OPERATOR S MANUAL. Crawler Dozer. OMT Issue C4 (ENGLISH) CALIFORNIA Proposition 65 Warning

Transcription

1 750C Series II and 850C Series II Crawler Dozer OPERATOR S MANUAL 750C Series II and 850C Series II Crawler Dozer OMT Issue C4 (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 B0) LITHO IN U.S.A.

2 Introduction Introduction 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 AND LEFT sides are determined by facing in the direction of forward travel. WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers chapter. 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. 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. T160591,IFC 19 11JUN96 1/ PN=2

3 Introduction T127184B UN 21JAN00 T160591,IFC 19 11JUN96 2/3 T127186B UN 21JAN00 T160591,IFC 19 11JUN96 3/ PN=3

4 Introduction PN=4

5 Introduction Crawler Dozer Warranty T FEB97 TX,INTR,BG APR97 1/ PN=5

6 Introduction HELP!! HELP!! HELP!! HELP!! We need your help to continually improve our technical publications. Please FAX or mail your comments, ideas and improvements. SEND TO: John Deere Dubuque Works P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, Iowa FAX NUMBER: Ideas, Comments (Please State Page Number): OVERALL, how would you rate the quality of "ALL" Manuals of this type provided to you? (Check one.) Poor Fair Good Very Good Excellent Company Name Address Phone FAX No. Dealer Acct. No. THANK YOU! TX,TM,FAX 19 05DEC96 1/ PN=6

7 Contents Page Page Safety Operator s Manual Holder Adjusting Seat Seat Belt Safety Signs Operator s Station Pre-Start Inspection Display Monitor Gauges and Indicators Inspect Machine Daily Before Starting Monitor Display Window Select Button Operation Operating the Engine Engine Coolant Temperature Gauge Check Instruments Before Starting Fuel Level Gauge Starting the Engine Engine Oil Pressure Gauge Starting Fluid Cold Weather Start Aid STOP-Engine Indicator and Alarm Using Booster Batteries 24-Volt System Service Required Indicator Using Coolant Heater If Equipped Engine Alternator Voltage Indicator Check Instruments After Starting Engine Air Filter Restriction Indicator Warm-Up Engine Transmission Oil Temperature Hot Indicator Engine Cold Weather Warm-Up Transmission Oil Filter Restriction Indicator Stalled Engine Hydraulic Oil Filter Restriction Indicator Stopping the Engine Normal Shutdown Return FNR with Transmission Speed-In-Grip to Neutral Indicator Driving the Machine Check Service Code Indicator Operating Suggestions Ether Injection Indicator Extend Undercarriage Life Fasten Seat Belt Indicator Operating Park Lock Lever Transmission Oil Pressure Gauge Driving the Machine Battery Disconnect Switch Travel Speed Blade Control Lever Steering with Transmission FNR with Park Lock Lever Transmission Speed-In-Grip Control Lever Engine Speed Lever Operating Brake Pedal FNR with Transmission Speed-In-Grip Stopping the Machine Buttons Parking the Machine Transmission Speed Reverse Ratio Knob Lock All Compartments Steering with FNR-Transmission Speed-In-Grip Lever Operating the Machine Foot Pedals Blade Operation Tips Work Lights If Equipped Blade Control Lever Operation Air Conditioner and Heat If Equipped Determining Blade Pitch Dome and Swivel Light Changing Blade Pitch Mirror Changing Blade Angle Mechanical Angle Door Latch Operating on Slopes Secondary Exits (Cab Units Only) Operating in Rough Terrain Cab Windows Side-by-Side Dozing Wiper and Washer Controls Grease Gun If Equipped 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 2004 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 2000, 2001 i PN=1

8 Contents Page Page Slot Dozing Check Coolant Level Tilt Dozer Ditching Lubricate Left and Right Track Frame Backfilling Pivot 750C series II If Equipped Leveling a Stockpile Lubricate Center Crossbar Pivot 750C Moving Boulders Series II If Equipped and 850C Series II Bench Cut Check Transmission Oil Level Brush Removal Check Hydraulic Oil Level Tree Removal Lubricate Dozer Linkage Stump Removal Lubricate All-Hydraulic Blade Transporting Maintenance Every 50 Hours Loading Machine on a Trailer Lubricate Left and Right Crossbar End Pivot Unloading Machine From Trailer Lubricate Lift Cylinder Pivots Towing Lubricate Track Adjust Cylinder Fuels and Lubricants Maintenance Every 250 Hours Diesel Fuel Change Engine Oil and Filter Elements Handling and Storing Diesel Fuel Check Inner and Outer Final Drive Fuel Tank Housings Oil Level Low Sulfur Diesel Fuel Conditioner Check Radiator Coolant Level Diesel Fuel Storage Diesel Engine Oil Transmission, Hydraulic, and Hand Pump Maintenance Every 500 Hours Reservoir Oil Change Primary Fuel Filter 750C Series II Inner and Outer Final Drive Oil Change Secondary Fuel Filter 750C Track Rollers, Front Idler, Carrier Roller Series II and Track Frame Outer Pivot Oil Change Primary Fuel Filter 850C Series II Grease Change Secondary Fuel Filter 850C Lubricant Storage Series II Alternative and Synthetic Lubricants Check Battery Electrolyte Level and Mixing of Lubricants Terminals Check Air Intake Hose Periodic Maintenance Check Coolant and Conditioner in Radiator Install Do Not Operate Tag Service Your Machine at Specified Intervals Maintenance Every 1000 Hours Check Hour Meter Regularly Clean Engine Crankcase Vent Tube Use Correct Fuels and Lubricants Check Left and Right Track Frame Pivot Prepare Machine for Maintenance Oil Level Maintenance and Repair Record Change Final Drive Oil Keeping System Remove and Inspect Air Filter Elements OILSCAN Plus, COOLSCAN Plus, DIESELSCAN and 3-Way Coolant Test Kit Maintenance Every 2000 Hours Maintenance and Repair Record Change Hydraulic Oil and Filter Keeping System Change Hydrostatic Transmission Oil and Filter Maintenance As Required Measure and Adjust Engine Valve Check Alternator Belt Tension Clearances 750C Series II Check Track Sag Measure and Adjust Engine Valve Adjust Track Sag Clearances 850C Series II Check Air Restriction Indicator Check Engine Speeds 750C Series II Engine Speed Adjustment 850C Series II Maintenance Every 10 Hours or Daily Check Engine Oil Level Continued on next page ii PN=2

9 Contents Page Page Maintenance Every 4500 Hours or 5 Years Engine Speed Adjustment 850C Series II Remove and Replace Engine Dampener Hardware Torque Specifications Checking Track Shoe Cap Screw Torque Maintenance Checking Track Shoe Cap Screw Torque Servicing the Cooling System Master Link Test the Coolant Freeze-Protection Level Metric Bolt and Cap Screw Torque Values Checking Coolant Hoses Additional Metric Cap Screw Torque Values Draining the Cooling System Service Recommendations for Metric Diesel Engine Coolant Series Four Bolt Flange Fitting Filling the Cooling System Unified Inch Bolt and Cap Screw Torque Engine Cold Weather Warm-Up Values Do Not Adjust Injection Pump Check Oil Lines and Fittings Do Not Service Injection Nozzles Service Recommendations for O-Ring Boss Drain Fuel Filter Sediment 850C Series II Fittings Fuel Drain and Shut-Off Valve Service Recommendations for Flat Face Clean Dusty Primary Element O-Ring Seal Fittings Clean Dust Unloader Valve O-Ring Groove Connections Prevent Battery Explosions Service Recommendations for Inch Prevent Acid Burns Series Four Bolt Flange Fittings Service Batteries Carefully Check Electrolyte Specific Gravity Operational Checkout Using Battery Charger Operational Checkout Precautions for Alternator and Regulator Battery Disconnect Switch, Relays, Using Booster Battery Gauges, Monitor and Transmission Replacing Batteries Controller Removing Batteries Park Lock, Park Brake, and Start Checks Fuse Specifications General Driving and Transmission Checks Fuse (Blade-Type) Color Codes Undercarriage Checks Adding 12-Volt Accessories Accessories and Cab Components Remove and Install Halogen Bulb Checking Neutral Start System Troubleshooting Change Reverse Warning Alarm Volume Using Troubleshooting Charts Track Sag General Information Engine Checking Idlers and Rollers for Oil Leakage Electrical System Checking Idler and Track Roller Oil Level Hydraulic System Checking Carrier Roller Oil Level Hydrostatic Transmission Checking Idler Horizontal Movement Brake System Checking Idler Vertical Movement Air Conditioning Cab or ROPS Tilting Procedure Transmission Controller Service Codes Check and Adjust Front Engine Controller Service Codes 850C Crossbar-to-Crossbar Support and Series II Main Frame Clearances 750C Series II If Equipped Adjusting Engine Speed Control Lever Storage Welding Procedure Prepare Machine for Storage Cleaning Cab Air Filter Lock All Compartments Cleaning Cab Air Filter Interior Monthly Storage Procedure Checking Fire Extinguisher If Equipped Checking Air Conditioner Refrigerant Machine Numbers Level If Equipped Record Product Identification Number (PIN) Service Control Valves, Cylinders, Pumps Record Engine Serial Number and Motors Check Engine Speeds 750C Series II Continued on next page iii PN=3

10 Contents Page Record C-Frame or Pushbeam Serial Number Record Transmission Serial Numbers Specifications 750C Series II Specifications C Series II Capacity Specifications C Series II General Specifications C LT Series II Dimensions C WT Series II Dimensions C LGP Series II Dimensions C Series II Specifications C Series II Capacity Specifications C Series II General Specifications C LT Series II Dimensions C WT Series II Dimensions C LGP Series II Dimensions 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 Checklists...CLIS-1 John Deere Service Keeps You On the Job AT YOUR SERVICE WHEN YOU NEED IT... IBC-1 iv PN=4

11 Safety 750C Series II and 850C Series II Crawler Dozer Safety Features TX,05,BG JAN00 1/1 T FEB PN=9

12 Safety 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=10

13 Safety 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 John Deere 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 expose the operator to intruding or flying objects. Using this machine in a forestry application or woods environment, or with attachments such as a winch, requires added guarding to protect the operator. Forestry protection packages or special screens should be installed when working in areas where logs or branches may strike the operator. A rear screen should always be used with a winch to protect against a snapping cable. Contact your authorized dealer for information on protective guarding before operating in any hazardous environment. T UN 05MAR01 TX03768,0000B MAR01 1/ PN=11

14 Safety Inspect Machine Inspect machine carefully each day by walking around it before starting. (See Pre-Start Inspection Chapter.) 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=12

15 Safety 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=13

16 Safety 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 John Deere dealer for a Material Safety Data Sheet (MSDS). 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 SEP00 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 John Deere 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=14

17 Safety 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. Before starting engine, sit in operator s seat. Ensure park lock lever is in lock position. Never attempt to start engine from the ground or tracks. Do not attempt to start engine by shorting across the starter solenoid terminals. T UN 07SEP00 TX03768,0000B FEB01 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=15

18 Safety Prevent Unintended Machine Movement Always move the park lock lever to the lock (B) position before leaving the operator s seat for any reason. Be careful not to accidentally actuate steering, travel or other controls. Engage park lock and lower work equipment to the ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow proper parking procedures before leaving the operator s station. T118007C UN 14JAN99 TX03768,0000B9C 19 04OCT01 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 working below ground level. Avoid or correct hazardous work situations. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Keep bystanders clear at all times. Use barricades or a signal person to keep vehicles and pedestrians away. Always keep signal person in view. Instruct co-workers and bystanders not to approach the machine while it is operating. Operate only on solid footing Use extra care when operating on stockpiles or near banks or excavations that may cave in and cause machine to tip or fall. Never allow the machine on a floor or structure until you are sure it will support the weight. Avoid contact with overhead electrical wires. Stay clear of 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. T UN 05MAR01 T UN 05MAR01 TX03768,0000B MAR01 1/ PN=16

19 Safety 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 22FEB01 TX03768,0000B FEB01 1/1 Avoid Backover Accidents Before moving machine, be sure all persons are clear of the machine travel path. Turn around and look directly for best visibility. Use mirror to assist in checking behind the machine. Keep windows and mirror clean and in good repair. Be certain backup 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 31MAR01 TX03768,0000B JAN01 1/ PN=17

20 Safety Avoid Machine Tipover 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 secured on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel. Be careful on slopes. Use extra care on soft, rocky or frozen ground because machine may slip sideways in these conditions. When traveling up or down steep slopes, keep the bucket or blade on uphill side and just above ground level. Ensure solid footing. Use extra care when operating on stockpile materials, or near banks or excavations that may cave-in and cause machine to tip or fall. T SEP00 T UN 22FEB01 T UN 22FEB01 TX03768,0000B6B 19 29JAN01 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 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 blade/bucket and attachments to the ground. Place park lock lever in lock position. Stop engine and remove key. Attach a Do Not Operate tag in an obvious place in the operator s station. Securely support machine or attachment before working under it. Do not support machine with blade/bucket or attachments. Do not support machine with cinder blocks or wooden pieces that may crumble or crush. Do not support machine with a single jack or other devices that may slip out of place. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work. T DEC01 TS229 UN 23AUG88 TX03768,0000B6A 19 29JAN01 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 Remove Paint Before Welding or Heating Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or grinding paint can also be hazardous. Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or grinding paint. If a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint stripper containers from work area and allow fumes to disperse at least 15 minutes before welding or heating. T UN 24AUG00 Work outside or in a well-ventilated area. Dispose of waste, paint and solvents properly. TX03679, SEP00 1/1 Make Welding Repairs Safely NOTE: To avoid machine damage, disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and machine 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 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 Signs Safety Sign T7972AP 19 22MAR93 T128124B UN 04FEB00 TX,06,RR JAN00 1/ PN=22

25 Safety Signs Safety Sign T6914AU 19 24FEB89 T127194B UN 21JAN00 TX,06,BG JAN00 1/ PN=23

26 Safety Signs Safety Sign T UN 10MAR97 T SEP96 TX,06,BG JAN00 1/ PN=24

27 Safety Signs Safety Sign T127295C UN 20JAN00 T8439AU 19 21MAR95 TX,06,RR JAN00 1/ PN=25

28 Safety Signs Safety Sign T UN 03JUN96 T7593AC 19 30AUG91 TX,06,RR,A JUN96 1/ PN=26

29 Safety Signs Safety Sign Engine Coolant Heater Cord Assembly T6735AC 19 01FEB89 TX06,FF MAR96 1/ PN=27

30 Operator s Station Display Monitor Gauges and Indicators T UN 31JAN00 1 Select Button 7 Transmission Oil Filter 12 Return FNR with 14 STOP Indicator 2 Display Window Restriction Indicator Transmission 15 Engine Alternator Voltage 3 Engine Coolant 8 Hydraulic Oil Filter Speed-In-Grip to Neutral Indicator Temperature Gauge Restriction Indicator FNR with Transmission 16 Engine Air Filter 4 Fuel Level Gauge 9 Fasten Seat Belt Indicator Indicator Restriction Indicator 5 Engine Oil Pressure Gauge 10 Ether Injection Indicator 13 Service Required Indicator 6 Transmission Oil 11 Check Service Code Temperature Hot Indicator Indicator NOTE: Battery disconnect switch must be in ON position for monitor to operate. (See Battery Disconnect Switch in this chapter.) Monitor has 16 functions and is connected to the engine and transmission controllers. This allows monitor to display transmission speed and control system service codes in the display window (B). (See Engine Controller Service Codes or Transmission Controller Service Codes in Troubleshooting chapter in this manual.) The display monitor has three modes of operation; they are: Key Off Mode: With battery disconnect switch ON and key switch OFF, each time the SELECT button is pressed, information displayed sequences from HOUR METER symbol to VOLTMETER symbol. If SELECT button is pressed and held, information will sequence every four seconds in the same order. While SELECT button is pressed, back lighting is supplied to engine coolant temperature gauge, fuel tank level gauge and engine oil pressure gauge. With SELECT button released, unswitched power is removed and information is no longer displayed. Bulb Check Mode: With battery disconnect switch ON, key switch ON, and the engine not running, display monitor will go into bulb check mode. All indicator lights, including red STOP light and service required indicator will glow and monitor alarm will begin to sound. Alarm sounds for five seconds to allow operator time to see that all display elements are functional. Continued on next page CED,OUO1032, JAN00 1/ PN=28

31 Operator s Station Engine Running Mode: Monitor determines engine is running when it detects engine oil pressure and frequency from the alternator. Monitor will display status of machine functions through its indicators and gauges. CED,OUO1032, JAN00 2/2 Monitor Display Window Monitor display window (A) is used to: Display engine rpm. Display battery voltage with key switch OFF or ON. Display engine hour meter reading with key switch OFF or ON. Display engine service codes. (See Engine Controller Service Codes in Troubleshooting chapter in this manual.) Display transmission speed setting. Display transmission service codes. (See Transmission Controller Service Codes in Troubleshooting chapter in this manual.) A Monitor Display Window T UN 09SEP98 Each time key is turned to ON position, monitor is started and engine is running, display window will show engine rpm. If engine is not running, display window will show hour meter. TX,10,RR,A JAN00 1/ PN=29

32 Operator s Station Select Button Operation With key switch OFF or ON, and engine running or stopped, pressing SELECT button will display the following data: Hour symbol and current data Volt symbol and current data With key switch ON, and engine running or stopped, pressing SELECT button will also display: Tachometer symbol and current data Transmission default speed Hour Symbol T8294AN 19 04DEC94 If SELECT button is pressed and held, information will sequence every four seconds. If SELECT button is released within one second after symbol is shown, that symbol will stay in the display window. The following values will be displayed; Engine RPM: The value should be approximately 930 at low idle. Transmission Speed: The default value is SP1.6. Top button (rabbit) will increase transmission speed. Lower button (turtle) will decrease transmission speed. (Transmission speed will also be displayed if park lock lever is moved or transmission speed buttons are pushed.) Battery Voltage: The value should be approximately Hour Meter: How long the machine has been in service. Volt Symbol T8294AL 19 04DEC94 Tachometer Symbol T8294AH 19 17DEC94 Transmission Speed T FEB00 TX,10,RR,A MAY96 1/ PN=30

33 Operator s Station Engine Coolant Temperature Gauge Engine coolant temperature gauge is a nine-segment analog gauge that is controlled by a signal received from the engine coolant temperature sender. Normal range of gauge should show at least three to seven segments. If temperature is too high, the ninth indicator segment (A) will stay on and the other eight segments will flash. The STOP-indicator light will flash and an audible alarm will sound. Immediately take load off the machine and run engine at high idle. If indicators continue to stay on after several minutes of operation, stop engine and check for problem. (See Troubleshooting chapter.) A Ninth Indicator Segment T8448AU UN 30MAR95 TX,10,RR,A JUN96 1/1 Fuel Level Gauge Fuel level gauge is a nine-segment analog gauge that is controlled by a signal received from the fuel level sender. If fuel level is low, the lowest segment (A) of gauge will flash. Approximate amount of fuel remaining: Specification Low Fuel Indicator 750C Series II Capacity... Low Fuel Indicator 850C Series II Capacity L (8 10 gal) Approximate L (16 18 gal) Approximate A Low Fuel Segment T8448AO UN 30MAR95 TX,10,RR,A MAY96 1/ PN=31

34 Operator s Station Engine Oil Pressure Gauge Engine oil pressure gauge is a nine-segment analog gauge that is controlled by a signal received from the engine sender. When engine is running and engine pressure drops below 69 kpa (10 psi), only segment (A) will light and flash, the STOP-indicator light will come on and an audible alarm will sound. Immediately park machine in a safe area and stop the engine. When engine is not running and key switch is on, the gauge light will be on, STOP light will not be on and audible alarm will not sound. A Low Oil Pressure Segment T8448AV UN 30MAR95 TX,10,RR,A MAY96 1/1 STOP-Engine Indicator and Alarm IMPORTANT: If STOP-engine indicator flashes and alarm sounds more than 10 seconds, stop machine immediately and investigate cause of problem. STOP-engine indicator flashes and alarm sounds when: Engine oil pressure is low. Engine coolant temperature is excessively high. If indicators do not function correctly, see Troubleshooting chapter. T7673AM UN 06JAN92 TX,10,RR,A MAY96 1/ PN=32

35 Operator s Station Service Required Indicator If service required indicator lights, a problem is developing. It is not necessary to stop engine immediately, but the cause should be investigated as soon as possible. Service required indicator lights when: Alternator voltage is low. Transmission oil filter is restricted. Hydraulic oil filter is restricted. Air filter elements are restricted. Transmission oil temperature is too high. T6201BL UN 18OCT88 TX,10,BG APR97 1/1 Engine Alternator Voltage Indicator Engine alternator voltage indicator light will come on when alternator voltage drops below 25 volts. T8381AO UN 03JAN95 TX,10,RR,A MAY96 1/1 Engine Air Filter Restriction Indicator Air filter restriction indicator will come on with service required indicator when engine is running with air filter restricted. Park machine in a safe area and shut engine off immediately. Check air filters for restrictions. T8381AN UN 03JAN95 TX,10,RR,A MAY96 1/ PN=33

36 Operator s Station Transmission Oil Temperature Hot Indicator When engine is running and transmission oil temperature is too hot, transmission hot and service required indicators will light. Park machine in a safe area immediately and run engine at 1/2 speed until transmission cools off. Shut engine off and check machine for proper oil levels. T8381AM UN 03JAN95 TX,10,RR,A MAY96 1/1 Transmission Oil Filter Restriction Indicator NOTE: Restriction indicator may stay on for several minutes until transmission oil is warm. When engine is running and transmission filter becomes restricted, transmission oil filter restriction and service required indicators will light. Replace transmission oil filter as necessary. See Change Hydrostatic Transmission Oil and Filter in Maintenance Every 2000 Hours chapter. T8381AL UN 03JAN95 TX,10,RR,A MAY96 1/1 Hydraulic Oil Filter Restriction Indicator NOTE: Restriction indicator may stay on for several minutes until hydraulic oil is warm. When engine is running and hydraulic oil filter becomes restricted, hydraulic oil filter restriction and service required indicators will light. Replace hydraulic oil filter as necessary. See Change Hydraulic Oil and Filter in Maintenance Every 2000 Hours chapter. T8381AG UN 03JAN95 TX,10,RR,A MAY96 1/ PN=34

37 Operator s Station Return FNR with Transmission Speed-In-Grip to Neutral Indicator With park lock levers in up position (locked) and FNR with Transmission Speed-In-Grip lever out of neutral position, turning key switch ON will cause Return FNR with Transmission to Neutral indicator to light. FNR with Transmission Speed-In-Grip lever must be moved back to neutral position for machine to start. Return FNR with Transmission to Neutral indicator will also light when brake pedal is depressed. Machine will move as brake pedal is released. T8381AP UN 03JAN95 TX,10,RR,A MAY96 1/1 Check Service Code Indicator Check service code indicator will light and flash when a problem is detected in the transmission or engine controller electrical systems. Indicator light will go out when machine is shut off. T UN 09SEP98 Indicator light will stay on but not flash when communication between controller and monitor is removed, or when a service code is displayed at monitor window. Indicator light will flash during transmission calibration procedure. TX,10,RR,A SEP98 1/1 Ether Injection Indicator Ether injection indicator will light when start aid switch is pressed. T8381AJ UN 03JAN95 TX,10,RR,A MAY96 1/ PN=35

38 Operator s Station Fasten Seat Belt Indicator Fasten seat belt indicator will light and stay on for five seconds after display monitor comes on, reminding the operator to fasten seat belt. T8381AI UN 03JAN95 TX,10,RR,A MAY96 1/1 Transmission Oil Pressure Gauge Transmission oil pressure gauge measures oil pressure in transmission. If reading falls into red segment, see your authorized dealer for service. T127377B UN 20JAN00 TX,10,RR,A JAN00 1/1 Battery Disconnect Switch Disconnect switch (A) is located next to machine batteries. Push switch to OFF position to disconnect electrical power to machine. A Battery Disconnect Switch T UN 03JUN96 TX,10,RR,A JUN96 1/ PN=36

39 Operator s Station Blade Control Lever Blade control lever (1) can be equipped to operate an all-hydraulic blade, dozer blade, or an angle blade. 1 Blade Control Lever All-Hydraulic Shown T127332C UN 20JAN00 TX,10,RR,A JAN00 1/1 Park Lock Lever Park lock lever (1) up (locked) to prevent machine from moving. 1 Park Lock Lever T127193B UN 21JAN00 TX,10,RR,A JAN00 1/2 Move park lock lever (1) down (unlock) to allow operation of machine. 1 Park Brake Lever T127204B UN 21JAN00 TX,10,RR,A JAN00 2/ PN=37

40 Operator s Station Engine Speed Lever Engine speed lever (1) adjusts engine rpm. Move lever rearward to increase rpm and forward to decrease rpm. 1 Engine Speed Lever 2 FNR with Transmission Speed-In-Grip Lever FNR with Transmission Speed-In-Grip T127219B UN 21JAN00 TX,10,RR,A JAN00 1/1 FNR with Transmission Speed-In-Grip Buttons The transmission speed button is located in FNR with Transmission Speed-In-Grip lever (2). Push top button (rabbit) to increase transmission speed. Push bottom button (turtle) to lower transmission speed. 1 Transmission Speed Increase 2 Horn 3 Transmission Speed Decrease T128172B UN 08FEB00 CED,OUO1065, JAN00 1/ PN=38

41 Operator s Station Transmission Speed Reverse Ratio Knob The reverse speed ratio knob located to left of FNR with Transmission Speed-In-Grip lever adjusts the reverse speed as a percentage of the transmission speed setting. The reverse speed percentage settings are 80%, 100%, 115%, and 130%. Transmission speed reverse setting, will not exceed transmission maximum speed of SP km/h (6.8 mph). [An example; If transmission speed is SP3.0, and the reverse ratio knob is set at 80%, then the reverse speed would be equivalent to 8.7 km/h (5.4 mph).] 1 Transmission Speed Reverse Ratio Knob T122745B UN 26JUL99 CED,OUO1065, JAN00 1/ PN=39

42 Operator s Station Steering with FNR-Transmission Speed-In-Grip Lever The FNR with Transmission Speed-In-Grip Control (2) controls the direction (forward and reverse), the steering (left turn, right turn), pivot turn, and counterrotation. 1 Engine Speed Control 2 FNR with Transmission Speed-In-Grip Control T127219B UN 21JAN00 T122746B UN 29JUL99 TX,10,RR,A JUN96 1/1 Foot Pedals CAUTION: Prevent possible injury from unexpected machine movement. Pushing on brake pedal will stop machine abruptly. NOTE: Release of brake pedal will allow machine to move. Brake pedal (A) should not be used to stop machine during normal operating conditions. Pushing on brake pedal will stop machine abruptly. Travel will resume as pedal is released. Pushing on decelerator pedal (B) will slow engine rpm and reduce machine ground speed. A Brake Pedal B Decelerator Pedal T UN 31MAY96 TX,10,RR,A JAN00 1/ PN=40

43 Operator s Station Work Lights If Equipped Push switch (B) to turn lights (A) on. A Work Lights B Work Light Switch T8404AU UN 22FEB95 T127197B UN 21JAN00 T8429AF UN 02MAR95 TX,10,RR JAN00 1/ PN=41

44 Operator s Station Air Conditioner and Heat If Equipped IMPORTANT: Do not operate air conditioner when air temperature is below 30 F ( 1 C). When warm weather begins, check refrigerant for proper charge before using air conditioner. (See Checking Air Conditioner Refrigerant Level in Maintenance chapter.) Push switch (B) to turn air conditioner on or off. T8404AY UN 22FEB95 NOTE: To increase temperature, make sure heater hose shut-off valve (D) on engine water pump housing is open. Turn temperature control knob (C) clockwise to increase temperature. Turn blower control knob (A) clockwise to increase blower speed. If temperature in cab becomes too cold, the temperature knob can be turned to add heat even though air conditioner is on. Move louvers left or right to direct or restrict air flow. A Blower Control Knob B Air Conditioner Switch C Heater Blower Control Knob D Heater Shut-Off Valve T UN 31MAY96 TX,10,BG APR97 1/1 Dome and Swivel Light Push switch (A) to operate dome light. Push switch (B) to operate swivel light. A Dome Light Switch B Swivel Light Switch T8404AZ UN 22FEB95 TX,10,RR MAR95 1/ PN=42

45 Operator s Station Mirror Mirror (A) can be adjusted to suit operator s preference. A Mirror T8432AQ UN 08MAR95 TX,10,RR MAR95 1/1 Door Latch Push out on door latch lever (1) to open door. Doors can be latched in the open position when pushed back against the cab side. 1 Door Latch T127381B UN 21JAN00 TX,10,RR JAN00 1/ PN=43

46 Operator s Station Secondary Exits (Cab Units Only) Exit cab through doors (2), side and rear windows (1 and 3) can be used as secondary exits. 1 Secondary Side Exit 2 Door 3 Secondary Rear Exit T127505B UN 26JAN00 T127425B UN 21JAN00 TX,10,RR,A JAN00 1/ PN=44

47 Operator s Station Cab Windows Squeeze latches (A) to raise and lower upper window. Squeeze latches (B) to raise and lower bottom window. 1 Upper Window Latches 2 Lower Window Latches T127763B UN 31JAN00 TX,10,RR MAR95 1/1 Wiper and Washer Controls Push switch (3) to operate front windshield wiper. Push switch (1) to operate windshield washer. Push switch (2) to operate door windshield wipers. 1 Washer Switch 2 Door Wiper Switch 3 Front Wiper Switch T127754B UN 31JAN00 CED,OUO1065, JAN00 1/ PN=45

48 Operator s Station Grease Gun If Equipped Store grease gun (A) in bracket. A Grease Gun T8439AV UN 24MAR95 TX,10,RR MAR95 1/1 Operator s Manual Holder Operator s manual holder (1) is located on front side of right control console for ROPS machines. For cab machines with cloth seats, operator s manual holder is located behind the back of seat. 1 Operators Manual Holder ROPS Shown T127332D UN 20JAN00 TX,10,RR,A JAN00 1/ PN=46

49 Operator s Station Adjusting Seat Use weight adjustment crank lever (E) to turn weight adjustment knob (F). Turn knob clockwise for firm ride and counterclockwise for soft ride. Rotate knob (C) to desired cushion position. Lift seat fore-aft lever (G) to move seat forward and rearward. Release handle at one of several positions. Remove your weight from seat. Lift up handle (D) and move seat to one of three positions for height adjustment. Move seat to mid-to-aft position. While sitting in seat, turn weight adjustment crank lever (E) to support weight. Check weight indicator (H) for appropriate weight setting and continue to turn until yellow pointer inside tube is flush with tube opening. While sitting in seat, lift lever (B) and allow cushion to angle forward or lean backward into desired position and release handle. A Lumbar Support Knob B Back Cushion Angle Adjustment Lever C Seat Cushion Adjustment Knob D Seat Height Adjustment Lever E Weight Adjustment Crank Lever F Weight Adjustment Knob G Fore and Aft Adjustment Lever H Weight Indicator T8439AI UN 22MAR95 While sitting in seat, rotate lumbar support knob (A) to increase or decrease support to lower back. TX,10,RR,A JUN96 1/ PN=47

50 Operator s Station Seat Belt T8415AA UN 09FEB95 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,DH FEB95 1/ PN=48

51 Pre-Start Inspection Inspect Machine Daily Before Starting Do periodic service checks in Maintenance Every 10 Hours or Daily chapter. Clean grille and radiator screens (A). Clean engine shields (B). Check pre-cleaner (C) and clean as necessary. Clean operator s station (D), check pedals for freedom of movement and fire extinguisher charge if equipped. Check fuel level. Remove fuel tank cap (E) and fill with proper fuel if necessary. (See Fuels and Lubricants chapter.) Check the following before starting: ELECTRICAL SYSTEM: Check for worn or frayed wires and loose or corroded connections. HYDRAULIC SYSTEM: Check for leaks, missing or loose clamps, kinked hoses, and lines or hoses that rub against each other or other parts. FUEL SYSTEM: Drain fuel filter. HARDWARE: Check for loose or missing parts. T8381AE UN 03FEB95 LUBRICATION: Check lubrication points on Periodic Maintenance Chart. (See Service Your Machine at Specified Intervals in the Periodic Maintenance chapter for location of chart.) SHEET METAL AND TRACKS: Check for bent, broken, loose or missing parts. A Grille and Radiator Screens B Engine Shields C Pre-Cleaner D Operator s Station E Fuel Tank Cap PROTECTIVE DEVICES: Check guards, shields, ROPS, and seat belt. SAFETY: Walk around machine to be sure all persons are clear from machine area. TX,20,RR,A JUN96 1/ PN=49

52 Operating the Engine Check Instruments Before Starting With battery disconnect switch ON, key switch ON and engine not running, display monitor will go into bulb check mode. All warning indicators, red STOP light, and yellow service required indicator are turned on. All indicators and displays on monitor will light and monitor alarm will sound for five seconds. If lights do not come on, check bulbs. T UN 09SEP98 TX,25,RR,A SEP98 1/1 Starting the Engine CAUTION: Prevent asphyxiation. Engine exhaust fumes can cause sickness or death to you or someone else. If you must operate engine in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and/or windows to bring enough outside air into the area. TS220 UN 23AUG88 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 starting circuitry is bypassed. NEVER start engine while standing on ground. Start engine only from operator s seat with FNR with Transmission Speed-In-Grip lever in neutral and park lock lever up. 1. Turn battery disconnect switch (A) clockwise to ON position to close electrical circuit. T6607AO UN 18OCT88 A Battery Disconnect Switch T UN 03JUN96 Continued on next page TX,25,RR,A JUN96 1/ PN=50

53 Operating the Engine CAUTION: Use seat belt to avoid being injured or killed in case of accident such as an overturn. 2. Sit in seat and fasten seat belt. TS175 UN 23AUG88 TX,25,RR,A JUN96 2/3 NOTE: Controls and switches must be in the positions described, before starting engine. 3. FNR with Transmission Speed-In-Grip lever (2) to Neutral position. 4. Park lock lever (3) in up (locked) position. IMPORTANT: To avoid engine damage, never start engine with speed control at high speed. 5. Engine speed control lever (1) to 1/3 speed. T127219B UN 21JAN00 6. Push horn switch to sound horn. IMPORTANT: Do not operate starter more than 20 seconds at a time or starter may be damaged. If engine does not start, wait at least two minutes before trying again. If engine does not start in four attempts, refer to Troubleshooting chapter. 7. Turn key switch clockwise to turn engine until it starts. With engine running, adjust engine rpm to 1200 (1/2 speed). (See Warm-Up Engine in this chapter for proper warm-up procedure.) 1 Engine Speed Control Lever 2 FNR with Transmission Speed-In-Grip Lever 3 Park Lock Lever T127295B UN 21JAN00 TX,25,RR,A JUN96 3/ PN=51

54 Operating the Engine Starting Fluid Cold Weather Start Aid 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. IMPORTANT: Prevent damage to engine. Use start aid when temperatures are below 4.4 C (40 F) and only when engine is COLD. T127295D UN 20JAN00 Using Starting Fluid IMPORTANT: To avoid engine damage, push start aid button only when engine is cold and cranking. Start aid fluid is being injected into engine as long as you push switch. NOTE: Crank engine for 20 seconds maximum, allowing two minutes between cranking periods. While cranking engine, push start aid switch (A). Replacing Start Aid Can 1. Remove clamp (B) from container. 2. Turn container (C) counterclockwise to remove. 3. Install new container by turning clockwise into starting valve. A Start Aid Switch B Clamp C Container T8594AE UN 09NOV95 Continued on next page TX,25,BG JAN00 1/ PN=52

55 Operating the Engine IMPORTANT: Protect start aid components from possible damage. Use dust cap on starting valve. 4. If no starting fluid is needed, remove container and install dust cap (D). D Dust Cap T8594AF UN 09NOV95 TX,25,BG JAN00 2/ PN=53

56 Operating the Engine Using Booster Batteries 24-Volt System Before boost starting, machine must be properly shut down 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. IMPORTANT: The machine electrical system is a 24-volt negative (-) ground. Connect two 12-volt booster batteries together as shown for 24-volts. 1. Connect one end of the positive cable to the positive terminal of the machine batteries and the other end to the positive terminal of the booster batteries. 2. Connect one end of the negative cable to the negative terminal of the booster batteries. Connect other end of the negative cable to the machine frame as far away from the machine batteries as possible. 3. Start engine. (See procedure in this chapter.) Two Battery Application T6713AH1 UN 24OCT91 4. Immediately after starting engine disconnect end of the negative cable from the machine frame. Then disconnect the other end of the negative cable from the negative terminal of the booster batteries. 5. Disconnect positive cable from booster batteries and machine batteries. A Machine Batteries B Booster Batteries T6979DE1 UN 24OCT91 TX,25,DH MAR99 1/ PN=54

57 Operating the Engine Using Coolant Heater If Equipped CAUTION: Use a grounded cord to connect coolant heater to electrical power. Connect coolant heater to 115-volt electrical power 10 hours before you start the engine. T53034 UN 01NOV88 TX,25,RR,A MAY96 1/1 Check Instruments After Starting With park lock lever up and engine running, fuel gauge, engine oil pressure gauge, engine coolant gauge, and monitor display window showing engine rpm must illuminate and indicate a measurement. T UN 09SEP98 TX,25,RR,A SEP98 1/1 Warm-Up Engine IMPORTANT: To ensure proper lubrication, idle engine at 1200 rpm with no load for five minutes. Extend period as necessary when operating at temperatures below freezing. 1. Before moving machine, run engine at 1/2 speed (1200 rpm) for five minutes. IMPORTANT: To avoid carbon build-up in engine and to use fuel in most efficient manner, do not allow machine to idle at low rpm. 2. Do not run engine at fast or slow idle. 3. Operate machine under light loads for first five minutes once engine is warm. 4. Check instruments regularly. TX,25,RR,A MAY96 1/ PN=55

58 Operating the Engine Engine Cold Weather Warm-Up IMPORTANT: If hydraulic oil is cold, hydraulic functions move slowly. Do not attempt machine operations until hydraulic functions move at close-to-normal cycle times. In extremely cold conditions, an extended warming-up period will be necessary. Avoid sudden operation of hydraulic functions until engine is thoroughly warmed up. Remove ice, snow, and mud before operation. NOTE: 850C Series II Machine: Use J20D HY-GARD oil in the hydraulic and transmission system to help start the engine when ambient temperature is below 18 C (0 F). 1. Run engine at 1/2 speed for five minutes. 2. Cycle all hydraulic functions to distribute warmed oil until all functions operate freely. HY-GARD is a registered trademark of Deere & Company TX,25,RR,A MAY96 1/1 Stalled Engine IMPORTANT: Engine damage may occur due to overheating after stalling when working under load. Follow restart procedure to keep coolant circulating through engine. RESTART ENGINE: Immediately remove load and restart engine. Run engine for 20 seconds at 1200 rpm (1/2 speed) before adding load and resuming work. See Stopping the Engine Normal Shutdown in this chapter for stopping procedure if machine is to be stopped after stalling. TX,25,RR,A MAY96 1/ PN=56

59 Operating the Engine Stopping the Engine Normal Shutdown IMPORTANT: Before stopping engine that has been operating at working load, idle engine at 1/2 speed for two minutes to cool hot engine parts. If engine stalls while operating under load, restart it immediately and idle at 1/2 speed for two minutes before stopping to allow coolant to continue circulating through engine. IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. T127219B UN 21JAN00 1. Park machine on a level surface. 2. Lower all equipment to ground. 3. Move FNR with Transmission Speed-In-Grip lever (2) to neutral position. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on FNR with Transmission Speed-In-Grip lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park lock lever to hold machine. 4. Move park lock lever (3) to up (locked) position. 5. Run engine at 1/2 speed without load for two minutes. 6. Move engine speed control lever (1) to slow idle position. 7. Turn key off to stop engine. Remove key. T127194C UN 21JAN00 8. Release hydraulic pressure by moving control lever(s) until equipment does not move. 1 Engine Speed Control Lever 2 Speed In Grip Lever 3 Park Lock Lever TX,25,RR,A JAN00 1/ PN=57

60 Driving the Machine Operating Suggestions Select engine rpm and ground speed to meet your needs. Consider ground conditions, operating area, work load and grade desired when making speed selection. Know your machine, its capabilities and its limits. TX,30,RR,A MAY96 1/ PN=58

61 Driving the Machine Extend Undercarriage Life Proper maintenance and adjustment of your machine s undercarriage will provide maximum wear life in many operating and soil conditions. You can and will make a difference in getting maximum wear life from the components. Here are some operating tips that will make a difference: PROPER TRACK SAG ADJUSTMENT Maintaining proper amount of track sag 51 mm (2.0 in.) is the most important adjustment to maintain. Tight tracks can reduce wear life by more than 50 percent and cause loading on undercarriage components, increasing the wear rate. Track sag should be adjusted as soil conditions change. Observe the amount of sag every day and adjust as needed. Refer to the periodic service interval in this manual or decal on machine for proper adjustment procedure. REDUCE OPERATING TIME IN REVERSE On all track machines, bushing and sprocket wear rate increases significantly when operating in reverse rather than forward. To get the most life out of undercarriage, minimize the amount of time operating in reverse. T7800AH UN 31JUL92 REDUCE OPERATING AND TRAVEL SPEED WHEN POSSIBLE As machine speed increases, wear rates increase. Operate at minimum ground speed required to match type of work. Excessive track slipping will also increase wear, particularly on grouser tips. REDUCE UNNECESSARY ADDED WEIGHT Additional machine weight due to attachments of counterweighting will cause faster wear rate. USE PROPER CHAIN GUIDES OR GUARDS Properly installed and maintained track guides or guards will keep chain aligned with roller and idler, extending wear life. SELECT PROPER TRACK PAD WIDTH Wider track pads increase loading and wear on undercarriage components. Use narrowest pad possible for operating conditions. TX,30,RR,A MAY96 1/ PN=59

62 Driving the Machine Operating Park Lock Lever T T UN 31JAN00 CAUTION: Prevent possible injury from unexpected machine movement. Before starting engine, FNR with Transmission Speed-In-Grip lever must be in neutral and park lock lever must be in up (locked) position. When park lock lever (1) is up (locked), movement of FNR with Transmission Speed-In-Grip lever will not operate machine. When park lock lever (2) is down (unlocked), movement of FNR with Transmission Speed-In-Grip lever will operate machine. 1 Locked Position 2 Unlocked Position TX,30,RR,A JAN00 1/ PN=60

63 Driving the Machine Driving the Machine CAUTION: Use a seat belt to minimize chance of injury from an accident such as an overturn. 1. Fasten seat belt. 2. Park lock lever must be in locked position (up). 3. FNR with Transmission Speed-In-Grip to NEUTRAL. 4. Move engine speed control lever (6) to low idle position. T7860AQ UN 09NOV92 5. Start engine. Monitor will display engine rpm. (See Operating the Engine chapter for starting and warm-up procedure.) 6. Depress decelerator pedal. 7. Move park lock lever (7) to down (unlocked) position. Monitor will display default transmission setting SP1.6. NOTE: Transmission speed buttons and reverse speed ratio knob adjust travel speed and may be adjusted at any time. T127329C UN 26JAN00 8. Place FNR with Transmission Speed-In-Grip (4) lever in desired position. 9. Press transmission speed buttons (1 and 3) to desired setting (SP1.0 SP3.0). 10. Adjust the reverse transmission speed ratio knob (5). (Reverse speed ratio of 80%, 100%, 115%, or 130% of transmission speed.) 11. Slowly release decelerator pedal to move machine. 12. Move engine speed lever to a desired rpm setting. 13. Move FNR with Transmission Speed-In-Grip lever in desired turning direction to steer. 1 Transmission Speed Button (Increase) 2 Horn 3 Transmission Speed Button (Decrease) 4 FNR with Transmission Speed-In-Grip Lever 5 Reverse Speed Ratio Knob 6 Engine Speed Control 7 Park Lock Lever T UN 31JAN00 TX,30,RR,A JAN00 1/ PN=61

64 Driving the Machine Travel Speed Hydrostatic dual path transmission provides variable travel speed (SP1.0 SP3.0) ranging from 0 11 km/h (0 6.8 mph) in forward or reverse. Reverse speed ratios of 80%, 100%, 115%, and 130% until maximum mph is reached, from 0 11 km/h (0 6.8 mph) in reverse. Transmission speed default speed of SP1.6 will be displayed by moving park lock lever, pushing transmission speed button, or pushing SELECT button on monitor. T127219C UN 21JAN00 1 Transmission Speed Button (Increase) 2 Horn 3 Transmission Speed Button (Decrease) 4 FNR with Transmission Speed-In-Grip 5 Reverse Speed Ratio Knob CED,OUO1065, JAN00 1/1 Steering with Transmission FNR with Transmission Speed-In-Grip Control Lever The FNR with Transmission Speed-In-Grip lever (2) controls the direction (forward and reverse), steering (left turn, right turn), pivot turn, and counterrotation. 1 Engine Speed Control 2 Fnr with Transmission Speed In Grip Control T127219B UN 21JAN00 T122746B UN 29JUL99 TX,10,RR,A JUN96 1/ PN=62

65 Driving the Machine Operating Brake Pedal CAUTION: Prevent possible injury from unexpected machine movement. Pushing on brake pedal will stop machine abruptly. NOTE: Machine will start to move as pedal is released. Depress brake pedal (A) only when machine must be stopped abruptly. To resume operation of machine, release brake pedal. T UN 31MAY96 A Brake Pedal TX,30,RR,A JUN96 1/1 Stopping the Machine NOTE: Brake automatically engages when engine is not running. Stop crawler by doing one of the following: CAUTION: Prevent possible injury from unexpected machine movement. Pushing on brake pedal will stop machine abruptly. Brake will release as pedal is released. Push brake pedal. Push decelerator pedal. Move FNR with Transmission Speed-In-Grip lever to neutral. Push park lock lever to up (locked) position. CAUTION: Machine may overturn if blade is dropped when moving rapidly down a steep hill. As a last resort, drop blade to stop machine. TX,30,RR,A MAY96 1/ PN=63

66 Driving the Machine Parking the Machine 1. Park machine on a level surface. 2. Lower blade to ground. 3. Move FNR with Transmission Speed-In-Grip lever (3) to NEUTRAL. 4. Move park lock lever (4) to up (locked) position. IMPORTANT: To avoid damage to turbocharger, run engine at 1/2 speed with no load for two minutes. T127329B UN 20JAN00 5. Run engine at 1/2 speed with no load for two minutes. 6. Move engine speed control lever (1) to slow idle position. 7. Turn key OFF to stop engine and remove key from switch. 8. Release hydraulic pressure by moving control lever(s) until equipment does not move. T127295E UN 26JAN00 9. Turn battery disconnect switch to OFF position. 1 Engine Speed Control Lever 2 Reverse Speed Ratio Knob 3 FNR with Transmission Speed-In-Grip Lever 4 Park Lock Lever TX,30,RR,A JAN00 1/1 Lock All Compartments The following areas can be locked with personal locks: radiator service door, fuel cap, left and right service access doors, and vandal shield (1) (if equipped). Lock these areas to help safeguard your machine. 1 Vandal Shield T127450C UN 04FEB00 TX,35,RR JAN00 1/ PN=64

67 Operating the Machine Blade Operation Tips When blade digs in, causing rear of tractor to rise, raise blade to continue even cut. When load is applied, transmission control system will automatically adjust machine speed to maintain adequate engine speed. Angle blade to: Fill a trench. Cut a road through a rough area. Side cast into a ditch. Level a grade. Tilt blade to: Cut into a hillside. Crown a road. Make a narrow cut or shallow ditch. Rough grade. Use float position to: Back drag (transmission in reverse). Push material over a hard surface. In float position, blade will follow contour of ground. When finishing or leveling, a partially loaded blade handles easier than an over-loaded or empty one. Do not turn with ripper teeth in ground. Teeth may bend or break. TX,30,RR,A MAY96 1/ PN=65

68 Operating the Machine Blade Control Lever Operation T127332B UN 20JAN00 T8448AM UN 30MAR95 IMPORTANT: To avoid overheating hydraulic oil, allow control lever to return to neutral position when cylinders reach end of stroke. Blade control lever is used for all hydraulic functions on all blade options. Point lever forward one position (B) to lower blade and rearward (D) to raise blade. Point lever to left (E) to tilt left and right (C) to tilt right. "Float" detent position (A) is used for backblading. When control lever is put into "float" position, it must be moved manually back to neutral position. A Blade "Float" Detent Position B Blade Lower C Blade Tilt Right D Blade Raise E Blade Tilt Left T8448AL UN 30MAR95 TX,30,RR,A JAN00 1/ PN=66

69 Operating the Machine Determining Blade Pitch Change pitch of blade to best suit type of work, soil conditions, or to change the feel of dozer performance. Pitching Blade Forward Advantages: Capacity of soil to be carried is diminished when blade is pitched forward. Weight of soil carried by blade adds to weight of dozer and moves the balance of weight on tracks forward. This can cause front idlers of the machine to sink in loose or soft soils. When idlers sink, the blade cuts unevenly. With blade forward, dozer balance does not change as much when blade is full; therefore, the tendency for idlers to sink is reduced. With blade forward, dirt is less likely to come over back when dozing uphill. It also makes it easier to drop dirt at end of a push when dozing uphill or in very sticky materials. Pitching Blade Back Advantages: With blade pitched back, cutting edge lies more horizontal, resulting in a heavier cut. Having cutting edge more horizontal also provides a smoother cut in heavy soils. More soil is carried by blade when it is pitched back. Carrying more soil on blade adds to overall weight. This added weight can increase push force in heavy soils. Soil carried by blade also moves the balance of weight forward on machine. In heavy soils, this can be an advantage because increased weight can help keep the front of machine down and keep the cutting edge penetrating during heavy cutting. TX,30,RR,A JUN96 1/ PN=67

70 Operating the Machine Changing Blade Pitch CAUTION: Prevent possible injury from falling blade or frame. NEVER work under a raised blade unless the blade or frame is supported. To change blade pitch, insert adjusting bar (A) and turn adjusting jack to extend or retract jack. Then extend or retract tilt cylinder the same amount to obtain desired pitch. A Adjusting Bar 750C WT Straight dozer Shown T8424AL UN 22FEB95 TX,30,RR,A MAY96 1/ PN=68

71 Operating the Machine Changing Blade Angle Mechanical Angle CAUTION: Prevent possible injury from falling blade or frame. NEVER work under a raised blade unless the blade or frame is supported. 1. Park crawler on a level surface. 2. Raise blade so cutting edge is off ground and put wooden blocks under C-frame. 3. Remove pins to disconnect struts from brackets on C-frame. NOTE: Maximum blade angle is 25 left or right. 4. Move blade to left or right angle position. NOTE: Adjusting blade tilt when installing last strut may ease assembly. 5. Install strut in rear bracket, then the front bracket. Install pins in struts. TX,30,RR,A MAY96 1/1 Operating on Slopes On slopes up to approximately 30, work parallel to the slope. Earth will fall to lower side of slope in windrow. This will help hold crawler and keep it from sliding down. On slopes over 30, work diagonally, starting from the base of slope, working upwards. Always travel at slow speeds with blade as low as possible. TX,30,RR,A MAY96 1/ PN=69

72 Operating the Machine Operating in Rough Terrain When possible, avoid obstacles, rough terrain, rocks, curbs, ditches, railroad tracks. Cross small obstructions at an angle at reduced speed in low gear. Ease up to the "break-over" point, balance slowly on the obstruction, ease down to minimize the impact of contact on the other side. Cross shallow gullies or ditches at an angle at reduced speed. 02T,35,J SEP95 1/1 Side-by-Side Dozing Use two machines side by side for high production of loose material. T6705AB UN 10FEB89 02T,35,J AUG92 1/1 Slot Dozing Make several dozing passes over the same path. As depth of cut or slot deepens, sides of cut hold material in, with less side spillage. When moving dirt from one area to another, follow the same path each time. As dirt spills from each side of blade, it will form ridges. These ridges help keep material in front of the blade. T6705AA UN 10FEB89 TX,30,RR,A MAY96 1/ PN=70

73 Operating the Machine Tilt Dozer Ditching Tilt dozer blade left (A) or right (B) to cut shallow "vee" ditches. A Blade Tilt Left B Blade Tilt Right T6508AW UN 19MAY89 02T,35,J JAN93 1/1 Backfilling CAUTION: Prevent possible injury from cave-in or machine overturn. Work a safe distance from trenches with deep vertical side walls. To backfill into shallow trenches with blade angled, travel parallel to ditch. T6705AD UN 10FEB89 02T,35,J MAR95 1/2 To backfill into deep trenches with blade straight, push at near a 90 angle to the ditch. T6705AE UN 10FEB89 02T,35,J MAR95 2/2 Leveling a Stockpile CAUTION: Prevent possible injury from cave-in or machine overturn. Operate slowly on hillsides, rough ground, and ramps. Work a safe distance from trenches and banks with deep vertical side walls. Small stockpiles: Move into edges until stockpile has been leveled. T6705AF1 UN 10FEB89 Continued on next page TX,30,RR,A MAY96 1/ PN=71

74 Operating the Machine Large stockpiles: Move into center of stockpile and divide it into two or more smaller stockpiles. Tall stockpiles: Build a ramp and remove the top of the stockpile. T6705AG UN 10FEB89 TX,30,RR,A MAY96 2/2 Moving Boulders CAUTION: Prevent possible injury from boulders moving unexpectedly. Move large boulders very carefully. Contact boulder at strongest part of blade. TX,30,RR,A MAY96 1/5 Angle dozer: Contact boulder with center of blade at slow speed. Angle Dozer T6705AI UN 10FEB89 Continued on next page TX,30,RR,A MAY96 2/ PN=72

75 Operating the Machine Straight dozer: Contact boulder at one side of blade. Straight Dozer T6705AJ UN 10FEB89 TX,30,RR,A MAY96 3/5 If boulder is too large to be directly pushed by dozer, move it by pushing alternate sides of boulder. Round boulders may be rolled by pushing forward while lifting blade. Large Boulder T6705AK UN 10FEB89 Continued on next page TX,30,RR,A MAY96 4/ PN=73

76 Operating the Machine Buried boulder: Dig around base to free boulder. Push boulder up and out. Fill under boulder as it is moved forward. Buried Boulder T6705AL UN 10FEB89 TX,30,RR,A MAY96 5/5 Bench Cut T6705AM1 UN 10FEB89 If possible, start cut downgrade and angle to outside of cut to cast material downhill. Make a final grading pass to straighten uphill bank and level bench. While turning with a full load of material, raise blade slightly to side cast material. Tilt blade rapidly from side to side to help remove material. TX,30,RR,A MAY96 1/ PN=74

77 Operating the Machine Brush Removal To remove brush and small trees, doze a few inches below ground and move forward. When brush is out, raise blade to loosen earth from roots. Windrow or stack brush, as best suits the area. Remove as little topsoil as possible. 02T,35,J JAN88 1/1 Tree Removal CAUTION: Prevent possible injury from falling trees. Use only ROPS equipped dozer for tree removal. Raise blade and back away quickly when the tree begins to fall. 1. Remove dead limbs. 2. Cut tree roots on side opposite direction of fall. T6705AN1 UN 10FEB89 3. Cut tree roots on sides parallel to direction of fall. CAUTION: Prevent possible injury or death or machine damage from falling tree. Do not jar or ram blade against a large tree that could be dead. It may snap off and fall on top of crawler. NOTE: Build earth ramp, if necessary, to contact tree at best height. 4. Push on tree mm (12 16 in.) above ground in direction of fall. Move forward while lifting blade. T6705AO1 UN 10FEB89 5. Back off and get under roots for next pass. 6. Do not drive onto stump while tree is falling. T6705AP1 UN 10FEB89 TX,30,RR,A MAY96 1/ PN=75

78 Operating the Machine Stump Removal Push on stump mm (12 16 in.) above ground. Lift and tilt blade while pushing. If stump cannot be pushed out, dig out the base of stump and cut large roots in the pattern shown. Push stump after each large root is cut; it may not be necessary to cut all roots. T6705AQ UN 10FEB89 T6705AR UN 10FEB89 TX,35,BG APR97 1/ PN=76

79 Transporting Loading Machine on a Trailer 1. Keep trailer bed clean. Put chocks (A) against truck wheels. 2. Use a ramp or loading dock. Ramps must be strong enough, have a low angle, and correct height. Load and unload machine on a level surface. 3. Fasten seat belt before starting engine. 4. Drive machine onto ramps squarely. Centerline of machine should be over centerline of trailer. A Chock Blocks T87155 UN 09NOV88 5. Lower all equipment onto blocks or trailer bed. 6. Move FNR with Transmission Speed-In-Grip lever to neutral position. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on FNR with Transmission Speed-In-Grip lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park lock levers to hold machine. 7. Move park lock levers to up (locked) position. IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 8. Run engine at 1/2 speed without load for two minutes. 9. Move speed control lever to slow idle position and stop engine. 10. Remove key from switch. 11. Release hydraulic pressure by moving control lever(s) until equipment does not move. 12. Turn battery disconnect switch to OFF position. Continued on next page TX,35,RR,A JUN96 1/ PN=77

80 Transporting IMPORTANT: Prevent possible machine damage. Fasten chains or cables to machine frame or track chain links, NOT to other places on the crawler. 13. Fasten each corner of machine to trailer with a chain or cable. 14. Put blocks in front of and behind tracks. 15. Cover exhaust stack opening to keep out rain. TX,35,RR,A JUN96 2/2 Unloading Machine From Trailer 1. Park on level surface. 2. Place chocks against all trailer wheels. 3. Clean trailer bed and remove chains. 4. Uncover exhaust pipe. 5. Use long ramps to unload machine. 6. Fasten seat belt. 7. Start machine and run engine at low idle for several minutes. 8. Raise blade approximately 1 foot. 9. Set transmission speed to SP Depress decelerator pedal and release park lock lever. 11. Drive slowly off trailer. CED,OUO1065, FEB00 1/ PN=78

81 Transporting Towing IMPORTANT: DO NOT tow faster than 2.4 km/h (1.5 mph) or extensive machine damage may result. NOTE: Engine cannot be started by towing machine. 1. Fasten a tow bar or chain to machine frame, drawbar (A) or tow hook (B) (if equipped). A Drawbar Pin B Tow Hook T8432AU UN 13MAR95 T8432AT UN 13MAR95 Continued on next page TX,35,RR,A SEP98 1/ PN=79

82 Transporting CAUTION: Prevent possible injury from unexpected machine movement. When brakes have been manually released, machine is free to move and there is no steering. After towing, apply brake pedal or move park lock lever up. IMPORTANT: Parking brakes are spring applied and hydraulically released. If machine cannot move and needs to be towed, it is necessary to manually release brakes. 2. Connect larger diameter hose (A) to quick coupler and smaller diameter hose to protective cap (B). 3. Move lever (C) out (pointed away from the machine.) 4. Move park lock lever down to unlocked position. NOTE: When pumping brakes off, oil is released to the transmission circuit causing continuous loss. Pump reservoir oil level should be checked at least every four to five cycles of pumping brakes off to be sure proper amount of oil is present at all times. See step 9 for checking and adding oil information. T8439AH UN 01JUL96 5. While sitting in seat, install handle in pump lever (D) and begin pumping using full, rapid strokes. After several strokes, resistance will increase, indicating that the brakes are released. It will be necessary to occasionally stroke the pump to make up for internal leakage and to maintain the brake released condition. A Larger Diameter Hose B Protective Cap C Lever D Pump Lever 6. Tow machine. Continued on next page TX,35,RR,A SEP98 2/ PN=80

83 Transporting 7. When towing is completed, brakes can be applied by placing park lock lever (1) in up (locked) position or applying the brake pedal. 1 Park Lock Lever T127193B UN 21JAN00 TX,35,RR,A SEP98 3/4 8. Move pump lever (C) to point toward front of the machine. 9. Check pump reservoir oil level at fill plug (B). Add oil if necessary. (See Fuels and Lubricants chapter.) A Not Used B Fill Plug C Pump Lever T8448AQ UN 30MAR95 TX,35,RR,A SEP98 4/ PN=81

84 Fuels and Lubricants 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 (5,000 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 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/ PN=82

85 Fuels and Lubricants 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. TS185 UN 23AUG88 CED,OUO1002, FEB98 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=83

86 Fuels and Lubricants Diesel Fuel Storage Proper fuel storage is critically important. Use clean storage and transfer tanks. Periodically drain water and sediment from bottom of tank. Store fuel in a convenient place away from buildings. IMPORTANT: DO NOT store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters, damage injection nozzles and injection pump. DO NOT use brass-coated containers for fuel storage. Brass is an alloy of copper and zinc. Store diesel fuel in plastic, aluminum, and steel containers specially coated for diesel fuel storage. Avoid storing fuel over long periods of time. If fuel is stored for more than a month prior to use, or there is a slow turnover in fuel tank or supply tank, add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather. Consult your John Deere engine distributor or servicing dealer for recommendations and local availability. Always follow manufacturer s directions on label. TX,45,JC JAN97 1/ PN=84

87 Fuels and Lubricants Diesel Engine Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oil is preferred: 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 CG-4 API Service Classification CF-4 ACEA Specification E3 ACEA Specification E2 TS1661 UN 10OCT97 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%. 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 10OCT97 1/ PN=85

88 Fuels and Lubricants Transmission, Hydraulic, and Hand Pump Reservoir Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oils are preferred: PLUS-50 TORQ-GARD SUPREME Other oils may be used if they meet one or more of the following: API Service Classification CG-4 API Service Classification CH-4 T UN 14SEP01 PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company TX03768,0000B SEP01 1/ PN=86

89 Fuels and Lubricants Inner and Outer Final Drive Oil T8448AT 19 26JUN95 Depending on the expected air temperature range between oil changes, use oil viscosity shown on the chart above. John Deere HY-GARD is preferred. John Deere Gear Lubricant API GL-5 (SAE 80W90) Arctic oils (such as Military Specifications MIL-L-46167B) may be used at temperatures below 30 C ( 22 F). Other oils may be used if they meet the following: HY-GARD is a trademark of Deere & Company TX,45,RR SEP98 1/ PN=87

90 Fuels and Lubricants Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oils are preferred: John Deere GEAR LUBRICANT HY-GARD API GL-5 (SAE 80W90) John Deere EXTREME-GARD The following oils are recommended: API Service Classification API GL-5 gear oil (SAE 80W90) Arctic oils such as (MIL-L-10324A) may be used at temperatures below 30 C ( 11 F). TX,45,RR JUL95 1/1 Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following greases are preferred: John Deere SD POLYUREA GREASE The following greases are also recommended: John Deere HD MOLY GREASE John Deere HD LITHIUM COMPLEX GREASE John Deere HD WATER RESISTANT GREASE John Deere GREASE-GARD Other greases may be used if they meet the following: NLGI Performance Classification GC-LB IMPORTANT: Some types of grease thickener are not compatible with others. TS1667 UN 30JUN99 DX,GREA JUL99 1/ PN=88

91 Fuels and Lubricants Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used. Use clean containers to handle all lubricants. Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation. Make certain that all containers are properly marked to identify their contents. Properly dispose of all old containers and any residual lubricant they may contain. DX,LUBST 19 18MAR96 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. Consult your John Deere dealer to obtain information and recommendations. Synthetic lubricants may be used if they meet the performance requirements as shown in this manual. The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils. Re-refined base stock products may be used if the finished lubricant meets the performance requirements. DX,ALTER 19 18MAR96 1/ PN=89

92 Fuels and Lubricants Mixing of Lubricants In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Consult your John Deere dealer to obtain specific information and recommendations. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. DX,LUBMIX 19 18MAR96 1/ PN=90

93 Periodic Maintenance Install Do Not Operate Tag CAUTION: To prevent serious injury or death by unexpected machine movement, attach a DO NOT OPERATE tag to front of monitor to alert others of service work being performed. T7447AO 19 22APR91 TX,45,RR,A JUN96 1/1 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. 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. A Periodic Maintenance Chart T8424AN UN 22FEB95 TX,50,RR MAR95 1/ PN=91

94 Periodic Maintenance Check Hour Meter Regularly Use the hour meter (A) to determine when your machine needs periodic maintenance. With key switch OFF, push SELECT button (B) to display hour usage. Intervals on the periodic maintenance chart are for operating in normal conditions. If you operate your machine in difficult conditions, you should service it at shorter intervals. T UN 09SEP98 A Hour Meter B Select Button TX,45,RR,A SEP98 1/1 Use Correct Fuels and Lubricants IMPORTANT: Refer to Fuels and Lubricants chapter when performing maintenance on machine. NOTE: Factory fill oil for transmission and hydraulic systems has red dye added to help in locating leaks. When adding oil, use specified oils in Fuels and Lubricants chapter. TX,45,RR,A MAY96 1/1 Prepare Machine for Maintenance Before performing maintenance procedures in the following chapters and before leaving operator s seat, park machine as described below unless another position is specified in the procedure. Continued on next page TX,45,RR,A JAN00 1/ PN=92

95 Periodic Maintenance IMPORTANT: Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. Do not pour waste onto the ground, down a drain, or into any water source. 1. Park machine on a level surface. 2. Lower all equipment to ground. TS1133 UN 26NOV90 Continued on next page TX,45,RR,A JAN00 2/ PN=93

96 Periodic Maintenance 3. Move FNR with Transmission Speed-In-Grip lever (2) to NEUTRAL position. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on FNR with Transmission Speed-In-Grip lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park lock lever to hold machine. 4. Move park lock lever (3) to up (locked) position. T127219B UN 21JAN00 IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 5. Run engine at 1/2 speed without load for two minutes. 6. Move engine speed control lever (1) to slow idle position. 7. Stop engine. NOTE: If maintenance must be performed with engine running, do not leave machine unattended. 8. Remove key from switch. 9. Release hydraulic pressure by moving control lever(s) until equipment does not move. 1 Engine Speed Control Lever 2 FNR with Transmission Speed-In-Grip Lever 3 Park Lock Lever T127194C UN 21JAN00 TX,45,RR,A JAN00 3/4 IMPORTANT: Before welding, avoid electronic component damage; turn electrical disconnect switch OFF. 10. Turn battery disconnect switch (A) OFF (counterclockwise) if making adjustments to electrical systems or welding on machine. A Battery Disconnect Switch T UN 03JUN96 TX,45,RR,A JAN00 4/ PN=94

97 Periodic Maintenance Maintenance and Repair Record Keeping System The checklist in this chapter 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 (perforated) copy of this form (inside the back cover). Do not tear out or mark on checklist in this chapter; keep it to make extra copies. T6828AA 19 03APR89 03T,50,K AUG92 1/ PN=95

98 Periodic Maintenance OILSCAN Plus, COOLSCAN Plus, DIESELSCAN and 3-Way Coolant Test Kit OILSCAN Plus T UN 16SEP97 3-Way Coolant Test Kit T UN 16SEP97 OILSCAN Plus, COOLSCAN Plus, DIESELSCAN and 3-Way Coolant Test Kits are John Deere fluid sampling products to help you monitor machine performance and system condition. The objective of a fluid sampling program is to insure 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 registered trademark of Deere & Company COOLSCAN Plus is a registered trademark of Deere & Company CED,OUO1040, NOV99 1/ PN=96

99 Periodic Maintenance Maintenance and Repair Record Keeping System Model 750C Series II 850C Series ii Customer: PIN/Serial Number: Delivery Date: Hour Meter Reading: BREAK-IN SERVICE INTERVALS After 100 hours refer to service intervals in chapter 50. SERVICE INTERVALS AFTER BREAK-IN 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. Check and replace belts Check air cleaner restriction indicator Every 10 Hours or Daily Check engine oil level Check coolant recovery tank Grease center crossbar pivot Grease crossbar left and right end pivot As Required Every 50 Hours Check transmission oil level Check and adjust track sag Check hydraulic system oil level Grease dozer linkage Grease lift cylinder pivots Model: 750C and 850C Customer: PIN/Serial Number: Delivery Date: Hour Meter Reading: 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. Continued on next page TX03768,0000B MAY02 1/ PN=97

100 Periodic Maintenance Description Unit Part Number ASI Hours Hours Hours Hours Hours Engine Oil 750C RE Filter Series II 850C RE Series II Engine Rocker 750C R Arm Cover Series Gasket II 850C R Series II Fuel Filter All RE (Primary) Fuel Filter 750C RE (Secondary) Series II Fuel Filter 850C RE (Secondary) Series II Transmission All AT Oil Filter (Element) Hydraulic Oil All AT Filter (Element) John Deere 750C TY L (5 19 L (5 19 L (5 19 L (5 19 L (5 PLUS-50 Oil Series gal) gal) gal) gal) gal) II 24 L 24 L 24 L ( L ( L ( C (5.25 gal) (5.25 gal) gal) gal) gal) Series II Air Filter 750C AR (Primary) Series II Air Filter 750C AR (Secondary) Series II Air Filter 850C AT (Primary) Series II Air Filter 850C AT (Secondary) Series II Crank Shaft All RE59355(750C) 1 Dampener & RE50091(850C) Continued on next page TX03768,0000B MAY02 2/ PN=98

101 Periodic Maintenance Description Unit Part Number ASI Hours Hours Hours Hours Hours Transmission All TY6389 (750C) Oil 83.3 L (22 gal) & (850C) L (27 gal) Hydraulic Oil All TY6389 (750C) 67 L (18 gal) & (850C) 81 L (21 gal) Gear Oil API Standard TY6382 (750C)68 L (750C) 68 GL-5 80W90 LGP (18 gal) & L (18 gal) 850C) 79 L & 850C) (21 gal) 79 L (21 gal) Final Drives Oil All TY L ( L (1.75 gal) gal) Coolant All TY16004 As Needed Conditioner OILSCAN Kits Diesel Engine All AT Oil Transmission All AT Oil Final Drive Oil All AT Hydraulic Oil All AT Coolscan Plus Kit All AT (Ten samples per kit) Dieselscan Kit (Six All AT As Needed samples per kit) 1 3-Way Heavy All TT16175 As Needed Duty Coolant TEst Kit OILSCAN is a registered trademark of Deere & Company Coolscan Plus is a registered trademark of Deere & Company TX03768,0000B MAY02 3/ PN=99

102 Maintenance As Required Check Alternator Belt Tension NOTE: All belts on 750C Series II and 850C Series II machines are self-adjusting. 1. Start engine and run for five minutes to properly warm engine. Stop engine when warm and check belts for wear or damage. 2. Belts should be replaced if damaged or worn. (See your authorized dealer for service.) TX,55,BG SEP98 1/ PN=100

103 Maintenance As Required Check Track Sag Maintaining proper track sag of mm ( in.) is the single most important adjustment. Tight tracks can reduced wear life by more than 50% over tracks which are properly maintained at 51 mm (2.0 in.) of sag. Tight tracks increase loading on undercarriage components and accelerate wear rate. Track sag should be adjusted as soil conditions change. See Track Sag General Information in Maintenance chapter. 1. Allow machine to slowly roll forward so track pin (A) is centered over carrier roller (B). 2. Measure track sag at longest span location on track. Measure track sag (C) from top of track grouser to a straightedge (E). If adjustment is needed, see Adjust Track Sag in this chapter. Specification Track Sag Distance... A Pin and Bushing B Carrier Roller C Track Sag D Front Idler E Straightedge mm ( in.) T6482AX UN 24MAY89 T7800AH UN 31JUL92 TX,55,BG APR97 1/ PN=101

104 Maintenance As Required Adjust Track Sag CAUTION: Grease for track adjuster cylinder is under high pressure. Never remove special grease fitting to release grease. If grease does not escape immediately from vent hole with relief valve open, slowly drive forward and reverse until grease escapes. DO NOT disassemble parts unless you know the correct procedure and have correct tools. See your authorized dealer for service. X9811 UN 23AUG88 If and accident occurs, see a doctor immediately. Any fluid injected into 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. IMPORTANT: DO NOT clean track before adjusting chain if ground conditions cause packing around sprocket and idlers. Grease fitting on adjuster head is used for track sag adjustment only. Fitting on barrel adjuster housing is used to fill cavity between cylinder barrel and adjuster housing to keep water and dirt out. To move piston, an kpa (552 bar) (8000 psi) maximum capacity grease gun must be used to avoid damaging seals. If piston does not move, check for seized track adjuster parts. Loosen cap screw and pivot access cover (A) up. T7800AH UN 31JUL92 A Access Cover T127339B UN 20JAN00 Continued on next page TX,55,BG JAN00 1/ PN=102

105 Maintenance As Required To Decrease Track Sag: 1. To decrease sag, apply grease to fitting (A) using an kpa (552 bar) (8000 psi) capacity grease gun. IMPORTANT: Each time track is adjusted, apply grease to adjuster housing fitting. This will prevent entry of water or dirt and possible seizing of parts. 2. After adding grease, operate unit to allow track adjuster cylinder to fully adjust and then check sag again. Each time track is adjusted, apply grease to fitting (C) on cylinder barrel adjuster housing until grease escapes past wiper seal. A Fitting B Check Valve C Fitting T7254BA UN 12MAR90 To Increase Track Sag: CAUTION: Grease for track adjuster cylinder is under high pressure. Never remove lubrication fitting to release grease. If grease does not escape immediately from vent hole, slowly drive unit in forward and reverse, then close check valve. 1. To increase sag, turn check valve (B) 1 3 turns counterclockwise to release grease through vent hole. Turn check valve clockwise to close it. After releasing grease, operate unit to allow track adjuster cylinder to fully adjust and then check sag again. IMPORTANT: Each time track is adjusted, apply grease to adjuster housing fitting. This will prevent entry of water or dirt and possible seizing of parts. 2. Apply grease to lubrication fitting on cylinder barrel adjuster housing until grease escapes past wiper seal. TX,55,BG JAN00 2/ PN=103

106 Maintenance As Required Check Air Restriction Indicator Check air restriction indicator (A). If indicator is on, replace air filter elements. See Remove and Inspect Air Filter Elements in Maintenance Every 1000 Hours chapter. A Air Restriction Indicator T UN 09SEP98 TX,50,RR,A SEP98 1/ PN=104

107 Maintenance Every 10 Hours or Daily Check Engine Oil Level IMPORTANT: Prevent possible engine damage. DO NOT run engine when oil level is below ADD mark on dipstick. The most accurate oil level reading is obtained when engine is cold, before operation. 1. Park machine on level surface and stop engine. 2. Engage brakes. 3. Remove filler cap (A). 750C Series II T UN 10MAR97 BEFORE ENGINE IS STARTED: Engine is full when oil level is in crosshatched area (B). It is acceptable to run engine when oil level is above the ADD mark. AFTER ENGINE HAS BEEN RUN: Allow oil to drain into pan for 10 minutes before checking level. Ten minutes after shutdown, engine oil level must be above the ADD mark. 4. Add oil as necessary. (See Fuels and Lubricants chapter.) 850C Series II T UN 03JUN96 A Oil Filler Cap B Crosshatched Area T UN 10MAR97 TX,60,BG JAN00 1/ PN=105

108 Maintenance Every 10 Hours or Daily Check Coolant Level CAUTION: Prevent possible injury from hot spraying coolant. Remove radiator cap only when cool enough to touch with bare hand. Turn cap slowly to stop so pressure is released before removing cap. With engine cold, coolant level must be between HOT and COLD marks on recovery tank (A). If coolant is below COLD mark, add coolant to recovery tank. TS281 UN 23AUG88 A Coolant Recovery Tank T8424AX UN 22FEB95 TX,60,BG APR97 1/2 If recovery tank is empty, check for leaks and repair as necessary. Add coolant to radiator and recovery tank. Coolant level must be at bottom of filler neck. NOTE: If recovery tank is full and radiator is low, check for leaks on radiator cap and hose connections. A Radiator Filler Cap T UN 10MAR97 TX,60,BG APR97 2/ PN=106

109 Maintenance Every 10 Hours or Daily Lubricate Left and Right Track Frame Pivot 750C series II If Equipped Open right-side service access door. Lubricate until grease escapes from joints. (See Fuels and Lubricants chapter.) Two Points (750C Series II Only If Equipped) T8439AL UN 21MAR95 CED,OUO1065, JAN00 1/ PN=107

110 Maintenance Every 10 Hours or Daily Lubricate Center Crossbar Pivot 750C Series II If Equipped and 850C Series II Open right-side service access door. Lubricate until grease escapes from joints. (See Fuels and Lubricants chapter.) T127340B UN 20JAN00 CED,OUO1065, JAN00 1/ PN=108

111 Maintenance Every 10 Hours or Daily Check Transmission Oil Level IMPORTANT: NEVER start engine without oil in reservoir or transmission may be damaged. 1. Machine must be on level surface with blade flat on ground. Check oil level before starting engine. NOTE: Sight glass decal has a scale for cold oil (blue in color) and warm oil (red in color). Read appropriate scale as it applies to machine operating temperature. 2. Check that oil level is midway in sight glass (A). Oil level may be higher if oil is warm. 3. Clean plug and area around plug. 4. Remove filler plug (B) to add oil. (See Fuels and Lubricants chapter.) 5. Install filler plug. A Transmission Oil Sight Glass B Transmission Oil Filler Cap With ROPS (750C Series II Shown) T8439AK UN 21MAR95 With Cab T8424BB UN 22FEB95 T UN 03JUN96 TX,60,BG APR97 1/ PN=109

112 Maintenance Every 10 Hours or Daily Check Hydraulic Oil Level IMPORTANT: NEVER start engine without oil in reservoir or transmission may be damaged. 1. With machine parked on level surface and blade flat on ground, check oil level before starting engine. NOTE: Sight glass decal has a scale for cold oil (blue in color) and warm oil (red in color). Read appropriate scale as it applies to machine operating temperature. 2. Check that oil level is midway in sight glass (B). Oil level may be higher if oil is warm. 3. Clean cap and area around cap. 4. Remove filler cap (A) to add oil. (See Fuels and Lubricants chapter.) 5. Install filler cap. A Hydraulic Oil Filler Cap B Hydraulic Oil Sight Glass With ROPS T8424BA UN 22FEB95 With Cab TX,60,BG1034 T UN 03JUN APR97 1/ PN=110

113 Maintenance Every 10 Hours or Daily Lubricate Dozer Linkage Apply grease to lubrication fittings until it escapes at joints. (See Fuels and Lubricants chapter.) T8448AN UN 30MAR95 T8424BE UN 02MAR95 T8424BF UN 02MAR95 TX,55,RR,A JUN96 1/ PN=111

114 Maintenance Every 10 Hours or Daily Lubricate All-Hydraulic Blade Two Points T8424BI UN 02MAR95 Three Points T8448AI UN 30MAR95 Apply grease to lubrication fittings until it escapes joints. (See Fuels and Lubricants chapter.) Four Points T8448AH UN 30MAR95 TX,55,RR,A JUN96 1/ PN=112

115 Maintenance Every 50 Hours Lubricate Left and Right Crossbar End Pivot Below crossbar and to inside of track at mount. Lubricate until grease escapes from joints. (See Fuels and Lubricants chapter.) Two Points (One Each Side) T127341B UN 20JAN00 TX,65,BG APR97 1/1 Lubricate Lift Cylinder Pivots 1. Lower blade and any rear-mounted equipment to ground and stop engine. 2. Lubricate grease fittings (6 points) until it escapes at joint. (See Grease in Fuels and Lubricants chapter.) Six Points Right Side Shown T8424BH UN 02MAR95 TX,65,BG APR97 1/ PN=113

116 Maintenance Every 50 Hours Lubricate Track Adjust Cylinder NOTE: Cap screw does not come out of cover. Loosen only. 1. Loosen cap screw and pivot access cover (A) up. NOTE: Lubrication fitting (C) is used only to adjust track sag. 2. Lubricate grease fitting (B) until it escapes around seal. (See Grease in Fuels and Lubricants chapter.) T127339B UN 20JAN00 A Access Cover B Grease Fitting C Track Sag Adjustment Lubrication Fitting Two Points (left side shown) T8262AY UN 18JUN94 TX,60,RR,A JAN00 1/ PN=114

117 Maintenance Every 250 Hours Change Engine Oil and Filter Elements IMPORTANT: If fuel sulfur content exceeds 0.5 percent, change oil at 1/2 the normal interval. 1. Run engine to warm oil. If engine has not run 250 hours before season changes, change oil. CAUTION: Prevent possible injury from unexpected machine movement. Before working on machine, lower all equipment to ground and stop engine. A Engine Oil Drain Plug T6044CC UN 01NOV88 2. Lower blade and any rear-mounted equipment to ground and stop engine. NOTE: Access cover is hinged to front bottom guard. 3. Remove cap screws from access cover and lower to ground. Remove drain plug (A) to drain oil. Drain oil into container and dispose of properly. 4. Remove engine side shield. Continued on next page CED,OUO1065, JAN00 1/ PN=115

118 Maintenance Every 250 Hours 5. Using a suitable filter wrench, turn filter counterclockwise and remove from base (A). Clean mounting surfaces on base. 6. Apply a film of oil to sealing ring on new filter and install. Turn element clockwise by hand until sealing ring contacts base, then torque an additional 1/2 3/4 turn with wrench. NOTE: Before installing plug, check condition of washer and replace as necessary. 7. Install plug with raised center of washer against head of plug. 750C Series II T UN 10MAR97 A Oil Filter Base Continued on next page 850C Series II CED,OUO1065,123 T UN 03JUN JAN00 2/ PN=116

119 Maintenance Every 250 Hours NOTE: See Diesel Engine Oil in Fuels and Lubricants chapter for proper type of oil to add to machine. 8. Fill engine with oil. Fill oil through filler tube cap/dipstick (A). (See Fuels and Lubricants, and Specifications chapters.) IMPORTANT: Before starting engine after a filter change, operate starter motor for 20 seconds without starting engine to refill the elements. NOTE: On 850C Series II machines, disconnect fuel shut-off solenoid wire at starter. 750C Series II T UN 10MAR97 9. Disconnect wiring lead at injection pump so engine will not start. Crank engine for 20 seconds, using starter motor and attach wiring lead to pump. 10. Start engine and run at slow idle. Check engine oil pressure gauge immediately. If not operating in green zone, stop engine and find cause. (See Engine in Troubleshooting chapter.) 11. Check for leakage at elements and tighten as necessary. 850C Series II A Filler Tube Cap/Dipstick T UN 03JUN96 NOTE: Dipstick is part of filler tube cap. 12. Stop engine and check oil level on dipstick (B). (See Check Engine Oil Level in Maintenance Every 10 Hours or Daily chapter.) CED,OUO1065, JAN00 3/ PN=117

120 Maintenance Every 250 Hours Check Inner and Outer Final Drive Housings Oil Level 1. Move machine so sprocket oil line (C) is parallel with ground and drain plugs (B) are at bottom of sprocket. 2. Remove filler plugs (A). 3. Oil level must be within 13 mm (1/2 in.) of bottom of hole. 4. Add oil as necessary. See Inner and Outer Final Drive Oil in Fuels and Lubricants chapter. 5. Install and tighten plugs. A Filler Plug B Drain Plug C Sprocket Oil Line Inner Final Drive Housing T8432AY UN 13MAR95 Outer Final Drive Housing TX,65,RR,A4 T8448AK UN 30MAR MAY96 1/ PN=118

121 Maintenance Every 250 Hours Check Radiator Coolant Level CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Remove filler cap only 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. 1. Remove radiator cap and check coolant level. Coolant must be level with bottom of filler neck. TS281 UN 23AUG88 2. Add coolant if necessary. (See Diesel Engine Coolant and Filling the Cooling System in Maintenance chapter for coolant type and amount.) T UN 10MAR97 TX,75,BG JAN00 1/ PN=119

122 Maintenance Every 500 Hours Change Primary Fuel Filter 750C Series II NOTE: Dispose of waste properly. 1. Turn retaining ring (A) counterclockwise to remove filter. Allow sediment to drain into a container. 2. Remove sediment bowl (B) from filter assembly. 3. Clean fuel filter base (F). 4. Remove hand pump (C) from filter base. Disassemble hand pump assembly and clean as necessary. T UN 10MAR97 NOTE: Do not attempt to turn filter element into base. 5. Install new filter element by aligning vertical locators (G) into slots (E) on filter base. Push filter element up firmly until it snaps snugly against base. 6. Install sediment bowl. 7. Place pan under filter. 8. Loosen air bleed screw (D) on fuel filter base and push pump (C) until fuel flow is free from air bubbles. T8387AE UN 17DEC94 9. Tighten bleed screw as hand primer is held in downward position. A Retaining Ring B Sediment Bowl C Hand Pump D Bleed Screw E Slots F Filter Base G Vertical Locators T8429AA UN 02MAR95 CED,OUO1065, JAN00 1/ PN=120

123 Maintenance Every 500 Hours Change Secondary Fuel Filter 750C Series II NOTE: Dispose of waste properly. 1. Turn retaining ring (A) clockwise to remove filter (B) and allow sediment to drain into a container. 2. Clean filter base. 3. Install new filter. (Follow instructions on filter.) 4. Place pan under filter. T UN 10MAR97 5. Loosen air bleed screw (C) on filter base and push pump (D) until fuel flow is free from air bubbles. 6. Tighten bleed screw as hand primer is held in downward position. A Retaining Ring B Filter C Bleed Screw D Pump CED,OUO1065, JAN00 1/ PN=121

124 Maintenance Every 500 Hours Change Primary Fuel Filter 850C Series II NOTE: Dispose of waste properly. 1. Turn retaining ring (A) counterclockwise to remove fuel filter and drain sediment into container. 2. Remove sediment bowl (B) from filter assembly. 3. Clean filter base (F). 4. Remove hand pump (C) from filter base. Disassemble hand pump assembly and clean as necessary. T UN 03JUN96 NOTE: Do not attempt to turn filter element into base. 5. Install new filter element by aligning vertical locators (G) into slots (E) on filter base. Push filter element up firmly until it snaps snugly against base. 6. Install sediment bowl. 7. Place pan under filter. 8. Open bleed screw (D) and push pump (C) until fuel flows free of bubbles from around the bleed screw. T8387AE UN 17DEC94 A Retaining Ring B Sediment Bowl C Hand Pump D Bleed Screw E Slots F Filter Base G Vertical Locators T8429AA UN 02MAR95 CED,OUO1065, JAN00 1/ PN=122

125 Maintenance Every 500 Hours Change Secondary Fuel Filter 850C Series II NOTE: Dispose of waste properly. 1. Close fuel shut-off valve at bottom of fuel tank (not illustrated). 2. Loosen bleed plug (C). NOTE: Position a container under drain plug to catch draining fuel. 3. Remove drain plug (B) to drain fuel from filter. 4. Remove filter by releasing springs and pulling off of guide pins (A). RG7051 UN 26NOV97 5. Install new filter and retain with bottom spring, then top spring. 6. Install new drain plug. A Guide Pins B Drain Plug C Bleed Plug 7. Turn key switch to ON position. CED,OUO1065, JAN00 1/2 8. Operate hand primer (A), on fuel supply pump, until fuel flows free of bubbles from around bleed plug. 9. With hand primer in down position, tighten bleed plug. 10. Start engine and check for leaks. A Hand Primer T UN 03JUN96 CED,OUO1065, JAN00 2/ PN=123

126 Maintenance Every 500 Hours Check Battery Electrolyte Level and Terminals CAUTION: 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. Using 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: TS203 UN 23AUG88 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. 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. TS204 UN 23AUG88 Always remove grounded ( ) battery clamp first and replace it last. 1. Remove hold-down clamps. Continued on next page TX,70,RR,A MAY96 1/ PN=124

127 Maintenance Every 500 Hours IMPORTANT: Add water to batteries in freezing weather before you begin operating your machine for the day, or else charge the batteries. 2. Fill each cell to within specified range (C) with distilled water. DO NOT overfill. A Battery Post B Fill Tube C Electrolyte Level Range Single Level Fill Tube Application T6996DB UN 09SEP03 Dual Level Fill Tube Application T6996DA UN 09SEP03 TX,70,RR,A MAY96 2/3 3. Disconnect battery clamps, grounded clamp first. 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. 7. Install hold-down clamps. T6758AA UN 21OCT88 A Battery Terminals B Lubricating Grease TX,70,RR,A MAY96 3/ PN=125

128 Maintenance Every 500 Hours Check Air Intake Hose 1. Check air intake hose for cracks and replace as necessary. 2. Check for loose connections and tighten clamps (A) as necessary. A Air Intake Hose Clamps 850C Series II Shown T UN 03JUN96 TX,70,RR,A JUN96 1/1 Check Coolant and Conditioner in Radiator T UN 10MAR97 TS281 UN 23AUG88 Continued on next page CED,OUO1065, JAN00 1/ PN=126

129 Maintenance Every 500 Hours CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Remove filler cap only 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. To avoid overheating engine, DO NOT add John Deere Coolant Conditioner to a system equipped with an operational filter conditioner system. Too much conditioner may cause silicate dropout, creating a gel-type deposit which restricts coolant passages in the radiator and engine. NOTE: Check conditioner every 500 hours or 6 months, or when replacing 1/3 or more of coolant. CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Remove filler cap only 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. 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. Continued on next page CED,OUO1065, JAN00 2/ PN=127

130 Maintenance Every 500 Hours 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. 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-chromate conditioner/rust inhibitor as necessary. Follow instructions on container for amount. Specification 750C Series II Cooling System Capacity L (7 gal) 850C Series II Cooling System Capacity L (9 gal) 3. Install cap. COOLSCAN Plus is a registered trademark of Deere & Company CED,OUO1065, JAN00 3/ PN=128

131 Maintenance Every 1000 Hours Clean Engine Crankcase Vent Tube 1. Remove vent tube (A) and clean interior using diesel fuel. 2. Check condition of O-ring in rocker arm cover and replace as necessary. A Vent Tube 750C Series II T UN 10MAR97 850C Series II CED,OUO1065,129 T UN 03JUN JAN00 1/1 Check Left and Right Track Frame Pivot Oil Level 1. Remove plug (B) (2 points) and check oil level. 2. If oil is not level to bottom of hole, remove filler plug (A) and add oil. (See Fuels and Lubricants chapter.) A Filler Plug B Oil Level Plug T8429AI UN 02MAR95 TX,75,RR,A MAY96 1/ PN=129

132 Maintenance Every 1000 Hours Change Final Drive Oil 1. Move machine so sprocket oil level line (C) is parallel to ground with outer drive drain plug (B) to bottom. NOTE: Dispose of oil properly. 2. Remove drain plugs and filler plugs (A and B) to drain oil. 3. Install and tighten drain plugs. 4. Fill final drives with oil according to specifications. (See Fuels and Lubricants chapter.) Specification 750C Series II Inner Final Drive Oil (Each Side) Capacity L (6.25 gal) 750C LGP Series II Inner Final Drive Oil (Each Side) Capacity L (7.35 gal) 850C LT Series II (Semi-U) Inner Final Drive Oil (Each Side) Capacity L (3.25 gal) 850C LT Series II (PAT) Inner Final Drive Oil (Each Side) Capacity L (4.35 gal) 850C WT Series II (Semi-U) Inner Final Drive Oil (Each Side) Capacity L (4.35 gal) 850C WT Series II (PAT) Inner Final Drive Oil (Each Side) Capacity L (10 gal) 850C LGP Series II Inner Final Drive Oil (Each Side) Capacity L (10 gal) All Machines Outer Final Drive Oil (Each Side) Capacity L (3.25 gal) Inner Final Drive Housing T8432AY UN 13MAR95 5. Install and tighten filler plugs. A Filler Plug B Drain Plug C Oil Level Line Outer Final Drive Housing TX,75,RR,A2 T8448AK UN 30MAR JUN96 1/ PN=130

133 Maintenance Every 1000 Hours Remove and Inspect Air Filter Elements Inspect elements when air filter restriction indicator comes on. See Display Monitor Gauges and Indicators in Operator s Station chapter for location of indicator light. 1. Open engine right-side service door C Series II: Loosen clips (A) to remove air cleaner cover. 750C Series II: Turn wing nut (B) to remove air cleaner cover. T8381AN UN 03JAN95 A Cover Clips B Wing Nut 850C Series II T UN 03JUN96 750C Series II T UN 11MAR97 Continued on next page CED,OUO1065, JAN00 1/ PN=131

134 Maintenance Every 1000 Hours C Series II: Remove wing nuts to remove primary (A) and secondary (B) elements. Wipe inside of air cleaner with a damp cloth to remove debris. A Primary Filter B Secondary Filter 750C Series II Primary Element T UN 11MAR97 750C Series II Secondary Element CED,OUO1065,130 T UN 11MAR JAN00 2/ C Series II: Slide primary (A) and secondary (B) elements out to remove. Wipe inside of air cleaner with a damp cloth to remove debris. A Primary Filter B Secondary Filter 850C Series II Primary Element T UN 03JUN96 Continued on next page 850C Series II Secondary Element CED,OUO1065,130 T UN 03JUN JAN00 3/ PN=132

135 Maintenance Every 1000 Hours IMPORTANT: Install a new primary element: If element shows damage If element will not clean DO NOT clean secondary element. Install new element: If primary element is damaged and needs replacement If element is visibly dirty NOTE: Air restriction indicator will not signal correctly if element is broken or is not correctly sealed in air cleaner housing. Replace element that has the slightest damage. T90684 UN 10NOV88 5. Inspect elements and gaskets for cleanliness or damage. Clean (primary only) or replace as necessary. See Clean Dusty Primary Element in Maintenance chapter for recommended procedures. 6. If gasket is broken or missing, install a new element. See Remove and Inspect Air Filter Elements in this chapter for removal. CED,OUO1065, JAN00 4/ PN=133

136 Maintenance Every 2000 Hours Change Hydraulic Oil and Filter IMPORTANT: Replace filter before recommended service interval if hydraulic oil filter indicator stays on after oil is warm. 1. Loosen filler plug (A) to relieve pressure. 2. Remove rear panel below fuel tank. NOTE: Dispose of waste oil properly. (See Dispose of Waste Properly in Safety chapter.) T UN 03JUN96 3. Remove plug (C) and drain oil into container. 4. Clean area around housing and remove filter (D) by turning counterclockwise. 5. Apply a film of oil to sealing ring on new filter. Install so gasket touches mounting surface and tighten an additional 3/4 to one turn with a suitable wrench. 6. Install drain plug. 7. Fill reservoir with oil to specification and install plug. (See Fuels and Lubricants chapter.) T UN 03JUN96 Specification 750C Series II Hydraulic System Oil Capacity C Series II Hydraulic System Oil Capacity L (18 gal) 81 L (21 gal) 8. Move FNR with Transmission Speed-In-Grip lever to neutral. Start engine and run at slow idle for five minutes before operating machine. This will allow filter element to refill and air to be purged from charge circuit. T UN 08APR97 9. Check for any leakage around element and tighten as necessary to stop leakage. 10. Check oil level in sight glass (B). Oil should be to midpoint. A Filler Plug B Sight Glass C Plug D Filter CED,OUO1065, JAN00 1/ PN=134

137 Maintenance Every 2000 Hours Change Hydrostatic Transmission Oil and Filter IMPORTANT: Replace filter before recommended service interval if hydraulic oil filter indicator stays on after oil is warm. 1. Loosen filler plug (A) to release pressure. 2. Remove rear panel below fuel tank. NOTE: Dispose of waste oil properly. (See Dispose of Waste Properly in Safety chapter.) T8429AP UN 02MAR95 3. Remove plug (B) and drain oil into container. A Transmission Filler Plug B Transmission Oil Drain Plug T UN 03JUN96 Continued on next page CED,OUO1065, JAN00 1/ PN=135

138 Maintenance Every 2000 Hours 4. Open left side access service door and turn filter housing (A) counterclockwise to remove. 5. Apply a film of oil to sealing ring on new filter. Install until it touches mounting surface and tighten an additional 3/4 to one turn with a suitable wrench. 6. Install drain plug. 7. Remove fill plug, fill reservoir with oil to specification and install plug. (See Fuels and Lubricants chapter.) Specification 750C Series II Transmission System Oil Capacity L (22 gal) 850C Series II Transmission System Oil Capacity L (27 gal) T UN 03JUN96 8. Move FNR with Transmission Speed-In-Grip lever to neutral. Start and run engine at slow idle for five minutes before operating machine. This will allow filter element to refill and purge air from charge circuit. 9. Check for leakage around element. Tighten element just enough to stop leakage. 10. Check oil level in sight glass (B). Oil should be to mid-point. A Transmission Oil Filter B Transmission Oil Sight Glass T UN 05JUN96 CED,OUO1065, JAN00 2/ PN=136

139 Maintenance Every 2000 Hours Measure and Adjust Engine Valve Clearances 750C Series II CAUTION: To prevent accidental starting of engine while preforming valve adjustments, always disconnect NEGATIVE (-) battery terminal. IMPORTANT: Valve clearance MUST be checked and adjusted with engine cold. NOTE: To gain access to valves, remove air cleaner cap, hood, air cleaner and hoses, muffler and support, exhaust stack, dipstick tube bracket, filler tube clamp (move tube out of the way), air restriction indicator and bracket, turbocharger oil line, starting fluid line, vent hose, front lifting bracket, and rocker arm cover. Close all openings using caps and plugs. 1. Remove rocker arm cover with ventilator tube. Clean tube using solvent or diesel fuel and check condition of O-ring in cover and replace as necessary. CED,OUO1065, JAN00 1/3 2. Remove plastic plugs (A and B) from cylinder block bores and install JDG820 Flywheel Turning Tool and JDE81-4 Timing Pin. 3. Rotate engine with flywheel turning tool until pin engages timing hole in flywheel. NOTE: No. 1 or No. 6 piston is at TDC if its push rods and rocker arms are loose. 4. If No. 6 cylinder is at TDC, rotate engine one full revolution so No. 1 is at TDC. T UN 31MAY96 A Flywheel Turning Plug B Timing Pin Plug Continued on next page CED,OUO1065, JAN00 2/ PN=137

140 Maintenance Every 2000 Hours 5. With engine lock-pinned at TDC of No. 1 piston s compression stroke, check and adjust (as needed) valve clearance at exhaust valves Nos. 1, 3 and 5 and intake valves Nos. 1, 2 and 4. Specification 750C Series II Exhaust Valves (E) Clearance mm (0.018 in.) 750C Series II Intake Valves (I) Clearance mm (0.014 in.) 6. If valve needs to be adjusted, loosen lock nut on rocker adjusting screw. Turn screw until feeler gauge slips with a slight drag. Hold screw from turning with screwdriver and tighten lock nut to specification. Check clearance again after tightening lock nut and adjust again as necessary. RG5241 UN 06DEC88 Specification Rocker Arm Adjusting Screw Jam Nut Torque N m (20 lb-ft) 7. Rotate flywheel 360 until No. 6 piston is at TDC of its compression stroke. 8. Check and adjust (as needed) valve clearance to same specifications on Nos. 2, 4 and 6 exhaust and Nos. 3, 5 and 6 intake valves. Torque valve adjusting screw lock nut to same specification. 9. Check clearance on all valves again after lock nut is tightened and readjust as necessary. A Fan End of Engine B No. 1 TDC Compression Stroke C No. 6 TDC Compression Stroke RG4777 UN 31OCT97 CED,OUO1065, JAN00 3/ PN=138

141 Maintenance Every 2000 Hours Measure and Adjust Engine Valve Clearances 850C Series II CAUTION: To prevent accidental starting of engine while preforming valve adjustments, always disconnect NEGATIVE (-) battery terminal. IMPORTANT: Valve clearance MUST be checked and adjusted with engine cold. NOTE: To gain access to valves, remove air cleaner cap, hood, air cleaner and hoses, muffler and support, exhaust stack, dipstick tube bracket, filler tube clamp (move tube out of the way), air restriction indicator and bracket, turbocharger oil line, starting fluid line, vent hose, front lifting bracket, and rocker arm cover. Close all openings using caps and plugs. 1. Remove rocker arm cover with ventilator tube. Clean tube using solvent or diesel fuel and check condition of O-ring in cover and replace as necessary. CED,OUO1065, JAN00 1/3 2. Remove plastic plugs (A and B) from cylinder block bores and install JDG820 Flywheel Turning Tool and JDE81-4 Timing Pin. 3. Rotate engine with flywheel turning tool until pin engages timing hole in flywheel. NOTE: No. 1 or No. 6 piston is at TDC if its push rods and rocker arms are loose. 4. If No. 6 cylinder is at TDC, rotate engine one full revolution so No. 1 is at TDC. T UN 31MAY96 A Flywheel Turning Plug B Timing Pin Plug Continued on next page CED,OUO1065, JAN00 2/ PN=139

142 Maintenance Every 2000 Hours 5. With engine lock-pinned at TDC of No. 1 piston s compression stroke, check and adjust (as needed) valve clearance at exhaust valves Nos. 1, 3 and 5 and intake valves Nos. 1, 2 and 4. Specification 850C Series II Exhaust Valves (E) Clearance mm (0.028 in.) 850C Series II Intake Valves (I) Clearance mm (0.018 in.) 6. If valve needs to be adjusted, loosen lock nut on rocker adjusting screw. Turn screw until feeler gauge slips with a slight drag. Hold screw from turning with screwdriver and tighten lock nut to specification. Check clearance again after tightening lock nut and adjust again as necessary. RG5241 UN 06DEC88 Specification Rocker Arm Adjusting Screw Jam Nut Torque N m (20 lb-ft) 7. Rotate flywheel 360 until No. 6 piston is at TDC of its compression stroke. 8. Check and adjust (as needed) valve clearance to same specifications on Nos. 2, 4 and 6 exhaust and Nos. 3, 5 and 6 intake valves. Torque valve adjusting screw lock nut to same specification. 9. Check clearance on all valves again after lock nut is tightened and readjust as necessary. A No. 1 TDC Compression Stroke B No. 6 TDC Compression Stroke C Fan End of Engine T6872AH UN 18OCT88 CED,OUO1065, JAN00 3/ PN=140

143 Maintenance Every 2000 Hours Check Engine Speeds 750C Series II 1. Warm engine to normal operating temperature. 2. Check speeds using display monitor. Specification Slow Idle (with decelerator pedal pressed) Speed rpm Fast Idle Speed ± 25 rpm If adjustment is necessary, see your authorized dealer. CED,OUO1065, JAN00 1/1 Engine Speed Adjustment 850C Series II NOTE: 850C uses electronic fuel injection, so a mechanical speed adjustment is not necessary. To set slow and fast idle, an engine calibration is performed. See your authorized dealer. T82,SKMA,AT 19 01AUG94 1/ PN=141

144 Maintenance Every 4500 Hours or 5 Years Remove and Replace Engine Dampener Engine dampener should be replaced at 4500 hours or 5 years. (See your authorized dealer.) CED,OUO1065, JAN00 1/ PN=142

145 Maintenance Servicing the Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. Drain and fill the cooling system every three years or 3000 hours if John Deere Coolant is used. See Check Radiator Coolant Level in Maintenance Every 250 Hours chapter. TS281 UN 23AUG88 T8214BE UN 27APR94 TX,90,BG SEP98 1/1 Test the Coolant Freeze-Protection Level See your John Deere dealer for JT05460 SERVICEGARD coolant and battery tester. Follow directions included with the tester. If you operate your engine in extremely cold temperatures, see your John Deere dealer for information on arctic operation. T85402 UN 10NOV88 SERVICEGARD is a trademark of Deere & Company T82,EXMA,CK 19 28JUL94 1/ PN=143

146 Maintenance Checking Coolant Hoses Check hoses (A) for cracks and leaks. Tighten clamps. Check radiator for dirt, damage, leaks, and loose or broken mountings. Clean radiator fins. A Radiator Hoses T8429AL UN 02MAR95 TX,85,RR,A MAY96 1/1 Draining the Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. Every five years or 5000 hours (if John Deere Coolant is used), replace thermostats, drain and flush cooling system using clean water and refill with new coolant. TS281 UN 23AUG88 Specification 750C Series II Coolant Capacity L (7 gal) 850C Series II Coolant Capacity L (9 gal) Continued on next page TX,90,BG APR97 1/ PN=144

147 Maintenance 1. Open grille (A). 2. Remove cover (B). 3. Remove left engine side shield. A Grille B Cover T8429AR UN 02MAR95 TX,90,BG APR97 2/4 4. Open drain plug (A) to drain engine block. A Drain Plug 850C Series II Shown T UN 03JUN96 Continued on next page TX,90,BG APR97 3/ PN=145

148 Maintenance 5. Open heater valve (A) to drain heater cord. 6. After coolant has drained, install plugs and close valve. A Heater Valve T UN 31MAY96 TX,90,BG APR97 4/4 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). 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. Other low silicate ethylene glycol base coolants for heavy-duty engines may 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 these specifications require use of supplemental coolant additives, formulated for heavy-duty diesel engines, for protection against corrosion and cylinder liner erosion and pitting. A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37 C (-34 F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations. Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate. IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives. Coolant Drain Intervals Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant after the first 3 years or 3000 hours of operation. Subsequent drain intervals are determined by the coolant used for service. At each interval, drain the coolant, flush the cooling system, and refill with new coolant. When John Deere COOL-GARD is used, the drain interval may be extended to 5 years or 5000 hours of operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive. If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation. DX,COOL FEB99 1/ PN=146

149 Maintenance Filling the Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. If radiator fill cap must be removed, do not remove when engine is hot. Shut off engine and wait until cap is cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure, before removing completely. TS281 UN 23AUG88 Specification 750C Series II Coolant Capacity L (7 gal) Approximate 850C Series II Coolant Capacity L (9 gal) Approximate Fill system so coolant level is to bottom of filler neck. IMPORTANT: Use only permanent-type low silicate, ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals. 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. 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. After filling radiator, operate engine minutes to purge air from engine block. Shut off engine and add coolant to radiator as necessary. Warm engine to normal operating temperature, stop engine and verify that radiator is completely full, and that recovery tank is at normal level. Add coolant to recovery tank as necessary. TX,85,RR,A SEP98 1/ PN=147

150 Maintenance Engine Cold Weather Warm-Up IMPORTANT: If hydraulic oil is cold, hydraulic functions move slowly. Do not attempt machine operations until hydraulic functions move at close-to-normal cycle times. In extremely cold conditions, an extended warming-up period will be necessary. Avoid sudden operation of hydraulic functions until engine is thoroughly warmed up. Remove ice, snow, and mud before operation. 1. Run engine at 1/2 speed for five minutes. 2. Cycle all hydraulic functions to distribute warmed oil until all functions operate freely. 02T,25,M MAR95 1/1 Do Not Adjust Injection Pump IMPORTANT: Never steam clean or pour cold water on an injection pump while the pump is running or while it is still warm. To do so may cause seizure of pump parts. Clean trash regularly from under injection pump. Changing the injection pump in any way not approved by the manufacturer will end the warranty. (See your copy of the John Deere warranty on this machine.) Do not service an injection pump that is not operating correctly. (See your authorized injection pump service center.) 04T,90,C SEP98 1/ PN=148

151 Maintenance Do Not Service Injection Nozzles IMPORTANT: Do not service or remove injection nozzles. The service life of the injection nozzles may be shortened by: Overheating Improper operation Poor quality fuel Excessive idling If injection nozzles are not working correctly or are dirty, the engine will not run normally. (See your authorized dealer for service.) TX,85,RR,A JUN96 1/1 Drain Fuel Filter Sediment 850C Series II Drain water and sediment as necessary. 1. Loosen drain screw (A). Drain liquid for several seconds. 2. Tighten drain screw. 3. Bleed fuel system. See Change Fuel Filter in Maintenance Every 500 Hours chapter for bleeding instructions. T7034AG UN 01MAY89 A Drain Screw TX,90,BG APR97 1/ PN=149

152 Maintenance Fuel Drain and Shut-Off Valve 1. Remove cover (A) at rear of machine. 2. Turn petcock (B) counterclockwise to drain fuel. 3. Turn lever (C) clockwise to shut off fuel. A Cover B Petcock C Lever T UN 03JUN96 TX,85,RR,A JUN96 1/1 Clean Dusty Primary Element 1. Tap element with the palm of your hand, NOT ON A HARD SURFACE. CAUTION: 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. T47764 UN 09NOV88 2. If this does not remove dust, use compressed air under 210 kpa (2.1 bar) (30 psi). 3. Direct air up and down the pleats from inside to outside. Be careful not to break element. TX,85,RR,A MAY96 1/ PN=150

153 Maintenance Clean Dust Unloader Valve IMPORTANT: A missing, damaged, or hardened dust unloader valve will make 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 air cleaner. If operating in high dust conditions, squeeze dust valve every couple of hours of operation to release dust. 850C Series II Shown T UN 05JUN96 A Dust Valve TX,90,BG APR97 1/1 Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16 C (60 F). TS204 UN 23AUG88 DX,SPARKS 19 03MAR93 1/ PN=151

154 Maintenance Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 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 2L(2quarts). 3. Get medical attention immediately. TS203 UN 23AUG88 DX,POISON 19 21APR93 1/ PN=152

155 Maintenance Service Batteries Carefully CAUTION: Do not attempt to service battery unless you have the proper equipment and experience to perform the job. Have it done by your John Deere dealer or other qualified dealer. If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in 4L(1gal) water, or 0.47 L (1 pt) household ammonia in 4 L(1 gal) water. N36877 UN 07OCT88 Proper battery maintenance is vital to dependable service. In conventional or New Dimension battery, keep water level even with bottom of cell filler neck and never below the top of cell plates. Do not add water in freezing weather unless engine is run two or three hours to mix electrolyte. Keep battery clean by wiping it with a damp cloth. Keep all connections clean and tight. Remove any corrosion, and wash terminals with solution of baking soda and water. Coat with grease prior to attaching cables. IMPORTANT: Electrolyte can damage paint and metal surfaces of your machine. Do not overfill the battery cells. If electrolyte spills on floor, use one of the following mixtures to neutralize acid: 0.5 kg (1 lb) baking soda in 4L(1gal) water 0.47 L (1 pt) household ammonia in 4 L(1 gal) water TX,85,RR,A MAY96 1/ PN=153

156 Maintenance Check Electrolyte Specific Gravity Check specific gravity of electrolyte in each battery cell. See your John Deere dealer for JT05460 SERVICEGARD battery and coolant tester. Follow directions included with the tester. NOTE: In tropical areas, use for the full charge reading. In cold areas, use for the full-charge reading. T85402 UN 10NOV88 A fully charged battery will have a corrected specific gravity reading of If the reading is below 1.200, charge the battery. SERVICEGARD is a trademark of Deere & Company TX,85,RR,A MAY96 1/1 Using Battery Charger IMPORTANT: Batteries which have been stored, particularly for long periods or in warm locations, will require longer charging time. If open-circuit voltage is less than 23.7 volts double the charging time. Be sure to observe all instructions and precautions furnished by the battery charger manufacturer. Ventilate the area where batteries are being charged. Do not charge a frozen battery. Warm to 16 C (60 F) before charging. Do not connect or disconnect live circuits. Turn off charger and connect ground cable last, away from battery. N36890 UN 07OCT88 Stop or cut back charging rate if battery case feels hot or is venting electrolyte. Battery temperature must not exceed 52 C (125 F). TX,85,RR,A JUN96 1/ PN=154

157 Maintenance 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. 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. 4. Do not ground alternator output terminal. 5. Do not disconnect or connect any alternator or regulator wires while batteries are connected or while alternator is operating. T82,EXMA,I 19 03AUG92 1/ PN=155

158 Maintenance Using Booster Battery CAUTION: Gas given off by batteries is explosive. Keep sparks and flames away from battery. Make last connection and first disconnection at a point away from battery. IMPORTANT: Always connect starter cable to positive (+) terminal of battery and battery ground cable to negative ( ) terminal of battery. Reversed polarity in battery or alternator can result in permanent damage to electrical system. N36877 UN 07OCT88 1. Connect positive (+) cable to positive post of discharged battery and the other end of the same cable to post marked positive (+) of booster battery. 2. Connect second cable (negative ( ) to negative post of booster battery. 3. Connect the other end of the negative ( ) cable to the engine block of the stalled machine, away from the battery. Stand clear. 4. Start machine and remove cables in reverse order of connection. TX,85,RR,A MAY96 1/ PN=156

159 Maintenance Replacing Batteries CAUTION: 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. Your machine has two 12-volt batteries with negative ( ) ground connected in series to provide 24-volts. Use only batteries which meet the following specifications. BATTERY SPECIFICATIONS BCI Group Cold Cranking Reserve Capacity Amps 0 F ( 18 C) (Minute of 25 Amp) T UN 03JUN96 TX,85,RR,A JUN96 1/1 Removing Batteries CAUTION: Prevent possible injury from exploding battery. Always remove grounded ( ) battery clamp first and replace it last. 1. Turn battery disconnect switch to OFF. 2. Disconnect negative ( ) battery cables first, then positive (+) cables. 3. Remove nuts and hold-down frames. Lift batteries from machine. 4. Check cables and clamps for damage and wear. Make certain the batteries are fully charged. T UN 03JUN96 5. Install batteries making sure they are level. 6. Install hold-down frames. Connect cables, positive then negative. 7. Turn battery disconnect switch to ON. TX,85,RR,A JUN96 1/ PN=157

160 Maintenance Fuse Specifications T JAN04 F1 10A Start Circuit Fuse F7 5A Transmission F15 20A Heater Blower Fuse F22 15A Spare Fuse F2 15A Engine Controller Controller Fuse F16 10A Condenser Fan Fuse F23 5A Spare Fuse Fuse 850C Series II only F8 15A Light Circuit Breaker F17 10A Condenser Fan Fuse K2 Heater/Blower Relay F3 15A Start Aid Fuse F9 5A Horn/Light Switch F18 5A A/C Compressor Fuse K3 Front Light Relay F4 5A Monitor Fuse Fuse F19 5A Radio Fuse K4 Light Relay (Optional) (UNSWITCHED) F10 5A Dome Light Fuse (SWITCHED) K5 Wiper, Washer, Dome F5 5A Monitor Fuse F11 5A Hydraulic Valve Fuse F20 5A Radio Fuse Light and Radio Relay (SWITCHED) F12 10A Front Wiper and (UNSWITCHED) K6 A/C Relay F6 15A Light Circuit Breaker Washer Fuse F21 10A Air Suspension Seat V1 Start Circuit Diode (Optional) F13 10A LH/RH Wiper Fuse (If Equipped) V2 Start Relay Diode F6 15A Optional Light Fuse F14 Fuse Block 850C Series II only IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload. The fuse block is located on left side of machine through access door. CED,OUO1065, JAN00 1/ PN=158

161 Maintenance Fuse (Blade-Type) Color Codes Amperage Rating Color 1 Black 3 Violet 4 Pink 5 Tan 7-1/2 Brown 10 Red 15 Light Blue 20 Yellow 25 Natural (White) 30 Light Green 04T,90,J SEP92 1/1 Adding 12-Volt Accessories IMPORTANT: This unit has a 24-volt electrical system. Installing 12-volt accessories without addition of 24-volt to 12-volt converter may cause battery failure. When possible, use 24-volt accessories. If 12-volt accessories are added, use a 24-volt to 12-volt converter. Converters are available from your authorized dealer (see the Industrial Equipment Attachment Guide) or electronic retail stores. This converter may be wired into the ACC terminal of the ignition switch (see drawing). Converter capacity requirements depend on the load of the accessories installed. Follow electronic dealer and manufacturer s recommendations to determine the capacity of the converter required and its installation requirements. A Battery B 24-Volts C Ignition Switch D ACC Terminal E Converter F 12-Volts G 12-Volt Accessory T7527DM UN 05JUN91 DO NOT connect an accessory to one battery. Connecting a 12-volt accessory to one battery will cause one battery to overcharge, and the other battery to undercharge, causing battery failure. TX,90,FF JUL94 1/ PN=159

162 Maintenance Remove and Install Halogen Bulb 1. Remove screws (A), cover (B), lamp (C), and housing (E). 2. Disconnect wiring lead and release retainer clip to remove bulb (D). CAUTION: Do not touch the halogen bulb with bare hands. Oil and moisture may cause premature bulb failure. Clean bulb glass if touched, using an oil-free cloth with alcohol. NOTE: Tighten screws alternately. To avoid stripping plastic, do not overtighten. 3. Install new bulb, lamp and assemble housing. A Screw (2 used) B Lamp Cover C Lamp D Bulb E Lamp Housing T7484AC UN 12MAR91 TX,90,BG APR97 1/ PN=160

163 Maintenance Checking Neutral Start System CAUTION: Avoid possible injury or death. Be sure all people are away from machine when neutral start checks are performed. 1. Place FNR with Transmission Speed-In-Grip lever in neutral "N" position. 2. Move park lock lever (A) to down (unlocked) position. 3. Turn key switch to start position. Starter must not engage. If engine starts, see your John Deere dealer. 1 Park Lock Lever (Unlocked Position) T127204B UN 21JAN00 4. Move park lock lever to up (locked) position. 5. Turn key switch to start position. Starter should engage, turning engine over. If engine does not turn over, see you John Deere dealer. 6. Move FNR with Transmission Speed-In-Grip lever to forward "F" or reverse "R". 7. Turn key switch to start position. Starter must not engage. 8. Move FNR with Transmission Speed-In-Grip lever to neutral "N". 9. Turn key switch to start position. Starter should engage. If starter does not engage, see your John Deere dealer. TX,90,BG APR97 1/ PN=161

164 Maintenance Change Reverse Warning Alarm Volume IMPORTANT: Reverse warning alarm is set on low volume at the factory. It may be necessary to adjust volume to meet local regulations. NOTE: Alarm shown removed for clarity. See John Deere Crawler Safety Features illustration in Safety chapter for location of alarm system. 1. To change alarm to high volume, remove nuts from terminals (B and C). 2. Attach shorting bar (A) to terminals (B and C). A Shorting Bar B High Volume Terminal C Low Volume Terminal T8594AC UN 09NOV95 TX,85,RR,A MAY96 1/ PN=162

165 Maintenance Track Sag General Information Properly adjusted tracks prolong chain life and allow maximum life of bushings, Improperly adjusted tracks wear at a more rapid rate. A tight track causes higher loading which will increase wear on pins, bushings, links, sprocket and front idler. Graph (A) shows how loading on chain increases significantly when tracks are too tight. Also, a tight track requires more horsepower, increasing fuel consumption and decreasing productivity. Periodically check track sag. See Check Track Sag in Maintenance As Required chapter. Tracks may require adjustment several times during a working day when moisture content of soil changes. Track Tension in kg (lb) vs Track Sag in mm (in.) T7800AJ UN 31JUL92 Tracks should be adjusted under operating conditions. If material packs in undercarriage, adjust tracks with material packed in components. When packing occurs, sag is taken up and must be loosened. Track spring will recoil and machine will continue to operate with tight track. However, continued operation without loosening the tracks will result in excessive pin and bushing wear, sprocket popping, tooth tip wear, and excessive loads on undercarriage and final drive system. With sealed chain, internal pin and bushing wear creates sag, reducing the effects of packing. However, if a sealed chain is too tight, accelerated bushing wear occurs. Lubricated chain is different, due to absence of internal pin and bushing wear. It is essential to keep sag adjusted to prevent wear of outside diameter of bushing. Maintaining track sag is very important, regardless of track being used. T7800AH UN 31JUL92 TX,85,RR,A MAY96 1/1 Checking Idlers and Rollers for Oil Leakage Check carrier rollers, front idlers, and track rollers for leaks. If any leaks are found, see your John Deere dealer. TX,85,RR,A MAY96 1/ PN=163

166 Maintenance Checking Idler and Track Roller Oil Level IMPORTANT: Because of idler shaft design, it is necessary to fill entire cavity with oil to prevent premature failure of bushings. If filled incorrectly, idler assembly will have an oil level below the centerline of shaft. Accurate oil level cannot be checked by removing the pipe plug in the end of shaft since oil present in shaft could be residual oil in the cross-drilled hole. T6035AB UN 01NOV88 NOTE: Clean JD313 Lube Nozzle (available from your John Deere dealer) before using. 1. Thoroughly clean area around plug. Check O-ring for cuts and replace as necessary. Grease O-ring for easy entry past threads of shaft ID. NOTE: There are seven track rollers per track. 2. Remove pipe plugs and O-rings from idlers and track rollers (B). Check condition of O-rings. NOTE: Pipe plug is to outside right idler and to inside of left idler. Front Idler T6035AD UN 01NOV88 3. Insert nozzle into shaft as far as it will go. Make sure flat side (A) of nozzle is facing up to allow bleeding of air from housing. 4. Force oil into shaft until oil flows from the fill hole, indicating it is full. (See Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil in Fuels and Lubricants chapter for recommended oil.) 5. Remove nozzle and install plug with O-ring. T UN 03JUN96 A JD313 Lube Nozzle B Track Rollers TX,90,BG APR97 1/ PN=164

167 Maintenance Checking Carrier Roller Oil Level 1. Remove plug from carrier roller. Oil must flow from hole. 2. Add oil as necessary. (See Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil in Fuels and Lubricants chapter for recommended oil.) 3. Install plug. T6044BH UN 01NOV88 TX,85,RR,A JUN96 1/1 Checking Idler Horizontal Movement NOTE: Idler horizontal adjustments are similar for 750C Series II and 850C Series II. 1. Center idler between track frame so dimensions (A and B) are equal. 2. Remove outer guides if required. Adjust right outer guide with shims (E) so dimensions (A and C) are equal. See your John Deere dealer for shims. 3. Adjust left outer guide with shims so dimensions (B and D) are equal. 4. Tighten outer guide cap screws to specification. T6045AG UN 01NOV88 Specification Outer Guide Cap Screws Torque N m (240 lb-ft) A Clearance B Clearance C Clearance D Clearance E Shims TX,85,RR,A MAY96 1/ PN=165

168 Maintenance Checking Idler Vertical Movement IMPORTANT: If idler vertical gap is excessive, ability to finish grade with crawler is affected and track adjuster may be damaged. 1. Drive crawler so front idler is on a block of wood or a pile of dirt approximately 150 mm (6 in.) high. 2. Check gap (A) between guide block assembly (B) and wear strip (C) on both sides of idler. If gap exceeds 3 mm (0.12 in.) perform the following steps as necessary. T6036AG UN 01NOV88 3. Remove two cap screws (D) and loosen cap screws in block (B). 4. Pry up between inner guide and guide block assembly. Insert shims (E) as needed. Set gap to 1 mm (0.040 in.) If more than 3 mm (0.12 in.) shim pack is required, J-bar and lower track frame wear strips may need replacing. If either wear strip is less than 3 mm (0.12 in.) thick, see your John Deere dealer for replacement. T6043BF UN 01NOV88 5. Install cap screws. A Gap B Guide Block Assembly C Wear Strip D Cap Screws (2 used) E Shims TX,85,RR,A JUN96 1/ PN=166

169 Maintenance Cab or ROPS Tilting Procedure CAUTION: Machine MUST be on level surface before attempting to tilt cab or ROPS. Cab or ROPS MUST be tilted to overcenter position and be resting against safety cable. IMPORTANT: Clear area of all objects before tilting cab or ROPS. 1. Park machine on level ground and turn battery disconnect switch OFF. IMPORTANT: Prevent possible damage to cab door if equipped. Damage to cab door may result if it is open when tilting cab. Close door when tilting the cab. IMPORTANT: Safety cable (A) MUST be attached to cylinder pins and in good condition. 2. Open both rear service doors. Cab doors must be closed if equipped. A Safety Cable T8439AP UN 01JUL96 Continued on next page CED,OUO1065, JAN00 1/ PN=167

170 Maintenance 3. Disconnect engine speed control linkage (A) at quick disconnect. CAUTION: Prevent possible injury from unexpected machine movement. When cab is lowered, linkage may contact valve, causing valve to function. Tie linkage to metal tab on reservoir wall to prevent accidental contact. NOTE: 850C Series II machines: Linkage is on right side of machine and can be accessed through engine side shield. 750C Series II T UN 11MAR97 4. Disconnect dozer control valve linkages (B) and retain to metal tab (C) on reservoir wall. A Engine Speed Control Linkage B Dozer Control Valve Linkages C Metal Tab 850C Series II T UN 03JUN96 T UN 03JUN96 CED,OUO1065, JAN00 2/5 5. Remove six cap screws (A) attaching cab or ROPS. A Cap Screw (6 used) T8439AY UN 01JUL96 Continued on next page CED,OUO1065, JAN00 3/ PN=168

171 Maintenance 6. Point valve lever (A) towards operator s seat (cab raise position). 7. Install handle (B) in pump lever. NOTE: Larger diameter hose (C) is to brake circuit for towing application only. (See Towing in Transporting chapter for information.) 8. Attach smaller diameter hose (D) to quick coupler and retain larger diameter hose in hose holder. NOTE: If pump operation is slow or spongy, air may be present in system. T UN 03JUN96 9. Operate hand pump using full strokes. Continue to stroke pump until safety cable is tight against pins. A Valve Lever B Handle C Hose D Hose T UN 03JUN96 Continued on next page CED,OUO1065, JAN00 4/ PN=169

172 Maintenance 10. To lower cab or ROPS, position pump selector lever (A) to point out from operator s seat. Operate hand pump the same as when raising the cab or ROPS. Cab or ROPS will free-fall a small amount as it goes over center. 11. Connect speed control linkage. CAUTION: Prevent possible injury from unstable ROPS. ROPS cap screws must be installed properly. T8439AS UN 01JUL Install cap screws and torque to specification. Specification Cab or ROPS Mounting Cap Screws Torque ± 224 N m (400 ± 165 lb-ft) A Pump Selector Lever B Reservoir Fill Plug 13. Check oil level of reservoir at fill plug (B) and add oil if necessary. (See Fuels and Lubricants chapter.) CED,OUO1065, JAN00 5/ PN=170

173 Maintenance Check and Adjust Front Crossbar-to-Crossbar Support and Main Frame Clearances 750C Series II If Equipped 1. Check clearance between front crossbar (D) and hold-down pad (C). Specification Front Crossbar-to-Crossbar Support Clearance... 5 mm (0.2 in.) 2. If adjustment is needed, remove two cap screws (A). T6044BF UN 01NOV88 3. Install shim(s) (B) under hold-down pad (C) until clearance is within specification. A minimum of three shims must be used to keep cap screws from protruding through the hold-down pad. Store any excess shims under the cap screw heads. 4. Tighten cap screws to specification. Specification Crossbar Cap Screws Torque N m (240 lb-ft) 5. Check clearance (E) between crossbar (D) and retainer (F) at center of crossbar. Specification 750C Crossbar-to-Retainer Clearance mm ( in.) 850C Crossbar-to-Retainer Clearance mm ( in.) 6. If clearance exceeds the maximum, remove special cap screws and washers (H) to remove channel retainer. A Cap Screws B Shims C Hold-Down Pad D Crossbar E Crossbar/Retainer Clearance F Shim Retainer G Shims H Special Cap Screws and Washers T6056AQ UN 01NOV88 7. Install shims under retainer (F) to obtain the minimum clearance using as many of the thicker shims as possible. 8. Install the shim retainer, cap screws and washers. Tighten cap screws to specification. Cap screws must not protrude through retainer more than one thread. Specification Special Crossbar Cap Screws Torque N m (120 lb-ft) CED,OUO1065, JAN00 1/ PN=171

174 Maintenance Adjusting Engine Speed Control Lever 1. Open the left-side service door. 2. Disconnect push-pull cable from speed control lever (A). 3. Torque lock nut (B) so that it takes N (7 9 lb-force) applied at top of knob on lever to start lever movement. A Control Lever B Lock Nut T8439AX UN 30MAR95 TX,90,BG APR97 1/1 Welding Procedure IMPORTANT: To avoid electronic component damage, turn battery disconnect switch to off position before welding on machine. 1. Turn battery disconnect switch (A) to off position. 2. Clamp welding ground clamp as close to point of welding as possible. A Battery Disconnect Switch T UN 03JUN96 TX,85,RR,A JUN96 1/ PN=172

175 Maintenance Cleaning Cab Air Filter 1. Loosen wing nuts (A) to remove filter. 2. Tap filter on flat surface with dirty side down to loosen and remove large portions of dirt. 3. Use compressed air under 210 kpa (2.1 bar) (30 psi). Direct air opposite to normal air flow. 4. Wash filter in warm, soapy water, rinse and dry. 5. If filter will not come clean, replace as necessary. 6. Install filter. Tighten wing nuts. A Wing Nuts T8594AJ UN 09NOV95 TX,90,BG APR97 1/1 Cleaning Cab Air Filter Interior 1. Loosen wing nuts (A) to remove filter. 2. Tap filter on flat surface with dirty side down to loosen and remove large portions of dirt. 3. Use compressed air under 210 kpa (2.1 bar) (30 psi). Direct air opposite of normal air flow. 4. Wash filter in warm, soapy water, rinse and dry. 5. If filter will not come clean, replace as necessary. NOTE: If removing filter case when taking out filter, install case so lip fits into bottom channel. A Wing Nuts T UN 08APR97 6. Install filter. Tighten wing nuts. TX,90,BG APR97 1/ PN=173

176 Maintenance Checking Fire Extinguisher If Equipped IMPORTANT: Charge fire extinguisher after each use. Check gauge regularly for correct charge. Pointer must be in green zone. If not, see your authorized dealer to get extinguisher charged. TX,85,RR,A JUN96 1/1 Checking Air Conditioner Refrigerant Level If Equipped 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 refrigerant. 1. Open left-side service door (A). T127462B UN 21JAN00 2. Check color of sight glass (B), to see if receiver/dryer is wet (pink) or dry (blue). 3. If wet (pink), see your authorized dealer within the next 100 machine hours to service receiver/dryer. A Left Side Door B Sight Glass T8429BA UN 02MAR95 TX,90,BG JAN00 1/1 Service Control Valves, Cylinders, Pumps and 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,BG APR97 1/ PN=174

177 Maintenance Check Engine Speeds 750C Series II 1. Warm engine to normal operating temperature. 2. Check speeds using display monitor. Specification Slow Idle (with decelerator pedal pressed) Speed rpm Fast Idle Speed ± 25 rpm If adjustment is necessary, see your authorized dealer. CED,OUO1065, JAN00 1/1 Engine Speed Adjustment 850C Series II NOTE: 850C Series II uses electronic fuel injection, so a mechanical speed adjustment is not necessary. To set slow and fast idle, an engine calibration is performed. See your authorized dealer. T82,SKMA,AT 19 01AUG94 1/1 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/ PN=175

178 Maintenance Checking Track Shoe Cap Screw Torque NOTE: Track shoe bolt torque specifications do not apply to split master link. Cap screw threads and bearing surface under head must be lubricated with SAE 30 oil. Item Measurement Specification 750C Series II Track Shoe 5/8 in. Torque 163 ± 16 N m (120 ± 12 lb-ft) Cap Screw Torque Turn 1/3 turn (120 ) 750C LGP Series II Track Shoe 5/8 Torque 163 ± 16 N m (120 ± 12 lb-ft) in. Cap Screw (with swamp shoe) Torque Turn 1/2 turn (180 ) Item Measurement Specification 850C Series II Track Shoe 3/4 in. Torque 298 ± 30 N m (220 ± 22 lb-ft) Cap Screw Torque Turn 1/3 turn (120 ) 850C LGP Series II Track Shoe 3/4 Torque 298 ± 30 N m (220 ± 22 lb-ft) in. Cap Screw (with swamp shoe) Torque Turn 3/4 turn (270 ) Track shoe cap screw torque should be periodically checked. If cap screws do not meet minimum torque specifications, remove shoes and clean mating surfaces of shoes and links before tightening. If machine is operated with loose track shoes, cap screw holes in the shoes and links will wear, making it difficult to keep the shoes tight. Loose shoes can also cause hardware failure and loss of shoes. Continued on next page TX,85,RR,A MAY96 1/ PN=176

179 Maintenance Install all nuts with rounded edges (A) against the link and chamfered edges (B) away. Be sure nut is properly positioned in link so there is full contact between nut and link. If cap screws check less than above specification, remove shoes and clean paint or other foreign material from chain and shoe mating surfaces. Lubricate cap screws and assemble shoes. A Rounded Edge B Chamfered Edge T6794AM UN 23FEB89 TX,85,RR,A MAY96 2/2 Checking Track Shoe Cap Screw Torque Master Link If cap screws check less than specification, remove shoe and clean paint or other foreign material from chain and shoe mating surfaces. Lubricate cap screw threads and bearing surface of cap screw head using PT569 John Deere NEVER-SEEZ Lubricant or equivalent. IMPORTANT: DO NOT use impact wrench to start master shoe cap screws to avoid cross-threading. Use only the torque turn method described below when assembling master track shoe. This method provides the optimum tightness level for this critical area. Install master shoe on master links and start cap screws by hand to avoid cross-threading. NEVER-SEEZ is a registered trademark of Emhart Chemical Group Continued on next page PN=177 TX,85,RR,A MAY96 1/2

180 Maintenance Tighten master cap screws in a crisscross sequence (A). Repeat sequence a second time. Use same tightening sequence for additional turns. Specification 750C Series II Master Link 5/8 in. Cap Screw Torque ± 16 N m (120 ± 12 lb-ft) Torque Turn... 1/3 turn (120 ) 750C LGP Series II Master Link 5/8 in. Cap Screw (with swamp shoe) Torque ± 16 N m (120 ± 12 lb-ft) Torque Turn... 1/2 turn (180 ) Specification 850C Series II Master Link 3/4 in. Cap Screw Torque ± 30 N m (220 ± 22 lb-ft) Torque Turn... 1/3 turn (120 ) 850C LGP Series II Master Link 3/4 in. Cap Screw (with swamp shoe) Torque ± 30 N m (220 ± 22 lb-ft) Torque Turn... 3/4 turn (270 ) A Master Link Tightening Sequence T96302 UN 01NOV88 TX,85,RR,A MAY96 2/ PN=178

181 Maintenance 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 N m Lubricated a Dry b N m Lubricated a Dry b N m Lubricated a Dry b N m N m (lb-ft) (lb-ft) N m (lb-ft) (lb-ft) N m (lb-ft) (lb-ft) N m (lb-ft) (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=179

182 Maintenance Additional Metric Cap Screw Torque Values CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application. 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 you properly start thread engagement. This will prevent them from failing when tightening. Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart. T6873AA UN 18OCT88 T6873AB UN 18OCT88 T6873AC UN 18OCT88 Continued on next page 04T,90,M SEP99 1/ PN=180

183 Maintenance METRIC CAP SCREW TORQUE VALUES a T-Bolt H-Bolt M-Bolt Nominal Dia N m lb-ft N m lb-ft N m lb-ft a Torque tolerance is ±10%. 04T,90,M SEP99 2/ PN=181

184 Maintenance Service Recommendations for Metric Series Four Bolt Flange Fitting T6890BB UN 01MAR90 A Sealing Surface B Split Flange C Pinched O-Ring D Single Piece Flange 1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. TORQUE CHART a Thread b N m lb-ft M M M M M M M M a Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures. b Metric standard thread. 04T,90,K SEP99 1/ PN=182

185 Maintenance 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 N m Lubricated b Dry c N m Lubricated b Dry c N m Lubricated b Dry c N m N m (lb-ft) (lb-ft) N m (lb-ft) (lb-ft) N m (lb-ft) (lb-ft) N m (lb-ft) (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=183

186 Maintenance Check Oil Lines and Fittings 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. 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. X9811 UN 23AUG88 Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately. Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings. TX,90,DH AUG94 1/ PN=184

187 Maintenance Service Recommendations for O-Ring Boss Fittings Straight Fitting 1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. T6243AE UN 18OCT88 Continued on next page 04T,90,K SEP99 1/ PN=185

188 Maintenance Angle Fitting 1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting. 2. Turn fitting into threaded boss until back-up washer contacts face of boss. 3. Turn fitting head-end counterclockwise to proper index (maximum of one turn). NOTE: Do not allow hoses to twist when tightening fittings. T6520AB UN 18OCT88 4. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value. STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size N m lb-ft 3/8-24 UNF 8 6 7/16-20 UNF /2-20 UNF /16-18 UNF /4-16 UNF /8-14 UNF /16-12 UN /16-12 UN /16-12 UN /8-12 UN /8-12 UN NOTE: Torque tolerance is ± 10%. 04T,90,K SEP99 2/ PN=186

189 Maintenance Service Recommendations for Flat Face O-Ring Seal Fittings 1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. 4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. T6243AD UN 18OCT88 5. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 6. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fitting. Do not allow hoses to twist when tightening fittings. FLAT FACE O-RING SEAL FITTING TORQUE Nominal Tube O.D. Swivel Nut Bulkhead Nut Thread Size mm in. Dash Size in. N m lb-ft N m lb-ft / / / / / / / NOTE: Torque tolerance is %. 04T,90,K SEP99 1/ PN=187

190 Maintenance O-Ring Groove Connections Face seal grooves (2 and 4) on fittings (3) should be identified before the O-ring (1) is installed into the fitting (use a O-ring pick to feel for the dovetail edge). Applying petroleum jelly on an O-ring to install it in a Standard Groove is appropriate. However, do not use petroleum jelly or grease on an O-ring to install it into a Half Dovetail Groove (Captive O-ring Groove). If petroleum jelly is used in a Half Dovetail groove, the jelly could push the O-ring out of the groove before the fitting is tighten. 1 O-Ring 2 Half Dovetail Groove 3 Fitting 4 Standard Groove Face Seal Groves T UN 31JAN00 CED,OUO1065, FEB00 1/ PN=188

191 Maintenance Service Recommendations for Inch Series Four Bolt Flange Fittings T6890BB UN 01MAR90 A Sealing Surface B Split Flange C Pinched O-Ring D Single Piece Flange 1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install O-ring (and backup washer if required) into groove, using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand-tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT overtighten. Continued on next page 04T,90,K AUG94 1/ PN=189

192 Maintenance TORQUE CHART a N m lb-ft Nominal Flange Size Cap Screw Size Min Max Min Max 1/2 5/16-18 UNC /4 3/8-16 UNC /8-16 UNC /4 7/16-14 UNC /2 1/2-13 UNC /2-13 UNC /2 1/2-13 UNC /8-11 UNC /2 5/8-11 UNC /8-11 UNC /8-11 UNC a Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Torques can be increased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond this maximum will result in flange and cap screw bending and connection failures. 04T,90,K AUG94 2/ PN=190

193 Operational Checkout Operational Checkout Use this procedure to check all systems and functions on machine. It is designed so you can make a quick check of operation of 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. Information you provide after completing the operational checkout will allow you or your dealer to pinpoint the specific test or repair work needed to restore machine to design specifications. 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. Complete necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) prior to checkout. Machine must be at operating temperature for many of the checks. Start at the top of left column and read completely down column before performing check. Follow sequence from left to right. In the far right column, if no problem is found (OK), you will be instructed to go to next check. If a problem is indicated (NOT OK), you will be referred to either a chapter in this manual or to your authorized dealer. TX,90,RR,A MAY96 1/1 1 Battery Disconnect Switch, Relays, Gauges, Monitor and Transmission Controller 1/ PN=191

194 Operational Checkout Battery Disconnect Switch Check NOTE: Disconnect switch is located on left side of machine through the battery access door. Turn battery disconnect switch OFF. Turn key switch ON. LOOK: Gauge needle must not move, and indicator lights must not illuminate. OK: Continue check. NOT OK: Check battery disconnect switch. See your authorized dealer. T6518AA UN 19OCT88 Turn battery disconnect switch ON. Turn key switch ON. LOOK: Indicator lights must illuminate and gauge needle must move. OK: Go to next check. NOT OK: Check battery disconnect switch. See your authorized dealer. 1/1 Key Switch Check NOTE: Turn battery disconnect switch ON for all following checks. OK: Go to next check. NOT OK: See your authorized dealer. T8404AE9 UN 08MAR95 Turn key switch ON. LOOK: All lights will blink on and off. Warning alarm will sound. Gauges will flash. 1/1 Voltage and Hour Meter Check Battery disconnect switch ON. Key switch OFF. Press and hold select button in. LOOK: Information will sequence from hour meter icon to voltage icon every four seconds. Start engine. OK: Check complete. NOT OK: Check battery disconnect switch. Check and recharge batteries. T8432AW UN 15MAR95 LOOK: RPM icon must display engine speed. 1/ PN=192

195 Operational Checkout Battery Check Key ON. Press SELECT button and hold until battery volts are displayed. LOOK: Battery volts must read a minimum of 25.2 volts. OK: Go to next check. NOT OK: See Alternator Output Check in this group. NOT OK: Check and recharge batteries. T8432AW UN 15MAR95 1/1 Alternator Output Check Key switch OFF. Measure and record battery voltage. Start and run engine at 1500 rpm. Check voltage across battery terminals. OK: Alternator is good. Check battery. NOT OK: Check alternator. See your authorized dealer. T7487AF UN 20MAR91 Does battery voltage increase? 1/ PN=193

196 Operational Checkout Monitor Service Code Check IMPORTANT: Engine must be OFF for this check. OK: Check complete. NOT OK: See your authorized dealer. T8620AA UN 04JAN96 Engine OFF. Key switch ON. Hour meter icon will be displayed, press select button until RPM icon appears and release. Press and HOLD select button until battery voltage icon appears; then release button within one second. Press and HOLD select button until hour meter icon is displayed; then release button within one second. Press and HOLD select button until RPM icon is displayed; then release button within one second. LOOK: DIAG will be displayed. Press select button within 5 seconds to view any service codes. LOOK: F900 will appear if there are no service codes. LOOK: If there is more than one service the monitor will scroll all stored service codes. Each service code will be displayed for five seconds. Record service codes. To exit diagnostic mode, turn key OFF. To delete service codes, press and immediately release select button while service code is displayed. 1/1 Transmission Controller to Monitor and Return-to-Neutral Check OK: Check complete. NOT OK: Check neutral start switch and transmission controller. See your authorized dealer. T8390AC UN 03JAN95 Key switch ON. Park lock lever up. FNR with Transmission Speed-In-Grip in forward or reverse. LOOK: Return FNR with Transmission Speed-In-Grip to Neutral light will be flashing. 1/ PN=194

197 Operational Checkout Start Relay, Wiper/Washer/Dome Light/Radio and Heater Blower Relay Check Battery disconnect ON. Key switch OFF. Turn on wiper, dome light, radio and heater. LOOK/LISTEN: With key OFF, no electrical components should be operating. OK: Check complete. NOT OK: Check relay. Relay could be stuck in energized position. See your authorized dealer. 1/1 FNR with Transmission Speed-In-Grip Neutral Start Switch Detent Check Key switch ON. Park lock lever up. Very slowly move FNR with Transmission Speed-In-Grip lever out of neutral toward forward. LOOK: When the Return FNR with Transmission Speed-In-Grip to Neutral light starts flashing, let go of FNR with Transmission Speed-In-Grip lever. It must return to the neutral detent. Very slowly move FNR with Transmission Speed-In-Grip lever out of neutral toward reverse. LOOK: When the Return FNR with Transmission Speed-In-Grip to Neutral light starts flashing, let go of FNR with Transmission Speed-In-Grip lever. It must return to the neutral detent. NOTE: It may be necessary to tap the top frame of the FNR with Transmission Speed-In-Grip and steering frame. OK: Check complete. NOT OK: See your authorized dealer. 1/1 2 Park Lock, Park Brake, and Start Checks 1/ PN=195

198 Operational Checkout Park Lock Lever Switch Check OK: Park lock lever switch is good. Check complete. NOT OK: See your authorized dealer. T8390AC UN 03JAN95 Key switch ON. Park lock lever down. Move FNR with Transmission Speed-In-Grip lever into forward or reverse. LOOK: Return FNR with Transmission Speed-In-Grip to Neutral light must be OFF. Return FNR with Transmission Speed-In-Grip lever to neutral and move back into forward or reverse. LOOK: Return FNR with Transmission Speed-In-Grip to Neutral light must be OFF. 1/1 Park Lock Lever/Brake Pedal Linkage Check Park lock lever in UP position. LOOK: Park brake pedal must be fully down against stop. Park lock lever in DOWN position. OK: Check complete. NOT OK: See your authorized dealer. T UN 31JAN00 LOOK: Park brake pedal must be fully up. 1/ PN=196

199 Operational Checkout Park Lock, Neutral Start Switch Check and Reverse Warning Alarm Check Park lock lever down. Turn key switch to START position. LOOK: Engine must not crank. OK: Check complete. NOT OK: See your authorized dealer. T UN 31JAN00 Park lock lever up and FNR with Transmission Speed-In-Grip lever in forward. Turn key switch to START position. LOOK: Engine must not crank. Move FNR with Transmission Speed-In-Grip lever to REVERSE and key switch to START position. LOOK: Engine must not crank. Key switch ON. Park lock lever fully down. Move FNR with Transmission Speed-In-Grip lever to REVERSE position. LISTEN: Reverse warning alarm must sound. 1/1 Park Lock Neutral Switch Adjustment Check Park lock lever down. Turn key switch to ON. Move FNR with Transmission Speed-In-Grip lever to FORWARD. OK: Check complete. NOT OK: See your authorized dealer. T UN 31JAN00 Slowly move the park lock levers to the UP position. LOOK: Carefully observe the Return FNR with Transmission Speed-In-Grip to Neutral indicator light and the park brake pedal movement. ON or slightly before the pedal reaches the half-way point of its total travel, the indicator light should flash. 1/1 3 General Driving and Transmission Checks 1/ PN=197

200 Operational Checkout Engine Speed Check NOTE: Engine speed MUST be correct for decelerator to function properly. Start engine. Engine speed control lever at slow idle and decelerator pedal fully depressed. LOOK: Engine speed must be rpm. Release decelerator pedal. LOOK: Engine speed must increase rpm. Move engine speed control lever to fast idle. LOOK: Engine speed must be 2250 ± 25 rpm. Park lock lever down, engine speed control lever at slow idle and decelerator pedal fully depressed. Shift FNR with Transmission Speed-In-Grip lever to FORWARD and then REVERSE. LOOK: Machine must not move in either direction. Release decelerator pedal. LOOK: Machine must move slowly in forward and in reverse. OK: Check complete. NOT OK: See your authorized dealer. 1/1 Decelerator Pedal Check Start engine. Move engine speed control lever to fast idle. LOOK: Engine speed must be rpm. Lift up on decelerator pedal. LOOK: Engine speed must not increase and decelerator pedal must not move up. Depress decelerator pedal and release quickly. LOOK/LISTEN: Engine must return to fast idle in 2.0 seconds. OK: Continue check. NOT OK: See your authorized dealer. Start engine. Park lock lever down, engine speed control lever at slow idle and decelerator pedal fully depressed. Shift FNR with Transmission Speed-In-Grip lever to FORWARD and then REVERSE. LOOK: Machine must not move in either direction. Release decelerator pedal. LOOK: Machine must move slowly in forward and in reverse. OK: Check complete. NOT OK: See your authorized dealer. 1/ PN=198

201 Operational Checkout Charging System Check Start engine. Move engine speed control lever to fast idle. Depress and HOLD select button until voltmeter icon appears. LOOK: Battery voltage must be to specification. Specification Battery Voltage... Between 26 and 28 volts OK: Continue check. NOT OK: See your authorized dealer. Transmission speed control lever at maximum speed position, FNR with Transmission Speed-In-Grip in FORWARD. Slowly increase engine speed from slow to fast idle using decelerator. LOOK: Machine speed should increase as engine rpm increases. OK: Check complete. NOT OK: See your authorized dealer. 1/1 Park Brake Valve Leakage and Transmission Control System Neutral Checks Operate machine for several minutes to heat hydrostatic oil to normal operating temperature. Position engine speed control at slow idle with park lock lever UP. LOOK: Observe transmission pressure gauge while moving park lock lever to DOWN position. LOOK: Observe tracks for any creep or movement. NOTE: If tracks creep in neutral, transmission calibration cannot be completed. LOOK: Pressure should drop a slight amount momentarily, then increase psi above original value. There is a small amount of leakage in the multi-function valves with the park lock levers up. LOOK: Pressure should not drop below the original value and remain there. OK: Check complete. NOT OK: See your authorized dealer. 1/1 Operating Charge Relief Valve Check Run engine at approximately 1800 rpm. Single lever steer machines: Transmission speed lever full forward at minimum speed. Move FNR with Transmission Speed-In-Grip to FORWARD. Pedal steer machines: Move FNR with Transmission Speed-In-Grip slightly out of neutral so that machine travel is slow. LOOK: As machine starts to move, transmission pressure should decrease approximately psi (3 4 needle widths). OK: Check complete. NOT OK: See your authorized dealer. 1/ PN=199

202 Operational Checkout Transmission Speed Control Lever Boot Check Inspect seal at top of boot and condition of boot. LOOK: Boot must be sealed to prevent water entry into speed and direction sensors. LOOK: Boot must be free of cracks to prevent water entry into sensors. OK: Check complete. NOT OK: See your authorized dealer. 1/1 Steering Checks Transmission speed at slow SP1.5 position. Run engine at approximately 1200 rpm. Move FNR with Transmission Speed-In-Grip lever to FORWARD and steering lever to right detent position. LOOK: The right track should stop and transmission pressure should remain in the green. Move the steering lever to maximum right position. LOOK: The right track must Counterrotate and transmission pressure should remain in the green. Repeat check for left track. OK: Check complete. NOT OK: See your authorized dealer. 1/1 Transmission PCP Check Engine speed at 1500 rpm. Transmission speed at SP1.5, make several shifts from NEUTRAL to FORWARD, then NEUTRAL to REVERSE with reverse ratio knob at (100%). LOOK: Observe how both tracks start to increase in speed. Both tracks must start at the same time and machine should move forward or reverse in a straight line. OK: Check complete. NOT OK: See your authorized dealer. 1/1 Transmission Motor Phase Check Engine speed at 1500 rpm. Transmission speed set at SP2.5, make several shuttle shifts from FORWARD to REVERSE on smooth level surface. LOOK: Observe how machine tracks forward to reverse. Disconnect tracking system by disconnecting right or left track motor speed sensor. LOOK: Machine tracking should be the same. NOTE: It is normal to get a service code when operating machine with tracking system disconnected. OK: Check complete. NOT OK: See your authorized dealer. 1/ PN=200

203 Operational Checkout Park Brake Pedal Linkage Check Run engine at 1200 rpm. Park lock lever DOWN. Put FNR with Transmission Speed-In-Grip lever in FORWARD. Push park pedal down with moderate effort. OK: Check complete. NOT OK: See your authorized dealer T8390AT UN 31JAN95 LOOK: As park pedal is pushed down, machine must stop. Put FNR with Transmission Speed-In-Grip lever in REVERSE. Push park pedal down with moderate effort. LOOK: As park pedal is pushed down, machine must stop. Release park brake pedal. LOOK: Machine must not move. 1/1 Park Brake Check Back machine up an incline. Depress park brake pedal. LOOK: Machine must stop and brakes must be able to hold machine on incline without creeping down. Put FNR with Transmission Speed-In-Grip lever in NEUTRAL. Release park brake pedal. Allow machine to creep down incline several feet and fully depress park brake pedal. LOOK: Machine must stop and brakes must be able to hold machine on incline without creeping down. OK: Check complete. NOT OK: See your authorized dealer. 1/1 Tracking and Maximum Speed Check IMPORTANT: Track sag must be at specification and machine must be driven on a level surface for all tracking checks. Transmission speed at SP3.0, maximum speed position, FNR with Transmission Speed-In-Grip in FORWARD. Slowly increase engine speed from slow to fast idle using decelerator. LOOK: Machine speed should increase as engine rpm increases. Tracking should be straight at all speeds. Repeat check in reverse. OK: Check complete. NOT OK: See your authorized dealer. 1/ PN=201

204 Operational Checkout Anti-Stall and Engine Performance Check Run engine at fast idle. Operate machine at maximum forward. Bottom blade tilt function and counter-rotate machine to the right. LOOK: Engine speed must not drop below 1800 rpm and both tracks must turn. Transmission pressure must remain in the green area. Bottom blade tilt function and counter-rotate machine to the left. LOOK: Engine speed must not drop below 1800 rpm and both tracks must turn. Transmission pressure must remain in the green area. OK: Check complete. NOT OK: See your authorized dealer. 1/1 Control Valve Linkage and Float Detent Check Engine OFF. Move control lever(s) to all positions and release. LOOK/FEEL: Lever(s) must move to all positions easily and return to neutral when released. OK: Go to next step in this check. NOT OK: See your authorized dealer. T8404AC UN 14FEB95 NOTE: Control lever will not return to neutral when released from blade float position (E). Lever must be manually pulled from float position. Run engine at slow idle. Slowly move control lever(s) to all positions except blade float (E) and release. LOOK/FEEL: Control lever must move to all positions easily and return to neutral when released. Hydraulic function must operate smoothly without hesitation. OK: Go to next check. NOT OK: See your authorized dealer. 1/1 Multi-Function Relief Valve Check (Closed Loop System Relief Valve) Engine at fast idle. Transmission speed at SP2.5 position. Machine at operating temperature. Place machine under heavy load with blade. LOOK: Machine must push straight and tracks maintain same speed. LISTEN: Engine must not cycle as heavy load is pushed. OK: Check complete. NOT OK: See your authorized dealer. 1/ PN=202

205 Operational Checkout Blade Control Valve Lift Check Poppet Check Run engine at slow idle. Tilt blade to right about half-way (A). Raise front of machine about 152 mm (6.0 in.) using blade lower function (D) and release control lever to neutral. OK: Go to next check. NOT OK: See your authorized dealer. T8404AC UN 14FEB95 Slowly move control lever to blade lower, then to blade tilt right. LOOK: Front of machine must not drop before rising as control lever is moved into blade lower or blade tilt. Front of machine must not drop or rise when control lever is in neutral. 1/1 Blade Float Detent Check Run engine at slow idle. Raise blade off ground. Move blade control lever into float position (E) and release. OK: Go to next check. NOT OK: See your authorized dealer. T8404AC UN 14FEB95 LOOK: Blade must drop to ground when lever is moved into float position. Lever must stay in float position when released. 1/1 Auxiliary Control Valve Lift Check Poppet Check (With Ripper) If Equipped Run engine at slow idle. Raise rear of machine about 152 mm (6.0 in.) using ripper lower function. Release control lever. Slowly move ripper control lever further into lower position to raise machine further. OK: Go to next check. NOT OK: See your authorized dealer. T6680DA UN 18OCT88 LOOK/FEEL: Ripper must raise rear of machine. Machine must not drift down with control lever in neutral. Machine must not drop before it rises as control lever is moved a second time. 1/ PN=203

206 Operational Checkout Auxiliary Control Valve Lift Check Poppet Check (With All-Hydraulic Dozer) Run engine at slow idle. Angle blade half-way to right. Release control lever to neutral. Position right end of blade against a solid object. OK: Go to next check. NOT OK: See your authorized dealer. T6680DB UN 18OCT88 Move FNR with Transmission Speed-In-Grip lever to FORWARD until tracks just start to move. Move angle control lever to angle blade to left. Repeat check, angling blade to right. LOOK: Blade must angle smoothly. Angle cylinder must not retract with lever in neutral. Angle cylinder must not retract before extending as control lever is moved to angle blade while pushing against a solid object. 1/1 Blade Lift Cylinder Bypass Valve Poppet Check OK: Go to next check. NOT OK: See your authorized dealer. T6680DC UN 18OCT88 T8404AT UN 13MAR95 Run engine at slow idle. Tilt blade full right. Raise blade to full height. Tilt blade full left, then full right. Pull control lever to raise blade to full height again. LOOK: Dozer frame must drop slightly when blade is tilted from full right to full left then back to full right. 1/1 Blade Drift Check Warm hydraulic oil until hydraulic filter inlet hose is warm to the touch, C ( F) by raising blade fully then holding lever in raise position. Position blade about 51 mm (2.0 in.) off ground. Stop engine, wait one minute. OK: Go to next check. NOT OK: See your authorized dealer. T8404AK UN 13MAR95 LOOK: Blade must not drop to ground. 1/ PN=204

207 Operational Checkout Dozer Pivot Checks Operate all dozer functions. NOTE: Looseness in pivot joints at lift cylinders, push-beams, struts, pitch jacks and tilt cylinders. LOOK: Pivot joints must not be excessively loose. OK: Go to next check. NOT OK: See your authorized dealer. T8404AJ UN 13MAR95 1/1 Hydraulic Pump Performance Check Warm hydraulic oil until hydraulic filter inlet hose is warm to the touch, C ( F) by raising blade fully then holding lever in raise position. Run engine at slow idle. Record time required to raise blade from ground to maximum height. OK: Go to next check. NOT OK: See your authorized dealer. T8404AT UN 13MAR95 Repeat 3 times and record average time. LOOK: Maximum times: All-Hydraulic Dozer sec. Dozer and Angle Dozer Machines sec. 1/1 Quick Drop Valve Check (Angle and Straight Dozers) If Equipped Engine at fast idle. Record time to lower blade to ground from maximum height. NOTE: Quick Drop is activated when control lever is in float position or when lever is at the end of power down position. LOOK: Maximum times: Power down Quick Drop activated 1.3 sec. Float down Quick Drop activated (750C Series II) 2.4 sec. Float down Quick Drop activated (850C Series II) 3.3 sec. Raise blade after blade has been lowered with quick drop valve. LOOK: Blade must rise immediately. OK: Go to next check. NOT OK: See your authorized dealer. 1/ PN=205

208 Operational Checkout Transmission Gauge and Charge Pressure Check Start engine and position engine speed control lever at low idle. LOOK: Needle must be in the green. Slowly increase engine speed to fast idle. LOOK: Needle must gradually rise as speed increases. At fast idle, needle must still be in the green with very minimal fluctuation. OK: Check complete. NOT OK: See your authorized dealer. 1/1 4 Undercarriage Checks NOTE: These checks should be used only as a guideline to general condition of the undercarriage. If abnormal or excessive wear is seen, refer to Undercarriage Appraisal Manual SP326 for measurements and analysis. Undercarriage wear is accelerated by tight track and by excessive high speed of reverse and counter-rotate operations. 1/1 Track Sag Check IMPORTANT: Track sag will change as ground conditions change. Track sag may need adjusting several times a day. Incorrect track sag will accelerate undercarriage wear. Operate machine a few minutes, then slowly come to a stop. Place straightedge on track grousers from front carrier roller to front idler. Measure between straightedge and top of grouser at lowest point. LOOK: Track must sag from 51 ± 6 mm (2.0 ± 0.25 in.) OK: Go to next check. NOT OK: Go to Adjust Track Sag in Maintenance As Required chapter. T6513AF UN 19OCT88 1/ PN=206

209 Operational Checkout Carrier and Track Roller Check OK: Go to next check. NOT OK: Go to Undercarriage Appraisal Manual SP326 for wear limits. T6680DD UN 18OCT88 T6680DF UN 18OCT88 T6680DE UN 18OCT88 NOT OK: See your authorized dealer. Inspect roller tread for excessive wear or flat spots. LOOK: Roller must not be worn more than 100%. Roller must not have flat spots or broken flanges. Inspect rollers for oil leakage. LOOK: Rollers must not be leaking oil. 1/1 Track Grouser Wear, Shoe Damage and Hardware Checks Operate unit slowly and observe track pads as they run over carrier roller. LOOK: Grousers must not be excessively worn or bent. Track pad hardware must be tight. OK: Go to next check. NOT OK: See your authorized dealer. T6513AH UN 19OCT88 1/1 Front Idler Visual Checks OK: Go to next check. NOT OK: Go to Undercarriage Appraisal Manual SP326 for wear limit measurements. T6680DG UN 18OCT88 T8404AH UN 13MAR95 Inspect front idler tread and flange area for unusual or excessive wear or damage. LOOK: Idler must not be worn excessively or damaged. Inspect idler shaft seals for oil leakage. LOOK: Oil must not be leaking past shaft seals. 1/ PN=207

210 Operational Checkout Track Pitch Check T6680DQ UN 18OCT88 NOTE: Track sag must be adjusted correctly before doing this check. Check position of front edge of idler block assembly and front edge of wear strip. LOOK: 750C Series II: Front edge of guide block must not be past front edge of wear strip. LOOK: 850C Series II: Front edge of guide block must not be closer than 25.4 mm (1.0 in.) to front edge of wear strip. OK: Go to next check. NOT OK: Go to Undercarriage Appraisal Manual SP-326 for wear limit measurements. NOT OK: See your authorized dealer. 1/1 Track Link Pin Boss Wear Check Check pin boss for wear. LOOK: Wear must not be excessive. Some wear is normal. OK: Go to next check. NOT OK: Go to Undercarriage Appraisal Manual SP326. T6484AZ UN 19OCT88 1/1 5 Accessories and Cab Components 1/1 Horn Circuit Check Engine OFF. Key switch ON. Push horn button. LISTEN: Horn must sound. OK: Go to next check. NOT OK: See your authorized dealer. T JAN00 1/ PN=208

211 Operational Checkout Dome Light Check Key OFF. Move each dome light toggle switch to ON position. LOOK: Dome lights must come on. Turn both switches OFF. OK: Go to next check. NOT OK: Check fuse and bulb. T7832AI UN 24AUG92 1/1 Window Check Inspect window seals. Open sliding window to maximum open position and back to 1/2 open notch and release latches (A). Close sliding window. OK: Go to next check. NOT OK: Oil latch. Replace window seals if necessary. T7409AQ UN 27NOV90 LOOK: Latches must hold window tightly closed, and hold in any notched position. LOOK: Window seals must not have gaps between seals and window frames. 1/1 Cab Door Lock Check Lock cab door. LOOK: Cab door handle must not move. FEEL: Lock must operate freely and key must not stick in lock. OK: Go to next check. NOT OK: Lubricate or repair lock. T6564PB UN 19OCT88 1/1 Light Circuit Check Engine OFF. Key switch ON. Push light switch ON. LOOK: Rear work lights and front lights must be on. OK: Go to next check. NOT OK: See your authorized dealer. T UN 31JAN00 1/ PN=209

212 Operational Checkout Seat Cushion Adjustment Check Rotate knob to desired cushion position. LOOK: Cushion tilt knob moves freely. Cushion tilts freely. OK: Go to next check. NOT OK: See your authorized dealer. T6513BC UN 19OCT88 1/1 Fore and Aft Positioning Check Lift seat fore-aft lever. Move seat forward and rearward. Release the handle at one of several positions. LOOK: Seat must move freely and lock in several positions OK: Go to next check. NOT OK: See your authorized dealer. T6513BC UN 19OCT88 1/1 Seat Height Adjustment Check Remove your weight from the seat. Lift handle up and then move the seat to one of three positions. LOOK: Lever must move freely and seat must lock in position. OK: Go to next check. NOT OK: See your authorized dealer. T6513BC UN 19OCT88 1/1 Seat Weight Adjustment Check Move seat to mid-to-aft position. Sit in seat. Turn weight adjuster lever plus or minus to support weight. OK: Go to next check. NOT OK: See your authorized dealer. T6513BC UN 19OCT88 LOOK: Lever must move freely. Check indicator for appropriate weight. 1/ PN=210

213 Operational Checkout Back Cushion Angle Adjustment Check Sit in seat. Lift handle and allow cushion to angle forward or lean backward into the cushion to desired position and release handle. LOOK: Lever must move freely. Cushion must lock in place. OK: Go to next check. NOT OK: See your authorized dealer. T6513BC UN 19OCT88 1/1 Lumbar Support Check Sit in seat. Rotate knob to either increase support or decrease support to the lower back. LOOK: Knob must move freely. Cushion back must lock in place. OK: Go to next check. NOT OK: See your authorized dealer. T6513BC UN 19OCT88 1/1 Seat Belt Check Fasten seat belt and move tighteners (A). Release belt by lifting buckle (B). LOOK: Seat belt must fasten securely. Tighteners must move freely. Tighteners must not loosen with belt fastened around operator. Belt must release when buckle is lifted. OK: Go to next check. NOT OK: See your authorized dealer. T6513BB UN 19OCT88 1/1 Start Aid Circuit Check IMPORTANT: Be prepared to stop engine if start aid button sticks. Engine may be damaged if too much starting fluid is injected. Run engine at slow idle. Quickly press start aid button and release. Listen for engine speed change. OK: Go to next check. NOT OK: See your authorized dealer. T UN 31JAN00 LISTEN: Engine speed must increase when start aid button is pressed. Engine must return to slow idle shortly after start aid button is released. 1/ PN=211

214 Operational Checkout Cab Door Latch Check Unlatch and open cab door. Close cab door with some force. LOOK/FEEL: Door must unlatch and open easily. Door must latch securely when closed. OK: Go to next check. NOT OK: See your authorized dealer. 1/1 Windshield and Door Wiper/Washer Circuit Checks Engine OFF. Key switch ON. Turn front windshield wiper switch to high and low speeds, then to off. LOOK: Wiper must operate in two speeds, then return to edge of windshield. Push washer/wiper switch in. LOOK: Washer solution must spray from washer jet onto windshield. OK: Go to next check. NOT OK: See your authorized dealer. 1/1 Rear Windshield Wiper Check Engine OFF. Key switch OFF. Rear wiper switch is located in upper rear corner of cab. NOTE: Wiper switch has two positions but only one is used. Turn rear wiper switch ON. LOOK: Rear wiper must have one operating speed. OK: Go to next check. NOT OK: See your authorized dealer. 1/1 Heater Checks NOTE: Air conditioner control must be OFF. Heater hose shut-off valve on water pump must be open. Warm engine to normal operating temperature. Turn heater control knob clockwise to maximum. FEEL: Warm air from louvers. OK: Check complete. NOT OK: See your authorized dealer. 1/ PN=212

215 Troubleshooting Using Troubleshooting Charts NOTE: Troubleshooting charts are arranged from the most likely and simplest to verify, to the least likely and 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. TX,FF, MAR96 1/1 Engine Symptom Problem Solution Engine Will Not Start or Starts Fuel tank empty Check fuel quantity. Hard Fuel tank vent pipe plugged Fuel tank shut-off not fully open Water in fuel or water frozen in fuel line Fuel filter(s) plugged Incorrect grade of fuel Air leak on suction side of fuel system Valve clearance Valves sticking or burned Loosen cap and listen for air rushing into tank. Replace cap. Open fuel tank shut-off. Drain water from fuel tank. Inspect fuel filter(s) for water. Change filter(s). Inspect and replace fuel filter(s). Drain fuel tank and add correct fuel. Check and tighten connection. Check fuel lines for damage. See your authorized dealer. Check and adjust valve clearance. See your authorized dealer. Continued on next page TX,100,RR MAR95 1/ PN=213

216 Troubleshooting Symptom Problem Solution Engine Surges or Stalls Fuel tank cap vent pipe plugged Remove fuel cap and listen for air Frequently rushing into tank. Replace cap. Fuel tank shut-off not fully open Incorrect grade of fuel Water in fuel or water frozen in line Fuel filter(s) plugged Air leak on suction side of fuel system Fuel pump Fuel return line from injection pump to tank restricted Worn or broken compression rings; cylinder head gasket leaking Open fuel tank shut-off. Drain fuel tank and add correct fuel. Drain water from fuel tank. Inspect fuel filter(s) for water. Change filter(s). Replace filter(s). Check and tighten connections. Check fuel lines for damage. Repair or replace fuel pump. See your authorized dealer. Disconnect fuel return line from injection pump. Connect a hose to pump and route fuel into a container. If engine now operates normally, return hose is restricted. See your authorized dealer. Engine Will Not Start Fuel injection pump out of time Check injection pump timing. See your authorized dealer. Engine overheating Injection nozzles Injection pump Test cooling system. See your authorized dealer. See your authorized dealer. See your authorized dealer. Continued on next page TX,100,RR MAR95 2/ PN=214

217 Troubleshooting Symptom Problem Solution Engine Misses Air in fuel Disconnect return hose from leak-off lines. Crank engine and check for air in fuel at leak-off lines. Tighten connections. Check fuel lines for damage. Incorrect grade of fuel Fuel injection pump out of time Slow idle speed too low Fuel pump Engine overheats Incorrect valve clearance Bent push rods Valve sticking or burned Drain fuel tank and add correct fuel. See your authorized dealer. Check slow idle speed. See your authorized dealer. Repair or replace fuel pump. See your authorized dealer. Test cooling system. See your authorized dealer. Check and adjust valve clearance. See your authorized dealer. Inspect and replace. See your authorized dealer. Disconnect fuel injection pump solenoid wire connector. Crank engine and listen for air leaking past valves or an uneven starter speed. See your authorized dealer. Cylinder head gasket leaking Worn or broken compression rings Injection nozzles Injection pump See your authorized dealer. See your authorized dealer. Test nozzles. See your authorized dealer. Remove and test injection pump. See your authorized dealer. Continued on next page TX,100,RR MAR95 3/ PN=215

218 Troubleshooting Symptom Problem Solution Engine Does Not Develop Full Fuel tank cap vent pipe plugged Remove fuel cap and listen for air Power rushing into tank. Replace fuel cap. Fuel tank shut-off not fully open Air intake system restricted Incorrect grade of fuel Tracks too tight Excess drag in brakes Fast idle speed set too low Fuel filter plugged Fuel line restricted Incorrect injection pump timing Air leak in intake manifold Incorrect valve clearance Fuel transfer pump Excessive restriction in hydraulic system or control valve unloading valve malfunction Open fuel tank shut-off. Check air filter elements and air filter restriction indicator. See Maintenance As Required chapter. Drain fuel tank and add correct fuel. See Fuels and Lubricants chapter. Check and adjust track tension. Check service and brake drag. See your authorized dealer. Check and adjust fast idle. See your authorized dealer. Change filter. Check for pinched or kinked lines or debris in lines. Route return line into separate container. If engine operation returns to normal, repair fuel return system lines. Check timing. See your authorized dealer. Test air intake system for leaks. See your authorized dealer. Check and adjust valve clearance. See your authorized dealer. See your authorized dealer. See your authorized dealer. Continued on next page TX,100,RR MAR95 4/ PN=216

219 Troubleshooting Symptom Problem Solution Turbocharger Muffler restricted Low compression Injection nozzles Incorrect camshaft timing Injection pump Remove air intake hose and exhaust elbow. Leading edge of compressor vanes must be sharp and straight. Spin compressor wheel and listen for noisy bearings. Turbine and compressor wheels must not rub in housing. Run engine without muffler. If engine operation is now normal, install a new muffler. Disconnect fuel injection pump solenoid wire connector. Crank engine and listen for air leaking past valves or an uneven starter speed. Start engine and observe blow-by from vent tube. See your authorized dealer. Remove and test nozzles. See your authorized dealer. Check timing. See your authorized dealer. Remove and test pump. See your authorized dealer. Continued on next page TX,100,RR MAR95 5/ PN=217

220 Troubleshooting Symptom Problem Solution Engine Emits Excessive Black or Restricted air filter Check air filter restriction indicator Gray Exhaust Smoke and air filters. See Maintenance As Required chapter. Replace. Incorrect grade of fuel Incorrect injection pump timing Air leak between turbocharger and manifold Excessive fuel delivery Injection nozzles Turbocharger Drain fuel tank and add correct fuel. See Fuels and Lubricants chapter. Time injection pump. See your authorized dealer. Test air intake system for leaks. See your authorized dealer. Remove and test fuel injection pump. See your authorized dealer. Remove and test nozzles. See your authorized dealer. Remove air intake hose and exhaust elbow. Leading edge of compressor vanes must be sharp and straight. Spin compressor wheel and listen for noisy bearings. Turbine and compressor wheels must not rub in housing. Continued on next page TX,100,RR MAR95 6/ PN=218

221 Troubleshooting Symptom Problem Solution Engine Emits Excessive Blue or Cranking speed too slow Check batteries and connections. White Smoke Incorrect grade of fuel Injection pump out of time Engine running too cold Injection nozzles Low compression Excessive wear in liners and/or piston rings stuck Worn valve guides Drain fuel tank and add correct fuel. See Fuel and Lubricants chapter. Time injection pump. See your authorized dealer. Check thermostats. See your authorized dealer. Remove and test nozzles. See your authorized dealer. Disconnect fuel injection pump solenoid wire connector. Crank engine and listen for air leaking past valves. Start engine and observe blow-by from vent tube. See your authorized dealer. Inspect and repair. See your authorized dealer. Inspect and repair. See your authorized dealer. Slow Acceleration Incorrect grade of fuel Drain fuel tank and add correct fuel. See Fuels and Lubricants chapter. Fuel injection pump Injection nozzles Remove and test fuel injection pump. See your authorized dealer. Remove and test nozzles. See your authorized dealer. Detonation Starting aid solenoid stuck open Inspect and repair. See your authorized dealer. Incorrect injection pump timing Incorrect injection pump advance Time injection pump. See your authorized dealer. Repair advance. See your authorized dealer. Continued on next page TX,100,RR MAR95 7/ PN=219

222 Troubleshooting Symptom Problem Solution Abnormal Engine Noise Low or incorrect engine oil Add correct oil. Start aid solenoid stuck Engine oil diluted with fuel Incorrect fuel injection pump timing Turbocharger Excessive valve clearance Bent push rods Worn rocker arm shafts Loose connecting rod caps Loose main bearing caps Worn main bearing Worn connecting rod bearings Incorrect camshaft timing Scored piston Remove start aid can from bracket and restart engine. Inspect engine oil. Inspect fuel pump spindle, seal, and housing. Time injection pump. See your authorized dealer. Remove air intake hose and check compressor wheel clearance between housing and wheel. Spin compressor wheel; check for worn bearings. Repair turbocharger. Adjust valve clearance. See Maintenance Every 1000 Hours chapter. Replace. See your authorized dealer. Replace. See your authorized dealer. Inspect and tighten connecting rod cap screws. See your authorized dealer. Inspect and tighten main bearing cap screws. See your authorized dealer. Replace bearings. See your authorized dealer. Replace bearings. See your authorized dealer. Check camshaft timing. See your authorized dealer. Replace. See your authorized dealer. Continued on next page TX,100,RR MAR95 8/ PN=220

223 Troubleshooting Symptom Problem Solution Worn piston pin bushings and pins Replace pins and bushings. See your authorized dealer. Low Oil Pressure Low oil level Add oil. Wrong viscosity oil or oil diluted with diesel fuel Oil pressure gauge or sensor Oil pressure regulating valve Turbocharger shaft seal leaking Plugged oil pump intake screen Loose oil pump drive gear Worn oil pump gear or housing Excessive main bearing clearance Excessive connecting rod bearing clearance Cracked cylinder block Piston cooling orifice missing Leakage at internal oil passage Change oil. Test gauge and sensor. See your authorized dealer. Replace or adjust regulating valve. See your authorized dealer. Inspect and repair. See your authorized dealer. Inspect and clean. See your authorized dealer. Inspect and repair. See your authorized dealer. Remove, inspect and repair. See your authorized dealer. Replace main bearings. See your authorized dealer. Replace connecting rod bearings. See your authorized dealer. Replace cylinder block. See your authorized dealer. Inspect piston cooling orifices. See your authorized dealer. Check all possible internal leakage paths. Repair. See your authorized dealer. Continued on next page TX,100,RR MAR95 9/ PN=221

224 Troubleshooting Symptom Problem Solution High Oil Pressure Wrong viscosity oil (too thick) Check for antifreeze in oil. Change oil. Oil pressure gauge or sender Oil pressure regulating valve Test gauge and sender. See your authorized dealer. Repair or adjust regulating valve. See your authorized dealer. Continued on next page TX,100,RR MAR95 10/ PN=222

225 Troubleshooting Symptom Problem Solution Engine Overheats Low coolant level Fill cooling system and check for leaks. Low engine oil level Loose or broken fan belt Fan on backwards, damaged, or wrong fan installed Radiator or oil cooler dirty, plugged, or fins damaged Radiator shroud missing, damaged, or baffles missing Engine overloaded Incorrect grade of fuel Radiator cap Fuel gauge or sender Incorrect injection pump timing Thermostats (stuck) Thermostats missing Cooling system coated with lime deposits Excessive brake drag Water pump Excessive fuel delivery Add oil. Tighten or replace belt. Check for correct fan installation. Check air flow. Clean radiator. Straighten fins. Inspect. Repair or replace. Reduce load. Drain fuel tank and add correct fuel. Replace cap. Test, repair, or replace. See your authorized dealer. Time injection pump. See your authorized dealer. Inspect thermostats. See your authorized dealer. Install thermostats. See your authorized dealer. Flush cooling system. Check brake drag. See your authorized dealer. Repair. See your authorized dealer. Remove injection pump. Check for proper fuel delivery. Adjust. See your authorized dealer. Continued on next page TX,100,RR MAR95 11/ PN=223

226 Troubleshooting Symptom Problem Solution Scored piston Combustion leak into cooling system. Replace piston. See your authorized dealer. Remove radiator cap. Start engine and check for bubbles in radiator. Engine Runs Cold Temperature gauge or sender Test gauge and sender. See your authorized dealer. Thermostat stuck open Replace thermostat. See your authorized dealer. Oil in Coolant or Coolant in Oil Leaking heat exchanger Air test and repair or replace. Leaking cylinder head gasket Leaking cylinder liner packings Cracked cylinder liner Cracked cylinder block Replace gasket. See your authorized dealer. Replace packings. See your authorized dealer. Replace liner. See your authorized dealer. Replace cylinder block. See your authorized dealer. Continued on next page TX,100,RR MAR95 12/ PN=224

227 Troubleshooting Symptom Problem Solution Excessive Fuel Consumption Air system restricted Check filter restriction indicator and air filters. Replace. See Maintenance As Required chapter. Leakage in fuel system Incorrect grade of fuel Incorrect injection pump timing Turbocharger Worn injection nozzles Inspect and repair. Drain and refill with correct fuel. Time injection pump. See your authorized dealer. Remove air intake hose and exhaust elbow. Leading edge of compressor vanes must be sharp and straight. Spin compressor wheel to check for rough bearings. Turbine and compressor wheels must not rub in housing. Test nozzles. Repair. See your authorized dealer. Turbocharger Excessively Noisy Bearings not lubricated Insufficient oil pressure. Check for or Vibrates restricted turbocharger oil line. Air leak in engine, intake or exhaust manifold Incorrect clearance between turbine wheel and turbine housing Broken blades on turbine Inspect and repair. See your authorized dealer. Remove exhaust elbow and air inlet hose. Inspect and repair. Remove exhaust elbow and air inlet hose. Inspect and repair. Oil Dripping from Turbocharger Damaged or worn bearings and/or Inspect compressor and turbine Adapter worn seals wheel for damaged blades. Check for proper engine service intervals or dirt entering engine. Excessive crankcase pressure Carbon build-up in turbocharger oil return line where line passes exhaust manifold Check for plugged vent tube. Clean. Remove line. Inspect and clean. Continued on next page TX,100,RR MAR95 13/ PN=225

228 Troubleshooting Symptom Problem Solution Excessive Drag in Turbocharger Carbon build-up behind turbine Inspect and clean. See your Rotating Members wheel caused by combustion authorized dealer. deposits Dirt build-up behind compressor wheel caused by air intake leaks Bearing seizure of dirty or worn bearings caused by excessive temperature, unbalanced wheel, dirty oil, oil starvation, or insufficient lubrication Inspect and repair. See your authorized dealer. See your authorized dealer. TX,100,RR MAR95 14/ PN=226

229 Troubleshooting Electrical System Symptom Problem Solution Nothing Works Power circuit components See your authorized dealer. Battery undercharged or dead Disconnect switch Start fuse failure Battery cables making poor connections See your authorized dealer. Check switch knob position. Replace fuse. Clean cable connections at battery and starter solenoid. Starter Will Not Crank Engine Battery undercharged or dead See your authorized dealer. Battery cables making poor connection Starter relay problem Starter solenoid problem Starter motor problem Starter motor pinion stuck in flywheel gear Key switch Major engine problem Clean connections at battery, starter, and ground to frame. See your authorized dealer. See your authorized dealer. See your authorized dealer. Repair starter motor. See your authorized dealer. See your authorized dealer. See your authorized dealer. Engine Cranks Slowly Batteries undercharged See your authorized dealer. Starter armature bearings worn causing starter "drag" Battery cable connections loose or corroded Repair or replace starter. See your authorized dealer. Clean and/or tighten connections. Starting Motor Turns, but Engine Starter pinion not engaging flywheel See your authorized dealer. Will Not Crank ring gear Starter pinion or flywheel gear teeth broken See your authorized dealer. Continued on next page TX,100,RR MAR96 1/ PN=227

230 Troubleshooting Symptom Problem Solution Starting Motor Continues to Run Starter solenoid stuck See your authorized dealer. after Engine Starts Starter not disengaging Starter relay stuck Key switch problem Wiring harness shorted See your authorized dealer See your authorized dealer. See your authorized dealer. See your authorized dealer. Battery Using Too Much Water Battery being overcharged See your authorized dealer. High ambient temperature Cracked battery case Refill with distilled water. Replace battery. Install hold-down correctly. Low Battery Output Low water level See Battery Using Too Much Water in this group. Dirty or wet battery top, causing discharge Corroded or loose battery cable ends Broken or loose battery posts Loose fan/alternator belt or worn pulleys Clean battery and wipe dry. Clean and tighten cable end clamps. Recharge battery. If machine has two batteries, recharge separately. Wiggle posts by hand. If posts are loose or will turn, replace battery. If machine has two batteries, replace both batteries. Inspect belt or pulley. Adjust or replace as necessary. Starter Solenoid Chatters Poor connections at batteries or Clean connections. starter Low battery charge Starter solenoid "hold-in" windings open Recharge or replace batteries. See your authorized dealer. Continued on next page TX,100,RR MAR96 2/ PN=228

231 Troubleshooting Symptom Problem Solution Engine Cranks but Does Not Key switch problem See your authorized dealer. Start Wiring harness problem See your authorized dealer. Start Aid Does Not Work Empty or misaligned start aid can A click, not a hiss, is heard when start aid button is pushed. Replace or adjust can. Start aid switch Start aid solenoid See your authorized dealer. See your authorized dealer. Noisy Alternator Start aid solenoid See your authorized dealer. Worn drive belt Pulley misaligned Alternator bearing worn Internal alternator failure Inspect and replace. Adjust alternator mount. Loosen alternator belts. Turn pulley by hand. If any roughness is felt, repair alternator. See your authorized dealer. Voltage Indicator Light Remains Loose or glazed alternator belt Check belt. Replace if glazed; On tighten if loose. Engine rpm low Excessive electrical load from added accessories Loose or corroded electrical connections on battery, ground strap, starter or alternator Alternator problem Display monitor problem Raise engine rpm. If light remains on, see your authorized dealer. Remove accessories or install higher output alternator. Inspect, clean, or tighten electrical connections. See your authorized dealer. See your authorized dealer. Continued on next page TX,100,RR MAR96 3/ PN=229

232 Troubleshooting Symptom Problem Solution Fuel Gauge Does Not Work Fuse Replace fuse. Fuel gauge problem Fuel gauge sender problem Wiring harness problem See your authorized dealer. See your authorized dealer. See your authorized dealer. Hydraulic Oil Filter Restriction Bulb Replace bulb. Light Does Not Work, Key On, Engine Off Hydraulic oil filter restriction diode (located in left corner of engine compartment) See your authorized dealer. Hydraulic Oil Filter Restriction Wiring harness or bulkhead See your authorized dealer. Light Does Not Work, Key On, connector Engine Off Bulb socket See your authorized dealer. Transmission Oil Filter Bulb Replace bulb. Restriction Indicator Light Does Not Work, Key On, Engine Off Transmission oil filter restriction indicator diode (located in left front corner of engine compartment) Wiring harness or bulkhead connector Bulb socket See your authorized dealer. See your authorized dealer. See your authorized dealer. Transmission Oil Filter Wiring harness or connection at bulk See your authorized dealer. Restriction Indicator Light Stays head connector On All the Time Filter Pin in filter housing Remove, inspect and replace. Make sure pin is not stuck against switch. Continued on next page TX,100,RR MAR96 4/ PN=230

233 Troubleshooting Symptom Problem Solution Hydraulic Oil Filter Restriction Restricted hydraulic oil filter Replace filter. Indicator Light Stays On All the Time Hydraulic oil filter restriction switch See your authorized dealer. Hour Meter Does Not Work Wiring harness or bad connection at See your authorized dealer. bulkhead connector Monitor fuse Wiring harness Replace fuse. See your authorized dealer. Voltage Indicator Indicates Low Regulator See your authorized dealer. Charge Wiring harness or connectors See your authorized dealer. Transmission Oil Temperature Gauge See your authorized dealer. Gauge Always Indicates HOT Sender Wiring harness See your authorized dealer. See your authorized dealer. Engine Oil Pressure Gauge Wire harness or bad connection at See your authorized dealer. Always Indicates HIGH bulkhead connector Indicator Sender Wiring harness High oil viscosity See your authorized dealer. See your authorized dealer. See your authorized dealer. Drain and add correct oil. Engine Oil Pressure Indicator Wiring harness See your authorized dealer. Indicates Low Sender Low oil level Low oil viscosity See your authorized dealer. Stop engine. Check level. Drain and add correct oil. Continued on next page TX,100,RR MAR96 5/ PN=231

234 Troubleshooting Symptom Problem Solution Transmission Oil Pressure Gauge See your authorized dealer. Indicator Reads HOT Sender See your authorized dealer. Horn Does Not Sound Wiring harness See your authorized dealer. Horn Horn switch See your authorized dealer. See your authorized dealer. Reverse Alarm Does Not Sound Wiring harness See your authorized dealer. Reverse alarm See your authorized dealer. Front or Rear Wiper Does Not Wiper fuse Replace fuse. Work Wiper switch problem Wiper motor problem Wiring harness problem See your authorized dealer. See your authorized dealer. See your authorized dealer. Defrost Fan Motor Does Not Fuse Replace fan fuse. Work Fan switch problem Fan motor resistor problem Wiring harness problem See your authorized dealer. See your authorized dealer. See your authorized dealer. Blower Motor Does Not Work Fan motor switch problem See your authorized dealer. Fan motor resistor problem Wiring harness problem See your authorized dealer. See your authorized dealer. Cab Work Lights Do Not Operate Fuse or Circuit breaker Replace fuse or reset breaker. Light switch problem Cab work light relay problem Wiring harness problem See your authorized dealer. See your authorized dealer. See your authorized dealer. Continued on next page TX,100,RR MAR96 6/ PN=232

235 Troubleshooting Symptom Problem Solution Driving Lights Do Not Work Fuse or Circuit breaker Replace fuse or reset breaker. Driving light switch problem Wiring harness problem See your authorized dealer. See your authorized dealer. Dome Light Does Not Work Bulb Replace bulb. Fuse Dome light switch problem Wiring harness problem Replace fuse. See your authorized dealer. See your authorized dealer. TX,100,RR MAR96 7/ PN=233

236 Troubleshooting Hydraulic System Symptom Problem Solution Blade Lifts and/or Blade Tilts Too Cold oil Allow oil to warm up. Slowly Oil viscosity too high (too thick) Control valve linkage malfunction Wrong engine speed (too slow) Unloading valve spool stuck in valve bore System relief valve stuck open Excessive internal leakage in cylinders or control valve circuits Worn hydraulic pump Air leak in pump suction line Suction line to hydraulic pump restricted Use correct oil. Inspect linkage. Repair or adjust. Check speed control linkage. Check engine speeds. (See Maintenance chapter.) See your authorized dealer. See your authorized dealer. Check components for excessive leakage. Check blade raise cycle time. Inspect. Repair. Inspect. Repair. Blade Fails to Lift and Blade Low hydraulic oil level Check. Add hydraulic oil. Fails to Tilt System relief valve poppet stuck open or not closing after start-up Unloading valve spool stuck in bore Failed hydraulic pump drive shaft or internal pump failure Quick drop spool stuck in open position See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. Continued on next page TX,100,RR MAR95 1/ PN=234

237 Troubleshooting Symptom Problem Solution Blade Drifts Down or Tilt Leaking hydraulic oil lines Inspect. Repair. Cylinder Extends under Load Failed cylinder packings or O-ring Control valve rod end relief cartridge (blade) leaking or relief plug seals leaking (tilt) or control valve spool worn Quick drop valve spool stuck or leaking See your authorized dealer. See your authorized dealer. See your authorized dealer. Blade Will Not Penetrate (Lift Leaking hydraulic oil lines Inspect. Repair. Cylinders Lift Up under Load) Blade control valve head-end relief cartridge or O-rings leaking Leaking cylinder packings or O-rings leaking Control valve spool worn Quick drop spool stuck in open position See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. Blade Hard to Control Control valve linkage out of See your authorized dealer. adjustment Front idler loose on side frames Adjust front idler to side frame clearance. See Maintenance chapter. Blade Drops as Control Lever Is Control valve lift check poppet See your authorized dealer. Slowly Moved from Hold to Raise damaged or leaking Position with Engine at Low Speed Control Lever Will Not Remain in Control valve detents worn See your authorized dealer. Float Position Parts worn See your authorized dealer. Continued on next page TX,100,RR MAR95 2/ PN=235

238 Troubleshooting Symptom Problem Solution Pump Excessively Noisy Cold oil Allow unit to warm up. Low oil level Oil viscosity too high (oil too thick) System relief valve set too low Intake hose to hydraulic pump restricted Hydraulic pump failed Low oil level Check, add oil. Change oil to correct viscosity oil. See your authorized dealer. See your authorized dealer. See your authorized dealer. Check, correct. Hydraulic Oil Overheats Operator holds control valve open Instruct operator on correct operation too long, causing system relief valve of dozer. to open Oil viscosity too high (oil too thick) System relief set too low Oil lines damaged, causing excessive internal restriction Change oil to correct viscosity. See your authorized dealer. Inspect, repair. Hydraulic Oil Foams Water in oil Inspect oil. Change. Using wrong oil Damaged hydraulic oil lines Air leak in suction line to hydraulic pump or pump shaft seal leaking Inspect. Change oil. Inspect. Change. Inspect. Repair. Blade Drops Slowly, when No electrical power to solenoid See your authorized dealer. Solenoid Is Actuated, on Quick Drop Valve Equipped Machine (Quick Drop Valve Is Not Used on All-Hydraulic Dozer Machines) Quick drop valve spool stuck in closed position Solenoid does not work See your authorized dealer. See your authorized dealer. TX,100,RR MAR95 3/ PN=236

239 Troubleshooting Hydrostatic Transmission Symptom Problem Solution Transmission Oil Filter Plugged filter Change filter. Restriction Indicator Light Remains On with the Unit at Operating Temperature Sender wire grounded Remove wires from sender. If light remains on, circuit is grounded. See your authorized dealer. Transmission Oil Overheats Low oil level Check and add transmission oil. Oil cooler core restricted with debris or fins damaged Radiator core restricted with debris Loose fan belts Worn gauge Transmission relief valves set too low Oil cooler bypass valve inoperative or internal restriction in oil cooler or circuit Clean core. Add sand screen to protect core. Clean core. Adjust belts. See your authorized dealer. See your authorized dealer. See your authorized dealer. Low Transmission Oil Pressure Low oil level Check. Add oil. (Filter Restriction Indicator Light May or May Not Be On) Plugged filter Faulty gauge Change filter. See your authorized dealer. Crawler Will Not Move Park lock switch Check service codes. Transmission problem Brake linkage problem Check service codes. See your authorized dealer. Continued on next page TX,100,RR MAR96 1/ PN=237

240 Troubleshooting Symptom Problem Solution Crawler Mistracks Air in transmission control circuit See your authorized dealer. Misadjusted motor Steering pedal sticks or does not return to full up position Left and right track sag not adjusted the same See your authorized dealer. Inspect linkage. See your authorized dealer. Adjust track sag to specifications. TX,100,RR MAR96 2/2 Brake System Symptom Problem Solution Crawler Will Not Move Linkage is worn, disconnected or out See your authorized dealer. of adjustment Low operating charge relief pressure Low hydrostatic oil level See your authorized dealer. Check and add oil. See Fuels and Lubricants chapter. TX,100,RR MAR95 1/ PN=238

241 Troubleshooting Air Conditioning Symptom Problem Solution Air Conditioning System Does Accessory relay See your authorized dealer. Not Operate Fuse Fan motor switch problem Fan motor resistor problem Fan motor problem A/C Freeze control switch problem Wiring harness problem Temperature control switch problem Low pressure switch High pressure switch Compressor clutch coil Relay Circuit breaker Condenser fan motor Wiring harness failure Replace fuse. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. See your authorized dealer. 05T,100,C SEP94 1/ PN=239

242 Troubleshooting Transmission Controller Service Codes IMPORTANT: Each lever or pedal MUST be moved through its full calibration travel during calibration, or a service code will occur during normal operation. NOTE: Transmission controller service codes will display when fault occurs. When service code appears, shut engine off and restart engine to check if service code is an intermittent problem. Recall and record all codes from monitor. Investigate circuit problem identified by service code. The service code number is indicated by an F6 plus two other digits. The letter F means that a fault has occurred. The number 6 means the transmission controller has diagnosed a problem in the transmission area and has sent a service code to the display monitor to be displayed. The CHECK SERVICE CODE light will also be turned ON. The last two digits of service code number would indicate problems as follows: SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F695 Controller Electronic Problem Transmission Shutdown See the technical manual or your authorized dealer F693 B20 Single Lever Steer Signal Wire Short to No Steer (1/2 mph) See the technical manual or Sensor Ground your authorized dealer Open Signal/ Ground No Steer (1/2 mph) See the technical manual or Wire your authorized dealer Open on Excitation Wire No Steer (1/2 mph) See the technical manual or your authorized dealer Sensor Not Moved No Steer (1/2 mph) See the technical manual or through Full Travel During your authorized dealer Calibration F691 B20 Steer Sensor Signal Wire Short to No Left Steer (1/2 mph) See the technical manual or Excitation Wire your authorized dealer Continued on next page TX,95,RR,A JUN96 1/ PN=240

243 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F685 B17 Rear Pump PCP, Short (+) PCP Forward Limited to Reverse Direction See the technical manual or your B27 Left Motor PCP Direction Only authorized dealer F683 B17 Rear Pump PCP, Short ( ) PCP Reverse Limited to Forward Direction See the technical manual or your B27 Left Motor PCP Direction Only authorized dealer F681 B18 Front Pump PCP, Short (+) PCP Forward Limited to Reverse Direction See the technical manual or your B28 Right Motor PCP Direction Only authorized dealer F680 Model ID Disconnected or Wrong Transmission Shutdown See the technical manual or your Machine Identity authorized dealer Connector F679 B18 Front Pump and B28 Short ( ) PCP Reverse Limited to Forward Direction See the technical manual or your Right Motor PCP Direction Only authorized dealer F677 B18 Front Pump and B28 Open (+) PCP Forward Limited to Reverse Direction See the technical manual or your Right Motor PCP Direction Only authorized dealer Continued on next page TX,95,RR,A JUN96 2/ PN=241

244 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F675 B18 Front Pump and B28 Open ( ) PCP Reverse Limited to Forward Direction See the technical manual or Right Motor PCP Direction Only your authorized dealer F673 B17 Rear Pump and B27 Open (+) PCP Forward Limited to Reverse Direction See the technical manual or Left Motor PCP Direction Only your authorized dealer F671 B17 Rear Pump and B27 Open ( ) PCP Reverse Limited to Forward Direction See the technical manual or Left Motor PCP Direction Only your authorized dealer F670 B11 Trans. Speed Control Excitation Short to Transmission Shutdown See the technical manual or Sensor Ground your authorized dealer Sensor Not Moved Transmission Shutdown See the technical manual or through Full Travel During your authorized dealer Calibration F669 B11 FNR Sensor Signal Wire Short to Transmission Shutdown See the technical manual or Ground your authorized dealer Open Signal/Ground Wire Transmission Shutdown See the technical manual or your authorized dealer Open on Excitation Wire Transmission Shutdown See the technical manual or your authorized dealer Sensor Not Moved Transmission Shutdown See the technical manual or through Full Travel During your authorized dealer Calibration F668 B11 FNR Sensor and B20 Excitation Short to Transmission Shutdown See the technical manual or Left and Right Steer Ground your authorized dealer Sensor Sensor Not Moved Transmission Shutdown See the technical manual or through Full Travel During your authorized dealer Calibration F667 B11 FNR Sensor Signal Wire Short to Transmission Shutdown See the technical manual or Excitation your authorized dealer Sensor Not Moved Transmission Shutdown See the technical manual or through Full Travel During your authorized dealer Calibration F666 Controller Electronic Problem Transmission Shutdown See the technical manual or your authorized dealer Continued on next page TX,95,RR,A JUN96 3/ PN=242

245 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F658 B9 Decelerator Sensor Excitation Short to 1/2 mph See the technical manual or and B12 Trans. Speed Ground your authorized dealer Control Sensor (Single Lever Steer) Sensor Not Moved 1/2 mph See the technical manual or through Full Travel During your authorized dealer Calibration F657 B12 Transmission Speed Signal Wire Short to 1/2 mph See the technical manual or Control Sensor Ground your authorized dealer Open Signal/Ground Wire 1/2 mph See the technical manual or your authorized dealer Open on Excitation Wire 1/2 mph See the technical manual or your authorized dealer Sensor Not Moved 1/2 mph See the technical manual or through Full Travel During your authorized dealer Calibration F656 B12 Transmission Speed Signal Wire Short to 1/2 mph See the technical manual or Control Sensor Excitation your authorized dealer Sensor Not Moved 1/2 mph See the technical manual or through Full Travel During your authorized dealer Calibration F655 Neutral Start Switch Input Wire Short 1/2 mph See the technical manual or your authorized dealer Switch Short 1/2 mph See the technical manual or your authorized dealer Sensor Not Moved 1/2 mph See the technical manual or through Full Travel During your authorized dealer Calibration F654 B12 (1/2 mph) Signal Voltage Under See the technical manual or Transmission Speed 0.5V your authorized dealer Control Switch F653 Neutral Start Switch Input Wire Open 1/2 mph See the technical manual or your authorized dealer Ground Wire Open 1/2 mph See the technical manual or your authorized dealer F652 B12 (1/2 MPH) Signal Voltage Over 3.5v See the technical manual or Transmission Speed your authorized dealer Control Switch Continued on next page TX,95,RR,A JUN96 4/ PN=243

246 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F651 Signal Wire Short to 1/2 mph See the technical manual or your B9 Decelerator Pedal Ground authorized dealer Open Signal/Ground Wire 1/2 mph See the technical manual or your authorized dealer Open Signal/Ground Wire 1/2 mph See the technical manual or your authorized dealer Sensor Not Moved 1/2 mph See the technical manual or your through Full Travel During authorized dealer Calibration F649 B9 Decelerator Pedal Signal Wire Short to 1/2 mph See the technical manual or your Excitation Wire authorized dealer Sensor Not Moved 1/2 mph See the technical manual or your through Full Travel During authorized dealer Calibration F648 B13 Engine Speed Excitation Short to Transmission Shutdown See the technical manual or your Control and B14 Hydro. Ground authorized dealer Pump Speed Sensor F647 B14 Hydro. Pump Speed Signal Wire Short to Transmission Shutdown See the technical manual or your Sensor Excitation/Ground authorized dealer F645 B14 Hydro. Pump Speed Signal/Ground Wire Open Transmission Shutdown See the technical manual or your Sensor authorized dealer Open on Excitation Wire Transmission Shutdown See the technical manual or your authorized dealer F640 B14 Hydro. Pump Speed No Feedback Transmission Shutdown See the technical manual or your Sensor authorized dealer F639 B13 Engine Speed Signal Wire Short to No Anti-Stall See the technical manual or your Control Sensor Ground authorized dealer Open Signal/Ground Wire No Anti-Stall See the technical manual or your authorized dealer Open on Excitation Wire No Anti-Stall See the technical manual or your authorized dealer Sensor Not Moved No Anti-Stall See the technical manual or your through Full Travel During authorized dealer Calibration F638 B13 Reverse Speed Ratio Signal Voltage Under See the technical manual or your Switch (115%) 0.99v authorized dealer F637 B13 Engine Speed Signal Wire Short to No Anti-Stall See the technical manual or your Control Sensor Excitation Wire authorized dealer Sensor Not Moved No Anti-Stall See the technical manual or your through Full Travel During authorized dealer Calibration Continued on next page TX,95,RR,A JUN96 5/ PN=244

247 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F636 B15 Left Track and B16 Excitation Short to Mistracking See the technical manual or your Right Track Motor Speed Ground authorized dealer Sensor F635 B15 Left Track Motor Signal Wire to Mistracking See the technical manual or your Speed Sensor Excitation/Short/Open authorized dealer SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION B13 Reverse Speed Ratio See the technical manual or F634 Switch (115%) Signal Voltage over 3.86v your authorized dealer F633 B15 Left Track Motor Ground Wire Open Mistracking See the technical manual or your Speed Sensor authorized dealer Excitation Wire Open Mistracking See the technical manual or your authorized dealer F631 B15 Left Direction Motor Signal Wire to Mistracking See the technical manual or your Speed Sensor Excitation/Short/Open authorized dealer F629 B15 Left Direction Motor Value Does not Match Mistracking See the technical manual or your Speed Sensor Calibration Value authorized dealer F628 B15 Left Track Motor No Feedback Mistracking See the technical manual or your Speed Sensor authorized dealer F627 B16 Right Track Motor Signal Wire to Mistracking See the technical manual or your Speed Sensor Excitation/Short/Open authorized dealer F625 B16 Right Track Motor Ground Wire Open Mistracking See the technical manual or your Speed Sensor authorized dealer Excitation Wire Open Mistracking See the technical manual or your authorized dealer F623 B16 Right Direction Motor Signal Wire to Mistracking See the technical manual or your Speed Sensor Excitation/Short/Open authorized dealer F621 B16 Right Direction Motor Value Does Not Match Mistracking See the technical manual or your Speed Sensor Calibration Value authorized dealer F620 B16 Right Track Motor No Feedback Mistracking See the technical manual or your Speed Sensor authorized dealer F619 Park Lock Lever Open Circuit Return to Neutral See the technical manual or your authorized dealer F618 Park Lock Lever Grounded Circuit Transmission Shut Down See the technical manual or your authorized dealer F617 Mistrack Motor PCP Coil Shorted Mistracking See the technical manual or your Internal Linkage, Motor authorized dealer Adjustment, Motor (PCP) Supply Pressure Low TX,95,RR,A JUN96 6/ PN=245

248 Troubleshooting Engine Controller Service Codes 850C Series II NOTE: Engine controller service codes will display when a fault occurs. When service code appears, shut engine off and restart to check if service code is an intermittent problem. Recall and record all codes from monitor. Investigate circuit problem identified by service code. The service code number is indicated by an F4 plus two other digits. The letter F means that a problem has occurred. The number 4 means the engine controller has diagnosed a problem and has sent a service code to the monitor to be displayed. The CHECK SERVICE CODE light will also be turned ON. The last two digits of service code number would indicate problems as follows: SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F471 Controller Signal Wire Short to Loss of Service Code Messages See the technical manual or your Excitation authorized dealer Controller Problem Loss of Service Code Messages See the technical manual or your authorized dealer F465 Controller Throttle Linkage Out of Limited Range of Throttle See the technical manual or your Adjustment authorized dealer Throttle Input Signal Limited Range of Throttle See the technical manual or your authorized dealer F455 Controller Controller Problem CAN Communication Errors See the technical manual or your authorized dealer Continued on next page TX,100,BG APR97 1/ PN=246

249 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F453 Rack Actuator Actuator/Pump Problem Erratic Performance See the technical manual or your authorized dealer Controller Problem Erratic Performance See the technical manual or your authorized dealer Actuator Wiring Fault Erratic Performance See the technical manual or your authorized dealer Rack Position Sensor Erratic Performance See the technical manual or your Wiring authorized dealer Rack Position Sensor Erratic Performance See the technical manual or your Problem authorized dealer F448 Rack Shutoff Solenoid Control Wire Short to Inability to Shut Down or Start See the technical manual or your Battery (+) or Ground, Engine authorized dealer Open Circuit F446 Key Switch Start Signal Wire Short to None See the technical manual or your Ground authorized dealer Key Switch Problem None See the technical manual or your authorized dealer F445 Primary/Auxiliary Speed Signal Wire Short to Erratic Engine Performance See the technical manual or your Sensors Ground authorized dealer Open Signal/Ground Wire Erratic Engine Performance See the technical manual or your authorized dealer Sensor Problem Erratic Engine Performance See the technical manual or your authorized dealer F444 Auxiliary Speed Sensor Sensor Problem Erratic Performance See the technical manual or your authorized dealer Controller Problem Erratic Performance See the technical manual or your authorized dealer Continued on next page TX,100,BG APR97 2/ PN=247

250 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F439 Primary Speed Sensor Sensor Problem Momentary Erratic Engine See the technical manual or your Speed authorized dealer Controller Problem Momentary Erratic Engine See the technical manual or your Speed authorized dealer F438 Fuel Temperature Sensor Signal Wire Short to Power Setting Change, Hard See the technical manual or your Ground Start, Slight Performance Loss authorized dealer Sensor Problem Power Setting Change, Hard See the technical manual or your Start, Slight Performance Loss authorized dealer Controller Problem Power Setting Change, Hard See the technical manual or your Start, Slight Performance Loss authorized dealer F437 Fuel Temperature Sensor Open Signal/Ground Wire Power Setting Change, Hard See the technical manual or your Start, Slight Performance Loss authorized dealer Sensor Problem Power Setting Change, Hard See the technical manual or your Start, Slight Performance Loss authorized dealer Controller Problem Power Setting Change, Hard See the technical manual or your Start, Slight Performance Loss authorized dealer F436 Rack Position Sensor Signal Wire Short to Erratic Engine Speed or Engine See the technical manual or your Ground Stalls authorized dealer Open Signal/Ground Wire Erratic Engine Speed or Engine See the technical manual or your Stalls authorized dealer Sensor Problem Erratic Engine Speed or Engine See the technical manual or your Stalls authorized dealer Controller Problem Erratic Engine Speed or Engine See the technical manual or your Stalls authorized dealer F435 Rack Position Sensor Signal Wire Short to Erratic Engine Speed or Engine See the technical manual or your Excitation Stalls authorized dealer Sensor Problem Erratic Engine Speed or Engine See the technical manual or your Stalls authorized dealer Controller Problem Erratic Engine Speed or Engine See the technical manual or your Stalls authorized dealer Continued on next page TX,100,BG APR97 3/ PN=248

251 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F434 Rack Actuator Actuator/Pump Problem Erratic Performance, Engine See the technical manual or your Shutdown authorized dealer Controller Problem Erratic Performance, Engine See the technical manual or your Shutdown authorized dealer Actuator Return Wire Erratic Performance, Engine See the technical manual or your Short to Ground Shutdown authorized dealer Rack Position Sensor Erratic Performance, Engine See the technical manual or your Wiring Fault Shutdown authorized dealer Rack Position Sensor Erratic Performance, Engine See the technical manual or your Problem Shutdown authorized dealer F431 Rack Actuator/Pump Rack Actuator/Pump Problem Inability to Start See the technical manual or your Position Sensor authorized dealer Controller Problem Inability to Start See the technical manual or your authorized dealer Actuator Return Wire Inability to Start See the technical manual or your Short to Ground authorized dealer Rack Position Sensor Inability to Start See the technical manual or your Wiring Fault authorized dealer Rack Position Sensor Inability to Start See the technical manual or your Problem authorized dealer Continued on next page TX,100,BG APR97 4/ PN=249

252 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F412 Throttle Position Sensor Signal/Excitation Wire Engine Speed Set to Low Idle See the technical manual or your Short to Ground authorized dealer Sensor Problem Engine Speed Set to Low Idle See the technical manual or your authorized dealer Controller Problem Engine Speed Set to Low Idle See the technical manual or your authorized dealer Sensor Adjustment Engine Speed Set to Low Idle See the technical manual or your authorized dealer Linkage Adjustment Engine Speed Set to Low Idle See the technical manual or your authorized dealer F411 Throttle Position Sensor Signal Wire Short to Engine Speed Set to Low Idle See the technical manual or your Excitation authorized dealer Open Signal/Return Wire Engine Speed Set to Low Idle See the technical manual or your authorized dealer Sensor Problem Engine Speed Set to Low Idle See the technical manual or your authorized dealer Controller Problem Engine Speed Set to Low Idle See the technical manual or your authorized dealer Sensor Adjustment Engine Speed Set to Low Idle See the technical manual or your authorized dealer Linkage Adjustment Engine Speed Set to Low Idle See the technical manual or your authorized dealer F419 Coolant Temperature Signal Wire Short to Enabling of Air Heater System See the technical manual or your Sensor Ground in Warm Temperature authorized dealer Conditions Sensor Problem Enabling of Air Heater System See the technical manual or your in Warm Temperature authorized dealer Conditions Controller Problem Enabling of Air Heater System See the technical manual or your in Warm Temperature authorized dealer Conditions F418 Coolant Temperature Open Signal/Ground Wire Enabling of Air Heater System See the technical manual or your Sensor in Warm Temperature authorized dealer Conditions Sensor Problem Enabling of Air Heater System See the technical manual or your in Warm Temperature authorized dealer Conditions Controller Problem Enabling of Air Heater System See the technical manual or your in Warm Temperature authorized dealer Conditions Continued on next page TX,100,BG APR97 5/ PN=250

253 Troubleshooting SERVICE CODE CIRCUIT POSSIBLE CAUSE MACHINE OPERATION SOLUTION F417 Air Temperature Sensor Signal Wire Short to Enabling of Air Heater System See the technical manual or Ground in Warm Temperature your authorized dealer Conditions Sensor Problem Enabling of Air Heater System See the technical manual or in Warm Temperature your authorized dealer Conditions Controller Problem Enabling of Air Heater System See the technical manual or in Warm Temperature your authorized dealer Conditions F416 Air Temperature Sensor Open Signal/Ground Wire Enabling of Air Heater System See the technical manual or in Warm Temperature your authorized dealer Conditions Sensor Problem Enabling of Air Heater System See the technical manual or in Warm Temperature your authorized dealer Conditions Controller Problem Enabling of Air Heater System See the technical manual or in Warm Temperature your authorized dealer Conditions TX,100,BG APR97 6/ PN=251

254 Storage Prepare Machine for Storage 1. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later. 2. Clean primary air cleaner element. T47764 UN 09NOV88 TX,105,RR, SEP94 1/3 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. 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. T5813AM UN 09FEB89 IMPORTANT: LPS3 Rust Inhibitor can destroy painted finish. DO NOT spray LPS3 Rust Inhibitor on painted surfaces. 4. Retract all hydraulic cylinders, if possible. If not, coat exposed cylinder rods with LPS3 Rust Inhibitor. 5. Lubricate all grease points. 6. Store machine in a dry, protected place. If stored outside, cover with a waterproof material. 7. If possible, park on a hard surface to prevent tracks from freezing to ground. LPS3 Rust Inhibitor is a registered trademark of Holt Lloyd Corporation. Continued on next page PN=252 TX,105,RR, SEP94 2/3

255 Storage IMPORTANT: Prevent possible machine damage form unauthorized persons operating machine. Attach a "DO NOT OPERATE" tag to the vandal cover latch. 8. Place a "DO NOT OPERATE" tag on the vandal cover latch. 9. Remove seat cushion and other perishable items. 10. Remove keys and lock all covers and doors. T7447AO 19 22APR91 TX,105,RR, SEP94 3/3 Lock All Compartments The following areas can be locked with personal locks: radiator service door, fuel cap, left and right service access doors, and vandal shield (1) if equipped. Lock these areas to help safeguard your machine. 1 Vandal Cover T127450C UN 04FEB00 TX,35,RR MAR95 1/1 Monthly Storage Procedure CAUTION: Engine exhaust fumes can cause sickness or death. Start engine ONLY in a well-ventilated area. 1. Drain water and sediment from fuel tank when air temperature is above freezing. Continued on next page TX,105,FF, OCT96 1/ PN=253

256 Storage 2. Remove LPS3 Rust Inhibitor from cylinder rods with a cleaning solvent. LPS3 Rust Inhibitor is a registered trademark of Holt Lloyd Corporation. Continued on next page TX,105,FF,400 T6191AA UN 18OCT OCT96 2/ PN=254

257 Storage IMPORTANT: During cold temperatures, check viscosity of engine oil on dipstick. If the oil appears waxy and/or jelly-like rather than liquid, DO NOT attempt to start engine. Use external heat source to warm the crankcase until oil appears fluid. 3. Check all fluid levels. If low, check for leaks and add oil as required. 4. Check belts. T6181AU UN 18OCT88 5. Check condition of all hoses and connections. 6. Check electrolyte level. Charge and install battery. 7. Fill fuel tank. 8. Pre-lubricate turbocharger bearings: a. Remove fuel shut-off solenoid wire (on injection pump). b. Turn engine crankshaft until engine oil pressure gauge needle moves off left index mark. c. Do not operate starter motor more than 30 seconds at a time. Wait 2 minutes between attempts. After needle moves off left index mark, install wire. d. Start engine. Run several minutes at 1/3 speed until engine is at normal operating temperature. 9. Bleed fuel system. If engine fails to start or runs poorly after starting, change fuel filter(s). Bleed fuel system again. 10. Operate all controls, levers, seat adjustments, etc. 11. Cycle all hydraulic functions several times. Check condition of all hoses and connections. 12. Check condition of tracks. Check track sag. 13. Park the machine with cylinder rods retracted. Continued on next page TX,105,FF, OCT96 3/ PN=255

258 Storage 14. Apply LPS3 Rust Inhibitor to the exposed cylinder rod areas. LPS3 Rust Inhibitor is a registered trademark of Holt Lloyd Corporation. TX,105,FF, OCT96 4/ PN=256

259 Machine Numbers Record Product Identification Number (PIN) Purchase Date NOTE: Make sure to record all 13 digits of the PIN number*. T8432AC UN 02MAR95 TX,110,RR MAR95 1/1 Record Engine Serial Number Engine Serial Number (A) A Engine Serial Number Plate T8432AD UN 02MAR95 TX,110,RR MAR95 1/1 Record C-Frame or Pushbeam Serial Number Serial Number NOTE: On straight dozers, the serial number tag is located on the right pushbeam ahead of the tilt cylinder mount. Serial number tag on all hydraulic and angle dozers is on top of C-frame to the right of the center mounting pin. T82,CRMN,P 19 05JUN91 1/1 Record Transmission Serial Numbers Serial Number Serial Number TX,110,RR MAR95 1/ PN=257

260 Specifications 750C Series II Specifications NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with ICED and SAE standards. Except where otherwise noted, these specifications are based on a unit equipped with 560 mm (22 in.) grousers, roll-over protective canopy, full fuel tank, 79 kg (175 lb) operator, and standard equipment. Net engine power is with standard equipment including air cleaner, exhaust system, alternator, and cooling fan, at standard conditions per SAE J1349 and DIN 6270B using No. 2-D fuel at 35 API gravity. No derating is required up to 3050 m (10,000 ft) altitude. Gross power is without cooling fan. Item Measurement Specification John Deere 6 Cylinder POWERTECH Turbocharged Diesel Engine 6068T Fuel Consumption, Typical Consumption L/h ( gal/hr) Rated Power at 2100 rpm Power 104 kw (140 hp) SAE net horsepower 110 kw (148 hp) SAE gross horsepower Bore and Stroke Distance x 127 mm (4.14 x 5.0 in.) Piston Displacement L (414 cu in.) Electrical System Voltage 24-volt with 45-amp alternator Maximum Net Torque at 1300 rpm Torque Rise 570 N m (420 lb-ft) Batteries Voltage Two 12-volt Cold Cranking Amps 625 amps each at 18 C (0 F) Reserve Capacity 160 minutes each at 18 C (0 F) Transmission Speed Infinite from 0 11 km/h (0 6.8 mph) forward and reverse Drawbar Pull at 1.9 km/h (1.2 mph) Force 141 kn (31,800 lb force) Hydraulic System (Open Center) Pressure kpa (2000 psi) Flow Rate 144 L/min (38 gpm) at 2100 rpm POWERTECHis a registered trademark of Deere & Company Continued on next page PN=258 TX,115,BG OCT98 1/3

261 Specifications Item Measurement Specification Undercarriage 750C Series II Track Shoes (Each Quantity 40 Side) 750C LGP Series II Track Shoes Quantity 42 (Each Side) 750C Series II Track Rollers Quantity 7 750C Series II Ground Contact Area cm 2 (4488 sq in.) Area (with 22 in. Shoes) 750C WT Series II Ground Contact Area cm 2 (6936 sq in.) Area (with 34 in. Shoes) 750C LGP Series II Ground Area cm 2 (7446 sq in.) Contact Area (with 34 in. Shoes) 750C Series II minimum with Clearance 371 mm (14.6 in.) single-bar grouser (excluding grouser height) 750C WT Series II minimum with Clearance 437 mm (17.2 in.) swamp shoe (including grouser height) 750C LT/750C WT Series II Track Pitch 190 mm (7.5 in.) Gauge 1880 mm (74 in.) 750 LGP Series II Track Pitch 190 mm (7.5 in.) Gauge 2083 mm (82 in.) 750C LT/750C WT Series II Track Distance 2591 mm (102 in.) Length on Ground 750 LPG Series II Track Length on Distance 2781 mm (109.5 in.) Ground Ground Pressure 750C LT Series II Ground Pressure 49.0 kpa (0.5 bar) (7.1 psi) Pressure Semi-U Blade 750C LT Series II Ground Pressure 51.7 kpa (0.52 bar) (7.5 psi) Pressure PAT Blade Continued on next page TX,115,BG OCT98 2/ PN=259

262 Specifications Item Measurement Specification 750C WT Series II Ground Pressure 33.6 kpa (0.3 bar) (4.9 psi) Pressure 750C LGP Series II Ground Pressure 33.9 kpa (0.4 bar) (4.91 psi) Pressure SAE Operating Weight 750C Series II with Semi-U Blade Weight kg (31,712 lb) (High Production) 750C Series II All-Hydraulic Dozer Weight kg (33,736 lb) (PAT) 750C WT Series II with Straight Weight kg (33,324 lb) Blade 750C WT Series II with Semi-U Weight kg (33,843 lb) Blade (High Production) 750C LGP Series II All-Hydraulic Weight kg (36,576 lb) Dozer (PAT) TX,115,BG OCT98 3/ PN=260

263 Specifications 750C Series II Capacity Specifications Item Measurement Specification Drain and Refill Capacities Cooling System (Including Capacity 26.5 L (7 gal) Recovery Tank) Fuel Tank Capacity 280 L (74 gal) Engine Oil (Including Filter) Capacity 24 L (6.3 gal) 750C LT/750C WT Series II Inner Capacity 23.6 L (6.25 gal) Final Drive (Each Side) 750C LGP Series II Inner Final Capacity 27.8 L (7.35 gal) Drive (Each Side) Outer Final Drive (Each Side) Capacity 12.3 L (3.25 gal) Hydraulic Reservoir Capacity 68 L (18 gal) Hydrostatic Transmission Capacity 83.3 L (22 gal) CED,OUO1065, JAN00 1/ PN=261

264 Specifications 750C Series II General Specifications Lubrication: Pressure system with full flow filters Cooling: Pressured with thermostat and controlled bypass Fan: Blower-type Air Cleaner: Dual-stage aspirated with restriction indicator Dry Transmission: Automatic, dual-path hydrostatic drive. Load sensing feature automatically adjusts speed and power to match changing load conditions. Dual path hydrostatic drive. Live power turns: Both tracks remain fully powered during turns. This affords greater maneuverability with larger loads and less ground disturbance. This feature also provides improved capability for working on soft ground, as well as the ability to counterbalance blade corner loads when benching, ditching or backfilling. Counter-rotation: Separate control allows the two transmissions to be driven in opposite directions, permitting spot turns with excellent maneuverability. Quick blade position changes can be made. Infinite speed selection: Infinitely variable ground speeds, from 0 11 km/h (0 6.8 mph), allow precise speed. Speed can be reduced without slowing engine rpm, so hydraulic power remains high and response time remains fast. Automatic load sensing: As a load increases and engine rpm lessens, the transmission automatically reduces ground speed to match load changes. This feature works at all throttle settings, providing full drawbar pull even at reduced engine speed. Continued on next page CED,OUO1032, OCT98 1/ PN=262

265 Specifications Dynamic braking: Positive speed reduction is provided on slopes. When shifted to neutral, oil flow between the pump and motor is blocked. The crawler stops without use of the service brakes. Steering: Single lever steering and direction control with decelerator, full power turn, counter-rotation and infinitely variable track speeds provide unlimited maneuverability and optimum control. Hydrostatic steering eliminates the need for steering clutches and steering brakes as well as the need for cross-steering when working on steep slopes. Brakes: Hydrostatic (dynamic) braking stops the machine when the direction/steering control lever is moved to neutral. Wet-disk brakes are automatically applied when engine is stopped or manually applied with center foot pedal during normal operation. Hydraulics: Open center system 10 micron filter in return line with bypass Gear-type pump Forestry Application: The dozer can be equipped for forestry applications with the addition of limb risers and screens for the roll-over protective structure. CED,OUO1032, OCT98 2/ PN=263

266 Specifications 750C LT Series II Dimensions T UN 10JAN00 Item Measurement Specification 750C LT Series II with Semi-U (High-Production) Blade: Blade Capacity 4.28 m 3 (5.60 cu yd) A Blade Lift Height 1072 mm (42.2 in.) B Blade Height 1283 mm (50.5 in.) C Digging Depth 513 mm (20.2 in.) D Overall Machine (with standard Length 5011 mm (16 ft 5 in.) drawbar) Continued on next page CED,OUO1065, JAN00 1/ PN=264

267 Specifications Item Measurement Specification E Tread Depth with Single-Bar Depth 56 mm (2.2 in.) Grouser (Moderate Duty) E Tread Depth with Single-Bar Depth 68 mm (2.7 in.) Grouser (Extreme Duty) F Overall Machine Height 3065 mm (10 ft 1 in.) G Blade Width 3216 mm (10 ft 6.6 in.) H Maximum Blade Tilt Height 700 mm (27.6 in.) 750C LT Series II All-Hydraulic Dozer (PAT) Blade Capacity 3.52 m 3 (4.60 cu yd) A Blade Lift Height 899 mm (35.4 in.) B Blade Height 1193 mm (47 in.) C Digging Depth 848 mm (33.4 in.) D Overall Machine (with standard Length 4955 mm (16 ft 3 in.) drawbar) E Tread Depth with Single-Bar Depth 56 mm (2.2 in.) Grouser (Moderate Duty) E Tread Depth with Single-Bar Depth 68 mm (2.7 in.) Grouser (Extreme Duty) F Overall Machine Height 3065 mm (10 ft 1 in.) G Blade Width 3283 mm (10 ft 9.3 in.) H Maximum Blade Tilt Height 413 mm (16.2 in.) I Width Over Track Width 2438 mm (8 ft 0 in.) J Overall Blade Width (with Blade Width 3011 mm (9 ft 10.5 in.) Angled) K Maximum Blade Angle 24 degrees L Blade Cut Reach Distance 89 mm (3.5 in.) Continued on next page CED,OUO1065, JAN00 2/ PN=265

268 Specifications Item Measurement Specification M Blade Cast Reach Distance 325 mm (12.8 in.) N Cutting Edge Angle 58 degrees CED,OUO1065, JAN00 3/ PN=266

269 Specifications 750C WT Series II Dimensions T UN 10JAN00 Item Measurement Specification 750C WT Series II with Straight Blade: Blade Capacity 2.48 m 3 (3.25 cu yd) A Blade Lift Height 1072 mm (42.2 in.) B Blade Height 976 mm (38.4 in.) C Digging Depth 513 mm (20.2 in.) D Overall Machine Length 4956 mm (16 ft 3 in.) Continued on next page CED,OUO1065, JAN00 1/ PN=267

270 Specifications Item Measurement Specification E Tread Depth with Single-Bar Depth 56 mm (2.2 in.) Grouser (Moderate Duty) E Tread Depth with Swamp Shoe Depth 80 mm (3.15 in.) F Overall Machine Height 3065 mm (10 ft 1 in.) G Blade Width 3363 mm (11 ft) H Maximum Blade Tilt Height 878 mm (34.6 in.) Item Measurement Specification 750C WT Series II with Semi-U (High Profile) Blade: Blade Capacity 4.28 m 3 (5.60 cu yd) A Blade Lift Height 1072 mm (42.2 in.) B Blade Height 1143 mm (45.0 in.) C Digging Depth 513 mm (20.2 in.) D Overall Machine Length 5011 mm (16 ft 5 in.) E Tread Depth with Single-Bar Depth 56 mm (2.2 in.) Grouser (Moderate Duty) E Tread Depth with Swamp Shoe Depth 80 mm (3.15 in.) F Overall Machine Height 3065 mm (10 ft 1 in.) G Blade Width 3658 mm (12 ft) H Maximum Blade Tilt Height 955 mm (37.6 in.) CED,OUO1065, JAN00 2/ PN=268

271 Specifications 750C LGP Series II Dimensions T UN 10JAN00 Item Measurement Specification 750C LGP Series II All-Hydraulic Dozer (PAT) Blade Capacity 4.84 m 3 (3.70 cu yd) A Blade Lift Height 899 mm (35.4 in.) B Blade Height 1143 mm (45 in.) C Digging Depth 848 mm (33.4 in.) D Overall Machine Length 4916 mm (16 ft 1 in.) Continued on next page CED,OUO1032, JAN00 1/ PN=269

272 Specifications Item Measurement Specification E Tread Depth with Single-Bar Depth 56 mm (2.2 in.) Grouser (Moderate Duty) F Overall Machine Height 3065 mm (10 ft 1 in.) G Blade Width 3861 mm (12 ft 8 in.) H Maximum Blade Tilt Height 484 mm (19.1 in.) I Width Over Track Width 2946 mm (9 ft 8 in.) J Overall Blade Width (with Blade Width 3541 mm (11 ft 7 in.) Angled) K Maximum Blade Angle 24 degrees L Blade Cut Reach Distance 144 mm (5.7 in.) M Blade Cast Reach Distance 366 mm (14.4 in.) N Cutting Edge Angle 60 degrees CED,OUO1032, JAN00 2/ PN=270

273 Specifications 850C Series II Specifications NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with ICED and SAE standards. Except where otherwise noted, these specifications are based on a unit equipped with 610 mm (24 in.) grousers, rigid drawbar, front hook, roll-over protective canopy, full fuel tank, 79 kg (175 lb) operator, and standard equipment. Net engine power is with standard equipment including air cleaner, exhaust system, alternator, and cooling fan, at standard conditions per SAE J1349 and DIN 6270B using No. 2-D fuel at 35 API gravity. No derating is required up to 3050 m (10,000 ft) altitude. Gross power is without cooling fan. Item Measurement Specification John Deere 6 Cylinder POWERTECH Turbocharged Diesel Engine 6081AT Fuel Consumption, Typical Consumption L/h ( gal/hr) Maximum Net Torque at 1300 rpm Torque Rise 815 N m (601 lb-ft) Rated Power at 2100 rpm Power 127 kw (170 hp) SAE net horsepower 135 kw (181 hp) SAE gross horsepower Bore and Stroke Distance x mm (4.56 x 5.06 in.) Piston Displacement 8.1 L (496 cu in.) Electrical System Voltage 24-volt with 45-amp alternator Batteries Voltage Two 12-volt Cold Cranking Amps 625 amps each at 18 C (0 F) Reserve Capacity 160 minutes each at 18 C (0 F) Transmission Speed Infinite from 0 11 km/h (0 6.8 mph) forward and reverse Drawbar Pull at 1.9 km/h (1.2 mph) Force 156 kn (35,200 lb force) Hydraulic System (Open Center) Pressure kpa (2250 psi) Flow Rate 166 L/min (44 gpm) at 2100 rpm POWERTECH is a registered trademark of Deere & Company Continued on next page PN=271 CED,OUO1032, JAN00 1/3

274 Specifications Item Measurement Specification Undercarriage: 850C LT/850C WT Series II Track Quantity 40 Shoes (Each Side) 850C LGP Series II Track Shoes Quantity 43 (Each Side) 850C Series II Ground Contact Area cm 2 (5184 sq in.) Area (with 24 in. Shoes) 850C WT Series II Ground Contact Area cm 2 (6480 sq in.) Area (with 30 in. Shoes) 850C LGP Series II Ground Area cm 2 (9196 sq in.) Contact Area (with 38 in. Shoes except PAT) 850C LGP Series II Ground Area cm 2 (8228 sq in.) Contact Area (with 38 in. Shoes with PAT) 850C LT/850C WT Series II Clearance 406 mm (16 in.) (Excluding Grouser Height) with Single-bar Grouser 850C LGP Series II (Including Clearance 483 mm (19.0 in.) Grouser Height) with Swamp Shoe 850C Series II Track Pitch 203 mm (8 in.) 850C LT Series II Semi-U Track Gauge 1880 mm (74 in.) 850C LT Series II PAT Track Gauge 2083 mm (82 in.) 850C WT Series II Semi-U Track Gauge 2032 mm (80 in.) 850C WT Series II PAT Track Gauge 2235 mm (88 in.) 850C LGP Series II Semi-U Track Gauge 2235 mm (88 in.) 850C LGP Series II PAT Track Gauge 2337 mm (92 in.) 850C LT/850C WT Series II Track Length 2743 mm (108 in.) on Ground Length Continued on next page CED,OUO1032, JAN00 2/ PN=272

275 Specifications Item Measurement Specification 850C LGP Series II Track on Length 3073 mm (121 in.) Ground Length Ground Pressure: 850C Series II Ground Pressure Pressure 53.8 kpa (0.5 bar) (7.8 psi) Semi-U 56.5 kpa (0.6 bar) (8.2 psi) PAT 850C WT Series II Ground Pressure 43.4 kpa (0.4 bar) (6.3 psi) Semi-U Pressure 46.2 kpa (0.5 bar) (6.7 psi) PAT 850C Series II LGP Ground Pressure 31.7 kpa (0.3 bar) (4.65 psi) Semi-U Pressure 37.2 kpa (0.4 bar) (5.4 psi) PAT 850C Series II SAE Operating Weight: 850C LT Series II with Semi-U Weight kg (40,485 lb) Blade (High Production) 850C WT Series II with Semi-U Weight kg (41,070 lb) Blade (High Production) 850C LGP Series II with Semi-U Weight kg (42,048 lb) Blade (High Production) 850C LT Series II with Weight kg (42,418 lb) All-Hydraulic (PAT) Dozer 850C WT Series II with Weight kg (43,366 lb) All-Hydraulic (PAT) Dozer 850C LGP Series II with Weight kg (44,582 lb) All-Hydraulic (PAT) Dozer CED,OUO1032, JAN00 3/ PN=273

276 Specifications 850C Series II Capacity Specifications Item Measurement Specification Drain and Refill Capacities: Cooling System Capacity 34 L (9 gal) Fuel Tank Capacity 348 L (92 gal) Engine Oil (Including Filter) Capacity 25.5 L (6.7 gal) 850C LT Series II Inner Final Drive Capacity 12.3 L (3.25 gal) Semi-U (Each Side) 16.5 L (4.35 gal) PAT 850C WT Series II Inner Final Capacity 16.5 L (4.35 gal) Semi-U Drive (Each Side) 37.9 L (10.0 gal) PAT 850C LGP Series II Inner Final Capacity 37.9 L (10 gal) Drive (Each Side) Outer Final Drive (Each Side) Capacity 12.3 L (3.25 gal) Hydraulic Reservoir Capacity 79.5 L (21 gal) Hydrostatic Transmission Capacity L (27 gal) CED,OUO1065, JAN00 1/ PN=274

277 Specifications 850C Series II General Specifications Lubrication: Pressure system with full flow filters Cooling: Pressured with thermostat and controlled bypass Fan: Blower-type Air Cleaner: Dual-stage aspirated with restriction indicator Dry Transmission: Automatic, dual-path hydrostatic drive. Load sensing feature automatically adjusts speed and power to match changing load conditions. Dual path hydrostatic drive. Live power turns: Both tracks remain fully powered during turns. This affords greater maneuverability with larger loads and less ground disturbance. This feature also provides improved capability for working on soft ground, as well as the ability to counterbalance blade corner loads when benching, ditching or backfilling. Counter-rotation: Separate control allows the two transmissions to be driven in opposite directions, permitting spot turns with excellent maneuverability. Quick blade position changes can be made. Infinite speed selection: Infinitely variable ground speeds, from 0 11 km/h (0 6.8 mph), allow precise speed. Speed can be reduced without slowing engine rpm, so hydraulic power remains high and response time remains fast. Automatic load sensing: As a load increases and engine rpm lessens, the transmission automatically reduces ground speed to match load changes. This feature works at all throttle settings, providing full drawbar pull even at reduced engine speed. Continued on next page CED,OUO1032, OCT98 1/ PN=275

278 Specifications Dynamic braking: Positive speed reduction is provided on slopes. When shifted to neutral, oil flow between the pump and motor is blocked. The crawler stops without use of the service brakes. Steering: Single lever steering and direction control with decelerator, full power turn, counter-rotation and infinitely variable track speeds provide unlimited maneuverability and optimum control. Hydrostatic steering eliminates the need for steering clutches and steering brakes as well as the need for cross-steering when working on steep slopes. Brakes: Hydrostatic (dynamic) braking stops the machine when the direction/steering control lever is moved to neutral. Wet-disk brakes are automatically applied when engine is stopped or manually applied with center foot pedal during normal operation. Hydraulics: Open center system 10 micron filter in return line with bypass Gear-type pump Forestry Application: The dozer can be equipped for forestry applications with the addition of limb risers and screens for the roll-over protective structure. CED,OUO1032, OCT98 2/ PN=276

279 Specifications 850C LT Series II Dimensions T UN 10JAN00 Item Measurement Specification 850C LT Series II with Semi-U (High-Production) Blade: Blade Capacity 5.69 m 3 (7.44 cu yd) A Blade Lift Height 1100 mm (43.3 in.) B Blade Height 1435 mm (56.5 in.) C Digging Depth 513 mm (20.2 in.) D Overall Machine Length 5262 mm (17 ft 3 in.) Continued on next page CED,OUO1032, JAN00 1/ PN=277

280 Specifications Item Measurement Specification E Tread Depth with Single-Bar Depth 65 mm (2.6 in.) Grouser (Moderate Duty) E Tread Depth with Single-Bar Depth 72 mm (2.8 in.) Grouser (Extreme Duty) F Overall Machine Height 3151 mm (10 ft 4 in.) G Blade Width 3259 mm (10 ft 8.3 in.) H Maximum Blade Tilt Height 730 mm (28.7 in.) 850C LT Series II with All-Hydraulic (PAT) Dozer: Blade Capacity 3.94 m 3 (5.15 cu yd) A Blade Lift Height 962 mm (38 in.) B Blade Height 1227 mm (48.3 in.) C Digging Depth 849 mm (33.4 in.) D Overall Machine Length 5160 mm (16 ft 11.1 in.) E Tread Depth with Single-Bar Depth 65 mm (2.6 in.) Grouser (Moderate Duty) E Tread Depth with Single-Bar Depth 72 mm (2.8 in.) Grouser (Extreme Duty) F Overall Machine Height 3151 mm (10 ft 4 in.) G Blade Width 3708 mm (12 ft 2 in.) H Maximum Blade Tilt Height 482 mm (19.0 in.) I Width Over Track Width 2692 mm (8 ft 10 in.) J Overall Blade Width (with Blade Width 3343 mm (10 ft 11.6 in.) Angled) K Maximum Blade Angle 25 degrees L Blade Cut Reach Distance 113 mm (4.5 in.) Continued on next page CED,OUO1032, JAN00 2/ PN=278

281 Specifications Item Measurement Specification M Blade Cast Reach Distance 538 mm (21.2 in.) N Cutting Edge Angle 60 degrees CED,OUO1032, JAN00 3/ PN=279

282 Specifications 850C WT Series II Dimensions T UN 10JAN00 Item Measurement Specification 850C WT Series II with Semi-U (High-Production) Blade: Blade Capacity 6.16 m 3 (8.06 cu yd) A Blade Lift Height 1100 mm (43.3 in.) B Blade Height 1435 mm (56.5 in.) C Digging Depth 513 mm (20.2 in.) D Overall Machine Length 5262 mm (17 ft 3 in.) Continued on next page CED,OUO1032, JAN00 1/ PN=280

283 Specifications Item Measurement Specification E Tread Depth with Single-Bar Depth 65 mm (2.6 in.) Grouser (Moderate Duty) F Overall Machine Height 3151 mm (10 ft 4 in.) G Blade Width 3556 mm (11 ft 8 in.) H Maximum Blade Tilt Height 878 mm (34.6 in.) 850C WT Series II with All-Hydraulic (PAT) Dozer: Blade Capacity 4.21 mm 3 (5.5 cu yd) A Blade Lift Height 962 mm (38 in.) B Blade Height 1227 mm (48.3 in.) C Digging Depth 849 mm (33.4 in.) D Overall Machine Length 5160 mm (16 ft 11.1 in.) E Tread Depth with Single-Bar Depth 65 mm (2.6 in.) Grouser (Moderate Duty) F Overall Machine Height 3151 mm (10 ft 4 in.) G Blade Width 4013 mm (13 ft 2 in.) H Maximum Blade Tilt Height 522 mm (20.5 in.) I Width Over Track Width 2997 mm (9 ft 10 in.) J Overall Blade Width (with Blade Width 3618 mm (11 ft 10.4 in.) Angled) K Maximum Blade Angle 25 degrees L Blade Cut Reach Distance 98 mm (3.9 in.) M Blade Cast Reach Distance 523 mm (20.5 in.) N Cutting Edge Angle 60 degrees CED,OUO1032, JAN00 2/ PN=281

284 Specifications 850C LGP Series II Dimensions T UN 10JAN00 Item Measurement Specification 850C LGP Series II with Semi-U (High-Production) Blade: Blade Capacity 5.46 m 3 (7.14 cu yd) A Blade Lift Height 1080 mm (42.5 in.) B Blade Height 1113 mm (43.8 in.) C Digging Depth 429 mm (16.9 in.) D Overall Machine Length 5651 mm (18 ft 6.5 in.) Continued on next page CED,OUO1032, JAN00 1/ PN=282

285 Specifications Item Measurement Specification E Tread Depth with Single-Bar Depth 65 mm (2.6 in.) Grouser (Moderate Duty) E Tread Depth with Swamp Shoe Depth 93 mm (3.7 in.) F Overall Machine Height 3151 mm (10 ft 4 in.) G Blade Width 3978 mm (13 ft 0.6 in.) H Maximum Blade Tilt Height 940 mm (37 in.) 850C LGP Series II with All-Hydraulic (PAT) Dozer: Blade Capacity 4.42 m 3 (5.78 cu yd) A Blade Lift Height 1034 mm (40.7 in.) B Blade Height 1227 mm (48.3 in.) C Digging Depth 893 mm (35.2 in.) D Overall Machine Length 5553 mm (18 ft 2.6 in.) E Tread Depth with Single-Bar Depth 65 mm (2.6 in.) Grouser (Moderate Duty) E Tread Depth with Swamp Shoe Depth 93 mm (3.7 in.) F Overall Machine Height 3151 mm (10 ft 4 in.) G Blade Width 4267 mm (14 ft 0 in.) H Maximum Blade Tilt Height 554 mm (21.8 in.) I Width Over Track Width 3200 mm (10 ft 6 in.) J Overall Blade Width (with Blade Width 3860 mm (12 ft 7.9 in.) Angled) K Maximum Blade Angle 25 degrees L Blade Cut Reach Distance 113 mm (4.5 in.) M Blade Cast Reach Distance 538 mm (21.2 in.) N Cutting Edge Angle 60 degrees CED,OUO1032, JAN00 2/ PN=283

286 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=284

287 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,110,DH DEC93 1/ PN=285

288 Crime Prevention Tips Report Thefts Immediately 1. Immediately notify your local law enforcement agency and insurance agent. 2. Provide a complete description of the machine, all of the documented identification numbers and color photographs. 3. Request verification of the identification numbers after they have been entered with any regional or national crime information center. Double check the numbers to be sure they are correct. 4. Notify your John Deere dealer of the theft and request that its loss be posted with full description and identification numbers. TS146 UN 09JAN89 DX,CRPRV,G 19 03MAR93 1/ PN=286

289 Maintenance and Repair Record Keeping System Checklists Model 705C Series II 850C Series ii Customer: PIN/Serial Number: Delivery Date: Hour Meter Reading: BREAK-IN SERVICE INTERVALS After 100 hours refer to service intervals in chapter 50. SERVICE INTERVALS AFTER BREAK-IN 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. Check and replace belts Check air cleaner restriction indicator Every 10 Hours or Daily Check engine oil level Check coolant recovery tank Grease center crossbar pivot Grease crossbar left and right end pivot As Required Every 50 Hours Check transmission oil level Check and adjust track sag Check hydraulic system oil level Grease dozer linkage Grease lift cylinder pivots Model: 750C and 850C Customer: PIN/Serial Number: Delivery Date: Hour Meter Reading: 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. Continued on next page TX03768,0000B MAY02 1/3 CLIS PN=287

290 Checklists Description Unit Part Number ASI Hours Hours Hours Hours Hours Engine Oil 750C RE Filter Series II 850C RE Series II Engine Rocker 750C R Arm Cover Series Gasket II 850C R Series II Fuel Filter All RE (Primary) Fuel Filter 750C RE (Secondary) Series II Fuel Filter 850C RE (Secondary) Series II Transmission All AT Oil Filter (Element) Hydraulic Oil All AT Filter (Element) John Deere 750C TY L (5 19 L (5 19 L (5 19 L (5 19 L (5 PLUS-50 Oil Series gal) gal) gal) gal) gal) II 24 L 24 L 24 L ( L ( L ( C (5.25 gal) (5.25 gal) gal) gal) gal) Series II Air Filter 750C AR (Primary) Series II Air Filter 750C AR (Secondary) Series II Air Filter 850C AT (Primary) Series II Air Filter 850C AT (Secondary) Series II Crank Shaft All RE59355(750C) 1 Dampener & RE50091(850C) Continued on next page TX03768,0000B MAY02 2/3 CLIS PN=288

291 Checklists Description Unit Part Number ASI Hours Hours Hours Hours Hours Transmission All TY6389 qt. (750C) and Hyddraulic 151 L (40 Oil gal) & (850C) 182 L (48 gal) Gear Oil API Standard TY6382 (750C)68 L (750C) 68 GL-5 80W90 LGP (18 gal) & L (18 gal) 850C) 104 & 850C) L ( L gal) (27.5 gal) Final Drives Oil All TY L ( L (1.75 gal) gal) Coolant All TY16004 As Needed Conditioner OILSCAN Kits Diesel Engine All AT Oil Transmission All AT Oil Final Drive Oil All AT Hydraulic Oil All AT Coolscan Plus Kit All AT (Ten samples per kit) Dieselscan Kit (Six All AT As Needed samples per kit) 1 3-Way Heavy All TT16175 As Needed Duty Coolant TEst Kit OILSCAN is a registered trademark of Deere & Company Coolscan Plus is a registered trademark of Deere & Company TX03768,0000B MAY02 3/3 CLIS PN=289

292 Checklists CLIS PN=290

293 Index Page Page A Lever Operating tips Accessories and cab components Pitch adjustment Accessory, 12 volt Boost starting Adjustment Brake Alternator belt System troubleshooting Blade angle Brake manual release Blade pitch Brake pedal Engine speed control lever Bulb replacement Seat Halogen bulb Track sag , 55-3 Button, select Air Cleaner element, clean Conditioning troubleshooting C Intake hose Restriction indicator C-frame serial number Air cleaner Cab Unloader valve, clean Light Air cleaner elements Capacity Remove and inspect C Series II machine Air conditioner 850C Series II machine Controls Carrier roller oil level Refrigerant level, check Codes, engine Air filter restriction indicator C Alarm Codes, transmission STOP-engine Conditioner, radiator Alternator Coolant Belt adjustment Conditioner Precaution Diesel engine Voltage indicator Heater Antifreeze Hose Level Level Antifreeze test Level, radiator Temperature gauge Test Cooling system B Filling Service Battery Coolscan Plus Booster Crankcase vent tube Check terminals Crossbar adjustment Disconnect switch Electrolyte level Removal Replace D Safety Battery disconnect switch, relays, gauges, monitor Daily inspection and transmission controller Dampener Blade Engine Angle adjustment Decelerator Control lever Pedal Determine pitch Diesel engine oil Index PN=1

294 Index Page Page Diesel fuel Hydraulic Diesel fuel conditioner Transmission oil Low sulfur Final drive Diesel fuel storage Oil change Display window , 10-2 Oil level Door latch Oil specification Driving the machine Fire extinguisher check FNR Forward Speed Switch E Lever Return to neutral indicator Electrical Steer lever Troubleshooting Speed-In-Grip , 30-5 Electrical accessory Front crossbar support clearance Electrolyte Front idler Specifications Oil specification Engine Fuel Air filter restriction indicator Diesel Alternator voltage indicator Filter change Cold weather warm-up , 90-6 Filter drain Coolant level Handling and storing Coolant temperature gauge Tank capacity Crankcase vent tube Fuel drain Dampener Fuel filter Ether injection aid Change secondary, 750C Series II Gauges and indicators Change, 850C Series II , 80-4 Oil change Replace, 750C Series II Oil filter change Fuel gauge Oil pressure gauge Fuel, diesel Serial number storage Speed , Fuse Speed lever Color codes Starting Specifications Starting fluid Stopping Troubleshooting Warm-up G Engine oil Diesel Ether aid Gauge Ether injection aid Check after starting engine Engine coolant Engine oil pressure Fuel F Transmission oil pressure Gauges Filter General driving and transmission checks Air, cab Grease Air, remove and inspect All-hydraulic blade Engine Crossbar center pivot Fuel , 80-3 Crossbar end pivots Fuel, drain Dozer linkage Index PN=2

295 Index Page Extreme pressure and multipurpose Lift cylinder pivot Track adjust cylinder Track frame pivots J Page Jump starting H Hardware Torque specifications Heater Coolant Heater valve Hose Air intake Coolant Hour meter , 50-2 Hydraulic Oil filter restriction indicator , 10-7 Oil level Hydraulic troubleshooting L Lever Blade , 35-2 Engine speed Engine speed control FNR Speed-In-Grip Park lock , 30-3 Steer Speed-In-Grip Light Cab Work Loading on a trailer Locks , Low sulfur diesel fuel conditioner Lubricant Alternative Mixing Storage I Synthetic Lubricate Idler Crossbar center pivot Check horizontal movement Dozer linkage Front, oil specification Track adjust cylinder Oil level Track frame pivots Vertical movement Inch torque values Indicator Check service code Engine air filter restriction , 55-5 Engine alternator voltage Ether injection Fasten seat belt Hydraulic oil filter restriction Return FNR to neutral Service required STOP-engine Transmission oil filter restriction Transmission oil temperature hot Indicators Injection Nozzles Pump M Machine serial number Maintenance Interval Prepare machine Schedule and record , CLIS-1 Maintenance repair record Metric torque values Mirror Mixing lubricants Monitor display window N Instrument Before starting check Neutral start check Index PN=3

296 Index Page Page O Releasing the brakes Repair record O-ring boss fittings Reverse Speed Oil Switch Change engine Reverse warning alarm Change final drive ROPS and cab tilting procedure Change hydraulic oil and filter Change transmission Check carrier roller Check idler and track roller S Filter engine Level final drive Level track frame pivot Seat adjustment Lines and fittings Seat belt Specification carrier roller Indicator Specification final drive Secondary exits Specification front idler Select button Specification track frame pivot Location Specification track roller Operation Specification transmission Serial number Oil level Service Hydraulic Interval Transmission reservoir Record , CLIS-1 Oil lines and fittings Valves, cylinders, pumps, motors Oilscan Plus Service codes Operating tips Indicator Blade Transmission controller service codes Operator manual, holder Service codes, 850C series II Engine controller service codes Service hour meter Service required indicator P Specification Carrier roller oil Park lock levers , 30-3 Final drive oil Park lock, park brake, and start checks Front idler oil Parking machine Track frame pivot oil Pedal Track roller oil Brake , 30-6 Transmission oil Decelerator C Series II machine Periodic maintenance chart C Series II machine Pre-start inspection Specifications Product identification number (PIN) Hardware torque Pushbeam serial number Speed Engine , Speed-In-Grip R FNR lever Starting Radiator Engine Coolant conditioner Instrument check, after Coolant level , 75-5 Instrument check, before Recovery tank coolant level STOP-engine Regulator precaution Indicator Index PN=4

297 Index Page Page Stopping Oil specification Engine Oil temperature hot indicator Machine Serial number Storage Speed switch Monthly Reverse Storing fuel Troubleshooting Storing lubricants Troubleshooting Switch Air conditioning Transmission reverse speed Brake system Transmission speed Electrical system Switch, battery disconnect Engine Synthetic lubricants Transmission Twelve volt accessory T U Temperature controls Undercarriage Torque specifications Extend life Hardware Unloader valve Torque value Air cleaner Flat face O-ring seal fitting Unloading from trailer Inch SAE four bolt flange fitting Metric cap screw Metric four bolt flange fitting O-Ring boss fitting V Torque values Inch Valve Metric Air cleaner dust unloader Towing Valve, heater, draining Track Frame pivot oil level Frame pivot oil specification W Oil leakage check Roller oil specification Welding procedure Track roller Window Oil level Cab Track sag Secondary exits Adjust Wiper controls Check Way test kit General information C engine speed Track shoe torque Engine speed Master link C series II engine speed Trailer Engine speed Unloading Trailer loading Transmission Indicators Oil and filter change Oil filter restriction indicator Oil level Oil pressure gauge Index PN=5

298 Index Index PN=6

299 John Deere Service Literature Available Technical Information Technical information is available from John Deere. Some of this information is available in electronic as well as printed form. Order from your John Deere dealer or call Please have available the model number, serial number, and name of the product. Available information includes: PARTS CATALOGS list service parts available for your machine with exploded view illustrations to help you identify the correct parts. It is also useful in assembling and disassembling. OPERATOR S MANUALS providing safety, operating, maintenance, and service information. These manuals and safety signs on your machine may also be available in other languages. OPERATOR S VIDEO TAPES showing highlights of safety, operating, maintenance, and service information. These tapes may be available in multiple languages and formats. TECHNICAL MANUALS outlining service information for your machine. Included are specifications, illustrated assembly and disassembly procedures, hydraulic oil flow diagrams, and wiring diagrams. Some products have separate manuals for repair and diagnostic information. Some components, such as engines, are available in separate component technical manuals FUNDAMENTAL MANUALS detailing basic information regardless of manufacturer: Agricultural Primer series covers technology in farming and ranching, featuring subjects like computers, the Internet, and precision farming. Farm Business Management series examines real-world problems and offers practical solutions in the areas of marketing, financing, equipment selection, and compliance. Fundamentals of Services manuals show you how to repair and maintain off-road equipment. Fundamentals of Machine Operation manuals explain machine capacities and adjustments, how to improve machine performance, and how to eliminate unnecessary field operations. TS189 UN 17JAN89 TS191 UN 02DEC88 TS224 UN 17JAN89 TS1663 UN 10OCT97 DX,SERVLIT 19 11NOV97 1/ PN=293