John Deere 410G Backhoe Loader Operator's Manual - PDF DOWNLAOD

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410G Backhoe Loader

OPERATOR’S MANUAL 410G Backhoe Loader OMT201153 Issue A4 (ENGLISH)

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

If this product contains a gasoline engine:

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

The State of California requires the above two warnings.

Worldwide Construction And Forestry Division (This manual replaces OMT166701 D1) LITHO IN U.S.A.

Introduction Foreword READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage.

This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.)

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

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

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

WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these

numbers when you order parts. File the identification numbers in a secure place off the machine.

WARRANTY is provided as part of John Deere’s support program for customers who operate and maintain their equipment as described in this manual.

The warranty is explained on the warranty certificate which you should have received from your dealer.

This warranty provides you the assurance that John Deere will back its products where defects appear within the warranty period. In some circumstances, John Deere also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.

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

DX,IFC7 –19–16NOV01–1/1

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Introduction

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

U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT

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

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.

–19–28JUN00

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."

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.

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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.

HG31779,0000015 –19–08APR02–1/1 012704

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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 P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, IA 52004-0538

FAX NUMBER:

563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one) Poor 1

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Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU!

TX,TM,FAX –19–03JUL01–1/1 012704

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Page

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

Safety—Safety Signs Safety Signs (S.N. —919463). . . . . . . . . . . . . . 1-5-1 Safety Signs (S.N. 919464—). . . . . . . . . . . . . . 1-5-3

Safety—General Precautions Recognize Safety Information. . . . . . . . . . . . . .

Follow Safety Instructions. . . . . . . . . . . . . . . . .

Operate Only If Qualified . . . . . . . . . . . . . . . . .

Wear Protective Equipment . . . . . . . . . . . . . . .

Avoid Unauthorized Machine Modifications. . . .

Inspect Machine . . . . . . . . . . . . . . . . . . . . . . . .

Stay Clear Of Moving Parts . . . . . . . . . . . . . . .

Avoid High-Pressure Fluids . . . . . . . . . . . . . . .

Beware Of Exhaust Fumes. . . . . . . . . . . . . . . .

Prevent Fires . . . . . . . . . . . . . . . . . . . . . . . . . .

Prevent Battery Explosions. . . . . . . . . . . . . . . .

Handle Chemical Products Safely. . . . . . . . . . .

Dispose Of Waste Properly . . . . . . . . . . . . . . .

Prepare For Emergencies. . . . . . . . . . . . . . . . .

Safety—Operating Precautions Use Steps And Handholds Correctly . . . . . . . .

Start Only From Operator’s Seat . . . . . . . . . . .

Use And Maintain Seat Belt . . . . . . . . . . . . . . .

Prevent Unintended Machine Movement . . . . .

Prevent Unintended Machine Movement—If Equipped With Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Avoid Work Site Hazards . . . . . . . . . . . . . . . . .

Keep Riders Off Machine . . . . . . . . . . . . . . . . .

Avoid Backover Accidents . . . . . . . . . . . . . . . .

Avoid Machine Tipover . . . . . . . . . . . . . . . . . . .

Add And Operate Attachments Safely . . . . . . .

Use Special Care When Operating. . . . . . . . . .

Operating Or Traveling On Public Roads . . . . .

Inspect and Maintain ROPS . . . . . . . . . . . . . . .

Safety—Maintenance Precautions Park And Prepare For Service Safely . . . . . . . .

Service Cooling System Safely. . . . . . . . . . . . .

Remove Paint Before Welding or Heating . . . .

Make Welding Repairs Safely. . . . . . . . . . . . . .

Drive Metal Pins Safely . . . . . . . . . . . . . . . . . .

Operation—Operator’s Station Pedals and Levers . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Pedals and Levers—If Equipped With Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Display Monitor Functions . . . . . . . . . . . . . . . . 2-1-2 Display Monitor Functions —If Equipped With Pilot Controls . . . . . . . . . . . . . . . . . . . . 2-1-5 Right-Side Console Functions . . . . . . . . . . . . . 2-1-8 Controls—Steering Console . . . . . . . . . . . . . . 2-1-11 Pilot Control Enable/Disable Switch—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 Pattern Select Switch—If Equipped (S.N. — 919463) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13 Defroster, Heater, and Air Conditioner Controls—If Equipped . . . . . . . . . . . . . . . . . 2-1-14 Side Windows—Secondary Exits . . . . . . . . . . 2-1-15 Rear Windows . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 Adjusting Seat . . . . . . . . . . . . . . . . . . . . . . . . 2-1-16 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-18 Steering Wheel Tilt Lever—If Equipped . . . . . 2-1-18 12-Volt Accessory Outlets . . . . . . . . . . . . . . . 2-1-19

1-2-1 1-2-1 1-2-2 1-2-2 1-2-2 1-2-3 1-2-3 1-2-3 1-2-4 1-2-4 1-2-4 1-2-5 1-2-5 1-2-5

1-3-1 1-3-1 1-3-1 1-3-2

1-3-2 1-3-3 1-3-3 1-3-4 1-3-4 1-3-5 1-3-5 1-3-6 1-3-6

Operation—Operating The Machine Inspect Machine Daily Before Starting . . . . . . . 2-2-1 Check Instruments Before Starting . . . . . . . . . . 2-2-2 Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 2-2-3 Starting Fluid—Cold Weather Start Aid— If Equipped (S.N.—910057) . . . . . . . . . . . . . 2-2-5 Starting Fluid—Cold Weather Start Aid— If Equipped (S.N. 910058—) . . . . . . . . . . . . . 2-2-6 Using Booster Batteries—12 Volt System. . . . . 2-2-8 Using Coolant Heater—If Equipped . . . . . . . . . 2-2-9 Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9 Cold Weather Warm-Up . . . . . . . . . . . . . . . . . 2-2-10 Ride Control Operation—If Equipped . . . . . . . 2-2-11 Pilot Control Operation—If Equipped . . . . . . . 2-2-13

1-4-1 1-4-1 1-4-2 1-4-2 1-4-3

Continued on next page

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT  2003 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual

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2-2-14 2-2-16 2-2-17 2-2-18

Maintenance and Repair Record Keeping System . . . . . . . . . . . . . . . . . . . . . . 3-2-6 OILSCAN PLUS, COOLSCAN PLUS, Dieselscan, and 3-Way Coolant Test Kit . . . . 3-2-7 Service Intervals. . . . . . . . . . . . . . . . . . . . . . . . 3-2-8 Required Parts . . . . . . . . . . . . . . . . . . . . . . . . 3-2-10

Driving the Machine . . . . . . . . . . . . . . . . . . . .

Operating Stabilizers . . . . . . . . . . . . . . . . . . .

Operating Boom Lock. . . . . . . . . . . . . . . . . . .

Operating Swing Lock . . . . . . . . . . . . . . . . . .

Operating Backhoe—John Deere Two-Lever Controls. . . . . . . . . . . . . . . . . . .

Operating Backhoe—Excavator Two-Lever Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Backhoe—John Deere Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Backhoe—Excavator Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Extendible Dipperstick—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Extendable Dipperstick Lock—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Backhoe Auxiliary Hydraulic Functions—If Equipped . . . . . . . . . . . . . . . .

Operating Loader . . . . . . . . . . . . . . . . . . . . . .

Operating Differential Lock . . . . . . . . . . . . . . .

Operating Mechanical Front Wheel Drive (MFWD)—If Equipped . . . . . . . . . . . . . . . . .

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking the Machine. . . . . . . . . . . . . . . . . . . .

Loading Machine on a Trailer . . . . . . . . . . . . .

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

2-2-19

Maintenance—As Required Inspect Loader Boom Service Lock . . . . . . . . . 3-3-1 Check and Adjust Boom Lock . . . . . . . . . . . . . 3-3-1 Check Tire Pressure. . . . . . . . . . . . . . . . . . . . . 3-3-2 Tire Inflation Pressures. . . . . . . . . . . . . . . . . . . 3-3-3 Check Wheel Fasteners . . . . . . . . . . . . . . . . . . 3-3-4 Clean Cab Air Filters . . . . . . . . . . . . . . . . . . . . 3-3-5 Inspect and Clean Hydraulic Reservoir Fill Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-6 Drain Fuel Tank Water and Sediment. . . . . . . . 3-3-6 Clean Engine Air Cleaner Dust Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-7 Clean or Replace Air Cleaner Elements . . . . . . 3-3-8 Inspect Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Grease MFWD Drive Shaft Splines—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Grease Extendible Dipperstick Side Rails— If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Grease Extendable Dipperstick Backhoes— If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-10 Grease Front Wheel Bearings—Non-Powered (S.N. —911143). . 3-3-10 Grease Front Wheel Bearings—Non-Powered (S.N. 911144—). . 3-3-11

2-2-20 2-2-21 2-2-22 2-2-23 2-2-24 2-2-25 2-2-26 2-2-27 2-2-28 2-2-29 2-2-30 2-2-31 2-2-32

Maintenance—Machine Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Sulfur Diesel Fuel Conditioner. . . . . . . . . .

Dieselscan Fuel Analysis . . . . . . . . . . . . . . . . .

Handling and Storing Diesel Fuel . . . . . . . . . . .

Alternative and Synthetic Lubricants. . . . . . . . .

Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . .

Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . .

Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. . . . . . . . .

Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease For Extendible Dipperstick, Sideshift Frame, And Stabilizer Leg Wear Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diesel Engine Coolant . . . . . . . . . . . . . . . . . . .

Maintenance—Periodic Maintenance Service Your Machine at Specified Intervals. . .

Check Hour Meter Regularly . . . . . . . . . . . . . .

Prepare Machine for Maintenance . . . . . . . . . .

Loader Boom Service Lock . . . . . . . . . . . . . . .

Opening and Closing Engine Hood (S.N. — 903478) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening and Closing Engine Hood (S.N. 903479—) . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1-1 3-1-1 3-1-2 3-1-2 3-1-3 3-1-3 3-1-4

Maintenance—Every 10 Hours or Daily Checking Hydraulic Reservoir Oil Level . . . . . . 3-4-1 Check Engine Oil Level . . . . . . . . . . . . . . . . . . 3-4-2 Check Coolant Level . . . . . . . . . . . . . . . . . . . . 3-4-3 Grease Loader Pivots. . . . . . . . . . . . . . . . . . . . 3-4-4 Grease 4-in-1 Bucket Pivots—If Equipped . . . . 3-4-5 Grease Stabilizer Pivots and Cylinder Pins. . . . 3-4-5 Grease Backhoe Linkage, Pivots, and Cylinder Rod Ends . . . . . . . . . . . . . . . . . . . . 3-4-6 Grease Non-Powered Front Axle and Steering Pivots (S.N. —911143) . . . . . . . . . . 3-4-8 Grease Non-Powered Front Axle Pivots (S.N. 911144—) . . . . . . . . . . . . . . . . . . . . . . 3-4-9 Grease MFWD Front Axle and Universal Joints—If Equipped . . . . . . . . . . . . . . . . . . . 3-4-10

3-1-5 3-1-6

3-1-6 3-1-7

3-2-1 3-2-1 3-2-2 3-2-3 3-2-4

Maintenance—After First 100 Hours Change Engine Break-In Oil And Replace Filter . . . . . . . . . . . . . . . . . . . . . . . . 3-5-1 Replace Transmission Oil Filter . . . . . . . . . . . . 3-5-3

3-2-5

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Maintenance—Every 250 Hours Check MFWD Planetary Housing Oil—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check MFWD Axle Oil Level—If Equipped . . . .

Check Battery Electrolyte Level and Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Rear Axle Oil Level . . . . . . . . . . . . . . . .

Check Transmission Oil Level . . . . . . . . . . . . .

Change Engine Oil And Replace Filter (S.N.—911915) . . . . . . . . . . . . . . . . . . . . . . .

Maintenance—Every 500 Hours Check Coolant and Add Conditioner. . . . . . . . .

Check Air Intake Hose . . . . . . . . . . . . . . . . . . .

Replace Hydraulic Oil Filter . . . . . . . . . . . . . . .

Check Boom-to-Dipperstick Pin Bolt Torque . . .

Replace Hydraulic Reservoir Breather . . . . . . .

Change Engine Oil And Replace Filter (S.N. 911916—) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replace Fuel Filter . . . . . . . . . . . . . . . . . . . . . .

Page

Do Not Service Or Adjust Injection Nozzles Or Injection Pump . . . . . . . . . . . . . . 4-1-5 Replace Engine Torsional Damper . . . . . . . . . . 4-1-6 Draining Fuel Filter Sediment . . . . . . . . . . . . . . 4-1-6 Precautions for Alternator and Regulator . . . . . 4-1-7 Handling, Checking And Servicing Batteries Carefully . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-8 Replacing Batteries . . . . . . . . . . . . . . . . . . . . . 4-1-9 Removing Batteries . . . . . . . . . . . . . . . . . . . . 4-1-10 Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . 4-1-11 Remove and Install Halogen Bulb. . . . . . . . . . 4-1-13 Checking Neutral Start System. . . . . . . . . . . . 4-1-13 Changing Loader Buckets . . . . . . . . . . . . . . . 4-1-14 Adding Front Counterweights . . . . . . . . . . . . . 4-1-15 Adding Liquid Ballast to Front Tires—410G . . 4-1-15 Welding on Machine . . . . . . . . . . . . . . . . . . . . 4-1-16 Checking Ride Control Accumulator—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-17 Discharge Ride Control System Hydraulic Pressure—If Equipped. . . . . . . . . 4-1-18 Discharge Pilot Control System Hydraulic Pressure—If Equipped. . . . . . . . . 4-1-19 Lowering Boom Without Electrical Power—For Machines With Pilot Controls. . 4-1-20 Check Park Brake . . . . . . . . . . . . . . . . . . . . . 4-1-21 Bleeding Service Brakes. . . . . . . . . . . . . . . . . 4-1-22 Service Recommendations For STC1 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24 Adjusting Speed Control Lever Tension (S.N.—913479) . . . . . . . . . . . . . . . . . . . . . . 4-1-26 Adjusting Speed Control Lever Tension (S.N. 913480—) . . . . . . . . . . . . . . . . . . . . . 4-1-27 Adjusting Pilot Control Wrist Rest —If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-27 Checking and Adjusting Toe-In (S.N. — 911143) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-28 Checking and Adjusting Toe-In (S.N. 911144—) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-29 Installing Teeth on Backhoe Bucket . . . . . . . . 4-1-30 Checking Machine Cycle Times—410G . . . . . 4-1-31 Do Not Service Control Valves, Cylinders, Pumps or Motors . . . . . . . . . . . . 4-1-32 Hardware Torque Specifications . . . . . . . . . . . 4-1-32 Keep ROPS Installed Properly . . . . . . . . . . . . 4-1-32 Metric Bolt and Cap Screw Torque Values . . . 4-1-33 Unified Inch Bolt and Cap Screw Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-34

3-6-1 3-6-1 3-6-2 3-6-4 3-6-4 3-6-5

3-7-1 3-7-2 3-7-2 3-7-2 3-7-3 3-7-4 3-7-6

Maintenance—Every 1000 Hours Clean, Pack, and Adjust Front Wheel Bearings—Non-Powered (S.N.—911143) . . . 3-8-1 Clean, Pack, and Adjust Front Wheel Bearings—Non-Powered (S.N. 911144—). . . 3-8-3 Change MFWD Front Wheel Planetary Housing Oil—If Equipped . . . . . . . . . . . . . . . 3-8-4 Change MFWD Front Axle Housing Oil—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-5 Clean Engine Crankcase Ventilation Tube . . . . 3-8-5 Change Transmission and Torque Converter Oil and Filter. . . . . . . . . . . . . . . . . 3-8-6 Change Rear Axle Oil. . . . . . . . . . . . . . . . . . . . 3-8-7 Replace Pilot Control Filter . . . . . . . . . . . . . . . . 3-8-7 Check Engine Speeds . . . . . . . . . . . . . . . . . . . 3-8-8 Check and Adjust Engine Speed Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-8 Change Hydraulic Reservoir Oil . . . . . . . . . . . . 3-8-9 Replace Engine Air Cleaner Elements . . . . . . 3-8-10 Maintenance—Every 2000 Hours Adjust Engine Valve Lash (Clearance) . . . . . . . 3-9-1 Miscellaneous—Machine External Service Brake Inspection . . . . . . . . . .

Inspecting And Cleaning Dusty Secondary And Primary Element . . . . . . . . .

Check Receiver-Dryer—If Equipped . . . . . . . . .

Checking Coolant Hoses and Radiator . . . . . . .

Draining the Cooling System . . . . . . . . . . . . . .

Filling the Cooling System . . . . . . . . . . . . . . . .

4-1-1 4-1-2 4-1-3 4-1-3 4-1-4 4-1-5

Miscellaneous—Operational Checkout Operational Checkout Procedure . . . . . . . . . . . 4-2-1 Gauge and Indicator Check With Engine Off . . 4-2-1 Continued on next page

iii

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Contents

Page

Page

FNR, Neutral Start Circuit and Reverse Warning Alarm Checks . . . . . . . . . . . . . . . . . 4-2-2 Park Brake, Indicator Light, and Engine Speed Control Linkage Checks . . . . . . . . . . . 4-2-3 Brake System Checks . . . . . . . . . . . . . . . . . . . 4-2-4 Steering System Checks . . . . . . . . . . . . . . . . . 4-2-5 Hydraulic System Checks. . . . . . . . . . . . . . . . . 4-2-6 Pilot Control Operation Checks—If Equipped . . 4-2-8 Check Operation Of Accessories (Engine Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-10 Cab Component Checks. . . . . . . . . . . . . . . . . 4-2-11 Miscellaneous Checks . . . . . . . . . . . . . . . . . . 4-2-12

Miscellaneous—Machine Numbers Record Product Identification Number (PIN) . . .

Record Engine Serial Number . . . . . . . . . . . . .

Record Transmission Serial Number— Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . .

Record Rear Axle Housing Serial Number . . . .

Record (MFWD) Front Axle Housing Serial Number—If Equipped . . . . . . . . . . . . .

4-7-1 4-7-1 4-7-1 4-7-1 4-7-2

Miscellaneous—Troubleshooting Troubleshooting Procedure. . . . . . . . . . . . . . . . 4-3-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . 4-3-6 Steering System . . . . . . . . . . . . . . . . . . . . . . . . 4-3-8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . 4-3-9 Gauges and Indicators . . . . . . . . . . . . . . . . . . 4-3-11 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-14 MFWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-14 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-15 Miscellaneous—Storage Prepare Machine For Storage . . . . . . . . . . . . . 4-4-1 Miscellaneous—Crime Prevention Tips Help Prevent Crime . . . . . . . . . . . . . . . . . . . . .

Record Construction Identification Numbers . . .

Keep Proof of Ownership . . . . . . . . . . . . . . . . .

Park Indoors Out of Sight . . . . . . . . . . . . . . . . .

When Parking Outdoors . . . . . . . . . . . . . . . . . .

Reduce Vandalism . . . . . . . . . . . . . . . . . . . . . .

Report Thefts Immediately . . . . . . . . . . . . . . . .

4-5-1 4-5-1 4-5-1 4-5-1 4-5-2 4-5-2 4-5-3

Miscellaneous—Specifications 410G Specifications . . . . . . . . . . . . . . . . . . . . . 4-6-1 Ground Speeds—410G . . . . . . . . . . . . . . . . . . 4-6-2 410G Backhoe Loader Dimensions . . . . . . . . . 4-6-3 410G Backhoe Loader . . . . . . . . . . . . . . . . . . . 4-6-9 410G Backhoe Loader Weight . . . . . . . . . . . . 4-6-11 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-12 410G Backhoe Loader Drain and Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-13 410G Backhoe Loader Lifting Capacities— Standard Dipperstick. . . . . . . . . . . . . . . . . . 4-6-14 410G Backhoe Loader Lifting Capacities—Extendible Dipperstick (Retracted) . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-15 410G Backhoe Loader Lifting Capacities—Extendible Dipperstick (Extended) . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-16

iv

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Safety—Safety Features Safety Features

2

3

1 17

5

16 6 13

4 12

7

14

10

8

9 –UN–05SEP01

15

T145296

11

T145296

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

1. Headlights/Taillights. Two front halogen driving/work lights and two rear halogen work lights.

2. Signal/Warning Lights. Roof mounted turning signal lights and warning lights for on-road use.

3. ROPS Protection. Certified rollover protection structure surrounds the operator. Integral roof provides overhead protection.

4. Seat Position Sensor. An audio/visual warning alerts operator when FNR is in forward/ reverse and the seat turned toward the backhoe position.

5. Interior Rearview Mirror. Offers the operator a view of activity behind him.

6. Handholds. Large and conveniently placed, make it easy to enter or exit the operator’s station.

7. Loader Boom Service Lock. Provided for working on or around this machine with the boom raised.

8. Engine Fan Guard. A secondary engine fan guard inside engine compartment encloses rotating fan blades.

9. Bypass Start Protection. Shielding over the starter solenoid helps prevent dangerous bypass starting.

10. Ground-Level Fueling, Daily Service Checks.

Ground-level fueling feature eliminates the need to climb on the machine to fuel it.

11. Steps. Wide, skid-resistant steps provide excellent footing for getting in/out of operator’s station.

12. Independent Parking/Secondary Brake.

Independent, electrically controlled, parking brake electrically engages when the engine is stopped.

13. Neutral Start. Prevents the engine from being started unless FNR control is in neutral.

14. Backup Alarm. Alerts bystanders when the machine is shifted into reverse.

15. Seat Belt Retractors. Seatbelt retractors help keep belts clean and convenient to use.

16. Exceptional Visibility. Views to either side and front or rear working tools are unrestricted.

17. Operator Manual Holder. A sealed manual holder keeps manual clean and dry.

TX03768,0000B8D –19–07SEP01–1/1

1-1-1

012704

PN=7

Safety—General Precautions This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury.

T133555

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

–UN–28AUG00

Recognize Safety Information

T133588

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

–19–28AUG00

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

TX03679,00016CC –19–21AUG00–1/1

T133556

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. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your authorized John Deere dealer.

–UN–24AUG00

Follow Safety Instructions

Be sure all operators of this machine understand every safety message. Replace operator’s manual and safety labels immediately if missing or damaged.

TX03679,00016F9 –19–28JAN03–1/1

1-2-1

012704

PN=8

Safety—General Precautions

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

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

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

Familiarize yourself with the job site and your surroundings before operating. Try all controls and

TX03679,00016FA –19–30OCT00–1/1

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

–UN–23AUG88

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

TS206

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.

TX03679,00016D0 –19–30OCT00–1/1

Avoid Unauthorized Machine Modifications Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance.

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

TX03679,00016B7 –19–12MAY03–1/1

1-2-2

012704

PN=9

Safety—General Precautions

Inspect Machine

T6607AQ

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.

–UN–18OCT88

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

TX03679,0001734 –19–25SEP00–1/1

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

Entanglements in moving parts can cause serious injury.

–UN–12SEP01

Stay Clear Of Moving Parts

TX03679,00016D2 –19–30OCT00–1/1

T133840

If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid must be removed surgically within hours or gangrene may result.

Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

T133509

Never search for leaks with your hands. Protect hands.

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

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

–UN–20SEP00

This machine uses a high-pressure hydraulic system.

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

–UN–31OCT00

Avoid High-Pressure Fluids

TX03679,00016D3 –19–30OCT00–1/1

1-2-3

012704

PN=10

Safety—General Precautions

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

T133546

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

–UN–24AUG00

Beware Of Exhaust Fumes

TX03679,00016D4 –19–14SEP00–1/1

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.

T133552 T133554

–UN–07SEP00

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

Know how to use extinguisher properly.

–UN–07SEP00

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

T133553

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

–UN–14SEP00

Prevent Fires

TX03679,00016F5 –19–25SEP00–1/1

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

–UN–23AUG88

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

TS204

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

TX03679,000174A –19–14SEP00–1/1

1-2-4

012704

PN=11

Safety—General Precautions

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 MSDS recommendations to handle chemical products safely.

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.

TX03679,00016D7 –19–05AUG02–1/1

Never pour waste onto the ground, down a drain, or into any water source.

T133567

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.

–UN–25AUG00

Dispose Of Waste Properly

Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified service center to recover and recycle used refrigerants.

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

TX03679,0001733 –19–17APR01–1/1

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

TS291

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B –19–14SEP00–1/1

1-2-5

012704

PN=12

Safety—Operating Precautions

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.

T133468

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

Never use machine controls as handholds.

–UN–30AUG00

Use Steps And Handholds Correctly

TX03679,00016F2 –19–14SEP00–1/1

T133715

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.

–UN–07SEP00

Start Only From Operator’s Seat

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

TX03679,0001799 –19–02MAY01–1/1

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.

T133716

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

–19–14SEP00

Use And Maintain Seat Belt

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

TX03679,00016DD –19–17OCT00–1/1

1-3-1

012704

PN=13

Safety—Operating Precautions

Prevent Unintended Machine Movement ON

PARK BRAKE

OFF

Always set parking brake before leaving seat.

After startup, cycle park brake switch ON/OFF to release park brake.

T147434

Be careful not to accidentally actuate steering, travel or other controls. Engage park brake and lower work equipment to the ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow proper parking procedures before leaving the operator’s station.

–19–26OCT01

Always set the park lock brake switch to the “ON” position before leaving the operator’s seat for any reason.

TX03768,0000B8A –19–26OCT01–1/1

T164252

Be careful not to accidentally actuate control levers when co-workers are present. Always lock hydraulics on backhoe during work interruptions. Lock hydraulics before allowing anyone to approach machine.

–UN–21JAN03

Prevent Unintended Machine Movement—If Equipped With Pilot Controls

HG31779,00001D2 –19–23JAN03–1/1

1-3-2

012704

PN=14

Safety—Operating Precautions

Avoid Work Site Hazards

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.

–UN–13DEC01

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

T147555

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.

T147554

–UN–01NOV01

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before you dig.

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

TX03768,0000BAA –19–21DEC01–1/1

Keep Riders Off Machine

T148715

Riders on machine are subject to injury such as being struck by foreign objects and being thrown off of the machine. Riders also obstruct the operator’s view resulting in the machine being operated in an unsafe manner.

–UN–06DEC01

Only allow the operator on the machine. Keep riders off.

TX03768,0000BAF –19–21NOV01–1/1

1-3-3

012704

PN=15

Safety—Operating Precautions

Be certain backup warning alarm is working properly.

T145317

Before moving machine, be sure all persons are clear of the machine travel path. Turn around and look directly for best visibility. Use mirror to assist in checking behind the machine. Keep windows and mirror clean and in good repair.

–UN–06SEP01

Avoid Backover Accidents

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.

TX03768,0000B8B –19–06SEP01–1/1

Avoid Machine Tipover Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and secured on a firm level surface. Use loading ramps and attach them properly to truck bed.

Be careful on slopes. Use extra care on soft, rocky or frozen ground because machine may slip sideways in these conditions.

T147495

–19–26OCT01

Ensure solid footing. Use extra care when operating on stockpile materials, or near banks or excavations that may cave-in and cause machine to tip or fall.

TX03768,0000BA3 –19–26OCT01–1/1

1-3-4

012704

PN=16

Safety—Operating Precautions

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 –19–14SEP00–1/1

Use Special Care When Operating

Be careful when lifting objects. Never attempt to lift objects too heavy for your machine. Assure machine stability and hydraulic capability with a test lift before attempting other maneuvers. Use an adequate chain or sling and proper rigging techniques to attach and stabilize loads.

T147438

Never lift an object above or near another person.

T148749

Ensure that objects in the bucket are secure. Do not attempt to lift or carry objects that are too big or too long to fit inside the bucket unless secured with an adequate chain or other device. Keep bystanders away from raised loads.

–UN–26OCT01

Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes on soft terrain. Drive and turn slowly with a raised load.

–UN–05DEC01

Never use the loader to lift people. Do not allow anyone to ride in the bucket or use the bucket as a work platform.

TX03768,0000B70 –19–21DEC01–1/1

1-3-5

012704

PN=17

Safety—Operating Precautions

Operating Or Traveling On Public Roads

–UN–22MAY01

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.

T141891

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.

TX03679,00017C8 –19–14JUN01–1/1

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.

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.

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

TX03679,000179F –19–20APR01–1/1

1-3-6

012704

PN=18

Safety—Maintenance Precautions Park And Prepare For Service Safely

T133332

• Park machine on a level surface and lower equipment to the ground.

• Engage park brake.

• Stop engine and remove key.

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

–19–14DEC01

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

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

• Do not support machine with any hydraulically actuated tools or attachments.

• Do not support machine with cinder blocks or wooden pieces that may crumble or crush.

• Do not support machine with a single jack or other devices that may slip out of place.

• Always install boom lock before working on or around this machine with the loader boom raised.

–UN–23AUG88

Securely support machine or attachment before working under it.

TX03679,0001809 –19–18SEP01–1/1

Service Cooling System Safely

TS281

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.

–UN–23AUG88

Explosive release of fluids from pressurized cooling system can cause serious burns.

DX,RCAP –19–04JUN90–1/1

1-4-1

012704

PN=19

Safety—Maintenance Precautions

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

• Remove paint a minimum of 101 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

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

Wear an approved respirator.

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

TS220

Remove paint before heating:

–UN–23AUG88

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

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

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.

T133547

NOTE: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.

–UN–31AUG00

Make Welding Repairs Safely

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

Use a qualified welding technician for structural repairs.

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

TX03679,00016D5 –19–02OCT00–1/1

1-4-2

012704

PN=20

Safety—Maintenance Precautions

Use a soft hammer or a brass bar between hammer and object to prevent chipping.

T133738

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.

–UN–14SEP00

Drive Metal Pins Safely

TX03679,0001745 –19–25SEP00–1/1

1-4-3

012704

PN=21

Safety—Safety Signs

T190246

–19–12MAY03

Safety Signs (S.N. —919463)

Safety Signs (S.N. —919463) Continued on next page

1-5-1

HG31779,0000282 –19–06MAY03–1/2 012704

PN=22

T164250

–19–21JAN03

Safety—Safety Signs

Safety Signs (S.N. —919463)

HG31779,0000282 –19–06MAY03–2/2

1-5-2

012704

PN=23

Safety—Safety Signs

T190116

–19–12MAY03

Safety Signs (S.N. 919464—)

Safety Signs (S.N. 919464—) Continued on next page

1-5-3

HG31779,00001C6 –19–21JAN03–1/2 012704

PN=24

T190117

–19–12MAY03

Safety—Safety Signs

Safety Signs (S.N. 919464—)

HG31779,00001C6 –19–21JAN03–2/2

1-5-4

012704

PN=25

Operation—Operator’s Station Pedals and Levers

T163833B

–UN–13JAN03

1—Backhoe Control Lever 2—Boom Lock Lever 3—Backhoe Auxiliary Hydraulic Function Foot Pedal

HG31779,00001C3 –19–13JAN03–1/1

Pedals and Levers—If Equipped With Pilot Controls

T163834B

–UN–13JAN03

1—Backhoe Pilot Controls 2—Boom Lock Lever 3—Backhoe Auxiliary Hydraulic Function Foot Pedal

HG31779,00001C4 –19–13JAN03–1/1

2-1-1

012704

PN=26

Operation—Operator’s Station

Display Monitor Functions

A

B

C

D

ENGINE COOLANT TEMP

E

CONV OIL TEMP

FUEL

SELECT

n/min

ENGINE OIL PRESSURE

ENGINE ALT VOLTS

ENGINE AIR FILTER

SEAT BELT

PARK BRAKE

STOP

HYD OIL FILTER

LOW BRAKE PRESS

G

H

I

J

K

L

M

–UN–25OCT00

P N

T134892

F

HYD OIL TEMP

T134892

Display Monitor A—Select Button B—Display Window C—Engine Coolant Temperature Gauge D—Transmission and Torque Converter Oil Temperature Gauge

E—Fuel Level Gauge F—STOP Indicator G—Engine Oil Pressure Indicator H—Alternator Voltage Indicator

The display monitor has three modes of operation:

IMPORTANT: Prevent possible machine damage.

Do not operate machine when monitor is inoperable, malfunctioning, or does not successfully complete self test.

• BULB CHECK MODE: With the engine not running, turning the key switch to ON puts the display monitor in bulb check mode. In this mode, the

I—Engine Air Filter Restriction Indicator J—Seat Belt Indicator K—Park Brake Indicator L—Hydraulic Oil High Temperature Indicator

M—Hydraulic Oil Filter Restriction Indicator N—Not Used

monitor alarm beeps, all gauges and indicators light, and all gauge needles cycle from minimum to 12-o’clock positions before registering current readings. Bulb check mode lasts five seconds, to allow the operator time to verify that all display elements are functional.

• KEY SWITCH ON, ENGINE NOT RUNNING MODE: With key switch ON but the engine not running, all gauges (C—E), the engine oil pressure indicator (G), and the alternator voltage indicator (H) remain lit.

Press and hold the select button to cycle the display window between three displays.

Continued on next page

2-1-2

OUO1079,00002C4 –19–25OCT00–1/3 012704

PN=27

Operation—Operator’s Station • ENGINE RUNNING MODE: Monitor panel enters engine running mode after bulb check mode when the engine is started. In engine running mode, current status of machine is displayed on the display window, gauges, and indicators. Press and hold the select button to cycle the display window between three displays.

with engine oil pressure indicator lit, stop machine immediately and investigate cause of problem.

If STOP indicator lights and alarm sounds for more than ten seconds with engine coolant temperature gauge needle in red zone, reduce load and run engine for 1—2 minutes at slow idle to allow time to cool. If STOP indicator remains lit and engine coolant temperature gauge needle does not fall to an acceptable operating temperature, stop engine and investigate problem. Do not restart engine until problem has been corrected.

A—Select Button: With key switch “On”, press and hold the select button to cycle between displays on the display window.

B—Display Window: The display window has four displays. Press and hold the select button to cycle between displays on the display window when the monitor panel is active: • • • •

Hour Meter Engine rpm Battery Voltage Hydraulic Oil Temperature

The STOP indicator lights and alarm sounds when:

C—Engine Coolant Temperature Gauge: When engine coolant temperature is too high the gauge needle will enter red zone, STOP indicator will light, and alarm will sound. Do not stop engine. Reduce load and run engine at slow idle for 1—2 minutes. If gauge needle does not fall to an acceptable operating level, stop engine. See your authorized dealer.

• • • •

Engine oil pressure is low.

Engine coolant temperature is excessively high.

Hydraulic oil temperature is excessively high.

FNR lever is shifted into “Forward” F or “Reverse” R with park brake ON. • FNR lever is shifted into “Forward” F or “Reverse” R with park brake OFF and seat rotated toward the backhoe position.

G—Engine Oil Pressure Indicator:

D—Transmission and Torque Converter Oil Temperature Gauge: When transmission oil temperature is too high, gauge needle will enter red zone, STOP indicator will light, and alarm will sound.

Reduce load immediately, shift into NEUTRAL and run engine at slow idle. Inspect for plugged oil cooler.

IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY.

E—Fuel Level Gauge: This gauge shows the level of fuel in the tank. Fuel level gauge needle will enter red zone when fuel level in tank is low.

When engine oil pressure is low, indicator will light, STOP indicator will flash and alarm will sound. Stop machine. STOP ENGINE IMMEDIATELY.

F—Stop Indicator:

H—Engine Alternator Voltage Indicator: Indicator will light when alternator output voltage drops below 12V. Check electrical system or recharge battery, if necessary.

IMPORTANT: If STOP indicator lights and alarm sounds for more than 10 seconds

Continued on next page

2-1-3

OUO1079,00002C4 –19–25OCT00–2/3 012704

PN=28

Operation—Operator’s Station I—Engine Air Filter Restriction Indicator: When air filter elements are restricted, indicator will light. Clean or change filter elements.

neutral. Run engine at slow idle. Inspect cooler and radiator area for debris that could cause plugging of the cooler.

J—Seat Belt Indicator: Indicator will light at engine startup and stay lit for 5 seconds. With engine running, indicator will light when park brake is engaged.

NOTE: No oil cooler flow when control valves are neutral.

M—Hydraulic Oil Filter Restriction Indicator:

K—Park Brake Indicator: Indicator will light when park brake is engaged.

Park brake indicator and STOP indicator will light and alarm will sound when: • FNR lever is shifted into “Forward” F or “Reverse”R with park brake ON. • FNR lever is shifted into “Forward” F or “Reverse” R with park brake OFF and seat rotated toward the backhoe position.

L—Hydraulic Oil Temperature Indicator: Indicator will light when hydraulic oil temperature is high.

Reduce load immediately and place control levers in

IMPORTANT: If hydraulic oil filter restriction indicator lights and hydraulic oil is warm, change filter as soon as possible to prevent damage.

Indicator will light when hydraulic oil filter element is restricted.

NOTE: Cold oil can cause indicator to light temporarily. Allow time for oil to warm up and indicator to go out before servicing filter.

N—Not Used

OUO1079,00002C4 –19–25OCT00–3/3

2-1-4

012704

PN=29

Operation—Operator’s Station

T153836D

–UN–10APR02

Display Monitor Functions —If Equipped With Pilot Controls

Display Monitor 1—Select Button 2—Display Window 3—Engine Coolant Temperature Gauge 4—Converter Oil Temperature Gauge

5—Fuel Level Gauge 6—Not Used 7—Hydraulic Oil Temperature Indicator 8—Hydraulic Oil Filter Indicator

9—Engine Air Filter Indicator 10—Seat Belt Indicator/Park Brake Indicator 11—Engine Alternator Voltage Indicator

12—Engine Oil Pressure 13—Check Service Code Indicator 14—Stop Indicator

• ENGINE RUNNING MODE: Monitor panel enters engine running mode after bulb check mode when the engine is started. In engine running mode, current status of machine is displayed on the display window, gauges, and indicators. Press and hold the select button to cycle the display window between three displays.

The display monitor has three modes of operation:

IMPORTANT: Prevent possible machine damage.

Do not operate machine when monitor is inoperable, malfunctioning, or does not successfully complete self test.

• BULB CHECK MODE: With the engine not running, turning the key switch to ON puts the display monitor in bulb check mode. In this mode, the monitor alarm beeps, all gauges and indicators light, and all gauge needles cycle from minimum to 12-o’clock positions before registering current readings. Bulb check mode lasts five seconds, to allow the operator time to verify that all display elements are functional.

• KEY SWITCH ON, ENGINE NOT RUNNING MODE: With key switch ON but the engine not running, all gauges (3—5), and the alternator voltage indicator (9) remain lit. Press and hold the select button to cycle the display window between three displays.

1—Select Button: With key switch “On”, press and hold the select button to cycle between displays on the display window.

2—Display Window: The display window has three displays. Press and hold the select button to cycle between displays on the display window when the monitor panel is active: • • • • •

Hour Meter Engine rpm Battery Voltage Hydraulic Oil Temperature Service Code

Continued on next page

2-1-5

HG31779,0000114 –19–17SEP02–1/3 012704

PN=30

Operation—Operator’s Station 3—Engine Coolant Temperature Gauge: When engine coolant temperature is too high the gauge needle will enter red zone, STOP indicator will light, and alarm will sound. Do not stop engine. Reduce load and run engine at slow idle for 1—2 minutes. If gauge needle does not fall to an acceptable operating level, stop engine. See your authorized dealer.

NOTE: Cold oil can cause indicator to light temporarily. Allow time for oil to warm up and indicator to go out before servicing filter.

4—Transmission and Torque Converter Oil Temperature Gauge: When transmission oil temperature is too high, gauge needle will enter red zone, STOP indicator will light, and alarm will sound.

Reduce load immediately, shift into NEUTRAL and run engine at slow idle. Inspect for plugged oil cooler.

10—Seat Belt/Park Brake Indicator: Indicator will light at engine startup and stay lit for 5 seconds. With engine running, indicator will come on when park brake is engaged.

5—Fuel Level Gauge: This gauge shows the level of fuel in the tank. Fuel level gauge needle will enter red zone when fuel level in tank is low.

9—Engine Air Filter Restriction Indicator: When air filter elements are restricted, indicator will light. Clean or change filter elements.

11—Engine Alternator Voltage Indicator: Indicator will light when alternator output voltage drops below 12V. Check electrical system or recharge battery, if necessary.

12—Engine Oil Pressure Indicator:

6—Not Used 7—Hydraulic Oil Temperature Indicator: Indicator will light when hydraulic oil temperature is high.

Reduce load immediately and place control levers in neutral. Run engine at slow idle. Inspect cooler and radiator area for debris that could cause plugging of the cooler.

NOTE: No oil cooler flow when control valves are neutral.

8—Hydraulic Oil Filter Restriction Indicator: IMPORTANT: If hydraulic oil filter restriction indicator lights and hydraulic oil is warm, change filter as soon as possible to prevent damage.

IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. When engine oil pressure is low, indicator will light, STOP indicator will flash and alarm will sound. Stop machine. STOP ENGINE IMMEDIATELY. 13—Check Service Code Indicator: A four digit service code will appear in display window. See your authorized dealer.

14—Stop Indicator:

Indicator will light when hydraulic oil filter element is restricted.

Continued on next page

2-1-6

HG31779,0000114 –19–17SEP02–2/3

012704

PN=31

Operation—Operator’s Station operating temperature, stop engine and investigate problem. Do not restart engine until problem has been corrected.

IMPORTANT: If STOP indicator lights and alarm sounds for more than 10 seconds with engine oil pressure indicator lit, stop machine immediately and investigate cause of problem.

The STOP indicator lights and alarm sounds when: If STOP indicator lights and alarm sounds for more than ten seconds with engine coolant temperature gauge needle in red zone, reduce load and run engine for 1—2 minutes at slow idle to allow time to cool. If STOP indicator remains lit and engine coolant temperature gauge needle does not fall to an acceptable

• Engine oil pressure is low.

• Engine coolant temperature is excessively high.

• FNR lever is shifted into “Forward” F or “Reverse” R with park brake ON. • FNR lever is shifted into “Forward” F or “Reverse” R with park brake OFF and seat rotated toward the backhoe position.

HG31779,0000114 –19–17SEP02–3/3

2-1-7

012704

PN=32

Operation—Operator’s Station

T155134E

–UN–05MAY03

Right-Side Console Functions

S.N.919464— Shown 1—Park Brake Switch 2—Start Aid Button—If Equipped 3—MFWD Switch—If Equipped 4—Ride Control Switch and Indicator—If Equipped 5—Beacon Switch—If Equipped 6—Quick Disconnect Switch— If Equipped

7—Key Switch 8—Air Suspension Seat Height Adjustment Switch—If Equipped 9—Not Used (S.N. —919463) 9—Rear Wiper Switch—If Equipped (S.N. 919464—) 10—Auxiliary Hydraulic Function Switch and Indicator—If Equipped

1—Park Brake Switch: Push left side of switch to engage park brake. Push right side of switch to disengage park brake.

2—Start Aid Button—If Equipped: Press and hold button when engine is cold and cranking to inject starting fluid into engine during cold weather start-up.

11—Defroster, Heater, and Air Conditioner Switch—If Equipped 12—Temperature Control Knob—If Equipped 13—Blower Speed Knob—If Equipped 14—Rear Wiper Switch—If Equipped (S.N. —919463)

14—Pattern Select Switch—If Equipped (S.N. 919464—) 15—Horn Button 16—Side Docking Lights Switch—If Equipped 17—Rear Work Lights Switch

4—Ride Control Switch and Indicator—If Equipped: Push upper half of switch to activate ride control.

Switch will light when ride control is activated. Push lower half of switch to deactivate ride control 5—Beacon Switch—If Equipped: Push upper half of switch to turn beacon on. Push lower half of switch to turn beacon off.

3—MFWD Switch—If Equipped: Push switch UP to engage the MFWD axle. Push switch DOWN to disengage the MFWD axle.

Continued on next page

2-1-8

HG31779,0000113 –19–19MAY03–1/3 012704

PN=33

Operation—Operator’s Station proper operation of the defroster, heater, or air conditioner.

6—Quick Disconnect Switch—If Equipped: Press and hold switch to release pins from front loader bucket when changing buckets.

7—Key Switch 8—Air Suspension Seat Height Adjustment Switch—If Equipped: Push upper half of switch to increase air suspension seat height and firmness of ride. Push lower half of switch to decrease air suspension seat height and firmness of ride.

The defroster, heater, and air conditioner switch has three positions: • Push lower half to activate the air conditioner.

• Push to middle position to activate the heater and vent. Turn the temperature control knob clockwise towards HOT for heated air, or counterclockwise to COLD for un-heated vent.

• Push upper half to activate the defroster.

9—Not Used (S.N. —919463) 9—Rear Wiper Switch—If Equipped (S.N. 919464— ): IMPORTANT: To avoid damage to wiper blades, DO NOT operate wipers if blades are frozen to windshield.

Push upper half of switch to turn rear windshield wiper on. Push lower half of switch to turn rear windshield wiper off.

10—Auxiliary Hydraulic Function Switch and Indicator—If Equipped: Push switch to activate and deactivate backhoe auxiliary hydraulic attachments.

The switch has three positions: • Push upper half to activate auxiliary hydraulic function • Push to middle position to transfer control to the backhoe auxiliary hydraulic function foot switch • Push lower half to deactivate the auxiliary hydraulic function 11—Defroster, Heater, and Air Conditioner Controls—If Equipped:

NOTE: Blower knob; defroster, heater, and air conditioner switch; and temperature control knob must be adjusted as a group to obtain

NOTE: Use the air conditioner with the temperature control knob in a middle-to-cool position to dehumidify air without overcooling.

12—Temperature Control Knob—If Equipped: Turn knob to adjust air temperature. Turn clockwise towards HOT (red) for warmer air (best for heating and defrosting). Turn counterclockwise towards COLD (blue) for cooler air (best for venting and air conditioning).

13—Blower Speed Knob—If Equipped: Turn knob clockwise to increase blower speed or counterclockwise to reduce blower speed. The blower knob has four speed settings plus an “Off” position.

14—Rear Wiper Switch—If Equipped (S.N.— 919463): IMPORTANT: To avoid damage to wiper blades, DO NOT operate wipers if blades are frozen to windshield.

Push right half of switch to turn rear windshield wiper on. Push left half of switch to turn rear windshield wiper off.

14—Pattern Select Switch—If Equipped (S.N. 919464—):

Continued on next page

2-1-9

HG31779,0000113 –19–19MAY03–2/3 012704

PN=34

Operation—Operator’s Station

CAUTION: Prevent possible injury from unexpected machine movemement. Always verify control response before operating backhoe.

Push backhoe symbol on switch to select backhoe hydraulic pattern. Push excavator symbol on switch to select excavator hydraulic pattern.

16—Side Docking Lights Switch—If Equipped: Push right half of switch to turn side docking lights on.

Push left half of switch to turn side docking lights off.

17—Rear Work Lights Switch: Push right half of switch to turn rear work lights on. Push left half of switch to turn rear work lights off.

15—Horn Button: Press button to sound the horn.

HG31779,0000113 –19–19MAY03–3/3

2-1-10

012704

PN=35

Operation—Operator’s Station

T131691H

–UN–25JAN02

Controls—Steering Console

1—Work and Drive Lights Switch

2—Warning Lights Switch 3—Front Windshield Washer Switch—If Equipped

4—Front Windshield Wiper Switch—If Equipped

1—Work and Drive Lights Switch: Push switch to operate work and drive lights, tail lights, and front work lights, if equipped. The switch has three positions: • Push upper half to turn work and drive lights, tail lights, and front work lights, if equipped, on.

• Push to middle position to turn work and drive lights and tail lights on.

• Push lower half to turn work and drive lights, tail lights, and front work lights, if equipped, off.

2—Warning Lights Switch: Push upper half of switch to turn amber turn signal or warning lights at front and rear of cab on. When warning lights switch is “On”, warning lights indicator, left turn indicator, and right turn indicator will flash. Push lower half of switch to turn amber turn signal or warning lights at front and rear of cab off.

5—Turn Signal Switch

3—Front Windshield Washer Switch—If Equipped: Push upper half of switch to turn front windshield washer on. Push lower half of switch to turn front windshield washer off.

4—Front Windshield Wiper Switch—If Equipped: IMPORTANT: To avoid damage to wiper blades, DO NOT operate wipers if blades are frozen to windshield.

Push switch to operate front windshield wiper. The switch has three positions: • Push upper half to turn front windshield wiper to “Fast” position • Push to middle to turn front windshield wiper on “Slow” position

Continued on next page

2-1-11

HG31779,000007B –19–14MAY02–1/2 012704

PN=36

Operation—Operator’s Station • Push lower half to turn front windshield wiper off

• Push right half to signal right turn. Right turn indicator will flash.

5—Turn Signal Switch: Push switch to signal turning direction. The switch has three positions: • Push left half to signal left turn. Left turn indicator will flash.

• Middle position is “Off”. Indicators will not flash unless warning lights switch is “On”.

Front amber turn signals or warning lights flash individually to signal direction of turn when left or right half of turn signal switch is pushed. Front amber turn signals or warning lights flash together when upper half of warning lights switch is pushed.

HG31779,000007B –19–14MAY02–2/2

Push upper half of switch (1) to “Unlock” position to enable pilot controls. Push lower half of switch to “Lock” position to disable pilot controls.

T163336B

CAUTION: Prevent injury from unexpected machine movement. Always lock hydraulics when not operating backhoe.

–UN–02JAN03

Pilot Control Enable/Disable Switch—If Equipped

If the seat changes operating position or the engine is shut off, the pilot controls are automatically disabled. To enable pilot controls, cycle switch to “Lock” position and back to “Unlocked” position.

HG31779,00001BC –19–28JAN03–1/1

CAUTION: Prevent possible injury from unexpected machine movement. Always verify control response before operating backhoe.

T163958B

Push backhoe symbol on switch (1) to select backhoe hydraulic pattern. Push excavator symbol on switch to select excavator hydraulic pattern.

–UN–14JAN03

Pattern Select Switch—If Equipped (S.N. — 919463)

HG31779,00002B0 –19–19MAY03–1/1

2-1-12

012704

PN=37

Operation—Operator’s Station

Horn Button Press the horn button (A) to sound the horn.

T156907B

–UN–01JUL02

A—Horn Button

HG31779,00000EA –19–09SEP02–1/1

2-1-13

012704

PN=38

Operation—Operator’s Station

Defroster, Heater, and Air Conditioner Controls—If Equipped NOTE: Blower knob; defroster, heater, and air conditioner switch; and temperature control knob must be adjusted as a group to obtain proper operation of the defroster, heater, or air conditioner.

T156908B

• Push lower half to activate the air conditioner. Adjust the blower knob and temperature control knob as appropriate.

• Push to middle position to activate the heater and vent.

Adjust the blower knob as appropriate. Turn the temperature control knob clockwise towards HOT for heated air, or counterclockwise to COLD for unheated vent.

• Push upper half to activate the defroster. Adjust the blower knob and temperature control knob as appropriate.

–UN–01JUL02

Push the defroster, heater, and air conditioner switch (A) to the appropriate setting. The defroster, heater, and air conditioner switch has three positions:

A—Defroster, Heater, and Air Conditioner Switch B—Blower Speed Knob C—Temperature Control Knob

Turn temperature control knob (C) to adjust air temperature. Turn clockwise towards HOT (red) for warmer air (best for heating and defrosting). Turn counterclockwise towards COLD (blue) for cooler air (best for venting and air conditioning).

NOTE: Use the air conditioner with the temperature control knob in a middle-to-cool position to dehumidify air without overcooling.

Turn blower knob (B) clockwise to increase blower speed or counterclockwise to reduce blower speed. The blower knob has four speed settings plus an “Off” position.

HG31779,00000EB –19–09SEP02–1/1

2-1-14

012704

PN=39

Operation—Operator’s Station

Side Windows—Secondary Exits The side windows and door windows can open 180°. The door windows can be used as secondary exits.

–UN–07NOV00

To open, pull handle (A) in and away from cab post latch.

T135173

Retain in open position against fixed window on same side by fastening knob (B) into socket (C). Turn knob until tension is felt to prevent window from swinging during operation.

Right Side Shown

T102093

–UN–16AUG96

A—Handle B—Fastening Knob (2 used) C—Socket (2 used)

CED,OUO1079,381 –19–28OCT02–1/1

Rear Windows

–UN–07NOV00

CAUTION: Prevent injury from unexpected machine movement.

Squeeze upper rear window latches (A) and slide upper rear window up or down.

Ensure all rear window latches lock into detent positions on window frame.

T131781B

Squeeze middle rear window latches (B) and slide middle rear window up or down.

A—Upper Rear Window Latch (2 used) B—Middle Rear Window Latch (2 used)

Always lock hydraulics when not operating backhoe or opening/closing window.

CED,OUO1079,378 –19–28JAN03–1/1

2-1-15

012704

PN=40

Operation—Operator’s Station

Adjusting Seat CAUTION: Ensure seat is locked in position before operating machine. A seat that is loose or not properly locked can cause loss of control of machine and injuries or death.

Non-Suspension Seat Lift pivot lever (1) up and pivot seat. Release pivot lever to lock seat in position.

Lift forward and aft lever (3) up and slide seat to desired position. Release forward and aft lever to lock seat in position.

–UN–22OCT99

Lift height adjustment lever (2) up and adjust seat to desired height. Release height adjustment lever to lock seat in position.

Grease seat base guide rails as needed.

T125402B

1—Pivot Lever 2—Height Adjustment Lever 3—Forward and Aft Lever

Continued on next page

2-1-16

CED,OUO1079,375 –19–29JAN03–1/2

012704

PN=41

Operation—Operator’s Station Suspension Seat—If Equipped CAUTION: Ensure seat is locked in position before operating machine. A seat that is loose or not properly locked can cause loss of control of machine and injuries or death.

–UN–30AUG00

NOTE: With weight adjustment knob turned counterclockwise (—) as far as it can go and with no weight on seat, the distance to the floor from top of seat is 48 cm (19 in.). With knob turned clockwise (+) as far as it can go, the distance to floor from top of seat is 53 cm (21 in.). The distances will decrease by 5 cm (2 in.) when an 86 kg (190 lb) person sits on seat.

Lift back tilt lever (B) up and adjust backrest to desired tilt angle. Release back tilt lever to lock backrest in position.

T131777B

While NOT sitting on seat, turn weight adjustment knob (A) to change seat height and ride stiffness.

Optional Cab Shown A—Weight Adjustment Knob B—Back Tilt Lever C—Lumbar Support Adjustment Knob

Turn lumbar support adjustment knob (C) to position lumbar support for operator’s preference.

CED,OUO1079,375 –19–29JAN03–2/2

2-1-17

012704

PN=42

Operation—Operator’s Station

T128685

–UN–01MAR00

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. A date label, to determine the age of the belt, is attached to each belt.

TX,10,DH3548 –19–14JUN00–1/1

Steering Wheel Tilt Lever—If Equipped

–UN–19JUN00

Lift steering wheel tilt lever (A) and tilt steering wheel (B) to operator’s preference. Release steering wheel tilt lever to lock steering wheel in position.

T131783B

A—Steering Wheel Tilt Lever B—Steering Wheel

CED,OUO1079,380 –19–14JUN00–1/1

2-1-18

012704

PN=43

Operation—Operator’s Station

12-Volt Accessory Outlets Accessory outlets (A) are positioned for operator’s convenience.

T131777C

–UN–19JUN00

A—12-Volt Accessory Outlet (3 used with Cab; 2 used with Canopy and Quarter-Cab)

T134837B

–UN–25OCT00

Optional Cab Shown

Optional Cab Shown

CED,OUO1079,383 –19–14JUN00–1/1

2-1-19

012704

PN=44

Operation—Operating The Machine Inspect Machine Daily Before Starting Perform periodic service checks.

• • • • • • •

Check and lubricate loader pivot pins (A).

Check engine oil level and air cleaner (B).

Check precleaner (C).

Check hydraulic oil level (D).

Clean operator’s station (E).

Check and lubricate backhoe pivot pins (F).

Check pedals and controls (G) for freedom of movement.

• Check inflation pressure of tires (H) and torque of wheel hardware.

• Clean radiator fins (I).

ELECTRICAL SYSTEM: Check for worn or frayed wires and loose or corroded connections.

HYDRAULIC SYSTEM: Check for leaks, missing or loose clamps, kinked hoses, and lines or hoses in areas that rub against each other or other parts.

BACKHOE AND LOADER: Check for loose, bent, broken or missing parts and hardware.

LUBRICATION: Check lubrication points.

PROTECTIVE DEVICES: Check ROPS, guards, shields, covers, seat belt, and reverse warning alarm.

PARK BRAKE: Check for correct operation.

T132586

SAFETY: Walk around machine to be sure all persons are clear from machine area.

–UN–18JUL00

FIRE PREVENTION: Clean machine of debris.

A—Loader Pivot Pins B—Engine Dipstick and Air Cleaner C—Precleaner (If Equipped) D—Hydraulic Oil Level Sight Tube E—Operator’s Station F—Backhoe Pivot Pins G—Pedals and Controls H—Tires I—Radiator Fins

HG31779,00000EC –19–09SEP02–1/1

2-2-1

012704

PN=45

Operation—Operating The Machine

Check Instruments Before Starting

A

B

C

D

ENGINE COOLANT TEMP

E

CONV OIL TEMP

FUEL

SELECT

n/min

ENGINE OIL PRESSURE

ENGINE ALT VOLTS

ENGINE AIR FILTER

SEAT BELT

PARK BRAKE

STOP

HYD OIL FILTER

LOW BRAKE PRESS

G

H

I

J

K

L

M

–UN–25OCT00

P N

T134892

F

HYD OIL TEMP

T134892

Turn key switch clockwise to ON. (Do not start engine.)

The following must occur:

–19–28JAN98

• The audible alarm must sound twice.

• All LCD segments in the display window (B) must light.

T112933

A—Select Button B—Display Window C—Engine Coolant Temperature Gauge D—Transmission and Torque Converter Oil Temperature Gauge E—Fuel Level Gauge F—STOP Indicator G—Engine Oil Pressure Indicator H—Alternator Voltage Indicator I—Engine Air Filter Restriction Indicator J—Seat Belt Indicator K—Park Brake Indicator L—Hydraulic Oil Temperature Indicator M—Hydraulic Oil Filter Restriction Indicator N—Service Brake Low Pressure Indicator

Continued on next page

2-2-2

OUO1079,00002C6 –19–27JAN04–1/2 012704

PN=46

Operation—Operating The Machine • (S.N. —905063) All gauges (C—E) must be backlit, and all gauge needles must cycle from minimum (left) to maximum (right) in approximately one second.

• (S.N. 905064—) All gauges (C—E) must be backlit, and all gauge needles must cycle from minimum (left) to center in approximately one second.

• (S.N. —905063) All indicators (F—N) must light for five seconds. With the engine not running, the engine oil pressure indicator (G) and alternator voltage indicator (H) must remain lit after other indicators go out.

• (S.N. 905064—) All indicators (F—N) must light for five seconds. With the engine not running, the alternator voltage indicator (H) must remain lit after other indicators go out.

See Operation—Operator’s Station for descriptions of indicators.

If any indicator fails to light, check the bulb. If bulb is good but indicator still fails to light, see your authorized dealer.

OUO1079,00002C6 –19–27JAN04–2/2

Starting the Engine

TS177

–UN–11JAN89

CAUTION: Avoid possible injury or death from a runaway machine. DO NOT start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed.

NEVER start engine while standing on ground.

Start engine only from operator’s seat, with FNR lever in “Neutral” and park brake engaged.

1. Sit in seat and fasten seat belt.

2. Sound horn.

Continued on next page

2-2-3

HG31779,00000ED –19–09SEP02–1/2

012704

PN=47

Operation—Operating The Machine NOTE: Controls and switches must be in the positions described before starting engine.

3. Move FNR lever (A) to N.

5. Push the lower half of the ride control switch (C), if equipped, to deactivate ride control.

IMPORTANT: To avoid engine damage, never start engine with engine speed control lever set at FAST IDLE.

T131691F

–UN–20JUN00

4. Push the left half of the park brake switch (B) to engage the park brake.

7. Turn key switch (D) clockwise to “Start” and hold in position until engine starts. Release key switch when engine starts. If engine does not start after 30 seconds, turn key switch to “Off” and wait 2 minutes before trying again.

T131729D

–UN–25OCT00

A—FNR Lever B—Park Brake Switch C—Ride Control Switch—If Equipped D—Key Switch E—Engine Speed Control Lever

T159414B

IMPORTANT: Do not operate starter motor for more than 30 seconds at a time, or it may be damaged. If engine does not start, wait at least 2 minutes before trying again.

–UN–16SEP02

6. Move engine speed control lever (E) to 1/3 speed.

HG31779,00000ED –19–09SEP02–2/2

2-2-4

012704

PN=48

Operation—Operating The Machine

Starting Fluid—Cold Weather Start Aid—If Equipped (S.N.—910057)

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.

–UN–11JUL00

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

T131504P

IMPORTANT: To avoid engine damage, push and hold start aid button only when engine is cold and cranking. Starting fluid is being injected into engine as long as the start aid button is held.

–UN–06JUL00

NOTE: If equipped with a high pressure KBI cold weather starting system, press and hold start aid button (A) to start engine.

NOTE: Crank engine for 30 seconds maximum, allowing 2 minutes between cranking periods.

T132014B

While cranking engine, push start aid button (A).

Replacing Starting Aid Can 1. Close engine hood. Raise front loader boom and install loader boom service lock. See Loader Boom Service Lock. (Section 3-2.)

A—Start Aid Button B—Start Aid Can

2. Open engine hood. See Opening and Closing Engine Hood. (Section 3-2.)

KBI is a registered trademark of Kold Band International LTD Company

Continued on next page

2-2-5

CED,OUO1079,393 –19–28JAN03–1/2 012704

PN=49

Operation—Operating The Machine 3. Turn container counterclockwise to remove.

4. Remove start aid can (B) from container.

5. Remove safety cap and spray button from new start aid can, and install can into container.

6. Install container clockwise into base.

7. Close engine hood.

CED,OUO1079,393 –19–28JAN03–2/2

Starting Fluid—Cold Weather Start Aid—If Equipped (S.N. 910058—)

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 container and install plug in base to protect start aid components from dust.

–UN–01JUL02

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

T156912B

IMPORTANT: To avoid engine damage, push and hold start aid button only when engine is cold and cranking. Starting fluid is being injected into engine as long as the start aid button is held.

A—Start Aid Button

NOTE: Crank engine for 30 seconds maximum, allowing 2 minutes between cranking periods.

While cranking engine, push start aid button (A).

Continued on next page

2-2-6

HG31779,0000087 –19–28JAN03–1/2 012704

PN=50

Operation—Operating The Machine REPLACING START AID CONTAINER

–UN–26JUL02

1. Close engine hood. Raise front loader boom and install loader boom service lock. See Loader Boom Service Lock. (Section 3-2.)

2. Open engine hood. See Opening and Closing Engine Hood. (Section 3-2.)

T155037B

3. Loosen hose clamp (B).

4. Turn start aid container (C) counterclockwise to remove.

B—Clamp C—Start Aid Can D—Plug

5. Remove safety cap from new container.

6. Turn container clockwise in starting aid base to install.

7. Tighten hose clamp.

8. Close engine hood.

OPERATING MACHINE WITHOUT START AID CONTAINER INSTALLED IMPORTANT: Protect start aid components from possible damage. Install start aid plug in start aid base.

Remove container and install plug (D) in base.

HG31779,0000087 –19–28JAN03–2/2

2-2-7

012704

PN=51

Operation—Operating The Machine

T6713AI1

T6508AE1

–UN–24OCT91

–UN–24OCT91

Using Booster Batteries—12 Volt System

Single-Battery Application

Dual-Battery Application

A—Machine Battery(s)

B—Booster Battery(s)

Before boost starting, machine must be properly shut down and secured to prevent unexpected machine movement when engine starts.

1. Connect one end of the positive cable to the positive terminal of the machine batteries and the other end to the positive terminal of the booster batteries.

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.

Always remove grounded (—) battery clamp first and replace it last.

2. Connect one end of the negative cable to the negative terminal of the booster batteries. Then connect other end of the negative cable to the machine frame as far away from the machine batteries as possible.

3. Start engine.

IMPORTANT: The machine electrical system is a 12-volt negative (—) ground. Use only 12-volt booster batteries.

Continued on next page

2-2-8

CED,TX14826,12658 –19–12JUN00–1/2 012704

PN=52

Operation—Operating The Machine 4. Immediately after starting engine, disconnect end of the negative cable from the machine frame and disconnect the other end of the negative cable from the negative terminal of the booster batteries.

5. Disconnect positive cable from booster batteries and machine batteries.

CED,TX14826,12658 –19–12JUN00–2/2

Using Coolant Heater—If Equipped CAUTION: Prevent possible personal injury from an electrical shock. Use a heavy-duty, grounded cord to connect heater to electrical power.

Plug coolant heater into a 115-volt outlet, as needed, before you start the engine.

HG31779,000015B –19–23OCT02–1/1

Warm-Up IMPORTANT: To ensure proper lubrication, idle engine at 1/3 speed for 5 minutes.

Extend period as necessary when operating at temperatures below freezing.

• Before moving machine, run at 1/3 speed for at least 5 minutes.

IMPORTANT: To avoid carbon build-up in engine and to use fuel in most efficient manner, do not allow machine to idle at low rpm.

• Do not run engine at fast or slow idle.

• Operate machine under light loads for first 5 minutes once engine is warm.

• Check instruments regularly.

TX,25,BD2082 –19–29JAN03–1/1

2-2-9

012704

PN=53

Operation—Operating The Machine

Cold Weather Warm-Up IMPORTANT: If hydraulic oil is cold, hydraulic functions move slowly. Do not attempt machine operations until hydraulic functions move at close-to-normal cycle times.

IMPORTANT: To prevent damage to bucket leveling tube due to cold oil, cycle bucket three times at hood height before using under normal operation.

In extremely cold conditions, an extended warming up period will be necessary.

2. Raise loader lift arms to hood height. Cycle bucket from stop to stop three times.

Avoid sudden operation of hydraulic functions until engine is thoroughly warmed up. Remove ice, snow, and mud from machine before operation.

3. Cycle all remaining hydraulic functions to distribute warmed oil until all functions operate freely.

1. Run engine at 1/2 speed for 15 minutes.

TX,25,BG240 –19–29AUG97–1/1

2-2-10

012704

PN=54

Operation—Operating The Machine

Ride Control Operation—If Equipped

T131504D

–UN–11JUL00

CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. Turn ignition switch “On”. Push ride control switch “On” and move loader control lever to “Float” position.

Do not have the ride control switch “On” when starting the machine; the machine may move if the ride control switch is “On” and the machine is started.

–UN–15JUN00

Do not have ride control engaged when operating the loader; the ride control system may cause unexpected movement.

T131717C

The ride control system has an accumulator and valve in the loader circuit.

Operating Ride Control Push upper half of ride control switch (A) to improve machine ride and reduce tire flexing when traveling over rough terrain at a high speed with loaded bucket, or when transporting with an empty bucket. The ride control indicator (B) will remain lit while ride control is engaged.

A—Ride Control Switch B—Ride Control Indicator

If engine is stopped with ride control engaged, ride control switch will remain in the “On” position and ride control will be engaged when the machine is restarted. Always push lower half of ride control switch to disengage ride control before starting the machine.

Continued on next page

2-2-11

HG31779,0000105 –19–13SEP02–1/2

012704

PN=55

Operation—Operating The Machine NOTE: With ride control engaged, the front end of the machine will not remain raised if lifted off the ground with the front loader. The front end of the machine will drift back to the ground. To hold front end up while using the backhoe, disengage ride control.

Always deactivate ride control when operating hydraulic functions.

NOTE: Disengage ride control when backdragging.

Discharging the Ride Control Circuit for Service Discharge hydraulic pressure from the ride control system before performing maintenance. See Discharge Ride Control System Hydraulic Pressure—If Equipped. (Section 4-1.)

HG31779,0000105 –19–13SEP02–2/2

2-2-12

012704

PN=56

Operation—Operating The Machine

Pilot Control Operation—If Equipped 1. Rotate seat to backhoe operation position.

–UN–02JAN03

2. Use pilot control wrist rests (1) to pull right and left pilot control towers towards operator.

CAUTION: Prevent possible injury from unexpected machine movement. Always lock hydraulics when not operating backhoe.

T162834B

3. Push pilot control enable/disable switch (2) to “Unlock” position to enable pilot controls.

1—Pilot Control Wrist Rests 2—Pilot Control Enable/Disable Switch

4. Push pilot control enable/disable switch to “Lock” position to disable pilot controls.

NOTE: Alarm will sound and monitor will display “Hoe” and “On” when pilot controls are enabled and seat is not in backhoe position.

If pilot controls are automatically disabled, cycle switch to “Lock” position and back to “Unlock” position to enable pilot controls.

Discharge hydraulic pressure from the pilot control system before performing maintenance. See Discharge Pilot Control System Hydraulic Pressure—If Equipped. (Section 4-1.)

HG31779,00001BB –19–02JAN03–1/1

2-2-13

012704

PN=57

Operation—Operating The Machine

Driving the Machine

–UN–05JUL00

CAUTION: Prevent possible injury from unexpected machine movement. Machine will turn in direction of brake pedal if only one brake pedal is applied. Connect brake pedals together before traveling at high speed.

T132020B

1. Engage brake pedal locking bar (A) to lock left and right brake pedals (B and C) together. Keep brake pedal locking bar engaged unless brakes are to be used to aid in turning.

A—Brake Pedal Locking Bar B—Left Brake Pedal C—Right Brake Pedal

CAUTION: Use a seat belt to minimize chance of injury from an accident such as an overturn.

2. Fasten seat belt.

HG31779,000010D –19–16SEP02–1/4

3.

–UN–16SEP02

NOTE: Park brake indicator will light, alarm will sound, and STOP indicator will light if FNR lever is moved out of “Neutral” while park brake is engaged. Disengage park brake before moving FNR lever out of “Neutral”.

T159414C

If park brake is disengaged when engine is stopped, it automatically engages. If engine is then started with right half of park brake switch pushed, operator must push left half of park brake switch, then right half of park brake switch before driving machine.

D—Park Brake Switch

Push right half of park brake switch (D) to disengage the park brake.

Continued on next page

2-2-14

HG31779,000010D –19–16SEP02–2/4 012704

PN=58

Operation—Operating The Machine

–UN–05JUL00

CAUTION: Prevent possible injury from unexpected machine movement. NEVER rely on FNR lever alone to keep machine from moving.

Always set park brake to hold machine.

• Reduce speed when changing direction of travel.

• Move FNR lever to F to travel forward and to R to travel in reverse.

• Move FNR lever to N when machine is not moving.

FNR lever will drop to a detented position when in “Neutral”.

T132026B

4. Use FNR lever (A) to change direction of travel. FNR lever can be operated without using the clutch disconnect.

A—FNR Lever B—Gear Range Pointer

5. FNR lever also selects forward gear ranges 1, 2, 3, and 4 and reverse ranges 1, 2, and 3. The fourth position in reverse provides the same speed range as the third position.

• Rotate handle on FNR lever to select gear position.

• Gear position is indicated by the gear range pointer (B).

HG31779,000010D –19–16SEP02–3/4

6. Vary travel speed when driving using engine speed control pedal (H).

T132022B

–UN–05JUL00

H—Engine Speed Control Pedal

HG31779,000010D –19–16SEP02–4/4

2-2-15

012704

PN=59

Operation—Operating The Machine

Before operating the backhoe, use stabilizers to lift and level the machine. Use the levers to move stabilizers from raised position (A and C) to lowered position (B and D).

T131729F

CAUTION: Prevent possible injury from unexpected machine movement. Stabilizers must be set on a firm surface. Do not dig under stabilizers. Be alert to possible machine movement when raising stabilizers and loader bucket.

–UN–25OCT00

Operating Stabilizers

Stabilizer feet are reversible for use on paved and unpaved surfaces. See Reversing Stabilizer Feet. (Section 4-1.)

T102200

–UN–24AUG96

A—Left Stabilizer Up B—Left Stabilizer Down C—Right Stabilizer Up D—Right Stabilizer Down

OUO1079,0000253 –19–09SEP02–1/1

2-2-16

012704

PN=60

Operation—Operating The Machine

Operating Boom Lock IMPORTANT: To prevent possible machine damage, unlock boom before operating backhoe.

Disengaging the Boom Lock 1. Raise boom against stops to release tension on boom lock (A).

–UN–19JUN00

2. Pull boom lock control lever (B) toward operator to disengage boom lock from boom hooks (unlocked position).

3. Lower boom so boom hooks are clear of boom lock.

Release boom lock control lever.

T131772B

Engaging the Boom Lock 1. Pull boom lock control lever toward operator to raise boom lock.

2. Raise boom against stops.

–UN–15JUN00

3. Release boom lock control lever to engage boom lock with boom hooks (locked position).

T131758C

4. After machine shutdown, move boom control lever to release hydraulic pressure and put tension on boom lock.

A—Boom Lock B—Boom Lock Control Lever

T162770B

–UN–12DEC02

Optional Two-Lever, Six-Function Configuration Shown

Optional Pilot Controls Shown HG31779,0000117 –19–12DEC02–1/1

2-2-17

012704

PN=61

Operation—Operating The Machine

Operating Swing Lock

Remove swing lock pin (A) from swing lock mounting hole (B) and install pin in storage position in operator’s station.

Engaging the Swing Lock

T132293B

Disengaging the Swing Lock

–UN–11JUL00

IMPORTANT: To prevent possible machine damage, remove swing lock pin before operating backhoe.

Remove swing lock pin from storage position in operator’s station and install pin in swing lock mounting hole.

T131772C

–UN–19JUN00

A—Swing Lock Pin B—Swing Lock Mounting Hole

OUO1079,0000255 –19–28OCT02–1/1

2-2-18

012704

PN=62

Operation—Operating The Machine

Prevent possible personal injury from unexpected machine movement. DO NOT operate backhoe unless you are in the operator’s seat in backhoe operation position with stabilizers down.

T132032B

CAUTION: Several control patterns are available for this backhoe. Always verify control response before operating.

–UN–11JUL00

Operating Backhoe—John Deere Two-Lever Controls

IMPORTANT: To avoid machine damage, do not swing boom into stabilizers.

NOTE: When seat is turned to backhoe operation position, seat position sensor will sound an audible alarm and light the STOP indicator if FNR lever is moved to F or R.

For faster cycle times, fully extend levers when moving and operate more than one component at a time.

T132029C

Operate backhoe with control levers. Move levers as shown to maneuver backhoe components in desired directions.

–UN–11JUL00

A conversion kit for changing controls is available from your authorized dealer. Labels corresponding to other controls MUST be installed.

A—Boom Lower B—Boom Raise C—Boom Swing Left D—Boom Swing Right E—Dipperstick Raise F—Dipperstick Lower G—Bucket Load H—Bucket Dump

CED,OUO1079,413 –19–07JUL00–1/1

2-2-19

012704

PN=63

Operation—Operating The Machine

Operating Backhoe—Excavator Two-Lever Controls

–UN–11JUL00

CAUTION: Several control patterns are available for this backhoe. Always verify control response before operating.

T132033B

Prevent possible personal injury from unexpected machine movement. DO NOT operate backhoe unless you are in the operator’s seat in backhoe operation position with stabilizers down.

IMPORTANT: To avoid machine damage, do not swing boom into stabilizers.

NOTE: When seat is turned to backhoe operation position, seat position sensor will sound an audible alarm and light the STOP indicator if FNR lever is moved to F or R.

–UN–11JUL00

A conversion kit for changing John Deere two-lever controls to excavator two-lever controls is available from your authorized dealer. Labels corresponding to the controls MUST be installed.

T132029C

Operate backhoe with control levers. Move levers as shown to maneuver backhoe components in desired directions.

For faster cycle times, fully extend levers when moving and operate more than one component at a time.

A—Boom Lower B—Boom Raise C—Boom Swing Left D—Boom Swing Right E—Dipperstick Raise F—Dipperstick Lower G—Bucket Load H—Bucket Dump

CED,OUO1079,414 –19–07JUL00–1/1

2-2-20

012704

PN=64

Operation—Operating The Machine

T162842B

CAUTION: Prevent possible injury from unexpected machine movement. Always lock hydraulics when not operating backhoe. Never place any part of body beyond window frame. It could be crushed by the boom if boom control lever is accidently bumped or otherwise engaged. Make sure you know the location and function of each control before operating.

–UN–12DEC02

Operating Backhoe—John Deere Pilot Controls

Never place any part of the body beyond the window frame. Replace missing or broken windows immediately.

The machine is factory equipped with the control pattern shown.

NOTE: With this control pattern, functions must correspond to the black-on-yellow labels located on the cab post.

A control pattern switch can be installed inside the cab.

See your authorized dealer for a control pattern selector valve kit. Installation instructions will be provided.

T132029C

A—Boom Lower B—Boom Raise C—Boom Swing Left D—Boom Swing Right E—Dipperstick Raise F—Dipperstick Lower G—Bucket Load H—Bucket Dump

–UN–11JUL00

When a lever is released, it will return to neutral. The machine will remain positioned.

TX17994,000034D –19–02DEC02–1/1

2-2-21

012704

PN=65

Operation—Operating The Machine

T163835B

CAUTION: Prevent injury from unexpected machine movement. Always lock hydraulics when not operating backhoe. Never place any part of body beyond window frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged.

Make sure you know the location and function of each control before operating.

–UN–13JAN03

Operating Backhoe—Excavator Pilot Controls

Never place any part of the body beyond the window frame. Replace missing or broken windows immediately.

NOTE: With this control pattern, functions must correspond to the black-on-white labels located on the cab post.

This pattern control is only available with the installation of the pattern selector valve kit.

When a lever is released, it will return to neutral. The machine will remain positioned.

T132029C

–UN–11JUL00

A—Boom Lower B—Boom Raise C—Boom Swing Left D—Boom Swing Right E—Dipperstick Raise F—Dipperstick Lower G—Bucket Load H—Bucket Dump

HG31779,00001C5 –19–13JAN03–1/1

2-2-22

012704

PN=66

Operation—Operating The Machine

Operating Extendible Dipperstick—If Equipped

–UN–11JUL00

Push extendible dipperstick control pedal with toe or heel to extend (I) or retract (J) the extendible dipperstick.

T132032C

I—Extendible Dipperstick Extend J—Extendible Dipperstick Retract

T162845B

–UN–12DEC02

Optional Two-Lever, Six-Function Configuration Shown

T132029D

–UN–11JUL00

Optional Pilot Controls Shown

HG31779,00001B4 –19–12DEC02–1/1

2-2-23

012704

PN=67

Operation—Operating The Machine

Operating Extendable Dipperstick Lock—If Equipped CAUTION: To prevent serious injury, always install locking pin from ground.

Always lower backhoe to ground and stop engine before removing or installing extendable dipperstick locking pin.

Disengaging Extendable Dipperstick Lock

–UN–19JUN00

1. Remove quick-lock pin from extendable dipperstick locking pin (A).

T131775B

2. Remove extendable dipperstick locking pin from locking position (C) and install extendable dipperstick locking pin in storage position (B).

3. Install quick-lock pin on extendable dipperstick locking pin.

A—Extendable Dipperstick Locking Pin B—Storage Position C—Locking Position

Engaging Extendable Dipperstick Lock 1. Remove quick-lock pin from extendable dipperstick locking pin.

2. Remove extendable dipperstick locking pin from storage position and install extendable dipperstick locking pin in locking position.

3. Install quick-lock pin on extendable dipperstick locking pin.

CED,OUO1079,412 –19–07JUL00–1/1

2-2-24

012704

PN=68

Operation—Operating The Machine

Operating Backhoe Auxiliary Hydraulic Functions—If Equipped Backhoe Auxiliary Hydraulic Function Switches

T156920B

–UN–01JUL02

Push the backhoe auxiliary hydraulic function switch (A) to activate and deactivate backhoe auxiliary hydraulic attachments. The backhoe auxiliary hydraulic function switch (A) has three positions: • Push upper half to activate the backhoe auxiliary hydraulic function.

• Push to middle position to transfer control to the backhoe auxiliary hydraulic function foot switch.

• Push lower half to deactivate the backhoe auxiliary hydraulic function.

T131758D

Push the backhoe auxiliary hydraulic function switch “Off” when no attachment is installed, when changing attachments, or when installed attachments are not in use.

–UN–11JUL00

When the backhoe auxiliary hydraulic function switch is in the middle position, push the backhoe auxiliary hydraulic function foot switch (B) to activate and deactivate backhoe auxiliary hydraulic attachments.

Optional Two-Lever, Six-Function Configuration Shown

Backhoe Auxiliary Hydraulic Function Switches

–UN–13DEC02

Operate backhoe auxiliary hydraulic function control pedal (C) to control the attachment. See your backhoe auxiliary hydraulic attachment operator’s manual for more information.

T162835B

A—Backhoe Auxiliary Hydraulic Function Switch B—Backhoe Auxiliary Hydraulic Function Foot Switch C—Backhoe Auxiliary Hydraulic Function Control Pedal

Optional Pilot Controls Shown

HG31779,00001E0 –19–28JAN03–1/1

2-2-25

012704

PN=69

Operation—Operating The Machine

Operating Loader

T131727D

IMPORTANT: Do not raise or lower the front loader boom while the engine hood is open.

Always close the engine hood fully before moving the front loader boom, or severe damage to the engine hood will occur. See Opening and Closing Engine Hood. (Section 3-2.)

–UN–21JUL00

CAUTION: Prevent possible injury from unexpected machine movement. Operate loader facing forward in the operator’s seat only.

Optional Three-Function Controls Shown

NOTE: Loader control lever will return to neutral if released during normal loader operation.

Push lever in following directions for corresponding loader movements:

NOTE: Loader control lever will detent in “Float” when moved fully forward (A). Loader control lever will stay in “Float” until it is manually moved.

–UN–11JUL00

NOTE: Loader control lever will detent in “Return-to-Dig” when bucket is dumped and lever is moved fully left (C). Lever will return to neutral when bucket is in dig position.

Use the “Float” and “Return-to-Dig” detents at the same time to quickly position the front loader bucket for loading, as when driving into a pile of material. When front loader boom and bucket are in correct position, the loader control lever will automatically release from “Return-to-Dig” detent, but will remain in “Float” detent.

T132341B

Loader control lever will give resistance when boom is raised and lever is held in “Bucket Roll-Back” (C). Lever will return to neutral when bucket is self-leveled.

A—Boom Lower and Float B—Boom Raise C—Bucket Roll-Back and Return-to-Dig D—Bucket Dump

For faster cycle times, fully extend lever in desired direction, run engine at fast idle, and move boom and bucket at same time.

CED,OUO1079,489 –19–20JUL00–1/1

2-2-26

012704

PN=70

Operation—Operating The Machine

Operating Differential Lock

–UN–11JUL00

CAUTION: Prevent injury from loss of machine control. DO NOT engage differential lock when driving at high speed, or steering will be limited.

Push and hold differential lock switch (A) to lock the rear differential. When rear differential is locked, both rear wheels turn at the same speed.

T131721C

Prevent injury from unexpected machine movement. When poor traction results in one rear tire spinning, slow the tire’s rotation before engaging differential lock.

A—Differential Lock Switch

Unequal traction will keep the rear differential locked. If the differential lock foot switch is released, the differential lock disengages automatically when traction evens out.

Hold differential lock switch continuously to keep rear differential locked when traction is even.

CED,OUO1079,422 –19–07JUL00–1/1

2-2-27

012704

PN=71

Operation—Operating The Machine

Operating Mechanical Front Wheel Drive (MFWD)—If Equipped

T156922B

–UN–01JUL02

IMPORTANT: Prevent possible gear damage.

Mechanical front wheel drive (MFWD) can be engaged and disengaged while driving, except in cases of unequal traction. Machine must be stopped before engaging MFWD during unequal traction.

NOTE: For best performance, fuel economy, and tire wear, operate MFWD only when needed.

To achieve best MFWD performance, be sure front tires are inflated to proper air pressure. See Tire Inflation Pressures. (Section 3-3.)

T131717B

–UN–15JUN00

NOTE: It may take several seconds for MFWD to engage or disengage depending on the mechanical gearing of the MFWD assembly.

Push MFWD switch (A) up to engage MFWD drive shaft.

MFWD indicator (B) will remain lit while MFWD is engaged.

A—MFWD Switch B—MFWD Indicator

Push MFWD switch down to disengage MFWD.

CED,OUO1079,390 –19–19JUN00–1/1

2-2-28

012704

PN=72

Operation—Operating The Machine

Lifting

–UN–17DEC96

CAUTION: Never move the load suddenly. Never move load over person’s head. DO NOT allow any persons near the load. Keep all persons away from raised load until blocks are supporting it or load is sitting on the ground.

1. For maximum lifting capability, attach chain/sling to buckets at positions shown. Refer to Specifications section for capacities of backhoe.

T105290

Make sure chain/sling is in good condition and is rated for load you are lifting.

Lifting With Front Loader

–UN–20NOV96

2. Attach a hand line to load for stability. Use long enough line to ensure that person holding it is a safe distance from load.

3. Before lifting, perform following test of load stability:

T105289

NOTE: If using backhoe to lift, raise rear tires off ground 50 mm (2 in.) and ensure machine is level. If ground is soft, place boards or other wide support under stabilizer feet to increase stability.

Lifting With Backhoe

a. Park machine close to load. b. Attach load to chain/sling. c. Raise load 50 mm (2 in.) above ground. d. If using backhoe, swing load all the way to one side. e. While keeping load close to the ground, extend it away from machine.

If there is any indication of reduced stability of your machine, lower load to the ground and make necessary adjustments so machine can successfully perform test. Do not lift load until machine can perform test at acceptable level.

TX,35,BG257 –19–29AUG97–1/1

2-2-29

012704

PN=73

Operation—Operating The Machine

Parking the Machine

T131691F

–UN–20JUN00

IMPORTANT: Before stopping engine that has been operating at working load, idle at 1/3 speed for 1—2 minutes to cool the engine. If engine stalls while operating under load, restart immediately and idle at 1/3 speed for 1—2 minutes before stopping to allow coolant to continue circulating through engine.

IMPORTANT: Turbocharger may be damaged if engine is not properly shut down.

1. Park machine on a level surface.

2. Lower all equipment to ground.

–UN–16SEP02

3. Move FNR lever (A) to N.

T159414D

CAUTION: Prevent possible injury from unexpected machine movement. NEVER rely on FNR lever alone to keep machine from moving.

Always engage park brake to hold machine.

4. Push left half of park brake switch (B) to engage park brake.

–UN–16SEP02

5. Move engine speed control lever (C) to 1/3 speed and run engine with no load for 1—2 minutes.

6. Move engine speed control lever to slow idle.

T131729G

7. Turn key switch (D) to “Off” to stop engine. Remove key from key switch.

8. Release hydraulic pressure by moving control levers until equipment does not move.

A—FNR Lever B—Park Brake Switch C—Engine Speed Control Lever D—Key Switch

HG31779,0000118 –19–17SEP02–1/1

2-2-30

012704

PN=74

Operation—Operating The Machine

Loading Machine on a Trailer 1. Keep trailer bed clean. Put wheel chocks against trailer wheels.

8. Stop engine.

2. Use a ramp or loading dock. Ramps must be strong enough, have a low angle, and correct height. Load and unload machine on a level surface.

IMPORTANT: Prevent possible hydraulic system damage. Fasten chains or cables to machine at proper locations.

3. Fasten seat belt before starting engine. Allow engine to run for several minutes.

9. Fasten chains or cables from trailer to frame tie-downs. Do not route chains or cables over or against hydraulic lines or hoses.

4. Install the extendable dipperstick locking pin, if equipped, and engage the backhoe swing lock.

10. Fasten backhoe bucket to trailer with chains or cables to prevent movement during transport.

5. Drive the machine up ramps slowly with centerline of machine over centerline of trailer.

11. Cover engine exhaust pipe opening with tape to keep dust and rain out of pipe.

6. Lower loader bucket onto blocks or trailer bed.

7. Lower backhoe boom until bucket rests on trailer bed.

HG31779,000007C –19–14MAY02–1/1

2-2-31

012704

PN=75

Operation—Operating The Machine

Towing IMPORTANT: Engine cannot be started by towing.

Damage to transmission may result. DO NOT tow machine faster than 10 km/hr (6 mph) or any longer than one hour.

Towing IS NOT recommended. If you MUST tow machine, use the following procedure: 1. Turn engine “Off”.

CAUTION: Prevent possible injury or death from unexpected machine movement. Block wheels to prevent machine movement before disengaging park brake.

2. Block tires securely.

3. Attach towing machine and towed machine as closely together as possible with chains.

4. If your machine is equipped with mechanical front wheel drive (MFWD), remove the front axle drive shaft.

5. Move FNR lever to N.

OUO1079,00002B0 –19–23OCT00–1/3

–UN–25JUL00

CAUTION: Prevent possible injury or death from unexpected machine movement. Release the park brake only through the access hole in floor of operator’s station.

T132861B

6. Remove front half of rubber mat from floor of operator’s station. Remove cap screws (A) and cab floor access plate (B).

A—Cap Screw (4 used) B—Cab Floor Access Plate

Continued on next page

2-2-32

OUO1079,00002B0 –19–23OCT00–2/3 012704

PN=76

Operation—Operating The Machine IMPORTANT: To avoid damage to park brake assembly from heat build-up, park brake must be manually disengaged.

–UN–13JUL00

7. Release park brake manually for towing. Loosen hex nuts (B) and turn both park brake adjustment cap screws (A) completely in.

T132351B

8. Remove blocks from tires and tow machine.

9. When towing is completed, block tires and engage park brake to hold machine. Turn both park brake adjustment cap screws out to specification (C) as illustrated.

–UN–10SEP96

Specification Park Brake Adjustment Cap Screw-to-Park Brake Housing— Distance ......................................................... 27 + 1 mm (1.06 + 0.04 in.)

10. Tighten hex nuts to lock cap screws in position.

T102655

11. Install central floor access plate and rubber floor mat.

12. Install front axle drive shaft, if removed.

A—Park Brake Adjustment Cap Screw (2 used) B—Hex Nut (2 used) C—Specification

OUO1079,00002B0 –19–23OCT00–3/3

2-2-33

012704

PN=77

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

Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test.

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

Sulfur content: • Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred.

• If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for engine oil and filter by 50%.

• DO NOT use diesel fuel with sulfur content greater than 1.0%.

Diesel fuels specified to EN 590 or ASTM D975 are recommended.

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

Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification.

Cetane number of 40 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).

DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C (9°F) below the expected low temperature.

DX,FUEL1 –19–24JAN00–1/1

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

3-1-1

012704

PN=78

Maintenance—Machine

Dieselscan Fuel Analysis DIESELSCAN is a John Deere fuel sampling program to help you monitor the quality of your fuel source. It verifies fuel type, cleanliness, water content, suitability for cold weather operation, and if fuel is within ASTM specifications. Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

DX,FUEL6 –19–06DEC00–1/1

Handling and Storing Diesel Fuel CAUTION: Handle fuel carefully. Do not fill the fuel tank when engine is running.

DO NOT smoke while you fill the fuel tank or service the fuel system.

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

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

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

Contact your fuel supplier for recommendations.

DX,FUEL4 –19–18MAR96–1/1

3-1-2

012704

PN=79

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.

Consult your John Deere dealer to obtain information and recommendations.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

DX,ALTER –19–15JUN00–1/1

Engine Break-In Oil IMPORTANT: Do not use John Deere PLUS-50 oil or engine oils meeting API CG4, API CF4, or CCMC D5 performance levels during the first 100 hours of operation of a new or rebuilt engine.

These oils will not allow the engine to break-in properly.

After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL.

New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level.

• API Service Classification • CCMC Specification D4

Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine.

If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil with oil viscosity based on the expected air temperature range, and meeting one of the following, during the first 100 hours of operation:

After the break-in period, use John Deere PLUS-50 or other diesel engine oil as recommended in this manual.

PLUS-50 is a trademark of Deere & Company.

TX,15,DX649 –19–19AUG99–1/1

3-1-3

012704

PN=80

Maintenance—Machine

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

The following oil is preferred: • John Deere PLUS-50 The following oil is also recommended:

Other oils may be used if they meet one or more of the following: API Service Classification CH-4 API Service Classification CG-4 API Service Classification CF-4 ACEA Specification E3 ACEA Specification E2

TS1661

• • • • •

–UN–10OCT97

• John Deere TORQ-GARD SUPREME

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by 50%.

Extended service intervals may apply when John Deere preferred engine oils are used. Consult your John Deere dealer for more information.

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

DX,ENOIL –19–24JAN00–1/1

3-1-4

012704

PN=81

Maintenance—Machine

Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oils are preferred: • John Deere HY-GARD • John Deere Low Viscosity HY-GARD Other oils may be used if they meet one of the following: –UN–10OCT97

• John Deere Standard JDM J20C • John Deere Standard JDM J20D

TS1660

Use the following oil when a biodegradable fluid is required: • John Deere BIO-HY-GARD

HY-GARD is a trademark of Deere & Company BIO-HY-GARD is a trademark of Deere & Company

TX03679,0001837 –19–18JAN02–1/1

3-1-5

012704

PN=82

Maintenance—Machine

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

The following greases are preferred: • John Deere SD POLYUREA GREASE The following greases are also recommended: John John John John

Deere Deere Deere Deere

HD MOLY GREASE HD LITHIUM COMPLEX GREASE HD WATER RESISTANT GREASE GREASE-GARD

–UN–30JUN99

• • • •

Other greases may be used if they meet the following:

TS1667

• NLGI Performance Classification GC-LB IMPORTANT: Some types of grease thickener are not compatible with others. Consult your grease supplier before mixing different types of grease.

DX,GREA1 –19–24JAN00–1/1

Grease For Extendible Dipperstick, Sideshift Frame, And Stabilizer Leg Wear Strips SAE Multipurpose Grease with Extreme Pressure (EP) performance and containing 3 to 5 per cent molybdenum disulfide (preferred).

TX,45,BD1972 –19–24SEP96–1/1

3-1-6

012704

PN=83

Maintenance—Machine

Diesel Engine Coolant The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (-34°F).

additives, formulated for protection of heavy duty diesel engines against corrosion and cylinder liner erosion and pitting. They also require periodic replenishment of additives during the drain interval.

John Deere COOL-GARD

Propylene glycol base coolants

The following engine coolant is preferred for service:

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

• John Deere COOL-GARD Prediluted Coolant

• ASTM D6211 prediluted coolant • ASTM D6211 coolant concentrate in a 40 to 60% mixture of concentrate with quality water

The following engine coolant is also recommended: • John Deere COOL-GARD Coolant Concentrate in a 40 to 60% mixture of concentrate with quality water.

Coolants meeting ASTM D6211 do not require use of supplemental coolant additives, except for periodic replenishment during the drain interval.

John Deere COOL-GARD coolants do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Freeze protection Ethylene glycol base coolants A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37°C (-34°F).

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

A 50% mixture of propylene glycol engine coolant in water provides freeze protection to -33°C (-27°F).

• ASTM D6210 prediluted coolant • ASTM D6210 coolant concentrate in a 40 to 60% mixture of concentrate with quality water

If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

Water quality

Coolants meeting ASTM D6210 do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Other low silicate ethylene glycol base coolants for heavy-duty engines may also be used if they meet one of the following specifications: • ASTM D5345 prediluted coolant • ASTM D4985 coolant concentrate in a 40 to 60% mixture of concentrate with quality water

Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives.

IMPORTANT: Do not mix ethylene glycol and propylene glycol base coolants.

Coolants meeting ASTM D5345 or ASTM D4985 require an initial charge of supplemental coolant

DX,COOL3 –19–18OCT01–1/1

3-1-7

012704

PN=84

Maintenance—Periodic Maintenance Service Your Machine at Specified Intervals

–UN–13JUL00

Lubricate and make service checks and adjustments at intervals shown on the periodic maintenance chart (A), greasing maintenance chart (B), and in the maintenance sections.

Intervals shown on charts and in this manual are for normal conditions. If operating in difficult conditions, service at shorter intervals.

T132353B

Perform service on items at multiples of the original requirement. For example, at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, and 10 hours or daily.

A—Periodic Maintenance Chart B—Greasing Maintenance Chart

CED,OUO1079,418 –19–10JUL00–1/1

Check Hour Meter Regularly

SELECT

n/min

T135101

T135101

A—Hour Meter

–UN–07NOV00

A

Check hour meter (A) to determine when your machine needs periodic maintenance.

OUO1079,00002C9 –19–02NOV00–1/1

3-2-1

012704

PN=85

Maintenance—Periodic Maintenance

Prepare Machine for Maintenance IMPORTANT: Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. Do not pour waste onto the ground, down a drain, or into any water source.

Before performing procedures in the maintenance chapters and before leaving the operator’s seat, park the machine, and release hydraulic pressure.

CAUTION: Prevent serious injury or death from unexpected machine movement.

Always install the loader boom service lock,

or lower the front loader boom fully to the ground, and move control levers to release hydraulic pressure before working near the front of the machine. See Loader Boom Service Lock in this section for installation instructions.

Raise the front loader boom and install the loader boom service lock before performing maintenance in the engine compartment. See Loader Boom Service Lock in this section.

If the machine is equipped with ride control, discharge hydraulic pressure from the ride control system before performing maintenance. See Discharge Ride Control System Hydraulic Pressure—If Equipped. (Section 4-1.)

CED,OUO1079,419 –19–10SEP02–1/1

3-2-2

012704

PN=86

Maintenance—Periodic Maintenance

Loader Boom Service Lock Install loader boom service lock (A) when front loader must be raised for service procedures.

T131855C

–UN–07NOV00

IMPORTANT: Do not raise or lower the front loader boom while the engine hood is open.

Always close the engine hood fully before moving the front loader boom, or severe damage to the engine hood will occur.

Installing the Loader Boom Service Lock A—Loader Boom Service Lock

1. Close engine hood.

2. Empty loader bucket and move bucket to dump position.

3. Raise boom until loader boom service lock can fit over cylinder rod.

4. Stop engine.

5. Remove cotter pin and retaining pin, and lower loader boom service lock onto cylinder rod.

6. Install retaining pin and cotter pin to attach loader boom service lock on cylinder rod.

7. Slowly lower boom until its weight settles onto the loader boom service lock.

Removing the Loader Boom Service Lock 1. Close engine hood.

2. Start engine and raise boom slightly to allow clearance between loader boom service lock and cylinder.

3. Remove cotter pin and retaining pin.

4. Lift loader boom service lock to storage position, and install retaining pin and cotter pin to retain.

HG31779,0000119 –19–17SEP02–1/1

3-2-3

012704

PN=87

Maintenance—Periodic Maintenance

Opening and Closing Engine Hood (S.N. — 903478)

T132355B

IMPORTANT: Do not raise or lower the front loader boom while the engine hood is open.

Always close the engine hood fully before moving the front loader boom, or severe damage to the engine hood will occur.

–UN–13JUL00

CAUTION: Prevent serious injury or death from unexpected machine movement. Always install the loader boom service lock, or lower the front loader boom fully to the ground, and move control levers to release hydraulic pressure before working near the front of the machine.

A—Hood Tilt Latch B—Handhold

NOTE: The engine hood can be partially opened when the front loader boom is lowered fully to the ground. To fully open the engine hood, the front loader boom must be fully raised and the loader boom service lock must be installed. See Loader Boom Service Lock in this section for installation instructions.)

Pull hood tilt latch (A) and lift hood with handhold (B) to open.

CED,OUO1079,578 –19–02JAN03–1/1

3-2-4

012704

PN=88

Maintenance—Periodic Maintenance

Opening and Closing Engine Hood (S.N. 903479—)

T158496B

IMPORTANT: Do not raise or lower front loader boom while the engine hood is open. Always close engine hood fully before moving front loader boom, or severe damage to hood will occur.

–UN–24OCT02

CAUTION: Prevent serious injury or death from unexpected machine movement. Always install the loader boom service lock, or lower the front loader boom fully to the ground, and move control levers to release hydraulic pressure before working near the front of the machine.

1—Hood Tilt Latch

NOTE: The engine hood can be partially opened when the front loader boom is lowered fully to the ground. To fully open the engine hood, the front loader boom must be fully raised and the loader boom service lock must be installed.

Push hood tilt latch (1) and lift hood to open.

HG31779,000007E –19–14MAY02–1/1

3-2-5

012704

PN=89

Maintenance—Periodic Maintenance

Maintenance and Repair Record Keeping System The checklist on the following pages 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.

–19–03APR89

As maintenance is performed, check off each item on the list and record date and hour meter reading. Use the second (perforated) copy of this form in the Checklists chapter.

T6828AA

Do not tear out or mark on Checklist in the Periodic Maintenance chapter. Keep it to make extra copies.

CED,OUO1040,41 –19–06MAY98–1/1

3-2-6

012704

PN=90

Maintenance—Periodic Maintenance

T111411

T111410

–UN–16SEP97

–UN–16SEP97

OILSCAN PLUS, COOLSCAN PLUS, Dieselscan, and 3-Way Coolant Test Kit

3-Way Coolant Test Kit

OILSCAN PLUS

OILSCAN PLUS, COOLSCAN PLUS, Dieselscan, and 3-Way Coolant Test Kits are John Deere fluid sampling products to help you monitor machine performance and system condition. The objective of a fluid sampling program is to insure machine availability when you need it and to reduce repair costs by identifying potential problems before they become critical.

and/or fluid change interval. Certain systems require more frequent sampling. Consult your John Deere dealer on a maintenance program for your specific application. Your dealer has the sampling products and expertise to assist you in lowering your overall operating costs through fluid sampling.

Oil and coolant samples should be taken from each system on a periodic basis, usually prior to a filter

OILSCAN PLUS is a trademark of Deere & Company COOLSCAN PLUS is a trademark of Deere & Company

CED,OUO1040,114 –19–10JUL00–1/1

3-2-7

012704

PN=91

Maintenance—Periodic Maintenance

Service Intervals SERVICE INTERVALS Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours, and 10 hours or daily.

As Required • • • • •

Check loader and backhoe boom locks Inspect tires and check pressure Check wheel fasteners Clean or replace cab fresh air and recirculation filters (if equipped) Inspect and clean hydraulic reservoir fill screen

• • • • • •

Drain water and sediment from fuel tank Clean air cleaner dust unloader valve Inspect belt Grease MFWD drive shaft spline (if equipped) Grease extendible dipperstick (if equipped) Grease non-powered front wheel bearings (if equipped)

Every 10 Hours or Daily • • • •

Check hydraulic reservoir oil level Check engine oil level Check coolant level Grease loader pivot points

• • • • •

Grease Grease Grease Grease Grease

stabilizers and pivots backhoe bucket linkage pivots and cylinder rod ends backhoe pivot points front axle and steering cylinder pivots MFWD front axle U-joints (if equipped)

After First 100 Hours • Change engine break-in oil and replace filter

• Replace transmission oil filter

Continued on next page

3-2-8

OUO1079,000024C –19–11SEP00–1/2

012704

PN=92

Maintenance—Periodic Maintenance Model: ❒ 410G PIN/Serial Number:

Customer: Delivery Date: Hour Meter Reading: OIL SAMPLING Oil samples should be taken from each system prior to its recommended drain or change interval indicated on this form: 250, 500, 1000 hours. Maintenance recommendations supplied by OILSCAN PLUS 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 ❒ Check MFWD planetary housing oil level (if equipped) ❒ Check MFWD front axle housing oil level (if equipped) ❒ Check battery electrolyte level and terminals

❒ Check rear axle oil level ❒ Check transmission oil level ❒ Drain and refill engine oil and replace engine oil filter (S.N. —911915)

Comments: Date: Maintenance Performed By:

Hour Meter Reading:

Every 500 Hours ❒ ❒ ❒ ❒

Check coolant conditioner Check air intake hose Replace hydraulic oil filter Check boom-to-dipperstick pivot pin bolt torque

❒ Replace hydraulic reservoir breather ❒ Drain and refill engine oil and replace engine oil filter (S.N. 911916—) ❒ Replace fuel filter

Comments: Date: Maintenance Performed By:

Hour Meter Reading:

Every 1000 Hours ❒ Clean, pack, and adjust non-power front wheel bearings (if equipped) ❒ Drain and refill MFWD planetary housing oil (if equipped) ❒ Drain and refill MFWD front axle housing oil (if equipped) ❒ Clean engine crankcase vent tube ❒ Replace transmission oil filter ❒ Drain and refill rear axle oil

❒ ❒ ❒ ❒ ❒

Replace pilot control filter (if equipped) Check and adjust engine speed control linkage Drain and refill hydraulic reservoir oil Drain and refill transmission and torque converter oil Replace engine air filter elements

Comments: Date: Maintenance Performed By:

Hour Meter Reading:

Every 2000 Hours ❒ Adjust engine valve lash Comments: Date: Maintenance Performed By:

Hour Meter Reading:

OUO1079,000024C –19–11SEP00–2/2

3-2-9

012704

PN=93

Maintenance—Periodic Maintenance

Required Parts REQUIRED PARTS Ensure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated parts are also on hand, i.e., filter O-rings.

Description Engine Oil Filter (S.N. — 911915) Engine Oil Filter (S.N. 911916—) Hydraulic Oil Filter Hydraulic Reservoir Breather Filter Fuel Filter Transmission Filter Air Filter (Primary) Air Filter (Secondary) Pilot Control Filter Cab Fresh Air Filter Cab Recirculation Filter Coolant Conditioner PLUS-50 Oil (S.N.— 911915) PLUS-50 Oil (S.N. 911916—)

Part Number RE59754

ASI 1

RE504836

1

250 Hours 1

AT195915 AT101565 RE62418 AT179323 AT175344 AT175345 AT183869 AT191102 AT184590 TY16004 TY6389

As Needed As Needed As Needed 13 L (13.7 qt)

TY6389

13 L (13.7 qt)

500 Hours 1

1000 Hours 1

2000 Hours 1

1

1

1

1 1

1 1

1 1

1

1 1 1 1 1

1 1 1 1 1

13 L 13.7 qt)

13 L (13.7 qt)

13 L (13.7 qt)

13 L (13.7 qt)

13 L (13.7 qt)

13 L (13.7 qt)

15 L (16 qt) 37 L (39 qt) 6.5 L (8.0 qt) 16 L (17 qt)

15 L (16 qt) 37 L (39 qt) 6.5 L (8.0 qt) 16 L (17 qt)

1 2

1 2

1 2

1 1

1 1

1 1

1

1

1

1

1

13 L (13.7 qt)

HY-GARD Transmission and Hydraulic Oil: Transmission TY6354 gal Hydraulic System TY6354 gal MFWD TY6354 gal Rear Axle TY6354 gal OILSCAN PLUS Kits: Diesel Engine Oil AT178840 Transmission Oil AT178844 and Gearbox/Axle Hydraulic Oil Tank AT178844 3-Way Heavy Duty TY16175 Coolant Test Kit COOLSCAN PLUS Kit AT183016 (Ten samples per kit) Dieselscan AT180344 Diesel Fuel Analysis (Six samples per kit)

1

OUO1079,0000276 –19–23JAN03–1/1

3-2-10

012704

PN=94

Maintenance—As Required Inspect Loader Boom Service Lock 1. Inspect loader boom service lock (A), cotter pin, and retaining pin to ensure that all are in good condition.

–UN–07NOV00

2. Verify that warning decal is in place.

T131855C

3. See your authorized dealer for replacement parts.

A—Loader Boom Service Lock

CED,OUO1079,579 –19–24AUG00–1/1

Check and Adjust Boom Lock Checking Boom Lock Operation

–UN–11DEC96

1. Operate the boom lock lever repeatedly to verify proper operation.

2. If boom lock is out of adjustment, adjust per procedure.

IMPORTANT: To avoid damage to lock, adjust lock so it is able to pass through full range of motion. Lock must go down to post (E) and up to stops (A).

Perform the following adjustment for both the left and right boom locks:

T105667

Adjusting the Boom Lock

Right Side Shown A—Stop (4 used) B—Pin (2 used) C—Yoke (2 used) D—Jam Nut (2 used) E—Post (2 used)

NOTE: Boom lock is not shim adjustable.

1. Operate the machine and engage the boom lock. Stop the engine.

2. Remove pin (B) from boom lock.

3. Adjust position of yoke (C) so when the boom lock control lever is at rest, yoke is aligned with pin mounting hole.

4. Tighten jam nut (D) to hold yoke in adjusted position.

5. Install pin.

6. Check boom lock operation per procedure to verify proper operation.

OUO1079,000025A –19–11SEP00–1/1

3-3-1

012704

PN=95

Maintenance—As Required

Check Tire Pressure CAUTION: Explosive separation of a tire and rim parts can cause serious injury or death.

Only attempt to mount a tire if you have the proper equipment and experience to perform the job. Have it done by your John Deere dealer or a qualified repair service.

Inspect tires and wheels daily. DO NOT operate with low pressure, cuts, bubbles, damaged rims, or missing lug bolts and nuts.

TS211

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.

–UN–23AUG88

Always maintain the correct tire pressure. DO NOT inflate the tires above the recommended pressure. NEVER cut or weld on an inflated tire or rim assembly, rim, or rim parts. Heat from welding could cause an increase in pressure and may result in a tire explosion.

Check tire pressure with an accurate gauge having 6.9 kPa (0.07 bar) (1 psi) graduations. If tires contain liquid ballast, use a special air-water gauge and measure with valve stem at bottom.

When inflating tires be sure to lock air chuck to valve stem and stand to front or rear of tire. See Tire Inflation Pressures in this section or in Miscellaneous— Specifications. (Section 4-6.)

TX,55,BD2138 –19–07OCT96–1/1

3-3-2

012704

PN=96

Maintenance—As Required

Tire Inflation Pressures 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.

Item

Measurement

Specification

11L-16 12PR F3

Pressure

441 kPa (4.4 bar) (64 psi)

12.5/80-18 10 PR (MFWD)

Pressure

414 kPa (4.1 bar) (60 psi)

14.5/75-16.1 10PR F3

Pressure

276 kPa (2.7 bar) (40 psi)

19.5L-24 10PR R4

Pressure

193 kPa (1.9 bar) (28 psi)

21L-24 10PR R4

Pressure

179 kPa (1.8 bar) (26 psi)

Front Tires

Rear Tires

OUO1079,00002BC –19–24OCT00–1/1

3-3-3

012704

PN=97

Maintenance—As Required

Check Wheel Fasteners

–UN–18OCT88

NOTE: Tighten wheel cap screws after first 50-100 hours of loaded operation after replacing or installing a new wheel. After that, tighten as required.

T6000AU

Tighten wheel cap screws and fasteners.

T87507

–UN–21OCT88

Standard Front Axle Shown

Rear Axle Shown Item

Measurement

Specification

Standard Front Axle Cap Screw

Torque

136 +20 —27 N•m (100 +15 —20 lb-ft)

MFWD Front Axle Cap Screw

Torque

300 +110 —40 N•m (221 +81 —29 lb-ft)

Rear Axle Cap Screw

Torque

495 +99 N•m (365 +73 lb-ft)

TX,90,DH1383 –19–06JAN03–1/1

3-3-4

012704

PN=98

Maintenance—As Required

Clean Cab Air Filters Cab Fresh Air Filter

–UN–18JUL00

1. Open latch (A) on inside of right-side window frame.

2. Remove fresh air filter cover (B) and fresh air filter.

T132588B

3. Inspect filter. Clean as necessary. Replace if damaged.

4. Install filter and filter cover.

5. Close latch.

A—Latch B—Fresh Air Filter Cover

CED,OUO1079,492 –19–24JUL00–1/2

Cab Recirculating Air Filter 1. Remove cab recirculating air filter cover (C) and cab recirculating air filter.

–UN–24JUL00

2. Inspect filter. Clean as necessary. Replace if damaged.

3. Install filter and filter cover.

CAUTION: Reduce compressed air to less than 210 kPa (2.10 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying debris, and wear personal protection equipment, including eye protection.

T132838B

Cleaning Cab Air Filters

C—Cab Recirculating Air Filter Cover

IMPORTANT: Always replace damaged air filters.

Clean filter(s) using one of the following methods: • Direct compressed air through filter(s), opposite normal air flow.

• Tap filter(s) on a flat surface with dirty side down.

• Wash in warm, soapy water and flush. Let filter(s) dry before reinstalling.

CED,OUO1079,492 –19–24JUL00–2/2

3-3-5

012704

PN=99

Maintenance—As Required

Inspect and Clean Hydraulic Reservoir Fill Screen 1. Remove hydraulic reservoir fill cap (A) from fill tube.

–UN–13JUL00

2. Remove retaining clip and hydraulic reservoir fill screen from fill tube.

4. Install hydraulic reservoir fill screen and retaining clip in fill tube.

T131716C

3. Inspect hydraulic reservoir fill screen and clean as necessary.

A—Hydraulic Reservoir Fill Cap

5. Install hydraulic reservoir fill cap in fill tube.

CED,OUO1079,423 –19–10JUL00–1/1

Drain Fuel Tank Water and Sediment

–UN–13JUL00

CAUTION: Handle fuel carefully. If the engine is hot or running, DO NOT drain fuel tank. DO NOT smoke while you drain fuel tank or work on fuel system.

T132358B

NOTE: Dispose of waste properly.

1. Loosen sediment drain plug (A) on front of fuel tank and allow fuel to flow for several seconds.

2. Tighten plug securely to stop fuel flow.

A—Sediment Drain Plug

CED,OUO1079,421 –19–10JUL00–1/1

3-3-6

012704

PN=100

Maintenance—As Required

Clean Engine Air Cleaner Dust Unloader Valve

–UN–07SEP00

IMPORTANT: A missing, damaged, or hardened dust unloader valve will make dust cup precleaner ineffective, causing very short element life. Valve should suck closed above 1/3 engine speed.

T133589C

Squeeze engine air cleaner dust unloader valve (A) to remove dust from air cleaner.

If operating in high dust conditions, squeeze dust valve every couple of hours of operation to release dust.

A—Engine Air Cleaner Dust Unloader Valve

CED,OUO1079,581 –19–31AUG00–1/1

3-3-7

012704

PN=101

Maintenance—As Required

Clean or Replace Air Cleaner Elements 1. Open engine hood.

–UN–04SEP02

2. Remove air cleaner cover by releasing clips (1).

3. Remove primary element (2).

T159080B

IMPORTANT: A damaged or dirty element may cause engine damage.

Install a new primary element: 1. If the element shows damage.

2. If element will not clean.

3. After 1000 hours service or annually.

–UN–04SEP02

Install a new secondary element (3):

T159081B

1. If the primary element is damaged and needs to be replaced.

2. If the element is visibly dirty.

3. After 1000 hours service or annually.

DO NOT clean a secondary element.

Install a new element carefully centering it in the canister.

4. Inspect element and gasket for damage.

T159082B

–UN–04SEP02

5. Air restriction indicator will not signal correctly if an element has a break or is not correctly sealed in air cleaner housing. Throw away element that has the slightest damage. If gasket is broken or missing, install a new element.

6. If air filter restriction indicator is lit, replace filter elements.

1—Clips (3 used) 2—Primary Element 3—Secondary Element

HG31779,00000FB –19–12SEP02–1/1

3-3-8

012704

PN=102

Maintenance—As Required

Inspect Belt

–UN–13JUL00

Inspect serpentine belt (A) for wear and damage. See your authorized dealer for replacement.

T132357B

A—Serpentine Belt

CED,OUO1079,420 –19–10JUL00–1/1

Grease MFWD Drive Shaft Splines—If Equipped

T125640B

Apply grease to lubrication fitting (1) until it escapes from joint. See Grease. (Section 3-1).

–UN–08NOV99

IMPORTANT: Lubricate daily when machine is used in mud.

1—Lubrication Fitting

CED,TX03768,2667 –19–03DEC02–1/1

Grease Extendible Dipperstick Side Rails—If Equipped

Lower backhoe to ground with full extension. Apply grease to side rails as necessary. See Grease For Extendable Dipperstick, Sideshift Frame, And Stabilizer Leg Wear Strips. (Section 3-1.)

T132378B

NOTE: Avoid excessive grease on dipperstick. A thin film provides adequate lubrication.

–UN–13JUL00

IMPORTANT: Lubricate daily when machine is used in mud.

CED,OUO1079,435 –19–03DEC02–1/1

3-3-9

012704

PN=103

Maintenance—As Required

T132377B

T132376C

–UN–13JUL00

–UN–13JUL00

Grease Extendable Dipperstick Backhoes—If Equipped

1 Point

3 Points

Lubricate extendable dipperstick with a low pressure grease gun with extendable dipperstick fully retracted.

See Grease For Extendable Dipperstick, Sideshift Frame, And Stabilizer Leg Wear Strips. (Section 3-1.)

HG31779,00000FA –19–12SEP02–1/1

Grease Front Wheel Bearings—Non-Powered (S.N. —911143)

2. Grease with approximately five low pressure strokes of grease. See Grease. (Section 3-1.)

3. Remove lubrication fitting and install plug.

T6000AK

1. Remove plug and install lubrication fitting.

–UN–18OCT88

IMPORTANT: Lubricate daily when machine is used in mud.

HG31779,00001BA –19–02JAN03–1/1

3-3-10

012704

PN=104

Maintenance—As Required

Grease Front Wheel Bearings—Non-Powered (S.N. 911144—)

2. Grease with approximately five low pressure strokes of grease. See Grease. (Section 3-1.)

3. Remove lubrication fitting and install plug.

T164479B

1. Remove plug and install lubrication fitting.

–UN–27JAN03

IMPORTANT: Lubricate daily when machine is used in mud.

TX,55,BD2143 –19–03DEC02–1/1

3-3-11

012704

PN=105

Maintenance—Every 10 Hours or Daily Checking Hydraulic Reservoir Oil Level

–UN–02JAN03

NOTE: Check hydraulic oil level with machine parked on a level surface. Check before starting engine, with backhoe and stabilizers in transport position, and front loader bucket lowered to ground.

Check when oil is cool.

T163385B

Sight glass decal has a scale for proper level of oil.

1. Stop engine. Allow time for hydraulic oil to cool.

1—Sight Glass

2. Check oil level in sight glass (1). Oil level should be in mid-range of decal.

CED,OUO1079,439 –19–02JAN03–1/2

Adding Oil to the Hydraulic Reservoir 1. If oil is below operating range in ADD range, remove fill cap (B) and add oil.

–UN–13JUL00

2. Install fill cap.

T131716D

B—Fill Cap

CED,OUO1079,439 –19–02JAN03–2/2

3-4-1

012704

PN=106

Maintenance—Every 10 Hours or Daily

Check Engine Oil Level

–UN–13JUL00

IMPORTANT: Prevent possible engine damage. DO NOT run engine when oil level is below the ADD mark.

The most accurate oil level reading is obtained when engine is cold before operation.

T132362B

1. Park machine on a level surface. Engage park brake.

CAUTION: Prevent serious injury or death from unexpected machine movement. Always install the loader boom service lock, or lower the front loader boom fully to the ground, and move control levers to release hydraulic pressure before working near the front of the machine.

–UN–15DEC88

2. Raise front loader boom and install loader boom service lock.

RG5421

3. Stop engine.

4. Fully open engine hood.

5. Remove engine oil dipstick (A) and check oil level.

BEFORE THE ENGINE IS STARTED: Engine is full when oil level is within cross-hatched area (C). It is acceptable to run engine as long as oil level is above the ADD mark.

A—Engine Oil Dipstick B—Engine Oil Fill Cap C—Cross-Hatched Area

AFTER THE ENGINE HAS BEEN RUN: Allow oil to drain into oil pan for ten minutes before checking the oil level. Ten minutes after shutdown, oil level must be above the ADD mark.

6. Remove engine oil fill cap (B) and add oil as necessary. See Diesel Engine Oil. (Section 3-1.)

7. Check oil level and add oil as necessary.

8. Close engine hood.

HG31779,00000EF –19–10SEP02–1/1

3-4-2

012704

PN=107

Maintenance—Every 10 Hours or Daily

1. With engine cold, coolant level must be between HOT and COLD marks on coolant recovery tank (A).

2. If coolant is below COLD mark, add coolant to recovery tank.

TS281

CAUTION: Prevent possible injury from hot spraying coolant. Remove radiator cap only when cool enough to touch with bare hands.

Then loosen cap slowly to stop so pressure is released from system before removing cap.

–UN–23AUG88

Check Coolant Level

A—Coolant Recovery Tank B—Radiator Cap

T155034C

3. If recovery tank is empty, check for leaks and repair as necessary. Add coolant at radiator cap (B) and recovery tank. See Diesel Engine Coolant. (Section 3-1.) Coolant level in radiator must be at bottom of filler neck.

–UN–20JUN02

NOTE: If recovery tank is full and radiator is low, check for leaks on radiator and hose connections.

HG31779,0000086 –19–17MAY02–1/1

3-4-3

012704

PN=108

Maintenance—Every 10 Hours or Daily

Grease Loader Pivots

T134630C

–UN–24OCT00

Apply grease to lubrication fittings until it escapes from joints. See Grease. (Section 3-1.)

T132371B

–UN–07NOV00

6 points—Right Side Shown

T132372B

–UN–12SEP00

9 points

2 Points—Left Side Shown OUO1079,000025B –19–03DEC02–1/1

3-4-4

012704

PN=109

Maintenance—Every 10 Hours or Daily

T132372C

–UN–12SEP00

Grease 4-in-1 Bucket Pivots—If Equipped

T132371C

–UN–07NOV00

4 Points—Left Side Shown

2 Points

Apply grease to lubrication fittings until it escapes from joints. See Grease. (Section 3-1.)

CED,OUO1079,581 –19–03DEC02–1/1

Grease Stabilizer Pivots and Cylinder Pins

T132374B

–UN–13JUL00

Apply grease to lubrication fittings until it escapes from joint. See Grease. (Section 3-1.)

4 points—Left Side Shown

OUO1079,000025C –19–03DEC02–1/1

3-4-5

012704

PN=110

Maintenance—Every 10 Hours or Daily

T131781C

–UN–07NOV00

Grease Backhoe Linkage, Pivots, and Cylinder Rod Ends

T132381B

–UN–13JUL00

3 Points—Optional Cab Shown

–UN–13JUL00 T132376B

T132375B

–UN–18JUL00

3 points

11 points—Right Side Shown

8 Points—Right Side Shown

All Backhoes Apply grease to lubrication fittings until it escapes from joint. See Grease. (Section 3-1.)

Continued on next page

3-4-6

OUO1079,000025D –19–03DEC02–1/2 012704

PN=111

T132377B

T132376C

–UN–13JUL00

–UN–13JUL00

Maintenance—Every 10 Hours or Daily

1 Point

Extendible Dipperstick Backhoes—If Equipped

3 Points

Sideshift Frame, And Stabilizer Leg Wear Strips.

(Section 3-1.)

Lubricate extendible dipperstick with a low pressure grease gun. See Grease For Extendable Dipperstick,

OUO1079,000025D –19–03DEC02–2/2

3-4-7

012704

PN=112

Maintenance—Every 10 Hours or Daily

3 Points—Left Side Shown

–UN–07NOV00 T135179B

T135178B

–UN–07NOV00

Grease Non-Powered Front Axle and Steering Pivots (S.N. —911143)

4 Points—Right Side Shown

Apply grease to lubrication fittings on steering pivots until it escapes from joints.

–UN–07NOV00

Apply 2 pumps of grease to each lubrication fitting on right side of frame to lubricate axle oscillating pivot.

T135180B

See Grease. (Section 3-1.)

HG31779,00001B9 –19–02JAN03–1/1

3-4-8

012704

PN=113

Maintenance—Every 10 Hours or Daily

Grease Non-Powered Front Axle Pivots (S.N. 911144—) Apply grease to lubrication fittings on steering pivots until it escapes from joints.

Apply 2 pumps of grease to each lubrication fitting on right side of frame to lubricate axle oscillating pivot.

T163182B

–UN–20DEC02

See Grease. (Section 3-1.)

T163176B

–UN–20DEC02

4 Points—Left Side Shown

2 Points

HG31779,00001B7 –19–20DEC02–1/1

3-4-9

012704

PN=114

Maintenance—Every 10 Hours or Daily

Grease MFWD Front Axle and Universal Joints—If Equipped

–UN–17SEP02

Apply grease to lubrication fittings until it escapes from joint.

T132373C

See Grease. (Section 3-1.)

4 Points—Left Side Shown

HG31779,00001DA –19–24JAN03–1/1

3-4-10

012704

PN=115

Maintenance—After First 100 Hours Change Engine Break-In Oil And Replace Filter NOTE: Change engine break-in oil after first 100 hours.

T132447B

–UN–13JUL00

IMPORTANT: If fuel sulfur content exceeds 0.5 percent, change engine oil at 1/2 the normal interval.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on FNR lever to keep machine from moving.

Always engage park brake to hold machine.

1. Run engine to warm oil. Park machine on a level surface. Engage park brake. Stop engine.

–UN–13JUL00

2. Remove engine oil drain plug (A). Allow oil to drain into a container.

T132362C

3. Using a suitable filter wrench, turn engine oil filter (B) counterclockwise and remove from base. Clean mounting surfaces of base as necessary. Dispose of waste oil properly.

4. Apply a thin film of oil to sealing ring on new engine oil filter, and install by turning new filter clockwise by hand until gasket touches mounting surface. Torque an additional 1/2—3/4 turn with filter wrench.

A—Engine Oil Drain Plug B—Engine Oil Filter C—Engine Oil Fill Cap

5. Install engine oil drain plug.

6. Remove engine oil fill cap (C) and fill engine with oil to specification. See Diesel Engine Oil. (Section 3-1.)

Specification Engine Oil—Capacity ........................................................... 13 L (13.7 qt)

Continued on next page

3-5-1

HG31779,00001F4 –19–24FEB03–1/2

012704

PN=116

Maintenance—After First 100 Hours IMPORTANT: Before starting engine after a filter change, crank engine for ten seconds without starting to fill new engine oil filter and pre-lubricate the turbocharger, if equipped.

7. Disconnect fuel pump electrical connector (D) to keep engine from starting. Turn key switch to “Start” and hold for ten seconds.

8. Connect fuel pump electrical connector, start engine, and run at a slow idle. If engine oil pressure light on monitor does not go out and alarm does not shut off, stop engine immediately and find the cause.

9. Stop engine. Check for leaks around drain plug and filter, and tighten as necessary. Check oil level.

T132451B

–UN–13JUL00

D—Fuel Pump Electrical Connector

HG31779,00001F4 –19–24FEB03–2/2

3-5-2

012704

PN=117

Maintenance—After First 100 Hours

Replace Transmission Oil Filter NOTE: Change after first 100 hours and then every 1000 hours.

1. Turn transmission oil filter (A) counterclockwise and remove.

3. Start engine and run for 3 minutes to allow filter element to refill and purge air from charge circuit.

4. With engine running at slow idle, remove transmission dipstick (B). Check transmission oil level and add oil through dipstick tube as necessary. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

T132445B

–UN–13JUL00

2. Apply film of oil to sealing ring on new transmission oil filter. Install new transmission oil filter. Turn clockwise until sealing ring touches mounting surface, then tighten an additional 3/4 to one turn with a suitable filter wrench.

6. Install transmission dipstick and turn handle clockwise to tighten.

T132362E

A—Transmission Oil Filter B—Transmission Dipstick

–UN–13JUL00

5. Check for leakage around filter. Tighten filter just enough to stop leaks.

HG31779,0000334 –19–01DEC03–1/1

3-5-3

012704

PN=118

Maintenance—Every 250 Hours Check MFWD Planetary Housing Oil—If Equipped

–UN–21NOV96

1. Rotate housing until OIL LEVEL line (B) is horizontal and fill plug (A) is above line as shown.

T105325

NOTE: MFWD is filled with HY-GARD gear oil at the factory. If oil level is low, use HY-GARD oil to fill to proper level.

2. Remove plug and check that oil is filled to bottom of plug hole.

3. Add oil to plug hole if necessary. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

A—MFWD Planetary Housing Oil Fill Plug B—Oil Level Line

4. Install plug.

5. Repeat procedure for opposite side wheel.

TX,75,BD2157 –19–17JUL00–1/1

Check MFWD Axle Oil Level—If Equipped 1. Remove plug (A) to check oil level. Oil should be filled to bottom of plug.

–UN–22AUG96

NOTE: MFWD is filled with HY-GARD gear oil at the factory. If oil level is low, use HY-GARD oil to fill to proper level.

T102819

2. Add oil as necessary through plug hole. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

A—Plug

3. Install plug.

TX,75,BD2152 –19–06MAY98–1/1

3-6-1

012704

PN=119

Maintenance—Every 250 Hours

Check Battery Electrolyte Level and Terminals CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

NEVER check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

ALWAYS remove grounded (-) battery clamp first and replace it last.

Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

–UN–23AUG88

Avoid the hazard by:

TS203

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: 1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

1. Remove battery box cover.

Continued on next page

3-6-2

TX,75,DH1574 –19–28APR93–1/3 012704

PN=120

2. Fill each cell to within specified range with distilled water. DO NOT overfill.

CAUTION: Prevent possible injury. ALWAYS remove grounded (—) battery clamp first and replace it last.

T6996DB

IMPORTANT: If water is added to batteries during freezing weather, batteries must be charged after water is added to prevent batteries from freezing. Charge battery using a battery charger or by running the engine.

–UN–09SEP03

Maintenance—Every 250 Hours

3. Disconnect battery clamps, grounded clamp first.

T6996DA

–UN–09SEP03

A—Battery Post B—Fill Tube C—Electrolyte Level Range

TX,75,DH1574 –19–28APR93–2/3

4. Clean battery terminals (A) and clamps with a stiff brush.

–UN–21OCT88

5. Apply lubricating grease (B) around battery terminal base only.

T6758AA

6. Install and tighten clamps, grounded clamp last.

TX,75,DH1574 –19–28APR93–3/3

3-6-3

012704

PN=121

Maintenance—Every 250 Hours

Check Rear Axle Oil Level 1. Remove plug (A) from axle and check oil level.

–UN–22NOV96

2. If oil is not level to bottom of hole, add oil. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

T104867

3. Replace plug.

A—Plug

CED,OUO1040,103 –19–25AUG00–1/1

Check Transmission Oil Level

–UN–13JUL00

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on FNR lever to keep machine from moving.

Always engage park brake to hold machine.

2. With engine running at slow idle, turn handle of transmission dipstick (A) counterclockwise and remove.

T132362D

1. Run engine for 3 minutes to warm transmission oil.

Park machine on a level surface. Move FNR lever to N. Engage park brake. See Prepare Machine for Maintenance. (Section 3-2.)

A—Transmission Dipstick

NOTE: Normal hot oil can be above full mark.

3. Check oil level on dipstick. If oil is not within operating range, add oil through dipstick tube. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

4. Install transmission dipstick and turn handle clockwise to tighten.

OUO1079,00002B1 –19–23OCT00–1/1

3-6-4

012704

PN=122

Maintenance—Every 250 Hours

Change Engine Oil And Replace Filter (S.N.— 911915)

–UN–13JUL00

IMPORTANT: If fuel sulfur content exceeds 0.5 percent, change engine oil at 1/2 the normal interval.

T132447B

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on FNR lever to keep machine from moving.

Always engage park brake to hold machine.

1. Run engine to warm oil. Park machine on a level surface. Engage park brake. Stop engine.

–UN–13JUL00

2. Remove engine oil drain plug (A). Allow oil to drain into a container.

T132362C

3. Using a suitable filter wrench, turn engine oil filter (B) counterclockwise and remove from base. Clean mounting surfaces of base as necessary. Dispose of waste oil properly.

4. Apply a thin film of oil to sealing ring on new engine oil filter, and install by turning new filter clockwise by hand until gasket touches mounting surface. Torque an additional 1/2—3/4 turn with filter wrench.

A—Engine Oil Drain Plug B—Engine Oil Filter C—Engine Oil Fill Cap

5. Install engine oil drain plug.

6. Remove engine oil fill cap (C) and fill engine with oil to specification. See Diesel Engine Oil. (Section 3-1.)

Specification Engine Oil—Capacity ........................................................... 13 L (13.7 qt)

Continued on next page

3-6-5

HG31779,00001F5 –19–24FEB03–1/2

012704

PN=123

Maintenance—Every 250 Hours IMPORTANT: Before starting engine after a filter change, crank engine for 10 seconds without starting to fill new engine oil filter and pre-lubricate the turbocharger, if equipped.

7. Disconnect fuel pump electrical connector (D) to keep engine from starting. Turn key switch to “Start” and hold for ten seconds.

8. Connect fuel pump electrical connector, start engine, and run at a slow idle. If engine oil pressure light on monitor does not go out and alarm does not shut off, stop engine immediately and find the cause.

9. Stop engine. Check for leaks around drain plug and filter, and tighten as necessary. Check oil level.

T132451B

–UN–13JUL00

D—Fuel Pump Electrical Connector

HG31779,00001F5 –19–24FEB03–2/2

3-6-6

012704

PN=124

Maintenance—Every 500 Hours Check Coolant and Add Conditioner

–UN–23AUG88

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

TS281

Remove radiator cap only when engine is cold or when cool enough to touch with bare hands.

Slowly loosen radiator 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.

–UN–20JUN02

NOTE: Check coolant every 500 hours or 6 months, or when replacing 1/3 or more of coolant. Add coolant conditioner as necessary.

T155034B

1. Remove radiator cap (A) and test coolant solution. Use one of the following kits to check coolant:

–UN–13AUG97

• 3-Way Heavy Duty Coolant Test Kit (TY16175): Coolant test strips provide an effective method to check freeze point and additive levels of engine coolant. See your authorized dealer for 3-Way Heavy Duty Coolant Test Kit and follow instructions on kit.

• COOLSCAN PLUS: For a more thorough evaluation of coolant, perform COOLSCAN PLUS analysis, where available. See your authorized dealer for information about COOLSCAN PLUS.

Specification Cooling System—Capacity ...................................................... 16 L (17 qt)

T111110

2. Add TY16004 John Deere Coolant Conditioner or equivalent non-chromate conditioner/rust inhibitor as necessary. Follow instructions on container for amount.

3-Way Test Kit

3. Install cap.

T111109

–UN–13AUG97

A—Radiator Cap

Coolscan Plus

CED,OUO1079,437 –19–23JAN03–1/1

3-7-1

012704

PN=125

Maintenance—Every 500 Hours

Check Air Intake Hose 1. Check engine air intake hose (A) for cracks and replace as necessary.

–UN–13JUL00

2. Check for loose connections and tighten hose clamps as necessary.

T132459B

A—Engine Air Intake Hose

CED,OUO1079,442 –19–11JUL00–1/1

Replace Hydraulic Oil Filter 1. Turn hydraulic oil filter (A) counterclockwise and remove.

2. Apply film of oil to sealing ring on new hydraulic oil filter and install. Turn hydraulic oil filter clockwise until sealing ring touches mounting surface, then tighten an additional 3/4-to-one turn with a suitable filter wrench.

3. Check hydraulic oil level.

–UN–24OCT00

4. Start engine and run for 2 minutes to allow hydraulic oil filter to fill with oil and to purge air from charge circuit.

T134790B

5. Stop engine and check hydraulic oil level. See Check Hydraulic Oil Level. (Section 3-6.)

6. Check for leakage around hydraulic filter. Tighten just enough to stop leaks, if necessary.

A—Hydraulic Oil Filter

HG31779,00000D8 –19–03SEP02–1/1

Check Boom-to-Dipperstick Pin Bolt Torque

Specification Backhoe Boom-to-Dipperstick Pivot Pin Bolt—Torque ................................................ 620 N•m (460 lb-ft)

T133574B

A—Backhoe Boom-to-Dipperstick Pivot Pin Bolt

–UN–30AUG00

Check torque on the backhoe boom-to-dipperstick pivot pin bolt (A). Torque the cap screw to specification.

CED,OUO1079,443 –19–11JUL00–1/1

3-7-2

012704

PN=126

Maintenance—Every 500 Hours

1. Open engine hood. Remove cap screws (A) and move loader mast cover (B) aside. Take care not to damage hose attached to bottom of windshield washer nozzle (C).

2. Remove hydraulic reservoir breather (D).

T132464B

NOTE: Avoid dripping hydraulic oil. Do not reroute hydraulic reservoir breather hoses.

–UN–13JUL00

Replace Hydraulic Reservoir Breather

3. Install new hydraulic reservoir breather with arrow pointing toward reservoir.

–UN–13JUL00

4. Install loader mast cover and cap screws. Close engine hood.

T132462B

A—Cap Screw (4 used) B—Loader Mast Cover C—Windshield Washer Nozzle D—Hydraulic Reservoir Breather

CED,OUO1079,582 –19–25AUG00–1/1

3-7-3

012704

PN=127

Maintenance—Every 500 Hours

Change Engine Oil And Replace Filter (S.N. 911916—)

–UN–13JUL00

IMPORTANT: If fuel sulfur content exceeds 0.5 percent, change engine oil at 1/2 the normal interval.

T132447B

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on FNR lever to keep machine from moving.

Always engage park brake to hold machine.

1. Run engine to warm oil. Park machine on a level surface. Engage park brake. Stop engine.

–UN–13JUL00

2. Remove engine oil drain plug (A). Allow oil to drain into a container.

T132362C

3. Using a suitable filter wrench, turn engine oil filter (B) counterclockwise and remove from base. Clean mounting surfaces of base as necessary. Dispose of waste oil properly.

4. Apply a thin film of oil to sealing ring on new engine oil filter, and install by turning new filter clockwise by hand until gasket touches mounting surface. Torque an additional 1/2—3/4 turn with filter wrench.

A—Engine Oil Drain Plug B—Engine Oil Filter C—Engine Oil Fill Cap

5. Install engine oil drain plug.

6. Remove engine oil fill cap (C) and fill engine with oil to specification. See Diesel Engine Oil. (Section 3-1.)

Specification Engine Oil—Capacity ........................................................... 13 L (13.7 qt)

Continued on next page

3-7-4

HG31779,00001B0 –19–03DEC02–1/2

012704

PN=128

Maintenance—Every 500 Hours IMPORTANT: Before starting engine after a filter change, crank engine for 10 seconds without starting to fill new engine oil filter and pre-lubricate the turbocharger, if equipped.

7. Disconnect fuel pump electrical connector (D) to keep engine from starting. Turn key switch to “Start” and hold for ten seconds.

8. Connect fuel pump electrical connector, start engine, and run at a slow idle. If engine oil pressure light on monitor does not go out and alarm does not shut off, stop engine immediately and find the cause.

9. Stop engine. Check for leaks around drain plug and filter, and tighten as necessary. Check oil level.

T132451B

–UN–13JUL00

D—Fuel Pump Electrical Connector

HG31779,00001B0 –19–03DEC02–2/2

3-7-5

012704

PN=129

Maintenance—Every 500 Hours

Replace Fuel Filter NOTE: Dispose of waste properly.

–UN–13JUL00

1. Turn retaining ring (A) counterclockwise and remove filter element (B). Allow sediment to drain into a container.

T132465B

2. Remove drain knob (C) from old filter element and install on new filter element.

3. Clean filter base (D).

NOTE: Do not attempt to turn filter element into base.

–UN–25NOV92

4. Install new fuel element by aligning vertical locators (F) into slots (E) on filter base. Push filter element up firmly until filter snaps against base.

5. Turn retaining ring clockwise into filter base until retaining ring clicks tightly into place.

T7896AJ

6. Loosen bleed screw (G) by turning knob counterclockwise.

7. Operate primer lever (H) until fuel flow from bleed screw is free of air bubbles.

–UN–13JUL00

NOTE: If there is no fuel flow, push primer lever toward engine and turn crankshaft using starter motor to reposition camshaft. Repeat step 7.

8. Tighten bleed screw.

T132465C

9. Push primer lever toward engine as far as possible.

A—Retaining Ring B—Filter Element C—Drain Knob D—Filter Base E—Slots F—Vertical Locators G—Bleed Screw H—Primer Lever

CED,OUO1079,444 –19–11JUL00–1/1

3-7-6

012704

PN=130

Maintenance—Every 1000 Hours Clean, Pack, and Adjust Front Wheel Bearings—Non-Powered (S.N.—911143)

–UN–21OCT88

1. Raise machine so steer wheels are off ground.

Remove hub cap (J), pull cotter pin (I) from spindle and remove slotted nut (K).

T87549

2. Slip off special washer (L) and outer bearing cone (H).

Remove wheel and hub assembly. Then remove seal (A) and inner bearing cone (C) from hub (E).

3. Clean all dirt and grease from bearings, bushing (B), spindles, and hub assemblies.

A—Seal B—Bushing C—Inner Bearing Cone D—Inner Bearing Cup E—Hub F—Pipe Plug G—Outer Bearing Cup H—Outer Bearing Cone I—Cotter Pin J—Hub Cap K—Nut L—Washer

4. Inspect bearing cups (D and G), and cones for damage or excessive wear and replace damaged parts as necessary.

5. If a new bearing cup must be installed, drive out the old one and install a new cup with the cupped face outward.

6. Inspect grease seals for damage or hardened lips and replace as necessary.

7. Pack bearings and coat seal lips with John Deere Multi-Purpose Grease or equivalent. See Grease.

(Section 3-1.)

8. Install seal (A), bushing (B), and inner bearing cup (D).

Fill gap between inner bearing cup and seal with grease. Assemble balance of parts except cotter pin and hub cap. Tighten slotted nut to specification.

Specification Front Wheel Bearing Slotted Nut—Torque .................................................................... 47 N•m (35 lb-ft)

9. Turn wheel several revolutions. Tighten nut again to specification. Turn nut counterclockwise to nearest slot and install cotter pin. If hole of spindle is in line with a slot after tightening, turn nut counterclockwise to next slot.

Continued on next page

3-8-1

TX,85,BD2164 –19–06MAY98–1/2 012704

PN=131

Maintenance—Every 1000 Hours 10. Remove pipe plug (F) from wheel hub and install lubrication fitting. Lubricate wheel hub assembly until grease starts to exit past outer bearing cone (H).

Remove lube fitting and install pipe plug. See Grease.

(Section 3-1.)

11. Lower machine to the ground and install hub caps.

TX,85,BD2164 –19–06MAY98–2/2

3-8-2

012704

PN=132

Maintenance—Every 1000 Hours

Clean, Pack, and Adjust Front Wheel Bearings—Non-Powered (S.N. 911144—)

3

5 1 6

7 8

9 10

T158732

4

T158732 1—Seal Ring 2—Bearing Cone 3—Wheel Hub

–UN–23AUG02

2

4—O-Ring 5—Stud 6—Bearing Cone

1. Raise machine and install jack stands so front wheels are off ground.

CAUTION: Prevent injury from falling components. Secure wheel hub (3) with a lift strap before removing any components.

2. Remove wheel.

3. Remove wheel hub cover plug (10) and remove wheel hub cover (9) using wedges. Remove and inspect O-ring (4), replace if necessary.

4. Remove three capscrews (8) and thrust washer (7).

5. Remove wheel bearing (6).

7—Thrust Washer 8—Cap Screw (3 used)

9—Wheel Hub Cover 10—Wheel Hub Cover Plug

6. Remove and inspect wheel hub (3) with bearing cups. To replace bearing cups, place wheel hub on flat surface and drive bearing cups out with a hammer and driver.

IMPORTANT: Removing seal ring (1) will destroy it. Do not remove seal ring unless damage is noted.

7. Remove bearing cone (2) using wedges.

8. Clean all dirt and grease from bearings, spindle and hub assembly.

9. Inspect grease seals for damage or hardened lips and replace as necessary.

Continued on next page

3-8-3

BT40170,000002C –19–23AUG02–1/2 012704

PN=133

Maintenance—Every 1000 Hours Specification Thrust Plate Cap Screws— Torque..................................................................... 120 N•m (89 lb-ft)

10. Pack bearings and coat seal lips with John Deere Multi-Purpose Grease or equivalent.

11. Install bearing cone (2) on spindle using a hammer and driver.

15. Grease and install O-ring (4) on wheel hub cover (9). Drive wheel hub cover into wheel hub.

12. Install wheel hub (3) on spindle.

16. Install hub cover plug (10) and tighten to specification.

13. Install bearing cone (6) to hub and spindle.

Specification Wheel Hub Cover Plug— Torque....................................................................... 15 N•m (11 lb-ft)

14. Apply TY9371 LOCTITE to cap screws (8).

Position thrust washer (7) on spindle in hub and install cap screws (8). Torque cap screws to specification.

17. Install wheel and repeat process for other side.

LOCTITE is a trademark of Loctite Corp.

BT40170,000002C –19–23AUG02–2/2

1. Rotate wheel so drain plug (A) is at its lowest point, remove plug and drain oil. Dispose of waste oil properly.

T7371AP

Specification MFWD Front Wheel Planetary Housing Oil—Capacity ............................................................. 1 L (1.1 qt)

–UN–02OCT90

Change MFWD Front Wheel Planetary Housing Oil—If Equipped

2. Install drain plug.

3. Rotate wheel so plug (A) is above OIL LEVEL line (B) when line is horizontal.

–UN–21NOV96

4. Add oil to bottom of fill plug hole and install plug. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

T105325

A—Plug B—Oil Level Line

TX,85,BD2169 –19–19OCT02–1/1

3-8-4

012704

PN=134

Maintenance—Every 1000 Hours

Change MFWD Front Axle Housing Oil—If Equipped

1. Remove drain plug (A) to drain oil. Dispose of waste oil properly.

T132466B

MFWD axle housing is filled with HY-GARD gear oil at the factory. Fill MFWD axle housing with HY-GARD oil to fill to proper level.

–UN–13JUL00

NOTE: Dispose of drain oil properly.

Specification MFWD Front Axle Housing Oil— Capacity .................................................................................... 6.5 L (7 qt)

T103126

3. Remove check plug (B) and add oil so it is level with bottom of check plug hole. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

–UN–05SEP96

2. Install drain plug.

4. Install check plug.

A—Drain Plug B—Check Plug

HG31779,00000E6 –19–06SEP02–1/1

Clean Engine Crankcase Ventilation Tube Remove vent tube (A) and clean interior using diesel fuel.

T105323

–UN–21NOV96

A—Vent Tube

TX,85,BD2167 –19–07OCT96–1/1

3-8-5

012704

PN=135

Maintenance—Every 1000 Hours

Change Transmission and Torque Converter Oil and Filter NOTE: Only approximately 8.0—8.5 L of oil will drain.

It is intended that the remainder of oil will remain in the cooler and torque converter.

1. Remove transmission drain plug (A) from bottom of transmission and drain oil into suitable container.

Dispose of waste properly.

–UN–13JUL00

Specification Powershift Transmission Oil— Capacity ................................................................................... 15 L (16 qt)

T132445C

2. Turn transmission oil filter (B) counterclockwise and remove.

3. Apply film of oil to sealing ring on new transmission oil filter. Install new transmission oil filter. Turn clockwise until sealing ring touches mounting surface, then tighten an additional 3/4 to one turn with a suitable filter wrench.

–UN–13JUL00

4. Install drain plug.

6. Start engine and run for 3 minutes to allow filter element to refill and purge air from charge circuit.

7. With engine running at slow idle, remove transmission dipstick. Check transmission oil level and add oil through dipstick tube as necessary. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

T132362F

5. Turn handle of transmission dipstick (C) counterclockwise and remove. Fill transmission with oil through dipstick tube. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

A—Transmission Drain Plug B—Transmission Oil Filter C—Transmission Dipstick

8. Check for leakage around filter. Tighten filter just enough to stop leaks.

9. Install transmission dipstick and turn handle clockwise to tighten.

HG31779,00001B1 –19–03DEC02–1/1

3-8-6

012704

PN=136

Maintenance—Every 1000 Hours

Change Rear Axle Oil

Specification Rear Axle Oil—Capacity.......................................................... 16 L (17 qt)

2. Remove check and fill plug (B) and fill with oil to bottom of port. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

T105316

1. Remove drain plug (A) and drain oil into a container.

Install plug.

–UN–21NOV96

NOTE: Dispose of waste oil properly.

NOTE: It will take approximately 5 minutes for oil to settle into outer housing when oil is warm.

–UN–22NOV96

3. Wait 5-10 minutes for oil to settle, then check level again and add oil as necessary. If oil is cold, settle time may increase.

T104868

4. Install plug.

A—Drain Plug B—Check and Fill Plug

CED,OUO1079,447 –19–03SEP02–1/1

Replace Pilot Control Filter NOTE: Filter element is located behind right rear axle.

–UN–06JAN03

1. Disconnect hose fitting (1) from filter element (2).

2. Remove filter element.

T163362B

3. Install new filter element.

4. Reconnect hose fitting to filter element.

1—Hose Fitting 2—Filter Element

HG31779,00001B6 –19–18DEC02–1/1

3-8-7

012704

PN=137

Maintenance—Every 1000 Hours

Check Engine Speeds A

1. Warm engine to normal operating temperature.

n/min

T135100

Adjust idle speeds if necessary. See Check and Adjust Engine Speed Control Linkage in this section.

T135100

SELECT

Specification Slow Idle—Speed .......................................................................... 850 rpm Fast Idle (Using Speed Control Pedal or Lever)—Speed ..................................................... 2375 ± 25 rpm

–UN–07NOV00

2. Use tachometer (A) to check engine speeds:

A—Tachometer

OUO1079,00002CA –19–02NOV00–1/1

Check and Adjust Engine Speed Control Linkage

Specification Forward Position (Slow Idle) Injection Pump Override— Distance ................................................................. 3—6 mm (1/8—1/4 in.)

T6030AU

2. Measure injection pump lever override. Override must be to specification.

–UN–18OCT88

1. Move speed control lever to SLOW IDLE.

3. Adjust yoke on speed control rod to provide override.

4. Move speed control lever to FAST IDLE and check override. Override must be to specification.

Specification Rear Position (Fast Idle) Injection Pump Override—Distance ............................... 1.5 mm (1/16 in.) Minimum

5. Check high idle override again.

If engine speed control pedal position requires adjustment, see your authorized dealer.

CED,OUO1079,486 –19–19JUL00–1/1

3-8-8

012704

PN=138

Maintenance—Every 1000 Hours

Change Hydraulic Reservoir Oil 1. Park machine on a level surface.

–UN–13JUL00

2. Move backhoe and stabilizers to transport position and lower loader bucket to ground. Stop engine.

3. Remove hydraulic reservoir fill cap (B).

T131716D

4. Remove cap screw (C) and bracket (D). Route drain hose (E) into a suitable container.

5. Remove cap (F) from end of drain hose and drain oil.

Allow adequate time for oil to drain. Dispose of waste oil properly.

–UN–24OCT00

Specification Hydraulic Reservoir Oil—Capacity .......................................... 37 L (39 qt)

6. Replace hydraulic oil filter. See Replace Hydraulic Oil Filter. (Section 3-7.)

T134809B

7. Install cap on drain hose.

8. Route drain hose for storage. Install bracket and cap screw.

9. Refill hydraulic reservoir. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3-1.)

B—Hydraulic Reservoir Fill Cap C—Cap Screw D—Bracket E—Drain Hose F—Cap

10. Check oil level.

11. Install hydraulic reservoir fill cap.

OUO1079,00002AB –19–03DEC02–1/1

3-8-9

012704

PN=139

Maintenance—Every 1000 Hours

Replace Engine Air Cleaner Elements Inspect elements when air filter restriction indicator lights.

2. Unfasten clips (A) and remove air cleaner cover.

IMPORTANT: Remove elements gently to avoid dislodging dust from the elements.

3. Slide primary element (B) and secondary element (C) out to remove.

T133589B

–UN–30AUG00

1. Open hood.

5. Install new secondary element and primary element.

Ensure that each element is properly centered and seated.

T133590B

6. Install air cleaner cover with dust unloader valve pointed down. Fasten clips.

–UN–30AUG00

4. Clean inside of air cleaner and outlet tube.

T133591B

–UN–30AUG00

A—Clip (3 used) B—Primary Element C—Secondary Element

CED,OUO1079,474 –19–17JUL00–1/1

3-8-10

012704

PN=140

Maintenance—Every 2000 Hours Adjust Engine Valve Lash (Clearance) See your authorized dealer.

TX03679,00017DD –19–08MAY01–1/1

3-9-1

012704

PN=141

Miscellaneous—Machine External Service Brake Inspection Do first inspection at 5000 hours followed by 1000 hour inspection intervals after the first 5000 hour inspection.

If the service brakes are subjected to severe duty, inspect more frequently.

1. Inspect brakes for wear through the external inspection ports (A).

–UN–18JUN98

2. Remove axle housing and replace brake disc if oil grooves (B) on facing material are no longer visible.

T8137AC

–UN–03DEC93

T115934

A—External Brake Inspection Port (2 used) B—Oil Grooves

CED,OUO1032,1075 –19–19JUN98–1/1

4-1-1

012704

PN=142

Miscellaneous—Machine

Inspecting And Cleaning Dusty Secondary And Primary Element

–UN–10NOV88

IMPORTANT: A damaged or dirty element may cause engine damage.

Install new elements:

–UN–09NOV88

1. Tap element with the palm of your hand, NOT ON A HARD SURFACE.

T47764

DO NOT clean a secondary element.

Install a new element carefully centering it in the canister.

T90684

• If the element shows damage and needs to be replaced.

• If element is visibly dirty and will not clean.

• After 1000 hours service or annually.

CAUTION: Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

2. If this does not remove dust, use compressed air under 210 kPa (2.1 bar) (30 psi).

NOTE: Air restriction indicator will not signal correctly if an element has a break or is not correctly sealed in air cleaner housing. Throw away element that has the slightest damage. If gasket is broken or missing, install a new element.

3. Direct air up and down the pleats from inside to outside. Be careful not to make a break in the element.

TX03679,00017E3 –19–31MAY01–1/1

4-1-2

012704

PN=143

Miscellaneous—Machine

Check Receiver-Dryer—If Equipped

–UN–04SEP02

IMPORTANT: Prevent possible compressor damage. If moisture sight glass color indicates wet (pink), dryer is saturated and should be changed within the next 100 machine hours to prevent further buildup of moisture in refrigerant.

T159106B

1. Open hood.

2. Check color in moisture sight glass (1). Color should be blue, indicating that refrigerant is dry.

3. Check air bubble sight glass (2) for air bubbles. No air bubbles, or few air bubbles, should be visible.

1—Moisture Sight Glass 2—Air Bubble Sight Glass

4. If moisture sight glass shows wet (pink), or if excessive air bubbles are visible, see your authorized dealer within the next 100 machine hours to service the receiver-dryer.

HG31779,00000DE –19–04SEP02–1/1

Checking Coolant Hoses and Radiator

–UN–14JUL00

Check upper radiator hose (A) and lower radiator hose (B) for cracks and leaks. Tighten hose clamps (C) as necessary.

T132486B

Check radiator for dirt, damage, leaks, and loose or broken mountings. Clean radiator fins.

T132487B

–UN–14JUL00

A—Upper Radiator Hose B—Lower Radiator Hose C—Hose Clamp (4 used)

CED,OUO1079,452 –19–12JUL00–1/1

4-1-3

012704

PN=144

Miscellaneous—Machine

Draining the Cooling System

Drain and flush cooling system every 3000 hours using clean water, and refill with new coolant.

TS281

Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

–UN–23AUG88

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

Specification Cooling System—Capacity ...................................................... 16 L (17 qt)

3. Turn radiator drain valve counterclockwise to open valve. Allow coolant to drain into a container.

4. Connect a hose to engine block coolant draincock (B).

T132488B

2. Connect a hose to radiator drain valve (A) on radiator.

–UN–14JUL00

1. Release pressure and remove cap.

5. Turn engine block coolant drain valve counterclockwise to open valve. Allow coolant to drain into a container.

–UN–14JUL00

6. Turn both drain valves clockwise to close valves and remove hoses.

T132489B

A—Radiator Drain Valve B—Engine Block Coolant Drain Valve

CED,OUO1079,453 –19–02JAN03–1/1

4-1-4

012704

PN=145

Miscellaneous—Machine

Filling the Cooling System

–UN–23AUG88

CAUTION: Prevent possible injury from hot spraying water. DO NOT remove radiator cap unless the engine is cool. Then turn cap slowly to the stop. Release all pressure before removing cap.

TS281

Specification Cooling System—Capacity ...................................................... 16 L (17 qt)

Remove radiator cap (A). Coolant level in radiator must be at bottom of filler neck.

–UN–20JUN02

IMPORTANT: Use only permanent-type low silicate, ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals.

FREEZING TEMPERATURES: Fill with permanent-type low silicate, ethylene glycol antifreeze (without stop-leak additive) and clean, soft water. Add TY16004 John Deere Coolant Conditioner or equivalent.

T155034B

NOTE: All machines are shipped from the factory with a 50-50 mixture for protection to —34°C (—30°F).

Adjust mixture accordingly to provide freeze protection for your machine.

A—Radiator Cap

CED,OUO1079,438 –19–23JAN03–1/1

Do Not Service Or Adjust Injection Nozzles Or Injection Pump If injection nozzles are not working correctly or are dirty, the engine will not run normally. (See your authorized dealer for service.)

Changing the injection pump in any way not approved by the manufacturer will end the warranty. (See your copy of the John Deere warranty on this machine.)

Do not service an injection pump that is not operating correctly. (See your authorized injection pump service center.)

TX,90,FF3116 –19–18JAN02–1/1

4-1-5

012704

PN=146

Miscellaneous—Machine

Replace Engine Torsional Damper The torsional damper assembly is not repairable and should be replaced every five years or 4500 hours, whichever occurs first, or whenever crankshaft is replaced. See your authorized dealer.

CED,TX03768,2668 –19–12JUL00–1/1

Draining Fuel Filter Sediment

2. Tighten knob.

3. Bleed fuel system. See Change Fuel Filter. (Section 3-7.)

T7896AI

1. Loosen knob (B) and drain fuel for several seconds from drain tube (A).

–UN–25NOV92

Drain water and sediment as necessary.

A—Drain Tube B—Knob

TX,90,BD2176 –19–07OCT96–1/1

4-1-6

012704

PN=147

Miscellaneous—Machine

Precautions for Alternator and Regulator When batteries are connected, follow these rules: 1. Disconnect negative (—) battery cable when you work on or near alternator or regulator.

2. DO NOT TRY TO POLARIZE ALTERNATOR OR REGULATOR. 3. Ensure alternator wires are correctly connected BEFORE you connect batteries.

6. Connect batteries or a booster battery in the correct polarity (positive [+] to positive [+] and negative [—] to negative [—]).

7. Do not disconnect the batteries when engine is running and alternator is charging.

8. Disconnect battery cables before you connect battery charger to the batteries.

4. Do not ground alternator output terminal.

5. Do not disconnect or connect any alternator or regulator wires while batteries are connected or while alternator is operating.

T82,EXMA,I –19–03AUG92–1/1

4-1-7

012704

PN=148

Miscellaneous—Machine

Handling, Checking And Servicing Batteries Carefully

–UN–23AUG88

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

TS204

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:

–UN–23AUG88

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.

TS203

If acid is swallowed: 1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Continued on next page

4-1-8

TX03679,0001788 –19–11MAY01–1/3 012704

PN=149

Miscellaneous—Machine If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda 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.

TX03679,0001788 –19–11MAY01–2/3

See your authorized 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 –19–11MAY01–3/3

Replacing Batteries

Volts

BCI Group

-18°C (0°F)

-29°C (-20°F)

Reserve Capacity (minutes at 25 amps)

12

31

750

600

150

TS204

Cold Cranking Amps

–UN–23AUG88

Your machine may be equipped with one or two 12-volt hybrid batteries with (—) negative ground. Use only batteries meeting following specifications:

TX,90,BG212 –19–23DEC96–1/1

4-1-9

012704

PN=150

Miscellaneous—Machine

Removing Batteries IMPORTANT: Check for worn or frayed wires and loose or corroded connections.

–UN–14JUL00

NOTE: The toolbox must be removed to access the battery box. Always empty the toolbox before lifting it.

2. Disconnect negative (—) battery cables first, then positive (+) cables.

T132012C

1. Remove cap screws (A) and lift toolbox out of battery box.

A—Cap Screw (3 used)

CED,OUO1079,454 –19–12JUL00–1/2

3. Remove nuts, washers, and hold-down brackets (A).

4. Lift batteries out of battery box.

T131990C

–UN–07NOV00

B—Hold-Down Bracket (1 or 2 used)

Optional Dual-Battery Configuration Shown

CED,OUO1079,454 –19–12JUL00–2/2

4-1-10

012704

PN=151

Miscellaneous—Machine

T131649

–19–28SEP00

Replacing Fuses

T131649

F1—7.5 Amp MFWD, Alternator, and Differential Lock Fuse F2—15 Amp Power Port and Auxiliary Power Fuse F5—5 Amp Unswitched Radio Fuse—If Equipped F6—10 Amp Dome Light and Radio Fuse—If Equipped F7—15 Amp Fuel Shutoff, Starting Aid, and Backup Alarm Fuse

F8—30 Amp Heater, Blower, and Air Conditioner Fuse—If Equipped F9—15 Amp Wiper and Washer Fuse—If Equipped F10—20 Amp Rear Work Lights Circuit Breaker F11—25 Amp Drive Lights, Work Lights, and Tail Lights Circuit Breaker F12—10 Amp FNR, Park Brake, and SG Pump Unloading Valve Fuse

F13—10 Amp Starter Motor Fuse F14—20 Amp Turn Signals, Brake Lights, Flashers, and Horn Fuse F15—15 Amp Side Docking Lights and Beacon Circuit Breaker—If Equipped F16—10 Amp Monitor Panel, STOP Indicator, and Audible Alarm Fuse

Continued on next page

4-1-11

F17—10 Amp Return-to-Dig Fuse F18—20 Amp Auxiliary Power and Air Suspension Seat Fuse K4—Backup Alarm Relay K5—Park Brake Latching Relay K6—Neutral Start Relay K8—Flasher Relay

CED,OUO1079,455 –19–13JUL00–1/2

012704

PN=152

Miscellaneous—Machine IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.

The following relay is located inside steering console, near fuse block: • K2—Accessory Relay The following relays are located inside right-side console, behind display monitor:

–UN–14JUL00

• K3—Selective Flow Control Relay • K7—Timer Relay • K10—Mode Door Relay

• • • • • •

K11-Seat Forward Position Relay K12-Seat In Position Relay K13-In Position Latch Relay K14-Out Of Position Latch Relay K15-Seat Not Rear Relay K16-Over Ride Relay

T132520B

The following relays for pilot controls are located inside side console behind display monitor:

Steering Console Top Cover Shown Removed

The following relay is located inside right rear of engine compartment: • K1—Start Relay

CED,OUO1079,455 –19–13JUL00–2/2

4-1-12

012704

PN=153

Miscellaneous—Machine

Remove and Install Halogen Bulb 1. Remove screws (A), cover (B), lamp (C), and lamp housing (E).

–UN–12MAR91

2. Disconnect wiring lead and release retainer clip to remove bulb (D).

T7484AC

IMPORTANT: Do not touch the halogen bulb with bare hands. Oil and moisture may cause premature bulb failure. Clean bulb glass if touched, using an oil-free cloth with alcohol.

A—Screw (2 used) B—Lamp Cover C—Lamp D—Bulb E—Lamp Housing

3. Install new bulb, lamp and assemble housing.

HG31779,0000155 –19–19OCT02–1/1

Checking Neutral Start System

–UN–14JUL00

CAUTION: Avoid possible injury or death. DO NOT attempt to start machine unless you are sitting in operator’s seat with FNR lever in “Neutral.” DO NOT bypass or disable any of the starting system parts.

This machine has a neutral start switch that is activated by the FNR lever (A).

T131691G

Set park brake before attempting to start engine.

A—FNR Lever

Engage the park brake.

Check the neutral start system to ensure that the machine: • WILL start with the FNR lever in “Neutral” position.

• WILL NOT start with FNR lever in any other position.

If starting system fails to operate correctly, have your authorized dealer repair the system immediately.

OUO1079,00002B2 –19–10SEP02–1/1

4-1-13

012704

PN=154

Miscellaneous—Machine

Changing Loader Buckets CAUTION: Prevent possible injury from falling hardware. Bucket cylinder and links will fall forward if bucket is in dig position when pins are removed. Remove pins only when bucket is on ground in full dump position.

1. Place bucket in dump position on floor.

2. Remove pin (A) and pivot links (B) to rear against cross tube (C).

3. Remove pin (D) and carefully lay cylinder (E) on cross tube.

–UN–17SEP96

CAUTION: Bucket is heavy and can cause injury if not moved properly. Use adequate lifting device to move bucket.

T103832

4. Remove pins (F) and bucket.

5. Position new bucket in dump position where previously removed bucket was. Install pins (F).

6. Connect bucket links and cylinder using previously removed pins (A and D) and retaining hardware.

A—Pin B—Pivot Links (2 used) C—Cross Tube D—Pin E—Cylinder F—Pins (2 used)

TX,35,BD2101 –19–07OCT96–1/1

4-1-14

012704

PN=155

Miscellaneous—Machine

Adding Front Counterweights

–UN–07NOV00

CAUTION: Counterweights are heavy and can cause serious injury if dropped. Ensure counterweights are properly supported with a forklift or other adequate lifting device before removing.

T135176B

Install front counterweights for added stability as necessary.

1. Support counterweights with a forklift before adding or removing weights. Insert forklift tines in slots (A).

A—Slot (2 used) B—Cap Screw (2 used)

2. Remove cap screws (B).

3. Remove or add counterweights as necessary.

4. Install cap screws.

TX,35,BD2105 –19–07JUL00–1/1

Adding Liquid Ballast to Front Tires—410G NOTE: See Maintenance—As Required chapter for tire pressure.

Weights given are for tires 75 percent full of liquid.

Water Only Tire Size 11L-16 12PR F3 14.5/75-16.1 10PR F3 12.5/80-18 10PR (MFWD)

Water/CaCl2 Solution *

Water Volume 57 L (15 gal) 110 L (29 gal)

Water Weight 57 kg (126 lb) 110 kg (243 lb)

Water Volume 49 L (13 gal) 95 L (25 gal)

Water Weight 21 kg (46 lb) 40 kg (88 lb)

Weight of Solution Per Tire 70 kg (155 lb) 134 kg (296 lb)

102 L (27 gal)

102 kg (225 lb)

95 L (25 gal)

28 kg (62 lb)

123 kg (269 lb)

*Approximately 1.6 kg (3.5 lb) CaCl2 per gallon of water will stay slush free to —24°C (—12°F) and will freeze solid at —47°C (—52°F).

OUO1079,00002BA –19–23OCT00–1/1

4-1-15

012704

PN=156

Miscellaneous—Machine

Welding on Machine IMPORTANT: Disconnect battery ground cables to prevent voltage spikes from damaging alternator or dash instruments.

Connect welder ground clamp close to each weld area so electrical current does not arc inside any bearings.

T131990D

–UN–07NOV00

NOTE: The toolbox must be removed to access the battery box. See Removing Batteries in this section for toolbox removal instructions.

Toolbox Shown Removed—Optional Dual-Battery Configuration Shown

CED,OUO1079,457 –19–13JUL00–1/1

4-1-16

012704

PN=157

Miscellaneous—Machine

Checking Ride Control Accumulator—If Equipped

X9811

–UN–23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard.

Protect hands and body from high pressure fluids.

CAUTION: The boom will jump upward during this check. Make sure area around bucket is clear.

–UN–11JUL00

1. Start engine.

T131504D

2. Push lower half of ride control switch (A) to deactivate ride control.

3. Raise boom to maximum height and hold loader control lever over relief for 2 seconds.

4. Lower boom and bucket to ground and stop engine.

Move loader control lever to “Neutral”.

A—Ride Control Switch

5. Turn key switch to “On”, but do not restart engine.

6. Push upper half of ride control switch to activate ride control. The boom should move up approximately 100 mm (4 in.).

7. If the boom does not move up, the accumulator has lost gas charge, see your authorized dealer for servicing the accumulator.

Before servicing or performing maintenance on the machine, discharge hydraulic oil pressure from the ride control system.

HG31779,00000F5 –19–10SEP02–1/1

4-1-17

012704

PN=158

Miscellaneous—Machine

Discharge Ride Control System Hydraulic Pressure—If Equipped

T131504D

–UN–11JUL00

CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. Turn key switch to “On”. Push upper half of ride control switch to activate ride control and move loader control lever to “Float” position.

Do not have ride control activated when starting the machine; the machine may move if ride control is activated when the machine is started.

A—Ride Control Switch

Do not have ride control activated when operating the loader; the ride control system may cause unexpected movement.

The ride control system has an accumulator and valve in the loader circuit.

Before servicing or performing maintenance on the machine, discharge hydraulic oil pressure from the ride control system as follows: 1. Ensure that area around bucket is clear.

2. Push lower half of ride control switch (A) to deactivate ride control.

3. Start the engine.

4. Position front loader boom so that the bucket is approximately 30 cm (1 ft) off the ground.

5. Stop the engine.

6. Turn key switch to “On” without restarting engine. Push upper half of ride control switch to activate ride control.

7. Move loader control lever to “Float” position. Bucket should lower to ground.

Continued on next page

4-1-18

HG31779,00000F6 –19–10SEP02–1/2 012704

PN=159

Miscellaneous—Machine 8. If ride control accumulator has lost gas charge, see Checking Ride Control Accumulator—If Equipped in this section.

HG31779,00000F6 –19–10SEP02–2/2

Discharge Pilot Control System Hydraulic Pressure—If Equipped

–UN–02JAN03

CAUTION: Prevent injury from unexpected machine movement. Turn engine off. Keep bystanders clear of machine.

T163349B

Before servicing or performing maintenance on the machine, discharge hydraulic oil pressure from the pilot control system as follows: 1. Ensure that area around bucket is clear.

1—Pilot Control Enable/Disable Switch 2—Pilot Controls

2. Turn off engine.

3. Turn key switch to “On” position.

4. Rotate seat to backhoe operation position.

5. Pull pilot control towers back to operating position.

6. Push pilot control enable/disable switch (1) to “Unlock” position to enable pilot controls.

7. Actuate pilot controls (2) in a circular pattern for five to ten rotations.

HG31779,00001BD –19–02JAN03–1/1

4-1-19

012704

PN=160

Miscellaneous—Machine

Lowering Boom Without Electrical Power— For Machines With Pilot Controls 1. Remove rear half of floor mat.

–UN–15JAN03

2. Remove cap screws (1) and plastic cover (2).

T163972B

3. Remove cap screws (3) and rear cab access floor plate (4).

1—Cap Screw (4 used) 2—Plastic Cover 3—Cap Screw (4 used) 4—Rear Cab Access Floor Plate

BT40170,0000043 –19–24JAN03–1/2

4. Disconnect hose (5) from bulkhead fitting (6).

5. Connect remote pressure source to bulkhead fitting (6).

Pressure source must be within specification.

T164626B

–UN–27JAN03

Specification Remote Pressure Source— Pressure ....................................................................... 1379—24 821 kPa 14—248 bar 200—3600 psi

6. Lower boom using pilot controls.

7. Disconnect remote pressure source.

5—Hose 6—Pilot Pressure Bulkhead Fitting

8. Connect hose (5) to bulkhead fitting (6).

9. Install rear access floor plate (4).

10. Install plastic cover (2) and floor mat.

BT40170,0000043 –19–24JAN03–2/2

4-1-20

012704

PN=161

Miscellaneous—Machine

Check Park Brake

–UN–15JUN00

CAUTION: Prevent possible injury from unexpected machine movement. Fasten seat belt before performing this check.

1. Fasten seat belt.

T131504F

2. Start machine on dry, hard pavement.

3. Raise loader and backhoe buckets off ground.

4. Push right half of park brake switch (A) to disengage the park brake.

A—Park Brake Switch

5. Disengage MFWD, if equipped.

6. Move the FNR lever to F. Move the range selector to 2nd gear.

7. Depress the speed control pedal to the floor and drive approximately 7 m (20 ft), then push left half of park brake switch to engage the park brake. The machine must stop within 2 m (6 ft) and transmission must shift to “Neutral”.

OUO1079,00002B3 –19–23OCT00–1/1

4-1-21

012704

PN=162

Miscellaneous—Machine

Bleeding Service Brakes

–UN–26OCT88

CAUTION: Do not operate machine if pedal travel exceeds specification while applying 267 N (60 lb-force). Operating machine with excessive brake travel could cause brakes not to stop machine on first application.

T6838AE

NOTE: Air will "gravity bleed" from brake system through brake valve without use of bleed screws. Brake lines must be inclined toward brake valve.

Low ambient temperature or aeration of oil will slow bleed process.

Bleeding Brakes Manually 1. Engage park brake. Run engine at fast idle. Dump and curl backhoe bucket five times.

2. Run engine at slow idle. Pump left-side brake pedal five times, allowing two seconds between each pump for air to escape.

3. Repeat steps 1 and 2 until the left-side brake pedal is solid.

4. Pump right-side brake pedal until pedal is solid, then pump both brake pedals together until both brake pedals are solid.

5. Check pedal travel.

Specification Dual Brake Pedal Travel— Distance ........................................................... 95 mm (3.75 in.) Maximum Single Brake Pedal Travel— Distance ........................................................... 114 mm (4.5 in.) Maximum

Bleeding Brakes with Vacuum Device 1. Engage park brake. Connect a vacuum to breather port on hydraulic reservoir. After 10 minutes, disconnect air pressure.

2. Leave hose from breather port to vacuum device connected until brake circuit is filled with oil. Both pedals should become solid.

Continued on next page

4-1-22

CED,OUO1079,579 –19–28AUG00–1/2 012704

PN=163

Miscellaneous—Machine 3. Check pedal travel.

Specification Dual Brake Pedal Travel— Distance ........................................................... 95 mm (3.75 in.) Maximum Single Brake Pedal Travel— Distance ........................................................... 114 mm (4.5 in.) Maximum

Brakes will continue to self-bleed as you operate machine and pedal firmness should improve. If unable to obtain firm brake pedal, inspect lines and connections for leakage. See your authorized dealer.

CED,OUO1079,579 –19–28AUG00–2/2

4-1-23

012704

PN=164

Miscellaneous—Machine

Service Recommendations For STC1 Fittings STC fittings are used on this machine. The fittings are designed to allow the hydraulic hose to rotate as needed when the system is not pressurized. This prevents the hydraulic hoses from binding when components are put back to their operating position.

T133974B

–UN–25SEP00

Fittings are easily disconnected using special tool, JDG1385 (1) (supplied with machine). The special tool has a different size slot cut into each end. The narrow slot is for -06 size fittings. The wide slot is for -08 size fittings.

Use appropriate end of special tool on fitting being disconnected. To connect fittings, simply push each half of fitting together.

JDG1385 Tool Storage Location—Earlier Machines

IMPORTANT: DO NOT pry against release sleeve or damage to fitting may result.

T161381C

–UN–14APR03

DO NOT force release sleeve beyond normal range of travel, otherwise, release sleeve may fall off when hose is disconnected. If this happens and fitting is connected without the release sleeve installed, fitting will not be able to be disconnected again.

1. Disconnect STC type fittings: JDG1385 Tool Storage Location In Toolbox—Later Machines

a. Clean area around fitting, especially around the release sleeve (3).

–UN–24OCT00

b. While keeping special tool JDG1385 perpendicular to the fitting, insert tool between release sleeve and shoulder. c. Gently push, DO NOT PRY, release sleeve away from shoulder to disconnect the fitting.

T134792C

d. Pull hose to disconnect.

1—Special Tool JDG1385 2—Shoulder Of Fitting 3—Release Sleeve

1

STC is a registered trademark of the Aeroquip Corporation.

Continued on next page

4-1-24

OUO1010,0000457 –19–28JAN03–1/2 012704

PN=165

Miscellaneous—Machine 2. Inspect STC fittings: a. Check seal mating surfaces for nicks, scratches, or flat spots.

–UN–21SEP00

b. Check O-ring (4), backup ring (5), and retaining ring (2) for wear or damage.

3. Connect STC fittings: a. Make sure fitting halves (3 and 6) are clean and free of contaminates. b. Make sure release sleeve (1) is on male half (6) of fitting before connecting fitting halves together.

T133922

c. Make sure O-ring, backup ring, and retaining ring are in position before connecting fitting halves together.

1—Release Sleeve 2—Retaining Ring 3—Female Half of STC Fitting 4—O-Ring 5—Backup Ring 6—Male Half of STC Fitting

c. Push fitting halves together until a definite snap and solid stop is felt. d. Pull back on hose to make sure fitting halves are locked together. e. To prevent hoses from binding, move component into position before pressurizing hydraulic system.

OUO1010,0000457 –19–28JAN03–2/2

4-1-25

012704

PN=166

Miscellaneous—Machine

2. Measure force required to move engine speed control lever (C). Put spring scale (D) on engine speed control lever just below knob.

Specification Speed Control Lever—Force...................................... 40—49 N (9—11 lb)

T131729C

1. Remove rear floor mat. Remove left and right stabilizer lever knobs (A and B). Remove screws. Remove lever console cover.

–UN–25OCT00

Adjusting Speed Control Lever Tension (S.N.—913479)

4. Repeat steps 2 and 3 if necessary until lever tension is at specification.

T134817B

5. Install lever console cover. Install screws. Install left and right stabilizer lever knobs. Install rear floor mat.

–UN–25OCT00

3. Tighten or loosen adjustment cap screw (E). Measure force again.

A—Left Stabilizer Lever Knob B—Right Stabilizer Lever Knob C—Engine Speed Control Lever D—Spring Scale E—Adjustment Cap Screw

OUO1079,000028D –19–28SEP00–1/1

4-1-26

012704

PN=167

Miscellaneous—Machine

2. Measure force required to move engine speed control lever (C). Put spring scale (D) on engine speed control lever just below knob.

Specification Speed Control Lever—Force.................................... 40—49 N (12—16 lb)

T131729C

1. Remove rear floor mat. Remove left and right stabilizer lever knobs (A and B). Remove screws. Remove lever console cover.

–UN–25OCT00

Adjusting Speed Control Lever Tension (S.N. 913480—)

4. Repeat steps 2 and 3 if necessary until lever tension is at specification.

T134817B

5. Install lever console cover. Install screws. Install left and right stabilizer lever knobs. Install rear floor mat.

–UN–25OCT00

3. Tighten or loosen adjustment cap screw (E). Measure force again.

A—Left Stabilizer Lever Knob B—Right Stabilizer Lever Knob C—Engine Speed Control Lever D—Spring Scale E—Adjustment Cap Screw

HG31779,00001D3 –19–23JAN03–1/1

Adjusting Pilot Control Wrist Rest —If Equipped

2. Adjust wrist rest (2) up or down to desired position.

T163361B

3. Turn lever clockwise to tighten.

–UN–02JAN03

1. Turn lever (1) counterclockwise to loosen.

HG31779,00001BE –19–02JAN03–1/1

4-1-27

012704

PN=168

Miscellaneous—Machine

T6157AF

T6159AC

–UN–18OCT88

–UN–18OCT88

Checking and Adjusting Toe-In (S.N. —911143)

1. Measure distance from ground to center of hub (A) and make a mark on front (B) and rear (C) of each front tire in center of tread.

–UN–02NOV88

2. Measure distance between front marks (B).

3. Measure distance between rear marks (C).

T6162AT

4. The distance between front marks must be less than distance between rear marks by the following amount.

Specification Toe-In Measurement—Standard Axle Distance between (B) and (C) ......................................................................... 6 ± 3 mm (1/4 ± 1/8 in.)

MFWD Axle Distance between (B) and (C)............................................................ 3 ± 3 mm (1/8 ± 1/8 in.)

Non-MFWD

Machines Without Mechanical Front Wheel Drive: –UN–03SEP96

1. To adjust toe-in, loosen both tie rod clamps (E) and turn tie rod tube (D).

T103499

2. Turn clamps so that cap screws are toward rear of machine and tipped down approximately 45°.

3. Tighten clamp cap screws to specification.

MFWD

Specification Toe-In Tie Rod Clamp Cap Screws—Torque .............................................. 95 ± 14 N•m (70 ± 10 lb-ft)

A—Center of Hub B—Front of Tire C—Rear of Tire D—Tie Rod Tube E—Tie Rod Clamp F—Nuts G—Rod End

Machines With Mechanical Front Wheel Drive: 1. To adjust toe-in, loosen nuts (F).

Continued on next page

4-1-28

TX,90,BD2189 –19–19NOV99–1/2 012704

PN=169

Miscellaneous—Machine 2. Turn rod end (G) to get proper toe-in.

3. Adjust toe-in equally on both tie rods.

4. Tighten nuts to specification.

Specification Toe-In Tie Rod Nuts—Torque ......................................... 50 N•m (35 lb-ft)

TX,90,BD2189 –19–19NOV99–2/2

Checking and Adjusting Toe-In (S.N. 911144—)

–UN–02NOV88

1. Measure distance from ground to hub center (A). At this height, mark front (B) and rear (C) in center of tread of each front tire.

T6382JW

2. Measure distance between front marks (B) and rear marks (C).

3. Front marks must be 3—6 mm (1/8—1/4 in.) closer than rear marks.

To adjust toe-in, loosen both locking nuts (E) and turn threaded rod (F) in or out depending upon needed adjustment.

–UN–09SEP02

Tighten locking nut (E) to specification.

T159214B

Specification Non-Powered Axle Locking Nut— Torque ......................................................................... 250 N•m (185 lb-ft) Powered Axle Locking Nut— Torque ......................................................................... 300 N•m (220 lb-ft)

A—Center of Hub B—Front of Tire C—Rear of Tire D—Tie Rod Tube E—Adjustment/Locking Nut F—Threaded Rod

BT40170,0000041 –19–30AUG02–1/1

4-1-29

012704

PN=170

Miscellaneous—Machine

Installing Teeth on Backhoe Bucket

If shank is badly worn, install new shank.

Install special teeth for digging in rock or frost.

T7646AP

NOTE: If "back" is stamped on the pin, this word must face the shank.

–UN–16DEC91

1. Position flex pin (C) with grooves (D) toward the tooth tip. The grooves are the locking mechanism.

2. To remove tooth tip (A), drive out flex pin (C).

3. To fasten tooth tip to shank (B), drive flex pin (C) in place.

T7646AN

–UN–16DEC91

T7646AO

–UN–16DEC91

A—Tooth Tip B—Tooth Shank C—Flex Pin D—Grooves

TX,90,BD2190 –19–07OCT96–1/1

4-1-30

012704

PN=171

Miscellaneous—Machine

Checking Machine Cycle Times—410G Operate each hydraulic control lever until all air is out of the hydraulic system and oil is warm. Check for freedom of movement of all controls and correct direction of travel before you check cycle times.

Use the times below as a guide. If cycle times vary greatly from those listed, troubleshoot the hydraulic system.

INDIVIDUAL CIRCUIT CYCLE TIME SPECIFICATIONS Oil temperature: 65 ± 5°C (150 ± 10°F) Engine speed: Fast idle Function

Operating Conditions

Maximum Cycle Time in Seconds

Loader boom raise

Bucket flat on ground to full height (includes bucket self-leveling)

4.9

Loader boom lower

2.8

Loader bucket dump

Bucket just clears ground

2.3

Loader bucket rollback

Bucket just clears ground

2.3

Backhoe boom raise

Backhoe at maximum reach with bucket teeth on ground up to cylinder cushion

2.7

Backhoe boom lower

Backhoe at maximum reach. Transport position to bucket teeth on ground

2.9

Crowd in

Boom in transport position

3.6

Crowd out

3.4

Backhoe bucket dump

2.1

Backhoe bucket curl

3.0

Backhoe swing

Boom raised to cushion, bucket curled, dipperstick parallel to ground. Time cycle to cylinder cushion

4.1

Right stabilizer down

Full up to ground level

2.8

Left stabilizer down

Full up to ground level

1.9

Stabilizer up left and right

Ground level to full up

2.4

Extendible dipperstick extend and retract

3.2

TURNS Steering right to left

Turns

2.3 to 3

Steering left to right

Turns

2.3 to 3

Steering right to left (MFWD)

Turns

2.3 to 3

Steering left to right (MFWD)

Turns

2.3 to 3

OUO1079,00002D2 –19–06NOV00–1/1

4-1-31

012704

PN=172

Miscellaneous—Machine

Do Not Service Control Valves, Cylinders, Pumps or Motors Special tools and information are needed to service control valves, cylinders, pumps, or motors.

If these parts need service, see your authorized dealer.

T82,EXMA,BJ –19–08JUN94–1/1

Hardware Torque Specifications Check cap screws and nuts to be sure they are tight. If hardware is loose, tighten to torque shown on the following charts unless a special torque is specified.

TX,90,FF1225 –19–15MAR93–1/1

The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered. A damaged ROPS should be replaced, not reused.

TS176

CAUTION: Make certain all parts are reinstalled correctly if the rollover protective structure (ROPS) is loosened or removed for any reason.

Tighten mounting bolts to proper torque.

–UN–23AUG88

Keep ROPS Installed Properly

When installation of equipment on a machine necessitates loosening or removing ROPS, mounting bolts must be tightened to specification.

Specification ROPS Mounting Bolts—Torque .................. 420 ± 84 N•m (310 ± 62 lb-ft)

TX,90,BD2192 –19–06MAY98–1/1

4-1-32

012704

PN=173

Miscellaneous—Machine

TORQ2

–UN–07SEP99

Metric Bolt and Cap Screw Torque Values

Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings Class 4.8 Size

a

Lubricated N•m (lb-ft)

Class 8.8 or 9.8 b

Dry N•m (lb-ft)

a

Class 10.9

b

Lubricated N•m (lb-ft)

Dry N•m (lb-ft)

a

Class 12.9 b

Lubricated N•m (lb-ft)

Dry N•m (lb-ft)

Lubricateda N•m (lb-ft)

Dryb N•m (lb-ft)

M6

4.7 (3.5)

6 (4.4)

9 (6.6)

11.5 (8.5)

13 (9.5)

16.5 (12.2)

15.5 (11.5)

19.5 (14.5)

M8

11.5 (8.5)

14.5 (10.7)

22 (16)

28 (20.5)

32 (23.5)

40 (29.5)

37 (27.5)

47 (35)

M10

23 (17)

29 (21)

43 (32)

55 (40)

63 (46)

80 (59)

75 (55)

95 (70)

M12

40 (29.5)

50 (37)

75 (55)

95 (70)

110 (80)

140 (105)

130 (95)

165 (120)

M14

63 (46)

80 (59)

120 (88)

150 (110)

175 (130)

220 (165)

205 (150)

260 (190)

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)

a

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

b

"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

Fasteners should be replaced with the same or higher property class.

If higher property class fasteners are used, these should only be tightened to the strength of the original.

DX,TORQ2 –19–01OCT99–1/1

4-1-33

012704

PN=174

Miscellaneous—Machine

TORQ1A

–UN–27SEP99

Unified Inch Bolt and Cap Screw Torque Values

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings Grade 1 (No Mark) Size

b

c

Grade 2a (No Mark) b

c

Dry N•m (lb-ft)

Grade 5, 5.1 or 5.2 b

Grade 8 or 8.2

Dry N•m (lb-ft)

Lubricatedb N•m (lb-ft)

Dryc N•m (lb-ft)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

Lubricated N•m (lb-ft)

c

Lubricated N•m (lb-ft)

Dry N•m (lb-ft)

Lubricated N•m (lb-ft)

1/4

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

3/8

13.5 (10)

17.5 (13)

22 (16)

27.5 (20)

35 (26)

44 (32.5)

49 (36)

63 (46)

7/16

22 (16)

28 (20.5)

35 (26)

44 (32.5)

56 (41)

70 (52)

80 (59)

100 (74)

1/2

34 (25)

42 (31)

53 (39)

67 (49)

85 (63)

110 (80)

120 (88)

155 (115)

9/16

48 (35.5)

60 (45)

76 (56)

95 (70)

125 (92)

155 (115)

175 (130)

220 (165)

5/8

67 (49)

85 (63)

105 (77)

135 (100)

170 (125)

215 (160)

240 (175)

305 (225)

3/4

120 (88)

150 (110)

190 (140)

240 (175)

300 (220)

380 (280)

425 (315)

540 (400)

7/8

190 (140)

240 (175)

190 (140)

240 (175)

490 (360)

615 (455)

690 (510)

870 (640)

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)

a

Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length. b

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

c

"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

DX,TORQ1 –19–01OCT99–1/1

4-1-34

012704

PN=175

Miscellaneous—Operational Checkout Operational Checkout Procedure 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 doing both a walk around inspection and performing specific checks from the operator’s seat.

Should you experience a problem with your machine, you will find helpful diagnostic information in this checkout that will pinpoint the cause. Use the table of contents to help find adjustment procedures. This information may allow you to perform simple repairs yourself, reducing machine down time.

The information obtained after completing the operational checkout will allow you or your authorized dealer to pinpoint a specific test or repair needed to restore the machine to specifications.

A location will be required which is level and has adequate space to complete the checks. No tools or equipment are needed to perform this checkout.

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.

Locate the check to be performed at the top of the left column and read completely down the column before performing the 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 to either a group in this manual or to your authorized dealer for repair.

HG31779,0000147 –19–03OCT02–1/1

Gauge and Indicator Check With Engine Off

– – –1/1

Check for Stored Diagnostic Trouble Codes (DTCs)

NOTE: A Diagnostic Trouble Code (DTC) is the same as a Service Code. The term DTC conforms with the standards set by the Society of Automotive Engineers (SAE).

IF OK: If no DTCs exist, proceed to the next check.

Turn key switch to ON position and hold. Check for any active or stored DTCs. IMPORTANT: If any DTCs appear during operational checkout procedure STOP and see your authorized dealer before proceeding.

NO: If DTCs exist, see your authorized dealer.

– – –1/1

4-2-1

012704

PN=176

Miscellaneous—Operational Checkout Monitor Indicator Lights and Alarm Checks

Turn key switch to ON position and hold.

YES: Go to next check.

LOOK: Are all monitor indicator lights on? Is STOP light ON and does alarm sound?

NO: Check monitor/gauge fuse. If motor starts and bulb check position is OK, key switch is failed or there is a short in wiring.

See your authorized dealer.

NOTE: Starting motor MUST NOT operate.

– – –1/1

FNR, Neutral Start Circuit and Reverse Warning Alarm Checks

– – –1/1

FNR Switch Check

Engine off.

YES: Go to next check.

Move FNR lever to forward (F), reverse (R), then neutral (N) position.

NO: If no "click", inspect neutral start relay. See your authorized dealer.

FEEL: Observe and feel forward, neutral and reverse detents.

T7447AH –UN–04JAN91

Turn key switch to ON position. Move FNR lever into forward and reverse.

LISTEN: Did you hear a "click" from the front console neutral start relay when the key switch was turned ON? – – –1/1

Neutral Start Check

Move FNR lever to forward (F) position and turn key switch to start position.

YES: Go to next check.

Move FNR lever to reverse (R) position and turn key switch to start position.

NO: See your authorized dealer.

LISTEN: Did starting motor operate?

– – –1/1

Start Circuit Check

Move FNR lever to neutral (N) position and turn key switch to START position.

Observe and listen to monitor as engine is cranking.

LISTEN: Did starting motor operate?

LISTEN: Did alarm sound?

T7447AH –UN–04JAN91

YES: Go to next check.

NO: If engine turns but does not start, check fuel shut-off/start aid/reverse alarm fuse. If starting motor does not operate check start fuse. See your authorized dealer.

LOOK: During engine cranking, were all indicator lights ON? Is STOP indicator ON?

– – –1/1

4-2-2

012704

PN=177

Miscellaneous—Operational Checkout Reverse Warning Alarm Check

Key switch ON.

YES: Go to next check.

Move FNR lever to reverse (R) position.

NO: See your authorized dealer.

LISTEN: Does reverse warning alarm sound?

T7447AI –UN–04JAN91

– – –1/1

Park Brake, Indicator Light, and Engine Speed Control Linkage Checks

– – –1/1

Park Brake Indicator Check

IMPORTANT: If engine oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY, check oil level.

Engage park brake.

Put FNR lever in neutral (N) and start the engine.

T7447AG –UN–04JAN91

Put FNR lever in forward (F) position.

LOOK: Is STOP indicator ON? Does alarm sound? Are all other indicator lights out?

YES: Go to next check.

NO: If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY and check oil level. If alternator indicator light is ON, increase engine speed to 1200 rpm and alternator light MUST go out.

Release park brake.

LOOK/LISTEN: Is park brake indicator and STOP light out? Alarm will not sound.

– – –1/1

Engine Speed Control Pedal Linkage Check

Depress speed control pedal

LISTEN: Does engine speed stay the same as with speed control lever in fast idle position?

YES: Yes: Go to next check.

NO: Adjust speed control linkage. See your authorized dealer.

T7394BF –UN–06JAN92

– – –1/1

4-2-3

012704

PN=178

Miscellaneous—Operational Checkout Brake System Checks

– – –1/1

Pedal Stop Check

Lift left and right brake pedals individually.

YES: Go to next check.

LOOK: Is there a minimal amount of travel before cap screws contact stop?

NO: See your authorized dealer.

NOTE: Gap between pedal stop screws and plate should be 0.127—0.381 mm (0.005—0.015 in.).

T134625 –UN–19OCT00

This travel ensures that brake check valves are opened and brakes are released.

– – –1/1

Brake System Leakage Check

Depress and hold left brake pedal, then right brake pedal using approximately 267 N (60 lb. force).

LOOK: Brake pedal must NOT feel spongy (caused by air in system). Does pedal settle more than 25 mm (1.0 in.) per minute?

T134626 –UN–19OCT00

NO: Go to next check.

YES: Bleed brake system.

Specification Brake System—Maximum Leakage ............................................. 25 mm (1.0 in.) per minute with approximately 267 N (60 lb. force) applied – – –1/1

4-2-4

012704

PN=179

Miscellaneous—Operational Checkout Park Brake Function Check

Start machine, move throttle to 1200 rpm.

Leave park brake ON. Put FNR lever in forward position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds in each gear.

YES: If the machine moves in any gear, see your authorized dealer.

YES: If the indicators do not work, see your authorized dealer.

NO: Go to next check.

Move FNR lever to reverse position.

Shift transmission starting with 1st. gear through 4th. gear, pausing for 5 seconds in each gear.

Move FNR lever back to neutral position.

Move throttle back to slow idle and shut the machine off.

LOOK: The machine MUST NOT move in any gear.

LOOK: Park Brake indicators MUST be lit.

LOOK: Stop light MUST be flashing.

LISTEN: An audible beeping alarm MUST be heard.

LISTEN: With the FNR In the reverse position, the reverse audible alarm MUST be heard.

– – –1/1

Steering System Checks

– – –1/1

Steering Check

Raise loader bucket above ground level.

YES: Go to next check.

Raise rear of machine off ground using stabilizers.

NO: See your authorized dealer.

Operate engine at approximately 1000 rpm.

Specification Steering Check—Approximate Engine Speed ................................................................................................................. 1000 rpm Turn steering wheel from full left to full right several times.

LOOK: Did front wheels move smoothly in both directions?

LOOK: When steering wheel was stopped, did front wheels stop moving?

NOTE: Internal leakage or a sticking steering valve spool can cause wheels to continue to move after steering wheel is stopped.

– – –1/1

4-2-5

012704

PN=180

Miscellaneous—Operational Checkout Hydraulic System Checks

– – –1/1

Stabilizer Cylinder and Valve Check

Operate machine at approximately 1500 rpm.

YES: Go to next check.

Specification Stabilizer Cylinder and Valve Check— Approximate Engine Speed ............................................................................... 1500 rpm

NO: Cylinders drift up or down. Inspect lock outs.

See your authorized dealer.

Position loader bucket above ground.

Lower each stabilizer cylinder and raise rear of machine off ground.

LOOK/FEEL: Do cylinders extend smoothly and hold machine up?

Retract each stabilizer cylinder.

LOOK/FEEL: Do cylinders retract smoothly and remain up?

– – –1/1

4-2-6

012704

PN=181

Miscellaneous—Operational Checkout NOTE: Feel backhoe cylinders. Cylinder must be warm to touch (38—52°C [100—125°F]). If cylinders are not warm, heat oil to specifications.

Backhoe and Loader Function Drift Check

With backhoe fully extended, put backhoe bucket at a 45° angle to ground.

T7374CI –UN–04OCT90

NO: Go to next check.

YES: Verify which function is drifting. See your authorized dealer.

Specification Hydraulic Oil— Temperature................................ 38—52°C (100—125°F) (Cylinders warm to touch) Lower boom until bucket cutting edge is 50 mm (2.0 in.) off the ground.

Position loader bucket same distance off ground as backhoe bucket.

Run engine at slow idle and observe bucket cutting edge.

Specification Backhoe and Loader Function Drift Check— Engine Speed ..................................................... Slow idle

LOOK: Do cutting edges touch ground within one minute?

Specification Backhoe and Loader Function—Maximum Drift ............. 50 mm (2.0 in.) in one minute

– – –1/1

Hydraulic Control Valve Lift Check Test

NOTE: Husco valves have one lift check for both work ports, and therefore only need to be checked in one direction.

Raise loader bucket 1 m (3.0 ft.) off the ground with the bucket level.

NO: Go to next check.

YES: Inspect control valve lift check. See your authorized dealer.

Position backhoe at maximum reach with bucket in dump position, 1 m (3.0 ft.) off the ground.

Stop the engine.

Activate each function one at a time.

• • • • •

Loader boom raise Loader bucket rollback Backhoe boom up Dipperstick extend Backhoe bucket dump

LOOK: Do functions move when the control lever is activated?

– – –1/1

4-2-7

012704

PN=182

Miscellaneous—Operational Checkout Loader Boom Float Check

Put loader bucket at maximum height position with bucket dumped.

YES: Go to next check.

Run engine at approximately 1500 rpm.

NO: If it jumps out of detent, check detent spring and detent balls.

See your authorized dealer.

Specification Loader Boom Float Check—Approximate Engine Speed ..................................................................................................... 1500 rpm Move the loader control lever forward into boom float detent position, and at the same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Does loader control lever remain in the boom float detent position?

– – –1/1

Loader Return-to-Dig Check

YES: Go to next check.

NO: Inspect return-to-dig switch and activation cam. See your authorized dealer.

T7374CH –UN–04OCT90

T164529B –UN–24JAN03

Early Machines

Later Machines

Run engine at approximately 1500 rpm.

Position loader and bucket 2 m (6.0 ft) above ground level with bucket in full dump position.

Move the loader control lever into bucket rollback detent position. Remove hand from control lever.

LOOK: Does loader control lever disengage from bucket rollback detent when bucket indicator pointer is aligned with mark (1) on boom pivot?

LOOK: When bucket is at ground level, bucket must be level and bucket indicator pointer must be aligned with mark (1) on the boom pivot.

Ride Control System Check

– – –1/1

Run engine at high idle.

YES: Go to next check.

Push ride control switch to on position.

NO: See your authorized dealer.

Raise boom to maximum height.

Power boom down half-way to ground.

Stop suddenly by releasing loader control lever.

LOOK: Is boom cushioned when loader control valve is released?

– – –1/1

Pilot Control Operation Checks—If Equipped

– – –1/1

4-2-8

012704

PN=183

Miscellaneous—Operational Checkout Pilot Control Tower Operating/Stored Position Check

Move pilot control towers into operating position.

YES: Go to next check.

Release towers.

NO: Inspect pilot control towers. See your authorized dealer.

LOOK/FEEL: Do towers stay in operating position?

Move pilot control towers into stored position.

LOOK/FEEL: Do towers stay in stored position?

– – –1/1

Pilot Control Enable/Disable Switch Check

Run engine at 1500 rpm.

NO: Continue with check.

Raise machine off ground with stabilizers and loader bucket.

YES: See your authorized dealer.

Disable pilot controls and move control levers.

LOOK: Do activated functions move?

Enable pilot controls and move control levers.

YES: Go to next check.

LOOK: Do activated functions move?

NO: See your authorized dealer.

– – –1/1

Pilot Control Pattern Select Switch Check

Enable pilot controls.

YES: Continue with check.

Select backhoe from the two position pattern select switch.

Activate left and right pilot control levers forward and backward.

NO: See your authorized dealer.

LOOK: Does backhoe boom move when left pilot control lever is activated?

Does backhoe crowd move when right pilot control lever is activated?

Select excavator from the two position pattern select switch.

YES: Go to next check.

Activate left and right pilot control levers forward and backward.

NO: See your authorized dealer.

LOOK: Does backhoe crowd move when left pilot control lever is activated?

Does backhoe boom move when right pilot control lever is activated?

– – –1/1

4-2-9

012704

PN=184

Miscellaneous—Operational Checkout Pilot Control Valve Check

Enable pilot controls.

YES: Go to next check.

Move pilot control levers in all directions.

NO: If pilot control levers bind during travel or do not return to neutral position, inspect controls and towers. See your authorized dealer.

FEEL/LOOK: Do levers move freely in all directions?

FEEL/LOOK: Do levers spring back to neutral when released?

– – –1/1

Pilot Control Accumulator Check

Run engine at 1500 rpm.

YES: Go to next check.

Operators seat in backhoe position.

NO: See your authorized dealer.

Enable pilot controls.

Disengage boom from boom lock.

Hold boom up function over relief for ten seconds.

Turn engine off, and turn key switch to on.

NOTE: Pilot control enable switch must be cycled after key switch is turned back into on position.

Cycle pilot enable switch to enable position.

Activate boom down function.

LOOK: Does boom lower when boom down function is activated?

– – –1/1

Check Operation Of Accessories (Engine Stopped)

– – –1/1

Front Light Switch Check

Turn key switch to ON position.

YES: Go to next check.

Push front light rocker switch to middle position.

NO: Check fuse and bulbs. Check wiring. See your authorized dealer.

LOOK: Are two front lights, two red tail lights and gauge lights ON? Push front light rocker switch in completely.

LOOK: Are four front lights (if equipped), two red tail lights and gauge lights ON?

– – –1/1

4-2-10

012704

PN=185

Miscellaneous—Operational Checkout Rear Light Switch Check

Turn key switch to ON position.

YES: Go to next check.

Push side console rear light rocker switch in.

NO: Check fuse and bulbs. Check wiring. See your authorized dealer.

LOOK: Are rear lights ON?

– – –1/1

Turn Signal Check

Turn key switch to ON position.

YES: Go to next check.

Push right side of turn signal rocker switch down.

NO: Check fuses and wiring. See your authorized dealer.

LOOK: Are right front and rear amber lights flashing? Does right indicator light on top of steering column flash?

Push left side of turn signal rocker switch down.

LOOK: Are left front and rear amber lights flashing? Does left indicator light on top of steering column flash?

– – –1/1

Brake Light Switch Check

Key switch in the ON position.

YES: Go to next check.

Depress and hold left brake pedal, then right brake pedal.

NO: Check fuse and bulbs. Check wiring. See your authorized dealer.

LOOK: Rear brake light must come ON when either pedal is depressed with key switch in ON position.

– – –1/1

Cab Component Checks

– – –1/1

Warning Light Check

Key switch ON.

YES: Go to next check.

Push bottom of warning light rocker switch in.

NO: Check fuses and wiring. See your authorized dealer.

LOOK: Are both front and rear amber lights ON? Are both turn signal indicators and light in warning light rocker switch flashing?

– – –1/1

Horn Check

Turn key switch to ON position.

YES: Go to next check.

Push horn button

NO: Check fuses and wiring. See your authorized dealer.

LISTEN: Did horn sound?

– – –1/1

4-2-11

012704

PN=186

Miscellaneous—Operational Checkout Air Conditioner

Engine at fast idle.

YES: Check complete.

Turn air conditioner switch to ON position.

NO: Go to your authorized dealer

Turn blower switch to high speed.

Wait for any warm air in duct system to dissipate.

Is air from ducts cool?

See Defroster, Heater, and Air Conditioner Controls—If Equipped. (See Section 2-1 for more detailed information.)

– – –1/1

Miscellaneous Checks

– – –1/1

Seat Control Check

Lift lever (1).

YES: Go to next check.

Move seat forward and rearward and release lever.

NO: Lubricate or repair linkage.

LOOK: Does seat move up or down and remain in desired position?

T103194 –UN–20AUG96

See your authorized dealer.

LOOK: Does seat latch move freely and hold seat in desired position?

LOOK: Does lever move freely and lock seat in desired position?

FEEL: Does lever move freely and hold seat in desired positions?

FEEL: Does lever move freely and hold seat in loader and backhoe positions?

– – –1/1

4-2-12

012704

PN=187

Miscellaneous—Operational Checkout Seat Position Switch Check

Engine speed at low idle.

YES: Continue with check.

Lower all equipment to ground.

NOTE: This check should be performed on level ground.

NO: See your authorized dealer.

Operators seat in backhoe position.

Release park brake.

FNR in forward or reverse.

LISTEN: Does monitor alarm sound and is stop indicator on?

The following two checks are for machines with pilot controls.

YES: Continue with check.

Operators seat in backhoe position.

NOTE: Pilot control towers should be in stored position for ease of rotating seat.

NO: See your authorized dealer.

Enable pilot controls (switch in unlock position).

Activate a function and rotate seat towards loader position.

LOOK: Does backhoe function stop after seat has been rotated at least 15° out of backhoe position?

Rotate operators seat to loader position.

YES: Go to next check.

Enable pilot controls.

NO: See your authorized dealer.

Release park brake.

FNR in forward or reverse.

LOOK/LISTEN: Does monitor alarm sound and does monitor display HOE On?

– – –1/1

Rear Windows Latch and Opener Checks

YES: Go to next check.

CAUTION: Prevent injury from unexpected machine movement.

Squeeze latches on both sides of upper rear window. Lower window to rubber bumpers.

NO: Check for obstructions. See your authorized dealer.

LOOK: Does window latch?

LOOK: Do window catches hold and not bow the windows in the up and down position?

Always lock hydraulics when not operating backhoe or opening/closing window.

– – –1/1

4-2-13

012704

PN=188

Miscellaneous—Operational Checkout Side Window Checks

Open front and rear side windows.

YES: Go to next check.

Fasten rear window against front window.

NO: Adjust windows. See your authorized dealer.

Fasten front window against rear window Fasten windows with latches T6171DF –UN–09DEC88

LOOK/FEEL: Do hinges move freely? Are locking latches equally loaded when closed?

– – –1/1

Miscellaneous Machine Components Checks

Verify the following are working properly and all mounting brackets and hardware are tight.

• • • • •

YES: Check complete.

NO: Repair or replace if necessary.

All latches and locks.

Hood and access doors.

Hoses and clamps.

Fan shroud and fan guard Fan direction

– – –1/1

4-2-14

012704

PN=189

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

HG31779,0000020 –19–16APR02–1/1

4-3-1

012704

PN=190

Miscellaneous—Troubleshooting

Engine Symptom

Problem

Solution

Engine Will Not Start or Starts Hard

Fuel tank empty

Check fuel quantity.

Fuel tank vent plugged

Remove cap and listen for sound of air entering tank. Replace cap.

No electrical power to injection pump solenoid

Turn key switch to ON position. Must hear click at injection pump. Replace fuse.

Water in fuel or water frozen in fuel line.

Drain water from fuel tank. Inspect fuel filter for water. Change filter.

Debris in fuel or wrong grade of fuel

Check fuel tank outlet strainer for type of fuel debris. Check bottom of fuel tank for debris. Clean tank. Add fuel. Check grade of fuel. Add correct fuel.

Air leak on suction side of fuel system

Check for bubbles in fuel filter and tighten connections. Inspect fuel lines for damage.

Fuel transfer pump diaphragm leaking

Check engine oil for fuel dilution.

Slow cranking speed

Check battery and connections.

Incorrect engine oil (cold weather).

Restricted air filter

Check air filter restriction indicator and air filters. Clean.

Continued on next page

4-3-2

TX,100,BG336 –19–09JAN97–1/4

012704

PN=191

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Engine Surges Or Stalls Frequently

Air in fuel

Inspect filter for evidence of air in fuel. Tighten connections and bleed fuel system.

Fuel tank vent plugged

Remove cap and listen for sound of air entering tank. Replace cap.

Debris in fuel or wrong grade of fuel

Check fuel tank outlet strainer for debris. Check bottom of fuel tank for debris. Clean tank. Add fuel. Check grade of fuel.

Water in fuel

Drain fuel tank and inspect filter element for water. Replace filters.

Fuel filter plugged

Replace filter.

Air in fuel

Check for evidence of air in filter.

Tighten connections and bleed fuel system.

Debris in fuel or wrong grade of fuel

Check fuel tank for water. Check fuel tank strainer and fuel filter for debris.

Clean. Check grade of fuel.

Fuel tank outlet strainer plugged

Check fuel tank for water or debris.

Remove and clean.

Fuel filter plugged

Replace fuel filter.

Wrong grade of fuel

Drain and add correct fuel.

Air system restricted

Check air filter restriction and air filters. Clean.

Incorrect high idle speed (too low) or linkage out adjustment

Adjust linkage. Check high idle speed. See your authorized dealer.

Restricted air filter

Check air filter restriction and air filters. Clean or replace.

Incorrect grade of fuel

Drain and add correct fuel.

Engine Misses

Engine Does Not Develop Power

Engine Emits Excessive Black or Gray Exhaust Smoke

Continued on next page

4-3-3

TX,100,BG336 –19–09JAN97–2/4 012704

PN=192

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Engine Emits Excessive Blue or White Smoke

Cranking speed too slow

Check batteries and connections.

Incorrect grade of fuel

Drain and add correct fuel.

Engine running too cold

Check thermostat operation.

Slow Acceleration

Wrong grade of fuel

Drain and add correct fuel.

Detonation (Excess Engine Knock)

Low engine oil level

Add oil.

Abnormal Engine Noise

Low or incorrect engine oil (too thin)

Add correct oil to proper level.

Engine oil diluted with fuel

Inspect engine oil. See your authorized dealer.

Low oil level

Add oil to proper level. Inspect engine oil.

Wrong viscosity oil/oil diluted with diesel fuel

Change oil.

Low coolant level

Fill cooling system and check for leaks.

Low engine oil level

Add oil.

Engine overloaded, operating in wrong gear

Reduce load.

Improper fuel

Drain and add correct fuel.

Radiator cap

Replace cap.

Excessive axle drag

Check axle drag. See Operational Checkout chapter.

Excessive brake drag

Check brake drag. See Operational Checkout chapter.

Low Oil Pressure (Oil Pressure Light On—Red "Stop" Flashing)

Engine Overheats (Engine Coolant Indicator Light On and Red "Stop" Flashing)

Continued on next page

4-3-4

TX,100,BG336 –19–09JAN97–3/4 012704

PN=193

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Excessive Fuel Consumption

Air system restricted

Check filter restriction indicator and air filters. Replace

Leakage in fuel system

Inspect. Repair.

Incorrect grade of fuel

Refill with correct fuel.

Operator holding hydraulics over relief.

Return control levers to neutral position.

TX,100,BG336 –19–09JAN97–4/4

4-3-5

012704

PN=194

Miscellaneous—Troubleshooting

Electrical System Symptom

Problem

Solution

Starting Motor Will Not Turn

Start fuse.

Check and replace if necessary.

Loose red connector at cab to engine harness junction.

Check under loader control lever and push connectors together.

Starter.

Listen for “click” from starter solenoid. If “click” is not heard, the starter control circuit is functioning. If “click” is not heard, repair starter.

Excessive power train load.

Depress clutch disconnect switch.

Starter Solenoid Chatters

Poor or corroded connections at battery, battery ground strap, or starter.

Inspect, clean, and tighten if necessary.

Engine Cranks Slowly

Loose or corroded battery cables.

Inspect and clean or tighten.

Loose battery ground cable.

Remove battery cover and inspect and tighten battery ground cable.

Excessive power train load.

Depress clutch disconnect switch.

Excessive engine load.

Change engine oil to proper grade for temperature.

Starter solenoid stuck.

Lightly tap on case of starter solenoid.

Starter not disengaging.

Lightly tap on starter case to determine if starter “shift” lever is stuck.

Starter relay stuck on.

Lightly tap on starter relay to determine if relay is stuck.

Cracked battery case.

Replace battery.

High ambient temperature.

Refill with distilled water.

Battery cell.

Check if one or more cells take more water than others.

Starting Motor Continues To Run

Battery Uses Too Much Water

Continued on next page

4-3-6

TX,100,BG337 –19–09JAN97–1/3 012704

PN=195

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Cracked Battery Case

No battery hold down clamp.

Replace battery and install hold down clamp.

Loose battery hold down clamp.

Replace battery and install hold down clamp.

Battery hold down clamp too tight.

Replace battery and install battery hold down clamp properly.

Frozen battery.

Keep battery full charged in cold weather.

Low water level.

Add water.

Dirty or wet battery top causing discharge.

Clean and wipe battery top dry.

Corroded or loose battery cables.

Clean and tighten battery cables.

Broken battery post.

Wiggle battery post by hand. If post wiggles or turns, replace battery.

Loose or glazed alternator belt.

Check belt. Replace if glazed.

Diode or phase winding.

Increase engine rpm to fast idle. If light goes out or gets dim, it indicates a worn diode or phase winding See your authorized dealer.

Loose or corroded electrical connections on battery, ground strap, starter, or alternator.

Inspect. Clean, or tighten electrical connections.

Monitor/gauge fuse.

Turn key switch to BULB CHECK position. If no lights, replace fuse.

Indicator light bulb.

Inspect and replace if necessary.

Loose wiring connector.

Inspect and repair.

Low Battery Output

Charging Indicator Light Remains On With Engine Running

Alternator Light Out But Low Charging System Voltage

Continued on next page

4-3-7

TX,100,BG337 –19–09JAN97–2/3 012704

PN=196

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Noisy Alternator

Worn bearings in alternator.

Remove belt and feel for rough bearing while turning alternator pulley.

Drive belt.

Inspect and replace if necessary.

Pulley not aligned.

Inspect

Loose alternator belt or mounting.

Inspect and replace if necessary.

TX,100,BG337 –19–09JAN97–3/3

Steering System Symptom

Problem

Solution

Slow or Hard Steering

Air in system.

Check oil level.

Check suction hose clamps.

Erratic ("Spongy") Steering

Steering lines or load sensing "LS" lines damaged (bent).

Check and replace.

Air in system.

Check oil level.

Check suction hose clamps.

No Response When Steering Wheel Is Turned

Low or no oil.

Check reservoir oil level.

TX,100,BG344 –19–09JAN97–1/1

4-3-8

012704

PN=197

Miscellaneous—Troubleshooting

Hydraulic System Symptom

Problem

Solution

No Hydraulics

Low oil level

Add oil to correct level.

Low Hydraulic Power

Hydraulic oil aerated

Incorrect oil, drain and refill. Suction hose has air leak. Inspect and tighten. See repair manual.

Low oil level

Check oil levels.

Low oil level

Add oil to correct level.

Engine rpm too low

Increase rpm or check engine speed.

Hydraulic oil aerated

Drain and refill. Suction hose has air leak. Inspect and tighten.

Hose or line leakage

Inspect and tighten fittings.

Low oil level (aeration of oil)

Add oil to correct level.

Hydraulic oil aerated

Drain and refill.

Low oil level

Add oil to correct level.

Hydraulic oil aerated

Drain and refill.

Excessive load

Reduce load.

Operator holding hydraulic system over relief

Return levers to neutral when not in use.

Oil levels too low in reservoir

Check levels and add oil.

Using low viscosity oil in hot weather

Use recommended oil.

Oil level too low or too high

Check oil level. Adjust to full mark on sight gauge.

Incorrect type of oil

Drain and replace. See Fuels and Lubricants chapter in this manual.

Slow Hydraulic Functions

Low Hydraulic Power (Low Hydraulic Pressure)

Hydraulic Function Makes "Chattering" Noise

Hydraulic Oil Overheats

Foaming Oil

Continued on next page

4-3-9

TX,100,BG345 –19–09JAN97–1/2 012704

PN=198

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Excessive Pump Noise

Low oil level

Add oil to correct level.

Hydraulic filter bypass valve chattering

Replace filter. Inspect, clean, and repair.

TX,100,BG345 –19–09JAN97–2/2

4-3-10

012704

PN=199

Miscellaneous—Troubleshooting

Gauges and Indicators Symptom

Problem

Solution

Fuel Gauge Does Not Move, No indicator Lights, Machine Will Not Crank

Start relay fuse.

Replace fuse.

Fuel Gauge Does Not Move, No Indicator Lights, But Machine Will Crank

Gauge fuse.

Replace fuse.

Machine Cranks But Will Not Start

Fuel shutoff fuse.

Replace fuse.

Wire to injection.

Repair wire.

Ground solenoid.

Repair ground.

Injection pump.

Replace solenoid.

Indicator light.

Turn key switch to BULB CHECK. If no light, replace bulb.

Sender.

Replace sender.

Gauge fuse.

Replace fuse.

Indicator light.

Turn key switch to BULB CHECK. If no light, replace bulb.

Wire, connector or sender.

Ground yellow wire at sender.

Indicator must light. If not, repair wiring or replace sender.

Monitor/gauge fuse.

Replace fuse.

Indicator light.

Turn key switch to BULB CHECK. If indicator does not light, replace bulb.

Monitor/gauge fuse.

Replace fuse.

Indicator light.

Replace bulb.

Engine Coolant Temperature Indicator Light Does Not Indicate Overheating Or Bulb Does Not Light In BULB CHECK Position

Engine Oil Pressure Indicator Will Not Light

Alternator Indicator Will Not Light

Monitor Lights Do Not Come On During BULB CHECK

Continued on next page

4-3-11

TX,100,BG338 –19–09JAN97–1/3 012704

PN=200

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Fuel Gauge Shows Empty At All Times

Poor ground connections at gauge.

Remove dash panel and check gauge mounting hardware.

Poor power connection at gauge.

Remove dash panel and check gauge mounting hardware.

Hole in fuel sender float.

Look at float in tank to see if it is floating. Replace sender unit.

Gauge.

Replace gauge.

Fuel Gauge Shows Full At All Times

Sender float stuck.

Look in fuel tank. See if float is above fuel level. Repair or replace sender. See your authorized dealer.

Horn Does Not Sound

Horn ground.

Ground horn to machine frame.

Horn fuse.

Check and replace.

Horn.

Replace horn.

Horn button.

Replace horn button.

Wiper fuse.

Check and replace.

Loose or broken wire.

Inspect wiring for breaks or loose connections. Repair.

Wiper switch.

See your authorized dealer.

Wiper motor.

See your authorized dealer.

Heater fuse.

Check and replace.

Loose or broken wire.

Inspect wiring for breaks or loose connections. Repair.

Driving light fuse.

Check and replace.

Poor ground.

Inspect and tighten.

Light switch.

See your authorized dealer.

Burned out bulb.

Replace with new bulb.

Windshield Wiper Does Not Operate

Heater Fan Does Not Operate

No Work Or Driving Lights

Continued on next page

4-3-12

TX,100,BG338 –19–09JAN97–2/3 012704

PN=201

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Rear Lights Do Not Operate

Loose connector in wiring harness of ROPS.

Inspect and reconnect.

Poor ground at light.

Inspect and tighten.

Low battery charge.

Check battery connections.

Low alternator output.

Check belt tension.

Poor ground at lights.

Clean and tighten.

Return-to-dig/beacon/pump fuse.

Replace fuse.

Boom switch out of adjustment.

Check cam to see if it activates switch. Adjust as required.

Wiring.

Inspect and repair wiring.

FNR/park brake fuse.

Replace fuse.

Wire.

Inspect and repair wire.

Solenoid.

Replace solenoid.

Dim Lights

Return-To-Dig Does Not Operate

Neutral Disconnect Does Not Disengage.

TX,100,BG338 –19–09JAN97–3/3

4-3-13

012704

PN=202

Miscellaneous—Troubleshooting

Transmission Symptom

Problem

Solution

Machine Will Not Move In Forward Or Reverse

Low oil level in transmission

Add oil to correct level.

Broken drive shafts

Inspect drive shafts and universal joints for external damage. See your authorized dealer.

Low oil level

Add oil.

Wrong oil grade

Change oil.

Oil level is low

Add oil to correct level.

Wrong oil, aerated oil

Change oil.

Brake dragging

Check for excessive heat in brake area of axle housing after operating machine.

Low or high oil level (aeration of oil)

Add oil or drain.

Wrong oil

Change oil.

Oil level too high or too low

Check oil level and correct.

Incorrect type of oil

Drain and replace oil.

Engine low idle too slow

See your authorized dealer.

Oil level low

Fill to correct oil level.

Shifting without using disconnect clutch

Depress clutch disconnect when shifting.

Transmission Slippage

Machine Lacks Power Or Moves Slow

Transmission Shifts Too Slow

Transmission Overheats

Excessive Power Train Noise

Excessive Gear Clash When Shifting

TX,100,BD2198 –19–07OCT96–1/1

MFWD

TX,100,BG340 –19–09JAN97–1/1

4-3-14

012704

PN=203

Miscellaneous—Troubleshooting

Rear Axle Symptom

Problem

Solution

No Differential Lock Operation

Problem in electrical circuit to solenoid

With engine stopped and key switch turn to accessory, activate differential lock and listen for a click from solenoid valve.

Do Differential Lock Operational Checks.

Differential Lock Will Not Release

Poor Service Brakes

Stuck foot switch

Inspect.

Problem in electrical circuit

With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve.

Air in brake valve or lines or piston

Bleed brakes.

Low oil level

Check oil level and fill.

NOTE: If any other problems are encountered which require special tools or machine knowledge to correct, see your authorized dealer.

TX,100,BG339 –19–09JAN97–1/1

4-3-15

012704

PN=204

Miscellaneous—Storage Prepare Machine For Storage

3. Wash the machine. Use low pressure wash operations (less than 1379 kPa (13.8 bar) (200 psi) until 30 days after receipt of machine have elapsed. Paint areas to prevent rust. Replace decals, where needed.

4. Apply waste oil to track chains. Run machine back and forth several times. Park machine on a hard surface to prevent tracks from freezing to ground.

–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 machines with high pressure. Use low pressure wash operations until 30 days have elapsed.

T5813AM

2. Clean primary air cleaner.

T47764

–UN–09NOV88

1. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later.

5. Store machine in a dry, protected place. If stored outside, cover with a waterproof material.

IMPORTANT: LPS 3 Rust Inhibitor can destroy painted finish. DO NOT spray LPS 3 Rust Inhibitor on painted areas.

6. Retract all hydraulic cylinders, if possible. If not, coat exposed cylinder rods with LPS 3 Rust Inhibitor.

7. Place a "DO NOT OPERATE" tag on the right control lever.

8. Lubricate all grease points.

9. Remove batteries.

10. Remove seat cushion and other perishable items.

11. Remove keys and lock all covers and doors.

LPS is a trademark of the Holt Lloyd Corporation.

TX,105,FF2313 –19–16NOV00–1/1

4-4-1

012704

PN=205

Miscellaneous—Crime Prevention Tips Help Prevent Crime

TS140

–19–07OCT88

You can help take a bite out of crime by properly documenting ownership and discouraging theft.

DX,CRPRV,A –19–03MAR93–1/1

Record Construction Identification Numbers

TS156

2. Record the Product Identification Number (PIN) of the unit and also individual component identification numbers for engines, axles, pumps, etc. Include the PIN numbers on all documentation, such as insurance, financial, and warranty papers.

–UN–23MAR89

1. Mark your machines with your own unique numbering system.

DX,CRPRV,H –19–04JUN90–1/1

Keep Proof of Ownership 1. Take color photographs from several angles of each machine.

TS157

3. Keep your documented identification numbers, color photographs, and inventory in a safe, secure location.

–UN–23MAR89

2. Maintain an up-to-date inventory of all your machines.

DX,CRPRV,I –19–04JUN90–1/1

Park Indoors Out of Sight Make machines hard to move:

–UN–23MAR89

Park large equipment in front of exits.

Lower equipment to the ground. Remove key.

Remove battery when unit is in storage.

Lock cab doors, windows, and vandal-proof devices.

Lock building.

TS158

• • • • •

DX,CRPRV,J –19–04JUN90–1/1

4-5-1

012704

PN=206

Miscellaneous—Crime Prevention Tips

When Parking Outdoors Make machines hard to move:

–UN–23AUG88

Park in a well-lighted, fenced area.

Lower all equipment to the ground.

Remove ignition key.

Remove battery when unit is storage.

Lock cab doors, windows, and vandal-proof devices.

TS144

• • • • •

DX,CRPRV,K –19–04JUN90–1/1

Reduce Vandalism

3. Regularly verify that identification plates have not been removed. If they have, notify law enforcement agency.

Order duplicate plates from your dealer.

TS145

2. Participate in a neighborhood watch program. Take written notes of suspicious vehicles or persons and report your findings to law enforcement agency.

–UN–23AUG88

1. Install vandal-proof devices.

DX,CRPRV,L –19–04JUN90–1/1

4-5-2

012704

PN=207

Miscellaneous—Crime Prevention Tips

Report Thefts Immediately 1. Immediately notify your local law enforcement agency and insurance agent.

2. Provide a complete description of the machine, all of the documented identification numbers and color photographs.

3. Request verification of the identification numbers after they have been entered with any regional or national crime information center. Double check the numbers to be sure they are correct.

TS146

–UN–09JAN89

4. Notify your John Deere dealer of the theft and request that its loss be posted with full description and identification numbers.

DX,CRPRV,G –19–03MAR93–1/1

4-5-3

012704

PN=208

Miscellaneous—Specifications

T115805

–UN–11JUN98

410G Specifications

OUO1079,000026D –19–12SEP00–1/1

4-6-1

012704

PN=209

Miscellaneous—Specifications

Ground Speeds—410G Travel speeds are as follows for machines using 19.5L-24 rear tires: Item

Measurement

Specification

1 Forward

Speed

5.8 km/hr (3.6 mph)

2 Forward

Speed

9.5 km/hr (5.9 mph)

3 Forward

Speed

22.4 km/hr (13.9 mph)

4 Forward

Speed

32.9 km/hr (20.5 mph)

1 Reverse

Speed

6.4 km/hr (4.0 mph)

2 Reverse

Speed

10.6 km/hr (6.6 mph)

3 Reverse

Speed

25.9 km/hr (16.1 mph)

4 Reverse

Speed

25.9 km/hr (16.1 mph)

With Powershift Transmission

OUO1079,000026A –19–12SEP00–1/1

4-6-2

012704

PN=210

Miscellaneous—Specifications

410G Backhoe Loader Dimensions NOTE: Specifications and design subject to change without notice. Whenever applicable, specifications are in accordance with SAE Standards. Unless otherwise noted, these specifications are based on a standard machine with 19.5L-24, 10PR, R4 rear tires; 11L-16, 12PR, F3 front tires; 0.86 m3 (1.12 cu yd) loader bucket; 610 mm (24 in.) backhoe bucket; ROPS/FOPS; full fuel tank, and 79 kg (175 lb) operator.

Item

Measurement

Specification

Backhoe w/o Ext. Dipperstick

Height

3.81 m (12 ft 6 in.)

Backhoe w/Ext. Dipperstick Retracted

Height

3.86 m (12 ft 8 in.)

Backhoe w/Ext. Dipperstick Extended

Height

4.72 m (15 ft 6 in.)

Backhoe w/o Ext. Dipperstick

Distance

5.99 m (19 ft 8 in.)

Backhoe w/Ext. Dipperstick Retracted

Distance

6.07 m (19 ft 11 in.)

Backhoe w/Ext. Dipperstick Extended

Distance

7.21 m (23 ft 8 in.)

Backhoe w/o Ext. Dipperstick

Distance

7.11 m (23 ft 4 in.)

Backhoe w/Ext. Dipperstick Retracted

Distance

7.19 m (23 ft 7 in.)

Backhoe w/Ext. Dipperstick Extended

Distance

8.33 m (27 ft 4 in.)

A—Loading Height, Truck Loading Position

B—Reach from Center of Swing Mast

C—Reach from Center of Rear Axle

Continued on next page

4-6-3

OUO1079,000026E –19–12SEP00–1/6 012704

PN=211

Miscellaneous—Specifications

Item

Measurement

Specification

Backhoe w/o Ext. Dipperstick

Depth

4.83 m (15 ft 10 in.)

Backhoe w/Ext. Dipperstick Retracted

Depth

4.90 m (16 ft 1 in.)

Backhoe w/Ext. Dipperstick Extended

Depth

6.10 m (20 ft 0 in.)

Backhoe w/o Ext. Dipperstick

Distance

4.78 m (15 ft 8 in.)

Backhoe w/Ext. Dipperstick Retracted

Distance

4.85 m (15 ft 11 in.)

Backhoe w/Ext. Dipperstick Extended

Distance

6.07 m (19 ft 11 in.)

Backhoe w/o Ext. Dipperstick

Distance

4.45 m (14 ft 7 in.)

Backhoe w/Ext. Dipperstick Retracted

Distance

4.55 m (14 ft 11 in.)

Backhoe w/Ext. Dipperstick Extended

Distance

5.82 m (19 ft 1 in.)

Backhoe w/o Ext. Dipperstick

Clearance

356 mm (14 in.)

Backhoe w/Ext. Dipperstick Retracted

Clearance

356 mm (14 in.)

Backhoe w/Ext. Dipperstick Extended

Clearance

356 mm (14 in.)

D—Maximum Digging Depth

E—Digging Depth (SAE)—610 mm (2 ft) Flat Bottom

F—Digging Depth (SAE)—2440 mm (8 ft) Flat Bottom

G—Ground Clearance Minimum

Continued on next page

4-6-4

OUO1079,000026E –19–12SEP00–2/6 012704

PN=212

Miscellaneous—Specifications

Item

Measurement

Specification

Backhoe w/o Ext. Dipperstick

Rotation

190°

Backhoe w/Ext. Dipperstick Retracted

Rotation

190°

Backhoe w/Ext. Dipperstick Extended

Rotation

190°

Height

3.94 m (12 ft 11 in.)

Length

7.29 m (23 ft 11 in.)

Width

2.18 m (7 ft 2 in.)

Width

3.10 m (10 ft 2 in.)

Width

3.53 m (11 ft 7 in.)

Width

2.18 m (7 ft 2 in.)

H—Bucket Rotation

I—Transport Height Backhoe

J—Overall Length, Transport Backhoe

K—Stabilizer Width, Transport Backhoe

L—Stabilizer Spread, Operating Backhoe

M—Overall Width, Stabilizer Spread (Less Loader Bucket) Backhoe

N—Width Over Tires Backhoe

O—Height to Cab/ROPS Top Backhoe

Height

2.82 m (9 ft 3 in.)

Continued on next page

4-6-5

OUO1079,000026E –19–12SEP00–3/6 012704

PN=213

Miscellaneous—Specifications

Item

Measurement

Specification

Distance

2.10 m (6 ft 11 in.)

Length

2.10 m (6 ft 10 in.)

Heavy Duty Long Lip 0.86 m3 (1.12 yd3)

Height

3.35 m (11 ft 0 in.)

Heavy Duty Long Lip 1.0 m3 (1.30 yd3)

Height

3.35 m (11 ft 0 in.)

Multipurpose 0.76 m3 (1.00 yd3)

Height

3.35 m (11 ft 0 in.)

Heavy Duty Long Lip 0.86 m3 (1.12 yd3)

Clearance

2.69 m (8 ft 10 in.)

Heavy Duty Long Lip 1.0 m3 (1.30 yd3)

Clearance

2.67 m (8 ft 9 in.)

Multipurpose 0.76 m3 (1.00 yd3)

Clearance

2.64 m (8 ft 8 in.)

Heavy Duty Long Lip 0.86 m3 (1.12 yd3)

Angle

45°

Heavy Duty Long Lip 1.0 m3 (1.30 yd3)

Angle

45°

Multipurpose 0.76 m3 (1.00 yd3)

Angle

45°

P—Front Wheel to Loader Dig Position Backhoe

Q—Wheelbase Backhoe

R—Maximum Height to Loader Bucket Hinge Pin

S—Dump Clearance, Loader Bucket at 45°

T—Maximum Loader Bucket Dump Angle

Continued on next page

4-6-6

OUO1079,000026E –19–12SEP00–4/6 012704

PN=214

Miscellaneous—Specifications

Item

Measurement

Specification

Heavy Duty Long Lip 0.86 m3 (1.12 yd3)

Distance

762 mm (30.0 in.)

Heavy Duty Long Lip 1.0 m3 (1.30 yd3)

Distance

787 mm (31.0 in.)

Multipurpose 0.76 m3 (1.00 yd3)

Distance

818 mm (32.2 in.)

Heavy Duty Long Lip 0.86 m3 (1.12 yd3)

Angle

40°

Heavy Duty Long Lip 1.0 m3 (1.30 yd3)

Angle

40°

Multipurpose 0.76 m3 (1.00 yd3)

Angle

40°

Heavy Duty Long Lip 0.86 m3 (1.12 yd3)

Depth

170 mm (6.7 in.)

Heavy Duty Long Lip 1.0 m3 (1.30 yd3)

Depth

157 mm (6.2 in.)

Multipurpose 0.76 m3 (1.00 yd3)

Depth

150 mm (5.9 in.)

Backhoe w/o Ext. Dipperstick

Force

65.8 kN (14,801 lb)

Backhoe w/Ext. Dipperstick Retracted

Force

66.7 kN (15,010 lb)

Backhoe w/Ext. Dipperstick Extended

Force

66.7 kN (15,010 lb)

U—Reach at Full Height, Loader Bucket at 45°

V—Loader Bucket Rollback at Ground Level

W—Dig Below Ground—Loader Bucket Level

Digging Force, Bucket Cylinder

Continued on next page

4-6-7

OUO1079,000026E –19–12SEP00–5/6 012704

PN=215

Miscellaneous—Specifications

Item

Measurement

Specification

Backhoe w/o Ext. Dipperstick

Force

38.9 kN (8741 lb)

Backhoe w/Ext. Dipperstick Retracted

Force

37.6 kN (8446 lb)

Backhoe w/Ext. Dipperstick Extended

Force

26.6 kN (5980 lb)

Backhoe w/o Ext. Dipperstick

Rotation

180°

Backhoe w/Ext. Dipperstick Retracted

Rotation

180°

Backhoe w/Ext. Dipperstick Extended

Rotation

180°

Backhoe w/o Ext. Dipperstick

Rotation

190°

Backhoe w/Ext. Dipperstick Retracted

Rotation

190°

Backhoe w/Ext. Dipperstick Extended

Rotation

190°

Backhoe w/o Ext. Dipperstick

Angle

18°

Backhoe w/Ext. Dipperstick Retracted

Angle

18°

Backhoe w/Ext. Dipperstick Extended

Angle

18°

Digging Force, Crowd Cylinder

Swing Arc

Bucket Rotation

Stabilizer Angle Rearward

OUO1079,000026E –19–12SEP00–6/6

4-6-8

012704

PN=216

Miscellaneous—Specifications

410G Backhoe Loader NOTE: Specifications and design subject to change without notice. Wherever applicable, Item

specifications are in accordance with Standards.

Measurement

Specification

Rated Power @ 2200 rpm

Power

SAE gross 73 kW (98 hp)

Rated Power @ 2200 rpm

Power

SAE net 68 kW (91 hp)

Power @ 2000 rpm

Power

SAE gross 72 kW (97 hp)

Power @ 2000 rpm

Power

SAE net 69 kW (92 hp)

Cylinders

Quantity

4

Displacement

Volume

4.52 L (276 in.3)

Engine Torque Rise

Torque

34%

Maximum Engine Net Torque

Torque

389 N•m (287 lb-ft)

Electrical System

Voltage

12-volt

Alternator

Amperage

65 amps

Alternator with Cab

Amperage

95 amps

Measurement

Specification

Gear 1

Speed

5.8 km/hr (3.6 mph)

Gear 2

Speed

9.5 km/hr (5.9 mph)

Gear 3

Speed

23.2 km/hr (14.4 mph)

Gear 4

Speed

39.3 km/hr (24.4 mph)

Engine—John Deere 4045T

Item

410G Forward Travel Speeds1 with Powershift Transmission

1

With standard 19.5L-24 rear tires.

Continued on next page

4-6-9

OUO1079,000026F –19–08JAN03–1/3 012704

PN=217

Miscellaneous—Specifications

Item

Measurement

Specification

Gear 1

Speed

6.4 km/hr (4.0 mph)

Gear 2

Speed

10.6 km/hr (6.6 mph)

Gear 3

Speed

25.9 km/hr (16.1 mph)

Gear 4

Speed

25.9 km/hr (16.1 mph)

410G Reverse Travel Speeds1 with Powershift Transmission

NOTE: With powershift transmission, third and fourth gear speeds are the same in reverse.

Item

Measurement

Specification

Non-Powered Axle Curb Turning Radius—Brakes Applied

Radius

3.23 m (10 ft 7 in.)

Non-Powered Axle Curb Turning Radius—Without Brakes

Radius

3.86 m (12 ft 8 in.)

Non-Powered Axle Bucket Clearance Circle—Brakes Applied

Radius

9.32 m (30 ft 7 in.)

Non-Powered Axle Bucket Clearance Circle—Without Brakes

Radius

10.46 m (34 ft 4 in.)

Steering: Hydrostatic Power

1

Non-Powered Axle Steering Wheel Quantity Turns—Stop-to-Stop

3.3 turns

Powered Axle (MFWD) Curb Turning Radius—Brakes Applied

Radius

3.56 m (11 ft 8 in.)

Powered Axle (MFWD) Curb Turning Radius—Without Brakes

Radius

4.04 m (13 ft 3 in.)

Powered Axle Bucket Clearance Circle—Brakes Applied

Radius

9.65 m (31 ft 8 in.)

With standard 19.5L-24 rear tires.

Continued on next page

4-6-10

OUO1079,000026F –19–08JAN03–2/3 012704

PN=218

Miscellaneous—Specifications

Item

Measurement

Specification

Powered Axle Bucket Clearance Circle—Without Brakes

Radius

10.59 m (34 ft 10 in.)

Powered Axle Steering Wheel Turns—Stop-to-Stop

Quantity

2.2 turns

Measurement

Specification

Main Pressure Relief Setting

Pressure

25 000 kPa (250 bar) (3625 psi)

Flow @ 2200 rpm, Backhoe

Flow Rate

159 L/min. (42 gpm)

Flow @ 2200 rpm, Loader

Flow Rate

159 L/min. (42 gpm)

Item

Hydraulic System: Closed Center

OUO1079,000026F –19–08JAN03–3/3

410G Backhoe Loader Weight Item

Measurement

Specification

SAE Operating Weight with ROPS

Weight

5806 kg (12,800 lb)

Cab Added

Weight

263 kg (580 lb)

MFWD with Tires Added

Weight

168 kg (370 lb)

Extendible Dipperstick

Weight

200 kg (440 lb)

Optional Front Counterweight

Weight

181 kg (400 lb)

Optional Front Counterweight

Weight

295 kg (650 lb)

Transporting

OUO1079,0000271 –19–12SEP00–1/1

4-6-11

012704

PN=219

Miscellaneous—Specifications

Buckets Width

Heaped Capacity

Weight

Loader:

mm

(In.)

m3

(Cu Yd)

kg

lb

Heavy duty long lip

2340

(92)

1.00

(1.30)

476

(1050)

2340

(92)

1.15

(1.50)

540

(1190)

Multipurpose

2340

(92)

0.96

(1.25)

703

(1550)

Backhoe:

mm

(In.)

m3

(Cu Ft)

kg

(lb)

Standard duty

610

(24)

0.21

(7.5)

159

(350)

Heavy duty with lift loops

305

(12)

0.09

(3.3)

134

(295)

457

(18)

0.14

(5.1)

152

(335)

610

(24)

0.21

(7.5)

181

(400)

762

(30)

0.25

(8.8)

191

(420)

Width

Extra heavy duty

Ditch cleaning

Heaped Capacity

Weight

914

(36)

0.35

(12.5)

231

(510)

457

(18)

0.14

(5.1)

164

(362)

610

(24)

0.21

(7.5)

193

(425)

610

(24)

0.25

(8.8)

206

(455)

762

(30)

0.28

(10.0)

215

(475)

914

(36)

0.35

(12.5)

231

(510)

TX,110,BD2212 –19–08OCT96–1/1

4-6-12

012704

PN=220

Miscellaneous—Specifications

410G Backhoe Loader Drain and Refill Capacities Item

Measurement

Specification

Engine Coolant

Capacity

16 L (17 qt)

Engine Oil (including filter)

Capacity

13 L (13.7 qt)

Torque Converter and Transmission System

Capacity

15 L (16 qt)

Rear Axle

Capacity

16 L (17 qt)

MFWD Front Axle Housing

Capacity

6.5 L (7 qt)

MFWD Front Wheel Planetary Housing (each)

Capacity

1 L (1.1 qt)

Fuel Tank

Capacity

136 L (36 gal)

Hydraulic System Reservoir

Capacity

37 L (39 qt)

OUO1079,0000272 –19–18DEC02–1/1

4-6-13

012704

PN=221

Miscellaneous—Specifications

410G Backhoe Loader Lifting Capacities— Standard Dipperstick Lifting capacity ratings are made with bucket hinge pin, loader bucket and stabilizers on firm, level ground. Lift capacities are hydraulically limited. Lifting capacities are 87 percent of the maximum lift over any point on the swing arc and do not exceed 75 percent of the tipping load. Angle between boom and ground is 65 degrees.

Machine is equipped with 610 mm (24 in.) standard bucket, standard or extendible dipperstick, and standard equipment.

T105558

–19–04DEC96

NOTE: Loader bucket on ground significantly improves side stability, therefore improving lift capacity to the side. Lift capacity over the rear is not affected.

Lift Capacity, Backhoe with Standard Dipperstick Based on SAE J31 (Except with Loader Bucket on Ground)

OUO1079,0000273 –19–12SEP00–1/1

4-6-14

012704

PN=222

Miscellaneous—Specifications

410G Backhoe Loader Lifting Capacities— Extendible Dipperstick (Retracted) Lifting capacity ratings are made with bucket hinge pin, loader bucket and stabilizers on firm, level ground. Lift capacities are hydraulically limited. Lifting capacities are 87 percent of the maximum lift over any point on the swing arc and do not exceed 75 percent of the tipping load. Angle between boom and ground is 65 degrees.

Machine is equipped with 610 mm (24 in.) standard bucket, standard or extendible dipperstick, and standard equipment.

T105559

–19–04DEC96

NOTE: Loader bucket on ground significantly improves side stability, therefore improving lift capacity to the side. Lift capacity over the rear is not affected.

Lift Capacity, Backhoe with Extendible Dipperstick, Retracted Based on SAE J31 (Except with Loader Bucket on Ground)

OUO1079,0000274 –19–12SEP00–1/1

4-6-15

012704

PN=223

Miscellaneous—Specifications

410G Backhoe Loader Lifting Capacities— Extendible Dipperstick (Extended) Lifting capacity ratings are made with bucket hinge pin, loader bucket and stabilizers on firm, level ground. Lift capacities are hydraulically limited. Lifting capacities are 87 percent of the maximum lift over any point on the swing arc and do not exceed 75 percent of the tipping load. Angle between boom and ground is 65 degrees.

Machine is equipped with 610 mm (24 in.) standard bucket, standard or extendible dipperstick, and standard equipment.

T105560

–19–04DEC96

NOTE: Loader bucket on ground significantly improves side stability, therefore improving lift capacity to the side. Lift capacity over the rear is not affected.

Lift Capacity, Backhoe with Extendible Dipperstick, Retracted Based on SAE J31 (Except with Loader Bucket on Ground)

OUO1079,0000275 –19–12SEP00–1/1

4-6-16

012704

PN=224

Miscellaneous—Machine Numbers Record Product Identification Number (PIN) Purchase Date

T132526B

NOTE: Record all 13 characters of Product Identification Number.

–UN–13JUL00

Product Identification Number

A—Product Identification Number Tag

CED,OUO1079,460 –19–13JUL00–1/1

Record Engine Serial Number

–UN–04SEP96

Engine Serial Number

T103543

A—Engine Serial Number Tag

05T,120,J3 –19–13JUL00–1/1

Record Transmission Serial Number— Powershift

–UN–13JUL00

Transmission Serial Number

T132445D

A—Transmission Serial Number Tag

CED,OUO1079,462 –19–13JUL00–1/1

Record Rear Axle Housing Serial Number

–UN–13JUL00

Rear Axle Housing Serial Number

T132527B

A—Rear Axle Serial Number Tag

CED,OUO1079,463 –19–13JUL00–1/1

4-7-1

012704

PN=225

Miscellaneous—Machine Numbers

Record (MFWD) Front Axle Housing Serial Number—If Equipped

–UN–04SEP96

MFWD Front Axle Housing Serial Number

T103544

A—MFWD Front Axle Serial Number Tag

TX,120,RR4373 –19–13JUL00–1/1

4-7-2

012704

PN=226

Index Page

A Accessory outlets, 12-volt. . . . . . . . . . . . . . . . 2-1-19 Accumulator Ride control, checking. . . . . . . . . . . . . . . . . 4-1-17 Acid Battery, check electrolyte level . . . . . . . . . . . 3-6-2 Adjustment Engine valve clearance . . . . . . . . . . . . . . . . . 3-9-1 Air Cleaner elements clean . . . . . . . . . . . . . . . . 3-3-8 Air cleaner, engine Elements, replace . . . . . . . . . . . . . . . . . . . . 3-8-10 Intake hose . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Air conditioning Controls . . . . . . . . . . . . . . . . . . . . . . 2-1-9, 2-1-14 Receiver-dryer . . . . . . . . . . . . . . . . . . . . . . . 4-1-3 Alternator Indicator . . . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-7 Axle Front, non-powered Lubricate oscillating pivot and steering pivots . . . . . . . . . . . . . . . . . . . . . . 3-4-8, 3-4-9 Lubricate wheel bearings. . . . . . . 3-3-10, 3-3-11 Toe-in, check and adjust . . . . . . . . . . . . . 4-1-28 MFWD Change oil, housing. . . . . . . . . . . . . . . . . . 3-8-5 Change oil, planetary. . . . . . . . . . . . . . . . . 3-8-4 Check oil, housing . . . . . . . . . . . . . . . . . . . 3-6-1 Check oil, planetary . . . . . . . . . . . . . . . . . . 3-6-1 Lubricate drive shaft splines . . . . . . . . . . . 3-3-9 Lubricate oscillating pivot and universal joints . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-10 Operating . . . . . . . . . . . . . . . . . . . . . . . . 2-2-28 Toe-in, check and adjust . . . . . . . . . . . . . 4-1-28 Troubleshooting. . . . . . . . . . . . . . . . . . . . 4-3-14 Rear Oil change . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-7 Operating differential lock . . . . . . . . . . . . 2-2-27 Troubleshooting. . . . . . . . . . . . . . . . . . . . 4-3-15 Axles Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5

B Backhoe Adjustment Boom lock . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 Boom-to-dipperstick pin bolt torque . . . . . . 3-7-2

Page

Auxiliary hydraulic function Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-2-25 Bucket teeth installation . . . . . . . . . . . . . . . 4-1-30 Counterweights Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-15 Liquid, in front tires . . . . . . . . . . . . . . . . . 4-1-15 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-31 Lubricate Extendible dipperstick rails . . . . . . . . . . . . 3-3-9 Pivots and cylinders. . . . . . . . . . . . . . . . . . 3-4-6 Specification, pivot and cylinder grease . . . 3-1-6 Specification, rails . . . . . . . . . . . . . . . . . . . 3-1-6 Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-5 Operating Auxiliary hydraulic function . . . . . . . . . . . 2-2-25 Boom lock . . . . . . . . . . . . . . . . . . . . . . . . 2-2-17 Extendible dipperstick . . . . . . . . . . . . . . . 2-2-23 ISO excavator two-lever controls . . . . . . . 2-2-20 John Deere two-lever controls . . . . . . . . . 2-2-19 Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . 2-2-16 Swing lock . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18 Stabilizers Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . 3-4-5 Ballast Counterweights, front of frame . . . . . . . . . . 4-1-15 Liquid, in front tires . . . . . . . . . . . . . . . . . . . 4-1-15 Battery Acid Burns from battery acid . . . . . . . . . . . . . . . 3-6-2 Electrolyte level check. . . . . . . . . . . . . . . . . . 3-6-2 Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-2 Explosions, prevent. . . . . . . . . . . . . . . . . . . . 1-2-4 Handling, checking, servicing . . . . . . . . . . . . 4-1-8 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8 Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-10 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 4-1-9 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-2 Bearings, front wheel . . . . . . . . . . . . . . . . . . . . 3-8-1 Belt inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Bleeding service brakes . . . . . . . . . . . . . . . . . 4-1-22 Brake Park brake Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21 Service brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-22 Inspection, external . . . . . . . . . . . . . . . . . . 4-1-1 Break-in Engine . . . . . . . . . . . . . . 3-1-3, 3-5-1, 3-6-5, 3-7-4 Breather, hydraulic reservoir. . . . . . . . . . . . . . . 3-7-3 Bucket Backhoe Installing teeth . . . . . . . . . . . . . . . . . . . . . 4-1-30

Index-1

012704

PN=1

Index

Page

Page

Front loader Changing buckets . . . . . . . . . . . . . . . . . . 4-1-14 Bulb replacement, halogen lights . . . . . . . . . . 4-1-13

Defroster controls . . . . . . . . . . . . . . . . . 2-1-9, 2-1-14 Diesel Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Differential lock foot switch . . . . . . . . . . . . . . . 2-2-27 Dipperstick, extendible Lock Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-2-24 Lubricant specification. . . . . . . . . . . . . . . . . . 3-1-6 Lubricate rails . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-23 Display monitor Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-5 Display window, monitor panel . . . . . . . . . . . . . 2-1-2 Drain engine coolant . . . . . . . . . . . . . . . . . . . . 4-1-4 Driving Steering wheel tilt lever. . . . . . . . . . . . . . . . 2-1-18 With powershift transmission. . . . . . . . . . . . 2-2-14 Dust unloader vlave Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-7

C Cab air filters . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-5 Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-8 Cold weather Machine warm-up . . . . . . . . . . . . . . . . . . . . 2-2-10 Starting . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5, 2-2-6 Controls Backhoe, ISO excavator two-lever Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20 Backhoe, John Deere two-lever Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-2-19 Steering console Locations. . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11 Steering wheel tilt lever. . . . . . . . . . . . . . . . 2-1-18 Coolant Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 3-1-7 Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3 Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 Cooling system Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Service safely . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1 COOLSCAN PLUS . . . . . . . . . . . . . . . . . . . . . . 3-2-7 Counterweights Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-15 Liquid, in front tires . . . . . . . . . . . . . . . . . . . 4-1-15 Crime prevention Document ownership . . . . . . . . . . . . . . . . . . 4-5-1 Keep proof of ownership . . . . . . . . . . . . . . . . 4-5-1 Park indoors out of sight . . . . . . . . . . . . . . . . 4-5-1 Record identification numbers . . . . . . . 4-5-1, 4-7-1 Reduce vandalism . . . . . . . . . . . . . . . . . . . . 4-5-2 Report thefts immediately . . . . . . . . . . . . . . . 4-5-3 When parking outdoors . . . . . . . . . . . . . . . . . 4-5-2 Cycle times. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-31 Cylinder service . . . . . . . . . . . . . . . . . . . . . . . 4-1-32

D Damper replacement, torsional . . . . . . . . . . . . . 4-1-6

E Electrical Accessory outlets, 12-volt . . . . . . . . . . . . . . 2-1-19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-6 Element Primary Cleaning and inspecting . . . . . . . . . . . . . . 4-1-2 Secondary Inspecting and cleaning . . . . . . . . . . . . . . . 4-1-2 Emergencies Prepare for . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5 Engine Air cleaner dust unloader valve, clean. . . . . . 3-3-7 Air filter restriction indicator . . . . . . . . . 2-1-4, 2-1-6 Alternator voltage indicator . . . . . . . . . 2-1-3, 2-1-6 Boost starting . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8 Break-in . . . . . . . . . . . . . 3-1-3, 3-5-1, 3-6-5, 3-7-4 Coolant heater . . . . . . . . . . . . . . . . . . . . . . . 2-2-9 Coolant temperature gauge. . . . . . . . . 2-1-3, 2-1-6 Crankcase vent tube . . . . . . . . . . . . . . . . . . . 3-8-5 Diesel engine oil . . . . . . . . . . . . . . . . . . . . . . 3-1-4 Hood, opening and closing . . . . . . . . . 3-2-4, 3-2-5 Oil check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Oil pressure indicator . . . . . . . . . . . . . 2-1-3, 2-1-6 Speed check . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-8 Speed control lever tension, adjust . . . . . . . 4-1-26, 4-1-27 Speed control linkage, adjust . . . . . . . . . . . . 3-8-8

Index-2

012704

PN=2

Index

Page

Page

Starting Powershift transmission . . . . . . . . . . . . . . . 2-2-3 Torsional damper replacement . . . . . . . . . . . 4-1-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-2 Valve clearance adjust . . . . . . . . . . . . . . . . . 3-9-1 Equipment, Protective Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-2 Extendible dipperstick Lock operation . . . . . . . . . . . . . . . . . . . . . . 2-2-24 Lubricant specification. . . . . . . . . . . . . . . . . . 3-1-6 Lubricate rails . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-23

Tank Drain water and sediment . . . . . . . . . . . . . 3-3-6 Fumes, exhaust Beware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-11

F Filter Cab air Clean and replace elements . . . . . . . . . . . 3-3-5 Engine air cleaner Dust unloader valve, clean . . . . . . . . . . . . 3-3-7 Replace elements . . . . . . . . . . . . . . . . . . 3-8-10 Fuel Drain water and sediment . . . . . . . . . . . . . 4-1-6 Replace element . . . . . . . . . . . . . . . . . . . . 3-7-6 Hydraulic Replace element . . . . . . . . . . . . . . . . . . . . 3-7-2 Fires, prevent . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4 Fluids, high pressure Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3 Front loader Boom service lock Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-3 Changing buckets . . . . . . . . . . . . . . . . . . . . 4-1-14 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-31 Lubricant specification. . . . . . . . . . . . . . . . . . 3-1-6 Lubrication . . . . . . . . . . . . . . . . . . . . . 3-4-4, 3-4-5 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26 Ride control Checking accumulator . . . . . . . . . . . . . . . 4-1-17 Discharge pressure for service . . . . . . . . 4-1-18 Front wheel drive Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Fuel Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2 Filter Drain water and sediment . . . . . . . . . . . . . 4-1-6 Replace element . . . . . . . . . . . . . . . . . . . . 3-7-6 Level gauge . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6

G Gauge Engine coolant temperature . . . . . . . . 2-1-3, 2-1-6 Fuel level . . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2 Transmission and torque converter oil temperature . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-3-11 Grease Alternative and synthetic lubricants . . . . . . . . 3-1-3 Axle MFWD drive shaft splines . . . . . . . . . . . . . 3-3-9 MFWD oscillating pivot and universal joints . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-10 Non-powered front wheel bearings . . . . . 3-3-10, 3-3-11 Axle, non-powered front Oscillating pivot and steering pivots. . . . . . 3-4-8, 3-4-9 Backhoe Extendible dipperstick rails . . . . . . . . . . . . 3-3-9 Pivots and cylinders. . . . . . . . . . . . . . . . . . 3-4-6 Stabilizers and cylinders . . . . . . . . . . . . . . 3-4-5 Front loader Pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-4 Pivots, bucket . . . . . . . . . . . . . . . . . . . . . . 3-4-5 Specification Pivots and cylinders. . . . . . . . . . . . . . . . . . 3-1-6 Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-6 Ground Speeds, 410G . . . . . . . . . . . . . . . . . . . 4-6-2

H Handholds Use correctly. . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1 Heater controls . . . . . . . . . . . . . . . . . . . 2-1-9, 2-1-14 Hood, opening and closing . . . . . . . . . . . 3-2-4, 3-2-5 Horn button . . . . . . . . . . . . . . . . . . . . 2-1-10, 2-1-13 Hose Crankcase ventilation . . . . . . . . . . . . . . . . . . 3-8-5 Engine air intake . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Radiator upper and lower . . . . . . . . . . . . . . . 4-1-3

Index-3

012704

PN=3

Index

Page

Page

Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1 Hydraulic Backhoe auxiliary function Operation . . . . . . . . . . . . . . . . . . . . . . . . 2-2-25 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-31 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-9 Filter, replace element . . . . . . . . . . . . . . . . 3-7-2 Oil filter restriction indicator . . . . . . . . . 2-1-4, 2-1-6 Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Reservoir Breather, replace . . . . . . . . . . . . . . . . . . . . 3-7-3 Fill screen, inspect and clean . . . . . . . . . . 3-3-6 Oil level check . . . . . . . . . . . . . . . . . . . . . . 3-4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-9

Lubricant specification. . . . . . . . . . . . . . . . . . 3-1-6 Lubrication . . . . . . . . . . . . . . . . . . . . . 3-4-4, 3-4-5 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-26 Ride control Checking accumulator . . . . . . . . . . . . . . . 4-1-17 Discharge pressure for service . . . . . . . . 4-1-18 Lubricant Alternative and synthetic lubricants . . . . . . . . 3-1-3 Specification Pivots and cylinders. . . . . . . . . . . . . . . . . . 3-1-6 Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-6 Lubricate Axle MFWD drive shaft splines . . . . . . . . . . . . . 3-3-9 MFWD oscillating pivot and universal joints . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-10 Non-powered front wheel bearings . . . . . 3-3-10, 3-3-11 Axle, non-powered front Oscillating pivot and steering pivots. . . . . . 3-4-8, 3-4-9 Backhoe Extendible dipperstick rails . . . . . . . . . . . . 3-3-9 Pivots and cylinders. . . . . . . . . . . . . . . . . . 3-4-6 Stabilizers and cylinders . . . . . . . . . . . . . . 3-4-5 Front loader Pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-4 Pivots, bucket . . . . . . . . . . . . . . . . . . . . . . 3-4-5

I Indicator Check service code. . . . . . . . . . . . . . . . . . . . 2-1-6 Engine air filter restriction . . . . . . . . . . 2-1-4, 2-1-6 Engine alternator voltage . . . . . . . . . . 2-1-3, 2-1-6 Engine oil pressure . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Hydraulic oil filter restriction . . . . . . . . 2-1-4, 2-1-6 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2 Park brake . . . . . . . . . . . . . . . . . . . . . 2-1-4, 2-1-6 Ride control . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Seat belt . . . . . . . . . . . . . . . . . . . . . . . 2-1-4, 2-1-6 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-3-11 Injection Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Inspection, pre-start . . . . . . . . . . . . . . . . . . . . . 2-2-1 Instrument Check before starting . . . . . . . . . . . . . . . . . . 2-2-2

L Lever Steering wheel tilt . . . . . . . . . . . . . . . . . . . . 2-1-18 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-29 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11 Loader Boom service lock Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-3 Changing buckets . . . . . . . . . . . . . . . . . . . . 4-1-14 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-31

M Machine Maintenance, preparation for. . . . . . . . . . . . . 3-2-2 Warm-up Cold weather . . . . . . . . . . . . . . . . . . . . . . 2-2-10 Normal conditions . . . . . . . . . . . . . . . . . . . 2-2-9 Machine modifications Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-2 Macine, inspect . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3 Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1 Preparation for . . . . . . . . . . . . . . . . . . . . . . . 3-2-2 Record . . . . . . . . . . . . . . . . . . . . . . . . 3-2-6, 3-2-8 Mechanical front wheel drive Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5 MFWD Lubricate Change axle housing oil . . . . . . . . . . . . . . 3-8-5 Change planetary housing oil . . . . . . . . . . 3-8-4 Check axle housing oil level . . . . . . . . . . . 3-6-1

Index-4

012704

PN=4

Index

Page

Page

Check planetary housing oil level . . . . . . . 3-6-1 Drive shaft splines . . . . . . . . . . . . . . . . . . . 3-3-9 Oscillating pivot and universal joints . . . . 3-4-10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-28 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-3-14 Miscellaneous checks Operational checkout . . . . . . . . . . . . . . . . . 4-2-12 Monitor Check service code indicator . . . . . . . . . . . . 2-1-6 Display window . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-5 Engine air filter restriction indicator . . . 2-1-4, 2-1-6 Engine alternator voltage indicator . . . 2-1-3, 2-1-6 Engine coolant temperature gauge . . . 2-1-3, 2-1-6 Engine oil pressure indicator . . . . . . . . 2-1-3, 2-1-6 Fuel level gauge . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-5 Hydraulic oil filter restriction indicator . . . . . . 2-1-4, 2-1-6 Park brake indicator . . . . . . . . . . . . . . . . . . . 2-1-4 Seat belt indicator . . . . . . . . . . . . . . . . . . . . . 2-1-4 Seat belt/park brake indicator . . . . . . . . . . . . 2-1-6 Select button. . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-5 Stop indicator . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Transmission and torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2 Motor service . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-32

Specification Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Diesel engine. . . . . . . . . . . . . . . . . . . . . . . 3-1-4 Hydraulic system . . . . . . . . . . . . . . . . . . . . 3-1-5 Mechanical front wheel drive . . . . . . . . . . . 3-1-5 Transmission . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 OILSCAN PLUS . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7 Operating tips Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-29 Operational checkout procedures . . . . . . . . . . . 4-2-1 Operational checks Accessories . . . . . . . . . . . . . . . . . . . . . . . . 4-2-10 Brake system . . . . . . . . . . . . . . . . . . . . . . . . 4-2-4 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-11 Gauge and indicator . . . . . . . . . . . . . . . . . . . 4-2-1 Hydraulic system. . . . . . . . . . . . . . . . . . . . . . 4-2-6 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-3 Steering system . . . . . . . . . . . . . . . . . . . . . . 4-2-5 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-2

N Neutral start system check . . . . . . . . . . . . . . . 4-1-13

O Oil Change Hydraulic reservoir. . . . . . . . . . . . . . . . . . . 3-8-9 MFWD front axle housing . . . . . . . . . . . . . 3-8-5 MFWD planetary housing . . . . . . . . . . . . . 3-8-4 Rear axle housing . . . . . . . . . . . . . . . . . . . 3-8-7 Transmission and torque converter . . . . . . 3-5-3, 3-8-6 Level Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Hydraulic reservoir. . . . . . . . . . . . . . . . . . . 3-4-1 MFWD housing . . . . . . . . . . . . . . . . . . . . . 3-6-1 MFWD planetary housing . . . . . . . . . . . . . 3-6-1 Rear axle housing . . . . . . . . . . . . . . . . . . . 3-6-4 Transmission . . . . . . . . . . . . . . . . . . . . . . . 3-6-4

P Park brake Check operation of . . . . . . . . . . . . . . . . . . . 4-1-21 Indicator . . . . . . . . . . . . . . . . . . . . . . . 2-1-4, 2-1-6 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Parking the machine. . . . . . . . . . . . . . . . . . . . 2-2-30 Parts, moving Stay clear . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3 Periodic maintenance chart . . . . . . . . . . . . . . . 3-2-1 Pins, metal Drive safely . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3 Pre-start inspection. . . . . . . . . . . . . . . . . . . . . . 2-2-1 Pump Service of pumps . . . . . . . . . . . . . . . . . . . . 4-1-32

R Receiver-dryer Check sight glasses . . . . . . . . . . . . . . . . . . . 4-1-3 Regulator precaution . . . . . . . . . . . . . . . . . . . . 4-1-7 Ride control Checking accumulator. . . . . . . . . . . . . . . . . 4-1-17 Discharge pressure for service . . . . . . . . . . 4-1-18 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-11 Switch and indicator . . . . . . . . . . . . . . . . . . . 2-1-8 Roads Operating or traveling . . . . . . . . . . . . . . . . . . 1-3-6

Index-5

012704

PN=5

Index

Page

Page

ROPS Inpsect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6 Keep properly installed . . . . . . . . . . . . . . . . 4-1-32 Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6

Oil Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Mechanical front wheel drive . . . . . . . . . . . 3-1-5 Transmission . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Oil, diesel engine . . . . . . . . . . . . . . . . . . . . . 3-1-4 Oil, differential. . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Oil, hand-operated cab tilt hydraulic pump . . 3-1-5 Oil, park brake . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Unified inch bolt and cap screw torque . . . . 4-1-34 Wheel fastener torque. . . . . . . . . . . . . . . . . . 3-3-4 410G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-1 Speed Engine speed control linkage adjustment . . . 3-8-8 Ground, 410G . . . . . . . . . . . . . . . . . . . . . . . . 4-6-2 Stabilizers Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-5 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-16 Starting fluid, cold weather start . . . . . . . 2-2-5, 2-2-6 Starting the engine Powershift transmission . . . . . . . . . . . . . . . . 2-2-3 Steering system . . . . . . . . . . . . . . . . . . . . . . . . 4-3-8 Steps Use correctly. . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1 Stop indicator . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-6 Storage Diesel fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1 Switch Air suspension seat height adjustment . . . . . 2-1-9 Defroster, heater, and air conditioner . . . . . . 2-1-9, 2-1-14 Differential lock foot switch . . . . . . . . . . . . . 2-2-27 Locations, steering console. . . . . . . . . . . . . 2-1-11 Mechanical front wheel drive (MFWD). . . . . 2-2-28 Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Ride control . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Turn signal . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11 Warning lights . . . . . . . . . . . . . . . . . . . . . . . 2-1-11 Windshield wiper, rear. . . . . . . . . . . . . . . . . . 2-1-9 Work and drive lights . . . . . . . . . . . . . . . . . 2-1-11

S Safety Information, recognize. . . . . . . . . . . . . . . . . . 1-2-1 Instructions, follow . . . . . . . . . . . . . . . . . . . . 1-2-1 Park and prepare for service safely. . . . . . . . 1-4-1 Screen, hydraulic reservoir fill Inspect and clean . . . . . . . . . . . . . . . . . . . . . 3-3-6 Seat Air suspension Switch, height adjustment . . . . . . . . . . . . . 2-1-9 Non-suspension Controls. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-16 Operational checkout . . . . . . . . . . . . . . . . . 4-2-12 Seat belt inspection and replacment . . . . . . 2-1-18 Suspension Controls. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-17 Seat belt Indicator . . . . . . . . . . . . . . . . . . . . . . . 2-1-4, 2-1-6 Use and maintain . . . . . . . . . . . . . . . . . . . . . 1-3-1 Secondary and primary element Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2 Secondary exits . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 Select button . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-5 Select button, monitor panel . . . . . . . . . . . . . . . 2-1-2 Serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . 4-7-1 Service Control valves, cylinders, pumps, and motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-32 Ride control, discharge pressure. . . . . . . . . 4-1-18 Service brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-22 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1 Service code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-6 Service interval checklist . . . . . . . . . . . . . . . . . 3-2-8 Service record . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-8 Specification Backhoe boom-to-dipperstick pin bolt torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Hardware torque . . . . . . . . . . . . . . . . . . . . . 4-1-32 Lubricant Pivots and cylinders. . . . . . . . . . . . . . . . . . 3-1-6 Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-6 Metric bolt and cap screw torque . . . . . . . . 4-1-33

T Teeth, backhoe bucket . . . . . . . . . . . . . . . . . . 4-1-30 Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-3 Pressure check . . . . . . . . . . . . . . . . . . . . . . . 3-3-2 Toe-in adjustment. . . . . . . . . . . . . . . . . . . . . . 4-1-29 Toe-in, check and adjust . . . . . . . . . . . . . . . . 4-1-28

Index-6

012704

PN=6

Index

Page

Page

Toolbox Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-10 Torque converter Oil change . . . . . . . . . . . . . . . . . . . . . 3-5-3, 3-8-6 Oil temperature gauge . . . . . . . . . . . . 2-1-3, 2-1-6 Torsional damper replacement . . . . . . . . . . . . . 4-1-6 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32 Transmissioin Oil temperature gauge . . . . . . . . . . . . 2-1-3, 2-1-6 Transmission Oil change . . . . . . . . . . . . . . . . . . . . . 3-5-3, 3-8-6 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-4 Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-3-14 Transporting On a trailer . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-31 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-32 Traveling On public roads. . . . . . . . . . . . . . . . . . . . . . . 1-3-6

3-Way Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7

V Valve Engine air cleaner dust unloader, clean . . . . 3-3-7 Hydraulic control valve service . . . . . . . . . . 4-1-32 Vent tube, engine . . . . . . . . . . . . . . . . . . . . . . . 3-8-5 Vibration Torsional damper replacement . . . . . . . . . . . 4-1-6

W Warm-up Machine, cold weather . . . . . . . . . . . . . . . . 2-2-10 Machine, normal conditions. . . . . . . . . . . . . . 2-2-9 Waste Dispose of properly . . . . . . . . . . . . . . . . . . . . 1-2-5 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-16 Welding repairs Make safely . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2 Wheel bearings, front . . . . . . . . . . . . . . . . . . . . 3-8-1 Wheel fasteners . . . . . . . . . . . . . . . . . . . . . . . . 3-3-4 Window Operational checkout . . . . . . . . . . . . . . . . . 4-2-12 Windows Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 Side, secondary exits . . . . . . . . . . . . . . . . . 2-1-15 Windshield wipers Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9 12-volt accessory outlets . . . . . . . . . . . . . . . . 2-1-19

Index-7

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Index

Index-8

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