (A). 2. Drain oil into a container. Dispose of waste oil properly. 3. Add John Deere HY-GARD oil. Allow oil to settle for approximately 2 minutes after filling. 4. Drain or add oil if necessary. 5. Install plug. T OCT02 A Plug HY-GARD is a trademark of Deere & Company. CED,OUOE002, OCT02 1/ PN=169

172 Maintenance Every 2000 Hours Adjust Engine Valve Lash (Clearance) See your authorized dealer. TX03679,00017DD 19 08MAY01 1/ PN=170

173 Maintenance Every 3000 Hours Change Hydraulic System Oil 1. Lower bucket to the ground. 2. Stop engine. 3. Turn key switch to On. NOTE: Return-to-carry (B) must be OFF for float detent to operate. 4. Move hydraulic control lever to float detent position. Later Machines One Lever Design T159423I UN 17SEP02 CAUTION: Prevent possible injury from unexpected boom movement. The bucket may jump up when ride control switch is turned ON. Clear all bystanders from area. 5. Cycle ride control switch (C) from OFF to ON. 6. Push pilot enable/boom down switch (A) to release accumulator pressure. 7. Turn key switch Off. Later Machines Two Lever Design T156774G UN 27JUN02 A Return-to-Carry Switch B Ride Control Switch C Pilot Enable/Boom Down Switch TX,87,JC OCT98 1/3 8. Remove hydraulic reservoir filler cap (A). A Filler Cap T UN 19FEB97 Continued on next page TX,87,JC OCT98 2/ PN=171

174 Maintenance Every 3000 Hours 9. Install hose on hydraulic reservoir drain valve (A). Loosen valve. Allow oil to drain into a container. Dispose of waste oil properly. 10. Flush reservoir with diesel fuel. 11. Tighten drain valve. 12. Fill reservoir. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.) Specification Hydraulic Reservoir and Filters Capacity L (31 gal) T107880C UN 06MAR Install filler cap. 14. Check oil level in sight glass (B). Oil should be in FULL range. A Drain Valve B Sight Glass T UN 19FEB97 TX,87,JC OCT98 3/3 Clean Hydraulic System Strainer 1. Remove hydraulic reservoir filler cap (A). 2. Remove snap ring. 3. Remove strainer (B) and clean with solvent. 4. Install strainer and snap ring. 5. Replace cap. A Filler Cap B Strainer CED,OUO1021,184 T UN 23MAR MAR98 1/ PN=172

175 Maintenance Every 3000 Hours Change Front and Rear Differential Oil CAUTION: Prevent possible injury from hot spraying oil. Slowly loosen dipstick to relieve any air pressure. NOTE: Axle Differential Recirculation Screen should also be cleaned at this time. See Clean Axle Differential Recirculation Screen later in this section. 1. Remove hose (A) and screen fitting (B). Allow oil to drain into a container. Dispose of waste oil properly. 2. Install screen fitting and hose. A Hose B Screen Fitting T UN 22SEP98 Specification Front Differential Oil Capacity... Rear Differential Oil Capacity L (26 qt) 20 L (21 qt) CED,OUOE002, NOV98 1/2 3. Remove dipstick (A). NOTE: Each differential housing has three separate components. To expedite filling differential, remove right axle plug. 4. Add oil slowly through dipstick port on left front and left rear differential. IMPORTANT: To properly check oil level, do not thread dipstick into dipstick port. 5. Check oil level. Left Front Differential Shown T106373B UN 29JAN97 6. Install dipstick and tighten A Dipstick CED,OUOE002, NOV98 2/ PN=173

176 Maintenance Every 3000 Hours Clean Axle Differential Recirculation Screen 1. Disconnect hose (A) and remove screen fitting (B). 2. Drain differential oil into a container. Dispose of waste properly. See Change Front and Rear Differential Oil in this section. NOTE: Fitting and screen are of a one piece design. Screen should be thoroughly cleaned and reused. 3. Clean screen with solvent. Front Differential Shown T UN 22SEP98 4. Install screen fitting. 5. Install hose. 6. Refill differential with oil. See Change Front and Rear Differential Oil in this section. A Hose B Screen Fitting Rear Differential Shown T UN 22SEP98 CED,OUOE035, NOV98 1/ PN=174

177 Miscellaneous Machine Draining the Cooling System CAUTION: 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. 1. Check upper (A) and lower radiator hoses for cracks and leaks. Replace, if necessary. TS281 UN 23AUG88 2. Tighten clamps. 3. Check radiator, oil cooler, and air-to-air cooler for dirt, damage, leaks, and loose or broken mountings. Clean radiator, oil cooler, and air-to-air cooler. 4. Connect a hose to drain valve (B) on radiator. 5. Turn drain valve counterclockwise to open. Allow coolant to drain into a container. Dispose of used coolant properly. Upper Radiator Hose Shown T111237C UN 27AUG97 6. Turn drain valve (C) counterclockwise to drain engine block. Allow coolant to drain into a container. Dispose of used coolant properly. A Radiator Hose B Radiator Drain Valve C Engine Drain Valve T111243B UN 03SEP97 T111245B UN 27AUG97 TX,90,JC OCT02 1/ PN=175

178 Miscellaneous Machine Filling the Cooling System CAUTION: Prevent possible injury from hot spraying coolant. DO NOT remove radiator cap unless the engine is cool. Then turn cap slowly to the stop. Release pressure before removing cap. Specification Cooling System Capacity L (23 qt) IMPORTANT: Use only permanent-type, low silicate, ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals. TS281 UN 23AUG88 FREEZING TEMPERATURES: Fill with permanent-type, low silicate, ethylene glycol antifreeze (without stop-leak additive) and clean, soft water. Add TY16004 John Deere Coolant Conditioner or equivalent. Continued on next page CED,OUOE002, OCT02 1/ PN=176

179 Miscellaneous Machine NOTE: All machines are shipped from the factory with a mixture for protection to -34 C (-30 F). Adjust mixture accordingly to provide freeze protection for your machine. FILL Fill radiator to the bottom of the radiator fill neck. Fill the 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. T UN 20FEB98 Start engine. Run engine until coolant reaches a warm temperature. Stop engine. Allow coolant to cool. Check coolant level at recovery tank. 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. CED,OUOE002, OCT02 2/2 Replacing Engine Vibration Damper The engine vibration damper should be replaced every 4500 hours or 5 years. See your authorized dealer. TX03679,00017F AUG01 1/ PN=177

180 Miscellaneous Machine Adjusting Pilot Controller Tower 1. Remove two cap screws (1) from front load center door. Open door. 2. Loosen four cap screws (2) under pilot controller tower. 3. Move tower to desired position. 4. Tighten cap screws (2). Specification Cap Screws Torque N m (27 lb-ft) T161077B UN 29OCT02 5. Close front load center door. Install cap screws (1). 1 Cap Screws (2 Used) 2 Cap Screws (4 Used) T161078B UN 29OCT02 HG31779, OCT02 1/1 Checking Fuel Tank Vent Hose IMPORTANT: If fuel tank vent hose is plugged, the fuel tank could collapse. 1. Remove clamp (A). 2. Check hose for debris. If plugged, clean hose or replace. 3. Install clamp. A Clamp T103762B UN 12DEC96 TX,90,JC SEP96 1/ PN=178

181 Miscellaneous Machine Bleeding Fuel System 1. Place container under filters (D and G). 2. Loosen bleed screw (A). 3. Pump hand primer (C) until bleed screw (A) has solid stream of fuel coming from it. Tighten bleed screw on final fuel filter (G). 4. Open bleed screw (B). Pump hand primer until bleed screw has solid stream of fuel coming from it. Tighten bleed screw on primary fuel filter (D). 5. Dispose of waste properly. A Bleed Screw (Final Fuel Filter) B Bleed Screw (Primary Fuel Filter) C Hand Primer D Primary Fuel Filter E Drain Valve (Primary Fuel Filter) F Drain Valve (Final Fuel Filter) G Final Fuel Filter T111238E UN 27AUG97 TX,90,JC SEP97 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. DO NOT TRY TO POLARIZE ALTERNATOR OR REGULATOR. 3. Be sure alternator wires are correctly connected BEFORE you connect batteries. 4. Do not ground alternator output terminal. 6. Connect batteries or a booster battery in the correct polarity (positive [+] to positive [+] and negative [-] to negative [-]). 7. Do not disconnect the batteries when engine is running and alternator is charging. 8. Disconnect battery cables before you connect battery charger to the batteries. If machine has more than one battery, each battery must be charged separately. 5. Do not disconnect or connect any alternator or regulator wires while batteries are connected or while alternator is operating. 04T,90,C JUL92 1/ PN=179

182 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. TS204 UN 23AUG88 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. TS203 UN 23AUG88 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. Continued on next page TX03679, MAY01 1/ PN=180

183 Miscellaneous Machine If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in4l(1gal) water, or 0.47 L (1 pt) household ammonia in4l(1gal) water. IMPORTANT: Do not overfill the battery cells. Check the specific gravity of electrolyte in each battery cell. TX03679, MAY01 2/3 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, MAY01 3/3 Replacing Batteries Your machine is equipped with a negative ground electrical system. It uses two 12-volt batteries. If one of the two batteries fails, both batteries must be replaced. Use only batteries meeting following specifications. Specification Battery BCI Group... 30H Cold Cranking Amps at -18 C (0 F) Reserve Capacity at 25 amps Minutes CED,OUOE002, SEP98 1/ PN=181

184 Miscellaneous Machine Removing Batteries NOTE: Turn off master shut-off, if equipped, before disconnecting cables. 1. Remove left side battery cover. CAUTION: To prevent injury from battery covers dropping, remove when servicing or replacing batteries. Hinge is in place to aid in removal only. Cover must not be held or propped open during servicing. CAUTION: To prevent injury from explosion or fire disconnect the left side battery first regardless of which battery is being removed. A Positive (+) Cable B Negative (-) Cable T103150C UN 12DEC96 2. Disconnect negative (-) battery cable first, then positive (+) cable (A). 3. Remove nuts and washers (B) and hold down bracket. 4. Lift battery out of compartment. TX,90,JC AUG96 1/ PN=182

185 Miscellaneous Machine Replacing Fuses One Lever Design T103541C UN 06JUL00 Two Lever Design T160038B UN 29OCT02 A Fuse Box Continued on next page HG31779, SEP02 1/ PN=183

186 Miscellaneous Machine K25 Drive Light Relay AT K27 Hi-Beam Light Relay AT K17 Rear Wiper Return to Park Relay AT Not Used K13 Return to Dig Relay AT Not Used K23 Left Signal/Flasher Relay AT K28 Brake Light Relay AT K18 Rear wiper Intermittent Relay AT K15 Front Wiper Return to Park Relay AT K19 Main Blower Relay AT K22 Horn Relay AT Not Used K24 Right Signal/Flasher Relay AT K32 Detent Enable Relay AT Not Used K16 Front Wiper Intermittent Relay AT Not Used Not Used K31 Ride Control Relay AT F18 F17 F30 Rear Wiper Motor 10 AMP Fuse 57M 7121 P33 (ACC) Front Wiper Motor 10 AMP Fuse P34 57M 7121 (ACC) Ride Control 7.5 AMP Fuse J01 99M 7064 (ACC) Cab Work Light 10 AMP CB T P45 (ACC) F29 Drive & Hi-Beam Light 10 AMP CB T P40 (BATT) F25 Not Used Pressurizer Motor 7.5 AMP Fuse A19 99M 7064 (ACC) Neutral Start Circuit 5 AMP Fuse P01 57M 7125 (ST) Horns 7.5 AMP Fuse P36 99M 7064 (ACC) F20 F3 F21 Engine Controller Switched 7.5 AMP FUSE P08 99M 7065 (IGN) Trans Controller Switched 5 AMP Fuse P24 57M 7125 (IGN) Pilot Enable 7.5 AMP Fuse 99M 7064 P28 (IGN) F5 F12 F16 Power for BHKO, RTD, RTC Switch 5 AMP Fuse P11 57M 7125 (IGN) CCU 12V Unswitched 5 AMP Fuse P31 57M 7125 (12V BATT) Spare Ignition 5 AMP Fuse P47 57M 7125 (IGN) F15 F9 F34 Not Used F10 Power for Pressure Switches 5 AMP Fuse P32 57M 7125 (ACC) Turn Signal/Flasher Light 7.5 AMP Fuse P37 99M 7064 (BATT) F22 F33 P49 Spare Accessory 5 AMP Fuse 57M 7125 (ACC) Blower Motor 25 AMP Fuse 99M 7069 P10 (BATT) F19 Monitor Display Switched 5 AMP Fuse P05 57M 7125 (IGN) F7 K30 Ride Control Boom Solenoid Relay AT T F24 F14 F23 Tail & Marker Light 7.5 AMP Fuse P39 99M 7064 (ACC) Diff Lock, Pin Disc Solenoid 5 AMP Fuse P42 57M 7125 (ACC) Power for Rocker Switches 5 AMP Fuse P27 57M 7125 (ACC) K6 Accessory Relay #2 AT Brake Light 7.5 Amp Fuse 99M 7064 P44 (BATT) Spare 15 AMP Fuse 99M 7065 P35 (BATT) F27 F35 F6 Engine Controller Unswitched 10 AMP Fuse P06 57M 7121 (BATT) K1 Neutral Start Relay AT Seat Adjust, Lighter 10 AMP Fuse P48 57M 7121 (ACC) F32 Rotary Beacon 10 AMP Fuse 57M 7121 P41 (ACC) Alternator Excitation 7.5 AMP Fuse J07 99M 7064 (IGN) F26 F1 K5 Accesory Relay #1 AT Dome Light, Boom Down & Radio Unswitched 7.5 AMP Fuse P14 99M 7064 (BATT) F28 Converter Unswitched 15 AMP Fuse P16 99M 7065 (BATT) F31 Monitor & Trans Controller Unswitched 5 AMP Fuse P02 57M 7125 (BATT) F4 K10 Back-Up Relay AT CCU 28 V Switched 7.5 AMP Fuse P25 99M 7064 (IGN) Park Brake, Back-up Alarm 5 AMP Fuse P26 57M 7125 (IGN) Start Aid, Converter & Sec. Strg 10 AMP Fuse P04 57M 7121 (IGN) K4 Ignition Relay AT F11 F13 F2 K21 Secondary Steering (Relay Coil) Relay AT T OCT02 IMPORTANT: Install fuses with correct amperage rating to prevent electrical system damage from overload. The fuse box (A) is in the electrical load center on the right side (outside) of the cab. Both fuses and circuit breakers are located in the load center. HG31779, SEP02 2/ PN=184

187 Miscellaneous Machine Fuse (Blade-Type) Color Codes Amperage Rating Color 1 Black 3 Violet 4 Pink 5 Tan 7.5 Brown 10 Red 15 Light Blue 20 Yellow 25 Natural (White) 30 Light Green TX,90,JC MAR97 1/ PN=185

188 Miscellaneous Machine Replacing Halogen Bulbs IMPORTANT: To get the correct lighting pattern, lens must be installed so the word "TOP" is on top when lamp is installed so wider section is on top when lamp is installed. Before disassembling, remember how bezel and lens are installed with respect to mounting stud. 1. Remove four screws (H) to remove bezel (G) and lens (F). T5894AG1 UN 17APR89 2. Disconnect wiring lead and release retainer clip to remove bulb (D). 3. To disconnect ground wiring lead, push tab up, then pull connector from terminal. IMPORTANT: Do not touch the halogen bulb with bare hands. Oil and moisture may cause premature bulb failure. Clean bulb using a soft, oil-free cloth and alcohol. T5894AI1 UN 20OCT88 4. Install new bulb so square notch is aligned with square tab on reflector back. 5. Install retainer clip into locking tabs on reflector back. 6. Connect wiring leads. Check wiring leads are free of clip. 7. Install lens assembly (F) in housing (C) making sure wires are not crimped, or keeping lens assembly from seating on gasket. 8. Install bezel so wider section is on top. Sealing flange must be inside housing on all four sides before tightening screws. 9. Tighten screws alternately. Do not overtighten as screws may strip out plastic. A Flange Nut B Lock Washer C Housing D Bulb E Gasket F Lens G Bezel H Screw T6249AU UN 19OCT88 TX,90,RR, MAR94 1/ PN=186

189 Miscellaneous Machine Engine Speeds Specification Engine Slow Idle Speed ± 25 rpm Fast Idle Speed ± 25 rpm TX,90,JC SEP97 1/1 Checking Neutral Start System CAUTION: Avoid possible injury or death. DO NOT attempt to start machine unless you are sitting in operator s seat with the transmission control lever in neutral "N" position. DO NOT bypass or disable any of the starting system parts. Park brake is automatically applied when engine stops and remains in park until the park brake switch is cycled. Check the neutral start system to ENSURE that the machine: 1. WILL start with the transmission control lever in neutral "N" position. 2. WILL NOT start with the transmission control lever in forward "F" or reverse "R" position. If starting system fails to operate correctly, have your John Deere dealer repair the system immediately. TX,90,JC FEB97 1/ PN=187

190 Miscellaneous Machine Servicing Air Conditioning System 1. Check compressor clutch engagement. 2. Check evaporator core for clogging. 3. Check air intake filters for clogging. 4. Check blowers for proper operation. 5. Check the condenser core to see that it is not partially or completely plugged with dirt or trash. Clean with compressed air or water when needed. 6. Run air conditioning system for several minutes. A Receiver Dryer Sight Glass T111214D UN 27AUG97 7. Check sight glass (A) on receiver dryer (from outside of cab). Bubbles must not be present in sight glass. If bubbles are present, see your authorized dealer for charging the air conditioning system. TX,90,JC SEP97 1/1 Welding on Machine IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to "OFF" to prevent voltage spikes through alternator or monitor. Connect welder ground clamp close to each weld area so electrical current does not arc inside any bearings, bushings or pins. NOTE: Machine is adequately grounded. It is not necessary to disconnect any controllers (microprocessors). TX,90,JC AUG96 1/ PN=188

191 Miscellaneous Machine External Service Brake Inspection Do first inspection at 5000 hours followed by 1000 hours inspection intervals after the first 5000 hours inspection. If the service brakes are subjected to severe duty, inspect more frequently. 1. Remove plug from brake inspection port. 2. Start engine and run for 1 minute. T105193B UN 02NOV98 3. Stop and apply the brakes. Block pedal or have someone hold brakes on. 4. Using a tool (A), measure the thickness of disks (B) at dimension (C). Check dimension of two different disks. Specification Disk Thickness mm (0.115 in.) new Thickness mm ( in.) used minimum 5. If either of the disks thickness at dimension (C) is less than the minimum specification, the brake packs must be replaced. A Feeler Gauge B Disks C Dimension D Plates T UN 23SEP98 T UN 10SEP98 CED,OUOE002, SEP98 1/ PN=189

192 Miscellaneous Machine Checking Brake Accumulators 1. Start engine. NOTE: If machine is equipped with return-to-carry, the return-to-carry switch must be in the Off position. 2. Lower boom by placing controller handle in float position. 3. Run engine for 1 minute at slow idle. Apply brake pedal four or five times. 4. Stop engine. 5. Turn key switch to On position. NOTE: Accumulators are precharged and must be replaced, not re-charged. 6. Apply brake pedal. The brake low pressure indicator light may come on after 18 to 35 full brake applications. If brake light comes on with less than 18 applications, see your authorized dealer. 7. Repeat procedure three times to ensure accurate results. TX,90,JC OCT02 1/ PN=190

193 Miscellaneous Machine Checking Ride Control Accumulator If Equipped CAUTION: 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. X9811 UN 23AUG88 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 may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. CAUTION: The boom will jump upward during this check. Make sure area around bucket is clear. 1. Start engine. Later Machines One Lever Design T159423Q UN 01NOV02 2. Push ride control switch (A) to OFF position. 3. Raise boom to maximum height and hold control lever over relief for 2 seconds. 4. Lower boom and bucket to ground and stop engine. Put boom control lever in neutral. A Ride Control Switch Later Machines Two Lever Design T156774H UN 27JUN02 Continued on next page HG31779, NOV02 1/ PN=191

194 Miscellaneous Machine NOTE: When ride control switch is in A (automatic) position, ride control works at 6 km/h (3.7 mph) or above. 5. Turn key switch to On. 6. Push ride control switch to center position. Switch will light. Boom will jump upward, approximately 100 mm (4.0 in.) as accumulator (A) pressure is released. 7. If ride control accumulator has lost gas charge, see your authorized dealer. T108328C UN 27AUG97 To Discharge Accumulator A Accumulator 1. Turn key switch to On. 2. Push ride control switch to ON (center) position. Switch will light. NOTE: If ride control switch is already in the On position, it must be cycled to OFF then back to ON (center) position. 3. Push pilot enable/boom down switch to boom lower position. 4. Hold hydraulic control lever in the boom float position. HG31779, NOV02 2/ PN=192

195 Miscellaneous Machine Transmission Oil Cooler, Hydraulic Oil Cooler, Air-To-Air Aftercooler, and Radiator External Cleaning Procedure 1. On machines equipped with air conditioning, remove three cap screws (A) and swing air conditioning condenser forward for better access to coolers. 2. If dust or debris is light, clean coolers by blowing air through the fins. Do not exceed 6 bar (90 psi). Blow air straight through fins to avoid bending them. 3. If air fails to clean the coolers, use a high-pressure washer with soap and water not to exceed 48 bar (700 psi). Direct water straight through fins to avoid bending them. A Cap Screw (3 used) Shown With Air Conditioning T111246B UN 27AUG97 TX,90,JC SEP97 1/ PN=193

196 Miscellaneous Machine Service Recommendations For STC 1 Fittings STC fittings are used on this machine. The fittings are designed to allow the hydraulic hose to rotate as needed when the system is not pressurized. This prevents the hydraulic hoses from binding when components are put back to their operating position. Fittings are easily disconnected using special tool, JDG1385 (1) (supplied in machine with Operator s Manual). The special tool has a different size slot cut into each end. The narrow slot is for -06 size fittings. The wide slot is for -08 size fittings. Use appropriate end of special tool on fitting being disconnected. To connect fittings, simply push each half of fitting together. 1 Special Tool JDG Shoulder Of Fitting 3 Release Sleeve T134792C UN 24OCT00 IMPORTANT: DO NOT pry against release sleeve (3) or damage to fitting may result. DO NOT force release sleeve beyond normal range of travel, otherwise, release sleeve may fall off when hose is disconnected. If this happens and fitting is connected without the release sleeve installed, fitting will not be able to be disconnected again. 1. Disconnect STC type fittings: a. Clean area around fitting, especially around the release sleeve (3). b. While keeping special tool JDG1385 (1) perpendicular to the fitting, insert tool between release sleeve (3) and shoulder (2). c. Gently push, DO NOT PRY, release sleeve away from shoulder to disconnect the fitting. d. Pull hose to disconnect. 1 STC is a registered trademark of the Aeroquip Corporation. Continued on next page OUO1010, NOV02 1/ PN=194

197 Miscellaneous Machine 2. Inspect STC fittings: a. Check seal mating surfaces for nicks, scratches, or flat spots. b. Check O-ring (4), backup ring (5), and retaining ring (2) for wear or damage. c. Make sure O-ring, backup ring, and retaining ring are in position before connecting fitting halves together. T UN 21SEP00 3. Connect STC fittings: a. Make sure fitting halves (3 and 6) are clean and free of contaminates. b. Make sure release sleeve (1) is on male half (6) of fitting before connecting fitting halves together. 1 Release Sleeve 2 Retaining Ring 3 Female Half of STC Fitting 4 O-Ring 5 Backup Ring 6 Male Half of STC Fitting c. Push fitting halves together until a definite snap and solid stop is felt. d. Pull back on hose to make sure fitting halves are locked together. e. To prevent hoses from binding, move component into position before pressurizing hydraulic system. OUO1010, NOV02 2/2 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,DH SEP92 1/ PN=195

198 Miscellaneous Machine Hardware Torque Specifications Check cap screws and nuts to be sure they are tight. If hardware is loose, tighten to torque shown on the following charts unless a special torque is specified. T82,SKMA,AT 19 01AUG94 1/1 Keep ROPS Installed Properly CAUTION: Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque. The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered. A damaged ROPS should be replaced, not reused. TS176 UN 23AUG88 When installation of equipment on a machine necessitates loosening or removing ROPS, mounting bolts must be tightened. Specification ROPS Mounting Bolt Torque N m (850 lb-ft) TX,90,JC MAR97 1/ PN=196

199 Miscellaneous Machine Metric Bolt and Cap Screw Torque Values Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings TORQ2 UN 07SEP99 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-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5) M (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35) M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70) M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120) M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190) M (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300) M (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410) M (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580) M (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800) M (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000) M (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475) M (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000) M (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730) M (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500) a "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. b "Dry" means plain or zinc plated without any lubrication. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. DX,TORQ OCT99 1/ PN=197

200 Miscellaneous Machine Unified Inch Bolt and Cap Screw Torque Values Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings TORQ1A UN 27SEP99 Grade 1 (No Mark) Grade 2 a (No Mark) Grade 5, 5.1 or 5.2 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-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) N m(lb-ft) 1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5) 5/ (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26) 3/ (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46) 7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74) 1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115) 9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165) 5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225) 3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400) 7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640) (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960) 1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350) 1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920) 1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500) 1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350) 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, or fasteners with phosphate and oil coatings. c "Dry" means plain or zinc plated without any lubrication. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. DX,TORQ OCT99 1/ PN=198

201 Miscellaneous Operational Checkout Operational Checkout Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of the operation of the machine while doing a walk around inspection and performing specific checks from the operator s seat. Should you experience a problem with your machine, you will find helpful diagnostic information in this checkout that will pinpoint the cause. This information may allow you to perform a simple adjustment which will reduce the downtime of your machine. Use the table of contents to help find adjustment procedures. The information you provide after completing the operational checkout will allow you or your authorized dealer to pinpoint the specific test or repair work needed to restore the machine to design specifications. Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) prior to doing the checkout. The machine must be at operating temperature for many of the checks. Before starting this operational checkout, check diagnostic Service codes in monitor. These service codes must be corrected or cleared before starting this checkout. Start at the top of the left column and read completely down column before performing check, follow this sequence from left to right. In the far right column, if no problem is found (YES), you will be instructed to go to next check. If a problem is indicated (NO) or (NOT OK), you will be referred to either a section in this manual or to your authorized dealer. A location will be required which is level and has adequate space to complete the checks. No tools or equipment are needed to perform the checkout. HG31779, MAY02 1/1 Checking and Clearing Diagnostic Trouble Codes From Monitor 1/ PN=199

202 Miscellaneous Operational Checkout Check Trouble Codes YES: Go to Battery Check. NO: Go to Check Service Codes. T UN 13SEP96 Turn key ON. After bulb check, Press MENU until diagnostic mode (d) is in Basic Display window. Press SELECT to get (d 01) displayed, then press SELECT to display service codes. T UN 09SEP96 LOOK: Does display read End? NOTE: Do NOT stop operating machine because service codes are displayed. The warning lights on dash will warn you if machines requires maintenance. If service codes are displayed, record them. 1/1 Clear Service Codes YES: Go to Battery Check. NO: See your authorized dealer. T UN 09SEP96 T UN 09SEP96 With key ON and diagnostic service codes displayed. Press NEXT to view each service code and read explanation in Message window. Record service codes. When service code is displayed, press SELECT to activate code, then hold SELECT for three seconds to delete code. NOTE: The service codes should disappear from window and next service codes be displayed or End displayed. If code can not be deleted, locate connector at sensor and disconnect it and reinstall it. Then repeat delete procedure. If code can not now be deleted, the service is active and repair must be done before code can be removed. Repeat this procedure until End appears in Basic display window. Press NEXT and End should still appear. Press MENU to return to operating display. LOOK: Are all the service codes deleted and End appears in Basic Display window? 1/ PN=200

203 Miscellaneous Operational Checkout Engine Off Checks 1/1 Battery Check Key OFF. Press SELECT button and hold until battery volts are displayed. LOOK: Does battery volts read a minimum of 24 volts? YES: Go to next check. NO: Check voltage on each battery before recharging. If one battery will not hold a charge, replace both batteries. T UN 10SEP96 1/1 Monitor Check Key switch ON. Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges). LOOK/LISTEN: Do all lights come ON and does alarm sound? Does Message Display and Basic Display window have 8s showing in every display? Do all the gauge indicators point to approximately 12:00 O clock position? Is backlighting of gauges ON? After 4 seconds observe changes in Monitor. LOOK: Do gauge indicators change from 12:00 O clock to normal readings? Does Message Display show John Deere? LOOK: Does Basic Display change to show gear, rpm, hourmeter and battery voltage readings? YES: Go to next check. NO: See your authorized dealer. 1/ PN=201

204 Miscellaneous Operational Checkout Cab System Checks Check the following for proper working order. Seat adjustment Seat belt Tilt wheel counsel Front and rear work lights Front and rear drive lights Turn signals Dome light Horn Front and rear windshield wiper and washer Four speed (five position) blower fan Door and window latches Side shield latches Grill housing door latch Radiator cap and fuel door checks Cab mount ladder Boom lock check Service decal check YES: Go to next check. NO: Repair as needed. 1/1 Neutral Start Check Move transmission control lever to 1st gear forward (1F), turn key switch to START. LISTEN: Starting motor must not run. NOTE: Gear display will not display F for forward or R for reverse until engine is started and park brake released. Move transmission control lever to 1st gear reverse (1R), turn key switch to START. LISTEN: Starting motor must not run. Backup alarm will sound. With transmission control lever in neutral (1N), turn key switch to START LISTEN: Does starting motor run with lever in neutral position only? YES: Go to next check. NO: Check neutral start fuse. If OK, see your authorized dealer. 1/1 Backup Alarm Check Move transmission control lever to reverse (R). LISTEN: Does reverse alarm sound when lever is in reverse (R)? YES: Go to next check. NO: Check transmission controller switched fuse and park brake and backup alarm fuse. If OK, see your authorized dealer. T UN 14FEB97 1/ PN=202

205 Miscellaneous Operational Checkout Diagnostic Trouble Codes (DTC) Check Diagnostic Trouble Codes (DTC). Record which (DTC) appear. Clear (DTC). If any (DTC) remain fix before continuing with checks, See Diagnostic Trouble Codes Quick Reference. IF OK: Continue on with check. 1/1 Engine Running Checks 1/1 Monitor Check Key switch ON. Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges). LOOK/LISTEN: Do all lights come ON and does alarm sound? Do Message Display and Basic Display windows have 8s showing in every display? Do all the gauge indicators point to approximately 12:00 O clock position? Is backlighting of gauges ON? After 4 seconds observe changes in Monitor. LOOK: Do gauge indicators change from 12:00 O clock to normal readings? Does Message Display show John Deere? LOOK: Does Basic Display change to show gear, rpm, hourmeter and battery voltage readings? YES: Go to next check. NO: Check monitor switched power fuse. If OK, see your authorized dealer. 1/ PN=203

206 LOADER HYDRAULICS ON OFF Miscellaneous Operational Checkout Park Brake Check Release park brake by pushing park brake switch to OFF position. LOOK: Does park brake indicator go off when brake is released? Will machine move if put into gear? YES: Go to next check. NO: See your authorized dealer. T UN 09SEP96 CAUTION: Seat belt must be worn during this check to prevent possible injury from sudden machine stops. Fasten seat belt. Put transmission in 1st gear forward. Drive machine at 3 MPH and push park brake switch to ON. LOOK/FEEL: Does machine come to a stop within 1 meters (3 feet) when park brake is engaged at 3 MPH? Does transmission shift to neutral? 1/1 Service Brake Check 1 YES: Go to next check. DRIVE WORK 4-WAY NEUTRAL AUTO A A/C NO: Inspect for leaks under machine or overfilling of non-difflock axle. See your authorized dealer. T UN 05SEP96 PERFORMANCE MANAGEMENT CARRY BEACON DETACH 2 RIDE 1 3 LPM A 4 5 T UN 14AUG01 A Left Service Brake B Right Service Brake 1 Clutch Cut-Off Switch Engine running. Push Clutch Cut-off switch (1) to OFF position. Fully apply either (A) or (B) service brake pedal. Release park brake and put transmission in 2nd forward. Increase engine speed to fast idle. LOOK: Does machine not move or move at a very slow speed? Repeat check three times to ensure accurate results. 1/ PN=204

207 Miscellaneous Operational Checkout Pilot Controller Lock Check YES: Go to next check. NO: Check pilot enable/boom down switch. T UN 04FEB97 T UN 09SEP96 Push Pilot Enable/Boom Down Switch to locked position. Hold boom control lever in boom raise position. Move Pilot Enable/Boom Down Switch to unlock and observe boom. LOOK: Does boom raise when switch is unlocked? Move Pilot Enable/Boom Down Switch to locked position and observe boom. LOOK/FEEL: Does boom stop when switch is LOCKED? Unlock Pilot Enable/Boom Down Switch and check all hydraulic functions. Boom Up/Down Bucket Roll/Dump Auxiliary functions (if equipped) Steering (Left and Right) Pin Disconnect (if equipped) 1/1 Pilot Enable/Boom Down Solenoid Check Raise Boom. Stop Engine. Turn key to ON position. Move Pilot Enable/Boom Down Switch in DOWN position. YES: Go to next check. NO: Check boom down fuse (dome light will not work if fuse is blown). IF OK: Check boom down solenoid. T UN 04FEB97 CAUTION: Boom will quickly lower to ground. Move control lever to boom lower position. LOOK: Does boom lower? 1/ PN=205

208 Miscellaneous Operational Checkout Pilot Control Valve Boom Float Check Run engine at slow idle. Push Ride Control switch off. Push Return-to-Carry switch off. With the bucket partially dumped, lower boom to raise front of machine. YES: Go to next check. NO: See your authorized dealer. T UN 07FEB97 Push control lever to the float detent position and release lever. LOOK: Does front of machine lower to the ground and valve remain in float position when lever is released? 1/1 Pin Disconnect System Check (If Equipped) Run engine at slow idle. Position bucket flat on the ground. Push and hold Pin Disconnect Switch (DETACH). LOOK: Does pin disconnect cylinder retract both pins while switch is pressed? YES: Go to next check. NO: Check differential lock and pin disconnect fuse. NO: Hold a screwdriver blade against the end of the pin disconnect solenoid valve and check for magnetism with the switch pushed, if magnetism switch is ok. IF OK: See your authorized dealer. 1/ PN=206

209 Miscellaneous Operational Checkout Ride Control Check T CAUTION: Boom will jump upward during this check. Make sure area around bucket is clear. UN 07FEB97 Push Ride Control Switch to OFF position. Raise boom to maximum height and hold control lever over relief for 2 seconds. Lower boom and bucket to eye level. Observe loader boom as ride control switch is switched to ON. LOOK/FEEL: Does boom jump upward 30 cm (12 in) or more? YES: Go to next check. NO: Check ride control fuse. NO: Check ride control boom solenoid. Check ride control On/Off solenoid. IF OK: Ride control accumulator charge pressure. Push Ride Control Switch to AUTO position. Switch will light. Raise boom to maximum height and hold control lever over relief for 2 seconds. Lower boom and bucket to eye level and slowly accelerate to 5 mph while watching speedometer and bucket. T UN 07FEB97 LOOK/FEEL: Does ride control come on at approximately 3 mph and bucket raise slightly? 1/1 Differential Lock Check Park unit on a hard surface. Release brakes. Push Differential Lock Switch and steer unit left and right. Release lock switch and steer unit left and right. LOOK: Do front wheels slide with differential lock ON? NOTE: It is normal to get a "clunk" sound when you release switch. LOOK: Do front wheels rotate in opposite directions with differential lock switch released? YES: Go to next check NO: See your authorized dealer. T UN 05SEP96 1/ PN=207

210 Miscellaneous Operational Checkout Clutch Cutoff Check Turn Clutch Cutoff Switch (NEUTRAL) on. Apply brake. Increase engine rpm to Turn NEUTRAL switch off. LISTEN/LOOK: Does engine rpm drop? FEEL: Can you feel machine pull through brakes? NOTE: Clutch cutoff switch can be adjusted to operator preference to match your loading needs by selecting one of three operating functions in the monitor. Transmission does not totally disengage, some effort to move by the machine can be felt. See your authorized dealer. YES: Go to next check. NO: See your authorized dealer. 1/1 Boom And Bucket Cylinder Drift Check Set bucket flat on the ground and raise about 50 mm (2 in.). Stop engine. Observe bucket for 1 minute. LOOK: Does bucket remain in position? Bucket should not settle to the ground. YES: Go to next check. NO: See your authorized dealer. T6564NZ UN 19OCT88 NOTE: Use good judgement to determine if the amount of drift is objectionable for your loader application. 1/ PN=208

211 Miscellaneous Operational Checkout Automatic Shift And Speedometer Check NOTE: In the AUTOMATIC mode, transmission will shift to highest gear selected as ground speed increases, or will down shift to 2nd as ground speed decreases. Transmission will never shift to 1st gear. In AUTO MODE TO FIRST the transmission will start in 1st when initially shifted from Neutral to Forward or Reverse. After the initial shift from Neutral, the transmission will downshift no lower than 2nd unless a high load is encountered. Transmission will upshift or downshift as ground speed dictates. Automatic transmission switch to AUTO. Perform this check in an open area away from other people and machinery. Release park brake and shift to (4th) forward. Drive machine on level ground and slowly accelerate to fast idle speed and note speed when shifts are made until engaged in 4th gear. Reduce engine rpm to idle and note speed when transmission makes each downshift. LOOK: Does the transmission shift at following approximate speeds? 724J Shift MPH Km/H 2nd-3rd 6 9 3rd-4th th-3rd rd-2nd 4 6 YES: Go to next check. NO: Monitor is programmed for wrong tire size. See your authorized dealer. NOTE: In 4th Forward automatic the transmission starts out in 2nd gear and up-shifts to 3rd then 4th. When transmission downshifts it returns to 2nd. Transmission will shift at different speeds depending on machine loads. Use only as reference. 1/ PN=209

212 Miscellaneous Operational Checkout Transmission Shift Mode Check Turn Automatic Transmission Shift switch to OFF. Press MENU until ACCESSORY shows in basic display, then press SELECT. Accessory will display in Message Display Window and A 02 Quick Shift in Basic Display Window. Press NEXT until A 021 Down/up displays, then press SELECT. Release park brake and shift to 3rd forward. Drive machine at approximately 1600 rpm and press Quick Shift Switch once. LOOK/FEEL: Does transmission shift to and remain in 2nd gear? Press Quick Shift Switch once more. LOOK/FEEL: Does transmission shift back to 3rd gear? NOTE: If Quick Shift Switch is pressed twice, transmission will shift down one gear then immediately back up to where it was. Quick Shift feature operates in all gears. In Basic Display Window with Quick Shift A 021 displayed press NEXT to get Downshift A 022 Down Only to display. Press SELECT to enable Down Only shift mode. Release park brake and shift to 4th forward. Drive machine at approximately 1200 rpm and press Quick Shift Switch once. LOOK/FEEL: Does transmission shift to and remain in 3rd gear? Press Quick Shift Switch once more. LOOK/FEEL: Does transmission shift to and remain in 2nd gear? Press Quick Shift Switch once more. LOOK/FEEL: Does transmission shift to and remain in 1st gear? Press Quick Shift Switch once more. LOOK/FEEL: Does transmission stay in 1st gear? NOTE: In DOWN ONLY mode pressing Quick Shift Switch will not change gears once 1st gear is reached, unless a direction or gear change is made. YES: Go to next check. NO: See your authorized dealer. 1/1 Axle Disconnect Check (If Equipped) T6601AA UN 19OCT88 Operate machine in an open area away from bystanders. With bucket partially dumped, lower boom to raise front wheels off the ground. Push Axle Disconnect Switch to ON position. Watch front wheels while operating the machine in reverse. Front wheels must not rotate as machine moves backwards. YES: Go to next check. NO: Check differential lock and pin disconnect fuse. IF OK: See your authorized dealer. LOOK: Do front wheels remain stationary while machine moves backwards? 1/ PN=210

213 Miscellaneous Operational Checkout Steering Valve Check Transmission in Neutral. Run engine at low idle. Remove foot from brake pedal. Release park brake. IF OK: Go to next check NO: See your authorized dealer. T6471AQ UN 19OCT88 Turn steering wheel until machine frames contact right and left frame stops. LOOK: Does machine steer smoothly in both directions? NOTE: It is normal for machine frames to drift away from frame stops when steering wheel is released. When steering wheel is stopped, frames must stop. FEEL: Is excessive effort required to turn steering wheel? 1/ PN=211

214 Miscellaneous Troubleshooting Troubleshooting Procedure 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 1. Operational Checkout Procedure Step 2. Troubleshooting Charts Step 3. Adjustments Step 4. See your authorized dealer. HG31779, APR02 1/ PN=212

215 Miscellaneous Troubleshooting Diagnostic Trouble Codes Quick Reference List CCU SERVICE CODES F0275 CCU Power Dissipation Excessive TRANSMISSION SYSTEM CODES: F0300 Oil Temperature High Long F0305 TCU Output Speed Zero F0306 TCU Voltage Low F0307 TCU Voltage High F0308 TCU Valve Solenoid Power F0309 TCU Park Brake Solenoid Power F0315 Oil Filter Circuit Short-to-Power F0320 1st Gear Clutch Slippage F0321 2nd Gear Clutch Slippage F0322 3rd Gear Clutch Slippage F0323 4th Gear Clutch Slippage F0324 Forward Gear Clutch Slippage F0325 Reverse Gear Clutch Slippage F0330 Clutch Cut-Off Circuit Voltage Low F0331 Clutch Cut-Off Circuit Voltage High F0336 TCU Configuration Bad F0337 TCU Memory Bad F0339 Temperature Sensor Voltage Short-to-Ground F0340 Temperature Sensor Voltage Short-to-Power F0341 Output Speed Signal Bad F0342 Output Speed Circuit Short-to-Ground F0343 Output Speed Circuit Short-to-Power F0344 Internal Clutch Speed Signal Bad F0345 Internal Clutch Speed Circuit Short-to-Ground F0346 Internal Clutch Speed Circuit Short-to-Power F0347 Turbine Speed Signal Bad F0348 Turbine Speed Circuit Short-to-Ground F0349 Turbine Speed Circuit Short-to-Power F0350 Input Speed Signal Bad F0351 Input Speed Circuit Short-to-Ground F0352 Input Speed Circuit Short-to-Power F0353 FWD High Range Clutch Pack Solenoid Open F0354 FWD High Range Clutch Pack Solenoid Short to Ground F0355 FWD High Range Clutch Pack Solenoid Short to Power F0356 Third Speed Clutch Pack Solenoid Open F0357 Third Speed Clutch Pack Solenoid Short-to-Ground F0358 Third Speed Clutch Pack Solenoid Short-to-Power F0359 Second Speed Clutch Pack Solenoid Open F0360 Second Speed Clutch Pack Solenoid Short-to-Ground F0361 Second Speed Clutch Pack Solenoid Short-to-Power F0362 First Speed Clutch Pack Solenoid Open F0363 First Speed Clutch Pack Solenoid Short-to-Ground F0364 First Speed Clutch Pack Solenoid Short-to-Power F0365 Reverse Clutch Pack Solenoid Open F0366 Reverse Clutch Pack Solenoid Short-to-Ground F0367 Reverse Clutch Pack Solenoid Short-to-Power F0368 FWD Low Range Clutch Pack Solenoid Open F0369 FWD Low Range Clutch Pack Solenoid Short-to-Ground F0370 FWD Low Range Clutch Pack Solenoid Short-to-Power F0375 Gear Selector F0377 Oil Temperature Circuit Short-to-Power F0378 Oil Temperature Circuit Open F0379 FNR Selector Switch Open F0380 Oil Filter Restricted F0384 Reverse Alarm Relay Short-to-Power F0385 Reverse Alarm Relay Short-to-Ground F0386 Reverse Alarm Relay Open F0387 Park Brake Solenoid Short-to-Power F0388 Park Brake Solenoid Short-to-Ground F0389 Park Brake Solenoid Open F0396 Oil Temperature High ENGINE SYSTEM CODES: F0400 Oil Pressure Low Long F0415 CCU Throttle Circuit Voltage Low F0416 CCU Throttle Circuit Voltage High F0423 Ambient Air Temperature Input Voltage High F0424 Ambient Air Temperature Input Voltage Low Continued on next page TX17961, OCT02 1/ PN=213

216 Miscellaneous Troubleshooting F0425 Engine Coolant Temperature Input Voltage High F0426 Engine Coolant Temperature Input Voltage Low F0431 Cylinder #1 EI Circuit F0432 Cylinder #2 EI Circuit F0433 Cylinder #3 EI Circuit F0434 Cylinder #4 EI Circuit F0435 Cylinder #5 EI Circuit F0436 Cylinder #6 EI Circuit F0437 Fuel Temperature Input Voltage High F0438 Fuel Temperature Input Voltage Too Low F0439 Pump Control Valve #1 Error F0440 Pump Control Valve #2 Error F0441 Crank Position Input Missing F0442 Crank Position Input Error F0443 Pump Position Sensor Input Missing F0444 Pump Position Sensor Input Error F0445 Crank Position/Pump Position Timing Moderately Out of Sync F0450 Fuel Rail Pressure Input Voltage High F0451 Fuel Rail Pressure Input Voltage Low F0453 Water in Fuel Signal Voltage High F0454 Water in Fuel Signal Voltage Low F0455 Manifold Air Temperature Moderately High F0456 Pump Control Valve #2 Fuel Flow Not Detected F0469 Pump Control Valve #1 Fuel Flow Not Detected F0470 Fuel Rail Pressure Control Error F0471 Fuel Rail Pressure Sensor Supply Voltage Low F0478 Engine Oil Pressure Circuit Voltage Low F0479 Engine Oil Pressure Circuit Voltage High F0485 Water in Fuel Detected F0499 Engine Oil Pressure Low F0500 Engine Coolant Temperature High Long F0515 Engine Air Filter Restriction Circuit F0516 Engine Fuel Level Circuit Voltage Low F0517 Engine Fuel Level Circuit Open F0576 Engine Coolant Temperature Circuit Noisy F0577 Engine Coolant Temperature Circuit Short-to-Ground F0578 Engine Coolant Temperature Circuit Open F0580 Engine Air Filter Restricted F0599 Engine Coolant Temperature High STEERING SYSTEM CODES: F0998 Steering Pressure Circuit F0999 Steering Pressure Low BRAKE SYSTEM CODES: F1097 Service Brake Pressure Circuit F1099 Service Brake Pressure Low ELECTRICAL SYSTEM CODES: F1620 CCU Spare Relay #1 Short F1621 CCU Spare Relay #3 Short F1622 CCU Spare Relay #4 Short F1623 CCU Spare Relay #5 Short F1624 Air Preheat Driver Short Ground F1625 Detent Enable Driver Short-to-Ground F1626 Ride Control Boom Driver Short-to-Ground F1628 Ride Control On Driver Short-to-Ground F1629 Left Turn Driver Short-to-Ground F1630 Right Turn Driver Short-to-Ground F1633 Secondary Steering Driver Short-to-Ground F1634 Rear Wiper Driver Short-to-Ground F1635 Front Wiper Driver Short-to-Ground F1636 CCU Relay Driver Overtemp F1637 CCU Timer Reset F1638 Proportional Fan Drive Solenoid Circuit Error F1639 Reverse Fan Drive Solenoid Circuit Error F1641 Drive Light Switch Circuit Open F1644 MDU Memory Bad F1645 CCU Memory Bad F1647 Machine Odometer Bad F1648 Machine Hourmeter Bad F1649 CCU Hourmeter Bad F1651 No ECU CAN Transmit F1653 No CCU CAN Transmit F1655 No TCU CAN Transmit F1658 Power Voltage Balance F1660 Alternator Voltage High F1661 Alternator Voltage Low F1662 Power Voltage High F1663 Power Voltage Low F1664 Brake Light Pressure Circuit F1665 Drive Light Switch Circuit F1667 Turn Switch Circuit Short Continued on next page TX17961, OCT02 2/ PN=214

217 Miscellaneous Troubleshooting F1668 Hazard Switch Circuit F1671 Return to Carry Detent Solenoid Circuit Error F1672 Boom Height Kickout Detent Solenoid Circuit Error F1699 Config Bad HYDRAULIC SYSTEM CODES: F2100 Oil Temperature High Long F3115 Oil Filter Restriction Circuit Short-to-Ground F3150 Oil Filter Restriction Circuit Short-to-Power F3160 Ride Control Circuit Short-to-Power F3161 Ride Control Auto Circuit Short-to-Ground F3162 Ride Control On Circuit Short-to-Ground F3163 Boom Position Voltage Low F3164 Boom Position Sensor Voltage High F3171 Hydraulic Oil Pressure Circuit Voltage Low F3172 Hydraulic Oil Pressure Circuit Voltage High F3173 Spin Control Mode Circuit F3174 Spin Control Enable Circuit Short-to-Ground F3175 Hydraulic Oil Temperature Circuit Short-to-Ground F3176 Hydraulic Oil Temperature Circuit Open F3177 Hydraulic Oil Temperature Circuit Noisy F3199 Hydraulic Oil Temperature High TX17961, OCT02 3/ PN=215

218 Miscellaneous Troubleshooting Engine Symptom Problem Solution Engine Cranks/Won t Start Fuel quality and quantity Check fuel quality and quantity. Engine cranking speed Oil viscosity Intake or exhaust restrictions Air heater not working Check engine cranking speed. Check for correct oil viscosity. Check for intake and exhaust restrictions. If engine has an air heater, verify air heater operation in cold temperatures. Engine Misfires/Runs Irregularly Intake manifold air leaks Check for intake manifold air leaks Mechanical problems Transmission problems Engine accessories cycling on and off Electronic interference Check for mechanical problems. Check for transmission problems. Check engine accessories, such as A/C, cycling on and off. Check for improperly installed radios, etc. Engine Does Not Develop Full Restricted or plugged air and fuel Check for restricted or plugged air Power filters and fuel filters. Fuel quality Transmission problems Engine mechanical problems Excessive load Check fuel quality. Check for transmission problems. Check for engine mechanical problems. Check for excessive load on the engine. Engine Emits Excessive White Fuel quantity and quality Check fuel quantity and quality. Exhaust Smoke Low engine coolant temperature Check for extremely low engine coolant temperature. Continued on next page TX17961,000000B 19 03OCT02 1/ PN=216

219 Miscellaneous Troubleshooting Symptom Problem Solution Engine Emits Excessive Black Or Fuel quantity and quality Check fuel quantity and quality. Gray Smoke Restricted or plugged air filter Excessively loaded engine Check for restricted or plugged air filter. Check for excessively loaded engine. Engine Will Not Crank Weak battery Replace battery. Corroded or loose battery connections Defective main switch or start safety switch Starter solenoid defective Starter defective Start circuit defective Engine is seized Clean battery terminals and connections. Repair switch as required. Replace solenoid. Replace starter. Check wiring, fuses, and relays. Check by rotating engine by hand. Engine Idles Poorly Poor fuel quality Drain fuel and replace with quality fuel of the proper grade. Air leak on suction side of air intake system Check hose and pipe connections for tightness; repair as required. TX17961,000000B 19 03OCT02 2/ PN=217

220 Miscellaneous Troubleshooting Transmission Symptom Problem Solution Transmission Clutch Slippage Low oil level See Transmission, Hydraulic System, Park Brake, And Differential Oil. Wrong oil grade Restricted Transmission pump suction screen See Transmission, Hydraulic System, Park Brake, And Differential Oil. Remove and clean screen. Machine Will Not Move Diagnostic Trouble Code (DTC) Check Diagnostic Trouble Codes to related problem define problem. See Monitor Display Unit User Diagnostics Menu. Applied park brake (electrical problem) Check park brake fuse. Check operation of park brake. Low oil level Clutch cutoff activated No power to transmission controller unit Check transmission oil level. Check that brake pedal is fully released. Check transmission controller switched 5A fuse. Check monitor and transmission controller unswitched fuse. Hydraulic failure of park brake Failed shift switch Broken drive shafts Check operation of park brake. Check that display window shows correct gear when shift switch is moved. Inspect drive shafts and universal joints for external damage. Continued on next page TX17961,000016A 19 03OCT02 1/ PN=218

221 Miscellaneous Troubleshooting Symptom Problem Solution Machine Does Not Engage In Clutch cutoff activated Check that brake pedal is fully Low Gear released. Shift switch problem Check Diagnostic Trouble Codes to define problem. See Monitor Display Unit User Diagnostics Menu. Machine Will Not Shift Correctly Speed sensor disconnected or failed Check electrical connectors on transmission speed sensors. Transmission Shifts Too Slow Low oil level (aeration of oil) Add oil. Restricted transmission pump suction screen Remove and clean suction screen. Transmission Hydraulic System High oil level Check transmission oil level. Overheats Transmission overfilled or hydraulic pump seal leaking. Low oil level Wrong oil grade Park brake dragging Pinched, restricted or leaking lube lines Malfunction in temperature gauge or sender Restricted air flow through oil cooler or radiator Check transmission oil level. Check oil type. Check for heat in park brake area. Check cooler lines. Install temperature sensor to verify temperature. Check oil cooler and radiator for debris. Clean if needed. Excessive Transmission Noise Too low engine slow idle Check engine slow idle speed. (under load or no load) Worn parts or damaged in transmission Damaged drive dampener Driveline or park brake Inspect suction screen for metal particles. Inspect drive dampener. Inspect drive line and park brake. Continued on next page TX17961,000016A 19 03OCT02 2/ PN=219

222 Miscellaneous Troubleshooting Symptom Problem Solution Foaming Oil Incorrect type of oil Check oil type. Change oil if needed. High oil level Low oil level Check oil level. Transmission overfilled or hydraulic pump seal leaking. Check oil level. Add oil if needed. Oil Ejected From Dipstick Plugged breather Inspect breather on top of transmission. Replace if needed. Machine Vibrates Aerated oil Check oil level. Add oil if needed. Low engine speed Failed universal joints on transmission drive shaft or differential drive shafts Damaged drive dampener. Check engine speed. Check universal joints. Inspect drive dampener. Machine Lacks Power And Engine fast idle speed set too low Check engine fast idle. Acceleration Incorrect transmission oil Aerated oil Drain transmission oil and refill. See Change Transmission Oil. Check oil level. Add oil if needed. TX17961,000016A 19 03OCT02 3/ PN=220

223 Miscellaneous Troubleshooting Differential And Axle Symptom Problem Solution No differential Lock Operation Malfunction in electrical circuit With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve. Stuck differential lock solenoid valve Excessive leakage in differential lock piston seals With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve. Check differential oil level. Differential Lock Slips Or Axle oil broken down Change axle oil. See Change Front Chatters When Engaged and Rear Differential Oil. Excessive leakage differential lock piston seals Check differential oil level. Differential Lock Will Not Release Stuck foot switch Inspect. Malfunction in electrical circuit Stuck differential lock solenoid valve With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve. With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve. Differential Low On Oil External leakage Inspect axle and differential for leaks. Excessive Differential And/Or Low oil level in differential Check oil. Remove drain plug and Axle Noise inspect for metal particles in differential case. See Check Front and Rear Differential Oil Level. Engaged differential lock Release lock. If circuit remains pressurized, check if foot switch is sticking. Remove and inspect. Check solenoid valve for sticking. Remove and inspect valve. Continued on next page TX17961,000016C 19 03OCT02 1/ PN=221

224 Miscellaneous Troubleshooting Symptom Problem Solution Oil Seeping From Outer Axle Dirt in face seal Inspect face seals. Seal Overfilled differential High pressure in axle Check differential lock oil return system for excessive internal restriction. Check axle breather. Axle Overheats Low differential oil Check oil level. Add oil if needed. Overfilled differential Axle recirculation motor dual pump screens plugged Check oil level. Add oil if needed. Inspect axle recirculation filter screen located in differential housing below input yoke. See Clean Axle Differential Recirculation Screen. TX17961,000016C 19 03OCT02 2/2 Service Brake Symptom Problem Solution Poor or No Brakes Axle overheated Check axle temperature. Brake disks worn or warped Inspect service brake pads. Aggressive Brakes Clutch cutoff mode set to steep Turn clutch cutoff switch OFF. slope Brakes Drag Brake pedal not returning Inspect floor mat and pedal. Brakes Chatter Brake disk friction material worn Inspect brake disks. Oil broken down Wrong oil in hydraulic system Change oil. See Change Front and Rear Differential Oil. Drain hydraulic reservoir and differentials. Refill with correct oil. See Change Front and Rear Differential Oil. TX17961,000016D 19 03OCT02 1/ PN=222

225 Miscellaneous Troubleshooting Drive Line Symptom Problem Solution Excessive Drive Line Vibration Yokes not in line on drive shafts Inspect. Align drive shaft yokes. Or Noise Lack of lube in park brake Bent drive shaft Loose yoke retaining nuts (drive shafts wobble at high speed) Rear axle oscillating support Lack of lubrication Inspect park brake oil level and adjust as required. See Check Park Brake Oil Level. Inspect all drive shafts. Inspect. Replace. Inspect. Lubricate with proper grade of grease. TX17961,000016E 19 03OCT02 1/ PN=223

226 Miscellaneous Troubleshooting Park Brake Symptom Problem Solution Brake Will Not Hold Breather plugged Inspect and clean breather. Malfunctioning park brake solenoid Inspect. Brake Overheats Overfilled with oil Adjust oil level. See Check Park Brake Oil Level. Breather plugged Inspect and clean breather. Park Brake Indicator In Monitor Low oil level Check oil level. Add oil if needed. Comes On When Shifting From Fwd to Rev (All Other Gears OK) Cold oil Warm oil. Park Brake Light Comes On For Cold oil Warm oil. Each Shift Park Brake Indicator In Monitor Faulty wiring or switch Inspect for loose or broken wires Does Not Come On When Brake between brake indicator switch and Applied indicator on dash. TX17961,000016F 19 03OCT02 1/ PN=224

227 Miscellaneous Troubleshooting Hydraulic System Symptom Problem Solution No Hydraulic Functions Pilot enable switch OFF Turn switch ON Pilot enable switch failed Check pilot enable switch. Slow Hydraulic Functions Cold oil Warm oil. Slow engine speed Suction line air leak Low oil supply Wrong oil viscosity Blocked or damaged line Check fast idle speed. Check for foamy oil. Add recommended oil. Use recommended oil. Inspect lines. Noisy Hydraulic Pump Low oil supply or wrong viscosity Fill reservoir with recommended oil. Plugged or pinched suction line Air in oil Loose or missing hydraulic line clamps Hydraulic lines in contact with frame Clean or replace line. Check for foamy oil. Tighten connections. Replace O-rings and/or lines. Tighten or replace clamps. Inspect and repair. Boom Float Function Does Not Return-to-carry switch ON Turn switch OFF. Work One Hydraulic Function Does Not Blockage in oil lines or valve Inspect lines for damage. Work Function Drifts Down Leaking cylinders Check cylinder leakage. Boom lower solenoid valve Leaking loader control valve Check Solenoid. Replace valve section. Continued on next page TX17961, OCT02 1/ PN=225

228 Miscellaneous Troubleshooting Symptom Problem Solution Boom Down Does Not Work Pilot enable/boom down switch not Push and hold pilot enable/boom (Engine Off) held down down switch as loader control lever is moved. Unswitched boom down, radio and dome light fuse failed Boom down solenoid failed Pilot enable/boom down switch failed. Replace fuse. Replace solenoid. Replace switch. Oil Overheats Low oil viscosity in hot weather Use recommended oil. Excessive load Cylinder Leakage Restriction in oil lines or loader valve Reduce load. Check cylinder leakage. Inspect for dented or kinked lines. Hydraulic Oil Foams Low oil level Add recommended oil. Wrong oil Water in oil Loose or faulty suction lines (air leak in system) Change to recommended oil. Drain oil from reservoir and cylinders. Fill with recommended oil. Tighten or install new lines. Pin Disconnect Cylinders Will Electrical circuit failure Hold a screwdriver against end of Not Retract pin disconnect solenoid valve and check for magnetism with switch pushed. Solenoid valve failure Cylinder binding Remove and inspect. Inspect cylinder and adjust loads. TX17961, OCT02 2/ PN=226

229 Miscellaneous Troubleshooting Steering Symptom Problem Solution No Steering Functions Frame locking bar in place Pin locking bar in unused position. Low oil level Pinched steering line Add recommended oil. Inspect and repair line. Erratic Steering Air in oil Check for foamy oil. Low oil level Add recommended oil. Spongy or Soft Steering Air in oil Check for foamy oil. Low oil level Add recommended oil. Machine Turns in Opposite Lines to cylinders connected to Connect lines to correct ports. Direction wrong ports at steering valve. TX17961, OCT02 1/ PN=227

230 Miscellaneous Troubleshooting Air Conditioning System Symptom Problem Solution Air Conditioning System Does Blower motor 25A fuse (F19) Replace fuse. Not Operate Pressurizer motor 7.5A fuse (F20) Blower/pressurizer motor relay (K19) Blower speed switch (S21) Blower speed resistor (R3) Main blower motor (M6) Pressurizer blower motor (M7) A/C (On/Off) switch (S22) Freeze control switch (B35) A/C low pressure switch (B36) A/C high pressure switch (B37) A/C compressor clutch solenoid (Y16) Replace fuse. Check Relay. Check switch. Check resistor. Check motor. Check motor. Check switch. Check switch. Check switch. Check switch. Check clutch operation. Continued on next page TX17961, OCT02 1/ PN=228

231 Miscellaneous Troubleshooting Symptom Problem Solution Air Conditioner Does Not Cool Fresh air filter clogged Clean or replace filter. Interior of Cab Condenser fins clogged with debris Recirculating air filter clogged Compressor pulley worn Refrigerant hose kinked, pinched or collapsed Heater or evaporator core fins clogged with dirt or dust Pressurizer blower motor failed or operating too slowly Compressor clutch slipping or failed Warm outside air leaking into cab Heater valve remaining open System refrigerant (R134A) charge low Evaporator fins frosting or freezing Clean condenser fins. Clean or replace filter. Replace pulley. Re-route or re-index hoses, replace kinked or collapsed hoses. Clean heater or evaporator core fins. Check motor speed. Inspect and/or replace compressor clutch. Inspect, repair or replace door and window seals. Inspect, repair, adjust or replace heater valve or cable. Inspect system for leaks. Freeze control switch capillary tube not positioned correctly in evaporator core. Air Conditioner Runs Constantly, Freeze control switch capillary tube Reposition capillary tube in Too Cold not positioned in evaporator correctly evaporator core Interior Windows Continue To Fresh air filter clogged Clean or replace filter. Fog A/C system off Turn A/C (ON/OFF) switch ON. TX17961, OCT02 2/ PN=229

232 Miscellaneous Troubleshooting Heater System Symptom Problem Solution Heater System Does Not Operate Blower motor fuse Replace fuse. Blower speed switch Check switch. Heater Does Not Warm Interior Fresh air filter clogged Clean or replace filter. Of Cab Recirculating air filter clogged Heater hose kinked, pinched or collapsed Heater core fins clogged with dirt or dust Heater valve remaining closed Temperature control switch failed Clean or replace filter. Re-route or re-index hoses, replace collapsed hoses. Clean heater fins. Inspect, repair, adjust or replace heater valve or cable. Inspect, repair or replace switch. Interior Windows Continue To Fresh air filter clogged Clean or replace filter. Fog A/C system off (if equipped) Turn A/C ON/OFF switch ON (if equipped). TX17961, OCT02 1/ PN=230

233 Miscellaneous Storage Prepare Machine For Storage 1. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later. 2. Check primary air cleaner. Replace filter, if necessary. 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. T5813AM UN 09FEB89 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 waste 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. 6. Retract all hydraulic cylinders, if possible. If not, coat exposed cylinder rods with LPS 3 Rust Inhibitor. 7. Place a "DO NOT OPERATE" tag on the right control lever. 8. Lubricate all grease points. 9. Remove batteries. 10. Remove seat cushion and other perishable items. 11. Remove keys and lock all covers and doors. LPS is a trademark of the Holt Lloyd Corporation. TX,105,FF NOV00 1/ PN=231

234 Miscellaneous Machine Numbers Record Product Identification Number (PIN) Purchase Date NOTE: Record all 13 characters of the Product Identification Number. A Product Identification Number T106371B UN 24JAN97 TX,110,JC JAN97 1/1 Record Engine Serial Number Engine Serial Number A Engine Serial Number T108431G UN 08APR97 TX,110,JC APR97 1/1 Record Transmission Serial Number Transmission Serial Number Located near lower left corner of case. A Transmission Serial Number T UN 11SEP98 CED,OUOE002, SEP98 1/1 Record Hydraulic Pump Serial Number Hydraulic Pump Serial Number A Hydraulic Pump Serial Number T106391B UN 24JAN97 TX,110,JC FEB97 1/ PN=232

235 Miscellaneous Machine Numbers Record Axle Serial Number Axle Serial Number A Axle Serial Number T UN 10SEP98 CED,OUOE002, SEP98 1/ PN=233

236 Miscellaneous Specifications 624H/TC62H Specifications T UN 19FEB97 A Bucket Hinge Height C Dump Reach E Wheelbase G Machine Overall Length B Dump Height D Machine Overall Height F Machine-to-Ground Clearance Item Measurement Specification A Bucket Hinge Height 624H 3961 mm (13 ft 0.0 in.) TC62H 4005 mm (13 ft 2.0 in.) B Dump Height 624H 2834 mm (9 ft 4.0 in.) TC62H 2907 mm (9 ft 6.0 in.) C Dump Reach 624H 1062 mm (3 ft 6.0 in.) TC62H 1278 mm (4 ft. 2.0 in.) D Overall Machine Height 3300 mm (10 ft 10.0 in.) E Wheelbase Length 3030 mm (9 ft 11 in.) Continued on next page CED,OUOE002, MAY00 1/ PN=234

237 Miscellaneous Specifications Item Measurement Specification F Machine-to-Ground Clearance 406 mm (16.0 in.) G Overall Machine Length 624H 7641 mm (25 ft 1.0 in.) TC62H 7671 mm (25 ft 2.0 in.) Weight 624H kg (30,492 lb) TC62H kg (30,532 lb) Counterweight 624H 509 kg (1,122 lb) TC62H 474 kg (1,045 lb) NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with SAE standards. Except where otherwise noted, specifications are based on a machine equipped with all standard equipment, with 474 kg (1,045 lb) optional counterweight, ROPS cab, diff lock front axle with standard rear axle, 2 spool valve with two lever control, heater and defroster, 79 kg (175 lb) operator and full fuel tank. CED,OUOE002, MAY00 2/ PN=235

238 Miscellaneous Specifications 624H High Lift Specifications T UN 22JUN00 A Bucket Hinge Height C Dump Reach E Wheelbase G Machine Overall Length B Dump Height D Machine Overall Height F Machine-to-Ground Clearance Item Measurement Specification A Bucket Hinge Height 4327 mm (14 ft 2.4 in.) B Dump Height 3224 mm (10 ft 7.0 in.) C Dump Reach 1125 mm (3 ft 8.3 in.) D Overall Machine Height 3300 mm (10 ft 10.0 in.) E Wheelbase Length 3030 mm (9 ft 11 in.) F Machine-to-Ground Clearance 406 mm (16.0 in.) G Overall Machine Length 8022 mm (26 ft 3.8 in.) Weight kg (30,089 lb) Counterweight 509 kg (1,122 lb) CED,TX03679, JUN00 1/ PN=236

239 Miscellaneous Specifications Drain and Refill Capacities 624H/TC62H Item Measurement Specification Cooling System Capacity 22 L (23 qt) Fuel Tank Capacity 265 L (70 gal) Engine Crankcase and Filter Capacity (S.N ) 20 L (21 qt) Capacity (S.N ) 21 L (22 qt) Transmission Case and Filter Capacity 27 L (29 qt) Front Differential Capacity 25 L (26 qt) Rear Differential Capacity 20 L (21 qt) Hydraulic Reservoir and Filters Capacity 117 L (31 gal) Park Brake Capacity L (10 oz) CED,OUOE002, DEC01 1/ PN=237

240 Miscellaneous Crime Prevention Tips Help Prevent Crime You can help take a bite out of crime by properly documenting ownership and discouraging theft. TS OCT88 DX,CRPRV,A 19 03MAR93 1/1 Record Identification Numbers 1. Mark your machines with your own unique numbering system. 2. Record the Product Identification Number (PIN) of the unit and also individual component identification numbers for engines, axles, pumps, etc. Include the PIN numbers on all documentation, such as insurance, financial, and warranty papers. TS156 UN 23MAR89 DX,CRPRV,H 19 04JUN90 1/1 Keep Proof of Ownership 1. Take color photographs from several angles of each machine. 2. Maintain an up-to-date inventory of all your machines. 3. Keep your documented identification numbers, color photographs, and inventory in a safe, secure location. TS157 UN 23MAR89 DX,CRPRV,I 19 04JUN90 1/1 Park Indoors Out of Sight Make machines hard to move: Park large equipment in front of exits. Lower equipment to the ground. Remove key. Remove battery when unit is in storage. Lock cab doors, windows, and vandal-proof devices. Lock building. TS158 UN 23MAR89 DX,CRPRV,J 19 04JUN90 1/ PN=238

241 Miscellaneous Crime Prevention Tips When Parking Outdoors Make machines hard to move: Park in a well-lighted, fenced area. Lower all equipment to the ground. Remove ignition key. Remove battery when unit is storage. Lock cab doors, windows, and vandal-proof devices. TS144 UN 23AUG88 DX,CRPRV,K 19 04JUN90 1/1 Reduce Vandalism 1. Install vandal-proof devices. 2. Participate in a neighborhood watch program. Take written notes of suspicious vehicles or persons and report your findings to law enforcement agency. 3. Regularly verify that identification plates have not been removed. If they have, notify law enforcement agency. Order duplicate plates from your dealer. T7223BB UN 22FEB90 TX,120,DH SEP92 1/ PN=239