John Deere 624H Loader & TC62H Tool Carrier Operator's Manual - PDF DOWNLOAD

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624H Loader and TC62H Tool Carrier

OPERATOR’S MANUAL 624H Loader and TC62H Tool Carrier OMT195360 Issue B3 (ENGLISH)

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

If this product contains a gasoline engine:

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

The State of California requires the above two warnings.

Worldwide Construction And Forestry Division (This manual replaces OMT180472 G0) 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.

T132126

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 102703

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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,II,FAX –19–10JUL01–1/1 102703

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Page

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

Operation—Operator’s Station Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2 Deluxe Monitor Panel (Earlier Machines) . . . . . 2-1-3 Deluxe Monitor Panel Functions (Earlier Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-4 Deluxe Monitor Panel (Later Machines) . . . . . . 2-1-7 Deluxe Monitor Panel Functions (Later Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Console Switches and Accessories (Later Machines—Single Lever Design) . . . 2-1-11 Console Switch and Accessory Functions (Later Machines—Single Lever Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 Console Switches and Accessories (Later Machines—Two Lever Design) . . . . . 2-1-14 Console Switch and Accessory Functions (Later Machines—Two Lever Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 Monitor Display Unit . . . . . . . . . . . . . . . . . . . . 2-1-17 Monitor Display Unit—Accessory Menu Normal Display . . . . . . . . . . . . . . . . . . . . . . 2-1-18 Clutch Cut-Off (A 01) . . . . . . . . . . . . . . . . . 2-1-20 Quick Shift Mode (A 02) . . . . . . . . . . . . . . . 2-1-23 Auto Mode to First (A 03) . . . . . . . . . . . . . . 2-1-25 Job Timer Mode (A 04) . . . . . . . . . . . . . . . . 2-1-26 Stop Watch Mode (A 05). . . . . . . . . . . . . . . 2-1-26 0.1 Hour Meter Mode (A 06) . . . . . . . . . . . . 2-1-27 Metric Units Mode (A 07) . . . . . . . . . . . . . . 2-1-27 Monitor Display Unit—User Diagnostics Menu Service Codes (d 01) . . . . . . . . . . . . . . . . . 2-1-28 Continuity Check (d 02) . . . . . . . . . . . . . . . 2-1-30 Battery Monitor (d 03) . . . . . . . . . . . . . . . . . 2-1-32 Engine Sensors (d 04) . . . . . . . . . . . . . . . . 2-1-33 Transmission Sensors (d 05) . . . . . . . . . . . 2-1-36 Hydraulic Sensors (d 06). . . . . . . . . . . . . . . 2-1-38 Fuel Sensor (d 07) . . . . . . . . . . . . . . . . . . . 2-1-40 (d08)-Not Used . . . . . . . . . . . . . . . . . . . . . . 2-1-41 Machine I.D. Mode (d 10) . . . . . . . . . . . . . . 2-1-41 Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-47

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

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

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

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

Avoid Unauthorized Machine Modifications. . . .

Add Cab Guarding For Special Uses . . . . . . . .

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

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

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

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

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

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

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

Dispose of Waste Properly . . . . . . . . . . . . . . . .

Prepare for Emergencies . . . . . . . . . . . . . . . . .

1-2-1 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

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

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

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

Prevent Unintended Machine Movement . . . . .

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

Use Special Care When Operating Loader. . . .

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

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

Avoid Machine Tip Over . . . . . . . . . . . . . . . . . .

Operating on Slopes. . . . . . . . . . . . . . . . . . . . .

Operating Or Traveling On Public Roads . . . . .

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

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

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

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 . . . . . . . . . . . . . . . . . .

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

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

Continued on next page

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

COPYRIGHT  2003 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright  1997, 1998, 2000, 2001, 2002

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Contents

Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioning Controls . . . . . . . . . . . . . . . .

Air Flow Knob. . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Steering Wheel Tilt . . . . . . . . . . . . .

Opening and Securing Side Door . . . . . . . . . .

Opening Side Window/Secondary Exit . . . . . .

Opening Rear Side Window . . . . . . . . . . . . . .

Adjusting Seat . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

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2-1-47 2-1-48 2-1-49 2-1-49 2-1-49 2-1-51 2-1-51 2-1-52 2-1-53

Transmission, Hydraulic System, Park Brake, and Differential Oil . . . . . . . . . . . . . . . 3-1-5 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-6 Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 3-1-7 Maintenance—Periodic Maintenance Service Your Machine at Specified Intervals. . .

Check the Monitor Display Unit Regularly. . . . .

Opening Engine Side Shields and Service Doors . . . . . . . . . . . . . . . . . . . . . . . .

Locking Machine Frame . . . . . . . . . . . . . . . . . .

Boom Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening Grille Door . . . . . . . . . . . . . . . . . . . . .

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Windshield Washer Fluid Level . . . . . . .

Maintenance and Repair Record Keeping System . . . . . . . . . . . . . . . . . . . . . .

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

Service Intervals. . . . . . . . . . . . . . . . . . . . . . . .

Operation—Operating the Machine Inspect Machine Daily Before Starting . . . . . . . 2-2-1 Check Instruments Before Starting . . . . . . . . . . 2-2-2 Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 2-2-2 Starting Fluid—If Equipped (Cold Weather Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-4 Battery Using Booster Batteries—24 Volt System . . . 2-2-6 Engine Air Heater—If Equipped . . . . . . . . . . . . 2-2-7 Using Coolant Heater—If Equipped . . . . . . . . . 2-2-7 Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8 Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . 2-2-8 Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8 Shifting the Transmission . . . . . . . . . . . . . . . . . 2-2-9 Park Brake Switch . . . . . . . . . . . . . . . . . . . . . 2-2-10 Boom and Bucket Control Lever—One Lever Design. . . . . . . . . . . . . . . . . . . . . . . . 2-2-11 Boom and Bucket Control Lever Two Lever Design. . . . . . . . . . . . . . . . . . . . 2-2-12 Quick Shift Switch . . . . . . . . . . . . . . . . . . . . . 2-2-13 Ride Control Switch—Earlier Machines (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14 Ride Control—Later Machines (If Equipped). . 2-2-16 Secondary Steering—If Equipped . . . . . . . . . . 2-2-17 Differential Lock Switch . . . . . . . . . . . . . . . . . 2-2-18 Boom Height Kickout Adjustment . . . . . . . . . . 2-2-18 Return-to-Carry Kickout Adjustment . . . . . . . . 2-2-19 Return-To-Dig Adjustment (S.N. —574603) . . 2-2-20 Return-To-Dig Adjustment (S.N. 574603— ). . 2-2-22 Fork Attachment . . . . . . . . . . . . . . . . . . . . . . . 2-2-24 Parking the Machine. . . . . . . . . . . . . . . . . . . . 2-2-26 Loading Machine on a Trailer . . . . . . . . . . . . . 2-2-27 Towing Procedure . . . . . . . . . . . . . . . . . . . . . 2-2-29 Lifting the Machine . . . . . . . . . . . . . . . . . . . . . 2-2-31 Maintenance—Machine Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Alternative And Synthetic Lubricants . . . . . . . .

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

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

3-2-1 3-2-1 3-2-2 3-2-3 3-2-4 3-2-5 3-2-5 3-2-5 3-2-6 3-2-7 3-2-8

Maintenance—As Required Check Tire Pressure. . . . . . . . . . . . . . . . . . . . .

Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten Wheel Retainer Cap Screws . . . . . . . .

Check Fire Extinguisher—If Equipped . . . . . . .

Clean or Replace Air Cleaner Elements . . . . . .

Check Air Inlet Cover . . . . . . . . . . . . . . . . . . . .

Inspect Serpentine Belt . . . . . . . . . . . . . . . . . .

Drain Fuel Tank Sediment . . . . . . . . . . . . . . . .

Drain and Clean Primary Fuel Filter . . . . . . . . .

3-3-1 3-3-2 3-3-2 3-3-3 3-3-4 3-3-4 3-3-5 3-3-6 3-3-7

Maintenance—Every 10 Hours or Daily Check Recovery Tank Coolant Level . . . . . . . .

Clean Air Cleaner Dust Unloader Valve . . . . . .

Check Engine Oil Level . . . . . . . . . . . . . . . . . .

Check Hydraulic Oil Level . . . . . . . . . . . . . . . .

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

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

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

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

Maintenance—Every 100 Hours Grease Loader Linkage and Cylinder Pivots. . . 3-6-1 Grease Front Steering Cylinder Pivots . . . . . . . 3-6-3 Grease Oscillating Rear Axle and Rear Steering Cylinder Pivots . . . . . . . . . . . . . . . . 3-6-3 Continued on next page

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Check Cab Fresh Air Filter—If Equipped With Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3 Check Cab Recirculating Air Filter—If Equipped With Cab . . . . . . . . . . . . . . . . . . . . 3-6-6

Precautions for Alternator and Regulator . . . . . 4-1-5 Handling, Checking And Servicing Batteries Carefully . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-6 Replacing Batteries . . . . . . . . . . . . . . . . . . . . . 4-1-7 Removing Batteries . . . . . . . . . . . . . . . . . . . . . 4-1-8 Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . 4-1-9 Fuse (Blade-Type) Color Codes . . . . . . . . . . . 4-1-11 Replacing Halogen Bulbs . . . . . . . . . . . . . . . . 4-1-12 Engine Speeds . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13 Checking Neutral Start System. . . . . . . . . . . . 4-1-13 Servicing Air Conditioning System . . . . . . . . . 4-1-14 Welding on Machine . . . . . . . . . . . . . . . . . . . . 4-1-14 External Service Brake Inspection . . . . . . . . . 4-1-15 Checking Brake Accumulators . . . . . . . . . . . . 4-1-16 Checking Ride Control Accumulator—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-17 Transmission Oil Cooler, Hydraulic Oil Cooler, Air-to-Air Aftercooler, and . . . . . . . . 4-1-19 Service Recommendations For STC1 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-20 Do Not Service Control Valves, Cylinders, Pumps or Motors . . . . . . . . . . . . 4-1-21 Hardware Torque Specifications . . . . . . . . . . . 4-1-22 Keep ROPS Installed Properly . . . . . . . . . . . . 4-1-22 Metric Bolt and Cap Screw Torque Values . . . 4-1-23 Unified Inch Bolt and Cap Screw Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24

Maintenance—Every 250 Hours Grease Front Driveline Sliding Joint . . . . . . . . .

Check Receiver Dryer Moisture Indicator . . . . .

Check Radiator Coolant Level . . . . . . . . . . . . .

Change Engine Oil and Replace Filter . . . . . . .

3-7-1 3-7-2 3-7-2 3-7-3

Maintenance—Every 500 Hours Lubricate Upper and Lower Drive Line Sliding Joints. . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1 Check Air Intake Hoses . . . . . . . . . . . . . . . . . . 3-8-2 Check Battery Electrolyte Level and Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-3 Replace Primary Fuel Filter . . . . . . . . . . . . . . . 3-8-5 Replace Final Fuel Filter. . . . . . . . . . . . . . . . . . 3-8-5 Replace Hydraulic System Return Filter . . . . . . 3-8-6 Grease Rear Oscillating Support Cover . . . . . . 3-8-6 Replace Hydraulic Reservoir Breather Filter . . . 3-8-7 Replace Transmission Oil Filter . . . . . . . . . . . . 3-8-8 Check Park Brake Oil Level . . . . . . . . . . . . . . 3-8-10 Check Front and Rear Differential Oil Level . . 3-8-11 Maintenance—Every 1000 Hours Clean Engine Crankcase Vent Tube. . . . . . . . .

Replace Air Cleaner Dust Unloader Valve . . . .

Replace Air Cleaner Elements . . . . . . . . . . . . .

Check Coolant . . . . . . . . . . . . . . . . . . . . . . . . .

Check Radiator Hoses . . . . . . . . . . . . . . . . . . .

Change Transmission Oil . . . . . . . . . . . . . . . . .

Grease Frame Hinge Pivots . . . . . . . . . . . . . . .

Check Park Brake . . . . . . . . . . . . . . . . . . . . . .

Change Park Brake Oil. . . . . . . . . . . . . . . . . . .

3-9-1 3-9-1 3-9-1 3-9-2 3-9-3 3-9-4 3-9-6 3-9-7 3-9-8

Miscellaneous—Operational Checkout Operational Checkout . . . . . . . . . . . . . . . . . . . .

Checking and Clearing Diagnostic Trouble Codes From Monitor . . . . . . . . . . . .

Engine Off Checks . . . . . . . . . . . . . . . . . . . . . .

Engine Running Checks . . . . . . . . . . . . . . . . . .

3-11-1 3-11-2 3-11-3 3-11-4

Miscellaneous—Machine Draining the Cooling System . . . . . . . . . . . . . .

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

Replacing Engine Vibration Damper . . . . . . . . .

Adjusting Pilot Controller Tower . . . . . . . . . . . .

Checking Fuel Tank Vent Hose . . . . . . . . . . . .

Bleeding Fuel System. . . . . . . . . . . . . . . . . . . .

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

Miscellaneous—Troubleshooting Troubleshooting Procedure. . . . . . . . . . . . . . . . 4-3-1 Diagnostic Trouble Codes Quick Reference List. . . . . . . . . . . . . . . . . . . . . . . . 4-3-2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-5 Diagnose Transmission System Malfunctions . . . . . . . . 4-3-7 Differential And Axle Malfunctions . . . . . . . . 4-3-10 Service Brake Malfunctions. . . . . . . . . . . . . 4-3-11 Drive Line Malfunctions. . . . . . . . . . . . . . . . 4-3-12 Park Brake Malfunctions . . . . . . . . . . . . . . . 4-3-13 Loader Hydraulic System Malfunctions . . . . 4-3-14 Steering Malfunctions . . . . . . . . . . . . . . . . . 4-3-16 Air Conditioning System . . . . . . . . . . . . . . . . . 4-3-17 Heater System . . . . . . . . . . . . . . . . . . . . . . . . 4-3-19

Maintenance—Every 2000 Hours Adjust Engine Valve Lash (Clearance) . . . . . . 3-10-1 Maintenance—Every 3000 Hours Change Hydraulic System Oil . . . . . . . . . . . . .

Clean Hydraulic System Strainer . . . . . . . . . .

Change Front and Rear Differential Oil. . . . . .

Clean Axle Differential Recirculation Screen. .

4-2-1

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

Continued on next page

iii

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Contents

Page

Miscellaneous—Storage Prepare Machine For Storage . . . . . . . . . . . . . 4-4-1 Miscellaneous—Machine Numbers Record Product Identification Number (PIN) . . .

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

Record Transmission Serial Number . . . . . . . .

Record Hydraulic Pump Serial Number . . . . . .

Record Axle Serial Number . . . . . . . . . . . . . . .

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

Miscellaneous—Specifications 624H/TC62H Specifications . . . . . . . . . . . . . . . 4-6-1 624H High Lift Specifications . . . . . . . . . . . . . . 4-6-3 Drain and Refill Capacities—624H/TC62H . . . . 4-6-4 Miscellaneous—Crime Prevention Tips Help Prevent Crime . . . . . . . . . . . . . . . . . . . . .

Record Identification Numbers . . . . . . . . . . . . .

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

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

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

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

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

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

iv

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Safety—Safety Features Safety Features 1 2 3 4 9

11

15 13

12

10

8 5 6

14

T138566

–UN–01JUN01

7

T138566

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

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

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

3. Mirrors. Large exterior mirrors on both sides and an inside mirror offers operator a broad view of area behind machine.

4. Large Windshield Wiper with Washer. Extra long wiper cleans large windshield area.

5. Loader Boom Service Lock. Loader includes a mechanical lock for securing boom in the raised position before work is started on or around the machine.

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

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

8. Handholds. Large, conveniently placed handholds make it easy to enter or exit the operator’s station or service area.

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

10. Independent Parking Brake. Electronically controlled and engages whenever the engine is stopped.

11. Seat Belt Retractors. Seat belt retractors help keep belts clean and convenient to use.

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

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

14. Back Up Alarm. Alerts bystanders when reverse travel direction is selected by operator.

15. Stop and Signal Lights. Highly visible stop lights are standard equipment.

TX03679,00016FD –19–14JUN01–1/1

1-1-1

102703

PN=7

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

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.

–19–28AUG00

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

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.

TX03679,00016CC –19–21AUG00–1/1

Follow Safety Instructions –UN–24AUG00

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

Review them frequently.

T133556

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 –19–14MAR01–1/1

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

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

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

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

TX03679,00016FA –19–30OCT00–1/1

1-2-1

102703

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Safety—General Precautions

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.

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 –19–30OCT00–1/1

Use load-clamping grapples to keep bulky loads from falling and add special screens or guarding when objects may be directed toward the cab. Contact your authorized dealer for information on devices intended to protect the operator from falling or flying objects in special work situations.

T141893

Special work situations or machine attachments may create an environment with falling or flying objects.

Loading logs, using fork attachments, or operating in waste management applications requires special work tools. Added cab guarding to protect the operator may also be required.

–UN–04MAY01

Add Cab Guarding For Special Uses

TX03679,00017C6 –19–01JUN01–1/1

1-2-2

102703

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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

102703

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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

102703

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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 dealer for more information.

TX03679,0001733 –19–14SEP00–1/1

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

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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

102703

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Safety—Operating Precautions

Prevent Unintended Machine Movement

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

T142001

Lower all equipment to the ground during work interruptions. Lock transmission control in neutral, engage park brake and stop engine before allowing anyone to approach the machine.

–UN–15MAY01

When co-workers are present, disable hydraulics.

TX03679,00017C7 –19–28OCT02–1/1

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

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.

T141670

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.

–UN–24APR01

T141894

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.

–UN–15JUN01

Avoid Work Site Hazards

T141672

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

–UN–04MAY01

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

TX03679,000179A –19–02MAY01–1/1

1-3-2

102703

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Safety—Operating Precautions

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

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

T141957 –UN–07MAY01

Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes or an unstable surface. Drive and turn slowly with a raised load.

T141902

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

–UN–15MAY01

Use Special Care When Operating Loader

TX03768,0000B70 –19–14MAY01–1/1

Keep Riders Off Machine

Riders may obstruct operator’s view or impair his ability to operate machine safely.

T141671

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.

–UN–04MAY01

Only allow operator on machine.

TX03679,000179B –19–20APR01–1/1

1-3-3

102703

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Safety—Operating Precautions

Be certain reverse warning alarm is working properly.

T141673

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

–UN–04MAY01

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.

TX03679,000179C –19–20APR01–1/1

Be careful on slopes. Avoid sharp turns. Balance loads so weight is evenly distributed and load is stable. Carry tools and loads close to the ground to aid visibility and lower center of gravity. Use extra care on soft, rocky or frozen ground.

Know the capacity of the machine. Do not overload. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability.

T133716 T141672

Ensure solid footing. Use extra care in soft ground conditions that may not uniformly support the wheels, especially when raising the boom. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall.

–UN–04MAY01

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

T141676

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

–UN–04MAY01

Use seat belt at all times.

–19–14SEP00

Avoid Machine Tip Over

TX03679,000179D –19–02MAY01–1/1

1-3-4

102703

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Safety—Operating Precautions

Select low gear speed before starting down slope. The grade of the slope will be limited by ground condition and load being handled.

Use service brakes to control speed. Sudden brake application with a loaded bucket on downhill side could cause machine to tip forward.

T141681

Avoid side slope travel whenever possible. Drive up steep slope in forward and down in reverse.

–UN–30APR01

Operating on Slopes

TX03679,000179E –19–14MAY01–1/1

Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition.

T141891

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.

–UN–22MAY01

Operating Or Traveling On Public Roads

TX03679,00017C8 –19–14JUN01–1/1

1-3-5

102703

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Safety—Operating Precautions

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

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

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

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

1-3-6

102703

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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.

• Install frame locking bar.

• 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 boom, bucket, or other hydraulically actuated equipment.

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

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

–UN–23AUG88

Securely support machine or attachment before working under it.

TX03679,00017A0 –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

102703

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

102703

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

102703

PN=21

Safety—Safety Signs

T161046

–19–30OCT02

Safety Signs

Left Side Shown Continued on next page

1-5-1

TX03679,00017F6 –19–07AUG01–1/2 102703

PN=22

T161047

–19–29OCT02

Safety—Safety Signs

Right Side Shown

TX03679,00017F6 –19–07AUG01–2/2

1-5-2

102703

PN=23

Operation—Operator’s Station

T117002

T156903B

–UN–01JUL02

–UN–10SEP98

Levers

Single Lever (Joystick) Design

T117004

T160584B

–UN–10SEP98

–UN–17OCT02

Two Lever Design

Single Lever (Joystick) with Auxiliary Control Design

Two Lever with Auxiliary Control Design

HG31779,0000152 –19–17OCT02–1/2

T113445

–UN–12FEB98

A—Transmission Control Lever B—Turn Signal

HG31779,0000152 –19–17OCT02–2/2

2-1-1

102703

PN=24

Operation—Operator’s Station

Pedals

T102536

–UN–10SEP96

A—Accelerator B—Brake/Clutch Cut-Off Pedal C—Brake/Clutch Cut-Off Pedal D—Differential Lock Foot Switch—If equipped

TX,10,JC1191 –19–21JUN96–1/1

2-1-2

102703

PN=25

Operation—Operator’s Station

T103806

–UN–25FEB97

Deluxe Monitor Panel (Earlier Machines)

A—Coolant Level Indicator B—Engine Air Filter Restriction Indicator C—Engine Oil Pressure Indicator D—Engine Preheat Indicator— If Equipped E—Left Turn Indicator F—STOP Indicator G—High Beams ON Indicator (not used)

H—Service Required Indicator I—Right Turn Indicator J—Park Brake Indicator K—Brake Oil Pressure Indicator L—Secondary Steering Warning Indicator—If Equipped M—Work Lights Indicator N—Fasten Seat Belt Indicator O—Hydraulic Oil Filter Restriction Indicator

• MENU provides initial entry into the accessories and diagnostics system. Each time MENU is pressed, display will cycle to the next menu. Once a main menu has been selected, pressing MENU again will return to the Normal Display Menu.

• BACK will back out of a menu, one item each time the key is pressed.

P—Hydraulic Oil Temperature Indicator Q—Message Display (Deluxe Monitor only) R—Transmission Service Indicator S—Transmission Filter Indicator T—Battery Voltage Indicator U—Engine Oil Pressure Gauge (Deluxe Monitor only)

V—Engine Coolant Temperature Gauge W—Hydraulic Oil Temperature Gauge (Deluxe Monitor only) X—Transmission Oil Temperature Gauge Y—Fuel Gauge Z—Basic Display Window

• NEXT will move to the next selection within a menu or mode.

• SELECT switches between volts/kilometers/hours during normal operation. During accessories or diagnostics modes, SELECT will activate the currently chosen menu.

TX,10,JC2254 –19–31AUG98–1/1

2-1-3

102703

PN=26

Operation—Operator’s Station

Deluxe Monitor Panel Functions (Earlier Machines) A—Check Engine Indicator: Indicator will light when excessive water is present in primary fuel filter (water separator). STOP indicator will light, alarm will sound and engine will derate to 50% of full power until water is drained.

When water is drained, indicators and alarm will go off and the engine will return to full power.

B—Engine Air Filter Restriction Indicator: Indicator will light and service required indicator will light when air elements are restricted. Clean or change elements.

The STOP indicator light flashes and alarm sounds when: • • • •

Engine oil pressure is low.

Engine coolant temperature is excessively high.

Transmission oil temperature is excessively high.

Transmission is shifted into gear with park brake engaged. Push park brake switch to OFF. • Brake pressure is low.

• Steering system pressure is low, and secondary steering is activated.

G—High Beams ON Indicator : Not used.

C—Engine Oil Pressure Indicator: IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. Indicator will light, STOP indicator will flash, and alarm will sound when engine oil pressure is low. Stop machine. STOP ENGINE IMMEDIATELY.

NOTE: Cold oil or extreme off level operation may cause indicator to light.

D—Engine Preheat Indicator—If Equipped:Indicator will light when key switch is turned clockwise to the ON position. Light will turn off approximately 15-45 seconds depending on engine temperature, indicating that preheating is completed. Light will turn off while cranking engine.

E—Left Turn Indicator: Indicator will light when left turn signal switch is engaged.

F—STOP Indicator: CAUTION: Prevent possible injury or machine damage. If STOP indicator light flashes and alarm sounds, stop immediately and investigate cause of problem.

H—Service Required Indicator (Yellow): Indicator will light when a problem is developing. It is not necessary to stop the engine immediately, but the cause should be investigated as soon as possible. The service required indicator lights when: • • • • •

Alternator voltage is low.

Transmission filter is restricted.

Engine air filter is restricted.

Hydraulic oil temperature is too high.

Hydraulic oil filter is restricted.

NOTE: Cold oil may cause hydraulic and transmission oil filter restriction indicators to light temporarily.

It is not necessary to stop the engine immediately but the cause should be investigated as soon as possible.

I—Right Turn Indicator: Indicator will light when right turn signal switch is engaged.

J—Park Brake Indicator: Indicator light will when park brake is engaged and transmission control lever is in neutral “N”.

If park brake is engaged and transmission control lever is in forward “F” or reverse “R”, the STOP indicator light will flash and alarm will sound. Push park brake switch to OFF.

Continued on next page

2-1-4

HG31779,000005F –19–29APR02–1/3 102703

PN=27

Operation—Operator’s Station NOTE: Cold oil may cause hydraulic oil filter restriction indicator light to light until oil is warm.

K—Brake Oil Pressure Indicator: CAUTION: Prevent possible injury or machine damage. If brake pressure indicator light comes on while operating, stop machine immediately.

P—Fuel Filter Restriction Indicator:

NOTE: Indicator may come on during cold startups or when machine is under heavy loads.

Indicator will light, STOP indicator will flash, and alarm will sound when brake oil pressure is low, or brake accumulator has lost its charge. Stop machine immediately and push park brake switch to ON.

A flickering light is an early warning that fuel filter needs to be changed.

Indicator will light when fuel pressure drops below 300 kPa (43.5 psi).

L—Secondary Steering Warning Indicator—If Equipped:

If pressure drops below 200 kPa (29 psi), indicator will remain on. SERVICE REQUIRED indicator will come on and engine will derate to 50% of full power.

IMPORTANT: Prevent possible damage to secondary steering system. Stop machine immediately if secondary steering indicator light and alarm come on while operating. THE SECONDARY STEERING SYSTEM IS NOT INTENDED FOR CONTINUOUS USE.

Replace primary fuel filter (water separator) element and primary fuel filter strainer.

Indicator will light, STOP indicator will flash and alarm will sound when secondary steering system is activated. Stop machine immediately and take corrective action. The secondary steering system is not intended for continuous use.

M—Work Lights Indicator: Indicator will light when work lights switch is on.

N—Fasten Seat Belt Indicator: Indicator will light for the first five seconds after the engine is started to warn the operator to fasten seat belt.

O—Hydraulic Oil Filter Restriction Indicator: IMPORTANT: Prevent possible hydraulic pump damage. Change hydraulic oil filter as soon as possible when a problem occurs.

Indicator will light and service required indicator will light when hydraulic filter element is restricted.

Q—Message Display: Displays a 12 character alpha-numeric message that provides a text description of the currently displayed mode. This message display supplements the information that is shown on the basic display window.

R—Transmission Service Indicator: Indicator will light and stay on when a transmission clutch slippage service code has been detected. The transmission will shift to “neutral” and then machine can only be moved in “limp home” mode. A service code will be logged in Monitor Display Unit. This code can be read by accessing the Monitor Diagnostic Mode (d).

The indicator light will go off when key switch has been turned to OFF. Every time clutch slippage occurs, the light will go on and will remain on until key switch is turned to OFF. See your authorized dealer for servicing.

S—Transmission Filter Indicator: Indicator will light and the service required indicator will light when the transmission filter is restricted.

Continued on next page

2-1-5

HG31779,000005F –19–29APR02–2/3 102703

PN=28

Operation—Operator’s Station T—Battery Voltage Indicator: Indicator will light and service required indicator will light when alternator output is low. Check battery charge by selecting battery voltage on digital display.

indicator points to red zone, hydraulic oil temperature is too high. Stop work cycle and cycle loader functions without load to lower indicator reading. If indicator still stays in red zone, stop machine and see your authorized dealer.

U—Engine Oil Pressure Gauge: IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. Indicator will light, STOP indicator will flash, and alarm will sound when engine oil pressure gauge indicates low pressure. Stop machine. STOP ENGINE IMMEDIATELY. If pointer deflects to the far right side of the scale, electronic communication is lost or a sensor error is active.

NOTE: Extreme off level operation may cause indicator to light.

V—Engine Coolant Temperature Gauge: STOP indicator light will flash, and audible alarm will sound when pointer is in red zone. Stop machine and allow engine to cool. Shut off engine and take corrective action.

If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active.

If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active.

X—Transmission Oil Temperature Gauge: If indicator is in red zone, STOP indicator light will flash, and audible alarm will sound indicating that the temperature is to high. Stop machine and allow transmission to cool. Shut off engine and take corrective action.

If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active.

Y—Fuel Gauge: Indicator will reflect fuel level in tank.

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

Z—Basic Display Window: The display window has six display: • • • • • •

Gear FNR Auto Tachometer Hour Meter Voltmeter/Odometer

W—Hydraulic Oil Temperature Gauge: Normal operating temperature is in green zone. If gauge

HG31779,000005F –19–29APR02–3/3

2-1-6

102703

PN=29

Operation—Operator’s Station

T155127B

–UN–24MAY02

Deluxe Monitor Panel (Later Machines)

1—Check Engine Indicator 2—Engine Air Filter Restriction Indicator 3—Engine Oil Pressure Indicator 4—Engine Preheat Indicator— If Equipped 5—Left Turn Indicator 6—STOP Indicator 7—High Beams ON Indicator (not used)

8—Service Required Indicator 9—Right Turn Indicator 10—Park Brake Indicator 11—Brake Oil Pressure Indicator 12—Secondary Steering Warning Indicator—If Equipped 13—Pin Disconnect Indicator 14—Fasten Seat Belt Indicator

• MENU provides initial entry into the accessories and diagnostics system. Each time MENU is pressed, display will cycle to the next menu. Once a main menu has been selected, pressing MENU again will return to the Normal Display Menu.

• BACK will back out of a menu, one item each time the key is pressed.

15—Hydraulic Oil Filter Restriction Indicator 16—Fuel Filter Restriction Indicator 17—Message Display 18—Transmission Service Indicator 19—Transmission Filter Indicator 20—Battery Voltage Indicator

21—Engine Oil Pressure Gauge 22—Engine Coolant Temperature Gauge 23—Hydraulic Oil Temperature Gauge 24—Transmission Oil Temperature Gauge 25—Fuel Gauge 26—Basic Display Window

• NEXT will move to the next selection within a menu or mode.

• SELECT switches between volts/kilometers/hours during normal operation. During accessories or diagnostics modes, SELECT will activate the currently chosen menu.

HG31779,0000060 –19–29APR02–1/1

2-1-7

102703

PN=30

Operation—Operator’s Station

Deluxe Monitor Panel Functions (Later Machines) 1—Check Engine Indicator: Indicator will light when excessive water is present in final fuel filter. STOP indicator will light, alarm will sound, and engine will derate to 50% of full power until water is drained.

The STOP indicator light flashes and alarm sounds when: • • • •

2—Engine Air Filter Restriction Indicator: Indicator will light and service required indicator will light when air elements are restricted.

Engine oil pressure is low.

Engine coolant temperature is excessively high.

Transmission oil temperature is excessively high.

Transmission is shifted into gear with park brake engaged.

• Brake pressure is low.

• Steering system pressure is low, and secondary steering is activated.

3—Engine Oil Pressure Indicator:

7—High Beams ON Indicator : Not used.

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

8—Service Required Indicator (Yellow): Indicator will light when a problem is developing. It is not necessary to stop the engine immediately, but the cause should be investigated as soon as possible. The service required indicator lights when:

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

• • • • • • •

When water is drained, indicators and alarm will turn off and the engine will return to full power.

NOTE: Cold oil or extreme off level operation may cause indicator to light.

4—Engine Preheat Indicator—If Equipped: Indicator will light when key switch is turned clockwise to the “On” position. Light will turn off approximately 15-45 seconds depending on engine temperature, indicating that preheating is completed. Light will turn off while cranking engine. Indicator will also light for approximately 15-45 seconds after engine is running, indicating post heat.

5—Left Turn Indicator: Indicator will light when left turn signal switch is engaged.

6—STOP Indicator:

Alternator voltage is low.

Transmission filter is restricted.

Engine air filter is restricted.

Hydraulic oil temperature is too high.

Hydraulic oil filter is restricted.

Fuel filter is restricted.

Transmission fault indication.

NOTE: Cold oil may cause hydraulic and transmission oil filter restriction indicators to light temporarily.

It is not necessary to stop the engine immediately but the cause should be investigated as soon as possible.

9—Right Turn Indicator: Indicator will light when right turn signal switch is engaged.

10—Park Brake Indicator: Indicator will light when park brake is engaged and transmission control lever is in N “Neutral”.

CAUTION: Prevent possible injury or machine damage. If STOP indicator light flashes and alarm sounds, stop immediately and investigate cause of problem.

Continued on next page

2-1-8

HG31779,000005F –19–29APR02–1/3 102703

PN=31

Operation—Operator’s Station If park brake is engaged and transmission control lever is in F “Forward” or R “Reverse”, the STOP indicator will flash and alarm will sound. Push park brake switch to OFF.

as soon as possible when a problem occurs.

Indicator will light and service required indicator will light when hydraulic filter element is restricted.

11—Brake Oil Pressure Indicator:

NOTE: Cold oil may cause hydraulic oil filter restriction indicator light to light until oil is warm.

CAUTION: Prevent possible injury or machine damage. If brake pressure indicator light comes on while operating, stop machine immediately.

16—Fuel Filter Restriction Indicator:

NOTE: Indicator may come on during cold startups or when machine is under heavy loads.

Indicator will light, STOP indicator will flash, and alarm will sound when brake oil pressure is low or brake accumulator has lost its charge. Stop machine immediately and push park brake switch to ON.

A flickering light is an early warning that fuel filter needs to be changed.

Indicator will light when fuel pressure drops below 300 kPa (43.5 psi).

12—Secondary Steering Warning Indicator—If Equipped:

If pressure drops below 200 kPa (29 psi), indicator will remain on. Service required indicator will light and engine will derate to 50% of full power.

IMPORTANT: Prevent possible damage to secondary steering system. Stop machine immediately if secondary steering indicator light and alarm come on while operating. THE SECONDARY STEERING SYSTEM IS NOT INTENDED FOR CONTINUOUS USE.

17—Message Display: Displays a 12 character alpha-numeric message that provides a text description of the currently displayed mode. This message display supplements the information that is shown on the basic display window.

Indicator will light, STOP indicator will flash, and alarm will sound when secondary steering system is activated. Stop machine immediately and take corrective action. The secondary steering system is not intended for continuous use.

13—Pin Disconnect Indicator: Indicator will light when pin disconnect switch is activated to retract cylinders for removal of attachments.

14—Fasten Seat Belt Indicator: Indicator will light for the first 5 seconds after the engine is started to warn the operator to fasten seat belt.

15—Hydraulic Oil Filter Restriction Indicator:

18—Transmission Service Indicator: Transmission service indicator and service required indicator will light and stay on when a transmission clutch slippage service code has been detected. The transmission will shift to “Neutral” and then machine can only be moved in “limp home” mode. A service code will be logged in Monitor Display Unit. This code can be read by accessing the Monitor Diagnostic Mode (d).

The indicator light will turn off when key switch has been turned off. Every time clutch slippage occurs, the transmission service indicator and service required indicator will light and will remain on until key switch is turned off.

IMPORTANT: Prevent possible hydraulic pump damage. Change hydraulic oil filter

Continued on next page

2-1-9

HG31779,000005F –19–29APR02–2/3 102703

PN=32

Operation—Operator’s Station 19—Transmission Filter Indicator: Indicator will light and the service required indicator will light when the transmission filter is restricted.

20—Battery Voltage Indicator: Indicator will light and service required indicator will light when alternator output is low. Check battery charge by selecting battery voltage on digital display.

If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active.

21—Engine Oil Pressure Gauge:

24—Transmission Oil Temperature Gauge: If indicator is in red zone, STOP indicator will flash and audible alarm will sound indicating that the temperature is too high. Stop machine and allow transmission to cool. Shut off engine and take corrective action.

IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. Indicator will light, STOP indicator will flash, and alarm will sound when engine oil pressure gauge indicates low pressure. Stop machine. STOP ENGINE IMMEDIATELY. If pointer deflects to the far right side of the scale, electronic communication is lost or a sensor error is active.

NOTE: Extreme off level operation may cause indicator to light.

22—Engine Coolant Temperature Gauge: STOP indicator will flash and audible alarm will sound when pointer is in red zone. Stop machine and allow engine to cool. Shut off engine and take corrective action.

If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active.

23—Hydraulic Oil Temperature Gauge: Normal operating temperature is in green zone. If gauge indicator points to red zone, hydraulic oil temperature is too high. Stop work cycle and cycle loader functions without load to lower indicator reading. If indicator still stays in red zone, stop machine and see your authorized dealer.

If pointer deflects to the far left of the scale, electronic communication is lost or a sensor error is active.

25—Fuel Gauge: Indicator will reflect fuel level in tank.

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

26—Basic Display Window: The display window has six displays: • • • • • •

Gear FNR Auto Tachometer Hour Meter Voltmeter/Odometer

HG31779,000005F –19–29APR02–3/3

2-1-10

102703

PN=33

Operation—Operator’s Station

T159422C

–UN–28OCT02

Console Switches and Accessories (Later Machines—Single Lever Design)

1—Pilot Enable/Boom Down Switch 2—Drive, Tail and Marker Switch 3—Cab Work Light Switch—If Equipped 4—4-Way Flasher Switch 5—Clutch Cut-Off Switch 6—Automatic Transmission Switch

7—Not Used 8—Front Wiper Knob 9—Rear Wiper Knob 10—Temperature Control Knob 11—Blower Speed Knob 12—Air Conditioning Switch— If Equipped 13—Axle Disconnect Switch— If Equipped

14—Beacon Switch—If Equipped 15—Pin Disconnect Switch—If Equipped 16—Spin Control Mode Knob—If Equipped 17—Spin Control Switch—If Equipped

18—Ride Control Switch—If Equipped 19—Return-to-Carry Switch—If Equipped 20—Boom Height Kickout Switch—If Equipped

HG31779,0000111 –19–17SEP02–1/1

2-1-11

102703

PN=34

Operation—Operator’s Station

Console Switch and Accessory Functions (Later Machines—Single Lever Design) 1—Pilot Enable/Boom Down Switch: The switch has three positions: • Push upper half to lower boom with engine off • Push to middle position to unlock pilot controllers; normal operation • Push lower half to lock pilot controllers; locks hydraulic controls

NOTE: The park brake will also disengage the transmission clutches. Release park brake before operating.

6—Automatic Transmission Switch: Push upper half of switch to the “Auto” position. Move transmission lever to 3 or 4. Transmission will start in 2nd gear. As speed increases, transmission will automatically shift to 3rd and 4th gear. As load increases or speed decreases, transmission will automatically shift to 3rd and 2nd gear.

2—Drive, Tail and Marker Switch: The switch has three positions: • Push upper half to turn on headlights, tail lights/brake lights and turn signal/4-way lights • Push switch to middle position to turn on tail lights/brake lights and turn signal/4-way lights • Push lower half of switch to turn lights off

7—Not Used 8—Front Wiper Knob: The knob has four positions: • • • •

3—Cab Work Light Switch—If Equipped: Push upper half of switch to turn front and rear work lights on. Push lower half of switch to turn work lights off.

First position is “Off” Second position is intermittent wiper operation Third position is low speed Fourth position is high speed

Push wiper/washer knob in to wash front window.

4—4-Way Flasher Switch: Push upper half of switch and front and rear amber lights will flash.

9—Rear Wiper Knob: The knob has four positions:

5—Clutch Cut-Off Switch: CAUTION: Prevent possible injury from unexpected machine movement. When stopping on inclines, push the lower half of the clutch cut-off switch to engage clutch cut-off before releasing left service brake.

This will prevent the machine from rolling downhill during transmission re-engagement cycle.

Push upper half of switch to disengage clutch before either brake pedal can be used to disengage transmission clutches.

• • • •

First position is “Off” Second position is intermittent wiper operation Third position is low speed Fourth position is high speed

Push wiper/washer knob in to wash rear window.

10—Temperature Control Knob: Turn knob to adjust air temperature. Turn knob clockwise to increase temperature. Turn counterclockwise to decrease temperature.

11—Blower Speed Knob: Turn knob clockwise to increase blower speed or counterclockwise to reduce blower speed. Blower knob has four speed settings.

Use the switch in situations such as truck loading where machine positioning and maximum hydraulics are needed.

Continued on next page

2-1-12

HG31779,0000112 –19–17SEP02–1/2 102703

PN=35

Operation—Operator’s Station • Push upper half to turn ride control on • Push to middle “Auto” position that functions the same as the “On” position with one exception. The ride control is turned off when ground speed is approximately 6 km/h (3—1/2 mph) or less • Push lower half to turn ride control off

12—Air Conditioning Switch—If Equipped: Push upper half of switch to turn air conditioning on. Push lower half of switch to turn air conditioning off.

13—Axle Disconnect Switch: Push upper half of switch to disconnect front axle.

14—Beacon Switch: Push upper half of switch to turn beacon light on. Push lower half of switch to turn beacon light off.

15—Pin Disconnect Switch—If Equipped: Push switch in then lift switch up to retract cylinders for removal of attachments.

16—Spin Control Mode Knob—If Equipped: Turn knob to a setting that minimizes wheel spin while filling the bucket.

NOTE: Spin control reduces engine rpm to minimize wheel spin and prolong tire life. The five different settings allow the operator to customize the machine to differing tractive conditions. Spin control only works in first gear.

19—Return-to-Carry Switch—If Equipped: The switch has three positions: • Push upper half to set return-to-carry height • Push to middle position to activate return-to-carry.

Push boom lever to float position. Boom will kick-out of float position when it reaches a preset distance from ground.

• Push lower half to deactivate return-to-carry

NOTE: Boom float will not work once the boom is below preset distance from ground. Push switch to “Off” position to activate boom float.

20—Boom Height Kickout Switch: The switch has three positions:

17—Spin Control Switch—If Equipped: Push upper half of switch to turn spin control on. Push lower half of switch to turn spin control off.

• Push upper half to set boom height • Push to middle position to activate boom height kickout. Pull lever to raise detent position. Boom will kick-out of detent position when it reaches a preset height from ground.

• Push lower half to deactivate boom height kickout

NOTE: If maximum power to wheels is needed, turn spin control switch off.

18—Ride Control Switch: The switch has three positions:

HG31779,0000112 –19–17SEP02–2/2

2-1-13

102703

PN=36

Operation—Operator’s Station

T156392B

–UN–24JUN02

Console Switches and Accessories (Later Machines—Two Lever Design)

1—Ride Control Switch—If Equipped 2—Reverse Fan Switch—If Equipped 3—Axle Disconnect Switch—If Equipped 4—Boom Height Kickout Switch—If Equipped 5—Return-to-Carry Switch—If Equipped

6—Pilot Enable/Boom Down Switch 7—Pin Disconnect Switch—If Equipped 8—Beacon Switch—If Equipped 9—Cab Work Light Switch—If Equipped 10—Drive, Tail and Marker Switch

11—4-Way Flasher Switch 12—Spin Control Mode Knob—If Equipped 13—Spin Control Switch—If Equipped 14—Not Used 15—Clutch Cut-Off Switch 16—Automatic Transmission Switch

17—Air Conditioning Switch— If Equipped 18—Blower Speed Knob 19—Temperature Control Knob 20—Front Wiper Knob 21—Rear Wiper Knob

HG31779,0000062 –19–24JUN02–1/1

2-1-14

102703

PN=37

Operation—Operator’s Station

Console Switch and Accessory Functions (Later Machines—Two Lever Design) • Push to middle position to unlock pilot controllers; normal operation • Push lower half to lock pilot controllers; locks hydraulic controls

1—Ride Control Switch: The switch has three positions: • Push right half to turn ride control on • Push to middle “Auto” position that functions the same as the “On” position with one exception. The ride control is turned off when ground speed is approximately 6 km/h (3—1/2 mph) or less • Push left half to turn ride control off

7—Pin Disconnect Switch—If Equipped: Push switch in then lift switch up to retract cylinders for removal of attachments.

8—Beacon Switch: Push upper half of switch to turn beacon light on. Push lower half of switch to turn beacon light off.

2—Reverse Fan Switch—If Equipped: Push upper half of switch to manually reverse the cooling fan.

3—Axle Disconnect Switch: Push upper half of switch to disconnect front axle.

9—Cab Work Light Switch—If Equipped: Push upper half of switch to turn front and rear work lights on. Push lower half of switch to turn work lights off.

4—Boom Height Kickout Switch: The switch has three positions: • Push upper half to set boom height • Push to middle position to activate boom height kickout. Pull lever to raise detent position. Boom will kick-out of detent position when it reaches a preset height from ground.

• Push lower half to deactivate boom height kickout

10—Drive, Tail and Marker Switch: The switch has three positions: • Push upper half to turn on headlights, tail lights/brake lights and turn signal/4-way lights • Push switch to middle position to turn on tail lights/brake lights and turn signal/4-way lights • Push lower half of switch to turn lights off

5—Return-to-Carry Switch—If Equipped: The switch has three positions:

11—4-Way Flasher Switch: Push upper half of switch and front and rear amber lights will flash.

• Push upper half to set return-to-carry height • Push to middle position to activate return-to-carry.

Push boom lever to float position. Boom will kick-out of float position when it reaches a preset distance from ground.

• Push lower half to deactivate return-to-carry

12—Spin Control Mode Knob—If Equipped: Turn knob to a setting that minimizes wheel spin while filling the bucket.

NOTE: Boom float will not work once the boom is below preset distance from ground. Push switch to “Off” position to activate boom float.

6—Pilot Enable/Boom Down Switch: The switch has three positions: • Push upper half to lower boom with engine off

NOTE: Spin control reduces engine rpm to minimize wheel spin and prolong tire life. The five different settings allow the operator to customize the machine to differing tractive conditions. Spin control only works in first gear.

13—Spin Control Switch—If Equipped: Push upper half of switch to turn spin control on. Push lower half of switch to turn spin control off.

Continued on next page

2-1-15

HG31779,0000063 –19–29APR02–1/2 102703

PN=38

Operation—Operator’s Station NOTE: If maximum power to wheels is needed, turn spin control switch off.

decreases, transmission will automatically shift to 3rd and 2nd gear.

14—Not Used

17—Air Conditioning Switch—If Equipped: Push lower half of switch to turn air conditioning on. Push upper half of switch to turn air conditioning off.

15—Clutch Cut-Off Switch: CAUTION: Prevent possible injury from unexpected machine movement. When stopping on inclines, push the lower half of the clutch cut-off switch to engage clutch cut-off before releasing left service brake.

This will prevent the machine from rolling downhill during transmission re-engagement cycle.

18—Blower Speed Knob: Turn knob clockwise to increase blower speed or counterclockwise to reduce blower speed. Blower knob has four speed settings.

19—Temperature Control Knob: Turn knob to adjust air temperature. Turn knob clockwise to increase temperature. Turn counterclockwise to decrease temperature.

20—Front Wiper Knob: The knob has four positions:

Push upper half of the clutch cut-off switch to disengage clutch before either brake pedal can be used to disengage transmission clutches.

• • • •

Use the switch in situations such as truck loading where machine positioning and maximum hydraulics are needed.

First position is “Off” Second position is intermittent wiper operation Third position is low speed Fourth position is high speed

Push wiper/washer knob in to wash front window.

NOTE: The park brake will also disengage the transmission clutches. Release park brake before operating.

21—Rear Wiper Knob: The knob has four positions:

16—Automatic Transmission Switch: Push upper half of switch to the “Auto” position. Move transmission lever to 3 or 4. Transmission will start in 2nd gear. As speed increases, transmission will automatically shift to 3rd and 4th gear. As load increases or speed

• • • •

First position is “Off” Second position is intermittent wiper operation Third position is low speed Fourth position is high speed

Push wiper/washer knob in to wash rear window.

HG31779,0000063 –19–29APR02–2/2

2-1-16

102703

PN=39

Operation—Operator’s Station

• “Normal” menu is displayed when the machine is first turned on, and no special functions are selected.

• “Accessory” menu allows the operator to make changes to various operating characteristics of the machine.

• “Diagnostics” menu provides a limited set of tools, and is intended to be used by service personnel and machine operator’s for diagnostic and troubleshooting functions.

• “Service” menu is for service personnel and requires a special procedure to gain access. This mode provides an additional and more sophisticated set of tools for diagnostics and troubleshooting.

T108065

The monitor display unit has a basic digital LCD display window. On machines equipped with the deluxe monitor display unit there is also a 12 character alpha-numeric message display that provides a text description of the currently displayed mode. This message display supplements the information that is shown on the basic display window. The four main menus are:

–UN–11MAR97

Monitor Display Unit

The monitor display unit keypad is used to navigate through the different menus and modes of operation. Key names and general functions are as follows: • MENU provides initial entry into the accessories and diagnostics system. Each time MENU is pressed, display will cycle to the next menu. Once a main menu has been selected, pressing MENU again will return to the Normal Display Menu.

• BACK will back out of a menu, one item each time the key is pressed.

• NEXT will move to the next selection within a menu or mode.

• SELECT switches between volts/kilometers, hours during normal operation. During accessories or diagnostics modes, SELECT will activate the currently chosen menu in Basic Display Window.

TX,10,JC1869 –19–20SEP02–1/1

2-1-17

102703

PN=40

Operation—Operator’s Station

Monitor Display Unit—Normal Display

–UN–22OCT97

When key switch is turned on, all lights on display monitor will come on, alarm will sound and stop and caution lights will flash.

T111852

The basic display window will show the bulb check mode.

The window will contain numerical digit 8’s and will be shown for approximately 5 seconds.

Then the machine model number will show in the basic display window.

Continued on next page

2-1-18

TX,10,JC2218 –19–15SEP98–1/3

102703

PN=41

Operation—Operator’s Station Approximately five seconds later, the Normal display will be shown.

–UN–22OCT97

NOTE: Press SELECT to alternate between Odometer and System Voltage display.

T111854

When the machine is in neutral, the gear display (A) shows the gear position of the shift lever. When the machine is not in neutral, it displays the gear that the transmission has engaged.

When the transmission controller service code F 1655 occurs, a "---" is shown in this part of the display window because there is a CAN transmittal failure.

A—Gear Display B—FNR Display C—Auto Display D—Tachometer Display E—Hour Meter Display F—Voltmeter/Odometer Display G—Basic Display Window H—Message Display Window (If Equipped)

The FNR Display (B) shows the forward, neutral, reverse status. When a transmission controller unit failure occurs, this display is blank.

The Auto Display (C) shows whether the transmission "Auto" mode is On or Off. When a transmission controller unit failure occurs, this display is blank.

The Tachometer Display (D) shows the torque converter input shaft rpm to the nearest 5 rpms. When a transmission controller unit malfunction occurs, a "---" is displayed and the icon is turned off.

The Hour Meter Display (E) shows the machine hours in whole hour increments. The hour meter accumulates hours only when the engine is on; and the icon flashes once per second. The engine is considered on when the tachometer is greater than 300 rpm or engine oil pressure is greater than 89.6 kPa (0.9 bar) (13 psi).

The hour meter displays up to 99,999 hours.

The Voltmeter/Odometer Display (F) shows either the voltmeter or odometer reading. Press SELECT to toggle between these readings.

On U.S. and Hitachi export machines, the display rotates from volts to miles to kilometers. On Hitachi domestic machines, the display rotates from kilometers to volts only.

Continued on next page

2-1-19

TX,10,JC2218 –19–15SEP98–2/3 102703

PN=42

Operation—Operator’s Station The voltmeter displays battery voltage when the machine is off and system voltage to the nearest tenth when the machine is on.

The odometer is capable of displaying up to 99,999.9 total miles (or 999,999 if the decimal point is disregarded).

From 0 to 62,111.7 miles (0 to 99,937.7 km), the odometer displays both miles and kilometers in tenths.

From 62,111.8 to 99,999.9 miles (99,937.8 to 160,889.8 km) miles are displayed in tenths and kilometers in ones.

From 100,000 miles (160,900 km) on, both miles and kilometers are displayed in ones. The odometer runs only when the engine is on.

When the 0.1 Hour Meter Mode is turned On in the Accessory Menu (A 06), machine hours will be displayed in tenths of hours in the volts/miles/km display. Press SELECT to toggle between hours and the volts/miles/km display.

TX,10,JC2218 –19–15SEP98–3/3

Monitor Display Unit—Accessory Menu— Clutch Cut-Off (A 01)

–UN–22OCT97

At Normal Mode display, press MENU once. Display window will show A, indicated Accessory Mode.

T111855

Press SELECT again; display window shows A 01, indicating Clutch Cut-Off Mode.

Continued on next page

2-1-20

CED,OUOE035,9 –19–03NOV98–1/3

102703

PN=43

Operation—Operator’s Station In the Clutch Cut-Off Mode of operation, there are three different functions to choose from:

–UN–22OCT97

• Level Ground • Small Slope • Steep Slope

T111856

On the Level Ground setting, clutch releases with low brake pedal pressure.

On the Small Slope setting, clutch releases with medium brake pedal pressure.

On Steep Slope setting, clutch releases with high brake pedal pressure.

By turning one of these functions On, the other two are automatically turned Off. Press SELECT again. Display shows A 011 Level Ground Setting, If setting shows Off, press SELECT again and it will be On, disabling the other two positions.

Press NEXT to move to A 012 Small Slope Setting, and NEXT again to A 013 Steep Slope Setting. Press SELECT to choose a setting and disable the other two settings.

Level Ground (A 011): When the Level Ground function is turned On in the monitor display unit, the clutch cut-off switch turned On, and the brake pedal pressed down, the clutch cut-off sensor (B33), which is a rotary potentiometer, will sense the position of the brake pedal linkage by the voltage reading. When it senses voltage higher than the low voltage set point, the transmission will “disengage” (release clutch) and modulate to neutral. In this position the machine will still roll slightly.

In “Auto” mode the transmission will “re-engage” and modulate into the appropriate gear (based on ground speed) if the pressure at the clutch cut-off sensor reaches the engagement pressure set point. This pressure is lower than the clutch cut-off set point.

The transmission will also re-engage if the clutch cut-off switch is turned to the Off position.

Continued on next page

2-1-21

CED,OUOE035,9 –19–03NOV98–2/3 102703

PN=44

Operation—Operator’s Station Small Slope (A 012): When the Small Slope function is turned On in the monitor display unit, the clutch cut-off switch turned On, and the brake pedal is pressed down, the clutch cut-off sensor will sense the hydraulic brake pressure. When it senses pressure higher than the medium pressure set point, the transmission will “disengage” and modulate to neutral.

In “Auto” mode the transmission will “re-engage” and modulate into the appropriate gear (based on ground speed) if the pressure at the clutch cut-off sensor reaches the engagement pressure set point. This pressure is lower than the clutch cut-off pressure set point.

The transmission will also re-engage if the clutch cut-off switch is turned to the Off position.

Steep Slope (A 013): When the Steep Slope is turned On in the monitor display unit, the clutch cut-off switch turned On, and the brake pedal is pressed down, the clutch cut-off sensor will sense the hydraulic brake pressure.

When it senses pressure higher than the high pressure set point, the transmission will “disengage” and modulate to neutral.

In “Auto” mode the transmission will “re-engage” and modulate into the appropriate gear (based on ground speed) if the pressure at the clutch cut-off sensor reaches the engagement pressure set point. This pressure is lower than the clutch cut-off pressure set point.

The transmission will also re-engage if the clutch cut-off switch is turned to the Off position.

CED,OUOE035,9 –19–03NOV98–3/3

2-1-22

102703

PN=45

Operation—Operator’s Station

Monitor Display Unit—Accessory Menu— Quick Shift Mode (A 02)

–UN–22OCT97

The Quick Shift mode allows the operator to choose between Down/Up and Down Only shift functions when the transmission is in manual or automatic operation.

T111858

Down/Up: When this function is turned On, the transmission will down shift one gear when the Quick Shift Switch (at top of pilot controller handle) is pressed down once. It is not possible to down shift more than one gear.

When the quick shift switch is pressed down again, the transmission will electronically shift up one gear again.

Down Only—Transmission in Manual Operation: When this function is turned On, each time the quick shift switch (at top of pilot controller handle) is pressed down, the transmission will shift down one gear (regardless of selected gear).

If the operator presses down on the quick shift switch while no shift is taking place, the controller will cause the transmission to shift down one gear (regardless of selected gear).

Once a down shift is made by pressing the quick shift switch, the transmission will not shift up again unless a direction or gear change is made.

Down Only—Transmission in Automatic Operation: If the operator presses the quick shift switch when the transmission is in automatic operation, the transmission will down shift to one gear below the gear displayed in basic display window. This change is made independent from shifter switch selection.

Down Only works basically the same in automatic as in manual, except it will shift Up or Down from the highest gear downshifted to.

If the operator presses down on the quick shift switch while an up shift is taking place, the transmission controller will cause the transmission to shift down to the previous gear.

Continued on next page

2-1-23

TX,10,JC2220 –19–26AUG97–1/5 102703

PN=46

Operation—Operator’s Station In “Auto” mode, if the operator presses down on the quick shift switch while a down shift is taking place, the transmission controller will ignore the request for the down shift.

Transmission will automatically shift up or down from the gear displayed in basic display window until shifter switch is moved to Neutral. This will cancel down shift mode and transmission will go back to fully automatic mode.

TX,10,JC2220 –19–26AUG97–2/5

T111857

–UN–22OCT97

Press SELECT at the A 02 display.

Deluxe Monitor Display Unit Shown

TX,10,JC2220 –19–26AUG97–3/5

If the A 021 display shows OFF, press SELECT to turn Down/Up shift function On and disable the Down Only function.

T111858

–UN–22OCT97

To choose the Down Only shift function, press NEXT.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-24

TX,10,JC2220 –19–26AUG97–4/5 102703

PN=47

Operation—Operator’s Station

T111859

–UN–22OCT97

At A 022 display, press SELECT to turn Down Only shift function On and to disable Down/Up function.

Deluxe Monitor Display Unit Shown

TX,10,JC2220 –19–26AUG97–5/5

Monitor Display Unit—Accessory Menu— Auto Mode to First (A 03)

–UN–22OCT97

In Auto Mode to First, the transmission will shift to first gear if a high load is sensed while the transmission is actually in second gear. This shift change is made independent from shifter switch selection.

T111860

A direction change during normal conditions will not cause the transmission to shift down into first gear. If a direction change is made during high transmission load conditions, the transmission will shift down into first gear.

Deluxe Monitor Display Unit Shown

Press SELECT at the A 03 display.

Press SELECT again to either turn this option On or Off.

TX,10,JC2221 –19–26AUG97–1/1

2-1-25

102703

PN=48

Operation—Operator’s Station

Monitor Display Unit—Accessory Menu—Job Timer Mode (A 04)

–UN–22OCT97

The job timer is a resetable hour meter that can be used to time tasks to the nearest tenth of an hour.

At the A 04 display, press SELECT.

T111861

Then press SELECT again to turn the timer On or Off. When the timer is Off, press NEXT to reset the timer.

Deluxe Monitor Display Unit Shown

TX,10,JC2223 –19–26AUG97–1/1

Monitor Display Unit—Accessory Menu— Stop Watch Mode (A 05)

–UN–22OCT97

The stop watch is a resetable timer that is used to measure time in seconds and tenths of seconds.

At the A 05 display, press SELECT.

T111862

Then press SELECT again to turn the timer On or Off. When the timer is Off, press NEXT to reset the timer.

Deluxe Monitor Display Unit Shown

TX,10,JC2224 –19–26AUG97–1/1

2-1-26

102703

PN=49

Operation—Operator’s Station

Monitor Display Unit—Accessory Menu—0.1 Hour Meter Mode (A 06) At the A 06 display, press SELECT.

T111863

When the 0.1 Hour Meter Mode is turned On, the hour meter reading can be accessed during normal machine operation by pressing SELECT. The odometer reading will switch to the voltmeter reading, and then to the hour meter reading (A) in hours and tenths of hour as SELECT is pressed.

–UN–22OCT97

Then press SELECT again to turn the 0.1 Hour Meter Mode On or Off.

Deluxe Monitor Display Unit Shown

–UN–22OCT97

When the 0.1 Hour Meter Mode is turned Off, only the odometer reading and voltmeter are available, by pressing SELECT. The 0.1 Hour Meter Mode On or Off position stays set after machine shut down.

T111864

A—Hour Meter Reading

Deluxe Monitor Display Unit Shown

TX,10,JC2225 –19–01SEP98–1/1

Monitor Display Unit—Accessory Menu— Metric Units Mode (A 07)

–UN–22OCT97

This mode allows the technician to choose between metric and English unit displays.

At the A 07 display, press SELECT.

When Metric Units mode is On, all values will be shown in metric. When Metric Units mode is Off, all values will be shown in English units.

T111865

Press SELECT to turn Metric Units display On or Off.

Deluxe Monitor Display Unit Shown

TX,TEST,HH229 –19–12SEP96–1/1

2-1-27

102703

PN=50

Operation—Operator’s Station

Monitor Display Unit—User Diagnostics Menu—Service Codes (d 01)

–UN–22OCT97

This mode displays the eight highest priority service codes which have occurred on the machine.

T111866

At the d 01 display, press SELECT.

Deluxe Monitor Display Unit Shown

TX,10,JC2227 –19–10NOV98–1/6

An F is shown in the display window to indicate service code mode. The first fault code number is shown.

To move to the second service code, press NEXT.

T111709

–UN–22OCT97

To obtain additional information about the first service code, press SELECT again.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-28

TX,10,JC2227 –19–10NOV98–2/6

102703

PN=51

Operation—Operator’s Station The display window will show the hour meter reading at first occurrence of the service.

T111710

–UN–22OCT97

To obtain additional information about the service code, press NEXT.

Deluxe Monitor Display Unit Shown

TX,10,JC2227 –19–10NOV98–3/6

T111708

–UN–22OCT97

The display window will show the hour meter reading at last occurrence of the fault and the total number of occurrences.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-29

TX,10,JC2227 –19–10NOV98–4/6

102703

PN=52

Operation—Operator’s Station To move to the second service code, press BACK until the Fxxxx display is shown. This example: F 1649.

T111709

–UN–22OCT97

Then press NEXT.

Deluxe Monitor Display Unit Shown

TX,10,JC2227 –19–10NOV98–5/6

T111868

–UN–22OCT97

Continue to scroll through service codes using this sequence until END is shown in the display window.

Deluxe Monitor Display Unit Shown

TX,10,JC2227 –19–10NOV98–6/6

Monitor Display Unit—User Diagnostics Menu—Continuity Check (d 02) In this diagnostic mode, sensors and circuits connected to the chassis computer unit (CCU) are monitored for a “state of change.” Examples of “state of change” are switches going from open to closed or closed to open, circuit shorts and opens, high rate of change from analog sensors, and changes in digital speed sensor outputs.

Continued on next page

2-1-30

TX,10,JC2222 –19–01SEP98–1/4 102703

PN=53

Operation—Operator’s Station At the d 02 display, press SELECT. Two different “continuity check” modes are provided.

Press SELECT to choose the mode wanted.

–UN–22OCT97

“With Speed Sensors” (d 021) mode monitors all circuits and sensors. This mode is useful when the machine is parked with the engine off.

T111869

“Without Speed Sensors” (d 022) monitors everything except the digital speed sensors. This mode is useful when the engine is running and/or the machine is rolling, when the engine, transmission and wheel speed sensors are pulsing continuously.

Deluxe Monitor Display Unit Shown

TX,10,JC2222 –19–01SEP98–2/4

T111870

–UN–22OCT97

After one of the continuity check modes is selected, the display window will be in a waiting position until a “state of change” is detected.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-31

TX,10,JC2222 –19–01SEP98–3/4

102703

PN=54

Operation—Operator’s Station

–UN–22OCT97

Whenever a “change of state” is detected, the warning horn will “beep” to inform the technician of the change.

The circuit device component number and section number as it appears on the system functional schematic will show on the basic display window.

T111871

Press SELECT to display sensor data and units in the message display window. Press SELECT again or BACK to remove the information from the message window.

Press NEXT to move to the next sensor display.

The audible alarm can be used to verify that a switch is changing state when it is activated (or isn’t changing state when it should be, if there is no beep.) Also, by moving a potentiometer type control slowly through its operating range, a break or “bad spot” can be detected.

Deluxe Monitor Display Unit Shown

TX,10,JC2222 –19–01SEP98–4/4

Monitor Display Unit—User Diagnostics Menu—Battery Monitor (d 03)

–UN–22OCT97

This mode allows the technician to view the current voltage of the left and right batteries.

At the d 03 display, press SELECT.

T111872

Battery voltage will be displayed in basic display window.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-32

TX,10,JC2228 –19–26SEP97–1/2

102703

PN=55

Operation—Operator’s Station

T111873

–UN–22OCT97

On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle the reading in and out of the alpha-numeric window.

Deluxe Monitor Display Unit Shown

TX,10,JC2228 –19–26SEP97–2/2

Monitor Display Unit—User Diagnostics Menu—Engine Sensors (d 04) This mode allows the technician to monitor all engine sensors that are accessible to the computer system.

TX,10,JC2229 –19–01SEP98–1/7

T111874

–UN–22OCT97

Press SELECT at the d 04 display.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-33

TX,10,JC2229 –19–01SEP98–2/7 102703

PN=56

Operation—Operator’s Station

T111875

–UN–22OCT97

The d 041 display for Engine Coolant Temperature will be shown. Temperature will be displayed in C° or F° (depending on setting selected in A 07 model) and sensor voltage will be displayed.

Deluxe Monitor Display Unit Shown

TX,10,JC2229 –19–01SEP98–3/7

On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle reading in and out of the alpha-numeric window.

T111876

–UN–22OCT97

Press NEXT.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-34

TX,10,JC2229 –19–01SEP98–4/7

102703

PN=57

Operation—Operator’s Station

T111877

–UN–22OCT97

The d 042 display for Engine Oil Pressure will be shown.

Pressure will be displayed in kPa or psi and sensor voltage will be displayed.

Deluxe Monitor Display Unit Shown

TX,10,JC2229 –19–01SEP98–5/7

On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle reading in and out of the alpha-numeric window.

T111881

–UN–22OCT97

Press NEXT.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-35

TX,10,JC2229 –19–01SEP98–6/7

102703

PN=58

Operation—Operator’s Station

T111882

–UN–22OCT97

The d 043 display for Throttle sensor voltage will be shown.

Deluxe Monitor Display Unit Shown

TX,10,JC2229 –19–01SEP98–7/7

Monitor Display Unit—User Diagnostics Menu—Transmission Sensors (d 05) This mode allows the technician to monitor all transmission sensors that are accessible to the computer system.

TX,10,JC2230 –19–01SEP98–1/4

T111884

–UN–22OCT97

Press SELECT at the d 05 display.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-36

TX,10,JC2230 –19–01SEP98–2/4 102703

PN=59

Operation—Operator’s Station

T111885

–UN–22OCT97

The d 051 Oil Temperature Sensor display will show the oil temperature in C° or F° (depending on setting selected in A 07 mode) and sensor voltage.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-37

TX,10,JC2230 –19–01SEP98–3/4

102703

PN=60

Operation—Operator’s Station On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle reading in and out of the alpha-numeric window.

–UN–22OCT97

Press NEXT.

T111887

The d 052 Clutch cut-off Sensor display will show the Clutch Cutoff Sensor pressure (early units) or voltage (later units).

Press NEXT. Deluxe Monitor Display Unit Shown

The d 053 Torque Input Speed Sensor display will show the speed in rpm.

Press NEXT. The d 054 Torque Output Speed Sensor display will show the speed in rpm.

Press NEXT. The d 055 Internal Clutch Speed Sensor display will show the speed in rpm.

Press NEXT. The d 056 Output Shaft Speed Sensor display will show the speed in rpm.

TX,10,JC2230 –19–01SEP98–4/4

Monitor Display Unit—User Diagnostics Menu—Hydraulic Sensors (d 06) This mode allows the technician to monitor all hydraulic sensors that are accessible to the computer system.

Continued on next page

2-1-38

TX,10,JC2231 –19–01SEP98–1/4 102703

PN=61

Operation—Operator’s Station

T111888

–UN–22OCT97

Press SELECT at the d 06 display.

Deluxe Monitor Display Unit Shown

TX,10,JC2231 –19–01SEP98–2/4

The d 061 Oil Temperature Sensor display will show the temperature in C° or F° (depending on setting selected in A 07 mode) and sensor voltage.

T111889

–UN–22OCT97

Press NEXT.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-39

TX,10,JC2231 –19–01SEP98–3/4

102703

PN=62

Operation—Operator’s Station

T115771

–UN–08JUN98

The d 062 Pump Output Pressure Sensor display will show the pump pressure in kPa or psi (depending on the setting selected in A 07 mode) and sensor voltage (This is only available on machines with Load Performance Management installed).

Deluxe Monitor Display Unit Shown

TX,10,JC2231 –19–01SEP98–4/4

Monitor Display Unit—User Diagnostics Menu—Fuel Sensor (d 07) This mode allows the fuel level sensor to be monitored.

–UN–22OCT97

Press SELECT at the d 07 Fuel Sensor display.

T111891

The Fuel Sensor display will show fuel level in gal or L (depending on setting selected in A 07 mode) and sensor voltage.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-40

TX,10,JC2232 –19–26SEP97–1/2

102703

PN=63

Operation—Operator’s Station

T111893

–UN–22OCT97

On machines equipped with deluxe monitor display, press SELECT again to display reading in the alpha-numeric message display. Pressing SELECT will toggle reading in and out of the alpha-numeric window.

Deluxe Monitor Display Unit Shown

TX,10,JC2232 –19–26SEP97–2/2

Monitor Display Unit—User Diagnostics Menu—(d 08)—Not Used

TX,9015,MM3001 –19–15APR98–1/1

Monitor Display Unit—User Diagnostics Menu—Machine I.D. Mode (d 10) This mode provides the technician with machine identification information for hour meter readings, part numbers and serial numbers of the monitor display unit and chassis controller unit.

Continued on next page

2-1-41

TX,10,JC2233 –19–01SEP98–1/10

102703

PN=64

Operation—Operator’s Station

T111894

–UN–22OCT97

Press SELECT at the d 10 display.

Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–01SEP98–2/10

T111896

–UN–22OCT97

The d 101 MDU Original display will show the monitor display unit hour meter reading and the original monitor display unit serial number.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-42

TX,10,JC2233 –19–01SEP98–3/10

102703

PN=65

Operation—Operator’s Station Press NEXT.

T111897

–UN–22OCT97

The d 102 CCU Original display will show the chassis controller unit hour meter reading and the original chassis controller serial number.

Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–01SEP98–4/10

Press NEXT.

T111899

–UN–22OCT97

The d 103 MDU Part Number display will show the monitor display unit part number and serial number.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-43

TX,10,JC2233 –19–01SEP98–5/10

102703

PN=66

Operation—Operator’s Station Press NEXT.

T111900

–UN–22OCT97

The d 104 CCU Part Number display will show the chassis controller unit part number and serial number.

Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–01SEP98–6/10

Press NEXT.

T111901

–UN–22OCT97

The d 105 MDU Software Number display will show the monitor display unit software number.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-44

TX,10,JC2233 –19–01SEP98–7/10

102703

PN=67

Operation—Operator’s Station Press NEXT.

T111902

–UN–22OCT97

The d 106 CCU Software Number display will show the chassis controller unit software number.

Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–01SEP98–8/10

Press NEXT.

T111711

–UN–22OCT97

The d 107 TCU Serial Number display will show the transmission controller unit serial number.

Deluxe Monitor Display Unit Shown

Continued on next page

2-1-45

TX,10,JC2233 –19–01SEP98–9/10

102703

PN=68

Operation—Operator’s Station Press NEXT.

T111712

–UN–22OCT97

The d 108 TCU Software Number display will show the transmission controller unit software number.

Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–01SEP98–10/10

2-1-46

102703

PN=69

Operation—Operator’s Station

Horn Button

T113450

–UN–12FEB98

A—Horn Button

Horn Button

TX,10,JC1739 –19–16OCT98–1/1

Turn Signals Push turn signal lever (A) forward to signal a left turn. Pull turn signal lever rearward to signal a right turn.

T113458

–UN–13FEB98

A—Signal Lever

CED,OUO1021,193 –19–20MAR98–1/1

2-1-47

102703

PN=70

Operation—Operator’s Station

Air Conditioning Controls NOTE: Open valve (D) before operating heater.

–UN–10SEP98

Turn temperature control knob (A) clockwise to increase temperature.

IMPORTANT: Before you start air conditioner first time in the season, check filters and condenser. Clean them if necessary.

Check refrigerant level.

T117017

Turn blower knob (B) clockwise to increase blower speed.

(Knob also turns on heater blower.) Blower has four speeds.

Earlier Machines

–UN–10OCT02

To operate air conditioning, press air conditioning switch (C).

T156775D

A—Temperature Control Knob B—Blower Knob C—Air Conditioning Switch D—Heater Valve

T111213B

–UN–27AUG97

Later Machines—Two Lever Design

TX,10,JC1788 –19–31OCT02–1/1

2-1-48

102703

PN=71

Operation—Operator’s Station

Air Flow Knob Air flow knob (1) has four air flow positions. The first position is for total defrost.

–UN–20SEP02

Turn knob clockwise to the second position for more defrost than vent air flow.

T159630B

Turn knob clockwise to the third position for more vent air flow and less defrost.

Turn the knob clockwise to the fourth position for total vent air flow.

1—Air Flow Knob

HG31779,000012E –19–20SEP02–1/1

Adjusting Steering Wheel Tilt Lift lever (A) to adjust steering column to desired tilt.

Release lever.

T113453

–UN–12FEB98

A—Lever

CED,OUO1021,30 –19–02MAR98–1/1

Opening and Securing Side Door

–UN–13JUN00

To open left side cab door from inside, push forward on lever (A).

T131654B

A—Lever

Continued on next page

2-1-49

CED,OUOE035,10 –19–14JUN00–1/2

102703

PN=72

Operation—Operator’s Station Open door until outside latch (A) fastens into notch (B).

Door must be secure against bumper (C). Adjust rubber bumper as necessary to maintain proper tension.

To release secured open door from inside the cab or on the ground, pull up on lever (D) located to the left of the operator’s seat.

–UN–02NOV98

Door will latch when closed.

T160585B

–UN–17OCT02

T118147

A—Outside Latch B—Notch C—Bumper D—Release Lever

CED,OUOE035,10 –19–14JUN00–2/2

2-1-50

102703

PN=73

Operation—Operator’s Station

Opening Side Window/Secondary Exit NOTE: The cab right side window can be used as a secondary exit.

Push up on lever (1) to open window.

Position outer notch (2) over catch to hold window open.

To release secured window, push down on lever (3) located behind cab seat.

T160250B

–UN–07OCT02

T160249B

–UN–07OCT02

1—Lever 2—Outer Notch 3—Lever

HG31779,000014D –19–07OCT02–1/1

Opening Rear Side Window Pull on latch tab (A) to release window lock.

T131655B

–UN–19JUN00

A—Latch Tab

TX,10,JC1589 –19–14JUN00–1/1

2-1-51

102703

PN=74

Operation—Operator’s Station

Adjusting Seat CAUTION: You can lose control of machine and be injured if seat is loose. Be sure seat is properly locked in position before operating the machine.

Use flip-out lever to turn weight adjustment knob (F). Turn knob clockwise for firm ride and counterclockwise for soft ride.

Lift fore-aft adjustment lever (H) to move seat forward and rearward. Release handle at one of several positions.

Remove your weight from seat. Lift seat height adjustment lever (E) and move seat to desired height.

T103679B

–UN–22NOV96

Move seat to mid-to-aft position. While sitting in seat, turn weight adjustment knob (F) to support weight. Check weight indicator (G) for appropriate weight setting and continue to turn until yellow pointer inside tube is flush with tube opening.

While sitting in seat, lift backrest tilt adjustment knob (D) and allow cushion to angle forward or lean backward into desired position and release handle.

While sitting in seat, rotate armrest adjustment knob (C) to tilt to desired armrest position.

–UN–26NOV96

To raise or lower armrest height, loosen two nuts on armrest height adjustment bracket (B) and adjust to desired position. Tighten nuts to secure.

On air ride equipped seats, to lower seat height or decrease firmness in ride, pull out on height/firmness adjustment knob (I). To raise seat or increase firmness in ride, turn key to “On” and push in on height/firmness adjustment knob.

T105452

While sitting in seat, rotate lumbar support lever (A) to increase or decrease support to lower back.

A—Lumbar Support Lever B—Armrest Height Adjustment Bracket C—Armrest Adjustment Knob D—Backrest Tilt Adjustment Knob E—Seat Height Adjustment Lever F—Weight Adjustment Knob G—Weight Indicator H—Fore-Aft Adjustment Lever I—Height/Firmness Adjustment Knob (Air Ride Seat only)

CED,OUO1021,141 –19–16MAR98–1/1

2-1-52

102703

PN=75

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,JC1623 –19–14JUN00–1/1

2-1-53

102703

PN=76

Operation—Operating the Machine Inspect Machine Daily Before Starting Do periodic service checks.

A—Check wheels (front and rear) for loose or missing hardware.

B—Clean operator’s station.

C—Check air inlet cover.

D—Clean radiator.

E—Check fuel level on monitor.

F—Check tires (front and rear).

–UN–18SEP96

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

BOOM, BUCKET, SHEET METAL: Check for bent, broken, loose, or missing parts.

T103802

HARDWARE: Check for loose or missing parts.

PARK BRAKE: Check for correct operation.

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

LUBRICATION: Check lubrication points shown on Periodic Maintenance Chart.

A—Wheels (Front and Rear) B—Operator’s Station C—Air Inlet Cover D—Radiator E—Fuel Level (Monitor) F—Tires

PROTECTIVE DEVICES: Check guards, shields, ROPS, covers, seat belt.

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

TX,20,JC1199 –19–18JUL02–1/1

2-2-1

102703

PN=77

Operation—Operating the Machine

Check Instruments Before Starting Turn key switch clockwise to “On” position.

T119011

–19–16DEC98

All indicators must light. If any indicator fails to light, the bulb may be burned out. If bulb is not burned out, but indicator light still fails to light, see your authorized dealer.

HG31779,00000B1 –19–18JUL02–1/1

Starting the Engine CAUTION: Avoid possible injury or death from a runaway machine.

–UN–11JAN89

DO NOT start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed.

TS177

NEVER start engine while standing on ground.

Start engine only from operator’s seat, with transmission control lever in “Neutral”. Engage park brake.

Use of seat belt with roll-over protective structure (ROPS) is recommended under all operating conditions.

1. Fasten seat belt.

Continued on next page

2-2-2

TX,25,JC1410 –19–18JUL02–1/2

102703

PN=78

Operation—Operating the Machine 2. Move transmission control lever (A) to N. Engage neutral lock (B).

–UN–13FEB98

3. Turn key switch to “On” position. Push horn button to sound horn to alert bystanders that machine will be started.

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

T113477

IMPORTANT: Never operate starter motor for more than 20 seconds at a time. If engine fails to start after two or three tries, return key switch to “Off” position. Wait for about 2 minutes, then try again.

A—Transmission Control Lever B—Neutral Lock

Engine will not start by towing or pushing. Permanent damage to transmission will result.

4. Turn key switch to “Start” position. DO NOT crank engine more than 20 seconds. Wait 2 minutes before trying again. Release key when engine starts.

IMPORTANT: If STOP indicator light does not go out within 10 seconds after starting engine, STOP THE ENGINE. Find and correct the cause.

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

IMPORTANT: If engine stops when operating under load, remove load. Restart engine immediately. Run 30 seconds at 1/2 speed before adding load.

TX,25,JC1410 –19–18JUL02–2/2

2-2-3

102703

PN=79

Operation—Operating the Machine

Starting Fluid—If Equipped (Cold Weather Starting Aid) USE STARTING FLUID

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 container from machine if engine does not need starting fluid.

IMPORTANT: Prevent damage to engine. Use starting aid when temperatures are below 4°C (40°F) and only when engine is COLD. 1. Turn key switch clockwise to “Start” position.

Continued on next page

2-2-4

CED,OUO1021,41 –19–18JUL02–1/2

102703

PN=80

Operation—Operating the Machine

–UN–13FEB98

IMPORTANT: Excess starting fluid could damage engine; press start aid button only when engine is cold and cranking.

Starting aid fluid is being injected into engine as long as you press button.

T113478

2. After one or two revolutions of engine crankshaft, press starting aid button (A) until engine starts. Crank engine for 20 seconds maximum, then allow 2 minutes between cranking periods.

REPLACING START AID CONTAINER 1. Loosen hose clamp (B).

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

–UN–15SEP98

3. Remove safety cap from new container.

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

T117175

5. Tighten hose clamp.

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

A—Starting Aid Button B—Hose Clamp C—Start Aid Container D—Plug

Remove container and install plug (D) in base.

CED,OUO1021,41 –19–18JUL02–2/2

2-2-5

102703

PN=81

Operation—Operating the Machine

Using Booster Batteries—24 Volt System

–UN–23AUG88

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

TS204

CAUTION: An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area.

Make sure the batteries are charged in a well ventilated area.

IMPORTANT: The machine electrical system is a 24-volt negative (-) ground. Connect two 12-volt booster batteries together in series as shown for 24 volts.

–UN–21MAY90

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

T7233JN

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

A—Machine Batteries B—Booster Batteries

3. Start the engine.

4. Immediately after starting the engine, disconnect the end of negative cable from the machine frame first.

Then disconnect the other end of negative cable from the negative terminal of booster batteries.

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

CED,TX14795,4152 –19–30SEP00–1/1

2-2-6

102703

PN=82

Operation—Operating the Machine

Engine Air Heater—If Equipped

–UN–22OCT97

IMPORTANT: DO NOT USE ETHER WITH THIS SYSTEM. Damage to your engine may occur.

1. Turn key switch to “On”. If engine temperature is below 10°C (50°F), engine preheat indicator (A) will light and stay on 0—30 seconds, depending on initial engine temperature. Light will turn off, indicating that preheating is completed.

T110374

NOTE: As long as monitor light remains on, air heater will be operating.

A—Engine Preheat Indicator

2. Turn key to “Start”. Light will turn off while cranking or if battery voltage drops below 20 volts.

3. If engine temperature is 20°C (68°F) or lower, preheat indicator will light and will remain on for approximately 30 seconds depending on current engine temperature.

IMPORTANT: Warm up at 1/2 speed and DO NOT accelerate rapidly during warm-up.

NOTE: Battery voltage light may come on during post heat and may remain on for a short period of time.

CED,OUO1021,162 –19–09OCT02–1/1

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

Connect the coolant heater to 115-volt electrical power 10 hours before you start the engine.

T82,25,C53 –19–03DEC91–1/1

2-2-7

102703

PN=83

Operation—Operating the Machine

Warm-Up Operate machine at less-than-normal loads and speeds for first few minutes until temperatures and pressures reach normal operating range.

TX,25,JC247 –19–29NOV94–1/1

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

Prepare machine to shift transmission as follows: • • • •

Machine—stopped Engine—slightly above low idle Bucket—off the ground and empty Brakes—apply right or left brake pedal with clutch cut-off disengaged • Parking brake—released • Cycle transmission 10 times by shifting: Neutral-F1—R1—F1—R1—F1—Neutral. Each cycle should be approximately 5 seconds.

1. Start engine. Run engine at minimum speed for 5 minutes.

2. Cycle boom with bucket stalled in rollback position until bucket functions move at normal speed.

4. Shift from F1-R1 without braking until transmission operates normally.

3. Check transmission oil level with engine at low idle.

TX,25,JC1942 –19–02SEP98–1/1

CAUTION: Prevent possible injury from unexpected machine movement. Always move transmission control lever to N “Neutral”, and engage neutral lock before starting or dismounting.

T113449

Move neutral lock (A) to the locked position to engage neutral lock. Move lock to the unlocked position to disengage neutral lock.

–UN–12FEB98

Neutral Lock

A—Neutral Lock

CED,OUO1021,47 –19–18JUL02–1/1

2-2-8

102703

PN=84

Operation—Operating the Machine

Shifting the Transmission Unlock neutral lock.

–UN–13FEB98

Release park brake.

Change direction of machine by moving transmission control lever (A) to F “Forward" or R “Reverse".

T113481

Change speed of machine by moving transmission control lever to desired gear. Machine has four forward gears and three reverse gears. Shifting to 4th gear reverse will give same travel speed as 3rd gear reverse. Select a gear suitable to operating and road conditions.

–UN–19SEP02

When automatic transmission switch (B) is on, transmission will shift up or down as required to highest gear selected. In automatic transmission mode, transmission starts out in 2nd gear.

T159423M

A—Transmission Control Lever B—Automatic Transmission Switch

T156774C

–UN–27JUN02

Later Machines—One Lever Design

Later Machines—Two Lever Design HG31779,000014E –19–07OCT02–1/1

2-2-9

102703

PN=85

Operation—Operating the Machine

Park Brake Switch

–UN–11MAY98

CAUTION: Prevent possible injury or death from machine runaway. Before disengaging park brake, be sure engine is running and service brakes are operational.

T115292

NOTE: Transmission clutches are disengaged when park brake is applied.

The park brake switch (A) has three positions: • Park brake ON • Neutral, center detented position • Park brake release, momentary position

A—Park Brake Switch

To engage park brake, move switch from the neutral, center detented position to the park brake ON, detented position.

To release park brake, move switch to the neutral, center detented position, then the park brake release momentary position.

NOTE: If park brake is engaged when engine is running and transmission control lever is in “Neutral”, park brake indicator will light.

If park brake is engaged when engine is running and transmission control lever is moved to F or R, park brake indicator will light, STOP indicator will light, and alarm will sound. Basic Display will read “N”. “F” or “R” will not appear until park brake is released.

If engine is stopped with park brake switch OFF, park brake is automatically applied. Press park brake switch to ON and then back to momentary position to release park brake after starting engine.

Park brake will come on if transmission pressure drops below 150 psi.

CED,OUO1021,50 –19–23SEP02–1/1

2-2-10

102703

PN=86

Operation—Operating the Machine

Boom and Bucket Control Lever—One Lever Design Move control lever forward (A) to lower boom, or rearward (D) to raise boom.

NOTE: Pilot enable/boom down switch must be pushed while moving control lever forward to lower boom with engine stopped.

NOTE: Return-to-carry (I) will override float position.

Return-to-carry must be off for float detent to operate.

NOTE: Boom float will not work once the boom is below preset distance from ground. Push switch to “Off” position to activate boom float.

T117034

Return-to-Carry (I)—If Equipped: With Return-to-Carry switch on, push boom down lever to “Float” position (lever in full forward detent position [B]). The boom will stop at a pre-set height and lever will return to neutral position automatically.

–UN–10SEP98

Move control lever left (F) to roll back bucket, or right (C) to dump bucket.

Earlier Machines A—Lower Boom B—Float C—Dump Bucket D—Raise Boom E—Boom Height Kickout F—Rollback Bucket G—Return-to-Dig H—Fast Bucket Dump I—Pilot Enable/Boom Down Switch J—Return-to-Carry Switch—If Equipped

Float (lever in full forward detent position [B]): This position allows oil to flow in and out both ends of cylinders so the bucket can follow the contour of the ground.

Manually release lever from this position.

Return-to-Dig (lever in full left detent position [G]): Bucket will return to set dig position.

Boom Height Kickout (lever in full rear detent position [E]): Lever will remain in this position until boom is at a pre-set height, then will return to neutral automatically.

Boom and bucket functions can be operated simultaneously by moving lever between positions. For example, to raise boom and roll back bucket, move lever between positions (D) and (F).

HG31779,00000B4 –19–18JUL02–1/1

2-2-11

102703

PN=87

Operation—Operating the Machine

Boom and Bucket Control Lever—Two Lever Design

–UN–10JUL02

Move left control lever forward (A) to dump bucket, or rearward (B) to roll back bucket.

T156928B

Return-to-Carry (I)—If Equipped: With Return-to-Carry switch on, push boom down lever to “Float” position (lever in full forward detent position [D]). The boom will stop at a pre-set height and lever will return to neutral position automatically.

NOTE: Pilot enable/boom down switch must be pushed while moving control lever forward to lower boom with engine stopped.

–UN–27JUN02

Move right control lever forward (E) to lower boom or rearward (F) to raise boom.

NOTE: Boom float will not work once the boom is below preset distance from ground. Push switch to “Off” position to activate boom float.

Float (right lever in full forward detent position [D]): This position allows oil to flow in and out both ends of cylinders so the bucket can follow the contour of the ground.

Manually release lever from this position.

Return-to-Dig (left lever in full rearward detent position [C]): Bucket will return to set dig position.

T156774D

NOTE: Return-to-carry (I) will override float position.

Return-to-carry must be off for float detent to operate.

Later Machines A—Dump Bucket B—Rollback Bucket C—Return-to-Dig D—Float E—Lower Boom F—Raise Boom G—Boom Height Kickout H—Fast Bucket Dump I—Return-to-Carry Switch—If Equipped

Boom Height Kickout (right lever in full rearward detent position [G]): Lever will remain in this position until boom is at a pre-set height, then will return to neutral automatically.

HG31779,00000B5 –19–18JUL02–1/1

2-2-12

102703

PN=88

Operation—Operating the Machine

Quick Shift Switch Down/Up

–UN–10SEP98

Press switch (A) to down shift from selected gear to next lower gear when transmission control lever is positioned in gears 2—4. Press again to return to original gear.

T117036

NOTE: Machine can be programmed with Monitor Accessory Mode 02 for down/up 021 or Down only 022.

Earlier Machines

Down Only

–UN–01JUL02

This mode will allow transmission to down shift one gear for each pressing of button. Once a down shift is made by pressing the quick shift switch, the transmission will not shift up again unless a direction or gear change is made.

T156926B

A—Switch

Later Machines—Two Lever Design HG31779,0000135 –19–25SEP02–1/1

2-2-13

102703

PN=89

Operation—Operating the Machine

Ride Control Switch—Earlier Machines (If Equipped)

T117395

–UN–25SEP98

CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with Ride Control. Ride control accumulator energy must be discharged when working on hydraulic components. Turn ignition switch to ON position, cycle the ride control switch from OFF to ON (center position). Boom will “jump up” if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds.

Side Console—Cab Units Shown A—Ride Control Switch

“ON” Position Turn ride control switch (A) ON to improve machine ride and reduce tire flexing when traveling over rough terrain at a high speed with loaded bucket.

If engine is stopped with ride control switch in ON position, ride control is automatically turned off.

Start the engine.

Press ride control switch to the Off position and then back to the On or Auto position to turn ride control on.

To discharge the energy in the ride control accumulator, do the following: 1. Make sure area around bucket is clear.

2. Turn ride control OFF. 3. Lower boom and bucket to ground position and stop engine.

NOTE: Return-to-carry must be off for float detent to operate.

4. Turn key switch on without starting the engine and cycle ride control switch to the ON position (middle switch position).

Continued on next page

2-2-14

TX,30,JC2012 –19–14JUN00–1/3 102703

PN=90

Operation—Operating the Machine 5. Press and hold the pilot enable/boom down switch while holding the boom control in the float position for five seconds.

TX,30,JC2012 –19–14JUN00–2/3

“Auto” Position

–UN–25SEP98

With the ride control switch (A) in the “Auto” position, the ride control functions the same as the “On” position with one exception. When ground speed is approximately 6 km/h (3—1/2 mph) or less, the ride control is turned off.

T117395

When the ground speed is greater than 6 km/h (3—1/2 mph), the operation will be the same as the “On” position.

A—Ride Control Switch

Side Console—Cab Units Shown

TX,30,JC2012 –19–14JUN00–3/3

2-2-15

102703

PN=91

Operation—Operating the Machine

Ride Control—Later Machines (If Equipped)

–UN–17SEP02

CAUTION: Prevent possible injury from unexpected boom. The bucket may “jump up”when ride control switch is turned ON. Clear all bystanders from area.

T159423D

Ride control will improve machine ride and reduce tire flexing when traveling through rough terrain at a high speed with loaded bucket.

“On” Position

Later Machines—One Lever Design

With the ride control switch (1) in the “On” position, ride control will remain on as long as engine is running. If engine is stopped with ride control switch in “On” position, ride control is automatically turned off.

–UN–18JUL02

“Auto” Position

T156774K

With the ride control switch in the “Auto” position, ride control will remain on as long as engine is running and ground speed is at least 6 km/h (3—1/2 mph).

“Off” Position Later Machines—Two Lever Design

Ride control is turned off.

1—Ride Control Switch

Operating Ride Control 1. Make sure area around bucket is clear.

2. Start the engine.

3. If ride control switch is in the “Off” position, push switch to “On” or “Auto” mode. If switch is already in “On” or “Auto” position, ride control will automatically reactivate as soon as a ground speed greater than 6 km/h (3.5 mph) is reached and will operate until engine is stopped or switch is turned “Off”.

Discharging Ride Control Accumulator 1. Make sure area around bucket is clear.

2. Turn ride control off.

3. Lower boom and bucket to ground and stop engine.

Continued on next page

2-2-16

HG31779,0000099 –19–25SEP02–1/2 102703

PN=92

Operation—Operating the Machine NOTE: Return-to-carry must be off for boom float to operate.

4. Turn key switch to “On” without starting the engine and cycle ride control switch to the “On” position (middle switch position).

5. Press and hold the pilot enable/boom down switch while holding the boom control in the float position for 5 seconds.

HG31779,0000099 –19–25SEP02–2/2

Secondary Steering—If Equipped

T117403

Steering pressure indicator light (B) will light, STOP indicator light (A) will flash, and audible alarm will sound when secondary steering system is activated. The light indicates low hydraulic pressure resulting from mechanical malfunction, such as loss of engine power. An electrically driven pump will actuate to provide steering

–UN–25SEP98

IMPORTANT: Prevent possible damage to secondary steering system. Stop machine immediately if steering pressure indicator light and audible alarm come on while operating. THE SECONDARY STEERING SYSTEM IS NOT INTENDED FOR CONTINUOUS USE.

A—STOP Indicator Light B—Steering Pressure Indicator Light

The secondary steering system will function only when key switch is on.

NOTE: Secondary steering is activated if the engine dies with key on. The secondary steering motor will stop when the key is turned off.

TX,35,JC1393 –19–24SEP98–1/1

2-2-17

102703

PN=93

Operation—Operating the Machine

Differential Lock Switch Hold switch (A) down to lock front differential or front and rear differential, if equipped.

–UN–13FEB98

Release switch to unlock differential.

T113525

NOTE: Use differential lock only when conditions require traction. Avoid using differential lock when steering.

A—Switch

TX,35,JC1943 –19–02SEP98–1/1

Boom Height Kickout Adjustment 1. Move loader control lever to boom raise detent position and release.

T106999B

–UN–06FEB97

2. After loader control lever returns to neutral, make a mark on the adjustable plate and loader frame for the tool carrier. For the loader, make a mark on plate edge and mounting block.

3. Position the boom in the desired boom height kickout position. Stop engine.

Loader

4. Loosen cap screws (A) and adjust plate to align marks on plate and loader frame or mounting block.

–UN–07FEB97

5. Inspect air gap between switch (B) and adjustable plate (C).

Specification Boom Height Kickout Switch-to-Adjustable Plate—Gap ................. 5—8 mm (0.197— 0.315 in.)

7. Start engine and check boom height kickout for correct adjustment. Readjust as required.

T107042B

6. If air gap is out of specifications, loosen hex nuts and adjust switch (B) to get correct air gap.

Tool Carrier A—Cap Screw (2 used) B—Switch C—Adjustable Plate

TX,20,SS3659 –19–05AUG96–1/1

2-2-18

102703

PN=94

Operation—Operating the Machine

Return-to-Carry Kickout Adjustment 1. Move Return-to-Carry switch on side dash to ON position. Raise boom to maximum height.

T107043B

3. Stop engine. Make a mark on the adjustable plate and loader frame for the tool carrier. For the loader, make a mark on plate edge and mounting block.

–UN–07FEB97

2. Put boom lever in “Float” detent position and observe at what position boom stops lowering and control lever releases from detent.

Loader

4. Start engine and position boom in desired Return-to-Carry position.

–UN–06FEB97

5. Stop engine. Loosen cap screws (A) and adjust plate (B) to align marks on plate and loader frame or mounting block.

Specification Boom Height Kickout Switch-to-Adjustable Plate—Gap ................. 5—8 mm (0.197— 0.315 in.)

7. If air gap is out of specifications, loosen hex nuts on switch and adjust switch (B) to get correct air gap.

T107041B

6. Inspect air gap between switch (B) and adjustable plate (C).

Tool Carrier A—Cap Screw (2 used) B—Switch C—Adjustable Plate

8. Start engine and check boom Return-to-Carry kickout for correct adjustment. Readjust as required.

NOTE: The boom “Float” position detent will not operate at ground level with Return-to-Carry switch ON. Turn Return-to-Carry switch off to activate normal “Float” function of boom.

TX,20,SS3660 –19–05AUG96–1/1

2-2-19

102703

PN=95

Operation—Operating the Machine

Return-To-Dig Adjustment (S.N. —574603) 5—8 mm (0.197— 0.315 in.)

Cap Screw Torque

121 Nm (89 lbft)

–UN–16AUG96

SPECIFICATIONS Air Gap Between Switch and Bar Distance

OTHER MATERIAL

T101721

T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE Products TY9473 Canadian Thread Lock and Sealer (Medium Strength)LOCTITE Products 242 Thread Lock and Sealer (Medium Strength)LOCTITE Products

A—Air Gap Switch-To-Bar B—Adjustable Bar C—Cap Screws D—Alignment Marks E—Adjusting Nuts (2) F—Switch

T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE Products TY9473 Canadian Thread Lock and Sealer (Medium Strength)LOCTITE Products 242 Thread Lock and Sealer (Medium Strength)LOCTITE Products TY6305 U.S. Clean And Cure PrimerLOCTITE Products TY9485 Canadian Clean And Cure PrimerLOCTITE Products 764 Clean And Cure PrimerLOCTITE Products

1. Raise boom approximately 300 mm (12 in.) above ground. Move bucket from full rollback to dump.

2. Move loader control lever to return-to-dig detent position and release.

3. After control lever returns to neutral, scribe a mark (D) on the switch bracket and adjustable bar (B) to align with each other.

4. Position the boom and bucket in the desired return-to-dig position. Stop engine.

5. Remove cap screws (C), one at a time and remove old thread lock and sealer using Clean and Cure Primer.

Apply medium strength thread lock and sealer to cap screws.

6. Install cap screws (C) but do not tighten. Adjust bar to align marks on switch bracket and end of bar. Torque cap screws to 121 Nm (89 lbft).

Specification Cap Screw—Torque ......................................................... 121 Nm (89 lbft)

LOCTITE is a trademark of Loctite Corp.

Continued on next page

2-2-20

TX,20,SS3661 –19–22JUN00–1/2 102703

PN=96

Operation—Operating the Machine 7. Loosen adjusting nuts to switch (F). Adjust air gap (A) between switch and adjustable bar (B) to 5—8 mm (0.197— 0.315 in.). Retighten adjusting nuts.

Specification Air Gap Between Switch and Bar—Distance............................................... 5—8 mm (0.197— 0.315 in.)

8. Raise boom. Cycle bucket from full rollback to dump.

Adjust as required to get desired position.

TX,20,SS3661 –19–22JUN00–2/2

2-2-21

102703

PN=97

Operation—Operating the Machine

T131917

–UN–26JUN00

Return-To-Dig Adjustment (S.N. 574603— )

A—Air Gap Switch-To-Bar B—Adjustable Bar

C—Cap Screws D—Alignment Marks

SPECIFICATIONS Cap Screw Torque

121 Nm (89 lbft)

Air Gap Between Switch and Bar Distance

5—8 mm (0.197— 0.315 in.)

Hex Nut Torque

75 N•m (55 lbft) OTHER MATERIAL

T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE Products TY9473 Canadian Thread Lock and Sealer (Medium Strength)LOCTITE Products 242 Thread Lock and Sealer (Medium Strength)LOCTITE Products T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE Products TY9473 Canadian Thread Lock and Sealer (Medium Strength)LOCTITE Products 242 Thread Lock and Sealer (Medium Strength)LOCTITE Products 

TY6305 U.S. Clean And Cure PrimerLOCTITE Products TY9485 Canadian Clean And Cure PrimerLOCTITE Products

E—Hex Nuts

F—Switch

1. Raise boom approximately 300 mm (12 in.) above ground. Move bucket from full rollback to dump.

2. Move loader control lever to return-to-dig detent position and release.

3. After control lever returns to neutral, scribe a mark (D) on the switch bracket and adjustable bar (B) to align with each other.

4. Position the boom and bucket in the desired return-to-dig position. Stop engine.

5. Remove cap screws (C), one at a time and remove old thread lock and sealer using Clean and Cure Primer. Apply medium strength thread lock and sealer to cap screws.

6. Install cap screws (C) but do not tighten. Adjust bar to align marks on switch bracket and end of bar.

Torque cap screws to 121 Nm (89 lbft).

764 Clean And Cure PrimerLOCTITE Products

LOCTITE is a trademark of Loctite Corp.

Continued on next page

2-2-22

CED,TX18076,44 –19–22JUN00–1/2 102703

PN=98

Operation—Operating the Machine Specification Cap Screw—Torque .................................................. 121 Nm (89 lbft)

7. Loosen hex nuts (E) to switch bracket. Adjust air gap (A) between switch and adjustable bar (B) to 5—8 mm (0.197— 0.315 in.). Torque hex nuts to 75

Nm (55 lbft).

Specification Air Gap Between Switch and Bar—Distance ........................................ 5—8 mm (0.197— 0.315 in.)

Hex Screw—Torque .................................................... 75 Nm (55 lbft)

CED,TX18076,44 –19–22JUN00–2/2

2-2-23

102703

PN=99

Operation—Operating the Machine

T110742

–UN–06AUG97

Fork Attachment

LOADING • • • •

DRIVING ON A SLOPE

Center forks and carriage before lifting.

Inspect load to ensure stability when lifted.

Never attempt to lift load with one fork.

Approach load slowly and squarely with fork tips level. Move forks slowly under load with load positioned equally on forks. Continue to drive forward until load is against backrest of forks.

CAUTION: Prevent possible injury from machine rollover, do not turn on slopes. Do not drive across slopes under any circumstances.

Driving up or down slope WITH load on forks: • Lower load near to ground.

• Keep mast tilted back to retain load. Slowly drive straight up or back straight down slope.

UNLOADING • Always use a signal person if you cannot see the placement area for the load. Make certain area is clear of all objects.

• Lower load to ground and tilt forks to a level position. Back away carefully to disengage forks.

Driving up or down slope WITHOUT load on forks: • Lower forks near to ground.

• Keep mast tilted back.

• Slowly drive straight down or back straight up slope.

ELEVATED LOADS • Slowly raise load with a slight back tilt to cradle load.

Never tilt load forward unless load is over landing area and ready to be set down.

• If there is any indication of load instability during the lift such as movement, leaning, or swaying, stop lifting immediately. Lower load and restock.

• As load approaches desired height, slow the lift speed to a minimum. Continue the lift until load is slightly higher than the landing point.

• After load is securely in place, retract forks clear of load and lower forks to traveling height before moving.

LIFTING CAPACITY To maintain stability, only lift loads equal to or less than mast capacity or rated operating capacity of machine, whichever is less. (See Specifications section for machine lifting capacities.)

TRAVELING • Operate machine controls from operator seat only.

• While driving, carry load low for good visibility and machine stability.

Continued on next page

2-2-24

CED,TX03679,5542 –19–03NOV99–1/2 102703

PN=100

Operation—Operating the Machine • Downshift with care. A sudden deceleration could shift or topple load.

• A sudden reversal of travel direction could tip load or over turn the machine. Come to a gradual stop before reversing directions.

• Slow travel speed when making turns to avoid an overturn.

• Use low gear for hillside or ramp operation. Never coast downhill with transmission in neutral. The machine could go out of control and tip over.

• Reduce speed when driving over rough terrain, carrying a heavy load, or working in a congested area. Avoid rocks, curbs, and ditches.

• Inspect hanger block welds for visible cracks.

• Check to see that the spring loaded keeper, with washer, is in position in the upper hanger block and that the keeper is functioning properly. (Spring in keeper must pull pin down into hanger block when pin is pulled out and released.)

• Inspect hanger blocks for any sign of deformation, cracks, and wear.

• Bent forks are not always detectable by sight.

Remove forks and measure the interior angle of each fork to detect a bent fork.

• Tapered tip forks have an interior angle of 90°.

Standard square tip forks have an interior angle of 87°. If angle is bent more than 3°, replace fork.

OPERATING TIPS • Never use the fork attachment as a working platform.

• Know locations of bystanders in the working area at all times.

• DO NOT touch, lean on, or reach through the mast, boom or lift mechanism or permit others to do so.

Never climb on the mast, boom, or attachments.

• NEVER allow anyone to stand or pass under the raised forks, mast, carriage, boom, or attachments.

• Reduce speed and sound horn at blind intersections, exits, and when approaching pedestrians.

FORK ADJUSTMENT To change fork position: CAUTION: To prevent injury, never stand under forks or any part of lift mechanism.

1. Lower forks to approximately 25 mm (1 in.) above ground.

CAUTION: To prevent injury when sliding forks, keep hands and fingers out of fork adjustment path.

FORK INSPECTION The forks are the main load bearing components of the mast. Forks must be maintained and checked periodically to assure safe operation.

Inspect forks daily. If any of the following conditions exist, replace forks before operating machine.

• Check for visibly bent forks and abrasions. If forks are bent more than 3°, replace forks. (Tapered forks are 90° nominal and standard forks are 87° nominal.) If a flat spot is clearly evident from abrasive wear, replace forks.

• Inspect forks for cracks along the inside radius of heel.

2. Lift pin and slide fork to desired position. Slide fork by placing a foot on tine and palm of other hand on top of fork. Alternately push fork with hand (top) and foot (lower) in a rocking motion until fork reaches desired position.

3. Release pin and check that fork is engaged in notch.

4. Check that mast backing plate pins are in place at each end. Measure backing plate pins for wear.

Pins should be equal in length on both sides of plate. Replace pins if worn or damaged.

CED,TX03679,5542 –19–03NOV99–2/2

2-2-25

102703

PN=101

Operation—Operating the Machine

Parking the Machine 1. Park machine on a level surface.

–UN–13FEB98

2. Lower bucket to ground.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine.

T113477

3. Move transmission control lever (A) to N. Engage neutral lock (B).

A—Transmission Control Lever B—Neutral Lock

4. Push park brake switch to ON. IMPORTANT: Turbocharger may be damaged if engine is not properly shut down.

5. Run engine at 1/2 speed without load for 2 minutes before stopping, to avoid damage to turbocharger.

Release accelerator pedal to slow idle.

6. Turn key switch to “Off”.

7. Turn battery disconnect switch OFF, if equipped.

CED,OUO1021,164 –19–18JUL02–1/1

2-2-26

102703

PN=102

Operation—Operating the Machine

Loading Machine on a Trailer 1. Keep the trailer bed clean. Put chock blocks against trailer wheels.

–UN–13FEB98

2. Use a ramp or loading dock. Ramps must be strong enough, have a low angle, and correct height.

T113477

3. Fasten seat belt before starting engine.

CAUTION: Position the machine so that its centerline is over the centerline of the truck bed. NEVER steer the machine while on the ramp. If changing direction is required on the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

A—Transmission Control Lever B—Neutral Lock

4. Drive the machine onto the ramp slowly. The centerline of the machine should be over the centerline of the trailer.

5. Lower all equipment onto blocks or trailer bed.

6. Move transmission control lever (A) to N. Engage neutral lock (B).

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn off engine or push park brake switch to ON to hold machine.

7. Push park brake switch to ON. 8. Connect frame locking bar.

9. Turn key switch to “Off”.

10. Turn battery disconnect switch OFF, if equipped.

11. Cover exhaust opening to prevent entry of debris and water.

Continued on next page

2-2-27

CED,OUO1021,62 –19–18JUL02–1/2 102703

PN=103

Operation—Operating the Machine 12. Fasten each corner of the machine to the trailer with a chain or cable with appropriate load binder.

13. Place blocks in front of and behind tires.

CED,OUO1021,62 –19–18JUL02–2/2

2-2-28

102703

PN=104

Operation—Operating the Machine

T138646

–UN–20MAR01

Towing Procedure

1—Front Driveshaft 2—Park Brake Fitting Plug

3—Park Brake Hose

4—Telescoping Driveshaft

CAUTION: Do not allow an operator on the machine being towed unless the operator can control the steering and brakes.

5—Rear Driveshaft

CAUTION: Prevent possible injury from unexpected machine movement. Place blocks at front and rear of tires to prevent machine from rolling.

IMPORTANT: Engine cannot be started by towing.

1. Place blocks at front and rear of tires.

Tow the machine off-road to the nearest location where repair work can be done. Haul the machine if it must be moved further than 460 m (500 yd).

2. Connect the towed and towing machines together.

NOTE: Frame locking bar is installed to prevent weaving as machine is towed.

Never tow machine faster than 3.2 km/hr (2 mph) to avoid transmission damage.

If the engine or the transmission hydraulic system are non-functional, the park brake is ON.

3. Start engine if possible, and install frame locking bar.

4. Move transmission control lever to “Neutral” position. Engage neutral lock.

Continued on next page

2-2-29

OUOE003,000009E –19–18JUL02–1/2 102703

PN=105

Operation—Operating the Machine 10. Pump handle until gauge needle indicates 1379 kPa (13.8 bar) (200 psi) which will be required to disengage park brake.

5. If park brake indicator does not come on, the park brake is OFF. Go to Step 11.

If park brake indicator is on, the park brake is ON. Go to Step 6.

To engage the park brake, open the valve in the hand-operated pump to relieve pressure.

6. Stop engine.

CAUTION: Prevent possible injury from unexpected machine movement. Never attempt to remove driveshafts without blocking front and rear tires.

CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar.

7. Disconnect park brake hose (3) from park brake fitting (2). Plug hose.

11. Remove driveshafts if a hand operated pump is not available to release the park brake.

8. Connect a hose from a hand operated hydraulic pump to the fitting on park brake.

Disconnect driveshafts (1 and 4) at differential and transmission and remove from machine.

NOTE: Keep hydraulic hand operated pump filled with oil.

CAUTION: Prevent possible injury from unexpected machine movement. Sit in operator’s seat when pumping the hydraulic pump. When towing the machine, maintain at least 1379 kPa (13.8 bar) (200 psi). If pressure is below 1379 (13.8 bar) (200 psi), park brake may engage.

9. Place hydraulic hand pump on left side of operator’s station floor.

CAUTION: Prevent possible injury from unexpected machine movement. Place blocks at front and rear of tires to prevent machine from rolling.

NOTE: Limit tow to 460 m (500 yd) maximum.

12. Tow the machine slowly.

13. Place blocks at front and at rear of tires.

14. Reapply park brake or reinstall driveshaft if it was removed. See your authorized dealer for installation information.

IMPORTANT: Do not pump pressure up to more than 2068 kPa (20.7 bar) (300 psi) to avoid damage to the park brake.

OUOE003,000009E –19–18JUL02–2/2

2-2-30

102703

PN=106

Operation—Operating the Machine

Lifting the Machine CAUTION: Prevent possible injury from unexpected machine movement. Clear all bystanders from lifting area. Select correct lifting cable strength for weight of machine.

Test lift by raising machine 0.3 m (1 ft) off the ground.

Specification 624H Loader—Weight ............................................. 11 736 kg (25,873 lb) TC62H Tool Carrier—Weight .................................. 13 849 kg (30,532 lb)

1. Install machine frame locking bar.

2. Attach cables (A) to machine so cables do not rub machine.

4. Test lift by raising machine 0.3 m (1 ft) off the ground.

T7477AV

5. Lift machine and swing to unloading area.

–UN–19MAR91

3. Attach a tether cable to machine to control machine as it is lifted.

A—Cables

CED,OUOE002,1782 –19–16SEP98–1/1

2-2-31

102703

PN=107

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 –19–12FEB99–1/1

Low Sulfur Diesel Fuel Conditioner When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulfur diesel fuels.

If the local fuel distributor will supply only low sulfur fuel, order and use John Deere PREMIUM DIESEL FUEL CONDITIONER. It provides lubricating

properties along with other useful benefits, such as cetane improver, anti-oxidant, fuel stabilizer, corrosion inhibitor and others. John Deere PREMIUM DIESEL FUEL CONDITIONER is specifically for use with low sulfur fuels. Nearly all other diesel fuel conditioners only improve cold weather flow and stabilize long-term fuel storage. They do not contain the lubrication additives needed by rotary fuel injection pumps.

TX,45,JC2126 –19–15AUG97–1/1

3-1-1

102703

PN=108

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 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.

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.

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.

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

DX,FUEL4 –19–18MAR96–1/1

Alternative And Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location.

In general, avoid mixing different brands or types of oil.

Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

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

Consult your authorized dealer to obtain specific information and recommendations.

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.

TX14740,0001C42 –19–20OCT00–1/1

3-1-2

102703

PN=109

Maintenance—Machine

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

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

After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL. If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation:

• ACEA Specification E1 After the break-in period, use John Deere PLUS-50 or other diesel engine oil as recommended in this manual.

IMPORTANT: Do not use PLUS-50 oil or engine oils meeting API CH-4, API CG4, API CF4, ACEA E3, or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.

• API Service Classification CE

PLUS-50 is a registered trademark of Deere & Company.

DX,ENOIL4 –19–24JAN00–1/1

3-1-3

102703

PN=110

Maintenance—Machine

• John Deere PLUS-50

30˚C

86˚F

20˚C

68˚F

10˚C

50˚F

0˚C

32˚F

-10˚C

14˚F

-20˚C

-4˚F

-30˚C

-22˚F

-40˚C

-40˚F

The following oil is also recommended: • John Deere TORQ-GARD SUPREME Other oils may be used if they meet one or more of the following: • • • • •

API Service Classification CH-4 API Service Classification CG-4 API Service Classification CF-4 ACEA Specification E3 ACEA Specification E2

Multi-viscosity diesel engine oils are preferred.

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

–UN–05OCT01

104˚F

TS1668

40˚C

SAE 5W-40

The following oil is preferred:

SAE 10W-40

122˚F

SAE 5W-30

50˚C

SAE 15W-40

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

SAE 30

Diesel Engine Oil

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

PLUS-50 is a registered trademark of Deere & Company.

TORQ-GARD SUPREME is a registered trademark of Deere & Company

DX,ENOIL –19–05OCT01–1/1

3-1-4

102703

PN=111

Maintenance—Machine

Transmission, Hydraulic System, Park Brake, and Differential Oil Use oil viscosity based on the expected air temperature range during the period between oil changes.

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

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

TS1660

Use John Deere BIO-HY-GARD1oil when a biodegradable fluid is required.

HY-GARD is a registered trademark of Deere & Company BIO-HY-GARD is a trademark of Deere & Company 1

BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD should not be mixed with mineral oils because this reduces the biodegradability and makes proper oil recycling impossible.

CED,TX03679,5800 –19–14JUN00–1/1

3-1-5

102703

PN=112

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

3-1-6

102703

PN=113

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

102703

PN=114

Maintenance—Periodic Maintenance Service Your Machine at Specified Intervals

A—Maintenance Chart

T111207B

Service items at multiples of the original requirement. For example, at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily.

–UN–27AUG97

Lubricate, make service checks and adjustments at intervals shown on the periodic maintenance chart (A) and on the following pages.

TX,50,JC2151 –19–02SEP97–1/1

Check the Monitor Display Unit Regularly At the A 06 display, press SELECT.

T111863

–UN–22OCT97

Then press SELECT again to turn the 0.1 Hour Meter Mode On or Off.

TX,50,JC2242 –19–29SEP97–1/2

–UN–22OCT97

When the 0.1 Hour Meter Mode is turned On, the hour meter reading (A) can be accessed during normal machine operation by pressing SELECT. The odometer reading will switch to the voltmeter reading, and then to the hour meter reading in hours and tenths of hour.

T111864

Intervals on the periodic maintenance chart are for operating in normal conditions. If you operate your machine in severe conditions, you should service it at SHORTER INTERVALS. A—Hour Meter Reading

TX,50,JC2242 –19–29SEP97–2/2

3-2-1

102703

PN=115

Maintenance—Periodic Maintenance

1. Pull out on latch (A) to open lower engine service door.

A—Latch

T106380B

CAUTION: Prevent possible injury from engine service door closing. Always keep service door in the open locked position when servicing the engine area.

–UN–24JAN97

Opening Engine Side Shields and Service Doors

TX,50,JC1806 –19–14JUN00–1/2

2. Open service door to full extent. Gas cylinder (A) will lock door in place.

T131518B

–UN–07JUN00

A—Cylinder

TX,50,JC1806 –19–14JUN00–2/2

3-2-2

102703

PN=116

Maintenance—Periodic Maintenance

CAUTION: Prevent possible injury from unexpected machine movement. Connect frame locking bar to both frames before you work in frame pivot area.

T161062B

1. Align machine frames.

–UN–29OCT02

Locking Machine Frame

2. Remove quick lock ring (1) and pull locking pin (2) from hole.

4. Install locking pin through hole in loader frame and end of locking bar. Install quick lock ring to secure locking bar in place.

T161061B

1—Quick Lock Ring 2—Locking Pin 3—Locking Bar

–UN–29OCT02

3. Rotate locking bar (3) to align with hole in machine frame.

HG31779,0000171 –19–29OCT02–1/1

3-2-3

102703

PN=117

Maintenance—Periodic Maintenance

Boom Lock

Empty bucket and place in dump position before installing boom lock.

1. Raise boom. Empty bucket and place in dump position before installing boom lock (1).

T161064B

–UN–29OCT02

CAUTION: Always install boom lock before working on or around this machine with the boom raised.

2. Loosen hand bolt (2) and remove boom lock from side of machine.

5. Before removing boom lock from cylinder, raise boom slightly to relieve pressure. Return boom lock to storage position on side of machine and tighten hand hold.

T161065B

4. Tighten hand bolt.

–UN–29OCT02

3. Install lock on boom cylinder and lock lever facing to outside of machine and lower boom onto lock.

1—Boom Lock 2—Hand Bolt

HG31779,0000172 –19–29OCT02–1/1

3-2-4

102703

PN=118

Maintenance—Periodic Maintenance

Opening Grille Door Press down on release lever (1) to open grille door fully.

Door will automatically lock open.

–UN–10AUG01

Rotate stop (2) to release door lock.

T146005B

–UN–26SEP01

T139740C

1—Release Lever 2—Stop

CED,OUOE002,1463 –19–27SEP01–1/1

Fuel Tank CAUTION: Handle fuel carefully. If the engine is hot or running, DO NOT fill the fuel tank.

DO NOT smoke while you fill fuel tank or work on fuel system.

Specification Fuel Tank—Capacity .................................................... 265 L (70 gal)

To avoid condensation, fill the fuel tank at the end of each day’s operation. Shut off engine before filling.

CED,OUOE002,1783 –19–16SEP98–1/1

Check Windshield Washer Fluid Level Open left engine side shield.

T111207C

During winter season, use all season windshield washer fluid which will not freeze.

–UN–27AUG97

Check fluid in windshield washer bottle (A).

A—Windshield Washer Bottle

TX,50,JC2243 –19–29SEP97–1/1

3-2-5

102703

PN=119

Maintenance—Periodic Maintenance

Maintenance and Repair Record Keeping System The checklist on the following page summarizes scheduled maintenance, and parts and oil required at each maintenance interval.

Use the checklist to:

As maintenance is performed, check off each item on the list and record date and hour meter reading. Use the second copy of this form (immediately preceding the Service Literature page inside the back cover).

T7511CO

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

–UN–27JUN91

• 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.

TX,50,RB280 –19–26JUN00–1/1

3-2-6

102703

PN=120

Maintenance—Periodic Maintenance

T111411

T111410

–UN–16SEP97

–UN–16SEP97

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

3-Way Coolant Test Kit

Oilscan Plus

Oilscan Plus, Coolscan Plus and 3-Way Coolant Test Kit are John Deere fluid sampling products to help you monitor machine performance and system condition.

The objective of a fluid sampling program is to ensure machine availability when you need it and to reduce repair costs by identifying potential problems before they become critical.

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

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

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

CED,OUO1040,114 –19–11JUN98–1/1

3-2-7

102703

PN=121

Maintenance—Periodic Maintenance

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

• • • •

Inspect tires and check pressure Check wheel retainer cap screws Clean or replace air cleaner elements Check and clean air inlet cover

• Check recovery tank coolant level • Clean air cleaner dust unloader valve • Check engine oil level • Change engine break-in oil and replace filter • Grease loader linkage and cylinder pivots • Grease front steering cylinder pivots • Grease oscillating rear axle Model: ❒ 624H PIN/Serial Number:

As Required • Inspect belts • Drain water from fuel tank • Drain and clean primary fuel filter

Every 10 Hours or Daily • Check hydraulic system oil level • Check transmission oil level

After First 100 Hours • Change transmission oil and replace filter Every 100 Hours • Grease rear steering cylinder pivots • Check and clean cab fresh air filter • Check and clean cab recirculating air filter Customer: Delivery Date:

Oil Sampling Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form. Maintenance recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you supply. Regular oil sampling will extend the operational life of your machine’s systems.

❒ Grease drive line sliding joints ❒ Check receiver dryer moisture indicator ❒ Check radiator coolant level Comments: Date:

Hour Meter Reading:

❒ Grease drive line sliding joints, upper and lower ❒ Check air intake hoses ❒ Check battery water level ❒ Check coolant conditioner ❒ Replace final fuel filter ❒ Replace primary fuel filter Comments: Date:

Hour Meter Reading:

OILSCAN is a trademark of Deere & Company.

Every 250 Hours ❒ Drain and refill engine oil ❒ Replace engine oil filter

Maintenance Performed By: Every 500 Hours ❒ Replace hydraulic system return filter ❒ Grease rear oscillating support cover ❒ Replace hydraulic reservoir breather filter ❒ Replace transmission oil filter ❒ Check park brake oil level ❒ Check front and rear differential oil level

Maintenance Performed By:

Continued on next page

3-2-8

CED,OUOE002,1785 –19–20DEC01–1/2 102703

PN=122

Maintenance—Periodic Maintenance Every 1000 Hours ❒ Drain and refill transmission oil ❒ Grease frame hinge pivots ❒ Drain and refill park brake oil

❒ Remove and clean engine crankcase vent tube ❒ Replace air cleaner dust unloader valve ❒ Replace air cleaner elements ❒ Check radiator coolant and hoses Comments: Date:

Hour Meter Reading:

Maintenance Performed By: Every 2000 Hours

❒ Check and adjust engine valve lash Comments: Date:

Hour Meter Reading:

Maintenance Performed By:

Every 3000 Hours ❒ Drain, flush and refill hydraulic system oil ❒ Clean hydraulic system fill strainer Comments Date:

❒ Drain and refill front and rear differential oil ❒ Clean axle differential recirculating screen

Hour Meter Reading:

Insure machine performance and availability; use parts are also on hand i.e. filter O-rings.

Part Number Engine Oil Filter RE59754 Primary Fuel Filter RE62424 Final Fuel Filter RE62419 Transmission Filter AT147496 (S.N. -572779) AT222005 (S.N. 572780-) Hydraulic System Return AT209204 Filter Air Filter Primary AT178583 Air Filter Secondary AT178584 Hydraulic Reservoir AM39653 Breather Filter John Deere PLUS-50 Oil (S.N. —582360) (S.N. 582361—) HY-GARD Transmission and Hydraulic Oil Coolant Conditioner (as TY16004 needed) OILSCAN PLUS Kit: (10 samples per kit) •Diesel Engine Oil AT178840 •Transmission Oil AT178840 •Axle Oil AT178840 •Hydraulic Oil AT178844 COOLSCAN PLUS Kit AT183016

Maintenance Performed By:

REQUIRED PARTS only genuine John Deere parts. Verify part numbers are current and that any associated ASI 1

250 HOURS 1

500 HOURS 1 1 1

1000 HOURS 1 1 1

3000 HOURS 1 1 1

1

1

1

1

1

1

1

1 1

1 1

1 1

1

1 1 1

1 1 1

20 L (21 qt) 21 L (22 qt)

20 L (21 qt) 21 L (22 qt)

20 L (21 qt) 21 L (22 qt)

72 L (76 qts)

1

PLUS-50 is a trademark of Deere & Company.

HY-GARD is a trademark of Deere & Company.

OILSCAN PLUS is a trademark of Deere & Company.

COOLSCAN PLUS is a trademark of Deere & Company.

1 1 2 1

20 L (21 qt) 21 L (22 qt)

20 L (21 qt) 21 L (22 qt)

28 L (30 qts)

189 L (50 gal)

1 1 2 1 1

1 1 2 1 1

CED,OUOE002,1785 –19–20DEC01–2/2

3-2-9

102703

PN=123

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

Always maintain the correct tire pressure. DO NOT inflate tires above the recommended pressure.

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

–UN–23AUG88

Carefully inspect any tire and rim assembly that has been run flat or severely underinflated before reinflating the tire. Damage to the rim and tire may have developed. Call your authorized dealer or a qualified repair service to inspect the rim and tire assembly and make necessary repairs.

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.

NEVER cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

–UN–12MAR97

Do not attempt to mount a tire if you do not have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service.

T108057B

Check tire pressure with an accurate gauge having 7.0 kPa (0.07 bar) (1 psi) graduations.

1. Remove pipe cap (A).

2. Shut off air supply to hose.

–UN–21OCT88

3. Move gauge hand to correct pressure.

T87502

4. Lock air chuck on tire valve.

A—Pipe Cap

Continued on next page

3-3-1

TX,55,JC1944 –19–11MAR97–1/2 102703

PN=124

Maintenance—As Required 5. Turn on air supply. Stand to front or rear of tire when you add air to tire.

6. After tire is at correct pressure, shut off air supply.

Release chuck. (See following Tire Pressure chart.)

7. Inspect tire for damage.

TX,55,JC1944 –19–11MAR97–2/2

Tire Pressures Item

Measurement

Specification

17.5—25 Bias Shipping Pressure

Front Pressure Rear Pressure

379 kPa (3.79 bar) (55 psi) 310 kPa (3.10 bar) (45 psi)

17.5—R25 Radial Shipping Pressure

Front Pressure Rear Pressure

414 kPa (4.14 bar) (60 psi) 276 kPa (2.75 bar) (40 psi)

20.5—25 Bias Shipping Pressure

Front Pressure Rear Pressure

310 kPa (3.10 bar) (45 psi) 241 kPa (2.41 bar) (35 psi)

20.5—R25 Radial Shipping Pressure

Front Pressure Rear Pressure

310 kPa (3.10 bar) (45 psi) 207 kPa (2.06 bar) (30 psi)

Tire Pressures1

1

Tire shipping pressure may not be the same as tire operating pressure.

You may change tire pressures to suit working condition according to tire manufacturer’s recommendations.

TX,55,JC2189 –19–09SEP97–1/1

Tighten Wheel Retainer Cap Screws NOTE: Tighten cap screws after first 10 hours, then again after first 50 hours of loaded operation. After that, tighten as required.

Tighten wheel cap screws.

Tighten Wheel Retainer Cap Screws—Specification Wheel Retainer Cap Screws—Dry Torque ......................................................................... 540 N•m (400 lb-ft)

TX,55,JC1924 –19–13AUG02–1/1

3-3-2

102703

PN=125

Maintenance—As Required

Check Fire Extinguisher—If Equipped IMPORTANT: Dry powder has a tendency to pack in the bottom of an extinguisher.

–UN–17FEB98

Before using extinguisher (A), turn it upside down and shake it until you feel the powder move.

T113598

Check gauge. If fire extinguisher is not fully charged, charge or replace it.

NOTE: The fire extinguisher must be charged or replaced after any use.

A—Fire Extinguisher

CED,OUO1021,79 –19–12MAR98–1/1

3-3-3

102703

PN=126

Maintenance—As Required

Clean or Replace Air Cleaner Elements 1. Open left service door.

–UN–27AUG97

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

3. Remove primary element (B).

T111216B

4. Remove secondary element (C).

T111212B

–UN–27AUG97

T111211B

–UN–27AUG97

A—Clips (3 used) B—Primary Element C—Secondary Element

TX,55,JC2154 –19–02SEP97–1/1

Check Air Inlet Cover 1. Open left engine side shield.

–UN–27AUG97

2. Check cover (A) for debris. Remove debris if necessary.

T111239B

3. Close side shield.

A—Inlet Cover

TX,55,JC2155 –19–02SEP97–1/1

3-3-4

102703

PN=127

Maintenance—As Required

T117523

T111242B

–UN–27AUG97

–UN–30SEP98

Inspect Serpentine Belt

With Air Conditioning

1. Check belt (A) regularly for wear, especially for cracks at the bottom of grooves and for frayed edges.

IMPORTANT: If belt is stretched to the point that the belt tensioner is against its stop, belt must be replaced.

3. Hold tension adjuster assembly away from belt while removing old belt and installing new belt.

T117524

A—Belt

–UN–30SEP98

2. If necessary, replace belt.

TX,55,JC2244 –19–29SEP97–1/1

3-3-5

102703

PN=128

Maintenance—As Required

Drain Fuel Tank Sediment NOTE: Petcock is located at left front of machine frame bottom guard (A).

1. Loosen petcock (B).

2. Drain water and sediment into a container.

3. Tighten petcock.

4. Dispose of waste properly.

T114390

–UN–19MAR98

T103144C

–UN–12DEC96

A—Bottom Guard B—Petcock

CED,OUOE002,1720 –19–03SEP98–1/1

3-3-6

102703

PN=129

Maintenance—As Required

Drain and Clean Primary Fuel Filter 1. Open left engine side shield to access primary fuel filter.

–UN–27AUG97

2. Put container under drain valves (B and C).

T111238D

3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base.

4. Remove hand primer (A) from fuel filter base.

Disassemble hand primer assembly and clean out any debris.

T8387AE

–UN–17DEC94

A—Hand Primer B—Drain Valve (Primary Fuel Filter) C—Drain Valve (Final Fuel Filter)

TX,55,JC2157 –19–02SEP97–1/2

5. Remove fuel inlet line (A) and fuel drain plug (C).

6. Flush any debris from filter base (B).

–UN–17DEC94

7. Install fuel inlet drain plug and fuel inlet line.

8. Assemble primer assembly and install onto fuel filter base.

T8387AD

9. Install filter element to fuel filter base.

10. Bleed fuel system.

A—Fuel Inlet line B—Filter Base C—Fuel Drain Plug

11. Close side shield.

12. Dispose of waste properly.

TX,55,JC2157 –19–02SEP97–2/2

3-3-7

102703

PN=130

Maintenance—Every 10 Hours or Daily Check Recovery Tank Coolant Level With the engine cold, coolant level must be between FULL and ADD marks on the recovery tank.

–UN–27AUG97

If coolant is below the ADD mark, add coolant to the recovery tank.

T111210B

CAUTION: Prevent possible injury from hot spraying coolant. DO NOT remove radiator filler cap unless engine is cool. Then turn cap slowly to the stop. Release all pressure before you remove cap.

–UN–18OCT88

If recovery tank is empty, check for leaks. Repair as required. Add coolant to the radiator and the recovery tank.

T6274AQ

NOTE: If recovery tank is full and radiator is low, check for leaks in radiator cap and hose connections between radiator and coolant recovery tank.

Coolant level must be at bottom of the filler neck.

Radiator Cap

A—Coolant Recovery Tank

TX,60,JC2158 –19–02SEP97–1/1

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

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

T111210C

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

–UN–27AUG97

Clean Air Cleaner Dust Unloader Valve

A—Dust Valve

TX,60,JC2159 –19–02SEP97–1/1

3-4-1

102703

PN=131

Maintenance—Every 10 Hours or Daily

Check Engine Oil Level

–UN–27AUG97

IMPORTANT: If oil level is low, the engine can be damaged. DO NOT operate the engine when oil level is below the ADD mark.

T111215B

The most accurate oil level reading is obtained when the engine is cold, before starting the engine for the day’s operation.

1. Park machine on a level surface.

2. Push park brake switch to ON. A—Dipstick B—Filler Cap

3. Make sure dipstick (A) is fully seated.

4. BEFORE THE ENGINE IS STARTED: The engine is full when oil level is in the cross hatched area. It is acceptable to run the engine when the oil level is above the ADD mark.

AFTER THE ENGINE HAS BEEN RUN: Allow the oil to drain into the oil pan for 10 minutes before checking the oil level. Ten minutes after shutdown the engine oil level must be above the ADD mark.

5. If necessary, remove filler cap (B) to add oil. See Diesel Engine Oil. (Section 3-1.)

TX,60,JC2160 –19–02SEP97–1/1

3-4-2

102703

PN=132

Maintenance—Every 10 Hours or Daily

Check Hydraulic Oil Level IMPORTANT: Prevent possible hydraulic pump damage. DO NOT operate engine without oil in the hydraulic reservoir.

1. Park machine on a level surface.

2. Lower equipment to the ground.

3. When oil is cold, oil level must be in FULL range on sight glass (B).

4. If necessary, remove filler cap (A) and add oil. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.)

5. Install filler cap.

T101195

–UN–19FEB97

A—Filler Cap B—Sight Glass

CED,OUO1021,89 –19–12MAR98–1/1

3-4-3

102703

PN=133

Maintenance—Every 10 Hours or Daily

Check Transmission Oil Level

–UN–24JAN97

IMPORTANT: Prevent possible transmission damage.

DO NOT operate engine when transmission oil level is low.

T106381B

1. Before starting engine, check oil level on dipstick (A). If oil is to lower mark when oil is cold, there is sufficient oil to start the engine.

2. If necessary, add oil at filler tube. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.)

3. Install dipstick.

4. Start engine.

–UN–23OCT96

5. Engage service brakes. Move clutch cut-off switch to disengaged position.

7. Move transmission control lever to 3rd speed forward "3F" position.

T101280

6. Move auto transmission switch to “Off” position.

Release park brake.

A—Dipstick

Operate engine at fast idle for 30 seconds. Reduce engine speed to slow idle and place transmission control lever in neutral “N” for 15 seconds.

Repeat this step until transmission oil reaches normal operating temperature (approximately (80° C) (175° F).

8. Move transmission control lever to neutral “N” and engage neutral lock. Lower all equipment to ground.

9. Push park brake switch to ON. 10. Release service brakes.

11. Check oil level with engine at slow idle. With oil at normal operating temperature, oil level should be between “HOT” marks on dipstick.

TX,60,JC1405 –19–01AUG96–1/1

3-4-4

102703

PN=134

Maintenance—After First 100 Hours Change Engine Break-In Oil and Replace Filter

–UN–08APR97

IMPORTANT: If fuel sulphur content exceeds 0.5 percent, change engine oil at 1/2 the normal interval.

1. Run engine to warm oil.

T108430B

2. Park machine on a level surface.

3. Lower equipment to ground.

4. Move transmission control lever to neutral "N". Engage neutral lock.

T106389B

–UN–24JAN97

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine.

5. Push park brake switch to ON.

A—Drain Valve

6. Turn key switch to “Off”.

7. Attach hose to drain valve (A). Allow oil to drain into a container. Dispose of waste oil properly.

Continued on next page

3-5-1

TX,75,JC2163 –19–20DEC01–1/2

102703

PN=135

Maintenance—After First 100 Hours 8. Turn filter (B) counterclockwise to remove.

9. Clean mounting surface. Apply thin film of oil to gasket of new filter.

–UN–27AUG97

NOTE: Before installing filter, to assure proper lubrication at start-up, fill the engine oil filter with engine oil.

T111215C

10. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface.

11. Tighten 1/2—1 turn more.

A—Filler Cap B—Filter

12. Tighten drain valve.

13. Remove filler cap (A).

14. Fill engine with oil. (See Fuels and Lubricants chapter.)

Engine Oil With Filter—Specification (S.N. —582360)—Capacity ..................................................... 20 L (21 qt) (S.N. 582361—)—Capacity ..................................................... 21 L (22 qt)

15. Install filler cap.

16. Start engine and run at slow idle.

17. Check that engine oil pressure light on monitor goes out and audible alarm stops immediately. If not, stop engine immediately and find cause.

18. Stop the engine. Check oil level. The engine is full when oil level is in the cross hatched area on the dipstick.

19. Check for any leakage at filter. Tighten filter only enough to stop leakage.

TX,75,JC2163 –19–20DEC01–2/2

3-5-2

102703

PN=136

Maintenance—After First 100 Hours

Change Transmission Oil NOTE: Change after first 100 hours and then every 1000 hours.

1. Operate machine under load until transmission oil reaches normal operating temperature.

2. Park machine on a level surface.

3. Lower bucket to ground.

4. Move transmission control lever to neutral "N". Engage neutral lock.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine.

5. Push park brake switch to ON. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing oil.

6. Install frame locking bar.

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

7. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger. Release accelerator pedal to slow idle.

8. Turn key switch to “Off”. Let machine sit for approximately 10 minutes.

Continued on next page

3-5-3

CED,OUOE002,1732 –19–10OCT02–1/3

102703

PN=137

Maintenance—After First 100 Hours NOTE: Drain plug is magnetic. If an excessive amount of metal particles appear on plug, see your John Deere dealer.

–UN–24JAN97

9. Remove bottom guard, if equipped. Remove plug (A), located inside hole in bottom guard, to drain oil. Allow oil to drain into a container. Dispose of waste oil properly.

T106393C

10. Install drain plug.

A—Drain Plug

CED,OUOE002,1732 –19–10OCT02–2/3

11. Remove transmission dipstick (A).

–UN–24JAN97

12. Fill transmission with oil. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.)

T106381B

Specification Transmission Case and Filter Oil—Capacity ........................................................................... 27 L (29 qt)

13. Start engine and run for 2 minutes.

14. Move transmission control lever to neutral "N", and engage neutral lock.

A—Dipstick

15. Check oil level with oil at operating temperature. Oil must be between marks on dipstick.

CED,OUOE002,1732 –19–10OCT02–3/3

3-5-4

102703

PN=138

Maintenance—After First 100 Hours

Replace Transmission Oil Filter 1. Operate machine under load until transmission oil reaches normal operating temperature.

2. Park machine on a level surface.

3. Lower bucket to ground.

4. Move transmission control lever to neutral "N". Engage neutral lock.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine.

5. Push park brake switch to ON. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing oil filter.

6. Install frame locking bar.

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

7. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger. Release accelerator pedal to slow idle.

8. Turn key switch to “Off”.

Continued on next page

3-5-5

TX,80,JC1827 –19–10OCT02–1/3

102703

PN=139

Maintenance—After First 100 Hours 9. Turn filter (A) counterclockwise to remove.

10. Clean mounting surface. Apply thin film of oil to gasket of new filter.

–UN–14JUN00

11. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface.

T131555C

12. Tighten 3/4 of a full turn more.

13. Start engine and run for 2 minutes.

14. Move transmission control lever to neutral "N", and engage neutral lock.

A—Transmission Oil Filter

TX,80,JC1827 –19–10OCT02–2/3

15. Check oil level. Oil must be between marks on dipstick (A). Add oil if necessary.

–UN–24JAN97

16. Check for leaks around the filter base. Tighten filter only enough to stop leaks.

T106381B

A—Dipstick

TX,80,JC1827 –19–10OCT02–3/3

3-5-6

102703

PN=140

Maintenance—Every 100 Hours

T106375B

T160586B

–UN–24JAN97

–UN–17OCT02

Grease Loader Linkage and Cylinder Pivots

Six Points

Three Points, Right Side Shown

CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating.

624H Loader Lubricating Points Lower bucket flat on ground.

–UN–10APR97

Lubricate following 13 points until grease escapes around seals. See Grease. (Section 3-1.)

T106379C

Lubricate every 10 hours when operating in severe conditions such as deep mud, water, or snow.

Four Points, Right Side Shown Continued on next page

3-6-1

TX,70,JC2161 –19–03SEP97–1/2

102703

PN=141

T106377B

T106376D

–UN–03SEP97

–UN–24JAN97

Maintenance—Every 100 Hours

2 Points, Left Side Shown

12 Points, Right Side Shown

TC62H Lubricating points Lower bucket flat on ground.

Lubricate following 26 points until grease escapes around seals. See Grease. (Section 3-1.)

T106378C

–UN–04MAR97

Lubricate every 10 hours when operating in severe conditions such as deep mud, water, or snow.

12 Points, Right Side Shown

TX,70,JC2161 –19–03SEP97–2/2

3-6-2

102703

PN=142

Maintenance—Every 100 Hours

Grease Front Steering Cylinder Pivots

–UN–28JAN97

CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating.

T106372B

Lubricate each point with three shots of grease. See Grease. (Section 3-1.)

Grease daily when operating in severe conditions such as deep mud, water or snow.

Two Points, Right Side Shown

TX,70,JC1817 –19–10OCT02–1/1

Grease Oscillating Rear Axle and Rear Steering Cylinder Pivots

–UN–24JAN97

CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating.

T106381C

Lubricate oscillating rear axle with 10 shots of grease and rear steering cylinder pivots with three shots of grease.

See Grease. (Section 3-1.) Grease daily when operating in severe conditions such as deep mud, water, or snow.

Four Points

TX,70,JC1468 –19–10OCT02–1/1

Check Cab Fresh Air Filter—If Equipped With Cab

–UN–12DEC96

1. Open cab fresh air filter door by pulling up on lever (A) to the left of the operator’s seat.

T105479B

A—Lever

Continued on next page

3-6-3

TX,70,JC2295 –19–03SEP98–1/3 102703

PN=143

Maintenance—Every 100 Hours 2. Remove filter assembly by turning knob (A).

T117050

–UN–10SEP98

A—Knob

Continued on next page

3-6-4

TX,70,JC2295 –19–03SEP98–2/3

102703

PN=144

Maintenance—Every 100 Hours NOTE: If operating in dusty conditions, cab fresh air filter should be checked and cleaned as necessary.

3. Release clips (B).

4. Remove filter (C). Replace if damaged.

5. Clean filter in one of these ways:

T105493B

• Tap filter on a flat surface with the dirty side down.

• Use compressed air opposite to the normal air flow.

• Wash the filter in warm, soapy water. Flush the filter.

Let it dry before using the heater, defroster, or air conditioner.

–UN–12DEC96

CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

6. Remove dust from filter housing.

7. Install filter and filter duct work.

8. Install filter assembly. Close cab fresh air filter door.

T105494B

–UN–12DEC96

B—Clips C—Filter

TX,70,JC2295 –19–03SEP98–3/3

3-6-5

102703

PN=145

Maintenance—Every 100 Hours

Check Cab Recirculating Air Filter—If Equipped With Cab

–UN–18SEP02

NOTE: The cab recirculating air filter is located next to the seat.

1. Loosen wing bolt (1) holding grille. Remove grille.

CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

T159520B

2. Remove filter.

1—Wing Bolt

3. Clean filter in one of these ways: • Tap it on a flat surface with the dirty side down.

• Use compressed air opposite to the normal air flow.

4. Install filter.

5. Install grille.

HG31779,0000121 –19–18SEP02–1/1

3-6-6

102703

PN=146

Maintenance—Every 250 Hours Grease Front Driveline Sliding Joint

–UN–29OCT02

CAUTION: Prevent possible injury from unexpected machine movement. Turn engine off and lower bucket to ground before lubricating.

T161066B

NOTE: To prevent plug loss, lubricate the machine when it is fully articulated or half articulated and NOT in the straight position.

Install frame lock bar using hole (1) for articulated position.

1—Frame Locking Bar

T118181

–UN–02NOV98

TX,75,JC1818 –19–10OCT02–1/2

Lubricate until grease escapes around vent holes in drive shaft end. See Grease. (Section 3-1.)

NOTE: Grease daily when operating in deep mud, water, or snow.

TX,75,JC1818 –19–10OCT02–2/2

3-7-1

102703

PN=147

Maintenance—Every 250 Hours

Check Receiver Dryer Moisture Indicator

T111214D

–UN–27AUG97

IMPORTANT: Prevent possible compressor damage. If receiver dryer moisture eye color indicates "WET" (pink) dryer is saturated and should be changed within the next 100 machine hours to prevent further buildup of moisture in the refrigerant.

1. Open right side engine side panel.

2. Check sight glass (A) to determine if color indicates dryer is dry (blue) or wet (pink).

A—Sight Glass

3. If wet (pink), see your authorized dealer within the next 100 machine hours to service the receiver dryer.

4. Close engine side panel.

TX,75,JC2162 –19–03SEP97–1/1

1. Slowly remove cap. Coolant level must be at bottom of the filler neck.

NOTE: If radiator coolant level is low, check for leaks on radiator cap, and hose connections between radiator and coolant recovery tank.

T6642EK

CAUTION: Prevent possible injury from hot spraying coolant. DO NOT remove radiator filler cap unless engine is cool. Then turn cap slowly to the stop. Release air to relieve all pressure before you remove cap.

–UN–01NOV88

Check Radiator Coolant Level

2. Add coolant, if necessary.

3. Install filler cap.

TX,75,JC1820 –19–31OCT02–1/1

3-7-2

102703

PN=148

Maintenance—Every 250 Hours

Change Engine Oil and Replace Filter

–UN–08APR97

IMPORTANT: If fuel sulphur content exceeds 0.5 percent, change engine oil at 1/2 the normal interval.

NOTE: If engine has not run 250 hours before the season changes, change oil.

T108430B

1. Run engine to warm oil.

2. Park machine on a level surface.

3. Lower equipment to ground.

–UN–24JAN97

4. Move transmission control lever to neutral "N". Engage neutral lock.

T106389B

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine.

A—Drain Valve

5. Push park brake switch to ON. 6. Turn key switch to “Off”.

7. Attach hose to drain valve (A). Allow oil to drain into a container. Dispose of waste oil properly.

Continued on next page

3-7-3

TX,75,JC2163 –19–20DEC01–1/2

102703

PN=149

Maintenance—Every 250 Hours 8. Turn filter (B) counterclockwise to remove.

9. Clean mounting surface. Apply thin film of oil to gasket of new filter.

–UN–27AUG97

NOTE: Before installing filter, to assure proper lubrication at start-up, fill the engine oil filter with engine oil.

T111215C

10. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface.

11. Tighten 1/2—1 turn more.

A—Filler Cap B—Filter

12. Tighten drain valve.

13. Remove filler cap (A).

14. Fill engine with oil. See Diesel Engine Oil. (Section 3-1.)

Engine Oil With Filter—Specification (S.N. —582360)—Capacity ..................................................... 20 L (21 qt) (S.N. 582361—)—Capacity ..................................................... 21 L (22 qt)

15. Install filler cap.

16. Start engine and run at slow idle.

17. Check that engine oil pressure light on monitor goes out and audible alarm stops immediately. If not, stop engine immediately and find cause.

18. Stop the engine. Check oil level. The engine is full when oil level is in the cross hatched area on the dipstick.

19. Check for any leakage at filter. Tighten filter only enough to stop leakage.

TX,75,JC2163 –19–20DEC01–2/2

3-7-4

102703

PN=150

Maintenance—Every 500 Hours Grease Upper and Lower Drive Line Sliding Joints

–UN–29OCT02

CAUTION: Prevent possible injury from unexpected machine movement. Turn engine off and lower bucket to ground before lubricating.

T161066B

Install frame lock bar using hole (1) for articulated position.

1—Frame Locking Bar

T118182

–UN–04NOV98

TX,80,JC1821 –19–10OCT02–1/2

Lubricate until grease escapes around vent holes in drive shaft end. See Grease. (Section 3-1.)

NOTE: Grease daily when operating in deep mud, water, or snow.

TX,80,JC1821 –19–10OCT02–2/2

3-8-1

102703

PN=151

Maintenance—Every 500 Hours

Check Air Intake Hoses Check hoses (A) for cracks.

Check hose clamps for tightness.

T111237B

–UN–27AUG97

A—Hose

TX,80,JC2164 –19–03SEP97–1/1

3-8-2

102703

PN=152

Maintenance—Every 500 Hours

Check Battery Electrolyte Level and Terminals CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

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

ALWAYS remove grounded (-) battery clamp first and replace it last.

Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

–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

3-8-3

TX,75,DH1574 –19–28APR93–1/3 102703

PN=153

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.

T6996DB

2. Fill each cell to within specified range with distilled water. DO NOT overfill.

–UN–09SEP03

Maintenance—Every 500 Hours

CAUTION: Prevent possible injury. ALWAYS remove grounded (-) battery clamp first and replace it last.

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.

6. Install and tighten clamps, grounded clamp last.

T6758AA

A—Battery Terminal B—Lubricating Grease

TX,75,DH1574 –19–28APR93–3/3

3-8-4

102703

PN=154

Maintenance—Every 500 Hours

Replace Primary Fuel Filter

–UN–27AUG97

1. Turn filter locking ring (A) counterclockwise to remove filter. Allow sediment to drain into a container. Dispose of waste properly.

2. Turn sediment bowl (B) counterclockwise to remove from filter assembly.

T111238C

3. Clean filter base.

4. Install new filter. (Follow instructions on filter.)

A—Filter Locking Ring B—Sediment Bowl

5. Install sediment bowl.

6. Bleed fuel system. See Bleeding Fuel System. (Section 3-1.)

TX,80,JC2166 –19–31OCT02–1/1

Replace Final Fuel Filter

–UN–27AUG97

1. Turn filter locking ring (A) counterclockwise to remove filter. Allow sediment to drain into a container. Dispose of waste properly.

2. Clean filter base.

T111238B

3. Install new filter. (Follow instructions on filter.)

4. Bleed fuel system A—Filter Locking Ring

TX,80,JC2245 –19–29SEP97–1/1

3-8-5

102703

PN=155

Maintenance—Every 500 Hours

Replace Hydraulic System Return Filter

–UN–08JUN00

CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing filter.

1. Turn filter (A) counterclockwise to remove.

3. Install new filter. Tighten filter 3/4 of a full turn after seal contacts mounting base.

T131555B

2. Clean mounting surface. Apply thin film of oil to gasket of new filter.

Cover removed for clarity of photograph A—Hydraulic System Return Filter

4. Fully loosen filter element. Repeat step 3.

5. Start engine. Check for leaks around filter base.

Tighten filter only enough to stop leaks.

6. Stop engine. Check oil level.

TX,80,JC1825 –19–14JUN00–1/1

Grease Rear Oscillating Support Cover

Grease daily when operating in severe conditions such as deep mud, water or snow.

T106389C

Lubricate point (A) with three shots of grease. See Grease (Section 3-1.)

–UN–31JAN97

CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating.

A—Lubrication Fitting

TX,70,JC1851 –19–04FEB97–1/1

3-8-6

102703

PN=156

Maintenance—Every 500 Hours

Replace Hydraulic Reservoir Breather Filter Hydraulic reservoir breather filter is located on back side of reservoir under the hood.

1. Turn filter (A) counterclockwise to remove.

2. Install new filter and tighten until snug.

T118143

–UN–02NOV98

A—Filter

CED,OUOE035,19 –19–03NOV98–1/1

3-8-7

102703

PN=157

Maintenance—Every 500 Hours

Replace Transmission Oil Filter 1. Operate machine under load until transmission oil reaches normal operating temperature.

2. Park machine on a level surface.

3. Lower bucket to ground.

4. Move transmission control lever to neutral "N". Engage neutral lock.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine.

5. Push park brake switch to ON. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing oil filter.

6. Install frame locking bar.

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

7. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger. Release accelerator pedal to slow idle.

8. Turn key switch to “Off”.

Continued on next page

3-8-8

TX,80,JC1827 –19–10OCT02–1/3

102703

PN=158

Maintenance—Every 500 Hours 9. Turn filter (A) counterclockwise to remove.

10. Clean mounting surface. Apply thin film of oil to gasket of new filter.

–UN–14JUN00

11. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface.

T131555C

12. Tighten 3/4 of a full turn more.

13. Start engine and run for 2 minutes.

14. Move transmission control lever to neutral "N", and engage neutral lock.

A—Transmission Oil Filter

TX,80,JC1827 –19–10OCT02–2/3

15. Check oil level. Oil must be between marks on dipstick (A). Add oil if necessary.

–UN–24JAN97

16. Check for leaks around the filter base. Tighten filter only enough to stop leaks.

T106381B

A—Dipstick

TX,80,JC1827 –19–10OCT02–3/3

3-8-9

102703

PN=159

Maintenance—Every 500 Hours

Check Park Brake Oil Level

2. Add oil if necessary. Allow 2 minutes for oil to settle to bottom of level plug.

T114802

IMPORTANT: Oil level must be at bottom of check plug on the side of the park brake. Too much oil can cause overheating. Too little oil can cause bearing failure.

–UN–14APR98

1. Remove plug (A). Check oil level.

3. Check oil level and install plug.

T161109

–19–29OCT02

A—Plug

CED,OUOE002,1730 –19–29OCT02–1/1

3-8-10

102703

PN=160

Maintenance—Every 500 Hours

Check Front and Rear Differential Oil Level NOTE: Dipsticks are located on left front and left rear axle housing.

–UN–29JAN97

1. Clean area around dipstick

T106373B

IMPORTANT: To properly check oil level, do not thread dipstick into dipstick port.

2. Remove dipstick (A).

Left Front Differential Shown

3. Oil must be to FULL level on dipstick.

IMPORTANT: Each differential housing has three separate components. Allow 10 minutes for oil to stabilize in each sump before checking.

A—Dipstick

4. If necessary, add oil. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.)

NOTE: If axle is hot and dipstick too warm to hold with bare hands, the oil will expand and it is normal for it to be up to 25 mm (1 in.) above FULL mark. Do not adjust level. If oil level is above FULL mark, drain oil and check oil level.

5. Install dipstick.

TX,80,JC1828 –19–03SEP98–1/1

3-8-11

102703

PN=161

Maintenance—Every 1000 Hours Clean Engine Crankcase Vent Tube

IMPORTANT: Do not pull on hose. Connector damage may occur.

T111240B

Remove crankcase vent tube (A) and clean.

–UN–27AUG97

Remove clamp at valve cover.

A—Crankcase Vent Tube

TX,85,JC2168 –19–16SEP98–1/1

Replace Air Cleaner Dust Unloader Valve NOTE: A missing, damaged, or hardened dust valve will cause the air filter elements to be ineffective.

–UN–27AUG97

Replace dust unloader valve (A).

T111210C

A—Dust Unloader Valve

TX,85,JC2169 –19–16SEP98–1/1

Replace Air Cleaner Elements 1. Remove cover.

3. Remove secondary element (B).

4. Clean air cleaner canister.

5. Install new elements making sure secondary element is centered in canister.

T117243

–UN–16SEP98

2. Remove primary element (A).

6. Install cover.

T117244

–UN–16SEP98

A—Primary Element B—Secondary Element

TX,85,JC2170 –19–16SEP98–1/1

3-9-1

102703

PN=162

Maintenance—Every 1000 Hours

Check Coolant

–UN–23AUG88

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

TS281

Only remove filler cap when engine is cold or when cool enough to touch with bare hands.

Slowly loosen cap to first stop to relieve pressure before removing completely.

IMPORTANT: John Deere Liquid Coolant Conditioner does not protect against freezing.

Coolant conditioner prevents rust, scale, and liner cavitation.

–UN–20FEB98

NOTE: Check coolant every 500 hours or 6 months, or when replacing 1/3 or more of coolant. Add coolant conditioner as necessary.

T113678

1. Remove radiator cap (A) and test coolant solution. Use one of the following kits to check coolant.

• 3-WAY Heavy Duty Coolant Test Kit (TY16175) Coolant test strips provide an effective method to check freeze point and additive levels of engine coolant. See your authorized dealer for 3-WAY Heavy Duty Coolant Test Kit and follow instructions on kit.

T111110

2. Add TY16004 John Deere Coolant Conditioner or equivalent non-chromatic conditioner/rust inhibitor as necessary. Follow instructions on container for amount.

–UN–13AUG97

• CoolScan Plus For a more thorough evaluation of coolant, perform CoolScan Plus analysis, where available. See your authorized dealer for information about CoolScan Plus.

3-Way Test Kit

Specification Cooling System—Capacity ................................. 22 L (23 qt) approximate

T111109

–UN–13AUG97

3. Install cap.

CoolScan Plus

CoolScan Plus is a trademark of Deere & Company.

CED,OUOE002,1786 –19–16SEP98–1/1

3-9-2

102703

PN=163

Maintenance—Every 1000 Hours

Check Radiator Hoses 1. Check upper (A) and lower radiator hoses for cracks and leaks. Replace if necessary.

T111237C

–UN–27AUG97

2. Tighten clamps.

Upper Radiator Hose Shown

CED,TX03679,5801 –19–19JUN00–1/1

3-9-3

102703

PN=164

Maintenance—Every 1000 Hours

Change Transmission Oil NOTE: Change after first 100 hours and then every 1000 hours.

1. Operate machine under load until transmission oil reaches normal operating temperature.

2. Park machine on a level surface.

3. Lower bucket to ground.

4. Move transmission control lever to neutral "N". Engage neutral lock.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always turn engine off or push park brake switch to ON to hold machine.

5. Push park brake switch to ON. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before changing oil.

6. Install frame locking bar.

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

7. Run engine at 1/2 speed for 2 minutes before stopping to avoid damage to turbocharger. Release accelerator pedal to slow idle.

8. Turn key switch to “Off”. Let machine sit for approximately 10 minutes.

Continued on next page

3-9-4

CED,OUOE002,1732 –19–10OCT02–1/3

102703

PN=165

Maintenance—Every 1000 Hours NOTE: Drain plug is magnetic. If an excessive amount of metal particles appear on plug, see your John Deere dealer.

–UN–24JAN97

9. Remove bottom guard, if equipped. Remove plug (A), located inside hole in bottom guard, to drain oil. Allow oil to drain into a container. Dispose of waste oil properly.

T106393C

10. Install drain plug.

A—Drain Plug

CED,OUOE002,1732 –19–10OCT02–2/3

11. Remove transmission dipstick (A).

–UN–24JAN97

12. Fill transmission with oil. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.)

T106381B

Specification Transmission Case and Filter Oil—Capacity ........................................................................... 27 L (29 qt)

13. Start engine and run for 2 minutes.

14. Move transmission control lever to neutral "N", and engage neutral lock.

A—Dipstick

15. Check oil level with oil at operating temperature. Oil must be between marks on dipstick.

CED,OUOE002,1732 –19–10OCT02–3/3

3-9-5

102703

PN=166

Maintenance—Every 1000 Hours

Grease Frame Hinge Pivots CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating.

T106386C

–UN–10MAR97

Lubricate each point with a minimum of three shots of grease and until grease escapes around the seals. See Grease. (Section 3-1.)

Two Points

TX,85,JC1832 –19–14JUN00–1/1

3-9-6

102703

PN=167

Maintenance—Every 1000 Hours

Check Park Brake 1. Start engine.

–UN–13FEB98

CAUTION: Prevent possible injury from sudden machine stop. Fasten seat belt for this check.

2. Fasten seat belt.

T113486

3. Move park brake switch (A) to OFF, and move transmission control lever to 1st gear forward.

4. Drive machine at 3 mph and move park brake switch to ON. Machine must stop within 2 m (6 ft), and transmission must shift to neutral.

A—Park Brake Switch

5. If repair is necessary, see your authorized dealer.

TX,85,JC1488 –19–03SEP98–1/1

3-9-7

102703

PN=168

Maintenance—Every 1000 Hours

Change Park Brake Oil

Park Brake Oil—Specification Park Brake Oil—Capacity ................................................. 300 mL (10 oz)

T114802

IMPORTANT: Oil must be at bottom of the check plug on the side of the park brake. Too much oil can cause overheating; too little can cause bearing failure.

–UN–14APR98

CAUTION: Prevent possible injury from unexpected machine movement. Always install frame locking bar.

1. Remove plug (A).

3. Add John Deere HY-GARD oil. Allow oil to settle for approximately 2 minutes after filling.

T161109

4. Drain or add oil if necessary.

–19–29OCT02

2. Drain oil into a container. Dispose of waste oil properly.

5. Install plug.

A—Plug

HY-GARD is a trademark of Deere & Company.

CED,OUOE002,1733 –19–29OCT02–1/1

3-9-8

102703

PN=169

Maintenance—Every 2000 Hours Adjust Engine Valve Lash (Clearance) See your authorized dealer.

TX03679,00017DD –19–08MAY01–1/1

3-10-1

102703

PN=170

Maintenance—Every 3000 Hours Change Hydraulic System Oil 1. Lower bucket to the ground.

–UN–17SEP02

2. Stop engine.

3. Turn key switch to “On.”

T159423I

NOTE: Return-to-carry (B) must be OFF for float detent to operate.

4. Move hydraulic control lever to float detent position.

Later Machines—One Lever Design

CAUTION: Prevent possible injury from unexpected boom movement. The bucket may “jump up” when ride control switch is turned ON. Clear all bystanders from area.

–UN–27JUN02

5. Cycle ride control switch (C) from OFF to ON.

T156774G

6. Push pilot enable/boom down switch (A) to release accumulator pressure.

7. Turn key switch “Off”.

Later Machines—Two Lever Design A—Return-to-Carry Switch B—Ride Control Switch C—Pilot Enable/Boom Down Switch

TX,87,JC1834 –19–19OCT98–1/3

8. Remove hydraulic reservoir filler cap (A).

T107063

–UN–19FEB97

A—Filler Cap

Continued on next page

3-11-1

TX,87,JC1834 –19–19OCT98–2/3

102703

PN=171

Maintenance—Every 3000 Hours 9. Install hose on hydraulic reservoir drain valve (A).

Loosen valve. Allow oil to drain into a container.

Dispose of waste oil properly.

12. Fill reservoir. See Transmission, Hydraulic System, Park Brake, and Differential Oil. (Section 3-1.)

Specification Hydraulic Reservoir and Filters— Capacity ............................................................................... 117 L (31 gal)

T107880C

11. Tighten drain valve.

–UN–06MAR97

10. Flush reservoir with diesel fuel.

13. Install filler cap.

14. Check oil level in sight glass (B). Oil should be in FULL range.

T107064

–UN–19FEB97

A—Drain Valve B—Sight Glass

TX,87,JC1834 –19–19OCT98–3/3

Clean Hydraulic System Strainer 1. Remove hydraulic reservoir filler cap (A).

2. Remove snap ring.

3. Remove strainer (B) and clean with solvent.

4. Install strainer and snap ring.

5. Replace cap.

T114483

–UN–23MAR98

A—Filler Cap B—Strainer

CED,OUO1021,184 –19–18MAR98–1/1

3-11-2

102703

PN=172

Maintenance—Every 3000 Hours

Change Front and Rear Differential Oil

–UN–22SEP98

CAUTION: Prevent possible injury from hot spraying oil. Slowly loosen dipstick to relieve any air pressure.

1. Remove hose (A) and screen fitting (B). Allow oil to drain into a container. Dispose of waste oil properly.

T117325

NOTE: Axle Differential Recirculation Screen should also be cleaned at this time. See Clean Axle Differential Recirculation Screen later in this section.

A—Hose B—Screen Fitting

2. Install screen fitting and hose.

Specification Front Differential Oil—Capacity ............................................... 25 L (26 qt) Rear Differential Oil—Capacity ............................................... 20 L (21 qt)

CED,OUOE002,1787 –19–03NOV98–1/2

3. Remove dipstick (A).

–UN–29JAN97

NOTE: Each differential housing has three separate components. To expedite filling differential, remove right axle plug.

4. Add oil slowly through dipstick port on left front and left rear differential.

T106373B

IMPORTANT: To properly check oil level, do not thread dipstick into dipstick port.

Left Front Differential Shown

5. Check oil level.

A—Dipstick

6. Install dipstick and tighten

CED,OUOE002,1787 –19–03NOV98–2/2

3-11-3

102703

PN=173

Maintenance—Every 3000 Hours

Clean Axle Differential Recirculation Screen 1. Disconnect hose (A) and remove screen fitting (B).

–UN–22SEP98

2. Drain differential oil into a container. Dispose of waste properly. See Change Front and Rear Differential Oil in this section.

3. Clean screen with solvent.

T117325

NOTE: Fitting and screen are of a one piece design.

Screen should be thoroughly cleaned and reused.

Front Differential Shown

4. Install screen fitting.

5. Install hose.

–UN–22SEP98

6. Refill differential with oil. See Change Front and Rear Differential Oil in this section.

T117326

A—Hose B—Screen Fitting

Rear Differential Shown CED,OUOE035,29 –19–05NOV98–1/1

3-11-4

102703

PN=174

Miscellaneous—Machine Draining the Cooling System

–UN–23AUG88

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

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.

1. Check upper (A) and lower radiator hoses for cracks and leaks. Replace, if necessary.

2. Tighten clamps.

–UN–27AUG97

3. Check radiator, oil cooler, and air-to-air cooler for dirt, damage, leaks, and loose or broken mountings. Clean radiator, oil cooler, and air-to-air cooler.

T111237C

4. Connect a hose to drain valve (B) on radiator.

5. Turn drain valve counterclockwise to open. Allow coolant to drain into a container. Dispose of used coolant properly.

Upper Radiator Hose Shown

6. Turn drain valve (C) counterclockwise to drain engine block. Allow coolant to drain into a container. Dispose of used coolant properly.

T111243B

–UN–03SEP97

T111245B

–UN–27AUG97

A—Radiator Hose B—Radiator Drain Valve C—Engine Drain Valve

TX,90,JC2246 –19–31OCT02–1/1

4-1-1

102703

PN=175

Miscellaneous—Machine

Filling the Cooling System

–UN–23AUG88

CAUTION: Prevent possible injury from hot spraying coolant. DO NOT remove radiator cap unless the engine is cool. Then turn cap slowly to the stop. Release pressure before removing cap.

TS281

Specification Cooling System—Capacity ...................................................... 22 L (23 qt)

IMPORTANT: Use only permanent-type, low silicate, ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals.

FREEZING TEMPERATURES: Fill with permanent-type, low silicate, ethylene glycol antifreeze (without stop-leak additive) and clean, soft water. Add TY16004 John Deere Coolant Conditioner or equivalent.

Continued on next page

4-1-2

CED,OUOE002,1788 –19–31OCT02–1/2

102703

PN=176

Miscellaneous—Machine 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.

–UN–20FEB98

FILL

T113678

• Fill radiator to the bottom of the radiator fill neck.

• Fill the recovery tank to the FULL mark.

DEAERATION The cooling system requires several warm-up and cool down cycles to deaerate. It will NOT deaerate during normal operation. Only during warm-up and cool down cycles will the system deaerate.

• Start engine. Run engine until coolant reaches a warm temperature.

• Stop engine. Allow coolant to cool.

• Check coolant level at recovery tank.

• Repeat Steps 1—3 until recovery tank coolant level is repeatedly at the same level (stabilized).

NOTE: The level of the coolant in the cooling system MUST BE repeatedly checked after all drain and refill procedures to insure that all air is out of the system which allows the coolant level to stabilize.

Check coolant level only when the engine is cold.

CED,OUOE002,1788 –19–31OCT02–2/2

Replacing Engine Vibration Damper The engine vibration damper should be replaced every 4500 hours or 5 years. See your authorized dealer.

TX03679,00017F8 –19–13AUG01–1/1

4-1-3

102703

PN=177

Miscellaneous—Machine

Adjusting Pilot Controller Tower

3. Move tower to desired position.

4. Tighten cap screws (2).

Specification Cap Screws—Torque ................................................... 36.6 N•m (27 lb-ft)

T161077B

2. Loosen four cap screws (2) under pilot controller tower.

–UN–29OCT02

1. Remove two cap screws (1) from front load center door. Open door.

5. Close front load center door. Install cap screws (1).

T161078B

–UN–29OCT02

1—Cap Screws (2 Used) 2—Cap Screws (4 Used)

HG31779,0000173 –19–29OCT02–1/1

Checking Fuel Tank Vent Hose IMPORTANT: If fuel tank vent hose is plugged, the fuel tank could collapse.

1. Remove clamp (A).

2. Check hose for debris. If plugged, clean hose or replace.

3. Install clamp.

T103762B

–UN–12DEC96

A—Clamp

TX,90,JC1604 –19–04SEP96–1/1

4-1-4

102703

PN=178

Miscellaneous—Machine

Bleeding Fuel System 1. Place container under filters (D and G).

–UN–27AUG97

2. Loosen bleed screw (A).

T111238E

3. Pump hand primer (C) until bleed screw (A) has solid stream of fuel coming from it. Tighten bleed screw on final fuel filter (G).

4. Open bleed screw (B). Pump hand primer until bleed screw has solid stream of fuel coming from it. Tighten bleed screw on primary fuel filter (D).

A—Bleed Screw (Final Fuel Filter) B—Bleed Screw (Primary Fuel Filter) C—Hand Primer D—Primary Fuel Filter E—Drain Valve (Primary Fuel Filter) F—Drain Valve (Final Fuel Filter) G—Final Fuel Filter

5. Dispose of waste properly.

TX,90,JC2176 –19–03SEP97–1/1

Precautions for Alternator and Regulator When batteries are connected, follow these rules: 1. Disconnect negative (-) battery cable when you work on or near alternator or regulator.

2. DO NOT TRY TO POLARIZE ALTERNATOR OR REGULATOR. 3. Be sure alternator wires are correctly connected BEFORE you connect batteries.

6. Connect batteries or a booster battery in the correct polarity (positive [+] to positive [+] and negative [-] to negative [-]).

7. Do not disconnect the batteries when engine is running and alternator is charging.

8. Disconnect battery cables before you connect battery charger to the batteries. If machine has more than one battery, each battery must be charged separately.

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.

04T,90,C151 –19–20JUL92–1/1

4-1-5

102703

PN=179

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

4-1-6

TX03679,0001788 –19–11MAY01–1/3 102703

PN=180

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 Your machine is equipped with a negative ground electrical system. It uses two 12-volt batteries. If one of the two batteries fails, both batteries must be replaced.

Use only batteries meeting following specifications.

Specification Battery—BCI Group.............................................................................. 30H Cold Cranking Amps at -18°C (0°F) ...................................................................................................... 625 Reserve Capacity at 25 amps ................................................ 160 Minutes

CED,OUOE002,1772 –19–15SEP98–1/1

4-1-7

102703

PN=181

Miscellaneous—Machine

Removing Batteries NOTE: Turn off master shut-off, if equipped, before disconnecting cables.

–UN–12DEC96

1. Remove left side battery cover.

CAUTION: To prevent injury from explosion or fire disconnect the left side battery first regardless of which battery is being removed.

T103150C

CAUTION: To prevent injury from battery covers dropping, remove when servicing or replacing batteries. Hinge is in place to aid in removal only. Cover must not be held or propped open during servicing.

A—Positive (+) Cable B—Negative (-) Cable

2. Disconnect negative (-) battery cable first, then positive (+) cable (A).

3. Remove nuts and washers (B) and hold down bracket.

4. Lift battery out of compartment.

TX,90,JC1600 –19–29AUG96–1/1

4-1-8

102703

PN=182

Miscellaneous—Machine

T103541C

–UN–06JUL00

Replacing Fuses

T160038B

–UN–29OCT02

One Lever Design

Two Lever Design A—Fuse Box

Continued on next page

4-1-9

HG31779,0000132 –19–20SEP02–1/2

102703

PN=183

Miscellaneous—Machine

K25 Drive Light Relay AT162863

K27 Hi-Beam Light Relay AT162863

K17 Rear Wiper Return to Park Relay AT162863

Not Used

K13 Return to Dig Relay AT162863

Not Used

K23 Left Signal/Flasher Relay AT206685

K28 Brake Light Relay AT162863

K18 Rear wiper Intermittent Relay AT162863

K15 Front Wiper Return to Park Relay AT162863

K19 Main Blower Relay AT162863

K22 Horn Relay AT162863

Not Used

K24 Right Signal/Flasher Relay AT206685

K32 Detent Enable Relay AT162863

Not Used

K16 Front Wiper Intermittent Relay AT162863

Not Used

Not Used

P33

(ACC)

P45

Ride Control 7.5 AMP Fuse 99M 7064 (ACC) J01

Cab Work Light 10 AMP CB T103463

(ACC)

Drive & Hi-Beam Light 10 AMP CB T103463

F25

P40

Pressurizer Motor 7.5 AMP Fuse 99M 7064 (ACC) A19

F20

Neutral Start Circuit F3 5 AMP Fuse P01 (ST) 57M 7125

Not Used

Front Wiper Motor F17 10 AMP Fuse 57M 7121 (ACC) P34

F30

(BATT)

F21 P36

Horns 7.5 AMP Fuse 99M 7064

(ACC)

Power for Pressure Switches F10 5 AMP Fuse 57M 7125 (ACC) P32

Turn Signal/Flasher Light F22 7.5 AMP Fuse 99M 7064 (BATT) P37

Spare Accessory F33 5 AMP Fuse 57M 7125 (ACC) P49

Tail & Marker Light 7.5 AMP Fuse 99M 7064 (ACC) P39

Brake Light F27 7.5 Amp Fuse 99M 7064 (BATT) P44

Seat Adjust, Lighter F32 10 AMP Fuse 57M 7121 (ACC) P48

F24 K30 Ride Control Boom Solenoid Relay AT162863

F29

Diff Lock, Solenoid F14 Pin5Disc AMP Fuse 57M 7125 (ACC) P42 Power for Rocker F23 Switches 5 AMP Fuse P27 57M 7125 (ACC)

K6 Accessory Relay #2 AT162863

F35 P35

Spare 15 AMP Fuse 99M 7065

(BATT)

Engine Controller F6 Unswitched 10 AMP Fuse 57M 7121 (BATT) P06

F26 P41

Engine Controller Switched

P08

7.5 AMP FUSE 99M 7065 (IGN)

Trans Controller Switched 5 AMP Fuse 57M 7125 (IGN) P24

Power for BHKO, RTD, RTC Switch F15 5 AMP Fuse 57M 7125 (IGN) P11

F12 F16

P28

F19 P10

CCU 12V Unswitched 5 AMP Fuse 57M 7125 (12V BATT)

F9

P31

Pilot Enable 7.5 AMP Fuse 99M 7064

Spare Ignition F34 5 AMP Fuse 57M 7125 (IGN) P47

Blower Motor 25 AMP Fuse 99M 7069

Monitor Display Switched F7 5 AMP Fuse 57M 7125 (IGN) P05

(IGN)

(BATT)

Dome Light, Boom Down & Radio Unswitched 7.5 AMP Fuse 99M 7064 (BATT) P14

CCU 28 V Switched F11 7.5 AMP Fuse P25 99M 7064 (IGN)

Converter Unswitched F31 15 AMP Fuse 99M 7065 (BATT) (ACC) P16

Park Brake, Back-up Alarm F13 5 AMP Fuse 57M 7125 (IGN) P26

F28

Rotary Beacon 10 AMP Fuse 57M 7121

Alternator Excitation 7.5 AMP Fuse 99M 7064 (IGN) J07

F1

K1 Neutral Start Relay AT162863

F5

K5 Accesory Relay #1 AT162863

Monitor & Trans Controller Unswitched 5 AMP Fuse P02 57M 7125 (BATT)

F4

K10 Back-Up Relay AT162863

Start Aid, Converter & Sec. Strg F2 10 AMP Fuse P04 57M 7121 (IGN)

Not Used

K21 Secondary Steering (Relay Coil) Relay AT162863

K4 Ignition Relay AT162863

T159002

K31 Ride Control Relay AT162863

Rear Wiper Motor 10 AMP Fuse 57M 7121

–19–24OCT02

F18

T159002

IMPORTANT: Install fuses with correct amperage rating to prevent electrical system damage from overload.

The fuse box (A) is in the electrical load center on the right side (outside) of the cab. Both fuses and circuit breakers are located in the load center.

HG31779,0000132 –19–20SEP02–2/2

4-1-10

102703

PN=184

Miscellaneous—Machine

Fuse (Blade-Type) Color Codes Amperage Rating

Color

1

Black

3

Violet

4

Pink

5

Tan

7.5

Brown

10

Red

15

Light Blue

20

Yellow

25

Natural (White)

30

Light Green

TX,90,JC1936 –19–10MAR97–1/1

4-1-11

102703

PN=185

Miscellaneous—Machine

Replacing Halogen Bulbs

–UN–17APR89

IMPORTANT: To get the correct lighting pattern, lens must be installed so the word "TOP" is on top when lamp is installed so wider section is on top when lamp is installed.

T5894AG1

Before disassembling, remember how bezel and lens are installed with respect to mounting stud.

1. Remove four screws (H) to remove bezel (G) and lens (F).

2. Disconnect wiring lead and release retainer clip to remove bulb (D).

–UN–20OCT88

3. To disconnect ground wiring lead, push tab up, then pull connector from terminal.

T5894AI1

IMPORTANT: Do not touch the halogen bulb with bare hands. Oil and moisture may cause premature bulb failure. Clean bulb using a soft, oil-free cloth and alcohol.

4. Install new bulb so square notch is aligned with square tab on reflector back.

5. Install retainer clip into locking tabs on reflector back.

–UN–19OCT88

6. Connect wiring leads. Check wiring leads are free of clip.

8. Install bezel so wider section is on top. Sealing flange must be inside housing on all four sides before tightening screws.

9. Tighten screws alternately. Do not overtighten as screws may strip out plastic.

T6249AU

7. Install lens assembly (F) in housing (C) making sure wires are not crimped, or keeping lens assembly from seating on gasket.

A—Flange Nut B—Lock Washer C—Housing D—Bulb E—Gasket F—Lens G—Bezel H—Screw

TX,90,RR,1725 –19–11MAR94–1/1

4-1-12

102703

PN=186

Miscellaneous—Machine

Engine Speeds Specification Engine—Slow Idle Speed .................................................... 900 ± 25 rpm Fast Idle Speed .................................................................. 2350 ± 25 rpm TX,90,JC2178 –19–03SEP97–1/1

Checking Neutral Start System CAUTION: Avoid possible injury or death. DO NOT attempt to start machine unless you are sitting in operator’s seat with the transmission control lever in neutral "N" position. DO NOT bypass or disable any of the starting system parts.

Park brake is automatically applied when engine stops and remains in park until the park brake switch is cycled.

Check the neutral start system to ENSURE that the machine: 1. WILL start with the transmission control lever in neutral "N" position.

2. WILL NOT start with the transmission control lever in forward "F" or reverse "R" position.

If starting system fails to operate correctly, have your John Deere dealer repair the system immediately.

TX,90,JC1862 –19–17FEB97–1/1

4-1-13

102703

PN=187

Miscellaneous—Machine

Servicing Air Conditioning System 1. Check compressor clutch engagement.

–UN–27AUG97

2. Check evaporator core for clogging.

3. Check air intake filters for clogging.

T111214D

4. Check blowers for proper operation.

5. Check the condenser core to see that it is not partially or completely plugged with dirt or trash. Clean with compressed air or water when needed.

A—Receiver Dryer Sight Glass

6. Run air conditioning system for several minutes.

7. Check sight glass (A) on receiver dryer (from outside of cab). Bubbles must not be present in sight glass. If bubbles are present, see your authorized dealer for charging the air conditioning system.

TX,90,JC2179 –19–03SEP97–1/1

Welding on Machine IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to "OFF" to prevent voltage spikes through alternator or monitor.

Connect welder ground clamp close to each weld area so electrical current does not arc inside any bearings, bushings or pins.

NOTE: Machine is adequately grounded. It is not necessary to disconnect any controllers (microprocessors).

TX,90,JC1603 –19–29AUG96–1/1

4-1-14

102703

PN=188

Miscellaneous—Machine

External Service Brake Inspection

If the service brakes are subjected to severe duty, inspect more frequently.

T105193B

1. Remove plug from brake inspection port.

–UN–02NOV98

Do first inspection at 5000 hours followed by 1000 hours inspection intervals after the first 5000 hours inspection.

2. Start engine and run for 1 minute.

3. Stop and apply the brakes. Block pedal or have someone hold brakes on.

5. If either of the disks thickness at dimension (C) is less than the minimum specification, the brake packs must be replaced.

T117102

Specification Disk—Thickness .................................................. 2.92 mm (0.115 in.) new Thickness......................................................... 2.22 mm (0.0874 in.) used minimum

–UN–10SEP98

4. Using a tool (A), measure the thickness of disks (B) at dimension (C). Check dimension of two different disks.

T117103

–UN–23SEP98

A—Feeler Gauge B—Disks C—Dimension D—Plates

CED,OUOE002,1738 –19–04SEP98–1/1

4-1-15

102703

PN=189

Miscellaneous—Machine

Checking Brake Accumulators 1. Start engine.

NOTE: If machine is equipped with return-to-carry, the return-to-carry switch must be in the “Off” position.

2. Lower boom by placing controller handle in “float” position.

3. Run engine for 1 minute at slow idle. Apply brake pedal four or five times.

4. Stop engine.

5. Turn key switch to “On” position.

NOTE: Accumulators are precharged and must be replaced, not re-charged.

6. Apply brake pedal. The brake low pressure indicator light may come on after 18 to 35 full brake applications.

If brake light comes on with less than 18 applications, see your authorized dealer.

7. Repeat procedure three times to ensure accurate results.

TX,90,JC2277 –19–14OCT02–1/1

4-1-16

102703

PN=190

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.

–UN–01NOV02

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

T159423Q

CAUTION: The boom will jump upward during this check. Make sure area around bucket is clear.

Later Machines—One Lever Design

1. Start engine.

2. Push ride control switch (A) to OFF position.

–UN–27JUN02

3. Raise boom to maximum height and hold control lever over relief for 2 seconds.

T156774H

4. Lower boom and bucket to ground and stop engine.

Put boom control lever in neutral.

A—Ride Control Switch

Later Machines—Two Lever Design

Continued on next page

4-1-17

HG31779,0000181 –19–01NOV02–1/2

102703

PN=191

Miscellaneous—Machine NOTE: When ride control switch is in “A” (automatic) position, ride control works at 6 km/h (3.7 mph) or above.

–UN–27AUG97

5. Turn key switch to On.

T108328C

6. Push ride control switch to center position. Switch will light. Boom will jump upward, approximately 100 mm (4.0 in.) as accumulator (A) pressure is released.

7. If ride control accumulator has lost gas charge, see your authorized dealer.

A—Accumulator

To Discharge Accumulator 1. Turn key switch to “On”.

2. Push ride control switch to ON (center) position. Switch will light.

NOTE: If ride control switch is already in the “On” position, it must be cycled to OFF then back to ON (center) position.

3. Push pilot enable/boom down switch to boom lower position.

4. Hold hydraulic control lever in the boom float position.

HG31779,0000181 –19–01NOV02–2/2

4-1-18

102703

PN=192

Miscellaneous—Machine

Transmission Oil Cooler, Hydraulic Oil Cooler, Air-To-Air Aftercooler, and Radiator External Cleaning Procedure 1. On machines equipped with air conditioning, remove three cap screws (A) and swing air conditioning condenser forward for better access to coolers.

2. If dust or debris is light, clean coolers by blowing air through the fins. Do not exceed 6 bar (90 psi). Blow air straight through fins to avoid bending them.

T111246B

–UN–27AUG97

3. If air fails to clean the coolers, use a high-pressure washer with soap and water not to exceed 48 bar (700 psi). Direct water straight through fins to avoid bending them.

A—Cap Screw (3 used)

Shown With Air Conditioning

TX,90,JC2181 –19–03SEP97–1/1

4-1-19

102703

PN=193

Miscellaneous—Machine

Service Recommendations For STC1 Fittings

–UN–24OCT00

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.

T134792C

Fittings are easily disconnected using special tool, JDG1385 (1) (supplied in machine with Operator’s Manual). The special tool has a different size slot cut into each end. The narrow slot is for -06 size fittings. The wide slot is for -08 size fittings. Use appropriate end of special tool on fitting being disconnected. To connect fittings, simply push each half of fitting together.

1—Special Tool JDG1385 2—Shoulder Of Fitting 3—Release Sleeve

IMPORTANT: DO NOT pry against release sleeve (3) or damage to fitting may result.

DO NOT force release sleeve beyond normal range of travel, otherwise, release sleeve may fall off when hose is disconnected. If this happens and fitting is connected without the release sleeve installed, fitting will not be able to be disconnected again.

1. Disconnect STC type fittings: a. Clean area around fitting, especially around the release sleeve (3). b. While keeping special tool JDG1385 (1) perpendicular to the fitting, insert tool between release sleeve (3) and shoulder (2). c. Gently push, DO NOT PRY, release sleeve away from shoulder to disconnect the fitting. d. Pull hose to disconnect.

1

STC is a registered trademark of the Aeroquip Corporation.

Continued on next page

4-1-20

OUO1010,0000457 –19–01NOV02–1/2 102703

PN=194

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 –19–01NOV02–2/2

Do Not Service Control Valves, Cylinders, Pumps or Motors Special tools and information are needed to service control valves, cylinders, pumps, or motors.

If these parts need service, see your authorized dealer.

TX,90,DH2537 –19–03SEP92–1/1

4-1-21

102703

PN=195

Miscellaneous—Machine

Hardware Torque Specifications Check cap screws and nuts to be sure they are tight. If hardware is loose, tighten to torque shown on the following charts unless a special torque is specified.

T82,SKMA,AT –19–01AUG94–1/1

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 roll-over 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.

Specification ROPS Mounting Bolt—Torque .................................. 1150 N•m (850 lb-ft)

TX,90,JC1925 –19–03MAR97–1/1

4-1-22

102703

PN=196

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

Lubricated N•m(lb-ft)

a

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

4-1-23

102703

PN=197

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

Lubricated N•m(lb-ft)

b

c

Grade 2a (No Mark) b

Dry N•m(lb-ft)

Lubricated N•m(lb-ft)

c

Dry N•m(lb-ft)

Grade 5, 5.1 or 5.2 b

Lubricated N•m(lb-ft)

c

Grade 8 or 8.2

Dry N•m(lb-ft)

Lubricatedb N•m(lb-ft)

Dryc N•m(lb-ft)

1/4

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

3/8

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

4-1-24

102703

PN=198

Miscellaneous—Operational Checkout Operational Checkout Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of the operation of the machine while doing a walk around inspection and performing specific checks from the operator’s seat.

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.

Should you experience a problem with your machine, you will find helpful diagnostic information in this checkout that will pinpoint the cause. This information may allow you to perform a simple adjustment which will reduce the downtime of your machine. Use the table of contents to help find adjustment procedures.

Before starting this operational checkout, check diagnostic Service codes in monitor. These service codes must be corrected or cleared before starting this checkout.

The information you provide after completing the operational checkout will allow you or your authorized dealer to pinpoint the specific test or repair work needed to restore the machine to design specifications.

Start at the top of the left column and read completely down column before performing check, follow this sequence from left to right. In the far right column, if no problem is found (YES), you will be instructed to go to next check. If a problem is indicated (NO) or (NOT OK), you will be referred to either a section in this manual or to your authorized dealer.

A location will be required which is level and has adequate space to complete the checks. No tools or equipment are needed to perform the checkout.

HG31779,0000074 –19–02MAY02–1/1

Checking and Clearing Diagnostic Trouble Codes From Monitor

– – –1/1

4-2-1

102703

PN=199

Miscellaneous—Operational Checkout Check Trouble Codes

YES: Go to Battery Check .

NO: Go to Check Service Codes .

T103702 –UN–13SEP96

Turn key ON. After bulb check, Press MENU until diagnostic mode (d) is in Basic Display window.

Press SELECT to get (d 01) displayed, then press SELECT to display service codes.

T103152 –UN–09SEP96

LOOK: Does display read “End”?

NOTE: Do NOT stop operating machine because service codes are displayed. The warning lights on dash will warn you if machines requires maintenance. If service codes are displayed, record them.

– – –1/1

Clear Service Codes

YES: Go to Battery Check .

NO: See your authorized dealer.

T103437 –UN–09SEP96

T103152 –UN–09SEP96

With key ON and diagnostic service codes displayed.

Press NEXT to view each service code and read explanation in Message window.

Record service codes.

When service code is displayed, press SELECT to activate code, then hold SELECT for three seconds to delete code.

NOTE: The service codes should disappear from window and next service codes be displayed or “End” displayed. If code can not be deleted, locate connector at sensor and disconnect it and reinstall it. Then repeat delete procedure. If code can not now be deleted, the service is active and repair must be done before code can be removed.

Repeat this procedure until “End” appears in Basic display window. Press NEXT and “End” should still appear.

Press MENU to return to operating display.

LOOK: Are all the service codes deleted and “End” appears in Basic Display window?

– – –1/1

4-2-2

102703

PN=200

Miscellaneous—Operational Checkout Engine Off Checks

– – –1/1

Battery Check

Key OFF.

YES: Go to next check .

Press SELECT button and hold until battery volts are displayed.

NO: Check voltage on each battery before recharging. If one battery will not hold a charge, replace both batteries.

LOOK: Does battery volts read a minimum of 24 volts?

T103154 –UN–10SEP96

– – –1/1

Monitor Check

Key switch ON.

YES: Go to next check.

Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges).

NO: See your authorized dealer.

LOOK/LISTEN: Do all lights come ON and does alarm sound?

Does Message Display and Basic Display window have “8s” showing in every display?

Do all the gauge indicators point to approximately 12:00 O’ clock position?

Is backlighting of gauges ON? After 4 seconds observe changes in Monitor.

LOOK: Do gauge indicators change from 12:00 O’clock to normal readings?

Does Message Display show John Deere?

LOOK: Does Basic Display change to show gear, rpm, hourmeter and battery voltage readings?

– – –1/1

4-2-3

102703

PN=201

Miscellaneous—Operational Checkout Cab System Checks

Check the following for proper working order.

YES: Go to next check.

• • • • • • • • • • • • • • • • •

NO: Repair as needed.

Seat adjustment Seat belt Tilt wheel counsel Front and rear work lights Front and rear drive lights Turn signals Dome light Horn Front and rear windshield wiper and washer Four speed (five position) blower fan Door and window latches Side shield latches Grill housing door latch Radiator cap and fuel door checks Cab mount ladder Boom lock check Service decal check

– – –1/1

Neutral Start Check

Move transmission control lever to 1st gear forward (1F), turn key switch to START.

YES: Go to next check.

LISTEN: Starting motor must not run.

NO: Check neutral start fuse. If OK, see your authorized dealer.

NOTE: Gear display will not display “F” for forward or “R” for reverse until engine is started and park brake released.

Move transmission control lever to 1st gear reverse (1R), turn key switch to START.

LISTEN: Starting motor must not run. Backup alarm will sound.

With transmission control lever in neutral (1N), turn key switch to START

LISTEN: Does starting motor run with lever in neutral position only?

– – –1/1

Backup Alarm Check

Move transmission control lever to reverse (R).

YES: Go to next check.

LISTEN: Does reverse alarm sound when lever is in reverse (R)?

NO: Check transmission controller switched fuse and park brake and backup alarm fuse. If OK, see your authorized dealer.

T106879 –UN–14FEB97

– – –1/1

4-2-4

102703

PN=202

Miscellaneous—Operational Checkout Diagnostic Trouble Codes (DTC)

Check Diagnostic Trouble Codes (DTC).

IF OK: Continue on with check.

Record which (DTC) appear.

Clear (DTC).

If any (DTC) remain fix before continuing with checks, See Diagnostic Trouble Codes Quick Reference .

– – –1/1

Engine Running Checks

– – –1/1

Monitor Check

Key switch ON.

YES: Go to next check .

Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges).

NO: Check monitor switched power fuse. If OK, see your authorized dealer.

LOOK/LISTEN: Do all lights come ON and does alarm sound?

Do Message Display and Basic Display windows have “8s” showing in every display?

Do all the gauge indicators point to approximately 12:00 O’ clock position?

Is backlighting of gauges ON? After 4 seconds observe changes in Monitor.

LOOK: Do gauge indicators change from 12:00 O’clock to normal readings?

Does Message Display show John Deere?

LOOK: Does Basic Display change to show gear, rpm, hourmeter and battery voltage readings?

– – –1/1

4-2-5

102703

PN=203

Miscellaneous—Operational Checkout Park Brake Check

Release park brake by pushing park brake switch to OFF position.

LOOK: Does park brake indicator go off when brake is released? Will machine move if put into gear?

YES: Go to next check .

NO: See your authorized dealer.

CAUTION: Seat belt must be worn during this check to prevent possible injury from sudden machine stops.

T103441 –UN–09SEP96

Fasten seat belt.

Put transmission in 1st gear forward.

Drive machine at 3 MPH and push park brake switch to ON.

LOOK/FEEL: Does machine come to a stop within 1 meters (3 feet) when park brake is engaged at 3 MPH? Does transmission shift to neutral?

– – –1/1

Service Brake Check

YES: Go to next check.

1 LOADER HYDRAULICS

DRIVE

WORK

4-WAY

NEUTRAL

AUTO

ON

A

OFF

A/C

T103453 –UN–05SEP96

CARRY

BEACON

DETACH

PERFORMANCE MANAGEMENT 2 3 1 LPM 4

NO: Inspect for leaks under machine or overfilling of non-difflock axle. See your authorized dealer.

RIDE A

5

T140157 –UN–14AUG01

A—Left Service Brake B—Right Service Brake 1—Clutch Cut-Off Switch Engine running.

Push Clutch Cut-off switch (1) to OFF position.

Fully apply either (A) or (B) service brake pedal. Release park brake and put transmission in 2nd forward.

Increase engine speed to fast idle.

LOOK: Does machine not move or move at a very slow speed?

Repeat check three times to ensure accurate results.

– – –1/1

4-2-6

102703

PN=204

Miscellaneous—Operational Checkout Pilot Controller Lock Check

YES: Go to next check .

NO: Check pilot enable/boom down switch.

T107029 –UN–04FEB97

T103429 –UN–09SEP96

Push Pilot Enable/Boom Down Switch to locked position.

Hold boom control lever in boom raise position.

Move Pilot Enable/Boom Down Switch to unlock and observe boom.

LOOK: Does boom raise when switch is unlocked?

Move Pilot Enable/Boom Down Switch to locked position and observe boom.

LOOK/FEEL: Does boom stop when switch is LOCKED? Unlock Pilot Enable/Boom Down Switch and check all hydraulic functions.

• • • • •

Boom Up/Down Bucket Roll/Dump Auxiliary functions (if equipped) Steering (Left and Right) Pin Disconnect (if equipped)

– – –1/1

Pilot Enable/Boom Down Solenoid Check

Raise Boom.

YES: Go to next check.

Stop Engine.

Turn key to ON position.

NO: Check boom down fuse (dome light will not work if fuse is blown).

Move Pilot Enable/Boom Down Switch in DOWN position.

IF OK: Check boom down solenoid.

T107030 –UN–04FEB97

CAUTION: Boom will quickly lower to ground.

Move control lever to boom lower position.

LOOK: Does boom lower?

– – –1/1

4-2-7

102703

PN=205

Miscellaneous—Operational Checkout Pilot Control Valve Boom Float Check

Run engine at slow idle.

YES: Go to next check .

Push Ride Control switch off.

NO: See your authorized dealer.

Push Return-to-Carry switch off.

With the bucket partially dumped, lower boom to raise front of machine.

T107137 –UN–07FEB97

Push control lever to the float detent position and release lever.

LOOK: Does front of machine lower to the ground and valve remain in float position when lever is released?

– – –1/1

Pin Disconnect System Check (If Equipped)

Run engine at slow idle.

YES: Go to next check .

Position bucket flat on the ground.

NO: Check differential lock and pin disconnect fuse.

Push and hold Pin Disconnect Switch (DETACH).

LOOK: Does pin disconnect cylinder retract both pins while switch is pressed?

NO: Hold a screwdriver blade against the end of the pin disconnect solenoid valve and check for magnetism with the switch pushed, if magnetism switch is ok.

IF OK: See your authorized dealer.

– – –1/1

4-2-8

102703

PN=206

Miscellaneous—Operational Checkout Ride Control Check

YES: Go to next check .

CAUTION: Boom will jump upward during this check. Make sure area around bucket is clear.

Push Ride Control Switch to OFF position.

Raise boom to maximum height and hold control lever over relief for 2 seconds.

Lower boom and bucket to eye level. Observe loader boom as ride control switch is switched to ON.

T107137 –UN–07FEB97

LOOK/FEEL: Does boom jump upward 30 cm (12 in) or more?

NO: Check ride control fuse.

NO: Check ride control boom solenoid. Check ride control On/Off solenoid.

IF OK: Ride control accumulator charge pressure.

Push Ride Control Switch to AUTO position. Switch will light.

Raise boom to maximum height and hold control lever over relief for 2 seconds.

Lower boom and bucket to eye level and slowly accelerate to 5 mph while watching speedometer and bucket.

T107037 –UN–07FEB97

LOOK/FEEL: Does ride control come on at approximately 3 mph and bucket raise slightly?

– – –1/1

Differential Lock Check

Park unit on a hard surface.

YES: Go to next check

Release brakes.

NO: See your authorized dealer.

Push Differential Lock Switch and steer unit left and right.

Release lock switch and steer unit left and right.

LOOK: Do front wheels slide with differential lock ON? NOTE: It is normal to get a "clunk" sound when you release switch.

LOOK: Do front wheels rotate in opposite directions with differential lock switch released?

T103168 –UN–05SEP96

– – –1/1

4-2-9

102703

PN=207

Miscellaneous—Operational Checkout Clutch Cutoff Check

Turn Clutch Cutoff Switch (NEUTRAL) on.

YES: Go to next check .

Apply brake.

NO: See your authorized dealer.

Increase engine rpm to 1500.

Turn NEUTRAL switch off.

LISTEN/LOOK: Does engine rpm drop?

FEEL: Can you feel machine pull through brakes?

NOTE: Clutch cutoff switch can be adjusted to operator preference to match your loading needs by selecting one of three operating functions in the monitor.

Transmission does not totally disengage, some effort to move by the machine can be felt. See your authorized dealer.

– – –1/1

Boom And Bucket Cylinder Drift Check

Set bucket flat on the ground and raise about 50 mm (2 in.).

Stop engine. Observe bucket for 1 minute.

YES: Go to next check .

NO: See your authorized dealer.

LOOK: Does bucket remain in position? Bucket should not settle to the ground.

T6564NZ –UN–19OCT88

NOTE: Use good judgement to determine if the amount of drift is objectionable for your loader application.

– – –1/1

4-2-10

102703

PN=208

Miscellaneous—Operational Checkout Automatic Shift And Speedometer Check

NOTE: In the AUTOMATIC mode, transmission will shift to highest gear selected as ground speed increases, or will down shift to 2nd as ground speed decreases.

Transmission will never shift to 1st gear. In AUTO MODE TO FIRST the transmission will start in 1st when initially shifted from Neutral to Forward or Reverse. After the initial shift from Neutral, the transmission will downshift no lower than 2nd unless a high load is encountered. Transmission will upshift or downshift as ground speed dictates.

YES: Go to next check .

NO: Monitor is programmed for wrong tire size. See your authorized dealer.

Automatic transmission switch to AUTO. Perform this check in an open area away from other people and machinery.

Release park brake and shift to (4th) forward.

Drive machine on level ground and slowly accelerate to fast idle speed and note speed when shifts are made until engaged in 4th gear. Reduce engine rpm to idle and note speed when transmission makes each downshift.

LOOK: Does the transmission shift at following approximate speeds?

724J Shift

MPH

Km/H

2nd-3rd

6

9

3rd-4th

10

16

4th-3rd

7

11

3rd-2nd

4

6

NOTE: In 4th Forward automatic the transmission starts out in 2nd gear and up-shifts to 3rd then 4th. When transmission downshifts it returns to 2nd. Transmission will shift at different speeds depending on machine loads. Use only as reference.

– – –1/1

4-2-11

102703

PN=209

Miscellaneous—Operational Checkout Transmission Shift Mode Check

Turn Automatic Transmission Shift switch to OFF.

YES: Go to next check .

Press MENU until ACCESSORY shows in basic display, then press SELECT.

NO: See your authorized dealer.

Accessory will display in Message Display Window and A 02 Quick Shift in Basic Display Window.

Press NEXT until A 021 Down/up displays, then press SELECT. Release park brake and shift to 3rd forward.

Drive machine at approximately 1600 rpm and press Quick Shift Switch once.

LOOK/FEEL: Does transmission shift to and remain in 2nd gear?

Press Quick Shift Switch once more.

LOOK/FEEL: Does transmission shift back to 3rd gear?

NOTE: If Quick Shift Switch is pressed twice, transmission will shift down one gear then immediately back up to where it was. Quick Shift feature operates in all gears.

In Basic Display Window with Quick Shift A 021 displayed press NEXT to get Downshift A 022 Down Only to display.

Press SELECT to enable Down Only shift mode.

Release park brake and shift to 4th forward.

Drive machine at approximately 1200 rpm and press Quick Shift Switch once.

LOOK/FEEL: Does transmission shift to and remain in 3rd gear?

Press Quick Shift Switch once more.

LOOK/FEEL: Does transmission shift to and remain in 2nd gear?

Press Quick Shift Switch once more.

LOOK/FEEL: Does transmission shift to and remain in 1st gear?

Press Quick Shift Switch once more.

LOOK/FEEL: Does transmission stay in 1st gear?

NOTE: In DOWN ONLY mode pressing Quick Shift Switch will not change gears once 1st gear is reached, unless a direction or gear change is made.

– – –1/1

Axle Disconnect Check (If Equipped)

Operate machine in an open area away from bystanders.

YES: Go to next check .

With bucket partially dumped, lower boom to raise front wheels off the ground.

NO: Check differential lock and pin disconnect fuse.

Push Axle Disconnect Switch to ON position.

T6601AA –UN–19OCT88

Watch front wheels while operating the machine in reverse. Front wheels must not rotate as machine moves backwards.

IF OK: See your authorized dealer.

LOOK: Do front wheels remain stationary while machine moves backwards?

– – –1/1

4-2-12

102703

PN=210

Miscellaneous—Operational Checkout Steering Valve Check

Transmission in Neutral.

IF OK: Go to next check

Run engine at low idle.

NO: See your authorized dealer.

Remove foot from brake pedal.

Release park brake.

T6471AQ –UN–19OCT88

Turn steering wheel until machine frames contact right and left frame stops.

LOOK: Does machine steer smoothly in both directions?

NOTE: It is normal for machine frames to drift away from frame stops when steering wheel is released.

When steering wheel is stopped, frames must stop.

FEEL: Is excessive effort required to turn steering wheel?

– – –1/1

4-2-13

102703

PN=211

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

102703

PN=212

Miscellaneous—Troubleshooting

Diagnostic Trouble Codes Quick Reference List CCU SERVICE CODES • F0275 CCU Power Dissipation Excessive TRANSMISSION SYSTEM CODES: • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

F0300 Oil Temperature High Long F0305 TCU Output Speed Zero F0306 TCU Voltage Low F0307 TCU Voltage High F0308 TCU Valve Solenoid Power F0309 TCU Park Brake Solenoid Power F0315 Oil Filter Circuit Short-to-Power F0320 1st Gear Clutch Slippage F0321 2nd Gear Clutch Slippage F0322 3rd Gear Clutch Slippage F0323 4th Gear Clutch Slippage F0324 Forward Gear Clutch Slippage F0325 Reverse Gear Clutch Slippage F0330 Clutch Cut-Off Circuit Voltage Low F0331 Clutch Cut-Off Circuit Voltage High F0336 TCU Configuration Bad F0337 TCU Memory Bad F0339 Temperature Sensor Voltage Short-to-Ground F0340 Temperature Sensor Voltage Short-to-Power F0341 Output Speed Signal Bad F0342 Output Speed Circuit Short-to-Ground F0343 Output Speed Circuit Short-to-Power F0344 Internal Clutch Speed Signal Bad F0345 Internal Clutch Speed Circuit Short-to-Ground F0346 Internal Clutch Speed Circuit Short-to-Power F0347 Turbine Speed Signal Bad F0348 Turbine Speed Circuit Short-to-Ground F0349 Turbine Speed Circuit Short-to-Power F0350 Input Speed Signal Bad F0351 Input Speed Circuit Short-to-Ground F0352 Input Speed Circuit Short-to-Power F0353 FWD High Range Clutch Pack Solenoid Open • F0354 FWD High Range Clutch Pack Solenoid Short to Ground • F0355 FWD High Range Clutch Pack Solenoid Short to Power • F0356 Third Speed Clutch Pack Solenoid Open

• F0357 Third Speed Clutch Pack Solenoid Short-to-Ground • F0358 Third Speed Clutch Pack Solenoid Short-to-Power • F0359 Second Speed Clutch Pack Solenoid Open • F0360 Second Speed Clutch Pack Solenoid Short-to-Ground • F0361 Second Speed Clutch Pack Solenoid Short-to-Power • F0362 First Speed Clutch Pack Solenoid Open • F0363 First Speed Clutch Pack Solenoid Short-to-Ground • F0364 First Speed Clutch Pack Solenoid Short-to-Power • F0365 Reverse Clutch Pack Solenoid Open • F0366 Reverse Clutch Pack Solenoid Short-to-Ground • F0367 Reverse Clutch Pack Solenoid Short-to-Power • F0368 FWD Low Range Clutch Pack Solenoid Open • F0369 FWD Low Range Clutch Pack Solenoid Short-to-Ground • F0370 FWD Low Range Clutch Pack Solenoid Short-to-Power • F0375 Gear Selector • F0377 Oil Temperature Circuit Short-to-Power • F0378 Oil Temperature Circuit Open • F0379 FNR Selector Switch Open • F0380 Oil Filter Restricted • F0384 Reverse Alarm Relay Short-to-Power • F0385 Reverse Alarm Relay Short-to-Ground • F0386 Reverse Alarm Relay Open • F0387 Park Brake Solenoid Short-to-Power • F0388 Park Brake Solenoid Short-to-Ground • F0389 Park Brake Solenoid Open • F0396 Oil Temperature High ENGINE SYSTEM CODES: • • • • •

F0400 F0415 F0416 F0423 F0424

Oil Pressure Low Long CCU Throttle Circuit Voltage Low CCU Throttle Circuit Voltage High Ambient Air Temperature Input Voltage High Ambient Air Temperature Input Voltage Low

Continued on next page

4-3-2

TX17961,0000174 –19–03OCT02–1/3 102703

PN=213

Miscellaneous—Troubleshooting • F0425 Engine Coolant Temperature Input Voltage High • F0426 Engine Coolant Temperature Input Voltage Low • F0431 Cylinder #1 EI Circuit • F0432 Cylinder #2 EI Circuit • F0433 Cylinder #3 EI Circuit • F0434 Cylinder #4 EI Circuit • F0435 Cylinder #5 EI Circuit • F0436 Cylinder #6 EI Circuit • F0437 Fuel Temperature Input Voltage High • F0438 Fuel Temperature Input Voltage Too Low • F0439 Pump Control Valve #1 Error • F0440 Pump Control Valve #2 Error • F0441 Crank Position Input Missing • F0442 Crank Position Input Error • F0443 Pump Position Sensor Input Missing • F0444 Pump Position Sensor Input Error • F0445 Crank Position/Pump Position Timing Moderately Out of Sync • F0450 Fuel Rail Pressure Input Voltage High • F0451 Fuel Rail Pressure Input Voltage Low • F0453 Water in Fuel Signal Voltage High • F0454 Water in Fuel Signal Voltage Low • F0455 Manifold Air Temperature Moderately High • F0456 Pump Control Valve #2 Fuel Flow Not Detected • F0469 Pump Control Valve #1 Fuel Flow Not Detected • F0470 Fuel Rail Pressure Control Error • F0471 Fuel Rail Pressure Sensor Supply Voltage Low • F0478 Engine Oil Pressure Circuit Voltage Low • F0479 Engine Oil Pressure Circuit Voltage High • F0485 Water in Fuel Detected • F0499 Engine Oil Pressure Low • F0500 Engine Coolant Temperature High Long • F0515 Engine Air Filter Restriction Circuit • F0516 Engine Fuel Level Circuit Voltage Low • F0517 Engine Fuel Level Circuit Open • F0576 Engine Coolant Temperature Circuit Noisy • F0577 Engine Coolant Temperature Circuit Short-to-Ground • F0578 Engine Coolant Temperature Circuit Open • F0580 Engine Air Filter Restricted • F0599 Engine Coolant Temperature High

STEERING SYSTEM CODES: • F0998 Steering Pressure Circuit • F0999 Steering Pressure Low BRAKE SYSTEM CODES: • F1097 Service Brake Pressure Circuit • F1099 Service Brake Pressure Low ELECTRICAL SYSTEM CODES: • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

F1620 F1621 F1622 F1623 F1624 F1625 F1626 F1628 F1629 F1630 F1633 F1634 F1635 F1636 F1637 F1638 F1639 F1641 F1644 F1645 F1647 F1648 F1649 F1651 F1653 F1655 F1658 F1660 F1661 F1662 F1663 F1664 F1665 F1667

CCU Spare Relay #1 Short CCU Spare Relay #3 Short CCU Spare Relay #4 Short CCU Spare Relay #5 Short Air Preheat Driver Short Ground Detent Enable Driver Short-to-Ground Ride Control Boom Driver Short-to-Ground Ride Control On Driver Short-to-Ground Left Turn Driver Short-to-Ground Right Turn Driver Short-to-Ground Secondary Steering Driver Short-to-Ground Rear Wiper Driver Short-to-Ground Front Wiper Driver Short-to-Ground CCU Relay Driver Overtemp CCU Timer Reset Proportional Fan Drive Solenoid Circuit Error Reverse Fan Drive Solenoid Circuit Error Drive Light Switch Circuit Open MDU Memory Bad CCU Memory Bad Machine Odometer Bad Machine Hourmeter Bad CCU Hourmeter Bad No ECU CAN Transmit No CCU CAN Transmit No TCU CAN Transmit Power Voltage Balance Alternator Voltage High Alternator Voltage Low Power Voltage High Power Voltage Low Brake Light Pressure Circuit Drive Light Switch Circuit Turn Switch Circuit Short

Continued on next page

4-3-3

TX17961,0000174 –19–03OCT02–2/3 102703

PN=214

Miscellaneous—Troubleshooting • F1668 Hazard Switch Circuit • F1671 Return to Carry Detent Solenoid Circuit Error • F1672 Boom Height Kickout Detent Solenoid Circuit Error • F1699 Config Bad HYDRAULIC SYSTEM CODES: • • • • •

F2100 F3115 F3150 F3160 F3161

Oil Temperature High Long Oil Filter Restriction Circuit Short-to-Ground Oil Filter Restriction Circuit Short-to-Power Ride Control Circuit Short-to-Power Ride Control Auto Circuit Short-to-Ground

• • • • • • • •

F3162 Ride Control On Circuit Short-to-Ground F3163 Boom Position Voltage Low F3164 Boom Position Sensor Voltage High F3171 Hydraulic Oil Pressure Circuit Voltage Low F3172 Hydraulic Oil Pressure Circuit Voltage High F3173 Spin Control Mode Circuit F3174 Spin Control Enable Circuit Short-to-Ground F3175 Hydraulic Oil Temperature Circuit Short-to-Ground • F3176 Hydraulic Oil Temperature Circuit Open • F3177 Hydraulic Oil Temperature Circuit Noisy • F3199 Hydraulic Oil Temperature High

TX17961,0000174 –19–03OCT02–3/3

4-3-4

102703

PN=215

Miscellaneous—Troubleshooting

Engine Symptom

Problem

Solution

Engine Cranks/Won’t Start

Fuel quality and quantity

Check fuel quality and quantity.

Engine cranking speed

Check engine cranking speed.

Oil viscosity

Check for correct oil viscosity.

Intake or exhaust restrictions

Check for intake and exhaust restrictions.

Air heater not working

If engine has an air heater, verify air heater operation in cold temperatures.

Intake manifold air leaks

Check for intake manifold air leaks

Mechanical problems

Check for mechanical problems.

Transmission problems

Check for transmission problems.

Engine accessories cycling on and off

Check engine accessories, such as A/C, cycling on and off.

Electronic interference

Check for improperly installed radios, etc.

Restricted or plugged air and fuel filters

Check for restricted or plugged air and fuel filters.

Fuel quality

Check fuel quality.

Transmission problems

Check for transmission problems.

Engine mechanical problems

Check for engine mechanical problems.

Excessive load

Check for excessive load on the engine.

Fuel quantity and quality

Check fuel quantity and quality.

Low engine coolant temperature

Check for extremely low engine coolant temperature.

Engine Misfires/Runs Irregularly

Engine Does Not Develop Full Power

Engine Emits Excessive White Exhaust Smoke

Continued on next page

4-3-5

TX17961,000000B –19–03OCT02–1/2 102703

PN=216

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Engine Emits Excessive Black Or Gray Smoke

Fuel quantity and quality

Check fuel quantity and quality.

Restricted or plugged air filter

Check for restricted or plugged air filter.

Excessively loaded engine

Check for excessively loaded engine.

Weak battery

Replace battery.

Corroded or loose battery connections

Clean battery terminals and connections.

Defective main switch or start safety switch

Repair switch as required.

Starter solenoid defective

Replace solenoid.

Starter defective

Replace starter.

Start circuit defective

Check wiring, fuses, and relays.

Engine is seized

Check by rotating engine by hand.

Poor fuel quality

Drain fuel and replace with quality fuel of the proper grade.

Air leak on suction side of air intake system

Check hose and pipe connections for tightness; repair as required.

Engine Will Not Crank

Engine Idles Poorly

TX17961,000000B –19–03OCT02–2/2

4-3-6

102703

PN=217

Miscellaneous—Troubleshooting

Transmission Symptom

Problem

Solution

Transmission Clutch Slippage

Low oil level

See Transmission, Hydraulic System, Park Brake, And Differential Oil.

Wrong oil grade

See Transmission, Hydraulic System, Park Brake, And Differential Oil.

Restricted Transmission pump suction screen

Remove and clean screen.

Diagnostic Trouble Code (DTC) related problem

Check Diagnostic Trouble Codes to define problem. See Monitor Display Unit—User Diagnostics Menu.

Applied park brake (electrical problem)

Check park brake fuse.

Machine Will Not Move

Check operation of park brake.

Low oil level

Check transmission oil level.

Clutch cutoff activated

Check that brake pedal is fully released.

No power to transmission controller unit

Check transmission controller switched 5A fuse.

Check monitor and transmission controller unswitched fuse.

Hydraulic failure of park brake

Check operation of park brake.

Failed shift switch

Check that display window shows correct gear when shift switch is moved.

Broken drive shafts

Inspect drive shafts and universal joints for external damage.

Continued on next page

4-3-7

TX17961,000016A –19–03OCT02–1/3 102703

PN=218

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Machine Does Not Engage In Low Gear

Clutch cutoff activated

Check that brake pedal is fully released.

Shift switch problem

Check Diagnostic Trouble Codes to define problem. See Monitor Display Unit—User Diagnostics Menu.

Machine Will Not Shift Correctly

Speed sensor disconnected or failed

Check electrical connectors on transmission speed sensors.

Transmission Shifts Too Slow

Low oil level (aeration of oil)

Add oil.

Restricted transmission pump suction screen

Remove and clean suction screen.

High oil level

Check transmission oil level.

Transmission Hydraulic System Overheats

Transmission overfilled or hydraulic pump seal leaking.

Excessive Transmission Noise (under load or no load)

Low oil level

Check transmission oil level.

Wrong oil grade

Check oil type.

Park brake dragging

Check for heat in park brake area.

Pinched, restricted or leaking lube lines

Check cooler lines.

Malfunction in temperature gauge or sender

Install temperature sensor to verify temperature.

Restricted air flow through oil cooler or radiator

Check oil cooler and radiator for debris. Clean if needed.

Too low engine slow idle

Check engine slow idle speed.

Worn parts or damaged in transmission

Inspect suction screen for metal particles.

Damaged drive dampener

Inspect drive dampener.

Driveline or park brake

Inspect drive line and park brake.

Continued on next page

4-3-8

TX17961,000016A –19–03OCT02–2/3 102703

PN=219

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Foaming Oil

Incorrect type of oil

Check oil type. Change oil if needed.

High oil level

Check oil level. Transmission overfilled or hydraulic pump seal leaking.

Low oil level

Check oil level. Add oil if needed.

Oil Ejected From Dipstick

Plugged breather

Inspect breather on top of transmission. Replace if needed.

Machine Vibrates

Aerated oil

Check oil level. Add oil if needed.

Low engine speed

Check engine speed.

Failed universal joints on transmission drive shaft or differential drive shafts

Check universal joints.

Damaged drive dampener.

Inspect drive dampener.

Engine fast idle speed set too low

Check engine fast idle.

Incorrect transmission oil

Drain transmission oil and refill. See Change Transmission Oil .

Aerated oil

Check oil level. Add oil if needed.

Machine Lacks Power And Acceleration

TX17961,000016A –19–03OCT02–3/3

4-3-9

102703

PN=220

Miscellaneous—Troubleshooting

Differential And Axle Symptom

Problem

Solution

No differential Lock Operation

Malfunction in electrical circuit

With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve.

Stuck differential lock solenoid valve

With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve.

Excessive leakage in differential lock piston seals

Check differential oil level.

Axle oil broken down

Change axle oil. See Change Front and Rear Differential Oil .

Excessive leakage differential lock piston seals

Check differential oil level.

Stuck foot switch

Inspect.

Malfunction in electrical circuit

With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve.

Stuck differential lock solenoid valve

With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve.

Differential Low On Oil

External leakage

Inspect axle and differential for leaks.

Excessive Differential And/Or Axle Noise

Low oil level in differential

Check oil. Remove drain plug and inspect for metal particles in differential case. See Check Front and Rear Differential Oil Level .

Engaged differential lock

Release lock.

Differential Lock Slips Or Chatters When Engaged

Differential Lock Will Not Release

If circuit remains pressurized, check if foot switch is sticking. Remove and inspect.

Check solenoid valve for sticking.

Remove and inspect valve.

Continued on next page

4-3-10

TX17961,000016C –19–03OCT02–1/2 102703

PN=221

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Oil Seeping From Outer Axle Seal

Dirt in face seal

Inspect face seals.

Overfilled differential

Check differential lock oil return system for excessive internal restriction.

High pressure in axle

Check axle breather.

Low differential oil

Check oil level. Add oil if needed.

Overfilled differential

Check oil level. Add oil if needed.

Axle recirculation motor dual pump screens plugged

Inspect axle recirculation filter screen located in differential housing below input yoke. See Clean Axle Differential Recirculation Screen .

Axle Overheats

TX17961,000016C –19–03OCT02–2/2

Service Brake Symptom

Problem

Solution

Poor or No Brakes

Axle overheated

Check axle temperature.

Brake disks worn or warped

Inspect service brake pads.

Aggressive Brakes

Clutch cutoff mode set to steep slope

Turn clutch cutoff switch OFF.

Brakes Drag

Brake pedal not returning

Inspect floor mat and pedal.

Brakes Chatter

Brake disk friction material worn

Inspect brake disks.

Oil broken down

Change oil. See Change Front and Rear Differential Oil .

Wrong oil in hydraulic system

Drain hydraulic reservoir and differentials. Refill with correct oil.

See Change Front and Rear Differential Oil .

TX17961,000016D –19–03OCT02–1/1

4-3-11

102703

PN=222

Miscellaneous—Troubleshooting

Drive Line Symptom

Problem

Solution

Excessive Drive Line Vibration Or Noise

Yokes not in line on drive shafts

Inspect. Align drive shaft yokes.

Lack of lube in park brake

Inspect park brake oil level and adjust as required. See Check Park Brake Oil Level .

Bent drive shaft

Inspect all drive shafts.

Loose yoke retaining nuts (drive shafts wobble at high speed)

Inspect. Replace.

Rear axle oscillating support

Inspect.

Lack of lubrication

Lubricate with proper grade of grease.

TX17961,000016E –19–03OCT02–1/1

4-3-12

102703

PN=223

Miscellaneous—Troubleshooting

Park Brake Symptom

Problem

Solution

Brake Will Not Hold

Breather plugged

Inspect and clean breather.

Malfunctioning park brake solenoid

Inspect.

Overfilled with oil

Adjust oil level. See Check Park Brake Oil Level .

Breather plugged

Inspect and clean breather.

Low oil level

Check oil level. Add oil if needed.

Cold oil

Warm oil.

Park Brake Light Comes On For Each Shift

Cold oil

Warm oil.

Park Brake Indicator In Monitor Does Not Come On When Brake Applied

Faulty wiring or switch

Inspect for loose or broken wires between brake indicator switch and indicator on dash.

Brake Overheats

Park Brake Indicator In Monitor Comes On When Shifting From Fwd to Rev (All Other Gears OK)

TX17961,000016F –19–03OCT02–1/1

4-3-13

102703

PN=224

Miscellaneous—Troubleshooting

Hydraulic System Symptom

Problem

Solution

No Hydraulic Functions

Pilot enable switch OFF

Turn switch ON

Pilot enable switch failed

Check pilot enable switch.

Cold oil

Warm oil.

Slow engine speed

Check fast idle speed.

Suction line air leak

Check for foamy oil.

Low oil supply

Add recommended oil.

Wrong oil viscosity

Use recommended oil.

Blocked or damaged line

Inspect lines.

Low oil supply or wrong viscosity

Fill reservoir with recommended oil.

Plugged or pinched suction line

Clean or replace line.

Air in oil

Check for foamy oil. Tighten connections. Replace O-rings and/or lines.

Loose or missing hydraulic line clamps

Tighten or replace clamps.

Hydraulic lines in contact with frame

Inspect and repair.

Boom Float Function Does Not Work

Return-to-carry switch ON

Turn switch OFF.

One Hydraulic Function Does Not Work

Blockage in oil lines or valve

Inspect lines for damage.

Function Drifts Down

Leaking cylinders

Check cylinder leakage.

Boom lower solenoid valve

Check Solenoid.

Leaking loader control valve

Replace valve section.

Slow Hydraulic Functions

Noisy Hydraulic Pump

Continued on next page

4-3-14

TX17961,0000170 –19–03OCT02–1/2 102703

PN=225

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Boom Down Does Not Work (Engine Off)

Pilot enable/boom down switch not held down

Push and hold pilot enable/boom down switch as loader control lever is moved.

Unswitched boom down, radio and dome light fuse failed

Replace fuse.

Boom down solenoid failed

Replace solenoid.

Pilot enable/boom down switch failed.

Replace switch.

Low oil viscosity in hot weather

Use recommended oil.

Excessive load

Reduce load.

Cylinder Leakage

Check cylinder leakage.

Restriction in oil lines or loader valve

Inspect for dented or kinked lines.

Low oil level

Add recommended oil.

Wrong oil

Change to recommended oil.

Water in oil

Drain oil from reservoir and cylinders. Fill with recommended oil.

Loose or faulty suction lines (air leak in system)

Tighten or install new lines.

Electrical circuit failure

Hold a screwdriver against end of pin disconnect solenoid valve and check for magnetism with switch pushed.

Solenoid valve failure

Remove and inspect.

Cylinder binding

Inspect cylinder and adjust loads.

Oil Overheats

Hydraulic Oil Foams

Pin Disconnect Cylinders Will Not Retract

TX17961,0000170 –19–03OCT02–2/2

4-3-15

102703

PN=226

Miscellaneous—Troubleshooting

Steering Symptom

Problem

Solution

No Steering Functions

Frame locking bar in place

Pin locking bar in unused position.

Low oil level

Add recommended oil.

Pinched steering line

Inspect and repair line.

Air in oil

Check for foamy oil.

Low oil level

Add recommended oil.

Air in oil

Check for foamy oil.

Low oil level

Add recommended oil.

Lines to cylinders connected to wrong ports at steering valve.

Connect lines to correct ports.

Erratic Steering

Spongy or Soft Steering

Machine Turns in Opposite Direction

TX17961,0000171 –19–03OCT02–1/1

4-3-16

102703

PN=227

Miscellaneous—Troubleshooting

Air Conditioning System Symptom

Problem

Solution

Air Conditioning System Does Not Operate

Blower motor 25A fuse (F19)

Replace fuse.

Pressurizer motor 7.5A fuse (F20)

Replace fuse.

Blower/pressurizer motor relay (K19)

Check Relay.

Blower speed switch (S21)

Check switch.

Blower speed resistor (R3)

Check resistor.

Main blower motor (M6)

Check motor.

Pressurizer blower motor (M7)

Check motor.

A/C (On/Off) switch (S22)

Check switch.

Freeze control switch (B35)

Check switch.

A/C low pressure switch (B36)

Check switch.

A/C high pressure switch (B37)

Check switch.

A/C compressor clutch solenoid (Y16)

Check clutch operation.

Continued on next page

4-3-17

TX17961,0000172 –19–03OCT02–1/2

102703

PN=228

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Air Conditioner Does Not Cool Interior of Cab

Fresh air filter clogged

Clean or replace filter.

Condenser fins clogged with debris

Clean condenser fins.

Recirculating air filter clogged

Clean or replace filter.

Compressor pulley worn

Replace pulley.

Refrigerant hose kinked, pinched or collapsed

Re-route or re-index hoses, replace kinked or collapsed hoses.

Heater or evaporator core fins clogged with dirt or dust

Clean heater or evaporator core fins.

Pressurizer blower motor failed or operating too slowly

Check motor speed.

Compressor clutch slipping or failed

Inspect and/or replace compressor clutch.

Warm outside air leaking into cab

Inspect, repair or replace door and window seals.

Heater valve remaining open

Inspect, repair, adjust or replace heater valve or cable.

System refrigerant (R134A) charge low

Inspect system for leaks.

Evaporator fins frosting or freezing

Freeze control switch capillary tube not positioned correctly in evaporator core.

Air Conditioner Runs Constantly, Too Cold

Freeze control switch capillary tube not positioned in evaporator correctly

Reposition capillary tube in evaporator core

Interior Windows Continue To Fog

Fresh air filter clogged

Clean or replace filter.

A/C system off

Turn A/C (ON/OFF) switch ON.

TX17961,0000172 –19–03OCT02–2/2

4-3-18

102703

PN=229

Miscellaneous—Troubleshooting

Heater System Symptom

Problem

Solution

Heater System Does Not Operate

Blower motor fuse

Replace fuse.

Blower speed switch

Check switch.

Fresh air filter clogged

Clean or replace filter.

Recirculating air filter clogged

Clean or replace filter.

Heater hose kinked, pinched or collapsed

Re-route or re-index hoses, replace collapsed hoses.

Heater core fins clogged with dirt or dust

Clean heater fins.

Heater valve remaining closed

Inspect, repair, adjust or replace heater valve or cable.

Temperature control switch failed

Inspect, repair or replace switch.

Fresh air filter clogged

Clean or replace filter.

A/C system off (if equipped)

Turn A/C ON/OFF switch ON (if equipped).

Heater Does Not Warm Interior Of Cab

Interior Windows Continue To Fog

TX17961,0000173 –19–03OCT02–1/1

4-3-19

102703

PN=230

Miscellaneous—Storage Prepare Machine For Storage

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. Check primary air cleaner. Replace filter, if necessary.

–UN–09FEB89

1. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later.

3. Wash the machine. Use low pressure wash operations (less than 1379 kPa (13.8 bar) (200 psi) until 30 days after receipt of machine have elapsed. Paint areas to prevent rust. Replace decals, where needed.

4. Apply waste oil to track chains. Run machine back and forth several times. Park machine on a hard surface to prevent tracks from freezing to ground.

5. Store machine in a dry, protected place. If stored outside, cover with a waterproof material.

IMPORTANT: LPS 3 Rust Inhibitor can destroy painted finish. DO NOT spray LPS 3 Rust Inhibitor on painted areas.

6. Retract all hydraulic cylinders, if possible. If not, coat exposed cylinder rods with LPS 3 Rust Inhibitor.

7. Place a "DO NOT OPERATE" tag on the right control lever.

8. Lubricate all grease points.

9. Remove batteries.

10. Remove seat cushion and other perishable items.

11. Remove keys and lock all covers and doors.

LPS is a trademark of the Holt Lloyd Corporation.

TX,105,FF2313 –19–16NOV00–1/1

4-4-1

102703

PN=231

Miscellaneous—Machine Numbers Record Product Identification Number (PIN) Purchase Date

–UN–24JAN97

NOTE: Record all 13 characters of the Product Identification Number.

T106371B

A—Product Identification Number

TX,110,JC1841 –19–31JAN97–1/1

Record Engine Serial Number

–UN–08APR97

Engine Serial Number

T108431G

A—Engine Serial Number

TX,110,JC1995 –19–08APR97–1/1

Record Transmission Serial Number Transmission Serial Number

–UN–11SEP98

Located near lower left corner of case.

T117070

A—Transmission Serial Number

CED,OUOE002,1740 –19–08SEP98–1/1

Record Hydraulic Pump Serial Number

–UN–24JAN97

Hydraulic Pump Serial Number

T106391B

A—Hydraulic Pump Serial Number

TX,110,JC1859 –19–05FEB97–1/1

4-5-1

102703

PN=232

Miscellaneous—Machine Numbers

Record Axle Serial Number

–UN–10SEP98

Axle Serial Number

T117115

A—Axle Serial Number

CED,OUOE002,1747 –19–09SEP98–1/1

4-5-2

102703

PN=233

Miscellaneous—Specifications

T107472

–UN–19FEB97

624H/TC62H Specifications

A—Bucket Hinge Height B—Dump Height

C—Dump Reach D—Machine Overall Height

E—Wheelbase F—Machine-to-Ground Clearance

G—Machine Overall Length

Item

Measurement

Specification

A—Bucket Hinge

Height

624H—3961 mm (13 ft 0.0 in.)

TC62H—4005 mm (13 ft 2.0 in.)

B—Dump

Height

624H—2834 mm (9 ft 4.0 in.)

TC62H—2907 mm (9 ft 6.0 in.)

C—Dump

Reach

624H—1062 mm (3 ft 6.0 in.)

TC62H—1278 mm (4 ft. 2.0 in.)

D—Overall Machine

Height

3300 mm (10 ft 10.0 in.)

E—Wheelbase

Length

3030 mm (9 ft 11 in.)

Continued on next page

4-6-1

CED,OUOE002,1791 –19–30MAY00–1/2 102703

PN=234

Miscellaneous—Specifications

Item

Measurement

Specification

F—Machine-to-Ground

Clearance

406 mm (16.0 in.)

G—Overall Machine

Length

624H—7641 mm (25 ft 1.0 in.)

TC62H—7671 mm (25 ft 2.0 in.)

624H—13 831 kg (30,492 lb) TC62H—13 849 kg (30,532 lb) 624H—509 kg (1,122 lb) TC62H—474 kg (1,045 lb)

Weight Counterweight

NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with SAE standards. Except where otherwise noted, specifications are based on a machine equipped with all standard equipment, with 474

kg (1,045 lb) optional counterweight, ROPS cab, diff lock front axle with standard rear axle, 2 spool valve with two lever control, heater and defroster, 79 kg (175 lb) operator and full fuel tank.

CED,OUOE002,1791 –19–30MAY00–2/2

4-6-2

102703

PN=235

Miscellaneous—Specifications

T131954

–UN–22JUN00

624H High Lift Specifications

A—Bucket Hinge Height B—Dump Height

C—Dump Reach D—Machine Overall Height

E—Wheelbase F—Machine-to-Ground Clearance

G—Machine Overall Length

Item

Measurement

Specification

A—Bucket Hinge

Height

4327 mm (14 ft 2.4 in.)

B—Dump

Height

3224 mm (10 ft 7.0 in.)

C—Dump

Reach

1125 mm (3 ft 8.3 in.)

D—Overall Machine

Height

3300 mm (10 ft 10.0 in.)

E—Wheelbase

Length

3030 mm (9 ft 11 in.)

F—Machine-to-Ground

Clearance

406 mm (16.0 in.)

G—Overall Machine

Length Weight Counterweight

8022 mm (26 ft 3.8 in.)

13 648 kg (30,089 lb) 509 kg (1,122 lb)

CED,TX03679,5802 –19–21JUN00–1/1

4-6-3

102703

PN=236

Miscellaneous—Specifications

Drain and Refill Capacities—624H/TC62H Item

Measurement

Specification

Cooling System

Capacity

22 L (23 qt)

Fuel Tank

Capacity

265 L (70 gal)

Engine Crankcase and Filter

Capacity (S.N. —582360) Capacity (S.N. 582361—)

20 L (21 qt) 21 L (22 qt)

Transmission Case and Filter

Capacity

27 L (29 qt)

Front Differential

Capacity

25 L (26 qt)

Rear Differential

Capacity

20 L (21 qt)

Hydraulic Reservoir and Filters

Capacity

117 L (31 gal)

Park Brake

Capacity

0.300 L (10 oz)

CED,OUOE002,1792 –19–20DEC01–1/1

4-6-4

102703

PN=237

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 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

4-7-1

102703

PN=238

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.

T7223BB

2. Participate in a neighborhood watch program. Take written notes of suspicious vehicles or persons and report your findings to law enforcement agency.

–UN–22FEB90

1. Install vandal-proof devices.

TX,120,DH1093 –19–16SEP92–1/1

4-7-2

102703

PN=239

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

4-7-3

102703

PN=240

Index Page

A Accessory menu Auto mode to first (A 03). . . . . . . . . . . . . . . 2-1-25 Clutch Cutoff (A 01) . . . . . . . . . . . . . . . . . . 2-1-20 Hour meter mode (A 06) . . . . . . . . . . . . . . . 2-1-27 Job timer mode (A 04) . . . . . . . . . . . . . . . . 2-1-26 Metric units mode (A 07). . . . . . . . . . . . . . . 2-1-27 Quick shift mode (A 02) . . . . . . . . . . . . . . . 2-1-23 Stop watch mode (A 05) . . . . . . . . . . . . . . . 2-1-26 Accumulator Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-16 Acid burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-3 Adjustment Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-5 Engine valve clearance . . . . . . . . . . . . . . . . 3-10-1 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-52 Steering wheel tilt . . . . . . . . . . . . . . . . . . . . 2-1-49 Air Cleaner elements clean . . . . . . . . . . . . . . . . 3-3-4 Cleaner elements replace . . . . . . . . . . . . . . . 3-9-1 Cleaner unloader valve . . . . . . . . . . . . . . . . . 3-4-1 Conditioning control . . . . . . . . . . . . . . . . . . 2-1-48 Conditioning service . . . . . . . . . . . . . . . . . . 4-1-14 Inlet cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-4 Intake hose . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-2 Air conditioning Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-17 Air flow knob . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-49 Air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7 Air to air aftercooler External cleaning . . . . . . . . . . . . . . . . . . . . 4-1-19 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Axle Clean recirculation screen. . . . . . . . . . . . . . 3-11-4

B Battery Acid burns. . . . . . . . . . . . . . . . . . . . . . . . . . .

Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrolyte level check. . . . . . . . . . . . . . . . . .

Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling, checking, servicing . . . . . . . . . . . .

Removing . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt Tension adjust . . . . . . . . . . . . . . . . . . . . . . .

3-8-3 2-2-6 3-8-3 3-8-3 4-1-6 4-1-8 4-1-7 3-8-3 3-3-5

Page

Bleed Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Boom Control lever-one lever design . . . . . . . . . . 2-2-11 Control lever-two lever design. . . . . . . . . . . 2-2-12 Height kickout adjustment . . . . . . . . . . . . . . 2-2-18 Boom Lock Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-4 Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . 4-1-16 Brakes External inspection . . . . . . . . . . . . . . . . . . . 4-1-15 Break-in engine oil . . . . . . . . . . . . . . . . . . . . . . 3-1-3 Bucket Control lever-one lever design . . . . . . . . . . 2-2-11 Control lever-two lever design. . . . . . . . . . . 2-2-12

C Cab Fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3 Recirculating air filter . . . . . . . . . . . . . . . . . . 3-6-6 Cab fresh air filter Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3 Cab recirculating air filter Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-6 Capacities, drain and refill 624H/TC62H . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-4 Control lever Shifting transmission . . . . . . . . . . . . . . . . . . . 2-2-9 Coolant Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 3-1-7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-2 Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7 Level radiator . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Level recovery tank. . . . . . . . . . . . . . . . . . . . 3-4-1 Cooling Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1 System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2 Coolscan Plus . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21

D Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1 Damper, engine vibration Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3 Diagnose Drive Line Malfunctions. . . . . . . . . . . . . . . . 4-3-12

Index-1

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PN=1

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Page

Diagnose malfunction Hydraulic system. . . . . . . . . . . . . . . . . . . . . 4-3-14 Transmission system . . . . . . . . . . . . . . . . . . 4-3-7 Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . 3-1-4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Diesel fuel conditioner Low sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Differential Clean axle recirculation screen . . . . . . . . . . 3-11-4 Lock pedal . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . 3-11-3 Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Differential oil Check level . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-11 Differential/axle Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-10 Door Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5 Locking open side . . . . . . . . . . . . . . . . . . . . 2-1-49 Drive belt Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-5 Dust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1

E Engine Air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7 Boost starting . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Cold weather warm-up . . . . . . . . . . . . . . . . . 2-2-8 Coolant conditioner . . . . . . . . . . . . . . . . . . . . 3-9-2 Oil change . . . . . . . . . . . . . . . . . . . . . 3-5-1, 3-7-3 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2 Valve clearance adjust . . . . . . . . . . . . . . . . 3-10-1 Vent tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1 Vibration damper, replace . . . . . . . . . . . . . . . 4-1-3 Engine oil Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-4 Engine side shields Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2

Page

Engine oil . . . . . . . . . . . . . . . . . . . . . . 3-5-1, Final fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel drain . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic reservoir breather . . . . . . . . . . . . .

Hydraulic return. . . . . . . . . . . . . . . . . . . . . . .

Primary fuel drain and clean . . . . . . . . . . . . .

Transmission oil . . . . . . . . . . . . . . . . . 3-5-5, Final fuel filter Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire extinguisher Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frame Machine lock bar. . . . . . . . . . . . . . . . . . . . . .

Front driveline Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter change . . . . . . . . . . . . . . . . . . . . . . . . .

Handling and storing . . . . . . . . . . . . . . . . . . .

System bleed . . . . . . . . . . . . . . . . . . . . . . . .

Tank capacity . . . . . . . . . . . . . . . . . . . . . . . .

Tank drain. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank vent hose Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7-3 3-8-5 3-8-5 3-3-7 3-8-7 3-8-6 3-3-7 3-8-8 3-8-5 3-3-3 3-2-3 3-7-1 3-1-1 3-8-5 3-1-2 4-1-5 3-2-5 3-3-6 4-1-4 4-1-9

G Gauge Engine coolant temperature . . . . . . . . 2-1-3, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3, Transmission oil temperature . . . . . . . 2-1-3, Grease Boom and cylinder pivots . . . . . . . . . . . . . . .

Extreme pressure and multipurpose . . . . . . .

Frame hinge pivots . . . . . . . . . . . . . . . . . . . .

Oscillating rear axle . . . . . . . . . . . . . . . . . . .

Steering cylinder pivots . . . . . . . . . . . . . . . . .

Grille door . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1-7 2-1-7 2-1-7 3-6-1 3-1-6 3-9-6 3-6-3 3-6-3 3-2-5

H F Filter Cab air recirculating . . . . . . . . . . . . . . . . . . . 3-6-6 Cab fresh air . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3

Halogen bulbs . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12 Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-48 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7 Engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7

Index-2

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PN=2

Index

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Page

Heater system Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-19 Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-47 Hose Air intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-2 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1 Hoses Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-3 Hydraulic Oil change . . . . . . . . . . . . . . . . . . . . . . . . . 3-11-1 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Pump serial number . . . . . . . . . . . . . . . . . . . 4-5-2 Reservoir breather filter. . . . . . . . . . . . . . . . . 3-8-7 Return filter . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6 Hydraulic oil cooler External cleaning . . . . . . . . . . . . . . . . . . . . 4-1-19 Hydraulic pump Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Hydraulic system Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . 4-3-14 Suction strainer . . . . . . . . . . . . . . . . . . . . . . 3-11-2

Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Lifting Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-31 Lock Bar, machine frame. . . . . . . . . . . . . . . . . . . . 3-2-3 Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8 Low sulfur diesel fuel conditioner . . . . . . . . . . . 3-1-1 Lubricant Alternative. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2 Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2 Lubricate Boom and cylinder pivots . . . . . . . . . . . . . . . 3-6-1 Frame hinge pivots . . . . . . . . . . . . . . . . . . . . 3-9-6 Front driveline . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1 Oscillating rear axle . . . . . . . . . . . . . . . . . . . 3-6-3 Rear driveline . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1 Rear oscillating support cover . . . . . . . . . . . . 3-8-6 Rear steering cylinder pivots . . . . . . . . . . . . . 3-6-3 Steering cylinder pivots . . . . . . . . . . . . . . . . . 3-6-3

M I Inch torque values . . . . . . . . . . . . . . . . . . . . . 4-1-24 Indicator Location . . . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-7 Receiver dryer . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Secondary steering . . . . . . . . . . . . . . . . . . . 2-2-17 Inspection External service brake. . . . . . . . . . . . . . . . . 4-1-15 Instruments Check before starting . . . . . . . . . . . . . . . . . . 2-2-2

J Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6

L Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lever Boom control-one lever design . . . . . . . . . .

Boom control-two lever design . . . . . . . . . .

Bucket control-one lever design . . . . . . . . .

Bucket control-two lever design. . . . . . . . . .

4-1-12 2-2-11 2-2-12 2-2-11 2-2-12

Machine Frame locking bar . . . . . . . . . . . . . . . . . . . . . 3-2-3 Maintenance Record keeping. . . . . . . . . . . . . . . . . . . . . . . 3-2-6 Service intervals . . . . . . . . . . . . . . . . . . . . . . 3-2-8 Metric torque values . . . . . . . . . . . . . . . . . . . . 4-1-23 Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . 3-1-2 Monitor display unit Accessory menu-auto mode to first (A 03). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25 Accessory menu-clutch cut-off (A 01) . . . . . 2-1-20 Accessory menu-job timer mode (A 04) . . . 2-1-26 Accessory menu-metric units mode (A 07). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-27 Accessory menu-quick shift mode (A 02) . . 2-1-23 Accessory menu-stop watch mode (A 05) . . 2-1-26 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1 Digital display . . . . . . . . . . . . . . . . . . . . . . . 2-1-17 Normal display . . . . . . . . . . . . . . . . . . . . . . 2-1-18 User diagnostics menu-battery monitor (d 03). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-32 User diagnostics menu-continuity check (d 02). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-30 User diagnostics menu-engine sensors (d 04). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-33 User diagnostics menu-fuel sensor (d 07) . . 2-1-40 User diagnostics menu-hydraulic sensors (d 06). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-38

Index-3

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Index

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Page

User diagnostics menu-machine i.d. mode (d 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-41 User diagnostics menu-service codes (d 01). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-28 User diagnostics menu-transmission sensors (d 05). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21

Pressure Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-2 Tire, check . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 Product Identification Number. . . . . . . . . . . . . . 4-5-1 Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21

N

Q

Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8 Start system check . . . . . . . . . . . . . . . . . . . 4-1-13

Quick shift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-13

O

R

Oil Change differential . . . . . . . . . . . . . . . . . . . 3-11-3 Change engine . . . . . . . . . . . . . . . . . . 3-5-1, 3-7-3 Change hydraulic . . . . . . . . . . . . . . . . . . . . 3-11-1 Change park brake . . . . . . . . . . . . . . . . . . . . 3-9-8 Change transmission . . . . . . . . . . . . . 3-5-3, 3-9-4 Check level park brake . . . . . . . . . . . . . . . . 3-8-10 Level engine . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Level hydraulic system . . . . . . . . . . . . . . . . . 3-4-3 Level transmission . . . . . . . . . . . . . . . . . . . . 3-4-4 Specification differential . . . . . . . . . . . . . . . . 3-1-5 Specification hydraulic system . . . . . . . . . . . 3-1-5 Specification park brake . . . . . . . . . . . . . . . . 3-1-5 Specification transmission . . . . . . . . . . . . . . . 3-1-5 Oilscan Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7

Radiator Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 External cleaning . . . . . . . . . . . . . . . . . . . . 4-1-19 Radiator hoses Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-3 Rear driveline Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1 Rear oscillating support cover Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6 Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6 Rear steering cylinder pivots lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3 Receiver dryer Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Recovery tank Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Return-to-carry Height kickout adjustment . . . . . . . . . . . . . . 2-2-19 Return-to-dig circuit Adjustment . . . . . . . . . . . . . . . . . . . 2-2-20, 2-2-22 Ride control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . 4-1-17 Switch . . . . . . . . . . . . . . . . . . . . . . . 2-2-14, 2-2-16 Roads Operating or traveling . . . . . . . . . . . . . . . . . . 1-3-5 Roll-over protective structure Torque value. . . . . . . . . . . . . . . . . . . . . . . . 4-1-22 ROPS Inpsect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6 Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6 Rust inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-2

P Park brake Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-8 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-7 Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-13 Oil level check . . . . . . . . . . . . . . . . . . . . . . 3-8-10 Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10 Pedal Differential lock . . . . . . . . . . . . . . . . . . . . . . 2-2-18 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2 Pilot Controller Tower Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4

Index-4

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PN=4

Index

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S Safety Add cab guarding for special uses . . . . . . . . 1-2-2 Avoid unauthorized machine modifications . . 1-2-2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1 Follow safety instructions . . . . . . . . . . . . . . . 1-2-1 Inspect machine . . . . . . . . . . . . . . . . . . . . . . 1-2-3 Operate only if qualified . . . . . . . . . . . . . . . . 1-2-1 Recognize safety information . . . . . . . . . . . . 1-2-1 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1 Stay clear of moving parts . . . . . . . . . . . . . . 1-2-3 Wear protective equipment . . . . . . . . . . . . . . 1-2-2 Seat Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-52 Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-53 Secondary steering Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-17 Serial number Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Hydraulic pump . . . . . . . . . . . . . . . . . . 4-5-1, 4-5-2 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Service Interval . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1, 3-3-1 Service brakes External inspection . . . . . . . . . . . . . . . . . . . 4-1-15 Service codes Quick reference list . . . . . . . . . . . . . . . . . . . . 4-3-2 Service Doors Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2 Service intervals Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-8 Shifting Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9 Specifications Cooling system . . . . . . . . . . . . . . . . . . . . . . . 3-9-2 Differential oil . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Transmission oil . . . . . . . . . . . . . . . . . . . . . . 3-1-5 624H high lift. . . . . . . . . . . . . . . . . . . . . . . . . 4-6-3 624H/TC62H . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-1 Speed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13 Start aid Starting fluid-cold weather. . . . . . . . . . . . . . . 2-2-4 Starting The engine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2 Starting fluid Cold weather start aid . . . . . . . . . . . . . . . . . . 2-2-4 Steering Wheel tilt adjust . . . . . . . . . . . . . . . . . . . . . 2-1-49

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Storage Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1 Storing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2 Suction strainer Hydraulic system. . . . . . . . . . . . . . . . . . . . . 3-11-2 Switch Park brake . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10 Quick shift. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-13 Ride control . . . . . . . . . . . . . . . . . . 2-2-14, 2-2-16 Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . 3-1-2

T Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-2 Pressure check . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 Torque value Roll-over protective structure. . . . . . . . . . . . 4-1-22 Wheel retaining cap screw . . . . . . . . . . . . . . 3-3-2 Torque values Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-23 Towing Procedure . . . . . . . . . . . . . . . . . . . . . 2-2-29 Transmission Oil change . . . . . . . . . . . . . . . . . . . . . 3-5-3, 3-9-4 Oil cooler external cleaning . . . . . . . . . . . . . 4-1-19 Oil filter replace. . . . . . . . . . . . . . . . . . 3-5-5, 3-8-8 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-4 Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9 Traveling On public roads. . . . . . . . . . . . . . . . . . . . . . . 1-3-5

U Unloader valve Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1 Users diagnostics menu Battery monitor (d 03) . . . . . . . . . . . . . . . . . 2-1-32 Continuity check (d 02) . . . . . . . . . . . . . . . . 2-1-30 Engine sensors (d 04). . . . . . . . . . . . . . . . . 2-1-33 Fuel sensor (d 07) . . . . . . . . . . . . . . . . . . . 2-1-40 Hydraulic sensors (d 06) . . . . . . . . . . . . . . . 2-1-38 Machine I.D. mode (d 10) . . . . . . . . . . . . . . 2-1-41 Service codes (d 01) . . . . . . . . . . . . . . . . . . 2-1-28 Transmission sensors (d 05) . . . . . . . . . . . . 2-1-36

Index-5

102703

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V Valve Air cleaner dust unloader . . . . . . . . . . . . . . . 3-4-1 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21 Dust unloader . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1 Vent tube Engine crankcase . . . . . . . . . . . . . . . . . . . . . 3-9-1

W Warm-up Engine, cold weather . . . . . . . . . . . . . . . . . . 2-2-8 Washer Windshield fluid level . . . . . . . . . . . . . . . . . . 3-2-5 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-14 Wheel Cap screw torque . . . . . . . . . . . . . . . . . . . . . 3-3-2 Window Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-51 Sliding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-51 Windshield Washer fluid . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5 3-Way Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7

Index-6

102703

PN=6