John Deere 250D & 300D Articulated Dump Trucks Operator's Manual - PDF DOWNLOAD

250D and 300D Articulated Dump Trucks

*OMT201340*

(Serial No. 200537 - 609165)

OPERATOR'S MANUAL 250D and 300D Articulated Dump Trucks OMT201340 ISSUE G2

(ENGLISH)

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

The State of California requires the above two warnings.

Additional Proposition 65 Warnings can be found in this manual.

Worldwide Construction And Forestry Division LITHO IN U.S.A.

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 authorized dealer to order.)

THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it.

MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.

RIGHT-HAND AND LEFT-HAND sides are determined by facing in the direction of forward travel.

WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers 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.

THE TIRE MANUFACTURER'S warranty supplied with your machine may not apply outside the U.S.

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Introduction

EMISSIONS CONTROL WARRANTY STATEMENT FOR NEW JOHN DEERE CONSTRUCTION EQUIPMENT (U.S. AND CANADA) To determine if the engine in your machine qualifies for the additional warranties set forth below, look for the "Engine Information" label located on your engine. If you reside in the United States and the engine label states: "Engine conforms to US EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control Warranty Statement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy duty non road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement."

U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT

Warranties stated on this certificate refer only to emissions-related parts and components of your engine. The complete machine warranty, less emisions-related parts and components, is provided separately as "John Deere "Secure Warranty" For New Construction Products."

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and John Deere are pleased to explain the emission control system on your new engine. In California, new heavy-duty engines must be designed, built and equipped to meet the State's stringent anti-smog standards. John Deere must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, or improper maintenance of your machine.

Your emissions control system includes: Fuel Metering System Fuel Injection System Air Induction System Intake Manifold Turbocharger System Charge Air Cooling System Miscellaneous Items used in Above Systems Where a warrantable condition exists, i.e. failure due to defect in John Deere-supplied material and/or workmanship, John Deere will repair your heavy-duty engine at no cost to you including diagnosis, parts and labor JOHN DEERE'S WARRANTY COVERAGE: The emission control system of your heavy-duty engine is warranted for five years or 3000 hours of operation, whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or replaced by John Deere.

Warranties stated on this certificate refer only to emissions-related parts and components of your engine. The complete machine warranty, less emissions-related parts and components, is provided separately as the "John Deere "Secure Warranty" For New Construction Products."

OWNER'S WARRANTY RESPONSIBILITIES: As the heavy-duty engine owner, you are responsible for the performance of the required maintenance as outlined in the

Operator's Manual. John Deere recommends that you retain all receipts covering maintenance on your heavy-duty engine, but John Deere cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

However, as the heavy-duty engine owner, you should be aware that John Deere may deny you warranty coverage if your heavyduty engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California's emissions requirements.

You are responsible for initiating the warranty process. The CARB suggests that you present your machine to the nearest authorized John Deere dealer as soon as a problem is suspected. The warranty repairs should be completed by the service dealer as expeditiously as possible.

If you have any questions regarding your warranty rights and responsibilities, you should contact John Deere at 1-319-2925400, or the State of California Air Resources Board, Mobile Source Operation Division, PO Box 8001, El Monte, CA 91731-2900 The warranty period begins on the date the machine is delivered to an ultimate purchaser, or when otherwise put into service.

John Deere warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board, and that it is free from defects in materials and workmanship which would cause the failure of a warranted part.

Any warranted part which is scheduled for replacement as required maintenance by the operator's manual is warranted by John Deere for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement point, the part shall be repaired or replaced under warranty. Any such part repaired or replaced under warranty is warranted for the remainder of the period prior to the first scheduled replacement point for that part.

Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of repairing or replacing as necessary, is warranted for the warranty period.

Repair or replacement of a warranted part will be performed at no charge to you by an authorized John Deere dealer. You will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed by a John Deere dealer.

John Deere is liable for damages to other engine components caused by failure under warranty of any warranted part.

John Deere is NOT liable for travel or mileage on extended emissions warranty service calls.

Any replacement part may be used in the performance of any maintenance or repairs, and such use will not reduce the warranty obligations of John Deere. However, the use of add-on or modified parts are grounds for disallowing a warranty claim.

T132126 —19—28JUN00

Emissions control-related parts and components are warranted

by John Deere for five years or 3000 hours of operation, whichever occurs first. John Deere further warrants that the engine covered by this warranty was designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards at the time of manufacture, and that it is free of defects in materials and workmanship which would cause it not to meet these standards within the period of five years or 3000 hours of operations, whichever occurs first.

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Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.

SEND TO:

John Deere Dubuque Works 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA

FAX NUMBER: 1-563-589-5800 (USA) Publication Number: Page Number: Ideas, Comments:

Name: Phone: Email Address: THANK YOU! TX,TM,FAX -19-03JUL01-1/1

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Operator Control Functions ...............................2-1-3 Instrument Panel ...............................................2-1-4 Instrument Panel Functions...............................2-1-5 Heater and Air Conditioner Controls..................2-1-6 Steering Column Lever......................................2-1-7 Circuit Breaker Compartment ............................2-1-8 Operator Seat and Instructional Seat ................2-1-9 Air Suspension Seat—If Equipped ..................2-1-10 Seat Belt ..........................................................2-1-10 Battery Disconnect Switch and Battery Circuit Breakers...........................................2-1-11 Miscellaneous Equipment................................2-1-12 Monitor Display Unit—Default Display Menu...2-1-14 Monitor Display Unit—Menu Function .............2-1-16

Safety—Safety Features Safety Features .................................................1-1-1

Safety—General Precautions Recognize Safety Information ...........................1-2-1 Follow Safety Instructions..................................1-2-1 Operate Only If Qualified ...................................1-2-1 Wear Protective Equipment...............................1-2-1 Avoid Unauthorized Machine Modifications.......1-2-2 Inspect Machine ................................................1-2-2 Stay Clear of Moving Parts................................1-2-2 Avoid High-Pressure Oils ..................................1-2-3 Beware of Exhaust Fumes ................................1-2-3 Prevent Fires .....................................................1-2-4 Prevent Battery Explosions ...............................1-2-4 Handle Chemical Products Safely .....................1-2-4 Dispose of Waste Properly ................................1-2-5 Prepare for Emergencies...................................1-2-5

Operation—Operating the Machine Before Starting Work .........................................2-2-1 Operator's Daily Machine Check Before Starting ..............................................2-2-1 Starting Engine ..................................................2-2-2 Replace Start Aid Can .......................................2-2-3 Driving Machine.................................................2-2-3 Steering Machine...............................................2-2-4 Shifting Transmission ........................................2-2-5 Using Range Hold .............................................2-2-6 Using Inter-Axle Lock ........................................2-2-6 Slowing and Stopping the Machine ...................2-2-7 Operating on a Hill.............................................2-2-8 Off-Road Operation ...........................................2-2-8 Loading and Unloading Dump Body..................2-2-9 Freeing Stuck Machine....................................2-2-10 Parking the Machine........................................2-2-10 Towing the Machine.........................................2-2-11 Releasing Park Brake for Towing ....................2-2-12 Mechanically Releasing Park Brake ................2-2-12 Machine Lifting Points .....................................2-2-13 Loading and Unloading Machine from Trailer ..2-2-14 Lock All Compartments ...................................2-2-15

Safety—Operating Precautions Use Steps and Handholds Correctly .................1-3-1 Start Only From Operator's Seat .......................1-3-1 Use and Maintain Seat Belt ...............................1-3-1 Prevent Unintended Machine Movement ..........1-3-1 Avoid Work Site Hazards...................................1-3-2 Keep Riders Off Machine ..................................1-3-2 Avoid Backover Accidents .................................1-3-2 Avoid Machine Tip Over ....................................1-3-3 Operating on Slopes..........................................1-3-3 Operating Or Traveling On Public Roads ..........1-3-3 Inspect and Maintain ROPS ..............................1-3-4 Add and Operate Attachments Safely ...............1-3-4

Safety—Maintenance Precautions Park And Prepare For Service Safely................1-4-1 Service Tires Safely...........................................1-4-1 Service Cooling System Safely .........................1-4-2 Remove Paint Before Welding or Heating.........1-4-2 Make Welding Repairs Safely ...........................1-4-2 Drive Metal Pins Safely .....................................1-4-3

Maintenance—Machine Diesel Fuel.........................................................3-1-1 Low Sulfur Diesel Fuel Conditioner ...................3-1-1 Testing Diesel Fuel ............................................3-1-1 Handling and Storing Diesel Fuel ......................3-1-2 Diesel Engine Oil ...............................................3-1-2 Diesel Engine Oil and Filter Service Intervals ...3-1-3 Hydraulic Oil ......................................................3-1-4

Safety—Safety Signs Safety Signs ......................................................1-5-1

Operation—Operator’s Station Operator Controls ..............................................2-1-1

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Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication.

The right is reserved to make changes at any time without notice.

COPYRIGHT © 2012 DEERE & COMPANY Moline, Illinois All rights reserved.

A John Deere ILLUSTRUCTION ® Manual Previous Editions Copyright © 2004, 2005, 2006, 2007, 2008, 2009

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Transmission and Transfer Case Oil .................3-1-4 Axle Gear Oil .....................................................3-1-5 Diesel Engine Coolant .......................................3-1-5 Grease...............................................................3-1-6 Oil Filters ...........................................................3-1-6 Lubricant Storage ..............................................3-1-6 Alternative And Synthetic Lubricants.................3-1-7

Lubricate Oscillation Tube, Articulation Joints, Steering Cylinder Rod Ends, and Oscillation Tube Through Drive Shaft Bearings...............................................3-6-5 Check Transmission Oil Level ...........................3-6-6 Clean and Inspect Hydraulic Reservoir Breather ........................................................3-6-7 Replace In-line Fuel Filter (S.N. 201015—).......3-6-7 Replace Fuel Filters (S.N.—201014).................3-6-8 Replace Final Fuel Filter (S.N. 201015—).........3-6-8 Check Coolant Conditioner in Radiator .............3-6-9

Maintenance—Periodic Maintenance Service Your Machine at Specified Intervals .....3-2-1 Use Correct Fuels and Lubricants .....................3-2-1 Prepare Machine for Maintenance ....................3-2-1 Install Dump Body Prop.....................................3-2-2 Install Articulation Safety Lock Bar ....................3-2-2 Lower and Raise Bottom Guard ........................3-2-2 Relieve Pneumatic Pressure .............................3-2-3 Tilt Cab ..............................................................3-2-4 Maintenance and Repair Record Keeping System ............................................3-2-5 Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit..................................3-2-5 Maintenance and Repair Record Keeping System ............................................3-2-6

Maintenance—Every 1000 Hours Check Axle Oil Levels........................................3-7-1 Check Final Drive Oil Levels .............................3-7-1 Replace Hydraulic Reservoir Breather ..............3-7-2 Check and Adjust Bin Shock Pad......................3-7-3 Grease Prop Shaft Slip Joint .............................3-7-3

Maintenance—Every 2000 Hours Adjust Engine Valve Clearance .........................3-8-1 Change Transmission Oil ..................................3-8-1 Replace Transmission Oil Filter.........................3-8-2 Change Transfer Case Oil.................................3-8-3 Change Axle Oil.................................................3-8-3 Change Final Drive Oil ......................................3-8-4 Replace Pneumatic System Dryer-Filter ...........3-8-4

Maintenance—As Required Service Engine Air Intake System .....................3-3-1 Inspect and Clean Cooling Systems..................3-3-2 Clean, Inspect, and Replace—Transmission, Transfer Case, and Axle Breathers.......................................................3-3-3 Inspect Tires, Check Pressure ..........................3-3-4 Drain Fuel Filters (S.N.—201014) .....................3-3-6 Drain Fuel Filters (S.N. 201015—) ....................3-3-6 Inspect Serpentine Belt .....................................3-3-6

Maintenance—Every 4000 Hours Change Hydraulic Oil.........................................3-9-1 Replace Hydraulic Suction Screen ....................3-9-2 Replace Pneumatic Block Silencer Filter...........3-9-2

Maintenance—Every 4500 Hours Replace Engine Crankshaft Dampener ...........3-10-1

Maintenance—Every 10 Hours or Daily Check Engine Coolant Level .............................3-4-1 Check Engine Oil Level .....................................3-4-1 Check Transfer Case Oil Level..........................3-4-2 Check Hydraulic Oil Level .................................3-4-2 Grease Dump Body Pivot Pins ..........................3-4-3 Lubricate Tailgate Pivots—If Equipped..............3-4-3

Maintenance—Every 5000 Hours Drain, Flush and Refill Engine Cooling System ........................................................3-11-1

Miscellaneous—Machine Do Not Service Control Valves, Cylinders, Pumps or Motors..........................4-1-1 Do Not Service Injection Nozzles ......................4-1-1 Bleeding Fuel System........................................4-1-1 Check Engine Air Intake System .......................4-1-2 Check Brake Accumulators ...............................4-1-3 Check Wheel Nuts.............................................4-1-3 Lubricate Hinges................................................4-1-3 Using Booster Batteries—24-Volt System .........4-1-3 Using Battery Charger .......................................4-1-4 Handling, Checking And Servicing Batteries Carefully.........................................4-1-5 Replace Batteries ..............................................4-1-6 Replace Front Turn Signal Bulb, Headlight Bulb, and Front Park Light Bulb ....4-1-7 Adjust Headlights...............................................4-1-9

Maintenance—Initial Service - 100 Hours Change Engine Oil and Replace Filter ..............3-5-1 Replace Hydraulic System Oil Return Filter ......3-5-2 Replace Primary Fuel Filter (S.N. 201015—) ....3-5-3 Change Transfer Case Oil.................................3-5-3 Change Axle Oil.................................................3-5-4 Change Final Drive Oil ......................................3-5-4

Maintenance—Every 500 Hours Check Park Brake Pad Wear.............................3-6-1 Check Dry Caliper Service Brake Pad Wear .....3-6-1 Check Front Axle Suspension Struts.................3-6-2 Inspect, Clean, and Replace Cab Air Filter .......3-6-3 Check Batteries, Clean and Tighten Terminals ..3-6-4

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Replace Backup Light and Work Light—If Equipped.......................................4-1-10 Replace Tail and Brake Light and Rear Turn Signal ..................................................4-1-10 Replace Dome Light Bulb and Circuit Breaker Compartment Light Bulb................4-1-11 Clean The Machine Regularly .........................4-1-11 Unified Inch Bolt and Screw Torque Values.....4-1-12 Metric Bolt and Screw Torque Values..............4-1-13 Imperial and SAE (Inch) Cap Screw and Nut Torque Values................................4-1-14 Metric Cap Screw and Nut Torque Values.......4-1-15 Welding on Machine ........................................4-1-16

Miscellaneous—Operational Checkout Operational Checkout........................................4-2-1

Miscellaneous—Troubleshooting Using Troubleshooting Charts ...........................4-3-1 Engine ...............................................................4-3-2 Transmission .....................................................4-3-4 Axle....................................................................4-3-5 Tires...................................................................4-3-6 Brakes ...............................................................4-3-6 Hydraulic System...............................................4-3-7 Instruments and Controls ..................................4-3-7 Electrical System ...............................................4-3-8 Rear Frame and Cab.........................................4-3-9 MDU Displayed Service Codes .......................4-3-10

Miscellaneous—Storage Prepare Machine for Storage ............................4-4-1

Miscellaneous—Serial Numbers Record Product Identification Number (PIN) .....4-5-1 Record Engine Serial Number...........................4-5-1 Record Transmission Serial Number.................4-5-1 Front Axle Serial Number ..................................4-5-2 Middle Axle Serial Number ................................4-5-2 Rear Axle Serial Number...................................4-5-2

Miscellaneous—Specifications 250D Articulated Dump Truck Specifications ....4-6-1 300D Articulated Dump Truck Specifications ....4-6-5 250D and 300D Engine Specifications ..............4-6-8 250D and 300D Travel Speeds .........................4-6-9 250D and 300D Drain and Refill Capacities ......4-6-9

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Safety—Safety Features Safety Features 1

16 15

14

4

12

2 8

13

5

T147632 —UN—19NOV01

11

3

10 6

7

9

T147632

Please remember, the operator is the key to preventing accidents.

1. ROPS/FOPS Cab Protection. Structures designed to help protect the operator are certified to ISO, SAE, and OSHA. Enclosures also deflect sun and rain.

2. Cab with Heater/Defroster. Cab ventilation system circulates both outside and inside air through filters for a clean working environment. Built in defroster vents direct air flow for effective window defogging/deicing.

3. Dump Body Service Lock. A mechanical lock is provided for working on or around this machine with the dump body raised.

4. Stop/Backup Lights. Highly visible lights are standard equipment.

5. Backup Alarm. Alerts bystanders when reverse travel direction is selected by operator.

6. Independent Parking Brake. Is air released/spring applied and engages whenever the key switch is turned off.

7. Articulation Locking Bar. A self-storing mechanical lock is provided for transport or service.

8. Secondary Steering. Ground driven, continuously in operation. Secondary steering indicator light will light.

9. Horn. Standard horn is useful when driving or signalling co-workers.

10. Halogen Lights and Turn Signals. High intensity halogen drive/work lights and high-visibility turn signals are standard equipment.

11. Engine Fan Guard. A secondary fan guard inside the engine compartment helps prevent contact with rotating fan blades.

12. Bypass Start Protection. Shielding over the starter terminals helps prevent dangerous bypass starting.

13. Transmission Retarder. Engages whenever the truck is in motion and the operator lets up on the accelerator.

14. Seatbelt Retractors. Help keep belts clean and convenient to use.

15. Mirrors. Large exterior mirrors on both sides offer the operator a view of activity behind him.

16. Large Windshield Wiper With Washer. Extra long wiper cleans large windshield area.

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Safety—General Precautions Recognize Safety Information T133555 —UN—28AUG00

This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for the potential of personal injury.

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

T133588 —19—28AUG00

On the machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

TX03679,00016CC -19-03JAN07-1/1

Follow Safety Instructions Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully.

Review them frequently.

Keep safety signs in good condition.

Be sure all operators of this machine understand every safety message. Replace operator's manual and safety signs immediately if missing or damaged. Replacement safety signs are available from your authorized dealer.

Be sure new equipment components and repair parts include the current safety signs.

TX14740,0000019 -19-10JAN07-1/1

Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruction.

Operator should be familiar with the job site and surroundings before operating. Try all controls and

machine functions with the machine in an open area before starting to work.

Know and observe all safety rules that may apply to every work situation and work site.

TX03679,00016FA -19-03JAN07-1/1

Wear Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

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

Wear close fitting clothing and safety equipment appropriate to the job.

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Safety—General Precautions

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance.

Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance.

Non-John Deere Parts, or any damage or failures resulting from their use are not covered by any John Deere warranty.

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator

or others near the machine. The installer of any modification which may affect this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. This applies to all aspects of the machine, including electronic controls.

Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

AM40430,0000084 -19-01OCT07-1/1

Inspect Machine

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

Inspect machine carefully each day by walking around it before starting.

TX03679,0001734 -19-03JAN07-1/1

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.

T133592 —UN—12SEP01

Stay Clear of Moving Parts

TX03679,00016D2 -19-03JAN07-1/1

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Safety—General Precautions

Avoid High-Pressure Oils

Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping oil.

Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

T133840 —UN—20SEP00

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

T133509 —UN—17MAR06

This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin causing serious injury.

TX03679,00016D3 -19-03NOV08-1/1

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

T133546 —UN—24AUG00

Beware of Exhaust Fumes

TX03679,00016D4 -19-03NOV08-1/1

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Safety—General Precautions

T133552 —UN—14SEP00

Prevent Fires Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

T133553 —UN—07SEP00

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.

Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine.

Know how to use extinguisher properly.

T133554 —UN—07SEP00

TX03679,00016F5 -19-03NOV08-1/1

Prevent Battery Explosions Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.

TS204 —UN—23AUG88

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).

TX03679,000174A -19-03NOV08-1/1

Handle Chemical Products Safely

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow

T133580 —UN—25AUG00

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous.

MSDS recommendations to handle chemical products safely.

TX03679,00016D7 -19-03JAN07-1/1

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Safety—General Precautions

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.

T133567 —UN—25AUG00

Dispose of Waste Properly

If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your dealer for more information.

TX03679,0001733 -19-03NOV08-1/1

Prepare for Emergencies Be prepared if an emergency occurs or a fire starts.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

TS291 —UN—23AUG88

Keep a first aid kit and fire extinguisher handy.

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Safety—Operating Precautions Use Steps and Handholds Correctly T133468 —UN—30AUG00

Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails.

Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

TX03679,00016F2 -19-15MAR07-1/1

T133715 —UN—07SEP00

Start Only From Operator's Seat Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure all controls and working tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

TX03679,0001799 -19-22APR10-1/1

Use and Maintain Seat Belt T133716 —19—14SEP00

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses.

Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.

The complete seat belt assembly should be replaced every 3 years, regardless of appearance.

TX03679,00016DD -19-03NOV08-1/1

Be careful not to accidentally actuate controls when co-workers are present.

Ensure dump body is lowered during work interruptions.

Place transmission control in neutral, engage park brake and stop engine before allowing anyone to approach the machine.

Follow these same precautions before standing up, leaving the operator's seat, or exiting the machine.

P

T143805 —UN—20JUL01

Prevent Unintended Machine Movement

TX14740,0001D31 -19-22JUN01-1/1

1-3-1

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PN=15

Safety—Operating Precautions

Avoid Work Site Hazards Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before starting work.

T143350 —UN—06JUL01

Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over.

Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

T143748 —UN—20JUL01

Keep bystanders clear at all times. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations.

Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine.

Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds

hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seatbelt.

VD76477,0001583 -19-06JUL07-1/1

Keep Riders Off Machine Only allow operator on machine except when necessary for instruction or short periods of observation.

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. They also may obstruct operator’s view or impair his ability to operate machine safely.

T143354 —UN—06JUL01

Use seat belt at all times.

Use the instructional seat only to accommodate trainers or persons needing to observe machine operation for short periods.

TX14740,0001D33 -19-23SEP10-1/1

Before moving machine, be sure all persons are clear of machine path. Where conditions permit, raise dump body for better visibility to the rear. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair.

Be certain backup 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.

T143356 —UN—06JUL01

Avoid Backover Accidents

TX14740,0001D34 -19-22JUN01-1/1

1-3-2

080112

PN=16

Safety—Operating Precautions

Use extra care when dump body is raised. Machine stability is greatly reduced when dump body is raised.

Drive slowly. Avoid sharp turns and uneven ground.

Be careful on slopes and soft, rocky, or frozen ground.

Traction and stability are reduced by slopes and adverse terrain. Avoid piles of dirt and banks or excavations that may cave in and cause the machine to tip or fall.

Do not overload the machine. Oversize loads reduce machine stability, increase tire flex, and erode travel surfaces. Braking capability and brake life are also reduced.

If machine tips, carefully inspect brake and hydraulic lines, electrical wiring, and machine structure before operating.

T144185 —UN—23JUL01

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.

T133716 —19—14SEP00

Avoid Machine Tip Over

TX14740,0001D3E -19-20JUL01-1/1

Operating on Slopes Check service brake condition frequently when operating on slopes.

Select low gear speed before starting down slope. The maximum slope you can operate on will be limited by ground conditions and the load being handled.

Use transmission retarder and service brakes, to control speed. Sudden brake application with a loaded dump body could cause loss of machine control.

T143361 —UN—27JUN01

Avoid sideslope travel whenever possible.

TX14740,0000003 -19-24JAN03-1/1

Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers.

Mirrors are especially important for the operator when on roadways.

Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine.

Check state and local regulations to assure compliance.

Keep these devices clean and in working condition.

T141891 —UN—22MAY01

Operating Or Traveling On Public Roads

TX03679,00017C8 -19-30APR01-1/1

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080112

PN=17

Safety—Operating Precautions

Inspect and Maintain ROPS A damaged roll-over protective structure (ROPS) should be replaced, not reused.

The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.

If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.

To maintain the ROPS:

• Replace missing hardware using correct grade hardware.

• Check hardware torque.

• Check isolation mounts for damage, looseness or wear; replace them if necessary.

• Check ROPS for cracks or physical damage.

TX03679,000179F -19-07SEP06-1/1

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.

TX03679,00016F0 -19-24JAN07-1/1

1-3-4

080112

PN=18

Safety—Maintenance Precautions Park And Prepare For Service Safely

• Park machine on a level surface.

• Lower dump body unless raised position is required for service.

• Engage park brake.

• Stop engine and remove key.

• Attach a “Do Not Operate” tag in an obvious place in the operator's station.

• Install the articulation safety locking bar.

• Install service locks if dump body or cab are raised for

T133332 —19—14DEC01

Warn others of service work. Always park and prepare your machine for service or repair properly.

service.

Securely support machine before working under it.

Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people whenever the engine must be running for service work.

TS229 —UN—23AUG88

Install wheel chocks to ensure machine cannot move backward or forward during service.

TX14740,0001D36 -19-22JUN01-1/1

Service Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion.

Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

TS211 —UN—23AUG88

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

DX,RIM -19-24AUG90-1/1

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080112

PN=19

Safety—Maintenance Precautions

Service Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns.

TS281 —UN—23AUG88

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.

DX,RCAP -19-04JUN90-1/1

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

TS220 —UN—23AUG88

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area • •

to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

DX,PAINT -19-24JUL02-1/1

Make Welding Repairs Safely

Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.

Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.

T133547 —UN—31AUG00

IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable.

Separate harness connectors to engine and vehicle microprocessors.

Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

TX03679,00016D5 -19-25APR08-1/1

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080112

PN=20

Safety—Maintenance Precautions

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.

T133738 —UN—14SEP00

Drive Metal Pins Safely

TX03679,0001745 -19-03JAN07-1/1

1-4-3

080112

PN=21

Safety—Safety Signs Safety Signs

CAUTION This instructional seat has been provided only for training operators or to diagnose machine problems. Keep all other riders off this machine. Always wear your seat belt.

Torque all wheel nuts to 650 N.m [480 LB.FT.] after the first 5 hours and then again after 50 hours. Repeat this procedure if wheels are changed.

CAUTION AVOID DEATH OR SERIOUS INJURY *READ AND UNDERSTAND OPERATOR'S MANUAL BEFORE OPERATING THIS MACHINE. *OPERATE ONLY FROM THE OPERATOR'S SEAT. *BEFORE LEAVING SEAT: LOWER BODY TO FRAME REST. PLACE TRANSMISSION IN NEUTRAL. APPLY PARK BRAKE. STOP ENGINE (TURN KEY SWITCH TO OFF). *DO NOT PERMIT RIDERS. *AVOID CONTACT WITH OVERHEAD OBSTACLES WHEN OPERATING OR HAULING THE TRUCK. *USE EXTRA CARE TO AVOID TIP-OVER WHEN DUMPER BODY IS RAISED.

WARNING

AVOID SERIOUS INJURY Block wheels to prevent machine movement before deactivating park brake for towing.

WARNING SPRING UNDER PRESSURE Read the manual before carrying out maintenance in this area

WARNING COMPRESSED AIR RESERVOIR Avoid injury, drain completely before carrying out maintenance.

Typical working pressure: 800 kPa (116 PSI).

WARNING

WARNING

WARNING

HIGH PRESSURE HYDRAULICS See manual for correct maintenance procedure.

Typical working pressure: 8000 kPa (1160 PSI).

AVOID INJURY Ensure propshaft guards are in place at all times

T148212

Continued on next page

1-5-1

T148212 —19—21NOV01

Ensure that the cab support is properly engaged before carrying out any maintenance in this area.

OUO1043,0000DF4 -19-30OCT01-1/2

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PN=22

T164920 —19—03FEB03

Safety—Safety Signs

OUO1043,0000DF4 -19-30OCT01-2/2

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Operation—Operator’s Station

T147633B —UN—08NOV01

Operator Controls

1— Dome Light Switch 2— Headlight Switch 3— Warning Lights Switch 4— Rear View Mirrors Defrost Switch—If Equipped 5— Air Vent (6 used) 6— Instrument Panel

12— Park Brake Lever 13— Dump Body Control Lever 14— Gearshift Control 15— Ash Tray (2 used) 16— Steering Wheel 17— Cigarette Lighter 18— Telescopic Steering Adjust Lever

7— Inter-Axle Lock Switch 8— Range Hold Switch 9— Start Aid Switch 10— Rear View Mirrors Adjustment Controls—If Equipped 11— Transmission Torque Retarder Control Lever

Continued on next page

2-1-1

19— Key Switch 20— Steering Column Lever 21— Tilt Steering Adjust Lever 22— Service Brake Pedal 23— Accelerator Pedal

OUO1043,0000DF5 -19-30OCT01-1/2

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PN=24

T142703C —UN—15NOV01

Operation—Operator’s Station

24— Operator's Manual Compartment 25— Dome Light

26— Radio—If Equipped 27— Circuit Breaker Compartment Latch

28— Circuit Breaker Compartment 29— Visor 30— Heater and Air Conditioner Control Panel OUO1043,0000DF5 -19-30OCT01-2/2

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PN=25

Operation—Operator’s Station

Operator Control Functions 1. Dome Light Switch: Push lower half of switch to turn dome light ON. Push upper half of switch to turn dome light OFF. 2. Headlight Switch:

CAUTION: Prevent possible injury from unexpected machine movement. DO NOT leave machine unattended with engine running.

NOTE: The parking lights, tail lights, and instrument panel lighting will light when headlight switch is in center position with key switch ON or OFF. The headlights will light only when switch is in down position with key switch ON.

3.

4.

5.

6.

7.

require, to adjust the percentage of torque retarder applied when accelerator pedal is released.

12. Park Brake Lever:

The headlight switch is a 3-position switch used to control headlights, tail lights and park lights.

- Upper half of switch pushed—lights OFF - Lower half of switch pushed to first detent—park lights, tail lights, and instrument panel lighting ON - Lower half of switch pushed to furthest position—headlights ON Warning Lights Switch: Push lower half of switch to turn warning lights ON. Push upper half of switch to turn warning lights OFF. Rear View Mirrors Defrost Switch (If Equipped): Push lower half of switch to turn mirror defrosters ON. Push upper half of switch to turn mirror defrosters OFF. Air Vent (6 Used): Adjust air vents to control air flow in the cab.

Instrument Panel: Contains instruments and indicators.

Inter-Axle Lock Switch: IMPORTANT: The inter-axle lock must only be used when ground conditions are very poor.

DO NOT use on graded or tarred surfaces.

Reduce engine speed (accelerator pedal less than 10% depressed) and push lower half of switch to engage inter-axle lock. Push upper half of switch to disengage inter-axle lock.

8. Range Hold Switch: Push lower half of switch to turn range hold ON. Push upper half of switch to turn range hold OFF. 9. Start Aid Switch: IMPORTANT: Never operate starter motor for more than 17 seconds at a time. If engine fails to start after 2 or 3 tries, return key switch to OFF. Wait for about 1 minute, then try again.

IMPORTANT: Prevent damage to engine. Use start aid when temperatures are below 0°C (32°F) and only when engine is COLD. If temperature is below 0°C (32°F) and engine is COLD, press start aid switch while starting engine.

10. Rear View Mirrors Adjustment Controls (If Equipped): Select left or right side mirror. Adjust mirror, up, down, left or right, to operator's preference.

11. Transmission Torque Retarder Control Lever: Move lever forward or rearward, as driving conditions

If the operator must leave machine with engine running, the operator MUST shift the transmission to neutral (N), engage the park brake, chock wheels and take all other steps necessary to prevent machine from moving.

IMPORTANT: After releasing park brake, wait until park brake indicator on instrument panel goes out before driving.

Lift and push lever forward to release park brake. Pull lever rearward until it locks into place to engage park brake.

13. Dump Body Control Lever: NOTE: The dump body control lever is spring-loaded and will return to center position when released.

Pull lever rearward to raise dump body. Push lever forward to lower dump body. Push lever forward to detent for dump body float.

14. Transmission Control Panel: Selects travel direction and maximum gear.

15. Ash Tray: Ash trays are provided for operator convenience.

16. Steering Wheel: Turn steering wheel to control machine steering.

17. Cigarette Lighter: Cigarette lighter is provided for operator convenience.

18. Telescopic Steering Adjust Lever: Loosens telescopic steering clamp to allow steering column to be pulled out or pushed in to operator preference.

19. Key Switch: Insert key and turn to start engine.

20. Steering Column Lever: Steering column lever controls horn, windshield wiper/washers, turn indicators and headlight beam intensity.

21. Tilt Steering Adjust Lever: Loosens tilt steering clamp to allow steering column to be tilted up or down to operator preference.

22. Service Brake Pedal: Push pedal to engage service brakes.

23. Accelerator Pedal: Push pedal to increase speed.

Release pedal to slow machine. Retarder will engage, as necessary, when pedal is released.

24. Operator's Manual Compartment: Store operator's manual in the operator's manual compartment.

25. Dome Light: Provides operator with light in the cab.

26. Radio (If Equipped): Provided for operator convenience.

27. Circuit Breaker Compartment Latch: Push latch button to open circuit breaker compartment.

Continued on next page

2-1-3

TX14740,0000008 -19-06FEB03-1/2

080112

PN=26

Operation—Operator’s Station 28. Circuit Breaker Compartment: Open circuit breaker compartment door to access machine circuit breakers.

29. Visor: Lower and adjust visor as necessary.

30. Heater and Air Conditioner Control Panel: Use heater and air conditioner control panel to control cab temperature.

TX14740,0000008 -19-06FEB03-2/2

Instrument Panel

1

9

10

11

12 14

EMERGENCY STEERING

ENGINE FAULT

COOLANT LEVEL

COLD START

8

4

3

2

PARK BRAKE

15

BRAKE PRESSURE

16

BRAKE TEMP

n/min

BATTERY CHARGE

5

RETARDER

6

13

TRANSMISSION FAULT

21

7

ENGINE OIL PRESSURE

30

COOLANT TEMP

20

31

29

40 20

27 TRANS OIL TEMP

DIFF LOCK

19

AUTO

20 MENU

23 BACK

24

40

70 0

n/min

50

NEXT

80

0

22

60

30 mph

10

INTER-AXLE DIFF LOCK

18

50

km/h

10 AIR PRESSURE

BIN UP

17 HYDRAULIC TEMP

25

30

28

T142483 —UN—03OCT01

FUEL

SELECT

26

volts MILES / Km

T142483

1— Cold Start Indicator 2— Coolant Level Indicator 3— Engine Service Indicator (Marked Engine Fault) 4— Secondary Steering Indicator (Marked Emergency Steering) 5— Battery Charge Indicator 6— Transmission Retarder Indicator 7— Transmission Service Indicator (Marked Transmission Fault)

8— Left Turn Indicator 9— Service Required Indicator 10— High Beam Indicator 11— Engine Overspeed Indicator 12— Right Turn Indicator 13— Message Display 14— Park Brake Indicator 15— Brake Oil Pressure Indicator 16— Brake Temperature Indicator

17— Hydraulic Oil Temperature Indicator 18— Dump Body Raised Indicator (Marked Bin Up) 19— Inter-Axle Lock Indicator (Marked Inter-Axle Diff Lock) 20— Differential Lock Indicator (Marked Diff Lock)—Not Used 21— Data Display 22— Menu Button 23— Back Button

24— Next Button 25— Select Button 26— Fuel Gauge 27— Speedometer 28— Transmission Oil Temperature Gauge 29— Coolant Temperature Gauge 30— Air Pressure Gauge 31— Engine Oil Pressure Gauge

OUO1043,0000DD0 -19-27JUL01-1/1

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Operation—Operator’s Station

Instrument Panel Functions 1. Cold Start Indicator: Indicator lights when key switch is turned clockwise to ON position. Indicator will go out after 20 seconds, depending on engine temperature, indicating that preheating is completed.

2. Coolant Level Indicator: IMPORTANT: If low coolant level indicator lights, stop machine and shut down engine immediately to prevent engine damage.

NOTE: Low engine coolant level indicator will flash briefly during start-up when ignition key is turned to the ON position.

Indicator lights when engine coolant level is low.

3. Engine Service Indicator (Marked Engine Fault): Engine service indicator lights and stays lit when an engine service code has been detected.

4. Secondary Steering Indicator (Marked Emergency Steering): IMPORTANT: If there is an engine or main pump malfunction, the ground-driven secondary steering system will enable operator to steer machine to a controlled stop.

Indicator will light when secondary steering system is activated. Stop machine and take corrective action.

Secondary steering system is ground driven and not intended for continuous use.

5. Battery Charge Indicator: Indicator lights when alternator output is low.

6. Transmission Retarder Indicator: Indicator lights when transmission retarder is engaged.

7. Transmission Service Indicator (Marked Transmission Fault): Transmission service indicator lights and stays lit when a transmission clutch slippage service code has been detected.

8. Left Turn Indicator: Indicator lights when left turn indicator is switched ON. 9. Service Required Indicator: Indicator lights if service is required. It is not necessary to stop engine immediately, but cause should be investigated and corrected as soon as possible.

10. High Beam Indicator: Indicator lights when headlight high beams are ON. 11. Engine Overspeed Indicator:

14. Park Brake Indicator: Indicator lights when park brake is engaged and transmission control lever is in neutral.

15. Brake Oil Pressure Indicator: Indicator lights when brake oil pressure is low or brake accumulator has lost its charge. Stop machine immediately and engage park brake. Take corrective action.

16. Brake Temperature Indicator: Indicator lights when brake temperature is too high.

17. Hydraulic Oil Temperature Indicator: Indicator lights when hydraulic oil temperature exceeds 104°C (220°F). If hydraulic oil temperature is too high, stop work. Allow engine to operate at high idle for 3 minutes and allow oil to cool. If indicator stays on, stop machine and see your authorized dealer.

18. Dump Body Raised Indicator (Marked Bin Up): Indicator lights when body is raised off the frame.

19. Inter-Axle Lock Indicator (Marked Inter-Axle Diff Lock): Indicator lights when inter-axle lock is engaged.

20. Differential Lock Indicator (Marked Diff Lock): Not used.

21. Data Display: Displays machine information.

22. Menu Button: Used to navigate through Monitor Display Unit.

23. Back Button: Used to navigate through Monitor Display Unit.

24. Next Button: Used to navigate through Monitor Display Unit.

25. Select Button: Used to navigate through Monitor Display Unit.

26. Fuel Gauge: Gauge indicates fuel level in tank.

Always fill fuel tank at end of day to eliminate condensation in fuel tank.

27. Speedometer: Speedometer indicates travel speed in kilometers per hour (km/hr) or miles per hour (mph).

28. Transmission Oil Temperature Gauge: IMPORTANT: DO NOT exceed maximum transmission operating temperature of 145°C (293°F) to avoid damage to the transmission.

Gauge indicates temperature of transmission oil.

Normal operating temperature is indicated by green zone. If indicator points to red zone, allow transmission to cool.

29. Coolant Temperature Gauge: IMPORTANT: To prevent machine damage, DO NOT operate machine when engine coolant temperature is high.

IMPORTANT: If engine overspeed indicator lights, reduce engine speed immediately using the service brake.

DO NOT exceed 2800 rpm or serious engine or transmission damage may occur.

Indicator lights when engine speed exceeds 2800 rpm.

12. Right Turn Indicator: Indicator lights when right turn indicator is switched ON. 13. Message Display: Displays machine information for operator.

Gauge indicates temperature of engine coolant.

Normal operating temperature is indicated by the green zone. If indicator points to red zone, stop machine and allow engine to cool.

30. Air Pressure Gauge: CAUTION: To prevent personal injury or machine damage, DO NOT operate machine when air pressure is low.

Continued on next page

2-1-5

OUO1043,0000DAE -19-06FEB03-1/2

080112

PN=28

Operation—Operator’s Station Gauge indicates system air pressure. Normal operating pressure is indicated by the green zone. If indicator points to red zone, stop machine and take corrective action.

31. Engine Oil Pressure Gauge:

Gauge indicates engine oil pressure. Normal operating pressure is indicated by the green zone. If indicator points to red zone, stop machine and take corrective action.

IMPORTANT: To prevent machine damage, DO NOT operate machine when engine oil pressure is low.

OUO1043,0000DAE -19-06FEB03-2/2

Heater and Air Conditioner Controls

T143696B —UN—05JUL01

1. Air Conditioner Switch: Push lower half of switch to turn air conditioner or defrost ON. Push upper half of switch to turn air conditioner or defrost OFF. 2. Temperature Control Knob: Turn counterclockwise for cooler air. Turn clockwise for warmer air.

3. Blower Speed Control Knob: Turn blower speed control knob to adjust blower speed.

4. Air Flow Control Knob: Turn knob to defrost, low, high or divided flow.

5. Recirculating Air Switch: Push lower half of switch to recirculate air. Push the upper half of the switch for fresh air.

1— Air Conditioner Switch 2— Temperature Control Knob 3— Blower Speed Control Knob

4— Air Flow Control Knob 5— Recirculating Air Switch

OUO1043,0000DC9 -19-03JUL01-1/1

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PN=29

Operation—Operator’s Station

Steering Column Lever 1. High Beam Headlight: Push lever forward to high beam headlight position (1).

2. Low Beam Headlight: Move lever to center dim headlight position (2).

T143150B —UN—20JUN01

3. Flash-to-Pass Headlight: Pull lever rearward to flash-to-pass headlight position (3). Lever will return to dim headlight position when released.

4. Horn Button: Push to sound horn.

5. Windshield Washer Button: With key switch in ON or ACCESSORY position, push to activate windshield washer.

6. Intermittent Windshield Wiper: With key switch in ON or ACCESSORY position, turn steering column lever forward to intermittent wiper position (6).

Intermittent wiper time interval can be adjusted using the monitor display unit (MDU).

7. Windshield Wiper Off: Turn steering column lever forward or rearward, as necessary, to windshield wiper OFF position (7) to turn wiper OFF. 8. Low Speed Windshield Wiper: With key switch in ON or ACCESSORY position, turn steering column lever rearward to low speed windshield wiper position (8) to activate low speed windshield wiper.

9. High Speed Windshield Wiper: With key switch in ON or ACCESSORY position, turn steering column lever rearward to high speed windshield wiper position (9) to activate high speed windshield wiper.

1— High Beam HeadLight Position 2— Low Beam HeadLight Position 3— Flash-to-Pass Headlight Position 4— Horn Button 5— Windshield Washer Button 6— Intermittent Windshield Wiper Position

7— Windshield Wiper Off Position 8— Low Speed Windshield Wiper Position 9— High Speed Windshield Wiper Position 10— Right Turn Indicator Position 11— Left Turn Indicator Position

11. Left Turn Indicator: Push steering column lever down to left turn indicator position (11) to activate left turn indicator.

10. Right Turn Indicator: Lift steering column lever up to right turn indicator position (10) to activate right turn indicator.

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Operation—Operator’s Station

T143685B —UN—05JUL01

T148487B —UN—29NOV01

Circuit Breaker Compartment

1— 15 Amp Circuit Breaker (F1)—Park Lights, Interior Lights, Brake Lights, Hazards/Indicators, Voltage Regulator 2— 30 Amp Circuit Breaker (F2)—Battery Supply to Fuses F12, F13, F18, F19, F20, and F21 3— 20 Amp Circuit Breaker (F3)—Ignition Supply to Fuses F11, F14, F15, and F16 4— 30 Amp Circuit Breaker (F4)—Back Up Lights, Headlights, Work Lights, and Rotating Beacon

5— 25 Amp Circuit Breaker (F5)—Air Conditioner, Headlights Relay 6— 15 Amp Circuit Breaker (F6)—Gear Hold, Bin Down Latch Solenoid, Park Brake Solenoid, CTD Solenoid, Automatic Greaser, and Fan Drive Solenoid 7— 25 Amp Circuit Breaker (F7)—Seat Pump, Wiper Motor, Mirror Defrost, Electrical Mirrors, Washer Motor, Horn Solenoid/Electrical Horn 8— 25 Amp Circuit Breaker (F8)—Cold Start

The circuit breaker panel consists of 9 circuit breakers which provide electrical overload protection for the identified circuits. Push circuit breaker button to reset a tripped circuit breaker.

9— 15 Amp Circuit Breaker (F9)—Bin Float Solenoid, Neutral Relay, Start Relay, MDU/CCU Power Relay 10— 10 Amp Fuse (F11)—Transmission, Engine Brake, and Voltage Regulator 11— 10 Amp Fuse (F12)—Transmission 12— 5 Amp Fuse (F13)—MDU/CCU (Battery to Relay), Hazard Input to CCU 13— 5 Amp Fuse (F14)—Alternator D+ 14— 10 Amp Fuse (F15)—CCU Program, MDU Program, Diagnostic

15— 20 Amp Fuse (F16)—Engine 16— 10 Amp Fuse (F17)—Reverse Camera, FM Radio—If Equipped 17— 5 Amp Fuse (F19)—MDU 18— 10 Amp Fuse (F20)—Diagnostic 19— 10 Amp Fuse (F21)—Battery Balancer, Accessory, Battery Balancer Enable 20— 15 Amp Fuse (F22)—2-Way Radio

The fuse block consists of 11 fuses which provide overload protection for the identified circuits. Replace fuses as necessary.

TX14740,0000009 -19-27JAN03-1/1

2-1-8

080112

PN=31

Operation—Operator’s Station

Operator Seat and Instructional Seat

CAUTION: Use seat belt to prevent personal injury. Check condition of seat belt and mounting hardware before operating machine.

Replace seat belt at least every 3 years, regardless of condition.

Seat belt must fit snugly over abdomen. Seat belt extends as necessary to fit comfortably.

6. Fore/Aft Adjustment Lever: Lift and hold seat cushion adjustment lever and adjust seat cushion angle as desired. Release lever to lock seat into position.

7. Instructional Seat: The instructional seat is non-adjustable and is equipped with a seat belt.

1— Backrest Angle Adjustment Knob 2— Weight Adjustment Lever 3— Seat Height Adjustment Lever 4— Arm Rest Angle Adjustment Knob

5— Seatbelt 6— Fore/Aft Adjustment Lever 7— Instructional Seat

T143728B —UN—24AUG01

1. Backrest Adjustment Knob: Turn knob to move backrest to desired position.

2. Weight Adjustment Lever: Use adjustment lever to obtain the most comfortable seat suspension.

3. Seat Height Adjustment Lever: Pull and hold adjustment lever up to obtain the most comfortable driving position.

4. Arm Rest Angle Adjustment Knob: The arm rests may be lifted to allow easier access to seat and then lowered for driver comfort. To adjust angle of arm rests, turn arm rest angle adjustment knob under arm rest clockwise or counterclockwise until the most comfortable position is reached.

5. Seat Belt:

T144959B —UN—24AUG01

The operator's seat is fully adjustable to suit operator's height, weight and reach.

OUO1043,0000DD1 -19-06FEB03-1/1

2-1-9

080112

PN=32

Operation—Operator’s Station

Air Suspension Seat—If Equipped The operator's seat is fully adjustable to suit operator's height, weight and reach.

1. Fore/Aft Adjustment Lever:Lift to move seat forward or rearward. Release lever to lock seat into position.

2. Air/Height Lever:Lift and hold air/height lever to obtain the most comfortable driving position.

3. Lumbar:Push lumbar support button to adjust seat back lumbar support to the most comfortable position.

4. Armrest Height:The armrests may be lifted to allow easier access to seat and then lowered for driver comfort.

5. Backrest Tilt:Lift seat back tilt lever to adjust seat back tilt. Release lever to lock seat back into position.

6. Fore/Aft Cushion Lock:Adjust cushion to improve operator comfort.

7. Ride Control/Stiffness:Adjust seat to improve overall ride control and to reduce stiffness.

5— Backrest Tilt 6— Fore/Aft Cushion Lock 7— Ride Control/Stiffness

T213148A —UN—02AUG05

1— Fore/Aft Adjustment Lever 2— Air/Height Lever 3— Lumbar 4— Armrest Height

AM40430,00000F4 -19-01AUG05-1/1

Seat Belt 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.

VD76477,0001581 -19-06JUL07-1/1

2-1-10

080112

PN=33

Operation—Operator’s Station

Battery Disconnect Switch and Battery Circuit Breakers

T147634B —UN—09NOV01

The battery disconnect switch (4) is located inside the battery compartment.

IMPORTANT: Always turn battery disconnect switch OFF when engine is stopped and machine is left unattended. If switch is left ON for long periods while engine is stopped, the batteries may become discharged.

IMPORTANT: Always turn battery disconnect switch OFF before any maintenance or repair is performed on machine's electrical system or any welding work is performed.

T147883B —UN—09NOV01

The battery disconnect switch is used to isolate electrical power from batteries to machine.

The battery disconnect switch has 2 positions, OFF and ON. Three circuit breakers are located in the battery compartment to protect the machine's electrical circuits from a possible overload condition or problem from batteries.

• The main circuit breaker (3) (marked Ignition) is rated at 60 amps.

• The battery balancer circuit breaker (2) (marked 12 V) is rated at 20 amps.

• The purging units, fuel filter and coolant level switch circuit breaker (1) is rated at 20 amps.

1— 20 Amp Circuit Breaker—Purging Units, Fuel Filter, and Coolant Level Switch 2— 20 Amp Circuit Breaker—Battery Balancer (Marked 12 V)

3— 60 Amp Circuit Breaker—Main (Marked Ignition) 4— Battery Disconnect Switch

OUO1043,0000DF7 -19-30OCT01-1/1

2-1-11

080112

PN=34

Operation—Operator’s Station

Miscellaneous Equipment High beam and low beam headlights (1) are controlled using the steering column lever.

Tail, brake and park lights (4) light when brake pedal is depressed or when accelerator pedal is released and torque retarder is activated.

Turn indicator lights (2 and 3) light when warning lights or turn signals are turned ON.

T147635B —UN—29NOV01

Lights

Back-up lights (5) light when machine transmission is shifted to reverse.

4— Tail, Brake and Park Light (2 used) 5— Back Up Light (3 used) T147636B —UN—09NOV01

1— Headlight and Front Park Light (2 used) 2— Front Turn Indicator Light (2 used) 3— Rear Turn Indicator Light (2 used)

TX14740,000000A -19-27JAN03-1/6

Secondary Exit If necessary, use the secondary exit tool (1) to break the glass of the right-side window.

T143573B —UN—06JUL01

1— Secondary Exit Tool

TX14740,000000A -19-27JAN03-2/6

12-Volt Accessory Outlet The 12-volt accessory outlet is used to power operator accessories, as necessary.

T144144B —UN—19JUL01

1— 12-Volt Accessory Outlet

Continued on next page

2-1-12

TX14740,000000A -19-27JAN03-3/6

080112

PN=35

Operation—Operator’s Station Storage Compartment Store items in compartment located behind the operator's seat to keep them clean and dry.

T144275B —UN—27JUL01

1— Storage Compartment

TX14740,000000A -19-27JAN03-4/6

Wheel Wrench and Brace NOTE: Brace is also used as cab tilt pump handle.

1— Wheel Wrench

T143737B —UN—06JUL01

The wheel wrench (1) and brace (2) are located at rear of cab, behind the operator's seat and are secured in position by 2 plates.

2— Brace

TX14740,000000A -19-27JAN03-5/6

Windshield Washer Reservoir The windshield washer reservoir (1) is located at front of cab under hood.

T143736B —UN—06JUL01

To fill reservoir: 1. Tilt hood.

2. Remove filler cap (2) and fill reservoir with washer cleaning fluid.

3. Install cap. Ensure that electrical connection and fluid delivery hose are also secure.

4. Close hood.

1— Windshield Washer Reservoir

2— Filler Cap

TX14740,000000A -19-27JAN03-6/6

2-1-13

080112

PN=36

Operation—Operator’s Station

1. Message Display: When key switch is turned ON or machine is started, the default menu will be displayed.

The default menu can be configured to suit the operator. The information on the bottom row can be changed by pressing the NEXT button.

When other menus are selected or service codes are detected, message display will show relevant, descriptive information.

2. Gear Display: When machine is in neutral (N), the gear display will show “0”. When machine is in drive (D), gear display will show the current of 6 forward gears that the machine is in. When machine is in reverse (R), the gear display will display “1”; there is only a single reverse gear.

3. Drive/Neutral/Reverse Display: When machine is in drive (D), display will show “F”. When machine is in neutral (N), display will show “N”. When machine is in reverse (R), display will show “R”.

4. NEXT Button: To change the information shown in the information display, press and hold NEXT button for 3 beeps to access default menu. Once default menu is accessed, push NEXT button repeatedly until message display (1) shows that desired default information is being shown in information display (5). Once default screen has been changed, the selected default information will be displayed any time the key switch is turned to the ON position or the machine is started.

5. Information Display: Information displayed varies, depending on which default display is currently

T144175 —UN—09OCT01

Monitor Display Unit—Default Display Menu

1— Message Display 2— Gear Display 3— Drive/Neutral/Reverse Display 4— NEXT Button

selected. When ignition is switched OFF and then ON again, the last selected information will be displayed.

6. Tachometer Display: Displays current engine speed rpm.

7. Hour Meter Display: Displays the machine hours in whole hour increments. The hour meter accumulates hours only when the engine is running.

Continued on next page

2-1-14

5— Information Display 6— Tachometer Display 7— Hour Meter Display

OUO1043,0000DCC -19-19JUL01-1/3

080112

PN=37

T143037 —UN—11OCT01

Operation—Operator’s Station

Default Menu Function Default Menu

Description

Machine Model

Message display shows machine model number. Data display shows machine system voltage in volts.

Bin Tip Counter

Data display shows number of times dump body was tipped since bin tip counter was last reset.

Trip Distance

Data display shows distance machine traveled, in kilometers or miles, since counter was last reset.

Trip Time

Data display shows machine operation time since counter was last reset.

Trip Fuel

Data display shows machine fuel consumption rate since trip fuel counter was last reset.

Odometer

Odometer displays total distance machine has travelled in kilometers or miles. Odometer cannot be reset.

Lockup Clutch

Data display shows ON/OFF status of lock up clutch.

Transmission Temperature

Data display shows transmission oil temperature in °C or °F.

Return Temperature

Data display shows transmission return oil temperature in °C or °F.

Retarder Torque

Data display shows transmission torque as a percentage of available torque.

Engine Temperature

Data display shows engine temperature in °C or °F.

Engine Oil Pressure

Data display shows engine oil pressure in bar or psi.

Engine Oil Level

Data display shows engine oil level as a percentage.

Fuel Consumption

Data display shows fuel consumption in L/h or gal/h.

Actual Torque

Data display shows machine torque as a percentage of available torque.

Engine Retarder Torque

Data display shows engine brake torque as a percentage of available torque.

Fuel Level

Data display shows fuel supply in L or gal.

System Air Pressure

Data display shows system air pressure in bar or psi.

Continued on next page

2-1-15

OUO1043,0000DCC -19-19JUL01-2/3

080112

PN=38

Operation—Operator’s Station Default Menu Function Default Menu

Description

Hydraulic Temperature

Data display shows hydraulic oil temperature in °C or °F.

Brake Temperature

If machine is equipped with wet brakes, data display shows wet brake temperature in °C or °F. OUO1043,0000DCC -19-19JUL01-3/3

1. Message Display: Shows description of current menu screen selected.

2. Menu Display: Shows which menu is currently selected.

3. Sub Menu Display: Shows which sub menu is currently selected.

4. Sub Sub Menu Display: Shows which sub sub menu is currently selected.

5. Information Display: Information displayed varies, depending on which menu screen is currently selected.

6. MENU Button: Push to advance through 5 menus (A, B, C, D, and E) and the default menu.

Push MENU at any time while navigating through a menu to return to default data display.

7. BACK Button: Push to return to the next higher menu. For example, if navigating in the A 01 sub menu level, pressing BACK will return the MDU data display to the A menu of the top menu level.

8. NEXT Button: Push to advance from one menu to the next in the same sub menu level or sub sub menu level. For example, if navigating in the A 01 sub level, push NEXT button once to go to the A 02 menu.

9. SELECT Button: Push to access the menu below the currently shown menu. For example, if sub level menu

T144178 —UN—24JUL01

Monitor Display Unit—Menu Function

1— Message Display 2— Menu Display 3— Sub Menu Display 4— Sub Sub Menu Display 5— Information Display

A 01 is currently displayed, press SELECT to display the A 011 sub sub level.

Continued on next page

2-1-16

6— MENU Button 7— BACK Button 8— NEXT Button 9— SELECT Button

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080112

PN=39

T143038 —UN—11OCT01

Operation—Operator’s Station

Continued on next page

2-1-17

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080112

PN=40

T143039 —UN—22OCT01

Operation—Operator’s Station

Continued on next page

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080112

PN=41

T143040 —UN—11OCT01

Operation—Operator’s Station

Continued on next page

2-1-19

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080112

PN=42

T143744 —UN—11OCT01

Operation—Operator’s Station

Continued on next page

2-1-20

OUO1043,0000DB5 -19-21JUN01-5/12

080112

PN=43

T143041 —UN—22OCT01

Operation—Operator’s Station

Continued on next page

2-1-21

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080112

PN=44

T143042 —UN—11OCT01

Operation—Operator’s Station

Continued on next page

2-1-22

OUO1043,0000DB5 -19-21JUN01-7/12

080112

PN=45

Operation—Operator’s Station Menu Functions Menu A 00

Counters A 01

Trip Information

Menu displays trip counter information since counters were last reset.

A 011

Trip Distance

Data display shows distance machine traveled, in kilometers or miles, since trip distance counter was last reset.

A 011 1

Press SELECT for longer than 3 beeps to reset trip distance counter.

A 012

A 013

A 014 A 02

A 03 B 00

Reset

Trip Time

Data display shows machine operation time since trip time counter was last reset.

A 012 1

Press SELECT for longer than 3 beeps to reset trip time counter.

Reset?

Trip Fuel

Data display shows machine fuel consumption rate since trip fuel counter was last reset.

A 013 1

Reset?

Press SELECT for longer than 3 beeps to reset trip fuel counter.

Reset All Trip Data?

Press SELECT for longer than 3 beeps to reset all trip counters.

Bin Tip Counter

Data display shows number of times dump body was tipped since bin tip counter was last reset.

A 021

Press SELECT for longer than 3 beeps to reset bin tip counter.

Reset?

Odometer

Actual Values B 01

Engine Values B 011

B 02

Engine Oil Pressure

Odometer displays distance machine has traveled in kilometers or miles. Odometer cannot be reset.

Menu displays machine sensor information.

Menu displays engine sensor information.

Data display shows engine oil pressure in bar or psi.

B 012

Engine Coolant Temperature

Data display shows engine coolant temperature in °C or °F.

B 013

Throttle Position

Data display shows throttle position as a percentage of full throttle.

B 014

Actual Torque

Data display shows actual engine torque as a percentage.

B 015

Engine Retarder Torque

Data display shows engine brake as a percentage.

B 016

Engine Oil Level

Data display shows engine oil level as a percentage of full.

B 017

Fuel Consumption

Data display shows fuel consumption in L/h or gal/h.

Transmission Values B 021

B 03

Description Menu displays counter information and allows counters to be reset.

Transmission Temperature

Menu displays transmission sensor information.

Data display shows transmission temperature in °C or °F.

B 022

Lock-Up Clutch

Data display shows ON/OFF status of lock-up clutch.

B 023

Current Gear

Data display shows the currently activated travel gear.

B 024

Retarder Torque

Data display shows actual transmission retarder torque as a percentage.

B 025

Retarder Oil Temperature

Data display shows retarder oil temperature in °C or °F.

Vehicle Values

Menu displays miscellaneous machine sensor information.

Continued on next page

2-1-23

OUO1043,0000DB5 -19-21JUN01-8/12

080112

PN=46

Operation—Operator’s Station Menu Functions Menu B 031

C 00

Air Pressure

B 032

Fuel Level

Data display shows fuel supply in L or gal.

B 033

Bin Position

Data display shows body position as a percentage of body in full up position.

B 034

Hydraulic Temperature

Data display shows hydraulic oil temperature in °C or °F.

B 035

Brake Temperature

If machine is equipped with wet brakes, data display shows wet brake temperature in °C or °F.

B 036

Inter-Axle Lock

Data display shows ON/OFF status of differential lock.

This menu is used to display service codes and diagnose inputs and outputs of CCU.

Diagnostics C 01

C 02

Actual Service Codes

Menu displays CCU service code. If service code appears, see Service Codes in Miscellaneous—Troubleshooting section.

C 011

Data display shows first active service code. See Service Codes in Miscellaneous—Troubleshooting section.

Service Code 1

C 012

Service Code 2

Data display shows second active service code. See Service Codes in Miscellaneous—Troubleshooting section.

C 01X

Service Code X

Continue to press NEXT button to advance through all active service codes.

C 01Y

End

Continue to press NEXT button until END is displayed on message display. Press NEXT button again to return to first active service code.

Stored Service Codes C 021

C 03

Description Data display shows system air pressure in bar or psi.

Clear Service Codes?

Menu displays CCU service code. If service code appears, see Service Codes in Miscellaneous—Troubleshooting section.

Press SELECT for longer than 3 beeps to reset trip time counter.

C 022

ECU/TCU/CCU Service Code

Data display shows first stored service code. See Service Codes in Miscellaneous—Troubleshooting section.

C 02X

ECU/TCU/CCU Service Code X

Continue to press NEXT button to advance through maximum of 5 stored service codes.

C 02Y

End

Continue to press NEXT button until END is displayed on data display. Press NEXT button again to return to “CLEAR FAULT CODES?” display.

CCU Inputs

Menu displays ON/OFF status of CCU digital inputs.

C 031

Low Coolant Level

C 032

Park Brake

C 033

Latch Control

C 034

Coldstart

C 035

Inter-Axle Lock Dash Switch

C 036

Left Indicator

C 037

Right Indicator

C 038

Hazards

C 039

Intermittent Wipers

C 031 0

Start Signal

Data display indicates if key switch is in START position. ON indicates key switch is in START position; OFF indicates key is not in start position.

C 031 1

Ignition

Data display indicates if key switch is in RUN position. ON indicates key switch is in RUN position; OFF indicates key is not in RUN position.

Data display shows ON/OFF status of low coolant level sensor.

Data display shows ON/OFF status of pressure switch controlling park brake light.

Data display shows ON/OFF status of park brake lever.

Data display shows ON/OFF status of machine coldstart function.

Data display shows ON/OFF status of inter-axle lock dash switch.

Data display shows ON/OFF status of left turn indicator input from steering column switch.

Data display shows ON/OFF status of right turn indicator input from steering column switch.

Data display shows ON/OFF status of hazard switch.

Data display shows ON/OFF status of intermittent wiper input from steering column switch.

Continued on next page

2-1-24

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080112

PN=47

Operation—Operator’s Station Menu Functions Menu

C 04

C 05

D 00

C 031 2

Brake

C 031 3

Gear Hold

Data display indicates ON/OFF status of range hold rocker switch.

CCU Analog Inputs

Menu displays CCU analog inputs in milivolts for analog sensors as measured at CCU input.

C 041

Bin Position

Data display shows milivolts of at bin position sensor at CCU input and the associated value of bin position as a percentage of full tip value.

C 042

Air Pressure

Data display shows milivolts of air pressure sensor as measured at CCU input and the air pressure value in bar or psi.

C 043

Hydraulic Temperature

Data display shows milivolts of hydraulic temperature sensor as measured at CCU input and temperature value in °C or °F.

C 044

Wet Brake Temperature

Data display shows milivolts of wet brake temperature sensor as measured at CCU input and temperature value in °C or °F.

C 045

Battery Voltage

C 046

Fuel Level

CCU Outputs C 051

Intermittent Wipers

C 052

Left Indicator

C 053

Right Indicator

C 054

Inter-Axle Lock

C 055

Park Brake

C 056

Overspeed

C 057

Hydraulic Cutout

C 058

Brake

C 059

Bin Float

C 051 0

Purging Unit

C 051 1

Engine Running

Data display shows milivolts of fuel level sensor as measured at CCU input and fuel level value in L or gal.

Menu displays CCU analog output signal ON/OFF status.

Data display shows CCU intermittent wiper output signal ON/OFF status.

Data display shows CCU left turn indicator output signal ON/OFF status.

Data display shows CCU right turn indicator output signal ON/OFF status.

Data display shows CCU inter-axle lock output signal ON/OFF status.

Data display shows CCU park brake output signal ON/OFF status.

Data display shows CCU overspeed output signal ON/OFF status.

Data display shows CCU hydraulic cutout output signal ON/OFF status.

Data display shows CCU brake light output signal ON/OFF status, activated with engine brake and transmission retarder.

Data display shows CCU bin float output signal ON/OFF status.

Data display shows CCU engine run output signal ON/OFF status.

Wiper Intermittent Timing D 011

Data display shows both single battery voltage and 2 battery voltage in volts.

Data display shows CCU purging unit output signal ON/OFF status.

Machine Configuration D 01

Description Data display indicates if brake pedal is being depressed. ON indicates brake pedal is being depressed. OFF indicates brake pedal is not being depressed.

3 Seconds

Menu displays the current machine settings and allows them to be adjusted, if necessary.

Menu displays current setting of intermittent wipers and allows setting to be changed.

Press NEXT as necessary to advance through screens, until desired intermittent wiper time interval is displayed. When desired interval is displayed, press SELECT for longer than 3 beeps to activate that interval.

D 012

4 seconds

Press NEXT as necessary to advance through screens, until desired intermittent wiper time interval is displayed. When desired interval is displayed, press SELECT for longer than 3 beeps to activate that interval.

D 01 XX

XX Seconds

Press NEXT as necessary to advance through screens, until desired intermittent wiper time interval is displayed. When desired interval is displayed, press SELECT for longer than 3 beeps to activate that interval.

Continued on next page

2-1-25

OUO1043,0000DB5 -19-21JUN01-10/12

080112

PN=48

Operation—Operator’s Station Menu Functions Menu D 012 0 D 02

Menu allows tire size to be selected to reflect tire size installed on machine.

NOTE: Value shown in data display is dynamic rolling radius of tire in mm.

Press NEXT as necessary to advance through screens, until machine tire size is displayed.

When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.

D 023

734

Press NEXT as necessary to advance through screens, until machine tire size is displayed.

When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.

D 02 XX

XXX

Press NEXT as necessary to advance through screens, until machine tire size is displayed.

When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.

D 021 7

YYY

Press NEXT as necessary to advance through screens, until machine tire size is displayed.

When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.

Imperial/English Units ON OFF

E 02

Menu allows operator to determine whether measurements will be displayed in Imperial/English units or metric units.

Press SELECT for 3 beeps to display Imperial/English units.

Press SELECT for 3 beeps to display metric units.

Bin Tip Angle

Menu allows operator to set bin full down and bin full up positions. Also allows operator to determine bin tip counter parameters.

D 041

With machine body in the full down position, press SELECT for longer than 3 beeps to set the zero position. Display will change to show 0%.

Set Zero

D 042

Set Full Tip

With machine body in the full up position, press SELECT for longer than 3 beeps to set the zero position. Display will change to show 100%.

D 043

Set Low Bin Counter Trigger

Before setting low bin count trigger, set zero and full tip values.

Low bin counter trigger default is body raised 10%.

To set low bin counter trigger, raise body to desired low bin counter trigger height. Data display will show current bin height percentage. Press SELECT for 12 beeps to set low bin counter trigger.

D 04

Set High Bin Counter Trigger

Before setting high bin count trigger, set zero and full tip values.

High bin counter trigger default is body raised 70%.

To set high bin counter trigger, raise body to desired high bin counter trigger height. Data display will show current bin height percentage. Press SELECT for 12 beeps to set high bin counter trigger.

Machine Identification E 01

Press NEXT as necessary to advance through screens, until machine tire size is displayed.

When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.

714

D 032

E 00

647

D 022

D 031

D 04

Description Press NEXT as necessary to advance through screens, until desired intermittent wiper time interval is displayed. When desired interval is displayed, press SELECT for longer than 3 beeps to activate that interval.

Tire Size D 021

D 03

20 Seconds

Menu displays machine identification information.

Menu displays engine control unit (ECU) identification information.

ECU E 011

EN XXXXXX

E 012

Software Version

Message display shows ECU part number.

Data display shows current ECU software version.

E 013

Hardware Version

Data display shows current ECU hardware version.

E 014

Serial Number

Message display shows ECU serial number.

E 015

Engine Hours

Data display shows engine hours logged on current ECU. Menu displays transmission control unit (TCU) identification information.

TCU E 021

TN XXXXXX

E 022

Software Version

E 023

Hardware Version

Message display shows TCU part number.

Data display shows current TCU software version.

Data display shows current TCU hardware version.

Continued on next page

2-1-26

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080112

PN=49

Operation—Operator’s Station Menu Functions Menu E 024 E 03

E 04

Serial Number

Description Message display shows TCU serial number.

Menu displays monitor display unit (MDU) identification information.

MDU E 031

VIN AEB XXXXX

E 032

Software Version

Message display shows the vehicle identification number of the machine.

Data display shows current MDU software version information.

E 033

Hardware Version

Data display shows current MDU hardware version.

E 034

Serial Number

Data display shows MDU serial number.

E 035

Engine Hours

Data display shows MDU hours on current MDU. Menu displays chassis control unit (CCU) identification information.

CCU E 041

VIN AEB XXXXXX

E 042

Software Version

Message display shows the vehicle identification number of the machine.

Data display shows current CCU software version information.

E 043

Hardware Version

Data display shows current CCU hardware version.

E 044

Serial Number

Message display shows CCU serial number.

E 045

Engine Hours

Data display shows CCU hours on current CCU. OUO1043,0000DB5 -19-21JUN01-12/12

2-1-27

080112

PN=50

Operation—Operating the Machine Before Starting Work T133556 —UN—24AUG00

Review the operating precautions in the Safety Section of this manual.

Use seat belt when operating your machine.

Remember to fasten seat belt even during brief periods of use.

TX03679,0001780 -19-02NOV00-1/1

Operator's Daily Machine Check Before Starting Safety and Protective Devices Checks

Check for bent, broken, loose or missing sheet metal.

Walk around machine to clear all persons from machine area before starting machine.

Check for loose or missing hardware.

Check back-up alarm, horn, turn signals and lights for correct operation.

Check for oil leaks, missing or loose hose clamps, kinked hoses and lines or hoses that rub against each other or other parts.

Check condition of guards, shields and covers.

Check brake accumulators precharge.See Check Brake Accumulators. (Section 4-1.)

Overall Machine Checks Check for worn or frayed electrical wires and loose or corroded connections.

OUO1043,0000DC2 -19-28JUN01-1/1

2-2-1

080112

PN=51

Operation—Operating the Machine

Starting Engine Before Starting the Engine 1. Turn battery disconnect switch to the ON position.

2. Fasten seat belt.

TS175 —UN—23AUG88

3. Turn key switch to ON position (1) and verify that the following happens during 3-second bulb check:

• All indicators will light or flash.

• All gauges and speedometer move to center position.

• Warning alarm sounds.

• All segments of MDU LCDs will display.

• All segments of transmission control LED display and mode button indicator will light.

T143521B —UN—03JUL01

After 3 seconds all gauges, LCD and LED displays will return to normal operation mode and warning alarm will silence. All indicators, except for secondary steering (marked emergency steering), battery charge and park brake indicators, will go out.

Air pressure indicator may also remain lit, depending on system air pressure. Cold start indicator may also remain lit, depending on ambient temperature.

Starting the Engine 1. Press horn button to sound horn and alert bystanders that machine will be started.

CAUTION: Prevent possible injury from unexpected machine movement. If hydraulic oil is cold, hydraulic functions move slowly. DO NOT attempt normal machine operation until hydraulic functions move at close-to-normal cycle times.

IMPORTANT: Never operate starter motor for more than 17 seconds at a time. If engine fails to start after 2 or 3 tries, return key switch to OFF. Wait for about 1 minute, then try again.

After a false start, do not turn key switch until engine stops or starter may be damaged.

Engine will not start by towing or pushing.

Permanent damage to transmission will result.

IMPORTANT: Prevent damage to engine. Use start aid when temperatures are below 0°C (32°F) and only when engine is COLD.

1— Key Switch ON Position

2— Key Switch START Position

engine is COLD, press start aid switch while starting engine.

3. Allow engine to idle until secondary steering (marked emergency steering) and air pressure indicators go out.

Warming the Engine IMPORTANT: Allow engine to idle at least 1/2 minute. Do not run engine at fast idle or under heavy load until engine oil, transmission and hydraulic oils have warmed up to normal operating temperatures.

Operate machine at less than normal loads and at slow idle speed until engine warms up.

2. Turn key switch to START position (2) and hold until engine starts. If temperature is below 0°C (32°F) and OUO1043,0000E40 -19-13NOV01-1/1

2-2-2

080112

PN=52

Operation—Operating the Machine

Replace Start Aid Can

TS281 —UN—23AUG88

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 can from machine if engine does not need starting fluid.

IMPORTANT: Remove can from container and install container upside-down to protect start aid components from dust.

1. Open hood.

2. Loosen clamp (1).

T148320B —UN—26NOV01

3. Turn start aid can (2) counterclockwise to remove from base.

4. Remove safety cap and spray button from new start aid can.

5. Install new start aid can. Hand tighten.

6. Tighten clamp.

7. Close hood.

1— Clamp

2— Start Aid Can OUO1043,0000E42 -19-15NOV01-1/1

Driving Machine IMPORTANT: Avoid serious transmission damage.

Never maintain a stall condition for more than 30 seconds at one time because of the rapid rise in oil temperature.

Before driving on public roads, check state and local laws that apply to tractors, self-propelled machines, and towed equipment. Additional lights, mirrors, SMV emblems, or reflectors may be required.

Operate the machine in accordance with site and road regulations.

Always adjust machine speed to road and traffic conditions.

When driving through a bend, do not drive too fast, especially while transporting a load. If road is slippery, the operator could lose control.

Do not use inter-axle lock when operating on smooth, graded surfaces.

Due to weight of machine, allow for long braking distances, especially on slippery roads.

OUO1043,0000E44 -19-27NOV01-1/1

2-2-3

080112

PN=53

Operation—Operating the Machine

Steering Machine Normal Steering NOTE: There is no self-centering function with normal steering. The machine must be straightened by turning steering wheel to the straight-ahead position.

Normal steering is operational when engine is running.

NOTE: If there is an engine or main pump malfunction, the ground-driven secondary steering system will allow operator to steer machine to a safe stop.

When engine or main pump malfunctions, the secondary steering indicator (marked emergency steering) will flash.

The machine's secondary steering system is ground driven and will not operate when machine is stopped.

Secondary Steering NOTE: There is no secondary steering when machine is traveling in reverse. Machine must be traveling forward for the secondary steering system to operate.

OUO1043,0000DB9 -19-27APR11-1/1

2-2-4

080112

PN=54

Operation—Operating the Machine

Shifting Transmission IMPORTANT: When transmission sump oil temperature is below 7°C (19°F), only neutral, reverse and second gears are available.

T147638B —UN—26NOV01

IMPORTANT: When transmission sump oil temperature is above 128°C (262°F), the TCU will restrict the use of higher gears.

NOTE: With dump body in raised position, transmission will not shift beyond first gear from neutral. If already in gear, transmission can downshift but not upshift.

The transmission has 6 forward gears and 1 reverse gear with automatic lock-up in all gears.

The transmission can be operated as a fully automatic transmission. All automatic gear shifting is controlled by the transmission control unit (TCU). Gear shifting is dependent upon engine speed (rpm) and operating conditions.

1— 1st Gear 2— 2nd Gear 3— 3rd Gear 4— Drive Gear

Shifting Transmission

5— Neutral 6— Reverse Gear 7— Gearshift Control

Move gear shift control to drive gear (D) to revert to normal operation, allowing the machine to shift through the full range of gears.

IMPORTANT: Stop machine before shifting from a forward gear to reverse gear.

Downshift or Reverse Inhibitor 1.

With engine running, park brake engaged, and gearshift control in neutral (N) (5) apply service brake.

2. Select drive (D) (4) or reverse (R) (6) using gearshift control (7).

3. Release park brake.

NOTE: Shifting from neutral (N) to drive (D) or reverse (R) is inhibited when engine speed is above 1100 rpm. Before shifting to drive (D) or reverse (R) engine speed must be below 1100 rpm.

Although there is no speed limitation on upshifting, there is on downshifting and shifts from neutral to drive or reverse. If a downshift or neutral-to-gear shift is selected when engine speed is too high, the TCU will prevent the shift until neutral is selected or engine speed is reduced.

4. Release service brake and increase engine speed.

When transmission is in drive (D), the transmission will sequentially select the next gear as machine speed increases and downshift as machine speed decreases.

Accelerator Control

Gear Pre-Selection

CAUTION: To avoid injury or property damage caused by sudden movement of machine, do not make shift from neutral (N) to drive (D) or reverse (R) while pressing accelerator.

NOTE: The transmission will shift to gear above pre-selected gear, up to gear 6, if an engine overspeed condition occurs.

A lower drive gear (1st gear (1), 2nd gear (2) or 3rd gear (3) may be pre-selected to match anticipated driving conditions, giving the operator better control on slick or icy roads and on downgrades. Pre-selecting a gear limits the maximum attainable gear to the gear selected. For example, if gear 3 is pre-selected, gear 4, gear 5 and gear 6 will not be attained unless an overspeed condition occurs.

Downshifting to a lower gear increases engine braking.

The selection of a lower gear often prevents cycling between that gear and the next higher gear on a series of up-and-down grades.

NOTE: Shifting from neutral (N) to drive (D) or reverse (R) is inhibited when engine speed is above 1100 rpm. Before shifting to drive (D) or reverse (R) engine speed must be below 1100 rpm.

Shifting transmission from neutral (N) to reverse (R) or drive (D) is not allowed if engine speed is above 1100 rpm. If shift is attempted while engine speed is above 1100 rpm, release accelerator and allow engine speed to drop below 1100 rpm, then attempt shift again.

The position of the accelerator pedal influences the timing at which automatic shifting occurs. When the pedal is fully depressed, upshifts will occur automatically at fast engine speeds.

Continued on next page

2-2-5

OUO1043,0000DF8 -19-30OCT01-1/2

080112

PN=55

Operation—Operating the Machine

A partially depressed accelerator pedal position will cause upshifts to occur at slow engine speeds.

OUO1043,0000DF8 -19-30OCT01-2/2

Using Range Hold

T147639B —UN—26NOV01

Under certain conditions, such as driving uphill, the transmission may start shift cycling or “gear hunting”, i.e., the transmission changes up and down between 2 gears at short intervals. This is because power is insufficient for operating in the higher gear but is sufficient for upshifting from the lower gear.

NOTE: The MDU will display the actual gear that the machine is in at anytime.

When this condition occurs, press lower half of range hold switch (1) to turn range hold ON. The transmission will hold the gear that it is in at the time the range hold switch is turned ON. Normal downshifting will occur, but transmission will NOT upshift to a higher gear until either the range hold switch is turned OFF or an overspeed condition occurs.

When level ground is reached, press upper half of range hold switch to switch range hold OFF. When range hold

1— Range Hold Switch

2— Gearshift Display Window

switch is turned OFF, normal automatic operation mode will continue.

OUO1043,0000DF9 -19-30OCT01-1/1

Using Inter-Axle Lock

T143346B —UN—28JUN01

IMPORTANT: The inter-axle lock must only be used when ground conditions are very poor and not on graded or tarred surfaces.

The inter-axle lock can be engaged while machine is moving.

To engage inter-axle lock, reduce engine speed (accelerator pedal less than 10% depressed), press lower half of inter-axle lock switch (1) and ensure that inter-axle lock indicator (2) lights.

To disengage inter-axle lock, press upper half of inter-axle lock switch.

1— Inter-Axle Lock Switch

2— Inter-Axle Lock Indicator OUO1043,0000E41 -19-13NOV01-1/1

2-2-6

080112

PN=56

Operation—Operating the Machine

Slowing and Stopping the Machine During normal operation, stop machine using service brakes. When machine is stopped for more than a few seconds, engage park brake.

T143568B —UN—06JUL01

CAUTION: Use a combination of downshifting and braking while going downhill.

Under normal driving conditions, the transmission prevents automatic upshifting above the lower gear selected.

However, during downhill operation, if engine governed speed is exceeded in the lower gear, the transmission may upshift to the next higher gear. This will reduce braking. Apply service brakes to prevent exceeding engine governed speed in the lower gear selected.

1— Transmission Retarder Lever

Remove foot from accelerator pedal to use engine as a braking force. The transmission will start to downshift.

Use service brakes to slow machine if machine is exceeding maximum speed for held gear.

Transmission Retarder Lever Position

Engine braking provides good speed control for traveling downhill. When machine is fully loaded, or slope is steep, it may be desirable to preselect a lower gear before reaching gradient. Downshifting to a lower gear increases engine braking and helps the operator maintain control of machine.

Using Transmission Retarder to Slow Machine The transmission retarder is automatically engaged when the accelerator pedal is completely released.

The retarder indicator light on the dash will light whenever the transmission retarder engages.

Using transmission retarder lever (1), select a level of retardation between 0 and 6 depending on the amount of retardation required for the operating conditions, with the 0 position having the least amount of retardation, 0%, and 6 having the maximum amount of retardation, 100%. The level of retardation can be changed while the machine is moving or stationary.

When brake pedal is applied and transmission retarder lever is set in positions 0, 1, 2, or 3, the transmission retarder will apply 50% retardation. When brake pedal is applied and transmission retarder lever is set in positions 4, 5, or 6, the transmission retarder will apply retardation indicated by lever setting.

0

0%

1

12%

2

24%

3

39%

4

57%

5

76%

6

100%

Service Brakes CAUTION: Prevent possible injury from loss of service brakes. Use transmission retarder in conjunction with service brakes.

1. Release accelerator pedal.

NOTE: When brake pedal is applied and transmission retarder lever is set in positions 0, 1, 2, or 3, the transmission retarder will apply 50% retardation. When brake pedal is applied and transmission retarder lever is set in positions 4, 5, or 6, the transmission retarder will apply retardation indicated by lever setting.

2. Depress service brake pedal.

To resume driving, release service brake pedal. The transmission will automatically select the lowest gear.

Continued on next page

2-2-7

Percentage of Retardation

TX14740,0000012 -19-06FEB03-1/2

080112

PN=57

Operation—Operating the Machine Park Brake

T147640B —UN—08NOV01

NOTE: Park brake will engage when key is turned to OFF position. If engine is stopped while park brake is not engaged, then when engine is started, park brake lever must be moved to the engaged position before park brake can be released.

NOTE: The park brake should be engaged only when machine is completely stationary.

1. Stop machine using service brake pedal.

2. Move park brake lever rearward until it locks in place to engage park brake.

1— Park Brake Lever

3. Release service brake.

4. Select neutral (N) on gearshift control.

TX14740,0000012 -19-06FEB03-2/2

Operating on a Hill Uphill Operation The machine operates in full automatic mode and the transmission will select the correct gear for traveling uphill.

Engage inter-axle lock to allow for even traction when operating on slippery roads.

Shift cycling or “gear hunting” on certain uphill applications can be eliminated by correct use of range hold switch.

Release accelerator pedal to reduce brake pad wear when driving downhill.

Slow down before going downhill so the transmission automatically selects a low gear.

Engage inter-axle lock to improve traction and braking effect when traveling on icy or other slippery conditions.

Downhill Operation Set retarder for desired operation.

TX14740,000000B -19-27JAN03-1/1

Off-Road Operation Do not operate too close to quarry edges, ramp edges, pier edges or soft edges that may collapse under the machine weight.

Use the articulation steering combined with inter-axle lock to negotiate difficult ground conditions.

Engage inter-axle lock during off-road operation when there is a risk of wheels slipping.

OUO1043,0000E46 -19-27NOV01-1/1

2-2-8

080112

PN=58

Operation—Operating the Machine

Loading and Unloading Dump Body CAUTION: DO NOT operate dump body control lever unless transmission is in neutral (N) (or dumping in 1st or reverse). This practice can effect machine stability and could cause damage to machine and/or personal injury.

CAUTION: Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to electric line than 3 m (10 ft) plus twice the line insulator length.

Back up to a loading machine in a single, straight position so that you can maintain eye contact at all times with the operator of the loading machine.

Steer machine so that it stays straight. This gives a clear and unobstructed vision through rear view mirrors. It may be difficult to observe the spotter and the loading machines if machine is articulated and not in straight-ahead position Stop machine on a firm, level surface.

Lower the dump body fully.

Do not overload machine.

Be sure there is sufficient space for machine before entering confined areas.

Keep bystanders clear of machine loading or unloading area.

Do not operate too closely to quarry edges, ramp edges, quay edges and soft edges that may collapse under machine weight.

Be aware of other machines and personnel when entering or leaving loading or dumping area.

Loading If a spotter is present, follow only his instructions.

Load machine evenly. An uneven load will cause tire and axle damage.

Unloading If a spotter is present, follow only his instructions.

Back up to unloading site in a single, straight position so you can maintain eye contact at all times with the spotter.

Steer machine so it stays straight. You must have clear and unobstructed vision through rear view mirrors. If machine is articulated and not in straight-ahead position, it may be difficult to observe the spotter and the dumping action.

OUO1043,0000DBF -19-06FEB03-1/1

2-2-9

080112

PN=59

Operation—Operating the Machine

Freeing Stuck Machine Turning Machine Free IMPORTANT: If the ground is soft, give constant attention to rear chassis angle. If rear chassis starts to lean sideways excessively, stop machine immediately.

1. Select neutral (N) on gearshift control.

2. Engage inter-axle lock.

IMPORTANT: If the wheels are stuck and not turning, do not apply full power for more than 30 seconds in either drive (D) or reverse (R) or transmission will overheat.

If transmission overheats, select neutral (N) on gear shift control and operate engine at 1500 rpm until it cools (2—3 minutes).

If machine is stuck in deep sand, snow or mud, it may be possible to rock it out as follows:

3. Select drive (D) on gearshift control.

4. Drive off slowly, keeping engine speed constant.

5. Turn steering wheel one way and then the other to assist with traction until machine is free and can be operated normally.

1. Select drive (D) on gearshift control and apply steady, light throttle (NOT full throttle).

2. When vehicle has rocked forward as far as it will go, apply service brakes.

3. Allow engine to return to slow idle.

Rocking Machine Free CAUTION: Prevent injury or property damage caused by sudden movement of machine. DO NOT shift from neutral (N) to drive (D) or reverse (R) when accelerator is depressed.

If shifting while pressing accelerator, the transmission will engage only if accelerator is released in the next 3 seconds causing transmission to remain in neutral (N).

Avoid this condition by making shifts from neutral (N) to drive (D) or reverse (R) only when accelerator is released.

4. Select reverse (R) on gearshift control.

5. Release service brakes and apply a steady, light throttle and allow machine to rock in reverse (R) as far as it will go.

6. Apply and hold service brake and allow engine to return to slow idle.

7. Repeat procedure.

OUO1043,0000E47 -19-27NOV01-1/1

Parking the Machine 1. Unload machine and lower dump body to fully-lowered position.

5. Allow engine to idle for 2 minutes before stopping engine. This allows turbocharger to cool down and receive proper lubrication and for all oil temperatures to stabilize.

2. Stop machine on firm, level ground.

6. Move all switches to OFF position.

3. Engage park brake.

7. Turn key switch to OFF.

4. Select neutral (N) on gearshift control.

8. If machine is to be parked overnight, turn battery disconnect switch to OFF and lock cab door, fuel cap and compartments.

IMPORTANT: DO NOT stop engine immediately after bringing machine to a halt. Allow engine to idle for 2 minutes before stopping engine.

This allows turbocharger to cool down and receive proper lubrication, and for all oil temperatures to stabilize.

If storing longer than overnight, see Prepare Machine for Storage in Miscellaneous—Storage section.

OUO1043,0000DC5 -19-28JUN01-1/1

2-2-10

080112

PN=60

Operation—Operating the Machine

Towing the Machine Towing a Machine with Inoperable Engine CAUTION: Prevent possible injury from unexpected machine movement. Always chock wheels to prevent machine from rolling before releasing park brake.

Ensure brake system of the towing machine is sufficient to hold the combined weight of towing machine and disabled machine.

To prevent damage to transmission, disconnect front and middle drive shafts before towing.

Removing front and middle drive shafts renders park brake inoperable.

NOTE: The park brake may be released mechanically but steering system will remain inoperative. Articulation can be obtained only by disconnecting steering cylinder hydraulic supply hoses.

With engine stopped, the machine hydraulic and pneumatic systems are inoperable, so there is no powered steering or braking system.

Disconnect front and middle drive shafts before towing.

See Releasing Park Brake for Towing in this section.

With brakes released and drive shafts disconnected, the towing machine must be capable of steering and stopping disabled machine.

Do not exceed 2 km/h (1—2 mph).

If the problem is in the transmission, DO NOT run engine, as the engine is directly coupled to the transmission.

Refer to Towing a Machine with Inoperable Engine in this procedure.

If the problem is in the transfer case, select neutral (N) on gearshift control, and disconnect drive shaft connecting transfer case to front differential and drive shaft connecting transfer case to through drive.

If the problem does not affect the braking system, release the park brake.

Towing a Machine with Inoperable Steering NOTE: If park brake was mechanically released and driveshafts remain connected for towing, secondary steering system may remain operable.

Use this procedure in conjunction with relevant Operable Engine or Inoperable Engine towing procedures. If machine must articulate while being towed and the steering system is inoperable, disconnect as follows: 1. Remove supply hoses from the T-pieces on left-hand steering cylinder.

NOTE: Some oil spillage will be unavoidable. Clean up any oil spillage as soon as possible.

Dispose of waste oil properly.

2. Block off 2 supply hoses using suitable plugs.

3. Loop 2 steering cylinder T-pieces together using a suitable hose.

Towing a Machine with an Operable Engine Operator must steer machine if there is no steering problem and engine can be run.

OUO1043,0000DC6 -19-07FEB03-1/1

2-2-11

080112

PN=61

Operation—Operating the Machine

Releasing Park Brake for Towing

T147641B —UN—08NOV01

CAUTION: Machine will roll freely when drive shafts are disconnected. To prevent injury, chock wheels and connect machine to towing vehicle before disconnecting drive shafts.

IMPORTANT: To prevent damage to transmission, disconnect front axle and middle axle drive shafts when towing a machine with an inoperable engine.

1. Chock wheels and connect machine to towing vehicle prior to disconnecting drive shafts.

Front Axle Drive Shaft

T147642B —UN—08NOV01

2. Remove U-joint cap screws (1) and disconnect front axle drive shaft (2) at rear of front axle. Move drive shaft aside and support to allow front axle drive shaft yoke to turn freely.

3. Remove U-joint cap screws (3) and disconnect middle axle drive shaft (4) at front of middle axle. Move drive shaft aside and support to allow middle axle drive shaft yoke to turn freely.

1— U-joint Cap Screw (4 used) 2— Front Axle Drive Shaft

3— U-joint Cap Screw (4 used) 4— Middle Axle Drive Shaft Middle Axle Drive Shaft

OUO1043,0000DFB -19-30OCT01-1/1

Mechanically Releasing Park Brake

T147643B —UN—08NOV01

CAUTION: Machine will roll freely when park brake is released. To prevent injury, chock wheels before releasing park brake.

1. Chock tires to prevent machine rollaway.

2. Remove release stud (1), nut (2) and washer (3) from storage position (4).

3. Install release stud in hole at rear of park brake actuator housing and rotate clockwise a 1/4 turn to lock into place.

4. Install washer and nut onto release stud and tighten until park brake releases.

1— Release Stud 2— Nut

3— Washer 4— Release Stud Storage Location OUO1043,0000DFC -19-30OCT01-1/1

2-2-12

080112

PN=62

Operation—Operating the Machine

T143386 —UN—28JUN01

Machine Lifting Points

T143386

Lifting the Machine

4. Attach lifting beam to a crane.

IMPORTANT: Install the articulation safety lock bar prior to lifting machine.

5. Raise the lifting beam until all the play in chain is removed.

NOTE: The machine lifting points are indicated on machine.

IMPORTANT: Move crane slowly to prevent excessive swinging of lifted machine.

1. Park the machine next to the crane.

NOTE: Lifting beam must be at least 1032 cm (406 in.) in length.

2. Engage park brake.

6. Lower lifting beam until the chain can be removed from the machine.

IMPORTANT: To prevent damage to hood, use a nylon sling for front lifting points.

3. Attach chains or straps to the lifting beam and the machine.

IMPORTANT: The crane must be able to carry total machine weight, 20 400 kg (44 500 lb) for 250D and 21 800 kg (48 100 lb) for 300D.

7. Raise the lifting beam with chains and move it away from machine.

8. Chock all wheels.

9. Secure machine to the trailer of transporting vehicle with chains.

MD04263,00000C3 -19-30JAN09-1/1

2-2-13

080112

PN=63

Operation—Operating the Machine

Loading and Unloading Machine from Trailer Loading Machine on Trailer

2. Drive machine onto the trailer slowly, following the instructions of the spotter.

• Always use the aid of spotters when loading machine

3. Engage park brake.

•

4. Chock all wheels.

• • •

onto the transporting vehicle.

Be sure the transporting vehicle is capable of safely carrying machine.

When driving the machine onto other transportation vehicles, do not install the articulation lock bar until the machine is secured.

When machine is lifted onto the transportation vehicle, install the articulation locking bar.

Chock wheels when securing the machine to the transporting vehicle.

1. Position transporting trailer against the loading ramp.

NOTE: The 250D and 300D machines have 6 tie-down points, two in the front, two in the middle and two in the rear.

5. Secure machine to the trailer of transporting vehicle with chains, using machine tie-down points (1).

6. Move vehicles mirrors inward to the sides of machine.

7. Drive transporting vehicle away slowly.

1

1

TX1022448 —UN—10MAY07

1

TX1022448 Right Side Shown 1— Tie-Down Points (6 Points Total)

IMPORTANT: Avoid sudden machine movement and machine damage; install the articulation locking bar.

2. If driving machine off transporting vehicle, remove articulation locking bar.

3. Release park brake.

Machine Tie-Down Points

4. If lifting machine off transporting vehicle, install the articulation locking bar.

1. Unloading Machine from Trailer Disconnect chains securing machine to transporting vehicle.

5. Always use the aid of spotters when unloading machine from transporting vehicle.

VD76477,000150B -19-15MAY07-1/1

2-2-14

080112

PN=64

Operation—Operating the Machine

Lock All Compartments Your machine is equipped with locks on cab door, battery compartment, fuel cap, storage compartments, and hood

access door. One key will fit all locks. Use these locks to help safeguard your machine.

OUO1043,0000DCE -19-23JUL01-1/1

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080112

PN=65

Maintenance—Machine Diesel Fuel Consult your local fuel distributor for properties of the diesel fuel available in your area.

In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 are recommended. Renewable diesel fuel produced by hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel. Renewable diesel that meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels.

Sulfur Content for Tier 3 and Stage III A Engines

• Use of diesel fuel with sulfur content less than 1000 mg/kg (1000 ppm) is RECOMMENDED

• Use of diesel fuel with sulfur content 1000–5000 mg/kg (1000–5000 ppm) REDUCES oil and filter change intervals.

• BEFORE using diesel fuel with sulfur content greater

than 5000 mg/kg (5000 ppm), contact your John Deere dealer

Sulfur Content for Tier 2 and Stage II Engines

Required Fuel Properties

• Use of diesel fuel with sulfur content less than 500

In all cases, the fuel shall meet the following properties:

• Use of diesel fuel with sulfur content 500–5000 mg/kg

Cetane number of 43 minimum. Cetane number greater than 47 is preferred, especially for temperatures below –20°C (–4°F) or elevations above 1500 m (5000 ft.).

Cold Filter Plugging Point (CFPP) should be at least 5°C (9°F) below the expected lowest temperature or Cloud Point below the expected lowest ambient temperature.

Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

Diesel fuel quality and sulfur content must comply with all existing emissions regulations for the area in which the engine operates. DO NOT use diesel fuel with sulfur content greater than 10 000 mg/kg (10 000 ppm).

Sulfur content for Interim Tier 4 and Stage III B engines

• Use ONLY ultra low sulfur diesel (ULSD) fuel with a maximum of 15 mg/kg (15 ppm) sulfur content.

mg/kg (500 ppm) is RECOMMENDED.

•

(500–5000 ppm) REDUCES the oil and filter change interval BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John Deere dealer

Sulfur Content for Other Engines

• Use of diesel fuel with sulfur content less than 5000 mg/kg (5000 ppm) is recommended.

• Use of diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) REDUCES the oil and filter change intervals.

IMPORTANT: Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel.

IMPORTANT: Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines.

DX,FUEL1 -19-11APR11-1/1

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.

CED,OUO1021,174 -19-17MAR98-1/1

Testing Diesel Fuel A fuel analysis program can help to monitor the quality of diesel fuel. The fuel analysis can provide critical data such as cetane number, fuel type, sulfur content, water content, appearance, suitability for cold weather

operations, bacteria, cloud point, acid number, particulate contamination, and whether the fuel meets specification.

Contact your John Deere dealer for more information on diesel fuel analysis.

DX,FUEL6 -19-14APR11-1/1

3-1-1

080112

PN=66

Maintenance—Machine

Handling and Storing Diesel Fuel CAUTION: Reduce the risk of fire. Handle fuel carefully. DO NOT fill the fuel tank when engine is running. DO NOT smoke while you fill the fuel tank or service the fuel system.

Fill the fuel tank at the end of each day's operation to prevent water condensation and freezing during cold weather.

Keep all storage tanks as full as practicable to minimize condensation.

Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering. Monitor water content of the fuel regularly.

When using biodiesel fuel, the fuel filter may require more frequent replacement due to premature plugging.

Check engine oil level daily prior to starting engine. A rising oil level may indicate fuel dilution of the engine oil.

IMPORTANT: The fuel tank is vented through the filler cap. If a new filler cap is required, always replace it with an original vented cap.

When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel conditioner to stabilize the fuel and prevent water condensation. Contact your fuel supplier for recommendations.

DX,FUEL4 -19-14APR11-1/1

104o F

John Deere Plus-50™ is also recommended.

30 o C

86 o F

20 o C

68 o F

10 o C

50 o F

0o C

32 o F

-10 o C

14 o F

-20 o C

-4 o F

-30 o C

-22 o F

-40 o C

-40 o F

Other oils may be used if they meet one or more of the following:

• John Deere Torq-Gard™ • API Service Category CJ-4 • API Service Category CI-4 PLUS • API Service Category CI-4 • API Service Category CH-4 • ACEA Oil Sequence E9 • ACEA Oil Sequence E7 • ACEA Oil Sequence E6 • ACEA Oil Sequence E5 • ACEA Oil Sequence E4 • ACEA Oil Sequence E3

TS1689 —UN—18JUL07

40 o C

SAE 5W-30

John Deere Plus-50™ II oil is preferred.

SAE 10W-30

122o F

SAE 15W-40

50 o C

SAE 10W-40

Use oil viscosity based on the expected air temperature range during the period between oil changes.

SAE 0W-40

Diesel Engine Oil

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates.

Oil Viscosities for Air Temperature Ranges

DO NOT use diesel fuel with sulfur content greater than 10 000 mg/kg (10 000 ppm).

Plus-50 is a trademark of Deere & Company Torq-Gard is a trademark of Deere & Company DX,ENOIL7 -19-11APR11-1/1

3-1-2

080112

PN=67

Maintenance—Machine

Diesel Engine Oil and Filter Service Intervals The oil and filter service intervals in the following table should be used as guidelines. Actual service intervals also depend on operation and maintenance practices. It is suggested to use oil analysis to determine the actual useful life of the oil and to aid in selection of the proper oil and filter service interval.

Oil and filter service intervals are based on a combination of oil pan capacity, type of engine oil and filter used, and sulfur content of the diesel fuel.

Engine Oil and Filter Service Intervals Standard Drain Oil Pan Fuel Sulfur

Extended Drain Oil Pan

375 hours

500 hours

Other Oils

250 hours

250 hours

Fuel Sulfur

275 hours

400 hours

Other Oils

150 hours

150 hours

Fuel Sulfur

0.50 - 1.00% (5000 - 10 000 mg/kg)

Plus-50

187 hours

250 hours

Other Oils

125 hours

125 hours

IMPORTANT: When using biodiesel blends greater than B20, reduce the oil and filter service interval by 50% or monitor engine oil based on test results from Oilscan.

Oil types in the table include:

API CJ-4, API CI-4 PLUS, API CI-4, API CH-4, ACEA E9, ACEA E7, ACEA E6, ACEA E5, ACEA E4, or ACEA E3 oils.

0.05 - 0.50% (500 - 5000 mg/kg)

Plus-50

•

to 0.50% (5000 mg/kg) may result in REDUCED oil and filter change intervals as shown in the table.

BEFORE using diesel fuel with sulfur content greater than 0.50% (5000 mg/kg), contact your John Deere dealer.

• John Deere Plus-50™ II and John Deere Plus-50 oils.

• “Other Oils” include John DeereTorq-Gard Supreme™,

Less than 0.05% (500 mg/kg)

Plus-50

• Use of diesel fuel with sulfur content 0.05% (500 mg/kg)

NOTE: The 500 hour extended oil and filter change interval is only allowed if all the following conditions are met:

• Engine equipped with an extended drain interval oil pan

The service interval of “Other Oils” may be extended only if oil analysis is performed to determine the actual service life, to a maximum not to exceed that of Plus-50.

Diesel fuel sulfur level will affect engine oil and filter service intervals. Higher fuel sulfur levels reduce oil and filter service intervals as shown in the table.

• Use of diesel fuel with sulfur content less than 0.05% (500 mg/kg)

• Use of John Deere Plus-50™ II or John Deere Plus-50 oil

• Use of an approved John Deere oil filter

• Use of diesel fuel with sulfur content less than 0.05% (500 mg/kg) is strongly recommended.

Plus-50 is a trademark of Deere & Company Torq-Gard Supreme is a trademark of Deere & Company DX,ENOIL12 -19-03AUG09-1/1

3-1-3

080112

PN=68

Maintenance—Machine

T122287 —19—14JUL99

Hydraulic Oil

Depending on the expected air temperature range between oil changes, use oil viscosity shown on the temperature chart above.

• John Deere HY-GARD® Hydraulic Oils.

• John Deere Low Viscosity HY-GARD® Hydraulic Oils.

• You may also use other oils meeting John Deere Standard J20C, or J20D.

The following oils are preferred: HY-GARD is a trademark of Deere & Company

OUO1043,0000DFD -19-30OCT01-1/1

T164955 —19—04FEB03

Transmission and Transfer Case Oil

Use only Allison/Castrol TransSynd™ or Castrol Transmax Z or S oils.

TX14740,000001B -19-03FEB03-1/1

3-1-4

080112

PN=69

Maintenance—Machine

104˚F

30˚C

86˚F

20˚C

68˚F

10˚C

50˚F

0˚C

32˚F

-10˚C

14˚F

-20˚C

-4˚F

-30˚C

-22˚F

-40˚C

-40˚F

TX1024300 —UN—31MAY07

40˚C

SAE 140

122˚F

SAE 90

• • •

JDM J11F ZF TE-ML-05C ZF TE-ML-05D

50˚C

SAE 75W

Other oils may be used if they meet the following:

SAE 75W-80 LS

Additive

SAE 75W-90

• John Deere GEAR LUBRICANT with Limited Slip

SAE 80W-140

The following oil is preferred:

SAE 80W-90 LS

Use oil viscosity based on the expected air temperature range during the period between oil changes.

SAE 85W-140 LS

Axle Gear Oil

VD76477,000152D -19-24MAY07-1/1

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

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.

The following engine coolant is also recommended:

• John Deere COOL-GARD Coolant Concentrate in a 40 to 60% mixture of concentrate with quality water.

Coolant Drain Intervals

• ASTM D5345 (prediluted coolant) • ASTM D4985 (coolant concentrate) in a 40 to 60%

Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant after the first 8 years or 8000 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.

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.

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.

Other low silicate ethylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications:

mixture of concentrate with quality water

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.

If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.

OUO1043,0000DF2 -19-29OCT01-1/1

3-1-5

080112

PN=70

Maintenance—Machine

T144281 —19—03AUG01

Grease

Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.

• SAE Multipurpose EP grease containing 3-to-5%

The following greases are preferred:

• John Deere MOLY HIGH TEMPERATURE EP GREASE

Molybdenum Disulfide

OUO1079,0000429 -19-26JUL01-1/1

Oil Filters

Use filters meeting John Deere performance specifications.

Filtration of oils is critical to proper operation and lubrication.

Always change filters regularly as specified in this manual.

DX,FILT -19-18MAR96-1/1

Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used.

Use clean containers to handle all lubricants.

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 -19-11APR11-1/1

3-1-6

080112

PN=71

Maintenance—Machine

Alternative And Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

IMPORTANT: Avoid mixing different brands or types of oils. Oil manufacturers engineer their oils to meet certain specifications and performance requirements. Mixing different oil types can degrade lubricant and machine performance.

Consult your authorized dealer to obtain specific information and recommendations.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

TX14740,0001C42 -19-17APR06-1/1

3-1-7

080112

PN=72

Maintenance—Periodic Maintenance Service Your Machine at Specified Intervals Lubricate, make service checks, and make adjustments at intervals shown on the periodic maintenance chart and on the following pages.

Perform service on items at multiples of the original requirement. For example, at 2000 hours also service those items (if applicable) listed under 1000 hours, 500 hours, and 10 hours or daily.

OUO1079,00003BF -19-18JUN01-1/1

Use Correct Fuels and Lubricants IMPORTANT: To prevent machine damage, use correct fuels and lubricants when servicing your machine. (See Maintenance—Machine section.)

OUO1079,00003C0 -19-18JUN01-1/1

Prepare Machine for Maintenance Before performing maintenance on machine:

9. If servicing the pneumatic system, relieve pneumatic pressure. See Relieve Pneumatic Pressure in this section.)

1. Unload dump body.

2. Wash machine.

3. Park machine on firm, level ground. Steer machine to straighten frames.

4. Install articulation safety lock bar. See Install Articulation Safety Lock Bar in this section.

5. Fully lower dump body, unless specifically instructed otherwise in a maintenance procedure. If dump body must be raised, install dump body prop. See Install Dump Body Prop in this section.

6. Stop engine and engage park brake.

7. Remove key from key switch and attach a DO NOT OPERATE sign to steering wheel.

8. Relieve hydraulic pressure: a. Turn steering wheel back and forth 3 times. b. If dump body is fully lowered, hydraulic pressure is automatically relieved. If dump body is raised and dump body prop is installed, move dump body control lever forward and rearward 3 times to ensure that the weight of the dump body is securely settled onto the dump body prop.

CAUTION: Prevent possible injury from unexpected machine movement. Prevent rollaway. Install wheel chocks on at least one axle.

10. Install wheel chocks to ensure that machine cannot move backward or forward during service.

CAUTION: Prevent possible injury. Be careful when working with hot equipment and fluids. Hot equipment and fluids can cause burns to unprotected skin.

11. Allow time for the engine and all fluids to cool, unless specifically instructed otherwise in a maintenance procedure.

NOTE: The air conditioning system is charged with gas under pressure. Air conditioning service should be performed only by a qualified technician with proper equipment. (See your authorized dealer.)

OUO1079,00003BD -19-07FEB03-1/1

3-2-1

080112

PN=73

Maintenance—Periodic Maintenance

Install Dump Body Prop

T143166B —UN—21JUN01

CAUTION: Prevent possible injury from unexpected machine movement. When the dump body is raised to perform maintenance tasks, the dump body prop must be installed.

NOTE: Operate the dump body control lever in the operator's station to raise and lower the dump body.

1. Raise dump body high enough to allow dump body prop (1) to be fully raised.

2. Use handle (4) to raise dump body prop. Ensure that stop bolt (3) is in firm contact with stop (2).

CAUTION: Prevent possible injury from unexpected machine movement. Check to ensure that the dump body prop is seated securely in retaining cup.

1— Dump Body Prop 2— Stop 3— Stop Bolt

4— Handle 5— Retaining Cup

3. Lower dump body until dump body prop is seated securely in retaining cup (5).

4. Relieve hydraulic pressure before servicing machine.

OUO1079,00003C9 -19-07FEB03-1/1

Install Articulation Safety Lock Bar 1. Steer machine to straighten articulation joint.

2. Stop engine and engage park brake.

T147644B —UN—09NOV01

3. Remove keys from key switch and attach a DO NOT OPERATE sign to steering wheel.

4. Remove pin (3) from articulation safety lock bar (2) and storage location (1).

5. Swing articulation safety bar rearward to locked position. Ensure that holes line up on locking lug (4).

6. Install pin through articulation safety lock bar and locking lug.

1— Storage Location 2— Articulation Safety Lock Bar

3— Pin 4— Locking Lug

OUO1043,0000DFE -19-30OCT01-1/1

Lower and Raise Bottom Guard

Lift bottom guard into place and install cap screws to raise bottom guards.

1— Front Bottom Guard Cap Screw 2— Front Bottom Guard

3— Rear Bottom Guard Cap Screw 4— Rear Bottom Guard

T147645B —UN—19NOV01

Remove front bottom guard cap screws (1) to lower front bottom guard (2) or remove rear bottom guard cap screws (3) to rear bottom guard lower rear bottom guard (4).

OUO1043,0000DFF -19-30OCT01-1/1

3-2-2

080112

PN=74

Maintenance—Periodic Maintenance

Relieve Pneumatic Pressure

1— Pneumatic Reservoir

T148041B —UN—15NOV01

Push and hold stem of drain valve (2) on pneumatic reservoir (1). Air will discharge through drain valve under pressure. Hold stem until “hiss” stops completely.

2— Drain Valve

OUO1043,0000E00 -19-30OCT01-1/1

3-2-3

080112

PN=75

Maintenance—Periodic Maintenance

Tilt Cab Raising Cab

T147647B —UN—08NOV01

1. Park the machine on level ground with dump body lowered. Engage park brake. Turn ignition switch OFF. Turn battery disconnect switch OFF. 2. Move mirrors to normal operating position. Ensure that no people or loose objects are inside cab or on right-side platform. Close cab door and right-side compartment access door securely.

3. Open hood.

Left-Rear Cab Mount Shown

4. Remove cab mounting cap screws, washers, and nuts (1) from left-front and left-rear cab mounts.

5. Rotate pump valve lever (8) counterclockwise to raise position.

NOTE: Pump handle is stored on floor of cab, to left of operator's seat.

T147648B —UN—08NOV01

6. Remove pump handle (6) from storage position. Insert pump handle into pump socket (5).

7. Operate pump using long, firm strokes to raise the cab. When cab is fully raised, support pin (3) must line up with detent slot (2) at top of support strut (4).

CAUTION: Prevent possible injury from unexpected machine movement. DO NOT work under the raised cab unless the support strut is properly engaged.

Cab Shown Lowered

8. While pushing support strut handle (7) toward machine, slowly rotate pump valve lever clockwise to lower position. Cab will begin to “float” down. Support pin MUST be seated securely in detent slot at top of support strut.

1— Cab Mounting Cap Screw, Washer, and Nut (4 used) 2— Detent Slot 3— Support Pin 4— Support Strut

5— Pump Socket 6— Pump Handle 7— Support Strut Handle 8— Pump Valve Lever

3. While pulling support strut handle away from machine, slowly rotate pump valve lever clockwise to lower position. Allow cab to lower until cab mounts are at rest.

9. Rotate pump valve lever counterclockwise to raise position.

Lowering Cab

CAUTION: Avoid possible injury from crushing and pinching. Use proper tools when installing cab mounting hardware. DO NOT grasp cab mounts with bare hands when support strut is not securely engaged.

1. Ensure that no people or foreign objects are present under the cab, and that the cab's movement is not obstructed.

2. Operate pump to raise cab fully. Support pin must slide free of detent slot at top of support strut.

NOTE: Install new mounting hardware when cab is lowered.

CAUTION: Prevent possible injury from unexpected machine movement. Cab will “float” down when pump valve lever is rotated clockwise. Stay clear of cab while lowering.

4. Install new cab mounting cap screws, washers, and nuts on left-side cab mounts. Tighten to specification.

Cab—Specification Mounting Cap Screws—Torque......................................................... 210 N·m (155 lb-ft)

NOTE: Support strut handle must be pulled away from machine while cab is lowered, or support pin will engage secondary detent position on support strut.

5. Remove pump handle from pump socket. Install pump handle in storage position.

Continued on next page

3-2-4

OUO1043,0000E01 -19-07FEB03-1/2

080112

PN=76

Maintenance—Periodic Maintenance

Maintenance and Repair Record Keeping System The checklist in this section summarizes scheduled maintenance, and parts and oil required at each maintenance interval.

Use the checklist to:

• Remind you to perform machine maintenance at specified intervals to minimize downtime.

• Calculate cost of machine operation and ownership allowing you to make better job estimates.

• Place yourself in a stronger position at trade-in time.

• Satisfy your SECURE contract requirements.

As maintenance is performed, check off each item on the list and record date and hour meter reading.

T7511CO —UN—27JUN91

Do not tear out or mark on checklist in this section; keep it to make extra copies.

TX,50,FF2898 -19-27SEP07-1/1

Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit

Engine, hydraulic, power train, and coolant samples should be taken from each system on a periodic basis, usually prior to a filter and/or fluid change interval. Certain systems require more frequent sampling. Consult your authorized John Deere dealer on a maintenance program for your specific application. Your authorized John Deere dealer has the sampling products and expertise to assist you in lowering your overall operating costs through fluid sampling.

TX1003513A —UN—20FEB06

Fluid Analysis Program Test Kits and the 3-Way Coolant Test Kit are John Deere fluid sampling products to help you monitor machine maintenance and system condition. The objective of a fluid sampling program is to ensure machine availability when you need it and to reduce repair costs by identifying potential problems before they become critical.

Fluid Analysis Kits

AM40430,00002FE -19-19OCT11-1/1

3-2-5

080112

PN=77

Maintenance—Periodic Maintenance

Maintenance and Repair Record Keeping System SERVICE INTERVALS Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 2000 hours, also service those items (if applicable) listed under 1000 hours, 500 hours, and 10 hours or daily.

As Required • Check and clean engine air cleaner and pre-cleaner bowl

• Check tire pressure

• Replace primary and secondary air cleaner filters

• Drain sediment from water separator and clean strainer

• Check and clean cooling system

• Inspect belt

• Check and clean axle, transmission and transfer case breathers Every 10 Hours or Daily • Check engine coolant level

• Check transfer case oil level

• Check engine oil level

• Check hydraulic system oil level

• Check transmission for leaks

• Grease dump body pivot pins

• Grease tailgate pivots-if equipped

• Grease steering cylinder rod ends

• Grease oscillation joint and thru drive bearing

• Grease articulation joints Initial Service - 100 Hours*

*Perform initial service once after the first 100 hours of operation • Change engine oil and replace filter

• Change transfer case oil

• Replace hydraulic system return filter

• Change axle oil

• Replace primary fuel filter

• Change final drive oil

Model: 250D and 300D Articulated Dump Truck

Customer: Delivery Date:

PIN/Serial Number:

OIL SAMPLING Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form: 500, 1000, 2000, 4000 hours. Maintenance recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you supply.

Regular oil sampling will extend the operational life of your machine’s systems.

Every 250 Hours □ Take diesel engine oil sample

□ Take hydraulic oil sample Every 500 Hours

□ Change engine oil and replace filter

□ Check transmission oil level

□ Check park brake pad wear

□ Check and clean hydraulic breather

□ Check service brake pad wear

□ Grease steering cylinder rod ends

□ Check suspension strut height, leakage, and boot condition

□ Replace in-line fuel filter strainer

□ Clean or replace cab air filter

□ Replace primary fuel filter

□ Check battery electrolyte level; clean and tighten terminals

□ Replace final fuel filter

□ Take transfer case oil sample

□ Take engine coolant sample

□ Take final drive oil sample

□ Take diesel fuel sample

□ Take transmission oil sample

□ Take axle oil sample Every 1000 Hours

□ Check axle and final drive oil levels

□ Check and adjust bin shock pad

□ Replace hydraulic breather filter

□ Grease prop shaft slip joint Every 2000 Hours

□ Check and adjust engine valve clearance

□ Drain and refill axle and final drive oil

□ Drain and refill transmission oil

□ Replace pneumatic system air dryer filter

□ Replace transmission filters

□ Replace hydraulic system return filter

□ Drain and refill transfer case oil Every 4000 Hours □ Drain and refill hydraulic tank

□ Replace pneumatic block silencer filters

□ Replace hydraulic suction screen Every 4500 Hours □ Replace engine torsional damper Every 5000 Hours Continued on next page

3-2-6

MD04263,000005A -19-26DEC08-1/3

080112

PN=78

Maintenance—Periodic Maintenance □ Drain, flush and refill engine cooling system REQUIRED PARTS Ensure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated parts are also on hand, i.e., filter O-rings.

Item

Part Number

Initial Service 100 Hours

Engine Oil Filter Kit

RE509672

Every 500 Hours

Every 1000 Every 2000 Every 4000 Hours Hours Hours

Every 4500 Hours

Every 5000 Hours

1

1

1

1

1

1

1

Primary Fuel TT206616 Filter (S.N. 200537--201014)

1

1

1

1

1

1

1

10 Micron Primary Fuel Filter (S.N. 201015—)

RE522687

1

1

1

1

1

1

1

Final Fuel Filter (S.N.—201014)

RE522372

1

1

1

1

1

1

2 Micron Final Fuel Filter (S.N. 201015—)

RE522688

1

1

1

1

1

1

In-Line Fuel Filter AT223493 (S.N. 201015—)

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Transmission Oil Filter

Every 250 Hours

TTZF21042 4

Pneumatic AT252831 System Air Dryer Filter Hydraulic System TT220735 Return Filter Hydraulic Reservoir Breather Filter

TT220010

Cab Air Filter

TT226019

1

1

1

Hydraulic Suction TT210497 Screen

1

Pneumatic Block TT226348 Silencer Filters

2

Engine Torsional Damper

RE500934

Transmission, Transfer Case and Axle Breather Filter

AT253791

As required

Air Cleaner Primary Element

TT220725

As required

Air Cleaner Secondary Element

TT220747

As required

Coolant Conditioner

TY16004

As required

PLUS-50™ Engine Oil

TY6389*

HY-GARD™ Hydraulic Oil

TY6354*

Allison/Castrol TransSynd Transmission Oil

TY25007*

4.7 L (5.0 qt)

27 L (7.1 gal)

27 L (7.1 gal)

API GL-5 Gear Oil with Limited Slip Additive

TY25050*

90 L (24 gal)

90 L (24 gal)

90 L (24 gal)

1

1

1

1

1

25.5 L (6.7 gal)

25.5 L (6.7 gal)

25.5 L (6.7 gal)

25.5 L (6.7 gal)

25.5 L (6.7 gal)

25.5 L (6.7 gal)

25.5 L (6.7 gal)

79 L (21 gal)

Pre-diluted TY16036 Radiator Coolant

26.5 L (7 gal) Continued on next page

3-2-7

MD04263,000005A -19-26DEC08-2/3

080112

PN=79

Maintenance—Periodic Maintenance REQUIRED PARTS Fluid Analysis Kits •Diesel Engine Oil

AT317904

1

1

1

1

1

1

1

•Hydraulic Oil

AT303189

1

1

1

1

1

1

1

•Transmission Oil AT303189

1

1

1

1

1

1

•Transfer Case Oil

AT303189

1

1

1

1

1

1

•Axle Oil

AT303189

3

3

3

3

3

3

•Final Drive Oil

AT303189

6

6

6

6

6

6

•DieselScan™

AT180344

1

1

1

1

1

1

•COOLSCAN PLUS™

AT183016

1

1

1

1

1

1

3 Way Heavy Duty Coolant Test

TY16175

1

1

1

1

*For oil type and oil viscosities based on operating temperatures see Maintenance-Machine. (Section 3-1).

PLUS-50 is a trademark of Deere & Company HY-GARD is a trademark of Deere & Company DieselScan is a trademark of Deere & Company COOLSCAN PLUS is a trademark of Deere & Company MD04263,000005A -19-26DEC08-3/3

3-2-8

080112

PN=80

Maintenance—As Required Service Engine Air Intake System 1. Empty the precleaner bowl.

b. Remove precleaner bowl (3). Empty precleaner bowl and wipe clean with a lint-free cloth. c. Install precleaner bowl and lid. Tighten wing nut.

2. Check service indicator (4). If window shows a red flag, service air cleaner filter elements. a. Unfasten clasps (5) and remove air cleaner cover (6).

T147649B —UN—09NOV01

a. Loosen wing nut (1) and remove lid (2).

NOTE: At minimum, secondary element must be replaced every third time primary element is replaced. c. Remove and inspect secondary element (8).

Replace, if necessary. d. Wipe dust from air cleaner housing (9) with a lint-free cloth. Squeeze unloader valve to empty air cleaner housing of dust and debris. Inspect air cleaner housing for damage.

T147650B —UN—09NOV01

b. Remove and inspect primary element (7). Replace, if necessary.

f. Install primary element, ensuring that it is firmly and evenly seated. g. Install air cleaner cover and fasten clasps.

3. Press top of service indicator to reset flag.

1— Wing Nut 2— Lid 3— Precleaner Bowl 4— Service Indicator 5— Clasp (4 used)

6— Air Cleaner Cover 7— Primary Element 8— Secondary Element 9— Air Cleaner Housing

T147651B —UN—09NOV01

e. Install secondary element, ensuring that it is firmly and evenly seated.

OUO1043,0000E03 -19-30OCT01-1/1

3-3-1

080112

PN=81

Maintenance—As Required

Inspect and Clean Cooling Systems Inspect Cooling Systems 1. Inspect components of cooling system for damage.

2. Inspect hoses and clamps for damage and tightness.

T147907B —UN—15NOV01

3. Inspect mountings and hardware for damage and tightness.

4. Inspect fins for damage and cleanliness. Ensure that there is no restriction to air flow. Clean cooling systems, if necessary.

Clean Cooling Systems 1. Turn battery disconnect switch OFF. 2. Remove cap screws, lock nuts (1) and fan guard (2).

IMPORTANT: Use a pressure washer and a mild detergent that is not caustic to aluminum when cleaning cooling systems.

Do not spray cooling system fins at an angle. Fins may bend.

T148541C —UN—28NOV01

3. Raise hood and wash front cooling system, spraying from rear face (3) to front face. Keep cooling system free of debris and obstructions which may restrict air flow.

4. Install fan guard, cap screws and lock nuts.

5. Open battery compartment door.

6. Spray outer face of transmission cooler (4). Keep cooling system free of debris and obstructions which may restrict air flow.

7. Turn battery disconnect switch ON and close hood and battery compartment door.

1— Lock Nut (6 used) 2— Fan Guard

3— Rear Face of Cooling System 4— Outer Face of Transmission Cooler OUO1043,0000E05 -19-30OCT01-1/1

3-3-2

080112

PN=82

Maintenance—As Required

Clean, Inspect, and Replace—Transmission, Transfer Case, and Axle Breathers

T147909B —UN—15NOV01

IMPORTANT: DO NOT spray steam, water or cleaning solution directly at breathers. Spray could be forced into housings.

NOTE: Breathers should be checked daily in adverse working conditions. The amount of dust and dirt encountered will determine the frequency of breather cleaning.

The cab must be tilted to access the transmission breather cap and front axle breather.

Located Under Hydraulic Reservoir

1. Clean dirt, dust, and debris from each breather (1—5) and from surrounding areas.

T147908B —UN—15NOV01

IMPORTANT: DO NOT crush or damage breathers during removal. Foreign matter may enter housings.

2. Inspect each breather for clogging, damage, and proper installation. If necessary, remove clogged breather(s) from machine and clean with water. Dry thoroughly before reinstalling. Replace any breather that appears damaged or cannot be unclogged.

Tighten to specification.

Breather—Specification Tightening—Torque................................... 12—16 N·m (106—142 lb-in.)

Located Under Cab

3. Inspect axle breather hoses for clogging, damage, and proper installation.

1— Transfer Case Breather 2— Transmission Breather Cap 3— Front Axle Breather

T147910B —UN—15NOV01

If necessary, clear breather hose(s). Replace any breather hose that appears damaged or cannot be unclogged.

4— Middle Axle Breather 5— Rear Axle Breather

Located Above Rear Axles OUO1043,0000E06 -19-30OCT01-1/1

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PN=83

Maintenance—As Required

Inspect Tires, Check Pressure

TX1021707 —19—20APR07

CAUTION: Prevent possible injury from tire blowout. Ensure that tires are properly inflated.

Improperly inflated tires can cause excessive heat build-up, excessive or uneven tire wear, or rim damage, resulting in blowouts.

NOTE: Shipping pressure may not be the same as operating pressure. You may change tire pressures to suit working condition according to tire manufacturer’s recommendations.

Maximum Permissible Differences in Tire Diameters

1. Ensure that valve caps are installed.

2. Check for wear and cuts to tires. Consult your authorized dealer if in doubt about the serviceability of a damaged tire.

3. Check tire pressures.

IMPORTANT: In the interest of the drivetrain reliability in the 6x6 ADT's, the maximum permissible difference in tire diameter across axles and between axles is 2%. Failure to adhere to this recommendation could result in premature drivetrain failure. Only factory approved tire sizes are to be used on all machines. Should retreaded tires be used, it is important to ensure that the original tire diameter is maintained and or falls within the 2% guideline.

Tires—250D 23.5 R 25—Michelin XADN—Specification Front Axle Tires—Pressure........................................................................... 250 kPa 2.50 bar 36 psi Middle Axle Tires—Pressure........................................................................... 303 kPa 3.03 bar 44 psi Rear Axle Tires—Pressure........................................................................... 275 kPa 2.75 bar 44 psi 23.5 R 25—Goodyear RL2+—Specification Front Axle Tires—Pressure........................................................................... 269 kPa 2.69 bar 39 psi Middle Axle Tires—Pressure........................................................................... 317 kPa 3.17 bar 46 psi Rear Axle Tires—Pressure........................................................................... 317 kPa 3.17 bar 46 psi

23.5 R 25—Bridgestone VLT—Specification Front Axle Tires—Pressure........................................................................... 352 kPa 3.52 bar 51 psi Middle Axle Tires—Pressure........................................................................... 400 kPa 4 bar 58 psi Rear Axle Tires—Pressure........................................................................... 400 kPa 4 bar 58 psi 23.5 R 25—Continental STL3/STL2+—Specification Front Axle Tires—Pressure........................................................................... 324 kPa 3.24 bar 47 psi Middle Axle Tires—Pressure........................................................................... 372 kPa 3.72 bar 54 psi Rear Axle Tires—Pressure........................................................................... 372 kPa 3.72 bar 54 psi 23.5 R 25—Yokohama RB31—Specification Front Axle Tires—Pressure........................................................................... 352 kPa 3.52 bar 51 psi Middle Axle Tires—Pressure........................................................................... 400 kPa 4 bar 58 psi Rear Axle Tires—Pressure........................................................................... 400 kPa 4 bar 58 psi 23.5 R 25—Pirelli RM94—Specification Front Axle Tires—Pressure........................................................................... 325 kPa 3.25 bar 47 psi

Continued on next page

3-3-4

VD76477,000047C -19-20APR07-1/3

080112

PN=84

Maintenance—As Required Middle Axle Tires—Pressure........................................................................... 350 kPa 3.50 bar 51 psi Rear Axle Tires—Pressure........................................................................... 350 kPa 3.50 bar 51 psi 23.5 R 25—Toyo T-331—Specification Front Axle Tires—Pressure........................................................................... 325 kPa 3.25 bar 47 psi Middle Axle Tires—Pressure........................................................................... 375 kPa 3.75 bar 54 psi Rear Axle Tires—Pressure........................................................................... 375 kPa 3.75 bar 54 psi 23.5 R 25—Triangle TB516—Specification Front Axle Tires—Pressure........................................................................... 325 kPa 3.25 bar 47 psi Middle Axle Tires—Pressure........................................................................... 375 kPa 3.75 bar 54 psi Rear Axle Tires—Pressure........................................................................... 375 kPa 3.75 bar 54 psi

Tires—300D 23.5 R 25—Michelin XADN—Specification Front Axle Tires—Pressure........................................................................... 275 kPa 2.75 bar 40 psi Middle Axle Tires—Pressure........................................................................... 375 kPa 3.75 bar 54 psi Rear Axle Tires—Pressure........................................................................... 375 kPa 3.75 bar 54 psi 750/65R25—Michelin XAD65-1—Specification Front Axle Tires—Pressure........................................................................... 250 kPa 2.50 bar 36 psi Middle Axle Tires—Pressure........................................................................... 275 kPa 2.75 bar 40 psi

Rear Axle Tires—Pressure........................................................................... 275 kPa 2.75 bar 40 psi 23.5 R 25—Goodyear RL2+—Specification Front Axle Tires—Pressure........................................................................... 300 kPa 3.00 44 psi Middle Axle Tires—Pressure........................................................................... 380 kPa 3.8 bar 55 psi Rear Axle Tires—Pressure........................................................................... 380 kPa 3.8 bar 55 psi 23.5 R 25—Bridgestone VLT—Specification Front Axle Tires—Pressure........................................................................... 375 kPa 3.75 bar 54 psi Middle Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi Rear Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi 23.5 R 25—Continental STL3/STL2+—Specification Front Axle Tires—Pressure........................................................................... 350 kPa 3.5 bar 51 psi Middle Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi Rear Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi 23.5 R 25—Yokohama RB31—Specification Front Axle Tires—Pressure........................................................................... 375 kPa 3.75 bar 54 psi Middle Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi Rear Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi

23.5 R 25—Pirelli RM94—Specification Front Axle Tires—Pressure........................................................................... 350 kPa 3.50 bar Continued on next page VD76477,000047C -19-20APR07-2/3

3-3-5

080112

PN=85

Maintenance—As Required 51 psi Middle Axle Tires—Pressure........................................................................... 400 kPa 4.0 bar 58 psi Rear Axle Tires—Pressure........................................................................... 400 kPa 4.0 bar 58 psi 23.5 R 25—Toyo T-331—Specification Front Axle Tires—Pressure........................................................................... 350 kPa 3.50 bar 51 psi Middle Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi

Rear Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi 23.5 R 25—Triangle TB516—Specification Front Axle Tires—Pressure........................................................................... 350 kPa 3.50 bar 51 psi Middle Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi Rear Axle Tires—Pressure........................................................................... 450 kPa 4.5 bar 65 psi VD76477,000047C -19-20APR07-3/3

Drain Fuel Filters (S.N.—201014) 1. Open hood.

T165115B —UN—11FEB03

2. Loosen drain valve (1). Drain liquid for several seconds or until water and sediment is removed.

3. Tighten drain valve.

1— Drain Valve

TX14740,0000180 -19-21JUL04-1/1

Drain Fuel Filters (S.N. 201015—) 1. Open hood.

T201824A —UN—22JUL04

2. Loosen drain valves (1). Drain liquid for several seconds or until water and sediment is removed.

3. Tighten drain valves.

1— Drain Valve

TX14740,000017C -19-21JUL04-1/1

Inspect Serpentine Belt Inspect serpentine belt for wear, fraying, splitting, cracking, damage, dirt, and debris.

Replace serpentine belt, if necessary. (See your authorized dealer.)

OUO1079,00003FF -19-19JUL01-1/1

3-3-6

080112

PN=86

Maintenance—Every 10 Hours or Daily Check Engine Coolant Level CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

TS281 —UN—23AUG88

Remove filler cap only when engine is cold or when cool enough to touch with bare hands.

Slowly loosen fill cap to first stop to relieve pressure before removing completely.

IMPORTANT: If this machine is factory filled with Caltex extended life coolant, Deere COOL-GARD® coolant can be used at top-off.

1. Check coolant level in expansion tank (1). Remove filler cap (2), or shine light through tank so coolant level is visible. Cold coolant should not be below the ADD mark. Hot coolant should not be above FULL mark.

T147658B —UN—09NOV01

NOTE: If expansion tank is overfilled while engine is cold, expansion tank will overflow and excess coolant will purge during machine operation.

IMPORTANT: When the system needs top-off the first time, add two pints (32 oz) of John Deere Coolant Conditioner. Finish topping-off with JD COOL-GARD. 2. Add coolant at fill port, if necessary.

1— Expansion Tank

2— Filler Cap

COOL-GARD is a trademark of Deere & Company TX14740,000001C -19-08AUG05-1/1

Check Engine Oil Level 1. Park machine on level ground.

2. Allow time for engine to cool and oil to settle in oil pan.

Open hood.

3. Remove dipstick (1) and wipe clean with a lint-free cloth.

4. Insert dipstick until fully seated.

T147659B —UN—19NOV01

NOTE: Check engine oil level with engine cold

1— Dipstick Continued on next page

3-4-1

OUO1043,0000E0A -19-30OCT01-1/2

080112

PN=87

Maintenance—Every 10 Hours or Daily

5. Remove dipstick and check oil level. Oil level should be in the full mark (2).

6. If oil level is in low mark (1), add oil as necessary.

2— Full Mark

T148256B —UN—19NOV01

1— Low Mark

OUO1043,0000E0A -19-30OCT01-2/2

Check Transfer Case Oil Level

2. Add or drain oil, if necessary. See Change Transfer Case Oil. Section 3-8.)

1— Sight Glass

T147662B —UN—19NOV01

1. Check oil level at sight glass (1). Oil level should be to middle of sight glass.

OUO1043,0000E0C -19-30OCT01-1/1

Check Hydraulic Oil Level

1. Fully lower the dump body.

2. Check oil level in sight glass (1). Oil level must be visible.

3. If no oil is visible in sight glass, add oil to hydraulic oil reservoir. If sight glass is completely filled with oil, drain excess oil. See Change Hydraulic Oil . (Section 3-9.)

T147663B —UN—19NOV01

IMPORTANT: Prevent damage to hydraulic system components. DO NOT run engine without oil in hydraulic oil reservoir.

1— Sight Glass OUO1043,0000E0D -19-30OCT01-1/1

3-4-2

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PN=88

Maintenance—Every 10 Hours or Daily

Grease Dump Body Pivot Pins

T148150B —UN—08JAN02

Apply grease to lubrication fittings (9) and (10) until it escapes at joints. See Grease. (Section 3-1.)

AM40430,00000E9 -19-29JUL05-1/1

Lubricate Tailgate Pivots—If Equipped Add 1 shot of grease at each lubrication fitting (1).

T148411B —UN—26NOV01

1— Lubrication Fitting—Tailgate Pivot (2 used)

OUO1043,0000E13 -19-30OCT01-1/1

3-4-3

080112

PN=89

Maintenance—Initial Service - 100 Hours Change Engine Oil and Replace Filter

T147664B —UN—19NOV01

NOTE: Perform this service after the first 100 hours of operation and at 500 hour intervals thereafter.

CAUTION: Be careful when draining hot engine oil. Hot engine oil can cause burns to unprotected skin.

NOTE: The engine oil will drain easier when engine is warm.

1. Run engine to warm oil slightly. Stop engine.

2. Open hood. Remove engine oil dipstick and fill cap.

3. Lower rear bottom guard. See Lower and Raise Bottom Guard. (Section 3-2.)

T147665B —UN—19NOV01

4. Install hose to drain valve with a hose clamp. Put end of hose into a container.

NOTE: Dispose of waste properly.

5. Loosen nut (2) and loosen valve stem (1). Drain oil into container.

Engine—Specification Oil—Capacity............................................................ 25.5 L approximate 6.7 gal

6. Tighten valve stem and tighten nut. Remove hose clamp (4) and hose (5). Wipe excess oil from drain valve (3).

1— Valve Stem 2— Nut 3— Drain Valve

4— Hose Clamp 5— Hose 6— Filter

7. Clean dirt and debris from engine oil filter cap and surrounding area.

11. Install engine oil dipstick and fill cap.

8. Remove engine oil filter (6).

12. Start engine and let it run at slow idle for 1 minute.

Check for oil leaks at engine oil filter and drain valve.

Tighten only enough to stop leaks.

9. Lubricate seal ring on new filter with a small amount of clean engine oil. Fill filter with clean engine oil and install to filter head. Hand-tighten.

13. Check engine oil level.

14. Raise rear bottom guard.

IMPORTANT: Do not overfill the engine with oil.

10. Add oil at fill port. Do not overfill. See Diesel Engine Oil. (Section 3-1.)

TX14740,0000011 -19-29JUL05-1/1

3-5-1

080112

PN=90

Maintenance—Initial Service - 100 Hours

Replace Hydraulic System Oil Return Filter

T147657B —UN—13NOV01

NOTE: Perform this service after the first 100 hours of operation and at 2000 hour intervals thereafter.

In dry and/or dusty conditions, this service may need to be performed every 1000 hours.

1. Remove nuts (2) and clamp (3) from dump body heater support and pipe, if equipped.

2. Remove cap screws (1) and access cover (4).

3. Turn hydraulic reservoir breather (2) counterclockwise and remove from machine.

4. Clean area around return filter cover (3).

T147656C —UN—13NOV01

CAUTION: Avoid personal injury. Remove return filter cover carefully. Spring is under load.

5. Remove filter cover. Loosen and remove opposite sets of cap screws (5) in sequence, to keep spring load distributed evenly. Hold filter cover securely in place while removing last 2 cap screws and washers, then release slowly to relieve spring load.

6. Inspect filter cover seal ring for damage and wear.

Replace, if necessary.

7. Grasp spring and remove spring and return filter assembly.

T143811C —UN—13NOV01

8. Clean filter seat. Do not allow dirt, debris, or foreign objects to fall into hydraulic reservoir.

9. Remove retaining screw (7). Remove element (8).

10. Inspect shoulder seal ring (9) and face seal ring (10) for damage and wear. Replace, if necessary.

IMPORTANT: Use only recommended filters which have correct micron filtration rating for the hydraulic system. (See your authorized dealer.)

11. Install new element. Install retaining screw. Ensure that element is centered on face seal ring.

12. Install spring and filter element assembly. Ensure that shoulder seal ring is properly seated in filter seat.

13. Install filter cover and cap screws. Ensure that filter cover is free of dirt and debris before installing. Tighten opposite cap screws and washers in sequence, to ensure that filter cover seal ring is compressed uniformly.

1— Cap Screw (4 used) 2— Nut—If Equipped (2 used) 3— Dump Body Heater Pipe Clamp—If Equipped 4— Access Cover 5— Filter Cover Cap Screw

6— Filter Cover 7— Retaining Screw 8— Element 9— Shoulder Seal Ring 10— Face Seal Ring

15. Install clamp and nuts to dump body heater support and pipe, if equipped.

14. Install access cover and cap screws.

OUO1043,0000E20 -19-13JUN06-1/1

3-5-2

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PN=91

Maintenance—Initial Service - 100 Hours

Replace Primary Fuel Filter (S.N. 201015—) NOTE: Perform this service after the first 100 hours of operation and at 500 hour intervals thereafter.

T213129A —UN—02AUG05

1. Disconnect the WIF sensor connector (1).

2. Turn primary fuel filter (2) counterclockwise to remove.

Allow sediment to drain into a container. Dispose of waste properly.

3. Clean filter base.

4. Install new filter. (Follow instructions on filter.)

5. Install sensor connector.

1— Sensor Connector 2— Primary Fuel Filter

6. Bleed fuel system. See Bleeding Fuel System.

Section 4-1.)

3— Final Fuel Filter

AM40430,00000EB -19-29JUL05-1/1

Change Transfer Case Oil NOTE: Perform this service after the first 100 hours of operation and at 2000 hour intervals thereafter.

T147975B —UN—19NOV01

1. Remove fill plug and sealing ring (1). Clean fill plug and sealing ring. Inspect sealing ring. Replace sealing ring, if necessary.

NOTE: Dispose of waste properly.

2. Put a container under drain plug (2). Remove drain plug and drain oil into container.

Transfer Case—Specification Oil—Capacity................................................................................... 4.7 L 5.0 qt

3. Clean drain plug thoroughly.

T147662C —UN—19NOV01

4. Install drain plug. Tighten to specification.

Transfer Case—Specification Drain Plug and Fill Plug Tightening—Torque............................................................... 25—32 N·m 38—45 lb-ft

5. Add oil at fill port. Do not overfill. Oil level should be to middle of sight glass (3).

6. Install fill plug and sealing ring.

7. Start engine. Drive machine in low gears for 1 minute.

Stop engine.

1— Fill Plug and Sealing Ring 2— Drain Plug

3— Sight Glass

8. Check for leaks at drain plug. Tighten only enough to stop leaks.

9. Check oil level at sight glass. Oil level should be to middle of sight glass. Add more oil, if necessary.

OUO1043,0000E1C -19-29JUL05-1/1

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080112

PN=92

Maintenance—Initial Service - 100 Hours

Change Axle Oil NOTE: Perform this service after the first 100 hours of operation and at 2000 hour intervals thereafter.

T147833B —UN—18DEC01

NOTE: Perform this procedure for each axle. The procedure is the same for all axles.

1. Clean axle housing around check and fill plug (1) and drain plug (2).

NOTE: Dispose of waste properly.

2. Remove axle drain plug (2) from axle housing and allow oil to drain into a container. For middle axle, remove adapter case drain plug (3).

Axle—Specification Oil (Each)—Capacity...................................................................... 21.9 L 5.8 gal

1— Check and Fill Plug 2— Axle Drain Plug

3— Adapter Case Drain Plug (Middle Axle Only)

5. Install check and fill plug.

3. Clean drain plug(s) and install in axle housing.

4. Add oil at check and fill port. See Axle and Final Drive Oil. (Section 3-1.)

OUO1043,0000E1D -19-29JUL05-1/1

Change Final Drive Oil NOTE: Perform this service after the first 100 hours of operation and at 2000 hour intervals thereafter.

NOTE: Perform this procedure for each final drive. The procedure is the same for all final drives.

1. Rotate wheel until drain plug (1) is at lowest point.

NOTE: Dispose of waste properly.

2. Remove drain plug from final drive and allow oil to drain into a container.

T147834B —UN—13NOV01

Final Drive—Specification Oil (Each)—Capacity........................................................................ 4.0 L 4.2 qt

3. Clean drain plug of oil and debris. Install drain plug tightly.

4. Remove check and fill plug (2) and fill final drive with clean oil, until oil flows from the check and fill port.

See See Axle and Final Drive Oil. (Section 3-1.)

1— Drain Plug

5. Install check and fill plug.

2— Check and Fill Plug OUO1043,0000E1E -19-29JUL05-1/1

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PN=93

Maintenance—Every 500 Hours Check Park Brake Pad Wear 1.

Raise the dump body and install the dump body prop.

2. Measure thickness of park brake pads.

3. If either of the brake pads has worn to minimum specified thickness, both brake pads must be replaced.

(See your authorized dealer.)

T124415B —UN—09SEP99

Park Brake—Specification Pad—Thickness............................................................3.0 mm minimum 0.12 in. minimum

OUO1079,00003CD -19-19MAY06-1/1

Check Dry Caliper Service Brake Pad Wear NOTE: If operating in wet or muddy conditions, check wear indicators every 250 hours.

T148251B —UN—26NOV01

1. Remove cap screws (2) and upper brake shield (1).

2. Inspect brake pads (3) for wear. If pads are not within specification, see your authorized dealer.

Service Brakes—Specification Pad—Thickness............................................... 3 mm (0.12 in.) Minimum

3. Install upper brake shield and cap screws.

250D Shown; 300D Similar

4. Repeat procedure for each wheel.

3— Brake Pad (2 used)

T148252B —UN—26NOV01

1— Upper Brake Shield 2— Cap Screw (2 used)

OUO1043,0000E0F -19-30OCT01-1/1

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080112

PN=94

Maintenance—Every 500 Hours

Check Front Axle Suspension Struts NOTE: If operating in wet or muddy conditions, check front axle suspension struts every 250 hours.

NOTE: Struts must be checked at ambient temperatures, i.e. when the machine has not been operating during the work shift.

1. Park machine on a level surface with an empty bin and install articulation lock.

A

2. Clean boot and surrounding area. Inspect boot for damage. Replace if necessary.

TX1008608 —UN—07JUN06

3. From a stand still and with the articulation lock installed, drive straight forward aggressively for approximately 5-10 m (16-33 ft.) and bring the machine to a stand still using the service brakes.

4. Reverse the machine gently and bring the machine back to it's original position without applying any brakes.

5. Repeat steps 3 and 4.

6. Once the machine has come to a stop, apply the park brake and switch off the engine.

7. Measure height from the centerline of the top mounting location to the centerline of the bottom mounting location. If height is not within specification, see your authorized dealer.

A—Height

Suspension Strut—Specification Centerline to Centerline—Height...................................................................... 646 mm 25.4 in.

VD76477,000046A -19-13JUN06-1/1

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PN=95

Maintenance—Every 500 Hours

Inspect, Clean, and Replace Cab Air Filter 1. Open storage compartment door (1).

T143532B —UN—06JUL01

2. Turn latches (2) 1/4-turn counterclockwise. Open access door (3).

3. Remove element (4). Inspect element for dust, debris, moisture, and damage. a. Replace element, if damaged.

CAUTION: Use compressed air regulated to 207 kPa (30 psi) to clean filter. If high pressure compressed air is used, filter may be damaged or personal injury may result.

T143533B —UN—06JUL01

b. Clean element, if necessary. Remove large debris by hand, then spray compressed air through element in direction opposite normal air flow. c. If element is moist, allow to dry before reinstalling.

Do not apply heat to element.

4. Install element. Ensure that “air flow” decal is at top, and arrows on decal point toward front of machine.

5. Close access door. Turn latches 1/4-turn clockwise.

Ensure latches are secure.

6. Close storage compartment door.

1— Storage Compartment Door 2— Latch (2 used)

3— Access Door 4— Element OUO1079,00003DE -19-02JUL01-1/1

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PN=96

Maintenance—Every 500 Hours

Check Batteries, Clean and Tighten Terminals 1. Open hood. Open battery compartment door (1).

T148322B —UN—26NOV01

2. Push top access door latch (2) inward and open top access door.

3. Clean debris from battery compartment.

4. Inspect circuit breaker box (3) and battery disconnect switch (4) for damage and secure installation. Tighten mounting hardware, if necessary. Replace damaged components. (See your authorized dealer.)

5. Inspect batteries and cables for damage. Replace, if necessary. See Replace Batteries. (Section 4-1.)

6. Inspect and clean terminals (6). Ensure that posts are secure in battery housings. Ensure that cables are securely installed on posts.

T148323B —UN—26NOV01

7. Ensure that mounting bracket assemblies (5) are secure. Tighten nuts, if necessary.

8. Check battery charge indicator (7) (if equipped) on each battery. The colors displayed are as follows:

• Green—Battery is fully charged.

• Black—Battery charge is low and must be charged.

See Using Battery Charger. (Section 4-1.)

Battery must be replaced.

• Yellow—Battery life has expired.

Outer Battery

9. Check electrolyte level if battery has level check/fill plugs.

1— Battery Compartment Door 2— Top Access Door Latch 3— Circuit Breaker Box 4— Battery Disconnect Switch

T148324B —UN—26NOV01

10. Start engine. After bulb check, verify that battery charge indicator on instrument panel is not lit. Verify battery voltages on monitor display unit.

5— Mounting Bracket Assembly (2 used) 6— Terminal (4 used) 7— Battery Charge Indicator (2 used) (If Equipped) Inner Battery

OUO1043,0000E11 -19-08AUG05-1/1

3-6-4

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PN=97

Maintenance—Every 500 Hours

Lubricate Oscillation Tube, Articulation Joints, Steering Cylinder Rod Ends, and Oscillation Tube Through Drive Shaft Bearings Add grease at each lubrication fitting (1—7) until grease escapes from joint. See Grease. (Section 3-1.)

T149788C —UN—01AUG05

5— Lubrication Fitting—Left Steering Cylinder Rod End 6— Lubrication Fitting—Oscillation Tube 7— Lubrication Fitting—Oscillation Tube Through Drive Shaft Rear Bearing

T213218A —UN—03AUG05

1— Lubrication Fitting—Upper Articulation Joint 2— Lubrication Fitting—Oscillation Tube Through Drive Shaft Front Bearing 3— Lubrication Fitting—Lower Articulation Joint 4— Lubrication Fitting—Right Steering Cylinder Rod End

AM40430,00000EC -19-29JUL05-1/1

3-6-5

080112

PN=98

Maintenance—Every 500 Hours

Check Transmission Oil Level NOTE: To obtain the most accurate transmission oil level readings, check transmission oil dipstick with engine running, transmission in neutral, transmission oil warm and machine parked on level ground.

T201846A —UN—22JUL04

1. Park machine on level ground and engage park brake.

2. Select neutral (N) and run engine at slow idle.

3. Raise cab.

4. Remove transmission dipstick (1) from fill tube. Turn handle counterclockwise to loosen. Wipe oil from dipstick and fill tube.

5. Fully insert transmission dipstick into fill tube. Remove transmission dipstick and read oil level. Repeat.

STOP

HOT

• Checking cold, engine not running—Oil level must be at or near STOP mark on dipstick.

• Checking cold, engine running—Oil level must be between lines of COLD mark.

• Checking hot, engine running—Oil level must be

T148377

COLD

T148377 —19—21NOV01

NOTE: STOP and COLD marks indicate sufficient oil levels for running machine. Check oil level with transmission oil at operating temperature for accurate reading.

between lines of HOT mark.

6. Add or drain transmission oil, as necessary. See Change Transmission Oil . (Section 3-8.)

1— Transmission Dipstick

7. Fully insert transmission dipstick into fill tube. Turn handle clockwise to tighten.

8. Lower cab.

TX14740,0000182 -19-22JUL04-1/1

3-6-6

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PN=99

Maintenance—Every 500 Hours

Clean and Inspect Hydraulic Reservoir Breather

T147657B —UN—13NOV01

1. Remove nuts (2) and clamp (3) from dump body heater support and pipe.

2. Remove access panel cap screws (1) and access panel (4).

IMPORTANT: DO NOT spray steam, water or cleaning solution directly at hydraulic reservoir breather.

Spray could be forced into hydraulic reservoir.

NOTE: Hydraulic reservoir breather should be checked daily in adverse working conditions. The amount of dust and dirt encountered will determine the frequency of breather cleaning.

T147656B —UN—13NOV01

3. Clean dirt, dust, and debris from hydraulic reservoir breather (5) and from surrounding area.

4. Inspect hydraulic reservoir breather for clogging, damage, and proper installation.

Replace hydraulic reservoir breather if it appears damaged or cannot be unclogged. See Replace Hydraulic Reservoir Breather, (Section 3-9.)

5. Install access panel and cap screws.

6. Install clamp and nuts to dump body heater support and pipe.

1— Access Panel Cap Screw (4 used) 2— Nut (2 used) 3— Clamp

4— Access Panel 5— Hydraulic Reservoir Breather

OUO1043,0000E07 -19-30OCT01-1/1

Replace In-line Fuel Filter (S.N. 201015—) 1. Open hood.

T201828A —UN—22JUL04

2. Loosen and slide hose clamps away from in-line fuel filter (1). Remove hoses.

3. Remove filter.

4. Install new filter.

5. Install hoses and tighten clamps.

TX14740,000017F -19-21JUL04-1/1

3-6-7

080112

PN=100

Maintenance—Every 500 Hours

Replace Fuel Filters (S.N.—201014) 1. Disconnect the WIF sensor connector (2).

T165115C —UN—11FEB03

2. Turn filter (1) counterclockwise to remove. Allow sediment to drain into a container. Dispose of waste properly.

3. Turn sediment bowl (3) counterclockwise to remove from filter assembly.

4. Clean filter base.

5. Install new filter. (Follow instructions on filter.)

6. Install sediment bowl.

7. Install sensor connector.

1— Filter 2— Sensor Connector

8. Bleed fuel system. See Bleeding Fuel System.

(Section 4-1.).

3— Sediment Bowl

TX14740,0000181 -19-21JUL04-1/1

Replace Final Fuel Filter (S.N. 201015—) 1. Disconnect the WIF sensor connector (1).

T213129A —UN—02AUG05

2. Turn final fuel filter (3) counterclockwise to remove.

Allow sediment to drain into a container. Dispose of waste properly.

3. Clean filter base.

4. Install new filter. (Follow instructions on filter.)

5. Install sensor connector.

6. Bleed fuel system. See Bleeding Fuel System.

(Section 4-1.).

1— Sensor Connector 2— Primary Fuel Filter

3— Final Fuel Filter

AM40430,00000ED -19-29JUL05-1/1

3-6-8

080112

PN=101

Maintenance—Every 500 Hours

Check Coolant Conditioner in Radiator CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

TS281 —UN—23AUG88

Remove fill 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.

T147658B —UN—09NOV01

NOTE: If Caltex coolant has been replaced with Deere COOL-GARD coolant, add coolant conditioner as necessary.

1. Remove fill cap (2) and test coolant solution in expansion tank (1). For Caltex coolant, use an appropriate test device to measure the specific gravity of coolant solution. If Caltex coolant has been replaced with Deere COOL-GARD, use one of the following kits to check coolant:

• 3-WAY Heavy Duty Coolant Test Kit (TY16175) (For

T111110 —UN—13AUG97

use with Deere COOL-GARD coolant.)

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 use with Deere COOL-GARD

coolant.)

For a more thorough evaluation of coolant, perform CoolScan Plus analysis, where available. See your authorized dealer for information about CoolScan Plus.

3-Way Test Kit

IMPORTANT: To prevent machine damage, ensure that all coolant additives are compatible with coolant system is currently filled with.

T111109 —UN—13AUG97

2. Add coolant conditioner or equivalent non-chromatic conditioner/rust inhibitor, as necessary. Follow instructions on container for amount.

3. Install fill cap.

1— Expansion Tank

2— Fill Cap

CoolScan Plus OUO1043,0000E19 -19-30OCT01-1/1

3-6-9

080112

PN=102

Maintenance—Every 1000 Hours Check Axle Oil Levels NOTE: The procedure is the same for all 3 axles.

T147833C —UN—13NOV01

1. Clean axle housing around check and fill plug (1).

2. Remove check and fill plug from axle housing.

3. Oil must be level with bottom of check and fill port.

4. Add oil through check and fill port, if necessary. See Change Axle Oil. (Section 3-8.)

5. Install check and fill plug.

1— Check and Fill Plug OUO1043,0000E16 -19-30OCT01-1/1

Check Final Drive Oil Levels NOTE: Perform this procedure for each final drive. The procedure is the same for all final drives.

T123135B —UN—29JUL99

1. Rotate wheel until check plug (1) is in a horizontal position.

2. Remove check plug and check oil level. Oil level must be even with bottom edge of check port.

3. If necessary, add oil. See Change Final Drive Oil. (Section3-8.)

4. Install check plug tightly.

1— Check Plug

OUO1043,0000E17 -19-30OCT01-1/1

3-7-1

080112

PN=103

Maintenance—Every 1000 Hours

Replace Hydraulic Reservoir Breather

1. Remove nuts (2) and clamp (3) from dump body heater support and pipe, if equipped.

2. Remove cap screws (1) and access panel (4).

3. Turn hydraulic reservoir breather (5) counterclockwise and remove from machine.

T147657B —UN—13NOV01

NOTE: Hydraulic reservoir breather should be replaced at scheduled intervals, or whenever found to be damaged or clogged.

4. Install new hydraulic reservoir breather. Hand-tighten.

5. Install access panel and cap screws.

1— Cap Screw (4 used) 2— Nut—If Equipped (2 used) 3— Dump Body Heater Pipe Clamp—If Equipped

T147656B —UN—13NOV01

6. Install clamp and nuts to dump body heater support and pipe, if equipped.

4— Access Cover 5— Hydraulic Reservoir Breather

OUO1043,0000E18 -19-07FEB03-1/1

3-7-2

080112

PN=104

Maintenance—Every 1000 Hours

Check and Adjust Bin Shock Pad IMPORTANT: Before starting procedure, make sure bin pads and chassis are clean of debris and that the bin pivots do not show any signs of excessive play or movement.

1. Ensure bin is completely empty.

2. Remove bin float relay from relay/fuse panel.

3. Lift the bin until all pads are off of the chassis.

4. Lower the bin until either the left or the right rear pad just contacts the chassis.

NOTE: If both pads contact the chassis at the same time or within 1 mm of each other the side-to-side rear pad spacing is acceptable. If the pads contact the chassis more than 1 mm apart, shims need to be added to the pad that contacts the chassis last.

T213202A —UN—02AUG05

5. Reinstall the bin float relay.

6. Lift the bin and allow it to float onto the rear pads.

7. Measure the gaps between the front pads and the chassis. If either of the front pad gaps are smaller than 3 mm, both left and right rear pads should have an equal number of shims added to lift the front pads.

For gaps that are larger than 3 mm, shims should be added to the front pads to meet the specification.

Specification 250D and 300D Bin Shock Pads—Distance.................................................................... 3 mm

1— Rear Bin Pads

2— Front Bin Pads

VD76477,000045F -19-15MAY06-1/1

Grease Prop Shaft Slip Joint Add grease at lubrication fitting (1) until grease escapes at joint. See Grease. (Section 3-1.)

T213146A —UN—02AUG05

1— Lubrication fitting

AM40430,00000F3 -19-29JUL05-1/1

3-7-3

080112

PN=105

Maintenance—Every 2000 Hours Adjust Engine Valve Clearance See your authorized dealer for engine valve clearance adjustment.

OUO1079,00003BC -19-13JUN01-1/1

NOTE: It is not necessary to change transmission oil until a contaminated OILSCAN PLUS® sample is indicated.

Draw sample from transmission oil at drain plug. For convenience, install a sampling valve in drain port.

NOTE: Dispose of waste properly.

1. Remove drain plug (1) and drain oil into a container.

2. Remove drain plug (2) and drain oil into a container.

Transmission—Specification Oil Pan—Capacity.......................................................................... 21.8 L 5.8 gal

T147672B —UN—21NOV01

Change Transmission Oil

4. Replace transmission oil filters. See Replace Transmission Oil Filters in this section.

5. Remove dipstick (3) and add oil at fill tube (4). See Transmission and Transfer Case Oil. Section 3-1.)

6. Check transmission oil level.

1— Drain Plug 2— Drain Plug

3— Dipstick 4— Fill Tube

T147661C —UN—21NOV01

3. Install drain plugs.

OILSCAN PLUS is a trademark of Deere & Company OUO1043,0000E1A -19-01AUG05-1/1

3-8-1

080112

PN=106

Maintenance—Every 2000 Hours

Replace Transmission Oil Filter

T148394B —UN—21NOV01

NOTE: Perform this service at every 2000 hours in normal operating conditions. In dry and dusty operating conditions, this service may need to be performed as often as every 1000 hours.

1. Drain transmission oil. See Change Transmission Oil in this section.

2. Put a container under filter assembly.

3. Remove cap screws (1) and filter assembly (2). Drain oil into container. Dispose of waste properly.

4. Remove filter element (3). Discard old element.

5. Install new filter element.

6. Replace filter cover o-ring.

T148546B —UN—28NOV01

7. Install filter cover and cap screws. Tighten to specification.

Transmission—Specification Oil Filter Cap Screw—Torque............................................................... 25 N·m (18 lb-ft)

8. Fill transmission oil. See Change Transmission Oil in this section.

9. Check transmission oil level.

1— Cap Screw (4 used) 2— Filter Cover

3— Filter Element

OUO1043,0000E1B -19-08AUG05-1/1

3-8-2

080112

PN=107

Maintenance—Every 2000 Hours

Change Transfer Case Oil

T147975B —UN—19NOV01

NOTE: Perform this service at every 2000 hours in normal operating conditions. In dry and dusty operating conditions, this service may need to be performed as often as every 1000 hours.

1. Remove fill plug and sealing ring (1). Clean fill plug and sealing ring. Inspect sealing ring. Replace sealing ring, if necessary.

NOTE: Dispose of waste properly.

2. Put a container under drain plug (2). Remove drain plug and drain oil into container.

Transfer Case—Specification Oil—Capacity.......................................................................4.7 L (5.0 qt)

T147662C —UN—19NOV01

3. Clean drain plug thoroughly.

4. Install drain plug. Tighten to specification.

Transfer Case—Specification Drain Plug and Fill Plug Tightening—Torque......................................... 25—32 N·m (38—45 lb-ft)

5. Add oil at fill port. Do not overfill. Oil level should be to middle of sight glass (3).

6. Install fill plug and sealing ring.

7. Start engine. Drive machine in low gears for 1 minute.

Stop engine.

8. Check for leaks at drain plug. Tighten only enough to stop leaks.

1— Fill Plug and Sealing Ring 2— Drain Plug

3— Sight Glass

9. Check oil level at sight glass. Oil level should be to middle of sight glass. Add more oil, if necessary.

OUO1043,0000E1C -19-30OCT01-1/1

Change Axle Oil

T147833B —UN—18DEC01

NOTE: Perform this service at every 2000 hours in normal operating conditions. In dry and dusty operating conditions, this service may need to be performed as often as every 1000 hours.

NOTE: Perform this procedure for each axle. The procedure is the same for all axles.

1. Clean axle housing around check and fill plug (1) and drain plug (2).

NOTE: Dispose of waste properly.

2. Remove axle drain plug (2) from axle housing and allow oil to drain into a container. For middle axle, remove adapter case drain plug (3).

Axle—Specification Oil (Each)—Capacity........................................................ 21.9 L (5.8 gal)

3. Clean drain plug(s) and install in axle housing.

1— Check and Fill Plug 2— Axle Drain Plug

3— Adapter Case Drain Plug (Middle Axle Only)

4. Add oil at check and fill port. See Axle and Final Drive Oil. (Section 3-1.)

5. Install check and fill plug.

OUO1043,0000E1D -19-08AUG05-1/1

3-8-3

080112

PN=108

Maintenance—Every 2000 Hours

Change Final Drive Oil NOTE: Perform this service at every 2000 hours in normal operating conditions. In dry and dusty operating conditions, this service may need to be performed as often as every 1000 hours.

NOTE: Perform this procedure for each final drive. The procedure is the same for all final drives.

1. Rotate wheel until drain plug (1) is at lowest point.

NOTE: Dispose of waste properly.

T147834B —UN—13NOV01

2. Remove drain plug from final drive and allow oil to drain into a container.

Final Drive—Specification Oil (Each)—Capacity............................................................4.0 L (4.2 qt)

3. Clean drain plug of oil and debris. Install drain plug tightly.

4. Remove check and fill plug (2) and fill final drive with clean oil, until oil flows from the check and fill port.

See See Axle and Final Drive Oil. (Section 3-1.)

1— Drain Plug

2— Check and Fill Plug

5. Install check and fill plug.

OUO1043,0000E1E -19-08AUG05-1/1

Replace Pneumatic System Dryer-Filter 1. Relieve pneumatic pressure.

T147646C —UN—09NOV01

2. Remove old element (1) from head (2). Discard old element.

3. Inspect O-ring on head. Clean or replace O-ring, if necessary.

4. Apply thin layers of oil to O-ring on head and O-ring on new element.

5. Install new element. Tighten until O-rings make contact, then tighten an additional 1/2-turn.

6. Start engine and let it run. When pneumatic system has reached normal operating pressure, stop engine and check for air leaks at head and element. Tighten element only enough to stop leaks.

1— Element

2— Head

OUO1043,0000E1F -19-30OCT01-1/1

3-8-4

080112

PN=109

Maintenance—Every 4000 Hours NOTE: Perform this service at every 4000 hours in normal operating conditions. In dry and/or dusty operating conditions, this service may need to be performed as often as every 2000 hours.

1. Install a drain hose and clamp to drain valve (3).

NOTE: Dispose of waste properly.

2. Loosen nut (1) and valve stem (2) to open drain valve.

Drain hydraulic oil.

T147782B —UN—13NOV01

Change Hydraulic Oil

Hydraulic System—Specification Reservoir Oil—Capacity................................................................. 78.8 L 20.8 gal

4. Remove fill cap (4). Fill hydraulic reservoir with new hydraulic oil. See Hydraulic Oil. (Section 3-1.)

5. Install fill cap.

6. Check for leaks at drain valve. Tighten plug only enough to stop leaks.

1— Nut 2— Valve Stem

T147784B —UN—13NOV01

3. Tighten valve stem and nut to close drain valve.

Remove drain hose and clamp from drain valve.

3— Drain Valve 4— Fill Cap OUO1043,0000E21 -19-29JUL05-1/1

3-9-1

080112

PN=110

Maintenance—Every 4000 Hours

Replace Hydraulic Suction Screen

1

1. Drain oil from hydraulic reservoir.

Specification Reservoir Oil—Capacity................................................................. 78.8 L 20.8 gal

2

2. Remove external hydraulic reservoir cover (1).

3. Remove internal hydraulic reservoir cover (2).

4. Remove suction screen from fitting (3).

3

5. Clean magnet (4) as necessary.

6. Insert new suction screen into fitting.

4

7. Replace reservoir covers (1 and 2).

8. Fill hydraulic reservoir and check hydraulic oil level.

3— Fitting 4— Magnet

T213160 —UN—08AUG05

1— External Hydraulic Reservoir Cover 2— Internal Hydraulic Reservoir Cover

AM40430,0000106 -19-08AUG05-1/1

Replace Pneumatic Block Silencer Filter 1. Park machine and turn engine off.

3. Thread bin tip lever exhaust silencer (1) out with a wrench and insert new silencer.

4. Thread park brake lever exhaust silencer (2) out with a wrench and insert new silencer.

1— Bin Tip Lever Exhaust Silencer

2— Park Brake Exhaust Silencer

T213145A —UN—02AUG05

2. Open hood and locate pneumatic manifold on the right hand side.

AM40430,00000F0 -19-29JUL05-1/1

3-9-2

080112

PN=111

Maintenance—Every 4500 Hours Replace Engine Crankshaft Dampener The crankshaft dampener assembly is not repairable and should be replaced every four years or 4000

hours, whichever occurs first, or whenever crankshaft is replaced. See your authorized John Deere dealer.

CED,TX03768,2668 -19-11NOV09-1/1

3-10-1

080112

PN=112

Maintenance—Every 5000 Hours Drain, Flush and Refill Engine Cooling System

T147658B —UN—09NOV01

IMPORTANT: If this machine is factory filled with Caltex extended life coolant which is good for 5000 operating hours, this coolant can be topped off with the Deere COOL-GARD coolant. When system needs to be refilled, it is recommended to drain and refill cooling system with Deere COOL-GARD coolant.

1. Open hood. Remove fill cap (2) from expansion tank (1).

2. Lower front bottom guard. See Lower and Raise Bottom Guard. (Section 3-2.)

T147677B —UN—19NOV01

3. Attach drain hose and hose clamp to drain valve nozzle (3).

NOTE: Dispose of waste properly.

4. Loosen nut (5) and valve stem (4) to open drain valve (6). Drain engine coolant into a container.

Engine—Specification Coolant—Capacity......................................................................... 26.5 L 7.0 gal

5. Tighten valve stem to close drain valve. Do not overtighten. Remove hose clamp and hose.

IMPORTANT: Engine coolant is often sold in concentrated form, and must be mixed with water to obtain correct specific gravity. Verify correct mixture before filling.

6. Add new engine coolant at expansion tank fill port.

Do not overfill.

7. With fill cap NOT installed, start engine. Run engine at slow idle for 3 minutes to purge air pockets from engine cooling system. Stop engine.

1— Expansion Tank 2— Fill Cap 3— Valve Nozzle

4— Valve Stem 5— Nut 6— Drain Valve

9. Raise front bottom guard.

10. Check coolant level in expansion tank. Cold coolant should not be below the ADD mark. Hot coolant should not be above FULL mark. Add more coolant, if necessary.

11. Install fill cap securely.

8. Check for leaks at drain valve. Tighten only enough to stop leaks.

AM40430,00000F2 -19-08AUG05-1/1

3-11-1

080112

PN=113

Miscellaneous—Machine Do Not Service Control Valves, Cylinders, Pumps or Motors

If these parts need service, see your authorized dealer.

Special tools and information are needed to service control valves, cylinders, pumps, or motors.

TX,90,FF3114 -19-18NOV92-1/1

• Poor quality fuel • Excessive idling

Do Not Service Injection Nozzles IMPORTANT: Do not service or remove injection nozzles. The service life of the injection nozzles may be shortened by:

If injection nozzles are not working correctly or are dirty, the engine will not run normally. (See your authorized dealer for service.)

• Overheating • Improper operation

TX,90,FF3116 -19-18NOV92-1/1

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting fuel or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles that eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

If ANY fluid is injected into the skin, a doctor familiar with this type of injury must surgically remove it within a few hours or gangrene may result.

X9811 —UN—23AUG88

Bleeding Fuel System

Whenever the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system.

Continued on next page

4-1-1

TX14740,000017E -19-21JUL04-1/2

080112

PN=114

Miscellaneous—Machine

1. Open drain valves (2) to drain water and contaminates from filters.

Loosen diagnostic port (1) located on back filter to allow air and fuel to escape. Attach a hose and bleed fuel into suitable container.

T201826A —UN—22JUL04

2.

3. Close drain valves.

4. Unlock and operate hand primer (3) until a steady flow of fuel (without bubbles) flows out of hose. This could take 270-330 strokes until fuel flow is free of bubbles.

5. Continue to pump hand primer while tightening diagnostic port to specification below.

Two Fuel Filter System Shown

Specification Diagnostic Port—Torque.................................................................................14 N·m 20 lb-ft

T159635B —UN—20SEP02

6. Start engine and run at 1200-1500 RPM for 3-5 minutes.

7. If engine fails to start, loosen high pressure fuel line fittings (4). Pump hand primer until steady flow of fuel escapes the fuel pump. This could take an additional 90-120 fuel line fittings to specification below and lock hand primer.

Specification High Pressure Fuel Lines—Torque...............................................................................27 N·m 20 lb-ft

1— Drain Valves 2— Diagnostic Port

3— Hand Primer 4— High Pressure Fuel Line Fittings

8. Crank engine up to 15 seconds. If engine does not start, wait 15 seconds and then crank for an additional 15 seconds. If engine starts, run at 1200-1500 RPM for 3-5 minutes.

TX14740,000017E -19-21JUL04-2/2

Check Engine Air Intake System 1. Check air cleaner assembly for damage to precleaner (1) and air cleaner housing (2).

3. Check rubber elbows (4), clamps (5), and pipes (6) for tightness, cracks, or damage.

1— Precleaner 2— Air Cleaner Housing 3— Service Indicator

4— Rubber Elbow (4 used) 5— Clamp (12 used) 6— Pipe (3 used)

T147679B —UN—09NOV01

2. Check that service indicator (3) is not showing a red flag. If red flag is shown, service air cleaner and reset service indicator.

OUO1043,0000E24 -19-30OCT01-1/1

4-1-2

080112

PN=115

Miscellaneous—Machine

Check Brake Accumulators

3. Turn key switch to OFF position to stop engine.

1. Start engine and wait until main pump has fully charged the accumulators.

4. Turn key switch to ON position and wait for bulb check to complete.

2. Press brake pedal repeatedly to make the main pump recharge the accumulators several times. Stop pushing pedal while in the middle of a recharge cycle, to ensure brakes are not consuming oil after main pump stops.

5. Press brake pedal repeatedly, counting the number of strokes before the brake indicator lights. Machine must allow 8 strokes of the brake pedal before brake pressure indicator on instrument panel lights. If it does not, see your authorized dealer.

OUO1043,0000E25 -19-30OCT01-1/1

Check Wheel Nuts

Ensure that wheel nuts are tight. Torque to specification.

IMPORTANT: Check torque on wheel nuts after the first 5 hours of use and again after 50 hours of use any time a wheel has been removed and reinstalled.

Wheel—Specification Nut—Torque............................................................... 650 N·m (480 lb-ft)

OUO1043,0000DF0 -19-25OCT01-1/1

Lubricate Hinges

• Battery compartment door hinges • Hood hinges • Bottom guard hinge

Lubricate the following with powdered graphite:

• Cab door hinges

OUO1043,0000E48 -19-27NOV01-1/1

Using Booster Batteries—24-Volt System

T7233JN —UN—21MAY90

Before boost starting, machine must be properly shutdown 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 (A) and the other end to the positive terminal of the booster batteries (B).

Booster Batteries, 2-Battery Application A—Machine Battery (2 used)

B—Booster Battery (2 used)

2. Connect one end of the negative cable to the negative terminal of the booster batteries. Connect the other end of the negative cable to the machine frame as far away from the machine batteries as possible.

4. Immediately after starting engine disconnect the 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.

3. Start engine.

5. Disconnect positive cable from booster batteries and machine batteries.

OUT4001,0000238 -19-12MAR12-1/1

4-1-3

080112

PN=116

Miscellaneous—Machine

Using Battery Charger

TS204 —UN—23AUG88

CAUTION: Prevent possible injury from exploding battery. Do not charge a battery if the battery is frozen or it may explode. Warm battery to 16°C (60°F) before charging.

Turn off charger before connecting or disconnecting it.

IMPORTANT: Do not use battery charger as a booster if a battery has a 1.150 specific gravity reading or lower.

Disconnect battery ground (-) clamp before you charge batteries in the machine to prevent damage to electrical components.

Prevent Battery Explosions

A battery charger may be used as a booster to start engine.

Ventilate the area where batteries are being charged.

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).

Charger OUT4001,0000239 -19-03JAN12-1/1

4-1-4

080112

PN=117

Miscellaneous—Machine

Handling, Checking And Servicing Batteries Carefully

TS204 —UN—23AUG88

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always remove grounded (-) battery clamp first and replace it last.

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself: 1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes.

Get medical attention immediately.

If acid is swallowed:

TS203 —UN—23AUG88

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in 4 L (1 gal) water.

IMPORTANT: DO NOT overfill the battery cells.

Check the specific gravity of electrolyte in each battery cell.

Continued on next page

4-1-5

TX03679,0001788 -19-16NOV00-1/2

080112

PN=118

Miscellaneous—Machine

See your John Deere dealer for JT05460 SERVICEGARD™ battery and coolant tester. Follow directions included with the tester.

T85402 —UN—10NOV88

A fully charged battery will have a corrected specific gravity reading of 1.260. If the reading is below 1.200, charge the battery.

SERVICEGARD is a trademark of Deere & Company TX03679,0001788 -19-16NOV00-2/2

Replace Batteries 1. Open hood. Open side access door (1).

T148322B —UN—26NOV01

2. Push top access door latch (2) inward and open top access door.

3. Turn battery disconnect switch (4) OFF. 4. Clean debris from battery compartment.

IMPORTANT: Ensure that all cables are reconnected properly. Note all connections while removing batteries, to prevent incorrect connections while installing batteries.

T147883B —UN—09NOV01

5. Disconnect all cables from battery terminals, beginning with outer battery negative (—) terminal. For each terminal, lift rubber terminal cover, remove nut, and remove washer and ring connector(s) from terminal.

Move all cables aside.

6. Remove outer battery from machine, then remove inner battery. a. Loosen nuts and washers on mounting bracket assembly. Remove mounting bracket assembly from machine. b. Lift battery from machine through side access door.

7. Install new inner battery. Turn battery so positive (+) terminal faces front of machine. Install and tighten mounting bracket assembly.

8. Install new outer battery. Turn battery so negative (—) terminal faces left side of machine. Install and tighten mounting bracket assembly.

9. Install all cables, beginning at inner battery positive (+) terminal. For each terminal, install ring connector(s), washer, and nut. Pull rubber terminal cover over terminal.

1— Side Access Door 2— Top Access Door Latch

3— Circuit Breaker Box 4— Battery Disconnect Switch

10. Turn battery disconnect switch ON. 11. Start engine. After bulb check, verify that battery charge indicator on instrument panel is not lit. Verify battery voltages on monitor display unit.

TX14740,0000013 -19-27JAN03-1/1

4-1-6

080112

PN=119

Miscellaneous—Machine

Replace Front Turn Signal Bulb, Headlight Bulb, and Front Park Light Bulb

T143214B —UN—28JUN01

IMPORTANT: Prevent bulb damage. Use a clean cloth or tissue paper to handle bulbs. If touched, clean glass thoroughly with rubbing alcohol and clean, lint-free cloth. DO NOT use a halogen bulb that is not clean.

1. Remove cap screws (1) and headlight grille (3) from headlight assembly.

2. Remove screws (2) securing headlight assembly to fender.

3. Swing headlight assembly out of fender.

1— Cap Screw (2 used) 2— Screw (2 used)

3— Headlight Grille—If Equipped OUO1079,00003D3 -19-20JUN01-1/3

4. Replace front turn signal bulb, if necessary:

b. Squeeze tabs (4) and remove front turn signal bulb from headlight assembly. c. Install new front turn signal bulb. d. Connect wire leads.

4— Tab (2 used) 5— Front Turn Signal Bulb

6— Wire Lead (2 used)

Continued on next page

4-1-7

T143218B —UN—28JUN01

a. Disconnect wire leads (6) from front turn signal bulb (5).

OUO1079,00003D3 -19-20JUN01-2/3

080112

PN=120

Miscellaneous—Machine

5. Replace headlight bulb, if necessary: a. Disconnect connector (7) from headlight bulb (9).

T143212B —UN—28JUN01

b. Squeeze retaining clips (8) to unfasten. Swing retaining clips downward. c. Remove headlight bulb from headlight assembly. d. Install new headlight bulb. e. Swing retaining clips upward. Squeeze retaining clips to fasten. f. Connect connector to headlight bulb.

6. Replace front park light bulb, if necessary: a. Disconnect wire leads (11) from front park light bulb (10).

7— Connector 8— Retaining Clips (2 used) 9— Headlight Bulb

10— Front Park Light Bulb 11— Wire Lead (2 used)

b. Twist front park light bulb counterclockwise to unfasten. Remove from headlight assembly. c. Install new front park light bulb. Twist clockwise to fasten. d. Connect wire leads to front park light bulb.

8. Install screws to secure headlight assembly to fender.

9. Adjust headlights. See Adjust Headlights in this section.

10. Install headlight grille and cap screws.

7. Swing headlight assembly into fender.

OUO1079,00003D3 -19-20JUN01-3/3

4-1-8

080112

PN=121

Miscellaneous—Machine

Adjust Headlights

T143221 —UN—14AUG01

1

2 T143221

1— Horizontal Adjustment Screw 2— Vertical Adjustment Screw

The headlights must be adjusted to correct height so that the operator can safely operate the machine at night or in poor light conditions.

When properly adjusted, headlight beams are parallel, angled neither right nor left, and low beams are angled downward at a 1% grade.

5. Use string line and tape to mark wall at center point between headlights.

6. Measure left and right on wall and mark wall at centers of headlights.

1. Verify that the tires are at the correct pressure.

7. Activate low-beam headlights. Turn vertical adjustment screw (2) to aim each headlight so the center of each beam is 5 cm (2 in.) lower than the tape mark.

2. Drive machine onto a level surface, directly facing a vertical wall with frames steered straight. Stop machine with headlights 5.0 m (16.4 ft) from wall.

8. Activate high-beam headlights. Adjust horizontal adjustment screw (1) to aim each headlight directly toward tape mark.

3. Measure width between centers of headlights. Mark grille with tape at center point.

4. Measure height from ground to center point between headlights.

OUO1079,00003D4 -19-21JUN01-1/1

4-1-9

080112

PN=122

Miscellaneous—Machine

Replace Backup Light and Work Light—If Equipped 1. Remove screws (1).

T143353B —UN—28JUN01

2. Remove bezel (2), lamp (3), and rubber seal (4) from housing (5).

3. Disconnect wire lead (7) from connector (8).

4. Disconnect connector from terminal (6).

5. Remove bezel and rubber seal from lamp. Discard lamp.

Shown Removed from Machine for Clarity of Photo

6. Install rubber seal and bezel on new lamp.

7. Connect connector to terminal.

1— Screw (2 used) 2— Bezel 3— Lamp 4— Rubber Seal

8. Connect wire lead to connector.

9. Install rubber seal, lamp, and bezel in housing.

5— Housing 6— Terminal 7— Wire Lead 8— Connector

10. Install screws.

11. Adjust position of light for best illumination. If housing is loose, tighten mounting hardware (not shown).

OUO1079,00003D5 -19-22JUN01-1/1

Replace Tail and Brake Light and Rear Turn Signal IMPORTANT: DO NOT use excessive force when removing lamp, or plastic or rubber may become damaged.

2. Pry gently around edges of lamp (3) to remove from rubber seal (4).

3. Disconnect connector (5). Discard lamp.

T147680B —UN—19NOV01

1. Remove cap screws (1) and protective grille (2).

4. Connect connector to new lamp.

5. Install lamp in rubber seal. Index lamp so “TOP” marking is at top. Push lamp into rubber seal with firm, even pressure. Ensure that lamp is securely seated.

1— Cap Screws (3 used) 2— Protective Grille 3— Lamp

T143366C —UN—19NOV01

6. Install protective grille and cap screws.

4— Rubber Seal 5— Connector

OUO1043,0000E3F -19-06NOV01-1/1

4-1-10

080112

PN=123

Miscellaneous—Machine

Replace Dome Light Bulb and Circuit Breaker Compartment Light Bulb

T143363B —UN—28JUN01

IMPORTANT: DO NOT use excessive force when removing lens cover, or plastic may become damaged.

1. Pry gently along edges of lens cover to remove.

2. Remove and replace dome light bulb (1) or fuse compartment light bulb (2).

3. Install lens cover. Push with gentle, even pressure until lens cover “snaps” into place. Lens cover should rock back and forth between 3 detent positions.

1— Dome Light Bulb

Lens Cover Removed for Clarity of Photo

2— Circuit Breaker Compartment Light Bulb OUO1079,00003D6 -19-22JUN01-1/1

Clean The Machine Regularly Remove any grease, oil, fuel, or debris build-up to avoid possible injury or machine damage.

High pressure washing (greater than 1379 kPa (13.8 bar) (200 psi) can damage freshly painted finishes. Paint should be allowed to air dry for 30 days minimum after receipt of machine before cleaning with high pressure. Use low pressure wash operations until 30 days have elapsed.

T6642EJ —UN—18OCT88

IMPORTANT: Directing pressurized water at electronic/electrical components or connectors, bearings and hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle.

Do not spray oil cooler fins at an angle. Fins may bend.

TX03679,00017E5 -19-06FEB03-1/1

4-1-11

080112

PN=124

Miscellaneous—Machine

Unified Inch Bolt and Screw Torque Values TS1671 —UN—01MAY03

Bolt or Screw Size 1/4 5/16 3/8 7/16

SAE Grade 2a

SAE Grade 1 b

c

Lubricatedb

Dry

Lubricated

SAE Grade 5, 5.1 or 5.2

Dryc

Lubricatedb

Dryc

SAE Grade 8 or 8.2 Lubricatedb

Dryc

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

3.7

33

4.7

42

6

53

7.5

66

9.5

84

12

106

13.5

120

17

150

N·m

lb.-ft.

N·m

lb.-ft.

28

20.5

35

26

7.7 13.5

68 120

22

194

N·m

lb.-ft.

9.8

86

12

106

15.5

137

17.5

155

22

194

27

240

N·m

lb.-ft.

N·m

lb.-ft.

N·m

lb.-ft.

28

20.5

35

26

44

32.5

lb.-in.

19.5

172

25

221

N·m

lb.-ft.

N·m

lb.-ft.

35

26

44

32.5

49

36

63

46

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

1

285

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

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

a

Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length.

“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. c “Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.

b

DX,TORQ1 -19-12JAN11-1/1

4-1-12

080112

PN=125

Miscellaneous—Machine

Metric Bolt and Screw Torque Values TS1670 —UN—01MAY03

Bolt or Screw Size M6 M8 M10

4.8

8.8

9.8

10.9

12.9

12.9

4.8

8.8

9.8

10.9

12.9

12.9

Class 4.8 Lubricateda

Class 8.8 or 9.8 Dryb

Lubricateda

Class 10.9

Dryb

Lubricateda

Class 12.9 Dryb

Lubricateda

Dryb

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

lb.-in.

N·m

4.7

42

6

53

8.9

79

11.3

100

13

115

16.5

146

15.5

137

19.5

172

N·m

lb.-ft.

N·m

lb.-ft.

N·m

lb.-ft.

N·m

lb.-ft.

32

23.5

40

29.5

37

27.5

47

35

63

46

80

59

75

55

95

70

11.5

102

14.5

128

22

194

27.5

243

N·m

lb.-ft.

N·m

lb.-ft.

N·m

lb.-ft.

29

21

43

32

55

40

lb.-in.

23

204

N·m

lb.-ft.

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

M16

100

74

125

92

190

140

240

175

275

200

350

255

320

235

400

300

M18

135

100

170

125

265

195

330

245

375

275

475

350

440

325

560

410

M20

190

140

245

180

375

275

475

350

530

390

675

500

625

460

790

580

M22

265

195

330

245

510

375

650

480

725

535

920

680

850

625

1080

800

M24

330

245

425

315

650

480

820

600

920

680

1150

850

1080

800

1350

1000

M27

490

360

625

460

950

700

1200

885

1350

1000

1700

1250

1580

1160

2000

1475

M30

660

490

850

625

1290

950

1630

1200

1850

1350

2300

1700

2140

1580

2700

2000

M33

900

665

1150

850

1750

1300

2200

1625

2500

1850

3150

2325

2900

2150

3700

2730

M36

1150

850

1450

1075

2250

1650

2850

2100

3200

2350

4050

3000

3750

2770

4750

3500

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

a

“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. b “Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.

DX,TORQ2 -19-12JAN11-1/1

4-1-13

080112

PN=126

Miscellaneous—Machine

T121289 —19—16SEP99

Imperial and SAE (Inch) Cap Screw and Nut Torque Values

CED,OUO1032,2601 -19-01SEP99-1/1

4-1-14

080112

PN=127

Miscellaneous—Machine

T121288 —19—16SEP99

Metric Cap Screw and Nut Torque Values

CED,OUO1032,2602 -19-01SEP99-1/1

4-1-15

080112

PN=128

Miscellaneous—Machine

Welding on Machine

T147681B —UN—26NOV01

IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF to prevent voltage spikes through alternator or monitor.

To prevent voltage spikes through microprocessors, disconnect harness connectors from the following controllers:

• Chassis Control Unit (CCU) (1) • Transmission Control Unit (TCU) (2) • Engine Control Unit (ECU) (3) • Battery Balancer (4) • Monitor Display Unit (MDU) Connect welder ground clamp close to each weld area so electrical current does not arc inside any bearings.

1— Chassis Control Unit (CCU) 2— Transmission Control Unit (TCU)

3— Engine Control Unit (ECU) 4— Battery Balancer

OUO1043,0000E29 -19-30OCT01-1/1

4-1-16

080112

PN=129

Miscellaneous—Operational Checkout Operational Checkout

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.

Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of machine operation while performing specific checks from the operator's seat.

Should you experience a problem with the 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 down time of the machine. Use the table of contents to help find adjustment procedures.

The information provided, after completing the operational checkout, will allow you to pinpoint a specific test or repair needed to restore the machine to design specifications.

Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) prior to doing the checkout. The machine must be at operating temperature for many of the checks.

Start at the top of the left column and read completely down column before performing check. Follow this sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to next check. If a problem is indicated, you will be referred either to a section in this manual for a specific procedure or to your authorized dealer.

OUO1043,0000E2A -19-30OCT01-1/15

Operator Station Checks—Key Switch ON, Engine Stopped OUO1043,0000E2A -19-30OCT01-2/15

Gauges and Indicator Lights Check

T144013B —UN—17JUL01

1— ON Position With battery disconnect switch ON, turn key switch to ON position (1).

LOOK/LISTEN: Does the following happen?

• All indicators light or flash.

• All gauges and speedometer move to center position.

• All segments of MDU LCDs will display.

• All segments of transmission control LED display and mode button indicator will light.

• Warning alarm sounds.

YES: Go to next check.

NOTE: Warning alarm will sound until air pressure reaches normal operating pressure. NO: Check circuit breakers. Reset if tripped.

Cold start indicator will remain lit for a maximum of 20 seconds in low ambient temperature conditions.

LOOK/LISTEN: After 3 seconds, do all gauges, LCD and LED displays return to normal IF OK: Check indicator operation mode and warning alarm silences? Do all indicators, except for secondary bulbs. Replace if necessary. steering (marked emergency steering), battery charge and park brake indicators go out?

Air pressure indicator may also remain lit, depending on system air pressure. Cold start IF OK: See your authorized indicator may also remain lit, depending on ambient temperature. dealer.

OUO1043,0000E2A -19-30OCT01-3/15

Operator Station Checks—Key Switch ON, Engine Running Continued on next page

4-2-1

OUO1043,0000E2A -19-30OCT01-4/15

080112

PN=130

Miscellaneous—Operational Checkout Key Switch Start Check

T144013C —UN—26JUL01

1— OFF Position 2— ON Position 3— START Position Turn key switch to ON position (2).

Turn key switch to START position (3).

IMPORTANT: DO NOT hold start switch for more than 17 seconds. If the engine does not start during this period, turn key switch to OFF position (1). Wait 1 minute and try again.

YES: Go to next check.

LISTEN: Starter motor will start the engine.

NO: Check battery disconnect switch.

Run engine for a few seconds then turn key switch to OFF position.

NO: Check battery.

LISTEN: Engine must stop immediately when key switch is turned OFF.

NO: See your authorized dealer.

Continued on next page

4-2-2

OUO1043,0000E2A -19-30OCT01-5/15

080112

PN=131

Miscellaneous—Operational Checkout Gauges and Indicators Checks

6

1

3 BATTERY CHARGE

EMERGENCY STEERING

ENGINE FAULT

COOLANT LEVEL

COLD START

PARK BRAKE

BRAKE PRESSURE

BRAKE TEMP

n/min

RETARDER

TRANSMISSION FAULT

ENGINE OIL PRESSURE

888888888888

30

COOLANT TEMP

20

40

60

30 mph

10

INTER-AXLE DIFF LOCK

AUTO

8888

40

70 0

TRANS OIL TEMP

8

50

km/h 20

10 AIR PRESSURE

BIN UP

DIFF LOCK

MENU

BACK n/min

50

NEXT

80

0

HYDRAULIC TEMP

88888

FUEL

88888.8

SELECT volts

MILES / Km

4

5

2

T144018 T144018 —UN—21AUG01

1— Park Brake Indicator 2— RPM Display of MDU 3— Engine Oil Pressure Gauge 4— Air Pressure Gauge 5— Transmission Oil Temperature Gauge 6— Coolant Temperature Gauge Start the engine.

NOTE: Warning alarm will sound until air pressure reaches normal operating pressure.

Transmission temperature gauge (5) will not begin to indicate temperature until transmission temperature is close to operating temperature.

LOOK: Do all the indicators, except park brake indicator (1), go out after the engine starts?

LOOK: Does the MDU display engine RPM (2)?

Observe engine oil pressure gauge (3).

LOOK: Does needle of gauge indicate pressure is increasing to normal (green)?

Observe air pressure gauge (4) immediately after the engine is started.

LOOK: Does needle of gauge indicate pressure is increasing to normal (green)?

Observe coolant temperature gauge (6) immediately after the engine is started.

YES: Go to next check.

LOOK: Does needle of gauge indicate temperature is increasing to normal (green)?

NO: See your authorized dealer.

OUO1043,0000E2A -19-30OCT01-6/15

Brake Accumulator Check Ensure brake accumulators are fully charged by pressing brake pedal repeatedly to make pump recharge accumulators several times.

Stop pumping during a recharge cycle to ensure brakes are not using oil after pump stops.

Stop engine.

Turn key switch to ON position and wait until warning indicator goes out.

Press brake pedal repeatedly. Count the number of applications the brake pedal is pressed before brake pressure indicator lights.

YES: Start machine and go to next check.

FEEL/LOOK: Does machine allow 8 full applications before brake pressure indicator lights?

NO: See your authorized dealer.

Continued on next page

4-2-3

OUO1043,0000E2A -19-30OCT01-7/15

080112

PN=132

Miscellaneous—Operational Checkout Service Brake Check

NOTE: Perform this check in an open area where machine can travel at full speed.

Drive machine slowly.

Push brake pedal to stop machine.

Release brake pedal.

LOOK/FEEL: Does brake pedal push easily without binding?

LOOK/FEEL: Does brake pedal return to the released position so brakes are not dragging?

LOOK/FEEL: Do brakes stop machine in a reasonable distance without pulling to one side or making noises?

Operate machine at full speed.

Release accelerator and apply service brakes to stop machine.

YES: Go to next check.

LOOK/FEEL: Do brakes stop machine in a reasonable distance without pulling to one side or making noises?

NO: See your authorized dealer.

OUO1043,0000E2A -19-30OCT01-8/15

Park Brake Check CAUTION: Machine will stop abruptly during this check. Fasten seat belt. Perform check in an open area.

NOTE: Park brake will not release if air pressure is below 410 kPa (4.1 bar) (60 psi).

T147682B —UN—19NOV01

1— Park Brake Lever Start engine.

Lift park brake lever (1) and move forward.

NOTE: Park brake will apply at any speed. Apply only when moving slowly.

Drive machine at slow idle in 1st gear.

With machine moving 5 km/h (3 mph) or less, pull park brake lever rearward until it locks into position.

YES: Continue check.

FEEL: Does park brake indicator come ON, park brake engage and machine stop?

NO: See your authorized dealer.

With the engine running, transmission in neutral (N) and park brake ON, lift park brake lever and move forward.

Shift transmission to drive (D).

Slowly increase engine speed.

LOOK/FEEL: Does machine move when engine speed is just above slow idle?

Return engine to slow idle.

YES: Go to next check.

Shift transmission to neutral (N).

NO: See your authorized dealer.

Continued on next page

4-2-4

OUO1043,0000E2A -19-30OCT01-9/15

080112

PN=133

Miscellaneous—Operational Checkout Steering Check

Move machine to an open area and park on a hard, level surface.

Turn inter-axle lock switch to OFF position.

Release park brake.

Release service brakes.

Run engine at slow idle.

Turn steering wheel fully left then fully right.

YES: Continue with check.

FEEL: Does machine turn both directions smoothly?

NO: If steering is jerky or steering wheel is hard to turn, see your authorized dealer.

Run engine at fast idle.

Turn steering wheel fully left then fully right.

YES: Go to next check.

FEEL: Does machine turn both directions smoothly?

NO: If steering is jerky or steering wheel is hard to turn, see your authorized dealer.

OUO1043,0000E2A -19-30OCT01-10/15

Dump Body Raise and Lower Checks

CAUTION: Ensure there is at least 7.6 m (25 ft) clearance above machine.

DO NOT perform this check within 4 m (13.1 ft) of a high voltage power line.

T144028B —UN—17JUL01

1— Dump Body Control Lever Perform this check in an open area away from other people.

Position the machine straight.

CAUTION: Clear all personnel from behind machine. Some material may slide out of dump body as it is raised.

CAUTION: Ensure area above dump body is clear of obstructions and power lines. Height of raised dump body is 7226 mm (23 ft 8.5 in.).

Ensure the dump body is empty.

Operate the engine at 1500 rpm.

Pull dump body control lever rearward to raise dump body.

When dump body is almost completely up, reduce engine speed to slow idle.

YES: Continue check.

LOOK: Does dump body raise to full height smoothly?

NO: See your authorized dealer.

Release dump body control lever.

YES: Continue check.

LOOK/FEEL: Does dump body control lever return to neutral position?

NO: See your authorized dealer.

Push dump body control lever to full forward detent dump body float position and release lever.

LOOK/FEEL: Does control lever return to neutral position?

YES: Go to next check.

LOOK: Does dump body lower to full down position smoothly?

NO: See your authorized dealer.

Continued on next page

4-2-5

OUO1043,0000E2A -19-30OCT01-11/15

080112

PN=134

Miscellaneous—Operational Checkout YES: Continue with check.

Lights Check

T147683B —UN—09NOV01

T147684B —UN—09NOV01

1— Front Turn Indicator Light (2 used) 2— Front Parking Light (2 used) 3— Headlight (2 used) 4— Rear Turn Indicator Light (2 used) 5— Tail, Brake and Parking Light (2 used) 6— Backup Light (2 used) Push lower half of headlight switch to first ON position.

LOOK: Are front parking lights (2) and tail, brake and parking lights (5) ON?

NO: See your authorized dealer.

Push lower half of headlight switch to second position ON.

YES: Continue with check.

LOOK: Are headlights (3) ON?

NO: See your authorized dealer.

Push steering column lever forward.

YES: Continue with check.

LOOK: Are high beam headlights and high beam indicator ON?

NO: See your authorized dealer.

With headlight switch in the OFF position, have a helper push the brake pedal.

YES: Continue with check.

LOOK: Are tail, brake and parking lights (5) ON?

NO: See your authorized dealer.

NOTE: Hazard lights will operate with the key switch in OFF position.

Press lower half of hazard switch.

YES: Continue with check.

LOOK: Do turn indicators (1 and 4) flash?

NO: See your authorized dealer.

CAUTION: Perform check in an open area. Machine may move unexpectedly.

Park brake ON. Push and hold service brake.

Shift transmission into reverse (R).

Have a helper look at backup lights (6).

YES: Go to next check.

LOOK: Are backup lights ON?

NO: See your authorized dealer.

OUO1043,0000E2A -19-30OCT01-12/15

Miscellaneous Checks Continued on next page

4-2-6

OUO1043,0000E2A -19-30OCT01-13/15

080112

PN=135

Miscellaneous—Operational Checkout Dump Body Warming System Check—If Equipped

YES: Go to next check.

CAUTION: Engine exhaust flows through tubes in sides of dump body. Tubes may be hot.

Check dump body warming system.

NO: Check to see that tubes aren't plugged.

FEEL: Do tubes in sides of dump body warm as engine temperature increases to normal?

NO: See your authorized dealer.

OUO1043,0000E2A -19-30OCT01-14/15

Service Decal Check

Check all service and safety decals, ensure they are in place and in readable condition. YES: Operational checkout complete.

NO: Replace safety decals. See your authorized dealer.

OUO1043,0000E2A -19-30OCT01-15/15

4-2-7

080112

PN=136

Miscellaneous—Troubleshooting Using Troubleshooting Charts

Step 1. Operational Checkout Procedure.

NOTE: Troubleshooting charts are arranged from the most likely, simplest to verify, to least likely, more difficult to verify. When diagnosing a problem, use all possible means to isolate the problem to a single component or system. Use the following steps to diagnose problems:

Step 2. Troubleshooting charts.

Step 3. Adjustments.

Step 4. See your authorized dealer.

CED,TX14740,6388 -19-21APR99-1/1

4-3-1

080112

PN=137

Miscellaneous—Troubleshooting

Engine Symptom

Problem

Solution

Starter Motor Turns Engine Too Slowly

Battery undercharged

Check battery charge. Charge or replace battery.

Loose or dirty battery terminals

Tighten or clean battery terminals.

Faulty engine ground connection

Repair, clean or tighten the connection.

Incorrect grade of engine oil

Change oil.See Change Engine Oil and Replace Filter. (Section 3-6.)

Engine Hard Starting when Cold

Engine starter motor turns engine too Check battery charge. Charge or slowly replace battery.

Incorrect use of cold start function

Instruct operator on correct use.

Engine Turns, but Does Not Start

Insufficient fuel in fuel tank

Fill fuel tank and bleed fuel system.

See Bleeding Fuel System. (Section 3-6.)

Engine Difficult to Start (Hot or Cold)

Starter motor turns too slowly

Check the battery charge. Charge or replace battery.

Air in fuel system

Bleed fuel system. See Bleeding Fuel System. (Section 3-6.)

Restricted air inlet

Service air filter system. See Service Engine Air Intake System. (Section 3-3.)

Restricted exhaust system

Locate and repair restriction.

Engine Cuts Out Soon After Starting Insufficient fuel in fuel tank

Engine Overheating

Fill fuel tank and bleed fuel system.

See Bleeding Fuel System. (Section 3-6.)

Air in fuel system

Bleed fuel system. See Bleeding Fuel System (Section 3-6.)

Blocked fuel tank air vent

Clean air vent and bleed fuel system.

See Bleeding Fuel System (Section 3-6.)

Blocked fuel filters

Replace fuel filters. See Replace Final Fuel Filter. (Section 3-6.)

Air filter restriction

Service air filter system. See Service Engine Air Intake System. (Section 3-3.)

Engine coolant level too low

Fill radiator. See Check Engine Coolant Level. Section 3-4.)

Continued on next page

4-3-2

OUO1043,0000E2B -19-30OCT01-1/3

080112

PN=138

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Drive belt slipping

Inspect, adjust or replace drive belt.

See Inspect Serpentine Belt. (Section 4-1.)

Radiator cap not sealing or worn

Replace cap.

Blocked radiator

Clean radiator. See Inspect and Clean Cooling Systems. (Section 3-3.)

Air intake is blocked

Clean as necessary.

Engine Knocking

Incorrect fuel grade

Drain and refill. See Bleeding Fuel System. (Section 3-6.)

Loss of Power

Air filter restriction

Service air filter system. See Service Engine Air Intake System. (Section 3-3.)

Excessive Fuel Consumption

External fuel tank leak

Check fuel tank, fuel lines and filter for leaks and/or damage. See your authorized dealer.

Low operating temperature

Check and repair cooling system. See Check Engine Coolant Level. (Section 3-4.)

Air filter restriction

Service air filter system. See Service Engine Air Intake System. (Section 3-3.)

Low Engine Oil Pressure

Incorrect grade of oil used

See Fuels and Lubricants section.

Abnormal Oil Consumption

Engine overfilled

Drain to proper level. Check drained oil to ensure there are no other oils in oil.

Engine oil leaks

Locate and repair oil leaks.

Incorrect grade of engine oil

See Fuels and Lubricants section.

Engine oil level too low

Fill to correct level. See Check Engine Oil Level. (Section 3-4.)

Oil Pressure Too High

Incorrect engine oil used

Drain engine sump. See Change Engine Oil and Replace Filter.

(Section 3-6.)

Engine Oil Sludge

Incorrect grade of oil used

Drain engine sump. See Change Engine Oil and Replace Filter(Section 3-6.)

Engine operating temperature too high or too low

Check and correct cooling system.

Continued on next page

4-3-3

OUO1043,0000E2B -19-30OCT01-2/3

080112

PN=139

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Oil in service for too long

Change oil and oil filters. See Change Engine Oil and Replace Filter.

(Section 3-6.)

Loose components (e.g., alternator, etc.)

Tighten all components including engine mounts and exhaust system.

Worn or damaged engine mountings

Check and replace engine mounting.

Air inlet system restricted

Service and repair inlet system. See Service Engine Air Intake System.

(Section 3-3.)

Incorrect grade of fuel

Drain and fill fuel tank. See Bleeding Fuel System. (Section 3-6.)

Blue Smoke from Exhaust

Engine oil level too high

Drain to correct level.

White Smoke from Exhaust

Engine running too cold

Check cooling system.

Water in fuel supply

Clean fuel system. See Bleeding Fuel System . (Section 3-6.)

Excessive Vibration at Any Speed

Black Smoke from Exhaust

OUO1043,0000E2B -19-30OCT01-3/3

Transmission Symptom

Problem

Solution

Low Clutch Pressure

Low oil level

Fill transmission. See Check Transmission Oil Level. (Section 3-4.)

Low Converter Charging Pump Output

Low oil level

Fill transmission. See Check Transmission Oil Level. (Section 3-4.)

Suction screen blocked

Clean suction screen.

Low oil level

Fill transmission. See Check Transmission Oil Level. (Section 3-4.)

Transmission Overheats

OUO1043,0000DDB -19-08AUG01-1/1

4-3-4

080112

PN=140

Miscellaneous—Troubleshooting

Axle Symptom

Problem

Solution

Final Drive Leaking Oil

Loose or damaged oil plugs

Tighten or replace oil plugs.

Oil level too high

Drain oil to correct level.

Final drive bolts loose

Tighten final drive bolts to correct torque.

Axle breather blocked

Check axle breather

Noisy Final Drive

Low oil level in final drive

Fill final drive. See Check Axle Oil Levels. (Section 3-7.)

Final Drive Overheating

Oil level too high

Drain oil to correct level.

Oil level too low

Fill final drive.See Check Axle Oil Levels (Section 3-7.)

Differential Assembly Leaking Oil

Bolts loose on main housing

Tighten bolts to correct torque.

Differential Assembly Noisy

Oil level too low

Fill the differential. See Check Axle Oil Levels (Section 3-7.)

Differential Assembly Overheating

Oil level too high

Drain oil to correct level.

Oil level too low

Fill the differential. See Check Axle Oil Levels (Section 3-7.)

Axle breather blocked

Clean axle breather. (See Clean, Inspect, and Replace Breathers—Transmission, Transfer Case, and Axles in Maintenance—As Required section.)

OUO1043,0000E2C -19-30OCT01-1/1

4-3-5

080112

PN=141

Miscellaneous—Troubleshooting

Tires Symptom

Problem

Solution

Tires Wearing in Tread Center

Tires over-inflated

Reduce tire pressure to correct level.

See Inspect Tires, Check Pressure.

(Section 3-3,)

Tires Wearing on Both Sides of Tread

Tires under-inflated

Reduce tire pressure to correct level.

See Inspect Tires, Check Pressure (Section 3-3.)

Rapid Tire Wear

Excessive speed

Follow proper safe driving procedures.

Poor road surface conditions

Recommend road surface maintenance.

Excessive speed

Follow proper safe driving procedures.

Tire Component Heat Separation

OUO1043,0000DD9 -19-08AUG01-1/1

Brakes Symptom

Problem

Solution

Poor or No Service Brakes

Service Brake Pedal

Check brake pedal for obstructions around and under pedal. Check that pedal can be pushed to the end of its stroke and it returns to the released position.

Worn brake pads

Replace brake pads.

Service Brake Pads and Disks Wearing Excessively

Driving technique—constantly using service brakes to slow machine.

Allow torque retarder to slow the machine.

Increased Stopping Distance

Worn brake pads

Replace brake pads.

Oil or grease on brake pads

Replace brake pads.

Squealing Noise from Brakes when Brake pads glazed Applied Brake disks warped or scored

Replace brake pads.

Brakes Do Not Fully Release

Replace brake caliper.

Brake caliper pistons sticking

Inspect brake disks for damage.

TX14740,000000C -19-27JAN03-1/1

4-3-6

080112

PN=142

Miscellaneous—Troubleshooting

Hydraulic System Symptom

Problem

Solution

Pump Not Delivering Hydraulic Oil

Hydraulic oil level in reservoir is too low

Fill hydraulic reservoir. See Check Hydraulic Oil Level. (Section 3-4.)

Outlet hose from tank to pump is blocked

Check suction strainer for blockages.

Clean if necessary.

Hydraulic oil viscosity and type is incorrect

Drain and fill hydraulic system. See Change Hydraulic Oil. (Section 3-9.)

Pump intake is partially blocked

Check suction strainer for blockages.

Clean if necessary.

Breather is blocked

Replace breather filter. See Replace Hydraulic Reservoir Breather.

(Section 3-9.)

Pump Making Noise

OUO1043,0000E2E -19-30OCT01-1/1

Instruments and Controls Symptom

Problem

Solution

Gauge Not Working Properly

Circuit breaker tripped

Investigate cause and correct problem.

Switch Not Working Properly

Circuit breaker tripped

Investigate cause and correct problem.

Warning Light Not Working

Warning light bulb

Replace bulb.

Circuit breaker tripped

Investigate cause and correct problem.

OUO1043,0000DD6 -19-08AUG01-1/1

4-3-7

080112

PN=143

Miscellaneous—Troubleshooting

Electrical System Symptom

Problem

Solution

Indicator light bulb Alternator Charge Indicator Does Not Illuminate when Master Switch Is in ON Position Poor battery connections Alternator Charge Indicator Illuminated when Engine Is ON Battery cells dry Batteries Do Not Hold Charge

Replace bulb.

Clean and check battery connections.

Check battery electrolyte level. Add water, if necessary.

Short running time with lights on

Remove batteries and charge or replace.

Batteries are low on charge

Charge or replace batteries

Batteries defective or damaged

Replace batteries.

Battery terminals loose or damaged

Tighten or clean battery terminals.

Circuit breaker tripped

Investigate and correct problem.

Headlight bulb defective

Replace bulb. See Replace Front Turn Signal Bulb, Headlight Bulb, and Front Park Light Bulb. (Section 4-1.)

Only High Beam or Low Beam Comes On

Headlight bulb defective

Replace bulb. See Replace Front Turn Signal Bulb, Headlight Bulb, and Front Park Light Bulb (Section 4-1.)

One Headlight Does Not Come On (High or Low Beam)

Headlight bulb defective

Replace bulb. See Replace Front Turn Signal Bulb, Headlight Bulb, and Front Park Light Bulb. (Section 4-1.)

High Beam Indicator Light Does Not Come On when High Beam Is Selected

Indicator bulb defective

Replace bulb. See Replace Front Turn Signal Bulb, Headlight Bulb, and Front Park Light Bulb. (Section 4-1.)

Tail Lights Do Not Come On

Tail light bulb defective

Replace bulb. See Replace Tail and Brake Light and Rear Turn Signal.

(Section 4-1.)

Stop Lights Do Not Come On

Stop light bulb defective

Replace bulb. See Replace Tail and Brake Light and Rear Turn Signal (Section 4-1.)

Turn Signal and Horn Do Not Work

Circuit breaker tripped

Investigate and correct cause.

Right Turn Signal Does Not Work

Turn signal light bulb defective

Replace bulb. See Replace Tail and Brake Light and Rear Turn Signal (Section 4-1.)

Starter Motor Does Not Turn or Turns Very Slowly

Headlights Do Not Work

Continued on next page

4-3-8

OUO1043,0000DD5 -19-08AUG01-1/2

080112

PN=144

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Left Turn Signal Does Not Work

Turn signal light bulb defective

Replace bulb. See Replace Tail and Brake Light and Rear Turn Signal.

(Section 4-1.)

Windshield Wiper Does Not Work

Circuit breaker tripped

Investigate and correct cause.

OUO1043,0000DD5 -19-08AUG01-2/2

Rear Frame and Cab Symptom

Problem

Solution

Excessive Cab Movement while Machine Is Operating

Loose or missing mounting bolt(s) or mounts

Tighten or replace mounting bolts or mounts.

A Smear Remains on the Windshield when the Windshield Wiper Is in Operation

Wiper blade damaged

Replace the wiper blade.

Oil or grease on windshield

Clean windshield

Obstruction in seat runner

Remove obstruction.

Lack of lubricant

Lubricate seat runners.

Seat Is Difficult to Adjust

Loose or missing retaining bolts Excessive Movement of the Wing Mirrors while Machine Is Operating Damaged wing mirror arm Wing Mirror Difficult to View

Tighten or replace retaining bolts.

Replace wing mirror arm.

Incorrect adjustment

Adjust as necessary.

Wing mirror cracked

Replace mirror.

NOTE: If any other problems are encountered which require special tools or machine knowledge, see your authorized dealer.

OUO1043,0000DD4 -19-08AUG01-1/1

4-3-9

080112

PN=145

Miscellaneous—Troubleshooting

MDU Displayed Service Codes

T146103B —UN—05OCT01

The MDU displayed service codes are shown as a combination of two numbers, one above the other, on the data display. In the MDU Displayed Service Codes table, the two numbers will be shown separated by a decimal point, with the first number being the bottom number (2) on the data display and the second number being the top number (1) on the data display. For example, the service code shown in the figure would be shown in the table as 1702.4.

1— Top Number

Continued on next page

4-3-10

2— Bottom Number

TX14740,0000001 -19-24JAN03-1/4

080112

PN=146

Miscellaneous—Troubleshooting MDU Displayed Service Codes Service Code

Service Code Name Engine Control Unit (ECU) Codes

91.3

Primary Throttle Input Voltage High

91.4

Primary Throttle Input Voltage Low

91.8

Primary Throttle has Abnormal Pulse Width or Frequency

94.3

Fuel Rail Pressure Voltage High

94.4

Fuel Rail Pressure Voltage Low

94.10

Fuel Rail Pressure Dropping Too Fast

94.17

At Starting, 10 Mpa of Rail Pressure Not Attained After Cranking Engine a Short Time.

97.3

Water in Fuel Voltage High

97.4

Water in Fuel Voltage Low

97.31

Water in Fuel

100.1

Engine Oil Pressure Extremely Low

100.3

Engine Oil Pressure Input Voltage High

100.4

Engine Oil Pressure Input Voltage Low

105.3

Manifold Air Temperature Voltage High

105.4

Manifold Air Temperature Voltage Low

105.16

Manifold Air Temperature Voltage High—Moderately Severe

110.0

Engine Coolant Temperature Extremely High

110.3

Engine Coolant Temperature Input Voltage High

110.4

Engine Coolant Temperature Input Voltage Low

110.16

Engine Coolant Temperature Moderately High

158.17

ECU Cannot Power Down

174.3

Fuel Temperature Input Voltage High

174.4

Fuel Temperature Input Voltage Low

174.16

Fuel Temperature Moderately High

190.0

Engine Overspeed

611.3

Short-To-Battery on Injector Lines

611.4

Short-To-Ground on Injector Lines

620.3

Accelerator Pedal Position Sensor Input Voltage High

620.4

Accelerator Pedal Position Sensor Input Voltage Low

627.1

All Injector Currents Are Out of Specification

629.13

Engine Control Unit (ECU) Internal Malfunction

636.2

Noise Detected On Engine Position Sensor in High Pressure Pump

636.8

Missing Signal From Engine Position Sensor in High Pressure Pump

636.10

Signal From Engine Position Sensor in High Pressure Pump Does Not Have Proper Pulse Pattern

637.2

Noise Detected On Engine Position Sensor on Crank Shaft

637.7

Relationship Between the Two Engine Position Signals is Incorrect

637.8

Missing Signal From Engine Position Sensor on Crank Shaft

637.10

Signal From Engine Position Sensor on Crank Shaft Does Not Have Proper Pulse Pattern

639.13

CAN Data Link Malfunction

651.5

Current to the Injector in Cylinder #1 is Less Than Expected

651.6

Current to the Injector in Cylinder #1 Increases Too Rapidly

651.7

Injector Fuel Flow at Cylinder #1 is Less Than Expected

652.5

Current to the Injector in Cylinder #2 is Less Than Expected

652.6

Current to the Injector in Cylinder #2 Increases Too 4-3-11 Rapidly

652.7

Injector Fuel Flow at Cylinder #2 is Less Than Expected

Continued on next page

TX14740,0000001 -19-24JAN03-2/4

080112

PN=147

Miscellaneous—Troubleshooting Continued on next page

4-3-12

TX14740,0000001 -19-24JAN03-3/4

080112

PN=148

Miscellaneous—Storage Prepare Machine for Storage 1. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later.

2. Wash the machine. [Use low pressure wash operations (less than 1379 kPa (13.8 bar) (200 psi) until 30 days after receipt of machine.] Paint areas to prevent rust. Replace decals, where needed.

3. Fill fuel tank, to prevent condensation.

4. Park machine on a hard surface to prevent tires from freezing to ground.

IMPORTANT: LPS 3 ® Rust Inhibitor can destroy painted finish. DO NOT spray LPS 3 Rust Inhibitor on painted surfaces.

5. Fully lower dump body. Install articulation safety lock bar. Coat exposed steering cylinder rods with LPS 3 Rust Inhibitor.

T5813AM —UN—09FEB89

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 machine with high pressure. Use low pressure wash operations until 30 days have elapsed.

7. Remove batteries.

8. Store machine in a dry, protected place. If stored outside, cover with a waterproof material.

IMPORTANT: Prevent possible machine damage from unauthorized persons operating machine. Attach a "DO NOT OPERATE" tag to steering wheel.

9. Put a "DO NOT OPERATE" tag on the steering wheel.

10. Close all vent louvers in the cab.

11. Remove keys and lock all covers and doors.

6. Apply grease at all lubrication fittings.

LPS 3 Rust Inhibitor is manufactured by Holt Lloyd Corporation.

OUO1079,0000415 -19-23JUL01-1/1

4-4-1

080112

PN=149

Miscellaneous—Serial Numbers Record Product Identification Number (PIN) PIN (1) Purchase Date

T147685B —UN—15NOV01

NOTE: Record all 13 characters of the Product Identification Number.

OUO1043,0000E30 -19-30OCT01-1/1

Record Engine Serial Number

T147686B —UN—15NOV01

Engine Serial Number (1)

OUO1043,0000E31 -19-30OCT01-1/1

Record Transmission Serial Number

T147687B —UN—15NOV01

Transmission Serial Number (1)

OUO1043,0000E32 -19-30OCT01-1/1

4-5-1

080112

PN=150

Miscellaneous—Serial Numbers

Front Axle Serial Number

T147688B —UN—15NOV01

Front Axle Serial Number (1)

OUO1043,0000E33 -19-30OCT01-1/1

Middle Axle Serial Number

T147689B —UN—15NOV01

Middle Axle Serial Number (1)

OUO1043,0000E34 -19-30OCT01-1/1

Rear Axle Serial Number

T147690B —UN—15NOV01

Rear Axle Serial Number (1)

OUO1043,0000E35 -19-30OCT01-1/1

4-5-2

080112

PN=151

Miscellaneous—Specifications 250D Articulated Dump Truck Specifications

7

10 11 1

6 2 3

8 5 12 4

16 14

15

17

13 18

19

23

20 21

24 9 T147691

Continued on next page

4-6-1

T147691 —UN—13NOV01

22

MD04263,00000C4 -19-30JAN09-1/3

080112

PN=152

Miscellaneous—Specifications 1— Height, Machine Overall—Dumped 2— Height, Top of Dump Body Side—Lowered 3— Height, Dump Body Lip—Lowered 4— Height, Dump Body Lip—Dumped 5— Clearance, Articulation Pivot-to-Ground 6— Height, Machine Overall—Lowered 7— Angle, Maximum Dump Body 8— Angle, Maximum Approach

9— Angle, Maximum Articulation 10— Length, Dump Body Overall 11— Length, Maximum Dump Body Load 12— Protrusion, Dump Body Rear Edge 13— Length, Dump Body Lip-to-Rear Axle Centerline—Lowered 14— Length, Rear Axle Centerline-to-Middle Axle Centerline 15— Length, Middle Axle Centerline-to-Front Axle Centerline—Articulation Frames Straightened

NOTE: Specifications and design subject to change without notice. Whenever applicable, specifications are in accordance with SAE standards. Except Item

16— Length, Articulation Pivot-to-Front Axle Centerline 17— Length, Front Axle Centerline-to-Front of Machine 18— Length, Machine Overall—Lowered, Articulation Frames Straightened 19— Width, Dump Body Overall 20— Clearance, Minimum Tire-to-Tire 21— Width, Tire Tread Centerline-to-Tire Tread Centerline

22— Width, Tires Overall 23— Radius, Inside Turning 24— Radius, Outside Turning

where otherwise noted, specifications are based on a machine equipped with all standard equipment, 79 kg (175 lb) operator, and full fuel tank.

Measurement

Specification

1—Machine Overall—Dumped

Height

6128 mm 20 ft 1 in.

2—Top of Dump Body Side—Lowered

Height

2629 mm 8 ft 7 in.

3—Dump Body Lip—Lowered

Height

1897 mm 6 ft 3 in.

4—Dump Body Lip—Dumped

Height

588 mm 1 ft 1 in.

5—Articulation Pivot-to-Ground

Clearance

447 mm 1 ft 6 in.

6—Machine Overall—Lowered

Height

3556 mm 11 ft 8 in.

7—Maximum Dump Body

Angle

70°

8—Maximum Approach

Angle

30°

9—Maximum Articulation

Angle

45°

10—Dump Body Overall

Length

5390 mm 17 ft 8 in.

11—Maximum Dump Body Load

Length

5242 mm 16 ft 10 in.

12—Dump Body Rear Edge

Protrusion

509 mm 1 ft 8 in.

13—Dump Body Lip-to-Rear Axle Centerline—Lowered

Length

1316 mm 4 ft 4 in.

14—Rear Axle Centerline-toMiddle Axle Centerline

Length

1670 mm 5 ft 8 in.

15—Middle Axle Centerline-toFront Axle Centerline—Articulation Frames Straightened

Length

4177 mm 13 ft 8 in.

16—Articulation Pivot-to-Front Axle Length Centerline

1363 mm 4 ft 5 in.

250D Articulated Dump Truck Dimensions

Continued on next page

4-6-2

MD04263,00000C4 -19-30JAN09-2/3

080112

PN=153

Miscellaneous—Specifications Item

Measurement

Specification

17—Front Axle Centerline-to-Front of Machine

Length

2337 mm 7 ft 8 in.

18—Machine Overall—Lowered, Articulation Frames Straightened

Length

9501 mm 31 ft 2 in.

19—Dump Body Overall

Width

2758 mm 9 ft 1 in.

20—Minimum Tire-to-Tire

Clearance

1570 mm 5 ft 2 in.

21—Tire Tread Centerline-to-Tire Tread Centerline

Width

2225 mm 7 ft 4 in.

22—Tires Overall

Width

2880 mm 9 ft 5 in.

23—Inside Turning

Radius

4167 mm 13 ft 8 in.

24—Outside Turning

Radius

7935 mm 26 ft

250D Articulated Dump Truck

Weight

20 400 kg 44 500 lb

250D Dump Body—Dump

Cycle Time

11.9 seconds

250D Dump Body—Lower

Cycle Time

6 seconds

250D Specifications

MD04263,00000C4 -19-30JAN09-3/3

4-6-3

080112

PN=154

Miscellaneous—Specifications

4-6-4

080112

PN=155

Miscellaneous—Specifications

300D Articulated Dump Truck Specifications

7

10 11 1

6 2 3

8 5 12 4

16 14

15

17

13 18

19

23

20 21

24 9 T147691

Continued on next page

4-6-5

T147691 —UN—13NOV01

22

MD04263,00000C5 -19-30JAN09-1/3

080112

PN=156

Miscellaneous—Specifications 1— Height, Machine Overall—Dumped 2— Height, Top of Dump Body Side—Lowered 3— Height, Dump Body Lip—Lowered 4— Height, Dump Body Lip—Dumped 5— Clearance, Articulation Pivot-to-Ground 6— Height, Machine Overall—Lowered 7— Angle, Maximum Dump Body 8— Angle, Maximum Approach

9— Angle, Maximum Articulation 10— Length, Dump Body Overall 11— Length, Maximum Dump Body Load 12— Protrusion, Dump Body Rear Edge 13— Length, Dump Body Lip-to-Rear Axle Centerline—Lowered 14— Length, Rear Axle Centerline-to-Middle Axle Centerline 15— Length, Middle Axle Centerline-to-Front Axle Centerline—Articulation Frames Straightened

NOTE: Specifications and design subject to change without notice. Whenever applicable, specifications are in accordance with SAE standards. Except Item

16— Length, Articulation Pivot-to-Front Axle Centerline 17— Length, Front Axle Centerline-to-Front of Machine 18— Length, Machine Overall—Lowered, Articulation Frames Straightened 19— Width, Dump Body Overall 20— Clearance, Minimum Tire-to-Tire 21— Width, Tire Tread Centerline-to-Tire Tread Centerline

22— Width, Tires Overall 23— Radius, Inside Turning 24— Radius, Outside Turning

where otherwise noted, specifications are based on a machine equipped with all standard equipment, 79 kg (175 lb) operator, and full fuel tank.

Measurement

Specification

1—Dump Body Backsplash—Dumped

Height

6207 mm 20 ft 4 in.

2—Top of Dump Body Side—Lowered

Height

2756 mm 9 ft

3—Dump Body Lip—Lowered

Height

1928 mm 6 ft 4 in.

4—Dump Body Lip—Dumped

Height

526 mm 1 ft 8 in.

5—Articulation Pivot-to-Ground

Clearance

447 mm 1 ft 5 in.

6—Machine Overall—Lowered

Height

3556 mm 11 ft 8 in.

7—Maximum Dump Body

Angle

70°

8—Maximum Approach

Angle

30°

9—Maximum Articulation

Angle

45°

10—Dump Body Overall

Length

5500 mm 18 ft

11—Maximum Dump Body Load

Length

5242 mm 17 ft 1 in.

12—Dump Body Rear Edge

Protrusion

565 mm 1 ft 10 in.

13—Dump Body Lip-to-Rear Axle Centerline—Lowered

Length

1392 mm 4 ft 7 in.

14—Rear Axle Centerline-toMiddle Axle Centerline

Length

1670 mm 5 ft 6 in.

15—Middle Axle Centerline-toFront Axle Centerline—Articulation Frames Straightened

Length

4177 mm 13 ft 8 in.

16—Articulation Pivot-to-Front Axle Length Centerline

1363 mm 4 ft 5 in.

300D Articulated Dump Truck Dimensions

Continued on next page

4-6-6

MD04263,00000C5 -19-30JAN09-2/3

080112

PN=157

Miscellaneous—Specifications Item

Measurement

Specification

17—Front Axle Centerline-to-Front of Machine

Length

2337 mm 7 ft 8 in.

18—Machine Overall—Lowered, Articulation Frames Straightened

Length

9577 mm 31 ft 5 in.

19—Dump Body Overall

Width

2990 mm 9 ft 10 in.

20—Minimum Tire-to-Tire

Clearance

1390 mm 4 ft 7 in.

21—Tire Tread Centerline-to-Tire Tread Centerline

Width

2176 mm 7 ft 2 in.

22—Tires Overall

Width

2960 mm 9 ft 8 in.

23—Inside Turning

Radius

4122 mm 13 ft 6 in.

24—Outside Turning

Radius

7980 mm 26 ft 2 in.

300D Articulated Dump Truck

Weight

21 800 kg 48 100 lb

300D Dump Body—Dump

Cycle Time

11.9 seconds

300D Dump Body—Lower

Cycle Time

6 seconds

300D Specifications

MD04263,00000C5 -19-30JAN09-3/3

4-6-7

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Miscellaneous—Specifications

250D and 300D Engine Specifications Item

Measurement

Specification

Model Configuration Aspiration Injection Type Gross Power

Deere 6081H In-line 6 Cylinder Turbocharged and Intercooled Direct 200 kW @ 2000 rpm 268 hp 1100 N·m @ 1200—1400 rpm 810 lb-ft

250D Engine Specifications

Gross Torque Idle Speed High Idle Speed Displacement

800 ± 20 rpm 2620 ± 50 rpm 8.1 L 494 in3

Oil Pressure

138 kPa @ Low Idle 1.38 bar 20 psi 400 kPa @ High Idle 4.0 bar 58 psi

300D Engine Specifications

Model Configuration

Deere 6081H In-line 6 Cylinder

Aspiration Injection Type Gross Power

Idle Speed

Turbocharged and Intercooled Direct 215 kW @ 2200 rpm 288 hp 1100 N·m @ 1200—1600 rpm 810 lb-ft 800 ± 20 rpm

High Idle Speed Displacement

2620 ± 50 rpm 8.1 L (494 in3)

Oil Pressure

138 kPa @ Low Idle 1.38 bar 20 psi

Gross Torque

400 kPa @ High Idle 4.0 bar 58 psi TX14740,000000D -19-01AUG05-1/1

4-6-8

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Miscellaneous—Specifications

250D and 300D Travel Speeds Item

Measurement

Specification

1st Forward

Speed

6.7 km/hr 4.2 mph

2nd Forward

Speed

10.8 km/hr 6.7 mph

3rd Forward

Speed

18.5 km/hr 11.5 mph

4th Forward

Speed

26.2 km/hr 16.3 mph

5th Forward

Speed

37.2 km/hr 23.1 mph

6th Forward

Speed

50.4 km/hr 31.3 mph

1st Reverse

Speed

7.9 km/hr 4.9 mph

250D and 300D Travel Speeds

OUO1043,0000E39 -19-01AUG05-1/1

250D and 300D Drain and Refill Capacities Item

Measurement

Specification

Capacity

340 L 90 gal

Oil

Capacity

25.5 L 6.7 gal

Coolant

Capacity

26.5 L 7.0 gal

Capacity

21.8 L 5.8 gal

Capacity

4.7 L 5.0 qt

Capacity

21.9 L 5.8 gal

Capacity

4.0 L 4.2 qt

Capacity

78.8 L 20.8 gal

Fuel System Tank Fuel Engine

Transmission Oil Transfer Case Oil Axle Oil (Each) Final Drive Oil (Each) Hydraulic System Reservoir Oil

OUO1043,0000E3A -19-01AUG05-1/1

4-6-9

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Index Page

Page

Accelerator pedal Location ................................................................. 2-1-1 Air conditioner Condenser, inspect and clean................................ 3-3-2 Controls.................................................................. 2-1-6 Filter ....................................................................... 3-6-3 Air pressure Gauge function....................................................... 2-1-5 Gauge location....................................................... 2-1-4 Air suspension Seat...................................................................... 2-1-10 Air, engine intake Inspect ................................................................... 4-1-2 Service ................................................................... 3-3-1 Air, pneumatic system Dryer-filter .............................................................. 3-8-4 Relieve pressure .................................................... 3-2-3 Articulation safety lock bar......................................... 3-2-2 Attachments Adding safely ......................................................... 1-3-4 Operating safely..................................................... 1-3-4 Axle Breather ................................................................. 3-3-3 gear oil ................................................................... 3-1-5 Oil Change.....................................................3-5-4, 3-8-3 Check level......................................................... 3-7-1 Serial number, front axle ........................................ 4-5-2 Serial number, middle axle..................................... 4-5-2 Serial number, rear axle......................................... 4-5-2 Suspension struts, inspect ..................................... 3-6-2 Troubleshooting ..................................................... 4-3-5

Bleed Fuel system............................................................ 4-1-1 Body raise and lower checks..................................... 4-2-5 Body warming system check ..................................... 4-2-7 Bolt and screw torque values Metric ................................................................... 4-1-13 Unified inch .......................................................... 4-1-12 Boost starting............................................................. 4-1-3 Bottom guard ............................................................. 3-2-2 Brake accumulator check .......................................... 4-2-3 Brake accumulators................................................... 4-1-3 Brake oil pressure indicator Location ................................................................. 2-1-4 Brake pedal Location ................................................................. 2-1-1 Brake temperature indicator Location ................................................................. 2-1-4 Brake, dry caliper Pad wear................................................................ 3-6-1 Brake, park Pad wear................................................................ 3-6-1 Brake, wet disk Oil, cooling Specifications ..................................................... 3-1-4 Brakes Park........................................................................ 2-2-8 Service ................................................................... 2-2-7 Transmission retarder, using.................................. 2-2-7 Troubleshooting ..................................................... 4-3-6 Breather Hydraulic reservoir Clean and inspect............................................... 3-6-7 Replace .............................................................. 3-7-2 Transmission, transfer case, axles ........................ 3-3-3

B

C

Back button Location ................................................................. 2-1-4 Batteries Disconnect switch ................................................ 2-1-11 Using battery charger............................................. 4-1-4 Battery Booster batteries.................................................... 4-1-3 Inspect, clean, tighten terminals ............................ 3-6-4 Replace, two-battery machines.............................. 4-1-6 Safety..................................................................... 4-1-5 Battery charge indicator Location ................................................................. 2-1-4 Battery explosions Prevent................................................................... 1-2-4 Before starting engine ............................................... 2-2-1 Before starting work................................................... 2-2-1 Belt, serpentine.......................................................... 3-3-6 Bin Shock pad .............................................................. 3-7-3

Cab Filter, air ................................................................. 3-6-3 Tilt .......................................................................... 3-2-4 Cab tilt pump handle Location ............................................................... 2-1-13 Charge air cooler Inspect and clean................................................... 3-3-2 Chemical products Handling................................................................. 1-2-4 Circuit breaker compartment Location ................................................................. 2-1-1 Circuit breakers Battery balancer................................................... 2-1-11 Identification........................................................... 2-1-8 Main ..................................................................... 2-1-11 Purging units, fuel filter and coolant level switch.. 2-1-11 Cold start indicator Location ................................................................. 2-1-4 Controls Functions ............................................................... 2-1-3 Locations................................................................ 2-1-1

A

Continued on next page

Index-1

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Page

Seat........................................................................ 2-1-9 Coolant Capacity, drain and refill......................................... 4-6-9 Coolant level indicator Location ................................................................. 2-1-4 Coolant temperature guage Location ................................................................. 2-1-4 Coolant, engine Change ................................................................ 3-11-1 Check condition ..................................................... 3-6-9 Check level ............................................................ 3-4-1 Specifications......................................................... 3-1-5 Crankshaft dampener replacement ......................... 3-10-1 Cylinder, do not service ............................................. 4-1-1

Troubleshooting ..................................................... 4-3-2 Valve clearance...................................................... 3-8-1 Engine overspeed indicator Location ................................................................. 2-1-4 Engine service indicator Location ................................................................. 2-1-4 Ether Aid Replace.................................................................. 2-2-3 Exhaust fumes........................................................... 1-2-3 Explosion Battery.................................................................... 1-2-4

D Dampener replacement, crankshaft ........................ 3-10-1 Data display Location ................................................................. 2-1-4 Defrost controls ......................................................... 2-1-6 Diesel fuel.................................................................. 3-1-1 Diesel fuel, testing Testing Diesel Fuel................................................. 3-1-1 Dome light Location ................................................................. 2-1-1 Dome light switch Location ................................................................. 2-1-1 Driving machine......................................................... 2-2-3 Driving metal pins ...................................................... 1-4-3 Dump body Pivot pins ............................................................... 3-4-3 Dump body control lever Location ................................................................. 2-1-1 Dump body prop ........................................................ 3-2-2 Dump body raised indicator Location ................................................................. 2-1-4

E Electrical system Troubleshooting ..................................................... 4-3-8 Emergency preparation ............................................. 1-2-5 Engine Coolant Change............................................................. 3-11-1 Check level......................................................... 3-4-1 Specifications ..................................................... 3-1-5 Coolant conditioner ................................................ 3-6-9 Crankshaft dampener replacement...................... 3-10-1 Filter, air Check ................................................................. 4-1-2 Service ............................................................... 3-3-1 Filter, oil.................................................................. 3-5-1 Oil Change............................................................... 3-5-1 Check level......................................................... 3-4-1 Serial number......................................................... 4-5-1 Starting................................................................... 2-2-2

F Filter Cab air ................................................................... 3-6-3 Engine air intake ..........................................3-3-1, 4-1-2 Engine oil ............................................................... 3-5-1 Final fuel ................................................................ 3-6-8 Fuel ........................................................................ 3-6-8 Fuel drain ............................................................... 3-3-6 Hydraulic breather Clean and inspect............................................... 3-6-7 Replace .............................................................. 3-7-2 Hydraulic return...................................................... 3-5-2 Pneumatic block silencer ....................................... 3-9-2 Pneumatic dryer-filter............................................. 3-8-4 Primary fuel............................................................ 3-5-3 Transmission.......................................................... 3-8-2 Final drive Oil Change.....................................................3-5-4, 3-8-4 Check levels ....................................................... 3-7-1 Fire prevention........................................................... 1-2-4 Fluid analysis test kit ................................................. 3-2-5 Freeing stuck machine ............................................ 2-2-10 Fuel Capacity ................................................................. 4-6-9 Diesel ..................................................................... 3-1-1 Do not service injection nozzles............................. 4-1-1 Filter replace ................................................3-5-3, 3-6-8 Gauge function....................................................... 2-1-5 Gauge location....................................................... 2-1-4 Handling and storing .............................................. 3-1-2 Low sulfur conditioner ............................................ 3-1-1 System bleed ......................................................... 4-1-1 Use correct fuels and lubricants............................. 3-2-1 Fuses Identification........................................................... 2-1-8

G Gauges Functions ............................................................... 2-1-5 Locations................................................................ 2-1-4 Gauges and indicator lights check............................. 4-2-1 Gauges and indicators checks .................................. 4-2-3 Gearshift control Location ................................................................. 2-1-1 Continued on next page

Index-2

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Page

Grease Alternative and synthetic lubricants ....................... 3-1-7 Cylinder pins, oscillation tube, articulation joints, oscillation tube through drive shaft bearings ............................................................... 3-6-5 Dump body pivot pins ............................................ 3-4-3 Hinges.................................................................... 4-1-3 Prop shaft slip joint................................................. 3-7-3 Specifications......................................................... 3-1-6 Tailgate pivots ........................................................ 3-4-3 Use correct fuels and lubricants............................. 3-2-1

In-line fuel Filter replace .......................................................... 3-6-7 Inch torque values Cap screw and nut ............................................... 4-1-14 Indicator Air cleaner service .......................................3-3-1, 4-1-2 Injection nozzle, do not service ................................. 4-1-1 Inspect machine ........................................................ 1-2-2 Instructional seat ....................................................... 2-1-9 Instrument panel Functions ............................................................... 2-1-5 Location .......................................................2-1-1, 2-1-4 Instruments and controls Troubleshooting ..................................................... 4-3-7 Inter-axle lock ............................................................ 2-2-6 Inter-axle lock indicator Location ................................................................. 2-1-4 Inter-axle lock switch Location ................................................................. 2-1-1

H Handhold Use............................................................ 1-3-1 Hardware torque values Metric ................................................................... 4-1-13 Unified inch .......................................................... 4-1-12 Headlight Intensity controls .................................................... 2-1-7 Headlight switch Location ................................................................. 2-1-1 Heater Controls.................................................................. 2-1-6 Heater and air conditioner control panel Location ................................................................. 2-1-1 High beam indicator Location ................................................................. 2-1-4 High-pressure oils Avoid ...................................................................... 1-2-3 Hill Operation ............................................................... 2-2-8 Hinges ....................................................................... 4-1-3 Horn button................................................................ 2-1-7 Hydraulic Filter, breather Inspect and clean ............................................... 3-6-7 Replace .............................................................. 3-7-2 Filter, return............................................................ 3-5-2 Oil Change............................................................... 3-9-1 Check level......................................................... 3-4-2 Specifications ..................................................... 3-1-4 Suction screen ....................................................... 3-9-2 Hydraulic oil temperature indicator Location ................................................................. 2-1-4 Hydraulic system Troubleshooting ..................................................... 4-3-7

I Identification Axle serial number, front ........................................ 4-5-2 Axle serial number, middle..................................... 4-5-2 Axle serial number, rear ......................................... 4-5-2 Engine serial number ............................................. 4-5-1 Product identification number ................................ 4-5-1 Transmission serial number................................... 4-5-1

J Jump starting ............................................................. 4-1-3

K Key switch Location ................................................................. 2-1-1

L Lever Steering column ..................................................... 2-1-7 Lifting points ............................................................ 2-2-13 Light Backup light, replace............................................ 4-1-10 Circuit breaker compartment light, replace .......... 4-1-11 Dome light, replace .............................................. 4-1-11 Headlight, adjust .................................................... 4-1-9 Headlight, replace .................................................. 4-1-7 Park light, front, replace ......................................... 4-1-7 Park light, rear, replace ........................................ 4-1-10 Tail and brake light, replace ................................. 4-1-10 Turn signal, front, replace ...................................... 4-1-7 Turn signal, rear, replace ..................................... 4-1-10 Work light, replace ............................................... 4-1-10 Lights Locations.............................................................. 2-1-12 Loading and unloading dump body Operation ............................................................... 2-2-9 Loading machine on trailer ...................................... 2-2-14 Lock ......................................................................... 2-2-15 Lubricant Storage Storage, Lubricant.................................................. 3-1-6 Lubricants Alternative and synthetic lubricants ....................... 3-1-7 Grease ................................................................... 3-1-6 Hydraulic and wet disk brake cooling oil ................ 3-1-4 Continued on next page

Index-3

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Index Page

Page

Transmission and transfer case oil ........................ 3-1-4 Lubricate Cylinder pins, oscillation tube, articulation joints, oscillation tube through drive shaft bearings ............................................................... 3-6-5 Dump body pivot pins ............................................ 3-4-3 Hinges.................................................................... 4-1-3 Tailgate pivots ........................................................ 3-4-3 Use correct fuels and lubricants............................. 3-2-1

Engine Change............................................................... 3-5-1 Check level......................................................... 3-4-1 Final drive Change.....................................................3-5-4, 3-8-4 Check levels ....................................................... 3-7-1 Hydraulic Change............................................................... 3-9-1 Check level......................................................... 3-4-2 Specifications ..................................................... 3-1-4 Pressure gauge function ........................................ 2-1-5 Pressure gauge location ........................................ 2-1-4 Transfer case Change.....................................................3-5-3, 3-8-3 Check level......................................................... 3-4-2 Specifications ..................................................... 3-1-4 Transmission Change............................................................... 3-8-1 Check condition.................................................. 3-8-1 Check level......................................................... 3-6-6 Specifications ..................................................... 3-1-4 Wet disk brake cooling Specifications ..................................................... 3-1-4 Oil filters..................................................................... 3-1-6 Oil gear axle ........................................................................ 3-1-5 Operation Freeing stuckmachine.......................................... 2-2-10 Hill .......................................................................... 2-2-8 Loading and unloading dump body........................ 2-2-9 Off-road.................................................................. 2-2-8 Parking machine .................................................. 2-2-10 Towing with inoperable engine............................. 2-2-11 Towing with inoperable steering........................... 2-2-11 Towing with operable engine................................ 2-2-11 Operation qualification............................................... 1-2-1 Operator controls Functions ............................................................... 2-1-3 Locations................................................................ 2-1-1 Operator's manual compartment Location ................................................................. 2-1-1 Outlet Accessory, 12-volt................................................ 2-1-12

M Machine Clean regularly..................................................... 4-1-11 Driving.................................................................... 2-2-3 Lifting points......................................................... 2-2-13 Loading onto trailer .............................................. 2-2-14 Shifting ................................................................... 2-2-5 Slowing and stopping............................................. 2-2-7 Steering.................................................................. 2-2-4 Storage .................................................................. 4-4-1 Machine inspection.................................................... 1-2-2 Maintenance Prepare machine.................................................... 3-2-1 Record keeping...................................................... 3-2-5 Schedule and record.............................................. 3-2-6 Menu button Location ................................................................. 2-1-4 Message display Location ................................................................. 2-1-4 Metal pins .................................................................. 1-4-3 Metric bolt and screw torque values ........................ 4-1-13 Metric torque values Cap screw and nut ............................................... 4-1-15 Monitor display unit (MDU) Default display menu ........................................... 2-1-14 Menu function ...................................................... 2-1-16 Service codes ...................................................... 4-3-10 Motor, do not service ................................................. 4-1-1 Moving parts Safety..................................................................... 1-2-2 Servicing ................................................................ 1-2-2

N

P

Next button Location ................................................................. 2-1-4

O Off-road Operation ............................................................... 2-2-8 Oil Alternative and synthetic lubricants ....................... 3-1-7 Axle Change.....................................................3-5-4, 3-8-3 Check level......................................................... 3-7-1 Capacities, drain and refill...................................... 4-6-9

Park brake Using...................................................................... 2-2-8 Park brake check....................................................... 4-2-4 Park brake lever Location ................................................................. 2-1-1 Parking light check .................................................... 4-2-6 Parking machine...................................................... 2-2-10 Parts catalog Location ............................................................... 2-1-13 Pneumatic Dryer-filter .............................................................. 3-8-4 Relieve pressure .................................................... 3-2-3

Continued on next page

Index-4

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Index Page

Page

Pneumatic block silencer Filter ....................................................................... 3-9-2 Pneumatic pressure Gauge function....................................................... 2-1-5 Gauge location....................................................... 2-1-4 Power supply, 12V................................................... 2-1-12 Pre-start inspection.................................................... 2-2-1 Prepare machine for maintenance ............................ 3-2-1 Pressure, tires ........................................................... 3-3-4 Product identification number .................................... 4-5-1 Prop shaft Slip joint ................................................................. 3-7-3 Protective equipment................................................. 1-2-1 Pump, do not service................................................. 4-1-1

Seat Air suspension ..................................................... 2-1-10 Belt....................................................................... 2-1-10 Controls.................................................................. 2-1-9 Instructional............................................................ 2-1-9 Seat belt Use and maintenance ............................................ 1-3-1 Secondary exit......................................................... 2-1-12 Secondary steering.................................................... 2-2-4 Secondary steering indicator Location ................................................................. 2-1-4 Select button Location ................................................................. 2-1-4 Serial number Axle, front............................................................... 4-5-2 Axle, middle ........................................................... 4-5-2 Axle, rear................................................................ 4-5-2 Engine.................................................................... 4-5-1 Product................................................................... 4-5-1 Transmission.......................................................... 4-5-1 Serpentine belt .......................................................... 3-3-6 Service Do not service control valves, cylinders, pumps or motors .................................................. 4-1-1 Do not service injection nozzles............................. 4-1-1 Service brake Using...................................................................... 2-2-7 Service brake pedal Location ................................................................. 2-1-1 Service brake pedal check ........................................ 4-2-4 Service codes Monitor display unit (MDU) .................................. 4-3-10 Service decal check................................................... 4-2-7 Service lock Articulation safety lock bar ..................................... 3-2-2 Cab support strut ................................................... 3-2-4 Dump body prop .................................................... 3-2-2 Service required indicator Location ................................................................. 2-1-4 Service your machine at specified intervals .............. 3-2-1 Shock pad Bin.......................................................................... 3-7-3 Slowing machine ....................................................... 2-2-7 Specifications 250D cycle times.................................................... 4-6-3 250D dimensions ................................................... 4-6-1 250D drain and refill capacities.............................. 4-6-9 250D engine........................................................... 4-6-8 250D tire pressure and radius................................ 3-3-4 250D weight ........................................................... 4-6-3 300D cycle times.................................................... 4-6-7 300D dimensions ................................................... 4-6-5 300D drain and refill capacities.............................. 4-6-9 300D engine........................................................... 4-6-8 300D tire pressure and radius................................ 3-3-4 300D weight ........................................................... 4-6-7 Coolant, engine............................................3-1-5, 3-6-9 Lubricants Grease................................................................ 3-1-6

R Radiator Coolant Change............................................................. 3-11-1 Check condition.................................................. 3-6-9 Check level......................................................... 3-4-1 Specifications ..................................................... 3-1-5 Inspect and clean................................................... 3-3-2 Radius, tires............................................................... 3-3-4 Range hold ................................................................ 2-2-6 Range hold switch Location ................................................................. 2-1-1 Rear frame and cab Troubleshooting ..................................................... 4-3-9 Rear view mirrors adjustment switch Location ................................................................. 2-1-1 Rear view mirrors defrost swtich Location ................................................................. 2-1-1 Replace Start Aid Can.......................................................... 2-2-3 Reservoir Windshield washer............................................... 2-1-13 Riders Keeping off machine .............................................. 1-3-2 Roads Operating or traveling ............................................ 1-3-3 Rocking machine free.............................................. 2-2-10 ROPS Inspect ................................................................... 1-3-4 Maintain ................................................................. 1-3-4 Rust inhibitor.............................................................. 3-6-9

S Safety Operator's seat ...................................................... 1-3-1 Safety equipment....................................................... 1-2-1 Safety features .......................................................... 1-1-1 Safety information Recognizing ........................................................... 1-2-1 Safety instructions ..................................................... 1-2-1 Safety signs ............................................................... 1-5-1 Safety symbols .......................................................... 1-2-1

Continued on next page

Index-5

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Page

Hydraulic and wet disk brake cooling oil ............ 3-1-4 Transmission and transfer case oil..................... 3-1-4 Travel speeds ........................................................ 4-6-9 Speed Machine travel speeds ........................................... 4-6-9 Speedometer Function ................................................................. 2-1-5 Locations................................................................ 2-1-4 Start Aid Replace.................................................................. 2-2-3 Start aid switch Location ................................................................. 2-1-1 Start switch check...................................................... 4-2-2 Starting Engine.................................................................... 2-2-2 Steering ..................................................................... 2-2-4 Steering check........................................................... 4-2-5 Steering column Lever ...................................................................... 2-1-7 Steering column lever Location ................................................................. 2-1-1 Steering wheel Location ................................................................. 2-1-1 Steps Use .................................................................. 1-3-1 Stopping machine...................................................... 2-2-7 Storage Machine ................................................................. 4-4-1 Storing fuel ................................................................ 3-1-2 Suction screen Replace.................................................................. 3-9-2 Switch Battery disconnect ............................................... 2-1-11 Range hold............................................................. 2-2-6

Transfer case Breather ................................................................. 3-3-3 Oil Change.....................................................3-5-3, 3-8-3 Check level......................................................... 3-4-2 Specifications ..................................................... 3-1-4 Transmission Breather ................................................................. 3-3-3 Cooler, inspect and clean....................................... 3-3-2 Filters ..................................................................... 3-8-2 Oil Change............................................................... 3-8-1 Check condition.................................................. 3-8-1 Check level......................................................... 3-6-6 Specifications ..................................................... 3-1-4 Serial number......................................................... 4-5-1 Shifting ................................................................... 2-2-5 Temperature gauge function .................................. 2-1-5 Temperature gauge locations................................. 2-1-4 Troubleshooting ..................................................... 4-3-4 Transmission retarder Using...................................................................... 2-2-7 Transmission retarder indicator Location ................................................................. 2-1-4 Transmission service indicator Location ................................................................. 2-1-4 Transmission torque retarder control lever Location ................................................................. 2-1-1 Transporting Lifting points......................................................... 2-2-13 Loading machine on trailer................................... 2-2-14 Travel speed.............................................................. 4-6-9 Traveling On public roads...................................................... 1-3-3 Troubleshooting Axle ........................................................................ 4-3-5 Brakes.................................................................... 4-3-6 Electrical system .................................................... 4-3-8 Engine.................................................................... 4-3-2 Hydraulic system.................................................... 4-3-7 Instruments and controls........................................ 4-3-7 Rear frame and cab ............................................... 4-3-9 Tire......................................................................... 4-3-6 Transmission.......................................................... 4-3-4 Turn indicator Controls.................................................................. 2-1-7 Turn indicators Location ................................................................. 2-1-4 Turning machine free............................................... 2-2-10

T Telescopic steering adjust lever Location ................................................................. 2-1-1 Tilt cab ....................................................................... 3-2-4 Tilt steering adjust lever Location ................................................................. 2-1-1 Tire Pressure and radius, 250D .................................... 3-3-4 Pressure and radius, 300D .................................... 3-3-4 Size, pressure, and radius ..................................... 3-3-4 Troubleshooting ..................................................... 4-3-6 Wheel nut torque.................................................... 4-1-3 Wheel wrench and brace location........................ 2-1-13 Torque Cap screw and nut, inch ...................................... 4-1-14 Cap screw and nut, metric ................................... 4-1-15 Wheel nuts ............................................................. 4-1-3 Torque charts Metric ................................................................... 4-1-13 Unified inch .......................................................... 4-1-12 Towing Inoperable engine ................................................ 2-2-11 Inoperable steering .............................................. 2-2-11 Operable engine .................................................. 2-2-11

U Unified inch bolt and screw torque values ............... 4-1-12

V Valve Engine valve clearance.......................................... 3-8-1 Valve, do not service ................................................. 4-1-1 Continued on next page

Index-6

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Page

Vibration Crankshaft dampener replacement...................... 3-10-1

Welding.................................................................... 4-1-16 Welding repairs.......................................................... 1-4-2 Wheel nut torque ....................................................... 4-1-3 Wheel wrench and brace......................................... 2-1-13 Windshield washer reservoir ................................... 2-1-13 Windshield wiper Controls.................................................................. 2-1-7

W Warning light switch Location ................................................................. 2-1-1 Waste disposal .......................................................... 1-2-5

Index-7

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Index

Index-8

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