PDF DOWNLOAD John Deere 210LE Landscape Loader Operator's Manual OMT186794

210LE Landscape Loader

OPERATOR’S MANUAL 210LE Landscape Loader OMT186794 ISSUE I0A

(ENGLISH)

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

If this product contains a gasoline engine:

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

The State of California requires the above two warnings.

Additional Proposition 65 Warnings can be found in this manual.

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

Introduction 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.)

equipment as described in this manual. The warranty is explained on the warranty certificate or statement which you should have received from your dealer.

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.

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.

RIGHT­HAND AND LEFT­HAND sides are determined by facing in the direction of forward travel.

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

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.

If you are not the original owner of this machine, it is in your interest to contact your local John Deere dealer to inform them of this unit’s serial number. This will help John Deere notify you of any issues or product improvements.

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

WARRANTY is provided as part of John Deere’s support program for customers who operate and maintain their DX,IFC7 ­19­03APR09­1/1

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Introduction

TX1053039 —19—19MAR10

Emissions Control Warranty Statement—U.S. and Canada

VD76477,000104E ­19­04JAN10­1/1

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Introduction

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

SEND TO:

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

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

Name: Phone: Email Address: THANK YOU! TX,TM,FAX ­19­03JUL01­1/1

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Page

Safety—Safety and Operator Conveniences

Safety Signs ......................................................1­5­2

Safety and Operator Convenience Features .....1­1­1

Operation—Operator’s Station Display Monitor Functions .................................2­1­1 Controls—Steering Console ..............................2­1­3 Front Loader Controls........................................2­1­4 Three­Point Hitch Levers and Engine Speed Control Knob......................................2­1­4 Seat Belt—Operation.........................................2­1­5 Seat Belt—Maintenance....................................2­1­5 Seat Controls—Suspension ..............................2­1­5 Seat Controls—Non­Suspension.......................2­1­6 Accessory Power Outlets—12 Volt—If Equipped .......................................................2­1­6 Operator’s Manual Holder .................................2­1­6 Vandal Protection ..............................................2­1­7 Fire Extinguisher................................................2­1­7

Safety—General Precautions Recognize Safety Information ...........................1­2­1 Follow Safety Instructions..................................1­2­1 Operate Only If Qualified ...................................1­2­1 Wear Protective Equipment...............................1­2­2 Avoid Unauthorized Machine Modifications.......1­2­2 Inspect Machine ................................................1­2­2 Stay Clear of Moving Parts................................1­2­2 Avoid High­Pressure Fluids ...............................1­2­3 Avoid High­Pressure Oils ..................................1­2­3 Work In Ventilated Area.....................................1­2­3 Prevent Fires .....................................................1­2­4 Prevent Battery Explosions ...............................1­2­4 Handle Chemical Products Safely .....................1­2­5 Dispose of Waste Properly ................................1­2­5 Prepare for Emergencies...................................1­2­5 Clean Debris from Machine ...............................1­2­6

Operation—Operating the Machine Inspect Machine Daily Before Starting ..............2­2­1 Check Instruments Before Starting....................2­2­2 Engine Break­In Period .....................................2­2­2 Starting the Engine ............................................2­2­3 Starting Fluid—Cold Weather Start Aid (S.N. —882699) ............................................2­2­5 Starting Fluid—Cold Weather Start Aid (S.N. 882700—) ............................................2­2­6 Using Coolant Heater—If Equipped ..................2­2­7 Warm­Up ...........................................................2­2­7 Cold Weather Warm­Up ....................................2­2­7 Driving the Machine...........................................2­2­8 Operating Loader.............................................2­2­10 Operating Three­Point Hitch............................2­2­11 Operating PTO—If Equipped...........................2­2­13 Operating Differential Lock ..............................2­2­13 Operating Mechanical Front Wheel Drive (MFWD)—If Equipped .......................2­2­13 Lifting ...............................................................2­2­14 Parking the Machine........................................2­2­15 Loading Machine on a Trailer ..........................2­2­16 Towing .............................................................2­2­17

Safety—Operating Precautions Use Steps and Handholds Correctly .................1­3­1 Start Only From Operator’s Seat.......................1­3­1 Use and Maintain Seat Belt ...............................1­3­1 Prevent Unintended Machine Movement ..........1­3­1 Avoid Work Site Hazards...................................1­3­2 Keep Riders Off Machine ..................................1­3­2 Avoid Backover Accidents .................................1­3­2 Avoid Machine Tipover ......................................1­3­3 Add and Operate Attachments Safely ...............1­3­3 Use Special Care When Operating ...................1­3­4 Operating or Traveling On Public Roads...........1­3­4 Inspect and Maintain ROPS ..............................1­3­4 Stay Clear of Rotating Drivelines.......................1­3­5

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

Maintenance—Machine Diesel Fuel.........................................................3­1­1 Lubricity of Diesel Fuel ......................................3­1­1 Handling and Storing Diesel Fuel ......................3­1­2 Biodiesel Fuel ....................................................3­1­3

Safety Signs Replace Safety Signs ........................................1­5­1

Continued on next page

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

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

COPYRIGHT © 2010 DEERE & COMPANY Moline, Illinois All rights reserved.

A John Deere ILLUSTRUCTION ® Manual Previous Editions Copyright © 1997, 1998, 1999, 2000, 2001, 2004, 2006, 2007, 2009

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Testing Diesel Fuel ............................................3­1­3 Minimizing the Effect of Cold Weather on Diesel Engines .........................................3­1­4 Low Sulfur Diesel Fuel Conditioner ...................3­1­5 Diesel Fuel Storage ...........................................3­1­5 Alternative and Synthetic Lubricants .................3­1­5 Diesel Engine Break­In™ Oil.............................3­1­6 Diesel Engine Oil ...............................................3­1­7 Diesel Engine Oil and Filter Service Intervals ...3­1­8 Engine Oil (S.N. —881401) ...............................3­1­9 Engine and Hydraulic Oil (S.N. 881402—) ......3­1­10 Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil (S.N. —881401) ..........................................3­1­11 Transmission, Axles, and Mechanical Front Wheel Drive Oil (S.N. 881402—).......3­1­11 Grease.............................................................3­1­12 PTO Gear Case Oil—If Equipped....................3­1­12 Heavy Duty Diesel Engine Coolant .................3­1­13 Drain Intervals for Diesel Engine Coolant........3­1­14 John Deere COOL­GARD™ II COOLANT EXTENDER ..............................3­1­14 Supplemental Coolant Additives......................3­1­15 Operating in Warm Temperature Climates ......3­1­15 Additional Information About Diesel Engine Coolants and John Deere COOL­GARD™ II COOLANT EXTENDER.................................................3­1­16 Testing Diesel Engine Coolant.........................3­1­17

Inspecting and Cleaning Dusty Secondary and Primary Element (S.N. 888001—) ............................................3­3­6 Draining Water Separator Sediment (S.N. 888001—) ............................................3­3­6 Lubricate MFWD Drive Shaft Splines—If Equipped (S.N. 888001—)..........3­3­7 Check Wheel Fasteners (S.N 888001—) ..........3­3­7 Check Coolant ...................................................3­3­8

Maintenance—Every 10 Hours or Daily Check Engine Oil Level .....................................3­4­1 Check Hydraulic Oil Level .................................3­4­2 Check Coolant Overflow Tank Level..................3­4­2 Lubricate Loader Pivots.....................................3­4­3 Lubricate 4­in­1 Bucket Pivots—If Equipped .....3­4­4 Lubricate MFWD Drive Shaft Splines—If Equipped (S.N. —888000)..........3­4­4 Lubricate Three­Point Hitch Pivots (S.N. —888000) ............................................3­4­5 Lubricate Three­Point Hitch Pivots (S.N. 888001—) ............................................3­4­6 Lubricate Lift Cylinder (S.N. —888000).............3­4­6 Lubricate MFWD Drive Shaft Universal Joints—If Equipped (S.N. —888000) ............3­4­7 Lubricate MFWD Front Axle Universal Joints—If Equipped .......................................3­4­7 Lubricate MFWD Front Axle Pivot—If Equipped (S.N. —888000) ............................3­4­8 Lubricate MFWD Front Axle Pivot (S.N. 888001—) .....................................................3­4­8 Lubricate Non­Powered Front Axle Steering—If Equipped ...................................3­4­9

Maintenance—Periodic Maintenance Service Machine at Specified Intervals..............3­2­1 Check Hour Meter Regularly .............................3­2­1 Battery Disconnect—If Equipped.......................3­2­2 Prepare Machine for Maintenance ....................3­2­2 Loader Boom Service Lock ...............................3­2­3 Opening and Closing Engine Hood (S.N. 882700— ) ...........................................3­2­3 Fuel Tank ...........................................................3­2­4 Fluid Analysis Program Test Kits and 3­Way Coolant Test Kit..................................3­2­4 Service Intervals (S.N. —888000) .....................3­2­5 Required Parts (S.N. —888000)........................3­2­7 Service Intervals (S.N. 888001—) .....................3­2­9 Required Parts (S.N. 888001—)......................3­2­11

Maintenance—Every 50 Hours Check Transmission Oil Level (S.N. 888001—) .....................................................3­5­1

Maintenance—Initial Service ­ 100 Hours Change Engine Break­In Oil and Replace Filter (S.N. —882699) .....................3­6­1 Change Engine Break­In Oil and Replace Filter (S.N. 882700—888000) .........3­6­2 Change Transmission and Torque Converter Oil and Replace Filter (S.N. —886534) ............................................3­6­3

Maintenance—As Required Inspect Loader Boom Service Lock (S.N —888000) .............................................3­3­1 Drain Fuel Tank Water and Sediment................3­3­2 Check Tire Pressure..........................................3­3­3 Tire Inflation Pressures......................................3­3­3 Check Park Brake (S.N. —888000)...................3­3­4 Inspect Belt........................................................3­3­4 Lubricate Front Non­Powered Axle Wheel Bearings (S.N. —888000)..................3­3­4 Lubricate Draft Link Wear Plates.......................3­3­5 Clean Dust Unloader Valve ...............................3­3­5

Maintenance—Initial Service ­ 250 Hours Change Engine Break­In Oil and Replace Filter (S.N. 888001— ) ....................3­7­1

Maintenance—Every 250 Hours Change Engine Oil and Replace Filter (S.N. —882699) ............................................3­8­1 Check MFWD Axle Oil—If Equipped .................3­8­2 Check MFWD Planetary Housing Oil—If Equipped ............................................3­8­2 Continued on next page

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Check Rear Axle Oil Level (S.N. —888000)......3­8­3 Check Rear Axle Oil Level (S.N. 888001—)......3­8­3 Check Battery Electrolyte Level and Terminals.......................................................3­8­4 Check Transmission Oil Level (S.N. —888000) .....................................................3­8­6 Take Engine Oil Sample ....................................3­8­6

Maintenance—Every 6000 Hours Draining the Cooling System ...........................3­12­1 Filling the Cooling System ...............................3­12­2

Miscellaneous—Machine Inspecting and Cleaning Dusty Secondary and Primary Element ..................4­1­1 Checking Coolant Hoses and Radiator .............4­1­1 Do Not Service or Adjust Injection Nozzles or Injection Pump ............................4­1­2 Draining Fuel Filter Sediment ............................4­1­2 Precautions for Alternator and Regulator ..........4­1­2 Handling, Checking and Servicing Batteries Carefully.........................................4­1­3 Using Booster Batteries—12­Volt System .........4­1­4 Replacing Batteries ...........................................4­1­4 Removing Batteries ...........................................4­1­5 Using Battery Charger .......................................4­1­6 Fuse Specifications—(S.N. —880053)..............4­1­7 Fuse Specifications—(S.N. 880054—882699) .........................................4­1­8 Fuse Specifications—(S.N. 882700—888000) .........................................4­1­9 Fuse Specifications—(S.N. 888001— )...........4­1­10 Remove and Install Halogen Bulb ...................4­1­11 Changing Backup Alarm Volume (S.N. —882699) ...................................................4­1­12 Checking Neutral Start System .......................4­1­13 Changing Loader Buckets ...............................4­1­13 Adding Attachments/Accessories to Roll­Over Protective Structure (ROPS).......4­1­14 Welding On Machine .......................................4­1­14 Welding Near Electronic Control Units ............4­1­14 Keep Electronic Control Unit Connectors Clean .......................................4­1­14 External Service Brake Inspection (S.N. —888000) ..........................................4­1­15 External Service Brake Inspection (S.N. 888001—) ..........................................4­1­16 Bleeding Service Brakes (S.N. —880907) ......4­1­17 Bleed Service Brakes (S.N. 880908— ) ..........4­1­18 Toe­In Check and Adjust (S.N. —888000) ......4­1­19 Toe­In Check and Adjust (S.N. 888001—) ......4­1­20 Rear Counterweights.......................................4­1­20 Adding Liquid Ballast to Rear Tires .................4­1­20 Adding Liquid Ballast to Front Tires.................4­1­21 Do Not Service Control Valves, Cylinders, Pumps or Motors........................4­1­21 Checking Wheel Fasteners (S.N. —888000) ..4­1­21 Keep ROPS Installed Properly ........................4­1­22 Hardware Torque Specifications......................4­1­22 Unified Inch Bolt and Screw Torque Values.....4­1­23 Metric Bolt and Screw Torque Values..............4­1­24

Maintenance—Every 500 Hours Check Air Intake Hose.......................................3­9­1 Change Engine Oil and Replace Filter (S.N. 882700— ) ...........................................3­9­2 Replace Hydraulic Oil Filter and PTO Filter—If Equipped (S.N. —888000) .............3­9­3 Replace Fuel Filter ............................................3­9­4 Inspect and Clean Hydraulic Reservoir Fill Screen and Breather Screen ...................3­9­4 Take Fluid Samples ...........................................3­9­5

Maintenance—Every 1000 Hours Change MFWD Front Axle Housing Oil—If Equipped (S.N. —888000) ...............3­10­1 Change MFWD Front Wheel Planetary Housing Oil—If Equipped (S.N —888000) ..3­10­1 Clean, Pack, and Adjust Front Non­Powered Axle Wheel Bearings—If Equipped ................................3­10­2 Change Rear Axle Oil (S.N. —888000)...........3­10­3 Replace Hydraulic Oil Filter and PTO Filter—If Equipped (S.N. 888001—) ...........3­10­4 Change Transmission and Torque Converter Oil and Replace Filter (S.N. —888000) ..........................................3­10­5 Change Transmission and Torque Converter Oil and Replace Filter (S.N. 888001—) ..........................................3­10­6 Change Hydraulic Reservoir Oil, Filter, PTO Oil and Filter—If Equipped (S.N. —888000) ..........................................3­10­7 Clean Engine Crankcase Vent Tube ...............3­10­8 Adjust Engine Speed Control Linkage (S.N. —882699) ........................................3­10­10 Adjust Engine Speed Control Linkage (S.N. 882700— ) .......................................3­10­11 Replace Air Cleaner Elements ......................3­10­12 Check Coolant ...............................................3­10­13

Maintenance—Every 2000 Hours Adjust Engine Valve Lash (Clearance) ............3­11­1 Change MFWD Front Axle Housing Oil—If Equipped (S.N. 888001—) ...............3­11­1 Change MFWD Front Wheel Planetary Housing Oil—If Equipped (S.N 888001—) ..3­11­1 Change Rear Axle and Planetary Housing Oil (S.N. 888001—).......................3­11­2 Change Hydraulic Reservoir Oil, Filter, PTO Oil and Filter—If Equipped (S.N. 888001—) ..........................................3­11­2

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

Continued on next page

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Miscellaneous—Troubleshooting Troubleshooting Procedure ...............................4­3­1 Engine ...............................................................4­3­2 Hydraulic System...............................................4­3­5 Electrical System ...............................................4­3­7 Gauges and Indicators ......................................4­3­9 Transmission ...................................................4­3­11 MFWD .............................................................4­3­12 Rear Axle.........................................................4­3­12

Miscellaneous—Storage Prepare Machine for Storage ............................4­4­1 Monthly Storage Procedure...............................4­4­2

Miscellaneous—Specifications 210LE Travel Speed (S.N. —888000)...............4­5­1 210LE Travel Speed (S.N. 888001—)...............4­5­1 210LE Landscape Loader Drain and Refill Capacities (S.N. —888000) .................4­5­2 210LE Landscape Loader Drain and Refill Capacities (S.N. 888001—) .................4­5­3 210LE Landscape Loader Dimensions..............4­5­4 210LE Landscape Loader .................................4­5­6 210LE Landscape Loader Weight .....................4­5­7 210LE Landscape Loader Buckets....................4­5­7

Miscellaneous—Machine Numbers Record Product Identification Number (PIN) .....4­6­1 Record Engine Serial Number...........................4­6­1 Record Transmission Serial Number—Manual Shift (S.N. —888000) .....................................................4­6­1 Record Transmission Serial Number—Powershift (S.N.—888000) ...........4­6­2 Record Transmission Serial Number (S.N. 888001—) ............................................4­6­2 Record Rear Axle Housing Serial Number ........4­6­2 Record (MFWD) Front Axle Housing Serial Number ...............................................4­6­3 Keep Proof of Ownership ..................................4­6­3 Keep Machines Secure .....................................4­6­4

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Safety—Safety and Operator Conveniences Safety and Operator Convenience Features 2

1

3 4

6 10

15 12

11

13

TX1018071 Please remember, the operator is the key to preventing accidents.

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

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

3. Signal/Warning Lights. Roof mounted turning signal lights and warning lights can also be used as flashers when traveling in traffic.

4. Headlights/Tailights. Canopy has two front halogen driving/work lights and two rear halogen work lights are optional.

5. Exceptional Visibility. Views to either side and to the front or rear are unrestricted.

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

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

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

7 TX1018071 —UN—19FEB07

14

8

5

9. Neutral Start. Neutral start feature prevents the engine from being started unless the transmission control lever (TCL) is in neutral.

10. Independent Parking/Secondary Brake.

Independent parking brake is electrically controlled and engages whenever the engine is stopped.

11. Steps. Wide, skid­resistant steps helps prevent slipping while entering or exiting the operator’s station.

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

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

14. Loader Boom Service Lock. A mechanical lock is provided for working on or around this machine with the boom raised.

15. Handholds. Large and conveniently placed handholds make it easy to enter or exit the operator’s station from the left side of machine.

ER79617,0000C56 ­19­16SEP10­1/1

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Safety—General Precautions Recognize Safety Information T133555 —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.

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

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

T133588 —19—28AUG00

On 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.

TX,RECOGNIZE ­19­28JUN10­1/1

Follow Safety Instructions

TS201 —UN—23AUG88

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator’s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

DX,READ ­19­16JUN09­1/1

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

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

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

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

TX03679,00016FA ­19­03JAN07­1/1

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Safety—General Precautions

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

TS206 —UN—23AUG88

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

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

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. Radio or music headphones are not suitable to use for hearing protection.

OUT4001,0000570 ­19­12FEB10­1/1

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

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

Non­John Deere parts, or any damage or failures resulting from their use are not covered by any John Deere warranty.

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or

reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance.

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

AM40430,00000A9 ­19­20AUG09­1/1

Inspect Machine

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

T6607AQ —UN—18OCT88

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

TX03679,0001734 ­19­08JAN08­1/1

Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining any part of machine with moving parts.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

T133592 —UN—12SEP01

Stay Clear of Moving Parts

TX03679,00016D2 ­19­08JAN08­1/1

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Safety—General Precautions

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

X9811 —UN—23AUG88

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 high­pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in

Moline, Illinois, U.S.A., by calling 1­800­822­8262 or +1 309­748­5636.

DX,FLUID ­19­20AUG09­1/1

Avoid High­Pressure Oils

Never search for leaks with your hands. Protect hands.

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

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

T133840 —UN—20SEP00

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

T133509 —UN—17MAR06

This machine uses a high­pressure hydraulic system.

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

TX03679,00016D3 ­19­03NOV08­1/1

Work In Ventilated Area

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

TS220 —UN—23AUG88

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

DX,AIR ­19­17FEB99­1/1

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Safety—General Precautions

T133552 —UN—14SEP00

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

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

T133553 —UN—07SEP00

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

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

Know how to use extinguisher properly.

T133554 —UN—07SEP00

TX03679,00016F5 ­19­26JUN09­1/1

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

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

TS204 —UN—23AUG88

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

DX,SPARKS ­19­03MAR93­1/1

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Safety—General Precautions

Handle Chemical Products Safely

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

TS1132 —UN—26NOV90

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

DX,MSDS,NA ­19­03MAR93­1/1

Dispose of Waste Properly

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

TS1133 —UN—26NOV90

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

DX,DRAIN ­19­03MAR93­1/1

Prepare for Emergencies Be prepared if a fire starts.

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

TS291 —UN—23AUG88

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 ­19­03MAR93­1/1

1­2­5

091710

PN=14

Safety—General Precautions

Clean Debris from Machine

Clean any oil spills or fuel spills on machine surfaces.

Temperature in engine compartment may go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.

T6669AG —UN—18OCT88

Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator’s station clean and free of debris.

OUT4001,00000E3 ­19­20AUG09­1/1

1­2­6

091710

PN=15

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

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

Never use machine controls as handholds.

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

TX03679,00016F2 ­19­12FEB07­1/1

T133715 —UN—07SEP00

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

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

TX03679,0001799 ­19­22APR10­1/1

Use and Maintain Seat Belt T133716 —19—14SEP00

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

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

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

TX03679,00016DD ­19­19MAR07­1/1

Prevent Unintended Machine Movement Always set park brake before leaving seat.

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

Be careful not to accidentally actuate steering, travel or other controls. Engage park brake and lower work equipment to the ground during work interruptions.

Stop the engine before allowing anyone to approach the machine. Follow proper parking procedures before leaving the operator’s station.

T196278

ON

P

OFF

T196278 —UN—12NOV03

PARK BRAKE

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

OUO1030,0000723 ­19­26JAN07­1/1

1­3­1

091710

PN=16

Safety—Operating Precautions

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

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

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. 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.

T196283 —UN—17NOV03

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.

T196283

Avoid working under over­hanging embankments or stockpiles that could collapse under or on machine.

Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seat belt.

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

ER79617,0000BF2 ­19­09JUL10­1/1

Keep Riders Off Machine Only allow the operator on the machine. Keep riders off.

TS290 —UN—23AUG88

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

DX,RIDER ­19­03MAR93­1/1

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

Be certain backup warning alarm is working properly.

Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

T196280

T196280 —UN—17NOV03

Avoid Backover Accidents

OUO1030,0000724 ­19­28FEB07­1/1

1­3­2

091710

PN=17

Safety—Operating Precautions

Avoid Machine Tipover Use seat belt at all times.

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

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

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

T147495 —19—26OCT01

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

TX03768,0000BA3 ­19­07SEP06­1/1

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 ­19­12FEB07­1/1

1­3­3

091710

PN=18

Safety—Operating Precautions

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

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.

T196282 —UN—17NOV03

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

T196282

Never lift an object above or near another person.

OUO1030,0000726 ­19­28FEB07­1/1

Operating or Traveling On Public Roads T141891 —UN—22MAY01

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

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

TX03679,00017C8 ­19­02MAR07­1/1

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

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

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

To maintain the ROPS:

• Replace missing hardware using correct grade hardware.

• Check hardware torque.

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

• Check ROPS for cracks or physical damage.

TX03679,000179F ­19­07SEP06­1/1

1­3­4

091710

PN=19

Safety—Operating Precautions

Stay Clear of Rotating Drivelines

Keep tractor master shield and driveline shields in place at all times. Make sure rotating shields turn freely.

Wear close fitting clothing. Stop the engine and be sure that PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.

Do not install any adapter device between the tractor and the primary implement PTO drive shaft that will allow a 1000 rpm tractor shaft to power a 540 rpm implement at speeds higher than 540 rpm.

TS1644 —UN—22AUG95

Entanglement in rotating driveline can cause serious injury or death.

Do not install any adapter device that results in a portion of the rotating implement shaft, tractor shaft, or the adapter to be unguarded. The tractor master shield shall overlap the end of the splined shaft and the added adaptor device as outlined in the table.

PTO Type

Diameter

1 2 3

n ± 5 mm (0.20 in.)

35 mm (1.378 in.)

6

85 mm (3.35 in.)

35 mm (1.378 in.)

21

85 mm (3.35 in.)

45 mm (1.772 in.)

20

100 mm (4.00 in.)

H96219 —UN—29APR10

Splines

DX,PTO ­19­30JUN10­1/1

1­3­5

091710

PN=20

Safety—Maintenance Precautions Park and Prepare for Service Safely Warn others of service work. Always park and prepare your machine for service or repair properly. to the ground.

• Engage park brake.

• Stop engine and remove key.

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

Securely support machine or attachment before working under it.

T133332 —19—14DEC01

• Park machine on a level surface and lower equipment

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

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

• Do not support machine with a single jack or other this machine with the loader boom raised.

Understand service procedures before beginning repairs.

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

TS229 —UN—23AUG88

devices that may slip out of place.

• Always install boom lock before working on or around

TX03679,0001809 ­19­02MAR07­1/1

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

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

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

Welding can structurally weaken or deform the wheel.

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

TS211 —UN—23AUG88

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

DX,RIM ­19­24AUG90­1/1

1­4­1

091710

PN=21

Safety—Maintenance Precautions

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

TS281 —UN—23AUG88

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

DX,RCAP ­19­04JUN90­1/1

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

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

TS220 —UN—23AUG88

Remove paint before heating:

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

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

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

Wear an approved respirator.

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

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

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

Dispose of paint and solvent properly.

DX,PAINT ­19­24JUL02­1/1

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

Separate harness connectors to engine and vehicle microprocessors.

Avoid welding or heating near pressurized fluid lines.

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

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

Use a qualified welding technician for structural repairs.

T133547 —UN—31AUG00

Make Welding Repairs Safely

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

TX03679,00016D5 ­19­24SEP07­1/1

1­4­2

091710

PN=22

Safety—Maintenance Precautions

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.

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

T133738 —UN—14SEP00

Drive Metal Pins Safely

TX03679,0001745 ­19­07SEP06­1/1

1­4­3

091710

PN=23

Safety Signs Replace Safety Signs

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator’s manual.

TS201 —UN—23AUG88

Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement.

DX,SIGNS ­19­18AUG09­1/1

1­5­1

091710

PN=24

Safety Signs

T196448 —19—07APR06

Safety Signs

Right Side Shown Continued on next page

1­5­2

ER79617,0000C55 ­19­16SEP10­1/2

091710

PN=25

T196447 —19—07APR06

Safety Signs

Left Side Shown ER79617,0000C55 ­19­16SEP10­2/2

1­5­3

091710

PN=26

Operation—Operator’s Station Display Monitor Functions The display monitor has three modes of operation:

T196285A —UN—17NOV03

IMPORTANT: Prevent possible machine damage.

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

• KEY SWITCH ON, ENGINE NOT RUNNING MODE:

With key switch “On” but the engine not running, park brake (A), seat belt (B), engine coolant temperature (D), alternator voltage (H), and fuel gauge (L) remain lit.

• BULB CHECK MODE: With the engine not running, turning the key switch to “Bulb Check” puts the display monitor in bulb check mode. In this mode, the monitor alarm beeps, all gauges and indicators light, and fuel gauge needle cycle from minimum to 12 o’clock positions before registering current reading.

• ENGINE RUNNING MODE: Monitor panel enters engine running mode after bulb check mode when the engine is started. In engine running mode, current status of machine is displayed on gauges and indicators.

A—Park Brake Indicator: Indicator will light at engine startup and stay lit until park brake is disengaged.

A—Park Brake Indicator B—Seat Belt Indicator C—STOP Indicator D—Engine Coolant Temperature Indicator E—Engine Oil Pressure Indicator F— Transmission Oil Temperature Indicator G—Hydraulic Oil Filter Indicator

H—Alternator Voltage Indicator I— Air Filter Restriction Indicator J— Beacon Indicator—If Equipped K—Mechanical Front Wheel Drive Indicator—If Equipped L— Fuel Gauge M—Hour Meter

B—Seat Belt Indicator: Indicator will light at engine startup and stay lit until park brake is disengaged.

• Engine oil pressure is low.

• Engine coolant temperature is excessively high.

• On machines (S.N. 882700— ) Diagnostic Trouble Code

C—Stop Indicator: On machines (S.N. —882699) the red STOP light will come on steady (high level) only.

(DTC) is stored in the ECU. See your authorized dealer.

On machines (S.N. 882700—884464) the red STOP light will indicate a medium or high level alarm by either flashing (medium level) or coming on steady (high level). The red STOP light is also used to display diagnostic trouble codes (DTC) that may be active or stored in the ECU.

On machines (S.N. 882700— ) the STOP indicator flashes (medium level) and alarm sounds when:

On machines (S.N. 884465—) the red OVERHEAT light will indicate a medium or high level alarm by either flashing (medium level) or coming on steady (high level). The red OVERHEAT light is also used to display diagnostic trouble codes (DTC) that may be active or stored in the ECU.

D—Engine Coolant Temperature Indicator: Engine coolant temperature and STOP indicators will light and alarm will sound when engine coolant is above 115°C (240°F). Do not stop engine when indicators light together or temperature will rise further. Reduce load and run engine at slow idle. If indicator does not go out after one to two minutes, stop engine and allow to cool before servicing.

IMPORTANT: If the STOP indicator comes on steady (high level) and alarm sounds for more than ten seconds with engine oil pressure indicator on, stop machine immediately and investigate cause of problem.

• Diagnostic Trouble Code (DTC) is stored in the ECU. See your authorized dealer.

E—Engine Oil Pressure Indicator:

If the STOP indicator comes on steady (high level) and alarm sounds for more than ten seconds with engine coolant temperature indicator on, reduce load and run engine for one to two minutes at slow idle to allow time to cool. If light continues to stay on, stop engine and investigate problem. Do not re­start engine until problem has been corrected.

IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY. When engine oil pressure is low, indicator will light, STOP indicator will flash and alarm will sound. Stop machine.

STOP ENGINE IMMEDIATELY.

The STOP indicator comes on steady (high level) and alarm sounds when: Continued on next page

2­1­1

OUO1030,0000731 ­19­26JAN07­1/2

091710

PN=27

Operation—Operator’s Station

F—Transmission Oil Temperature Indicator: Transmission oil temperature indicator will light when transmission oil temperature is high. Reduce load immediately, shift into neutral and run engine at slow idle.

Inspect for plugged oil cooler.

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

Indicator will light when hydraulic oil filter element is restricted.

NOTE: Cold oil can cause indicator to light temporarily.

Allow time for oil to warm up and indicator to go out before servicing filter.

H—Engine Alternator Voltage Indicator: Indicator will light when alternator output voltage drops below 12 volt.

Check electrical system or recharge battery, if necessary.

I—Engine Air Filter Restriction Indicator: Indicator will light when air filter elements are restricted. Clean or change filter elements.

J—Beacon Light Indicator—If Equipped: Indicator will light when beacon light is turned “ON”.

K—Mechanical Front Wheel Drive Indicator—If Equipped: Indicator will light when mechanical front wheel drive is engaged with switch.

L—Fuel Level Gauge: The gauge shows the level of fuel in the tank.

M—Hour Meter: Use hour meter to determine when to perform service and maintenance procedures.

OUO1030,0000731 ­19­26JAN07­2/2

2­1­2

091710

PN=28

Operation—Operator’s Station

Controls—Steering Console A—Stop Indicator:

T104939 —UN—07NOV96

On machines (S.N. 8844645—) the red OVERHEAT light will indicate a medium or high level alarm by either flashing (medium level) or coming on steady (high level). The red OVERHEAT light is also used to display diagnostic trouble codes (DTC) that may be active or stored in the ECU. On machines (S.N. 882700—8844644) the red STOP light will indicate a medium or high level alarm by either flashing (medium level) or coming on steady (high level).

The red STOP light is also used to display diagnostic trouble codes (DTC) that may be active or stored in the ECU. On machines (S.N. —882699) the red STOP light will come on steady (high level) only.

If the STOP indicator comes on steady (high level) and alarm sounds for more than ten seconds with engine coolant temperature indicator on, reduce load and run engine for one to two minutes at slow idle to allow time to cool. If light continues to stay on, stop engine and investigate problem. Do not re­start engine until problem has been corrected.

The STOP indicator comes on steady (high level) and alarm sounds when:

• Engine oil pressure is low.

• Engine coolant temperature is excessively high.

• On machine (S.N. 882700— ) Diagnostic Trouble Code

T196286A —UN—17NOV03

IMPORTANT: If the STOP indicator comes on steady (high level) and alarm sounds for more than ten seconds with engine oil pressure indicator on, stop machine immediately and investigate cause of problem.

A—Stop Indicator B—Key Switch C—Fuel Gauge D—Hour Meter E—Work and Drive Lights Switch F— Warning Lights Switch

G—Mechanical Front Wheel Drive Switch—If Equipped H—Turn Signal Switch I— Park Brake Switch J— Start Aid Switch K—Horn

• Push upper half to turn work and drive lights, tail lights, and front work lights, if equipped, on.

(DTC) is stored in the ECU. See your authorized dealer.

• Push to middle position to turn work and drive lights

On machine (S.N. 882700—8844644) the STOP indicator flashes (medium level) and alarm sounds when:

• Push lower half to turn work and drive lights, tail lights,

• Diagnostic Trouble Code (DTC) is stored in the ECU. See your authorized dealer.

On machine (S.N. 8844645—) the STOP indicator flashes (medium level) and alarm sounds when:

• Diagnostic Trouble Code (DTC) is stored in the ECU.

and tail lights on.

and front work lights, if equipped, off.

F—Warning Lights Switch: Push upper half of switch to turn warning lights on. When warning lights switch is ON, warning lights indicator, left turn indicator, and right turn indicator will flash. Push lower half of switch to turn warning lights off.

G—Mechanical Front Wheel Drive Switch—If Equipped: Push top half of switch up to engage the MFWD axle. Push bottom half of switch to disengage the MFWD axle.

See your authorized dealer.

B—Key Switch C—Fuel Gauge: The gauge shows the level of fuel in the tank.

H—Turn Signal Switch: Push switch to signal turning direction. The switch has three positions:

D—Hour Meter: Use hour meter to determine when to perform service and maintenance procedures.

• Push left half to signal left turn. Left turn indicator will flash.

E—Work and Drive Lights Switch: Push switch to operate work and drive lights, tail lights, and front work lights, if equipped. The switch has three positions:

• Middle position is OFF. Indicators will not flash unless warning lights switch is ON.

Continued on next page

2­1­3

OUO1030,0000732 ­19­02MAR07­1/2

091710

PN=29

Operation—Operator’s Station

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

NOTE: When turn signal is applied with warning lights on, direction light will continue to blink while other amber light illuminates steady.

J—Start Aid Switch—If Equipped: Press and hold button when engine is cold and cranking to inject starting fluid into engine during cold weather start­up.

K—Horn: Press button to sound horn.

I—Park Brake Switch: Push top half of switch to engage park brake. Push bottom half of switch to disengage park brake.

OUO1030,0000732 ­19­02MAR07­2/2

Front Loader Controls Use controls (A and B or C) for operating front loader.

C—Third Function Control Lever—If Equipped T122072B —UN—01JUL99

A—Clutch Disconnect Switch B—Loader Control Lever

(S.N. —882699) Shown TX,10,BG429 ­19­17NOV03­1/1

Three­Point Hitch Levers and Engine Speed Control Knob

T122175C —UN—09JUL99

Use levers (A—D) to operate hitch, knob (E) to control engine speed and knob (F) to operate PTO (if equipped).

NOTE: Some machines may be equipped with two auxiliary mounted equipment levers (D).

A—Float Position Lever B—Pitch Cylinder Lever C—Tilt Cylinder Lever

D—Auxiliary Mounted Equipment Lever E—Speed Control Knob—If Equipped F— PTO Control Knob—If Equipped

(S.N. —882699) Shown TX,10,BG430 ­19­20JUL10­1/1

2­1­4

091710

PN=30

Operation—Operator’s Station

Seat Belt—Operation 1. Pull out belt (A) from right side of seat.

2. Insert belt into catch (B) on left side of seat to lock in place.

3. Press red release button to unlock seat belt.

B—Catch

T104956 —UN—04FEB97

A—Seat Belt

Suspension Seat Shown TX,10,BG431 ­19­20MAR07­1/1

Seat Belt—Maintenance 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.

OUO1043,00001F5 ­19­28FEB07­1/1

Seat Controls—Suspension CAUTION: Be sure seat is locked in position before operating machine. A seat which is loose or not properly locked can cause loss of control of machine and injuries or death.

Lift pivot lever (A) up and pivot seat. Release pivot lever to lock seat in position.

Lift fore­aft lever (B) up and slide seat to desired position.

Release forward and aft lever to lock seat in position.

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

Pull height lever (E) up and move seat to desired height.

Release height lever to lock seat in position.

A—Pivot Lever B—Fore­Aft Lever C—Backrest Angle Adjuster

D—Weight Adjuster E—Height Adjuster

T104954 —UN—31JAN97

Adjust backrest position lever (C) to adjust position of backrest.

TX,10,BG432 ­19­17NOV03­1/1

2­1­5

091710

PN=31

Operation—Operator’s Station

Seat Controls—Non­Suspension Use fore­aft lever (1) to slide seat to desired position.

Release lever to lock seat in to position.

Remove seat mounting cap screws (2) to pivot seat to desired angle. Install cap screws into mounting holes and tighten.

2— Seat Mounting Cap Screws (4 used)

TX1037557A —UN—06MAR08

1— Fore­Aft Lever

TX,10,BG433 ­19­17NOV03­1/1

Accessory Power Outlets—12 Volt—If Equipped

T196449A —UN—18NOV03

The 12 volt accessory outlets are used to power operator accessories, as necessary.

A—Accessory Power Outlets

OUO1030,0000733 ­19­27FEB08­1/1

Operator’s Manual Holder

T104971 —UN—08NOV96

Operator’s manual holder is located inside of left fender.

TX,10,BG436 ­19­15JAN97­1/1

2­1­6

091710

PN=32

Operation—Operator’s Station

Vandal Protection 1. Remove wing nut (A) and vandal protection cover (B) from storage position.

C—Vandal Protection Mounting Location

T105023 —UN—11NOV96

A—Wing Nut B—Vandal Protection Cover

TX1019249A —UN—15FEB07

2. Place cover over front instrument panel and lock in place at location (C).

VD76477,0001420 ­19­15FEB07­1/1

Fire Extinguisher NOTE: All fire extinguishers do not operate the same.

Read operating instructions on canister.

TX1081734 —UN—09SEP10

This portable fire extinguisher (1) is used to aid in the extinguishing of small fires. Refer to individual manufacturers’ instructions and proper fire fighting procedures before the need to use the fire extinguisher arises. For fire prevention safety rules, see Prevent Fires.

(Section 1­2.)

IMPORTANT: Avoid possible machine damage.

Make sure the fire extinguisher is charged or replaced after any use.

Fire Extinguisher

The designated location for the fire extinguisher is left of the operator’s seat. Check gauge (if equipped) on fire extinguisher. If fire extinguisher is not fully charged, charge or replace it.

1— Fire Extinguisher

Dry powder has a tendency to pack in the bottom of a fire extinguisher. Before using fire extinguisher, turn it upside down and shake it until the powder moves.

ER79617,0000C54 ­19­09SEP10­1/1

2­1­7

091710

PN=33

Operation—Operating the Machine Inspect Machine Daily Before Starting Perform periodic service checks in the Maintenance—Ev­ ery 10 Hours or Daily. (Section 3­4.)

• Check precleaner (A).

• Check hydraulic oil level (B).

• Clean operator’s station (C).

• Check pedals and controls for freedom of movement (D).

• Check inflation pressure of tires (E) and hardware torque of wheels.

• Clean radiator fins (F).

• Check and lubricate hitch pivot points (G).

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

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

T104973 —UN—04FEB97

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

LUBRICATION: Check lubrication points shown on Periodic Maintenance Chart or in Maintenance—Every 10 Hours or Daily. (Section 3­4).

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

FIRE PREVENTION: Clean machine of debris.

PARK BRAKE: Check for correct operation.

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

A—Precleaner B—Hydraulic Oil Level C—Operators Station D—Pedals and Controls

E—Tire Pressure F— Radiator Fins G—Hitch Pivot Points

TX,20,BG441 ­19­28FEB07­1/1

2­2­1

091710

PN=34

Operation—Operating the Machine

Check Instruments Before Starting Turn key switch clockwise and hold in BULB CHECK position.

T103810 —19—07OCT96

All indicators on monitor panel (A) must light. For description of indicators, see Display Monitor Functions.

(Section 2­1).

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

T106070 —UN—03JAN97

A—Monitor Panel

Monitor Panel TX,25,BG442 ­19­20JUL10­1/1

Engine Break­In Period NOTE: To avoid engine damage it is critical to observe the engine break­in period. Extra care during the first 250 hours of operation will result in more satisfactory long­term engine performance and life. DO NOT exceed 250 hours of operation with break­in oil.

1. Operate the machine at heavy or normal loads with minimal idling during the break­in period. During the first 20 hours, avoid prolonged periods of engine idling or sustained maximum load operation. If engine will idle longer than 5 minutes, stop engine.

2. Check engine oil level more frequently during the engine break­in period.

IMPORTANT: DO NOT add make­up oil until the oil level is BELOW the ADD mark on the dipstick. John Deere Break­In™ Engine Oil

should be used to make up any oil consumed during the break­in period.

3. Change oil and oil filter after first 250 hours (maximum). Fill crankcase with the normal seasonal viscosity grade oil. See Maintenance—Machine.

(Section 3­1.)

4. Watch coolant temperature gauge closely. If coolant temperature rises above specified limits on the gauge, reduce load on engine. Unless temperature drops quickly, stop the engine and determine the cause before resuming operation. See Troubleshooting.

(Section 4­3.)

5. Watch oil pressure gauge for pressure within specification.

6. Check serpentine belt for proper alignment and seating in pulley grooves.

Break­In is a trademark of Deere & Company.

VD76477,00016F2 ­19­26JUL10­1/1

2­2­2

091710

PN=35

Operation—Operating the Machine

Starting the Engine CAUTION: Prevent asphyxiation. Engine exhaust fumes can cause sickness or death to you or someone else.

TS220 —UN—23AUG88

If you must operate engine in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and/or windows to bring enough outside air into the area.

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

TS177 —UN—11JAN89

NEVER start engine while standing on ground.

Start engine only from operator’s seat, with transmission control lever (TCL) in neutral and park brake engaged.

1. Sit in seat and fasten seat belt.

2. Sound horn.

Continued on next page

2­2­3

TX,25,BG443 ­19­01FEB07­1/2

091710

PN=36

Operation—Operating the Machine

NOTE: Controls and switches must be in the positions described before starting engine.

3. With manual shift transmission: Move gearshift lever (A) and TCL (B) levers to neutral.

T106233 —UN—09JAN97

With power shift transmission: Move TCL (B) lever/range lever to N. 4. Engage park brake using switch (C).

IMPORTANT: To avoid engine damage, never start engine with engine speed control at high speed.

5. Move engine speed control to 1/3 speed.

Manual Transmission Shown

IMPORTANT: Do not operate starter more than 15 seconds at a time or it may be damaged. If engine does not start, wait at least two minutes before trying again. If engine does not start in four attempts, refer to Troubleshooting chapter.

6. Turn key switch clockwise until engine starts, then release key. If engine does not start after 15 seconds, wait two minutes before trying again.

T106234 —UN—09JAN97

NOTE: For machines equipped with engine speed control knob (D), turn knob to 1/3 speed.

A—Gearshift Lever—If Equipped B—Transmission Control Lever (TCL)

C—Park Brake Switch D—Engine Speed Control Knob—If Equipped

T106235 —UN—09JAN97

7. After engine is warm and has run for a five­minute warm­up period, allow engine to return to slow idle.

Use speed control pedal to adjust engine idle during operation.

TX,25,BG443 ­19­01FEB07­2/2

2­2­4

091710

PN=37

Operation—Operating the Machine

Starting Fluid—Cold Weather Start Aid (S.N. —882699)

TS281 —UN—23AUG88

CAUTION: Prevent possible injury from exploding container. Starting fluid is highly flammable.

Keep container away from heat, sparks, and open flame. Contents are pressurized. Do not puncture or incinerate container. Remove can from machine if engine does not need starting fluid.

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

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

T106239 —UN—09JAN97

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

USING START AID IMPORTANT: To avoid engine damage, push starting aid button only when engine is cold and cranking. Starting aid fluid is being injected into engine as long as you push and release button (A).

T106238 —UN—09JAN97

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

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

REPLACING START AID CONTAINER 1. Turn container counterclockwise to remove.

2. Remove can (B) from container.

3. Remove safety cap and spray button from new can and install into container.

A—Start Aid Fluid Button

4. Install container clockwise into base.

B—Start Aid Can OUO1030,0000749 ­19­05JAN04­1/1

2­2­5

091710

PN=38

Operation—Operating the Machine

Starting Fluid—Cold Weather Start Aid (S.N. 882700—)

TS281 —UN—23AUG88

CAUTION: Prevent possible injury from exploding container. Starting fluid is highly flammable.

Keep container away from heat, sparks, and open flame. Contents are pressurized. Do not puncture or incinerate container. Remove can from machine if engine does not need starting fluid.

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

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

T106239 —UN—09JAN97

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

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

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

A—Start Aid Button

OUO1030,0000746 ­19­20MAR07­1/2

REPLACING START AID CONTAINER 1. Open engine hood. See Opening and Closing Engine Hood. (Section 3­2.)

2. Loosen hose clamp (B).

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

4. Remove safety cap from new container.

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

6. Tighten hose clamp.

T197014A —UN—18DEC03

7. Close engine hood.

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

Remove container and install plug (D) in base.

B—Clamp C—Start Aid Can

D—Plug

OUO1030,0000746 ­19­20MAR07­2/2

2­2­6

091710

PN=39

Operation—Operating the Machine

Using Coolant Heater—If Equipped

Plug coolant heater into a 115­volt outlet 10 hours before starting the engine.

CAUTION: Prevent possible personal injury from an electrical shock. Use a heavy­duty, grounded cord to connect heater to electrical power.

TX,25,BD2080 ­19­02MAR07­1/1

Warm­Up

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

IMPORTANT: To ensure proper lubrication, idle engine at 1/3 speed for 5 minutes. Extend period as necessary when operating at temperatures below freezing.

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

• Do not run engine at fast or slow idle.

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

• Check instruments regularly.

TX,25,BD2082 ­19­15OCT08­1/1

Cold Weather Warm­Up IMPORTANT: If hydraulic oil is cold, hydraulic functions move slowly. Do not attempt machine operations until hydraulic functions move at close­to­normal cycle times.

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

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

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

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

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

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

TX,25,BG240 ­19­29AUG97­1/1

2­2­7

091710

PN=40

Operation—Operating the Machine

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

T135857C —UN—01DEC00

1. Connect brake pedals (A) by engaging lock bar (B) between pedals. Keep lock bar engaged unless brakes are to be used to aid in turning.

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

2. Fasten seat belt.

B—Brake Locking Bar

TS205 —UN—23AUG88

A—Brake Pedals

Brake Pedals

Continued on next page

2­2­8

MD04263,0000014 ­19­19JUL10­1/3

091710

PN=41

Operation—Operating the Machine

3. Move engine speed control knob (A) (if equipped) to 1/3 idle and start engine. See Starting the Engine.

(Section 2­2.)

T106242 —UN—09JAN97

NOTE: Park brake indicator will light, alarm will sound, and STOP indicator will come on if transmission control lever (TCL) is engaged while park brake is set. Turn park brake off before engaging TCL. If park brake is disengaged when engine stops, it will automatically engage. If machine is started with switch in off position, turn switch on, then off, before driving machine.

(S.N. —882699) Shown

4. Set park brake switch (B) to disengaged position.

5. After engine is warm, turn speed control knob (if equipped) to slow idle position.

Manual Shift Transmission

• Push clutch disconnect button (D) to remove engine

T106243 —UN—09JAN97

power from drive train and engage gear shift lever (E) to appropriate gear for travel.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on TCL and gearshift lever to keep machine from moving. Always engage park brake to hold machine.

• Use TCL (C) to change direction of travel. TCL can be operated without using the clutch disconnect button.

reverse.

• Move TCL to N when machine is not moving. TCL will drop to a detented position when in Neutral.

Vary travel speed when driving using speed control pedal.

When removing foot from pedal, engine speed will return to setting of speed control knob.

A—Engine Speed Control Knob—If Equipped B—Park Brake Switch C—Transmission Control Lever (TCL)

T106244 —UN—09JAN97

• Reduce speed when changing direction of travel.

• Move TCL to F to travel forward and to R to travel in

D—Clutch Disconnect Button E—Gear Shift Lever F— Speed Control Pedal

Continued on next page

2­2­9

MD04263,0000014 ­19­19JUL10­2/3

091710

PN=42

Operation—Operating the Machine Power Shift Transmission

• TCL also selects forward gear ranges 1, 2, 3, and 4 and T196287A —UN—17NOV03

reverse ranges 1 and 2. The third and fourth position in reverse provides the same speed range as the second position.

• Rotate handle on TCL (A) to select gear position.

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

Vary travel speed when driving using speed control pedal.

When removing foot from pedal, engine speed will return to setting of speed control knob.

A—TCL

B—Gear Range Pointer MD04263,0000014 ­19­19JUL10­3/3

Operating Loader

T122072C —UN—01JUL99

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

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

Push lever in following directions for corresponding loader movements: NOTE: Moving lever completely forward (A) will place loader in float position. Lever will stay in float position until it is manually moved.

(S.N. —882699) Shown

• A—Lever Forward: Lower Boom • B—Lever Rearward: Raise Boom NOTE: Moving lever completely to the left (roll back) will hold it in position until bucket is level. Once bucket is level, lever will return to neutral.

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

• E—Lever Rearward: Third Function (Open) • F—Lever Forward: Third Function (Closed) A—Lower Boom B—Raise Boom C—Roll Back Bucket

D—Dump Bucket E—Third Function Control (Open)—If Equipped F— Third Function Control (Closed)—If Equipped

T105012 —UN—08NOV96

• C—Lever Left: Roll Back Bucket • D—Lever Right: Dump Bucket

TX,35,BG451 ­19­29OCT03­1/1

2­2­10

091710

PN=43

Operation—Operating the Machine

Operating Three­Point Hitch

Use control levers to raise, lower and adjust the pitch and tilt of rear mounted equipment.

A—Lift Cylinder—Raise Rockshaft B—Lift Cylinder—Lower Rockshaft and Float Position C—Pitch Cylinder—Raise Cutting Edge D—Pitch Cylinder—Lower Cutting Edge E—Tilt Cylinder—Lower Right Side of Box Scraper

F— Tilt Cylinder—Raise Right Side of Box Scraper G—Auxiliary Mounted Equipment H—Float Position Lever J— Auxiliary Mounted Equipment

Continued on next page

2­2­11

TX1019083A —UN—20MAR07

NOTE: Some machines may be equipped with two auxiliary mounted equipment levers (G).

VD76477,000145A ­19­20JUL10­1/2

091710

PN=44

T122105B —UN—02JUL99

Operation—Operating the Machine

TX1019151A —UN—15FEB07

(S.N. 880054—888000) Shown

(S.N. 888001—)

Move lever (H) all the way forward into detent for “float” position. In float position, three­point hitch equipment can move freely up and down to follow ground contour.

VD76477,000145A ­19­20JUL10­2/2

2­2­12

091710

PN=45

Operation—Operating the Machine

Operating PTO—If Equipped Use PTO control knob (A) to engage or disengage PTO.

TX1019056A —UN—14FEB07

To engage PTO, lift knob and turn clockwise.

To disengage PTO, push knob down.

A—PTO Control Knob

Operating PTO—If Equipped VD76477,000141C ­19­14FEB07­1/1

Operating Differential Lock

TX1018387A —UN—01FEB07

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

To prevent injury from unexpected movement, DO NOT engage lock with machine stopped and only one wheel spinning.

Press down on foot switch (A) to lock differential. When differential is locked, both rear wheels turn at the same speed.

Unequal traction will keep differential locked. When traction evens out, differential lock disengages automatically if switch is released. If traction is constant, hold switch down to keep lock engaged.

Differential Lock Switch A—Differential Lock Switch

VD76477,00013ED ­19­31JAN07­1/1

Operating Mechanical Front Wheel Drive (MFWD)—If Equipped

T106319 —UN—11JAN97

IMPORTANT: Prevent possible gear damage.

MFWD can be engaged and disengaged while driving, except in cases of unequal traction.

Machine must be stopped before engaging MFWD during unequal traction.

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

To achieve best MFWD performance, be sure front tires are inflated to proper air pressure.

See Tire Pressures. (Section 3­3.)

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

1— MFWD Switch

2— MFWD Indicator

Push top of switch (1) to engage MFWD. Indicator light (2) will remain on while MFWD is engaged.

TX,35,BG459 ­19­01MAR08­1/1

2­2­13

091710

PN=46

Operation—Operating the Machine

Lifting

TX1014618A —UN—03NOV06

CAUTION: Prevent possible injury from unexpected machine movement. Never move the load suddenly. Never move load over person’s head. Do not allow any persons near the load. Keep all persons away from raised load until blocks are supporting it or load is sitting on the ground.

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

1. For maximum lifting capability, attach chain/sling to buckets at positions shown.

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

3. Before lifting, perform following test of load stability: a. Park machine close to load. b. Attach load to chain/sling.

d. While keeping load close to the ground, extend it away from machine.

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

c. Raise load 50 mm (2 in.) above ground.

VD76477,00013E4 ­19­29JAN07­1/1

2­2­14

091710

PN=47

Operation—Operating the Machine

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

2. Lower front loader to ground.

T106233 —UN—09JAN97

3. Manual Shift Transmission: Move transmission control lever (TCL) (B) and gearshift lever (A) to N. Power Shift Transmission: Move TCL (B) to N. 4. Engage park brake with switch (C).

IMPORTANT: To avoid damage to engine, operate engine slow idle with no load for 2 minutes before shutting down.

Manual Transmission Shown

5. Operate engine at slow idle with no load and idle for 2 minutes.

T106234 —UN—09JAN97

NOTE: STOP indicator and park brake indicator will stay on until engine has completely stopped.

6. Turn key to OFF position and remove from switch.

7. Release hydraulic pressure by moving control lever until equipment does not move.

C—Park Brake Switch D—Engine Speed Control Knob—If Equipped

T106235 —UN—09JAN97

A—Gear Shift Lever B—Transmission Control Lever (TCL)

(S.N. —882699) Shown TX,30,BG450 ­19­02MAR07­1/1

2­2­15

091710

PN=48

Operation—Operating the Machine

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

TX1070084 —UN—26JAN10

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

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

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

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

Machine Tie Down Locations

6. Lower loader bucket onto blocks or trailer bed.

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

8. Stop engine.

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

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

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

9. Fasten chains or cables from trailer to frame tie­downs.

Do not route chains or cables over or against hydraulic lines or hoses.

HG31779,000007C ­19­26JAN10­1/1

2­2­16

091710

PN=49

Operation—Operating the Machine

Towing

T106985 —UN—31JAN97

IMPORTANT: Engine cannot be started by towing.

Damage to transmission may result. DO NOT tow machine faster than 10 km/h (6.21 mph) or any longer than 1 hour.

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

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

Access Plate

2. Block tires.

T105056 —UN—04FEB97

CAUTION: Prevent possible injury or death from unexpected machine movement. Only release the park brake through the access hole in floor of operator’s station IMPORTANT: To avoid damage to park brake assembly from heat build­up, brake must be manually disengaged.

NOTE: When turning cap screws, turn one screw 1/2 turn, then the other, and continue to alternate between cap screws.

T102655 —UN—10SEP96

3. Remove access plate on floor to access park brake.

4. Move transmission control lever (TCL) and gear shift levers to neutral.

5. Release park brake for tow by turning cap screws (A) completely in. Loosen hex nuts (B) to adjust park brake screws (A).

6. Remove blocks from tires.

Access Plate Removed

7. When towing is completed, block tires and enable park brake to hold machine by turning both cap screws out to specification (C) as illustrated.

Specification Brake Cap Screws­to­ Housing—Distance.................................................................. 27 + 1 mm 1.06 + 0.04 in.

A—Cap Screws B—Hex Nuts

C—Cap Screw Specification

8. Tighten hex nuts (B) to lock cap screws in position.

TX,40,BG474 ­19­20FEB07­1/1

2­2­17

091710

PN=50

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

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

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

Sulfur Content for Interim Tier 4 and EU Stage IIIB Engines

• Diesel fuel quality and fuel sulfur content must comply

with all existing emissions regulations for the area in which the engine operates.

• Use ONLY ultra low sulfur diesel (ULSD) fuel with a maximum of 0.0015% (15 mg/kg) sulfur content.

Sulfur Content for Other Engines

• Diesel fuel quality and fuel sulfur content must comply

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

with all existing emissions regulations for the area in which the engine operates.

• Use of diesel fuel with sulfur content less than 0.10% (1000 mg/kg) is STRONGLY recommended.

• Use of diesel fuel with sulfur content 0.10% (1000 mg/kg) to 0.50% (5000 mg/kg) may result in REDUCED oil and filter change intervals. Refer to table in Diesel Engine Oil and Filter Service Intervals.

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

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

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

Required Fuel Properties In all cases, the fuel shall meet the following properties: Cetane number of 43 minimum. Cetane number greater than 47 is preferred, especially for temperatures below –20°C (–4°F) or elevations above 1500 m (5000 ft).

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

DX,FUEL1 ­19­03AUG09­1/1

Lubricity of Diesel Fuel Most diesel fuels manufactured in the United States, Canada, and the European Union have adequate lubricity to ensure proper operation and durability of fuel injection system components. However, diesel fuels manufactured in some areas of the world may lack the necessary lubricity.

IMPORTANT: Make sure the diesel fuel used in your machine demonstrates good lubricity characteristics.

If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.

Lubricity of Biodiesel Fuel Significant improvement in lubricity can occur with biodiesel blends up to B20. The gain in lubricity above a 20% blend is limited.

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

DX,FUEL5 ­19­05OCT07­1/1

3­1­1

091710

PN=51

Maintenance—Machine

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

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

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

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

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

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

Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering.

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

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

Monitor water content of the fuel regularly.

DX,FUEL4 ­19­19DEC03­1/1

3­1­2

091710

PN=52

Maintenance—Machine

Biodiesel Fuel Biodiesel is a fuel comprised of mono­alkyl esters of long chain fatty acids derived from vegetable oils or animal fats. Biodiesel blends are biodiesel mixed with petroleum diesel fuel on a volume basis.

Biodiesel users in the U.S. are strongly encouraged to purchase biodiesel blends from a BQ­9000 Certified Marketer and sourced from a BQ­9000 Accredited Producer (as certified by the National Biodiesel Board).

Certified Marketers and Accredited Producers can be found at the following website: http://www.bq­9000.org.

While 5% blends are preferred (B5), biodiesel concentrations up to a 20% blend (B20) in petroleum diesel fuel can be used in all John Deere engines.

Biodiesel blends up to B20 can be used ONLY if the biodiesel (100% biodiesel or B100) meets ASTM D6751 (US), EN 14214 (EU), or equivalent specification. Expect a 2% reduction in power and a 3% reduction in fuel economy when using B20.

John Deere approved fuel conditioners containing detergent/dispersant additives are recommended when using lower biodiesel blends, but are required when using blends of B20 or greater.

John Deere engines can also operate on biodiesel blends above B20 (up to 100% biodiesel) ONLY if the biodiesel meets the EN 14214 specification (primarily available in Europe). Engines operating on biodiesel blends above B20 may not fully comply with all applicable emissions regulations. Expect up to a 12% reduction in power and an 18% reduction in fuel economy when using 100% biodiesel. John Deere approved fuel conditioners containing detergent/dispersant additives are required.

The petroleum diesel portion of biodiesel blends must meet the requirements of ASTM D975 (US) or EN 590 (EU) commercial standards.

Biodiesel blends up to B20 must be used within 90 days of the date of biodiesel manufacture. Biodiesel blends from B21 to B100 must be used within 45 days of the date of biodiesel manufacture.

Request a certificate of analysis from your fuel distributor to ensure that the fuel is compliant with the above specifications.

Consult your John Deere dealer for approved biodiesel fuel conditioners to improve storage and performance with biodiesel fuels.

When using biodiesel fuel, the engine oil level must be checked daily. If oil becomes diluted with fuel, shorten oil change intervals. Refer to Diesel Engine Oil and Filter Service Intervals for more details regarding biodiesel and engine oil change intervals.

The following must be considered when using biodiesel blends up to B20:

• Cold weather flow degradation • Stability and storage issues (moisture absorption, oxidation, microbial growth)

• Possible filter restriction and plugging (usually a

problem when first switching to biodiesel on used engines.)

• Possible fuel leakage through seals and hoses • Possible reduction of service life of engine components

The following must also be considered when using biodiesel blends above B20.

• Possible coking and/or blocked injector nozzles,

resulting in power loss and engine misfire if John Deere approved fuel conditioners containing detergent/dispersant additives are not used • Possible crankcase oil dilution, requiring more frequent oil changes • Possible corrosion of fuel injection equipment • Possible lacquering and/or seizure of internal components • Possible formation of sludge and sediments • Possible thermal oxidation of fuel at elevated temperatures • Possible elastomer seal and gasket material degradation ( primarily an issue with older engines) • Possible compatibility issues with other materials (including copper, lead, zinc, tin, brass, and bronze) used in fuel systems and fuel handling equipment • Possible reduction in water separator efficiency • Potential high acid levels within fuel system • Possible damage to paint if exposed to biodiesel IMPORTANT: Raw pressed vegetable oils are NOT acceptable for use as fuel in any concentration in John Deere engines. Their use could cause engine failure.

DX,FUEL7 ­19­04OCT07­1/1

Testing Diesel Fuel DIESELSCAN™ is a John Deere fuel analysis program that can be used to monitor the quality of your fuel. The DIESELSCAN analysis verifies fuel type, cleanliness,

water content, suitability for cold weather operation, and whether the fuel meets specifications.

Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company DX,FUEL6 ­19­14NOV05­1/1

3­1­3

091710

PN=53

Maintenance—Machine

Minimizing the Effect of Cold Weather on Diesel Engines John Deere diesel engines are designed to operate effectively in cold weather.

However, for effective starting and cold­weather operation, a little extra care is necessary. The following information outlines steps that can minimize the effect that cold weather may have on starting and operation of your engine. See your John Deere dealer for additional information and local availability of cold­weather aids.

Use Winter Grade Fuel When temperatures fall below 0 °C (32 °F), winter grade fuel (No. 1­D in North America) is best suited for cold­weather operation. Winter grade fuel has a lower cloud point and a lower pour point.

Cloud point is the temperature at which wax will begin to form in the fuel and this wax causes fuel filters to plug.

Pour point is the lowest temperature at which movement of the fuel is observed.

NOTE: On an average, winter grade diesel fuel has a lower BTU (heat content) rating. Using winter grade fuel may reduce power and fuel efficiency, but should not cause any other engine performance effects. Check the grade of fuel being used before troubleshooting for low­power complaints in cold­weather operation.

Air Intake Heater An air intake heater is an available option for some engines to aid cold weather starting.

Ether An ether port on the intake is available to aid cold weather starting.

CAUTION: Ether is highly flammable. Do not use ether when starting an engine equipped with glow plugs or an air intake heater.

chemistry, or equivalent fuel conditioner to treat non­winter grade fuel (No. 2­D in North America) during the cold­weather season. This generally extends operability to about 10 °C (18 °F) below the fuel cloud point. For operability at even lower temperatures, use winter grade fuel.

IMPORTANT: Treat fuel when outside temperature drops below 0 °C (32 °F). For best results, use with untreated fuel. Follow all recommended instructions on label.

BioDiesel When operating with biodiesel blends, wax formation can occur at warmer temperatures. Begin using John Deere PREMIUM BIODIESEL FUEL CONDITIONER (winter formula) at 5 °C (41 °F) to treat biodiesel fuels during the cold­weather season. Use B5 or lower blends at temperatures below 0 °C (32 °F). Use only winter grade petroleum diesel fuel at temperatures below ­10 °C (14 °F).

Winterfronts Use of fabric, cardboard, or solid winterfronts is not recommended with any John Deere engine. Their use can result in excessive engine coolant, oil, and charge air temperatures. This can lead to reduced engine life, loss of power and poor fuel economy. Winterfronts may also put abnormal stress on fan and fan drive components potentially causing premature failures.

If winterfronts are used, they should never totally close off the grill frontal area. Approximately 25% area in the center of the grill should remain open at all times. At no time should the air blockage device be applied directly to the radiator core.

Radiator Shutters

Coolant Heater An engine block heater (coolant heater) is an available option to aid cold weather starting.

Seasonal Viscosity Oil and Proper Coolant Concentration Use seasonal grade viscosity engine oil based on the expected air temperature range between oil changes and a proper concentration of low silicate antifreeze as recommended. (See DIESEL ENGINE OIL and ENGINE COOLANT requirements in this section.)

If equipped with a thermostatically controlled radiator shutter system, this system should be regulated in such a way that the shutters are completely open by the time the coolant reaches 93 °C (200 °F) to prevent excessive intake manifold temperatures. Manually controlled systems are not recommended.

If air­to­air aftercooling is used, the shutters must be completely open by the time the intake manifold air temperature reaches the maximum allowable temperature out of the charge air cooler.

For more information, see your John Deere dealer.

Diesel Fuel Flow Additive Use John Deere PREMIUM DIESEL FUEL CONDITIONER (winter formula), which contains anti­gel DX,FUEL10 ­19­03AUG09­1/1

3­1­4

091710

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Maintenance—Machine

Low Sulfur Diesel Fuel Conditioner When possible, use existing fuel formulations for engines used off­highway. 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, anti­oxidant, 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 stabilizer long­term fuel storage. They do not contain the lubrication additives needed by rotary fuel injection pumps.

TX,45,BG348 ­19­01OCT97­1/1

Diesel Fuel Storage Proper fuel storage is critically important. Use clean storage and transfer tanks. Periodically drain water and sediment from bottom of tank. Store fuel in a convenient place away from buildings.

IMPORTANT: DO NOT store diesel fuel in galvanized containers. Diesel fuel stored in galvanized containers reacts with zinc coating on container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters, damage injection nozzles and injection pump.

DO NOT use brass­coated containers for fuel storage. Brass is an alloy of copper and zinc.

Store diesel fuel in plastic, aluminum, and steel containers specially coated for diesel fuel storage.

Avoid storing fuel over long periods of time. If fuel is stored for more than a month prior to use, or there is a slow turnover in fuel tank or supply tank, add a fuel conditioner such as John Deere PREMIUM DIESEL FUEL CONDITIONER or equivalent to stabilize the fuel and prevent water condensation. John Deere PREMIUM DIESEL FUEL CONDITIONER is available in winter and summer formulas. Fuel conditioner also reduces fuel gelling and controls wax separation during cold weather.

Consult your John Deere engine distributor or servicing dealer for recommendations and local availability. Always follow manufacturer’s directions on label.

TX,45,BG288 ­19­08JAN97­1/1

Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

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

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

Avoid mixing different brands or types of oils. Oil manufacturers blend base stock and additives to create their oils and to meet certain specifications and performance requirements. Mixing different oils can interfere with proper functioning of these formulations and degrade lubricant performance.

Consult your authorized John Deere dealer to obtain specific information and recommendations.

Re­refined base stock products may be used if the finished lubricant meets the performance requirements.

DX,ALTER ­19­11NOV09­1/1

3­1­5

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PN=55

Maintenance—Machine

Diesel Engine Break­In™ Oil New engines are filled at the factory with either John Deere Break­In™ or Break­In™ Plus Engine Oil. During the break­in period, add John Deere Break­In™ or Break­In™ Plus Engine Oil, respectively, as needed to maintain the specified oil level.

Operate the engine under various conditions, particularly heavy loads with minimal idling, to help seat engine components properly.

Change the oil and filter at 250 hours maximum for Break­In™ Oil or 500 hours maximum for Break­In™ Plus Oil during the initial operation of a new or rebuilt engine.

IMPORTANT: Do not use Plus­50™ II, Plus­50™ or engine oils meeting any of the following for the initial break­in of a new or rebuilt engine: API CJ­4

ACEA E9

API CI­4 PLUS

ACEA E7

API CI­4

ACEA E6

API CH­4

ACEA E5

API CG­4

ACEA E4

API CF­4

ACEA E3

API CF­2 API CF

After engine overhaul, fill the engine with either John Deere Break­In™ or Break­In™ Plus Engine Oil. If John Deere Break­In™ or Break­In™ Plus Engine Oil is not available, use a 10W­30 diesel engine oil meeting one of the following during the first 250 hours of operation:

• API Service Classification CE • API Service Classification CD • API Service Classification CC • ACEA Oil Sequence E2 • ACEA Oil Sequence E1

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

John Deere Break­In™ Plus Engine Oil can be used for all John Deere diesel engines at all emission certification levels.

After the break­in period, use John Deere Plus­50™ II, John Deere Plus­50™, or other diesel engine oil as recommended in this manual.

Break­In is a trademark of Deere & Company.

Plus­50 is a trademark of Deere & Company.

VD76477,0001322 ­19­16JUL10­1/1

3­1­6

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John Deere Plus­50™ II oil is preferred.

30 o C

86 o F

20 o C

68 o F

10 o C

50 o F

0o C

32 o F

-10 o C

14 o F

-20 o C

-4 o F

-30 o C

-22 o F

-40 o C

-40 o F

John Deere Plus­50™ is also recommended.

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

• John Deere Torq­Gard Supreme™ • API Service Category CJ­4 • API Service Category CI­4 PLUS • API Service Category CI­4 • ACEA Oil Sequence E9 • ACEA Oil Sequence E7 • ACEA Oil Sequence E6 • ACEA Oil Sequence E5 • ACEA Oil Sequence E4 Multi­viscosity diesel engine oils are preferred.

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

TS1691 —UN—18JUL07

104o F

SAE 10W-40

40 o C

SAE 10W-30

122o F

SAE 15W-40

50 o C

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

SAE 5W-30

Diesel Engine Oil

SAE 0W-40

Maintenance—Machine

Oil Viscosities for Air Temperature Ranges

DO NOT use diesel fuel with sulfur content greater than 1.0% (10 000 mg/kg).

Plus­50 is a trademark of Deere & Company Torq­Gard Supreme is a trademark of Deere & Company DX,ENOIL11 ­19­03AUG09­1/1

3­1­7

091710

PN=57

Maintenance—Machine

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

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

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

• John Deere Plus­50™ II and John Deere Plus­50 • “Other Oils” include John Deere Torq­Gard Supreme™,

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

Use of lower specification oils in Tier 3 engines may result in premature engine failure.

• Use of diesel fuel with sulfur content less than 0.10%

(1000 mg/kg) is strongly recommended.

• Use of diesel fuel with sulfur content 0.10% (1000 mg/kg) to 0.50% (5000 mg/kg) may result in REDUCED oil and filter change intervals as shown in the table.

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

• DO NOT use diesel fuel with sulfur content greater than 1.00% (10 000 mg/kg).

Oil types in the table include:

API CJ­4, API CI­4 PLUS, API CI­4, ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils.

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

• Engine equipped with an extended drain interval oil pan

• Use of diesel fuel with sulfur content less than 0.50% (5000 mg/kg)

• Use of John Deere Plus­50™ II or John Deere Plus­50 oil

• Use of an approved John Deere oil filter

U.S. Tier 3 and EU Stage III A ­ PowerTech Plus™

U.S. Tier 3 and EU Stage III A ­ PowerTech™

Oil Pan Size (L/kW) Oil pan capacity

Greater than or equal to 0.10

Fuel Sulfur

Greater than or equal to 0.12

Greater than or equal to 0.14

Oil Pan Size (L/kW) Greater than or equal to 0.22

Greater than or equal to 0.10

Less than 0.10% (1000 mg/kg)

Greater than or equal to 0.12

Greater than or equal to 0.14

Less than 0.10% (1000 mg/kg)

Plus­50

375 hours

500 hours

500 hours

500 hours

375 hours

500 hours

500 hours

Other Oils

250 hours

250 hours

250 hours

250 hours

250 hours

250 hours

250 hours

Fuel Sulfur

0.10 ­ 0.20% (1000 ­ 2000 mg/kg)

0.10 ­ 0.20% (1000 ­ 2000 mg/kg)

Plus­50

300 hours

300 hours

500 hours

500 hours

300 hours

400 hours

500 hours

Other Oils

200 hours

200 hours

250 hours

250 hours

200 hours

200 hours

250 hours

Fuel Sulfur

0.20 ­ 0.50% (2000 ­ 5000 mg/kg)

0.20 ­ 0.50% (2000 ­ 5000 mg/kg)

Plus­50

250 hours

250 hours

300 hours

500 hours

275 hours

350 hours

500 hours

Other Oils

150 hours

150 hours

200 hours

250 hours

150 hours

175 hours

250 hours

Fuel Sulfur

0.50 ­ 1.00% (5000 ­ 10 000 mg/kg)

Plus­50

Contact John Deere Dealer (dealer refers to DTAC solutions)

187 hours

0.50 ­ 1.00% (5000 ­ 10 000 mg/kg) 250 hours

250 hours

Other Oils

Contact John Deere Dealer (dealer refers to DTAC solutions)

125 hours

125 hours

125 hours

The service interval of “Other Oils” may be extended only if oil analysis is performed to determine the actual service life, to a maximum not to exceed that of Plus­50.

Plus­50 is a trademark of Deere & Company Torq­Gard Supreme is a trademark of Deere & Company PowerTech Plus is a trademark of Deere & Company PowerTech is a trademark of Deere & Company DX,ENOIL13 ­19­03AUG09­1/1

3­1­8

091710

PN=58

Maintenance—Machine

TS1681 —UN—09OCT06

Engine Oil (S.N. —881401)

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

John Deere PLUS­50™ II oil is preferred Oils meeting one of the following specifications are also recommended:

• ACEA Oil Sequence E7 • ACEA Oil Sequence E6 • ACEA Oil Sequence E5 • ACEA Oil Sequence E4

• API Service Category CI­4 PLUS • API Service Category CI­4 • API Service Category CH­4 • API Service Category CG­4 • API Service Category CF­4 • ACEA Oil Sequence E3 • ACEA Oil Sequence E2 If oils meeting API CG­4, API CF­4, or ACEA E2 are used, reduce the service interval by 50%.

Multi­viscosity diesel engine oils are preferred.

Extended service intervals may apply when John Deere PLUS­50 II, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 engine oils are used. Consult your John Deere dealer for more information.

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

Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates. If diesel fuel with sulfur content greater than 0.50% (5000 ppm) is used, reduce the service interval by 50%. DO NOT use diesel fuel with sulfur content greater than 1.00% (10 000 ppm).

• John Deere TORQ­GARD SUPREME™ PLUS­50 is a trademark of Deere & Company TORQ­GARD SUPREME is a trademark of Deere & Company AM40430,0000381 ­19­16AUG10­1/1

3­1­9

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PN=59

Maintenance—Machine

TS1681 —UN—09OCT06

Engine and Hydraulic Oil (S.N. 881402—)

Oil Viscosities for Air Temperature Ranges

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

John Deere PLUS­50™ II oil is preferred.

Oils meeting one of the following specifications are also recommended:

• API Service Category CI­4 PLUS • API Service Category CI­4 • API Service Category CH­4 • API Service Category CG­4 • API Service Category CF­4 • ACEA Oil Sequence E3 • ACEA Oil Sequence E2

• ACEA Oil Sequence E7 • ACEA Oil Sequence E6 • ACEA Oil Sequence E5 • ACEA Oil Sequence E4

If oils meeting API CG­4, API CF­4, or ACEA E2 are used, reduce the service interval by 50%.

Extended service intervals may apply when John Deere PLUS­50 II, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 engine oils are used. Consult your John Deere dealer for more information.

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

Multi­viscosity diesel engine oils are preferred.

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

• John Deere TORQ­GARD SUPREME™ • API Service Category CJ­4

If diesel fuel with sulfur content greater than 0.50% (5000 ppm) is used, reduce the service interval by 50%.

DO NOT use diesel fuel with sulfur content greater than 1.00% (10 000 ppm).

PLUS­50 is a trademark of Deere & Company TORQ­GARD SUPREME is a trademark of Deere & Company VD76477,000141B ­19­16AUG10­1/1

3­1­10

091710

PN=60

Maintenance—Machine

Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil (S.N. —881401) Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oils are preferred:

• John Deere HY­GARD® • John Deere Low Viscosity HY­GARD® Other oils may be used if they meet one of the following:

TS1660 —UN—10OCT97

• John Deere Standard JDM J20C • John Deere Standard JDM J20D Use the following oil when a biodegradable fluid is required:

• John Deere BIO­HY­GARD™

HY­GARD is a trademark of Deere & Company BIO­HY­GARD is a trademark of Deere & Company AM40430,000037E ­19­03APR06­1/1

Transmission, Axles, and Mechanical Front Wheel Drive Oil (S.N. 881402—) Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oils are preferred:

• John Deere HY­GARD® • John Deere Low Viscosity HY­GARD® Other oils may be used if they meet one of the following:

• John Deere Standard JDM J20C • John Deere Standard JDM J20D TS1660 —UN—10OCT97

Use the following oil when a biodegradable fluid is required:

• John Deere BIO­HY­GARD™

HY­GARD is a trademark of Deere & Company BIO­HY­GARD is a trademark of Deere & Company AM40430,000037F ­19­03APR06­1/1

3­1­11

091710

PN=61

Maintenance—Machine

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

John Deere SD POLYUREA GREASE is preferred.

The following greases are also recommended

• John Deere HD LITHIUM COMPLEX GREASE • John Deere HD WATER RESISTANT GREASE • John Deere GREASE­GARD™ Other greases may be used if they meet the following: NLGI Performance Classification GC­LB TS1673 —UN—31OCT03

IMPORTANT: Some types of grease thickeners are not compatible with others. Consult your grease supplier before mixing different types of grease.

GREASE­GARD is a trademark of Deere & Company DX,GREA1 ­19­07NOV03­1/1

PTO Gear Case Oil—If Equipped

The following oils are recommended:

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

• API Service Classification GL­5 gear oil (SAE 90) • Arctic oils such as MIL­L­10324A may be used at temperatures below ­30°C (­11°F)

The following oils are preferred:

• John Deere GEAR LUBRICANT (SAE 90) CED,OUO1032,1445 ­19­09JUL10­1/1

3­1­12

091710

PN=62

Maintenance—Machine

Heavy Duty Diesel Engine Coolant The engine cooling system is filled to provide year­round protection against corrosion and cylinder liner pitting, and winter freeze protection to ­37°C (­34°F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

John Deere COOL­GARD™ II Premix Coolant is preferred.

John Deere COOL­GARD II Premix is available in a concentration of 50% ethylene glycol.

Additional Recommended Coolants The following engine coolants are also recommended:

unavailable in the geographical area where service is performed.

If these coolants are unavailable, use a coolant concentrate or prediluted coolant intended for use with heavy duty diesel engines and with a minimum of the following chemical and physical properties:

• Is formulated with a quality nitrite­free additive package.

• Provides cylinder liner cavitation protection according to

either the John Deere Cavitation Test Method or a fleet study run at or above 60% load capacity.

• Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion.

• John Deere COOL­GARD II Concentrate in a 40% to

The additive package must be part of one of the following coolant mixtures:

• John Deere COOL­GARD Premix (available in a

• ethylene glycol or propylene glycol base prediluted

60% mixture of concentrate with quality water.

concentration of 50% ethylene glycol).

• John Deere COOL­GARD Concentrate in a 40% to 60% mixture of concentrate with quality water.

• John Deere COOL­GARD PG Premix (available in a concentration of 55% propylene glycol).

John Deere COOL­GARD II Premix and COOL­GARD II Concentrate coolants do not require use of supplemental coolant additives.

John Deere COOL­GARD Premix, COOL­GARD Concentrate, and COOL­GARD PG Premix do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Use John Deere COOL­GARD PG Premix when a non­toxic coolant formulation is required.

(40% to 60%) heavy duty coolant

• ethylene glycol or propylene glycol base heavy duty coolant concentrate in a 40% to 60% mixture of concentrate with quality water

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

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

Do not mix ethylene glycol and propylene glycol base coolants.

Other Coolants

Do not use coolants that contain nitrites.

It is possible that John Deere COOL­GARD II, COOL­GARD, and COOL­GARD PG coolants are COOL­GARD is a trademark of Deere & Company DX,COOL3 ­19­03NOV08­1/1

3­1­13

091710

PN=63

Maintenance—Machine

Drain Intervals for Diesel Engine Coolant Drain and flush the cooling system and refill with fresh coolant at the indicated interval, which varies with the coolant used.

John Deere COOL­GARD™ II Premix and COOL­GARD II Concentrate are maintenance free coolants for up to 6 years or 6000 hours of operation, provided that the cooling system is topped off using only John Deere COOL­GARD II Premix. Test the coolant condition annually with Coolant Test Strips designed for use with John Deere COOL­GARD II coolants. If the test strip chart indicates that additive is required, add John Deere COOL­GARD II COOLANT EXTENDER as directed.

When John Deere COOL­GARD Premix, COOL­GARD Concentrate or John Deere COOL­GARD PG Premix coolants are used, the drain interval may be extended to 5 years or 5000 hours of operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive.

additives are not replenished by adding John Deere COOL­GARD II COOLANT EXTENDER, the drain interval is 4 years or 4000 hours of operation. This drain interval only applies to COOL­GARD II coolants that have been maintained within a 40% to 60% mixture of concentrate with quality water.

If John Deere COOL­GARD Premix, COOL­GARD Concentrate, or COOL­GARD PG Premix is used, but the coolant is not tested OR additives are not replenished by adding a supplemental coolant additive, the drain interval is 3 years or 3000 hours of operation. This drain interval only applies to COOL­GARD Premix, COOL­GARD Concentrate, and COOL­GARD PG Premix that have been maintained within a 40% to 60% mixture of concentrate with quality water.

If a coolant other than COOL­GARD II, COOL­GARD, or COOL­GARD PG is used, reduce the drain interval to 2 years or 2000 hours of operation.

If John Deere COOL­GARD II Premix or COOL­GARD II Concentrate is used, but the coolant is not tested OR COOL­GARD is a trademark of Deere & Company DX,COOL11 ­19­08JAN09­1/1

John Deere COOL­GARD™ II COOLANT EXTENDER Some coolant additives will gradually deplete during engine operation. For John Deere COOL­GARD™ II Premix and COOL­GARD II Concentrate, replenish coolant additives between drain intervals by adding John Deere COOL­GARD II COOLANT EXTENDER. John Deere COOL­GARD II COOLANT EXTENDER should not be added unless indicated by coolant testing.

John Deere COOL­GARD II COOLANT EXTENDER is a chemically matched additive system approved for use with John Deere COOL­GARD II coolants in all John Deere engines.

John Deere COOL­GARD II COOLANT EXTENDER is not designed for use with John Deere COOL­GARD coolants.

IMPORTANT: Do not add a supplemental coolant additive when the cooling system is drained and refilled with any of the following:

• John Deere COOL­GARD II • John Deere COOL­GARD • John Deere COOL­GARD PG The use of non­recommended supplemental coolant additives may result in additive drop­out, gelation of the coolant, or corrosion of cooling system components.

Add the recommended concentration of John Deere COOL­GARD II COOLANT EXTENDER. DO NOT add more than the recommended amount.

COOL­GARD is a trademark of Deere & Company DX,COOL16 ­19­03NOV08­1/1

3­1­14

091710

PN=64

Maintenance—Machine

Supplemental Coolant Additives Some coolant additives will gradually deplete during engine operation. For John Deere COOL­GARD™ Premix, COOL­GARD Concentrate, or John Deere COOL­GARD PG Premix, replenish coolant additives between drain intervals by adding a supplemental coolant additive as determined necessary by coolant testing.

John Deere LIQUID COOLANT CONDITIONER is recommended as a supplemental coolant additive for John Deere COOL­GARD Premix, COOL­GARD Concentrate, and COOL­GARD PG Premix.

John Deere LIQUID COOLANT CONDITIONER is not designed for use with COOL­GARD II Premix or COOL­GARD II Concentrate.

• John Deere COOL­GARD II • John Deere COOL­GARD • John Deere COOL­GARD PG If other coolants are used, consult the coolant supplier and follow the manufacturer’s recommendation for use of supplemental coolant additives.

The use of non­recommended supplemental coolant additives may result in additive drop­out and gelation of the coolant.

Add the manufacturer’s recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

IMPORTANT: Do not add a supplemental coolant additive when the cooling system is drained and refilled with any of the following: COOL­GARD is a trademark of Deere & Company DX,COOL4 ­19­03NOV08­1/1

Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants.

Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.

John Deere COOL­GARD™ II Premix is available in a concentration of 50% ethylene glycol. However, there are situations in warm temperature climates where a coolant with lower glycol concentration (approximately 20% ethylene glycol) has been approved. In these cases, the low glycol formulation has been modified to provide the same level of corrosion inhibitor as John Deere COOL­GARD II Premix (50/50).

IMPORTANT: Water may be used as coolant in emergency situations only.

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended glycol base engine coolant as soon as possible.

COOL­GARD is a trademark of Deere & Company DX,COOL6 ­19­03NOV08­1/1

3­1­15

091710

PN=65

Maintenance—Machine

Additional Information About Diesel Engine Coolants and John Deere COOL­GARD™ II COOLANT EXTENDER Engine coolants are a combination of three chemical components: ethylene glycol or propylene glycol antifreeze, inhibiting coolant additives, and quality water.

Coolant Specifications John Deere COOL­GARD™ II Premix is a fully formulated coolant that contains all three components in their correct concentrations. DO NOT add an initial charge of John Deere COOL­GARD II COOLANT EXTENDER to COOL­GARD II Premix. DO NOT add any other supplemental coolant additive or water to COOL­GARD II Premix.

John Deere COOL­GARD II Concentrate contains both ethylene glycol and inhibiting coolant additives. Mix this product with quality water, but DO NOT add an initial charge of John Deere COOL­GARD II COOLANT EXTENDER or any other supplemental coolant additive.

Avoid Automotive­type Coolants Never use automotive­type coolants (such as those meeting ASTM D3306). These coolants do not contain the correct additives to protect heavy­duty diesel engines. Do not treat an automotive engine coolant with supplemental coolant additives because the high concentration of additives can result in additive fallout.

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

All water used in the cooling system should meet the following minimum specifications for quality: Chlorides

<40 mg/L

Replenish Coolant Additives

Sulfates

<100 mg/L

Total dissolved solids

<340 mg/L

Some coolant additives will gradually deplete during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL­GARD II Premix or COOL­GARD II Concentrate is used. Follow the recommendations in this manual for the use of John Deere COOL­GARD II COOLANT EXTENDER.

Total hardness

<170 mg/L

pH

5.5 to 9.0

Why use John Deere COOL­GARD II COOLANT EXTENDER? Operating without proper coolant additives will result in increased corrosion, cylinder liner erosion and pitting, and other damage to the engine and cooling system. A simple mixture of ethylene glycol or propylene glycol and water will not give adequate protection.

John Deere COOL­GARD II COOLANT EXTENDER is a chemically matched additive system designed to fortify the proprietary additives used in John Deere COOL­GARD II Premix and COOL­GARD II Concentrate and to provide optimum protection for up to 6 years or 6000 hours of operation.

Freeze Protection The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit.

Ethylene Glycol

Freeze Protection Limit

40%

­24°C (­12°F)

50%

­37°C (­34°F)

60%

­52°C (­62°F)

Propylene Glycol

Freeze Protection Limit

40%

­21°C (­6°F)

50%

­33°C (­27°F)

60%

­49°C (­56°F)

DO NOT use a coolant­water mixture greater than 60% ethylene glycol or 60% propylene glycol.

COOL­GARD is a trademark of Deere & Company DX,COOL17 ­19­03NOV08­1/1

3­1­16

091710

PN=66

Maintenance—Machine

Testing Diesel Engine Coolant Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting.

Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating.

Coolant Test Strips Coolant test strips are available from your John Deere dealer. These test strips provide a simple, effective method to check the freeze point and additive levels of your engine coolant.

When Using John Deere COOL­GARD II John Deere COOL­GARD™ II Premix and COOL­GARD II Concentrate are maintenance free coolants for up to 6 years or 6000 hours of operation, provided that the cooling system is topped off using only John Deere COOL­GARD II Premix coolant. Test the coolant condition annually with coolant test strips designed for use with John Deere

COOL­GARD II coolants. If the test strip chart indicates that additive is required, add John Deere COOL­GARD II COOLANT EXTENDER as directed.

Add only the recommended concentration of John Deere COOL­GARD II COOLANT EXTENDER. DO NOT add more than the recommended amount.

When Using John Deere COOL­GARD Compare the test strip results to the supplemental coolant additive (SCA) chart to determine the amount of inhibiting additives in your coolant and whether more John Deere LIQUID COOLANT CONDITIONER should be added.

Add only the recommended concentration of John Deere LIQUID COOLANT CONDITIONER. DO NOT add more than the recommended amount.

CoolScan and CoolScan PLUS For a more thorough evaluation of your coolant, perform a CoolScan™ or CoolScan PLUS™ analysis, where available. See your John Deere dealer for information.

COOL­GARD is a trademark of Deere & Company CoolScan is a trademark of Deere & Company CoolScan PLUS is a trademark of Deere & Company DX,COOL9 ­19­03NOV08­1/1

3­1­17

091710

PN=67

Maintenance—Periodic Maintenance Service Machine at Specified Intervals Lubricate and make service checks and adjustments at intervals shown on the periodic maintenance charts (A) and in the maintenance chapters.

T105057 —UN—12NOV96

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

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

(S.N. —882699) Location Shown

T196288A —UN—17NOV03

A—Periodic Maintenance Chart

(S.N. 882700—) Location Shown TX,50,BG478 ­19­29JAN07­1/1

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

T104970 —UN—08NOV96

A—Hour Meter

TX,50,BG479 ­19­16JAN97­1/1

3­2­1

091710

PN=68

Maintenance—Periodic Maintenance

Battery Disconnect—If Equipped For (S.N. —888000), the battery disconnect switch (A) is located on rear of right control console.

T196284A —UN—17NOV03

For (S.N. 888001—), the battery disconnect switch (A) is located under the hood on the right side of machine.

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

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

(S.N. —888000) Shown

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

The battery disconnect switch has 2 positions, OFF and ON. TX1020717A —UN—16MAR07

A—Battery Disconnect Switch

(S.N. 888001—) Shown OUO1030,0000720 ­19­19JUL10­1/1

Prepare Machine for Maintenance IMPORTANT: Improperly disposing of waste can threaten the environment and ecology.

Potentially harmful waste used with John Deere equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Do not pour waste onto the ground, down a drain, or into any water source.

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

the loader boom service lock, or lower the front loader boom fully to the ground, and move control levers to release hydraulic pressure before working near the front of the machine. See Loader Boom Service Lock. (Section 3­2.)

Raise the front loader boom and install the loader boom service lock before performing maintenance in the engine compartment. See Loader Boom Service Lock. (Section 3­2.)

CAUTION: Prevent serious injury or death from unexpected machine movement. Always install OUO1030,000071F ­19­02MAR07­1/1

3­2­2

091710

PN=69

Maintenance—Periodic Maintenance

Loader Boom Service Lock

TX1037607A —UN—06MAR08

Use front boom lock channel when front loader must be raised for service procedures. To lock front boom in up position: 1. Empty loader bucket and place in dump position.

2. Raise boom until lock channel (2) can fit over cylinder rod.

3. Stop engine and lower channel over cylinder rod.

4. Lower boom until it is stopped by lock channel.

5. Place pin (1) and cotter pin in mounting hole to retain channel in locked position.

Boom Locked

To return front boom to storage position:

TX1037608A —UN—06MAR08

1. Start engine and raise boom slightly to remove pressure from lock channel.

2. Remove pin and cotter pin from lock.

3. Lift lock channel (2) up so tab is positioned through hole in boom arm.

4. Retain in storage position with pin (1) and cotter pin.

1— Locking Pin

2— Channel Boom Locking Pin in Storage Position

TX,50,BG482 ­19­17MAR08­1/1

Opening and Closing Engine Hood (S.N. 882700— )

T196289A —UN—17NOV03

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

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

A—Hood Tilt Latch

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

OUO1030,000071E ­19­29OCT03­1/1

3­2­3

091710

PN=70

Maintenance—Periodic Maintenance

Fuel Tank

TS185 —UN—23AUG88

CAUTION: Handle fuel carefully. If the engine is hot or running, DO NOT fill fuel tank.

DO NOT smoke while you fill fuel tank or work on fuel system.

To avoid condensation, fill the fuel tank at the end of each day’s operation. Shut off engine before filling.

Specification Fuel Tank—Capacity.................................................... 98 L Approximate 26 gal Approximate

TX,45,BG476 ­19­29OCT03­1/1

Fluid Analysis Program Test Kits and 3­Way Coolant Test Kit

Engine, hydraulic, power train, and coolant samples should be taken from each system on a periodic basis, usually prior to a filter and/or fluid change interval. Certain systems require more frequent sampling. Consult your authorized John Deere dealer on a maintenance program for your specific application. Your authorized John Deere dealer has the sampling products and expertise to assist

TX1003513A —UN—20FEB06

Fluid Analysis Program Test Kits and the 3­Way Coolant Test Kit are John Deere fluid sampling products to help you monitor machine maintenance and system condition.

The objective of a fluid sampling program is to ensure machine availability when you need it and to reduce repair costs by identifying potential problems before they become critical.

you in lowering your overall operating costs through fluid sampling.

AM40430,00002FE ­19­25MAR10­1/1

3­2­4

091710

PN=71

Maintenance—Periodic Maintenance

Service Intervals (S.N. —888000) Model: 210LE

PIN/Serial Number:

Hour Meter Reading: 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.

FLUID SAMPLING Take fluid samples from each system as indicated on this form. The manufacturer of the fluid analysis kits will provide maintenance recommendations based upon the results of the fluid analysis and the operating information you supply. Regular fluid sampling extends the operational life of your machine.

As Required □ Check loader boom lock

□ Inspect belt

□ Drain water and sediment from fuel tank

□ Lubricate draft link wear plates

□ Inspect tires and check pressure

□ Clean air cleaner dust unloader valve

□ Check park break

□ Check coolant

□ Lubricate non­powered front axle wheel bearings—if equipped Every 10 Hours or Daily □ Check engine oil level

□ Lubricate 3 point hitch pivots

□ Check hydraulic reservoir oil level

□ Lubricate lift cylinder pivot points

□ Check coolant level

□ Lubricate MFWD drive shaft universal joints—if equipped

□ Lubricate loader pivots

□ Lubricate MFWD front axle universal joints—if equipped

□ Lubricate MFWD front axle pivot

□ Lubricate non­powered front axle steering pivot points—if equipped

□ Lubricate multipurpose (4­in­1) bucket—if equipped Initial Service ­ 100 Hours1 □ Change transmission and torque converter oil and replace filter (S.N —886534)

□ Change engine break­in oil and replace filter (—888000) 1

Perform initial service once after the first 100 hours of operation.

Every 250 Hours

□ Take engine oil sample

□ Check rear axle oil level

□ Check MFWD front axle housing oil level—if equipped

□ Check battery electrolyte level and terminals

□ Check MFWD planetary housing oil level—if equipped

□ Check transmission oil level

□ Drain and refill engine oil and replace filter (S.N. —882699) Every 500 Hours □ Check air intake hose

□ Replace fuel filter

□ Drain and refill engine oil and replace filter

□ Take hydraulic oil sample

□ Replace hydraulic oil filter and PTO filter—if equipped

□ Inspect and clean hydraulic reservoir fill screen and breather screen

□ Take front and rear gear case oil sample

□ Take transmission oil sample

□ Take diesel fuel sample

□ Take engine coolant sample Every 1000 Hours

□ Drain and refill MFWD front axle housing oil—if equipped

□ Drain and refill transmission and torque converter oil

□ Drain and refill MFWD planetary housing oil—if equipped

□ Replace engine air filter elements

□ Check coolant

□ Clean engine crankcase vent tube

□ Drain and refill rear axle oil

□ Check engine speed

□ Clean, pack, and adjust non­power front wheel bearings—if equipped

□ Change hydraulic oil, filter, and PTO filter—if equipped

Every 2000 Hours □ Adjust engine valve lash Continued on next page

3­2­5

ER79617,0000BEE ­19­17AUG10­1/2

091710

PN=72

Maintenance—Periodic Maintenance

Every 6000 Hours □ Drain, flush, and refill cooling system ER79617,0000BEE ­19­17AUG10­2/2

3­2­6

091710

PN=73

Maintenance—Periodic Maintenance

Required Parts (S.N. —888000) REQUIRED PARTS Ensure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated parts are also on hand, i.e., filter O­rings.

Description

Part Number

Initial Service Every 250 ­ 100 Hours1 Hours

Every 500 Hours

Every 1000 Hours

Every 2000 Hours

Every 6000 Hours

Engine Oil Filter Turbocharged (S.N. —882699)

RE504836

1

1

1

1

1

1

Engine Oil Filter Naturally Aspirated (S.N. —882699)

RE59754

1

1

1

1

1

1

Hydraulic Oil Filter (S.N. 882701—)

AT308274

1

1

1

1

Hydraulic Oil Filter (S.N. —882700)

AT184206

1

1

1

1

PTO Filter—If Equipped

AN203010

1

1

1

1

Fuel Filter Turbocharged

RE509031

1

1

1

1

Fuel Filter Naturally Aspirated

RE62418

1

1

1

1

Transmission Filter

AT179323

1

1

1

Air Filter (Primary) (S.N. —882699)

AT171853

1

1

1

Air Filter (Primary) (S.N.882700—888000)

KV16429

1

1

1

Air Filter (Secondary)

AT171854

1

1

1

Engine Rocker Arm Cover Gasket

R123542

1

1

Coolant Extender

TY26603

COOL­GARD™II Pre­Mix

TY26575

1

As Required 12.3 L (3.25 gal)

PLUS­50™ II Oil Engine

TY266742

12.3 L (3.25 gal)

12.3 L (3.25 gal) (S.N. —882699)

12.3 L (3.25 gal)

Hydraulic TY266742 System (S.N. 881402—888000)

12.3 L (3.25 gal)

12.3 L (3.25 gal)

12.3 L (3.25 gal)

54.5 L (14.4 gal)

54.5 L (14.4 gal)

54.5 L (14.4 gal)

15 L (4 gal)

15 L (4 gal)

15 L (4 gal)

HY­GARD™ Oil: Transmission

TY63542

Hydraulic System (S.N. —881401)

TY63542

54.5 L (14.4 gal)

54.5 L (14.4 gal)

54.5 L (14.4 gal)

MFWD (Axle and Planetary Housing)

TY63542

8.5 L (2.25 gal)

8.5 L (2.25 gal)

8.5 L (2.25 gal)

Rear Axle (S.N. —851673)

TY63542

13 L (3.43 gal)

13 L (3.43 gal)

13 L (3.43 gal)

Rear TY63542 Axle (S.N. 851674—888000)

16 L (4.23 gal)

16 L (4.23 gal)

16 L (4.23 gal)

1

1

1

1

2

2

2

2

15 L (4 gal)

Fluid Analysis Kits3: Diesel Engine Oil

AT317904

Transmission Oil and Gear Case/Axle

AT303189

1

Hydraulic Oil Tank

AT303189

1

1

1

1

Engine Coolant

AT183016

1

1

1

1

Diesel Fuel

AT180344

1

1

1

1

COOL­GARD™ Test Strips

TY26605

1

1

1

1

1

Continued on next page

3­2­7

ER79617,0000BF0 ­19­16AUG10­1/2

091710

PN=74

Maintenance—Periodic Maintenance 1

Perform initial service once after the first 100 hours of operation.

2

For recommended oil type and oil viscosities based on operating temperatures, see Maintenance­Machine.

(Section 3­1.)

3

Based on fluid analysis results, intervals may need to be adjusted for operating conditions. Consult your local authorized dealer.

COOL­GARD is a trademark of Deere & Company PLUS­50 is a trademark of Deere & Company HY­GARD is a trademark of Deere & Company ER79617,0000BF0 ­19­16AUG10­2/2

3­2­8

091710

PN=75

Maintenance—Periodic Maintenance

Service Intervals (S.N. 888001—) Model: 210LE

PIN/Serial Number:

Hour Meter Reading: 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.

FLUID SAMPLING Take fluid samples from each system as indicated on this form. The manufacturer of the fluid analysis kits will provide maintenance recommendations based upon the results of the fluid analysis and the operating information you supply. Regular fluid sampling extends the operational life of your machine.

As Required □ Clean/replace engine air cleaner elements

□ Inspect belt

□ Drain water and sediment from fuel tank

□ Lubricate draft link wear plates

□ Inspect tires and check pressure

□ Clean air cleaner dust unloader valve

□ Drain water and sediment from water separator

□ Check wheel fastener torque

□ Lubricate MFWD drive shaft spline

□ Check coolant Every 10 Hours or Daily

□ Check engine oil level

□ Lubricate 3 point hitch pivots

□ Check hydraulic reservoir oil level

□ Lubricate MFWD front axle pivot

□ Check coolant level

□ Lubricate (4­in­1) multipurpose bucket —if equipped

□ Lubricate loader pivots

□ Lubricate MFWD front axle universal joints Every 50 Hours

□ Check transmission oil level Initial Service ­ 250 Hours1 □ Change engine break­in oil and replace filter 1

Perform initial service once after the first 250 hours of operation.

Every 250 Hours

□ Check MFWD front axle housing oil level

□ Check rear axle oil level

□ Check MFWD planetary housing oil level

□ Check battery electrolyte level and terminals

□ Take engine oil sample Every 500 Hours □ Check air intake hose

□ Take diesel fuel sample

□ Drain and refill engine oil and replace filter

□ Take front and rear axle gear case oil samples

□ Replace fuel filter

□ Take transmission oil sample

□ Take hydraulic oil sample

□ Take engine coolant sample

□ Inspect and clean hydraulic reservoir fill screen and breather screen Every 1000 Hours □ Clean engine crankcase vent tube

□ Replace engine air filter elements

□ Check coolant

□ Check engine speed

□ Change transmission and torque converter oil and filter

□ Clean, pack and adjust front non­powered axle wheel bearings—if equipped Every 2000 Hours

□ Adjust engine valve lash

□ Drain and refill MFWD front axle housing oil

□ Drain and refill MFWD front wheel planetary housing oil—if equipped

□ Change hydraulic oil, filter, and PTO filter—if equipped

□ Drain and refill MFWD rear axle and planetary oil

Continued on next page

3­2­9

ER79617,0000BEF ­19­26JUL10­1/2

091710

PN=76

Maintenance—Periodic Maintenance Every 6000 Hours □ Drain, flush, and refill cooling system ER79617,0000BEF ­19­26JUL10­2/2

3­2­10

091710

PN=77

Maintenance—Periodic Maintenance

Required Parts (S.N. 888001—) REQUIRED PARTS Ensure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated parts are also on hand, i.e., filter O­rings.

Initial Service Every 250 ­ 250 Hours1 Hours

Every 500 Hours

Every 1000 Hours

Every 2000 Hours

Every 6000 Hours

Engine Oil Filter Turbocharged RE504836

1

1

1

1

1

Engine Oil Filter Naturally Aspirated

RE59754

1

1

1

1

1

Hydraulic Oil Filter (S.N. 882701—)

AT308274

1

1

1

1

Hydraulic Oil Filter (S.N. —882700)

AT184206

1

1

1

1

Description

Part Number

PTO Filter—If Equipped

AN203010

1

1

1

Fuel Filter Turbocharged

RE509031

1

1

1

1

Fuel Filter Naturally Aspirated

RE62418

1

1

1

1

Transmission Filter

AT179323

1

1

1

Primary Air Filter

KV16429

1

1

1

Secondary Air Filter

AT171854

1

1

1

Engine Rocker Arm Cover Gasket

R123542

1

1

Coolant Extender

TY26603

COOL­GARD™II Pre­Mix

TY26575 12.3 L (3.25 gal)

12.3 L (3.25 gal)

54.5 L (14.4 gal)

54.5 L (14.4 gal)

15.1 L (4 gal)

15.1 L (4 gal)

As Required

PLUS­50™ II Oil Engine

TY266742

Hydraulic System

TY266742

12.3 L (3.25 gal)

12.3 L (3.25 gal)

12.3 L (3.25 gal)

HY­GARD™ Oil: Transmission

TY63542

MFWD (Axle and Planetary Housing)

TY63542

8.5 L (2.25 gal)

8.5 L (2.25 gal)

Rear Axle and Planetary (S.N. 888001—)

TY63542

18 L (4.8 gal)

18 L (4.8 gal)

15.1 L (4 gal)

Fluid Analysis Kits3: Diesel Engine Oil

AT317904

Transmission Oil and Gear Case/Axle

AT303189

Hydraulic Oil Tank

AT303189

Engine Coolant

AT183016

Diesel Fuel

AT180344

COOL­GARD™ Test Strips

TY26605

1

1

1 Perform initial service once after the first 250 hours of operation.

2

For recommended oil type and oil viscosities based on operating temperatures, see Maintenance­Machine.

(Section 3­1.)

1

1

1

1

2

2

2

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

Based on fluid analysis results, intervals may need to be adjusted for operating conditions. Consult your local John Deere dealer.

COOL­GARD is a trademark of Deere & Company PLUS­50 is a trademark of Deere & Company HY­GARD is a trademark of Deere & Company ER79617,0000BF1 ­19­16AUG10­1/1

3­2­11

091710

PN=78

Maintenance—As Required Inspect Loader Boom Service Lock (S.N —888000) 1. Inspect loader boom lock channel (2), lock pin (1), and cotter pin to ensure that all are in good condition.

2. Verify that warning decal is in place.

3. See your authorized dealer for replacement parts.

2— Boom Lock Channel

T136593B —UN—19DEC00

1— Lock Pin

TX,55,BG485 ­19­08JUL10­1/1

3­3­1

091710

PN=79

Maintenance—As Required

Drain Fuel Tank Water and Sediment 1. Loosen plug (A) on bottom of fuel tank until fuel flows for several seconds, to remove water and sediment.

T105152 —UN—12NOV96

2. Tighten plug.

A—Fuel Tank Plug

TX1018396A —UN—01FEB07

(S.N. —830778) Shown

(S.N. 888001­­) Shown VD76477,00013EE ­19­08JUL10­1/1

3­3­2

091710

PN=80

Maintenance—As Required

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

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

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

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

TS211 —UN—23AUG88

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

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

When inflating tires be sure to lock air chuck to valve stem and stand to front or rear of tire.

TX,55,BD2138 ­19­07OCT96­1/1

Tire Inflation Pressures

changed to suit working condition according to tire manufacturer’s recommendations.

NOTE: Shipping pressure may not be the same as operating pressure. Tire pressures may be Item

Measurement

Specification

11L­15 8PR F3 (S.N. —888000) only

Pressure

306 kPa 3.0 bar 44 psi

12L­16.5 8PR NHS

Pressure

414 kPa 4.1 bar 50 psi

Pressure

193 kPa 1.9 bar 28 psi

Front Tires

Rear Tires 16.9­24 8PR R4

VD76477,0001422 ­19­08JUL10­1/1

3­3­3

091710

PN=81

Maintenance—As Required

Check Park Brake (S.N. —888000)

T106339 —UN—13JAN97

CAUTION: Prevent possible injury from unexpected machine movement. Fasten seat belt before performing this check.

1. Fasten seat belt.

2. Start machine on dry, hard pavement.

3. Raise loader bucket and rear mounted equipment (if equipped) off ground.

4. Move the park brake switch (A) to the OFF position.

5. Disengage MFWD, if equipped.

A—Park Brake Switch

6. Move the transmission control lever (TCL) to forward F position and the gear shifter to 2nd gear.

7. Depress the speed control pedal to the floor and drive approximately 7 m (20 ft) before moving the park brake switch to ON position. The machine must stop within 2 m (6 ft) and transmission must shift to neutral N.

8. If necessary, check adjustment of park brake cap screws. See Towing. (Section 2­2.)

Specification Park Brake Stopping—Distance............................................................................ 2 m 6 ft TX,55,BG489 ­19­08JUL10­1/1

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

T132357B —UN—13JUL00

A—Serpentine Belt

CED,OUO1079,420 ­19­24MAR09­1/1

Lubricate Front Non­Powered Axle Wheel Bearings (S.N. —888000)

T6000AK —UN—18OCT88

IMPORTANT: When machine is used in mud, lubricate daily.

1. Remove plug and install lubrication fitting.

2. Grease with approximately five low pressure strokes of grease.

3. Remove lubrication fitting and install plug.

(S.N. —888000) Shown OUO1030,0000730 ­19­08JUL10­1/1

3­3­4

091710

PN=82

Maintenance—As Required

Lubricate Draft Link Wear Plates 1. Inspect wear plates. Brush grease on wear plates (A and B), if necessary.

B—Hitch Side Wear Plate

T110722 —UN—23JUL97

T110721 —UN—23JUL97

A—Lower Link Wear Plate

CED,OUO1032,925 ­19­28FEB07­1/1

Clean Dust Unloader Valve

T106441 —UN—14JAN97

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

Inspect unloader valve (A) for wear or damage and replace as necessary.

A—Dust Unloader Valve

TX1019385A —UN—19FEB07

(S.N. —848458) Shown

S.N. (888001­­) Shown VD76477,000142E ­19­08JUL10­1/1

3­3­5

091710

PN=83

Maintenance—As Required

Inspecting and Cleaning Dusty Secondary and Primary Element (S.N. 888001—) IMPORTANT: A damaged or dirty element may cause engine damage.

T90684 —UN—10NOV88

Install new elements:

• If the element shows damage and needs to be replaced.

• If element is visibly dirty and will not clean.

• After 1000 hours service or annually.

DO NOT clean a secondary element. Install a new element carefully centering it in the canister.

T47764 —UN—09NOV88

1. Tap element with the palm of your hand, NOT ON A HARD SURFACE. CAUTION: Prevent possible injury from flying objects. Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

2. If this does not remove dust, use compressed air under 210 kPa (2.1 bar) (30 psi).

has the slightest damage. If gasket is broken or missing, install a new element.

NOTE: Air restriction indicator will not signal correctly if an element has a break or is not correctly sealed in air cleaner housing. Throw away element that

3. Direct air up and down the pleats from inside to outside. Be careful not to make a break in the element.

VD76477,000146B ­19­08JUL10­1/1

Draining Water Separator Sediment (S.N. 888001—) NOTE: Dispose of waste properly.

1. Loosen knob (2) and drain fuel for several seconds from drain tube (1).

2. Tighten knob.

3. Bleed fuel system. See Replace Fuel Filter. (Section 3­9.)

1— Water Separator Drain Tube

TX1019984A —UN—28FEB07

Drain water and sediment as necessary.

2— Water Separator Knob VD76477,000146C ­19­08JUL10­1/1

3­3­6

091710

PN=84

Maintenance—As Required

Lubricate MFWD Drive Shaft Splines—If Equipped (S.N. 888001—)

T125640B —UN—08NOV99

IMPORTANT: Lubricate daily when machine is used in mud.

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

1— Lubrication Fitting

VD76477,000146D ­19­08JUL10­1/1

Check Wheel Fasteners (S.N 888001—) NOTE: Tighten wheel cap screws after first 50­100 hours of loaded operation after replacing or installing a new wheel. After that, tighten as required.

TX1002086 —UN—04JAN06

TX1002084 —UN—04JAN06

Tighten wheel cap screws and fasteners.

Item

Measurement

Specification

Standard Front Axle Cap Screw

Torque

136 ± 20 N∙m 100 ± 14 lb­ft

MFWD Front Axle Cap Screw

Torque

725 ± 72 N∙m 535 ± 53 lb­ft

Rear Axle Cap Screw

Torque

725 ± 72 N∙m 535 ± 53 lb­ft VD76477,0001457 ­19­08JUL10­1/1

3­3­7

091710

PN=85

Maintenance—As Required

Check Coolant CAUTION:

TS281 —UN—23AUG88

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

Remove radiator cap only when engine is cold or when cool enough to touch with bare hands.

Slowly loosen radiator cap to first stop to relieve pressure before removing completely.

IMPORTANT: John Deere COOL­GARD™ II Coolant Extender does not protect against freezing. Coolant extender prevents rust, scale, and liner cavitation.

Pressurized Fluids

T104924 —UN—08NOV96

NOTE: Check coolant every 1000 hours or 1 year, or when replacing 1/3 or more of coolant. Add coolant extender as indicated by John Deere COOL­GARD™ II test strips.

1. Remove radiator cap (A) and test coolant solution.

Use the following kit to check coolant:

• COOL­GARD II Test Strips

Coolant test strips provide an effective method to check freeze point and additive levels of engine coolant. See your authorized dealer for COOL­GARD II test strips and follow instructions on kit.

(S.N. —882699) Shown

TX1020859A —UN—20MAR07

2. Add John Deere COOL­GARD II Coolant Extender as necessary. Follow instructions on container for amount.

Specification Cooling System—Capac­ ity (S.N. —888000)............................................................................ 16 L 4.2 gal Cooling System—Capac­ ity (S.N. 888001—)............................................................................ 14 L 3.75 gal (S.N. 882701—)

3. Install cap.

A—Radiator Cap COOL­GARD is a trademark of Deere & Company

ER79617,0000BF3 ­19­20JUL10­1/1

3­3­8

091710

PN=86

Maintenance—Every 10 Hours or Daily Check Engine Oil Level IMPORTANT: Prevent possible engine damage.

DO NOT run engine when oil level is below the ADD mark.

T105159 —UN—13JAN97

The most accurate oil level reading is obtained when engine is cold before operation.

1. Park machine on a level surface, stop engine, and engage park brake.

2. Remove dipstick (A) and check oil level. when oil level is within crosshatched area (C). It is acceptable to run engine as long as oil level is above the ADD mark.

• AFTER THE ENGINE HAS BEEN RUN: Allow oil to drain into oil pan for 10 minutes before checking the oil level. Ten minutes after shutdown, oil level must be above the ADD mark.

(S.N. —848458) Shown

TX1018214A —UN—30JAN07

• BEFORE THE ENGINE IS STARTED: Engine is full

3. Remove filler cap (B) and add oil as necessary. See Diesel Engine Oil. (Section 3­1.)

C—Crosshatched Area on Dipstick (S.N. 888001—) Shown

RG5421 —UN—15DEC88

A—Engine Oil Dipstick B—Engine Oil Filler Cap

VD76477,00013E6 ­19­08JUL10­1/1

3­4­1

091710

PN=87

Maintenance—Every 10 Hours or Daily

Check Hydraulic Oil Level NOTE: Check hydraulic oil level when oil is cool, with machine parked on a level surface. Check before starting engine with loader bucket lowered to ground.

1. Check oil level in sight gauge (A).

T105189 —UN—13NOV96

2. If oil is below sight gauge, remove filler cap (B) and add oil. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

3. Install filler cap.

A—Hydraulic Oil Level Sight Gauge

B—Hydraulic Oil Filler Cap

TX,75,BG499 ­19­02MAR07­1/1

T105166 —UN—13NOV96

Check Coolant Overflow Tank Level

T122077B —UN—01JUL99

(S.N. —848458) Shown

(S.N. 848459—882699 ) Shown

NOTE: Check overflow tank with engine cold.

TX1018404A —UN—01FEB07

NOTE: If overflow tank is full and radiator is low, check for leaks on radiator and hose connections.

Coolant level must be between HOT and COLD marks on overflow tank (A) when engine is cold.

On (S.N. 882701—) machines coolant must be between the FULL HOT and FULL COLD marks on overflow tank when engine is cold.

A—Coolant Overflow Tank (S.N. 882701—) Shown VD76477,00013EF ­19­20JUL10­1/1

3­4­2

091710

PN=88

Maintenance—Every 10 Hours or Daily

T102796 —UN—22AUG96

Lubricate Loader Pivots

T136890B —UN—03JAN01

2 Points

TX1021051A —UN—26MAR07

T106368 —UN—13JAN97

6 Points—Left Side Shown

(S.N. 885923—) 5 Points

(S.N. —885922) 9 Points

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

TX,60,BG492 ­19­08JUL10­1/1

3­4­3

091710

PN=89

Maintenance—Every 10 Hours or Daily

Lubricate 4­in­1 Bucket Pivots—If Equipped

T132372C —UN—12SEP00

Apply grease to lubrication fittings until it escapes from joints. See Grease. (Section 3­1.)

4 Points—Left Side Shown CED,OUO1079,581 ­19­02MAR07­1/1

Lubricate MFWD Drive Shaft Splines—If Equipped (S.N. —888000)

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

1— Lubrication Fitting

T125640B —UN—08NOV99

IMPORTANT: Lubricate daily when machine is used in mud.

CED,TX03768,2667 ­19­08JUL10­1/1

3­4­4

091710

PN=90

Maintenance—Every 10 Hours or Daily

Lubricate Three­Point Hitch Pivots (S.N. —888000)

T105167 —UN—13NOV96

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

T105168 —UN—13NOV96

2 Points

6 Points VD76477,0001438 ­19­08JUL10­1/1

3­4­5

091710

PN=91

Maintenance—Every 10 Hours or Daily

Lubricate Three­Point Hitch Pivots (S.N. 888001—)

TX1019448A —UN—21FEB07

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

TX1019408A —UN—19FEB07

2 Points

2 Points VD76477,0001439 ­19­08JUL10­1/1

Lubricate Lift Cylinder (S.N. —888000)

T105175 —UN—20JAN97

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

2 Points CED,OUO1032,926 ­19­08JUL10­1/1

3­4­6

091710

PN=92

Maintenance—Every 10 Hours or Daily

Lubricate MFWD Drive Shaft Universal Joints—If Equipped (S.N. —888000) Apply grease to lubrication fitting(s) until it escapes from joint. See Grease. (Section 3­1.)

T105165 —UN—13NOV96

NOTE: Front drive shaft (if equipped) on early model machines requires lubrication. Front drive shaft (if equipped) on later model machines has permanent lube U­joints and will not need to be lubricated.

Early Model With Front Drive Shaft Shown OUO1043,00001EB ­19­08JUL10­1/1

Lubricate MFWD Front Axle Universal Joints—If Equipped

T102816 —UN—22AUG96

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

T132373C —UN—17SEP02

2 Points—Left Side Shown (S.N. —888000)

4 Points­­Left Side Shown (S.N. 888001—) TX,60,BG668 ­19­08JUL10­1/1

3­4­7

091710

PN=93

Maintenance—Every 10 Hours or Daily

Lubricate MFWD Front Axle Pivot—If Equipped (S.N. —888000)

T105176 —UN—20JAN97

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

1 Point Each Side—Axle Pivot Point OUO1030,0000745 ­19­08JUL10­1/1

Lubricate MFWD Front Axle Pivot (S.N. 888001—) TX1021354A —UN—30MAR07

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

1 Point VD76477,00014D1 ­19­08JUL10­1/1

3­4­8

091710

PN=94

Maintenance—Every 10 Hours or Daily

3 Points—Left Side

T135179B —UN—07NOV00

T135178B —UN—07NOV00

Lubricate Non­Powered Front Axle Steering—If Equipped

4 Points—Right Side

T105176 —UN—20JAN97

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

1 Point—Axle Pivot Point OUO1030,0000744 ­19­02MAR07­1/1

3­4­9

091710

PN=95

Maintenance—Every 50 Hours Check Transmission Oil Level (S.N. 888001—)

TX1018442A —UN—06FEB07

1. Park machine on level surface.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever (TCL) alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park brake to hold machine.

2. Engage park brake.

(S.N. 888001—) Shown

3. Move gear shifter and TCL to neutral.

A—Transmission Oil Dipstick

4. Start engine and run at slow idle for 3 minutes to warm transmission oil.

5. With engine running at slow idle, turn dipstick handle (A) counterclockwise and remove.

NOTE: Normal hot oil can be above full mark.

6. Check oil level on dipstick. If oil is not within operating range, add oil. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.).

7. Install dipstick and turn clockwise to tighten.

VD76477,0001466 ­19­08JUL10­1/1

3­5­1

091710

PN=96

Maintenance—Initial Service ­ 100 Hours Change Engine Break­In Oil and Replace Filter (S.N. —882699)

T132447B —UN—13JUL00

NOTE: Change after first 100 hours and then every 250 hours.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever (TCL) and gearshift lever to keep machine from moving. Always engage park brake to hold machine.

1. Run engine to warm oil. Park machine on a level surface. Engage park brake. Stop engine.

2. Remove engine oil drain plug (A). Allow oil to drain into a container.

T132362C —UN—13JUL00

3. Using a suitable filter wrench, turn engine oil filter (B) counterclockwise and remove from base. Clean mounting surfaces of base as necessary. Dispose of waste oil properly.

4. Apply a thin film of oil to sealing ring on new engine oil filter, and install by turning new filter clockwise by hand until gasket touches mounting surface. Torque an additional 1/2—3/4 turn with filter wrench.

5. Install engine oil drain plug.

6. Remove engine oil fill cap (C) and fill engine with oil to specification. See Diesel Engine Oil. (Section 3­1.)

Engine Oil—Specification Engine Oil and Filter—Capacity.............................................................................. 12.3 L 3.25 gal

IMPORTANT: Before starting engine after a filter change, crank engine for 10 seconds without starting to fill new engine oil filter and pre­lubricate the turbocharger, if equipped.

A—Engine Oil Drain Plug B—Engine Oil Filter

C—Engine Oil Fill Cap

7. Run engine for 2 minutes and then stop engine. Check for leaks around drain plug and filter, and tighten as necessary. Check oil level. See Check Engine Oil Level. (Section 3­4.)

VD76477,000048C ­19­07MAR07­1/1

3­6­1

091710

PN=97

Maintenance—Initial Service ­ 100 Hours

Change Engine Break­In Oil and Replace Filter (S.N. 882700—888000)

T132447B —UN—13JUL00

NOTE: Change after first 100 hours and then every 500 hours.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever (TCL) and gearshift lever to keep machine from moving. Always engage park brake to hold machine.

1. Run engine to warm oil. Park machine on a level surface. Engage park brake. Stop engine.

2. Remove engine oil drain plug (A). Allow oil to drain into a container.

T132362C —UN—13JUL00

3. Using a suitable filter wrench, turn engine oil filter (B) counterclockwise and remove from base. Clean mounting surfaces of base as necessary. Dispose of waste oil properly.

4. Apply a thin film of oil to sealing ring on new engine oil filter, and install by turning new filter clockwise by hand until gasket touches mounting surface. Torque an additional 1/2—3/4 turn with filter wrench.

5. Install engine oil drain plug.

6. Remove engine oil fill cap (C) and fill engine with oil to specification. See Diesel Engine Oil. (Section 3­1.)

Engine Oil—Specification Engine Oil and Filter—Capacity.............................................................................. 12.3 L 3.25 gal

IMPORTANT: Before starting engine after a filter change, crank engine for 10 seconds without starting to fill new engine oil filter and pre­lubricate the turbocharger, if equipped.

A—Engine Oil Drain Plug B—Engine Oil Filter

C—Engine Oil Fill Cap

7. Run engine for 2 minutes and then stop engine. Check for leaks around drain plug and filter, and tighten as necessary. Check oil level. See Check Engine Oil Level. (Section 3­4.)

HG31779,0000014 ­19­08JUL10­1/1

3­6­2

091710

PN=98

Maintenance—Initial Service ­ 100 Hours

Change Transmission and Torque Converter Oil and Replace Filter (S.N. —886534) NOTE: Change after first 100 hours and then every 1000 hours.

NOTE: This procedure does not drain all of the oil from the manual shift transmission. Only approximately 8.0—8.5 L of oil will drain.

It is intended that the remainder of oil will remain in the cooler and torque converter.

T134818C —UN—25OCT00

1. Remove transmission drain plug (A) from bottom of transmission and drain oil into suitable container.

Dispose of waste oil properly.

Specification Transmission System Oil—Capacity.................................................................................... 15 L 16 qt

2. Install drain plug.

3. Turn transmission oil filter (B) counterclockwise and remove.

Manual Shift Transmission Shown

T132362F —UN—13JUL00

4. Apply film of oil to sealing ring on new transmission oil filter. Install new transmission oil filter. Turn clockwise until sealing ring touches mounting surface, then tighten an additional 3/4 to one turn with a suitable filter wrench.

5. Start engine and run for 3 minutes to allow filter element to refill and purge air from charge circuit.

6.

With engine running at slow idle, remove transmission dipstick (C). Check transmission oil level and add oil through dipstick tube as necessary. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

7. Check for leakage around filter. Tighten filter just enough to stop leaks.

8. Install drain plug.

9. Turn handle of transmission dipstick counterclockwise and remove. Fill transmission with oil through dipstick tube. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

A—Transmission Drain Plug B—Transmission Oil Filter

C—Transmission Dipstick

11. With engine running at slow idle, check oil level on transmission dipstick. If oil is not within operating range, add oil.

12. Install transmission dipstick and turn handle clockwise to tighten.

10. Start engine and run at slow idle for 3 minutes.

VD76477,000048D ­19­08JUL10­1/1

3­6­3

091710

PN=99

Maintenance—Initial Service ­ 250 Hours Change Engine Break­In Oil and Replace Filter (S.N. 888001— )

T132447B —UN—13JUL00

NOTE: Change after first 250 hours and then every 500 hours.

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever (TCL) and gearshift lever to keep machine from moving. Always engage park brake to hold machine.

1. Run engine to warm oil. Park machine on a level surface. Engage park brake. Stop engine.

2. Remove engine oil drain plug (A). Allow oil to drain into a container.

T132362C —UN—13JUL00

3. Using a suitable filter wrench, turn engine oil filter (B) counterclockwise and remove from base. Clean mounting surfaces of base as necessary. Dispose of waste oil properly.

4. Apply a thin film of oil to sealing ring on new engine oil filter, and install by turning new filter clockwise by hand until gasket touches mounting surface. Torque an additional 1/2—3/4 turn with filter wrench.

5. Install engine oil drain plug.

6. Remove engine oil fill cap (C) and fill engine with oil to specification. See Diesel Engine Oil. (Section 3­1.)

Engine Oil—Specification Engine Oil and Filter—Capacity.............................................................................. 12.3 L 3.25 gal

IMPORTANT: Before starting engine after a filter change, crank engine for 10 seconds without starting to fill new engine oil filter and pre­lubricate the turbocharger, if equipped.

A—Engine Oil Drain Plug B—Engine Oil Filter

C—Engine Oil Fill Cap

7. Run engine for 2 minutes and then stop engine. Check for leaks around drain plug and filter, and tighten as necessary. Check oil level. See Check Engine Oil Level. (Section 3­4.)

VD76477,00014D2 ­19­08JUL10­1/1

3­7­1

091710

PN=100

Maintenance—Every 250 Hours Change Engine Oil and Replace Filter (S.N. —882699) IMPORTANT: If fuel sulfur content exceeds 0.5 percent, change engine oil at one­half the normal interval.

T105185 —UN—13NOV96

If engine has not run 250 hours before the season changes, change oil.

1. Run engine to warm oil. Park machine on a level surface, Engage park brake. Stop engine.

2. Remove drain plug (A). Allow oil to drain.

3. Using a suitable filter wrench, turn filter (B) counterclockwise and remove from base. Clean mounting surfaces of base as necessary.

T105186 —UN—13NOV96

4. Apply a thin film of oil to sealing on new filter and install by turning new filter clockwise by hand until gasket touches mounting surface. Then torque an additional 1/2—3/4 turn with wrench.

5. Install drain plug.

6. Remove filler cap (C) and fill engine with 8.5 L (9.0 qt) of new oil. See Diesel Engine Oil. (Section 3­1.)

Specification Engine Oil and Filter—Capacity.............................................................................. 12.3 L 3.25 gal

T105187 —UN—13NOV96

IMPORTANT: Before starting engine after a filter change, crank engine for 10 seconds without starting to refill filter and pre­lubricate engine.

7. Start engine and run at a slow idle. If engine oil pressure light on monitor does not go out and alarm shut off, stop engine immediately and find the cause.

8. Stop engine, check for leaks around drain plug and filter, and tighten filter as necessary. Check oil level.

See Check Engine Oil Level. (Section 3­4.)

A—Engine Oil Drain Plug B—Engine Oil Filter

(S.N. —848458) Shown

C—Engine Oil Filler Cap

TX,75,BG497 ­19­07MAR07­1/1

3­8­1

091710

PN=101

Maintenance—Every 250 Hours

Check MFWD Axle Oil—If Equipped 1. Remove plug (A) to check oil level. Oil should be filled to bottom of plug.

T105182 —UN—13NOV96

2. Add oil as necessary through plug hole. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

3. Install plug.

A—MFWD Oil Level Plug

TX1018669A —UN—08FEB07

(S.N. —888000) Shown

(S.N. 888001—) Shown VD76477,0001409 ­19­08JUL10­1/1

Check MFWD Planetary Housing Oil—If Equipped 1. Rotate housing until OIL LEVEL line (B) is horizontal and fill plug (A) is above line as shown.

T105325 —UN—21NOV96

2. Remove plug and check that oil is filled to bottom of plug hole.

3. Add oil to plug hole if necessary. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

4. Install plug.

5. Repeat procedure for opposite side wheel.

A—MFWD Housing Fill Plug

B—MFWD Oil Level Line TX,75,BG501 ­19­02MAR07­1/1

3­8­2

091710

PN=102

Maintenance—Every 250 Hours

Check Rear Axle Oil Level (S.N. —888000) 1. Remove plug (A) from axle and check oil level.

T104867 —UN—22NOV96

2. If oil is not level to bottom of hole, add oil. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

A—Rear Axle Oil Level Plug

T122145B —UN—09JUL99

(S.N. —851673) Shown

(S.N. 851674—888000) Shown CED,OUO1040,103 ­19­08JUL10­1/1

Check Rear Axle Oil Level (S.N. 888001—)

TX1021377A —UN—30MAR07

NOTE: If the backhoe has been run in high­speed transport, wait 30 minutes for the axle oil level to stabilize before checking oil.

1. Move machine onto level ground.

2. Remove rear axle oil level plug (1). Oil should run out of plug hole if the oil level is correct.

3. If oil level is not correct, add oil as necessary. See Transmission, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

4. Install plug.

1— Rear Axle Oil Level Plug VD76477,00014F1 ­19­08JUL10­1/1

3­8­3

091710

PN=103

Maintenance—Every 250 Hours

Check Battery Electrolyte Level and Terminals CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

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

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

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

TS203 —UN—23AUG88

1. Filling batteries in a well­ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Using proper jump start procedure.

If you spill acid on yourself: 1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes.

Get medical attention immediately.

2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

If acid is swallowed: 1. Remove battery box cover.

1. Do not induce vomiting.

Continued on next page

3­8­4

TX,75,DH1574 ­19­25FEB08­1/3

091710

PN=104

Maintenance—Every 250 Hours

2. Fill each cell to within specified range with distilled water. DO NOT overfill.

CAUTION: Prevent possible injury. ALWAYS remove grounded (—) battery clamp first and replace it last.

T6996DB —UN—10FEB89

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.

3. Disconnect battery clamps, grounded clamp first.

C—Electrolyte Level Range

T6996DA —UN—10FEB89

A—Battery Post B—Fill Tube

TX,75,DH1574 ­19­25FEB08­2/3

4. Clean battery terminals (A) and clamps with a stiff brush.

5. Apply lubricating grease (B) around battery terminal base only.

A—Battery Terminals

T6758AA —UN—21OCT88

6. Install and tighten clamps, grounded clamp last.

B—Grease

TX,75,DH1574 ­19­25FEB08­3/3

3­8­5

091710

PN=105

Maintenance—Every 250 Hours

Check Transmission Oil Level (S.N. —888000) 1. Park machine on level surface.

T105191 —UN—13NOV96

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever (TCL) alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park brake to hold machine.

2. Engage park brake.

(S.N. —848458) Shown

3. Move gear shifter and TCL to neutral.

4. Start engine and run at slow idle for 3 minutes to warm transmission oil.

5. With engine running at slow idle, turn dipstick handle (A) counterclockwise and remove.

A—Transmission Oil Dipstick

7. Install dipstick and turn clockwise to tighten.

NOTE: Normal hot oil can be above full mark.

6. Check oil level on dipstick. If oil is not within operating range, add oil. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

VD76477,00013F1 ­19­08JUL10­1/1

Take Engine Oil Sample See your authorized dealer.

OUT4001,000039B ­19­25FEB09­1/1

3­8­6

091710

PN=106

Maintenance—Every 500 Hours Check Air Intake Hose NOTE: Air intake hose (A) is located at back side of air cleaner housing and extends to tube on top of valve cover.

T106400 —UN—13JAN97

1. Check hose for cracks and replace as necessary.

2. Check for loose connections and tighten clamps as necessary.

A—Air Intake Hose

T196292A —UN—17NOV03

Non­Turbo Engine Shown

Turbo Engine Shown TX,80,BG503 ­19­17JAN97­1/1

3­9­1

091710

PN=107

Maintenance—Every 500 Hours

Change Engine Oil and Replace Filter (S.N. 882700— )

T132447B —UN—13JUL00

CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever (TCL) and gearshift lever to keep machine from moving. Always engage park brake to hold machine.

1. Run engine to warm oil. Park machine on a level surface. Engage park brake. Stop engine.

2. Remove engine oil drain plug (A). Allow oil to drain into a container.

T132362C —UN—13JUL00

3. Using a suitable filter wrench, turn engine oil filter (B) counterclockwise and remove from base. Clean mounting surfaces of base as necessary. Dispose of waste oil properly.

4. Apply a thin film of oil to sealing ring on new engine oil filter, and install by turning new filter clockwise by hand until gasket touches mounting surface. Torque an additional 1/2—3/4 turn with filter wrench.

5. Install engine oil drain plug.

6. Remove engine oil fill cap (C) and fill engine with oil to specification. See Diesel Engine Oil. (Section 3­1.)

Engine Oil—Specification Engine Oil and Filter—Capacity.............................................................................. 12.3 L 3.25 gal

IMPORTANT: Before starting engine after a filter change, crank engine for 10 seconds without starting to fill new engine oil filter and pre­lubricate the turbocharger, if equipped.

A—Engine Oil Drain Plug B—Engine Oil Filter

C—Engine Oil Fill Cap

7. Run engine for 2 minutes and then stop engine. Check for leaks around drain plug and filter, and tighten as necessary. Check oil level. See Check Engine Oil Level. (Section 3­4.)

HG31779,0000014 ­19­07MAR07­1/1

3­9­2

091710

PN=108

Maintenance—Every 500 Hours

Replace Hydraulic Oil Filter and PTO Filter—If Equipped (S.N. —888000) 1. Turn filters (A and C) counterclockwise and remove.

T105194 —UN—13NOV96

2. Apply film of oil to sealing ring on new filter. Install until it touches mounting surface and tighten an additional 3/4 to one turn with a suitable wrench.

3. Check hydraulic oil level at sight gauge (B).

4. Start engine and run for 2 minutes to allow filter element to refill and purge air from charge circuit.

5. Stop the engine, check hydraulic oil level, and add as necessary.

(S.N. —888000) Shown

6. Check for leakage around filter. Tighten filter just enough to stop leaks.

T124271B —UN—10SEP99

C—PTO Oil Filter—If Equipped

T106401 —UN—13JAN97

A—Hydraulic Oil Filter B—Hydraulic Oil Level Sight Gauge

VD76477,0001430 ­19­08JUL10­1/1

3­9­3

091710

PN=109

Maintenance—Every 500 Hours

Replace Fuel Filter NOTE: Dispose of waste properly.

T106412 —UN—14JAN97

1. Turn locking ring (A) counterclockwise and remove filter element (B). Allow sediment to drain into a container.

2. Remove fuel drain knob (C) from filter element and install to new filter.

3. Clean filter base (D).

NOTE: Do not attempt to turn filter element into base.

4. Install new fuel element by aligning vertical locators (F) into slots (E) on filter base. Push filter element up firmly until filter snaps against base.

(S.N. —848458) Shown

TX1019417A —UN—19FEB07

5. Turn retaining ring clockwise into filter base until retaining ring clicks tightly into place.

6. Loosen bleed screw (G) by turning knob counterclockwise.

7. Operate primer lever (H) until fuel flow from bleed screw is free of air bubbles.

NOTE: If there is no fuel flow, push primer lever toward engine and turn crankshaft using starter motor to reposition camshaft. Repeat step 6.

(S.N. 888001—) Shown

8. Tighten bleed screw.

9. Push primer lever toward engine as far as possible.

E—Slots F— Vertical Locators G—Bleed Screw H—Primer Lever

T7896AJ —UN—25NOV92

A—Locking Ring B—Filter C—Drain Knob D—Filter Base

Replace Fuel Filter VD76477,0001431 ­19­20JUL10­1/1

Inspect and Clean Hydraulic Reservoir Fill Screen and Breather Screen 2. Inspect and clean fill screen (B). Replace screen if damaged. See your authorized dealer for screen.

3. Clean breather screen (C).

4. Install filler cap.

A—Hydraulic Reservoir Filler Cap B—Hydraulic Oil Fill Screen

C—Hydraulic Oil Breather Screen

T105195 —UN—04FEB97

1. Remove filler cap (A) from hydraulic reservoir.

TX,80,BG505 ­19­20MAR07­1/1

3­9­4

091710

PN=110

Maintenance—Every 500 Hours

Take Fluid Samples See your authorized dealer for taking the following fluid samples:

• Hydraulic Oil

• Transmission Oil • Front Axle Gear Case Oil • Rear Axle Gear Case Oil • Coolant • Diesel Fuel ER79617,0000C10 ­19­26JUL10­1/1

3­9­5

091710

PN=111

Maintenance—Every 1000 Hours Change MFWD Front Axle Housing Oil—If Equipped (S.N. —888000) NOTE: Dispose of drain oil properly.

T106417 —UN—14JAN97

1. Remove plug (A) to drain oil.

2. Install plug.

3. Remove plug (B) and add oil so it is level with bottom of filler hole. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

Specification MFWD Front Axle Housing—Capacity...................................................... 6.5 L Approximate 1.7 gal Approximate

4.

Drain Plug

Install plug.

B—MFWD Filler Hole T106418 —UN—14JAN97

A—MFWD Drain Plug

Filler Hole TX,85,BG509 ­19­09JUL10­1/1

Change MFWD Front Wheel Planetary Housing Oil—If Equipped (S.N —888000)

2. Install drain plug.

3. Rotate wheel so plug (A) is above OIL LEVEL line (B) when line is horizontal.

4. Add oil to bottom of fill plug hole and install plug. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

T7371AP —UN—02OCT90

1. Rotate wheel so plug (A) is at its lowest point, remove plug and drain oil.

Specification MFWD Planetary Hous­ ing (each)—Capacity...................................................... 1 L Approximate 1.1 qt Approximate B—Oil Level Line T105325 —UN—21NOV96

A—MFWD Planetary Housing Drain Plug

TX,85,BD2169 ­19­09JUL10­1/1

3­10­1

091710

PN=112

Maintenance—Every 1000 Hours

Clean, Pack, and Adjust Front Non­Powered Axle Wheel Bearings—If Equipped

T87549 —UN—21OCT88

1. Raise machine so steer wheels are off ground.

Remove hub cap (J), pull cotter pin (I) from spindle and remove slotted nut (K).

2. Slip off special washer (L) and outer bearing cone (H).

Remove wheel and hub assembly. Then remove seal (A) and inner bearing cone (C) from hub (E).

3. Clean all dirt and grease from bearings, bushing (B), spindles, and hub assemblies.

4. Inspect bearing cups (D and G) and cones (C and H) for damage or excessive wear. Replace damaged parts as necessary.

5. If a new bearing cup must be installed, drive out the old one and install a new cup with the cupped face outward.

6. Inspect grease seals for damage or hardened lips and replace as necessary.

7. Pack bearings and coat seal lips with John Deere Multi­Purpose Grease or equivalent. See Grease.

(Section 3­1.)

8. Install seal (A), bushing (B), and inner bearing cup (D). Fill gap between inner bearing cup and seal with grease. Assemble balance of parts except cotter pin and hub cap. Tighten slotted nut to specification.

Specification Front Wheel Bearing Slotted Nut—Torque......................................................................47 N∙m 35 lb­ft

A—Seal B—Bushing C—Inner Bearing Cone D—Inner Bearing Cup E—Hub F— Pipe Plug

G—Outer Bearing Cup H—Outer Bearing Cone I— Cotter Pin J— Hub Cap K—Slotted Nut L— Washer

9. Turn wheel several revolutions. Tighten nut again to specification. Turn nut counterclockwise to nearest slot and install cotter pin. If hole of spindle is in line with a slot after tightening, turn nut counterclockwise to next slot.

10. Remove pipe plug (F) from wheel hub and install lubrication fitting. Lubricate wheel hub assembly until grease starts to exit past outer bearing cone (H).

Remove lube fitting and install pipe plug.

11. Lower machine to the ground and install hub caps.

TX,85,BD2164 ­19­02MAR07­1/1

3­10­2

091710

PN=113

Maintenance—Every 1000 Hours

Change Rear Axle Oil (S.N. —888000) NOTE: Dispose of waste oil properly.

T105316 —UN—21NOV96

1. Remove plug (A) and drain oil into a container. Install plug.

Specification Rear Axle Oil—Capacity (S.N. —851673)........................................................... 13 L Approximate 14 qt Approximate Capacity (S.N. 851674—888000)........................................................ 16 L Approximate 17 qt Approximate

2. Remove plug (B) and fill with oil to bottom of filler hole.

See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

NOTE: Read decal next to fill hole for correct oil fill quantity.

T104868 —UN—22NOV96

It will take approximately 5 minutes for oil to settle into outer housing when oil is warm.

3. Wait 5­10 minutes for oil to settle, recheck level and add as necessary. If oil is cold, settle time may increase.

4. Install plug.

B—Rear Axle Filler Plug

T122145C —UN—09JUL99

A—Rear Axle Drain Plug

(S.N. —851673) Shown

(S.N. 851674—888000) Shown VD76477,0001432 ­19­09JUL10­1/1

3­10­3

091710

PN=114

Maintenance—Every 1000 Hours

Replace Hydraulic Oil Filter and PTO Filter—If Equipped (S.N. 888001—) 1. Turn filters (A and C) counterclockwise and remove.

2. Apply film of oil to sealing ring on new filter. Install until it touches mounting surface and tighten an additional 3/4 to one turn with a suitable wrench.

3. Check hydraulic oil level at sight gauge (B).

4. Start engine and run for 2 minutes to allow filter element to refill and purge air from charge circuit.

TX1051716A —UN—18NOV08

5. Stop the engine, check hydraulic oil level, and add as necessary.

6. Check for leakage around filter. Tighten filter just enough to stop leaks.

C—PTO Oil Filter—If Equipped

T124271B —UN—10SEP99

(S.N. 888001—) Shown

T106401 —UN—13JAN97

A—Hydraulic Oil Filter B—Hydraulic Oil Level Sight Gauge

MD04263,0000024 ­19­09JUL10­1/1

3­10­4

091710

PN=115

Maintenance—Every 1000 Hours

Change Transmission and Torque Converter Oil and Replace Filter (S.N. —888000) NOTE: This procedure does not drain all of the oil from the manual shift transmission. Only approximately 8.0—8.5 L of oil will drain.

It is intended that the remainder of oil will remain in the cooler and torque converter.

1. Remove transmission drain plug (A) from bottom of transmission and drain oil into suitable container.

Dispose of waste oil properly.

T134818C —UN—25OCT00

Specification Transmission System Oil—Capacity.................................................................................... 15 L 16 qt

2. Install drain plug.

3. Turn transmission oil filter (B) counterclockwise and remove.

4. Apply film of oil to sealing ring on new transmission oil filter. Install new transmission oil filter. Turn clockwise until sealing ring touches mounting surface, then tighten an additional 3/4 to one turn with a suitable filter wrench.

Manual Shift Transmission Shown

6.

T132362F —UN—13JUL00

5. Start engine and run for 3 minutes to allow filter element to refill and purge air from charge circuit.

With engine running at slow idle, remove transmission dipstick (C). Check transmission oil level and add oil through dipstick tube as necessary. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

7. Check for leakage around filter. Tighten filter just enough to stop leaks.

A—Transmission Drain Plug B—Transmission Oil Filter

8. Install drain plug.

9. Turn handle of transmission dipstick counterclockwise and remove. Fill transmission with oil through dipstick tube. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

C—Transmission Dipstick

12. Install transmission dipstick and turn handle clockwise to tighten.

10. Start engine and run at slow idle for 3 minutes.

11. With engine running at slow idle, check oil level on transmission dipstick. If oil is not within operating range, add oil.

VD76477,0001434 ­19­09JUL10­1/1

3­10­5

091710

PN=116

Maintenance—Every 1000 Hours

Change Transmission and Torque Converter Oil and Replace Filter (S.N. 888001—) NOTE: This procedure does not drain all of the oil from the transmission. Only approximately 8.0—8.5 L (2.1—2.3 gal) of oil will drain.

It is intended that the remainder of oil will remain in the cooler and torque converter.

1. Remove transmission drain plug (A) from bottom of transmission and drain oil into suitable container.

Dispose of waste oil properly.

TX1051708A —UN—18NOV08

Specification Transmission System Oil—Capacity................................................................................. 15.1 L 4 gal

2. Install drain plug.

3. Turn transmission oil filter (B) counterclockwise and remove.

TX1051714A —UN—18NOV08

4. Apply film of oil to sealing ring on new transmission oil filter. Install new transmission oil filter. Turn clockwise until sealing ring touches mounting surface, then tighten an additional 3/4 to one turn with a suitable filter wrench.

5. Start engine and run for 3 minutes to allow filter element to refill and purge air from charge circuit.

6.

With engine running at slow idle, remove transmission dipstick (C). Check transmission oil level and add oil through dipstick tube as necessary. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

7. Check for leakage around filter. Tighten filter just enough to stop leaks.

TX1018606A —UN—22FEB07

8. Turn handle of transmission dipstick counterclockwise and remove. Fill transmission with oil through dipstick tube. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

9. Start engine and run at slow idle for 3 minutes.

10. With engine running at slow idle, check oil level on transmission dipstick. If oil is not within operating range, add oil.

11. Install transmission dipstick and turn handle clockwise to tighten.

A—Transmission Drain Plug B—Transmission Oil Filter

C—Transmission Dipstick

MD04263,0000023 ­19­09JUL10­1/1

3­10­6

091710

PN=117

Maintenance—Every 1000 Hours

Change Hydraulic Reservoir Oil, Filter, PTO Oil and Filter—If Equipped (S.N. —888000) 1. Park machine on a level surface.

T106436 —UN—14JAN97

2. Lower loader bucket to ground and stop engine.

3. Remove reservoir filler tube cap.

NOTE: Dispose of waste oil properly.

4. Remove drain plug (A) from bottom of reservoir tank and drain oil.

5. Replace plug.

6. Replace hydraulic oil filter and PTO filter (if equipped).

See Replace Hydraulic Oil Filter and PTO Filter—If Equipped (S.N. —888000). (Section 3­9.)

7. Refill hydraulic reservoir. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

A—Hydraulic Reservoir Drain Plug

8. Check oil level.

Specification Hydraulic Reservoir—Capacity................................................. 54.5 L Approximate 14.4 gal Approximate TX,85,BG516 ­19­09JUL10­1/1

3­10­7

091710

PN=118

Maintenance—Every 1000 Hours

Clean Engine Crankcase Vent Tube

B—Engine Crankcase Vent Tube

T122077B —UN—01JUL99

(S.N. —848458) Shown

(S.N. 848459—888000) Shown

T196293A —UN—17NOV03

A—Coolant Overflow Tank

T105166 —UN—13NOV96

NOTE: On machines (S.N. —888000), vent tube is attached to valve cover behind coolant overflow tank (A).

(S.N. 882700— ) Shown Continued on next page

3­10­8

VD76477,00013F2 ­19­09JUL10­1/2

091710

PN=119

Maintenance—Every 1000 Hours

Remove vent tube (B) and clean interior using diesel fuel.

T106422 —UN—14JAN97

B—Engine Crankcase Vent Tube

View from Underside VD76477,00013F2 ­19­09JUL10­2/2

3­10­9

091710

PN=120

Maintenance—Every 1000 Hours

Adjust Engine Speed Control Linkage (S.N. —882699) 1. Move accelerator pedal to fast idle position.

T105960 —UN—07JAN97

2. Measure injection pump lever override. Override must be with specification.

Specification Injection Pump Lever Override (Fast Idle)—Distance...........................................................................3—6 mm 0.12—0.25 in.

3. Adjust stop screw (A) (located at bottom of accelerator pedal) to provide proper override.

4. Release accelerator pedal to slow idle position. Check override. Slow idle override must be to specification.

T107262 —UN—12FEB97

Specification Injection Pump Lever Override (Slow Idle)—Distance..............................................................0.5 mm Minimum 0.02 in. Minimum

If slow idle override is less than minimum distance, shorten speed control rod by turning ball joint at injection pump until minimum override can be obtained.

5. Check fast idle again for minimum override.

A—Accelerator Stop Screw

Specification Injection Pump Lever Override (Fast Idle)—Distance.................................................................3 mm Minimum 0.12 in. Minimum

If fast idle override is less than minimum distance, check and adjust pedal and pump rods to initial lengths.

Rod—Specification (S.N. —872334) Pedal­to­Cross Shaft Rod Initial Stud­to­Stud—Length............................................................... 193.5 mm 7.62 in.

Cross Shaft­to­Injection Pump Rod Initial Stud­to­Stud—Length.................................................................. 870 mm 34.25 in.

(S.N. 872335— ) Pedal­to­Cross Shaft Rod Initial Stud­to­Stud—Length............................................................... 203.2 mm 8.0 in.

Cross Shaft­to­Injection Pump Rod Initial Stud­to­Stud—Length.................................................................. 884 mm 34.8 in.

6.

Repeat steps 1—5.

Continued on next page

3­10­10

OUO1030,0000750 ­19­28FEB07­1/3

091710

PN=121

Maintenance—Every 1000 Hours

7. On machines (S.N. —872334) with hand throttle, perform the following: a. Disconnect hand throttle cable from cross shaft.

T107263 —UN—12FEB97

b. Allow accelerator pedal to go to slow idle position (fully up). Make sure hand throttle is at slow idle (fully down). c. Adjust ball joint (B) on end of throttle cable so threaded end fits into hole of bellcrank on cross shaft.

NOTE: Hand throttle cable has more travel available than is utilized by this machine.

With Hand Throttle (S.N. —872334)

d. Move hand throttle from slow to fast idle to check injection pump lever override. Override should match pedal override.

T115765 —UN—09JUN98

8. On machines (S.N. —872334) without hand throttle, adjust stationary rod until length (A) is to specification.

Specification (S.N. —872334) Stationary Rod (w/o Hand Throttle) Bracket Clip­to­Stud—Length................................................................... 159 mm 6.25 in.

A—Rod Length

Without Hand Throttle (S.N. —872334)

B—Ball Joint

OUO1030,0000750 ­19­28FEB07­2/3

9.

On machines (S.N. 872335— ) with hand throttle, perform the following: a. Disconnect hand throttle cable yoke (C) from pin on injection pump lever.

T123199B —UN—04AUG99

b. Allow accelerator pedal to go to slow idle position (fully up). Make sure hand throttle is at slow idle (fully down). c. With cable attached to support bracket adjust cable yoke (C) to fit onto guide pin (B) on injection pump.

Tighten jam nut (D). Yoke should move on guide pin without binding.

NOTE: Hand throttle cable has more travel available than is utilized by this machine. d. Move hand throttle from slow to fast idle to check injection pump lever override. Override should match pedal override.

With Hand Throttle (S.N. 872335— ) A—Gap B—Guide and Nut C—Cable Yoke

D—Jam Nut E—Cable Bracket

OUO1030,0000750 ­19­28FEB07­3/3

Adjust Engine Speed Control Linkage (S.N. 882700— ) See your authorized dealer.

OUO1030,000072E ­19­19MAR07­1/1

3­10­11

091710

PN=122

Maintenance—Every 1000 Hours

Replace Air Cleaner Elements Inspect elements when air filter restriction indicator comes on. See Engine Air Filter Restriction Indicator. (Section 2­1.)

T6201BE —UN—18OCT88

1. (S.N. —882699): Remove right­hand side cover.

(S.N. 882700—): Open hood. See Opening and Closing Engine Hood. (Section 3­2.)

2. Loosen clips (A) to remove air cleaner cover.

IMPORTANT: Remove filter gently to avoid dislodging dust from the filter.

3. Slide primary (B) and secondary (C) elements out to remove.

4. Clean inside of outlet tube.

T103381 —UN—06SEP96

C—Secondary Element

T103382 —UN—06SEP96

(S.N. —882699) Shown

(S.N. —882699) Shown

T103383 —UN—06SEP96

A—Air Cleaner Cover Clips (3 used) B—Primary Element

(S.N. —882699) Shown CED,OUO1040,45 ­19­02MAR07­1/1

3­10­12

091710

PN=123

Maintenance—Every 1000 Hours

Check Coolant CAUTION:

TS281 —UN—23AUG88

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

Remove radiator cap only when engine is cold or when cool enough to touch with bare hands.

Slowly loosen radiator cap to first stop to relieve pressure before removing completely.

IMPORTANT: John Deere COOL­GARD™ II Coolant Extender does not protect against freezing. Coolant extender prevents rust, scale, and liner cavitation.

Pressurized Fluids

T104924 —UN—08NOV96

NOTE: Check coolant every 1000 hours or 1 year, or when replacing 1/3 or more of coolant. Add coolant extender as indicated by John Deere COOL­GARD™ II test strips.

1. Remove radiator cap (A) and test coolant solution.

Use the following kit to check coolant:

• COOL­GARD II Test Strips

Coolant test strips provide an effective method to check freeze point and additive levels of engine coolant. See your authorized dealer for COOL­GARD II test strips and follow instructions on kit.

(S.N. —882699) Shown

TX1020859A —UN—20MAR07

2. Add John Deere COOL­GARD II Coolant Extender as necessary. Follow instructions on container for amount.

Specification Cooling System—Capac­ ity (S.N. —888000)............................................................................ 16 L 4.2 gal Cooling System—Capac­ ity (S.N. 888001—)............................................................................ 14 L 3.75 gal (S.N. 882701—)

3. Install cap.

A—Radiator Cap COOL­GARD is a trademark of Deere & Company

ER79617,0000BF3 ­19­20JUL10­1/1

3­10­13

091710

PN=124

Maintenance—Every 2000 Hours Adjust Engine Valve Lash (Clearance) See your authorized dealer.

TX03679,00017DD ­19­08MAY01­1/1

Change MFWD Front Axle Housing Oil—If Equipped (S.N. 888001—) NOTE: Dispose of drain oil properly.

TX1002311A —UN—06JAN06

MFWD axle housing is filled with HY­GARD gear oil at the factory. Fill MFWD axle housing with HY­GARD oil to fill to proper level.

1. Remove drain plug (1) to drain oil. Dispose of waste oil properly.

Specification MFWD Front Axle Housing Oil—Capacity..................................................................... 6.2 L 1.6 gal

MFWD Axle Drain Plug 1— Drain Plug

2. Install drain plug.

3. Remove fill plug (2) and add oil so it is level with bottom of fill plug hole. See Transmission, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

4.

2— Fill Plug

Install fill plug.

VD76477,000140B ­19­09JUL10­1/1

Change MFWD Front Wheel Planetary Housing Oil—If Equipped (S.N 888001—) 1. Rotate wheel so plug (A) is at its lowest point, remove plug and drain oil.

T7371AP —UN—02OCT90

2. Install drain plug.

3. Rotate wheel so plug (A) is above OIL LEVEL line (B) when line is horizontal.

4. Add oil to bottom of fill plug hole and install plug. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

Specification MFWD Planetary Housing—Capacity...................................................... 0.7 L Approximate 0.75 qt Approximate B—Oil Level Line

T105325 —UN—21NOV96

A—MFWD Planetary Housing Drain Plug

Drain Plug

Oil Level Line VD76477,0001468 ­19­09JUL10­1/1

3­11­1

091710

PN=125

Maintenance—Every 2000 Hours

Change Rear Axle and Planetary Housing Oil (S.N. 888001—) NOTE: Dispose of waste oil properly.

TX1003130A —UN—21FEB06

1. Drain rear axle and both planetary housings oil into a container using drain plugs (1 and 2). Install plugs.

Specification Rear Axle and Planetary Housing Oil—Capacity................................................................... 15.6 L 4.1 gal

2. Rotate wheel so plug (2) is above OIL LEVEL line (3) when line is horizontal as shown.

Rear Axle Drain and Fill Plugs

3. Remove rear axle check and fill plug (4) and fill with oil until level with bottom of fill plug hole. See Check Rear Axle and Rear Planetary Oil Level (S.N. 888001—).

(Section 3­8.)

NOTE: It will take approximately 5 minutes for oil to settle into outer housing when oil is warm.

TX1002260A —UN—06JAN06

4. Wait 5­10 minutes for oil to settle, then check level again and add oil as necessary. If oil is cold, settle time may increase.

5. Install all plugs.

1— Rear Axle Drain Plug 2— Planetary Housing Drain and Fill Plug

3— Planetary Housing Oil Level Line 4— Rear Axle Check and Fill Plug

Planetary Drain And Fill Plug VD76477,00014F2 ­19­09JUL10­1/1

Change Hydraulic Reservoir Oil, Filter, PTO Oil and Filter—If Equipped (S.N. 888001—) 1. Park machine on a level surface.

T106436 —UN—14JAN97

2. Lower loader bucket to ground and stop engine.

3. Remove reservoir filler tube cap.

NOTE: Dispose of waste oil properly.

4. Remove drain plug (A) from bottom of reservoir tank and drain oil.

5. Replace plug.

6. Replace hydraulic oil filter and PTO filter (if equipped).

See Replace Hydraulic Oil Filter and PTO Filter—If Equipped (S.N. 888001—). (Section 3­10.)

7. Refill hydraulic reservoir. See Transmission, Hydraulic, Axles, and Mechanical Front Wheel Drive Oil. (Section 3­1.)

Specification Hydraulic Reservoir—Capacity...................................................................... 45.5 L 12 gal

A—Hydraulic Reservoir Drain Plug

PTO Gear Case—if equipped—Capacity....................................................................... 1.86 L 1.96 qt

8. Check oil level.

VD76477,0001469 ­19­09JUL10­1/1

3­11­2

091710

PN=126

Maintenance—Every 6000 Hours Draining the Cooling System CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

TS281 —UN—23AUG88

Shut off engine. Remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

T196294A —UN—17NOV03

NOTE: When John Deere COOL­GARD is used, the drain interval is 3000 hours or 36 months. The drain interval may be extended to 5000 hours or 60 months of operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive (SCA).If COOL­GARD is not used, the flushing interval is 2000 hours or 24 months of operation.

Specification Cooling System—Capac­ ity (S.N. 888000—)............................................................................ 16 L 4.23 gal Specification Cooling System—Capac­ ity (S.N. 888001—)............................................................................ 14 L 3.75 gal

1. Release pressure and remove cap.

T196295A —UN—17NOV03

2. Turn radiator drain valve (A) counterclockwise to open valve. Allow coolant to drain into a container.

3. Connect a hose to engine block coolant drain valve (B).

4. Turn engine block coolant drain valve counterclockwise to open valve. Allow coolant to drain into a container.

5. Turn both drain valves clockwise to close valves and remove hoses.

A—Radiator Drain Valve

B—Engine Block Coolant Drain Valve ER79617,0000C00 ­19­09JUL10­1/1

3­12­1

091710

PN=127

Maintenance—Every 6000 Hours

Filling the Cooling System

TS281 —UN—23AUG88

CAUTION: Prevent possible injury from hot spraying water. Do not remove radiator cap unless the engine is cool. Then turn cap slowly to the stop. Release all pressure before removing cap.

1. Open engine hood.

2. Remove radiator cap (A). Coolant level must be at bottom of filler neck.

Specification Cooling System—Capac­ ity (S.N. 888000—)............................................................................ 16 L 4.23 gal

TX1020859A —UN—20MAR07

Specification Cooling System—Capac­ ity (S.N. 888001—)............................................................................ 14 L 3.75 gal

IMPORTANT: Use only permanent­type low silicate, ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals.

NOTE: All machines are shipped from the factory with a 50­50 mixture for protection to —34°C (—30°F). Adjust mixture accordingly to provide freeze protection for your machine.

FREEZING TEMPERATURES: Fill with permanent­type low silicate, ethylene glycol antifreeze (without stop­leak

A—Radiator Cap

additive) and clean, soft water. Add TY16004 John Deere Coolant Conditioner or equivalent.

ER79617,0000BFF ­19­09JUL10­1/1

3­12­2

091710

PN=128

Miscellaneous—Machine Inspecting and Cleaning Dusty Secondary and Primary Element IMPORTANT: A damaged or dirty element may cause engine damage.

T90684 —UN—10NOV88

Install new elements:

• If the element shows damage and needs to be replaced.

• If element is visibly dirty and will not clean.

• After 1000 hours service or annually.

DO NOT clean a secondary element. Install a new element carefully centering it in the canister.

T47764 —UN—09NOV88

1. Tap element with the palm of your hand, NOT ON A HARD SURFACE. CAUTION: Prevent possible injury from flying objects. Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

2. If this does not remove dust, use compressed air under 210 kPa (2.1 bar) (30 psi).

has the slightest damage. If gasket is broken or missing, install a new element.

NOTE: Air restriction indicator will not signal correctly if an element has a break or is not correctly sealed in air cleaner housing. Throw away element that

3. Direct air up and down the pleats from inside to outside. Be careful not to make a break in the element.

TX03679,00017E3 ­19­02MAR07­1/1

Checking Coolant Hoses and Radiator Check hoses (A) for cracks and leaks. Tighten clamps as necessary.

T106443 —UN—14JAN97

Check radiator for dirt, damage, leaks, and loose or broken mountings. Clean radiator fins.

T106444 —UN—14JAN97

A—Coolant Hoses

TX,90,BG528 ­19­17JAN97­1/1

4­1­1

091710

PN=129

Miscellaneous—Machine

Do Not Service or Adjust Injection Nozzles or Injection Pump If injection nozzles are not working correctly or are dirty, the engine will not run normally. See your authorized dealer for service.

Changing the injection pump in any way not approved by the manufacturer will end the warranty. See your copy of the John Deere warranty on this machine.

Do not service an injection pump that is not operating correctly. See your authorized injection pump service center.

TX,90,FF3116 ­19­03NOV08­1/1

Draining Fuel Filter Sediment Drain water and sediment as necessary.

T7896AI —UN—25NOV92

1. Loosen knob (B) and drain fuel for several seconds from drain tube (A).

2. Tighten knob.

3. Bleed fuel system. See Replace Fuel Filter. (Section 3­8.)

A—Fuel Filter Drain Tube

B—Fuel Filter Knob

TX,90,BD2176 ­19­02MAR07­1/1

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.

6. Connect batteries or a booster battery in the correct polarity (positive [+] to positive [+] and negative [­] to negative [­]).

2. DO NOT TRY TO POLARIZE ALTERNATOR OR REGULATOR.

7. Do not disconnect the batteries when engine is running and alternator is charging.

3. Be sure alternator wires are correctly connected BEFORE you connect batteries.

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.

CED,OUO1021,185 ­19­05NOV08­1/1

4­1­2

091710

PN=130

Miscellaneous—Machine

Handling, Checking and Servicing Batteries Carefully

TS204 —UN—23AUG88

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

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

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

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1. Filling batteries in a well­ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself: 1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes.

Get medical attention immediately.

If acid is swallowed:

TS203 —UN—23AUG88

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 qt).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in 4 L (1 gal) water.

IMPORTANT: Do not overfill the battery cells.

Check the specific gravity of electrolyte in each battery cell.

Continued on next page

4­1­3

TX03679,0001788 ­19­03NOV08­1/2

091710

PN=131

Miscellaneous—Machine

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 ­19­03NOV08­2/2

Using Booster Batteries—12­Volt System Before boost starting, machine must be properly shut down to prevent unexpected machine movement when engine starts.

TS204 —UN—23AUG88

CAUTION: Prevent possible injury from exploding battery. 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 12­volt negative (­) ground. Use only 12­volt booster batteries.

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

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

3. Start engine.

4. Immediately after starting engine disconnect end of the negative cable from the machine. Then disconnect the other end of the negative cable from the negative terminal of the booster batteries.

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

OUT4001,00000E1 ­19­02JUL09­1/1

Replacing Batteries Your machine may be equipped with one or two 12 volt hybrid batteries with (—) negative ground. Use only batteries meeting following specifications:

Volts

BCI Group

—18°C (0°F)

Reserve Capacity (minutes at 25 amps)

12

31

950

190

TS204 —UN—23AUG88

Cold Cranking Amps

TX,90,BG669 ­19­03FEB97­1/1

4­1­4

091710

PN=132

Miscellaneous—Machine

Removing Batteries IMPORTANT: Check for worn or frayed wires and loose or corroded connections.

T196296A —UN—17NOV03

1. Remove two cap screws (A) and cover (B).

2. Disconnect negative (—) battery cables first, then positive (+) cables.

3. Remove nuts and hold­down brackets.

4. Lift batteries out of compartment.

B—Battery Cover

(S.N. 882700—) Dual Battery Option Shown

T196297A —UN—17NOV03

A—Cap Screws (2 used)

(S.N. 882700—) Dual Battery Option Shown TX,90,BG531 ­19­07JAN04­1/1

4­1­5

091710

PN=133

Miscellaneous—Machine

Using Battery Charger

TS204 —UN—23AUG88

CAUTION: Prevent possible injury from exploding battery. Do not charge a battery if the battery is frozen or it may explode. Warm battery to 16°C (60°F) before charging.

Turn off charger before connecting or disconnecting it.

IMPORTANT: Do not use battery charger as a booster if a battery has a 1.150 specific gravity reading or lower.

Disconnect battery ground (­) clamp before you charge batteries in the machine to prevent damage to electrical components.

A battery charger may be used as a booster to start engine.

Stop or cut back charging rate if battery case feels hot, or is venting electrolyte. Battery temperature must not exceed 52°C (125°F).

N36890 —UN—07OCT88

Ventilate the area where batteries are being charged.

OUT4001,0000239 ­19­16MAR10­1/1

4­1­6

091710

PN=134

Miscellaneous—Machine

T115678 —UN—05JUN98

Fuse Specifications—(S.N. —880053)

H3—Display Monitor Alarm F1— 30 Amp Start Protect Fuse F2— 30 Amp Accessory Fuse F3— 10 Amp Alternator Protect Fuse F4— 5 Amp Differential Lock Fuse F5— 5 Amp MFWD Fuse

F12— 5 Amp Return­to­Dig Fuse F6— 10 Amp Start Aid Fuse F7— 10 Amp Fuel Shut­Off Fuse F13— 5 Amp Fuel Gauge Fuse F8— 10 Amp Reverse Alarm Fuse F14— 10 Amp Monitor Fuse K1—Ignition Relay F9— 10 Amp Park Brake FNR K2—Neutral Start Relay Fuse K3—Start Relay F10— 10 Amp Horn Fuse F11— 5 Amp Beacon Fuse

K4—Accessory Relay K5—Reverse Alarm Relay K6—Park Brake Protect Relay K7—Park Brake Latching Relay

IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.

TX,16,BG160 ­19­01JUL99­1/1

4­1­7

091710

PN=135

Miscellaneous—Machine

T196350 —UN—04DEC03

Fuse Specifications—(S.N. 880054—882699)

F1— 10 Amp Start Relay Fuse F2— 10 Amp Auxiliary PTO Fuse F3— 7.5 Amp Alternator, MFWD, Differential Lock Fuse F4— 10 Amp Fuel, Start Aid, Back­Up Alarm Fuse

F5— 10 Amp FNR, Park Brake, Monitor Fuse F6— 5 Amp Return­to­Dig, Beacon, Fuel Gauge Fuse F7— 25 Amp Drive/Work/Tail Lights Fuse F8— 20 Amp Horn, Turn Signal, Stop Light, Flasher Fuse

H5—Display Monitor Alarm K1—Neutral Start Relay K2—Start Relay (Not Shown) K3—Accessory Relay

K4—Back­Up Alarm Relay K5—Park Brake latching Relay

IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.

CED,OUO1032,1419 ­19­28FEB07­1/1

4­1­8

091710

PN=136

Miscellaneous—Machine

Fuse Specifications—(S.N. 882700—888000)

T196351 —UN—04DEC03

IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.

F1— 10 Amp Start Relay Fuse F2— 10 Amp Auxiliary PTO Fuse F3— 7.5 Amp Alternator, MFWD, Differential Lock Fuse F4— 10 Amp Fuel, Start Aid, Back­Up Alarm Fuse

F5— 10 Amp FNR, Park Brake, Monitor Fuse F6— 5 Amp Return­to­Dig, Beacon, Fuel Gauge Fuse F7— 25 Amp Drive/Work/Tail Lights Fuse F8— 20 Amp Horn, Turn Signal, Stop Light, Flasher Fuse

F10— 20 Amp 12­Volt Power Outlet Fuse H5—Display Monitor Alarm K1—Neutral Start Relay K2—Start Relay (Not Shown)

Continued on next page

4­1­9

K3—Accessory Relay K4—Back­Up Alarm Relay K5—Park Brake Latching Relay

OUO1030,000072D ­19­09JUL10­1/2

091710

PN=137

T196614 —UN—01DEC03

Miscellaneous—Machine

F9

T196614 F9— 10 Amp Engine Control Unit (ECU) Fuse

OUO1030,000072D ­19­09JUL10­2/2

Fuse Specifications—(S.N. 888001— ) IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.

The fuse block is located under the front console.

Removal of a panel is necessary to access the fuse block.

F6— Return­to­Dig/Fuel Gauge/Beacon Light 5 A Fuse F7— Drive Light/Work Light/Tail Light 25 A Fuse F8— Horn/Turn Signal/Brake Light/4­Way Flasher 20 A Fuse F10— 12 Volt Power Ports 20 A Fuse—If Equipped

TX1020579A —UN—19MAR07

F1— Starter Relay 10 A Fuse F2— Auxiliary (PTO) 10 A Fuse—If Equipped F3— Alternator/MFWD/Differ­ ential Lock 7.5 A Fuse F4— ECU/Start Aid/Backup Alarm 10 A Fuse F5— TCL/Park Brake/Display Monitor 10 A Fuse

Fuse Location—Fuse Block Continued on next page

4­1­10

VD76477,00014B0 ­19­09JUL10­1/2

091710

PN=138

Miscellaneous—Machine

TX1020596A —UN—16MAR07

F9— ECU/Service ADVISOR™ Battery Power 10 A Fuse

Fuse Location—Engine Left VD76477,00014B0 ­19­09JUL10­2/2

Remove and Install Halogen Bulb

2. Disconnect wiring lead and release retainer clip to remove bulb (D).

IMPORTANT: Do not touch the halogen bulb with bare hands. Oil and moisture may cause premature bulb failure. Clean bulb glass if touched, using an oil­free cloth with alcohol.

3. Install new bulb, lamp and assemble housing.

A—Screw (4 used) B—Lamp Cover C—Lamp

T7484AC —UN—12MAR91

1. Remove screws (A), cover (B), lamp (C), and lamp housing (E).

D—Bulb E—Lamp Housing

OUO1030,000072C ­19­05NOV03­1/1

4­1­11

091710

PN=139

Miscellaneous—Machine

Changing Backup Alarm Volume (S.N. —882699) IMPORTANT: It may be necessary to adjust the volume to meet local regulations.

NOTE: Backup alarm is shipped in low volume position.

NOTE: Backup alarm volume cannot changed on (S.N. 882700—) machines.

To change alarm to high volume, loosen nut (A) and connect bar (B) between “POS HI” and “POS LOW” terminals.

T106986 —UN—31JAN97

B—Bar

T106987 —UN—31JAN97

A—Nut

TX,90,BG670 ­19­02MAR07­1/1

4­1­12

091710

PN=140

Miscellaneous—Machine

Checking Neutral Start System

T106455 —UN—15JAN97

CAUTION: Avoid possible injury or death.

Do not attempt to start machine unless you are sitting in operator’s seat with the clutch switch depressed. Do not bypass or disable any of the starting system parts.

Set park brake before attempting to start engine.

This machine has a neutral start switch that is activated by the transmission control lever (TCL) (A).

Engage park brake.

NOTE: With a manual shift transmission move gearshift lever to N.

A—Transmission Control Lever (TCL)

Check the neutral start system to ensure that the machine:

• WILL start with the TCL in neutral “N” position.

• WILL NOT start with TCL in any other position.

If starting system fails to operate correctly, have your authorized dealer repair the system immediately.

TX,90,BG534 ­19­15FEB07­1/1

Changing Loader Buckets CAUTION: Prevent possible injury from falling hardware. Bucket cylinder and links will fall forward if bucket is in dig position when pins are removed. Remove pins only when bucket is on ground in full dump position.

1. Place bucket in dump position on hard, level surface.

2. Remove pin (A) and pivot links (B) to rear against cross tube (C).

3. Remove pin (D) and carefully lay cylinder (E) on cross tube.

CAUTION: Bucket is heavy and can cause injury if not moved properly. Use adequate lifting device to move bucket.

5. Position new bucket in dump position where previously removed bucket was. Install pins (F).

6. Connect bucket links and cylinder using previously removed pins (A and D) and retaining hardware.

A—Pin B—Pivot Link (2 used) C—Cross Tube

D—Pin E—Cylinder F— Pin (2 used)

T122073B —UN—01JUL99

4. Remove pins (F) and bucket.

TX,35,BG457 ­19­06JUL09­1/1

4­1­13

091710

PN=141

Miscellaneous—Machine

Adding Attachments/Accessories to Roll­Over Protective Structure (ROPS)

Improper attachment may impair the protection offered by the ROPS.

Do not add attachments or accessories to the ROPS without contacting your authorized dealer for information.

045,90,K117 ­19­08JUN94­1/1

Welding On Machine IMPORTANT: Disconnect both negative and positive battery cables and microprocessor unit (if applicable).

weld area so electrical current does not pass through any bearings.

Remove or protect all parts that can be damaged by heat or weld splatter.

Have only a qualified welder do this job.

Connect welder ground clamp close to each VD76477,00004EE ­19­20AUG09­1/1

Welding Near Electronic Control Units IMPORTANT: Do not jump­start engines with arc welding equipment. Currents and voltages are too high and may cause permanent damage.

TS953 —UN—15MAY90

1. Disconnect the negative (­) battery cable(s).

2. Disconnect the positive (+) battery cable(s).

3. Connect the positive and negative cables together. Do not attach to vehicle frame.

4. Clear or move any wiring harness sections away from welding area.

5. Connect welder ground close to welding point and away from control units.

6. After welding, reverse Steps 1—5.

DX,WW,ECU02 ­19­14AUG09­1/1

Keep Electronic Control Unit Connectors Clean

RG16946 —UN—31MAR09

IMPORTANT: Do not open control unit and do not clean with a high­pressure spray.

Moisture, dirt, and other contaminants may cause permanent damage.

1. Keep terminals clean and free of foreign debris.

Moisture, dirt, and other contaminants may cause the terminals to erode over time and not make a good electrical connection.

2. If a connector is not in use, put on the proper dust cap or an appropriate seal to protect it from foreign debris and moisture.

3. Control units are not repairable.

4. Since control units are the components LEAST likely to fail, isolate failure before replacing by completing a diagnostic procedure. (See your John Deere dealer.)

5. The wiring harness terminals and connectors for electronic control units are repairable.

DX,WW,ECU04 ­19­11JUN09­1/1

4­1­14

091710

PN=142

Miscellaneous—Machine

External Service Brake Inspection (S.N. —888000)

T115644 —UN—01JUN98

NOTE: The service brake inspection ports are located at the front of the rear axle.

1. Remove plugs (A) from inspection port (C).

2. Start engine. Do not release park brake.

3. Apply the service brakes.

NOTE: Gap (B) equals the overall thickness of brake disk (E) when service brake is applied.

A piece of metal bar stock with a thickness of 5 mm (0.197 in.) can be used as a gauge to check gap (B). If the 5 mm (0.197 in.) gauge cannot fit between two separator disks (D), replace brake disks.

4. Check gap (B) between two separator disks (D) using a feeler gauge.

5. Replace brake disks if gap (B) is less than 5 mm (0.197 in.). (See your authorized dealer.)

D—Separator Disk (4 used) E—Brake Disk (3 used)

T115634 —UN—01JUN98

A—Plugs B—Gap [5 mm (0.197 in.) minimum] C—Inspection Port

Service Brake Inspection VD76477,0001437 ­19­09JUL10­1/1

4­1­15

091710

PN=143

Miscellaneous—Machine

External Service Brake Inspection (S.N. 888001—)

TX1002474A —UN—10JAN06

Do first inspection at 5000 hours followed by 1000 hour inspection intervals after the first 5000 hour inspection.

If the service brakes are subjected to severe duty, inspect more frequently.

1. Inspect brakes for wear through the external inspection ports (1 and 2).

2. Remove axle housing and replace brake disc if oil grooves (3) on facing material are no longer visible.

Right Rear Wheel External Inspection Port

TX1002475A —UN—10JAN06

3— Oil Grooves

Left Rear Wheel External Inspection Port

3

TX1002476A —UN—10JAN06

1— Right Rear Wheel External Inspection Port 2— Left Rear Wheel External Inspection Port

VD76477,0001436 ­19­09JUL10­1/1

4­1­16

091710

PN=144

Miscellaneous—Machine

CAUTION: Prevent possible injury from reduced brake capacity. Do not operate machine if pedal travel exceeds 133 mm (5.25 in.) while applying 267 N (60 lb­force). Operating machine with excessive brake travel could cause brakes not to stop machine on first application.

NOTE: Air will "gravity bleed" from brake system through brake valve without use of bleed screws. Brake lines must be inclined toward brake valve.

Low ambient temperature or aeration of oil will slow bleed process.

1. Engage park brake. Lock brake pedals so to bleed both brakes at the same time.

2. Operate engine at high speed and cycle a hydraulic function such as the loader bucket to fill brake reservoir.

Service Brakes (S.N. —880907)—Specification Engine Speed—Speed.............................................................. 2200 rpm

T6838AE —UN—26OCT88

Bleeding Service Brakes (S.N. —880907)

in.) or less. Brakes will continue to self­bleed as you operate machine and pedal firmness should improve.

Service Brakes (S.N. —880907)—Specification Brake Pedal Travel—Distance.......................................................Firm within 133 mm Firm within 5.25 in.

5. If unable to obtain firm brake pedal, inspect lines and connections for leakage. If no external leaks, see your authorized dealer.

3. Release brake pedals completely and wait a minimum of 10 seconds.

4. Repeat steps 2 and 3 until a firm pedal is obtained with pedal travel within specified distance of 133 mm (5.25 OUO1043,00001E2 ­19­02MAR07­1/1

4­1­17

091710

PN=145

Miscellaneous—Machine

Bleed Service Brakes (S.N. 880908— )

T6838AE —UN—26OCT88

The service brakes can be bled using one of two methods.

Method One does not involve loosening the bleed screws, but requires a considerable amount of pumping the brake pedals. Method Two requires less pumping of the brake pedals, but involves loosening the bleed screws and attaching clear tubing. Use the method that is best for your situation.

All fittings must be inspected for leaks and tightened if leaks occur.

CAUTION: Prevent possible injury from reduced brake capacity. Do not operate machine if pedal travel exceeds 114 mm (4.5 in.) while applying 267 N (60 lb­force). Operating machine with excessive brake travel could cause brakes not to stop machine on first application.

NOTE: Air will "gravity bleed" from brake system through brake valve without use of bleed screws. Brake lines must be inclined toward brake valve.

Low ambient temperature or aeration of oil will slow bleed process.

2. Acquire two pieces of 6.4 mm (1/4 in.) ID clear tubing that are approximately 2438 mm (8 ft) long.

3. Loosen the two service brake bleed screws located on rear axle. Remove the fill cap from the hydraulic reservoir.

4. Attach an end of one of the tubes to one of the bleed screws. Insert the other end into fill neck of the hydraulic reservoir. Do the same for the other tube, but attach it to the remaining bleed screw.

Method One

5. Lock the brake pedals together.

1. Engage park brake.

6. Start and operate engine at slow idle.

2. While operating engine at fast idle, turn steering wheel from lock to lock and cycle a hydraulic function, such as the loader bucket, five times.

7. Pump brake pedals while turning the steering wheel back and forth to force hydraulic oil into the brake valve reservoir.

3. Operate engine at slow idle.

8. With brake pedals locked together, pump the pedals until a continuous stream of fluid with no bubbles is seen flowing through the clear tubes.

4. Pump left brake pedal five times, allowing 2 seconds between each pump for air to escape.

9. Tighten bleed screws.

5. Repeat steps 2—4 until the left pedal is solid.

6. Pump right pedal until pedal is solid, then pump both pedals at the same time until pedals are solid.

7. Check pedal travel.

Bleed Service Brakes (S.N. 880908— )—Specification Maximum Dual Brake Pedal Travel—Distance...............................................Firm within 95 mm Firm within 3.75 in.

Maximum Single Brake Pedal Travel—Distance............................................. Firm within 114 mm Firm within 4.50 in.

8. If unable to obtain firm brake pedal, inspect lines and connections for leakage. If no external leaks, see your authorized dealer.

Method Two

10. Check pedal travel.

Bleed Service Brakes (S.N. 880908— )—Specification Maximum Dual Brake Pedal Travel—Distance...............................................Firm within 95 mm Firm within 3.75 in.

Maximum Single Brake Pedal Travel—Distance............................................. Firm within 114 mm Firm within 4.50 in.

11. Disconnect the clear tubes from the bleed screws and drain remaining oil inside the tubes into the reservoir.

12. Install reservoir fill cap.

13. If unable to obtain firm brake pedal, inspect lines and connections for leakage. If no external leaks, see your authorized dealer.

1. Engage park brake.

OUO1043,0000237 ­19­02MAR07­1/1

4­1­18

091710

PN=146

Miscellaneous—Machine

T6157AF —UN—18OCT88

T6159AC —UN—18OCT88

Toe­In Check and Adjust (S.N. —888000)

1. Measure distance from ground to center of hub (A) and make a mark on front (B) and rear (C) of each front tire in center of tread.

2. Measure distance between front marks (B).

T6162AT —UN—02NOV88

3. Measure distance between rear marks (C).

4. The distance between front marks must be less than distance between rear marks by the following amount.

Specification Toe­In Measure­ ment—Standard Axle Distance between (B) and (C)...................................................................................... 6 ± 3 mm 1/4 ± 1/8 in.

MFWD Axle Distance between (B) and (C) ................................................................. 3 ± 3 mm 1/8 ± 1/8 in.

T103499 —UN—03SEP96

Non­MFWD

Machines Without Mechanical Front Wheel Drive: 1. To adjust toe­in, loosen both tie rod clamps (E) and turn tie rod tube (D).

2. Turn clamps so that cap screws are toward rear of machine and tipped down approximately 45°.

MFWD

3. Tighten clamp cap screws to specification.

Specification Toe­In Tie Rod Clamp Cap Screws—Torque............................................................95 ± 14 N∙m 70 ± 10 lb­ft

A—Center of Hub B—Front of Tire C—Rear of Tire D—Tie Rod Tube

E—Tie Rod Clamp F— Nuts G—Rod End

Machines With Mechanical Front Wheel Drive: 1. To adjust toe­in, loosen nuts (F).

Specification Toe­In Tie Rod Nuts—Torque................................................................................50 N∙m 35 lb­ft

2. Turn rod end (G) to get proper toe­in.

3. Adjust toe­in equally on both tie rods.

4. Tighten nuts to specification.

VD76477,0001451 ­19­09JUL10­1/1

4­1­19

091710

PN=147

Miscellaneous—Machine

Toe­In Check and Adjust (S.N. 888001—) SPECIFICATIONS Toe­In Measurement

3—6 mm 0.13—0.25 in.

T6382JW —UN—02NOV88

1. Park machine on a flat level surface with the front wheels in the straight ahead position.

2. Measure ground­to­center of hub distance (A).

3. At tread center line at front of tire, measure from ground up using value obtained in step 2. Put a mark on the tire tread at location measured. Do same at tread center line at rear of tire.

Toe­In Measurement

4. Repeat steps 2 and 3 for other front wheel.

A—Ground­to­Center of Hub Distance B—Distance at Front of Tires

5. Measure distance at front of tires (B) (from tread center line to tread center line where marked).

6. Measure distance at rear of tires (C) (from tread center line to tread center line where marked).

C—Distance at Rear of Tires D—Tie Rod Tube

Specification Toe­In Measure­ ment—Distance..........................................................................3—6 mm 0.13—0.25 in.

7. Distance (B) must be less than distance (C) as specified.

VD76477,0001450 ­19­13JUL10­1/1

Rear Counterweights

T105030 —UN—11NOV96

CAUTION: Counterweights are heavy and can cause serious injury if dropped. Be sure counterweights are properly supported with a fork lift or other adequate lifting device before removing.

NOTE: (S.N. 882239—) machines have a one piece counterweight. One piece counterweights weight 227 kg (500 lb) Rear counterweights are provided for added stability.

Remove counterweights as necessary.

(S.N. —880053) Shown TX,35,BG460 ­19­28FEB07­1/1

Adding Liquid Ballast to Rear Tires

Weights given are for tires 75 percent full of liquid.

NOTE: See Tire Inflation Pressures. (Section 3­3.)

Water Only

Water/CaCl2 Solution *

Tire Size

Water Volume

Water Weight

Water Volume

Water Weight

Weight of Solution Per Tire

16.9 x 24 8PR R4

231 L (61 gal)

231 kg (510 lb)

197 L (52 gal)

82 kg (181 lb)

279 kg (615 lb)

*Approximately 1.6 kg (3.5 lb) CaCl2 per gallon of water will stay slush free to —24°C (—12°F) and will freeze solid at —47°C (—52°F).

OUO1030,0000729 ­19­02MAR07­1/1

4­1­20

091710

PN=148

Miscellaneous—Machine

Adding Liquid Ballast to Front Tires

Weights given are for tires 75 percent full of liquid.

NOTE: See Tire Inflation Pressures. (Section 3­3.)

Water Only

Water/CaCl2 Solution *

Tire Size

Water Volume

Water Weight

Water Volume

Water Weight

Weight of Solution Per Tire

11L­15 8PR F3 (S.N. —888000)

53 L (14 gal)

53 kg (117 lb)

45 L (12 gal)

19 kg (42 lb)

64 kg (142 lb)

12­16.5 8PR NHS

57 L (15 gal)

57 kg (126 lb)

49 L (13 gal)

21 kg (46 lb)

70 kg (155 lb)

*Approximately 1.6 kg (3.5 lb) CaCl2 per gallon of water will stay slush free to —24°C (—12°F) and will freeze solid at —47°C (—52°F).

VD76477,0001421 ­19­20JUL10­1/1

Do Not Service Control Valves, Cylinders, Pumps or Motors

If these parts need service, see your authorized John Deere dealer.

Special tools and information are needed to service control valves, cylinders, pumps, or motors.

TX,90,DH2537 ­19­05NOV08­1/1

Checking Wheel Fasteners (S.N. —888000) Front Axle—Specification 2WD Axle—Torque......................................................................136 N∙m 100 lb­ft MFWD Axle—Torque...................................................................339 N∙m 250 lb­ft

T87507 —UN—21OCT88

Rear Axle—Specification Standard Axle—Torque...............................................................420 N∙m 310 lb­ft

T6000AU —UN—18OCT88

Tighten wheel cap screws and fasteners to specification.

VD76477,0001456 ­19­09JUL10­1/1

4­1­21

091710

PN=149

Miscellaneous—Machine

Keep ROPS Installed Properly

T122071B —UN—01JUL99

CAUTION: Prevent possible injury from during rollover. Make certain all parts are reinstalled correctly if the roll­over protective structure (ROPS) is loosened or removed for any reason.

Tighten mounting bolts to proper torque.

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.

When installation of equipment on a machine necessitates loosening or removing ROPS, mounting bolts (A) must be tightened to specification.

A—Mounting Bolts

Specification ROPS Mounting Bolt—Torque........................................................................379 ± 76 N∙m 280 ± 56 lb­ft TX,90,BG599 ­19­01FEB07­1/1

Hardware Torque Specifications Check cap screws and nuts to be sure they are tight.

If hardware is loose, tighten to torque shown on the following charts unless a special torque is specified.

TX,90,FF1225 ­19­15MAR93­1/1

4­1­22

091710

PN=150

Miscellaneous—Machine

Unified Inch Bolt and Screw Torque Values TS1671 —UN—01MAY03

Bolt or

SAE Grade 2a

SAE Grade 1 Lubricated

Screw Size 1/4 5/16 3/8 7/16

b

c

Lubricatedb

Dry

SAE Grade 5, 5.1 or 5.2

Dryc

Lubricatedb

SAE Grade 8 or 8.2

Dryc

Lubricatedb

Dryc

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

3.7

33

4.7

42

6

53

7.5

66

9.5

84

12

106

13.5

120

17

150

N∙m

lb.­ft.

N∙m

lb.­ft.

28

20.5

35

26

7.7 13.5

68 120

22

194

N∙m

lb.­ft.

9.8

86

12

106

15.5

137

17.5

155

22

194

27

240

N∙m

lb.­ft.

N∙m

lb.­ft.

N∙m

lb.­ft.

28

20.5

35

26

44

32.5

lb.­in.

19.5

172

25

221

N∙m

lb.­ft.

N∙m

lb.­ft.

35

26

44

32.5

49

36

63

46

56

41

70

52

80

59

100

74

1/2

34

25

42

31

53

39

67

49

85

63

110

80

120

88

155

115

9/16

48

35.5

60

45

76

56

95

70

125

92

155

115

175

130

220

165

5/8

67

49

85

63

105

77

135

100

170

125

215

160

240

175

305

225

3/4

120

88

150

110

190

140

240

175

300

220

380

280

425

315

540

400

7/8

190

140

240

175

190

140

240

175

490

360

615

455

690

510

870

640

1

285

210

360

265

285

210

360

265

730

540

920

680

1030

760

1300

960

1­1/8

400

300

510

375

400

300

510

375

910

670

1150

850

1450

1075

1850

1350

1­1/4

570

420

725

535

570

420

725

535

1280

945

1630

1200

2050

1500

2600

1920

1­3/8

750

550

950

700

750

550

950

700

1700

1250

2140

1580

2700

2000

3400

2500

1­1/2

990

730

1250

930

990

730

1250

930

2250

1650

2850

2100

3600

2650

4550

3350

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U­bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

a

Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length.

“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C zinc flake coating. c “Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating. b

DX,TORQ1 ­19­08DEC09­1/1

4­1­23

091710

PN=151

Miscellaneous—Machine

Metric Bolt and Screw Torque Values TS1670 —UN—01MAY03

Bolt or

4.8

8.8

9.8

10.9

12.9

12.9

4.8

8.8

9.8

10.9

12.9

12.9

Class 4.8

Class 8.8 or 9.8

Size

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

lb.­in.

N∙m

M6

4.7

42

6

53

8.9

79

11.3

100

13

115

16.5

146

15.5

137

19.5

172

N∙m

lb.­ft.

N∙m

lb.­ft.

N∙m

lb.­ft.

N∙m

lb.­ft.

32

23.5

40

29.5

37

27.5

47

35

63

46

80

59

75

55

95

70

M10

11.5

102

Lubricateda

Dryb

Lubricateda

Class 12.9

Lubricateda

M8

Dryb

Class 10.9

Screw

14.5

128

22

194

27.5

243

N∙m

lb.­ft.

N∙m

lb.­ft.

N∙m

lb.­ft.

29

21

43

32

55

40

Dryb

Lubricateda

Dryb lb.­in.

23

204

N∙m

lb.­ft.

M12

40

29.5

50

37

75

55

95

70

110

80

140

105

130

95

165

120

M14

63

46

80

59

120

88

150

110

175

130

220

165

205

150

260

190

M16

100

74

125

92

190

140

240

175

275

200

350

255

320

235

400

300

M18

135

100

170

125

265

195

330

245

375

275

475

350

440

325

560

410

M20

190

140

245

180

375

275

475

350

530

390

675

500

625

460

790

580

M22

265

195

330

245

510

375

650

480

725

535

920

680

850

625

1080

800

M24

330

245

425

315

650

480

820

600

920

680

1150

850

1080

800

1350

1000

M27

490

360

625

460

950

700

1200

885

1350

1000

1700

1250

1580

1160

2000

1475

M30

660

490

850

625

1290

950

1630

1200

1850

1350

2300

1700

2140

1580

2700

2000

M33

900

665

1150

850

1750

1300

2200

1625

2500

1850

3150

2325

2900

2150

3700

2730

M36

1150

850

1450

1075

2250

1650

2850

2100

3200

2350

4050

3000

3750

2770

4750

3500

Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U­bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.

a

“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with JDM F13C zinc flake coating. b “Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.

DX,TORQ2 ­19­08DEC09­1/1

4­1­24

091710

PN=152

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 machine operation while doing both a walk­around inspection and performing specific checks from the operator’s seat.

A location will be required which is level and has adequate space to complete the checks. No tools or equipment are needed to perform this checkout.

Should you experience a problem with your machine, you will find helpful diagnostic information in this checkout that will pinpoint the cause. Use the table of contents to help find adjustment procedures. This information may allow you to perform simple repairs yourself, reducing machine down time.

The information obtained after completing the operational checkout will allow you or your authorized dealer to pinpoint a specific test or repair needed to restore the machine to specifications.

Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) prior to doing the checkout. The machine must be at operating temperature for many of the checks.

Locate the check to be performed at the top of the left column and read completely down the column before performing the check. Follow this sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to next check. If a problem is indicated, you will be referred to either a group in this manual or to your authorized dealer for repair.

VD76477,00014A9 ­19­19MAR07­1/59

Diagnostic Trouble Codes VD76477,00014A9 ­19­19MAR07­2/59

Display and Clear Trouble Codes

Always check for diagnostic trouble codes and correct them before performing the operational checkout.

Diagnostic trouble codes can be displayed by using two methods:

• Standard Display Monitor (SDM)

YES: Correct all diagnostics trouble codes before proceeding. See your authorized dealer.

• Service Advisor

NO: Proceed with operational checkout.

VD76477,00014A9 ­19­19MAR07­3/59

Gauge and Indicator Check with Engine Off Continued on next page

4­2­1

VD76477,00014A9 ­19­19MAR07­4/59

091710

PN=153

Miscellaneous—Operational Checkout Monitor Indicator Lights and Alarm Checks

Turn key switch to BULB CHECK position and hold.

LOOK: Are all monitor indicator lights on?

LOOK/LISTEN: Is STOP light ON and does alarm sound for three seconds?

YES: Go to next check.

NOTE: Starting motor MUST NOT operate.

NO: Check monitor/gauge fuse.

If STOP light stays ON and alarm sounds longer than three seconds, see your authorized dealer.

If motor starts and bulb check position is OK, key switch is failed or there is a short in wiring, see your authorized dealer.

VD76477,00014A9 ­19­19MAR07­5/59

Transmission Control Lever (TCL), Neutral Start Circuit and Reverse Warning Alarm Checks VD76477,00014A9 ­19­19MAR07­6/59

TCL Switch Check

Engine OFF. Move transmission control lever (TCL) lever to FORWARD "F", REVERSE "R", then NEUTRAL "N" position.

FEEL: Observe and feel forward, neutral and reverse detents.

Turn key switch to ON position. Move transmission control lever (TCL) lever into FORWARD "F" and REVERSE "R".

YES: Go to next check.

LISTEN: Did you hear a "click" from the neutral start relay behind right side of dash panel pedestal as transmission control lever (TCL) lever was moved?

NO: If no "click", inspect neutral start relay. See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­7/59

Neutral Start Check

Move transmission control lever (TCL) lever to FORWARD "F" position and turn key switch to START position.

Move transmission control lever (TCL) lever to REVERSE "R" position and turn key switch to START position.

YES: See your authorized dealer.

LISTEN: Did starting motor operate?

NO: Go to next check.

Continued on next page

4­2­2

VD76477,00014A9 ­19­19MAR07­8/59

091710

PN=154

Miscellaneous—Operational Checkout Start Circuit Check

Move transmission control lever (TCL) lever to NEUTRAL "N" position and turn key switch to START position.

Observe and listen to monitor as engine is cranking.

LISTEN: Did starting motor operate?

LISTEN: Did alarm sound?

YES: Go to next check.

LOOK: During engine cranking, were all indicator lights ON? Is STOP indicator ON?

NO: If engine turns but does not start, on machines (S.N. —880053) check fuel shut­off/start aid/reverse alarm fuses. On machines (S.N. 880054—) check fuel shut­off/start aid/reverse alarm fuse. If starting motor does not operate, check start fuse. See your authorized dealer. If indicator lights are NOT ON, check monitor/gauge fuse.

See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­9/59

Backup Warning Alarm Check

Key switch ON. Move transmission control lever (TCL) lever to reverse "R" position.

YES: Go to next check.

LISTEN: Does backup warning alarm sound?

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­10/59

Park Brake, Charge Indicator Light, Hour Meter Circuit and Engine Speed Control Linkage Checks Continued on next page

4­2­3

VD76477,00014A9 ­19­19MAR07­11/59

091710

PN=155

Miscellaneous—Operational Checkout Park Brake Indicator Check

IMPORTANT: If engine oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY, check oil level.

Engage park brake.

Put transmission control lever (TCL) lever in NEUTRAL "N" and start the engine.

Put transmission control lever (TCL) lever in FORWARD "F" position.

LOOK: Is STOP indicator ON? Does alarm sound? Are park brake and seat belt lights ON? Are all other indicator lights out?

Release park brake.

YES: Go to next check.

LOOK/LISTEN: Are park brake indicator and STOP lights out? Alarm will not sound.

NO: If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY and check oil level. See Check Engine Oil Level. (Section 3­4). If alternator indicator light is ON, increase engine speed to approximately 1/3 throttle and alternator light MUST go out. If no park brake light, see your authorized dealer.

VD76477,00014A9 ­19­19MAR07­12/59

Hour Meter Circuit Check

IMPORTANT: If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY and check oil level.

Engage park brake.

Put transmission control lever (TCL) lever in NEUTRAL "N" and start the engine.

YES: Go to next check.

LOOK/LISTEN: Is hour meter indicator rotating?

NO: If park brake indicator light stays ON, see your authorized dealer. If no hour meter movement, see your authorized dealer.

Continued on next page

4­2­4

VD76477,00014A9 ­19­19MAR07­13/59

091710

PN=156

Miscellaneous—Operational Checkout Engine Speed Hand Control Linkage Check (If Equipped)

Engage park brake.

Put transmission control lever (TCL) lever in NEUTRAL "N" and start engine.

Use a tachometer to check rpm.

Move hand throttle knob to fast idle position.

LOOK: Does tachometer read 900 + 25 — 0 rpm (slow idle) or 2350 + 50 — 0 rpm (fast idle?)

NO: Check engine speed.

See your authorized dealer.

LOOK: Does speed control lever remain at selected position?

YES: Go to next check.

VD76477,00014A9 ­19­19MAR07­14/59

Engine Speed Control Pedal Linkage Check

Engage park brake.

Put transmission control lever (TCL) lever in NEUTRAL "N" and start engine.

Use a tachometer to check rpm.

Depress speed control pedal.

YES: Go to next check.

LOOK: Does tachometer read 900 + 25 — 0 rpm (slow idle) or 2350 + 50 — 0 rpm (fast idle?)

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­15/59

Brake System Checks VD76477,00014A9 ­19­19MAR07­16/59

Pedal Stop Check

Lift left and right brake pedals.

LOOK: Are brake pedals against pedal stop screws?

YES: Go to next check.

NOTE: This ensures that brake check valves are opened and brakes released.

NO: See your authorized dealer.

Continued on next page

4­2­5

VD76477,00014A9 ­19­19MAR07­17/59

091710

PN=157

Miscellaneous—Operational Checkout Brake System Leakage Check

Depress and hold left brake pedal, then right brake pedal, using approximately 267 N (60 lb force).

NO: Go to next check.

LOOK: Brake pedal must NOT feel spongy (caused by air in system). Does pedal settle more than 25 mm (1.0 in.) per minute?

YES: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­18/59

Brake Drag/Park Brake Capacity Check

Put seat belt on.

Position machine on a gradual slope with front of machine downhill.

Lift bucket so it clears ground.

Shift transmission control lever (TCL) lever to NEUTRAL "N", differential lock control up, disengage park brake and release service brakes.

Let machine coast freely for several feet. Apply park brake.

LOOK: Did machine stop?

Release park brake.

LOOK: Did machine move or coast freely?

YES: Go to next check.

NOTE: If machine does not move freely on slope, drive the machine for five minutes.

Feel axle housing area to locate which brake is dragging.

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­19/59

Steering System Checks VD76477,00014A9 ­19­19MAR07­20/59

Steering Check

Raise loaded bucket to place added weight on front wheels.

Operate engine at slow idle.

Turn steering wheel from full left to full right several times.

LOOK: Did front wheels move smoothly in both directions?

LOOK: When steering wheel was stopped, did front wheels stop moving?

YES: Go to next check.

NOTE: Internal leakage or a sticking steering valve spool can cause wheels to continue to move after steering wheel is stopped.

NO: See your authorized dealer.

Continued on next page

4­2­6

VD76477,00014A9 ­19­19MAR07­21/59

091710

PN=158

Miscellaneous—Operational Checkout Steering Leakage Check

NOTE: Hydraulic oil must be at operating temperature.

Run engine at slow idle. Turn steering wheel until wheels are in maximum right turn position. Continue turning steering wheel, using approximately 11.3 N∙m (100 lb­in.) force while counting steering wheel rpm.

Repeat leakage check, turning steering wheel to the left.

YES: Go to next check.

LOOK: Did steering wheel turn five rpm or less to the left or right? This represents acceptable steering wheel movement during normal operation.

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­22/59

Steering Priority Valve Check

Operate engine at slow idle.

Turn steering wheel to stop left and right. Note effort required to turn wheel.

Turn wheel to stop and apply constant pressure.

NOTE: The priority relief valve pressure must be set to the correct specification to obtain smooth steering.

LOOK/FEEL: Does wheel stop at both axle stops and require normal steering wheel effort?

YES: Go to next check.

LISTEN: Does engine rpm decrease when steering wheel is held against stop?

NO: Steers hard and no decrease in engine rpm.

See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­23/59

Transmission Neutral Disconnect Circuit Check VD76477,00014A9 ­19­19MAR07­24/59

Neutral Disconnect Circuit Check

CAUTION: Machine will move forward as transmission control lever (TCL) is moved and may cause injury to bystanders. Ensure machine has enough free space for this check.

Start engine, set idle speed at approximately 1/3 throttle.

Put transmission in fourth gear.

Release park brake and apply service brakes.

Shift transmission control lever (TCL) lever to forward "F" position.

LISTEN: When transmission control lever (TCL) lever is shifted to forward "F" position, can a noticeable drop in engine speed be heard?

Press Neutral Disconnect Switch on gear shift lever or loader control lever individually and note sound of engine.

YES: Go to next check.

LISTEN: Does engine rpm increase when the neutral solenoid switches are depressed?

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­25/59

Driving Checks VD76477,00014A9 ­19­19MAR07­26/59

Transmission Shift Linkage, Synchronizer and Noise Check

IMPORTANT: Press neutral disconnect switch on gear shift lever when shifting gears.

Run engine at approximately 1/2 throttle with transmission control lever (TCL) lever in FORWARD "F" position.

Shift transmission into each gear and drive for a short distance.

NO: Go to next check.

LISTEN: Can excessive gear noise be heard when shifting between gears?

YES: See your authorized dealer.

Continued on next page

4­2­7

VD76477,00014A9 ­19­19MAR07­27/59

091710

PN=159

Miscellaneous—Operational Checkout Differential Lock Check

Raise rear of loader onto floor stands so rear wheels are off ground.

Unlock brake pedals. Turn mechanical front wheel drive (MFWD) switch OFF (if equipped).

Operate machine at approximately 1/2 throttle in 1st forward.

Depress differential lock control.

Apply one brake pedal.

YES: Go to next check.

LOOK: Both wheels must stop.

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­28/59

Differential Gear and Pinion Check

Shift transmission to first gear and operate engine at approximately 1/2 throttle.

Move transmission control lever (TCL) lever to FORWARD "F" position.

Steer machine in a maximum left turn and depress left brake pedal to stop the left wheel.

Steer machine in a maximum right turn and depress right brake pedal to stop the right wheel.

NO: Go to next check.

LISTEN: Can excessive gear noise be heard in the differential or pinion gear area?

YES: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­29/59

Front Wheel Alignment (Toe­In) Check

Drive machine in fourth gear forward on a surface with loose material.

NO: Go to next check.

LOOK: Is material from behind front wheels thrown excessively inward or outward?

YES: If material is thrown, excessive tire wear will result. See Toe­In Check and Adjust. (Section 4­1.)

Continued on next page

4­2­8

VD76477,00014A9 ­19­19MAR07­30/59

091710

PN=160

Miscellaneous—Operational Checkout Engine and Torque Converter Check (Without MFWD)

Position machine with loader bucket at ground level against dirt bank or immovable object.

Shift transmission into fourth gear.

Move transmission control lever (TCL) lever to FORWARD "F" position.

Engage differential lock.

Increase engine speed to fast idle.

LOOK: Do rear wheels stall?

NO: Go to next check.

NOTE: This test will give a general indication of engine, transmission and torque converter performance.

YES: If the wheels can be easily stalled, see your authorized dealer.

VD76477,00014A9 ­19­19MAR07­31/59

Transmission Hydraulic System Check

Run engine at approximately 1/2 throttle.

Shift transmission into third gear.

Move transmission control lever (TCL) lever to FORWARD "F" position.

Make several shifts from third forward to third reverse. Start counting the number of seconds when transmission control lever (TCL) lever is moved to opposite direction.

LOOK: Is shift from one direction to the other completed in three seconds?

YES: Go to next check.

NOTE: If longer in one direction ONLY, check the slower direction clutch pack.

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­32/59

Mechanical Front Wheel Drive (MFWD) Driving Check — If Equipped VD76477,00014A9 ­19­19MAR07­33/59

MFWD Switch Check

Push switch and engage mechanical front wheel drive (MFWD).

LOOK: Does mechanical front wheel drive (MFWD) light in display monitor come ON when switch is pressed?

Push switch to disengage mechanical front wheel drive (MFWD).

LOOK: Is mechanical front wheel drive (MFWD) light in display monitor OFF with MFWD disengaged?

YES: Go to next check.

NOTE: Indicator light in mechanical front wheel drive (MFWD) switch will remain ON while MFWD is engaged. If MFWD is turned OFF while operating, light will go out but MFWD could stay engaged until load on drive train is released.

NO: See your authorized dealer.

Continued on next page

4­2­9

VD76477,00014A9 ­19­19MAR07­34/59

091710

PN=161

Miscellaneous—Operational Checkout Engine and Torque Converter Check (With MFWD)

With loader bucket level and cutting edge at the centerline of front wheels, put machine against a dirt bank or immovable object.

Engage mechanical front wheel drive (MFWD) and differential lock.

Move shift lever to first gear.

Put transmission control lever (TCL) lever in FORWARD "F" position.

Increase engine speed to fast idle.

YES: Go to next check.

LOOK: Do both rear wheels and both front wheels turn?

NO: If all wheels stop, a torque converter or transmission control valve problem is indicated. If the front wheels stop, mechanical front wheel drive (MFWD) problem is indicated. See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­35/59

MFWD Gear and Pinion Check

Drive machine at transport speed with mechanical front wheel drive (MFWD) engaged, then disengaged.

LISTEN: Does mechanical front wheel drive (MFWD) “whine” when disengaged?

NO: Go to next check.

NOTE: It is normal for mechanical front wheel drive (MFWD) to “whine” when engaged. YES: If mechanical front wheel drive (MFWD) whines when disengaged, check oil levels and fill to correct levels.

VD76477,00014A9 ­19­19MAR07­36/59

Hydraulic System Checks VD76477,00014A9 ­19­19MAR07­37/59

Main Hydraulic Pump Performance Check

NOTE: If hydraulic oil is not at operating temperature, heat oil to 38—52°C (100—125°F).

Put loader bucket flat on ground.

Transmission in NEUTRAL "N", transmission control lever (TCL) in FORWARD "F".

Run engine at slow idle.

Measure cycle time to raise loader to maximum height (including bucket leveling).

LOOK: Does loader rise to maximum height in 15 seconds or less?

YES: Go to next check.

NOTE: Take the average cycle time for at least three cycles. This time will give a general indication of hydraulic pump performance.

NO: If cycle time slow, see your authorized dealer.

Continued on next page

4­2­10

VD76477,00014A9 ­19­19MAR07­38/59

091710

PN=162

Miscellaneous—Operational Checkout Loader Function Drift Check

NOTE: Cylinder oil temperature should be 38—52°C (100—125°F).

If not, heat oil to specifications.

Position loader bucket cutting edge 50 mm (2.0 in.) off the ground.

Run engine at slow idle and observe bucket cutting edge.

NO: Go to next check.

LOOK: Does cutting edge touch ground within one minute?

YES: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­39/59

Loader Boom Float Check Put loader bucket at maximum height position with bucket dumped.

Run engine at approximately 1/2 throttle.

Move the loader control lever forward into boom float detent position. Remove hand from control lever.

YES: Go to next check.

LOOK: Does loader control lever remain in the boom float detent position?

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­40/59

Loader Return­to­Dig Check

T6171AT —UN—09DEC88

T7374CH —UN—04OCT90

Raise loader bucket to approximately 2/3 height position with bucket dumped.

Run engine at approximately 2/3 throttle.

Move the loader control lever forward into boom float detent position, and at the same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Does the loader control lever disengage from the bucket rollback detent when the bucket is level?

LOOK: When the bucket is at ground level, bucket must be level and the bucket indicator pointer should be aligned with mark on the boom pivot. Alignment will vary according to each operator’s eye level and preferences.

YES: Go to next check.

NOTE: Under low idle condition, when return­to­dig is used with loader boom in full up position, the bucket leveling linkage will move the bucket control valve out of return­to­dig position before bucket is actually level.

NO: See your authorized dealer.

Continued on next page

4­2­11

VD76477,00014A9 ­19­19MAR07­41/59

091710

PN=163

Miscellaneous—Operational Checkout Bucket Leveling Linkage Check

NOTE: The loader bucket leveling feature functions during the boom rise cycle only. When bucket is lowered, the operator can manually level the bucket or use the return­to­dig.

Put loader bucket in the rollback position with the boom near ground level.

Raise the loader and at the same time hold the control lever in the bucket rollback position.

Observe bucket and loader control lever as the loader rises.

YES: Go to next check.

LOOK/FEEL: Does loader control lever move into the bucket dump position and the NO: See your authorized bucket dump function slowly activate? When the loader control lever moves to activate dealer. the bucket dump function, does the bucket position remain stationary the remainder of the loader boom rise cycle?

VD76477,00014A9 ­19­19MAR07­42/59

3­Point Hitch Hydraulic Function Check

Operate machine at approximately 1/3 throttle.

Operate controls to check each hitch cylinder function.

LOOK/FEEL: Does each cylinder extend smoothly?

YES: Go to next check.

LOOK/FEEL: Does each cylinder retract smoothly?

NO: See your authorized dealer.

Continued on next page

4­2­12

VD76477,00014A9 ­19­19MAR07­43/59

091710

PN=164

Miscellaneous—Operational Checkout 3­Point Hitch Down Force and Float Check

T107266 —UN—17FEB97

T107267 —UN—17FEB97

Put 305 mm (12 in.) high blocks under ends of the lower links.

With engine at slow idle, move the lift lever to the DOWN position.

YES: Go to next step in this check.

LOOK: Does the lift cylinder down force relax the rear tire bulge without lifting the rear wheels off the ground?

NO: See your authorized dealer.

T107268 —UN—17FEB97

Move the lift lever farther to FLOAT position.

YES: Go to next check.

LOOK: Does the tire bulge reappear?

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­44/59

PTO Function Check — If Equipped

Operate machine at approximately full throttle.

Operate control to check engagement function.

LOOK/LISTEN: Does PTO engage and disengage?

LISTEN/FEEL: Does PTO engage and rotate smoothly?

YES: Go to next check.

LISTEN/LOOK: Does PTO disengage and stop rotating?

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­45/59

Check Operation of Accessories (Engine Off) VD76477,00014A9 ­19­19MAR07­46/59

Drive Light Check

Key switch in the ON position.

Push light rocker switch to middle position.

YES: Go to next check.

LOOK: Are two front lights, two red tail lights and gauge lights ON?

NO: Check fuse and bulbs.

See your authorized dealer.

Continued on next page

4­2­13

VD76477,00014A9 ­19­19MAR07­47/59

091710

PN=165

Miscellaneous—Operational Checkout Work Light Check

Key switch in the ON position.

Push light rocker switch to upper (WORK) position.

YES: Go to next check.

LOOK: Are two front lights, two red tail lights, gauge lights and two rear white lights (if equipped) ON?

NO: Check fuse and bulbs.

See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­48/59

Turn Signal Check

Key switch in the ON position.

Push right side of turn signal rocker switch down.

LOOK: Is right amber light flashing? Does right indicator light on switch flash? Does left amber light remain on steady?

Push left side of turn signal rocker switch down.

YES: Go to next check.

LOOK: Is left amber light flashing? Does left indicator light on top of steering column flash? Does right amber light remain on steady?

NO: Check fuses and wiring. See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­49/59

Brake Light Switch Check Key switch in the ON position.

Depress and hold left brake pedal, then right brake pedal.

YES: Go to next check.

LOOK: Rear brake light must come ON when either pedal is depressed with key switch NO: Check fuse and bulbs. in ON position.

See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­50/59

Warning Light Check

Key switch in the ON position.

Push bottom of warning light rocker switch in.

YES: Go to next check.

LOOK: Are both amber lights flashing? Are both turn signal indicators and light in warning light rocker switch flashing?

NO: Check fuses and wiring. See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­51/59

Horn Check

Key switch in the ON position.

Push horn button.

YES: Go to next check.

LISTEN: Did horn sound?

NO: Check fuses and wiring. See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­52/59

Operator Station Checks VD76477,00014A9 ­19­19MAR07­53/59

Seat Linkage Check

Move lever sideways.

Move seat forward and rearward and release lever.

YES: Go to next check.

LOOK: Does lever move freely and lock seat in desired position?

NO: Repair linkage. See your authorized dealer.

Continued on next page

4­2­14

VD76477,00014A9 ­19­19MAR07­54/59

091710

PN=166

Miscellaneous—Operational Checkout Suspension Seat Height Adjustment Check

Turn knob or lift lever to raise or lower seat to desired position.

YES: Go to next check.

LOOK: Does seat move up or down and remain in desired position?

NO: See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­55/59

Suspension Seat Swivel Linkage Check

T106529 —UN—27JAN97

Pull lever forward. Swivel seat clockwise to stop and release lever.

Repeat steps to return seat to normal forward facing position.

LOOK: Does seat stop about 15 degrees clockwise from normal forward facing position?

YES: Go to next check.

FEEL: Does lever move freely and hold seat in positions?

NO: Lubricate linkage.

See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­56/59

Suspension Seat Back Linkage Check

Turn lever to position seat back as desired.

YES: Go to next check.

FEEL: Does lever move freely and hold seat in desired positions?

NO: Lubricate linkage.

See your authorized dealer.

VD76477,00014A9 ­19­19MAR07­57/59

Miscellaneous Checks VD76477,00014A9 ­19­19MAR07­58/59

Check Periodic Maintenance Decal

Check periodic maintenance decal on right front frame.

YES: Operational Checkout Complete.

LOOK: Is periodic maintenance decal legible?

NO: Replace decal.

VD76477,00014A9 ­19­19MAR07­59/59

4­2­15

091710

PN=167

Miscellaneous—Troubleshooting Troubleshooting Procedure

Step 1. Operational Checkout 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 2. Troubleshooting Charts Step 3. Adjustments Step 4. See your authorized John Deere dealer.

HG31779,0000020 ­19­06MAY10­1/1

4­3­1

091710

PN=168

Miscellaneous—Troubleshooting

Engine Symptom

Problem

Solution

Engine Will Not Start or Starts Hard Fuel tank empty

Check fuel quantity.

Fuel tank vent plugged

Remove cap and listen for sound of air entering tank. Replace cap.

No electrical power to injection pump solenoid (S.N. —882699)

Turn key switch to ON. Must hear click at injection pump. Replace fuse.

Repair wiring.

No electrical power to ECU (S.N. 882700—)

Turn key switch to ON. Replace fuse.

Repair wiring.

Water in fuel or water frozen in fuel line

Drain water from fuel tank. Inspect fuel filter for water. Change filter.

Debris in fuel or wrong grade of fuel

Check fuel tank outlet strainer for type of fuel debris. Check bottom of fuel tank for debris. Clean tank. Add fuel.

Check grade of fuel. Add correct fuel.

Air leak on suction side of fuel system Check for bubbles in fuel filter and tighten connections. Inspect fuel lines for damage.

Fuel transfer pump diaphragm leaking Check engine oil for fuel dilution. See your authorized dealer.

Slow cranking speed

Check battery and connections.

Incorrect engine oil (cold weather).

Restricted air filter

Check air filter restriction indicator and air filters. Clean.

Stuck injection pump metering valve (S.N. —882699)

Tap injection pump housing (lightly). If engine now starts, replace metering valve. See your authorized dealer.

Faulty electric shutoff (S.N. —882699) Test shutoff solenoid. See your authorized dealer.

ECU fuse (S.N. 882700—) Engine Surges or Stalls Frequently Air in fuel

Replace fuse.

Inspect filter for evidence of air in fuel.

Tighten connections and bleed fuel system.

Fuel tank vent plugged

Continued on next page

4­3­2

Remove cap and listen for sound of air entering tank. Replace cap.

TX,100,BG600 ­19­28FEB07­1/3

091710

PN=169

Miscellaneous—Troubleshooting Symptom

Engine Misses

Engine Does Not Develop Power

Engine Emits Excessive Black or Gray Exhaust Smoke

Engine Emits Excessive Blue or White Smoke

Slow Acceleration

Problem

Solution

Debris in fuel or wrong grade of fuel

Check fuel tank outlet strainer for debris. Check bottom of fuel tank for debris. Clean tank. Add fuel. Check grade of fuel.

Water in fuel

Drain fuel tank and inspect filter element for water. Replace filters.

Fuel filter plugged

Replace filter.

Incorrect valve clearance

Check and adjust valve clearance.

See your authorized dealer.

Air in fuel

Check for evidence of air in filter.

Tighten connections and bleed fuel system.

Debris in fuel or wrong grade of fuel

Check fuel tank for water. Check fuel tank strainer and fuel filter for debris.

Clean. Check grade of fuel.

Incorrect valve clearance

Check and adjust valve clearance.

See your authorized dealer.

Fuel tank outlet strainer plugged

Check fuel tank for water or debris.

Remove and clean.

Fuel filter plugged

Replace fuel filter.

Wrong grade of fuel

Drain and add correct fuel.

Air system restricted

Check air filter restriction and air filters. Clean.

Incorrect valve clearance

Adjust valve clearance.

Restricted air filter

Check air filter restriction and air filters. Clean or replace.

Incorrect grade of fuel

Drain and add correct fuel.

Incorrect injection pump timing

See your authorized dealer.

Excessive fuel delivery

See your authorized dealer.

Injection nozzle(s)

See your authorized dealer.

Cranking speed too slow

Check batteries and connections.

Incorrect grade of fuel

Drain and add correct fuel.

Wrong grade of fuel

Drain and add correct fuel.

Continued on next page

4­3­3

TX,100,BG600 ­19­28FEB07­2/3

091710

PN=170

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Detonation (Excess Engine Knock) Low engine oil level

Add oil.

Abnormal Engine Noise

Low or incorrect engine oil (too thin)

Add correct oil to proper level.

Engine oil diluted with fuel

Inspect engine oil. See your authorized dealer.

Excessive valve clearance

Adjust valve clearance. See your authorized dealer.

Low oil level

Add oil to proper level. Inspect engine oil.

Wrong viscosity oil/oil diluted with diesel fuel

Change oil and see your authorized dealer.

Low Oil Pressure (Oil Pressure Light On—Red "Stop" Flashing)

Engine Overheats (Engine Coolant Low coolant level Indicator Light On and Red "Stop" Flashing) Low engine oil level

Excessive Fuel Consumption

Fill cooling system and check for leaks.

Add oil.

Engine overloaded, operating in wrong gear Improper fuel

Reduce load.

Radiator cap

Replace cap.

Air system restricted

Check filter restriction indicator and air filters. Replace.

Leakage in fuel system

Inspect. Repair.

Incorrect grade of fuel

Refill with correct fuel.

Drain and add correct fuel.

Operator holding hydraulics over relief Return control levers to neutral position.

Excessive Drag In Turbocharger Rotating Members

Bearing seizure or dirty or worn bearings caused by excessive temperature, unbalanced wheel, dirty oil, oil starvation, or insufficient lubrication.

Check for plugged air filters.

TX,100,BG600 ­19­28FEB07­3/3

4­3­4

091710

PN=171

Miscellaneous—Troubleshooting

Hydraulic System Symptom

Problem

Solution

No Loader, Hitch or Steering Hydraulics

Low oil level

Add oil to correct level.

Suction screen plugged

Remove and clean screen in hydraulic reservoir.

Pump Problem

Remove hydraulic filter and inspect.

If filter contains excessive amounts of metal material see your authorized dealer.

Obstruction in oil lines or valves

Inspect for pinched lines or stuck valve spools.

Hydraulic oil aerated

Incorrect oil; drain and refill. Suction hose has air leak; inspect and tighten.

Low oil level

Check oil levels.

Low oil level

Add oil to correct level.

Hydraulic oil aerated

Incorrect oil; drain and refill. Suction hose has air leak; inspect and tighten.

Hose or line leakage

Inspect and tighten fittings.

Low Hydraulic Power

Slow Hydraulic Functions

Loader or Hitch Operates Slowly in Control lever and linkage out of One Function adjustment

Inspect lever and linkage. See your authorized dealer.

Circuit relief valve or plug leakage in control valve

Remove, inspect and repair sealing rings on relief valve or plug. See your authorized dealer.

Hydraulic cylinder leakage

Inspect hydraulic cylinders. See your authorized dealer.

Bent or restricted line or hose

Inspect hydraulic lines and hoses.

See your authorized dealer.

Control lever and linkage out of adjustment

Inspect lever and linkage. See your authorized dealer.

Bent or restricted line or hose

Inspect hydraulic lines and hoses.

See your authorized dealer.

Slow Loader and Hitch Hydraulics (Low Pump Output)

Hydraulic oil aerated

Incorrect oil; drain and refill. Suction hose has air leak; inspect and tighten.

Low Hydraulic Power (Low Hydraulic Pressure)

Low oil level (no aeration of oil)

Add oil to correct level.

Hydraulic oil aerated

Incorrect oil; drain and refill. Suction hose has air leak; inspect and tighten.

No Loader or Hitch Power in One Function

Continued on next page

4­3­5

TX,9025,BG628 ­19­02MAR07­1/2

091710

PN=172

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Hydraulic Function Makes "Chattering" Noise

Low oil level

Add oil to correct level.

Hydraulic oil aerated

Incorrect oil; drain and refill. Suction hose has air leak; inspect and tighten.

Excessive load

Reduce load.

Operator holding hydraulic system over relief

Return levers to neutral when not in use.

Oil level too low in reservoir

Check level and add oil. Use recommended oil.

Using low viscosity oil in hot weather

Use recommended oil.

Hydraulic cooling system restricted

Clean radiator and cooler.

Oil level too low or too high

Check oil level. Adjust to full on sight gauge.

Incorrect type of oil

Use recommended oil.

Oil maintenance not performed

Perform correct maintenance.

Low oil level

Add oil to correct level.

Hydraulic Oil Overheats

Foaming Oil

Excessive Pump Noise

Hydraulic filter bypass valve chattering Replace filter. Inspect, clean, and repair.

Worn transmission hydraulic pump drive

Inspect and repair. See your authorized dealer.

Oil lines in contact with operator’s station (worn transmission rubber isolators) Pump attaching hardware loose

Inspect, repair or replace. See your authorized dealer.

No Response when Steering Wheel Low oil level Is Turned Machine Turns in Opposite Steering cylinder lines not connected Direction to proper ports

Tighten to specification. See your authorized dealer.

Check reservoir oil level.

Connect steering cylinder lines to opposite ports. See your authorized dealer.

TX,9025,BG628 ­19­02MAR07­2/2

4­3­6

091710

PN=173

Miscellaneous—Troubleshooting

Electrical System Symptom

Problem

Solution

Starting Motor Will Not Turn

Start fuse

Check and replace if necessary.

Starter

Be sure transmission control lever (TCL) is in neutral. Listen for “click” from starter solenoid. If “click” is heard, the starter control circuit is functioning. If “click” is not heard, repair starter. See your authorized dealer.

Start relay

With the machine in neutral and clutch disconnect switch depressed, remove left­hand engine side shield and listen for “click” from starter relay when the key switch is moved to START position. If “click” is heard, the key switch, circuit breaker, start fuse, connectors, and neutral start switch are functioning and the starter relay, relay ground, or starter is worn. See your authorized dealer.

Starter Solenoid Chatters

Poor or corroded connections at Inspect, clean, and tighten if battery, battery ground strap, or starter necessary.

Engine Cranks Slowly

Loose or corroded battery cables

Inspect and clean or tighten.

Loose battery ground cable

Remove battery cover and inspect and tighten battery ground cable.

Excessive power train load

Depress clutch disconnect switch.

Excessive engine load

Change engine oil to proper grade for temperature.

Starter solenoid stuck

Lightly tap on case of starter solenoid.

Starter not disengaging

Lightly tap on starter case to determine if starter “shift” lever is stuck.

Starter relay stuck on

Lightly tap on starter relay to determine if relay is stuck.

Cracked battery case

Replace battery.

High ambient temperature

Refill with distilled water.

Battery cell

Check if one or more cells take more water than others.

No battery hold­down clamp

Replace battery and install hold­down clamp.

Starting Motor Continues to Run

Battery Uses Too Much Water

Cracked Battery Case

Continued on next page

4­3­7

TX,100,BG337 ­19­01FEB07­1/2

091710

PN=174

Miscellaneous—Troubleshooting Symptom

Low Battery Output

Charging Indicator Light Remains On with Engine Running

Problem

Solution

Loose battery hold­down clamp

Replace battery and install hold­down clamp.

Battery hold­down clamp too tight

Replace battery and install battery hold­down clamp properly.

Frozen battery

Keep battery fully charged in cold weather.

Low water level

Add water.

Dirty or wet battery top causing discharge Corroded or loose battery cables

Clean and wipe battery top dry.

Clean and tighten battery cables.

Broken battery post

Wiggle battery post by hand. If post wiggles or turns, replace battery.

Loose or glazed alternator belt

Check belt. Replace if glazed.

Engine rpm low

Raise engine rpm above 1000 rpm. If light remains on, see your authorized dealer.

Loose or corroded electrical Inspect. Clean, or tighten electrical connections on battery, ground strap, connections. starter, or alternator Monitor/gauge fuse Turn key switch to BULB CHECK position. If no lights, replace fuse.

Alternator Light Out but Low Charging System Voltage

Noisy Alternator

Indicator light bulb

Inspect and replace if necessary.

Loose wiring connector

Inspect and repair.

Worn bearings in alternator

Remove belt and feel for rough bearing while turning alternator pulley.

Drive belt

Inspect and replace if necessary.

Pulley not aligned

Inspect

Loose alternator belt or mounting

Inspect and replace if necessary.

TX,100,BG337 ­19­01FEB07­2/2

4­3­8

091710

PN=175

Miscellaneous—Troubleshooting

Gauges and Indicators Symptom

Problem

Solution

Fuel Gauge Does Not Move, No indicator Lights, Machine Will Not Crank

Start relay fuse

Replace fuse.

Poor or loose red connector from relay Push red connector together under loader control lever.

Fuel Gauge Does Not Move, No Indicator Lights, But Machine Will Crank

Poor or loose ground connection

Check ground screw under loader control lever.

Monitor/gauge fuse

Replace fuse.

Poor or loose ground connection

Check ground screw under loader control lever.

Indicator light Engine Coolant Temperature Indicator Light Does Not Indicate Overheating or Bulb Does Not Light In BULB CHECK Position Sender

Turn key switch to BULB CHECK. If no light, replace bulb.

Engine Oil Pressure Indicator Will Not Light

Monitor/gauge fuse

Replace fuse.

Indicator light

Turn key switch to BULB CHECK. If no light, replace bulb.

Wire, connector or sender

Ground yellow wire at sender.

Indicator must light. If not, repair wiring or replace sender.

Monitor/gauge fuse

Replace fuse.

Indicator light

Turn key switch to BULB CHECK. If indicator does not light, replace bulb.

Monitor/gauge fuse

Replace fuse.

Indicator light

Replace bulb.

Poor ground connections at gauge

Remove dash panel and check gauge mounting hardware.

Poor power connection at gauge

Remove dash panel and check gauge mounting hardware.

Hole in fuel sender float

Replace sender unit. Ground fuel sender. Gauge must indicate full. If it does not, the wiring is defective.

Repair wiring. See your authorized dealer.

Gauge

Replace gauge.

Alternator Indicator Will Not Light

Monitor Lights Do Not Come On During BULB CHECK

Fuel Gauge Shows Empty At All Times

Replace sender.

Continued on next page

4­3­9

HG31779,0000024 ­19­28FEB07­1/2

091710

PN=176

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Fuel Gauge Shows Full At All Times Open circuit at sender or wire

Horn Does Not Sound

No Work or Driving Lights

Rear Lights Do Not Operate

Dim Lights

Return­to­Dig Does Not Operate

Neutral Disconnect Does Not Disengage

Remove wire at sender. If gauge still indicates full, locate and repair short between sender and gauge.

Sender float stuck

Repair or replace sender. Remove sender wire. If gauge still indicates full, replace gauge.

Horn ground

Ground horn to machine frame.

Horn fuse

Check and replace.

Horn

Replace horn.

Horn button

Replace horn button.

Driving light fuse

Check and replace.

Poor ground

Inspect and tighten.

Burned out bulb

Replace with new bulb.

Loose connector in wiring harness of ROPS Poor ground at light

Inspect and reconnect.

Low battery charge

Check battery connections.

Low alternator output

Check belt tension and adjust.

Poor ground at lights

Clean and tighten.

Return­to­dig/beacon/pump fuse

Replace fuse.

Boom switch out of adjustment

Check cam to see if it activates switch.

See your authorized dealer.

Wiring

Inspect and repair wiring.

TCL/park brake fuse

Replace fuse.

Wire

Inspect and repair wire.

Solenoid

Replace solenoid. See your authorized dealer.

Inspect and tighten.

HG31779,0000024 ­19­28FEB07­2/2

4­3­10

091710

PN=177

Miscellaneous—Troubleshooting

Transmission Symptom

Problem

Solution

Machine Will Not Move in Forward or Reverse

Low oil level in transmission

Add oil to correct level.

Broken drive shafts.

Inspect drive shafts and universal joints for external damage. See your authorized dealer.

Low oil level

Add oil.

Wrong oil grade

Change oil.

Oil level is low

Add oil to correct level.

Wrong oil, aerated oil

Change oil.

Brake dragging

Check for excessive heat in brake area of axle housing after operating machine. See your authorized dealer.

Low or high oil level (aeration of oil)

Add oil or drain.

Wrong oil

Change oil.

Oil level too high or too low

Check oil level and correct.

Incorrect type of oil

Drain and replace oil.

Oil cooler air flow restricted

Inspect and clean exterior of cooler.

See your authorized dealer.

Transmission or coolant oil leak

See your authorized dealer.

Fan or shroud damaged

See your authorized dealer.

Attempt to shift too fast

See Driving the Machine. (Section 2­2.)

Shifting without using neutral disconnect

Depress neutral disconnect when shifting.

Engine low idle too slow

See your authorized dealer.

Oil level low

Fill to correct oil level.

Transmission Slippage

Machine Lacks Power or Moves Slow

Transmission Shifts Too Slow

Transmission Overheats

Excessive Gear Clash when Shifting

Excessive Power Train Noise

NOTE: If any other problems are encountered which require special tools or machine knowledge to correct, see your authorized dealer.

VD76477,000145D ­19­02MAR07­1/1

4­3­11

091710

PN=178

Miscellaneous—Troubleshooting

MFWD Symptom

Problem

Solution

Excessive Noise

Oil level low

Fill to correct oil level.

VD76477,000145B ­19­23FEB07­1/1

Rear Axle Symptom

Problem

Solution

No Differential Lock Operation

Problem in electrical circuit to solenoid With engine stopped and key switch turn to accessory, activate differential lock and listen for a click from solenoid valve.

Do Differential Lock Operational Checks.

Stuck foot switch

Inspect.

Problem in electrical circuit

With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve.

Air in brake valve or lines or piston

Bleed brakes.

Low oil level

Check oil level and fill.

Excessive Noise/Heat

Low oil level

Check oil level and fill.

Park Brake Will Not Engage

Tow release screws turned in

See your authorized dealer.

Differential Lock Will Not Release

Poor Service Brakes

NOTE: If any other problems are encountered which require special tools or machine knowledge to correct, see your authorized dealer.

VD76477,000145C ­19­23FEB07­1/1

4­3­12

091710

PN=179

Miscellaneous—Storage Prepare Machine for Storage T47764 —UN—09NOV88

1.

Before storage, operate engine on at least one complete tank of petroleum diesel fuel to purge the fuel system. Ensure that the fuel tank is full during storage to prevent water build up due to condensation.

T5813AM —UN—09FEB89

NOTE: For up to and including B20, it is recommended that biodiesel be used within 3 months of its manufacture. For blends greater than B20, it is recommended that the biodiesel be used within 45 days. The poor oxidation stability characteristic of biodiesel can result in longterm storage problems.

John Deere does not recommend using biodiesel in engines powering standby applications or vehicles operating on a seasonal basis. Consult your John Deere dealer or fuel supplier for additives to improve fuel storage and performance of biodiesel fuels.

These additives must be added to the biodiesel close to its time of production for them to be effective.

2. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later.

3. Loosen alternator and fan belts.

4. Clean primary air cleaner element.

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.

5. 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.

6. Remove seat cushion and other perishable items.

T7447AO —19—22APR91

IMPORTANT: LPS 3™1 Rust Inhibitor can destroy painted finish. DO NOT spray LPS 3 Rust Inhibitor on painted surfaces.

7. Retract all hydraulic cylinders, if possible. If not, coat exposed cylinder rods with LPS 3 Rust Inhibitor.

8. Lubricate all grease points.

9. If possible, raise machine high enough so tires do not touch the ground. If not, park on a hard surface to prevent tires from freezing to ground.

10. Store machine in a dry, protected place. If stored outside, cover with a waterproof material.

11. Place a “DO NOT OPERATE” tag on the steering wheel.

IMPORTANT: Prevent possible machine damage from unauthorized persons operating machine.

Attach a DO NOT OPERATE tag to steering wheel.

12. Remove keys and lock all covers and doors.

1

LPS 3 Rust Inhibitor is manufactured by Holt Lloyd Corporation.

ER79617,0000C01 ­19­09JUL10­1/1

4­4­1

091710

PN=180

Miscellaneous—Storage

Monthly Storage Procedure

T6191AA —UN—18OCT88

CAUTION: Prevent possible injury or death from asphyxiation. Engine exhaust fumes can cause sickness or death. Start engine ONLY in a well­ventilated area.

1. Drain water and sediment from fuel tank when air temperature is above freezing.

2. Remove LPS 3 ® Rust Inhibitor from cylinder rods with a cleaning solvent.

LPS 3 Rust Inhibitor is manufactured by Holt Lloyd Corporation.

VD76477,00016A3 ­19­08JAN08­1/2

T6181AU —UN—18OCT88

IMPORTANT: Prevent possible engine damage.

During cold temperatures, check fluidity of engine oil on dipstick. If the oil appears waxy and/or jelly­like rather than liquid, DO NOT attempt to start engine. Use external heat source to warm the crankcase until oil appears fluid.

3. Check all fluid levels. If low, check for leaks and add oil as required.

4. Check belts.

5. Check condition of all hoses and connections.

6. Check battery electrolyte level. Charge and install battery.

7. For machines with tires, check condition of tires and tire pressure.

For machines with tracks, check condition of tracks and track sag.

On crawler machines with non sealed­and­lubricated track chains, apply oil to the pin­to­bushing joints. Run machine back and forth several times.

8. Park machine on a hard surface to prevent tracks from freezing to ground.

9. Fill fuel tank.

run until it reaches operating temperature. Run at 1/2 speed for five minutes. Do not run at fast or slow idle.

• If engine fails to start or runs poorly after starting, change fuel filter(s). Bleed fuel system.

12. Operate all controls, levers, seat adjustments, etc.

CAUTION: Prevent possible injury from unexpected machine movement. Clear the area of all persons before running machine through the operation procedure.

13. Make sure the area is clear to allow for movement.

Cycle all hydraulic functions several times. Check condition of all hoses and connections.

10. Pre­lubricate turbocharger bearings, if equipped: a. Disconnect fuel shutoff fuse.

14. Park the machine with cylinder rods retracted, if possible. Turn key switch to OFF.

b. Crank engine for 10 seconds. c. Connect fuel shutoff fuse.

11. Inspect engine compartment, and remove any foreign material that may have accumulated. Start engine and

15. Apply LPS 3 Rust Inhibitor to exposed cylinder rod areas.

VD76477,00016A3 ­19­08JAN08­2/2

4­4­2

091710

PN=181

Miscellaneous—Specifications 210LE Travel Speed (S.N. —888000) Travel speeds are for machines using 16.9 x 24 8 PR standard rear tires: With Manual Shift Transmission—Specification 1 Forward—Speed.................................................................... 6.0 km/hr 3.7 mph 2 Forward—Speed.................................................................... 9.8 km/hr 6.1 mph 3 Forward—Speed.................................................................. 23.7 km/hr 14.8 mph 4 Forward—Speed.................................................................. 37.5 km/hr 23.3 mph 1 Reverse—Speed.................................................................... 6.7 km/hr 4.1 mph 2 Reverse—Speed.................................................................. 10.9 km/hr 6.8 mph 3 Reverse—Speed.................................................................. 26.5 km/hr 16.5 mph 4 Reverse—Speed.................................................................. 41.9 km/hr 26.0 mph

With Powershift Transmission—Specification 1 Forward—Speed.................................................................... 6.0 km/hr 3.7 mph 2 Forward—Speed.................................................................... 9.8 km/hr 6.1 mph 3 Forward —Speed................................................................. 23.7 km/hr 14.8 mph 4 Forward —Speed................................................................. 37.5 km/hr 23.3 mph 1 Reverse—Speed.................................................................... 6.7 km/hr 4.1 mph 2 Reverse—Speed.................................................................. 10.9 km/hr 6.8 mph 3 Reverse—Speed.................................................................. 26.5 km/hr 16.5 mph 4 Reverse—Speed.................................................................. 26.5 km/hr 16.5 mph

OUO1030,0000739 ­19­09JUL10­1/1

210LE Travel Speed (S.N. 888001—) Travel speeds are for machines using 16.9 x 24 8 PR standard rear tires: With Powershift Transmission—Specification 1 Forward—Speed.................................................................... 5.8 km/hr 3.6 mph 2 Forward—Speed.................................................................... 9.3 km/hr 5.8 mph 3 Forward —Speed................................................................. 22.4 km/hr 13.9 mph

4 Forward —Speed................................................................. 33.0 km/hr 20.5 mph 1 Reverse—Speed.................................................................... 6.4 km/hr 4.0 mph 2 Reverse—Speed.................................................................. 10.8 km/hr 6.7 mph 3 Reverse—Speed.................................................................. 25.9 km/hr 16.1 mph

VD76477,00014C1 ­19­09JUL10­1/1

4­5­1

091710

PN=182

Miscellaneous—Specifications

210LE Landscape Loader Drain and Refill Capacities (S.N. —888000) Item

Measurement

Specification

Engine Coolant

Capacity

16 L Approximate 4.23 gal Approximate

Engine Oil (including filter)

Capacity

12.3 L 3.25 gal

Torque Converter and Transmission

Capacity

15 L Approximate 3.96 gal Approximate

Rear Axle Oil

Capacity (S.N. —851673)

13 L Approximate 3.43 gal Approximate 16 L Approximate 4.23 gal Approximate

Drain and Refill Capacities

Capacity (S.N. 851674—888000) MFWD Axle Housing

Capacity

6.5 L Approximate 1.72 gal Approximate

MFWD Planetary Housing (each)

Capacity

1 L Approximate 1.1 qt Approximate

Fuel Tank

Capacity

98 L Approximate 26 gal Approximate

Hydraulic System Reservoir

Capacity

54.5 L Approximate 14.4 gal Approximate

PTO Gear Case—if equipped

Capacity

1.86 L .5 gal MD04263,0000380 ­19­20JUL10­1/1

4­5­2

091710

PN=183

Miscellaneous—Specifications

210LE Landscape Loader Drain and Refill Capacities (S.N. 888001—) Item

Measurement

Specification

Engine Coolant

Capacity

14 L 3.75 gal

Engine Oil (including filter)

Capacity

12.3 L 3.25 gal

Torque Converter and Transmission

Capacity

15.1 L 4 gal

Rear Axle and Planetary Housing

Capacity

18 L 4.8 gal

MFWD Axle Housing

Capacity

6.5 L 1.7 gal

MFWD Planetary Housing (each)

Capacity

1L 1 qt

Fuel Tank

Capacity

98 L 26 gal

Hydraulic System Reservoir

Capacity

54.5 L 14.4 gal

PTO Gear Case—if equipped

Capacity

1.86 L 1.96 qt

Drain and Refill Capacities

VD76477,0001423 ­19­09JUL10­1/1

4­5­3

091710

PN=184

Miscellaneous—Specifications

T115557 —UN—28MAY98

210LE Landscape Loader Dimensions

NOTE: Specifications and design subject to change without notice. Whenever applicable, specifications are in accordance with SAE standards unless otherwise noted. These specifications are based

on a standard machine with 16.9 x 24 R4 rear tires; 12 x 16.5 NHS front tires; 0.76 m3 (1.0 cu. yd.) loader bucket; ROPS/FOPS; full fuel tank and 79 kg (175 lb) operator.

Item

Measurement

Specification

A—Maximum height to bucket hinge pin

Height

3.47 m 11 ft 5 in.

B—Dump clearance, bucket at 45°

Clearance

2.6 m 8 ft 5 in.

Continued on next page

4­5­4

TX,9000,BG375 ­19­04MAR08­1/3

091710

PN=185

Miscellaneous—Specifications Item

Measurement

Specification

C—Bucket pin 280 mm (11 in.) off ground

Angle

44°

D—Maximum bucket dump angle

Angle

42° at full height

E—Reach at full height

Distance

875 mm 34.5 in.

—Bucket at 45°

Distance

940 mm 37 in.

F—Rear axle to rear of hitch (S.N. —880053)

Distance

1.07 m 3 ft 6 in.

F—Rear axle to rear of hitch (S.N. 880054— )

Distance

1.14 m 3 ft 9 in.

G—Dig below ground—bucket level

Depth

245 mm 9.64 in.

H—Front wheel to loader dig position

Distance

1.98 m 6 ft 6 in.

I—Wheel Base

Distance

2.11 m 6 ft 11 in.

J—Height to ROPS top

Height

2.48 m 8 ft 2 in.

K—Overall length (S.N. —880053)

Length

5.17 m 16 ft 11 in.

K—Overall length (S.N. 880054— )

Length

5.23 m 17 ft 2 in.

L—Lower link pin center

Distance

39.7 mm 1.5 in.

M—Top link hole height

Height

783 mm 30.8 in.

N—Rear axle height

Height

584 mm 23.0 in.

O—Top link hole from rear axle

Distance

450 mm 17.7 in.

P—Height of lower link point

Height

465 mm 18.3 in.

Q—Low link point from rear axle

Distance

356 mm 14.0 in.

R—Pitch cylinder—Retracted

Length

572 mm 22.5 in.

—Pitch cylinder—Extended

Length

798 mm 31.0 in.

S—Lower link length

Length

749 mm 29.5 in.

T—Maximum height lower link—Nominal

Height

714 mm 28.1 in.

T—Maximum height lower link—Tilt Cylinder Retracted

Height

902 mm 35.5 in.

Continued on next page

4­5­5

TX,9000,BG375 ­19­04MAR08­2/3

091710

PN=186

Miscellaneous—Specifications Item

Measurement

Specification

U—Minimum height lower link

Height

196 mm 7.7 in.

V—Height of drawbar

Height

325 mm 12.8 in.

W—Hitch pin from center axle

Distance

843 mm 33.2 in.

X—Machine width

Width

2184 mm 7 ft 2 in.

TX,9000,BG375 ­19­04MAR08­3/3

210LE Landscape Loader NOTE: Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with Standards.

Item

Measurement

Specification

Rated Power @ 2200 rpm

Power

SAE gross 63 kW SAE gross 84 hp

Rated Power @ 2200 rpm

Power

SAE net 60 kW SAE net 80 hp

Cylinders

Quantity

4

Displacement

Volume

4.52 L 276 in.3

Engine Torque Rise

Torque

30%

Maximum Engine Net Torque

Torque

346 N∙m 255 lb­ft

Electrical System

Voltage

12­volt

Amperage

65 amps

Rated Power @ 2200 rpm

Power

SAE gross 58 kW (78 hp)

Rated Power @ 2200 rpm

Power

SAE net 54 kW (73 hp)

Cylinders

Quantity

4

Displacement

Volume

4.52 L 276 in.3

Engine Torque Rise

Torque

26%

Maximum Engine Net Torque

Torque

298 N∙m 220 lb­ft

Electrical System

Voltage

12­volt

Alternator

Amperage

65 amps

Engine—John Deere 4045T—Altitude Compensated

Alternator Engine—John Deere 4045D NA

OUO1030,0000735 ­19­04MAR08­1/1

4­5­6

091710

PN=187

Miscellaneous—Specifications

210LE Landscape Loader Weight Item

Measurement

Specification

SAE Operating Weight

Weight

4612 kg 10 170 lb

MFWD w/Tires Added

Weight

168 kg 370 lb

Hitch Weights

Weight

240 kg 530 lb

Wheel Weights

Weight

503 kg 1100 lb

84” Box Scraper w/Ripper Bar

Weight

690 kg 1520 lb

Transporting:

TX,00,BD2748 ­19­04MAR08­1/1

210LE Landscape Loader Buckets Width

Weight

Heaped Capacity

Loader:

in.

(mm)

cu yd

(m3 )

lb

kg

Heavy duty, long lip

86

(2180)

1.00

(0.76)

710

(332)

86

(2180)

1.12

(0.86)

940

(426)

86

(2180)

1.00

(0.76)

1450

(658)

Multipurpose

SPECIFICATIONS Function Breakout force Lifting capacity—full height

0.76 m3 (1.0 cu yd) bucket

0.86 m3 (1.12 cu yd) bucket

35.14 kN (7900 lb) force

34.47 kN (7750 lb) force

2395 kg (5280 lb)

2313 kg (5100 lb) TX,9000,BG378 ­19­04MAR08­1/1

4­5­7

091710

PN=188

Miscellaneous—Machine Numbers Record Product Identification Number (PIN) Purchase Date Machine Serial Number (A) T122076B —UN—01JUL99

NOTE: Record all 13 characters of Product Identification Number.

TX,120,BG539 ­19­06JUL99­1/1

Record Engine Serial Number Engine Serial Number

T103543 —UN—04SEP96

A—Engine Serial Number Tag

TX,120,BD2207 ­19­01FEB07­1/1

Record Transmission Serial Number—Manual Shift (S.N. —888000) Transmission Serial Number

T134818D —UN—25OCT00

A—Transmission Serial Number Tag

OUO1079,000028B ­19­09JUL10­1/1

4­6­1

091710

PN=189

Miscellaneous—Machine Numbers

Record Transmission Serial Number—Powershift (S.N.—888000) Transmission Serial Number

T132445D —UN—13JUL00

A—Transmission Serial Number Tag

CED,OUO1079,462 ­19­20JUL10­1/1

Record Transmission Serial Number (S.N. 888001—)

TX1018451A —UN—22FEB07

Transmission Serial Number A—Transmission Serial Number Tag

VD76477,00013F7 ­19­20JUL10­1/1

Record Rear Axle Housing Serial Number Rear Axle Housing Serial Number

T196298A —UN—17NOV03

A—Rear Axle Serial Number Tag

OUO1030,000072F ­19­01FEB07­1/1

4­6­2

091710

PN=190

Miscellaneous—Machine Numbers

Record (MFWD) Front Axle Housing Serial Number MFWD Axle Housing Serial Number

T103544 —UN—04SEP96

A—MFWD Axle Serial Number Tag

TX1019450A —UN—22FEB07

(S.N. —888000) Shown

(S.N. 888001—) Shown VD76477,000143A ­19­20JUL10­1/1

1. Maintain in a secure location an up­to­date inventory of all product and component serial numbers.

2. Regularly verify that identification plates have not been removed. Report any evidence of tampering to law enforcement agencies and order duplicate plates.

3. Other steps you can take: ­ Mark your machine with your own numbering system ­ Take color photographs from several angles of each machine

TS1680 —UN—09DEC03

Keep Proof of Ownership

DX,SECURE1 ­19­18NOV03­1/1

4­6­3

091710

PN=191

Miscellaneous—Machine Numbers

1. Install vandal­proof devices.

2. When machine is in storage: ­ Lower equipment to the ground ­ Set wheels to widest position to make loading more difficult ­ Remove any keys and batteries 3. When parking indoors, put large equipment in front of exits and lock your storage buildings.

4. When parking outdoors, store in a well­lighted and fenced area.

5. Make note of suspicious activity and report any thefts immediately to law enforcement agencies.

6. Notify your John Deere dealer of any losses.

TS230 —UN—24MAY89

Keep Machines Secure

DX,SECURE2 ­19­18NOV03­1/1

4­6­4

091710

PN=192

Index Page

A Accessory power outlets............................................ 2­1­6 Accidents Avoid backover ...................................................... 1­3­2 Acid burns.................................................................. 3­8­4 Adjustment Backup warning alarm volume............................. 4­1­12 Engine speed control linkage (S.N. ­­882699) ... 3­10­10 Engine speed control linkage (S.N. 882700­­) ... 3­10­11 Engine valve clearance........................................ 3­11­1 Park brake.............................................................. 3­3­4 Seat belt................................................................. 2­1­5 Toe­in .......................................................4­1­19, 4­1­20 Air cleaner element Replace.............................................................. 3­10­12 Air intake hoses ......................................................... 3­9­1 Alarm Backup warning ................................................... 4­1­12 Alternator ................................................................... 4­1­2 Indicator ................................................................. 2­1­2 Attachments Adding safely ......................................................... 1­3­3 Operating safely..................................................... 1­3­3 Axle Front, non­powered Toe­in, check and adjust.......................4­1­19, 4­1­20 MFWD Change oil, housing (S.N. 888001—)............................................ 3­11­1 Lubricate drive shaft splines.....................3­3­7, 3­4­4 Toe­in, check and adjust.......................4­1­19, 4­1­20 Troubleshooting................................................ 4­3­12 Rear Oil change ........................................................ 3­11­2 Troubleshooting................................................ 4­3­12 Axle oil, MFWD Change (S.N. —888000) ............................................... 3­10­1 Axle oil, rear Change ................................................................ 3­10­3 Axles Oil specification.................................................... 3­1­11

B Backup warning alarm ............................................. 4­1­12 Ballast Liquid, in front tires............................................... 4­1­21 Liquid, in rear tires ............................................... 4­1­20 Batteries Boost starting ......................................................... 4­1­4 Using battery charger............................................. 4­1­6 Battery Acid burns .............................................................. 3­8­4 Disconnect switch .................................................. 3­2­2 Electrolyte level check ........................................... 3­8­4

Page

Explosion ............................................................... 3­8­4 Handling, checking, servicing ................................ 4­1­3 Rating..................................................................... 4­1­4 Removal................................................................. 4­1­5 Replacement.......................................................... 4­1­4 Terminals................................................................ 3­8­4 Bearings, front wheel............................................... 3­10­2 Belt inspection ........................................................... 3­3­4 Bolt and screw torque values Metric ................................................................... 4­1­24 Unified inch .......................................................... 4­1­23 Brake Bleeding (S.N. 880908­ ) ..................................... 4­1­18 Park brake adjust ................................................... 3­3­4 Service brake Inspection, external .......................................... 4­1­16 Service inspection (external)................................ 4­1­15 Brakes Bleeding (S.N. ­880907) ...................................... 4­1­17 Break­in Engine (S.N. ­­882699) .......................................... 3­6­1 Engine (S.N. 882700­­888000) .............................. 3­6­2 Engine (S.N. 888001—)......................................... 3­7­1 Break­In engine oil..................................................... 3­1­6 Bucket Changing.............................................................. 4­1­13 Dimensions ............................................................ 4­5­7 Specifications......................................................... 4­5­7 Bulb replacement, halogen lights ............................ 4­1­11

C Cap screw torque .................................................... 4­1­21 Capacity Drain and refill..............................................4­5­2, 4­5­3 Check engine speed.............................................. 3­10­11 Checklist (S.N. —888000) ..................................................... 3­2­5 (S.N. 888001—) ..................................................... 3­2­9 Cold weather Machine warm­up .................................................. 2­2­7 Starting (S.N. ­882699) .......................................... 2­2­5 Starting (S.N. 882700­­)......................................... 2­2­6 Controls Front loader............................................................ 2­1­4 Steering console Locations ............................................................ 2­1­3 COOL­GARD II test strips ...........................3­3­8, 3­10­13 Coolant Add coolant extender ...............................3­3­8, 3­10­13 Additional information .......................................... 3­1­16 Check.......................................................3­3­8, 3­10­13 Check overflow level .............................................. 3­4­2 Diesel engine ....................................................... 3­1­13 Drain .................................................................... 3­12­1 Heater .................................................................... 2­2­7 Hoses..................................................................... 4­1­1 Continued on next page

Index­1

091710

PN=1

Index Page

Page

John Deere COOL­GARD II COOLANT EXTENDER........................................................ 3­1­14 Sample................................................................... 3­9­5 Supplemental additives........................................ 3­1­15 Test ..........................................................3­3­8, 3­10­13 Testing.................................................................. 3­1­17 Warm temperature climates................................. 3­1­15 Cooling system Draining................................................................ 3­12­1 Filling.................................................................... 3­12­2 Counterweights, rear ............................................... 4­1­20 Cylinder ................................................................... 4­1­21

Oil check ................................................................ 3­4­1 Oil filter (S.N. ­­882699) ......................................... 3­8­1 Oil filter (S.N. 882700­­) ......................................... 3­9­2 Oil pressure indicator ............................................. 2­1­1 Oil specification Break­In.............................................................. 3­1­6 Speed control linkage, adjust (S.N. ­­882699) ... 3­10­10 Speed control linkage, adjust (S.N. 882700­­) ... 3­10­11 Starting................................................................... 2­2­3 Troubleshooting ..................................................... 4­3­2 Valve clearance adjust ......................................... 3­11­1 Engine oil Diesel .........................................................3­1­9, 3­1­10 Engine speed Check................................................................. 3­10­11

D Decals Safety..................................................................... 1­5­2 Diagnose malfunctions Troubleshooting procedure .................................... 4­3­1 Diesel engine oil ............................................3­1­9, 3­1­10 Diesel fuel........................................................3­1­1, 3­1­3 Sample................................................................... 3­9­5 Storage .................................................................. 3­1­5 Diesel fuel conditioner ............................................... 3­1­5 Differential Lock pedal............................................................ 2­2­13 Display monitor Functions ............................................................... 2­1­1 Draft link wear plates Grease ................................................................... 3­3­5 Drain engine coolant................................................ 3­12­1 Driving ....................................................................... 2­2­8 Dust unloader valve Clean...................................................................... 3­3­5

E Electrical Troubleshooting ..................................................... 4­3­7 Element Primary Cleaning and inspecting ...........................3­3­6, 4­1­1 Secondary Inspecting and cleaning............................3­3­6, 4­1­1 Elements, air cleaner Replace.............................................................. 3­10­12 Engine Air filter restriction indicator.................................... 2­1­2 Alternator voltage indicator .................................... 2­1­2 Break­in.................................................................. 2­2­2 Break­in (S.N. ­­882699)........................................ 3­6­1 Break­in (S.N. 882700­­888000)............................ 3­6­2 Break­in (S.N. 888001—)....................................... 3­7­1 Coolant heater ....................................................... 2­2­7 Coolant temperature indicator................................ 2­1­1 Crankcase vent tube ............................................ 3­10­8 Hood, opening and closing (S.N. 882700­­)........... 3­2­3 Oil change (S.N. ­­882699) .................................... 3­8­1 Oil change (S.N. 882700­­) .................................... 3­9­2

F Filter Engine oil (S.N. ­­882699) ..................................... 3­8­1 Engine oil (S.N. 882700­­) ..................................... 3­9­2 Fuel ..............................................................3­3­6, 4­1­2 Fuel, change .......................................................... 3­9­4 Hydraulic oil system ...................................3­9­3, 3­10­4 Fire extinguisher Location ................................................................. 2­1­7 Fires, prevent............................................................. 1­2­4 Fluid analysis test kit ................................................. 3­2­4 Front axle and steering pivots ................................... 3­4­9 Front wheel drive Oil specification.................................................... 3­1­11 Fuel Diesel ...........................................................3­1­1, 3­1­3 Filter drain sediment ....................................3­3­6, 4­1­2 Filter, change ......................................................... 3­9­4 Handling and storing .............................................. 3­1­2 Level gauge ........................................................... 2­1­2 Lubricity.................................................................. 3­1­1 Tank capacity ......................................................... 3­2­4 Tank drain .............................................................. 3­3­2 Fuse Location (S.N. ­880053)......................................... 4­1­7 Location (S.N. 880054­­882699)............................ 4­1­8 Location (S.N. 882700­­888000)............................ 4­1­9 Location (S.N. 888001­­)...................................... 4­1­10 Specifications (S.N. ­880053) ................................ 4­1­7 Specifications (S.N. 880054­­882699) ................... 4­1­8 Specifications (S.N. 882700­­888000) ................... 4­1­9 Specifications (S.N. 888001­­) ............................. 4­1­10

G Gauge Fuel level................................................................ 2­1­2 Hour meter ............................................................. 2­1­2 Troubleshooting ..................................................... 4­3­9 General information ................................................... 4­2­1

Continued on next page

Index­2

091710

PN=2

Index Page

Page

Grease Axle MFWD drive shaft splines ........................3­3­7, 3­4­4 Bucket pivots.......................................................... 3­4­4 Draft link wear plates ............................................. 3­3­5 Extreme pressure and multipurpose .................... 3­1­12 Front axle and steering pivots................................ 3­4­9 Front wheel bearings ............................................. 3­3­4 Lift cylinder............................................................. 3­4­6 Loader pivots ......................................................... 3­4­3 MFWD drive shaft universal joints ......................... 3­4­7 MFWD front axle pivot ........................................... 3­4­8 MFWD front axle universal joints ........................... 3­4­7 Three­point hitch ..........................................3­4­5, 3­4­6

Pump...................................................................... 4­1­2 Inspection, pre­start................................................... 2­2­1 Instrument Check before starting............................................. 2­2­2

H Handholds Use correctly .......................................................... 1­3­1 Hardware torque values Metric ................................................................... 4­1­24 Unified inch .......................................................... 4­1­23 Hazards Avoiding ................................................................. 1­3­2 High­pressure oils Avoid ...................................................................... 1­2­3 Hood, opening and closing (S.N. 882700­­) .............. 3­2­3 Hoses Air intake ................................................................ 3­9­1 Coolant................................................................... 4­1­1 Hour meter Check..................................................................... 3­2­1 Gauge .................................................................... 2­1­2 Hydraulic Oil filter.......................................................3­9­3, 3­10­4 Oil filter restriction indicator.................................... 2­1­2 Oil specification.................................................... 3­1­11 Reservoir oil change ................................ 3­10­7, 3­11­2 Reservoir oil level................................................... 3­4­2 Reservoir screens inspect and clean ..................... 3­9­4 Troubleshooting ..................................................... 4­3­5 Hydraulic oil ............................................................. 3­1­10

I Indicator Engine air filter restriction ...................................... 2­1­2 Engine alternator voltage ....................................... 2­1­2 Engine coolant temperature................................... 2­1­1 Engine oil pressure ................................................ 2­1­1 Hydraulic oil filter restriction ................................... 2­1­2 Mechanical front wheel drive (MFWD)................... 2­1­2 Park brake.............................................................. 2­1­1 Seat belt................................................................. 2­1­1 Stop........................................................................ 2­1­1 Transmission oil temperature................................. 2­1­2 Troubleshooting ..................................................... 4­3­9 Injection Nozzle .................................................................... 4­1­2

L Landscape loader Bucket .................................................................... 4­5­7 Capacity, drain and refill...............................4­5­2, 4­5­3 Dimensions ............................................................ 4­5­4 Safety features....................................................... 1­1­1 Specifications......................................................... 4­5­6 Weight.................................................................... 4­5­7 Lever Loader control ...................................................... 2­2­10 Three­point hitch .................................................... 2­1­4 Lift cylinder Lubricate ................................................................ 3­4­6 Lifting ....................................................................... 2­2­14 Lights ......................................................................... 2­1­3 Loader Bucket changing .................................................. 4­1­13 Controls................................................................ 2­2­10 Loader boom lock ...................................................... 3­2­3 Check..................................................................... 3­3­1 Lubricate Axle MFWD drive shaft splines ........................3­3­7, 3­4­4 Bucket pivots.......................................................... 3­4­4 Draft link wear plates ............................................. 3­3­5 Front axle and steering pivots................................ 3­4­9 Front wheel bearings ............................................. 3­3­4 Lift cylinder............................................................. 3­4­6 Loader pivots ......................................................... 3­4­3 MFWD drive shaft universal joints ......................... 3­4­7 MFWD front axle pivot ........................................... 3­4­8 MFWD front axle universal joints ........................... 3­4­7 Three­point hitch ..........................................3­4­5, 3­4­6 Lubricity of diesel fuel ................................................ 3­1­1

M Machine Maintenance, preparation for ................................. 3­2­2 Warm­up Cold weather ...................................................... 2­2­7 Normal conditions............................................... 2­2­7 Machine modifications Avoid ...................................................................... 1­2­2 Machine tipover Avoid ...................................................................... 1­3­3 Machine, inspect........................................................ 1­2­2 Maintenance Chart ...................................................................... 3­2­1 Preparation for ....................................................... 3­2­2 Record (S.N. —888000) ................................................. 3­2­5 (S.N. 888001—) ................................................. 3­2­9 Continued on next page

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Manual Operator's .............................................................. 2­1­6 Mechanical front wheel drive Front axle housing oil............................................. 3­8­2 Front axle housing oil change (S.N. —888000) ............................................... 3­10­1 Oil specification.................................................... 3­1­11 Planetary housing oil.............................................. 3­8­2 Switch .................................................................. 2­2­13 Metric bolt and screw torque values ........................ 4­1­24 MFWD Axle housing oil level ............................................. 3­8­2 Front axle housing oil change (S.N. —888000) ............................................... 3­10­1 Grease axle pivot ................................................... 3­4­8 Grease axle universal joints................................... 3­4­7 Grease drive shaft universal joints......................... 3­4­7 Indicator ................................................................. 2­1­2 Lubricate Change axle housing oil (S.N. 888001—)............................................ 3­11­1 Drive shaft splines ....................................3­3­7, 3­4­4 Operation ............................................................. 2­2­13 Planetary housing oil level ..................................... 3­8­2 Troubleshooting ................................................... 4­3­12 Wheel planetary housing oil change ................................................... 3­10­1, 3­11­1 Monitor Engine air filter restriction indicator........................ 2­1­2 Engine alternator voltage indicator ........................ 2­1­2 Engine coolant temperature indicator .................... 2­1­1 Engine oil pressure indicator.................................. 2­1­1 Fuel level gauge..................................................... 2­1­2 Functions ............................................................... 2­1­1 Hour meter ............................................................. 2­1­2 Hydraulic oil filter restriction indicator .................... 2­1­2 Mechanical front wheel drive ................................. 2­1­2 Park brake indicator ............................................... 2­1­1 Seat belt indicator .................................................. 2­1­1 Stop indicator ......................................................... 2­1­1 Transmission oil temperature indicator .................. 2­1­2 Motor ....................................................................... 4­1­21

(S.N. 888001­­) ............................................. 3­10­6 Change, hydraulic reservoir ..................... 3­10­7, 3­11­2 Change, MFWD front axle housing (S.N. —888000) ............................................... 3­10­1 Change, PTO (if equipped) ...................... 3­10­7, 3­11­2 Change, rear axle ................................................ 3­10­3 Engine sample ....................................................... 3­8­6 Front axle gear case sample.................................. 3­9­5 Hydraulic sample ................................................... 3­9­5 Level, engine.......................................................... 3­4­1 Level, hydraulic reservoir ....................................... 3­4­2 Level, MFWD front axle housing............................ 3­8­2 Level, MFWD planetary housing............................ 3­8­2 Level, rear axle (S.N. ­­888000)................................................... 3­8­3 (S.N. 888001—­) ................................................ 3­8­3 Level, transmission ......................................3­5­1, 3­8­6 PTO gear case..................................................... 3­1­12 Rear axle gear case sample .................................. 3­9­5 Specification Axles................................................................. 3­1­11 Hydraulic system .............................................. 3­1­11 Mechanical front wheel drive............................ 3­1­11 Transmission .................................................... 3­1­11 Transmission sample ............................................. 3­9­5 Oil change Engine (S.N. ­­882699) .......................................... 3­8­1 Engine (S.N. 882700­­) .......................................... 3­9­2 MFWD planetary housing ........................ 3­10­1, 3­11­1 Operating Differential lock .................................................... 2­2­13 Mechanical front wheel drive (MFWD)................. 2­2­13 Operating machine Use special care .................................................... 1­3­4 Operation qualification............................................... 1­2­1 Operational checks Accessories.......................................................... 4­2­13 Brake system ......................................................... 4­2­5 Cab ...................................................................... 4­2­14 Clutch disconnect solenoid .................................... 4­2­7 Driving.................................................................... 4­2­7 Hydraulic system.................................................. 4­2­10 Indicators ............................................................... 4­2­3 MFWD.................................................................... 4­2­9 Miscellaneous ...................................................... 4­2­15 Steering system ..................................................... 4­2­6 Switches................................................................. 4­2­2 Operator's manual holder .......................................... 2­1­6

N Neutral Start system check............................................... 4­1­13

O

P

Oil Change MFWD front axle housing (S.N. 888001—)............................................ 3­11­1 Planetary housing............................................. 3­11­2 Rear axle housing ............................................ 3­11­2 Transmission and torque converter (S.N. ­­886534) ............................................... 3­6­3 (S.N. ­­888000) ............................................. 3­10­5

Park brake Adjust ..................................................................... 3­3­4 Check..................................................................... 3­3­4 Check and adjust ................................................... 3­3­4 Indicator ................................................................. 2­1­1 Switch .................................................................... 2­1­4 Parking .................................................................... 2­2­15

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Parts, moving Stay clear ............................................................... 1­2­2 Pedal Differential lock .................................................... 2­2­13 Periodic maintenance chart ....................................... 3­2­1 Pins, metal Drive safely ............................................................ 1­4­3 Planetary housing Oil change............................................................ 3­11­2 Power outlets 12 volt accessory ................................................... 2­1­6 Pre­start Inspection............................................................... 2­2­1 PTO Gear case oil........................................................ 3­1­12 Operating ............................................................. 2­2­13 Pump Service ................................................................. 4­1­21

Screens, hydraulic reservoir Clean...................................................................... 3­9­4 Seat belt Indicator ................................................................. 2­1­1 Maintenance .......................................................... 2­1­5 Operation ............................................................... 2­1­5 Use and maintain ................................................... 1­3­1 Seat controls Non­suspension ..................................................... 2­1­6 Suspension ............................................................ 2­1­5 Secondary and primary element Cleaning.......................................................3­3­6, 4­1­1 Serial number Engine Record................................................................ 4­6­1 Front axle housing Record................................................................ 4­6­3 MFWD Record................................................................ 4­6­3 Rear axle housing Record................................................................ 4­6­2 Transmission, (S.N. 888001­­) Record................................................................ 4­6­2 Transmission, Manual Record................................................................ 4­6­1 Transmission, Powershift (S.N.­­888000) Record................................................................ 4­6­2 Serial numbers .......................................................... 4­6­1 Service brake Inspection............................................................. 4­1­16 Service brakes Inspection (external) ............................................ 4­1­15 Service interval checklist (S.N. —888000) ..................................................... 3­2­5 (S.N. 888001—) ..................................................... 3­2­9 Service record (S.N. —888000) ..................................................... 3­2­5 (S.N. 888001—) ..................................................... 3­2­9 Specification Fuses (S.N. ­880053)............................................. 4­1­7 Fuses (S.N. 880054­­882699) ............................... 4­1­8 Fuses (S.N. 882700­­888000) ............................... 4­1­9 Fuses (S.N. 888001­­) ......................................... 4­1­10 Hardware torque .................................................. 4­1­22 Landscape loader .................................................. 4­5­6 Oil Axle .................................................................. 3­1­11 Hydraulic .......................................................... 3­1­11 Mechanical front wheel drive............................ 3­1­11 Transmission .................................................... 3­1­11 Oil, differential ...................................................... 3­1­11 Oil, hand­operated cab tilt hydraulic pump .......... 3­1­11 Oil, park brake...................................................... 3­1­11 Wheel fastener torque............................................ 3­3­7 Speed control knob.................................................... 2­1­4 Starting fluid, cold weather start (S.N. ­882699)........ 2­2­5 Starting fluid, cold weather start (S.N. 882700­­) ...... 2­2­6 Starting the engine .................................................... 2­2­3

R Radiator Inspect ................................................................... 4­1­1 Rear axle Check oil level (S.N. ­­888000)................................................... 3­8­3 Recognize Safety, information ................................................. 1­2­1 Regulator ................................................................... 4­1­2 Relay Location (S.N. ­880053)......................................... 4­1­7 Location (S.N. 880054­­882699)............................ 4­1­8 Location (S.N. 882700­­888000)............................ 4­1­9 Location (S.N. 888001­­)...................................... 4­1­10 Required parts (S.N. —888000) ..................................................... 3­2­7 (S.N. 888001—) ................................................... 3­2­11 Reservoir Hydraulic oil change................................. 3­10­7, 3­11­2 Oil level check, hydraulic ....................................... 3­4­2 Roads Operating or traveling ............................................ 1­3­4 ROPS Attachment........................................................... 4­1­14 Inspect ................................................................... 1­3­4 Maintain ................................................................. 1­3­4 Torque .................................................................. 4­1­22

S Safety Clean debris from machine .................................... 1­2­6 Operator's seat ...................................................... 1­3­1 Park and prepare for service safely ....................... 1­4­1 Protective equipment ............................................. 1­2­2 Safety signs ............................................................... 1­5­2 Safety, information Recognize .............................................................. 1­2­1

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Steps Use correctly .......................................................... 1­3­1 Stop indicator............................................................. 2­1­1 Storage ...................................................................... 4­4­1 Monthly .................................................................. 4­4­2 Storing fuel ................................................................ 3­1­2 Switch Battery disconnect ................................................. 3­2­2 Locations, steering console ................................... 2­1­3 Mechanical front wheel drive (MFWD)................. 2­2­13 Park brake.............................................................. 2­1­4 Turn signal ............................................................. 2­1­3 Warning lights ........................................................ 2­1­3 Work and drive lights ............................................. 2­1­3

(S.N. ­­888000)................................................. 3­10­5 (S.N. 888001­­)................................................. 3­10­6 Oil level ........................................................3­5­1, 3­8­6 Oil specification.................................................... 3­1­11 Troubleshooting ................................................... 4­3­11 Transporting On a trailer ........................................................... 2­2­16 Travel speeds ............................................................ 4­5­1 Traveling On public roads...................................................... 1­3­4 Troubleshooting procedure........................................ 4­3­1 Turn signal Switch .................................................................... 2­1­3

U

T

Unified inch bolt and screw torque values ............... 4­1­23 Three­point hitch Levers .................................................................... 2­1­4 Lubricate pivots............................................3­4­5, 3­4­6 Operating ............................................................. 2­2­11 Tire Pressure................................................................. 3­3­3 Pressure check ...................................................... 3­3­3 Toe­in, check and adjust..............................4­1­19, 4­1­20 Torque charts Metric ................................................................... 4­1­24 Unified inch .......................................................... 4­1­23 Torque converter Oil change (S.N. ­­886534)................................................... 3­6­3 (S.N. ­­888000)................................................. 3­10­5 (S.N. 888001­­)................................................. 3­10­6 Torque value ROPS bolts .......................................................... 4­1­22 Wheel cap screw.................................................. 4­1­21 Towing ..................................................................... 2­2­17 Transmissioin Oil temperature indicator........................................ 2­1­2 Transmission Oil change (S.N. ­­886534)................................................... 3­6­3

V Valve Control ................................................................. 4­1­21 Vandal protection....................................................... 2­1­7 Vent tube, engine .................................................... 3­10­8

W Warm­up Machine, cold weather ........................................... 2­2­7 Machine, normal conditions ................................... 2­2­7 Weight ....................................................................... 4­5­7 Welding.................................................................... 4­1­14 Welding repairs Make safely............................................................ 1­4­2 Wheel bearings, front .............................................. 3­10­2 Wheel fasteners.............................................3­3­7, 4­1­21 Work site hazards Avoid ...................................................................... 1­3­2

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