744J and 824J Loaders

(S.N. —590069)

OPERATOR’S MANUAL
744J and 824J Loaders
OMT182029 Issue B8 (ENGLISH)

CALIFORNIA
Proposition 65 Warning

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth
defects, and other reproductive harm.

If this product contains a gasoline engine:

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

The State of California requires the above two warnings.

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

READ THIS MANUAL carefully to learn how to operate numbers when you order parts. File the identification
and service your machine correctly. Failure to do so numbers in a secure place off the machine.
could result in personal injury or equipment damage.
This manual and safety signs on your machine may WARRANTY is provided as part of John Deere’s
also be available in other languages. (See your John support program for customers who operate and
Deere dealer to order.) maintain their equipment as described in this manual.
The warranty is explained on the warranty certificate
THIS MANUAL SHOULD BE CONSIDERED a which you should have received from your dealer.
permanent part of your machine and should remain
with the machine when you sell it. This warranty provides you the assurance that John
Deere will back its products where defects appear
MEASUREMENTS in this manual are given in both within the warranty period. In some circumstances,
metric and customary U.S. unit equivalents. Use only John Deere also provides field improvements, often
correct replacement parts and fasteners. Metric and without charge to the customer, even if the product is
inch fasteners may require a specific metric or inch out of warranty. Should the equipment be abused, or
wrench. modified to change its performance beyond the original
factory specifications, the warranty will become void
RIGHT-HAND AND LEFT-HAND sides are determined and field improvements may be denied. Setting fuel
by facing in the direction of forward travel. delivery above specifications or otherwise
overpowering machines will result in such action.
WRITE PRODUCT IDENTIFICATION NUMBERS
(P.I.N.) in the Machine Numbers section. Accurately THE TIRE MANUFACTURER’S warranty supplied with
record all the numbers to help in tracing the machine your machine may not apply outside the U.S.
should it be stolen. Your dealer also needs these

DX,IFC7 –19–16NOV01–1/1

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 Introduction

Emission Control Statement

EMISSIONS CONTROL WARRANTY STATEMENT FOR

NEW JOHN DEERE CONSTRUCTION EQUIPMENT (U.S. AND CANADA)
To determine if the engine in your machine qualifies for the additional warranties set forth below, look for the "Engine Information"
label located on your engine. If you reside in the United States and the engine label states: "Engine conforms to
US EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control Warranty
Statement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy duty
non road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement."
U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT
Emissions control-related parts and components are warranted Operator's Manual. John Deere recommends that you retain all
by John Deere for five years or 3000 hours of operation, whichever receipts covering maintenance on your heavy-duty engine, but
occurs first. John Deere further warrants that the engine covered John Deere cannot deny warranty solely for the lack of receipts
by this warranty was designed, built, and equipped so as to or for your failure to ensure the performance of all scheduled
conform at the time of sale with all U.S. emissions standards at maintenance.
the time of manufacture, and that it is free of defects in materials
and workmanship which would cause it not to meet these However, as the heavy-duty engine owner, you should be aware
standards within the period of five years or 3000 hours of that John Deere may deny you warranty coverage if your heavy-
operations, whichever occurs first. duty engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Warranties stated on this certificate refer only to emissions-related
parts and components of your engine. The complete machine Your engine is designed to operate on diesel fuel only. Use of
warranty, less emisions-related parts and components, is any other fuel may result in your engine no longer operating in
provided separately as "John Deere "Secure Warranty" For New compliance with California's emissions requirements.
Construction Products."
You are responsible for initiating the warranty process. The CARB
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT suggests that you present your machine to the nearest authorized
YOUR WARRANTY RIGHTS AND OBLIGATIONS John Deere dealer as soon as a problem is suspected. The
warranty repairs should be completed by the service dealer as
The California Air Resources Board (CARB) and John Deere are expeditiously as possible.
pleased to explain the emission control system on your new If you have any questions regarding your warranty rights and
engine. In California, new heavy-duty engines must be designed, responsibilities, you should contact John Deere at 1-319-292-
built and equipped to meet the State's stringent anti-smog 5400, or the State of California Air Resources Board, Mobile Source
standards. John Deere must warrant the emission control system Operation Division, PO Box 8001, El Monte, CA 91731-2900
on your engine for the periods of time listed below provided there
has been no abuse, neglect, or improper maintenance of your The warranty period begins on the date the machine is delivered
machine. to an ultimate purchaser, or when otherwise put into service.
John Deere warrants to the ultimate purchaser and each
subsequent purchaser that the engine is designed, built and
Your emissions control system includes: equipped so as to conform with all applicable regulations adopted
by the Air Resources Board, and that it is free from defects in
Fuel Metering System materials and workmanship which would cause the failure of a
Fuel Injection System warranted part.
Air Induction System Any warranted part which is scheduled for replacement as
Intake Manifold required maintenance by the operator's manual is warranted by
Turbocharger System John Deere for the period of time prior to the first scheduled
Charge Air Cooling System replacement point for that part. If the part fails prior to the first
scheduled replacement point, the part shall be repaired or
Miscellaneous Items used in Above Systems replaced under warranty. Any such part repaired or replaced
under warranty is warranted for the remainder of the period prior
to the first scheduled replacement point for that part.
Where a warrantable condition exists, i.e. failure due to defect in
John Deere-supplied material and/or workmanship, John Deere Any warranted part which is not scheduled for replacement as
will repair your heavy-duty engine at no cost to you including required maintenance, or which is scheduled only for regular
diagnosis, parts and labor inspection to the effect of repairing or replacing as necessary, is
warranted for the warranty period.
JOHN DEERE'S WARRANTY COVERAGE:
Repair or replacement of a warranted part will be performed at no
The emission control system of your heavy-duty engine is charge to you by an authorized John Deere dealer. You will not
warranted for five years or 3000 hours of operation, whichever be charged for diagnostic labor which leads to the determination
occurs first. If any emission-related part on your engine is that a warranted part is defective, if the diagnostic work is
defective, the part will be repaired or replaced by John Deere. performed by a John Deere dealer.
Warranties stated on this certificate refer only to emissions-related
parts and components of your engine. The complete machine John Deere is liable for damages to other engine components
caused by failure under warranty of any warranted part.
–19–28JUN00

warranty, less emissions-related parts and components, is

provided separately as the "John Deere "Secure Warranty" For John Deere is NOT liable for travel or mileage on extended
New Construction Products." emissions warranty service calls.
OWNER'S WARRANTY RESPONSIBILITIES: Any replacement part may be used in the performance of any
maintenance or repairs, and such use will not reduce the warranty
T132126

As the heavy-duty engine owner, you are responsible for the obligations of John Deere. However, the use of add-on or
performance of the required maintenance as outlined in the modified parts are grounds for disallowing a warranty claim.

OUO1065,000006C –19–08JAN08–1/1

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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

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

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

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

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THANK YOU!

TX,II,FAX –19–10JUL01–1/1

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 Contents
Page Page

Safety—Safety Features Operation—Operator’s Station

Safety and Operator Convenience Features . . . 1-1-1 Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1
Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2
Safety—General Precautions Deluxe Monitor Panel . . . . . . . . . . . . . . . . . . . . 2-1-3
Recognize Safety Information. . . . . . . . . . . . . . 1-2-1 Deluxe Monitor Panel Functions . . . . . . . . . . . . 2-1-4
Follow Safety Instructions. . . . . . . . . . . . . . . . . 1-2-1 Console Switches and Accessories (Single
Operate Only If Qualified . . . . . . . . . . . . . . . . . 1-2-1 Lever Design) . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7
Wear Protective Equipment . . . . . . . . . . . . . . . 1-2-2 Console Switch and Accessory
Avoid Unauthorized Machine Modifications. . . . 1-2-2 Functions (Single Lever Design) . . . . . . . . . . 2-1-8
Add Cab Guarding For Special Uses . . . . . . . . 1-2-3
Console Switches and Accessories (Two
Inspect Machine . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Lever Design) . . . . . . . . . . . . . . . . . . . . . . . 2-1-10
Stay Clear of Moving Parts. . . . . . . . . . . . . . . . 1-2-3
Console Switch and Accessory
Avoid High-Pressure Oils . . . . . . . . . . . . . . . . . 1-2-4
Functions (Two Lever Design) . . . . . . . . . . 2-1-11
Beware of Exhaust Fumes . . . . . . . . . . . . . . . . 1-2-4
Monitor Display Unit . . . . . . . . . . . . . . . . . . . . 2-1-13
Prevent Fires . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Monitor Display Unit—Normal Display . . . . . . 2-1-14
Prevent Battery Explosions. . . . . . . . . . . . . . . . 1-2-5
Monitor Display Unit—Accessory
Handle Chemical Products Safely. . . . . . . . . . . 1-2-6
Menu—Clutch Cut-Off (A 01) . . . . . . . . . . . 2-1-16
Dispose of Waste Properly . . . . . . . . . . . . . . . . 1-2-6
Monitor Display Unit—Accessory
Prepare for Emergencies . . . . . . . . . . . . . . . . . 1-2-6
Menu—Quick Shift Mode (A 02) . . . . . . . . . 2-1-19
Safety—Operating Precautions Monitor Display Unit—Accessory
Use Steps and Handholds Correctly . . . . . . . . . 1-3-1 Menu—Auto Mode to First (A 03) . . . . . . . . 2-1-21
Start Only From Operator’s Seat . . . . . . . . . . . 1-3-1 Monitor Display Unit—Accessory
Use and Maintain Seat Belt . . . . . . . . . . . . . . . 1-3-1 Menu—Job Timer Mode (A 04) . . . . . . . . . . 2-1-22
Prevent Unintended Machine Movement . . . . . 1-3-2 Monitor Display Unit—Accessory
Avoid Work Site Hazards . . . . . . . . . . . . . . . . . 1-3-2 Menu—Stop Watch Mode (A 05) . . . . . . . . 2-1-22
Use Special Care When Operating Loader. . . . 1-3-3 Monitor Display Unit—Accessory
Keep Riders Off Machine . . . . . . . . . . . . . . . . . 1-3-3 Menu—0.1 Hour Meter Mode (A 06) . . . . . . 2-1-22
Avoid Backover Accidents . . . . . . . . . . . . . . . . 1-3-4 Monitor Display Unit—Accessory
Avoid Machine Tip Over . . . . . . . . . . . . . . . . . . 1-3-4 Menu—Metric Units Mode (A 07) . . . . . . . . 2-1-23
Operating on Slopes. . . . . . . . . . . . . . . . . . . . . 1-3-5 Monitor Display Unit—User Diagnostics
Operating or Traveling On Public Roads . . . . . 1-3-5 Menu—Service Codes (d 01) . . . . . . . . . . . 2-1-24
Inspect and Maintain ROPS . . . . . . . . . . . . . . . 1-3-6 Monitor Display Unit--User Diagnostics
Add and Operate Attachments Safely. . . . . . . . 1-3-6 Menu
Continuity Check (d 02) . . . . . . . . . . . . . . . 2-1-27
Safety—Maintenance Precautions Monitor Display Unit—User Diagnostics
Park And Prepare For Service Safely . . . . . . . . 1-4-1 Menu
Service Cooling System Safely. . . . . . . . . . . . . 1-4-1 Battery Monitor (d 03) . . . . . . . . . . . . . . . . . 2-1-28
Remove Paint Before Welding or Heating . . . . 1-4-2 Engine Sensors (d 04) . . . . . . . . . . . . . . . . 2-1-29
Make Welding Repairs Safely. . . . . . . . . . . . . . 1-4-2 Transmission Sensors (d 05) . . . . . . . . . . . 2-1-32
Drive Metal Pins Safely . . . . . . . . . . . . . . . . . . 1-4-3 Hydraulic Sensors (d 06). . . . . . . . . . . . . . . 2-1-33
Fuel Sensor (d 07) . . . . . . . . . . . . . . . . . . . 2-1-35
Safety—Safety Signs
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1 Continued on next page

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2008
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2002, 2003

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(d08)-Not Used . . . . . . . . . . . . . . . . . . . . . . 2-1-35 Maintenance—Machine

Monitor Display Unit--User Diagnostics Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1
Menu Low Sulfur Diesel Fuel Conditioner. . . . . . . . . . 3-1-2
Spin Control Mode (d 09) . . . . . . . . . . . . . . 2-1-36 Testing Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . 3-1-2
Monitor Display Unit—User Diagnostics Handling and Storing Diesel Fuel . . . . . . . . . . . 3-1-3
Menu Alternative And Synthetic Lubricants . . . . . . . . 3-1-3
Machine I.D. Mode (d 10) . . . . . . . . . . . . . . 2-1-36 Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . 3-1-4
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-40 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . 3-1-5
Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-41 Transmission, Hydraulic System, Park
Heating and Air Conditioning Controls . . . . . . 2-1-41 Brake, and Differential Oil . . . . . . . . . . . . . . . 3-1-6
Air Flow Knob. . . . . . . . . . . . . . . . . . . . . . . . . 2-1-42 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-7
Adjusting Steering Wheel Tilt . . . . . . . . . . . . . 2-1-42 Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 3-1-8
Opening and Securing Side Door . . . . . . . . . . 2-1-42
Opening Side Window/Secondary Exit . . . . . . 2-1-44 Maintenance—Periodic Maintenance
Opening Rear Side Window . . . . . . . . . . . . . . 2-1-44 Service Your Machine at Specified Intervals. . . 3-2-1
Adjusting Seat . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45 Check the Monitor Display Unit Regularly. . . . . 3-2-1
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-46 Prepare Machine for Maintenance . . . . . . . . . . 3-2-2
12-Volt Power Plug. . . . . . . . . . . . . . . . . . . . . 2-1-46 Locking Machine Frame . . . . . . . . . . . . . . . . . . 3-2-4
Boom Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5
Opening Engine Side Shields and
Operation—Operating the Machine Service Doors . . . . . . . . . . . . . . . . . . . . . . . . 3-2-6
Inspect Machine Daily Before Starting . . . . . . . 2-2-1 Opening Grille Door . . . . . . . . . . . . . . . . . . . . . 3-2-7
Check Instruments Before Starting . . . . . . . . . . 2-2-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 2-2-2 Check Windshield Washer Fluid Level . . . . . . . 3-2-8
Starting Fluid—If Equipped (Cold Weather Maintenance and Repair Record
Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-4 Keeping System . . . . . . . . . . . . . . . . . . . . . . 3-2-8
Battery OILSCAN PLUS, COOLSCAN PLUS,
Using Booster Batteries—24 Volt System . . . 2-2-6 and 3-Way Coolant Test Kit . . . . . . . . . . . . . 3-2-9
Engine Air Heater—If Equipped . . . . . . . . . . . . 2-2-7 Service Intervals. . . . . . . . . . . . . . . . . . . . . . . 3-2-10
Using Coolant Heater—If Equipped . . . . . . . . . 2-2-7 Required Parts . . . . . . . . . . . . . . . . . . . . . . . . 3-2-12
Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8
Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . 2-2-8 Maintenance—As Required
Spin Control—If Equipped . . . . . . . . . . . . . . . . 2-2-9 Check Tire Pressure. . . . . . . . . . . . . . . . . . . . . 3-3-1
Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10 Tire Pressures (744J) . . . . . . . . . . . . . . . . . . . . 3-3-2
Shifting the Transmission . . . . . . . . . . . . . . . . 2-2-11 Tire Pressures (824J) . . . . . . . . . . . . . . . . . . . . 3-3-5
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . 2-2-12 Tighten Wheel Retainer Cap Screws . . . . . . . . 3-3-8
Boom and Bucket Control Lever Replace Air Cleaner Elements . . . . . . . . . . . . . 3-3-8
One Lever Design . . . . . . . . . . . . . . . . . . . . 2-2-13 Check Air Inlet Cover . . . . . . . . . . . . . . . . . . . . 3-3-9
Two Lever Design. . . . . . . . . . . . . . . . . . . . 2-2-14 Inspect Serpentine Belts. . . . . . . . . . . . . . . . . . 3-3-9
Quick Shift Switch . . . . . . . . . . . . . . . . . . . . . 2-2-15 Drain Fuel Tank Sediment . . . . . . . . . . . . . . . 3-3-10
Ride Control—If Equipped . . . . . . . . . . . . . . . 2-2-16 Inspect Fuel Filler Drain Hose and Tank
Secondary Steering—If Equipped . . . . . . . . . . 2-2-17 Breather Hose. . . . . . . . . . . . . . . . . . . . . . . 3-3-10
Differential Lock Switch . . . . . . . . . . . . . . . . . 2-2-18 Drain Primary Fuel Filter. . . . . . . . . . . . . . . . . 3-3-11
Boom Height Kickout Adjustment . . . . . . . . . . 2-2-18 Replace Primary Fuel Filter . . . . . . . . . . . . . . 3-3-11
Return-to-Carry Kickout Adjustment . . . . . . . . 2-2-19 Clean Water Separator Bowl . . . . . . . . . . . . . 3-3-13
Return-To-Dig Adjustment . . . . . . . . . . . . . . . 2-2-20
Fork Attachment . . . . . . . . . . . . . . . . . . . . . . . 2-2-21 Maintenance—Every 10 Hours or Daily
Arm Attachment . . . . . . . . . . . . . . . . . . . . . . . 2-2-23 Check Recovery Tank Coolant Level . . . . . . . . 3-4-1
Parking the Machine. . . . . . . . . . . . . . . . . . . . 2-2-24 Clean Air Cleaner Dust Unloader Valve . . . . . . 3-4-1
Loading Machine on a Trailer . . . . . . . . . . . . . 2-2-25 Check Engine Oil Level . . . . . . . . . . . . . . . . . . 3-4-2
Towing Procedure . . . . . . . . . . . . . . . . . . . . . 2-2-27
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . 2-2-29 Continued on next page

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Check Hydraulic Oil Level . . . . . . . . . . . . . . . . 3-4-3 Maintenance—Every 2000 Hours

Check Transmission Oil Level . . . . . . . . . . . . . 3-4-4 Check and Adjust Engine Valve Lash
and Electronic Injector Preload . . . . . . . . . . . 3-9-1
Maintenance—After 100 Hours
Change Engine Break-In Oil and Maintenance—Every 3000 Hours
Replace Filter . . . . . . . . . . . . . . . . . . . . . . . . 3-5-1 Change Hydraulic System Oil . . . . . . . . . . . . . 3-10-1
Change Transmission Oil . . . . . . . . . . . . . . . . . 3-5-3 Clean Hydraulic System Strainer . . . . . . . . . . 3-10-3
Replace Transmission Oil Filter . . . . . . . . . . . . 3-5-5 Replace Differential Lock Return Filter(s)—
If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 3-10-3
Maintenance—Every 100 Hours Change Front and Rear Differential Oil. . . . . . 3-10-4
Grease Loader Linkage and Cylinder Pivots. . . 3-5-1
Grease Front Steering Cylinder Pivots . . . . . . . 3-5-2 Miscellaneous—Machine
Grease Oscillating Rear Axle and Rear Draining the Cooling System . . . . . . . . . . . . . . 4-1-1
Steering Cylinder Pivots . . . . . . . . . . . . . . . . 3-5-2 Cooling System Fill and Deaeration
Check Cab Fresh Air Filter—If Equipped . . . . . 3-5-3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2
Check Cab Recirculating Air Filter . . . . . . . . . . 3-5-4 Replacing Engine Vibration Damper . . . . . . . . . 4-1-2
Adjusting Pilot Controller Tower . . . . . . . . . . . . 4-1-3
Maintenance—Every 250 Hours Checking Fuel Tank Vent Hose . . . . . . . . . . . . 4-1-3
Grease Front Driveline Sliding Joints . . . . . . . . 3-6-1 Bleeding Fuel System. . . . . . . . . . . . . . . . . . . . 4-1-4
Check Radiator Coolant Level . . . . . . . . . . . . . 3-6-2 Cleaning Water Separator Bowl . . . . . . . . . . . . 4-1-5
Change Engine Oil and Replace Filter . . . . . . . 3-6-3 Checking Fire Extinguisher—If Equipped . . . . . 4-1-6
Precautions for Alternator and Regulator . . . . . 4-1-6
Maintenance—Every 500 Hours Handling, Checking And Servicing Batteries
Grease Rear Driveline Sliding Joint and Carefully . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-7
U-Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1 Batteries
Check Air Intake Hoses . . . . . . . . . . . . . . . . . . 3-7-3 Using Charger. . . . . . . . . . . . . . . . . . . . . . . . 4-1-8
Check Battery Electrolyte Level and Remove and Install . . . . . . . . . . . . . . . . . . . . 4-1-9
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-4 Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . 4-1-10
Replace Primary Fuel Filter . . . . . . . . . . . . . . . 3-7-6 Fuse (Blade-Type) Color Codes . . . . . . . . . . . 4-1-12
Replace Primary Fuel Filter Strainer. . . . . . . . . 3-7-8 Resetting Circuit Breakers . . . . . . . . . . . . . . . 4-1-12
Replace Hydraulic System Return Filters . . . . . 3-7-9 Replacing Halogen Bulbs . . . . . . . . . . . . . . . . 4-1-13
Replace Hydraulic Reservoir Breather Filter . . . 3-7-9 Checking Neutral Start System. . . . . . . . . . . . 4-1-15
Replace Transmission Oil Filter . . . . . . . . . . . 3-7-10 Servicing Air Conditioning System—If
Check Park Brake Oil Level . . . . . . . . . . . . . . 3-7-11 Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-15
Check Front Differential Oil Level—If Welding On Machine . . . . . . . . . . . . . . . . . . . 4-1-15
Equipped With Differential Lock Axle . . . . . 3-7-11 External Service Brake Inspection . . . . . . . . . 4-1-16
Check Rear Differential Oil Level—If Checking Brake Accumulators . . . . . . . . . . . . 4-1-18
Equipped With Differential Lock Axle . . . . . 3-7-13 Checking Ride Control Accumulator—If
Check Front Differential Oil Level—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-19
Equipped With Standard Axle . . . . . . . . . . . 3-7-14 Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . 4-1-21
Check Rear Differential Oil Level—If Radiator, Oil Cooler, and Charge Air Cooler
Equipped With Standard Axle . . . . . . . . . . . 3-7-15 Cleaning Procedure . . . . . . . . . . . . . . . . . . 4-1-22
Service Recommendations For STC1
Maintenance—Every 1000 Hours Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-23
Replace Air Cleaner Dust Unloader Valve . . . . 3-8-1 Do Not Service Control Valves,
Replace Air Cleaner Elements . . . . . . . . . . . . . 3-8-1 Cylinders, Pumps or Motors . . . . . . . . . . . . 4-1-24
Clean Engine Crankcase Vent Tube. . . . . . . . . 3-8-2 Keep ROPS Installed Properly . . . . . . . . . . . . 4-1-25
Check Radiator Hoses . . . . . . . . . . . . . . . . . . . 3-8-2 Hardware Torque Specifications . . . . . . . . . . . 4-1-25
Change Transmission Oil . . . . . . . . . . . . . . . . . 3-8-3 Metric Bolt and Screw Torque Values. . . . . . . 4-1-26
Grease Frame Hinge Pivots . . . . . . . . . . . . . . . 3-8-5 Unified Inch Bolt and Screw Torque Values . . 4-1-27
Change Park Brake Oil. . . . . . . . . . . . . . . . . . . 3-8-5
Check Park Brake . . . . . . . . . . . . . . . . . . . . . . 3-8-6 Continued on next page

iii 022808
PN=3
 Contents

Page

Miscellaneous—Operational Checkout
Operational Checkout . . . . . . . . . . . . . . . . . . . . 4-2-1
Checking and Clearing Diagnostic
Trouble Codes From Monitor . . . . . . . . . . . . 4-2-1
Engine Off Checks . . . . . . . . . . . . . . . . . . . . . . 4-2-3
Engine Running Checks . . . . . . . . . . . . . . . . . . 4-2-5

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

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

Miscellaneous—Machine Numbers
Record Product Identification Number (PIN) . . . 4-5-1
Record Engine Serial Number . . . . . . . . . . . . . 4-5-1
Record Transmission Serial Number . . . . . . . . 4-5-1
Record Hydraulic Pump Serial Number . . . . . . 4-5-1

Miscellaneous—Specifications
744J Specifications. . . . . . . . . . . . . . . . . . . . . . 4-6-1
Drain and Refill Capacities—744J . . . . . . . . . . 4-6-4
824J Specifications. . . . . . . . . . . . . . . . . . . . . . 4-6-5
Drain and Refill Capacities—824J . . . . . . . . . . 4-6-8

Miscellaneous—Crime Prevention Tips

Help Prevent Crime . . . . . . . . . . . . . . . . . . . . . 4-7-1
Keep Proof of Ownership . . . . . . . . . . . . . . . . . 4-7-1
Park Indoors Out of Sight . . . . . . . . . . . . . . . . . 4-7-1
When Parking Outdoors . . . . . . . . . . . . . . . . . . 4-7-1
Reduce Vandalism . . . . . . . . . . . . . . . . . . . . . . 4-7-2
Report Thefts Immediately . . . . . . . . . . . . . . . . 4-7-2

iv 022808

PN=4
 Safety—Safety Features
Safety and Operator Convenience Features

1
2
3

4
9
11 15
8 12
5 10
6 13
14

–UN–22NOV06
TX1014200
TX1014200

Please remember, the operator is the key to 7. Articulation Locking Bar. A self-storing
preventing accidents. mechanical lock is provided for transport or service.
8. Handholds. Large, conveniently placed handholds
1. ROPS, FOPS, and OPS. Structures designed to make it easy to enter or exit the operator’s station
help protect the operator are certified to ISO, SAE, or service area.
and OSHA. Enclosures also deflect sun and rain. 9. Horn. Standard horn is useful when driving or
2. Pressurized Cab with Heater/Defroster. Positive signaling coworkers.
pressure ventilation system circulates both outside 10. Independent Parking Brake. Electronically
and inside air through filters for a clean working controlled and engages whenever the engine is
environment. Built in defroster vents direct air flow stopped.
for effective window defogging/deicing. 11. Seat Belt Retractors. Seat belt retractors help
3. Mirrors. Large exterior mirrors on both sides and keep belts clean and convenient to use.
an inside mirror offers operator a broad view of 12. Bypass Start Protection. Shielding over the
area behind machine. starter terminals helps prevent dangerous bypass
4. Large Windshield Wiper with Washer. Extra long starting.
wiper cleans large windshield area. 13. Engine Fan Guard. A secondary fan guard inside
5. Loader Boom Service Lock. Loader includes a the engine compartment helps prevent contact
mechanical lock for securing boom in the raised with the rotating fan blades.
position before work is started on or around the 14. Back Up Alarm. Alerts bystanders when reverse
machine. travel direction is selected by operator.
6. Halogen Lights and Turn Signals. High intensity 15. Stop and Signal Lights. Highly visible stop lights
halogen drive/work lights and high-visibility turn are standard equipment.
signals are standard equipment.

HG31779,000013B –19–08MAR07–1/1

1-1-1 022808
PN=7
 Safety—General Precautions
Recognize Safety Information

This is the safety alert symbol. When you see this

–UN–28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.

Follow the precautions and safe operating practices

T133555
highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.

–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

T133588
labels.

TX03679,00016CC –19–01OCT07–1/1

Follow Safety Instructions

Read the safety messages in this manual and on the

–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently.

Be sure all operators of this machine understand every

T133556
safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.

TX03679,00016F9 –19–01OCT07–1/1

Operate Only If Qualified

Do not operate this machine unless you have read the machine functions with the machine in an open area
operator’s manual carefully and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Familiarize yourself with the job site and your your work situation and your work site.
surroundings before operating. Try all controls and

TX03679,00016FA –19–01OCT07–1/1

1-2-1 022808
PN=8
 Safety—General Precautions

Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.

Wear close fitting clothing and safety equipment

appropriate to the job.

–UN–23AUG88
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

TS206
uncomfortable loud noises.

TX03679,00016D0 –19–01OCT07–1/1

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John machine stability or reliability, and may create a hazard
Deere replacement parts to ensure machine for the operator or others near the machine.
performance. Never substitute genuine John Deere
parts with alternate parts not intended for the Always contact an authorized dealer before making
application as these can create hazardous situations or machine modifications that change the intended use,
hazardous performance. Non-John Deere Parts, or any weight or balance of the machine, or that alter
damage or failures resulting from their use are not machine controls, performance or reliability.
covered by any John Deere warranty.

Modifications of this machine, or addition of

unapproved products or attachments, may affect

TX03679,00016B7 –19–12SEP07–1/1

1-2-2 022808
PN=9
 Safety—General Precautions

Add Cab Guarding For Special Uses

Special work situations or machine attachments may

create an environment with falling or flying objects.
Loading logs, using fork attachments, or operating in
waste management applications requires special work

–UN–04MAY01
tools. Added cab guarding to protect the operator may
also be required.

Use load-clamping grapples to keep bulky loads from

T141893
falling and add special screens or guarding when objects
may be directed toward the cab. Contact your authorized
John Deere dealer for information on devices intended to
protect the operator from falling or flying objects in special
work situations.

TX03679,00017C6 –19–18OCT07–1/1

Inspect Machine

Inspect machine carefully each day by walking around it

before starting.

Keep all guards and shields in good condition and

–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.

T6607AQ
TX03679,0001734 –19–01OCT07–1/1

Stay Clear of Moving Parts

Entanglements in moving parts can cause serious injury. –UN–12SEP01

Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
T133592

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.

TX03679,00016D2 –19–01OCT07–1/1

1-2-3 022808
PN=10
 Safety—General Precautions

Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system.

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

–UN–17MAR06
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.

T133509
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.

–UN–20SEP00
T133840
TX03679,00016D3 –19–10JAN07–1/1

Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

–UN–24AUG00
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring

T133546
outside air into the area.

TX03679,00016D4 –19–03JAN07–1/1

1-2-4 022808
PN=11
 Safety—General Precautions

Prevent Fires

–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.

T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.

–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil

T133553
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.

–UN–07SEP00
Know how to use extinguisher properly.

T133554
TX03679,00016F5 –19–08MAR07–1/1

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.

Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.

–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F). TS204

TX03679,000174A –19–03JAN07–1/1

1-2-5 022808
PN=12
 Safety—General Precautions

Handle Chemical Products Safely

Exposure to hazardous chemicals can cause serious

–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.

T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.

TX03679,00016D7 –19–03JAN07–1/1

Dispose of Waste Properly

Improper disposal of waste can threaten the environment.

–UN–25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or into

T133567
any water source.

Air conditioning refrigerants can damage the atmosphere.

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

If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your dealer for
more information.

TX03679,0001733 –19–28NOV06–1/1

Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88

hospital, and fire department near your telephone.

TS291

TX03679,000174B –19–31JAN07–1/1

1-2-6 022808
PN=13
 Safety—Operating Precautions
Use Steps and Handholds Correctly

Prevent falls by facing the machine when getting on and

–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present

T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.

TX03679,00016F2 –19–15MAR07–1/1

Start Only From Operator’s Seat

–UN–07SEP00
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.

T133715
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.

TX03679,0001799 –19–03JAN07–1/1

Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to

–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.

T133716
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.

The complete seat belt assembly should be replaced

every 3 years, regardless of appearance.

TX03679,00016DD –19–20MAR07–1/1

1-3-1 022808
PN=14
 Safety—Operating Precautions

Prevent Unintended Machine Movement

When coworkers are present, disable hydraulics.

–UN–15MAY01
Lower all equipment to the ground during work
interruptions. Lock transmission control in neutral, engage
park brake and stop engine before allowing anyone to
approach the machine.

T142001
Follow these same precautions before standing up,
leaving the operator’s seat, or exiting the machine.

TX03679,00017C7 –19–08MAR07–1/1

Avoid Work Site Hazards

Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all

–UN–15JUN01
underground utilities before starting work.

Prepare work site properly. Avoid operating near

structures or objects that could fall onto the machine.

T141894
Clear away debris that could move unexpectedly if run
over.

Avoid boom or attachment contact with overhead

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

–UN–24APR01
Keep bystanders clear at all times. Use barricades or a
signal person to keep vehicles and pedestrians away. Use
a signal person if moving machine in congested areas or
T141670
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient to

support machine. Be especially alert working near
embankments or excavations.
–UN–04MAY01

Avoid working under over-hanging embankments or

stockpiles that could collapse on machine.
T141672

TX03679,000179A –19–02MAY01–1/1

1-3-2 022808
PN=15
 Safety—Operating Precautions

Use Special Care When Operating Loader

Never use the loader to lift people. Do not allow

anyone to ride in the bucket or use the bucket as a

–UN–15MAY01
work platform.

Operate carefully with raised loads. Raising the load

reduces machine stability, especially on side slopes or an

T141957
unstable surface. Drive and turn slowly with a raised load.

Ensure that objects in the bucket are secure. Do not

attempt to lift or carry objects that are too big or too long
to fit inside the bucket unless secured with an adequate
chain or other device. Keep bystanders away from raised
loads.

–UN–07MAY01
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

T141902
attempting other maneuvers. Use an adequate chain or
sling and proper rigging techniques to attach and stabilize
loads. Never lift an object above or near another person.

TX03768,0000B70 –19–14MAY01–1/1

Keep Riders Off Machine

Only allow operator on machine.

–UN–04MAY01
Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects.

T141671
Riders may obstruct operator’s view or impair his ability to
operate machine safely.

TX03679,000179B –19–20APR01–1/1

1-3-3 022808
PN=16
 Safety—Operating Precautions

Avoid Backover Accidents

Before moving machine, be sure all persons are clear

of machine path. Turn around and look directly for best

–UN–04MAY01
visibility. Use mirrors to assist in checking all around
machine. Keep windows and mirrors clean, adjusted, and
in good repair.

T141673
Be certain reverse 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.

TX03679,000179C –19–20APR01–1/1

Avoid Machine Tip Over

Use seat belt at all times.

–19–14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.

T133716
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.

Be careful on slopes. Avoid sharp turns. Balance loads

so weight is evenly distributed and load is stable. Carry
tools and loads close to the ground to aid visibility and
lower center of gravity. Use extra care on soft, rocky or

–UN–04MAY01
frozen ground.

Know the capacity of the machine. Do not overload. Be

careful with heavy loads. Using oversize buckets or lifting
T141676
heavy objects reduces machine stability.

Ensure solid footing. Use extra care in soft ground

conditions that may not uniformly support the wheels,
especially when raising the boom. Do not operate close to
banks or open excavations that may cave in and cause
machine to tip or fall.
–UN–04MAY01
T141672

TX03679,000179D –19–02MAY01–1/1

1-3-4 022808
PN=17
 Safety—Operating Precautions

Operating on Slopes

Avoid side slope travel whenever possible. Drive up steep

slope in forward and down in reverse.

–UN–30APR01
Select low gear speed before starting down slope. The
grade of the slope will be limited by ground condition and
load being handled.

T141681
Use service brakes to control speed. Sudden brake
application with a loaded bucket on downhill side could
cause machine to tip forward.

TX03679,000179E –19–14MAY01–1/1

Operating or Traveling On Public Roads

Machines that work near vehicle traffic or travel slower

than normal highway speeds must have proper lighting

–UN–22MAY01
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

T141891
make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.

TX03679,00017C8 –19–02MAR07–1/1

1-3-5 022808
PN=18
 Safety—Operating Precautions

Inspect and Maintain ROPS

A damaged roll-over protective structure (ROPS) To maintain the ROPS:

should be replaced, not reused.
• Replace missing hardware using correct grade
The protection offered by ROPS will be impaired if hardware.
ROPS is subjected to structural damage, is involved in • Check hardware torque.
an overturn incident, or is in any way altered by • Check isolation mounts for damage, looseness or
welding, bending, drilling, or cutting. wear; replace them if necessary.
• Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason,
inspect it carefully before operating the machine again.

TX03679,000179F –19–07SEP06–1/1

Add and Operate Attachments Safely

Always verify compatibility of attachments by that all connections are secure and attachment
contacting your authorized dealer. Adding unapproved responds properly to controls.
attachments may affect machine stability or reliability,
and may create a hazard for others near the machine. Carefully read attachment manual and follow all
instructions and warnings. In an area free of
Ensure that a qualified person is involved in bystanders and obstructions, carefully operate
attachment installation. Add guards to machine if attachment to learn its characteristics and range of
operator protection is required or recommended. Verify motion.

TX03679,00016F0 –19–24JAN07–1/1

1-3-6 022808
PN=19
 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.

• Park machine on a level surface and lower equipment

–19–14DEC01
to the ground.
• Engage park brake.
• Stop engine and remove key.
• Install frame locking bar.

T133332
• Attach a “Do Not Operate” tag in an obvious place in
the operator’s station.

Securely support machine or attachment before working

under it.

• Do not support machine with boom, bucket, or other

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

–UN–23AUG88
• Do not support machine with a single jack or other
devices that may slip out of place.

Understand service procedures before beginning repairs.

TS229
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.

TX03679,00017A0 –19–18SEP01–1/1

Service Cooling System Safely

Explosive release of fluids from pressurized cooling

system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88

to relieve pressure before removing completely.

TS281

DX,RCAP –19–04JUN90–1/1

1-4-1 022808
PN=20
 Safety—Maintenance Precautions

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.

–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,

TS220
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.

Do not use a chlorinated solvent in areas where welding

will take place.

Do all work in an area that is well ventilated to carry toxic

fumes and dust away.

Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

Make Welding Repairs Safely

NOTE: Disable electrical power before welding. Turn off

–UN–31AUG00
main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and
vehicle microprocessors. T133547

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

TX03679,00016D5 –19–03JAN07–1/1

1-4-2 022808
PN=21
 Safety—Maintenance Precautions

Drive Metal Pins Safely

–UN–14SEP00
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.

T133738
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.

TX03679,0001745 –19–03JAN07–1/1

1-4-3 022808

PN=22
 Safety—Safety Signs
Safety Signs

–19–30OCT02
T159570

Left Side Shown

Continued on next page HG31779,000013C –19–26SEP02–1/2

1-5-1 022808

PN=23
Safety—Safety Signs

–19–26SEP02
T159894

Right Side Shown

HG31779,000013C –19–26SEP02–2/2

1-5-2 022808

PN=24
 Operation—Operator’s Station
Levers

–UN–10SEP98

–UN–01JUL02
T117002

T156903B
Single Lever (Joystick) Design
Two Lever Design

–UN–17OCT02
–UN–10SEP98
T117004

T160584B
Single Lever (Joystick) with Auxiliary Control Design Two Lever with Auxiliary Control Design

HG31779,0000152 –19–17OCT02–1/2

A—Transmission Control Lever

B—Turn Signal

–UN–12FEB98
T113445

HG31779,0000152 –19–17OCT02–2/2

2-1-1 022808
PN=25
 Operation—Operator’s Station

Pedals

A—Accelerator pedal: Depress to increase speed of

machine.

B and C— Brake pedal: Depress left brake pedal (C) or

–UN–29AUG01
right brake pedal (B) to stop machine.

NOTE: Brake pedals also serve as clutch cut-off pedals

when clutch cut-off switch is in “clutch

T145128
disengaged” position.

D—Differential Lock Foot Switch—If Equipped:

Depress switch (D) down to lock front axle differential. A—Accelerator
Release switch to unlock differential. B—Brake/Clutch Cut-Off Pedal
C—Brake/Clutch Cut-Off Pedal
D—Differential Lock Foot Switch—If Equipped
NOTE: Use differential lock only when conditions require
traction. Avoid using differential lock when
steering.

TX,10,JC1191 –19–27AUG01–1/1

2-1-2 022808

PN=26
 Operation—Operator’s Station

Deluxe Monitor Panel

–UN–24MAY02
T155127B
1—Check Engine Indicator 8—Service Required Indicator 15—Hydraulic Oil Filter 21—Engine Oil Pressure
2—Engine Air Filter Restriction 9—Right Turn Indicator Restriction Indicator Gauge
Indicator 10—Park Brake Indicator 16—Fuel Filter Restriction 22—Engine Coolant
3—Engine Oil Pressure 11—Brake Oil Pressure Indicator Temperature Gauge
Indicator Indicator 17—Message Display 23—Hydraulic Oil Temperature
4—Engine Preheat Indicator— 12—Secondary Steering 18—Transmission Service Gauge
If Equipped Warning Indicator—If Indicator 24—Transmission Oil
5—Left Turn Indicator Equipped 19—Transmission Filter Temperature Gauge
6—STOP Indicator 13—Pin Disconnect Indicator Indicator 25—Fuel Gauge
7—High Beams ON Indicator 14—Fasten Seat Belt Indicator 20—Battery Voltage Indicator 26—Basic Display Window
(not used)

• MENU provides initial entry into the accessories and • NEXT will move to the next selection within a menu
diagnostics system. Each time MENU is pressed, or mode.
display will cycle to the next menu. Once a main • SELECT switches between volts/kilometers/hours
menu has been selected, pressing MENU again will during normal operation. During accessories or
return to the Normal Display Menu. diagnostics modes, SELECT will activate the
• BACK will back out of a menu, one item each time currently chosen menu.
the key is pressed.

HG31779,0000060 –19–29APR02–1/1

2-1-3 022808

PN=27
 Operation—Operator’s Station

Deluxe Monitor Panel Functions

1—Check Engine Indicator: Indicator will light when The STOP indicator light flashes and alarm sounds
excessive water is present in final fuel filter. STOP when:
indicator will light, alarm will sound, and engine will
derate to 50% of full power until water is drained. • Engine oil pressure is low.
• Engine coolant temperature is excessively high.
When water is drained, indicators and alarm will turn • Transmission oil temperature is excessively high.
off and the engine will return to full power. • Transmission is shifted into gear with park brake
engaged.
2—Engine Air Filter Restriction Indicator: Indicator • Brake pressure is low.
will light and service required indicator will light when • Steering system pressure is low, and secondary
air elements are restricted. steering is activated.

3—Engine Oil Pressure Indicator: 7—High Beams ON Indicator : Not used.

IMPORTANT: Prevent possible engine damage. If 8—Service Required Indicator (Yellow): Indicator will
engine oil pressure indicator light light when a problem is developing. It is not necessary
comes on while operating, stop to stop the engine immediately, but the cause should
machine. STOP ENGINE be investigated as soon as possible. The service
IMMEDIATELY. required indicator lights when:

Indicator will light, STOP indicator will flash, and alarm • Alternator voltage is low.
will sound when engine oil pressure is low. Stop • Transmission filter is restricted.
machine. STOP ENGINE IMMEDIATELY. • Engine air filter is restricted.
• Hydraulic oil temperature is too high.
NOTE: Cold oil or extreme off level operation may • Hydraulic oil filter is restricted.
cause indicator to light. • Fuel filter is restricted.
• Transmission fault indication.
4—Engine Preheat Indicator—If Equipped: Indicator
will light when key switch is turned clockwise to the NOTE: Cold oil may cause hydraulic and transmission
“On” position. Light will turn off approximately 15-45 oil filter restriction indicators to light
seconds depending on engine temperature, indicating temporarily.
that preheating is completed. Light will turn off while
cranking engine. Indicator will also light for It is not necessary to stop the engine immediately but
approximately 15-45 seconds after engine is running, the cause should be investigated as soon as possible.
indicating post heat.
9—Right Turn Indicator: Indicator will light when right
5—Left Turn Indicator: Indicator will light when left turn signal switch is engaged.
turn signal switch is engaged.
10—Park Brake Indicator: Indicator will light when
6—STOP Indicator: park brake is engaged and transmission control lever
is in N “Neutral”.
CAUTION: Prevent possible injury or
machine damage. If STOP indicator light
flashes and alarm sounds, stop immediately
and investigate cause of problem.

Continued on next page HG31779,000005F –19–29APR02–1/3

2-1-4 022808

PN=28
 Operation—Operator’s Station

If park brake is engaged and transmission control lever as soon as possible when a problem
is in F “Forward” or R “Reverse”, the STOP indicator occurs.
will flash and alarm will sound. Push park brake switch
to OFF. Indicator will light and service required indicator will
light when hydraulic filter element is restricted.
11—Brake Oil Pressure Indicator:
NOTE: Cold oil may cause hydraulic oil filter restriction
indicator light to light until oil is warm.
CAUTION: Prevent possible injury or
machine damage. If brake pressure indicator
16—Fuel Filter Restriction Indicator:
light comes on while operating, stop
machine immediately.
NOTE: Indicator may come on during cold startups or
when machine is under heavy loads.
Indicator will light, STOP indicator will flash, and alarm
will sound when brake oil pressure is low or brake
A flickering light is an early warning that fuel
accumulator has lost its charge. Stop machine
filter needs to be changed.
immediately and push park brake switch to ON.
Indicator will light when fuel pressure drops below 300
12—Secondary Steering Warning Indicator—If
kPa (43.5 psi).
Equipped:
If pressure drops below 200 kPa (29 psi), indicator will
IMPORTANT: Prevent possible damage to
remain on. Service required indicator will light and
secondary steering system. Stop
engine will derate to 50% of full power.
machine immediately if secondary
steering indicator light and alarm
17—Message Display: Displays a 12 character
come on while operating. THE
alpha-numeric message that provides a text
SECONDARY STEERING SYSTEM IS
description of the currently displayed mode. This
NOT INTENDED FOR CONTINUOUS
message display supplements the information that is
USE.
shown on the basic display window.
Indicator will light, STOP indicator will flash, and alarm
18—Transmission Service Indicator: Transmission
will sound when secondary steering system is
service indicator and service required indicator will light
activated. Stop machine immediately and take
and stay on when a transmission clutch slippage
corrective action. The secondary steering system is not
service code has been detected. The transmission will
intended for continuous use.
shift to “Neutral” and then machine can only be moved
in “limp home” mode. A service code will be logged in
13—Pin Disconnect Indicator: Indicator will light
Monitor Display Unit. This code can be read by
when pin disconnect switch is activated to retract
accessing the Monitor Diagnostic Mode (d).
cylinders for removal of attachments.
The indicator light will turn off when key switch has
14—Fasten Seat Belt Indicator: Indicator will light for
been turned off. Every time clutch slippage occurs, the
the first 5 seconds after the engine is started to warn
transmission service indicator and service required
the operator to fasten seat belt.
indicator will light and will remain on until key switch is
turned off.
15—Hydraulic Oil Filter Restriction Indicator:

IMPORTANT: Prevent possible hydraulic pump

damage. Change hydraulic oil filter

Continued on next page HG31779,000005F –19–29APR02–2/3

2-1-5 022808

PN=29
 Operation—Operator’s Station

19—Transmission Filter Indicator: Indicator will light 23—Hydraulic Oil Temperature Gauge: Normal
and the service required indicator will light when the operating temperature is in green zone. If gauge
transmission filter is restricted. indicator points to red zone, hydraulic oil temperature
is too high. Stop work cycle and cycle loader functions
20—Battery Voltage Indicator: Indicator will light and without load to lower indicator reading. If indicator still
service required indicator will light when alternator stays in red zone, stop machine and see your
output is low. Check battery charge by selecting authorized dealer.
battery voltage on digital display.
If pointer deflects to the far left of the scale, electronic
21—Engine Oil Pressure Gauge: communication is lost or a sensor error is active.

IMPORTANT: Prevent possible engine damage. If 24—Transmission Oil Temperature Gauge: If

engine oil pressure indicator light indicator is in red zone, STOP indicator will flash and
comes on while operating, stop audible alarm will sound indicating that the
machine. STOP ENGINE temperature is too high. Stop machine and allow
IMMEDIATELY. transmission to cool. Shut off engine and take
corrective action.
Indicator will light, STOP indicator will flash, and alarm
will sound when engine oil pressure gauge indicates If pointer deflects to the far left of the scale, electronic
low pressure. Stop machine. STOP ENGINE communication is lost or a sensor error is active.
IMMEDIATELY.
25—Fuel Gauge: Indicator will reflect fuel level in
If pointer deflects to the far right side of the scale, tank.
electronic communication is lost or a sensor error is
active. Always fill tank at the end of the day to eliminate
condensation in fuel tank.
NOTE: Extreme off level operation may cause
indicator to light. 26—Basic Display Window: The display window has
six displays:
22—Engine Coolant Temperature Gauge: STOP
indicator will flash and audible alarm will sound when • Gear
pointer is in red zone. Stop machine and allow engine • FNR
to cool. Shut off engine and take corrective action. • Auto
• Tachometer
If pointer deflects to the far left of the scale, electronic • Hour Meter
communication is lost or a sensor error is active. • Voltmeter/Odometer

HG31779,000005F –19–29APR02–3/3

2-1-6 022808

PN=30
 Operation—Operator’s Station

Console Switches and Accessories (Single Lever Design)

–UN–28OCT02
T159422C
1—Pilot Enable/Boom Down 7—Not Used 14—Beacon Switch—If 18—Ride Control Switch—If
Switch 8—Front Wiper Knob Equipped Equipped
2—Drive, Tail and Marker 9—Rear Wiper Knob 15—Pin Disconnect Switch—If 19—Return-to-Carry Switch—If
Switch 10—Temperature Control Knob Equipped Equipped
3—Cab Work Light Switch—If 11—Blower Speed Knob 16—Spin Control Mode 20—Boom Height Kickout
Equipped 12—Air Conditioning Switch— Knob—If Equipped Switch—If Equipped
4—4-Way Flasher Switch If Equipped 17—Spin Control Switch—If
5—Clutch Cut-Off Switch 13—Axle Disconnect Switch— Equipped
6—Automatic Transmission If Equipped
Switch

HG31779,0000111 –19–17SEP02–1/1

2-1-7 022808

PN=31
 Operation—Operator’s Station

Console Switch and Accessory Functions (Single Lever Design)

1—Pilot Enable/Boom Down Switch: The switch has NOTE: The park brake will also disengage the
three positions: transmission clutches. Release park brake
before operating.
• Push upper half to lower boom with engine off
• Push to middle position to unlock pilot controllers; 6—Automatic Transmission Switch: Push upper half
normal operation of switch to the “Auto” position. Move transmission
• Push lower half to lock pilot controllers; locks lever to 3 or 4. Transmission will start in 2nd gear. As
hydraulic controls speed increases, transmission will automatically shift to
3rd and 4th gear. As load increases or speed
2—Drive, Tail and Marker Switch: The switch has decreases, transmission will automatically shift to 3rd
three positions: and 2nd gear.

• Push upper half to turn on headlights, tail 7—Not Used

lights/brake lights and turn signal/4-way lights
• Push switch to middle position to turn on tail 8—Front Wiper Knob: The knob has four positions:
lights/brake lights and turn signal/4-way lights
• Push lower half of switch to turn lights off • First position is “Off”
• Second position is intermittent wiper operation
3—Cab Work Light Switch—If Equipped: Push • Third position is low speed
upper half of switch to turn front and rear work lights • Fourth position is high speed
on. Push lower half of switch to turn work lights off.
Push wiper/washer knob in to wash front window.
4—4-Way Flasher Switch: Push upper half of switch
and front and rear amber lights will flash. 9—Rear Wiper Knob: The knob has four positions:

5—Clutch Cut-Off Switch: • First position is “Off”

• Second position is intermittent wiper operation
• Third position is low speed
CAUTION: Prevent possible injury from
• Fourth position is high speed
unexpected machine movement. When
stopping on inclines, push the lower half of
Push wiper/washer knob in to wash rear window.
the clutch cut-off switch to engage clutch
cut-off before releasing left service brake.
10—Temperature Control Knob: Turn knob to adjust
This will prevent the machine from rolling
air temperature. Turn knob clockwise to increase
downhill during transmission re-engagement
temperature. Turn counterclockwise to decrease
cycle.
temperature.
Push upper half of switch to disengage clutch before
11—Blower Speed Knob: Turn knob clockwise to
either brake pedal can be used to disengage
increase blower speed or counterclockwise to reduce
transmission clutches.
blower speed. Blower knob has four speed settings.
Use the switch in situations such as truck loading
where machine positioning and maximum hydraulics
are needed.

Continued on next page HG31779,0000112 –19–17SEP02–1/2

2-1-8 022808

PN=32
 Operation—Operator’s Station

12—Air Conditioning Switch—If Equipped: Push • Push upper half to turn ride control on
upper half of switch to turn air conditioning on. Push • Push to middle “Auto” position that functions the
lower half of switch to turn air conditioning off. same as the “On” position with one exception. The
ride control is turned off when ground speed is
13—Axle Disconnect Switch: Push upper half of approximately 6 km/h (3—1/2 mph) or less
switch to disconnect front axle. • Push lower half to turn ride control off

14—Beacon Switch: Push upper half of switch to turn 19—Return-to-Carry Switch—If Equipped: The
beacon light on. Push lower half of switch to turn switch has three positions:
beacon light off.
• Push upper half to set return-to-carry height
15—Pin Disconnect Switch—If Equipped: Push • Push to middle position to activate return-to-carry.
switch in then lift switch up to retract cylinders for Push boom lever to float position. Boom will kick-out
removal of attachments. of float position when it reaches a preset distance
from ground.
16—Spin Control Mode Knob—If Equipped: Turn • Push lower half to deactivate return-to-carry
knob to a setting that minimizes wheel spin while filling
the bucket. NOTE: Boom float will not work once the boom is
below preset distance from ground. Push
NOTE: Spin control reduces engine rpm to minimize switch to “Off” position to activate boom float.
wheel spin and prolong tire life. The five
different settings allow the operator to 20—Boom Height Kickout Switch: The switch has
customize the machine to differing tractive three positions:
conditions. Spin control only works in first
gear. • Push upper half to set boom height
• Push to middle position to activate boom height
17—Spin Control Switch—If Equipped: Push upper kickout. Pull lever to raise detent position. Boom will
half of switch to turn spin control on. Push lower half of kick-out of detent position when it reaches a preset
switch to turn spin control off. height from ground.
• Push lower half to deactivate boom height kickout
NOTE: If maximum power to wheels is needed, turn
spin control switch off.

18—Ride Control Switch: The switch has three

positions:

HG31779,0000112 –19–17SEP02–2/2

2-1-9 022808

PN=33
 Operation—Operator’s Station

Console Switches and Accessories (Two Lever Design)

–UN–24JUN02
T156392B
1—Ride Control Switch—If 6—Pilot Enable/Boom Down 11—4-Way Flasher Switch 17—Air Conditioning Switch—
Equipped Switch 12—Spin Control Mode If Equipped
2—Reverse Fan Switch—If 7—Pin Disconnect Switch—If Knob—If Equipped 18—Blower Speed Knob
Equipped Equipped 13—Spin Control Switch—If 19—Temperature Control Knob
3—Axle Disconnect Switch—If 8—Beacon Switch—If Equipped 20—Front Wiper Knob
Equipped Equipped 14—Not Used 21—Rear Wiper Knob
4—Boom Height Kickout 9—Cab Work Light Switch—If 15—Clutch Cut-Off Switch
Switch—If Equipped Equipped 16—Automatic Transmission
5—Return-to-Carry Switch—If 10—Drive, Tail and Marker Switch
Equipped Switch

HG31779,0000062 –19–24JUN02–1/1

2-1-10 022808

PN=34
 Operation—Operator’s Station

Console Switch and Accessory Functions (Two Lever Design)

1—Ride Control Switch: The switch has three • Push to middle position to unlock pilot controllers;
positions: normal operation
• Push lower half to lock pilot controllers; locks
• Push right half to turn ride control on hydraulic controls
• Push to middle “Auto” position that functions the
same as the “On” position with one exception. The 7—Pin Disconnect Switch—If Equipped: Push
ride control is turned off when ground speed is switch in then lift switch up to retract cylinders for
approximately 6 km/h (3—1/2 mph) or less removal of attachments.
• Push left half to turn ride control off
8—Beacon Switch: Push upper half of switch to turn
2—Reverse Fan Switch—If Equipped: Push upper beacon light on. Push lower half of switch to turn
half of switch to manually reverse the cooling fan. beacon light off.

3—Axle Disconnect Switch: Push upper half of 9—Cab Work Light Switch—If Equipped: Push
switch to disconnect front axle. upper half of switch to turn front and rear work lights
on. Push lower half of switch to turn work lights off.
4—Boom Height Kickout Switch: The switch has
three positions: 10—Drive, Tail and Marker Switch: The switch has
three positions:
• Push upper half to set boom height
• Push to middle position to activate boom height • Push upper half to turn on headlights, tail
kickout. Pull lever to raise detent position. Boom will lights/brake lights and turn signal/4-way lights
kick-out of detent position when it reaches a preset • Push switch to middle position to turn on tail
height from ground. lights/brake lights and turn signal/4-way lights
• Push lower half to deactivate boom height kickout • Push lower half of switch to turn lights off

5—Return-to-Carry Switch—If Equipped: The switch 11—4-Way Flasher Switch: Push upper half of switch
has three positions: and front and rear amber lights will flash.

• Push upper half to set return-to-carry height 12—Spin Control Mode Knob—If Equipped: Turn
• Push to middle position to activate return-to-carry. knob to a setting that minimizes wheel spin while filling
Push boom lever to float position. Boom will kick-out the bucket.
of float position when it reaches a preset distance
from ground. NOTE: Spin control reduces engine rpm to minimize
• Push lower half to deactivate return-to-carry wheel spin and prolong tire life. The five
different settings allow the operator to
NOTE: Boom float will not work once the boom is customize the machine to differing tractive
below preset distance from ground. Push conditions. Spin control only works in first
switch to “Off” position to activate boom float. gear.

6—Pilot Enable/Boom Down Switch: The switch has 13—Spin Control Switch—If Equipped: Push upper
three positions: half of switch to turn spin control on. Push lower half of
switch to turn spin control off.
• Push upper half to lower boom with engine off

Continued on next page HG31779,0000063 –19–29APR02–1/2

2-1-11 022808

PN=35
 Operation—Operator’s Station

NOTE: If maximum power to wheels is needed, turn decreases, transmission will automatically shift to 3rd
spin control switch off. and 2nd gear.

14—Not Used 17—Air Conditioning Switch—If Equipped: Push

lower half of switch to turn air conditioning on. Push
15—Clutch Cut-Off Switch: upper half of switch to turn air conditioning off.

18—Blower Speed Knob: Turn knob clockwise to

CAUTION: Prevent possible injury from
increase blower speed or counterclockwise to reduce
unexpected machine movement. When
blower speed. Blower knob has four speed settings.
stopping on inclines, push the lower half of
the clutch cut-off switch to engage clutch
19—Temperature Control Knob: Turn knob to adjust
cut-off before releasing left service brake.
air temperature. Turn knob clockwise to increase
This will prevent the machine from rolling
temperature. Turn counterclockwise to decrease
downhill during transmission re-engagement
temperature.
cycle.
20—Front Wiper Knob: The knob has four positions:
Push upper half of the clutch cut-off switch to
disengage clutch before either brake pedal can be
• First position is “Off”
used to disengage transmission clutches.
• Second position is intermittent wiper operation
• Third position is low speed
Use the switch in situations such as truck loading
• Fourth position is high speed
where machine positioning and maximum hydraulics
are needed.
Push wiper/washer knob in to wash front window.
NOTE: The park brake will also disengage the
21—Rear Wiper Knob: The knob has four positions:
transmission clutches. Release park brake
before operating.
• First position is “Off”
• Second position is intermittent wiper operation
16—Automatic Transmission Switch: Push upper
• Third position is low speed
half of switch to the “Auto” position. Move transmission
• Fourth position is high speed
lever to 3 or 4. Transmission will start in 2nd gear. As
speed increases, transmission will automatically shift to
Push wiper/washer knob in to wash rear window.
3rd and 4th gear. As load increases or speed

HG31779,0000063 –19–29APR02–2/2

2-1-12 022808

PN=36
 Operation—Operator’s Station

Monitor Display Unit

The monitor display unit has a basic digital LCD display

window. On machines equipped with the deluxe monitor
display unit there is also a 12 character alpha-numeric
message display that provides a text description of the

–UN–11MAR97
currently displayed mode. This message display
supplements the information that is shown on the basic
display window. The four main menus are:

T108065
• “Normal” menu is displayed when the machine is first
turned on, and no special functions are selected.
• “Accessory” menu allows the operator to make changes
to various operating characteristics of the machine.
• “Diagnostics” menu provides a limited set of tools, and
is intended to be used by service personnel and
machine operator’s for diagnostic and troubleshooting
functions.
• “Service” menu is for service personnel and requires a
special procedure to gain access. This mode provides
an additional and more sophisticated set of tools for
diagnostics and troubleshooting.

The monitor display unit keypad is used to navigate

through the different menus and modes of operation. Key
names and general functions are as follows:

• MENU provides initial entry into the accessories and

diagnostics system. Each time MENU is pressed,
display will cycle to the next menu. Once a main menu
has been selected, pressing MENU again will return to
the Normal Display Menu.
• BACK will back out of a menu, one item each time the
key is pressed.
• NEXT will move to the next selection within a menu or
mode.
• SELECT switches between volts/kilometers, hours
during normal operation. During accessories or
diagnostics modes, SELECT will activate the currently
chosen menu in Basic Display Window.

TX,10,JC1869 –19–20SEP02–1/1

2-1-13 022808

PN=37
 Operation—Operator’s Station

Monitor Display Unit—Normal Display

When key switch is turned on, all lights on display monitor

will come on, alarm will sound and stop and caution lights
will flash.

–UN–08JUN98
The basic display window will show the bulb check mode.
The window will contain numerical digit 8’s and will be
shown for approximately 5 seconds.

T115772
Then the machine model number will show in the basic
display window.

Continued on next page TX,10,JC1624 –19–08MAY98–1/3

2-1-14 022808

PN=38
 Operation—Operator’s Station

Approximately 5 seconds later, the Normal display will be

shown.

NOTE: Press SELECT to alternate between Odometer

and System Voltage display.

–UN–22OCT97
When machine is in neutral, the gear display (A) shows
the gear position of the shift lever. When the machine is
not in neutral, it displays the gear that the transmission
has engaged.

T111854
When the transmission controller service code 1655
occurs, a “---” is shown in this part of the display window
A—Gear Display
because there is an electronic communication failure. See B—FNR Display
your authorized dealer. C—Auto Display
D—Tachometer Display
The FNR Display (B) shows the forward, neutral, reverse E—Hour Meter Display
status. When a transmission controller unit failure occurs, F—Voltmeter/Odometer Display
G—Basic Display Window
this display is blank. H—Message Display Window (If Equipped)

The Auto Display (C) shows whether the transmission

“Auto” mode is On or Off. When a transmission controller
unit failure occurs, this display is blank.

The Tachometer Display (D) shows the torque converter

input shaft rpm to the nearest 5 rpm. When a transmission
controller unit malfunction occurs, a “---” is displayed and
the icon is turned off.

The Hour Meter Display (E) shows the machine hours in

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

The hour meter displays up to 99,999 hours.

The Voltmeter/Odometer Display (F) shows either the

voltmeter or odometer reading. Press SELECT to toggle
between these readings.

The voltmeter displays battery voltage when the machine

is off and system voltage to the nearest tenth when the
machine is on.

Continued on next page TX,10,JC1624 –19–08MAY98–2/3

2-1-15 022808

PN=39
 Operation—Operator’s Station

The odometer is capable of displaying up to 99,999.9 total

miles (or 999,999 if the decimal point is disregarded).
From 0 to 62,111.7 miles (0 to 99,937.7 km), the
odometer displays both miles and kilometers in tenths.
From 62,111.8 to 99,999.9 miles (99,937.8 to 160,889.8
km) miles are displayed in tenths and kilometers in ones.
From 100,000 miles (160,900 km) on, both miles and
kilometers are displayed in ones. The odometer runs only
when the engine is on.

When the 0.1 Hour Meter Mode is turned On in the

Accessory Menu (A 06), machine hours will be displayed
in tenths of hours in the volts/miles/km display. Press
SELECT to toggle between hours and the volts/miles/km
display.

TX,10,JC1624 –19–08MAY98–3/3

Monitor Display Unit—Accessory Menu—

Clutch Cut-Off (A 01)

At Normal Mode display, press MENU once. Display

window will show A, indicated Accessory Mode.

–UN–22OCT97
Press SELECT again; display window shows A 01,
indicating Clutch Cut-Off Mode.

In the Clutch Cut-Off Mode of operation, there are three

T111855
different functions to choose from:

• Level Ground
• Small Slope
• Steep Slope

On the Level Ground setting, clutch releases with low

brake pedal pressure.

On the Small Slope setting, clutch releases with medium

brake pedal pressure.

On Steep Slope setting, clutch releases with high brake

pedal pressure.

By turning one of these functions On, the other two are

automatically turned Off.

Continued on next page OUOE003,000008C –19–02MAR01–1/3

2-1-16 022808
PN=40
 Operation—Operator’s Station

Press SELECT again. Display shows A 011 Level Ground

Setting, If setting shows Off, press SELECT again and it
will be On, disabling the other two positions.

Press NEXT to move to A 012 Small Slope Setting, and

NEXT again to A 013 Steep Slope Setting. Press SELECT

–UN–22OCT97
to choose a setting and disable the other two settings.

Level Ground (A 011): When the Level Ground function

is turned On in the monitor display unit, the clutch cut-off

T111856
switch turned On, and the brake pedal pressed down, the
clutch cut-off sensor (B33), which is a rotary
potentiometer, will sense the position of the brake pedal
linkage by the voltage reading. When it senses voltage
higher than the low voltage set point, the transmission will
“disengage” (release clutch) and modulate to neutral. In
this position the machine will still roll slightly.

In “Auto” mode the transmission will “re-engage” and

modulate into the appropriate gear (based on ground
speed) if the pressure at the clutch cut-off sensor reaches
the engagement pressure set point. This pressure is lower
than the clutch cut-off set point.

The transmission will also re-engage if the clutch cut-off

switch is turned to the Off position.

Small Slope (A 012): When the Small Slope function is

turned On in the monitor display unit, the clutch cut-off
switch turned On, and the brake pedal is pressed down,
the clutch cut-off sensor will sense the hydraulic brake
pressure. When it senses pressure higher than the
medium pressure set point, the transmission will
“disengage” and modulate to neutral.

In “Auto” mode the transmission will “re-engage” and

modulate into the appropriate gear (based on ground
speed) if the pressure at the clutch cut-off sensor reaches
the engagement pressure set point. This pressure is lower
than the clutch cut-off pressure set point.

The transmission will also re-engage if the clutch cut-off

switch is turned to the Off position.

Continued on next page OUOE003,000008C –19–02MAR01–2/3

2-1-17 022808

PN=41
 Operation—Operator’s Station

Steep Slope (A 013): When the Steep Slope is turned On

in the monitor display unit, the clutch cut-off switch turned
On, and the brake pedal is pressed down, the clutch
cut-off sensor will sense the hydraulic brake pressure.
When it senses pressure higher than the high pressure
set point, the transmission will “disengage” and modulate
to neutral.

In “Auto” mode the transmission will “re-engage” and

modulate into the appropriate gear (based on ground
speed) if the pressure at the clutch cut-off sensor reaches
the engagement pressure set point. This pressure is lower
than the clutch cut-off pressure set point.

The transmission will also re-engage if the clutch cut-off

switch is turned to the Off position.

OUOE003,000008C –19–02MAR01–3/3

2-1-18 022808

PN=42
 Operation—Operator’s Station

Monitor Display Unit—Accessory Menu—

Quick Shift Mode (A 02)

The Quick Shift mode allows the operator to choose

between Down/Up and Down Only shift functions when
the transmission is in manual or automatic operation.

–UN–22OCT97
Down/Up: When this function is turned On, the
transmission will down shift one gear when the Quick Shift
Switch (at top of pilot controller handle) is pressed down

T111858
once. It is not possible to down shift more than one gear.

When the quick shift switch is pressed down again, the

transmission will electronically shift up one gear again.

Down Only—Transmission in Manual Operation: When

this function is turned On, each time the quick shift switch
(at top of pilot controller handle) is pressed down, the
transmission will shift down one gear (regardless of
selected gear).

If the operator presses down on the quick shift switch

while no shift is taking place, the controller will cause the
transmission to shift down one gear (regardless of
selected gear).

Once a down shift is made by pressing the quick shift

switch, the transmission will not shift up again unless a
direction or gear change is made.

Down Only—Transmission in Automatic Operation: If

the operator presses the quick shift switch when the
transmission is in automatic operation, the transmission
will down shift to one gear below the gear displayed in
basic display window. This change is made independent
from shifter switch selection.

Down Only works basically the same in automatic as in

manual, except it will shift Up or Down from the highest
gear downshifted to.

If the operator presses down on the quick shift switch

while an up shift is taking place, the transmission
controller will cause the transmission to shift down to the
previous gear.

Continued on next page TX,10,JC2220 –19–26AUG97–1/5

2-1-19 022808

PN=43
 Operation—Operator’s Station

In “Auto” mode, if the operator presses down on the quick

shift switch while a down shift is taking place, the
transmission controller will ignore the request for the down
shift.

Transmission will automatically shift up or down from the

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

TX,10,JC2220 –19–26AUG97–2/5

Press SELECT at the A 02 display.

–UN–20MAR01
T139966
T139966

Deluxe Monitor Display Unit Shown

TX,10,JC2220 –19–26AUG97–3/5

If the A 021 display shows OFF, press SELECT to turn

Down/Up shift function On and disable the Down Only
function.

To choose the Down Only shift function, press NEXT.

–UN–22OCT97
T111858

Deluxe Monitor Display Unit Shown

Continued on next page TX,10,JC2220 –19–26AUG97–4/5

2-1-20 022808

PN=44
 Operation—Operator’s Station

At A 022 display, press SELECT to turn Down Only shift

function On and to disable Down/Up function.

–UN–22OCT97
T111859
Deluxe Monitor Display Unit Shown

TX,10,JC2220 –19–26AUG97–5/5

Monitor Display Unit—Accessory Menu—

Auto Mode to First (A 03)

In Auto Mode to First, the transmission will shift to first

gear if a high load is sensed while the transmission is
actually in second gear. This shift change is made

–UN–20MAR01
independent from shifter switch selection.

A direction change during normal conditions will not cause

the transmission to shift down into first gear. If a direction

T139967
change is made during high transmission load conditions, T139967
the transmission will shift down into first gear.

Press SELECT at the A 03 display.

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

TX,10,JC2221 –19–16JUL01–1/1

2-1-21 022808
PN=45
 Operation—Operator’s Station

Monitor Display Unit—Accessory Menu—Job

Timer Mode (A 04)

The job timer is a resetable hour meter that can be used

to time tasks to the nearest tenth of an hour.

–UN–22OCT97
At the A 04 display, press SELECT.

Then press SELECT again to turn the timer On or Off.

T111861
When the timer is Off, press NEXT to reset the timer.
Deluxe Monitor Display Unit Shown

TX,10,JC2223 –19–26AUG97–1/1

Monitor Display Unit—Accessory Menu—

Stop Watch Mode (A 05)

The stop watch is a resetable timer that is used to

measure time in seconds and tenths of seconds.

–UN–20MAR01
At the A 05 display, press SELECT.

Then press SELECT again to turn the timer On or Off.

T139969
When the timer is Off, press NEXT to reset the timer. T139969

TX,10,JC2224 –19–16JUL01–1/1

Monitor Display Unit—Accessory Menu—0.1

Hour Meter Mode (A 06)
–UN–22OCT97
T111863

Continued on next page TX,10,JC2225 –19–02MAR01–1/2

2-1-22 022808

PN=46
 Operation—Operator’s Station

At the A 06 display, press SELECT.

Then press SELECT again to turn the 0.1 Hour Meter

Mode On or Off.

When the 0.1 Hour Meter Mode is turned On, the hour

–UN–22OCT97
meter reading can be accessed during normal machine
operation by pressing SELECT. The odometer reading will
switch to the voltmeter reading, and then to the hour
meter reading (A) in hours and tenths of hour as SELECT

T111864
is pressed.

When the 0.1 Hour Meter Mode is turned Off, only the
A—Hour Meter Reading
odometer reading and voltmeter are available, by pressing
SELECT.

The 0.1 Hour Meter Mode On or Off position stays set

after machine shut down.

TX,10,JC2225 –19–02MAR01–2/2

Monitor Display Unit—Accessory Menu—

Metric Units Mode (A 07)

This mode allows the technician to choose between metric

and English unit displays.

–UN–22OCT97
At the A 07 display, press SELECT.

Press SELECT to turn Metric Units display On or Off.

T111865
When Metric Units mode is On, all values will be shown in
metric. When Metric Units mode is Off, all values will be Deluxe Monitor Display Unit Shown
shown in English units.

TX,TEST,HH229 –19–12SEP96–1/1

2-1-23 022808
PN=47
 Operation—Operator’s Station

Monitor Display Unit—User Diagnostics

Menu—Service Codes (d 01)

This mode displays the eight highest priority service codes

which have occurred on the machine.

–UN–22OCT97
At the d 01 display, press SELECT.

T111866
Deluxe Monitor Display Unit Shown

HG31779,0000165 –19–28OCT02–1/6

An F is shown in the display window to indicate service

code mode. The first service code number is shown.

To move to the second service code, press NEXT.

To obtain additional information about the first service

–UN–22OCT97
code, press SELECT again.

T111709
Deluxe Monitor Display Unit Shown

Continued on next page HG31779,0000165 –19–28OCT02–2/6

2-1-24 022808
PN=48
 Operation—Operator’s Station

The display window will show the hour meter reading at

first occurrence of the service.

To obtain additional information about the service code,

press NEXT.

–UN–22OCT97
T111710
Deluxe Monitor Display Unit Shown

HG31779,0000165 –19–28OCT02–3/6

The display window will show the hour meter reading at

last occurrence of the service and the total number of
occurrences.

–UN–22OCT97
T111708
Deluxe Monitor Display Unit Shown

Continued on next page HG31779,0000165 –19–28OCT02–4/6

2-1-25 022808
PN=49
 Operation—Operator’s Station

To move to the second service code, press BACK until

the Fxxxx display is shown. This example: F 1645.

Then press NEXT.

–UN–22OCT97
T111709
Deluxe Monitor Display Unit Shown

HG31779,0000165 –19–28OCT02–5/6

Continue to scroll through service codes using this

sequence until END is shown in the display window.

–UN–22OCT97
T111868
Deluxe Monitor Display Unit Shown

HG31779,0000165 –19–28OCT02–6/6

2-1-26 022808
PN=50
 Operation—Operator’s Station

Monitor Display Unit—User Diagnostics

Menu—Continuity Check (d 02)

In this diagnostic mode, sensors and circuits connected to

the chassis computer unit (CCU) are monitored for a
“state of change.” Examples of “state of change” are

–UN–22OCT97
switches going from open to closed or closed to open,
circuit shorts and opens, high rate of change from analog
sensors, and changes in digital speed sensor outputs.

T111869
At the d 02 display, press SELECT.

Two different “continuity check” modes are provided. Deluxe Monitor Display Unit Shown
Press SELECT to choose the mode wanted.

“With Speed Sensors” (d 021) mode monitors all circuits

and sensors. This mode is useful when the machine is
parked with the engine off.

“Without Speed Sensors” (d 022) monitors everything

except the digital speed sensors. This mode is useful
when the engine is running and/or the machine is rolling,
when the engine, transmission and wheel speed sensors
are pulsing continuously.

TX,10,JC2222 –19–26SEP97–1/3

After one of the continuity check modes is selected, the

display window will be in a waiting position until a “state of
change” is detected.

–UN–22OCT97
T111870

Deluxe Monitor Display Unit Shown

Continued on next page TX,10,JC2222 –19–26SEP97–2/3

2-1-27 022808
PN=51
 Operation—Operator’s Station

Whenever a “change of state” is detected, the warning

horn will “beep” to inform the technician of the change.
The circuit device component number and section number
as it appears on the system functional schematic will
show on the basic display window.

–UN–22OCT97
Press SELECT to display sensor data and units in the
message display window. Press SELECT again or BACK
to remove the information from the message window.
Press NEXT to move to the next sensor display.

T111871
The audible alarm can be used to verify that a switch is
Deluxe Monitor Display Unit Shown
changing state when it is activated (or isn’t changing state
when it should be, if there is no beep.) Also, by moving a
potentiometer type control slowly through its operating
range, a break or “bad spot” can be detected.

TX,10,JC2222 –19–26SEP97–3/3

Monitor Display Unit—User Diagnostics

Menu—Battery Monitor (d 03)

This mode allows the technician to view the current

voltage of the left and right batteries.

–UN–20MAR01
At the d 03 display, press SELECT.

Battery voltage will be displayed in basic display window.

T139974
- +
T139974 VOLTS

OUOE003,00000D3 –19–19MAR01–1/2

On machines equipped with deluxe monitor display, press

SELECT again to display reading in the alpha-numeric
message display. Pressing SELECT will toggle the
reading in and out of the alpha-numeric window.
–UN–20MAR01
T139975

- +
T139975 VOLTS

OUOE003,00000D3 –19–19MAR01–2/2

2-1-28 022808
PN=52
 Operation—Operator’s Station

Monitor Display Unit—User Diagnostics

Menu—Engine Sensors (d 04)

This mode allows the technician to monitor all engine

sensors that are accessible to the computer system.

–UN–22OCT97
Press SELECT at the d 04 display.

T111874
OUOE003,00000D4 –19–19MAR01–1/14

The d 041 display for Engine Coolant Temperature will be

shown. Temperature will be displayed in C° or F°
(depending on setting selected in A 07 model) and sensor
voltage will be displayed.

–UN–20MAR01
T139977
- +
T139977 VOLTS

OUOE003,00000D4 –19–19MAR01–2/14

On machines equipped with deluxe monitor display, press

SELECT again to display reading in the alpha-numeric
message display. Pressing SELECT will toggle reading in
and out of the alpha-numeric window.

Press NEXT.

–UN–20MAR01
T139984
- +
T139984 VOLTS

OUOE003,00000D4 –19–19MAR01–3/14

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

Pressure will be displayed in kPa or psi and sensor
voltage will be displayed.
–UN–22OCT97
T111877

Continued on next page OUOE003,00000D4 –19–19MAR01–4/14

2-1-29 022808

PN=53
 Operation—Operator’s Station

On machines equipped with deluxe monitor display, press

SELECT again to display reading in the alpha-numeric
message display. Pressing SELECT will toggle reading in
and out of the alpha-numeric window.

Press NEXT.

–UN–22OCT97
T111881
OUOE003,00000D4 –19–19MAR01–5/14

The d 043 display for Throttle sensor voltage will be

shown.

–UN–20MAR01
T139987
- +
T139987 VOLTS

OUOE003,00000D4 –19–19MAR01–6/14

The d 044 display for Fuel Temperature will be shown.

Temperature will be displayed in C° or F° (depending on
setting selected in A 07 mode) and sensor voltage will be
displayed.

–UN–20MAR01
T139990

T139990

OUOE003,00000D4 –19–19MAR01–7/14

Press SELECT again to display reading in the

alpha-numeric message display. Pressing SELECT will
toggle reading in and out of the alpha-numeric window.

Press NEXT.
–UN–20MAR01
T139992

T139992

Continued on next page OUOE003,00000D4 –19–19MAR01–8/14

2-1-30 022808
PN=54
 Operation—Operator’s Station

The d 046 Fuel Pressure will show fuel pressure in psi or

kPa.

–UN–20MAR01
T138502
T138502

OUOE003,00000D4 –19–19MAR01–9/14

Press SELECT again to display the reading in the

alpha-numeric message display. Pressing SELECT will
toggle reading in and out of the alpha-numeric window.

Press NEXT.

–UN–20MAR01
T138512
T138512

OUOE003,00000D4 –19–19MAR01–10/14

The d 047 Intake Manifold Air Temperature will show

temperature in °F or °C.

–UN–20MAR01
T138503
T138503

OUOE003,00000D4 –19–19MAR01–11/14

Press SELECT to display the reading in the alpha-numeric

message display. Pressing SELECT will toggle reading in
and out of the alpha-numeric window.

Press NEXT.
–UN–20MAR01
T138511

T138511

Continued on next page OUOE003,00000D4 –19–19MAR01–12/14

2-1-31 022808

PN=55
 Operation—Operator’s Station

The d 048 Intake Manifold Air Pressure will show air

pressure in psi or kPa.

–UN–20MAR01
T138504
T138504

OUOE003,00000D4 –19–19MAR01–13/14

Press SELECT to display the reading in the alpha-numeric

message display. Pressing SELECT will toggle reading in
and out of the alpha-numeric window.

Press NEXT to go to d 041 display.

–UN–20MAR01
T138510
T138510

OUOE003,00000D4 –19–19MAR01–14/14

Monitor Display Unit—User Diagnostics

Menu—Transmission Sensors (d 05)

This mode allows the technician to monitor all

transmission sensors that are accessible to the computer
system.

–UN–22OCT97
Press SELECT at the d 05 display.

T111884

TX,10,JC2230 –19–02MAR01–1/3

The d 051 Oil Temperature Sensor display will show the

oil temperature in C° or F° (depending on setting selected
in A 07 mode) and sensor voltage.
–UN–22OCT97
T111885

Continued on next page TX,10,JC2230 –19–02MAR01–2/3

2-1-32 022808
PN=56
 Operation—Operator’s Station

On machines equipped with deluxe monitor display, press

SELECT again to display reading in the alpha-numeric
message display. Pressing SELECT will toggle reading in
and out of the alpha-numeric window.

Press NEXT.

–UN–22OCT97
The d 052 Clutch Cut-Off Sensor display will show the
Clutch Cut-Off Sensor voltage.

T111887
Press NEXT.

The d 053 Torque Input Speed Sensor display will show Deluxe Monitor Display Unit Shown
the speed in rpm.

Press NEXT.

The d 054 Torque Output Speed Sensor display will show

the speed in rpm.

Press NEXT.

The d 055 Internal Clutch Speed Sensor display will show

the speed in rpm.

Press NEXT.

The d 056 Output Shaft Speed Sensor display will show

the speed in rpm.

TX,10,JC2230 –19–02MAR01–3/3

Monitor Display Unit—User Diagnostics

Menu—Hydraulic Sensors (d 06)

This mode allows the technician to monitor all hydraulic

sensors that are accessible to the computer system.
–UN–22OCT97
Press SELECT at the d 06 display.
T111888

Deluxe Monitor Display Unit Shown

Continued on next page TX,10,JC2231 –19–26SEP97–1/3

2-1-33 022808
PN=57
 Operation—Operator’s Station

The d 061 Oil Temperature Sensor display will show the

temperature in C° or F° (depending on setting selected in
A 07 mode) and sensor voltage.

Press NEXT.

–UN–22OCT97
T111889
Deluxe Monitor Display Unit Shown

TX,10,JC2231 –19–26SEP97–2/3

The d 062 Pump Output Pressure Sensor display will

show the pump pressure in kPa or psi (depending on the
setting selected in A 07 mode) and sensor voltage (This is
only available on machines with Loader Performance
Management installed).

–UN–08JUN98
T115771
Deluxe Monitor Display Unit Shown

TX,10,JC2231 –19–26SEP97–3/3

2-1-34 022808
PN=58
 Operation—Operator’s Station

Monitor Display Unit—User Diagnostics

Menu—Fuel Sensor (d 07)

This mode allows the fuel level sensor to be monitored.

Press SELECT at the d 07 Fuel Sensor display.

–UN–22OCT97
The Fuel Sensor display will show fuel level in gal or L
(depending on setting selected in A 07 mode) and sensor
voltage.

T111891
Deluxe Monitor Display Unit Shown

TX,10,JC2232 –19–26SEP97–1/2

On machines equipped with deluxe monitor display, press

SELECT again to display reading in the alpha-numeric
message display. Pressing SELECT will toggle reading in
and out of the alpha-numeric window.

–UN–22OCT97
T111893
Deluxe Monitor Display Unit Shown

TX,10,JC2232 –19–26SEP97–2/2

Monitor Display Unit—User Diagnostics

Menu—(d 08)—Not Used

TX,9015,MM3001 –19–15APR98–1/1

2-1-35 022808
PN=59
 Operation—Operator’s Station

Monitor Display Unit—User Diagnostics

Menu—Spin Control Mode (d 09)

This mode allows the technician to monitor the spin

control operation.

Press SELECT at the d 09 display.

The spin control mode display will show the spin control
number and the spin control rotary sensor voltage.

SPECIFICATIONS
DISPLAY WINDOW MESSAGE COMPONENT MONITORED SPECIFICATION
d 09 Spin Control Mode Spin Control Mode Switch (S33) Position 1: 0.0—0.15 volts
Position 2: 0.15—0.53 volts
Position 3: 0.53—1.09 volts
Position 4: 1.09—1.96 volts
Position 5: 1.96—3.75 volts

TX,9015,MM3002 –19–11DEC02–1/1

Monitor Display Unit—User Diagnostics

Menu—Machine I.D. Mode (d 10)

This mode provides the technician with machine

identification information for hour meter readings, part
numbers and serial numbers of the monitor display unit

–UN–22OCT97
and chassis controller unit.

T111894

Deluxe Monitor Display Unit Shown

Continued on next page TX,10,JC2233 –19–26SEP97–1/9

2-1-36 022808
PN=60
 Operation—Operator’s Station

Press SELECT at the d 10 display.

The d 101 MDU Original display will show the monitor

display unit hour meter reading and the original monitor
display unit serial number.

–UN–22OCT97
T111896
Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–26SEP97–2/9

Press NEXT.

The d 102 CCU Original display will show the chassis

controller unit hour meter reading and the original chassis
controller serial number.

–UN–22OCT97
T111897
Deluxe Monitor Display Unit Shown

Continued on next page TX,10,JC2233 –19–26SEP97–3/9

2-1-37 022808
PN=61
 Operation—Operator’s Station

Press NEXT.

The d 103 MDU Part Number display will show the

monitor display unit part number and serial number.

–UN–22OCT97
T111899
Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–26SEP97–4/9

Press NEXT.

The d 104 CCU Part Number display will show the

chassis controller unit part number and serial number.

–UN–22OCT97
T111900
Deluxe Monitor Display Unit Shown

Continued on next page TX,10,JC2233 –19–26SEP97–5/9

2-1-38 022808
PN=62
 Operation—Operator’s Station

Press NEXT.

The d 105 MDU Software Number display will show the

monitor display unit software number.

–UN–22OCT97
T111901
Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–26SEP97–6/9

Press NEXT.

The d 106 CCU Software Number display will show the

chassis controller unit software number.

–UN–22OCT97
T111902
Deluxe Monitor Display Unit Shown

Continued on next page TX,10,JC2233 –19–26SEP97–7/9

2-1-39 022808
PN=63
 Operation—Operator’s Station

Press NEXT.

The d 107 TCU Serial Number display will show the

transmission controller unit serial number.

–UN–22OCT97
T111711
Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–26SEP97–8/9

Press NEXT.

The d 108 TCU Software Number display will show the

transmission controller unit software number.

–UN–22OCT97
T111712
Deluxe Monitor Display Unit Shown

TX,10,JC2233 –19–26SEP97–9/9

Horn Button

A—Horn Button
–UN–12FEB98
T113450

CED,OUO1021,27 –19–01JUN98–1/1

2-1-40 022808
PN=64
 Operation—Operator’s Station

Turn Signals

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

A—Signal Lever

–UN–13FEB98
T113458
CED,OUO1021,193 –19–20MAR98–1/1

Heating and Air Conditioning Controls

Turn temperature control knob (A) clockwise to increase

temperature.

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

–UN–01NOV02
(Knob also turns on heater blower.) Blower has four
speeds.

IMPORTANT: Prior to initial use at the beginning of

T159423P
the season, check filters and
condenser. Clean them if necessary.
Check refrigerant level. One Lever Design

To operate air conditioning, press air conditioning switch

(C) if equipped.

A—Temperature Control Knob

B—Blower Knob

–UN–10OCT02
C—Air Conditioning Switch

T156775D
Two Lever Design
HG31779,0000153 –19–17OCT02–1/1

2-1-41 022808
PN=65
 Operation—Operator’s Station

Air Flow Knob

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

Turn knob clockwise to the second position for more

–UN–20SEP02
defrost than vent air flow.

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

T159630B
Turn the knob clockwise to the fourth position for total
vent air flow.

1—Air Flow Knob

HG31779,000012E –19–20SEP02–1/1

Adjusting Steering Wheel Tilt

Depress lever (A) to adjust steering column to desired tilt.

Release lever.

–UN–10SEP96
A—Lever

T103027
TX,10,JC1371 –19–30JUL96–1/1

Opening and Securing Side Door

To open left side cab door from inside, push forward on

lever (A).
–UN–13JUN00

A—Lever
T131654B

Continued on next page CED,OUOE035,10 –19–14JUN00–1/2

2-1-42 022808
PN=66
 Operation—Operator’s Station

Open door until outside latch (A) fastens into notch (B).

Door must be secure against bumper (C). Adjust rubber

bumper as necessary to maintain proper tension.

To release secured open door from inside the cab or on

the ground, pull up on lever (D) located to the left of the
operator’s seat.

Door will latch when closed.

–UN–02NOV98
A—Outside Latch
B—Notch
C—Bumper
D—Release Lever

T118147
–UN–17OCT02
T160585B
CED,OUOE035,10 –19–14JUN00–2/2

2-1-43 022808

PN=67
 Operation—Operator’s Station

Opening Side Window/Secondary Exit

NOTE: The cab right side window can be used as a

secondary exit.

Push up on lever (1) to open window.

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

To release secured window, push down on lever (3)

located behind cab seat.

1—Lever
2—Outer Notch

–UN–07OCT02
3—Lever

T160249B
–UN–07OCT02
T160250B
HG31779,000014D –19–07OCT02–1/1

Opening Rear Side Window

Pull out on latch tab (1) to release window lock.

1—Latch Tab
–UN–28AUG01

1
T138368

OUOE003,0000093 –19–02MAR01–1/1

2-1-44 022808
PN=68
 Operation—Operator’s Station

Adjusting Seat

CAUTION: You can lose control of machine and

be injured if seat is loose. Be sure seat is
properly locked in position before operating the
machine.

Use flip-out lever to turn weight adjustment knob (F). Turn

knob clockwise for firm ride and counterclockwise for soft
ride.

Lift fore-aft adjustment lever (H) to move seat forward and

rearward. Release handle at one of several positions.

Remove your weight from seat. Lift seat height adjustment

lever (E) and move seat to desired height.

Move seat to mid-to-aft position. While sitting in seat, turn

weight adjustment knob (F) to support weight. Check

–UN–22NOV96
weight indicator (G) for appropriate weight setting and
continue to turn until yellow pointer inside tube is flush
with tube opening.

T103679B
While sitting in seat, lift backrest tilt adjustment knob (D)
and allow cushion to angle forward or lean backward into
desired position and release handle.

While sitting in seat, rotate armrest adjustment knob (C) to

tilt to desired armrest position.

To raise or lower armrest height, loosen two nuts on

armrest height adjustment bracket (B) and adjust to
desired position. Tighten nuts to secure.

–UN–26NOV96
While sitting in seat, rotate lumbar support lever (A) to
increase or decrease support to lower back.

T105452
On air ride equipped seats, to lower seat height or
decrease firmness in ride, pull out on height/firmness
adjustment knob (I). To raise seat or increase firmness in A—Lumbar Support Lever
ride, turn key to “On” and push in on height/firmness B—Armrest Height Adjustment Bracket
adjustment knob. C—Armrest Adjustment Knob
D—Backrest Tilt Adjustment Knob
E—Seat Height Adjustment Lever
F—Weight Adjustment Knob
G—Weight Indicator
H—Fore-Aft Adjustment Lever
I—Height/Firmness Adjustment Knob (Air Ride
Seat only)

CED,OUO1021,141 –19–16MAR98–1/1

2-1-45 022808

PN=69
 Operation—Operator’s Station

Seat Belt

–UN–01MAR00
T128685
Seat belt and mounting hardware must be inspected Replace the complete seat belt assembly every three
for wear or damage before operating the machine. years regardless of appearance. A date label, to
Replace the belt or mounting hardware if worn or determine the age of the belt, is attached to each belt.
damaged.

TX,10,DH3548 –19–24FEB00–1/1

12-Volt Power Plug

To be used with any 12-volt accessory.

–UN–06SEP01
T145322B

CED,OUOE002,1322 –19–06SEP01–1/1

2-1-46 022808
PN=70
 Operation—Operating the Machine
Inspect Machine Daily Before Starting

Do periodic service checks.

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

hardware.

B—Clean operator’s station.

C—Check air inlet cover.

D—Clean radiator.

E—Check fuel level on monitor.

F—Check tires (front and rear).

ELECTRICAL SYSTEM: Check for worn or frayed wires

and loose or corroded connections.

–UN–18SEP96
BOOM, BUCKET, SHEET METAL: Check for bent,
broken, loose, or missing parts.

HARDWARE: Check for loose or missing parts.

T103802
PARK BRAKE: Check for correct operation.

HYDRAULIC SYSTEM: Check for leaks, missing or loose A—Wheels (Front and Rear)
clamps, kinked hoses, and lines or hoses that rub against B—Operator’s Station
C—Air Inlet Cover
each other or other parts.
D—Radiator
E—Fuel Level (Monitor)
LUBRICATION: Check lubrication points shown on F—Tires
Periodic Maintenance Chart.

PROTECTIVE DEVICES: Check guards, shields, ROPS,

covers, seat belt.

SAFETY: Walk around machine to clear all persons from

machine area.

TX,20,JC1199 –19–18JUL02–1/1

2-2-1 022808

PN=71
 Operation—Operating the Machine

Check Instruments Before Starting

Turn key switch clockwise to “On” position.

All indicators must light. If any indicator fails to light, the

bulb may be burned out. If bulb is not burned out, but

–19–16DEC98
indicator light still fails to light, see your authorized dealer.

T119011
HG31779,00000B1 –19–18JUL02–1/1

Starting the Engine

CAUTION: Avoid possible injury or death from a

runaway machine.

DO NOT start engine by shorting across starter

–UN–11JAN89
terminals. Machine will start in gear if normal
circuitry is bypassed.

NEVER start engine while standing on ground.

TS177
Start engine only from operator’s seat, with
transmission control lever in “Neutral”. Engage
park brake.

Use of seat belt with roll-over protective

structure (ROPS) is recommended under all
operating conditions.

1. Fasten seat belt.

Continued on next page TX,25,JC1410 –19–18JUL02–1/2

2-2-2 022808
PN=72
 Operation—Operating the Machine

2. Move transmission control lever (A) to N. Engage

neutral lock (B).

3. Turn key switch to “On” position. Push horn button to

sound horn to alert bystanders that machine will be
started.

–UN–13FEB98
IMPORTANT: Never operate starter motor for more
than 20 seconds at a time. If engine
fails to start after two or three tries,

T113477
return key switch to “Stop” position.
Wait for about 2 minutes, then try again.

After a false start, DO NOT turn key A—Transmission Control Lever

switch until engine stops or starter may B—Neutral Lock
be damaged.

Engine will not start by towing or

pushing. Permanent damage to
transmission will result.

4. Turn key switch to “Start” position. DO NOT crank

engine more than 20 seconds. Wait 2 minutes before
trying again. Release key when engine starts.

IMPORTANT: If STOP indicator light does not go out

within 10 seconds after starting engine,
STOP THE ENGINE. Find and correct
the cause.

5. Operate machine at less than normal loads and at slow

idle speed until engine warms up.

IMPORTANT: If engine stops when operating under

load, remove load. Restart engine
immediately. Run 30 seconds at 1/2
speed before adding load.

TX,25,JC1410 –19–18JUL02–2/2

2-2-3 022808

PN=73
 Operation—Operating the Machine

Starting Fluid—If Equipped (Cold Weather

Starting Aid)

USE STARTING FLUID

CAUTION: Prevent possible injury from

–UN–23AUG88
exploding container. Starting fluid is highly
flammable. Keep container away from heat,
sparks, and open flame. Contents are
pressurized. DO NOT puncture or incinerate

TS281
container. Remove container from machine if
engine does not need starting fluid.

IMPORTANT: Prevent damage to engine. Use starting

aid when temperatures are below 4°C
(40°F) and only when engine is COLD.

1. Turn key switch clockwise to “Start” position.

Continued on next page HG31779,0000162 –19–28OCT02–1/2

2-2-4 022808

PN=74
 Operation—Operating the Machine

IMPORTANT: Excess starting fluid could damage

engine; press start aid button only
when engine is cold and cranking.
Starting aid fluid is being injected into
engine as long as you press button.

–UN–13FEB98
2. After one or two revolutions of engine crankshaft, press
starting aid button (A) until engine starts. Crank engine
for 20 seconds maximum, then allow 2 minutes
between cranking periods.

T113478
REPLACING START AID CONTAINER

1. Loosen hose clamp (B).

2. Turn start aid container (C) counterclockwise to

remove.

3. Remove safety cap from new container.

–UN–28OCT02
4. Turn container clockwise in starting aid base to install.

5. Tighten hose clamp.

T161037B
OPERATING MACHINE WITHOUT START AID
CONTAINER INSTALLED
A—Start Aid Button
B—Hose Clamp
IMPORTANT: Protect starting aid components from
C—Start Aid Container
possible damage. Install starting aid D—Plug
plug in starting aid base.

Remove container and install plug (D) in base.

HG31779,0000162 –19–28OCT02–2/2

2-2-5 022808

PN=75
 Operation—Operating the Machine

Using Booster Batteries—24 Volt System

Before boost starting, machine must be properly shut

down and secured to prevent unexpected machine
movement when engine starts.

–UN–23AUG88
CAUTION: An explosive gas is produced while
batteries are in use or being charged. Keep
flames or sparks away from the battery area.
Make sure the batteries are charged in a well

TS204
ventilated area.

IMPORTANT: The machine electrical system is a

24-volt negative (-) ground. Connect two
12-volt booster batteries together in
series as shown for 24 volts.

1. Connect one end of the positive cable to the positive

terminal of machine batteries (A) and the other end to

–UN–21MAY90
the positive terminal of booster batteries (B).

2. Connect one end of the negative cable to the negative

terminal of booster batteries. Then connect the other

T7233JN
end of negative cable to the machine frame as far
away from the machine batteries as possible.
A—Machine Batteries
3. Start the engine. B—Booster Batteries

4. Immediately after starting the engine, disconnect the

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

5. Disconnect the positive cable from the booster

batteries and machine batteries.

CED,TX14795,4152 –19–30SEP00–1/1

2-2-6 022808

PN=76
 Operation—Operating the Machine

Engine Air Heater—If Equipped

IMPORTANT: DO NOT USE ETHER WITH THIS

SYSTEM. Damage to your engine may
occur.

–UN–28JUN02
NOTE: As long as monitor light remains on, air heater will
be operating.

1. Turn key switch to “On” position. If engine temperature

T155127C
is below 10°C (50°F), engine preheat indicator (A) will
light and stay on 15—45 seconds, depending on initial
engine temperature. Light will turn off, indicating that
preheating is completed. A—Engine Preheat Indicator

2. Turn key switch to “Start” position. Light will turn off

while cranking or if battery voltage drops below 20
volts.

3. If engine temperature is 4.45°C (40°F) or lower,

preheat indicator will light and will remain on for
approximately 30 seconds depending on current
engine temperature.

IMPORTANT: Warm up at half speed and DO NOT

accelerate rapidly during warm-up.

NOTE: Battery voltage light may come on during post

heat and may remain on for a short period of
time.

HG31779,00000B3 –19–18JUL02–1/1

Using Coolant Heater—If Equipped

CAUTION: Prevent possible injury from fire

from an overheated electrical cord. Use a
heavy-duty, grounded cord to connect heater to
electrical power.

Connect the coolant heater to 115-volt electrical power 10

hours before you start the engine.

T82,25,C53 –19–03DEC91–1/1

2-2-7 022808
PN=77
 Operation—Operating the Machine

Warm-Up

Operate machine at less-than-normal loads and speeds

for first few minutes until temperatures and pressures
reach normal operating range.

CED,OUO1021,163 –19–17MAR98–1/1

Cold Weather Warm-Up

IMPORTANT: If hydraulic oil and transmission oil Prepare machine to shift transmission as follows:
are cold, functions move slowly. Do
not attempt normal machine • Machine—stopped
operations until hydraulic and • Engine—slightly above low idle
transmission functions move at • Bucket—off the ground and empty
close-to-normal cycle times. • Brakes—apply right brake pedal or left brake
pedal (clutch cut-off disengaged)
1. Start engine. Run engine at minimum speed for 5 • Parking brake—released
minutes. • Cycle transmission 10 times by shifting:
Neutral-F1—R1—F1—R1—F1—Neutral. Each
2. Cycle boom with bucket stalled in rolled back cycle should be approximately 5 seconds.
position until functions move at normal speed.
4. Shift from F-R1 without braking until transmission
3. Check transmission oil level with engine at low idle. operates normally.

TX,25,JC1202 –19–15APR98–1/1

2-2-8 022808
PN=78
 Operation—Operating the Machine

Spin Control—If Equipped

Spin control provides selectable control of the crowd force

based on hydraulic load. It reduces wheel spin (tire wear),
provides better multi-function smoothness, and increases
fuel savings.

–UN–19SEP02
1. Push spin control switch (2) to the “On" position.

2. Turn mode switch (1) to a setting that minimizes wheel

T159423L
spin while filling the bucket.

NOTE: The spin control system only operates in first gear One Lever Design
forward. The system must be turned ON with the
rocker switch. There are 5 sensitivity
(aggressiveness) settings controlled by a rotary
switch on the right console. This switch sends a
signal to the chassis computer in the load center.
Spin control is activated when the pressure in the

–UN–27JUN02
hydraulic system exceeds the value for each
setting. Spin control reduces the crowd force by
modulating the engine.

T156774B
The correct setting is selected by experimentation by the
operator for their specific application. The setting varies
based on ground conditions and material being loaded. In Two Lever Design
general, the firmer the ground, the lower (numerically) the
setting. (Firm ground -1; sand -5). Start with 1 and keep 1—Mode Switch
increasing the setting until boom stall and wheel spin are 2—Spin Control Switch
eliminated.

HG31779,0000163 –19–28OCT02–1/1

2-2-9 022808

PN=79
 Operation—Operating the Machine

Neutral Lock

CAUTION: Prevent possible injury from

unexpected machine movement. Always move
transmission control lever to N “Neutral”, and
engage neutral lock before starting or

–UN–12FEB98
dismounting.

Move neutral lock (A) to the locked position to engage

neutral lock. Move lock to the unlocked position to

T113449
disengage neutral lock.

A—Neutral Lock

CED,OUO1021,47 –19–18JUL02–1/1

2-2-10 022808

PN=80
 Operation—Operating the Machine

Shifting the Transmission

Unlock neutral lock.

Release park brake.

–UN–13FEB98
Change direction of machine by moving transmission
control lever (A) to F “Forward" or R “Reverse".

Change speed of machine by moving transmission control

T113481
lever to desired gear. Machine has four forward gears and
three reverse gears. Shifting to 4th gear reverse will give
same travel speed as 3rd gear reverse. Select a gear
suitable to operating and road conditions.

When automatic transmission switch (B) is on,

transmission will shift up or down as required to highest
gear selected. In automatic transmission mode,
transmission starts out in 2nd gear.

–UN–19SEP02
A—Transmission Control Lever
B—Automatic Transmission Switch

T159423M
One Lever Design

–UN–27JUN02
T156774C
Two Lever Design

HG31779,000014E –19–07OCT02–1/1

2-2-11 022808

PN=81
 Operation—Operating the Machine

Park Brake Switch

CAUTION: Prevent possible injury or death from

machine runaway. Before disengaging park
brake, be sure engine is running and service
brakes are operational.

–UN–11MAY98
NOTE: Transmission clutches are disengaged when park
brake is applied.

T115292
The park brake switch (A) has three positions:

• Park brake ON A—Park Brake Switch

• Neutral, center detented position
• Park brake release, momentary position

To apply park brake, move switch from the neutral, center

detented position to the park brake ON, detented position.

To release park brake, move switch to the neutral, center

detented position, then the park brake release momentary
position.

NOTE: If park brake is engaged when engine is running

and transmission control lever is in “Neutral”, park
brake indicator will light.

If park brake is engaged when engine is running

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

If engine is stopped with park brake switch OFF,

park brake is automatically applied. Press park
brake switch to ON and then back to momentary
position to release park brake after starting
engine.

Park brake will come on if transmission pressure

drops below 150 psi.

CED,OUO1021,50 –19–09MAR98–1/1

2-2-12 022808

PN=82
 Operation—Operating the Machine

Boom and Bucket Control Lever—One Lever

Design

Move control lever forward (A) to lower boom, or rearward

(D) to raise boom.

NOTE: Pilot enable/boom down switch must be pushed

while moving control lever forward to lower boom
with engine stopped.

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

–UN–11SEP98
to dump bucket.

Return-to-Carry (I)—If Equipped: With Return-to-Carry

T117151
switch on, push boom down lever to “Float” position (lever
in full forward detent position [B]). The boom will stop at a
pre-set height and lever will return to neutral position
automatically.

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

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

–UN–17SEP02
NOTE: Boom float will not work once the boom is below
preset distance from ground. Push switch to “Off”
position to activate boom float.

T159423C
Float (lever in full forward detent position [B]): This
position allows oil to flow in and out both ends of cylinders
so the bucket can follow the contour of the ground.
Manually release lever from this position. A—Lower Boom
B—Float
Return-to-Dig (lever in full left detent position [G]): Bucket C—Dump Bucket
D—Raise Boom
will return to set dig position.
E—Boom Height Kickout
F—Rollback Bucket
Boom Height Kickout (lever in full rear detent position [E]): G—Return-to-Dig
Lever will remain in this position until boom is at a pre-set H—Fast Bucket Dump
height, then will return to neutral automatically. I—Return-to-Carry Switch—If Equipped

Boom and bucket functions can be operated

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

HG31779,00000B4 –19–18JUL02–1/1

2-2-13 022808

PN=83
 Operation—Operating the Machine

Boom and Bucket Control Lever—Two Lever

Design

Move left control lever forward (A) to dump bucket, or

rearward (B) to roll back bucket.

–UN–10JUL02
Return-to-Carry (I)—If Equipped: With Return-to-Carry
switch on, push boom down lever to “Float” position (lever
in full forward detent position [D]). The boom will stop at a
pre-set height and lever will return to neutral position

T156928B
automatically.

NOTE: Pilot enable/boom down switch must be pushed

while moving control lever forward to lower boom
with engine stopped.

Move right control lever forward (E) to lower boom or

rearward (F) to raise boom.

–UN–27JUN02
NOTE: Return-to-carry (I) will override float position.
Return-to-carry must be off for float detent to
operate.

T156774D
NOTE: Boom float will not work once the boom is below
preset distance from ground. Push switch to “Off”
position to activate boom float.
A—Dump Bucket
B—Rollback Bucket
Float (right lever in full forward detent position [D]): This C—Return-to-Dig
position allows oil to flow in and out both ends of cylinders D—Float
so the bucket can follow the contour of the ground. E—Lower Boom
Manually release lever from this position. F—Raise Boom
G—Boom Height Kickout
H—Fast Bucket Dump
Return-to-Dig (left lever in full rearward detent position I—Return-to-Carry Switch—If Equipped
[C]): Bucket will return to set dig position.

Boom Height Kickout (right lever in full rearward detent

position [G]): Lever will remain in this position until boom
is at a pre-set height, then will return to neutral
automatically.

HG31779,00000B5 –19–18JUL02–1/1

2-2-14 022808

PN=84
 Operation—Operating the Machine

Quick Shift Switch

Down/Up

Press switch (A) to down shift from selected gear to next

lower gear when transmission control lever is positioned in

–UN–10SEP98
gears 2—4. Press again to return to original gear.

NOTE: Machine can be programmed with Monitor

Accessory Mode 02 for down/up 021 or Down

T117036
only 022.
One Lever Design
Down Only

This mode will allow transmission to down shift one gear

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

–UN–01JUL02
A—Switch

T156926B
Two Lever Design
HG31779,0000135 –19–25SEP02–1/1

2-2-15 022808

PN=85
 Operation—Operating the Machine

Ride Control—If Equipped

CAUTION: Prevent possible injury from

unexpected boom. The bucket may “jump
up”when ride control switch is turned ON. Clear

–UN–17SEP02
all bystanders from area.

Ride control will improve machine ride and reduce tire

flexing when traveling through rough terrain at a high

T159423D
speed with loaded bucket.

“On” Position One Lever Design

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

“Auto” Position

–UN–18JUL02
With the ride control switch in the “Auto” position, ride
control will remain on as long as engine is running and
ground speed is at least 6 km/h (3—1/2 mph).

T156774K
“Off” Position
Two Lever Design
Ride control is turned off.
1—Ride Control Switch

Operating Ride Control

1. Make sure area around bucket is clear.

2. Start the engine.

3. If ride control switch is in the “Off” position, push switch

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

Discharging Ride Control Accumulator

1. Make sure area around bucket is clear.

2. Turn ride control off.

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

Continued on next page HG31779,0000099 –19–25SEP02–1/2

2-2-16 022808

PN=86
 Operation—Operating the Machine

NOTE: Return-to-carry must be off for boom float to

operate.

4. Turn key switch to “On” without starting the engine and

cycle ride control switch to the “On” position (middle
switch position).

5. Press and hold the pilot enable/boom down switch

while holding the boom control in the float position for
5 seconds.

HG31779,0000099 –19–25SEP02–2/2

Secondary Steering—If Equipped

IMPORTANT: Prevent possible damage to secondary

steering system. Stop machine
immediately if steering pressure
indicator and audible alarm come on

–UN–28JUN02
while operating. THE SECONDARY
STEERING SYSTEM IS NOT INTENDED
FOR CONTINUOUS USE.

T155127D
Steering pressure indicator (B) will light, STOP indicator
(A) will flash, and audible alarm will sound when
secondary steering system is activated. The light indicates
low hydraulic pressure resulting from mechanical A—Stop Indicator
B—Steering Pressure Indicator
malfunction, such as loss of engine power. An electrically
driven pump will actuate to provide steering

The secondary steering system will function only when

key switch is “On”.

NOTE: Secondary steering is activated if the engine dies

with key switch “On”. The secondary steering
motor will stop when the key switch is turned to
“Off”.

CED,OUO1021,57 –19–29SEP98–1/1

2-2-17 022808
PN=87
 Operation—Operating the Machine

Differential Lock Switch

Hold switch (A) down to lock front differential or front and

rear differential, if equipped.

Release switch to unlock differential.

–UN–13FEB98
NOTE: Use differential lock only when conditions require
traction. Avoid using differential lock when
steering.

T113525
A—Switch

CED,OUO1021,58 –19–09MAR98–1/1

Boom Height Kickout Adjustment

1. Position boom in desired boom height kickout position.

2. Press and hold upper half of boom height kickout

switch (1) until audible alarm sounds.

–UN–17SEP02
NOTE: The boom height kickout position will remain the
same until a new position is set.

T159423E
1—Boom Height Kickout Switch

One Lever Design

–UN–11JUL02
T156774J

Two Lever Design

HG31779,000009E –19–08JUL02–1/1

2-2-18 022808
PN=88
 Operation—Operating the Machine

Return-to-Carry Kickout Adjustment

1. Position boom in desired return-to-carry position.

2. Press and hold upper half of return-to-carry switch (1)

until audible alarm sounds.

–UN–17SEP02
NOTE: The return-to-carry position will remain the same
until a new position is set.

T159423F
1—Return-to-Carry Switch

One Lever Design

–UN–02JUL02
T156774I
Two Lever Design
HG31779,000009F –19–08JUL02–1/1

2-2-19 022808

PN=89
 Operation—Operating the Machine

Return-To-Dig Adjustment

–UN–26JUN00
T131917
A—Air Gap Switch-To-Bar C—Cap Screws E—Hex Nuts F—Switch
B—Adjustable Bar D—Alignment Marks

1. Raise boom approximately 300 mm (12 in.) above 6. Install cap screws but do not tighten. Adjust bar to
ground. Move bucket from full rollback to dump. align marks on switch bracket and end of bar.
Torque cap screws to 121 N•m (89 lb-ft).
2. Move loader control lever to return-to-dig detent
position and release. Specification
Cap Screw—Torque ............................................... 121 N•m (89 lb-ft)
3. After control lever returns to neutral, scribe a mark
(D) on the switch bracket and adjustable bar (B) to 7. Loosen hex nuts (E) to switch bracket. Adjust air
align with each other. gap (A) between switch and adjustable bar to 5—8
mm (0.197— 0.315 in.). Torque hex nuts to 75 N•m
4. Position the boom and bucket in the desired (55 lb-ft).
return-to-dig position. Stop engine.
Specification
Air Gap Between Switch and
5. Remove cap screws (C), one at a time and remove Bar—Distance ........................................ 5—8 mm (0.197— 0.315 in.)
old thread lock and sealer using Clean and Cure Hex Screw—Torque ................................................. 75 N•m (55 lb-ft)
Primer. Apply medium strength thread lock and
sealer to cap screws.

CED,TX03679,5807 –19–18JUL02–1/1

2-2-20 022808

PN=90
 Operation—Operating the Machine

Fork Attachment

–UN–06AUG97
T110742
LOADING DRIVING ON A SLOPE

• Center forks and carriage before lifting.

CAUTION: Prevent possible injury from
• Inspect load to ensure stability when lifted.
machine rollover, do not turn on slopes. Do
• Never attempt to lift load with one fork.
not drive across slopes under any
• Approach load slowly and squarely with fork tips
circumstances.
level. Move forks slowly under load with load
positioned equally on forks. Continue to drive
Driving up or down slope WITH load on forks:
forward until load is against backrest of forks.
• Lower load near to ground.
UNLOADING
• Keep mast tilted back to retain load. Slowly drive
straight up or back straight down slope.
• Always use a signal person if you cannot see the
placement area for the load. Make certain area is
Driving up or down slope WITHOUT load on forks:
clear of all objects.
• Lower load to ground and tilt forks to a level
• Lower forks near to ground.
position. Back away carefully to disengage forks.
• Keep mast tilted back.
• Slowly drive straight down or back straight up slope.
ELEVATED LOADS
LIFTING CAPACITY
• Slowly raise load with a slight back tilt to cradle load.
Never tilt load forward unless load is over landing
To maintain stability, only lift loads equal to or less
area and ready to be set down.
than mast capacity or rated operating capacity of
• If there is any indication of load instability during the
machine, whichever is less.
lift such as movement, leaning, or swaying, stop
lifting immediately. Lower load and restock.
TRAVELING
• As load approaches desired height, slow the lift
speed to a minimum. Continue the lift until load is
• Operate machine controls from operator seat only.
slightly higher than the landing point.
• While driving, carry load low for good visibility and
• After load is securely in place, retract forks clear of
machine stability.
load and lower forks to traveling height before
moving.

Continued on next page CED,TX03679,5542 –19–11JUL01–1/2

2-2-21 022808

PN=91
 Operation—Operating the Machine

• Downshift with care. A sudden deceleration could • Inspect hanger block welds for visible cracks.
shift or topple load. • Check to see that the spring loaded keeper, with
• A sudden reversal of travel direction could tip load or washer, is in position in the upper hanger block and
over turn the machine. Come to a gradual stop that the keeper is functioning properly. (Spring in
before reversing directions. keeper must pull pin down into hanger block when
• Slow travel speed when making turns to avoid an pin is pulled out and released.)
overturn. • Inspect hanger blocks for any sign of deformation,
• Use low gear for hillside or ramp operation. Never cracks, and wear.
coast downhill with transmission in neutral. The • Bent forks are not always detectable by sight.
machine could go out of control and tip over. Remove forks and measure the interior angle of
• Reduce speed when driving over rough terrain, each fork to detect a bent fork.
carrying a heavy load, or working in a congested • Tapered tip forks have an interior angle of 90°.
area. Avoid rocks, curbs, and ditches. Standard square tip forks have an interior angle of
87°. If angle is bent more than 3°, replace fork.
OPERATING TIPS
FORK ADJUSTMENT
• Never use the fork attachment as a working
platform. To change fork position:
• Know locations of bystanders in the working area at
all times.
CAUTION: To prevent injury, never stand
• DO NOT touch, lean on, or reach through the mast,
under forks or any part of lift mechanism.
boom or lift mechanism or permit others to do so.
Never climb on the mast, boom, or attachments.
1. Lower forks to approximately 25 mm (1 in.) above
• NEVER allow anyone to stand or pass under the
ground.
raised forks, mast, carriage, boom, or attachments.
• Reduce speed and sound horn at blind intersections,
exits, and when approaching pedestrians. CAUTION: To prevent injury when sliding
forks, keep hands and fingers out of fork
FORK INSPECTION adjustment path.

The forks are the main load bearing components of the 2. Lift pin and slide fork to desired position. Slide fork
mast. Forks must be maintained and checked by placing a foot on tine and palm of other hand on
periodically to assure safe operation. top of fork. Alternately push fork with hand (top)
and foot (lower) in a rocking motion until fork
Inspect forks daily. If any of the following conditions reaches desired position.
exist, replace forks before operating machine.
3. Release pin and check that fork is engaged in
• Check for visibly bent forks and abrasions. If forks notch.
are bent more than 3°, replace forks. (Tapered forks
are 90° nominal and standard forks are 87° 4. Check that mast backing plate pins are in place at
nominal.) If a flat spot is clearly evident from each end. Measure backing plate pins for wear.
abrasive wear, replace forks. Pins should be equal in length on both sides of
• Inspect forks for cracks along the inside radius of plate. Replace pins if worn or damaged.
heel.

CED,TX03679,5542 –19–11JUL01–2/2

2-2-22 022808

PN=92
 Operation—Operating the Machine

Arm Attachment

–UN–06AUG97
T110741
LIFTING 4. Attach a hand line to load and make sure person
holding it is away from load.
CAUTION: Prevent possible injury. Never
5. Before starting job, test your load.
move the load suddenly. Never move load
over a person’s head. DO NOT allow any
• Park your machine close to load.
person near load.
• Attach load to machine.
• Raise load 50 mm (2 in.) above the ground.
Keep all persons away from raised load until
• Swing the load all the way to one side.
blocks are supporting it or load is sitting on
• While keeping load close to the ground, move it
the ground.
away from machine.
• If there is any indication of reduced stability of
Check chart on the right window or lifting
your machine, lower load to the ground.
capacity specification of this manual before
lifting with machine.
6. Lift load only as high as necessary.
DO NOT use bucket function with arm
OPERATE ATTACHMENT SAFELY
attachment.
An attachment may change the capabilities of your
DO NOT lift with damaged or worn sling or
machine in any or all of these ways:
chain.
• Safe range of motion
1. Secure sling/chain tightly to load being lifted.
• Machine stability
• Hydraulic performance
2. Coordinate hand signals with your signal man
• Engine performance
before starting.

3. Know location of all persons in working area.

Continued on next page CED,TX03679,5543 –19–11DEC02–1/2

2-2-23 022808

PN=93
 Operation—Operating the Machine

In an area free of bystanders and obstructions, See your dealer to match attachment demands to
carefully operate the attachment to learn the available machine performance.
range of motion. Anticipate how objects manipulated
by the attachment, or the attachment itself, may
contact the machine, especially the operator’s station.

CED,TX03679,5543 –19–11DEC02–2/2

Parking the Machine

1. Park machine on a level surface.

2. Lower bucket to ground.

–UN–13FEB98
3. Move transmission control lever (A) to N. Engage
neutral lock (B).

CAUTION: Prevent possible injury from

T113477
unexpected machine movement. Never rely on
transmission control lever alone to keep
machine from moving. Machine can A—Transmission Control Lever
unexpectedly roll or move under power, B—Neutral Lock
resulting in death or serious injury. Always turn
engine off or push park brake switch to ON to
hold machine.

4. Push park brake switch to ON.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

5. Run engine at 1/2 speed without load for 2 minutes

before stopping, to avoid damage to turbocharger.
Release accelerator pedal to slow idle.

6. Turn key switch to “Off”.

7. Turn battery disconnect switch OFF, if equipped.

CED,OUO1021,164 –19–18JUL02–1/1

2-2-24 022808
PN=94
 Operation—Operating the Machine

Loading Machine on a Trailer

1. Keep the trailer bed clean. Put chock blocks against

trailer wheels.

2. Use a ramp or loading dock. Ramps must be strong

–UN–13FEB98
enough, have a low angle, and correct height.

3. Fasten seat belt before starting engine.

T113477
CAUTION: Position the machine so that its
centerline is over the centerline of the truck
bed. NEVER steer the machine while on the A—Transmission Control Lever
ramp. If changing direction is required on the B—Neutral Lock
ramp, unload the machine from the ramp,
reposition the machine on the ground, then try
loading again.

4. Drive the machine onto the ramp slowly. The centerline

of the machine should be over the centerline of the
trailer.

5. Lower all equipment onto blocks or trailer bed.

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

neutral lock (B).

CAUTION: Prevent possible injury from

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

7. Push park brake switch to ON.

8. Connect frame locking bar.

9. Turn key switch to “Off”.

10. Turn battery disconnect switch OFF, if equipped.

11. Cover exhaust opening to prevent entry of debris and

water.

Continued on next page CED,OUO1021,62 –19–18JUL02–1/2

2-2-25 022808

PN=95
 Operation—Operating the Machine

12. Fasten each corner of the machine to the trailer with

a chain or cable with appropriate load binder.

13. Place blocks in front of and behind tires.

CED,OUO1021,62 –19–18JUL02–2/2

2-2-26 022808

PN=96
 Operation—Operating the Machine

Towing Procedure

–UN–20MAR01
T138646
1—Front Driveshaft 3—Park Brake Hose 4—Telescoping Driveshaft 5—Rear Driveshaft
2—Park Brake Fitting Plug

CAUTION: Do not allow an operator on the CAUTION: Prevent possible injury from
machine being towed unless the operator unexpected machine movement. Place
can control the steering and brakes. blocks at front and rear of tires to prevent
machine from rolling.
IMPORTANT: Engine cannot be started by towing.
1. Place blocks at front and rear of tires.
Tow the machine off-road to the
nearest location where repair work 2. Connect the towed and towing machines together.
can be done. Haul the machine if it
must be moved further than 460 m NOTE: Frame locking bar is installed to prevent
(500 yd). weaving as machine is towed.

Never tow machine faster than 3.2 3. Start engine if possible, and install frame locking
km/hr (2 mph) to avoid transmission bar.
damage.
4. Move transmission control lever to “Neutral”
If the engine or the transmission hydraulic system are position. Engage neutral lock.
non-functional, the park brake is ON.

Continued on next page OUOE003,000009E –19–18JUL02–1/2

2-2-27 022808

PN=97
 Operation—Operating the Machine

5. If park brake indicator does not come on, the park 10. Pump handle until gauge needle indicates 1379
brake is OFF. Go to Step 11. kPa (13.8 bar) (200 psi) which will be required to
disengage park brake.
If park brake indicator is on, the park brake is ON.
Go to Step 6. To engage the park brake, open the valve in the
hand-operated pump to relieve pressure.
6. Stop engine.
CAUTION: Prevent possible injury from
CAUTION: Prevent possible injury from unexpected machine movement. Never
unexpected machine movement. Install attempt to remove driveshafts without
frame locking bar. blocking front and rear tires.

7. Disconnect park brake hose (3) from park brake 11. Remove driveshafts if a hand operated pump is
fitting (2). Plug hose. not available to release the park brake.

8. Connect a hose from a hand operated hydraulic Disconnect driveshafts (1 and 4) at differential and
pump to the fitting on park brake. transmission and remove from machine.

NOTE: Keep hydraulic hand operated pump filled with

CAUTION: Prevent possible injury from
oil.
unexpected machine movement. Place
blocks at front and rear of tires to prevent
CAUTION: Prevent possible injury from machine from rolling.
unexpected machine movement. Sit in
operator’s seat when pumping the hydraulic NOTE: Limit tow to 460 m (500 yd) maximum.
pump. When towing the machine, maintain at
least 1379 kPa (13.8 bar) (200 psi). If 12. Tow the machine slowly.
pressure is below 1379 (13.8 bar) (200 psi),
park brake may engage. 13. Place blocks at front and at rear of tires.

9. Place hydraulic hand pump on left side of 14. Reapply park brake or reinstall driveshaft if it was
operator’s station floor. removed. See your authorized dealer for
installation information.
IMPORTANT: Do not pump pressure up to more
than 2068 kPa (20.7 bar) (300 psi) to
avoid damage to the park brake.

OUOE003,000009E –19–18JUL02–2/2

2-2-28 022808

PN=98
 Operation—Operating the Machine

Lifting the Machine

CAUTION: Prevent possible injury from

unexpected machine movement. Clear all
bystanders from lifting area. Select correct
lifting cable strength for weight of machine.
Test lift by raising machine 0.3 m (1 ft) off the
ground.

Specification
Machine—744J—Approximate
Weight......................................................................................... 23 360 kg
51,500 lb
Machine—824J—Approximate
Weight......................................................................................... 26 172 kg
57,700 lb

1. Install machine frame locking bar.

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

machine.

–UN–19MAR91
3. Attach a tether cable to machine to control machine as
it is lifted.

T7477AV
4. Test lift by raising machine 0.3 m (1 ft) off the ground.

5. Lift machine and swing to unloading area.

A—Cable

HG31779,0000164 –19–28OCT02–1/1

2-2-29 022808

PN=99
 Maintenance—Machine
Diesel Fuel

Consult your local fuel distributor for properties of the Fuel lubricity should pass a maximum scar diameter
diesel fuel available in your area. of 0.45 mm as measured by ASTM D6079 or ISO
12156-1.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in Sulfur content:
which they are marketed.
• Diesel fuel quality and fuel sulfur content must
Diesel fuels specified to EN 590 or ASTM D975 are comply with all existing emissions regulations for the
recommended. Renewable diesel is basically identical area in which the engine operates.
to petroleum diesel fuel that is created by • Use of diesel fuel with sulfur content less than
Hydrotreating fats and oils. Renewable diesel that 0.10% (1000 ppm) is STRONGLY recommended.
meets EN 590 or ASTM D975 is acceptable for use at • Use of diesel fuel with sulfur content 0.10% (1000
all percentage mixture levels. ppm) to 0.50% (5000 ppm) may result in REDUCED
oil and filter change intervals as shown in the table.
Required fuel properties • BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 ppm), contact your John Deere
In all cases, the fuel shall meet the following dealer.
properties:
IMPORTANT: Do not mix used diesel engine oil or
Cetane number of 45 minimum. Cetane number any other type of lubricating oil with
greater than 50 is preferred, especially for diesel fuel.
temperatures below –20°C (–4°F) or elevations above
1500 m (5000 ft). IMPORTANT: Improper fuel additive usage may
cause damage on fuel injection
Cold Filter Plugging Point (CFPP) should be at least equipment of diesel engines.
5°C (9°F) below the expected lowest temperature or
Cloud Point below the expected lowest ambient
temperature.

DX,FUEL1 –19–05OCT07–1/1

3-1-1 022808

PN=100
 Maintenance—Machine

Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations for engines

used off-highway. This fuel will not require any additives
to provide good performance and engine reliability.
However, many local fuel distributors will not carry both
low and regular sulfur diesel fuels.

If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere PREMIUM DIESEL FUEL
CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
anti-oxidant, fuel stabilizer, corrosion inhibitor and others.
John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other
diesel fuel conditioners only improve cold weather flow
and stabilize long-term fuel storage. They do not contain
the lubrication additives needed by rotary fuel injection
pumps.

TX,45,JC2126 –19–15AUG97–1/1

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 –19–14NOV05–1/1

3-1-2 022808
PN=101
 Maintenance—Machine

Handling and Storing Diesel Fuel

When using bio-diesel fuel, the fuel filter may require

CAUTION: Handle fuel carefully. Do not fill
more frequent replacement due to premature plugging.
the fuel tank when engine is running.
Check engine oil level daily prior to starting engine. A
DO NOT smoke while you fill the fuel tank or
rising oil level may indicate fuel dilution of the engine
service the fuel system.
oil.
Fill the fuel tank at the end of each day’s operation to
IMPORTANT: The fuel tank is vented through the
prevent water condensation and freezing during cold
filler cap. If a new filler cap is
weather.
required, always replace it with an
original vented cap.
Keep all storage tanks as full as practicable to
minimize condensation.
When fuel is stored for an extended period or if there
is a slow turnover of fuel, add a fuel conditioner to
Ensure that all fuel tank caps and covers are installed
stabilize the fuel and prevent water condensation.
properly to prevent moisture from entering.
Contact your fuel supplier for recommendations.
Monitor water content of the fuel regularly.

DX,FUEL4 –19–19DEC03–1/1

Alternative And Synthetic Lubricants

Conditions in certain geographical areas may require In general, avoid mixing different brands or types of oil.
lubricant recommendations different from those printed Oil manufacturers blend additives in their oils to meet
in this manual. Some John Deere brand coolants and certain specifications and performance requirements.
lubricants may not be available in your location. Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
Synthetic lubricants may be used if they meet the performance.
performance requirements as shown in this manual.
Consult your authorized dealer to obtain specific
The temperature limits and service intervals shown in information and recommendations.
this manual apply to both conventional and synthetic
oils.

Re-refined base stock products may be used if the

finished lubricant meets the performance requirements.

TX14740,0001C42 –19–20OCT00–1/1

3-1-3 022808
PN=102
 Maintenance—Machine

Diesel Engine Break-In Oil

New engines are filled at the factory with John Deere After the break-in period, use John Deere PLUS-50
ENGINE BREAK-IN OIL. During the break-in period, or other diesel engine oil as recommended in this
add John Deere ENGINE BREAK-IN OIL as needed to manual.
maintain the specified oil level.
IMPORTANT: Do not use PLUS-50 oil or engine
Change the oil and filter after the first 100 hours of oils meeting any of the following
operation of a new or rebuilt engine. during the first 100 hours of
operation of a new or rebuilt engine:
After engine overhaul, fill the engine with John Deere
ENGINE BREAK-IN OIL. API CJ-4 ACEA E7
API CI-4 PLUS ACEA E6
API CI-4 ACEA E5
If John Deere ENGINE BREAK-IN OIL is not available, API CH-4 ACEA E4
use a diesel engine oil meeting one of the following API CG-4 ACEA E3
during the first 100 hours of operation: API CF-4
API CF-2
• API Service Classification CE API CF
• API Service Classification CD
These oils will not allow the engine
• API Service Classification CC
to break-in properly.
• ACEA Oil Sequence E2
• ACEA Oil Sequence E1

PLUS-50 is a trademark of Deere & Company. DX,ENOIL4 –19–13SEP06–1/1

3-1-4 022808

PN=103
 Maintenance—Machine

Diesel Engine Oil

50 o C 122o F

Use oil viscosity based on the expected air temperature

40 o C 104o F
range during the period between oil changes.

SAE 40
30 o C 86 o F
John Deere PLUS-50 oil is preferred.

SAE-15W-40

SAE 30
SAE 10W-40
20 o C 68 o F
Oils meeting one of the following specifications are also

SAE 10W-30

SAE 0W-40
SAE 5W-30
recommended: 10 o C 50 o F

• ACEA Oil Sequence E7 0o C 32 o F

• ACEA Oil Sequence E6
• ACEA Oil Sequence E5 -10 o C 14 o F
• ACEA Oil Sequence E4
-20 o C -4 o F

–UN–18JUL07
Extended service intervals may apply when John Deere
PLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 -30 o C -22 o F
engine oils are used. Consult your John Deere dealer for
-40 o C -40 o F
more information.

TS1687
Other oils may be used if they meet one or more of the Oil Viscosities for Air Temperature Ranges
following:

• John Deere TORQ-GARD SUPREME

• API Service Category CJ-4
• API Service Category CI-4 PLUS
• API Service Category CI-4
• API Service Category CH-4
• API Service Category CG-4
• API Service Category CF-4
• ACEA Oil Sequence E3
• ACEA Oil Sequence E2

If oils meeting API CG-4, API CF-4, or ACEA E2 are

used, reduce the service interval by 50%.

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must comply

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

If diesel fuel with sulfur content greater than 0.50% (5000

ppm) is used, reduce the service interval by 50%.

PLUS-50 is a trademark of Deere & Company

TORQ-GARD SUPREME is a trademark of Deere & Company Continued on next page DX,ENOIL –19–06APR07–1/2

3-1-5 022808
PN=104
 Maintenance—Machine

DO NOT use diesel fuel with sulfur content greater than

1.00% (10 000 ppm).

DX,ENOIL –19–06APR07–2/2

Transmission, Hydraulic System, Park Brake,

and Differential Oil

Use oil viscosity based on the expected air temperature

range during the period between oil changes.

The following oils are preferred:

• John Deere HY-GARD

• John Deere Low Viscosity HY-GARD

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

• John Deere Standard JDM J20C

–UN–10OCT97
• John Deere Standard JDM J20D

Use John Deere BIO-HY-GARD1oil when a

biodegradable fluid is required.

TS1660
HY-GARD is a registered trademark of Deere & Company
BIO-HY-GARD is a trademark of Deere & Company

1
BIO-HY-GARD meets or exceeds the minimum biodegradability of 80%
within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD
should not be mixed with mineral oils because this reduces the
biodegradability and makes proper oil recycling impossible.
CED,TX03679,5800 –19–14JUN00–1/1

3-1-6 022808
PN=105
 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 GREASE-GARD

Other greases may be used if they meet the following:

–UN–31OCT03
NLGI Performance Classification GC-LB

IMPORTANT: Some types of grease thickeners are

not compatible with others. Consult

TS1673
your grease supplier before mixing
different types of grease.

GREASE-GARD is a trademark of Deere & Company DX,GREA1 –19–07NOV03–1/1

3-1-7 022808

PN=106
 Maintenance—Machine

Diesel Engine Coolant

The engine cooling system is filled to provide Other low silicate ethylene glycol base coolants for
year-round protection against corrosion and cylinder heavy-duty engines may also be used if they meet one
liner pitting, and winter freeze protection to -37°C of the following specifications:
(-34°F). If protection at lower temperatures is required,
consult your John Deere dealer for recommendations. • ASTM D4985 ethylene glycol base prediluted (50%)
coolant
John Deere COOL-GARD Prediluted Coolant is • ASTM D4985 ethylene glycol base coolant
preferred for service. concentrate in a 40% to 60% mixture of concentrate
with quality water
John Deere COOL-GARD Prediluted Coolant is
available in a concentration of either 50% ethylene Coolants meeting ASTM D4985 require an initial
glycol or 55% propylene glycol. charge of supplemental coolant additives, formulated
for protection of heavy duty diesel engines against
Additional recommended coolants corrosion and cylinder liner erosion and pitting. They
also require periodic replenishment of additives during
The following engine coolant is also recommended: the drain interval.

• John Deere COOL-GARD Coolant Concentrate in a Other coolants

40% to 60% mixture of concentrate with quality
water. It is possible that neither John Deere COOL-GARD nor
coolants meeting one of the coolant standards listed
John Deere COOL-GARD coolants do not require use above is available in the geographical area where
of supplemental coolant additives, except for periodic service is performed. If these coolants are unavailable,
replenishment of additives during the drain interval. use a coolant concentrate or prediluted coolant with a
quality additive package that provides cylinder liner
Other fully formulated coolants cavitation protection and protects the cooling system
metals (cast iron, aluminum alloys, and copper alloys
Other fully formulated low silicate ethylene or such as brass) from corrosion.
propylene glycol base coolants for heavy-duty engines
may be used if they meet one of the following The additive package must be part of one of the
specifications: following coolant mixtures:

• ASTM D6210 prediluted (50%) coolant • ethylene glycol or propylene glycol base prediluted
• ASTM D6210 coolant concentrate in a 40% to 60% (40% to 60%) coolant
mixture of concentrate with quality water • ethylene glycol or propylene glycol base coolant
concentrate in a 40% to 60% mixture of concentrate
Coolants meeting ASTM D6210 do not require use of with quality water
supplemental coolant additives, except for periodic
replenishment of additives during the drain interval. Water quality

Coolants requiring supplemental coolant additives

COOL-GARD is a trademark of Deere & Company Continued on next page DX,COOL3 –19–27OCT05–1/2

3-1-8 022808

PN=107
 Maintenance—Machine

Water quality is important to the performance of the IMPORTANT: Do not mix ethylene glycol and
cooling system. Distilled, deionized, or demineralized propylene glycol base coolants.
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.

DX,COOL3 –19–27OCT05–2/2

3-1-9 022808

PN=108
 Maintenance—Periodic Maintenance
Service Your Machine at Specified Intervals

Lubricate, make service checks and adjustments at

intervals shown on the periodic maintenance chart (1) and
on the following pages.

–UN–10OCT01
Service items at multiples of the original requirement. For
example, at 500 hours also service those items (if
applicable) listed under 250 hours, 100 hours, 50 hours
and 10 hours or daily.

T146537B
1—Periodic Maintenance Chart

CED,OUOE002,1460 –19–09OCT01–1/1

Check the Monitor Display Unit Regularly

At the A 06 display, press SELECT.

Then press SELECT again to turn the 0.1 Hour Meter

Mode On or Off.

–UN–22OCT97
T111863
TX,50,JC2242 –19–29SEP97–1/2

When the 0.1 Hour Meter Mode is turned On, the hour
meter reading (A) can be accessed during normal
machine operation by pressing SELECT. The odometer
reading will switch to the voltmeter reading, and then to
the hour meter reading in hours and tenths of hour.
–UN–22OCT97
Intervals on the periodic maintenance chart are for
operating in normal conditions. If you operate your
machine in severe conditions, you should service it at
SHORTER INTERVALS.
T111864

A—Hour Meter Reading

TX,50,JC2242 –19–29SEP97–2/2

3-2-1 022808
PN=109
 Maintenance—Periodic Maintenance

Prepare Machine for Maintenance

CAUTION: Prevent possible injury from

unexpected boom movement. The bucket may
“jump up” when ride control switch is turned

–UN–17SEP02
ON. Clear all bystanders from area.

Before performing maintenance procedures given in the

following sections, and before leaving the operator’s seat,

T159423G
park the machine as described below unless another
position is specified in the procedure.
One Lever Design
1. Park machine on a level surface.

2. Move return-to-carry switch (A ) to “Off” position, if

equipped.

3. Lower equipment to ground. Put boom in float detent

position.

–UN–27JUN02
4. Move ride control switch (B) to the “On” position
(center position), if equipped, to discharge ride control
accumulator.

T156774E
A—Return-to-Carry Switch
Two Lever Design
B—Ride Control Switch

Continued on next page HG31779,00000B6 –19–18JUL02–1/2

3-2-2 022808

PN=110
 Maintenance—Periodic Maintenance

NOTE: Pilot enable/boom down switch (C) must be

engaged while moving control lever forward to
lower boom with engine stopped.

5. Move transmission control lever (A) to N. Engage

neutral lock (B).

–UN–13FEB98
CAUTION: Prevent possible injury from
unexpected machine movement. Never rely on
transmission control lever alone to keep

T113477
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always turn
engine off or push park brake switch to ON to
hold machine.

6. Push park brake switch to ON.

–UN–19SEP02
7. Turn key switch to “Off”. If maintenance must be
performed with engine running, do not leave machine
unattended.

T159423H
8. Turn battery disconnect switch OFF, if equipped.

A—Transmission Control Lever One Lever Design

B—Neutral Lock Lever
C—Pilot Enable/Boom Down Switch

–UN–27JUN02
T156774F
Two Lever Design

HG31779,00000B6 –19–18JUL02–2/2

3-2-3 022808

PN=111
 Maintenance—Periodic Maintenance

Locking Machine Frame

CAUTION: Prevent possible injury from

unexpected machine movement. Connect frame
locking bar to both frames before you work in

–UN–29OCT02
frame pivot area.

1. Align machine frames.

T161062B
2. Remove quick lock ring (1) and pull locking pin (2)
from hole.

3. Rotate locking bar (3) to align with hole in machine

frame.

4. Install locking pin through hole in loader frame and end

of locking bar. Install quick lock ring to secure locking
bar in place.

–UN–29OCT02
1—Quick Lock Ring
2—Locking Pin
3—Locking Bar

T161061B
HG31779,0000171 –19–29OCT02–1/1

3-2-4 022808

PN=112
 Maintenance—Periodic Maintenance

Boom Lock

CAUTION: Always install boom lock before

working on or around this machine with the
boom raised.

–UN–29OCT02
Empty bucket and place in dump position
before installing boom lock.

T161064B
1. Raise boom. Empty bucket and place in dump position
before installing boom lock (1).

2. Loosen hand bolt (2) and remove boom lock from side
of machine.

3. Install lock on boom cylinder and lock lever facing to

outside of machine and lower boom onto lock.

–UN–29OCT02
4. Tighten hand bolt.

5. Before removing boom lock from cylinder, raise boom

slightly to relieve pressure. Return boom lock to

T161065B
storage position on side of machine and tighten hand
hold.

1—Boom Lock
2—Hand Bolt

HG31779,0000172 –19–29OCT02–1/1

3-2-5 022808

PN=113
 Maintenance—Periodic Maintenance

Opening Engine Side Shields and Service

Doors

CAUTION: Prevent possible injury from engine

service door closing. Always keep service door

–UN–10JUL01
in the open locked position when servicing the
engine area.

1. Pull out on latch (1) to open lower engine service door.

T139710C
2. Pull rod (2) to open upper engine service door.

3. Open door until gas cylinder rod (3) is fully extended.

1—Latch
2—Rod
3—Gas Cylinder

–UN–10JUL01
T139711C
–UN–10JUL01
T139712C

OUOE003,00000AE –19–10JUL01–1/1

3-2-6 022808

PN=114
 Maintenance—Periodic Maintenance

Opening Grille Door

Press down on release lever (1) to open grille door fully.

Door will automatically lock open.

Rotate stop (2) to release door lock.

–UN–10AUG01
1—Release Lever
2—Stop

T139740C
–UN–26SEP01
T146005B
CED,OUOE002,1463 –19–27SEP01–1/1

Fuel Tank

CAUTION: Handle fuel carefully. If the engine is

hot or running, do not fill the fuel tank. Do not
smoke while you fill fuel tank or work on fuel
system.

To avoid condensation, fill the fuel tank at the end of each

day’s operation.

The fuel tank capacity is 462 L (122 gal).

Specification
Fuel Tank—Capacity ......................................................................... 462 L
122 gal

CED,OUOE002,1352 –19–01NOV02–1/1

3-2-7 022808
PN=115
 Maintenance—Periodic Maintenance

Check Windshield Washer Fluid Level

Open lower left engine side shield.

Check fluid in windshield washer bottle (A).

–UN–11MAY98
During winter season, use all season windshield washer
fluid which will not freeze.

A—Windshield Washer Bottle

T115303
CED,OUOE002,1462 –19–08MAY98–1/1

Maintenance and Repair Record Keeping

System

The checklist in this section summarizes scheduled

maintenance, and parts and oil required at each
maintenance interval.

Use the checklist to:

• Remind you to perform machine maintenance at

specified intervals to minimize downtime.
• Calculate cost of machine operation and ownership
allowing you to make better job estimates.
• Place yourself in a stronger position at trade-in time.
• Satisfy your SECURE contract requirements.

As maintenance is performed, check off each item on the

list and record date and hour meter reading.

Do not tear out or mark on checklist in this section; keep it

–UN–27JUN91
to make extra copies.

T7511CO

TX,50,FF2898 –19–27SEP07–1/1

3-2-8 022808
PN=116
 Maintenance—Periodic Maintenance

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

–UN–16SEP97
–UN–16SEP97

T111410
T111411
Oilscan Plus 3-Way Coolant Test Kit

OILSCAN PLUS, COOLSCAN PLUS and 3-Way and/or fluid change interval. Certain systems require
Coolant Test Kit are John Deere fluid sampling more frequent sampling. Consult your authorized
products to help you monitor machine performance dealer on a maintenance program for your specific
and system condition. The objective of a fluid sampling application. Your dealer has the sampling products and
program is to ensure machine availability when you expertise to assist you in lowering your overall
need it and to reduce repair costs by identifying operating costs through fluid sampling.
potential problems before they become critical.

Oil and coolant samples should be taken from each

system on a periodic basis, usually prior to a filter

OILSCAN PLUS is a trademark of Deere & Company.

COOLSCAN PLUS is a trademark of Deere & Company. CED,OUO1040,114 –19–11JUN98–1/1

3-2-9 022808

PN=117
 Maintenance—Periodic Maintenance

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

As Required
• Inspect tires and check pressure • Inspect belts
• Check wheel retainer cap screws • Drain and clean fuel tank strainer
• Clean or replace air cleaner elements • Drain or replace primary fuel filter and lean water separator bowl
• Check and clean air inlet cover

Every 10 Hours or Daily

• Check recovery tank coolant level • Check hydraulic system oil level
• Clean air cleaner dust unloader valve • Check transmission oil level
• Check engine oil level

After First 100 Hours

• Change engine break-in oil and replace filter • Change transmission oil and replace filter

Every 100 Hours

• Grease loader linkage and cylinder pivots • Check and clean cab fresh air filter
• Grease front steering cylinder pivots • Check and clean cab recirculating air filter
• Grease oscillating rear axle and rear steering cylinder pivots

Continued on next page HG31779,000011E –19–17SEP02–1/2

3-2-10 022808

PN=118
 Maintenance—Periodic Maintenance

Model: ❒ 744J/824J Customer:

PIN/Serial Number: Delivery Date: Hour Meter Reading:
OIL SAMPLING
Oil samples should be taken from each system prior to its recommended drain or change interval indicated on this form: 250, 500, 1000
hours. Maintenance recommendations supplied by OILSCAN PLUS will be provided based upon the oil analysis and operating information
you supply. Regular oil sampling will extend the operational life of your machine’s systems.

Every 250 Hours

❒ Grease front driveline sliding joints ❒ Change engine oil and replace filter
❒ Check radiator coolant level

Comments:

Date: Hour Meter Reading:

Maintenance Performed By:

Every 500 Hours

❒ Grease rear driveline sliding joints and driveline U-joints ❒ Replace hydraulic system return filter
❒ Check air intake hoses ❒ Replace hydraulic reservoir breather filter
❒ Check battery electrolyte level and terminals ❒ Replace transmission oil filter
❒ Replace primary fuel filter ❒ Check park brake oil level
❒ Replace primary fuel filter strainer ❒ Check front and rear differential oil level

Comments:

Date: Hour Meter Reading:

Maintenance Performed By:

Every 1000 Hours

❒ Replace air cleaner dust unloader valve ❒ Change transmission oil
❒ Replace air cleaner elements ❒ Grease frame hinge pivots
❒ Clean engine crankcase vent tube ❒ Change park brake oil
❒ Check radiator hoses

Comments:

Date: Hour Meter Reading:

Maintenance Performed By:

Every 2000 Hours

❒ Check and adjust engine valve lash and electronic unit injector
preload

Comments:

Date: Hour Meter Reading:

Maintenance Performed By:

Every 3000 Hours

❒ Change hydraulic system oil ❒ Replace differential lock return filters (if equipped)
❒ Clean hydraulic strainer ❒ Change front and rear differential oil

Comments:

Date: Hour Meter Reading:

Maintenance Performed By:

HG31779,000011E –19–17SEP02–2/2

3-2-11 022808

PN=119
 Maintenance—Periodic Maintenance

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

Description Part Number ASI 250 HOURS 500 HOURS 1000 HOURS 3000 HOURS
Engine Oil Filter RE58935 1 1 1 1 1
Primary Fuel Filter RE507284 1 1 1
Primary Fuel Filter Strainer AT223493 1 1 1
Transmission Filter AT147496 1 1 1 1
Hydraulic System Return AT228474 2 2 2
Filter (2)
Air Filter Primary AT220822 1 1
Air Filter Secondary AT203051 1 1
Hydraulic Reservoir AM39653 1 1 1
Breather Filter
Differential Lock Return T19044 2
Filter(s)
TORQ-GARD SUPREME TY6389 38 L (40 qt) 38 L (40 qt) 38 L (40 qt) 38 L (40 qt) 38 L (40 qt)
PLUS-50 Oil
HY-GARD Transmission
and Hydraulic Oil
744J TY6354 28 L (30 qt) 28 L (30 qt) 264 L (70 gal)
744J—With TY6354 28 L (30 qt) 28 L (30 qt) 270 L (71 gal)
Optional Wide Axle
824J TY6354 28 L (30 qt) 28 L (30 qt) 270 L (71 gal)
Coolant Conditioner (as TY16004 1 1
needed)
Oilscan Plus Test
Packages:
•Diesel Engine Oil AT178840 1 1 1 1
•Transmission Oil AT178840 1 1 1
•Axle Oil AT178840 2 2 2
•Hydraulic and Hydrostatic AT178844 1 1 1
Oil
Coolscan Plus Kit AT183016 1 1

PLUS-50 is a trademark of Deere & Company.

HY-GARD is a trademark of Deere & Company.
Oilscan Plus is a trademark of Deere & Company.
Coolscan Plus is a trademark of Deere & Company. HG31779,0000108 –19–01NOV02–1/1

3-2-12 022808

PN=120
 Maintenance—As Required
Check Tire Pressure

CAUTION: Explosive separation of a tire and

rim parts can cause serious injury or death.

Always maintain the correct tire pressure. DO

NOT inflate tires above the recommended
pressure.

Inspect tires and wheels daily. DO NOT operate

with low pressure, cuts, bubbles, damaged
rims, or missing lug bolts.

Carefully inspect any tire and rim assembly that

has been run flat or severely underinflated
before reinflating the tire. Damage to the rim
and tire may have developed. Call your
authorized dealer or a qualified repair service to
inspect the rim and tire assembly and make
necessary repairs.

–UN–23AUG88
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to
stand to one side and NOT in front of or over

TS211
the tire assembly. Use a safety cage if available.

NEVER cut or weld on an inflated tire or rim

assembly. Heat from welding could cause an
increase in pressure and may result in tire
explosion.

Do not attempt to mount a tire if you do not

have the proper equipment and experience to

–UN–12MAR97
perform the job. Have it done by your
authorized dealer or a qualified repair service.

Check tire pressure with an accurate gauge having 7.0

T108057B
kPa (0.07 bar) (1 psi) graduations.

1. Remove pipe cap (A).

2. Shut off air supply to hose.

3. Move gauge hand to correct pressure.

–UN–21OCT88

4. Lock air chuck on tire valve.

T87502

A—Pipe Cap

Continued on next page CED,OUO1021,181 –19–17MAR98–1/2

3-3-1 022808

PN=121
 Maintenance—As Required

5. Turn on air supply. Stand to front or rear of tire when

you add air to tire.

6. After tire is at correct pressure, shut off air supply.

Release chuck. (See following Tire Pressure chart.)

7. Inspect tire for damage.

CED,OUO1021,181 –19–17MAR98–2/2

Tire Pressures (744J)

Recommended Tire Pressures (PSI) for 50,000 pound

loader with 5.25 cubic yard bucket, handling 3400 pounds
per cubic yard material.

To increase side-to-side stability, increase front tire

pressures in 2 PSI increments.

To adjust fore-aft stability, increase or decrease rear tire

pressures in 2 PSI increments.

See Tire Manufacturer’s charts for detailed load, pressure

and distance recommendations.

Continued on next page TX,55,JC1225 –19–25JUN96–1/4

3-3-2 022808
PN=122
 Maintenance—As Required

Bridgestone Firestone General Goodyear

Size Front Rear Ply Front Rear Ply Front Rear Ply Front Rear Ply
Rating Rating Rating Rating
23.5-25 L2, L2/E2, 475 241 24 475 241 24 475 kPa 241 kPa 24 482 kPa 241 24
L2/E2/G2 kPa kPa kPa kPa (4.75 (2.41 (4.82 kPa
(4.75 (2.41 (4.75 (2.41 bar) (69 bar) (35 bar) (70 (2.41
bar) bar) bar) bar) psi) psi) psi) bar)
(69 (35 psi) (69 (35 (35
psi) psi) psi) psi)
L3, L3/E3, 475 241 24 475 241 24 475 kPa 241 kPa 24 482 kPa 241 24
L3/E3/G3 kPa kPa kPa kPa (4.75 (2.41 (4.82 kPa
(4.75 (2.41 (4.75 (2.41 bar) (69 bar) (35 bar) (70 (2.41
bar) bar) bar) bar) psi) psi) psi) bar)
(69 (35 psi) (69 (35 (35
psi) psi) psi) psi)
L4 475 241 24 475 241 24 475 kPa 241 kPa 24 482 kPa 241 24
kPa kPa kPa kPa (4.75 (2.41 (4.82 kPa
(4.75 (2.41 (4.75 (2.41 bar) (69 bar) (35 bar) (70 (2.41
bar) bar) bar) bar) psi) psi) psi) bar)
(69 (35 psi) (69 (35 (35
psi) psi) psi) psi)
L5 475 241 24 475 241 24 475 kPa 241 kPa 24 482 kPa 241 24
kPa kPa kPa kPa (4.75 (2.41 (4.82 kPa
(4.75 (2.41 (4.75 (2.41 bar) (69 bar) (35 bar) (70 (2.41
bar) bar) bar) bar) psi) psi) psi) bar)
(69 (35 psi) (69 (35 (35
psi) psi) psi) psi)
26.5-25 L2, L2/L3, 324 172 20 324 158 20 324 kPa 158 kPa 20 310 kPa 158 20
L2/E2/G2 kPa kPa kPa kPa (3.24 (1.58 (3.10 kPa
(3.24 (1.72 (3.24 (1.58 bar) (47 bar) (23 bar) 45 (1.58
bar) bar) bar) bar) psi) psi) psi) bar)
(47 (25 psi) (47 (23 (23
psi) psi) psi) psi)
L3, L3/E3, 324 172 20 324 158 20 324 kPa 158 kPa 20 310 kPa 158 20
L3/E3/G3 kPa kPa kPa kPa (3.24 (1.58 (3.10 kPa
(3.24 (1.72 (3.24 (1.58 bar) (47 bar) (23 bar) 45 (1.58
bar) bar) bar) bar) psi) psi) psi) bar)
(47 (25 psi) (47 (23 (23
psi) psi) psi) psi)
L4 324 172 20 324 158 20 324 kPa 158 kPa 20 310 kPa 158 20
kPa kPa kPa kPa (3.24 (1.58 (3.10 kPa
(3.24 (1.72 (3.24 (1.58 bar) (47 bar) (23 bar) 45 (1.58
bar) bar) bar) bar) psi) psi) psi) bar)
(47 (25 psi) (47 (23 (23
psi) psi) psi) psi)
L5 324 172 20 324 158 20 324 kPa 158 kPa 20 310 kPa 158 20
kPa kPa kPa kPa (3.24 (1.58 (3.10 kPa
(3.24 (1.72 (3.24 (1.58 bar) (47 bar) (23 bar) 45 (1.58
bar) bar) bar) bar) psi) psi) psi) bar)
(47 (25 psi) (47 (23 (23
psi) psi) psi) psi)

Continued on next page TX,55,JC1225 –19–25JUN96–2/4

3-3-3 022808
PN=123
 Maintenance—As Required

Bridgestone Firestone Goodyear Michelin

Size Front Rear Star Front Rear Star Front Rear Star Front Rear Star
Rating Rating Rating Rating
23.5R25 L2, L2/L3, 524 262 ** 524 262 ** 551 275 kPa ** 351 151 *
L2/E2/G2 kPa kPa kPa kPa kPa (2.75 kPa kPa
(5.24 (2.62 (5.24 (2.62 (5.51 bar) (40 (3.51 (1.51
bar) bar) (38 bar) bar) bar) psi) bar) 51 bar)
(76 psi) psi) (76 (38 psi) (80 psi) (22 psi)
psi) psi)
L3, L3/E3, 524 262 ** 524 262 ** 551 275 kPa ** 303 151 *
L3/E3/G3 kPa kPa kPa kPa kPa (2.75 kPa kPa
(5.24 (2.62 (5.24 (2.62 (5.51 bar) (40 (3.03 (1.51
bar) bar) (38 bar) bar) bar) psi) bar) bar)
(76 psi) psi) (76 (38 psi) (80 (44 psi) (22 psi)
psi) psi)
L4 524 262 ** 524 262 ** 551 275 kPa ** 303 151 *
kPa kPa kPa kPa kPa (2.75 kPa kPa
(5.24 (2.62 (5.24 (2.62 (5.51 bar) (40 (3.03 (1.51
bar) bar) (38 bar) bar) bar) psi) bar) bar)
(76 psi) psi) (76 (38 psi) (80 (44 psi) (22 psi)
psi) psi)
L5 524 262 ** 524 262 ** 551 275 kPa ** 303 151 *
kPa kPa kPa kPa kPa (2.75 kPa kPa
(5.24 (2.62 (5.24 (2.62 (5.51 bar) (40 (3.03 (1.51
bar) bar) (38 bar) bar) bar) psi) bar) bar)
(76 psi) psi) (76 (38 psi) (80 (44 psi) (22 psi)
psi) psi)
750/65R25 L3 303 199 *
kPa kPa
(3.03 (1.99
bar) bar)
(44 psi) (29 psi)
26.5R25 L2, L2/E2, 399 199 * 399 199 * 413 206 kPa *
L2/E2/G2 kPa kPa kPa kPa kPa (2.06
(3.99 (1.99 (3.99 (1.99 (4.13 bar) (30
bar) bar) (29 bar) bar) bar) psi)
(58 psi) psi) (58 (29 psi) (60
psi) psi)
L3, L3/E3, 399 199 * 399 199 * 413 206 kPa * 303 151 *
L3/E3/G3 kPa kPa kPa kPa kPa (2.06 kPa kPa
(3.99 (1.99 (3.99 (1.99 (4.13 bar) (30 (3.03 (1.51
bar) bar) (29 bar) bar) bar) psi) bar) bar)
(58 psi) psi) (58 (29 psi) (60 (44 psi) (22 psi)
psi) psi)

Continued on next page TX,55,JC1225 –19–25JUN96–3/4

3-3-4 022808
PN=124
 Maintenance—As Required

L4 399 199 * 199 * 413 206 kPa * 303 151 *

kPa kPa kPa kPa (2.06 kPa kPa
(3.99 (1.99 (1.99 (4.13 bar) (30 (3.03 (1.51
bar) bar) (29 bar) bar) psi) bar) bar)
(58 psi) psi) (29 psi) (60 (44 psi) (22 psi)
psi)
L5 399 199 * 399 199 * 413 206 kPa * 303 151 *
kPa kPa kPa kPa kPa (2.06 kPa kPa
(3.99 (1.99 (3.99 (1.99 (4.13 bar) (30 (3.03 (1.51
bar) bar) (29 bar) bar) bar) psi) bar) bar)
(58 psi) psi) (58 (29 psi) (60 (44 psi) (22 psi)
psi) psi)

NOTE: Tire shipping pressure may not be the same as

tire operating pressure. You may change tire
pressures to suit working condition according to
tire manufacturer’s recommendations

TX,55,JC1225 –19–25JUN96–4/4

Tire Pressures (824J)

Recommended Tire Pressures (PSI) for 57,000 pound

loader with 6.00 cubic yard bucket, handling 3400 pounds
per cubic yard material.

To increase side-to-side stability, increase front tire

pressures in 2 PSI increments.

To adjust fore-aft stability, increase or decrease rear tire

pressures in 2 PSI increments.

See Tire Manufacturer’s charts for detailed load, pressure

and distance recommendations.

Continued on next page HG31779,0000150 –19–07OCT02–1/4

3-3-5 022808
PN=125
 Maintenance—As Required

Bridgestone Firestone General Goodyear

Size Front Rear Ply Front Rear Ply Front Rear Ply Front Rear Ply
Rating Rating Rating Rating
26.5-25 L2, L2/E2, 427 213 20 427 213 20 448 220 20 413 206 20
L2/E2/G2 kPa kPa kPa kPa kPa kPa kPa kPa
(4.27 (2.13 (4.27 (2.13 (4.48 (2.20 (4.13 (2.06
bar) ( bar) bar) ( bar) bar) bar) bar) bar)
62 psi) (31 psi) 62 psi) (31 (65 (32 (60 psi) (30
psi) psi) psi) psi)
L3, L3/E3, 427 213 20 427 213 20 448 220 20 413 206 20
L3/E3/G3 kPa kPa kPa kPa kPa kPa kPa kPa
(4.27 (2.13 (4.27 (2.13 (4.48 (2.20 (4.13 (2.06
bar) ( bar) bar) ( bar) bar) bar) bar) bar)
62 psi) (31 psi) 62 psi) (31 (65 (32 (60 psi) (30
psi) psi) psi) psi)
L4 427 213 20 427 213 20 448 220 20 413 206 20
kPa kPa kPa kPa kPa kPa kPa kPa
(4.27 (2.13 (4.27 (2.13 (4.48 (2.20 (4.13 (2.06
bar) ( bar) bar) ( bar) bar) bar) bar) bar)
62 psi) (31 psi) 62 psi) (31 (65 (32 (60 psi) (30
psi) psi) psi) psi)
L5 427 213 20 427 213 20 448 220 20 413 206 20
kPa kPa kPa kPa kPa kPa kPa kPa
(4.27 (2.13 (4.27 (2.13 (4.48 (2.20 (4.13 (2.06
bar) ( bar) bar) ( bar) bar) bar) bar) bar)
62 psi) (31 psi) 62 psi) (31 (65 (32 (60 psi) (30
psi) psi) psi) psi)
29.5-25 L2, L2/L3, 303 151 22 303 151 22 303 151 22 310 22
L2/E2/G2 kPa kPa kPa kPa kPa kPa kPa
(3.03 (1.51 (3.03 (1.51 (3.03 (1.51 (3.10
bar) bar) bar) bar) bar) bar) bar)
(44 (22 psi) (44 (22 (44 (22 (45 psi)
psi) psi) psi) psi) psi)
L3, L3/E3, 303 151 22 303 151 22 303 151 22 310 158 22
L3/E3/G3 kPa kPa kPa kPa kPa kPa kPa kPa
(3.03 (1.51 (3.03 (1.51 (3.03 (1.51 (3.10 (1.58
bar) bar) bar) bar) bar) bar) bar) bar)
(44 (22 psi) (44 (22 (44 (22 (45 psi) (23
psi) psi) psi) psi) psi) psi)
L4 303 151 22 303 151 22 303 151 22 310 158 22
kPa kPa kPa kPa kPa kPa kPa kPa
(3.03 (1.51 (3.03 (1.51 (3.03 (1.51 (3.10 (1.58
bar) bar) bar) bar) bar) bar) bar) bar)
(44 (22 psi) (44 (22 (44 (22 (45 psi) (23
psi) psi) psi) psi) psi) psi)
L5 303 151 22 303 151 22 303 151 22 310 158 22
kPa kPa kPa kPa kPa kPa kPa kPa
(3.03 (1.51 (3.03 (1.51 (3.03 (1.51 (3.10 (1.58
bar) bar) bar) bar) bar) bar) bar) bar)
(44 (22 psi) (44 (22 (44 (22 (45 psi) (23
psi) psi) psi) psi) psi) psi)

Continued on next page HG31779,0000150 –19–07OCT02–2/4

3-3-6 022808
PN=126
 Maintenance—As Required

Bridgestone Firestone Goodyear Michelin

Size Front Rear Star Front Rear Star Front Rear Star Front Rear Star
Rating Rating Rating Rating
26.5R25 L2, L2/L3, 475 241 * 475 241 * 482 241 *
L2/E2/G2 kPa kPa kPa kPa kPa kPa
(4.75 (2.41 (4.75 (2.41 (4.82 (2.41
bar) bar) bar) bar) bar) bar)
(69 psi) (35 (69 (35 psi) (70 psi) (35
psi) psi) psi)
L3, L3/E3, 475 241 * 475 241 * 482 241 * 448 227 *
L3/E3/G3 kPa kPa kPa kPa kPa kPa kPa kPa
(4.75 (2.41 (4.75 (2.41 (4.82 (2.41 (4.48 2.27
bar) bar) bar) bar) bar) bar) bar) bar)
(69 psi) (35 (69 (35 psi) (70 psi) (35 (65 psi) (33 psi)
psi) psi) psi)
L4 475 241 * 475 241 * 482 241 * 448 227 *
kPa kPa kPa kPa kPa kPa kPa kPa
(4.75 (2.41 (4.75 (2.41 (4.82 (2.41 (4.48 2.27
bar) bar) bar) bar) bar) bar) bar) bar)
(69 psi) (35 (69 (35 psi) (70 psi) (35 (65 psi) (33 psi)
psi) psi) psi)
L5 475 241 * 475 241 * 482 241 * 448 227 *
kPa kPa kPa kPa kPa kPa kPa kPa
(4.75 (2.41 (4.75 (2.41 (4.82 (2.41 (4.48 2.27
bar) bar) bar) bar) bar) bar) bar) bar)
(69 psi) (35 (69 (35 psi) (70 psi) (35 (65 psi) (33 psi)
psi) psi) psi)
29.5R25 L2, L2/E2, 399 199 * 399 199 * 379 193 * 351
L2/E2/G2 kPa kPa kPa kPa kPa kPa kPa
(3.99 (1.99 (3.99 (1.99 (3.79 (1.93 (3.51
bar) bar) bar) bar) bar) bar) bar)
(58 psi) (29 (58 (29 psi) (55 psi) (28 (51 psi)
psi) psi) psi)
L3, L3/E3, 399 199 * 399 199 * 379 193 * 351 179 *
L3/E3/G3 kPa kPa kPa kPa kPa kPa kPa kPa
(3.99 (1.99 (3.99 (1.99 (3.79 (1.93 (3.51 (1.79
bar) bar) bar) bar) bar) bar) bar) bar)
(58 psi) (29 (58 (29 psi) (55 psi) (28 (51 psi) (26 psi)
psi) psi) psi)
L4 399 199 * 399 199 * 379 193 * 351 179 *
kPa kPa kPa kPa kPa kPa kPa kPa
(3.99 (1.99 (3.99 (1.99 (3.79 (1.93 (3.51 (1.79
bar) bar) bar) bar) bar) bar) bar) bar)
(58 psi) (29 (58 (29 psi) (55 psi) (28 (51 psi) (26 psi)
psi) psi) psi)
L5 399 199 * 399 199 * 379 193 * 351 179 *
kPa kPa kPa kPa kPa kPa kPa kPa
(3.99 (1.99 (3.99 (1.99 (3.79 (1.93 (3.51 (1.79
bar) bar) bar) bar) bar) bar) bar) bar)
(58 psi) (29 (58 (29 psi) (55 psi) (28 (51 psi) (26 psi)
psi) psi) psi)

Continued on next page HG31779,0000150 –19–07OCT02–3/4

3-3-7 022808
PN=127
 Maintenance—As Required

NOTE: Tire shipping pressure may not be the same as

tire operating pressure. You may change tire
pressures to suit working condition according to
tire manufacturer’s recommendations
HG31779,0000150 –19–07OCT02–4/4

Tighten Wheel Retainer Cap Screws

NOTE: Tighten cap screws after first 10 hours, then again

after first 50 hours of loaded operation. After that,
tighten as required.

Tighten wheel cap screws to 1070 N•m (789 lb-ft).

Specification
Wheel Cap Screw—Torque........................................................ 1070 N•m
789 lb-ft

TX,55,JC1592 –19–28AUG96–1/1

Replace Air Cleaner Elements

1. Open right service door.

2. Remove air inlet cover.

–UN–12DEC96
3. Remove primary element (A).

4. Remove secondary element (B).

T103190B
A—Primary Element
B—Secondary Element

–UN–12DEC96
T103189B

TX,55,JC1573 –19–10OCT01–1/1

3-3-8 022808
PN=128
 Maintenance—As Required

Check Air Inlet Cover

1. Loosen hose clamp (A).

2. Remove air inlet cover (B).

–UN–26JUN02
3. Check cover for debris. Remove debris if necessary.

A—Hose Clamp

T156026B
B—Air Inlet Cover

HG31779,00000A1 –19–21OCT02–1/1

Inspect Serpentine Belts

1. Check belts (1 and 2) regularly for wear, especially for

cracks at the bottom of grooves and for frayed edges.

IMPORTANT: If either belt is stretched to the point

that the belt tensioner is against its
stop, belt must be replaced.

2. If necessary, replace belt.

3. Remove lower fan guard.

NOTE: Alternator belt requires a 1/2 inch square drive

tool and fan belt requires a 3/4 inch square drive
tool to release belt tension.

4. Hold tension adjuster assembly away from belt while

removing old belt and installing new belt.

–UN–20MAR01
5. Install fan guard.

1—Belt

T139776B
2—Belt

OUOE003,00000B1 –19–14MAR01–1/1

3-3-9 022808
PN=129
 Maintenance—As Required

Drain Fuel Tank Sediment

NOTE: Drain valve is located at the bottom of the fuel

tank to the left of machine center line.

1. Remove cap screws (1) and cover (2).

2. Drain water and sediment into a container.

3. Tighten drain valve.

–UN–20MAR01
4. Install cover and tighten cap screws.

5. Dispose of waste properly.

T139780B
1—Cap Screw (2 used)
2—Rock Guard Cover (Optional)
3—Drain Valve

–UN–20MAR01
T139781B

OUOE003,00000B2 –19–08MAR07–1/1

Inspect Fuel Filler Drain Hose and Tank

Breather Hose

Inspect hoses for cracks or wear. Tighten clamps if

necessary.
–UN–24SEP01

1—Tank Breather Hose

2—Fuel Filler Drain Hose
T145905B

TX03679,000180D –19–24SEP01–1/1

3-3-10 022808
PN=130
 Maintenance—As Required

Drain Primary Fuel Filter

1. Open engine left side shield to access primary fuel

filter.

2. Place container under drain hose (2).

–UN–16AUG01
3. Loosen drain valve and press pump (1) to extract
water from fuel system.

T144885D
4. Tighten drain valve.

5. Close side shield.

1—Pump
2—Drain Hose
6. Dispose of waste properly.

TX03679,00017F1 –19–17AUG01–1/1

Replace Primary Fuel Filter

CAUTION: If engine has been running, engine

and fuel filter housing may be hot.

–UN–16AUG01
1. Clean entire top area of fuel filter assembly to keep
debris from entering fuel system.

2. Remove cap (1) from fuel filter housing.

T144885C
1—Cap

TX03679,00017F2 –19–26SEP01–1/4

NOTE: Relieve vacuum in filter housing by operating

hand primer until fuel filter “pops up”. If filter does
not “pop up” after about 30 strokes of primer,
insert a small screwdriver as shown to carefully
pry under filter flange to relieve vacuum in the
housing.
–UN–27MAY04
RG10303

Continued on next page TX03679,00017F2 –19–26SEP01–2/4

3-3-11 022808
PN=131
 Maintenance—As Required

3. Remove filter element as shown. Hold filter suspended

straight up in top of housing to drain fuel from filter.

4. Dispose of used filter properly.

5. Drain fuel from water separator bowl.

NOTE: If sediment in bowl cannot be flushed out by

pumping primer, remove bowl to clean.

–UN–02SEP99
6. Clean sediment from water separator bowl. See Clean
Water Separator Bowl. (Section 3-3.)

RG10304
TX03679,00017F2 –19–26SEP01–3/4

IMPORTANT: Fuel level below the MIN indication may

result in trapped air in the filter causing
the engine to stall and not restart
without additional system purging. Fuel
level above the MAX indication may
cause fuel to overflow from the filter

–UN–02SEP99
housing during insertion of filter
element.

7. Pump primer until fuel reaches the MAX (A) level.

RG10305
8. Carefully insert new (dry) fuel filter into filter housing.

9. Install fuel filter cap and hand tighten. A—Maximum Level 63 mm (2-1/2 in.) From Top of
Housing
B—Minimum Level 127 mm (5 in.) From Top of
10. Pump primer at least 20 strokes. Housing

11. Start engine and run at slow idle for 5 minutes.

TX03679,00017F2 –19–26SEP01–4/4

3-3-12 022808
PN=132
 Maintenance—As Required

Clean Water Separator Bowl

IMPORTANT: Use the least amount of force

necessary with strap wrench when
removing and installing separator bowl
to prevent plastic bowl from cracking.

1. Disconnect wiring connector from water-in-fuel sensor.

–UN–13SEP99
2. Drain fuel from separator bowl.

3. Position a strap wrench (A) as close as possible to top

edge of separator bowl. While applying pressure with

RG10351
strap wrench, grip bowl and twist with other hand, as
shown, to remove bowl.

4. Clean water separator bowl. A—Strap Wrench

5. Install separator bowl and tighten by hand until seal

makes contact.

Specification
Water Separator Bowl-to-Filter
Housing—Torque.............................................................. 6 N•m (55 lb-in.)

6. Connect wiring connector to water-in-fuel sensor.

7. Remove cap. Lift filter up until fuel level can be

observed.

TX14740,0001D3B –19–26SEP01–1/2

8. Pump primer until fuel is within 6 inches of filter

canister top.

9. Press filter to seal.

10. Install filter cap. –UN–02SEP99

11. Pump primer at least 20 strokes.

12. Start engine. Run engine at slow idle for 5 minutes.

RG10305

A—Maximum Level 63 mm (2-1/2 in.) From Top of

Housing (New filter)
B—Minimum Level 152 mm (6 in.) from Top of
Housing (Reused Filter)

TX14740,0001D3B –19–26SEP01–2/2

3-3-13 022808
PN=133
 Maintenance—Every 10 Hours or Daily
Check Recovery Tank Coolant Level

With the engine cold, coolant level must be between FULL

and ADD marks on the recovery tank.

If coolant is below the ADD mark, add coolant to the

recovery tank.

CAUTION: Prevent possible injury from hot

spraying water. DO NOT remove radiator filler

–UN–20MAR01
cap unless engine is cool. Then turn cap slowly
to the stop. Release all pressure before you
remove cap.

T139808B
If recovery tank is empty, check for leaks. Repair as
required. Add coolant to the radiator and the recovery
tank.

NOTE: If recovery tank is full and radiator is low, check

for leaks in radiator cap and hose connections
between radiator and coolant recovery tank.

Coolant level must be at bottom of the filler neck.

–UN–18OCT88
T6274AQ
OUOE003,00000B4 –19–14MAR01–1/1

Clean Air Cleaner Dust Unloader Valve

IMPORTANT: A missing, damaged, or hardened dust

unloader valve will make the dust cup
precleaner ineffective, causing very
short element life. Valve should suck
closed above 1/3 engine speed.

Squeeze dust valve (A) to remove dust from the air

cleaner.
–UN–20MAR01

If operating in high dust conditions, squeeze dust valve

every couple of hours of operation to release dust.
T139810B

A—Dust Valve

HG31779,0000136 –19–25SEP02–1/1

3-4-1 022808
PN=134
 Maintenance—Every 10 Hours or Daily

Check Engine Oil Level

IMPORTANT: If oil level is low, the engine can be

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

The most accurate oil level reading is obtained when the

engine is cold, before starting the engine for the day’s
operation.

–UN–10OCT01
1. Park machine on a level surface.

2. Engage park brake.

T144885G
3. Make sure dipstick (1) is fully seated.

4. BEFORE THE ENGINE IS STARTED: The engine is

full when oil level is in the cross hatched area. It is
1—Dipstick
acceptable to run the engine when the oil level is 2—Filler Cap
above the ADD mark.

AFTER THE ENGINE HAS BEEN RUN: Allow the oil

to drain into the oil pan for 10 minutes before checking
the oil level. Ten minutes after shutdown the engine oil
level must be above the ADD mark.

5. If necessary, remove filler cap (2) to add oil. See

Diesel Engine Oil. (Section 3-1.)

OUOE003,00000B6 –19–31OCT02–1/1

3-4-2 022808

PN=135
 Maintenance—Every 10 Hours or Daily

Check Hydraulic Oil Level

IMPORTANT: Prevent possible hydraulic pump

damage. DO NOT operate engine
without oil in the hydraulic reservoir.

1. Park machine on a level surface.

2. Lower equipment to the ground.

3. When oil is cold, oil level must be in FULL range on

sight glass (B).

4. If necessary, remove filler cap (A) and add oil. See

Transmission, Hydraulic System, Park Brake, and
Differential Oil. (Section 3-1.)

5. Install filler cap.

A—Filler Cap

–UN–19FEB97
B—Sight Glass

T101195
CED,OUOE012,290 –19–10JUL01–1/1

3-4-3 022808

PN=136
 Maintenance—Every 10 Hours or Daily

Check Transmission Oil Level

IMPORTANT: Prevent possible transmission damage.

DO NOT operate engine when
transmission oil level is low.

–UN–20SEP02
1. Before starting engine, check oil level on sight gauge
(1). If oil level is higher than the sight gauge, there is
sufficient oil to start the engine.

T159631B
2. If necessary, add oil at filler tube (2). See
Transmission, Hydraulic System, Park Brake, and
Differential Oil. (Section 3-1.)

3. Start engine.

4. Engage service brakes. Move clutch cut-off switch to

disengaged position.

5. Move auto transmission switch to “Off” position.

Release park brake.

6. Move transmission control lever to 3rd speed forward

"3F" position.

Operate engine at fast idle for 30 seconds. Reduce

engine speed to slow idle and place transmission
control lever in neutral "N", for 15 seconds.

Repeat this step until transmission oil reaches normal

operating temperature (approximately (80°C) (175°F).

7. Move transmission control lever to neutral "N", and

–19–01NOV02
engage neutral lock. Lower all equipment to ground.

8. Push park brake switch to ON.

T161201
9. Release service brakes.

10. Allow 2 minutes for oil level to stabilize.

1—Sight Gauge
11. Check oil level with engine at slow idle. With oil at 2—Filler Tube
normal operating temperature, oil level should be
between HOT marks on sight gauge.

12. If necessary, add oil. See Transmission, Hydraulic

System, Park Brake, and Differential Oil. (Section
3-1.)

HG31779,000012F –19–20SEP02–1/1

3-4-4 022808

PN=137
 Maintenance—After 100 Hours
Change Engine Break-In Oil and Replace
Filter

1. Run engine to warm oil.

2. Park machine on a level surface.

3. Lower equipment to ground.

4. Move transmission control lever to N. Engage neutral

–UN–27MAR01
lock.

CAUTION: Prevent possible injury from

unexpected machine movement. Never rely on

T139286B
transmission control lever alone to keep
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always 1—Drain Valve T-Handle
engage park brake to hold machine.

5. Engage park brake.

6. Turn key switch to “Off”.

NOTE: Oil drain hose is located at lower left front corner

of fuel tank mount.

7. Turn T-handle (1) on drain valve counterclockwise.

Allow oil to drain into a container. Dispose of waste oil
properly.

Continued on next page HG31779,00001A5 –19–25NOV02–1/2

3-5-1 022808

PN=138
 Maintenance—After 100 Hours

8. Turn filter (1) counterclockwise to remove.

9. Clean mounting surface. Apply thin film of oil to gasket

of new filter.

NOTE: Before installing filter, to ensure proper lubrication

at start-up, fill the engine oil filter with engine oil.

10. Install new filter. Turn filter clockwise by hand until

gasket touches mounting surface.

–UN–16AUG01
11. Tighten 1/2—3/4 turn more.

12. Tighten drain valve.

T144885F
13. Remove filler cap (2).

14. Fill engine with oil. Approximate oil capacity with filter
1—Filter
is 38 L (10 gal). See Diesel Engine Oil. (Section 3-1.) 2—Filler Cap

15. Install filler cap.

16. Start engine and run at slow idle.

17. Check that engine oil pressure light on monitor goes

out and audible alarm stops immediately. If not, stop
engine immediately and find cause.

18. Stop the engine. Check oil level. The engine is full
when oil level is in the cross hatched area on the
dipstick.

19. Check for any leakage at filter. Tighten filter only

enough to stop leakage.

HG31779,00001A5 –19–25NOV02–2/2

3-5-2 022808

PN=139
 Maintenance—After 100 Hours

Change Transmission Oil

NOTE: Change after first 100 hours and then every 1000
hours.

1. Operate machine under load until transmission oil

reaches normal operating temperature.

2. Park machine on a level surface.

3. Lower bucket to ground.

4. Move transmission control lever to neutral “N”. Engage

neutral lock.

CAUTION: Prevent possible injury from

unexpected machine movement. Never rely on
transmission control lever alone to keep
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.

5. Engage park brake.

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before changing oil.

6. Install frame locking bar.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

7. Run engine at 1/2 speed for 2 minutes before stopping

to avoid damage to turbocharger. Release accelerator
pedal to slow idle.

8. Turn key switch to STOP. Let machine sit for

approximately 10 minutes.

Continued on next page HG31779,000014C –19–07OCT02–1/2

3-5-3 022808

PN=140
 Maintenance—After 100 Hours

9. Remove bottom guard, if equipped. Remove plug (A),

located inside hole in bottom guard, to drain oil. Allow
oil to drain into a container. Dispose of waste oil
properly.

10. Install drain plug.

–UN–12DEC96
11. Fill transmission with oil at filler tube (B). See
Transmission, Hydraulic System, Park Brake, and
Differential Oil. (Section 3-1.)

T103344B
Specification
Transmission Oil—Capacity
(Includes Filter) ........................................................................ 28 L (30 qt)

12. Start engine and run for 2 minutes.

13. Move transmission control lever to N and engage

neutral lock.

–UN–07OCT02
14. Check oil level with oil at operating temperature. Oil
must be between marks on sight gauge (C).

T159631D
A—Plug
B—Filler Tube
C—Sight Gauge

HG31779,000014C –19–07OCT02–2/2

3-5-4 022808

PN=141
 Maintenance—After 100 Hours

Replace Transmission Oil Filter

NOTE: Change after first 100 hours and then every 500
hours.

1. Operate machine under load until transmission oil

reaches normal operating temperature.

2. Park machine on a level surface.

3. Stop engine.

4. Turn filter (1) counterclockwise to remove.

5. Clean mounting surface. Apply thin film of oil to gasket

of new filter.

6. Install new filter. Turn filter clockwise by hand until

gasket touches mounting surface.

–UN–20MAR01
7. Tighten 1/2 to 3/4 turn more.

8. Start engine and run for 2 minutes.

T139862
9. Move transmission control lever to neutral "N", and
engage neutral lock.

1—Transmission Oil Filter

HG31779,000014B –19–07OCT02–1/2

10. Check oil level. Oil must be between HOT marks on

sight gauge (B). Add oil if necessary.

11. Check for leaks around the filter base. Tighten filter
only enough to stop leaks.
–UN–20SEP02

B—Sight Gauge
T159631C

HG31779,000014B –19–07OCT02–2/2

3-5-5 022808
PN=142
 Maintenance—Every 100 Hours
Grease Loader Linkage and Cylinder Pivots

–UN–20MAR01

–UN–21MAY96
T139815B

T101199
Four Points
Three Points, Right Side Shown

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before lubricating.

Lower bucket flat on ground.

Lubricate following 13 points until grease escapes around

seals. See Grease. (Section 3-1.)

Lubricate bucket/working attachment hinge pins every 10

hours when operating in severe conditions such as deep
mud, water, or snow. –UN–19MAY98
T101200

Six Points, Right Side Shown

OUOE003,00000B7 –19–21OCT02–1/1

3-5-1 022808

PN=143
 Maintenance—Every 100 Hours

Grease Front Steering Cylinder Pivots

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before lubricating.

–UN–21MAY96
Lubricate each point with three shots of grease. See
Grease. (Section 3-1.)

Grease daily when operating in severe conditions such as

T101202
deep mud, water or snow.
Two Points, Left Side Shown
A—Left Steering Cylinder (Head End)
B—Right Steering Cylinder (Head End)

–UN–03SEP96
T102520
TX,70,JC1466 –19–21OCT02–1/1

Grease Oscillating Rear Axle and Rear

Steering Cylinder Pivots

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame

–UN–24MAR98
locking bar before lubricating.

Lubricate each point with 10 shots of grease. See Grease.

(Section 3-1.) Grease daily when operating in severe
T114501
conditions such as deep mud, water, or snow.

A—Rear Axle Front Oscillating Pivot Four Points

B—Rear Axle Rear Oscillating Pivot
–UN–03SEP96
T103215

CED,OUOE002,1345 –19–21OCT02–1/1

3-5-2 022808

PN=144
 Maintenance—Every 100 Hours

Check Cab Fresh Air Filter—If Equipped

1. Open cab fresh air filter door by pulling up on lever (A)

to the left of the operator’s seat.

–UN–12DEC96
A—Lever

T105479B
CED,OUO1021,94 –19–18JUL02–1/2

2. Remove filter assembly by turning knob (A).

NOTE: If operating in dusty conditions, cab fresh air filter

should be checked and cleaned as necessary.

3. Release clips.

4. Remove filter. Replace if damaged.

5. Clean filter in one of these ways:

–UN–10SEP98
CAUTION: Prevent possible injury from flying
chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Reduce compressed air to

T117050
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 A—Knob
protection equipment including eye protection.

• Tap filter on a flat surface with the dirty side down.

• Use compressed air opposite to the normal air flow.
• Wash the filter in warm, soapy water. Flush the filter.
Let it dry before using the heater, defroster, or air
conditioner.

6. Remove dust from filter housing.

7. Install filter and filter duct work.

8. Install filter assembly. Close cab fresh air filter door.

CED,OUO1021,94 –19–18JUL02–2/2

3-5-3 022808
PN=145
 Maintenance—Every 100 Hours

Check Cab Recirculating Air Filter

NOTE: The cab recirculating air filter is located next to

the seat.

1. Loosen wing bolt (1) holding grille. Remove grille.

–UN–18SEP02
2. Remove filter.

T159520B
CAUTION: Prevent possible injury from flying
chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Reduce compressed air to
less than 210 kPa (2.1 bar) (30 psi) when using 1—Wing Bolt
for cleaning purposes. Clear area of bystanders,
guard against flying chips, and wear personal
protection equipment including eye protection.

3. Clean filter in one of these ways:

• Tap it on a flat surface with the dirty side down.

• Use compressed air opposite to the normal air flow.

4. Install filter.

5. Install grille.

HG31779,0000121 –19–18SEP02–1/1

3-5-4 022808

PN=146
 Maintenance—Every 250 Hours
Grease Front Driveline Sliding Joints

CAUTION: Prevent possible injury from

unexpected machine movement. Turn engine off
and lower bucket to ground before lubricating.

–UN–29OCT02
NOTE: To prevent plug loss, lubricate the machine when
it is fully articulated or half articulated and NOT in
the straight position.

T161066B
Install frame lock bar using hole (1) for articulated
position.

1—Frame Locking Bar

HG31779,0000174 –19–29OCT02–1/2

–UN–03SEP96
T102891
Lubricate until grease escapes around vent holes in NOTE: Grease daily when operating in deep mud,
drive shaft end. See Grease. (Section 3-1.) water, or snow.

HG31779,0000174 –19–29OCT02–2/2

3-6-1 022808
PN=147
 Maintenance—Every 250 Hours

Check Radiator Coolant Level

CAUTION: Prevent possible injury from hot

spraying coolant. DO NOT remove radiator filler
cap unless engine is cool. Then turn cap slowly
to the stop. Release air to relieve all pressure

–UN–01NOV88
before you remove cap.

1. Slowly remove cap. Coolant level must be at bottom of

the filler neck.

T6642EK
NOTE: If radiator coolant level is low, check for leaks on
radiator cap, and hose connections between
radiator and coolant recovery tank.

2. Add coolant, if necessary.

3. Install filler cap.

CED,OUO1021,97 –19–18JUL02–1/1

3-6-2 022808

PN=148
 Maintenance—Every 250 Hours

Change Engine Oil and Replace Filter

IMPORTANT: If fuel sulphur content exceeds 0.5

percent, change engine oil at 1/2 the
normal interval.

NOTE: If engine has not run 250 hours before the season
changes, change oil.

1. Run engine to warm oil.

–UN–27MAR01
2. Park machine on a level surface.

3. Lower equipment to ground.

T139286B
4. Move transmission control lever to N. Engage neutral
lock.
1—Drain Valve T-Handle
CAUTION: Prevent possible injury from
unexpected machine movement. Never rely on
transmission control lever alone to keep
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.

5. Engage park brake.

6. Turn key switch to “Off”.

NOTE: Oil drain hose is located at lower left front corner

of fuel tank mount.

7. Turn T-handle (1) on drain valve counterclockwise.

Allow oil to drain into a container. Dispose of waste oil
properly.

Continued on next page OUOE003,00000B9 –19–17AUG01–1/2

3-6-3 022808

PN=149
 Maintenance—Every 250 Hours

8. Turn filter (1) counterclockwise to remove.

9. Clean mounting surface. Apply thin film of oil to gasket

of new filter.

NOTE: Before installing filter, to ensure proper lubrication

at start-up, fill the engine oil filter with engine oil.

10. Install new filter. Turn filter clockwise by hand until

gasket touches mounting surface.

–UN–16AUG01
11. Tighten 1/2—3/4 turn more.

12. Tighten drain valve.

T144885F
13. Remove filler cap (2).

14. Fill engine with oil. Approximate oil capacity with filter
1—Filter
is 38 L (10 gal). See Diesel Engine Oil. (Section 3-1.) 2—Filler Cap

15. Install filler cap.

16. Start engine and run at slow idle.

17. Check that engine oil pressure light on monitor goes

out and audible alarm stops immediately. If not, stop
engine immediately and find cause.

18. Stop the engine. Check oil level. The engine is full
when oil level is in the cross hatched area on the
dipstick.

19. Check for any leakage at filter. Tighten filter only

enough to stop leakage.

OUOE003,00000B9 –19–17AUG01–2/2

3-6-4 022808

PN=150
 Maintenance—Every 500 Hours
Grease Rear Driveline Sliding Joint and
U-Joints

CAUTION: Prevent possible injury from

unexpected machine movement. Turn engine off

–UN–29OCT02
and lower bucket to ground before lubricating.

Install frame locking bar (1) using hole for articulated

position.

T161066B
1—Frame Locking Bar

Continued on next page HG31779,0000157 –19–22OCT02–1/2

3-7-1 022808

PN=151
 Maintenance—Every 500 Hours

–UN–03SEP96
T103426
–UN–09AUG96
T102890

Six Points

Lubricate each point until grease purges from each

CAUTION: Prevent possible injury from
cap. Lubricate daily or every 10 hours when operating
unexpected machine movement. Install
in deep mud, water, or snow.
frame locking bar before lubricating.

IMPORTANT: Potential U-joint damage may occur

if grease does not purge from each
cap.

HG31779,0000157 –19–22OCT02–2/2

3-7-2 022808

PN=152
 Maintenance—Every 500 Hours

Check Air Intake Hoses

Air Intake Hose

Check air intake hose (1) for cracks. Replace as

necessary.

–UN–15AUG01
Tighten clamps.

T139808C
1—Air Intake Hose

OUOE003,00000BA –19–10OCT01–1/2

Charge Air Cooler Hoses

Check connections and tubes between the turbocharger

compressor outlet and the charge air cooler and also
between the engine intake manifold and the charge air
cooler for cracks or leaks.

–UN–20MAR01
T139838
T139838

OUOE003,00000BA –19–10OCT01–2/2

3-7-3 022808
PN=153
 Maintenance—Every 500 Hours

Check Battery Electrolyte Level and

Terminals

CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.

NEVER check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.

ALWAYS remove grounded (-) battery clamp

first and replace it last.

Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.

Avoid the hazard by:

–UN–23AUG88
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is

TS203
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 15—30
minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do
not exceed 1.9 L (2 quarts).
3. Get medical attention immediately.

1. Remove battery box cover.

Continued on next page TX,75,DH1574 –19–28APR93–1/3

3-7-4 022808

PN=154
 Maintenance—Every 500 Hours

IMPORTANT: If water is added to batteries during

freezing weather, batteries must be
charged after water is added to prevent
batteries from freezing. Charge battery
using a battery charger or by running
the engine.

–UN–09SEP03
2. Fill each cell to within specified range with distilled
water. DO NOT overfill.

T6996DB
CAUTION: Prevent possible injury. ALWAYS
remove grounded (-) battery clamp first and
replace it last.

3. Disconnect battery clamps, grounded clamp first.

A—Battery Post
B—Fill Tube

–UN–09SEP03
C—Electrolyte Level Range

T6996DA
TX,75,DH1574 –19–28APR93–2/3

4. Clean battery terminals (A) and clamps with a stiff

brush.

5. Apply lubricating grease (B) around battery terminal

base only.

–UN–21OCT88
6. Install and tighten clamps, grounded clamp last.

A—Battery Terminal
B—Lubricating Grease

T6758AA
TX,75,DH1574 –19–28APR93–3/3

3-7-5 022808
PN=155
 Maintenance—Every 500 Hours

Replace Primary Fuel Filter

CAUTION: If engine has been running, engine

and fuel filter housing may be hot.

–UN–16AUG01
1. Clean entire top area of fuel filter assembly to keep
debris from entering fuel system.

2. Remove cap (1) from fuel filter housing.

T144885C
1—Cap

TX03679,00017F2 –19–26SEP01–1/4

NOTE: Relieve vacuum in filter housing by operating

hand primer until fuel filter “pops up”. If filter does
not “pop up” after about 30 strokes of primer,
insert a small screwdriver as shown to carefully
pry under filter flange to relieve vacuum in the
housing.

–UN–27MAY04
RG10303
TX03679,00017F2 –19–26SEP01–2/4

3. Remove filter element as shown. Hold filter suspended

straight up in top of housing to drain fuel from filter.

4. Dispose of used filter properly.

5. Drain fuel from water separator bowl.

NOTE: If sediment in bowl cannot be flushed out by

pumping primer, remove bowl to clean.
–UN–02SEP99

6. Clean sediment from water separator bowl. See Clean

Water Separator Bowl. (Section 3-3.)
RG10304

Continued on next page TX03679,00017F2 –19–26SEP01–3/4

3-7-6 022808
PN=156
 Maintenance—Every 500 Hours

IMPORTANT: Fuel level below the MIN indication may

result in trapped air in the filter causing
the engine to stall and not restart
without additional system purging. Fuel
level above the MAX indication may
cause fuel to overflow from the filter

–UN–02SEP99
housing during insertion of filter
element.

7. Pump primer until fuel reaches the MAX (A) level.

RG10305
8. Carefully insert new (dry) fuel filter into filter housing.

9. Install fuel filter cap and hand tighten. A—Maximum Level 63 mm (2-1/2 in.) From Top of
Housing
B—Minimum Level 127 mm (5 in.) From Top of
10. Pump primer at least 20 strokes. Housing

11. Start engine and run at slow idle for 5 minutes.

TX03679,00017F2 –19–26SEP01–4/4

3-7-7 022808

PN=157
 Maintenance—Every 500 Hours

Replace Primary Fuel Filter Strainer

IMPORTANT: Unit injectors are very sensitive to fuel

cleanliness, therefore the change
interval on the filters must be
maintained. If filter is not changed until
the engine power is reduced due to a
plugged filter, damage to the unit
injectors could occur.

–UN–16AUG01
1. Remove clamps (1).

2. Disconnect upper and lower hoses.

T144885E
3. Connect hoses to strainer (2) with arrow on filter
pointing toward primary fuel filter.

IMPORTANT: Bleed fuel system whenever the fuel

1—Clamp (2 used)
system has been opened up for service 2—Strainer
or engine start-up will be affected. The
procedure removes air from the system.

4. Bleed fuel system. See Bleed Fuel System. (Section

4-1.)

OUOE003,00000BC –19–17AUG01–1/1

3-7-8 022808

PN=158
 Maintenance—Every 500 Hours

Replace Hydraulic System Return Filters

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before changing filters.

1. Turn filters (1) counterclockwise to remove.

2. Clean mounting surface. Apply thin film of oil to gasket

of new filter.

–UN–20MAR01
3. Install new filters. Tighten each filter 3/4—1 full turn
after seal contacts mounting base.

T139860B
4. Fully loosen each filter element. Repeat step 3.

5. Start engine. Check for leaks around each filter base.

Tighten filters only enough to stop leaks. 1—Hydraulic System Return Filter (2 used)

6. Stop engine. Check oil level.

OUOE003,00000BD –19–14MAR01–1/1

Replace Hydraulic Reservoir Breather Filter

Hydraulic reservoir breather filter is located on back side

of reservoir under the hood.

1. Turn filter (1) counterclockwise to remove.

2. Install new filter.

1—Hydraulic Reservoir Breather Filter

–UN–07SEP01
T139861B

OUOE003,00000BE –19–14MAR01–1/1

3-7-9 022808
PN=159
 Maintenance—Every 500 Hours

Replace Transmission Oil Filter

1. Operate machine under load until transmission oil

reaches normal operating temperature.

2. Park machine on a level surface.

3. Stop engine.

4. Turn filter (1) counterclockwise to remove.

5. Clean mounting surface. Apply thin film of oil to gasket

of new filter.

6. Install new filter. Turn filter clockwise by hand until

gasket touches mounting surface.

7. Tighten 1/2 to 3/4 turn more.

8. Start engine and run for 2 minutes.

–UN–20MAR01
9. Move transmission control lever to neutral "N", and
engage neutral lock.

T139862
1—Transmission Oil Filter

HG31779,000014B –19–07OCT02–1/2

10. Check oil level. Oil must be between HOT marks on

sight gauge (B). Add oil if necessary.

11. Check for leaks around the filter base. Tighten filter
only enough to stop leaks.
–UN–20SEP02

B—Sight Gauge
T159631C

HG31779,000014B –19–07OCT02–2/2

3-7-10 022808
PN=160
 Maintenance—Every 500 Hours

Check Park Brake Oil Level

1. Remove Plug (A). Check oil level.

IMPORTANT: Oil level must be at bottom of check

plug on the side of the park brake. Too

–UN–14APR98
much oil can cause overheating. Too
little oil can cause bearing failure.

2. Add oil if necessary. Allow 2 minutes for oil to settle to

T114802
bottom of level plug.

3. Check oil level and install plug.

A—Plug

HG31779,000016B –19–28OCT02–1/1

Check Front Differential Oil Level—If

Equipped With Differential Lock Axle

CAUTION: Prevent possible injury from hot

spraying oil. Slowly loosen dipstick to relieve
any air pressure.

NOTE: Each differential housing has three sumps. Fill

center housing slowly to let oil drain into all
sumps. If machine has been driven, allow time for
oil to stabilize in each sump before checking.

1. Remove service door (B).

–UN–03SEP96
A—Drain Plug
B—Service Door

T101208

Continued on next page TX,80,JC1710 –19–21OCT02–1/2

3-7-11 022808
PN=161
 Maintenance—Every 500 Hours

2. Clean area surrounding dipstick.

3. Remove dipstick (C). Oil must be to FULL mark on

dipstick. If not, install dipstick and tighten.

4. Start engine.

5. Hold down differential lock pedal for 1 minute with

engine running at slow idle.

6. Stop engine.

–UN–21MAY96
7. Slowly remove dipstick. Oil must be to FULL mark on
dipstick. If not, install dipstick and repeat steps 3—5
until oil is to FULL mark.

T101209
8. If necessary, add oil to hydraulic reservoir. See
Transmission, Hydraulic System, Park Brake, and
Differential Oil. (Section 3-1.)
C—Dipstick
NOTE: If differential housing is overfilled, install dipstick
and tighten. Start engine and run at high idle
under load for several minutes. Turbo boost
pressure to differential should return excess oil to
hydraulic reservoir. Check differential oil level.

If oil level has lowered, continue to operate

machine. Oil level will stabilize.

If oil level remains overfilled or increases, see

your authorized dealer.

TX,80,JC1710 –19–21OCT02–2/2

3-7-12 022808

PN=162
 Maintenance—Every 500 Hours

Check Rear Differential Oil Level—If

Equipped With Differential Lock Axle

CAUTION: Prevent possible injury from hot

spraying oil. Slowly loosen dipstick to relieve

–UN–12DEC96
any air pressure.

NOTE: Each differential housing has three sumps. Fill

center housing slowly to let oil drain into all

T105480B
sumps. If machine has been driven, allow time for
oil to stabilize in each sump before checking.

1. Remove lower left engine side panel. D—Dipstick

2. Clean area surrounding dipstick.

3. Remove dipstick (D). Oil must be to FULL mark on

dipstick. If not, install dipstick and tighten.

4. Start engine.

5. Hold down differential lock pedal for 1 minute with

engine running at slow idle.

6. Stop engine.

7. Slowly remove dipstick. Oil must be to FULL mark on

dipstick. If not, install dipstick and repeat steps 3—5
until oil is to FULL mark.

8. If necessary, add oil to hydraulic reservoir. See

Transmission, Hydraulic System, Park Brake, and
Differential Oil . (Section 3-1.)

NOTE: If differential housing is overfilled, install dipstick

and tighten. Start engine and run at high idle
under load for several minutes. Turbo boost
pressure to differential should return excess oil to
hydraulic reservoir. Check differential oil level.

If oil level has lowered, continue to operate

machine. Oil level will stabilize.

If oil level remains overfilled or increases, see

your authorized dealer.

TX,80,JC1711 –19–11JUL01–1/1

3-7-13 022808

PN=163
 Maintenance—Every 500 Hours

Check Front Differential Oil Level—If

Equipped With Standard Axle

NOTE: Each differential housing has three sumps. Fill

center housing slowly to let oil drain into all
sumps. If machine has been driven, allow time for
oil to stabilize in each sump before checking.

1. Remove service door (B).

2. Clean area around dipstick.

A—Drain Plug
B—Service Door

–UN–03SEP96
T101208
TX,80,JC1712 –19–21OCT02–1/2

3. Remove dipstick (C).

4. Oil must be to FULL level on dipstick.

NOTE: Remove complete dipstick tube assembly for ease

of filling.

5. If necessary, add oil. See Transmission, Hydraulic

System, Park Brake, and Differential Oil. (Section 3-1.)

NOTE: If axle is hot and dipstick too warm to hold with

bare hands, the oil will expand and it is normal for
–UN–21MAY96

it to be up to 25 mm (1 in.) above FULL mark. Do

not adjust level. If oil level is above FULL mark,
see your authorized dealer.
T101209

6. Install dipstick.

C—Dipstick

TX,80,JC1712 –19–21OCT02–2/2

3-7-14 022808
PN=164
 Maintenance—Every 500 Hours

Check Rear Differential Oil Level—If

Equipped With Standard Axle

NOTE: Each differential housing has three sumps. Fill

center housing slowly to let oil drain into all

–UN–12DEC96
sumps. If machine has been driven, allow time for
oil to stabilize in each sump before checking.

1. Remove lower left engine side panel.

T105480B
2. Clean area around dipstick.

3. Remove dipstick (D). D—Dipstick

NOTE: Remove complete dipstick tube assembly for ease

of filling.

4. Oil must be to FULL level on dipstick.

5. If necessary, add oil. See Transmission, Hydraulic

System, Park Brake, and Differential Oil. (Section 3-1.)

NOTE: If axle is hot and dipstick too warm to hold with

bare hands, the oil will expand and it is normal for
it to be up to 25 mm (1 in.) above FULL mark. Do
not adjust level. If oil level is above FULL mark,
see your authorized dealer.

6. Install dipstick.

TX,80,JC1713 –19–21OCT02–1/1

3-7-15 022808

PN=165
 Maintenance—Every 1000 Hours
Replace Air Cleaner Dust Unloader Valve

NOTE: A missing, damaged, or hardened dust valve will

cause the air filter elements to be ineffective.

Replace dust unloader valve (1).

1—Dust Unloader Valve

–UN–20MAR01
T139810B
HG31779,0000138 –19–25SEP02–1/1

Replace Air Cleaner Elements

1. Remove cover.

2. Remove primary element (A).

–UN–12DEC96
3. Remove secondary element (B).

4. Clean inside of air cleaner canister.

T103190B
5. Install new elements making sure secondary element is
centered in canister.

6. Install cover.

A—Primary Element
B—Secondary Element –UN–12DEC96
T103189B

HG31779,00000A6 –19–08JUL02–1/1

3-8-1 022808
PN=166
 Maintenance—Every 1000 Hours

Clean Engine Crankcase Vent Tube

Remove clamp at valve cover.

Remove hose (1). Clean hose.

IMPORTANT: Do not pull on hose. Connector damage

may occur.

1—Engine Crankcase Vent Hose

–UN–07SEP01
T139861C
OUOE003,00000C2 –19–14MAR01–1/1

Check Radiator Hoses

Check hoses (1) for cracks and leaks. Replace if

necessary.

Tighten clamps.

–UN–05SEP01
1—Radiator Hoses

T144860C
TX03679,00017FA –19–15AUG01–1/1

3-8-2 022808
PN=167
 Maintenance—Every 1000 Hours

Change Transmission Oil

1. Operate machine under load until transmission oil

reaches normal operating temperature.

2. Park machine on a level surface.

3. Lower bucket to ground.

4. Move transmission control lever to neutral “N”. Engage

neutral lock.

CAUTION: Prevent possible injury from

unexpected machine movement. Never rely on
transmission control lever alone to keep
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.

5. Engage park brake.

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before changing oil.

6. Install frame locking bar.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

7. Run engine at 1/2 speed for 2 minutes before stopping

to avoid damage to turbocharger. Release accelerator
pedal to slow idle.

8. Turn key switch to STOP. Let machine sit for

approximately 10 minutes.

Continued on next page HG31779,000014C –19–07OCT02–1/2

3-8-3 022808

PN=168
 Maintenance—Every 1000 Hours

9. Remove bottom guard, if equipped. Remove plug (A),

located inside hole in bottom guard, to drain oil. Allow
oil to drain into a container. Dispose of waste oil
properly.

10. Install drain plug.

–UN–12DEC96
11. Fill transmission with oil at filler tube (B). See
Transmission, Hydraulic System, Park Brake, and
Differential Oil. (Section 3-1.)

T103344B
Specification
Transmission Oil—Capacity
(Includes Filter) ........................................................................ 28 L (30 qt)

12. Start engine and run for 2 minutes.

13. Move transmission control lever to N and engage

neutral lock.

–UN–07OCT02
14. Check oil level with oil at operating temperature. Oil
must be between marks on sight gauge (C).

T159631D
A—Plug
B—Filler Tube
C—Sight Gauge

HG31779,000014C –19–07OCT02–2/2

3-8-4 022808

PN=169
 Maintenance—Every 1000 Hours

Grease Frame Hinge Pivots

CAUTION: Prevent possible injury from

unexpected machine movement. Always install
frame locking bar.

Lubricate each point with a minimum of three shots of

grease and until grease escapes from around the seals.
See Grease. (Section 3-1.)

–UN–18FEB98
T113669
Two Points
CED,OUO1021,115 –19–18OCT02–1/1

Change Park Brake Oil

IMPORTANT: Oil must be at level mark. Too much oil

can cause overheating; too little can
cause bearing failure.

–UN–07NOV96
Specification
Park Brake Oil—Capacity ................................................. 600 mL (20 oz)

1. Remove plug (B). T104817

2. Drain oil into a container. Dispose of waste oil properly.

3. Install plug. A—Plug

B—Plug
4. Remove plug (A) and add oil. See Transmission,
Hydraulic System, Park Brake, and Differential Oil.
(Section 3-1.) Allow oil to settle for approximately 2
minutes after filling.

5. Drain or add oil if necessary.

6. Install plug.

HG31779,000016D –19–28OCT02–1/1

3-8-5 022808
PN=170
 Maintenance—Every 1000 Hours

Check Park Brake

1. Start engine.

CAUTION: Prevent possible injury from sudden

machine stop. Fasten seat belt for this check.

–UN–11MAY98
2. Fasten seat belt.

T115292
3. Move park brake switch (A) to OFF, and move
transmission control lever to 1st gear forward.

4. Drive machine at 3 mph and move park brake switch A—Park Brake Switch
to ON. Machine must stop within 2 m (6 ft), and
transmission must shift to neutral.

5. If repair is necessary, see your authorized dealer.

TX,85,JC1488 –19–12JAN06–1/1

3-8-6 022808

PN=171
 Maintenance—Every 2000 Hours
Check and Adjust Engine Valve Lash and
Electronic Injector Preload

See your authorized dealer.

TX03679,00017EF –19–08FEB07–1/1

3-9-1 022808

PN=172
 Maintenance—Every 3000 Hours
Change Hydraulic System Oil

1. Lower bucket to ground.

2. Stop engine.

–UN–17SEP02
3. Turn key switch to “On”.

NOTE: Return-to-carry (A) must be OFF for float detent to

operate.

T159423I
4. Move hydraulic control lever to float detent position.
One Lever Design

CAUTION: Prevent possible injury from

unexpected boom movement. The bucket may
“jump up” when ride control switch is turned
ON. Clear all bystanders from area.

5. Cycle ride control switch (B) from OFF to ON.

–UN–27JUN02
6. Push pilot enable/boom down switch (C) to release
accumulator pressure.

T156774G
7. Turn key switch “Off”.

Two Lever Design

A—Return-to-Carry Switch
B—Ride Control Switch
C—Pilot Enable/Boom Down Switch

HG31779,00000B9 –19–18JUL02–1/4

8. Remove hydraulic reservoir filler cap (A).

A—Hydraulic Reservoir Filler Cap

–UN–19FEB97
T107063

Continued on next page HG31779,00000B9 –19–18JUL02–2/4

3-10-1 022808
PN=173
 Maintenance—Every 3000 Hours

9. Install hose on hydraulic reservoir drain valve (A).

Loosen valve. Allow oil to drain into a container.
Dispose of waste oil properly.

10. Flush reservoir with diesel fuel.

–UN–12DEC96
11. Tighten drain valve.

12. Fill reservoir. Approximate capacity is 144 L (38 gal).

See Transmission, Hydraulic System, Park Brake,

T103644B
and Differential Oil. (Section 3-1.)

Specification
Hydraulic Reservoir—Capacity............................................ 144 L (38 gal) A—Reservoir Drain Valve

HG31779,00000B9 –19–18JUL02–3/4

13. Install filler cap (A).

14. Check oil level in sight glass (B). Oil should be in

FULL range.

A—Hydraulic Reservoir Filler Cap

B—Sight Glass

–UN–19FEB97
T101195

HG31779,00000B9 –19–18JUL02–4/4

3-10-2 022808
PN=174
 Maintenance—Every 3000 Hours

Clean Hydraulic System Strainer

1. Remove hydraulic reservoir filler cap (A).

2. Remove snap ring.

3. Remove strainer (B) and clean with solvent.

4. Install strainer and snap ring.

5. Replace cap.

A—Filler Cap

–UN–23MAR98
B—Strainer

T114483
CED,OUO1021,184 –19–18MAR98–1/1

Replace Differential Lock Return Filter(s)—If

Equipped

1. Remove hydraulic reservoir filler cap (A).

2. Remove cap screws from reservoir cover (B) and

remove cover.

3. Remove hydraulic strainer (C).

A—Hydraulic Reservoir Filler Cap

B—Reservoir Cover
C—Hydraulic Strainer

–UN–21MAY96
T101287
Continued on next page TX,87,JC1495 –19–09AUG96–1/2

3-10-3 022808
PN=175
 Maintenance—Every 3000 Hours

4. Turn filter(s) (D) counterclockwise to remove.

5. Install new filter(s). Turn filter(s) clockwise by hand

until tight.

6. Inspect cover gasket (E). Replace if necessary.

–UN–21MAY96
7. Install cover, cap screws, and filler cap.

D—Differential Lock Return Filter(s)

T101288
E—Cover Gasket

TX,87,JC1495 –19–09AUG96–2/2

Change Front and Rear Differential Oil

CAUTION: Prevent possible injury from hot

spraying oil. Slowly loosen dipstick to relieve
any air pressure.

1. Remove drain plug (A). Allow oil to drain into a

container. Dispose of waste oil properly.

NOTE: It is normal for differential lock axles to be filled

approximately 1—2 L (1—2 qt) above brake
inspection plug.

2. Install drain plug.

–UN–03SEP96
3. Remove service door (B) and open lower left engine
side panel. T101208

A—Drain Plug
B—Service Door
Front Differential Shown

Continued on next page TX,87,JC1731 –19–13JAN06–1/2

3-10-4 022808
PN=176
 Maintenance—Every 3000 Hours

4. Remove dipsticks and dipstick tubes.

5. Add oil slowly through port on front differential (C) and

rear differential (D).

Specification
744J—Differential Oil (Each) ............................................................... 46 L
48.5 qt
744J—With Optional Wide Axle—
Differential Oil (Each) .......................................................................... 49 L
52 qt
824J—Differential Oil (Each) ............................................................... 46 L
49 qt

–UN–21MAY96
NOTE: Each differential housing has three sumps. Fill
center housing slowly so oil drains into all sumps.

T101209
6. Install dipstick tubes. Check oil level at dipsticks.

7. Repeat steps 4 and 5 until FULL mark on dipstick is Front Differential

reached.

8. Install dipstick tubes and dipsticks.

9. Install service door and engine side panel.

–UN–12DEC96
C—Dipstick
D—Dipstick

T105480B
Rear Differential

TX,87,JC1731 –19–13JAN06–2/2

3-10-5 022808

PN=177
 Miscellaneous—Machine
Draining the Cooling System

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns

–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.

TS281
1. Check hoses (2) for cracks and leaks. Replace if
necessary.

2. Tighten clamps.

3. Check radiator, oil cooler, and charge air cooler for dirt,
damage, leaks, and loose or broken mountings. Clean

–UN–16AUG01
radiator, oil cooler, and charge air cooler fins.

4. Install hose or drain valve (3) and place in container.

T144860B
5. Turn drain valve counterclockwise to open. Allow
coolant to drain into a container. Approximate cooling
system capacity is 38 L (40 qt). Dispose of used
coolant properly.

1—Engine Coolant Drain Valve

2—Hose (2 used)
3—Radiator Drain Valve

–UN–20MAR01
T138034C

Continued on next page OUOE003,00000C4 –19–31OCT02–1/2

4-1-1 022808

PN=178
 Miscellaneous—Machine

6. Turn drain valve (1) counterclockwise to drain engine

block. Allow coolant to drain into a container. Dispose
of used coolant properly.

1—Drain Valve

–UN–12OCT01
T144885H
OUOE003,00000C4 –19–31OCT02–2/2

Cooling System Fill and Deaeration Procedure

IMPORTANT: Use only permanent-type low silicate 2. Stop engine. Allow coolant to cool.
ethylene glycol base antifreeze in
coolant solution. Other types of 3. Check coolant level at recovery tank.
antifreeze may damage cylinder
seals. 4. Repeat steps 1—3 until recovery tank coolant level
is repeatedly at the same level (stabilized).
FREEZING TEMPERATURES: Fill with
permanent-type, low silicate, ethylene glycol antifreeze NOTE: The level of the coolant in the cooling system
(without stop-leak additive) and clean, soft water. Add MUST BE repeatedly checked after all drain
TY16004 John Deere Coolant Conditioner or and refill procedures to insure that all air is out
equivalent. of the system which allows the coolant level to
stabilize. Check coolant level only when the
Fill engine is cold.

Fill radiator to the bottom of the radiator fill neck. 5. If necessary, fill recovery tank to FULL mark.
Cooling system capacity is approximately 38 L (40
Fill the recovery tank to the FULL mark. qt).

Deaeration Specification
Cooling System—Capacity ........................................................... 38 L
40 qt
The cooling system requires several warm-up and cool
down cycles to deaerate. It will NOT deaerate during
6. Install recovery tank and radiator caps.
normal operation. Only during warm-up and cool down
cycles will the system deaerate.
Coolant level must be at bottom of filler neck.
1. Start engine. Run engine until coolant reaches a
warm temperature.

OUOE003,00000C5 –19–13AUG01–1/1

Replacing Engine Vibration Damper

The engine vibration damper should be replaced every

4500 hours or 5 years. See your authorized dealer.
TX03679,00017F8 –19–13AUG01–1/1

4-1-2 022808
PN=179
 Miscellaneous—Machine

Adjusting Pilot Controller Tower

1. Remove two cap screws (1) from front load center

door. Open door.

2. Loosen four cap screws (2) under pilot controller tower.

–UN–29OCT02
3. Move tower to desired position.

4. Tighten cap screws (2).

T161077B
Specification
Cap Screws—Torque ................................................... 36.6 N•m (27 lb-ft)

5. Close front load center door. Install cap screws (1).

1—Cap Screws (2 Used)

2—Cap Screws (4 Used)

–UN–29OCT02
T161078B
HG31779,0000173 –19–29OCT02–1/1

Checking Fuel Tank Vent Hose

IMPORTANT: If fuel filler drain hose is clogged, the

fuel tank could collapse.

1. Remove clamp (A).

–UN–11MAY98
2. Check hose for debris. If clogged, clean hose or
replace.
T115326
3. Install clamp.

A—Clamp

HG31779,0000154 –19–18OCT02–1/1

4-1-3 022808
PN=180
 Miscellaneous—Machine

Bleeding Fuel System

NOTE: Under normal conditions, fuel system bleeding is

not required. Priming system with hand primer (B)
is normally sufficient. If necessary to bleed the
system, use the following procedure.

–UN–02SEP99
1. Drain water and contaminates from clear water
separator sediment bowl by opening drain valve (C)
and operating primer (B) until bowl is clear of water.

RG10309
2. Attach an open line to diagnostic port (A) and place
end of line in suitable container for diesel fuel.
3. Pump hand primer (B) until a steady flow of fuel Bleed Fuel System
(without bubbles) comes out of line. A—Diagnostic Port
B—Hand Primer
NOTE: It can take up to 200 strokes until fuel comes out C—Water Drain Valve
steadily.

4. Disconnect line from diagnostic port (A).

5. Pump hand primer (B).

NOTE: If engine has been run out of fuel, 200 strokes will
be necessary.

6. Start engine and run for five minutes.

NOTE: If engine does not start after 20 seconds of

cranking, pump hand primer an additional 100
strokes, and attempt to start engine again.

DPSG,RG40854,356 –19–29OCT02–1/1

4-1-4 022808

PN=181
 Miscellaneous—Machine

Cleaning Water Separator Bowl

IMPORTANT: Use the least amount of force

necessary with strap wrench when
removing and installing separator bowl
to prevent plastic bowl from cracking.

1. Disconnect wiring connector from water-in-fuel sensor.

–UN–13SEP99
2. Drain fuel from separator bowl.

3. Position a strap wrench (A) as close as possible to top

edge of separator bowl. While applying pressure with

RG10351
strap wrench, grip bowl and twist with other hand, as
shown, to remove bowl.

4. Clean water separator bowl. A—Strap Wrench

5. Install separator bowl and tighten by hand until seal

makes contact.

Specification
Water Separator Bowl-to-Filter
Housing—Torque.............................................................................. 6 N•m
55 lb-in.

6. Connect wiring connector to water-in-fuel sensor.

7. Remove cap. Lift filter up until fuel level can be

observed.

HG31779,00001A4 –19–25NOV02–1/2

8. Pump primer until fuel is within 6 inches of filter

canister top.

9. Press filter to seal.

10. Install filter cap.

–UN–02SEP99

11. Pump primer at least 20 strokes.

12. Start engine. Run engine at slow idle for 5 minutes.

RG10305

A—Maximum Level 63 mm (2-1/2 in.) From Top of

Housing (New filter)
B—Minimum Level 152 mm (6 in.) from Top of
Housing (Reused Filter)

HG31779,00001A4 –19–25NOV02–2/2

4-1-5 022808
PN=182
 Miscellaneous—Machine

Checking Fire Extinguisher—If Equipped

IMPORTANT: Dry powder has a tendency to pack in

the bottom of an extinguisher.

Before using extinguisher (A), turn it

–UN–17FEB98
upside down and shake it until you feel
the powder move.

Check gauge. If fire extinguisher is not fully charged,

T113598
charge or replace it.

NOTE: The fire extinguisher must be charged or replaced

after any use. A—Fire Extinguisher

CED,OUO1021,79 –19–12MAR98–1/1

Precautions for Alternator and Regulator

When batteries are connected, follow these rules: 6. Connect batteries or a booster battery in the correct
polarity (positive [+] to positive [+] and negative [-]
1. Disconnect negative (-) battery cable when you to negative [-]).
work on or near alternator or regulator.
7. Do not disconnect the batteries when engine is
2. DO NOT TRY TO POLARIZE ALTERNATOR OR running and alternator is charging.
REGULATOR.
8. Disconnect battery cables before you connect
3. Be sure alternator wires are correctly connected battery charger to the batteries. If machine has
BEFORE you connect batteries. more than one battery, each battery must be
charged separately.
4. Do not ground alternator output terminal.

5. Do not disconnect or connect any alternator or

regulator wires while batteries are connected or
while alternator is operating.

04T,90,C151 –19–20JUL92–1/1

4-1-6 022808
PN=183
 Miscellaneous—Machine

Handling, Checking And Servicing Batteries

Carefully

CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.

–UN–23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.

TS204
Always remove grounded (-) battery clamp first
and replace it last.

Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize
the acid.

–UN–23AUG88
3. Flush your eyes with water for 15—30
minutes. Get medical attention immediately.

If acid is swallowed:
TS203
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do
not exceed 1.9 L (2 quarts).
3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.

Continued on next page TX03679,0001788 –19–11MAY01–1/3

4-1-7 022808

PN=184
 Miscellaneous—Machine

If electrolyte spills on the floor, use one of the following

mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda
in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia
in 4 L (1 gal) water.

IMPORTANT: Do not overfill the battery cells.

Check the specific gravity of electrolyte in each battery

cell.

TX03679,0001788 –19–11MAY01–2/3

See your authorized dealer for JT05460 SERVICEGARD

battery and coolant tester. Follow directions included with
the tester.

A fully charged battery will have a corrected specific

gravity reading of 1.260. If the reading is below 1.200,

–UN–10NOV88
charge the battery.

T85402
SERVICEGARD is a trademark of Deere & Company TX03679,0001788 –19–11MAY01–3/3

Using Battery Charger

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). Disconnect battery

–UN–23AUG88
ground (—) clamp before you charge batteries
in the machine to prevent damage to electrical
components.

TS204
IMPORTANT: Do not use a battery charger as a
booster if a battery has a 1.150 specific
gravity reading or lower. Turn off
charger before connecting or
disconnecting it.

A battery charger may be used as a booster to start

engine.

TX,FF,121 –19–15MAR93–1/1

4-1-8 022808
PN=185
 Miscellaneous—Machine

Removing and Installing Batteries

CAUTION: To prevent injury from battery covers

dropping, remove when servicing or replacing
batteries. Hinge is in place to aid in removal
only. Cover must not be held or propped open
during servicing.

NOTE: Your machine is equipped with a negative ground

electrical system. It uses two 12-volt batteries. If

–UN–20MAR01
one of the two batteries fails, both batteries must
be replaced.

IMPORTANT: Turn off master shut-off before

T139946B
disconnecting cables.

1. Remove left side battery cover. Battery—Left Side

CAUTION: To prevent injury from explosion or

fire, disconnect the left side battery first
regardless of which battery is being removed.

2. Disconnect negative (-) battery cable (2) first, then

positive (+) battery cable (1).

3. Remove nuts (3), washers, and hold-down bracket (4).

–UN–20MAR01
4. Lift battery out of compartment.

5. Remove right side battery cover.

T139927B
6. Disconnect both battery cables.

7. Remove nuts (6), washers, and hold-down bracket (7).

Battery—Right Side

8. Replace parts as necessary. 1—Positive (+) Battery Cable

2—Negative (-) Battery Cable
9. Install left side battery. Connect cables. 3—Nut (2 used)
4—Hold-Down Bracket
5—Battery Cable (2 used)
10. Install right side battery. Connect positive (+) battery 6—Nut (2 used)
cable, then negative (-) battery cable. 7—Hold-Down Bracket

11. Install battery covers.

OUOE003,00000C6 –19–15MAR01–1/1

4-1-9 022808

PN=186
 Miscellaneous—Machine

Replacing Fuses

–UN–06JUL00
T103541C
One Lever Design

–UN–29OCT02
T160038B
Two Lever Design

A—Fuse Box

Continued on next page HG31779,0000132 –19–20SEP02–1/2

4-1-10 022808

PN=187
 Miscellaneous—Machine

K25 K27 K17 Rear Wiper K13

Drive Light Hi-Beam Light Return to Park Not Return to Dig
Relay Relay Relay Used Relay
AT162863 AT162863 AT162863 AT162863

K23 Left K28 K18 Rear wiper K15 Front Wiper K19 K22
Not Signal/Flasher Brake Light Intermittent Return to Park Main Blower
Used Horn Relay
Relay Relay Relay Relay Relay AT162863
AT206685 AT162863 AT162863 AT162863 AT162863
K24 Right K32 K16 Front Wiper
Not Signal/Flasher Detent Enable Not Intermittent Not Not
Used Relay Relay Used Relay Used Used
AT206685 AT162863 AT162863
Rear Wiper Motor Cab Work Light Pressurizer Engine Controller Power for BHKO, RTD,
10 AMP Fuse Motor Switched RTC Switch
F18 57M 7121
F29 10 AMP CB
T103463
F20 7.5 AMP Fuse F5 7.5 AMP FUSE 5 AMP Fuse F15
P33 (ACC) P45 (ACC) A19 99M 7064 (ACC) P08 99M 7065 (IGN) P11 57M 7125 (IGN)
K31 Trans Controller CCU 12V
Not Neutral Start
Ride Control Front Wiper Motor Circuit Switched Unswitched Not
F17 10 AMP Fuse Used F3 5 AMP Fuse
F12 5 AMP Fuse 5 AMP Fuse F9
Relay P34 57M 7121 (ACC) P01 57M 7125 (ST) P24 57M 7125 (IGN) P31
57M 7125
(12V BATT) Used
AT162863 Ride
Drive & Hi-Beam Light Pilot Enable
Spare
Control Horns Ignition
F30 7.5 AMP Fuse F25 10 AMP CB F21 7.5 AMP Fuse F16 7.5 AMP Fuse 5 AMP Fuse F34
T103463 99M 7064 99M 7064 57M 7125 (IGN)
J01 99M 7064 (ACC) P40 (BATT) P36 (ACC) P28 (IGN) P47

Power for Pressure Turn Signal/Flasher Spare Blower Motor Monitor Display
Switches Light Accessory 25 AMP Fuse Switched
F10 5 AMP Fuse F22 7.5 AMP Fuse F33 5 AMP Fuse F19 99M 7069 5 AMP Fuse F7
P32 57M 7125 (ACC) P37 99M 7064 (BATT) P49 57M 7125 (ACC) P10 (BATT) P05 57M 7125 (IGN)

Brake Light Seat Adjust, Dome Light, Boom CCU 28 V

Tail & Marker Light Lighter Down & Radio
Switched
F24 7.5 AMP Fuse F27 7.5 Amp Fuse F32 10 AMP Fuse F28 Unswitched
7.5 AMP Fuse 7.5 AMP Fuse F11
99M 7064 (ACC) 99M 7064 (BATT)
P39 P44 P48 57M 7121 (ACC) P14 99M 7064 (BATT) P25 99M 7064 (IGN)
K30 Ride K21 Secondary
Control Boom Diff Lock, Spare Rotary Beacon Converter Park Brake, Steering
F14 Pin Disc Solenoid F35 F26 F31 Unswitched Back-up Alarm F13
Solenoid 5 AMP Fuse
15 AMP Fuse
99M 7065
10 AMP Fuse
15 AMP Fuse 5 AMP Fuse
(Relay Coil)
57M 7121
Relay P42 57M 7125 (ACC) P35 (BATT) P41 (ACC) P16 99M 7065 (BATT) P26 57M 7125 (IGN) Relay
AT162863 Power for Rocker Engine Controller Alternator Monitor & Trans Controller Start Aid,
AT162863
F23 Switches F6 Unswitched F1 Excitation
F4 Unswitched Converter & Sec. Strg F2
5 AMP Fuse 10 AMP Fuse 7.5 AMP Fuse 5 AMP Fuse 10 AMP Fuse
P27 57M 7125 (ACC) P06 57M 7121 (BATT) J07 99M 7064 (IGN) P02 57M 7125 (BATT) P04 57M 7121 (IGN)

K6 K1 K5 K10 K4

–19–24OCT02
Accessory Neutral Start Accesory Back-Up Ignition
Relay #2 Relay Relay #1 Relay Relay
AT162863 AT162863 AT162863 AT162863 AT162863

T159002
T159002

IMPORTANT: Install fuses with correct amperage The fuse box (A) is in the electrical load center on the
rating to prevent electrical system right side (outside) of the cab. Both fuses and circuit
damage from overload. breakers are located in the load center.

HG31779,0000132 –19–20SEP02–2/2

4-1-11 022808
PN=188
 Miscellaneous—Machine

Fuse (Blade-Type) Color Codes

Amperage Rating Color

1 Black
3 Violet
4 Pink
5 Tan
7-1/2 Brown
10 Red
15 Light Blue
20 Yellow
25 Natural (White)
30 Light Green

04T,90,J22 –19–28SEP92–1/1

Resetting Circuit Breakers

Air conditioning system contains two circuit breakers. If

circuit breakers open because of a short circuit or
overloading, air conditioner will shut off.

Turn off air conditioning switch. Wait a couple of minutes

before restarting, to allow a cooling off period. Circuit
breaker will reset itself. If circuit breaker opens repeatedly,
see your authorized dealer.

04T,90,C155 –19–12JUL01–1/1

4-1-12 022808

PN=189
 Miscellaneous—Machine

Replacing Halogen Bulbs

IMPORTANT: To get the correct lighting pattern, lens

must be installed so the word “TOP” is
on top when lamp is installed so wider
section is on top when lamp is

–UN–17APR89
installed.

Before disassembling, remember how bezel and lens are

installed with respect to mounting stud.

T5894AG1
–UN–20OCT88
T5894AI1
Continued on next page TX,90,RR,1725 –19–11MAR94–1/2

4-1-13 022808

PN=190
 Miscellaneous—Machine

1. Remove four screws (H) to remove bezel (G) and lens

(F).

2. Disconnect wiring lead and release retainer clip to

remove bulb (D).

–UN–19OCT88
3. To disconnect ground wiring lead, push tab up, then
pull connector from terminal.

IMPORTANT: Do not touch the halogen bulb with

T6249AU
bare hands. Oil and moisture may
cause premature bulb failure. Clean
bulb using a soft, oil-free cloth and
alcohol. A—Flange Nut
B—Lock Washer
C—Housing
4. Install new bulb so square notch is aligned with square D—Bulb
tab on reflector back. E—Gasket
F—Lens
5. Install retainer clip into locking tabs on reflector back. G—Bezel
H—Screw
6. Connect wiring leads. Check wiring leads are free of
clip.

7. Install lens assembly (F) in housing (C) making sure

wires are not crimped, or keeping lens assembly from
seating on gasket.

8. Install bezel so wider section is on top. Sealing flange

must be inside housing on all four sides before
tightening screws.

9. Tighten screws alternately. Do not overtighten as

screws may strip out plastic.

TX,90,RR,1725 –19–11MAR94–2/2

4-1-14 022808

PN=191
 Miscellaneous—Machine

Checking Neutral Start System

Check the neutral start system to ENSURE that the

CAUTION: Avoid possible injury or death.
machine:
DO NOT attempt to start machine unless you
are sitting in operator’s seat with the
1. WILL start with the transmission control lever in
transmission control lever in neutral “N”
neutral “N” position.
position. DO NOT bypass or disable any of
the starting system parts.
2. WILL NOT start with the transmission control lever
in forward “F” or reverse “R” position.
Engage park brake before attempting to start
engine.
If starting system fails to operate correctly, have your
authorized dealer repair the system immediately.
This machine’s neutral start switch is activated by the
transmission Electronic Control Unit (ECU).

TX,90,JC1580 –19–20AUG96–1/1

Servicing Air Conditioning System—If Equipped

1. Check compressor belt. 5. Check blowers for correct operation.

2. Check compressor clutch engagement. 6. Check the condenser core to see that it is not
partially or completely clogged with dirt or trash.
3. Check evaporator core for clogging. Clean with compressed air or water when needed.

4. Check air intake filters for clogging. 7. Run air conditioning system for several minutes.

OUOE003,00000C8 –19–15MAR01–1/1

Welding On Machine

IMPORTANT: Disconnect battery ground strap or turn

battery disconnect switch to “OFF” to
prevent voltage spikes through
alternator or monitor.

Connect welder ground clamp close to

each weld area so electrical current
does not arc inside any bearings,
bushings or pins.

NOTE: Machine is adequately grounded. It is not

necessary to disconnect any controllers
(microprocessors).

TX,90,JC1603 –19–29AUG96–1/1

4-1-15 022808
PN=192
 Miscellaneous—Machine

External Service Brake Inspection

CAUTION: Prevent possible injury from hot

spraying oil. Slowly loosen plug to relieve any
air pressure.

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.

TX,90,JC263 –19–29NOV94–1/4

1. Remove brake inspection port plug (A).

A—Port Plug

–UN–25OCT88
T6523BZ
TX,90,JC263 –19–29NOV94–2/4

2. Inspect the brake linings (A) on brake disk.

A—Brake Lining

–UN–25OCT88
T6138AZ

Continued on next page TX,90,JC263 –19–29NOV94–3/4

4-1-16 022808
PN=193
 Miscellaneous—Machine

3. Remove axle housing and replace brake disc if oil

grooves (B) on facing material are no longer visible.

4. If further inspection of brake elements or replacement

of brake linings is necessary, see your authorized
dealer.

B—Oil Grooves

–UN–03DEC93
T8137AC
TX,90,JC263 –19–29NOV94–4/4

4-1-17 022808

PN=194
 Miscellaneous—Machine

Checking Brake Accumulators

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten

–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.

1. Start engine.

2. Run engine for one minute at slow idle. Apply brake

pedal four or five times.

3. Stop engine.

4. Turn key switch to ON position.

OUOE003,00000C9 –19–15MAR01–1/2

NOTE: Accumulators are precharged and must be

replaced, not recharged.

5. Apply brake pedal. The brake low pressure indicator

light may come on after three to four full brake
applications. The indicator light will stay on 2—3
seconds after each application and then go off. After
six to seven applications, indicator light will stay on.

If brake light comes on with less than three

–UN–20MAR01

applications, individual accumulators (1) should be

replaced.

6. Repeat procedure three times to ensure accurate

T139953B

results.

1—Brake Accumulator (2 used)

OUOE003,00000C9 –19–15MAR01–2/2

4-1-18 022808
PN=195
 Miscellaneous—Machine

Checking Ride Control Accumulator—If

Equipped

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before

–UN–23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure

X9811
fluids.

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,

–UN–23AUG88
or other knowledgeable medical source.

CAUTION: The boom will jump upward during

this check. Make sure area around bucket is

X9811
clear.

1. Start engine.

2. Push ride control switch (1) to “Off” position.

3. Raise boom to maximum height and hold control lever

over relief for two seconds.

–UN–17SEP02
4. Lower boom and bucket to ground and stop engine.
Put boom control lever in neutral.

T159423D
1—Ride Control Switch

One Lever Design

–UN–18JUL02
T156774K

Two Lever Design

Continued on next page OUOE003,00000CA –19–15OCT02–1/2

4-1-19 022808

PN=196
 Miscellaneous—Machine

NOTE: When ride control switch is in “A” (automatic)

position, ride control works at 6 km/h (3.7 mph) or
above.

5. Push ride control switch to center position. Boom will

jump upward, approximately 100 mm (4.0 in.) as
accumulator (A) pressure is released.

6. If ride control accumulator has lost gas charge, see

your authorized dealer.

A—Accumulator

–UN–20MAR98
T114389
OUOE003,00000CA –19–15OCT02–2/2

4-1-20 022808

PN=197
 Miscellaneous—Machine

Bleeding Brakes

CAUTION: Escaping fluid under pressure can

penetrate skin causing serious injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before

–UN–23AUG88
applying pressure. Keep hands and body away
from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your

X9811
hand.

If ANY fluid is injected into skin, it must be

surgically removed within a few hours by a
doctor familiar with this type of injury or
gangrene may result.

NOTE: Two people are required to bleed brake system

oil, one to operate brake valve and the other to
open and close bleed screws.

1. Install frame locking bar.

2. Start engine and run at slow idle.

3. Push and hold brake pedal down until brake bleeding

procedure is complete.

TX,DH,114 –19–06JUN91–1/2

4. Put a clear plastic tube on bleed screw (A) to route

flow to hydraulic reservoir filler tube or to a container.

5. Open one bleed screw on differential and axle

assembly until hydraulic oil starts to flow. Close bleed
screw when oil is free of air.
–UN–12DEC96

6. Repeat steps 2—4 for each bleed screw (two bleed

screws on each differential).
T103358B

7. Release brake pedal and stop engine.

8. Check hydraulic oil level. See Check Hydraulic Oil

Level in Maintenance—Every 10 Hours or Daily A—Bleed Screw
chapter.

TX,DH,114 –19–06JUN91–2/2

4-1-21 022808
PN=198
 Miscellaneous—Machine

Radiator, Oil Cooler, and Charge Air Cooler

External Cleaning Procedure

1. If dust or debris is light, clean oil cooler by blowing air

through the fins. Do not exceed 6 bar (90 psi). Blow air
straight through fins to avoid bending them.

–UN–17OCT02
2. If air fails to clean the oil cooler, use a high-pressure
washer with soap and water. Direct water straight
through fins to avoid bending them.

T160597
Specification
Water—Pressure ............................................................. 48 bar maximum
700 psi 1—Charge Air Cooler
2—Hydraulic Oil Cooler
3—Radiator
4—Transmission Oil Cooler

OUOE003,00000D7 –19–19MAR01–1/1

4-1-22 022808

PN=199
 Miscellaneous—Machine

Service Recommendations For STC1 Fittings

STC fittings are used on this machine. The fittings are

designed to allow the hydraulic hose to rotate as needed
when the system is not pressurized. This prevents the
hydraulic hoses from binding when components are put

–UN–24OCT00
back to their operating position.

Fittings are easily disconnected using special tool,

JDG1385 (1) (supplied in machine with Operator’s

T134792C
Manual). The special tool has a different size slot cut into
each end. The narrow slot is for -06 size fittings. The wide
slot is for -08 size fittings. Use appropriate end of special
tool on fitting being disconnected. To connect fittings, 1—Special Tool JDG1385
2—Shoulder Of Fitting
simply push each half of fitting together.
3—Release Sleeve

IMPORTANT: DO NOT pry against release sleeve (3)

or damage to fitting may result.

DO NOT force release sleeve beyond

normal range of travel, otherwise,
release sleeve may fall off when hose is
disconnected. If this happens and fitting
is connected without the release sleeve
installed, fitting will not be able to be
disconnected again.

1. Disconnect STC type fittings:

a. Clean area around fitting, especially around the

release sleeve (3).

b. While keeping special tool JDG1385 (1)

perpendicular to the fitting, insert tool between
release sleeve (3) and shoulder (2).

c. Gently push, DO NOT PRY, release sleeve away

from shoulder to disconnect the fitting.

d. Pull hose to disconnect.

1
STC is a registered trademark of the Aeroquip Corporation.
Continued on next page OUO1010,0000457 –19–01NOV02–1/2

4-1-23 022808

PN=200
 Miscellaneous—Machine

2. Inspect STC fittings:

a. Check seal mating surfaces for nicks, scratches, or

flat spots.

b. Check O-ring (4), backup ring (5), and retaining ring

–UN–21SEP00
(2) for wear or damage.

c. Make sure O-ring, backup ring, and retaining ring

are in position before connecting fitting halves

T133922
together.

3. Connect STC fittings:

1—Release Sleeve
2—Retaining Ring
a. Make sure fitting halves (3 and 6) are clean and 3—Female Half of STC Fitting
free of contaminates. 4—O-Ring
5—Backup Ring
b. Make sure release sleeve (1) is on male half (6) of 6—Male Half of STC Fitting
fitting before connecting fitting halves together.

c. Push fitting halves together until a definite snap and

solid stop is felt.

d. Pull back on hose to make sure fitting halves are

locked together.

e. To prevent hoses from binding, move component

into position before pressurizing hydraulic system.

OUO1010,0000457 –19–01NOV02–2/2

Do Not Service Control Valves, Cylinders,

Pumps or Motors

Special tools and information are needed to service

control valves, cylinders, pumps, or motors.

If these parts need service, see your authorized dealer.

TX,90,DH2537 –19–03SEP92–1/1

4-1-24 022808
PN=201
 Miscellaneous—Machine

Keep ROPS Installed Properly

CAUTION: Make certain all parts are reinstalled

correctly if the roll-over protective structure
(ROPS) is loosened or removed for any reason.
Tighten mounting bolts to proper torque.

–UN–23AUG88
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or

TS176
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 must be
tightened to 620 ± 120 N•m (457 ± 88 lb-ft).

Specification
ROPS Mounting Bolts—Torque ......................................... 620 ± 120 N•m
457 ± 88 lb-ft

04T,90,MM8 –19–25JUN91–1/1

Hardware Torque Specifications

Check cap screws and nuts to be sure they are tight. If

hardware is loose, tighten to torque shown on the
following charts unless a special torque is specified.

T82,SKMA,AT –19–01AUG94–1/1

4-1-25 022808
PN=202
 Miscellaneous—Machine

Metric Bolt and Screw Torque Values

–UN–01MAY03
4.8 8.8 9.8 10.9 12.9 12.9

4.8 8.8 9.8 10.9 12.9 12.9

TS1670
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
a b a b a b
Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Dryb
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 lb-in
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
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N•m lb-ft N•m lb-ft N•m lb-ft
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
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 Shear bolts are designed to fail under predetermined loads. Always
of the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fasteners
value or tightening procedure is given for a specific application. For with the same or higher property class. If higher property class
stainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Make
instructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start thread
crimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fasteners
shown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless different
specific application. 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 –19–24APR03–1/1

4-1-26 022808

PN=203
 Miscellaneous—Machine

Unified Inch Bolt and Screw Torque Values

TS1671 –UN–01MAY03

Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c b c b c
Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedb Dryc
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 lb-in
1/4 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
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N•m lb-ft N•m lb-ft
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N•m lb-ft N•m lb-ft N•m lb-ft
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N•m lb-ft
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higher
bolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of the
tightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that you
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricate
U-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel bolts
bolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for the
bolts with identical grade. 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.
b
“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.

DX,TORQ1 –19–24APR03–1/1

4-1-27 022808
PN=204
 Miscellaneous—Operational Checkout
Operational Checkout

Use this procedure to check all systems and functions Complete the necessary visual checks (oil levels, oil
on the machine. It is designed so you can make a condition, external leaks, loose hardware, linkage,
quick check of the operation of the machine while wiring, etc.) prior to doing the checkout. The machine
doing a walk around inspection and performing specific must be at operating temperature for many of the
checks from the operator’s seat. checks.

Should you experience a problem with your machine, Before starting this operational checkout, check
you will find helpful diagnostic information in this diagnostic Service codes in monitor. These service
checkout that will pinpoint the cause. This information codes must be corrected or cleared before starting this
may allow you to perform a simple adjustment which checkout.
will reduce the downtime of your machine. Use the
table of contents to help find adjustment procedures. Start at the top of the left column and read completely
down column before performing check, follow this
The information you provide after completing the sequence from left to right. In the far right column, if
operational checkout will allow you or your authorized no problem is found (YES), you will be instructed to go
dealer to pinpoint the specific test or repair work to next check. If a problem is indicated (NO) or (NOT
needed to restore the machine to design OK), you will be referred to either a section in this
specifications. manual or to your authorized dealer.

A location will be required which is level and has

adequate space to complete the checks. No tools or
equipment are needed to perform the checkout.

HG31779,0000074 –19–02MAY02–1/1

Checking and Clearing Diagnostic Trouble Codes From Monitor

– – –1/1

4-2-1 022808
PN=205
 Miscellaneous—Operational Checkout

Check Trouble Codes YES: Go to Battery

Check.

NO: Go to Check Service

Codes.

T103702 –UN–13SEP96

Turn key ON.

After bulb check, Press MENU until diagnostic mode (d)

is in Basic Display window.

Press SELECT to get (d 01) displayed, then press

SELECT to display service codes.

T103152 –UN–09SEP96 LOOK: Does display read “End”?

NOTE: Do NOT stop operating machine because service

codes are displayed. The warning lights on dash will
warn you if machines requires maintenance. If service
codes are displayed, record them.

– – –1/1

Clear Service Codes YES: Go to Battery

Check.

NO: See your authorized

dealer.

T103437 –UN–09SEP96 T103152 –UN–09SEP96

With key ON and diagnostic service codes displayed.

Press NEXT to view each service code and read explanation in Message window.

Record service codes.

When service code is displayed, press SELECT to activate code, then hold SELECT
for three seconds to delete code.

NOTE: The service codes should disappear from window and next service codes be
displayed or “End” displayed. If code can not be deleted, locate connector at sensor
and disconnect it and reinstall it. Then repeat delete procedure. If code can not now be
deleted, the service is active and repair must be done before code can be removed.

Repeat this procedure until “End” appears in Basic display window. Press NEXT and
“End” should still appear.

Press MENU to return to operating display.

LOOK: Are all the service codes deleted and “End” appears in Basic Display window?

– – –1/1

4-2-2 022808
PN=206
 Miscellaneous—Operational Checkout

Engine Off Checks

– – –1/1

Battery Check Key OFF. YES: Go to next check.

Press SELECT button and hold until battery volts are NO: Check voltage on
displayed. each battery before
recharging. If one battery
LOOK: Does battery volts read a minimum of 24 volts? will not hold a charge,
replace both batteries.

T103154 –UN–10SEP96

– – –1/1

Monitor Check Key switch ON. YES: Go to next check.

Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges). NO: See your authorized
dealer.
LOOK/LISTEN: Do all lights come ON and does alarm sound?

Does Message Display and Basic Display window have “8s” showing in every display?

Do all the gauge indicators point to approximately 12:00 O’ clock position?

Is backlighting of gauges ON?

After 4 seconds observe changes in Monitor.

LOOK: Do gauge indicators change from 12:00 O’clock to normal readings?

Does Message Display show John Deere?

LOOK: Does Basic Display change to show gear, rpm, hourmeter and battery voltage
readings?

– – –1/1

4-2-3 022808
PN=207
 Miscellaneous—Operational Checkout

Cab System Checks Check the following for proper working order. YES: Go to next check.

• Seat adjustment NO: Repair as needed.

• Seat belt
• Tilt wheel counsel
• Front and rear work lights
• Front and rear drive lights
• Turn signals
• Dome light
• Horn
• Front and rear windshield wiper and washer
• Four speed (five position) blower fan
• Door and window latches
• Side shield latches
• Grill housing door latch
• Radiator cap and fuel door checks
• Cab mount ladder
• Boom lock check
• Service decal check

– – –1/1

Neutral Start Check Move transmission control lever to 1st gear forward (1F), turn key switch to START. YES: Go to next check.

LISTEN: Starting motor must not run. NO: Check neutral start
fuse. If OK, see your
NOTE: Gear display will not display “F” for forward or “R” for reverse until engine is authorized dealer.
started and park brake released.

Move transmission control lever to 1st gear reverse (1R), turn key switch to START.

LISTEN: Starting motor must not run. Backup alarm will sound.

With transmission control lever in neutral (1N), turn key switch to START

LISTEN: Does starting motor run with lever in neutral position only?
– – –1/1

Backup Alarm Check Move transmission control lever to reverse (R). YES: Go to next check.

LISTEN: Does reverse alarm sound when lever is in NO: Check transmission
reverse (R)? controller switched fuse
and park brake and
backup alarm fuse. If OK,
see your authorized
dealer.
T106879 –UN–14FEB97

– – –1/1

4-2-4 022808
PN=208
 Miscellaneous—Operational Checkout

Diagnostic Trouble Check Diagnostic Trouble Codes (DTC). IF OK: Continue on with
Codes (DTC) check.
Record which (DTC) appear.

Clear (DTC).

If any (DTC) remain fix before continuing with checks, See Diagnostic Trouble Codes
Quick Reference.

– – –1/1

Engine Running Checks

– – –1/1

Monitor Check Key switch ON. YES: Go to next check.

Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges). NO: Check monitor
switched power fuse. If
LOOK/LISTEN: Do all lights come ON and does alarm sound? OK, see your authorized
dealer.
Do Message Display and Basic Display windows have “8s” showing in every display?

Do all the gauge indicators point to approximately 12:00 O’ clock position?

Is backlighting of gauges ON?

After 4 seconds observe changes in Monitor.

LOOK: Do gauge indicators change from 12:00 O’clock to normal readings?

Does Message Display show John Deere?

LOOK: Does Basic Display change to show gear, rpm, hourmeter and battery voltage
readings?

– – –1/1

4-2-5 022808
PN=209
 Miscellaneous—Operational Checkout

Park Brake Check Release park brake by pushing park brake switch to YES: Go to next check.
OFF position.
NO: See your authorized
LOOK: Does park brake indicator go off when brake is dealer.
released? Will machine move if put into gear?

CAUTION: Seat belt must be worn during this

T103441 –UN–09SEP96
check to prevent possible injury from sudden
machine stops.

Fasten seat belt.

Put transmission in 1st gear forward.

Drive machine at 3 MPH and push park brake switch to

ON.

LOOK/FEEL: Does machine come to a stop within 1

meters (3 feet) when park brake is engaged at 3 MPH?
Does transmission shift to neutral?

– – –1/1

Service Brake Check YES: Go to next check.

1
NO: Inspect for leaks
LOADER HYDRAULICS DRIVE WORK 4-WAY NEUTRAL AUTO under machine or
ON

overfilling of non-difflock
A

OFF

A/C
axle. See your authorized
dealer.
PERFORMANCE MANAGEMENT
CARRY BEACON DETACH 2 3 RIDE

T103453 –UN–05SEP96 1
4
LPM A

T140157 –UN–14AUG01

A—Left Service Brake

B—Right Service Brake
1—Clutch Cut-Off Switch

Engine running.

Push Clutch Cut-off switch (1) to OFF position.

Fully apply either (A) or (B) service brake pedal. Release park brake and put
transmission in 2nd forward.

Increase engine speed to fast idle.

LOOK: Does machine not move or move at a very slow speed?

Repeat check three times to ensure accurate results.

– – –1/1

4-2-6 022808

PN=210
 Miscellaneous—Operational Checkout

Pilot Controller Lock YES: Go to next check.

Check
NO: Check pilot
enable/boom down
switch.

T107029 –UN–04FEB97 T103429 –UN–09SEP96

Push Pilot Enable/Boom Down Switch to locked position.

Hold boom control lever in boom raise position.

Move Pilot Enable/Boom Down Switch to unlock and observe boom.

LOOK: Does boom raise when switch is unlocked?

Move Pilot Enable/Boom Down Switch to locked position and observe boom.

LOOK/FEEL: Does boom stop when switch is LOCKED?

Unlock Pilot Enable/Boom Down Switch and check all hydraulic functions.

• Boom Up/Down
• Bucket Roll/Dump
• Auxiliary functions (if equipped)
• Steering (Left and Right)
• Pin Disconnect (if equipped)

– – –1/1

Pilot Enable/Boom Down Raise Boom. YES: Go to next check.

Solenoid Check
Stop Engine. NO: Check boom down
fuse (dome light will not
Turn key to ON position. work if fuse is blown).

Move Pilot Enable/Boom Down Switch in DOWN IF OK: Check boom

position. down solenoid.
T107030 –UN–04FEB97

CAUTION: Boom will quickly lower to

ground.

Move control lever to boom lower position.

LOOK: Does boom lower?

– – –1/1

4-2-7 022808
PN=211
 Miscellaneous—Operational Checkout

Pilot Control Valve Boom Run engine at slow idle. YES: Go to next check.
Float Check
Push Ride Control switch off. NO: See your authorized
dealer.
Push Return-to-Carry switch off.

With the bucket partially dumped, lower boom to raise

front of machine.
T107137 –UN–07FEB97
Push control lever to the float detent position and
release lever.

LOOK: Does front of machine lower to the ground and

valve remain in float position when lever is released?

– – –1/1

Pin Disconnect System Run engine at slow idle. YES: Go to next check.
Check (If Equipped)
Position bucket flat on the ground. NO: Check differential
lock and pin disconnect
Push and hold Pin Disconnect Switch (DETACH). fuse.

LOOK: Does pin disconnect cylinder retract both pins while switch is pressed? NO: Hold a screwdriver
blade against the end of
the pin disconnect
solenoid valve and check
for magnetism with the
switch pushed, if
magnetism switch is ok.

IF OK: See your

authorized dealer.

– – –1/1

4-2-8 022808
PN=212
 Miscellaneous—Operational Checkout

Ride Control Check YES: Go to next check.

CAUTION: Boom will jump upward during this check. Make sure area
around bucket is clear. NO: Check ride control
fuse.
Push Ride Control Switch to OFF position.
Raise boom to maximum height and hold control lever NO: Check ride control
over relief for 2 seconds. boom solenoid. Check
ride control On/Off
Lower boom and bucket to eye level. Observe loader solenoid.
boom as ride control switch is switched to ON.
IF OK: Ride control
LOOK/FEEL: Does boom jump upward 30 cm (12 in) or accumulator charge
T107137 –UN–07FEB97
more? pressure.

Push Ride Control Switch to AUTO position. Switch will

light.

Raise boom to maximum height and hold control lever

over relief for 2 seconds.

Lower boom and bucket to eye level and slowly

accelerate to 5 mph while watching speedometer and
bucket.

LOOK/FEEL: Does ride control come on at

approximately 3 mph and bucket raise slightly?
T107037 –UN–07FEB97

– – –1/1

Differential Lock Check Park unit on a hard surface. YES: Go to next check.

Release brakes. NO: See your authorized

dealer.
Push Differential Lock Switch and steer unit left and
right.

Release lock switch and steer unit left and right.

LOOK: Do front wheels slide with differential lock ON?

NOTE: It is normal to get a "clunk" sound when you

release switch.

LOOK: Do front wheels rotate in opposite directions with

differential lock switch released?

T103168 –UN–05SEP96

– – –1/1

4-2-9 022808
PN=213
 Miscellaneous—Operational Checkout

Clutch Cutoff Check Turn Clutch Cutoff Switch (NEUTRAL) on. YES: Go to next check.

Apply brake. NO: See your authorized

dealer.
Increase engine rpm to 1500.

Turn NEUTRAL switch off.

LISTEN/LOOK: Does engine rpm drop?

FEEL: Can you feel machine pull through brakes?

NOTE: Clutch cutoff switch can be adjusted to operator preference to match your
loading needs by selecting one of three operating functions in the monitor.
Transmission does not totally disengage, some effort to move by the machine can be
felt. See your authorized dealer.

– – –1/1

Boom And Bucket Set bucket flat on the ground and raise about 50 mm (2 YES: Go to next check.
Cylinder Drift Check in.).
NO: See your authorized
Stop engine. Observe bucket for 1 minute. dealer.

LOOK: Does bucket remain in position? Bucket should

not settle to the ground.

NOTE: Use good judgement to determine if the amount

T6564NZ –UN–19OCT88
of drift is objectionable for your loader application.

– – –1/1

4-2-10 022808
PN=214
 Miscellaneous—Operational Checkout

Automatic Shift And NOTE: In the AUTOMATIC mode, transmission will shift to highest gear selected as YES: Go to next check.
Speedometer Check ground speed increases, or will down shift to 2nd as ground speed decreases.
Transmission will never shift to 1st gear. In AUTO MODE TO FIRST the transmission NO: Monitor is
will start in 1st when initially shifted from Neutral to Forward or Reverse. After the initial programmed for wrong
shift from Neutral, the transmission will downshift no lower than 2nd unless a high load tire size. See your
is encountered. Transmission will upshift or downshift as ground speed dictates. authorized dealer.

Automatic transmission switch to AUTO.

Perform this check in an open area away from other people and machinery.

Release park brake and shift to (4th) forward.

Drive machine on level ground and slowly accelerate to fast idle speed and note speed
when shifts are made until engaged in 4th gear. Reduce engine rpm to idle and note
speed when transmission makes each downshift.

LOOK: Does the transmission shift at following approximate speeds?

724J
Shift MPH Km/H
2nd-3rd 6 9
3rd-4th 10 16
4th-3rd 7 11
3rd-2nd 4 6

NOTE: In 4th Forward automatic the transmission starts out in 2nd gear and up-shifts
to 3rd then 4th. When transmission downshifts it returns to 2nd. Transmission will shift
at different speeds depending on machine loads. Use only as reference.
– – –1/1

4-2-11 022808
PN=215
 Miscellaneous—Operational Checkout

Transmission Shift Mode Turn Automatic Transmission Shift switch to OFF. YES: Go to next check.
Check
Press MENU until ACCESSORY shows in basic display, then press SELECT. NO: See your authorized
dealer.
Accessory will display in Message Display Window and A 02 Quick Shift in Basic
Display Window.

Press NEXT until A 021 Down/up displays, then press SELECT.

Release park brake and shift to 3rd forward.

Drive machine at approximately 1600 rpm and press Quick Shift Switch once.

LOOK/FEEL: Does transmission shift to and remain in 2nd gear?

Press Quick Shift Switch once more.

LOOK/FEEL: Does transmission shift back to 3rd gear?

NOTE: If Quick Shift Switch is pressed twice, transmission will shift down one gear
then immediately back up to where it was. Quick Shift feature operates in all gears.

In Basic Display Window with Quick Shift A 021 displayed press NEXT to get
Downshift A 022 Down Only to display.

Press SELECT to enable Down Only shift mode.

Release park brake and shift to 4th forward.

Drive machine at approximately 1200 rpm and press Quick Shift Switch once.

LOOK/FEEL: Does transmission shift to and remain in 3rd gear?

Press Quick Shift Switch once more.

LOOK/FEEL: Does transmission shift to and remain in 2nd gear?

Press Quick Shift Switch once more.

LOOK/FEEL: Does transmission shift to and remain in 1st gear?

Press Quick Shift Switch once more.

LOOK/FEEL: Does transmission stay in 1st gear?

NOTE: In DOWN ONLY mode pressing Quick Shift Switch will not change gears once
1st gear is reached, unless a direction or gear change is made.

– – –1/1

Axle Disconnect Check Operate machine in an open area away from bystanders. YES: Go to next check.
(If Equipped)
With bucket partially dumped, lower boom to raise front NO: Check differential
wheels off the ground. lock and pin disconnect
fuse.
Push Axle Disconnect Switch to ON position.
IF OK: See your
Watch front wheels while operating the machine in authorized dealer.
reverse. Front wheels must not rotate as machine moves
T6601AA –UN–19OCT88
backwards.

LOOK: Do front wheels remain stationary while machine

moves backwards?

– – –1/1

4-2-12 022808
PN=216
 Miscellaneous—Operational Checkout

Steering Valve Check Transmission in Neutral. IF OK: Go to next check.

Run engine at low idle. NO: See your authorized

dealer.
Remove foot from brake pedal.

Release park brake.

Turn steering wheel until machine frames contact right

T6471AQ –UN–19OCT88
and left frame stops.

LOOK: Does machine steer smoothly in both directions?

NOTE: It is normal for machine frames to drift away from

frame stops when steering wheel is released.

When steering wheel is stopped, frames must stop.

FEEL: Is excessive effort required to turn steering

wheel?

– – –1/1

4-2-13 022808

PN=217
 Miscellaneous—Troubleshooting
Troubleshooting Procedure

NOTE: Troubleshooting charts are arranged from the

simplest to verify, to least likely, more difficult to
verify. When diagnosing a problem, use all
possible means to isolate the problem to a single
component or system. Use the following steps to
diagnose problems:

Step 1. Operational Checkout Procedure

Step 2. Troubleshooting Charts

Step 3. Adjustments

Step 4. See your authorized John Deere dealer.

HG31779,0000020 –19–08JAN08–1/1

4-3-1 022808

PN=218
 Miscellaneous—Troubleshooting

Diagnostic Trouble Codes Quick Reference List

CCU SERVICE CODES • F0357 Third Speed Clutch Pack Solenoid

Short-to-Ground
• F0275 CCU Power Dissipation Excessive • F0358 Third Speed Clutch Pack Solenoid
Short-to-Power
TRANSMISSION SYSTEM CODES: • F0359 Second Speed Clutch Pack Solenoid Open
• F0360 Second Speed Clutch Pack Solenoid
• F0300 Oil Temperature High Long Short-to-Ground
• F0305 TCU Output Speed Zero • F0361 Second Speed Clutch Pack Solenoid
• F0306 TCU Voltage Low Short-to-Power
• F0307 TCU Voltage High • F0362 First Speed Clutch Pack Solenoid Open
• F0308 TCU Valve Solenoid Power • F0363 First Speed Clutch Pack Solenoid
• F0309 TCU Park Brake Solenoid Power Short-to-Ground
• F0315 Oil Filter Circuit Short-to-Power • F0364 First Speed Clutch Pack Solenoid
• F0320 1st Gear Clutch Slippage Short-to-Power
• F0321 2nd Gear Clutch Slippage • F0365 Reverse Clutch Pack Solenoid Open
• F0322 3rd Gear Clutch Slippage • F0366 Reverse Clutch Pack Solenoid
• F0323 4th Gear Clutch Slippage Short-to-Ground
• F0324 Forward Gear Clutch Slippage • F0367 Reverse Clutch Pack Solenoid
• F0325 Reverse Gear Clutch Slippage Short-to-Power
• F0330 Clutch Cut-Off Circuit Voltage Low • F0368 FWD Low Range Clutch Pack Solenoid Open
• F0331 Clutch Cut-Off Circuit Voltage High • F0369 FWD Low Range Clutch Pack Solenoid
• F0336 TCU Configuration Bad Short-to-Ground
• F0337 TCU Memory Bad • F0370 FWD Low Range Clutch Pack Solenoid
• F0339 Temperature Sensor Voltage Short-to-Ground Short-to-Power
• F0340 Temperature Sensor Voltage Short-to-Power • F0375 Gear Selector
• F0341 Output Speed Signal Bad • F0377 Oil Temperature Circuit Short-to-Power
• F0342 Output Speed Circuit Short-to-Ground • F0378 Oil Temperature Circuit Open
• F0343 Output Speed Circuit Short-to-Power • F0379 FNR Selector Switch Open
• F0344 Internal Clutch Speed Signal Bad • F0380 Oil Filter Restricted
• F0345 Internal Clutch Speed Circuit Short-to-Ground • F0384 Reverse Alarm Relay Short-to-Power
• F0346 Internal Clutch Speed Circuit Short-to-Power • F0385 Reverse Alarm Relay Short-to-Ground
• F0347 Turbine Speed Signal Bad • F0386 Reverse Alarm Relay Open
• F0348 Turbine Speed Circuit Short-to-Ground • F0387 Park Brake Solenoid Short-to-Power
• F0349 Turbine Speed Circuit Short-to-Power • F0388 Park Brake Solenoid Short-to-Ground
• F0350 Input Speed Signal Bad • F0389 Park Brake Solenoid Open
• F0351 Input Speed Circuit Short-to-Ground • F0396 Oil Temperature High
• F0352 Input Speed Circuit Short-to-Power
• F0353 FWD High Range Clutch Pack Solenoid ENGINE SYSTEM CODES:
Open
• F0354 FWD High Range Clutch Pack Solenoid Short • F0400 Oil Pressure Low Long
to Ground • F0415 CCU Throttle Circuit Voltage Low
• F0355 FWD High Range Clutch Pack Solenoid Short • F0416 CCU Throttle Circuit Voltage High
to Power • F0423 Ambient Air Temperature Input Voltage High
• F0356 Third Speed Clutch Pack Solenoid Open • F0424 Ambient Air Temperature Input Voltage Low

Continued on next page TX17961,0000174 –19–03OCT02–1/3

4-3-2 022808

PN=219
 Miscellaneous—Troubleshooting

• F0425 Engine Coolant Temperature Input Voltage STEERING SYSTEM CODES:

High
• F0426 Engine Coolant Temperature Input Voltage • F0998 Steering Pressure Circuit
Low • F0999 Steering Pressure Low
• F0431 Cylinder #1 EI Circuit
• F0432 Cylinder #2 EI Circuit BRAKE SYSTEM CODES:
• F0433 Cylinder #3 EI Circuit
• F0434 Cylinder #4 EI Circuit • F1097 Service Brake Pressure Circuit
• F0435 Cylinder #5 EI Circuit • F1099 Service Brake Pressure Low
• F0436 Cylinder #6 EI Circuit
• F0437 Fuel Temperature Input Voltage High ELECTRICAL SYSTEM CODES:
• F0438 Fuel Temperature Input Voltage Too Low
• F0439 Pump Control Valve #1 Error • F1620 CCU Spare Relay #1 Short
• F0440 Pump Control Valve #2 Error • F1621 CCU Spare Relay #3 Short
• F0441 Crank Position Input Missing • F1622 CCU Spare Relay #4 Short
• F0442 Crank Position Input Error • F1623 CCU Spare Relay #5 Short
• F0443 Pump Position Sensor Input Missing • F1624 Air Preheat Driver Short Ground
• F0444 Pump Position Sensor Input Error • F1625 Detent Enable Driver Short-to-Ground
• F0445 Crank Position/Pump Position Timing • F1626 Ride Control Boom Driver Short-to-Ground
Moderately Out of Sync • F1628 Ride Control On Driver Short-to-Ground
• F0450 Fuel Rail Pressure Input Voltage High • F1629 Left Turn Driver Short-to-Ground
• F0451 Fuel Rail Pressure Input Voltage Low • F1630 Right Turn Driver Short-to-Ground
• F0453 Water in Fuel Signal Voltage High • F1633 Secondary Steering Driver Short-to-Ground
• F0454 Water in Fuel Signal Voltage Low • F1634 Rear Wiper Driver Short-to-Ground
• F0455 Manifold Air Temperature Moderately High • F1635 Front Wiper Driver Short-to-Ground
• F0456 Pump Control Valve #2 Fuel Flow Not • F1636 CCU Relay Driver Overtemp
Detected • F1637 CCU Timer Reset
• F0469 Pump Control Valve #1 Fuel Flow Not • F1638 Proportional Fan Drive Solenoid Circuit Error
Detected • F1639 Reverse Fan Drive Solenoid Circuit Error
• F0470 Fuel Rail Pressure Control Error • F1641 Drive Light Switch Circuit Open
• F0471 Fuel Rail Pressure Sensor Supply Voltage • F1644 MDU Memory Bad
Low • F1645 CCU Memory Bad
• F0478 Engine Oil Pressure Circuit Voltage Low • F1647 Machine Odometer Bad
• F0479 Engine Oil Pressure Circuit Voltage High • F1648 Machine Hourmeter Bad
• F0485 Water in Fuel Detected • F1649 CCU Hourmeter Bad
• F0499 Engine Oil Pressure Low • F1651 No ECU CAN Transmit
• F0500 Engine Coolant Temperature High Long • F1653 No CCU CAN Transmit
• F0515 Engine Air Filter Restriction Circuit • F1655 No TCU CAN Transmit
• F0516 Engine Fuel Level Circuit Voltage Low • F1658 Power Voltage Balance
• F0517 Engine Fuel Level Circuit Open • F1660 Alternator Voltage High
• F0576 Engine Coolant Temperature Circuit Noisy • F1661 Alternator Voltage Low
• F0577 Engine Coolant Temperature Circuit • F1662 Power Voltage High
Short-to-Ground • F1663 Power Voltage Low
• F0578 Engine Coolant Temperature Circuit Open • F1664 Brake Light Pressure Circuit
• F0580 Engine Air Filter Restricted • F1665 Drive Light Switch Circuit
• F0599 Engine Coolant Temperature High • F1667 Turn Switch Circuit Short

Continued on next page TX17961,0000174 –19–03OCT02–2/3

4-3-3 022808

PN=220
 Miscellaneous—Troubleshooting

• F1668 Hazard Switch Circuit • F3162 Ride Control On Circuit Short-to-Ground

• F1671 Return to Carry Detent Solenoid Circuit Error • F3163 Boom Position Voltage Low
• F1672 Boom Height Kickout Detent Solenoid Circuit • F3164 Boom Position Sensor Voltage High
Error • F3171 Hydraulic Oil Pressure Circuit Voltage Low
• F1699 Config Bad • F3172 Hydraulic Oil Pressure Circuit Voltage High
• F3173 Spin Control Mode Circuit
HYDRAULIC SYSTEM CODES: • F3174 Spin Control Enable Circuit Short-to-Ground
• F3175 Hydraulic Oil Temperature Circuit
• F2100 Oil Temperature High Long Short-to-Ground
• F3115 Oil Filter Restriction Circuit Short-to-Ground • F3176 Hydraulic Oil Temperature Circuit Open
• F3150 Oil Filter Restriction Circuit Short-to-Power • F3177 Hydraulic Oil Temperature Circuit Noisy
• F3160 Ride Control Circuit Short-to-Power • F3199 Hydraulic Oil Temperature High
• F3161 Ride Control Auto Circuit Short-to-Ground

TX17961,0000174 –19–03OCT02–3/3

4-3-4 022808

PN=221
 Miscellaneous—Troubleshooting

Engine
Symptom Problem Solution

Engine Cranks/Won’t Start Fuel quality and quantity Check fuel quality and quantity.

Engine cranking speed Check engine cranking speed.

Oil viscosity Check for correct oil viscosity.

Intake or exhaust restrictions Check for intake and exhaust

restrictions.

Air heater not working If engine has an air heater, verify air
heater operation in cold
temperatures.

Engine Misfires/Runs Irregularly Intake manifold air leaks Check for intake manifold air leaks

Mechanical problems Check for mechanical problems.

Transmission problems Check for transmission problems.

Engine accessories cycling on and Check engine accessories, such as

off A/C, cycling on and off.

Electronic interference Check for improperly installed radios,

etc.

Engine Does Not Develop Full Restricted or plugged air and fuel Check for restricted or plugged air
Power filters and fuel filters.

Fuel quality Check fuel quality.

Transmission problems Check for transmission problems.

Engine mechanical problems Check for engine mechanical

problems.

Excessive load Check for excessive load on the

engine.

Engine Emits Excessive White Fuel quantity and quality Check fuel quantity and quality.
Exhaust Smoke

Low engine coolant temperature Check for extremely low engine

coolant temperature.

Continued on next page TX17961,000000B –19–03OCT02–1/2

4-3-5 022808

PN=222
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Engine Emits Excessive Black Or Fuel quantity and quality Check fuel quantity and quality.
Gray Smoke

Restricted or plugged air filter Check for restricted or plugged air

filter.

Excessively loaded engine Check for excessively loaded

engine.

Engine Will Not Crank Weak battery Replace battery.

Corroded or loose battery Clean battery terminals and

connections connections.

Defective main switch or start safety Repair switch as required.

switch

Starter solenoid defective Replace solenoid.

Starter defective Replace starter.

Start circuit defective Check wiring, fuses, and relays.

Engine is seized Check by rotating engine by hand.

Engine Idles Poorly Poor fuel quality Drain fuel and replace with quality
fuel of the proper grade.

Air leak on suction side of air intake Check hose and pipe connections
system for tightness; repair as required.

TX17961,000000B –19–03OCT02–2/2

4-3-6 022808

PN=223
 Miscellaneous—Troubleshooting

Transmission
Symptom Problem Solution

Transmission Clutch Slippage Low oil level See Transmission, Hydraulic

System, Park Brake, And Differential
Oil.

Wrong oil grade See Transmission, Hydraulic

System, Park Brake, And Differential
Oil.

Restricted Transmission pump Remove and clean screen.

suction screen

Machine Will Not Move Diagnostic Trouble Code (DTC) Check Diagnostic Trouble Codes to
related problem define problem. See Monitor Display
Unit—User Diagnostics Menu.

Applied park brake (electrical Check park brake fuse.

problem)

Check operation of park brake.

Low oil level Check transmission oil level.

Clutch cutoff activated Check that brake pedal is fully

released.

No power to transmission controller Check transmission controller

unit switched 5A fuse.

Check monitor and transmission

controller unswitched fuse.

Hydraulic failure of park brake Check operation of park brake.

Failed shift switch Check that display window shows

correct gear when shift switch is
moved.

Broken drive shafts Inspect drive shafts and universal

joints for external damage.

Continued on next page TX17961,000016A –19–03OCT02–1/3

4-3-7 022808

PN=224
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Machine Does Not Engage In Clutch cutoff activated Check that brake pedal is fully
Low Gear released.

Shift switch problem Check Diagnostic Trouble Codes to

define problem. See Monitor Display
Unit—User Diagnostics Menu.

Machine Will Not Shift Correctly Speed sensor disconnected or failed Check electrical connectors on
transmission speed sensors.

Transmission Shifts Too Slow Low oil level (aeration of oil) Add oil.

Restricted transmission pump Remove and clean suction screen.

suction screen

Transmission Hydraulic System High oil level Check transmission oil level.
Overheats

Transmission overfilled or hydraulic

pump seal leaking.

Low oil level Check transmission oil level.

Wrong oil grade Check oil type.

Park brake dragging Check for heat in park brake area.

Pinched, restricted or leaking lube Check cooler lines.

lines

Malfunction in temperature gauge or Install temperature sensor to verify

sender temperature.

Restricted air flow through oil cooler Check oil cooler and radiator for
or radiator debris. Clean if needed.

Excessive Transmission Noise Too low engine slow idle Check engine slow idle speed.
(under load or no load)

Worn parts or damaged in Inspect suction screen for metal

transmission particles.

Damaged drive dampener Inspect drive dampener.

Driveline or park brake Inspect drive line and park brake.

Continued on next page TX17961,000016A –19–03OCT02–2/3

4-3-8 022808

PN=225
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Foaming Oil Incorrect type of oil Check oil type. Change oil if needed.

High oil level Check oil level. Transmission

overfilled or hydraulic pump seal
leaking.

Low oil level Check oil level. Add oil if needed.

Oil Ejected From Dipstick Plugged breather Inspect breather on top of

transmission. Replace if needed.

Machine Vibrates Aerated oil Check oil level. Add oil if needed.

Low engine speed Check engine speed.

Failed universal joints on Check universal joints.

transmission drive shaft or
differential drive shafts

Damaged drive dampener. Inspect drive dampener.

Machine Lacks Power And Engine fast idle speed set too low Check engine fast idle.
Acceleration

Incorrect transmission oil Drain transmission oil and refill. See

Change Transmission Oil.

Aerated oil Check oil level. Add oil if needed.

TX17961,000016A –19–03OCT02–3/3

4-3-9 022808

PN=226
 Miscellaneous—Troubleshooting

Differential And Axle

Symptom Problem Solution

No differential Lock Operation Malfunction in electrical circuit With engine stopped and key switch
on, activate differential lock and
listen for a click from solenoid valve.

Stuck differential lock solenoid valve With engine stopped and key switch
on, activate differential lock and
listen for a click from solenoid valve.

Excessive leakage in differential lock Check differential oil level.

piston seals

Differential Lock Slips Or Axle oil broken down Change axle oil. See Change Front
Chatters When Engaged and Rear Differential Oil.

Excessive leakage differential lock Check differential oil level.

piston seals

Differential Lock Will Not Release Stuck foot switch Inspect.

Malfunction in electrical circuit With engine stopped and key switch

on, activate differential lock and
listen for a click from solenoid valve.

Stuck differential lock solenoid valve With engine stopped and key switch
on, activate differential lock and
listen for a click from solenoid valve.

Differential Low On Oil External leakage Inspect axle and differential for
leaks.

Excessive Differential And/Or Low oil level in differential Check oil. Remove drain plug and
Axle Noise inspect for metal particles in
differential case. See Check Front
and Rear Differential Oil Level.

Engaged differential lock Release lock.

If circuit remains pressurized, check

if foot switch is sticking. Remove and
inspect.

Check solenoid valve for sticking.

Remove and inspect valve.

Continued on next page TX17961,000016C –19–03OCT02–1/2

4-3-10 022808

PN=227
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Oil Seeping From Outer Axle Dirt in face seal Inspect face seals.
Seal

Overfilled differential Check differential lock oil return

system for excessive internal
restriction.

High pressure in axle Check axle breather.

Axle Overheats Low differential oil Check oil level. Add oil if needed.

Overfilled differential Check oil level. Add oil if needed.

Axle recirculation motor dual pump Inspect axle recirculation filter screen
screens plugged located in differential housing below
input yoke. See Clean Axle
Differential Recirculation Screen.

TX17961,000016C –19–03OCT02–2/2

Service Brake
Symptom Problem Solution

Poor or No Brakes Axle overheated Check axle temperature.

Brake disks worn or warped Inspect service brake pads.

Aggressive Brakes Clutch cutoff mode set to steep Turn clutch cutoff switch OFF.
slope

Brakes Drag Brake pedal not returning Inspect floor mat and pedal.

Brakes Chatter Brake disk friction material worn Inspect brake disks.

Oil broken down Change oil. See Change Front and

Rear Differential Oil.

Wrong oil in hydraulic system Drain hydraulic reservoir and

differentials. Refill with correct oil.
See Change Front and Rear
Differential Oil.

TX17961,000016D –19–03OCT02–1/1

4-3-11 022808
PN=228
 Miscellaneous—Troubleshooting

Drive Line
Symptom Problem Solution

Excessive Drive Line Vibration Yokes not in line on drive shafts Inspect. Align drive shaft yokes.
Or Noise

Lack of lube in park brake Inspect park brake oil level and
adjust as required. See Check Park
Brake Oil Level.

Bent drive shaft Inspect all drive shafts.

Loose yoke retaining nuts (drive Inspect. Replace.

shafts wobble at high speed)

Rear axle oscillating support Inspect.

Lack of lubrication Lubricate with proper grade of

grease.

TX17961,000016E –19–03OCT02–1/1

4-3-12 022808

PN=229
 Miscellaneous—Troubleshooting

Park Brake
Symptom Problem Solution

Brake Will Not Hold Breather plugged Inspect and clean breather.

Malfunctioning park brake solenoid Inspect.

Brake Overheats Overfilled with oil Adjust oil level. See Check Park
Brake Oil Level.

Breather plugged Inspect and clean breather.

Park Brake Indicator In Monitor Low oil level Check oil level. Add oil if needed.
Comes On When Shifting From
Fwd to Rev (All Other Gears OK)

Cold oil Warm oil.

Park Brake Light Comes On For Cold oil Warm oil.

Each Shift

Park Brake Indicator In Monitor Faulty wiring or switch Inspect for loose or broken wires
Does Not Come On When Brake between brake indicator switch and
Applied indicator on dash.

TX17961,000016F –19–03OCT02–1/1

4-3-13 022808

PN=230
 Miscellaneous—Troubleshooting

Hydraulic System
Symptom Problem Solution

No Hydraulic Functions Pilot enable switch OFF Turn switch ON

Pilot enable switch failed Check pilot enable switch.

Slow Hydraulic Functions Cold oil Warm oil.

Slow engine speed Check fast idle speed.

Suction line air leak Check for foamy oil.

Low oil supply Add recommended oil.

Wrong oil viscosity Use recommended oil.

Blocked or damaged line Inspect lines.

Noisy Hydraulic Pump Low oil supply or wrong viscosity Fill reservoir with recommended oil.

Plugged or pinched suction line Clean or replace line.

Air in oil Check for foamy oil. Tighten

connections. Replace O-rings and/or
lines.

Loose or missing hydraulic line Tighten or replace clamps.

clamps

Hydraulic lines in contact with frame Inspect and repair.

Boom Float Function Does Not Return-to-carry switch ON Turn switch OFF.
Work

One Hydraulic Function Does Not Blockage in oil lines or valve Inspect lines for damage.
Work

Function Drifts Down Leaking cylinders Check cylinder leakage.

Boom lower solenoid valve Check Solenoid.

Leaking loader control valve Replace valve section.

Continued on next page TX17961,0000170 –19–03OCT02–1/2

4-3-14 022808

PN=231
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Boom Down Does Not Work Pilot enable/boom down switch not Push and hold pilot enable/boom
(Engine Off) held down down switch as loader control lever
is moved.

Unswitched boom down, radio and Replace fuse.

dome light fuse failed

Boom down solenoid failed Replace solenoid.

Pilot enable/boom down switch Replace switch.

failed.

Oil Overheats Low oil viscosity in hot weather Use recommended oil.

Excessive load Reduce load.

Cylinder Leakage Check cylinder leakage.

Restriction in oil lines or loader valve Inspect for dented or kinked lines.

Hydraulic Oil Foams Low oil level Add recommended oil.

Wrong oil Change to recommended oil.

Water in oil Drain oil from reservoir and

cylinders. Fill with recommended oil.

Loose or faulty suction lines (air leak Tighten or install new lines.
in system)

Pin Disconnect Cylinders Will Electrical circuit failure Hold a screwdriver against end of
Not Retract pin disconnect solenoid valve and
check for magnetism with switch
pushed.

Solenoid valve failure Remove and inspect.

Cylinder binding Inspect cylinder and adjust loads.

TX17961,0000170 –19–03OCT02–2/2

4-3-15 022808

PN=232
 Miscellaneous—Troubleshooting

Steering
Symptom Problem Solution

No Steering Functions Frame locking bar in place Pin locking bar in unused position.

Low oil level Add recommended oil.

Pinched steering line Inspect and repair line.

Erratic Steering Air in oil Check for foamy oil.

Low oil level Add recommended oil.

Spongy or Soft Steering Air in oil Check for foamy oil.

Low oil level Add recommended oil.

Machine Turns in Opposite Lines to cylinders connected to Connect lines to correct ports.
Direction wrong ports at steering valve.

TX17961,0000171 –19–03OCT02–1/1

4-3-16 022808

PN=233
 Miscellaneous—Troubleshooting

Air Conditioning System

Symptom Problem Solution

Air Conditioning System Does Blower motor 25A fuse (F19) Replace fuse.
Not Operate

Pressurizer motor 7.5A fuse (F20) Replace fuse.

Blower/pressurizer motor relay (K19) Check Relay.

Blower speed switch (S21) Check switch.

Blower speed resistor (R3) Check resistor.

Main blower motor (M6) Check motor.

Pressurizer blower motor (M7) Check motor.

A/C (On/Off) switch (S22) Check switch.

Freeze control switch (B35) Check switch.

A/C low pressure switch (B36) Check switch.

A/C high pressure switch (B37) Check switch.

A/C compressor clutch solenoid Check clutch operation.

(Y16)

Continued on next page TX17961,0000172 –19–03OCT02–1/2

4-3-17 022808

PN=234
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Air Conditioner Does Not Cool Fresh air filter clogged Clean or replace filter.
Interior of Cab

Condenser fins clogged with debris Clean condenser fins.

Recirculating air filter clogged Clean or replace filter.

Compressor pulley worn Replace pulley.

Refrigerant hose kinked, pinched or Re-route or re-index hoses, replace

collapsed kinked or collapsed hoses.

Heater or evaporator core fins Clean heater or evaporator core fins.

clogged with dirt or dust

Pressurizer blower motor failed or Check motor speed.

operating too slowly

Compressor clutch slipping or failed Inspect and/or replace compressor

clutch.

Warm outside air leaking into cab Inspect, repair or replace door and
window seals.

Heater valve remaining open Inspect, repair, adjust or replace

heater valve or cable.

System refrigerant (R134A) charge Inspect system for leaks.

low

Evaporator fins frosting or freezing Freeze control switch capillary tube

not positioned correctly in evaporator
core.

Air Conditioner Runs Constantly, Freeze control switch capillary tube Reposition capillary tube in
Too Cold not positioned in evaporator correctly evaporator core

Interior Windows Continue To Fresh air filter clogged Clean or replace filter.
Fog

A/C system off Turn A/C (ON/OFF) switch ON.

TX17961,0000172 –19–03OCT02–2/2

4-3-18 022808

PN=235
 Miscellaneous—Troubleshooting

Heater System
Symptom Problem Solution

Heater System Does Not Operate Blower motor fuse Replace fuse.

Blower speed switch Check switch.

Heater Does Not Warm Interior Fresh air filter clogged Clean or replace filter.
Of Cab

Recirculating air filter clogged Clean or replace filter.

Heater hose kinked, pinched or Re-route or re-index hoses, replace

collapsed collapsed hoses.

Heater core fins clogged with dirt or Clean heater fins.

dust

Heater valve remaining closed Inspect, repair, adjust or replace

heater valve or cable.

Temperature control switch failed Inspect, repair or replace switch.

Interior Windows Continue To Fresh air filter clogged Clean or replace filter.
Fog

A/C system off (if equipped) Turn A/C ON/OFF switch ON (if
equipped).

TX17961,0000173 –19–03OCT02–1/1

4-3-19 022808

PN=236
 Miscellaneous—Storage
Prepare Machine For Storage

1. Repair worn or damaged parts. Install new parts, if

necessary, to avoid needless delays later.

2. Check primary air cleaner. Replace filter, if necessary.

–UN–09FEB89
IMPORTANT: High pressure washing greater than
1379 kPa (13.8 bar) (200 psi) can
damage freshly painted finishes. Paint

T5813AM
should be allowed to air dry for 30 days
minimum after receipt of machine
before cleaning parts or machines with
high pressure. Use low pressure wash
operations until 30 days have elapsed.

3. Wash the machine. Use low pressure wash operations

(less than 1379 kPa (13.8 bar) (200 psi) until 30 days
after receipt of machine have elapsed. Paint areas to
prevent rust. Replace decals, where needed.

4. Apply waste oil to track chains. Run machine back and

forth several times. Park machine on a hard surface to
prevent tracks from freezing to ground.

5. Store machine in a dry, protected place. If stored

outside, cover with a waterproof material.

IMPORTANT: LPS 3 Rust Inhibitor can destroy

painted finish. DO NOT spray LPS 3
Rust Inhibitor on painted areas.

6. Retract all hydraulic cylinders, if possible. If not, coat

exposed cylinder rods with LPS 3 Rust Inhibitor.

7. Place a "DO NOT OPERATE" tag on the right control

lever.

8. Lubricate all grease points.

9. Remove batteries.

10. Remove seat cushion and other perishable items.

11. Remove keys and lock all covers and doors.

LPS is a trademark of the Holt Lloyd Corporation. TX,105,FF2313 –19–16NOV00–1/1

4-4-1 022808

PN=237
 Miscellaneous—Machine Numbers
Record Product Identification Number (PIN)

Purchase Date

NOTE: Record all 13 characters of the Product

–UN–12DEC96
Identification Number (A).

T105500B
TX,110,JC1733 –19–03DEC96–1/1

Record Engine Serial Number

Engine Serial Number (A)

–UN–12DEC96
T103191B
TX,110,JC1582 –19–20AUG96–1/1

Record Transmission Serial Number

Transmission Serial Number (A)

Located on right side of transmission case, near lower

right corner of case.

–UN–12DEC96
T103192B

TX,110,JC1583 –19–20AUG96–1/1

Record Hydraulic Pump Serial Number

Hydraulic Pump Serial Number (A)
–UN–12DEC96
T103357B

TX,110,JC1523 –19–12AUG96–1/1

4-5-1 022808
PN=238
 Miscellaneous—Specifications
744J Specifications

–UN–16AUG96
T102977
A—Bucket Hinge Height 4281 C—Dump Reach 1270 mm (4 ft E—Wheelbase 3400 mm (11 ft G—Overall Length 8586 m (28
mm (14 ft 0.6 in.) 2 in.) 2 in.) ft 2 in.)
B—Dump Height 3042 mm (9 ft D—Overall Height 3520 mm F—Ground Clearance 465 mm
10 in.) (11 ft 6.6 in.) (18.3 in.)

Item Measurement Specification

Bucket Hinge-To-Ground Height Distance 4281 mm

14 ft 0.6 in.

Bucket Dump-To-Ground Height Distance 3042 mm

9 ft 10 in.

Bucket Dump-To-Tire Reach Distance 1270 mm

4 ft 2 in.

Machine Overall Height 3520 mm

11 ft 6.6 in.

Continued on next page TX,115,JC1524A –19–08MAR07–1/3

4-6-1 022808

PN=239
 Miscellaneous—Specifications

Item Measurement Specification

Machine Wheelbase Length 3400 mm

11 ft 2 in.

Machine Ground Clearance 465 mm

18.3 in.

Machine Overall Length 8403 m

28 ft 2 in.

Machine Operating Weight 23 360 kg

51 500 lb

Assumed Operator Weight 79 kg

175 lb

NOTE: Specifications and design subject to change kg (1248 lb) optional counterweight, ROPS
without notice. Wherever applicable, cab, diff lock front axle with standard rear axle,
specifications are in accordance with SAE 2 spool valve with two lever control, heater
standards. Except where otherwise noted, and defroster, 79 kg (175 lb) operator and full
specifications are based on a machine fuel tank.
equipped with all standard equipment, with 566

Item Measurement Specification

John Deere 6125A Turbocharged

And Aftercooled Diesel Engine:

Gear 1: Power 240 hp @ 2000 rpm

Gears 2-4: Power 260 hp @ 2000 rpm

Piston Displacement Distance 12.5 L

766 cu in.

Air Cleaner w/Safety Element And Type Dual stage dry type with restriction
Restriction Indicator indicator

Electrical System Voltage 24 volt with 80-amp alternator

Cold Cranking Capacity At -18°C Current 950 amps

(0°F)

Reserve Capacity Time 190 min.

Torque Converter Type Single phase, single stage

Continued on next page TX,115,JC1524A –19–08MAR07–2/3

4-6-2 022808

PN=240
 Miscellaneous—Specifications

Item Measurement Specification

Transmission

Countershaft Type Computer controlled powershift

Forward Travel:

1 Speed 7.4 km/h

4.6 mph

2 Speed 13.9 km/h

8.6 mph

3 Speed 21.2 km/h

13.1 mph

4 Speed 39.5 km/h

24.5 mph

Reverse Travel:

1 Speed 7.4 km/h

4.6 mph

2 Speed 13.9 km/h

8.6 mph

3 Speed 31.0 km/h

19.3 mph

NOTE: All travel speeds are with 26.5—25 20PR (L3)

tires.

TX,115,JC1524A –19–08MAR07–3/3

4-6-3 022808

PN=241
 Miscellaneous—Specifications

Drain and Refill Capacities—744J

Item Measurement Specification

Cooling system Capacity 38 L

40 qt

Fuel tank Capacity 462 L

122 gal

Engine crankcase and filter Capacity 38 L

40 qt

Transmission case and filter Capacity 28 L

30 qt

Front differential Capacity 46 L

48.5 qt

Rear differential Capacity 46 L

48.5 qt

Front differential—With Optional Capacity 49 L

Wide Axle 52 qt

Rear differential—With Optional Wide Capacity 49 L

Axle 52 qt

Hydraulic reservoir and filters Capacity 144 L

38 gal

Park brake Capacity 600 mL

20 oz

TX,115,JC1526 –19–17AUG01–1/1

4-6-4 022808

PN=242
 Miscellaneous—Specifications

824J Specifications

–UN–16AUG96
T103085
A—Bucket Hinge Height 4510 C—Dump Reach 1260 mm (4 ft E—Wheelbase 3400 mm (11 ft G—Overall Length 8825 mm
mm (14 ft 10 in.) 1 in.) 2 in.) (28 ft 11 in.)
B—Dump Height 3202 mm (10 D—Overall Height 3520 mm F—Ground Clearance 465 mm
ft 6 in.) (11 ft 6.6 in.) (18.3 in.)

Item Measurement Specification

Bucket Hinge Height 4281 mm

14 ft 10 in.

Dump Height 3202 mm

10 ft 6 in.

Dump Reach Distance 1260 mm

4 ft 1 in.

Overall Height 3520 mm

11 ft 6.6 in.

Continued on next page TX,115,JC1560A –19–27SEP01–1/3

4-6-5 022808

PN=243
 Miscellaneous—Specifications

Item Measurement Specification

Wheelbase Distance 3400 mm

11 ft 2 in.

Ground Clearance 465 mm

18.3 in.

Overall Length 8991 mm

29 ft 6 in.

Standard Operating Weight 23 450 kg

57 710 lb

Assumed Operator Weight 79 kg

175 lb

NOTE: Specifications and design subject to change kg (1248 lb) optional counterweight, ROPS
without notice. Wherever applicable, cab, diff lock front axle with standard rear axle,
specifications are in accordance with SAE 2 spool valve with two lever control, heater
standards. Except where otherwise noted, and defroster, 79 kg (175 lb) operator and full
specifications are based on a machine fuel tank.
equipped with all standard equipment, with 566

Item Measurement Specification

John Deere 6125A Turbocharged

And Aftercooled Diesel Engine:

Engine: Net Rated Power 275 hp @ 2000 rpm

Piston Displacement Distance 12.5 L

766 cu in.

Air Cleaner w/Safety Element And Type Dual stage dry type with restriction
Restriction Indicator indicator

Electrical System Voltage 24 volt with 80-amp alternator

Cold Cranking Capacity At -18°C Current 950 amps

(0°F)

Reserve Capacity Time 190 min.

Torque Converter Type Single phase, single stage

Transmission Type Countershaft, computer controlled

powershift

Continued on next page TX,115,JC1560A –19–27SEP01–2/3

4-6-6 022808

PN=244
 Miscellaneous—Specifications

Item Measurement Specification

Forward Travel:

1 Speed 7.4 km/h

4.6 mph

2 Speed 13.9 km/h

8.6 mph

3 Speed 21.2 km/h

13.1 mph

4 Speed 39.5 km/h

24.5 mph

Reverse Travel:

1 Speed 7.4 km/h

4.6 mph

2 Speed 13.9 km/h

8.6 mph

3 Speed 31.1 km/h

19.3 mph

NOTE: All travel speeds are with 26.5—25 tires.

TX,115,JC1560A –19–27SEP01–3/3

4-6-7 022808

PN=245
 Miscellaneous—Specifications

Drain and Refill Capacities—824J

Item Measurement Specification

Cooling system Capacity 38 L (40 qt)

Fuel tank Capacity 462 L (122gal)

Engine crankcase and filter Capacity 38 L (40 qt)

Transmission case and filter Capacity 28 L (30 qt)

Front differential Capacity 49 L (52 qt)

Rear differential Capacity 49 L (52 qt)

Hydraulic reservoir and filters Capacity 144 L (38 gal)

Park brake Capacity 600 mL (20 oz)

TX,115,JC1561 –19–17AUG01–1/1

4-6-8 022808

PN=246
 Miscellaneous—Crime Prevention Tips
Help Prevent Crime

You can help take a bite out of crime by properly

documenting ownership and discouraging theft.

–19–07OCT88
TS140
DX,CRPRV,A –19–03MAR93–1/1

Keep Proof of Ownership

1. Take color photographs from several angles of each

machine.

2. Maintain an up-to-date inventory of all your machines.

–UN–23MAR89
3. Keep your documented identification numbers, color
photographs, and inventory in a safe, secure location.

TS157
DX,CRPRV,I –19–04JUN90–1/1

Park Indoors Out of Sight

Make machines hard to move:

• Park large equipment in front of exits.

• Lower equipment to the ground. Remove key.
• Remove battery when unit is in storage.

–UN–23MAR89
• Lock cab doors, windows, and vandal-proof devices.
• Lock building.

TS158
DX,CRPRV,J –19–04JUN90–1/1

When Parking Outdoors

Make machines hard to move:

• Park in a well-lighted, fenced area.

• Lower all equipment to the ground.
• Remove ignition key.
–UN–23AUG88

• Remove battery when unit is storage.

• Lock cab doors, windows, and vandal-proof devices.
TS144

DX,CRPRV,K –19–04JUN90–1/1

4-7-1 022808

PN=247
 Miscellaneous—Crime Prevention Tips

Reduce Vandalism

1. Install vandal-proof devices.

2. Participate in a neighborhood watch program. Take

written notes of suspicious vehicles or persons and

–UN–22FEB90
report your findings to law enforcement agency.

3. Regularly verify that identification plates have not been

removed. If they have, notify law enforcement agency.

T7223BB
Order duplicate plates from your dealer.

TX,120,DH1093 –19–16SEP92–1/1

Report Thefts Immediately

1. Immediately notify your local law enforcement agency

and insurance agent.

2. Provide a complete description of the machine, all of

the documented identification numbers and color
photographs.

3. Request verification of the identification numbers after

they have been entered with any regional or national
crime information center. Double check the numbers to
be sure they are correct.

4. Notify your John Deere dealer of the theft and request

that its loss be posted with full description and
identification numbers. –UN–09JAN89
TS146

DX,CRPRV,G –19–03MAR93–1/1

4-7-2 022808
PN=248
 Index
Page Page

A Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-8
Electrolyte level check. . . . . . . . . . . . . . . . . . 3-7-4
Accessory menu Explosion . . . . . . . . . . . . . . . . . . . . . . 3-7-4, 4-1-8
Auto mode to first (A 03). . . . . . . . . . . . . . . 2-1-21 Monitor mode (d 03)
Clutch cut-off (A 01) . . . . . . . . . . . . . . . . . . 2-1-16 User diagnostics menu . . . . . . . . . . . . . . 2-1-28
Hour meter mode (A 06) . . . . . . . . . . . . . . . 2-1-22 Remove and install . . . . . . . . . . . . . . . . . . . . 4-1-9
Job timer mode (A 04) . . . . . . . . . . . . . . . . 2-1-22 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-7
Metric units mode (A 07). . . . . . . . . . . . . . . 2-1-23 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-4
Quick shift mode (A 02) . . . . . . . . . . . . . . . 2-1-19 Battery explosions
Stop watch mode (A 05) . . . . . . . . . . . . . . . 2-1-22 Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Accumulator Belt
Brake Serpentine
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-18 Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9
Ride control . . . . . . . . . . . . . . . . . . . . . . . . 4-1-19 Bleed
Acid burns . . . . . . . . . . . . . . . . . . . . . . . 3-7-4, 4-1-8 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21
Adjustment Bleeding fuel system . . . . . . . . . . . . . . . . . . . . 4-1-4
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45 Boom
Steering wheel tilt . . . . . . . . . . . . . . . . . . . . 2-1-42 Control lever-one lever design . . . . . . . . . . 2-2-13
Air Control lever-two lever design. . . . . . . . . . . 2-2-14
Charge cooler hose Height kickout adjustment . . . . . . . . . . . . . . 2-2-18
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-3 Boom Lock
Cleaner elements Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-8 Brake
Cleaner elements replace . . . . . . . . . . . . . . . 3-8-1 Accumulator
Cleaner unloader valve . . . . . . . . . . . . . . . . . 3-4-1 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-18
Conditioning controls. . . . . . . . . . . . . . . . . . 2-1-41 Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21
Conditioning system External inspection . . . . . . . . . . . . . . . . . . . 4-1-16
Service . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-15 Park, change oil . . . . . . . . . . . . . . . . . . . . . . 3-8-5
Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7 Park, check . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6
Inlet cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Break-in engine oil . . . . . . . . . . . . . . . . . . . . . . 3-1-4
Intake hose Bucket
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-3 Control lever-one lever design . . . . . . . . . . 2-2-13
Air conditioning Control lever-two lever design. . . . . . . . . . . 2-2-14
Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-17 Button, horn . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-40
Air flow knob . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-42
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-6
Attachment
Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-23 C
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-21
Attachments Cab
Adding safely . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6 Fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . 3-5-3
Operating safely . . . . . . . . . . . . . . . . . . . . . . 1-3-6 Recirculating air filter . . . . . . . . . . . . . . . . . . 3-5-4
Auto mode to first (A 03) Cab fresh air filter
Accessory menu . . . . . . . . . . . . . . . . . . . . . 2-1-21 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5-3
Cab recirculating air filter
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5-4
Charge air cooler
B Cleaning procedure. . . . . . . . . . . . . . . . . . . 4-1-22
Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-10
Battery Chemical products
Acid burns. . . . . . . . . . . . . . . . . . . . . . 3-7-4, 4-1-8 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12

Index-1 022808
PN=1
 Index

Page Page

Cleaning procedure Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-6

Charge air cooler . . . . . . . . . . . . . . . . . . . . 4-1-22 Rear
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-22 Oil level check . . . . . . . . . . . . . . . . . . . . . 3-7-13
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-22 Rear (standard axle)
Clutch Oil level check . . . . . . . . . . . . . . . . . . . . . 3-7-15
Cut-off (A 01) Differential/axle
Accesory menu . . . . . . . . . . . . . . . . . . . . 2-1-16 Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-10
Continuity check (d 02) Door
Users diagnostics menu . . . . . . . . . . . . . . . 2-1-27 Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7
Control lever Locking open side . . . . . . . . . . . . . . . . . . . . 2-1-42
Shifting transmission . . . . . . . . . . . . . . . . . . 2-2-11 Doors
Controls Engine side shields and service
Heating and air conditioning . . . . . . . . . . . . 2-1-41 Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-6
Coolant
Drive line
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 3-1-8
U-Joints
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1
Fill procedure . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2
Driveline
Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7
Front sliding joints, lubricate . . . . . . . . . . . . . 3-6-1
Level radiator . . . . . . . . . . . . . . . . . . . . . . . . 3-6-2
Level recovery tank. . . . . . . . . . . . . . . . . . . . 3-4-1 Driving metal pins. . . . . . . . . . . . . . . . . . . . . . . 1-4-3
Coolscan Plus . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-9 Dust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24
Pivot
Front steering, lubricate . . . . . . . . . . . . . . . 3-5-2
Pivots, lubricate. . . . . . . . . . . . . . . . . . . . . . . 3-5-1 E

Element
Air cleaner
D Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-8
Emergency preparation . . . . . . . . . . . . . . . . . . 1-2-6
Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1 Engine
Damper, engine vibration Air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2 Boost starting . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6
Diagnose Check and adjust valve lash . . . . . . . . . . . . . 3-9-1
Drive Line Malfunctions. . . . . . . . . . . . . . . . 4-3-12 Cold weather warm-up . . . . . . . . . . . . . . . . . 2-2-8
Diagnose malfunction Oil change . . . . . . . . . . . . . . . . . . . . . 3-5-1, 3-6-3
Hydraulic system. . . . . . . . . . . . . . . . . . . . . 4-3-14
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2
Transmission system . . . . . . . . . . . . . . . . . . 4-3-7
Sensors (d 04)
Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . 3-1-5
Users diagnostics menu . . . . . . . . . . . . . 2-1-29
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1
Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1
Diesel fuel conditioner
Side shields and service doors
Low sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2
Differential Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-6
Front Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2
Oil level, check . . . . . . . . . . . . . . . . . . . . 3-7-11 Vent tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-2
Front and rear Vibration damper, replace . . . . . . . . . . . . . . . 4-1-2
Oil change . . . . . . . . . . . . . . . . . . . . . . . . 3-10-4 Engine oil
Front (standard axle) Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-4
Oil level check . . . . . . . . . . . . . . . . . . . . . 3-7-14 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5
Lock foot switch . . . . . . . . . . . . . . . . . . . . . . 2-1-2 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Lock pedal . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18 Explosion
Lock return filter(s), replace . . . . . . . . . . . . 3-10-3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5

Index-2 022808
PN=2
 Index

Page Page

F Transmission oil temperature . . . . . . . . . . . . 2-1-3

Grease
Fault codes mode (d 01) Boom and cylinder pivots . . . . . . . . . . . . . . . 3-5-1
Users diagnostics menu . . . . . . . . . . . . . . . 2-1-24 Extreme pressure and multipurpose . . . . . . . 3-1-7
Features Frame hinge pivots . . . . . . . . . . . . . . . . . . . . 3-8-5
Operator convenience . . . . . . . . . . . . . . . . . . 1-1-1 Oscillating rear axle . . . . . . . . . . . . . . . . . . . 3-5-2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1 Steering cylinder pivots . . . . . . . . . . . . . . . . . 3-5-2
Filter Grille door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7
Cab air recirculating . . . . . . . . . . . . . . . . . . . 3-5-4
Cab fresh air . . . . . . . . . . . . . . . . . . . . . . . . . 3-5-3
Differential lock return, replace . . . . . . . . . . 3-10-3
Engine oil, replace . . . . . . . . . . . . . . . 3-5-1, 3-6-3 H
Fuel (water separator)
Replace . . . . . . . . . . . . . . . . . . . . . 3-3-11, 3-7-6 Halogen bulbs . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13
Hydraulic reservoir breather, replace. . . . . . . 3-7-9 Handhold use . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
Hydraulic return, replace . . . . . . . . . . . . . . . . 3-7-9 Hardware
Primary fuel filter Torque specifications . . . . . . . . . . . . . . . . . 4-1-25
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-8 Heater
Transmission oil . . . . . . . . . . . . . . . . 3-5-5, 3-7-10 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-41
Water separator, drain . . . . . . . . . . . . . . . . 3-3-11 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7
Fire extinguisher Engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-6 Heater system
Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5 Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-19
Fork attachment . . . . . . . . . . . . . . . . . . . . . . . 2-2-21 High-pressure oils
Frame Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Machine lock bar. . . . . . . . . . . . . . . . . . . . . . 3-2-4 Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-40
Front driveline Hose
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-1 Air Intake
Fuel Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-3
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Charge air cooler
Filter, primary Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-3
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-11 Coolant
Handling and storing . . . . . . . . . . . . . . . . . . . 3-1-3 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
Sensor (d 07) Fuel filler drain hose
Users diagnostic menu . . . . . . . . . . . . . . 2-1-35 Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-10
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-2
Tank drain. . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-10 Tank breather hose
Fuel system Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-10
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 Hour meter mode (A 06)
Fuel tank Accessory menu . . . . . . . . . . . . . . . . . . . . . 2-1-22
Vent hose Hydraulic
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . 3-10-1
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-10 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-3
Color codes . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12 Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-6
Pump serial number . . . . . . . . . . . . . . . . . . . 4-5-1
Reservoir breather filter, replace . . . . . . . . . . 3-7-9
Return filter, replace . . . . . . . . . . . . . . . . . . . 3-7-9
G Sensors (d 06)
Users diagnostics menu . . . . . . . . . . . . . 2-1-33
Gauge Hydraulic system
Engine coolant temperature . . . . . . . . . . . . . 2-1-3 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . 4-3-14
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3 Suction strainer . . . . . . . . . . . . . . . . . . . . . . 3-10-3

Index-3 022808
PN=3
 Index

Page Page

I I.D. mode (d 10)

Users diagnostics mode . . . . . . . . . . . . . 2-1-36
Indicator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3 Maintenance
Secondary steering . . . . . . . . . . . . . . . . . . . 2-2-17 Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-10
Instruments Record keeping. . . . . . . . . . . . . . . . . . . . . . . 3-2-8
Check before starting . . . . . . . . . . . . . . . . . . 2-2-2 Metal pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3
Metric units mode (A 07)
Accessory menu . . . . . . . . . . . . . . . . . . . . . 2-1-23
J Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . 3-1-3
Monitor display unit
Job timer mode (A 04) Auto mode to first (A 03). . . . . . . . . . . . . . . 2-1-21
Accessory menu . . . . . . . . . . . . . . . . . . . . . 2-1-22 Battery monitor (d 03) . . . . . . . . . . . . . . . . . 2-1-28
Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Monitor Display Unit
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1
Monitor display unit
L Clutch cut-off (A 01) . . . . . . . . . . . . . . . . . . 2-1-16
Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13 Continuity check (d 02) . . . . . . . . . . . . . . . . 2-1-27
Lever Digital display . . . . . . . . . . . . . . . . . . . . . . . 2-1-13
Boom control-one lever design . . . . . . . . . . 2-2-13 Engine sensors (d 04). . . . . . . . . . . . . . . . . 2-1-29
Boom control-two lever design . . . . . . . . . . 2-2-14 Fuel sensor (d 07) . . . . . . . . . . . . . . . . . . . 2-1-35
Bucket control-one lever design . . . . . . . . . 2-2-13 Hydraulic sensors (d 06) . . . . . . . . . . . . . . . 2-1-33
Bucket control-two lever design. . . . . . . . . . 2-2-14 Job timer mode (A 04) . . . . . . . . . . . . . . . . 2-1-22
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Machine ID mode (d 10) . . . . . . . . . . . . . . . 2-1-36
Lifting Metric units mode (A 07). . . . . . . . . . . . . . . 2-1-23
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-29 Normal display . . . . . . . . . . . . . . . . . . . . . . 2-1-14
Loader linkage Quick shift mode (A 02) . . . . . . . . . . . . . . . 2-1-19
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5-1 Service codes (d 01) . . . . . . . . . . . . . . . . . . 2-1-24
Lock spin control mode (d 09) . . . . . . . . . . . . . . . 2-1-36
Bar, machine frame. . . . . . . . . . . . . . . . . . . . 3-2-4 Stop watch mode (A 05) . . . . . . . . . . . . . . . 2-1-22
Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10 Transmission sensors (d 05) . . . . . . . . . . . . 2-1-32
Low sulfur diesel fuel conditioner . . . . . . . . . . . 3-1-2 0.1 hour meter mode (A 06) . . . . . . . . . . . . 2-1-22
LPM Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24
Mode (d 09)
Users diagnostics menu . . . . . . . . . . . . . 2-1-36
Lubricant N
Alternative. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3 Neutral
Lubricate Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10
Boom and cylinder pivots . . . . . . . . . . . . . . . 3-5-1 Start system check . . . . . . . . . . . . . . . . . . . 4-1-15
Drive line U-joints . . . . . . . . . . . . . . . . . . . . . 3-7-1
Frame hinge pivots . . . . . . . . . . . . . . . . . . . . 3-8-5
Front driveline . . . . . . . . . . . . . . . . . . . . . . . . 3-6-1
Oscillating rear axle . . . . . . . . . . . . . . . . . . . 3-5-2 O
Rear steering cylinder pivots . . . . . . . . . . . . . 3-5-2
Steering cylinder pivots . . . . . . . . . . . . . . . . . 3-5-2 Oil
Change engine . . . . . . . . . . . . . . . . . . 3-5-1, 3-6-3
Check level park brake . . . . . . . . . . . . . . . . 3-7-11
M Differential, front and rear, change . . . . . . . 3-10-4
Front differential level check . . . . . . . . . . . . 3-7-11
Machine Front differential (standard axle) level
Frame locking bar . . . . . . . . . . . . . . . . . . . . . 3-2-4 check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-14

Index-4 022808
PN=4
 Index

Page Page

Hydraulic, change . . . . . . . . . . . . . . . . . . . . 3-10-1 R

Level engine . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2
Level hydraulic system . . . . . . . . . . . . . . . . . 3-4-3 Radiator
Level transmission . . . . . . . . . . . . . . . . . . . . 3-4-4 Cleaning procedure. . . . . . . . . . . . . . . . . . . 4-1-22
Park brake, change. . . . . . . . . . . . . . . . . . . . 3-8-5 Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-2
Rear differential level check . . . . . . . . . . . . 3-7-13 Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-2
Rear differential (standard axle) level Rear side window
check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-15 Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-44
Specification differential . . . . . . . . . . . . . . . . 3-1-6 Recovery tank
Specification hydraulic system . . . . . . . . . . . 3-1-6 Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1
Specification park brake . . . . . . . . . . . . . . . . 3-1-6 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-6
Specification transmission . . . . . . . . . . . . . . . 3-1-6 Return-to-carry
Transmission, change . . . . . . . . . . . . . 3-5-3, 3-8-3 Height kickout adjustment . . . . . . . . . . . . . . 2-2-19
Oil cooler Return-to-dig circuit
Cleaning procedure. . . . . . . . . . . . . . . . . . . 4-1-22 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-20
Oilscan Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-9 Ride control
Accumulator check . . . . . . . . . . . . . . . . . . . 4-1-19
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-16
P Roads
Operating or traveling . . . . . . . . . . . . . . . . . . 1-3-5
Roll-over protective structure
Park brake
Torque values . . . . . . . . . . . . . . . . . . . . . . . 4-1-25
Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-5
ROPS
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6
Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-13
Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6
Oil level check . . . . . . . . . . . . . . . . . . . . . . 3-7-11
Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
S
Pedal
Differential lock . . . . . . . . . . . . . . . . . . . . . . 2-2-18
Pedals Safety
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2 Add cab guarding for special uses . . . . . . . . 1-2-3
Pilot Controller Tower Avoid unauthorized machine modifications . . 1-2-2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
Pivots Follow safety instructions . . . . . . . . . . . . . . . 1-2-1
Oscillating rear axle, lubricate . . . . . . . . . . . . 3-5-2 Inspect machine . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Rear steering, cylinder lubricate . . . . . . . . . . 3-5-2 Operate only if qualified . . . . . . . . . . . . . . . . 1-2-1
Primary fuel filter Operator’s seat . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
Replace . . . . . . . . . . . . . . . . . . . . . . 3-3-11, 3-7-6 Recognize safety information . . . . . . . . . . . . 1-2-1
Strainer, replace . . . . . . . . . . . . . . . . . . . . . . 3-7-8 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
Product Identification Number. . . . . . . . . . . . . . 4-5-1 Stay clear of moving parts . . . . . . . . . . . . . . 1-2-3
Pump Wear protective equipment . . . . . . . . . . . . . . 1-2-2
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24 Seat
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-45
Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-46
Seat belt
Q Use and maintenance . . . . . . . . . . . . . . . . . . 1-3-1
Secondary steering
Quick shift Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-17
Mode (A 02) Serial number
Accessory menu . . . . . . . . . . . . . . . . . . . 2-1-19 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15 Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . 4-5-1

Index-5 022808
PN=5
 Index

Page Page

Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 T
Serpentine belt
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Tire
Service Pressure check . . . . . . . . . . . . . . . . . . . . . . . 3-3-1
Doors Torque specifications
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-6 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-25
Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 Torque values
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1 Roll-over protective structure. . . . . . . . . . . . 4-1-25
Service codes Wheel retaining cap screw . . . . . . . . . . . . . . 3-3-8
Towing Procedure . . . . . . . . . . . . . . . . . . . . . 2-2-27
Quick reference list . . . . . . . . . . . . . . . . . . . . 4-3-2
Transmission
Service interval checklist . . . . . . . . . . . . . . . . 3-2-10
Oil change . . . . . . . . . . . . . . . . . . . . . 3-5-3, 3-8-3
Service record . . . . . . . . . . . . . . . . . . . . . . . . 3-2-10
Oil filter, replace . . . . . . . . . . . . . . . . 3-5-5, 3-7-10
Shifting Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-4
Transmission. . . . . . . . . . . . . . . . . . . . . . . . 2-2-11 Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-6
Side shields, engine Sensors (d 05)
Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-6 Users diagnostics menu . . . . . . . . . . . . . 2-1-32
Specifications Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1
Differential oil . . . . . . . . . . . . . . . . . . . . . . . . 3-1-6 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-11
Hardware torque . . . . . . . . . . . . . . . . . . . . . 4-1-25 Traveling
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-6 On public roads. . . . . . . . . . . . . . . . . . . . . . . 1-3-5
Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-6 Troubleshooting procedure . . . . . . . . . . . . . . . . 4-3-1
Transmission oil . . . . . . . . . . . . . . . . . . . . . . 3-1-6
Spin Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9
Start aid
U
Starting fluid-cold weather. . . . . . . . . . . . . . . 2-2-4
Starting
Unloader valve
The engine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1
Starting fluid Users diagnostics menu
Cold weather start aid . . . . . . . . . . . . . . . . . . 2-2-4 Battery monitor (d 03) . . . . . . . . . . . . . . . . . 2-1-28
Steering Continuity check (d 02) . . . . . . . . . . . . . . . . 2-1-27
Wheel tilt adjust . . . . . . . . . . . . . . . . . . . . . 2-1-42 Engine sensors (d 04). . . . . . . . . . . . . . . . . 2-1-29
Steps use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1 Fault codes (d 01). . . . . . . . . . . . . . . . . . . . 2-1-24
Stop watch mode (A 05) Fuel sensor (d 07) . . . . . . . . . . . . . . . . . . . 2-1-35
Accessory menu . . . . . . . . . . . . . . . . . . . . . 2-1-22 Hydraulic sensors (d 06) . . . . . . . . . . . . . . . 2-1-33
Storage Machine I.D. mode (d 10) . . . . . . . . . . . . . . 2-1-36
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1 spin control mode (d 09) . . . . . . . . . . . . . . . 2-1-36
Storing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3 Transmission sensors (d 05) . . . . . . . . . . . . 2-1-32
Strainer
Primary fuel
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-8
V
Suction strainer
Hydraulic system. . . . . . . . . . . . . . . . . . . . . 3-10-3
Valve
Switch Air cleaner dust unloader . . . . . . . . . . . . . . . 3-4-1
Differential lock . . . . . . . . . . . . . . . . . . . . . . . 2-1-2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24
Park brake . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12 Dust unloader . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1
Quick shift. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15 Valve lash, engine
Ride control . . . . . . . . . . . . . . . . . . . . . . . . 2-2-16 Check and adjust . . . . . . . . . . . . . . . . . . . . . 3-9-1
Spin Control . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9 Vent tube
Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . 3-1-3 Engine crankcase . . . . . . . . . . . . . . . . . . . . . 3-8-2

Index-6 022808

PN=6
 Index

Page

Warm-up
Engine, cold weather . . . . . . . . . . . . . . . . . . 2-2-8
Washer
Windshield fluid level . . . . . . . . . . . . . . . . . . 3-2-8
Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Water separator
Bowl, clean . . . . . . . . . . . . . . . . . . . . 3-3-13, 4-1-5
Replace . . . . . . . . . . . . . . . . . . . . . . 3-3-11, 3-7-6
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-15
Welding repairs . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
Wheel
Cap screw torque . . . . . . . . . . . . . . . . . . . . . 3-3-8
Window
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-44
Rear side
Opening. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-44
Windshield
Washer fluid . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-8
12-Volt Power Plug. . . . . . . . . . . . . . . . . . . . . 2-1-46
3-Way Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-9

Index-7 022808
PN=7
 Index

Index-8 022808

PN=8