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624H Loader and TC62HTool Carrier

OPERATOR’S MANUAL624H Loader and TC62H Tool

Carrier

OMT195360 Issue B3 (ENGLISH)

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of its constituents areknown 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 chemicalsknown to the State of California to cause cancer, birth

defects or other reproductive harm.

The State of California requires the above two warnings.

Worldwide ConstructionAnd Forestry Division

(This manual replaces OMT180472 G0)LITHO IN U.S.A.

Introduction

DX,IFC7 –19–16NOV01–1/1

Foreword

READ THIS MANUAL carefully to learn how to operateand service your machine correctly. Failure to do socould result in personal injury or equipment damage.This manual and safety signs on your machine mayalso be available in other languages. (See your JohnDeere dealer to order.)

THIS MANUAL SHOULD BE CONSIDERED apermanent part of your machine and should remainwith the machine when you sell it.

MEASUREMENTS in this manual are given in bothmetric and customary U.S. unit equivalents. Use onlycorrect replacement parts and fasteners. Metric andinch fasteners may require a specific metric or inchwrench.

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

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

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

WARRANTY is provided as part of John Deere’ssupport program for customers who operate andmaintain their equipment as described in this manual.The warranty is explained on the warranty certificatewhich you should have received from your dealer.

This warranty provides you the assurance that JohnDeere will back its products where defects appearwithin the warranty period. In some circumstances,John Deere also provides field improvements, oftenwithout charge to the customer, even if the product isout of warranty. Should the equipment be abused, ormodified to change its performance beyond the originalfactory specifications, the warranty will become voidand field improvements may be denied. Setting fueldelivery above specifications or otherwiseoverpowering machines will result in such action.

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

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Introduction

HG31779,0000015 –19–08APR02–1/1

Emission Control Statement

EMISSIONS CONTROL WARRANTY STATEMENT FORNEW 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 toUS EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control WarrantyStatement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy dutynon road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement."

U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

Emissions control-related parts and components are warrantedby John Deere for five years or 3000 hours of operation, whicheveroccurs first. John Deere further warrants that the engine coveredby this warranty was designed, built, and equipped so as toconform at the time of sale with all U.S. emissions standards atthe time of manufacture, and that it is free of defects in materialsand workmanship which would cause it not to meet thesestandards within the period of five years or 3000 hours ofoperations, whichever occurs first.

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

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

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

You are responsible for initiating the warranty process. The CARBsuggests that you present your machine to the nearest authorizedJohn Deere dealer as soon as a problem is suspected. Thewarranty repairs should be completed by the service dealer asexpeditiously as possible.

If you have any questions regarding your warranty rights andresponsibilities, you should contact John Deere at 1-319-292-5400, or the State of California Air Resources Board, Mobile SourceOperation Division, PO Box 8001, El Monte, CA 91731-2900

The warranty period begins on the date the machine is deliveredto an ultimate purchaser, or when otherwise put into service.John Deere warrants to the ultimate purchaser and eachsubsequent purchaser that the engine is designed, built andequipped so as to conform with all applicable regulations adoptedby the Air Resources Board, and that it is free from defects inmaterials and workmanship which would cause the failure of awarranted part.

Any warranted part which is scheduled for replacement asrequired maintenance by the operator's manual is warranted byJohn Deere for the period of time prior to the first scheduledreplacement point for that part. If the part fails prior to the firstscheduled replacement point, the part shall be repaired orreplaced under warranty. Any such part repaired or replacedunder warranty is warranted for the remainder of the period priorto the first scheduled replacement point for that part.

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

Repair or replacement of a warranted part will be performed at nocharge to you by an authorized John Deere dealer. You will notbe charged for diagnostic labor which leads to the determinationthat a warranted part is defective, if the diagnostic work isperformed by a John Deere dealer.

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

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

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

Warranties stated on this certificate refer only to emissions-relatedparts and components of your engine. The complete machinewarranty, less emisions-related parts and components, isprovided separately as "John Deere "Secure Warranty" For NewConstruction Products."

YOUR WARRANTY RIGHTS AND OBLIGATIONS

JOHN DEERE'S WARRANTY COVERAGE:

OWNER'S WARRANTY RESPONSIBILITIES:

As the heavy-duty engine owner, you are responsible for theperformance of the required maintenance as outlined in the

The California Air Resources Board (CARB) and John Deere arepleased to explain the emission control system on your newengine. In California, new heavy-duty engines must be designed,built and equipped to meet the State's stringent anti-smogstandards. John Deere must warrant the emission control systemon your engine for the periods of time listed below provided therehas been no abuse, neglect, or improper maintenance of yourmachine.

Where a warrantable condition exists, i.e. failure due to defect inJohn Deere-supplied material and/or workmanship, John Deerewill repair your heavy-duty engine at no cost to you includingdiagnosis, parts and labor

The emission control system of your heavy-duty engine iswarranted for five years or 3000 hours of operation, whicheveroccurs first. If any emission-related part on your engine isdefective, the part will be repaired or replaced by John Deere.Warranties stated on this certificate refer only to emissions-relatedparts and components of your engine. The complete machinewarranty, less emissions-related parts and components, isprovided separately as the "John Deere "Secure Warranty" ForNew Construction Products."

Your emissions control system includes:

Fuel Metering SystemFuel Injection System

Air Induction SystemIntake ManifoldTurbocharger SystemCharge Air Cooling System

Miscellaneous Items used in Above Systems

T13

2126

–19–

28JU

N00

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Introduction

TX,II,FAX –19–10JUL01–1/1

Technical Information Feedback Form

We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.

SEND TO: John Deere Dubuque WorksP.O. Box 538Attn: Publications Supervisor, Dept. 303Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

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

Poor Fair Good Very Good Excellent1 2 3 4 5 6 7 8 9 10

Company Name:

Technician Name:

Address:

Phone:

Fax No.:

Dealer Acct. No.:

THANK YOU!

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ContentsPage Page

Safety—Safety Features Operation—Operator’s StationSafety Features . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1 Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1

Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2Safety—General Precautions Deluxe Monitor Panel (Earlier Machines) . . . . . 2-1-3Recognize Safety Information. . . . . . . . . . . . . . 1-2-1 Deluxe Monitor Panel Functions (EarlierFollow Safety Instructions. . . . . . . . . . . . . . . . . 1-2-1 Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-4Operate Only If Qualified . . . . . . . . . . . . . . . . . 1-2-1 Deluxe Monitor Panel (Later Machines) . . . . . . 2-1-7Wear Protective Equipment . . . . . . . . . . . . . . . 1-2-2 Deluxe Monitor Panel Functions (LaterAvoid Unauthorized Machine Modifications. . . . 1-2-2 Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8Add Cab Guarding For Special Uses . . . . . . . . 1-2-2 Console Switches and AccessoriesInspect Machine . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3 (Later Machines—Single Lever Design) . . . 2-1-11Stay Clear Of Moving Parts . . . . . . . . . . . . . . . 1-2-3 Console Switch and AccessoryAvoid High-Pressure Fluids . . . . . . . . . . . . . . . 1-2-3 Functions (Later Machines—Single LeverBeware Of Exhaust Fumes. . . . . . . . . . . . . . . . 1-2-4

Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12Prevent Fires . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4

Console Switches and AccessoriesPrevent Battery Explosions. . . . . . . . . . . . . . . . 1-2-4

(Later Machines—Two Lever Design) . . . . . 2-1-14Handle Chemical Products Safely. . . . . . . . . . . 1-2-5Console Switch and AccessoryDispose of Waste Properly . . . . . . . . . . . . . . . . 1-2-5

Functions (Later Machines—Two LeverPrepare for Emergencies . . . . . . . . . . . . . . . . . 1-2-5Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15

Monitor Display Unit . . . . . . . . . . . . . . . . . . . . 2-1-17Safety—Operating PrecautionsMonitor Display Unit—Accessory MenuUse Steps And Handholds Correctly . . . . . . . . 1-3-1

Normal Display . . . . . . . . . . . . . . . . . . . . . . 2-1-18Start Only From Operator’s Seat . . . . . . . . . . . 1-3-1Clutch Cut-Off (A 01) . . . . . . . . . . . . . . . . . 2-1-20Use And Maintain Seat Belt . . . . . . . . . . . . . . . 1-3-1Quick Shift Mode (A 02) . . . . . . . . . . . . . . . 2-1-23Prevent Unintended Machine Movement . . . . . 1-3-2Auto Mode to First (A 03) . . . . . . . . . . . . . . 2-1-25Avoid Work Site Hazards . . . . . . . . . . . . . . . . . 1-3-2Job Timer Mode (A 04) . . . . . . . . . . . . . . . . 2-1-26Use Special Care When Operating Loader. . . . 1-3-3Stop Watch Mode (A 05). . . . . . . . . . . . . . . 2-1-26Keep Riders Off Machine . . . . . . . . . . . . . . . . . 1-3-30.1 Hour Meter Mode (A 06) . . . . . . . . . . . . 2-1-27Avoid Backover Accidents . . . . . . . . . . . . . . . . 1-3-4Metric Units Mode (A 07) . . . . . . . . . . . . . . 2-1-27Avoid Machine Tip Over . . . . . . . . . . . . . . . . . . 1-3-4

Monitor Display Unit—User DiagnosticsOperating on Slopes. . . . . . . . . . . . . . . . . . . . . 1-3-5MenuOperating Or Traveling On Public Roads . . . . . 1-3-5Service Codes (d 01) . . . . . . . . . . . . . . . . . 2-1-28Inspect and Maintain ROPS . . . . . . . . . . . . . . . 1-3-6Continuity Check (d 02) . . . . . . . . . . . . . . . 2-1-30Add And Operate Attachments Safely . . . . . . . 1-3-6Battery Monitor (d 03) . . . . . . . . . . . . . . . . . 2-1-32Engine Sensors (d 04) . . . . . . . . . . . . . . . . 2-1-33Safety—Maintenance PrecautionsTransmission Sensors (d 05) . . . . . . . . . . . 2-1-36Park And Prepare For Service Safely . . . . . . . . 1-4-1Hydraulic Sensors (d 06). . . . . . . . . . . . . . . 2-1-38Service Cooling System Safely. . . . . . . . . . . . . 1-4-1Fuel Sensor (d 07) . . . . . . . . . . . . . . . . . . . 2-1-40Remove Paint Before Welding or Heating . . . . 1-4-2(d08)-Not Used . . . . . . . . . . . . . . . . . . . . . . 2-1-41Make Welding Repairs Safely. . . . . . . . . . . . . . 1-4-2Machine I.D. Mode (d 10) . . . . . . . . . . . . . . 2-1-41Drive Metal Pins Safely . . . . . . . . . . . . . . . . . . 1-4-3

Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-47Safety—Safety SignsSafety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1 Continued on next page

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

COPYRIGHT 2003DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 1997, 1998, 2000, 2001, 2002

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Contents

Page Page

Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-47 Transmission, Hydraulic System, ParkBrake, and Differential Oil . . . . . . . . . . . . . . . 3-1-5Air Conditioning Controls . . . . . . . . . . . . . . . . 2-1-48

Air Flow Knob. . . . . . . . . . . . . . . . . . . . . . . . . 2-1-49 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-6Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 3-1-7Adjusting Steering Wheel Tilt . . . . . . . . . . . . . 2-1-49

Opening and Securing Side Door . . . . . . . . . . 2-1-49Opening Side Window/Secondary Exit . . . . . . 2-1-51 Maintenance—Periodic MaintenanceOpening Rear Side Window . . . . . . . . . . . . . . 2-1-51 Service Your Machine at Specified Intervals. . . 3-2-1Adjusting Seat . . . . . . . . . . . . . . . . . . . . . . . . 2-1-52 Check the Monitor Display Unit Regularly. . . . . 3-2-1Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-53 Opening Engine Side Shields and

Service Doors . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2Operation—Operating the Machine Locking Machine Frame . . . . . . . . . . . . . . . . . . 3-2-3Inspect Machine Daily Before Starting . . . . . . . 2-2-1 Boom Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-4Check Instruments Before Starting . . . . . . . . . . 2-2-2 Opening Grille Door . . . . . . . . . . . . . . . . . . . . . 3-2-5Starting the Engine. . . . . . . . . . . . . . . . . . . . . . 2-2-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5Starting Fluid—If Equipped (Cold Weather Check Windshield Washer Fluid Level . . . . . . . 3-2-5

Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-4 Maintenance and Repair RecordBattery Keeping System . . . . . . . . . . . . . . . . . . . . . . 3-2-6

Using Booster Batteries—24 Volt System . . . 2-2-6 OILSCAN PLUS, COOLSCAN PLUS,Engine Air Heater—If Equipped . . . . . . . . . . . . 2-2-7 and 3-Way Coolant Test Kit . . . . . . . . . . . . . 3-2-7Using Coolant Heater—If Equipped . . . . . . . . . 2-2-7 Service Intervals. . . . . . . . . . . . . . . . . . . . . . . . 3-2-8Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . 2-2-8 Maintenance—As RequiredNeutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8 Check Tire Pressure. . . . . . . . . . . . . . . . . . . . . 3-3-1Shifting the Transmission . . . . . . . . . . . . . . . . . 2-2-9 Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-2Park Brake Switch . . . . . . . . . . . . . . . . . . . . . 2-2-10 Tighten Wheel Retainer Cap Screws . . . . . . . . 3-3-2Boom and Bucket Control Lever—One Check Fire Extinguisher—If Equipped . . . . . . . 3-3-3

Lever Design. . . . . . . . . . . . . . . . . . . . . . . . 2-2-11 Clean or Replace Air Cleaner Elements . . . . . . 3-3-4Boom and Bucket Control Lever Check Air Inlet Cover . . . . . . . . . . . . . . . . . . . . 3-3-4

Two Lever Design. . . . . . . . . . . . . . . . . . . . 2-2-12 Inspect Serpentine Belt . . . . . . . . . . . . . . . . . . 3-3-5Quick Shift Switch . . . . . . . . . . . . . . . . . . . . . 2-2-13 Drain Fuel Tank Sediment . . . . . . . . . . . . . . . . 3-3-6Ride Control Switch—Earlier Machines (If Drain and Clean Primary Fuel Filter . . . . . . . . . 3-3-7

Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14Ride Control—Later Machines (If Equipped). . 2-2-16

Maintenance—Every 10 Hours or DailySecondary Steering—If Equipped. . . . . . . . . . 2-2-17Check Recovery Tank Coolant Level . . . . . . . . 3-4-1Differential Lock Switch . . . . . . . . . . . . . . . . . 2-2-18Clean Air Cleaner Dust Unloader Valve . . . . . . 3-4-1Boom Height Kickout Adjustment . . . . . . . . . . 2-2-18Check Engine Oil Level . . . . . . . . . . . . . . . . . . 3-4-2Return-to-Carry Kickout Adjustment . . . . . . . . 2-2-19Check Hydraulic Oil Level . . . . . . . . . . . . . . . . 3-4-3Return-To-Dig Adjustment (S.N. —574603) . . 2-2-20Check Transmission Oil Level . . . . . . . . . . . . . 3-4-4Return-To-Dig Adjustment (S.N. 574603— ). . 2-2-22

Fork Attachment . . . . . . . . . . . . . . . . . . . . . . . 2-2-24Maintenance—After First 100 HoursParking the Machine. . . . . . . . . . . . . . . . . . . . 2-2-26Change Engine Break-In Oil andLoading Machine on a Trailer . . . . . . . . . . . . . 2-2-27

Replace Filter . . . . . . . . . . . . . . . . . . . . . . . . 3-5-1Towing Procedure . . . . . . . . . . . . . . . . . . . . . 2-2-29Change Transmission Oil . . . . . . . . . . . . . . . . . 3-5-3Lifting the Machine . . . . . . . . . . . . . . . . . . . . . 2-2-31Replace Transmission Oil Filter . . . . . . . . . . . . 3-5-5

Maintenance—MachineDiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Maintenance—Every 100 Hours

Grease Loader Linkage and Cylinder Pivots. . . 3-6-1Low Sulfur Diesel Fuel Conditioner. . . . . . . . . . 3-1-1Dieselscan Fuel Analysis . . . . . . . . . . . . . . . . . 3-1-2 Grease Front Steering Cylinder Pivots . . . . . . . 3-6-3

Grease Oscillating Rear Axle and RearHandling and Storing Diesel Fuel . . . . . . . . . . . 3-1-2Alternative And Synthetic Lubricants . . . . . . . . 3-1-2 Steering Cylinder Pivots . . . . . . . . . . . . . . . . 3-6-3Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . 3-1-3Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . 3-1-4 Continued on next page

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Check Cab Fresh Air Filter—If Equipped Precautions for Alternator and Regulator . . . . . 4-1-5With Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3 Handling, Checking And Servicing Batteries

Check Cab Recirculating Air Filter—If Carefully . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-6Equipped With Cab. . . . . . . . . . . . . . . . . . . . 3-6-6 Replacing Batteries . . . . . . . . . . . . . . . . . . . . . 4-1-7

Removing Batteries . . . . . . . . . . . . . . . . . . . . . 4-1-8Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . 4-1-9Maintenance—Every 250 Hours

Grease Front Driveline Sliding Joint . . . . . . . . . 3-7-1 Fuse (Blade-Type) Color Codes . . . . . . . . . . . 4-1-11Check Receiver Dryer Moisture Indicator . . . . . 3-7-2 Replacing Halogen Bulbs . . . . . . . . . . . . . . . . 4-1-12Check Radiator Coolant Level . . . . . . . . . . . . . 3-7-2 Engine Speeds . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13Change Engine Oil and Replace Filter . . . . . . . 3-7-3 Checking Neutral Start System. . . . . . . . . . . . 4-1-13

Servicing Air Conditioning System . . . . . . . . . 4-1-14Maintenance—Every 500 Hours Welding on Machine. . . . . . . . . . . . . . . . . . . . 4-1-14Lubricate Upper and Lower Drive Line External Service Brake Inspection . . . . . . . . . 4-1-15

Sliding Joints. . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1 Checking Brake Accumulators . . . . . . . . . . . . 4-1-16Check Air Intake Hoses . . . . . . . . . . . . . . . . . . 3-8-2 Checking Ride Control Accumulator—IfCheck Battery Electrolyte Level and Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-17

Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-3 Transmission Oil Cooler, Hydraulic OilReplace Primary Fuel Filter . . . . . . . . . . . . . . . 3-8-5 Cooler, Air-to-Air Aftercooler, and . . . . . . . . 4-1-19Replace Final Fuel Filter. . . . . . . . . . . . . . . . . . 3-8-5 Service Recommendations For STC1

Replace Hydraulic System Return Filter . . . . . . 3-8-6 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-20Grease Rear Oscillating Support Cover . . . . . . 3-8-6 Do Not Service Control Valves,Replace Hydraulic Reservoir Breather Filter . . . 3-8-7 Cylinders, Pumps or Motors . . . . . . . . . . . . 4-1-21Replace Transmission Oil Filter . . . . . . . . . . . . 3-8-8 Hardware Torque Specifications . . . . . . . . . . . 4-1-22Check Park Brake Oil Level . . . . . . . . . . . . . . 3-8-10 Keep ROPS Installed Properly . . . . . . . . . . . . 4-1-22Check Front and Rear Differential Oil Level . . 3-8-11 Metric Bolt and Cap Screw Torque Values . . . 4-1-23

Unified Inch Bolt and Cap Screw TorqueMaintenance—Every 1000 Hours Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24Clean Engine Crankcase Vent Tube. . . . . . . . . 3-9-1Replace Air Cleaner Dust Unloader Valve . . . . 3-9-1

Miscellaneous—Operational CheckoutReplace Air Cleaner Elements . . . . . . . . . . . . . 3-9-1Operational Checkout . . . . . . . . . . . . . . . . . . . . 4-2-1Check Coolant . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-2Checking and Clearing DiagnosticCheck Radiator Hoses . . . . . . . . . . . . . . . . . . . 3-9-3

Trouble Codes From Monitor . . . . . . . . . . . . 4-2-1Change Transmission Oil . . . . . . . . . . . . . . . . . 3-9-4Engine Off Checks . . . . . . . . . . . . . . . . . . . . . . 4-2-3Grease Frame Hinge Pivots . . . . . . . . . . . . . . . 3-9-6Engine Running Checks . . . . . . . . . . . . . . . . . . 4-2-5Check Park Brake . . . . . . . . . . . . . . . . . . . . . . 3-9-7

Change Park Brake Oil. . . . . . . . . . . . . . . . . . . 3-9-8Miscellaneous—TroubleshootingTroubleshooting Procedure. . . . . . . . . . . . . . . . 4-3-1Maintenance—Every 2000 HoursDiagnostic Trouble Codes QuickAdjust Engine Valve Lash (Clearance) . . . . . . 3-10-1

Reference List. . . . . . . . . . . . . . . . . . . . . . . . 4-3-2Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-5Maintenance—Every 3000 HoursDiagnoseChange Hydraulic System Oil . . . . . . . . . . . . . 3-11-1

Transmission System Malfunctions . . . . . . . . 4-3-7Clean Hydraulic System Strainer . . . . . . . . . . 3-11-2Differential And Axle Malfunctions. . . . . . . . 4-3-10Change Front and Rear Differential Oil. . . . . . 3-11-3Service Brake Malfunctions. . . . . . . . . . . . . 4-3-11Clean Axle Differential Recirculation Screen. . 3-11-4Drive Line Malfunctions. . . . . . . . . . . . . . . . 4-3-12Park Brake Malfunctions . . . . . . . . . . . . . . . 4-3-13Miscellaneous—MachineLoader Hydraulic System Malfunctions . . . . 4-3-14Draining the Cooling System . . . . . . . . . . . . . . 4-1-1Steering Malfunctions . . . . . . . . . . . . . . . . . 4-3-16Filling the Cooling System . . . . . . . . . . . . . . . . 4-1-2

Air Conditioning System . . . . . . . . . . . . . . . . . 4-3-17Replacing Engine Vibration Damper . . . . . . . . . 4-1-3Adjusting Pilot Controller Tower . . . . . . . . . . . . 4-1-4 Heater System . . . . . . . . . . . . . . . . . . . . . . . . 4-3-19Checking Fuel Tank Vent Hose . . . . . . . . . . . . 4-1-4Bleeding Fuel System. . . . . . . . . . . . . . . . . . . . 4-1-5 Continued on next page

iii 102703

PN=3

Contents

Page

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

Miscellaneous—Machine NumbersRecord Product Identification Number (PIN) . . . 4-5-1Record Engine Serial Number . . . . . . . . . . . . . 4-5-1Record Transmission Serial Number . . . . . . . . 4-5-1Record Hydraulic Pump Serial Number . . . . . . 4-5-1Record Axle Serial Number . . . . . . . . . . . . . . . 4-5-2

Miscellaneous—Specifications624H/TC62H Specifications . . . . . . . . . . . . . . . 4-6-1624H High Lift Specifications . . . . . . . . . . . . . . 4-6-3Drain and Refill Capacities—624H/TC62H . . . . 4-6-4

Miscellaneous—Crime Prevention TipsHelp Prevent Crime . . . . . . . . . . . . . . . . . . . . . 4-7-1Record Identification Numbers . . . . . . . . . . . . . 4-7-1Keep Proof of Ownership . . . . . . . . . . . . . . . . . 4-7-1Park Indoors Out of Sight . . . . . . . . . . . . . . . . . 4-7-1When Parking Outdoors . . . . . . . . . . . . . . . . . . 4-7-2Reduce Vandalism . . . . . . . . . . . . . . . . . . . . . . 4-7-2Report Thefts Immediately . . . . . . . . . . . . . . . . 4-7-3

iv 102703

PN=4

Safety—Safety Features

TX03679,00016FD –19–14JUN01–1/1

Safety Features

1

2

3

4

65

7

98

1213 10

14

15

T138566

11

T13

8566

–UN

–01J

UN

01

Please remember, the operator is the key topreventing accidents.

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

2. Pressurized Cab with Heater/Defroster. Positivepressure ventilation system circulates both outsideand inside air through filters for a clean workingenvironment. Built in defroster vents direct air flowfor effective window defogging/deicing.

3. Mirrors. Large exterior mirrors on both sides andan inside mirror offers operator a broad view ofarea behind machine.

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

5. Loader Boom Service Lock. Loader includes amechanical lock for securing boom in the raisedposition before work is started on or around themachine.

6. Halogen Lights and Turn Signals. High intensityhalogen drive/work lights and high-visibility turnsignals are standard equipment.

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

8. Handholds. Large, conveniently placed handholdsmake it easy to enter or exit the operator’s stationor service area.

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

10. Independent Parking Brake. Electronicallycontrolled and engages whenever the engine isstopped.

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

12. Bypass Start Protection. Shielding over thestarter terminals helps prevent dangerous bypassstarting.

13. Engine Fan Guard. A secondary fan guard insidethe engine compartment helps prevent contactwith the rotating fan blades.

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

15. Stop and Signal Lights. Highly visible stop lightsare standard equipment.

1-1-1 102703

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Safety—General Precautions

TX03679,00016CC –19–21AUG00–1/1

Recognize Safety Information

T13

3555

–UN

–28A

UG

00T

1335

88–1

9–28

AU

G00

This is the safety alert symbol. When you see thissymbol on your machine or in this manual, be alertfor the potential of personal injury.

Follow the precautions and safe operating practiceshighlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — isused with the safety alert symbol. DANGER identifies themost serious hazards.

On your machine, DANGER signs are red in color,WARNING signs are orange, and CAUTION signs areyellow. DANGER and WARNING signs are located nearspecific hazards. General precautions are on CAUTIONlabels.

TX03679,00016F9 –19–14MAR01–1/1

Follow Safety Instructions

T13

3556

–UN

–24A

UG

00

Read the safety messages in this manual and on themachine. Follow these warnings and instructions carefully.Review them frequently.

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

TX03679,00016FA –19–30OCT00–1/1

Operate Only If Qualified

Do not operate this machine unless you have read theoperator’s manual carefully and you have beenqualified by supervised training and instruction.

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

machine functions with the machine in an open areabefore starting to work.

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

1-2-1 102703

PN=8


TX03679,00016D0 –19–30OCT00–1/1

Wear Protective Equipment

TS

206

–UN

–23A

UG

88

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

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

TX03679,00016B7 –19–30OCT00–1/1

Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition ofunapproved products or attachments, may affectmachine stability or reliability, and may create a hazardfor the operator or others near the machine.

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

TX03679,00017C6 –19–01JUN01–1/1

Add Cab Guarding For Special Uses

T14

1893

–UN

–04M

AY

01

Special work situations or machine attachments maycreate an environment with falling or flying objects.Loading logs, using fork attachments, or operating inwaste management applications requires special worktools. Added cab guarding to protect the operator mayalso be required.

Use load-clamping grapples to keep bulky loads fromfalling and add special screens or guarding when objectsmay be directed toward the cab. Contact your authorizeddealer for information on devices intended to protect theoperator from falling or flying objects in special worksituations.

1-2-2 102703

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TX03679,0001734 –19–25SEP00–1/1

Inspect Machine

T66

07A

Q–U

N–1

8OC

T88

Inspect machine carefully each day by walking around itbefore starting.

Keep all guards and shields in good condition andproperly installed. Fix damage and replace worn or brokenparts immediately. Pay special attention to hydraulichoses and electrical wiring.

TX03679,00016D2 –19–30OCT00–1/1

Stay Clear Of Moving Parts

T13

3592

–UN

–12S

EP

01Entanglements in moving parts can cause serious injury.

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

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

TX03679,00016D3 –19–30OCT00–1/1

Avoid High-Pressure Fluids

T13

3509

–UN

–31O

CT

00T

1338

40–U

N–2

0SE

P00

This machine uses a high-pressure hydraulic system.Escaping fluid under pressure can penetrate the skincausing serious injury.

Never search for leaks with your hands. Protect hands.Use a piece of cardboard to find location of escaping fluid.Stop engine and relieve pressure before disconnectinglines or working on hydraulic system.

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

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TX03679,00016D4 –19–14SEP00–1/1

Beware Of Exhaust Fumes

T13

3546

–UN

–24A

UG

00

Prevent asphyxiation. Engine exhaust fumes can causesickness or death.

If you must operate in a building, provide adequateventilation. Use an exhaust pipe extension to remove theexhaust fumes or open doors and windows to bringoutside air into the area.

TX03679,00016F5 –19–25SEP00–1/1

Prevent Fires

T13

3552

–UN

–14S

EP

00T

1335

53–U

N–0

7SE

P00

T13

3554

–UN

–07S

EP

00

Handle Fuel Safely: Store flammable fluids away fromfire hazards. Never refuel machine while smoking or whennear sparks or flame.

Clean Machine Regularly: Keep trash, debris, greaseand oil from accumulating in engine compartment, aroundfuel lines, hydraulic lines and electrical wiring. Never storeoily rags or flammable materials inside a machinecompartment.

Maintain Hoses and Wiring: Replace hydraulic hosesimmediately if they begin to leak, and clean up any oilspills. Examine electrical wiring and connectors frequentlyfor damage.

Keep A Fire Extinguisher Available: Always keep amulti-purpose fire extinguisher on or near the machine.Know how to use extinguisher properly.

TX03679,000174A –19–14SEP00–1/1

Prevent Battery Explosions

TS

204

–UN

–23A

UG

88

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 objectacross the posts. Use a voltmeter or hydrometer.

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

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TX03679,00016D7 –19–05AUG02–1/1

Handle Chemical Products Safely

T13

3580

–UN

–25A

UG

00

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

If uncertain about safe handling or use of these chemicalproducts, contact your authorized dealer for a MaterialSafety Data Sheet (MSDS) or go to internet websitehttp://www.jdmsds.com. The MSDS describes physicaland health hazards, safe use procedures, and emergencyresponse techniques for chemical substances. FollowMSDS recommendations to handle chemical productssafely.

TX03679,0001733 –19–14SEP00–1/1

Dispose of Waste Properly

T13

3567

–UN

–25A

UG

00

Improper disposal of waste can threaten the environment.Fuel, oils, coolants, filters and batteries used with thismachine may be harmful if not disposed of properly.

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

Air conditioning refrigerants can damage the atmosphere.Government regulations may require using a certifiedservice center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact yourlocal environmental or recycling center or your dealer formore information.

TX03679,000174B –19–14SEP00–1/1

Prepare for Emergencies

TS

291

–UN

–23A

UG

88

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,hospital, and fire department near your telephone.

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Safety—Operating Precautions

TX03679,00016F2 –19–14SEP00–1/1

Use Steps And Handholds Correctly

T13

3468

–UN

–30A

UG

00

Prevent falls by facing the machine when you get on andoff. Maintain 3-point contact with steps and handrails.Never use machine controls as handholds.

Use extra care when mud, snow, or moisture presentslippery conditions. Keep steps clean and free of greaseor oil. Never jump when exiting machine. Never mount ordismount a moving machine.

TX03679,0001799 –19–02MAY01–1/1

Start Only From Operator’s Seat

T13

3715

–UN

–07S

EP

00Avoid unexpected machine movement. Start engine onlywhile sitting in operator’s seat. Ensure all controls andworking tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do notattempt to start engine by shorting across the startersolenoid terminals.

TX03679,00016DD –19–17OCT00–1/1

Use And Maintain Seat Belt

T13

3716

–19–

14S

EP

00Use seat belt when operating machine. Remember tofasten seat belt when loading and unloading from trucksand during other uses.

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

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

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TX03679,00017C7 –19–28OCT02–1/1

Prevent Unintended Machine Movement

T14

2001

–UN

–15M

AY

01

When co-workers are present, disable hydraulics.

Lower all equipment to the ground during workinterruptions. Lock transmission control in neutral, engagepark brake and stop engine before allowing anyone toapproach the machine.

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

TX03679,000179A –19–02MAY01–1/1

Avoid Work Site Hazards

T14

1894

–UN

–15J

UN

01T

1416

70–U

N–2

4AP

R01

T14

1672

–UN

–04M

AY

01

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

Prepare work site properly. Avoid operating nearstructures or objects that could fall onto the machine.Clear away debris that could move unexpectedly if runover.

Avoid boom or attachment contact with overheadobstacles or overhead electrical lines. Never move anypart of machine or load closer than 3 m (10 ft) plus twicethe line insulator length to overhead wires.

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

Operate only on solid footing with strength sufficient tosupport machine. Be especially alert working nearembankments or excavations.

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

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TX03768,0000B70 –19–14MAY01–1/1

Use Special Care When Operating Loader

T14

1957

–UN

–15M

AY

01T

1419

02–U

N–0

7MA

Y01

Never use the loader to lift people. Do not allowanyone to ride in the bucket or use the bucket as awork platform.

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

Ensure that objects in the bucket are secure. Do notattempt to lift or carry objects that are too big or too longto fit inside the bucket unless secured with an adequatechain or other device. Keep bystanders away from raisedloads.

Be careful when lifting objects. Never attempt to liftobjects too heavy for your machine. Assure machinestability and hydraulic capability with a test lift beforeattempting other maneuvers. Use an adequate chain orsling and proper rigging techniques to attach and stabilizeloads. Never lift an object above or near another person.

TX03679,000179B –19–20APR01–1/1

Keep Riders Off Machine

T14

1671

–UN

–04M

AY

01

Only allow operator on machine.

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

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

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TX03679,000179C –19–20APR01–1/1

Avoid Backover Accidents

T14

1673

–UN

–04M

AY

01

Before moving machine, be sure all persons are clearof machine path. Turn around and look directly for bestvisibility. Use mirrors to assist in checking all aroundmachine. Keep windows and mirrors clean, adjusted, andin good repair.

Be certain reverse warning alarm is working properly.

Use a signal person when backing if view isobstructed or when in close quarters. Keep signalperson in view at all times. Use prearranged hand signalsto communicate.

TX03679,000179D –19–02MAY01–1/1

Avoid Machine Tip Over

T13

3716

–19–

14S

EP

00T

1416

76–U

N–0

4MA

Y01

T14

1672

–UN

–04M

AY

01

Use seat belt at all times.

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

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

Be careful on slopes. Avoid sharp turns. Balance loadsso weight is evenly distributed and load is stable. Carrytools and loads close to the ground to aid visibility andlower center of gravity. Use extra care on soft, rocky orfrozen ground.

Know the capacity of the machine. Do not overload. Becareful with heavy loads. Using oversize buckets or liftingheavy objects reduces machine stability.

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

1-3-4 102703

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TX03679,000179E –19–14MAY01–1/1

Operating on Slopes

T14

1681

–UN

–30A

PR

01

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

Select low gear speed before starting down slope. Thegrade of the slope will be limited by ground condition andload being handled.

Use service brakes to control speed. Sudden brakeapplication with a loaded bucket on downhill side couldcause machine to tip forward.

TX03679,00017C8 –19–14JUN01–1/1

Operating Or Traveling On Public Roads

T14

1891

–UN

–22M

AY

01

Machines that work near vehicle traffic or travel slowerthan normal highway speeds must have proper lightingand 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 tomake the machine visible and identify it as a workmachine. Check state and local regulations to assurecompliance. Keep these devices clean and in workingcondition.

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TX03679,000179F –19–20APR01–1/1

Inspect and Maintain ROPS

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

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

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

To maintain the ROPS:

• Replace missing hardware using correct gradehardware.

• Check hardware torque.• Check isolation mounts for damage, looseness or

wear; replace them if necessary.• Check ROPS for cracks or physical damage.

TX03679,00016F0 –19–14SEP00–1/1

Add And Operate Attachments Safely

Always verify compatibility of attachments bycontacting your authorized dealer. Adding unapprovedattachments may affect machine stability or reliability,and may create a hazard for others near the machine.

Ensure that a qualified person is involved inattachment installation. Add guards to machine ifoperator protection is required or recommended. Verify

that all connections are secure and attachmentresponds properly to controls.

Carefully read attachment manual and follow allinstructions and warnings. In an area free ofbystanders and obstructions, carefully operateattachment to learn its characteristics and range ofmotion.

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Safety—Maintenance Precautions

TX03679,00017A0 –19–18SEP01–1/1

Park And Prepare For Service Safely

T13

3332

–19–

14D

EC

01T

S22

9–U

N–2

3AU

G88

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

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

• Engage park brake.• Stop engine and remove key.• Install frame locking bar.• Attach a “Do Not Operate” tag in an obvious place in

the operator’s station.

Securely support machine or attachment before workingunder it.

• Do not support machine with boom, bucket, or otherhydraulically actuated equipment.

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

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

Understand service procedures before beginning repairs.Keep service area clean and dry. Use two peoplewhenever the engine must be running for service work.

DX,RCAP –19–04JUN90–1/1

Service Cooling System Safely

TS

281

–UN

–23A

UG

88

Explosive release of fluids from pressurized coolingsystem can cause serious burns.

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

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DX,PAINT –19–24JUL02–1/1

Remove Paint Before Welding or Heating

TS

220

–UN

–23A

UG

88

Avoid potentially toxic fumes and dust.

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

Remove paint before heating:

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

• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

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

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

Dispose of paint and solvent properly.

TX03679,00016D5 –19–02OCT00–1/1

Make Welding Repairs Safely

T13

3547

–UN

–31A

UG

00

NOTE: Disable electrical power before welding. Turn offmain battery switch or disconnect positive batterycable. Separate harness connectors to engine andvehicle microprocessors.

Avoid welding or heating near pressurized fluid lines.Flammable spray may result and cause severe burns ifpressurized lines fail as a result of heating. Do not let heatgo 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 protectionand protective equipment when welding.

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TX03679,0001745 –19–25SEP00–1/1

Drive Metal Pins Safely

T13

3738

–UN

–14S

EP

00Always wear protective goggles or safety glasses andother protective equipment before striking hardened parts.Hammering hardened metal parts such as pins andbucket teeth may dislodge chips at high velocity.

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

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Safety—Safety Signs

TX03679,00017F6 –19–07AUG01–1/2

Safety Signs

T16

1046

–19–

30O

CT

02

Left Side Shown

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Continued on next page

Safety—Safety Signs

TX03679,00017F6 –19–07AUG01–2/2

T16

1047

–19–

29O

CT

02

Right Side Shown

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PN=23

Operation—Operator’s Station

HG31779,0000152 –19–17OCT02–1/2

Levers

T11

7002

–UN

–10S

EP

98

Single Lever (Joystick) Design

T15

6903

B–U

N–0

1JU

L02

Two Lever Design

T11

7004

–UN

–10S

EP

98

Single Lever (Joystick) with Auxiliary Control Design

T16

0584

B–U

N–1

7OC

T02

Two Lever with Auxiliary Control Design

HG31779,0000152 –19–17OCT02–2/2

T11

3445

–UN

–12F

EB

98

A—Transmission Control LeverB—Turn Signal

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TX,10,JC1191 –19–21JUN96–1/1

Pedals

T10

2536

–UN

–10S

EP

96

A—AcceleratorB—Brake/Clutch Cut-Off PedalC—Brake/Clutch Cut-Off PedalD—Differential Lock Foot Switch—If equipped

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TX,10,JC2254 –19–31AUG98–1/1

Deluxe Monitor Panel (Earlier Machines)

T10

3806

–UN

–25F

EB

97

A—Coolant Level Indicator H—Service Required Indicator P—Hydraulic Oil Temperature V—Engine CoolantB—Engine Air Filter I—Right Turn Indicator Indicator Temperature Gauge

Restriction Indicator J—Park Brake Indicator Q—Message Display (Deluxe W—Hydraulic Oil TemperatureC—Engine Oil Pressure K—Brake Oil Pressure Monitor only) Gauge (Deluxe Monitor

Indicator Indicator R—Transmission Service only)D—Engine Preheat Indicator— L—Secondary Steering Indicator X—Transmission Oil

If Equipped Warning Indicator—If S—Transmission Filter Temperature GaugeE—Left Turn Indicator Equipped Indicator Y—Fuel GaugeF—STOP Indicator M—Work Lights Indicator T—Battery Voltage Indicator Z—Basic Display WindowG—High Beams ON Indicator N—Fasten Seat Belt Indicator U—Engine Oil Pressure Gauge

(not used) O—Hydraulic Oil Filter (Deluxe Monitor only)Restriction Indicator

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

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

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

• SELECT switches between volts/kilometers/hoursduring normal operation. During accessories ordiagnostics modes, SELECT will activate thecurrently chosen menu.

2-1-3 102703

PN=26


HG31779,000005F –19–29APR02–1/3

Deluxe Monitor Panel Functions (Earlier Machines)

A—Check Engine Indicator: Indicator will light whenexcessive water is present in primary fuel filter (waterseparator). STOP indicator will light, alarm will soundand engine will derate to 50% of full power until wateris drained.

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

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

C—Engine Oil Pressure Indicator:

IMPORTANT: Prevent possible engine damage. Ifengine oil pressure indicator lightcomes on while operating, stopmachine. STOP ENGINEIMMEDIATELY.

Indicator will light, STOP indicator will flash, and alarmwill sound when engine oil pressure is low. Stopmachine. STOP ENGINE IMMEDIATELY.

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

D—Engine Preheat Indicator—If Equipped:Indicatorwill light when key switch is turned clockwise to theON position. Light will turn off approximately 15-45seconds depending on engine temperature, indicatingthat preheating is completed. Light will turn off whilecranking engine.

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

F—STOP Indicator:

CAUTION: Prevent possible injury ormachine damage. If STOP indicator lightflashes and alarm sounds, stop immediatelyand investigate cause of problem.

The STOP indicator light flashes and alarm soundswhen:

• Engine oil pressure is low.• Engine coolant temperature is excessively high.• Transmission oil temperature is excessively high.• Transmission is shifted into gear with park brake

engaged. Push park brake switch to OFF.• Brake pressure is low.• Steering system pressure is low, and secondary

steering is activated.

G—High Beams ON Indicator : Not used.

H—Service Required Indicator (Yellow): Indicatorwill light when a problem is developing. It is notnecessary to stop the engine immediately, but thecause should be investigated as soon as possible. Theservice required indicator lights when:

• Alternator voltage is low.• Transmission filter is restricted.• Engine air filter is restricted.• Hydraulic oil temperature is too high.• Hydraulic oil filter is restricted.

NOTE: Cold oil may cause hydraulic and transmissionoil filter restriction indicators to lighttemporarily.

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

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

J—Park Brake Indicator: Indicator light will when parkbrake is engaged and transmission control lever is inneutral “N”.

If park brake is engaged and transmission control leveris in forward “F” or reverse “R”, the STOP indicatorlight will flash and alarm will sound. Push park brakeswitch to OFF.

2-1-4 102703

PN=27



HG31779,000005F –19–29APR02–2/3

K—Brake Oil Pressure Indicator:

CAUTION: Prevent possible injury ormachine damage. If brake pressure indicatorlight comes on while operating, stopmachine immediately.

Indicator will light, STOP indicator will flash, and alarmwill sound when brake oil pressure is low, or brakeaccumulator has lost its charge. Stop machineimmediately and push park brake switch to ON.

L—Secondary Steering Warning Indicator—IfEquipped:

IMPORTANT: Prevent possible damage tosecondary steering system. Stopmachine immediately if secondarysteering indicator light and alarmcome on while operating. THESECONDARY STEERING SYSTEM ISNOT INTENDED FOR CONTINUOUSUSE.

Indicator will light, STOP indicator will flash and alarmwill sound when secondary steering system isactivated. Stop machine immediately and takecorrective action. The secondary steering system is notintended for continuous use.

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

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

O—Hydraulic Oil Filter Restriction Indicator:

IMPORTANT: Prevent possible hydraulic pumpdamage. Change hydraulic oil filteras soon as possible when a problemoccurs.

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

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

P—Fuel Filter Restriction Indicator:

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

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

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

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

Replace primary fuel filter (water separator) elementand primary fuel filter strainer.

Q—Message Display: Displays a 12 characteralpha-numeric message that provides a textdescription of the currently displayed mode. Thismessage display supplements the information that isshown on the basic display window.

R—Transmission Service Indicator: Indicator willlight and stay on when a transmission clutch slippageservice code has been detected. The transmission willshift to “neutral” and then machine can only be movedin “limp home” mode. A service code will be logged inMonitor Display Unit. This code can be read byaccessing the Monitor Diagnostic Mode (d).

The indicator light will go off when key switch hasbeen turned to OFF. Every time clutch slippageoccurs, the light will go on and will remain on until keyswitch is turned to OFF.

See your authorized dealer for servicing.

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

2-1-5 102703

PN=28



HG31779,000005F –19–29APR02–3/3

T—Battery Voltage Indicator: Indicator will light andservice required indicator will light when alternatoroutput is low. Check battery charge by selectingbattery voltage on digital display.

U—Engine Oil Pressure Gauge:


Indicator will light, STOP indicator will flash, and alarmwill sound when engine oil pressure gauge indicateslow pressure. Stop machine. STOP ENGINEIMMEDIATELY.

If pointer deflects to the far right side of the scale,electronic communication is lost or a sensor error isactive.

NOTE: Extreme off level operation may causeindicator to light.

V—Engine Coolant Temperature Gauge: STOPindicator light will flash, and audible alarm will soundwhen pointer is in red zone. Stop machine and allowengine to cool. Shut off engine and take correctiveaction.

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

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

indicator points to red zone, hydraulic oil temperatureis too high. Stop work cycle and cycle loader functionswithout load to lower indicator reading. If indicator stillstays in red zone, stop machine and see yourauthorized dealer.


X—Transmission Oil Temperature Gauge: Ifindicator is in red zone, STOP indicator light will flash,and audible alarm will sound indicating that thetemperature is to high. Stop machine and allowtransmission to cool. Shut off engine and takecorrective action.


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

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

Z—Basic Display Window: The display window hassix display:

• Gear• FNR• Auto• Tachometer• Hour Meter• Voltmeter/Odometer

2-1-6 102703

PN=29


HG31779,0000060 –19–29APR02–1/1

Deluxe Monitor Panel (Later Machines)

T15

5127

B–U

N–2

4MA

Y02

1—Check Engine Indicator 8—Service Required Indicator 15—Hydraulic Oil Filter 21—Engine Oil Pressure2—Engine Air Filter Restriction 9—Right Turn Indicator Restriction Indicator Gauge

Indicator 10—Park Brake Indicator 16—Fuel Filter Restriction 22—Engine Coolant3—Engine Oil Pressure 11—Brake Oil Pressure Indicator Temperature Gauge

Indicator Indicator 17—Message Display 23—Hydraulic Oil Temperature4—Engine Preheat Indicator— 12—Secondary Steering 18—Transmission Service Gauge

If Equipped Warning Indicator—If Indicator 24—Transmission Oil5—Left Turn Indicator Equipped 19—Transmission Filter Temperature Gauge6—STOP Indicator 13—Pin Disconnect Indicator Indicator 25—Fuel Gauge7—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 anddiagnostics system. Each time MENU is pressed,display will cycle to the next menu. Once a mainmenu has been selected, pressing MENU again willreturn to the Normal Display Menu.

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

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

• SELECT switches between volts/kilometers/hoursduring normal operation. During accessories ordiagnostics modes, SELECT will activate thecurrently chosen menu.

2-1-7 102703

PN=30


HG31779,000005F –19–29APR02–1/3

Deluxe Monitor Panel Functions (Later Machines)

1—Check Engine Indicator: Indicator will light whenexcessive water is present in final fuel filter. STOPindicator will light, alarm will sound, and engine willderate to 50% of full power until water is drained.

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

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

3—Engine Oil Pressure Indicator:


Indicator will light, STOP indicator will flash, and alarmwill sound when engine oil pressure is low. Stopmachine. STOP ENGINE IMMEDIATELY.

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

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

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

6—STOP Indicator:

CAUTION: Prevent possible injury ormachine damage. If STOP indicator lightflashes and alarm sounds, stop immediatelyand investigate cause of problem.

The STOP indicator light flashes and alarm soundswhen:

• Engine oil pressure is low.• Engine coolant temperature is excessively high.• Transmission oil temperature is excessively high.• Transmission is shifted into gear with park brake

engaged.• Brake pressure is low.• Steering system pressure is low, and secondary

steering is activated.

7—High Beams ON Indicator : Not used.

8—Service Required Indicator (Yellow): Indicator willlight when a problem is developing. It is not necessaryto stop the engine immediately, but the cause shouldbe investigated as soon as possible. The servicerequired indicator lights when:

• Alternator voltage is low.• Transmission filter is restricted.• Engine air filter is restricted.• Hydraulic oil temperature is too high.• Hydraulic oil filter is restricted.• Fuel filter is restricted.• Transmission fault indication.

NOTE: Cold oil may cause hydraulic and transmissionoil filter restriction indicators to lighttemporarily.

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

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

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

2-1-8 102703

PN=31



HG31779,000005F –19–29APR02–2/3

If park brake is engaged and transmission control leveris in F “Forward” or R “Reverse”, the STOP indicatorwill flash and alarm will sound. Push park brake switchto OFF.

11—Brake Oil Pressure Indicator:

CAUTION: Prevent possible injury ormachine damage. If brake pressure indicatorlight comes on while operating, stopmachine immediately.

Indicator will light, STOP indicator will flash, and alarmwill sound when brake oil pressure is low or brakeaccumulator has lost its charge. Stop machineimmediately and push park brake switch to ON.

12—Secondary Steering Warning Indicator—IfEquipped:

IMPORTANT: Prevent possible damage tosecondary steering system. Stopmachine immediately if secondarysteering indicator light and alarmcome on while operating. THESECONDARY STEERING SYSTEM ISNOT INTENDED FOR CONTINUOUSUSE.

Indicator will light, STOP indicator will flash, and alarmwill sound when secondary steering system isactivated. Stop machine immediately and takecorrective action. The secondary steering system is notintended for continuous use.

13—Pin Disconnect Indicator: Indicator will lightwhen pin disconnect switch is activated to retractcylinders for removal of attachments.

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

15—Hydraulic Oil Filter Restriction Indicator:

IMPORTANT: Prevent possible hydraulic pumpdamage. Change hydraulic oil filter

as soon as possible when a problemoccurs.

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

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

16—Fuel Filter Restriction Indicator:

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

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

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

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

17—Message Display: Displays a 12 characteralpha-numeric message that provides a textdescription of the currently displayed mode. Thismessage display supplements the information that isshown on the basic display window.

18—Transmission Service Indicator: Transmissionservice indicator and service required indicator will lightand stay on when a transmission clutch slippageservice code has been detected. The transmission willshift to “Neutral” and then machine can only be movedin “limp home” mode. A service code will be logged inMonitor Display Unit. This code can be read byaccessing the Monitor Diagnostic Mode (d).

The indicator light will turn off when key switch hasbeen turned off. Every time clutch slippage occurs, thetransmission service indicator and service requiredindicator will light and will remain on until key switch isturned off.

2-1-9 102703

PN=32



HG31779,000005F –19–29APR02–3/3

19—Transmission Filter Indicator: Indicator will lightand the service required indicator will light when thetransmission filter is restricted.

20—Battery Voltage Indicator: Indicator will light andservice required indicator will light when alternatoroutput is low. Check battery charge by selectingbattery voltage on digital display.

21—Engine Oil Pressure Gauge:


Indicator will light, STOP indicator will flash, and alarmwill sound when engine oil pressure gauge indicateslow pressure. Stop machine. STOP ENGINEIMMEDIATELY.

If pointer deflects to the far right side of the scale,electronic communication is lost or a sensor error isactive.

NOTE: Extreme off level operation may causeindicator to light.

22—Engine Coolant Temperature Gauge: STOPindicator will flash and audible alarm will sound whenpointer is in red zone. Stop machine and allow engineto cool. Shut off engine and take corrective action.


23—Hydraulic Oil Temperature Gauge: Normaloperating temperature is in green zone. If gaugeindicator points to red zone, hydraulic oil temperatureis too high. Stop work cycle and cycle loader functionswithout load to lower indicator reading. If indicator stillstays in red zone, stop machine and see yourauthorized dealer.


24—Transmission Oil Temperature Gauge: Ifindicator is in red zone, STOP indicator will flash andaudible alarm will sound indicating that thetemperature is too high. Stop machine and allowtransmission to cool. Shut off engine and takecorrective action.


25—Fuel Gauge: Indicator will reflect fuel level intank.

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

26—Basic Display Window: The display window hassix displays:

• Gear• FNR• Auto• Tachometer• Hour Meter• Voltmeter/Odometer

2-1-10 102703

PN=33


HG31779,0000111 –19–17SEP02–1/1

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

T15

9422

C–U

N–2

8OC

T02

1—Pilot Enable/Boom Down 7—Not Used 14—Beacon Switch—If 18—Ride Control Switch—IfSwitch 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—IfSwitch 10—Temperature Control Knob Equipped Equipped

3—Cab Work Light Switch—If 11—Blower Speed Knob 16—Spin Control Mode 20—Boom Height KickoutEquipped 12—Air Conditioning Switch— Knob—If Equipped Switch—If Equipped

4—4-Way Flasher Switch If Equipped 17—Spin Control Switch—If5—Clutch Cut-Off Switch 13—Axle Disconnect Switch— Equipped6—Automatic Transmission If Equipped

Switch

2-1-11 102703

PN=34


HG31779,0000112 –19–17SEP02–1/2

Console Switch and Accessory Functions (Later Machines—Single Lever Design)

1—Pilot Enable/Boom Down Switch: The switch hasthree positions:

• Push upper half to lower boom with engine off• Push to middle position to unlock pilot controllers;

normal operation• Push lower half to lock pilot controllers; locks

hydraulic controls

2—Drive, Tail and Marker Switch: The switch hasthree positions:

• Push upper half to turn on headlights, taillights/brake lights and turn signal/4-way lights

• Push switch to middle position to turn on taillights/brake lights and turn signal/4-way lights

• Push lower half of switch to turn lights off

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

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

5—Clutch Cut-Off Switch:

CAUTION: Prevent possible injury fromunexpected machine movement. Whenstopping on inclines, push the lower half ofthe clutch cut-off switch to engage clutchcut-off before releasing left service brake.This will prevent the machine from rollingdownhill during transmission re-engagementcycle.

Push upper half of switch to disengage clutch beforeeither brake pedal can be used to disengagetransmission clutches.

Use the switch in situations such as truck loadingwhere machine positioning and maximum hydraulicsare needed.

NOTE: The park brake will also disengage thetransmission clutches. Release park brakebefore operating.

6—Automatic Transmission Switch: Push upper halfof switch to the “Auto” position. Move transmissionlever to 3 or 4. Transmission will start in 2nd gear. Asspeed increases, transmission will automatically shift to3rd and 4th gear. As load increases or speeddecreases, transmission will automatically shift to 3rdand 2nd gear.

7—Not Used

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

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

Push wiper/washer knob in to wash front window.

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


Push wiper/washer knob in to wash rear window.

10—Temperature Control Knob: Turn knob to adjustair temperature. Turn knob clockwise to increasetemperature. Turn counterclockwise to decreasetemperature.

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

2-1-12 102703

PN=35



HG31779,0000112 –19–17SEP02–2/2

12—Air Conditioning Switch—If Equipped: Pushupper half of switch to turn air conditioning on. Pushlower half of switch to turn air conditioning off.

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

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

15—Pin Disconnect Switch—If Equipped: Pushswitch in then lift switch up to retract cylinders forremoval of attachments.

16—Spin Control Mode Knob—If Equipped: Turnknob to a setting that minimizes wheel spin while fillingthe bucket.

NOTE: Spin control reduces engine rpm to minimizewheel spin and prolong tire life. The fivedifferent settings allow the operator tocustomize the machine to differing tractiveconditions. Spin control only works in firstgear.

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

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

18—Ride Control Switch: The switch has threepositions:

• Push upper half to turn ride control on• Push to middle “Auto” position that functions the

same as the “On” position with one exception. Theride control is turned off when ground speed isapproximately 6 km/h (3—1/2 mph) or less

• Push lower half to turn ride control off

19—Return-to-Carry Switch—If Equipped: Theswitch has three positions:

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

Push boom lever to float position. Boom will kick-outof float position when it reaches a preset distancefrom ground.

• Push lower half to deactivate return-to-carry

NOTE: Boom float will not work once the boom isbelow preset distance from ground. Pushswitch to “Off” position to activate boom float.

20—Boom Height Kickout Switch: The switch hasthree positions:

• Push upper half to set boom height• Push to middle position to activate boom height

kickout. Pull lever to raise detent position. Boom willkick-out of detent position when it reaches a presetheight from ground.

• Push lower half to deactivate boom height kickout

2-1-13 102703

PN=36


HG31779,0000062 –19–24JUN02–1/1

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

T15

6392

B–U

N–2

4JU

N02

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 KnobEquipped Equipped 13—Spin Control Switch—If 19—Temperature Control Knob

3—Axle Disconnect Switch—If 8—Beacon Switch—If Equipped 20—Front Wiper KnobEquipped Equipped 14—Not Used 21—Rear Wiper Knob

4—Boom Height Kickout 9—Cab Work Light Switch—If 15—Clutch Cut-Off SwitchSwitch—If Equipped Equipped 16—Automatic Transmission

5—Return-to-Carry Switch—If 10—Drive, Tail and Marker SwitchEquipped Switch

2-1-14 102703

PN=37


HG31779,0000063 –19–29APR02–1/2

Console Switch and Accessory Functions (Later Machines—Two Lever Design)

1—Ride Control Switch: The switch has threepositions:

• Push right half to turn ride control on• Push to middle “Auto” position that functions the

same as the “On” position with one exception. Theride control is turned off when ground speed isapproximately 6 km/h (3—1/2 mph) or less

• Push left half to turn ride control off

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

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

4—Boom Height Kickout Switch: The switch hasthree positions:

• Push upper half to set boom height• Push to middle position to activate boom height

kickout. Pull lever to raise detent position. Boom willkick-out of detent position when it reaches a presetheight from ground.

• Push lower half to deactivate boom height kickout

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

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

Push boom lever to float position. Boom will kick-outof float position when it reaches a preset distancefrom ground.

• Push lower half to deactivate return-to-carry

NOTE: Boom float will not work once the boom isbelow preset distance from ground. Pushswitch to “Off” position to activate boom float.

6—Pilot Enable/Boom Down Switch: The switch hasthree positions:

• Push upper half to lower boom with engine off

• Push to middle position to unlock pilot controllers;normal operation

• Push lower half to lock pilot controllers; lockshydraulic controls

7—Pin Disconnect Switch—If Equipped: Pushswitch in then lift switch up to retract cylinders forremoval of attachments.

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

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

10—Drive, Tail and Marker Switch: The switch hasthree positions:

• Push upper half to turn on headlights, taillights/brake lights and turn signal/4-way lights

• Push switch to middle position to turn on taillights/brake lights and turn signal/4-way lights

• Push lower half of switch to turn lights off

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

12—Spin Control Mode Knob—If Equipped: Turnknob to a setting that minimizes wheel spin while fillingthe bucket.

NOTE: Spin control reduces engine rpm to minimizewheel spin and prolong tire life. The fivedifferent settings allow the operator tocustomize the machine to differing tractiveconditions. Spin control only works in firstgear.

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

2-1-15 102703

PN=38



HG31779,0000063 –19–29APR02–2/2

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

14—Not Used

15—Clutch Cut-Off Switch:

CAUTION: Prevent possible injury fromunexpected machine movement. Whenstopping on inclines, push the lower half ofthe clutch cut-off switch to engage clutchcut-off before releasing left service brake.This will prevent the machine from rollingdownhill during transmission re-engagementcycle.

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

Use the switch in situations such as truck loadingwhere machine positioning and maximum hydraulicsare needed.

NOTE: The park brake will also disengage thetransmission clutches. Release park brakebefore operating.

16—Automatic Transmission Switch: Push upperhalf of switch to the “Auto” position. Move transmissionlever to 3 or 4. Transmission will start in 2nd gear. Asspeed increases, transmission will automatically shift to3rd and 4th gear. As load increases or speed

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

17—Air Conditioning Switch—If Equipped: Pushlower half of switch to turn air conditioning on. Pushupper half of switch to turn air conditioning off.

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

19—Temperature Control Knob: Turn knob to adjustair temperature. Turn knob clockwise to increasetemperature. Turn counterclockwise to decreasetemperature.

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


Push wiper/washer knob in to wash front window.

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


Push wiper/washer knob in to wash rear window.

2-1-16 102703

PN=39


TX,10,JC1869 –19–20SEP02–1/1

Monitor Display Unit

T10

8065

–UN

–11M

AR

97

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

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

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

• “Diagnostics” menu provides a limited set of tools, andis intended to be used by service personnel andmachine operator’s for diagnostic and troubleshootingfunctions.

• “Service” menu is for service personnel and requires aspecial procedure to gain access. This mode providesan additional and more sophisticated set of tools fordiagnostics and troubleshooting.

The monitor display unit keypad is used to navigatethrough the different menus and modes of operation. Keynames and general functions are as follows:

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

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

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

• SELECT switches between volts/kilometers, hoursduring normal operation. During accessories ordiagnostics modes, SELECT will activate the currentlychosen menu in Basic Display Window.

2-1-17 102703

PN=40


TX,10,JC2218 –19–15SEP98–1/3

Monitor Display Unit—Normal Display

T11

1852

–UN

–22O

CT

97

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

The basic display window will show the bulb check mode.The window will contain numerical digit 8’s and will beshown for approximately 5 seconds.

Then the machine model number will show in the basicdisplay window.


2-1-18 102703

PN=41


TX,10,JC2218 –19–15SEP98–2/3

T11

1854

–UN

–22O

CT

97

A—Gear DisplayB—FNR DisplayC—Auto DisplayD—Tachometer DisplayE—Hour Meter DisplayF—Voltmeter/Odometer DisplayG—Basic Display WindowH—Message Display Window (If Equipped)

Approximately five seconds later, the Normal display willbe shown.

NOTE: Press SELECT to alternate between Odometerand System Voltage display.

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

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

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

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

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

The Hour Meter Display (E) shows the machine hours inwhole hour increments. The hour meter accumulateshours only when the engine is on; and the icon flashesonce per second. The engine is considered on when thetachometer is greater than 300 rpm or engine oil pressureis 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 thevoltmeter or odometer reading. Press SELECT to togglebetween these readings.

On U.S. and Hitachi export machines, the display rotatesfrom volts to miles to kilometers. On Hitachi domesticmachines, the display rotates from kilometers to voltsonly.

2-1-19 102703

PN=42



TX,10,JC2218 –19–15SEP98–3/3

The voltmeter displays battery voltage when the machineis off and system voltage to the nearest tenth when themachine is on.

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

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

CED,OUOE035,9 –19–03NOV98–1/3

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

T11

1855

–UN

–22O

CT

97

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

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


2-1-20 102703

PN=43


CED,OUOE035,9 –19–03NOV98–2/3

T11

1856

–UN

–22O

CT

97

In the Clutch Cut-Off Mode of operation, there are threedifferent functions to choose from:

• Level Ground• Small Slope• Steep Slope

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

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

On Steep Slope setting, clutch releases with high brakepedal pressure.

By turning one of these functions On, the other two areautomatically turned Off.

Press SELECT again. Display shows A 011 Level GroundSetting, If setting shows Off, press SELECT again and itwill be On, disabling the other two positions.

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

Level Ground (A 011): When the Level Ground functionis turned On in the monitor display unit, the clutch cut-offswitch turned On, and the brake pedal pressed down, theclutch cut-off sensor (B33), which is a rotarypotentiometer, will sense the position of the brake pedallinkage by the voltage reading. When it senses voltagehigher than the low voltage set point, the transmission will“disengage” (release clutch) and modulate to neutral. Inthis position the machine will still roll slightly.

In “Auto” mode the transmission will “re-engage” andmodulate into the appropriate gear (based on groundspeed) if the pressure at the clutch cut-off sensor reachesthe engagement pressure set point. This pressure is lowerthan the clutch cut-off set point.

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

2-1-21 102703

PN=44



CED,OUOE035,9 –19–03NOV98–3/3

Small Slope (A 012): When the Small Slope function isturned On in the monitor display unit, the clutch cut-offswitch turned On, and the brake pedal is pressed down,the clutch cut-off sensor will sense the hydraulic brakepressure. When it senses pressure higher than themedium pressure set point, the transmission will“disengage” and modulate to neutral.

In “Auto” mode the transmission will “re-engage” andmodulate into the appropriate gear (based on groundspeed) if the pressure at the clutch cut-off sensor reachesthe engagement pressure set point. This pressure is lowerthan the clutch cut-off pressure set point.


Steep Slope (A 013): When the Steep Slope is turned Onin the monitor display unit, the clutch cut-off switch turnedOn, and the brake pedal is pressed down, the clutchcut-off sensor will sense the hydraulic brake pressure.When it senses pressure higher than the high pressureset point, the transmission will “disengage” and modulateto neutral.

In “Auto” mode the transmission will “re-engage” andmodulate into the appropriate gear (based on groundspeed) if the pressure at the clutch cut-off sensor reachesthe engagement pressure set point. This pressure is lowerthan the clutch cut-off pressure set point.


2-1-22 102703

PN=45


TX,10,JC2220 –19–26AUG97–1/5

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

T11

1858

–UN

–22O

CT

97

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

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

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

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

If the operator presses down on the quick shift switchwhile no shift is taking place, the controller will cause thetransmission to shift down one gear (regardless ofselected gear).

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

Down Only—Transmission in Automatic Operation: Ifthe operator presses the quick shift switch when thetransmission is in automatic operation, the transmissionwill down shift to one gear below the gear displayed inbasic display window. This change is made independentfrom shifter switch selection.

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

If the operator presses down on the quick shift switchwhile an up shift is taking place, the transmissioncontroller will cause the transmission to shift down to theprevious gear.

2-1-23 102703

PN=46



TX,10,JC2220 –19–26AUG97–2/5

In “Auto” mode, if the operator presses down on the quickshift switch while a down shift is taking place, thetransmission controller will ignore the request for the downshift.

Transmission will automatically shift up or down from thegear displayed in basic display window until shifter switchis moved to Neutral. This will cancel down shift mode andtransmission will go back to fully automatic mode.

TX,10,JC2220 –19–26AUG97–3/5

T11

1857

–UN

–22O

CT

97

Deluxe Monitor Display Unit Shown

Press SELECT at the A 02 display.

TX,10,JC2220 –19–26AUG97–4/5

T11

1858

–UN

–22O

CT

97


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

To choose the Down Only shift function, press NEXT.

2-1-24 102703

PN=47



TX,10,JC2220 –19–26AUG97–5/5

T11

1859

–UN

–22O

CT

97


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

TX,10,JC2221 –19–26AUG97–1/1

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

T11

1860

–UN

–22O

CT

97


In Auto Mode to First, the transmission will shift to firstgear if a high load is sensed while the transmission isactually in second gear. This shift change is madeindependent from shifter switch selection.

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

2-1-25 102703

PN=48


TX,10,JC2223 –19–26AUG97–1/1

Monitor Display Unit—Accessory Menu—JobTimer Mode (A 04)

T11

1861

–UN

–22O

CT

97


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

At the A 04 display, press SELECT.

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

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

TX,10,JC2224 –19–26AUG97–1/1

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

T11

1862

–UN

–22O

CT

97


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


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

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

2-1-26 102703

PN=49


TX,10,JC2225 –19–01SEP98–1/1

Monitor Display Unit—Accessory Menu—0.1Hour Meter Mode (A 06)

T11

1863

–UN

–22O

CT

97


T11

1864

–UN

–22O

CT

97


A—Hour Meter Reading


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

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

When the 0.1 Hour Meter Mode is turned Off, only theodometer reading and voltmeter are available, by pressingSELECT.

The 0.1 Hour Meter Mode On or Off position stays setafter machine shut down.

TX,TEST,HH229 –19–12SEP96–1/1

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

T11

1865

–UN

–22O

CT

97


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


Press SELECT to turn Metric Units display On or Off.

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

2-1-27 102703

PN=50


TX,10,JC2227 –19–10NOV98–1/6

Monitor Display Unit—User DiagnosticsMenu—Service Codes (d 01)

T11

1866

–UN

–22O

CT

97


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

At the d 01 display, press SELECT.

TX,10,JC2227 –19–10NOV98–2/6T

1117

09–U

N–2

2OC

T97


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

To move to the second service code, press NEXT.

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


2-1-28 102703

PN=51


TX,10,JC2227 –19–10NOV98–3/6

T11

1710

–UN

–22O

CT

97


The display window will show the hour meter reading atfirst occurrence of the service.

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

TX,10,JC2227 –19–10NOV98–4/6T

1117

08–U

N–2

2OC

T97


The display window will show the hour meter reading atlast occurrence of the fault and the total number ofoccurrences.


2-1-29 102703

PN=52


TX,10,JC2227 –19–10NOV98–5/6

T11

1709

–UN

–22O

CT

97


To move to the second service code, press BACK untilthe Fxxxx display is shown. This example: F 1649.

Then press NEXT.

TX,10,JC2227 –19–10NOV98–6/6

T11

1868

–UN

–22O

CT

97


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

TX,10,JC2222 –19–01SEP98–1/4

Monitor Display Unit—User DiagnosticsMenu—Continuity Check (d 02)

In this diagnostic mode, sensors and circuits connected tothe chassis computer unit (CCU) are monitored for a“state of change.” Examples of “state of change” areswitches going from open to closed or closed to open,circuit shorts and opens, high rate of change from analogsensors, and changes in digital speed sensor outputs.

2-1-30 102703

PN=53



TX,10,JC2222 –19–01SEP98–2/4

T11

1869

–UN

–22O

CT

97



Two different “continuity check” modes are provided.Press SELECT to choose the mode wanted.

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

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

TX,10,JC2222 –19–01SEP98–3/4

T11

1870

–UN

–22O

CT

97


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


2-1-31 102703

PN=54


TX,10,JC2222 –19–01SEP98–4/4

T11

1871

–UN

–22O

CT

97


Whenever a “change of state” is detected, the warninghorn will “beep” to inform the technician of the change.The circuit device component number and section numberas it appears on the system functional schematic willshow on the basic display window.

Press SELECT to display sensor data and units in themessage display window. Press SELECT again or BACKto remove the information from the message window.Press NEXT to move to the next sensor display.

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

TX,10,JC2228 –19–26SEP97–1/2

Monitor Display Unit—User DiagnosticsMenu—Battery Monitor (d 03)

T11

1872

–UN

–22O

CT

97


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


Battery voltage will be displayed in basic display window.


2-1-32 102703

PN=55


TX,10,JC2228 –19–26SEP97–2/2

T11

1873

–UN

–22O

CT

97


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

TX,10,JC2229 –19–01SEP98–1/7

Monitor Display Unit—User DiagnosticsMenu—Engine Sensors (d 04)

This mode allows the technician to monitor all enginesensors that are accessible to the computer system.

TX,10,JC2229 –19–01SEP98–2/7

T11

1874

–UN

–22O

CT

97


Press SELECT at the d 04 display.

2-1-33 102703

PN=56



TX,10,JC2229 –19–01SEP98–3/7

T11

1875

–UN

–22O

CT

97


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

TX,10,JC2229 –19–01SEP98–4/7T

1118

76–U

N–2

2OC

T97


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

Press NEXT.


2-1-34 102703

PN=57


TX,10,JC2229 –19–01SEP98–5/7

T11

1877

–UN

–22O

CT

97


The d 042 display for Engine Oil Pressure will be shown.Pressure will be displayed in kPa or psi and sensorvoltage will be displayed.

TX,10,JC2229 –19–01SEP98–6/7T

1118

81–U

N–2

2OC

T97



Press NEXT.


2-1-35 102703

PN=58


TX,10,JC2229 –19–01SEP98–7/7

T11

1882

–UN

–22O

CT

97


The d 043 display for Throttle sensor voltage will beshown.

TX,10,JC2230 –19–01SEP98–1/4

Monitor Display Unit—User DiagnosticsMenu—Transmission Sensors (d 05)

This mode allows the technician to monitor alltransmission sensors that are accessible to the computersystem.

TX,10,JC2230 –19–01SEP98–2/4

T11

1884

–UN

–22O

CT

97



2-1-36 102703

PN=59



TX,10,JC2230 –19–01SEP98–3/4

T11

1885

–UN

–22O

CT

97


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


2-1-37 102703

PN=60


TX,10,JC2230 –19–01SEP98–4/4T

1118

87–U

N–2

2OC

T97



Press NEXT.

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

Press NEXT.

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

Press NEXT.

The d 054 Torque Output Speed Sensor display will showthe speed in rpm.

Press NEXT.

The d 055 Internal Clutch Speed Sensor display will showthe speed in rpm.

Press NEXT.

The d 056 Output Shaft Speed Sensor display will showthe speed in rpm.

TX,10,JC2231 –19–01SEP98–1/4

Monitor Display Unit—User DiagnosticsMenu—Hydraulic Sensors (d 06)

This mode allows the technician to monitor all hydraulicsensors that are accessible to the computer system.

2-1-38 102703

PN=61



TX,10,JC2231 –19–01SEP98–2/4

T11

1888

–UN

–22O

CT

97



TX,10,JC2231 –19–01SEP98–3/4

T11

1889

–UN

–22O

CT

97


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

Press NEXT.


2-1-39 102703

PN=62


TX,10,JC2231 –19–01SEP98–4/4

T11

5771

–UN

–08J

UN

98


The d 062 Pump Output Pressure Sensor display willshow the pump pressure in kPa or psi (depending on thesetting selected in A 07 mode) and sensor voltage (This isonly available on machines with Load PerformanceManagement installed).

TX,10,JC2232 –19–26SEP97–1/2

Monitor Display Unit—User DiagnosticsMenu—Fuel Sensor (d 07)

T11

1891

–UN

–22O

CT

97


This mode allows the fuel level sensor to be monitored.

Press SELECT at the d 07 Fuel Sensor display.

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


2-1-40 102703

PN=63


TX,10,JC2232 –19–26SEP97–2/2

T11

1893

–UN

–22O

CT

97



TX,9015,MM3001 –19–15APR98–1/1

Monitor Display Unit—User DiagnosticsMenu—(d 08)—Not Used

TX,10,JC2233 –19–01SEP98–1/10

Monitor Display Unit—User DiagnosticsMenu—Machine I.D. Mode (d 10)

This mode provides the technician with machineidentification information for hour meter readings, partnumbers and serial numbers of the monitor display unitand chassis controller unit.


2-1-41 102703

PN=64


TX,10,JC2233 –19–01SEP98–2/10

T11

1894

–UN

–22O

CT

97



TX,10,JC2233 –19–01SEP98–3/10T

1118

96–U

N–2

2OC

T97


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


2-1-42 102703

PN=65


TX,10,JC2233 –19–01SEP98–4/10

T11

1897

–UN

–22O

CT

97


Press NEXT.

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

TX,10,JC2233 –19–01SEP98–5/10T

1118

99–U

N–2

2OC

T97


Press NEXT.

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


2-1-43 102703

PN=66


TX,10,JC2233 –19–01SEP98–6/10

T11

1900

–UN

–22O

CT

97


Press NEXT.

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

TX,10,JC2233 –19–01SEP98–7/10T

1119

01–U

N–2

2OC

T97


Press NEXT.

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


2-1-44 102703

PN=67


TX,10,JC2233 –19–01SEP98–8/10

T11

1902

–UN

–22O

CT

97


Press NEXT.

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

TX,10,JC2233 –19–01SEP98–9/10T

1117

11–U

N–2

2OC

T97


Press NEXT.

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


2-1-45 102703

PN=68


TX,10,JC2233 –19–01SEP98–10/10

T11

1712

–UN

–22O

CT

97


Press NEXT.

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

2-1-46 102703

PN=69


TX,10,JC1739 –19–16OCT98–1/1

Horn Button

T11

3450

–UN

–12F

EB

98

Horn Button

A—Horn Button

CED,OUO1021,193 –19–20MAR98–1/1

Turn Signals

T11

3458

–UN

–13F

EB

98

A—Signal Lever

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

2-1-47 102703

PN=70


TX,10,JC1788 –19–31OCT02–1/1

Air Conditioning Controls

T11

7017

–UN

–10S

EP

98

Earlier Machines

T15

6775

D–U

N–1

0OC

T02

Later Machines—Two Lever Design

T11

1213

B–U

N–2

7AU

G97

A—Temperature Control KnobB—Blower KnobC—Air Conditioning SwitchD—Heater Valve

NOTE: Open valve (D) before operating heater.

Turn temperature control knob (A) clockwise to increasetemperature.

Turn blower knob (B) clockwise to increase blower speed.(Knob also turns on heater blower.) Blower has fourspeeds.

IMPORTANT: Before you start air conditioner firsttime in the season, check filters andcondenser. Clean them if necessary.Check refrigerant level.

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

2-1-48 102703

PN=71


HG31779,000012E –19–20SEP02–1/1

Air Flow Knob

T15

9630

B–U

N–2

0SE

P02

1—Air Flow Knob

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

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

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

Turn the knob clockwise to the fourth position for totalvent air flow.

CED,OUO1021,30 –19–02MAR98–1/1

Adjusting Steering Wheel Tilt

T11

3453

–UN

–12F

EB

98

A—Lever

Lift lever (A) to adjust steering column to desired tilt.Release lever.

CED,OUOE035,10 –19–14JUN00–1/2

Opening and Securing Side Door

T13

1654

B–U

N–1

3JU

N00A—Lever

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


2-1-49 102703

PN=72


CED,OUOE035,10 –19–14JUN00–2/2

T11

8147

–UN

–02N

OV

98T

1605

85B

–UN

–17O

CT

02

A—Outside LatchB—NotchC—BumperD—Release Lever

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

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

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

Door will latch when closed.

2-1-50 102703

PN=73


HG31779,000014D –19–07OCT02–1/1

Opening Side Window/Secondary Exit

T16

0249

B–U

N–0

7OC

T02

T16

0250

B–U

N–0

7OC

T02

1—Lever2—Outer Notch3—Lever

NOTE: The cab right side window can be used as asecondary 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.

TX,10,JC1589 –19–14JUN00–1/1

Opening Rear Side Window

T13

1655

B–U

N–1

9JU

N00

A—Latch Tab

Pull on latch tab (A) to release window lock.

2-1-51 102703

PN=74


CED,OUO1021,141 –19–16MAR98–1/1

Adjusting Seat

T10

3679

B–U

N–2

2NO

V96

T10

5452

–UN

–26N

OV

96A—Lumbar Support LeverB—Armrest Height Adjustment BracketC—Armrest Adjustment KnobD—Backrest Tilt Adjustment KnobE—Seat Height Adjustment LeverF—Weight Adjustment KnobG—Weight IndicatorH—Fore-Aft Adjustment LeverI—Height/Firmness Adjustment Knob (Air Ride

Seat only)

CAUTION: You can lose control of machine andbe injured if seat is loose. Be sure seat isproperly locked in position before operating themachine.

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

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

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

Move seat to mid-to-aft position. While sitting in seat, turnweight adjustment knob (F) to support weight. Checkweight indicator (G) for appropriate weight setting andcontinue to turn until yellow pointer inside tube is flushwith tube opening.

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

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

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

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

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

2-1-52 102703

PN=75


TX,10,JC1623 –19–14JUN00–1/1

Seat Belt

T12

8685

–UN

–01M

AR

00

Seat belt and mounting hardware must be inspectedfor wear or damage before operating the machine.Replace the belt or mounting hardware if worn ordamaged.

Replace the complete seat belt assembly every threeyears regardless of appearance. A date label, todetermine the age of the belt, is attached to each belt.

2-1-53 102703

PN=76

Operation—Operating the Machine

TX,20,JC1199 –19–18JUL02–1/1

Inspect Machine Daily Before Starting

T10

3802

–UN

–18S

EP

96

A—Wheels (Front and Rear)B—Operator’s StationC—Air Inlet CoverD—RadiatorE—Fuel Level (Monitor)F—Tires

Do periodic service checks.

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

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 wiresand loose or corroded connections.

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

HARDWARE: Check for loose or missing parts.

PARK BRAKE: Check for correct operation.

HYDRAULIC SYSTEM: Check for leaks, missing or looseclamps, kinked hoses, and lines or hoses that rub againsteach other or other parts.

LUBRICATION: Check lubrication points shown onPeriodic Maintenance Chart.

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

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

2-2-1 102703

PN=77


HG31779,00000B1 –19–18JUL02–1/1

Check Instruments Before Starting

T11

9011

–19–

16D

EC

98

Turn key switch clockwise to “On” position.

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

TX,25,JC1410 –19–18JUL02–1/2

Starting the Engine

TS

177

–UN

–11J

AN

89

CAUTION: Avoid possible injury or death from arunaway machine.

DO NOT start engine by shorting across starterterminals. Machine will start in gear if normalcircuitry is bypassed.

NEVER start engine while standing on ground.Start engine only from operator’s seat, withtransmission control lever in “Neutral”. Engagepark brake.

Use of seat belt with roll-over protectivestructure (ROPS) is recommended under alloperating conditions.

1. Fasten seat belt.


2-2-2 102703

PN=78


TX,25,JC1410 –19–18JUL02–2/2

T11

3477

–UN

–13F

EB

98

A—Transmission Control LeverB—Neutral Lock

2. Move transmission control lever (A) to N. Engageneutral lock (B).

3. Turn key switch to “On” position. Push horn button tosound horn to alert bystanders that machine will bestarted.

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

After a false start, DO NOT turn keyswitch until engine stops or starter maybe damaged.

Engine will not start by towing orpushing. Permanent damage totransmission will result.

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

IMPORTANT: If STOP indicator light does not go outwithin 10 seconds after starting engine,STOP THE ENGINE. Find and correctthe cause.

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

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

2-2-3 102703

PN=79


CED,OUO1021,41 –19–18JUL02–1/2

Starting Fluid—If Equipped (Cold WeatherStarting Aid)

TS

281

–UN

–23A

UG

88

USE STARTING FLUID

CAUTION: Prevent possible injury fromexploding container. Starting fluid is highlyflammable. Keep container away from heat,sparks, and open flame. Contents arepressurized. DO NOT puncture or incineratecontainer. Remove container from machine ifengine does not need starting fluid.

IMPORTANT: Prevent damage to engine. Use startingaid when temperatures are below 4°C(40°F) and only when engine is COLD.

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


2-2-4 102703

PN=80


CED,OUO1021,41 –19–18JUL02–2/2T

1134

78–U

N–1

3FE

B98

T11

7175

–UN

–15S

EP

98

A—Starting Aid ButtonB—Hose ClampC—Start Aid ContainerD—Plug

IMPORTANT: Excess starting fluid could damageengine; press start aid button onlywhen engine is cold and cranking.Starting aid fluid is being injected intoengine as long as you press button.

2. After one or two revolutions of engine crankshaft, pressstarting aid button (A) until engine starts. Crank enginefor 20 seconds maximum, then allow 2 minutesbetween cranking periods.

REPLACING START AID CONTAINER

1. Loosen hose clamp (B).

2. Turn start aid container (C) counterclockwise toremove.

3. Remove safety cap from new container.

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

5. Tighten hose clamp.

OPERATING MACHINE WITHOUT START AIDCONTAINER INSTALLED

IMPORTANT: Protect starting aid components frompossible damage. Install starting aidplug in starting aid base.

Remove container and install plug (D) in base.

2-2-5 102703

PN=81


CED,TX14795,4152 –19–30SEP00–1/1

Using Booster Batteries—24 Volt System

TS

204

–UN

–23A

UG

88T

7233

JN–U

N–2

1MA

Y90

A—Machine BatteriesB—Booster Batteries

Before boost starting, machine must be properly shutdown and secured to prevent unexpected machinemovement when engine starts.

CAUTION: An explosive gas is produced whilebatteries are in use or being charged. Keepflames or sparks away from the battery area.Make sure the batteries are charged in a wellventilated area.

IMPORTANT: The machine electrical system is a24-volt negative (-) ground. Connect two12-volt booster batteries together inseries as shown for 24 volts.

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

2. Connect one end of the negative cable to the negativeterminal of booster batteries. Then connect the otherend of negative cable to the machine frame as faraway from the machine batteries as possible.

3. Start the engine.

4. Immediately after starting the engine, disconnect theend of negative cable from the machine frame first.Then disconnect the other end of negative cable fromthe negative terminal of booster batteries.

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

2-2-6 102703

PN=82


CED,OUO1021,162 –19–09OCT02–1/1

Engine Air Heater—If Equipped

T11

0374

–UN

–22O

CT

97

A—Engine Preheat Indicator

IMPORTANT: DO NOT USE ETHER WITH THISSYSTEM. Damage to your engine mayoccur.

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

1. Turn key switch to “On”. If engine temperature is below10°C (50°F), engine preheat indicator (A) will light andstay on 0—30 seconds, depending on initial enginetemperature. Light will turn off, indicating thatpreheating is completed.

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

3. If engine temperature is 20°C (68°F) or lower, preheatindicator will light and will remain on for approximately30 seconds depending on current engine temperature.

IMPORTANT: Warm up at 1/2 speed and DO NOTaccelerate rapidly during warm-up.

NOTE: Battery voltage light may come on during postheat and may remain on for a short period oftime.

T82,25,C53 –19–03DEC91–1/1

Using Coolant Heater—If Equipped

CAUTION: Prevent possible injury from firefrom an overheated electrical cord. Use aheavy-duty, grounded cord to connect heater toelectrical power.

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

2-2-7 102703

PN=83


TX,25,JC247 –19–29NOV94–1/1

Warm-Up

Operate machine at less-than-normal loads and speedsfor first few minutes until temperatures and pressuresreach normal operating range.

TX,25,JC1942 –19–02SEP98–1/1

Cold Weather Warm-Up

IMPORTANT: If hydraulic oil and transmission oilare cold, functions move slowly. Donot attempt normal machineoperations until hydraulic andtransmission functions move atclose-to-normal cycle times.

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

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

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

Prepare machine to shift transmission as follows:

• Machine—stopped• Engine—slightly above low idle• Bucket—off the ground and empty• Brakes—apply right or left brake pedal with clutch

cut-off disengaged• Parking brake—released• Cycle transmission 10 times by shifting:

Neutral-F1—R1—F1—R1—F1—Neutral. Eachcycle should be approximately 5 seconds.

4. Shift from F1-R1 without braking until transmissionoperates normally.

CED,OUO1021,47 –19–18JUL02–1/1

Neutral Lock

T11

3449

–UN

–12F

EB

98

A—Neutral Lock

CAUTION: Prevent possible injury fromunexpected machine movement. Always movetransmission control lever to N “Neutral”, andengage neutral lock before starting ordismounting.

Move neutral lock (A) to the locked position to engageneutral lock. Move lock to the unlocked position todisengage neutral lock.

2-2-8 102703

PN=84


HG31779,000014E –19–07OCT02–1/1

Shifting the Transmission

T11

3481

–UN

–13F

EB

98T

1594

23M

–UN

–19S

EP

02

Later Machines—One Lever Design

T15

6774

C–U

N–2

7JU

N02


A—Transmission Control LeverB—Automatic Transmission Switch

Unlock neutral lock.

Release park brake.

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

Change speed of machine by moving transmission controllever to desired gear. Machine has four forward gears andthree reverse gears. Shifting to 4th gear reverse will givesame travel speed as 3rd gear reverse. Select a gearsuitable to operating and road conditions.

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

2-2-9 102703

PN=85


CED,OUO1021,50 –19–23SEP02–1/1

Park Brake Switch

T11

5292

–UN

–11M

AY

98

A—Park Brake Switch

CAUTION: Prevent possible injury or death frommachine runaway. Before disengaging parkbrake, be sure engine is running and servicebrakes are operational.

NOTE: Transmission clutches are disengaged when parkbrake is applied.

The park brake switch (A) has three positions:

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

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

To release park brake, move switch to the neutral, centerdetented position, then the park brake release momentaryposition.

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

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

If engine is stopped with park brake switch OFF,park brake is automatically applied. Press parkbrake switch to ON and then back to momentaryposition to release park brake after startingengine.

Park brake will come on if transmission pressuredrops below 150 psi.

2-2-10 102703

PN=86


HG31779,00000B4 –19–18JUL02–1/1

Boom and Bucket Control Lever—One LeverDesign

T11

7034

–UN

–10S

EP

98

Earlier Machines

A—Lower BoomB—FloatC—Dump BucketD—Raise BoomE—Boom Height KickoutF—Rollback BucketG—Return-to-DigH—Fast Bucket DumpI—Pilot Enable/Boom Down SwitchJ—Return-to-Carry Switch—If Equipped

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

NOTE: Pilot enable/boom down switch must be pushedwhile moving control lever forward to lower boomwith engine stopped.

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

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

NOTE: Return-to-carry (I) will override float position.Return-to-carry must be off for float detent tooperate.

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

Float (lever in full forward detent position [B]): Thisposition allows oil to flow in and out both ends of cylindersso the bucket can follow the contour of the ground.Manually release lever from this position.

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

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

Boom and bucket functions can be operatedsimultaneously by moving lever between positions. Forexample, to raise boom and roll back bucket, move leverbetween positions (D) and (F).

2-2-11 102703

PN=87


HG31779,00000B5 –19–18JUL02–1/1

Boom and Bucket Control Lever—Two LeverDesign

T15

6928

B–U

N–1

0JU

L02

T15

6774

D–U

N–2

7JU

N02

Later Machines

A—Dump BucketB—Rollback BucketC—Return-to-DigD—FloatE—Lower BoomF—Raise BoomG—Boom Height KickoutH—Fast Bucket DumpI—Return-to-Carry Switch—If Equipped

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

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

NOTE: Pilot enable/boom down switch must be pushedwhile moving control lever forward to lower boomwith engine stopped.

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

NOTE: Return-to-carry (I) will override float position.Return-to-carry must be off for float detent tooperate.

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

Float (right lever in full forward detent position [D]): Thisposition allows oil to flow in and out both ends of cylindersso the bucket can follow the contour of the ground.Manually release lever from this position.

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

Boom Height Kickout (right lever in full rearward detentposition [G]): Lever will remain in this position until boomis at a pre-set height, then will return to neutralautomatically.

2-2-12 102703

PN=88


HG31779,0000135 –19–25SEP02–1/1

Quick Shift Switch

T11

7036

–UN

–10S

EP

98

Earlier Machines

T15

6926

B–U

N–0

1JU

L02


A—Switch

Down/Up

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

NOTE: Machine can be programmed with MonitorAccessory Mode 02 for down/up 021 or Downonly 022.

Down Only

This mode will allow transmission to down shift one gearfor each pressing of button. Once a down shift is made bypressing the quick shift switch, the transmission will notshift up again unless a direction or gear change is made.

2-2-13 102703

PN=89


TX,30,JC2012 –19–14JUN00–1/3

Ride Control Switch—Earlier Machines (IfEquipped)

T11

7395

–UN

–25S

EP

98

Side Console—Cab Units Shown

A—Ride Control Switch

CAUTION: Prevent possible injury fromunexpected boom or bucket movement whenequipped with Ride Control. Ride controlaccumulator energy must be discharged whenworking on hydraulic components. Turn ignitionswitch to ON position, cycle the ride controlswitch from OFF to ON (center position). Boomwill “jump up” if ride control accumulator isenergized. Press boom enable switch and movethe control lever into the float position and holdfor 5 seconds.

“ON” Position

Turn ride control switch (A) ON to improve machine rideand reduce tire flexing when traveling over rough terrainat a high speed with loaded bucket.

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

Start the engine.

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

To discharge the energy in the ride control accumulator,do the following:

1. Make sure area around bucket is clear.

2. Turn ride control OFF.

3. Lower boom and bucket to ground position and stopengine.

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

4. Turn key switch on without starting the engine andcycle ride control switch to the ON position (middleswitch position).

2-2-14 102703

PN=90



TX,30,JC2012 –19–14JUN00–2/3

5. Press and hold the pilot enable/boom down switchwhile holding the boom control in the float position forfive seconds.

TX,30,JC2012 –19–14JUN00–3/3

T11

7395

–UN

–25S

EP

98

Side Console—Cab Units Shown


“Auto” Position

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

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

2-2-15 102703

PN=91


HG31779,0000099 –19–25SEP02–1/2

Ride Control—Later Machines (If Equipped)

T15

9423

D–U

N–1

7SE

P02


T15

6774

K–U

N–1

8JU

L02


1—Ride Control Switch

CAUTION: Prevent possible injury fromunexpected boom. The bucket may “jumpup”when ride control switch is turned ON. Clearall bystanders from area.

Ride control will improve machine ride and reduce tireflexing when traveling through rough terrain at a highspeed with loaded bucket.

“On” Position

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

“Auto” Position

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

“Off” Position

Ride control is turned off.

Operating Ride Control


2. Start the engine.

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

Discharging Ride Control Accumulator


2. Turn ride control off.

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

2-2-16 102703

PN=92



HG31779,0000099 –19–25SEP02–2/2

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

4. Turn key switch to “On” without starting the engine andcycle ride control switch to the “On” position (middleswitch position).

5. Press and hold the pilot enable/boom down switchwhile holding the boom control in the float position for5 seconds.

TX,35,JC1393 –19–24SEP98–1/1

Secondary Steering—If Equipped

T11

7403

–UN

–25S

EP

98

A—STOP Indicator LightB—Steering Pressure Indicator Light

IMPORTANT: Prevent possible damage to secondarysteering system. Stop machineimmediately if steering pressureindicator light and audible alarm comeon while operating. THE SECONDARYSTEERING SYSTEM IS NOT INTENDEDFOR CONTINUOUS USE.

Steering pressure indicator light (B) will light, STOPindicator light (A) will flash, and audible alarm will soundwhen secondary steering system is activated. The lightindicates low hydraulic pressure resulting from mechanicalmalfunction, such as loss of engine power. An electricallydriven pump will actuate to provide steering

The secondary steering system will function only whenkey switch is on.

NOTE: Secondary steering is activated if the engine dieswith key on. The secondary steering motor willstop when the key is turned off.

2-2-17 102703

PN=93


TX,35,JC1943 –19–02SEP98–1/1

Differential Lock Switch

T11

3525

–UN

–13F

EB

98

A—Switch

Hold switch (A) down to lock front differential or front andrear differential, if equipped.

Release switch to unlock differential.

NOTE: Use differential lock only when conditions requiretraction. Avoid using differential lock whensteering.

TX,20,SS3659 –19–05AUG96–1/1

Boom Height Kickout Adjustment

T10

6999

B–U

N–0

6FE

B97

Loader

T10

7042

B–U

N–0

7FE

B97

Tool Carrier

A—Cap Screw (2 used)B—SwitchC—Adjustable Plate

1. Move loader control lever to boom raise detent positionand release.

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

3. Position the boom in the desired boom height kickoutposition. Stop engine.

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

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

SpecificationBoom Height KickoutSwitch-to-Adjustable Plate—Gap 5—8 mm (0.197— 0.315 in.).................

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

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

2-2-18 102703

PN=94


TX,20,SS3660 –19–05AUG96–1/1

Return-to-Carry Kickout Adjustment

T10

7043

B–U

N–0

7FE

B97

Loader

T10

7041

B–U

N–0

6FE

B97

Tool Carrier

A—Cap Screw (2 used)B—SwitchC—Adjustable Plate

1. Move Return-to-Carry switch on side dash to ONposition. Raise boom to maximum height.

2. Put boom lever in “Float” detent position and observeat what position boom stops lowering and control leverreleases from detent.

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

4. Start engine and position boom in desiredReturn-to-Carry position.

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

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

SpecificationBoom Height KickoutSwitch-to-Adjustable Plate—Gap 5—8 mm (0.197— 0.315 in.).................

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

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

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

2-2-19 102703

PN=95


TX,20,SS3661 –19–22JUN00–1/2

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

T10

1721

–UN

–16A

UG

96

A—Air Gap Switch-To-BarB—Adjustable BarC—Cap ScrewsD—Alignment MarksE—Adjusting Nuts (2)F—Switch

SPECIFICATIONS

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

Cap Screw Torque 121 Nm (89 lbft)

OTHER MATERIAL

T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE

Products

TY9473 Canadian Thread Lock and Sealer (MediumStrength)LOCTITE Products

242 Thread Lock and Sealer (Medium Strength)LOCTITE Products

T43512 U.S. Thread Lock and Sealer (Medium Strength)LOCTITE

Products


242 Thread Lock and Sealer (Medium Strength)LOCTITE Products

TY6305 U.S. Clean And Cure PrimerLOCTITE Products

TY9485 Canadian Clean And Cure PrimerLOCTITE Products

764 Clean And Cure PrimerLOCTITE Products

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

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

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

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

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

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

SpecificationCap Screw—Torque 121 Nm (89 lbft).........................................................

LOCTITE is a trademark of Loctite Corp.

2-2-20 102703

PN=96



TX,20,SS3661 –19–22JUN00–2/2

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

SpecificationAir Gap Between Switch andBar—Distance 5—8 mm (0.197— 0.315 in.)...............................................

8. Raise boom. Cycle bucket from full rollback to dump.Adjust as required to get desired position.

2-2-21 102703

PN=97


CED,TX18076,44 –19–22JUN00–1/2

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

T13

1917

–UN

–26J

UN

00

A—Air Gap Switch-To-Bar C—Cap Screws E—Hex Nuts F—SwitchB—Adjustable Bar D—Alignment Marks

SPECIFICATIONS

Cap Screw Torque 121 Nm (89 lbft)

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

Hex Nut Torque 75 N•m (55 lbft)

OTHER MATERIAL

T43512 U.S. Thread Lock and Sealer (MediumStrength)LOCTITE Products


242 Thread Lock and Sealer (Medium Strength)LOCTITE

Products

T43512 U.S. Thread Lock and Sealer (MediumStrength)LOCTITE Products


242 Thread Lock and Sealer (Medium Strength)LOCTITE

Products

TY6305 U.S. Clean And Cure PrimerLOCTITE Products

TY9485 Canadian Clean And Cure PrimerLOCTITE Products

764 Clean And Cure PrimerLOCTITE Products

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

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

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

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

5. Remove cap screws (C), one at a time and removeold thread lock and sealer using Clean and CurePrimer. Apply medium strength thread lock andsealer to cap screws.

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

LOCTITE is a trademark of Loctite Corp.

2-2-22 102703

PN=98



CED,TX18076,44 –19–22JUN00–2/2

SpecificationCap Screw—Torque 121 Nm (89 lbft)..................................................

7. Loosen hex nuts (E) to switch bracket. Adjust airgap (A) between switch and adjustable bar (B) to5—8 mm (0.197— 0.315 in.). Torque hex nuts to 75

Nm (55 lbft).

SpecificationAir Gap Between Switch andBar—Distance 5—8 mm (0.197— 0.315 in.)........................................Hex Screw—Torque 75 Nm (55 lbft)....................................................

2-2-23 102703

PN=99


CED,TX03679,5542 –19–03NOV99–1/2

Fork Attachment

T11

0742

–UN

–06A

UG

97

LOADING

• Center forks and carriage before lifting.• Inspect load to ensure stability when lifted.• Never attempt to lift load with one fork.• Approach load slowly and squarely with fork tips

level. Move forks slowly under load with loadpositioned equally on forks. Continue to driveforward until load is against backrest of forks.

UNLOADING

• Always use a signal person if you cannot see theplacement area for the load. Make certain area isclear of all objects.

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

ELEVATED LOADS

• Slowly raise load with a slight back tilt to cradle load.Never tilt load forward unless load is over landingarea and ready to be set down.

• If there is any indication of load instability during thelift such as movement, leaning, or swaying, stoplifting immediately. Lower load and restock.

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

• After load is securely in place, retract forks clear ofload and lower forks to traveling height beforemoving.

DRIVING ON A SLOPE

CAUTION: Prevent possible injury frommachine rollover, do not turn on slopes. Donot drive across slopes under anycircumstances.

Driving up or down slope WITH load on forks:

• Lower load near to ground.• Keep mast tilted back to retain load. Slowly drive

straight up or back straight down slope.

Driving up or down slope WITHOUT load on forks:

• Lower forks near to ground.• Keep mast tilted back.• Slowly drive straight down or back straight up slope.

LIFTING CAPACITY

To maintain stability, only lift loads equal to or lessthan mast capacity or rated operating capacity ofmachine, whichever is less. (See Specifications sectionfor machine lifting capacities.)

TRAVELING

• Operate machine controls from operator seat only.• While driving, carry load low for good visibility and

machine stability.

2-2-24 102703

PN=100



CED,TX03679,5542 –19–03NOV99–2/2

• Downshift with care. A sudden deceleration couldshift or topple load.

• A sudden reversal of travel direction could tip load orover turn the machine. Come to a gradual stopbefore reversing directions.

• Slow travel speed when making turns to avoid anoverturn.

• Use low gear for hillside or ramp operation. Nevercoast downhill with transmission in neutral. Themachine could go out of control and tip over.

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

OPERATING TIPS

• Never use the fork attachment as a workingplatform.

• Know locations of bystanders in the working area atall times.

• DO NOT touch, lean on, or reach through the mast,boom or lift mechanism or permit others to do so.Never climb on the mast, boom, or attachments.

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

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

FORK INSPECTION

The forks are the main load bearing components of themast. Forks must be maintained and checkedperiodically to assure safe operation.

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

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

• Inspect forks for cracks along the inside radius ofheel.

• Inspect hanger block welds for visible cracks.• Check to see that the spring loaded keeper, with

washer, is in position in the upper hanger block andthat the keeper is functioning properly. (Spring inkeeper must pull pin down into hanger block whenpin is pulled out and released.)

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

• Bent forks are not always detectable by sight.Remove forks and measure the interior angle ofeach fork to detect a bent fork.

• Tapered tip forks have an interior angle of 90°.Standard square tip forks have an interior angle of87°. If angle is bent more than 3°, replace fork.

FORK ADJUSTMENT

To change fork position:

CAUTION: To prevent injury, never standunder forks or any part of lift mechanism.

1. Lower forks to approximately 25 mm (1 in.) aboveground.

CAUTION: To prevent injury when slidingforks, keep hands and fingers out of forkadjustment path.

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

3. Release pin and check that fork is engaged innotch.

4. Check that mast backing plate pins are in place ateach end. Measure backing plate pins for wear.Pins should be equal in length on both sides ofplate. Replace pins if worn or damaged.

2-2-25 102703

PN=101


CED,OUO1021,164 –19–18JUL02–1/1

Parking the Machine

T11

3477

–UN

–13F

EB

98


1. Park machine on a level surface.

2. Lower bucket to ground.


CAUTION: Prevent possible injury fromunexpected machine movement. Never rely ontransmission control lever alone to keepmachine from moving. Machine canunexpectedly roll or move under power,resulting in death or serious injury. Always turnengine off or push park brake switch to ON tohold machine.

4. Push park brake switch to ON.

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

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

2-2-26 102703

PN=102


CED,OUO1021,62 –19–18JUL02–1/2

Loading Machine on a Trailer

T11

3477

–UN

–13F

EB

98


1. Keep the trailer bed clean. Put chock blocks againsttrailer wheels.

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

3. Fasten seat belt before starting engine.

CAUTION: Position the machine so that itscenterline is over the centerline of the truckbed. NEVER steer the machine while on theramp. If changing direction is required on theramp, unload the machine from the ramp,reposition the machine on the ground, then tryloading again.

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

5. Lower all equipment onto blocks or trailer bed.


CAUTION: Prevent possible injury fromunexpected machine movement. Never rely ontransmission control lever alone to keepmachine from moving. Machine canunexpectedly roll or move under power,resulting in death or serious injury. Always turnoff engine or push park brake switch to ON tohold machine.


8. Connect frame locking bar.


10. Turn battery disconnect switch OFF, if equipped.

11. Cover exhaust opening to prevent entry of debris andwater.

2-2-27 102703

PN=103



CED,OUO1021,62 –19–18JUL02–2/2

12. Fasten each corner of the machine to the trailer witha chain or cable with appropriate load binder.

13. Place blocks in front of and behind tires.

2-2-28 102703

PN=104


OUOE003,000009E –19–18JUL02–1/2

Towing Procedure

T13

8646

–UN

–20M

AR

01

1—Front Driveshaft 3—Park Brake Hose 4—Telescoping Driveshaft 5—Rear Driveshaft2—Park Brake Fitting Plug

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

IMPORTANT: Engine cannot be started by towing.

Tow the machine off-road to thenearest location where repair workcan be done. Haul the machine if itmust be moved further than 460 m(500 yd).

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

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

CAUTION: Prevent possible injury fromunexpected machine movement. Placeblocks at front and rear of tires to preventmachine from rolling.

1. Place blocks at front and rear of tires.

2. Connect the towed and towing machines together.

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

3. Start engine if possible, and install frame lockingbar.

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

2-2-29 102703

PN=105



OUOE003,000009E –19–18JUL02–2/2

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

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

6. Stop engine.

CAUTION: Prevent possible injury fromunexpected machine movement. Installframe locking bar.

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

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

NOTE: Keep hydraulic hand operated pump filled withoil.

CAUTION: Prevent possible injury fromunexpected machine movement. Sit inoperator’s seat when pumping the hydraulicpump. When towing the machine, maintain atleast 1379 kPa (13.8 bar) (200 psi). Ifpressure is below 1379 (13.8 bar) (200 psi),park brake may engage.

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

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

10. Pump handle until gauge needle indicates 1379kPa (13.8 bar) (200 psi) which will be required todisengage park brake.

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

CAUTION: Prevent possible injury fromunexpected machine movement. Neverattempt to remove driveshafts withoutblocking front and rear tires.

11. Remove driveshafts if a hand operated pump isnot available to release the park brake.

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

CAUTION: Prevent possible injury fromunexpected machine movement. Placeblocks at front and rear of tires to preventmachine from rolling.

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

12. Tow the machine slowly.

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

14. Reapply park brake or reinstall driveshaft if it wasremoved. See your authorized dealer forinstallation information.

2-2-30 102703

PN=106


CED,OUOE002,1782 –19–16SEP98–1/1

Lifting the Machine

T74

77A

V–U

N–1

9MA

R91

A—Cables

CAUTION: Prevent possible injury fromunexpected machine movement. Clear allbystanders from lifting area. Select correctlifting cable strength for weight of machine.Test lift by raising machine 0.3 m (1 ft) off theground.

Specification624H Loader—Weight 11 736 kg (25,873 lb).............................................TC62H Tool Carrier—Weight 13 849 kg (30,532 lb)..................................

1. Install machine frame locking bar.

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

3. Attach a tether cable to machine to control machine asit is lifted.

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

5. Lift machine and swing to unloading area.

2-2-31 102703

PN=107

Maintenance—Machine

DX,FUEL1 –19–12FEB99–1/1

Diesel Fuel

Consult your local fuel distributor for properties of thediesel fuel available in your area.

In general, diesel fuels are blended to satisfy the lowtemperature requirements of the geographical area inwhich they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 arerecommended.

In all cases, the fuel shall meet the followingproperties:

Cetane number of 40 minimum. Cetane numbergreater than 50 is preferred, especially fortemperatures below -20°C (-4°F) or elevations above1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below theexpected low temperature OR Cloud Point at least5°C (9°F) below the expected low temperature.

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

Sulfur content:

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

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

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

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

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

TX,45,JC2126 –19–15AUG97–1/1

Low Sulfur Diesel Fuel Conditioner

When possible, use existing fuel formulations forengines used off-highway. This fuel will not require anyadditives to provide good performance and enginereliability. However, many local fuel distributors will notcarry both low and regular sulfur diesel fuels.

If the local fuel distributor will supply only low sulfurfuel, order and use John Deere PREMIUM DIESELFUEL CONDITIONER. It provides lubricating

properties along with other useful benefits, such ascetane improver, anti-oxidant, fuel stabilizer, corrosioninhibitor and others. John Deere PREMIUM DIESELFUEL CONDITIONER is specifically for use with lowsulfur fuels. Nearly all other diesel fuel conditionersonly improve cold weather flow and stabilize long-termfuel storage. They do not contain the lubricationadditives needed by rotary fuel injection pumps.

3-1-1 102703

PN=108


DX,FUEL6 –19–06DEC00–1/1

Dieselscan Fuel Analysis

DIESELSCAN is a John Deere fuel sampling program tohelp you monitor the quality of your fuel source. It verifiesfuel type, cleanliness, water content, suitability for coldweather operation, and if fuel is within ASTMspecifications. Check with your John Deere dealer foravailability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

DX,FUEL4 –19–18MAR96–1/1

Handling and Storing Diesel Fuel

CAUTION: Handle fuel carefully. Do not fillthe fuel tank when engine is running.

DO NOT smoke while you fill the fuel tank orservice the fuel system.

Fill the fuel tank at the end of each day’s operation toprevent condensation and freezing during coldweather.

IMPORTANT: The fuel tank is vented through thefiller cap. If a new filler cap isrequired, always replace it with anoriginal vented cap.

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

TX14740,0001C42 –19–20OCT00–1/1

Alternative And Synthetic Lubricants

Conditions in certain geographical areas may requirelubricant recommendations different from those printedin this manual. Some John Deere brand coolants andlubricants may not be available in your location.

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

The temperature limits and service intervals shown inthis manual apply to both conventional and syntheticoils.

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

In general, avoid mixing different brands or types of oil.Oil manufacturers blend additives in their oils to meetcertain specifications and performance requirements.Mixing different oils can interfere with the properfunctioning of these additives and degrade lubricantperformance.

Consult your authorized dealer to obtain specificinformation and recommendations.

3-1-2 102703

PN=109


DX,ENOIL4 –19–24JAN00–1/1

Diesel Engine Break-In Oil

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

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

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

If John Deere ENGINE BREAK-IN OIL is not available,use a diesel engine oil meeting one of the followingduring the first 100 hours of operation:

• API Service Classification CE

• ACEA Specification E1

After the break-in period, use John Deere PLUS-50 orother diesel engine oil as recommended in thismanual.

IMPORTANT: Do not use PLUS-50 oil or engineoils meeting API CH-4, API CG4, APICF4, ACEA E3, or ACEA E2performance levels during the first100 hours of operation of a new orrebuilt engine. These oils will notallow the engine to break-inproperly.

PLUS-50 is a registered trademark of Deere & Company.

3-1-3 102703

PN=110


DX,ENOIL –19–05OCT01–1/1

Diesel Engine Oil

SA

E 1

0W-4

0

SA

E 1

5W-4

0

SA

E 5

W-4

0

SA

E 5

W-3

0

SA

E 3

0

50˚C 122˚F

40˚C 104˚F

30˚C 86˚F

20˚C 68˚F

10˚C 50˚F

0˚C 32˚F

-10˚C 14˚F

-20˚C -4˚F

-30˚C -22˚F

-40˚C -40˚F

TS

1668

–UN

–05O

CT

01

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

The following oil is preferred:

• John Deere PLUS-50

The following oil is also recommended:

• John Deere TORQ-GARD SUPREME

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

• API Service Classification CH-4• API Service Classification CG-4• API Service Classification CF-4• ACEA Specification E3• ACEA Specification E2

Multi-viscosity diesel engine oils are preferred.

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

Extended service intervals may apply when John Deerepreferred engine oils are used. Consult your John Deeredealer for more information.

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

Company

3-1-4 102703

PN=111


CED,TX03679,5800 –19–14JUN00–1/1

Transmission, Hydraulic System, Park Brake,and Differential Oil

TS

1660

–UN

–10O

CT

97

Use oil viscosity based on the expected air temperaturerange 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• John Deere Standard JDM J20D

Use John Deere BIO-HY-GARD1oil when abiodegradable fluid is required.

HY-GARD is a registered trademark of Deere & CompanyBIO-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-GARDshould not be mixed with mineral oils because this reduces thebiodegradability and makes proper oil recycling impossible.

3-1-5 102703

PN=112


DX,GREA1 –19–24JAN00–1/1

Grease

TS

1667

–UN

–30J

UN

99

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

The following greases are preferred:

• John Deere SD POLYUREA GREASE

The following greases are also recommended:

• John Deere HD MOLY GREASE• 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:

• NLGI Performance Classification GC-LB

IMPORTANT: Some types of grease thickener are notcompatible with others. Consult yourgrease supplier before mixing differenttypes of grease.

3-1-6 102703

PN=113


DX,COOL3 –19–18OCT01–1/1

Diesel Engine Coolant

The engine cooling system is filled to provideyear-round protection against corrosion and cylinderliner pitting, and winter freeze protection to -37°C(-34°F).

John Deere COOL-GARD

The following engine coolant is preferred for service:

• John Deere COOL-GARD Prediluted Coolant

The following engine coolant is also recommended:

• John Deere COOL-GARD Coolant Concentrate in a40 to 60% mixture of concentrate with quality water.

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

Ethylene glycol base coolants

Other fully formulated low silicate ethylene orpropylene glycol base coolants for heavy-duty enginesmay be used if they meet one of the followingspecifications:

• ASTM D6210 prediluted coolant• ASTM D6210 coolant concentrate in a 40 to 60%

mixture of concentrate with quality water

Coolants meeting ASTM D6210 do not require use ofsupplemental coolant additives, except for periodicreplenishment of additives during the drain interval.

Other low silicate ethylene glycol base coolants forheavy-duty engines may also be used if they meet oneof the following specifications:



Coolants meeting ASTM D5345 or ASTM D4985require an initial charge of supplemental coolant

additives, formulated for protection of heavy dutydiesel engines against corrosion and cylinder linererosion and pitting. They also require periodicreplenishment of additives during the drain interval.

Propylene glycol base coolants

Fully formulated low silicate propylene glycol basecoolants for heavy-duty engines may be used if theymeet one of the following specifications:



Coolants meeting ASTM D6211 do not require use ofsupplemental coolant additives, except for periodicreplenishment during the drain interval.

Freeze protection

A 50% mixture of ethylene glycol engine coolant inwater provides freeze protection to -37°C (-34°F).

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

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

Water quality

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycoland propylene glycol base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealingadditives or antifreeze that containssealing additives.

IMPORTANT: Do not mix ethylene glycol andpropylene glycol base coolants.

3-1-7 102703

PN=114

Maintenance—Periodic Maintenance

TX,50,JC2151 –19–02SEP97–1/1

Service Your Machine at Specified Intervals

T11

1207

B–U

N–2

7AU

G97

A—Maintenance Chart

Lubricate, make service checks and adjustments atintervals shown on the periodic maintenance chart (A) andon the following pages.

Service items at multiples of the original requirement. Forexample, at 500 hours also service those items (ifapplicable) listed under 250 hours, 100 hours, 50 hoursand 10 hours or daily.

TX,50,JC2242 –19–29SEP97–1/2

Check the Monitor Display Unit Regularly

T11

1863

–UN

–22O

CT

97


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

TX,50,JC2242 –19–29SEP97–2/2

T11

1864

–UN

–22O

CT

97

A—Hour Meter Reading

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

Intervals on the periodic maintenance chart are foroperating in normal conditions. If you operate yourmachine in severe conditions, you should service it atSHORTER INTERVALS.

3-2-1 102703

PN=115


TX,50,JC1806 –19–14JUN00–1/2

Opening Engine Side Shields and ServiceDoors

T10

6380

B–U

N–2

4JA

N97

A—Latch

CAUTION: Prevent possible injury from engineservice door closing. Always keep service doorin the open locked position when servicing theengine area.

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

TX,50,JC1806 –19–14JUN00–2/2

T13

1518

B–U

N–0

7JU

N00

A—Cylinder

2. Open service door to full extent. Gas cylinder (A) willlock door in place.

3-2-2 102703

PN=116


HG31779,0000171 –19–29OCT02–1/1

Locking Machine Frame

T16

1062

B–U

N–2

9OC

T02

T16

1061

B–U

N–2

9OC

T02

1—Quick Lock Ring2—Locking Pin3—Locking Bar

CAUTION: Prevent possible injury fromunexpected machine movement. Connect framelocking bar to both frames before you work inframe pivot area.

1. Align machine frames.

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

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

4. Install locking pin through hole in loader frame and endof locking bar. Install quick lock ring to secure lockingbar in place.

3-2-3 102703

PN=117


HG31779,0000172 –19–29OCT02–1/1

Boom Lock

T16

1064

B–U

N–2

9OC

T02

T16

1065

B–U

N–2

9OC

T02

1—Boom Lock2—Hand Bolt

CAUTION: Always install boom lock beforeworking on or around this machine with theboom raised.

Empty bucket and place in dump positionbefore installing boom lock.

1. Raise boom. Empty bucket and place in dump positionbefore installing boom lock (1).

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

3. Install lock on boom cylinder and lock lever facing tooutside of machine and lower boom onto lock.

4. Tighten hand bolt.

5. Before removing boom lock from cylinder, raise boomslightly to relieve pressure. Return boom lock tostorage position on side of machine and tighten handhold.

3-2-4 102703

PN=118


CED,OUOE002,1463 –19–27SEP01–1/1

Opening Grille Door

T13

9740

C–U

N–1

0AU

G01

T14

6005

B–U

N–2

6SE

P01

1—Release Lever2—Stop

Press down on release lever (1) to open grille door fully.Door will automatically lock open.

Rotate stop (2) to release door lock.

CED,OUOE002,1783 –19–16SEP98–1/1

Fuel Tank

CAUTION: Handle fuel carefully. If the engineis hot or running, DO NOT fill the fuel tank.DO NOT smoke while you fill fuel tank orwork on fuel system.

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

SpecificationFuel Tank—Capacity 265 L (70 gal)....................................................

TX,50,JC2243 –19–29SEP97–1/1

Check Windshield Washer Fluid Level

T11

1207

C–U

N–2

7AU

G97

A—Windshield Washer Bottle

Open left engine side shield.

Check fluid in windshield washer bottle (A).

During winter season, use all season windshield washerfluid which will not freeze.

3-2-5 102703

PN=119


TX,50,RB280 –19–26JUN00–1/1

Maintenance and Repair Record KeepingSystem

T75

11C

O–U

N–2

7JU

N91

The checklist on the following page summarizesscheduled maintenance, and parts and oil required ateach maintenance interval.

Use the checklist to:

• Remind you to perform machine maintenance atspecified intervals to minimize downtime.

• Calculate cost of machine operation and ownershipallowing 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 thelist and record date and hour meter reading. Use thesecond copy of this form (immediately preceding theService Literature page inside the back cover).

Do not tear out or mark on Checklist in the PeriodicMaintenance chapter; keep it to make extra copies.

3-2-6 102703

PN=120


CED,OUO1040,114 –19–11JUN98–1/1

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

T11

1411

–UN

–16S

EP

97Oilscan Plus

T11

1410

–UN

–16S

EP

97

3-Way Coolant Test Kit

Oilscan Plus, Coolscan Plus and 3-Way Coolant TestKit are John Deere fluid sampling products to help youmonitor machine performance and system condition.The objective of a fluid sampling program is to ensuremachine availability when you need it and to reducerepair costs by identifying potential problems beforethey become critical.

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

and/or fluid change interval. Certain systems requiremore frequent sampling. Consult your John Deeredealer on a maintenance program for your specificapplication. Your dealer has the sampling products andexpertise to assist you in lowering your overalloperating costs through fluid sampling.

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

3-2-7 102703

PN=121


CED,OUOE002,1785 –19–20DEC01–1/2

Service Intervals

SERVICE INTERVALSService your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at500 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 water from fuel tank• Clean or replace air cleaner elements • Drain and clean primary fuel filter• 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 • Grease rear steering cylinder pivots• Grease front steering cylinder pivots • Check and clean cab fresh air filter• Grease oscillating rear axle • Check and clean cab recirculating air filter

Model: ❒ 624H Customer:PIN/Serial Number: Delivery Date:

Oil SamplingOil samples should be taken from each system prior to its recommended drain/change interval indicated on this form. Maintenancerecommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you supply. Regular oilsampling will extend the operational life of your machine’s systems.

Every 250 Hours❒ Grease drive line sliding joints ❒ Drain and refill engine oil❒ Check receiver dryer moisture indicator ❒ Replace engine oil filter❒ Check radiator coolant levelComments:

Date: Hour Meter Reading: Maintenance Performed By:

Every 500 Hours❒ Grease drive line sliding joints, upper and lower ❒ Replace hydraulic system return filter❒ Check air intake hoses ❒ Grease rear oscillating support cover❒ Check battery water level ❒ Replace hydraulic reservoir breather filter❒ Check coolant conditioner ❒ Replace transmission oil filter❒ Replace final fuel filter ❒ Check park brake oil level❒ Replace primary fuel filter ❒ Check front and rear differential oil levelComments:


OILSCAN is a trademark of Deere & Company.

3-2-8 102703

PN=122



CED,OUOE002,1785 –19–20DEC01–2/2

Every 1000 Hours❒ Remove and clean engine crankcase vent tube ❒ Drain and refill transmission oil❒ Replace air cleaner dust unloader valve ❒ Grease frame hinge pivots❒ Replace air cleaner elements ❒ Drain and refill park brake oil❒ Check radiator coolant and hosesComments:

Date: Hour Meter Reading: Maintenance Performed By:Every 2000 Hours

❒ Check and adjust engine valve lashComments:


Every 3000 Hours❒ Drain, flush and refill hydraulic system oil ❒ Drain and refill front and rear differential oil❒ Clean hydraulic system fill strainer ❒ Clean axle differential recirculating screenComments


REQUIRED PARTSInsure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associatedparts are also on hand i.e. filter O-rings.

Part Number ASI 250 HOURS 500 HOURS 1000 HOURS 3000 HOURSEngine Oil Filter RE59754 1 1 1 1 1Primary Fuel Filter RE62424 1 1 1Final Fuel Filter RE62419 1 1 1Transmission Filter AT147496 (S.N.

-572779) 1 1 1 1 1AT222005 (S.N.572780-) 1 1 1 1 1

Hydraulic System Return AT209204 1 1 1FilterAir Filter Primary AT178583 1 1Air Filter Secondary AT178584 1 1Hydraulic Reservoir AM39653 1 1 1Breather FilterJohn Deere PLUS-50 Oil (S.N. —582360) 20 L (21 qt) 20 L (21 qt) 20 L (21 qt) 20 L (21 qt) 20 L (21 qt)

(S.N. 582361—) 21 L (22 qt) 21 L (22 qt) 21 L (22 qt) 21 L (22 qt) 21 L (22 qt)HY-GARD Transmissionand Hydraulic Oil 72 L (76 qts) 28 L (30 qts) 189 L (50 gal)Coolant Conditioner (as TY16004needed)OILSCAN PLUS Kit: (10 samples per kit)•Diesel Engine Oil AT178840 1 1 1 1•Transmission Oil AT178840 1 1 1•Axle Oil AT178840 2 2 2•Hydraulic Oil AT178844 1 1 1COOLSCAN 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.

3-2-9 102703

PN=123

Maintenance—As Required

TX,55,JC1944 –19–11MAR97–1/2

Check Tire Pressure

TS

211

–UN

–23A

UG

88T

1080

57B

–UN

–12M

AR

97T

8750

2–U

N–2

1OC

T88

A—Pipe Cap

CAUTION: Explosive separation of a tire andrim parts can cause serious injury or death.

Always maintain the correct tire pressure. DONOT inflate tires above the recommendedpressure.

Inspect tires and wheels daily. DO NOT operatewith low pressure, cuts, bubbles, damagedrims, or missing lug bolts.

Carefully inspect any tire and rim assembly thathas been run flat or severely underinflatedbefore reinflating the tire. Damage to the rimand tire may have developed. Call yourauthorized dealer or a qualified repair service toinspect the rim and tire assembly and makenecessary repairs.

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

NEVER cut or weld on an inflated tire or rimassembly. Heat from welding could cause anincrease in pressure and may result in tireexplosion.

Do not attempt to mount a tire if you do nothave the proper equipment and experience toperform the job. Have it done by yourauthorized dealer or a qualified repair service.

Check tire pressure with an accurate gauge having 7.0kPa (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.

4. Lock air chuck on tire valve.

3-3-1 102703

PN=124



TX,55,JC1944 –19–11MAR97–2/2

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

6. After tire is at correct pressure, shut off air supply.Release chuck. (See following Tire Pressure chart.)

7. Inspect tire for damage.

TX,55,JC2189 –19–09SEP97–1/1

Tire Pressures

Item Measurement Specification

Tire Pressures1

17.5—25 Bias Shipping Pressure Front Pressure 379 kPa (3.79 bar) (55 psi)Rear Pressure 310 kPa (3.10 bar) (45 psi)

17.5—R25 Radial Shipping Front Pressure 414 kPa (4.14 bar) (60 psi)Pressure Rear Pressure 276 kPa (2.75 bar) (40 psi)

20.5—25 Bias Shipping Pressure Front Pressure 310 kPa (3.10 bar) (45 psi)Rear Pressure 241 kPa (2.41 bar) (35 psi)

20.5—R25 Radial Shipping Front Pressure 310 kPa (3.10 bar) (45 psi)Pressure Rear Pressure 207 kPa (2.06 bar) (30 psi)

1Tire shipping pressure may not be the same as tire operating pressure.You may change tire pressures to suit working condition according to tiremanufacturer’s recommendations.

TX,55,JC1924 –19–13AUG02–1/1

Tighten Wheel Retainer Cap Screws

NOTE: Tighten cap screws after first 10 hours, then againafter first 50 hours of loaded operation. After that,tighten as required.

Tighten wheel cap screws.

Tighten Wheel Retainer Cap Screws—SpecificationWheel Retainer Cap Screws—DryTorque 540 N•m (400 lb-ft).........................................................................

3-3-2 102703

PN=125


CED,OUO1021,79 –19–12MAR98–1/1

Check Fire Extinguisher—If Equipped

T11

3598

–UN

–17F

EB

98

A—Fire Extinguisher

IMPORTANT: Dry powder has a tendency to pack inthe bottom of an extinguisher.

Before using extinguisher (A), turn itupside down and shake it until you feelthe powder move.

Check gauge. If fire extinguisher is not fully charged,charge or replace it.

NOTE: The fire extinguisher must be charged or replacedafter any use.

3-3-3 102703

PN=126


TX,55,JC2154 –19–02SEP97–1/1

Clean or Replace Air Cleaner Elements

T11

1216

B–U

N–2

7AU

G97

T11

1211

B–U

N–2

7AU

G97

T11

1212

B–U

N–2

7AU

G97

A—Clips (3 used)B—Primary ElementC—Secondary Element

1. Open left service door.

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

3. Remove primary element (B).

4. Remove secondary element (C).

TX,55,JC2155 –19–02SEP97–1/1

Check Air Inlet Cover

T11

1239

B–U

N–2

7AU

G97

A—Inlet Cover

1. Open left engine side shield.

2. Check cover (A) for debris. Remove debris ifnecessary.

3. Close side shield.

3-3-4 102703

PN=127


TX,55,JC2244 –19–29SEP97–1/1

Inspect Serpentine Belt

T11

1242

B–U

N–2

7AU

G97

With Air Conditioning

T11

7523

–UN

–30S

EP

98T

1175

24–U

N–3

0SE

P98

A—Belt

1. Check belt (A) regularly for wear, especially for cracksat the bottom of grooves and for frayed edges.

IMPORTANT: If belt is stretched to the point that thebelt tensioner is against its stop, beltmust be replaced.

2. If necessary, replace belt.

3. Hold tension adjuster assembly away from belt whileremoving old belt and installing new belt.

3-3-5 102703

PN=128


CED,OUOE002,1720 –19–03SEP98–1/1

Drain Fuel Tank Sediment

T10

3144

C–U

N–1

2DE

C96

T11

4390

–UN

–19M

AR

98

A—Bottom GuardB—Petcock

NOTE: Petcock is located at left front of machine framebottom guard (A).

1. Loosen petcock (B).

2. Drain water and sediment into a container.

3. Tighten petcock.

4. Dispose of waste properly.

3-3-6 102703

PN=129


TX,55,JC2157 –19–02SEP97–1/2

Drain and Clean Primary Fuel Filter

T11

1238

D–U

N–2

7AU

G97

T83

87A

E–U

N–1

7DE

C94

A—Hand PrimerB—Drain Valve (Primary Fuel Filter)C—Drain Valve (Final Fuel Filter)

1. Open left engine side shield to access primary fuelfilter.

2. Put container under drain valves (B and C).

3. Rotate retaining ring around filter elementcounterclockwise 1/4 turn. Lifting ring as it is rotatedhelps get it past retaining detent. Ring should dropdown and release filter from base.

4. Remove hand primer (A) from fuel filter base.Disassemble hand primer assembly and clean out anydebris.

TX,55,JC2157 –19–02SEP97–2/2

T83

87A

D–U

N–1

7DE

C94

A—Fuel Inlet lineB—Filter BaseC—Fuel Drain Plug

5. Remove fuel inlet line (A) and fuel drain plug (C).

6. Flush any debris from filter base (B).

7. Install fuel inlet drain plug and fuel inlet line.

8. Assemble primer assembly and install onto fuel filterbase.

9. Install filter element to fuel filter base.

10. Bleed fuel system.

11. Close side shield.


3-3-7 102703

PN=130

Maintenance—Every 10 Hours or Daily

TX,60,JC2158 –19–02SEP97–1/1

Check Recovery Tank Coolant Level

T11

1210

B–U

N–2

7AU

G97

T62

74A

Q–U

N–1

8OC

T88

Radiator CapA—Coolant Recovery Tank

With the engine cold, coolant level must be between FULLand ADD marks on the recovery tank.

If coolant is below the ADD mark, add coolant to therecovery tank.

CAUTION: Prevent possible injury from hotspraying coolant. DO NOT remove radiator fillercap unless engine is cool. Then turn cap slowlyto the stop. Release all pressure before youremove cap.

If recovery tank is empty, check for leaks. Repair asrequired. Add coolant to the radiator and the recoverytank.

NOTE: If recovery tank is full and radiator is low, checkfor leaks in radiator cap and hose connectionsbetween radiator and coolant recovery tank.

Coolant level must be at bottom of the filler neck.

TX,60,JC2159 –19–02SEP97–1/1

Clean Air Cleaner Dust Unloader Valve

T11

1210

C–U

N–2

7AU

G97

A—Dust Valve

IMPORTANT: A missing, damaged, or hardened dustunloader valve will make the dust cupprecleaner ineffective, causing veryshort element life. Valve should suckclosed above 1/3 engine speed.

Squeeze dust valve (A) to remove dust from the aircleaner.

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

3-4-1 102703

PN=131


TX,60,JC2160 –19–02SEP97–1/1

Check Engine Oil Level

T11

1215

B–U

N–2

7AU

G97

A—DipstickB—Filler Cap

IMPORTANT: If oil level is low, the engine can bedamaged. DO NOT operate the enginewhen oil level is below the ADD mark.

The most accurate oil level reading is obtained when theengine is cold, before starting the engine for the day’soperation.



3. Make sure dipstick (A) is fully seated.

4. BEFORE THE ENGINE IS STARTED: The engine isfull when oil level is in the cross hatched area. It isacceptable to run the engine when the oil level isabove the ADD mark.

AFTER THE ENGINE HAS BEEN RUN: Allow the oilto drain into the oil pan for 10 minutes before checkingthe oil level. Ten minutes after shutdown the engine oillevel must be above the ADD mark.

5. If necessary, remove filler cap (B) to add oil. SeeDiesel Engine Oil. (Section 3-1.)

3-4-2 102703

PN=132


CED,OUO1021,89 –19–12MAR98–1/1

Check Hydraulic Oil Level

T10

1195

–UN

–19F

EB

97

A—Filler CapB—Sight Glass

IMPORTANT: Prevent possible hydraulic pumpdamage. DO NOT operate enginewithout oil in the hydraulic reservoir.


2. Lower equipment to the ground.

3. When oil is cold, oil level must be in FULL range onsight glass (B).

4. If necessary, remove filler cap (A) and add oil. SeeTransmission, Hydraulic System, Park Brake, andDifferential Oil. (Section 3-1.)

5. Install filler cap.

3-4-3 102703

PN=133


TX,60,JC1405 –19–01AUG96–1/1

Check Transmission Oil Level

T10

6381

B–U

N–2

4JA

N97

T10

1280

–UN

–23O

CT

96

A—Dipstick

IMPORTANT: Prevent possible transmission damage.DO NOT operate engine whentransmission oil level is low.

1. Before starting engine, check oil level on dipstick (A). Ifoil is to lower mark when oil is cold, there is sufficientoil to start the engine.

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

3. Install dipstick.

4. Start engine.

5. Engage service brakes. Move clutch cut-off switch todisengaged position.

6. Move auto transmission switch to “Off” position.Release park brake.

7. Move transmission control lever to 3rd speed forward"3F" position.

Operate engine at fast idle for 30 seconds. Reduceengine speed to slow idle and place transmissioncontrol lever in neutral “N” for 15 seconds.

Repeat this step until transmission oil reaches normaloperating temperature (approximately (80° C) (175° F).

8. Move transmission control lever to neutral “N” andengage neutral lock. Lower all equipment to ground.


10. Release service brakes.

11. Check oil level with engine at slow idle. With oil atnormal operating temperature, oil level should bebetween “HOT” marks on dipstick.

3-4-4 102703

PN=134

Maintenance—After First 100 Hours

TX,75,JC2163 –19–20DEC01–1/2

Change Engine Break-In Oil and ReplaceFilter

T10

8430

B–U

N–0

8AP

R97

T10

6389

B–U

N–2

4JA

N97

A—Drain Valve

IMPORTANT: If fuel sulphur content exceeds 0.5percent, change engine oil at 1/2 thenormal interval.

1. Run engine to warm oil.


3. Lower equipment to ground.

4. Move transmission control lever to neutral "N". Engageneutral lock.




7. Attach hose to drain valve (A). Allow oil to drain into acontainer. Dispose of waste oil properly.


3-5-1 102703

PN=135


TX,75,JC2163 –19–20DEC01–2/2

T11

1215

C–U

N–2

7AU

G97

A—Filler CapB—Filter

8. Turn filter (B) counterclockwise to remove.

9. Clean mounting surface. Apply thin film of oil to gasketof new filter.

NOTE: Before installing filter, to assure proper lubricationat start-up, fill the engine oil filter with engine oil.

10. Install new filter. Turn filter clockwise by hand untilgasket touches mounting surface.

11. Tighten 1/2—1 turn more.

12. Tighten drain valve.

13. Remove filler cap (A).

14. Fill engine with oil. (See Fuels and Lubricantschapter.)

Engine Oil With Filter—Specification(S.N. —582360)—Capacity 20 L (21 qt).....................................................(S.N. 582361—)—Capacity 21 L (22 qt).....................................................


16. Start engine and run at slow idle.

17. Check that engine oil pressure light on monitor goesout and audible alarm stops immediately. If not, stopengine immediately and find cause.

18. Stop the engine. Check oil level. The engine is fullwhen oil level is in the cross hatched area on thedipstick.

19. Check for any leakage at filter. Tighten filter onlyenough to stop leakage.

3-5-2 102703

PN=136


CED,OUOE002,1732 –19–10OCT02–1/3

Change Transmission Oil

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

1. Operate machine under load until transmission oilreaches normal operating temperature.






CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before changing oil.

6. Install frame locking bar.


7. Run engine at 1/2 speed for 2 minutes before stoppingto avoid damage to turbocharger. Release acceleratorpedal to slow idle.

8. Turn key switch to “Off”. Let machine sit forapproximately 10 minutes.


3-5-3 102703

PN=137


CED,OUOE002,1732 –19–10OCT02–2/3

T10

6393

C–U

N–2

4JA

N97

A—Drain Plug

NOTE: Drain plug is magnetic. If an excessive amount ofmetal particles appear on plug, see your JohnDeere dealer.

9. Remove bottom guard, if equipped. Remove plug (A),located inside hole in bottom guard, to drain oil. Allowoil to drain into a container. Dispose of waste oilproperly.

10. Install drain plug.

CED,OUOE002,1732 –19–10OCT02–3/3T

1063

81B

–UN

–24J

AN

97

A—Dipstick

11. Remove transmission dipstick (A).

12. Fill transmission with oil. See Transmission, HydraulicSystem, Park Brake, and Differential Oil. (Section3-1.)

SpecificationTransmission Case and FilterOil—Capacity 27 L (29 qt)...........................................................................

13. Start engine and run for 2 minutes.

14. Move transmission control lever to neutral "N", andengage neutral lock.

15. Check oil level with oil at operating temperature. Oilmust be between marks on dipstick.

3-5-4 102703

PN=138


TX,80,JC1827 –19–10OCT02–1/3

Replace Transmission Oil Filter







CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before changing oil filter.






3-5-5 102703

PN=139


TX,80,JC1827 –19–10OCT02–2/3

T13

1555

C–U

N–1

4JU

N00

A—Transmission Oil Filter

9. Turn filter (A) counterclockwise to remove.

10. Clean mounting surface. Apply thin film of oil togasket of new filter.


12. Tighten 3/4 of a full turn more.



TX,80,JC1827 –19–10OCT02–3/3

T10

6381

B–U

N–2

4JA

N97

A—Dipstick

15. Check oil level. Oil must be between marks ondipstick (A). Add oil if necessary.

16. Check for leaks around the filter base. Tighten filteronly enough to stop leaks.

3-5-6 102703

PN=140

Maintenance—Every 100 Hours

TX,70,JC2161 –19–03SEP97–1/2

Grease Loader Linkage and Cylinder Pivots

T16

0586

B–U

N–1

7OC

T02

Six Points

T10

6375

B–U

N–2

4JA

N97

Three Points, Right Side Shown

T10

6379

C–U

N–1

0AP

R97

Four Points, Right Side Shown

CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before lubricating.

624H Loader Lubricating Points

Lower bucket flat on ground.

Lubricate following 13 points until grease escapes aroundseals. See Grease. (Section 3-1.)

Lubricate every 10 hours when operating in severeconditions such as deep mud, water, or snow.


3-6-1 102703

PN=141


TX,70,JC2161 –19–03SEP97–2/2

T10

6376

D–U

N–0

3SE

P97

12 Points, Right Side Shown

T10

6377

B–U

N–2

4JA

N97

2 Points, Left Side Shown

T10

6378

C–U

N–0

4MA

R97

12 Points, Right Side Shown

TC62H Lubricating points

Lower bucket flat on ground.

Lubricate following 26 points until grease escapes aroundseals. See Grease. (Section 3-1.)

Lubricate every 10 hours when operating in severeconditions such as deep mud, water, or snow.

3-6-2 102703

PN=142


TX,70,JC1817 –19–10OCT02–1/1

Grease Front Steering Cylinder Pivots

T10

6372

B–U

N–2

8JA

N97

Two Points, Right Side Shown


Lubricate each point with three shots of grease. SeeGrease. (Section 3-1.)

Grease daily when operating in severe conditions such asdeep mud, water or snow.

TX,70,JC1468 –19–10OCT02–1/1

Grease Oscillating Rear Axle and RearSteering Cylinder Pivots

T10

6381

C–U

N–2

4JA

N97

Four Points


Lubricate oscillating rear axle with 10 shots of grease andrear steering cylinder pivots with three shots of grease.See Grease. (Section 3-1.) Grease daily when operatingin severe conditions such as deep mud, water, or snow.

TX,70,JC2295 –19–03SEP98–1/3

Check Cab Fresh Air Filter—If Equipped WithCab

T10

5479

B–U

N–1

2DE

C96

A—Lever

1. Open cab fresh air filter door by pulling up on lever (A)to the left of the operator’s seat.

3-6-3 102703

PN=143



TX,70,JC2295 –19–03SEP98–2/3

T11

7050

–UN

–10S

EP

98

A—Knob

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


3-6-4 102703

PN=144


TX,70,JC2295 –19–03SEP98–3/3

T10

5493

B–U

N–1

2DE

C96

T10

5494

B–U

N–1

2DE

C96

B—ClipsC—Filter

NOTE: If operating in dusty conditions, cab fresh air filtershould be checked and cleaned as necessary.

3. Release clips (B).

4. Remove filter (C). Replace if damaged.

5. Clean filter in one of these ways:

CAUTION: Prevent possible injury from flyingchips if compressed air is more than 210 kPa(2.1 bar) (30 psi). Reduce compressed air toless than 210 kPa (2.1 bar) (30 psi) when usingfor cleaning purposes. Clear area of bystanders,guard against flying chips, and wear personalprotection 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 airconditioner.

6. Remove dust from filter housing.

7. Install filter and filter duct work.

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

3-6-5 102703

PN=145


HG31779,0000121 –19–18SEP02–1/1

Check Cab Recirculating Air Filter—IfEquipped With Cab

T15

9520

B–U

N–1

8SE

P02

1—Wing Bolt

NOTE: The cab recirculating air filter is located next tothe seat.

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

2. Remove filter.

CAUTION: Prevent possible injury from flyingchips if compressed air is more than 210 kPa(2.1 bar) (30 psi). Reduce compressed air toless than 210 kPa (2.1 bar) (30 psi) when usingfor cleaning purposes. Clear area of bystanders,guard against flying chips, and wear personalprotection 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.

3-6-6 102703

PN=146


TX,75,JC1818 –19–10OCT02–1/2

Grease Front Driveline Sliding Joint

T16

1066

B–U

N–2

9OC

T02

1—Frame Locking Bar

CAUTION: Prevent possible injury fromunexpected machine movement. Turn engine offand lower bucket to ground before lubricating.

NOTE: To prevent plug loss, lubricate the machine whenit is fully articulated or half articulated and NOT inthe straight position.

Install frame lock bar using hole (1) for articulatedposition.

TX,75,JC1818 –19–10OCT02–2/2

T11

8181

–UN

–02N

OV

98

Lubricate until grease escapes around vent holes indrive shaft end. See Grease. (Section 3-1.)

NOTE: Grease daily when operating in deep mud,water, or snow.

3-7-1 102703

PN=147


TX,75,JC2162 –19–03SEP97–1/1

Check Receiver Dryer Moisture Indicator

T11

1214

D–U

N–2

7AU

G97

A—Sight Glass

IMPORTANT: Prevent possible compressor damage. Ifreceiver dryer moisture eye colorindicates "WET" (pink) dryer issaturated and should be changed withinthe next 100 machine hours to preventfurther buildup of moisture in therefrigerant.

1. Open right side engine side panel.

2. Check sight glass (A) to determine if color indicatesdryer is dry (blue) or wet (pink).

3. If wet (pink), see your authorized dealer within the next100 machine hours to service the receiver dryer.

4. Close engine side panel.

TX,75,JC1820 –19–31OCT02–1/1

Check Radiator Coolant Level

T66

42E

K–U

N–0

1NO

V88

CAUTION: Prevent possible injury from hotspraying coolant. DO NOT remove radiator fillercap unless engine is cool. Then turn cap slowlyto the stop. Release air to relieve all pressurebefore you remove cap.

1. Slowly remove cap. Coolant level must be at bottom ofthe filler neck.

NOTE: If radiator coolant level is low, check for leaks onradiator cap, and hose connections betweenradiator and coolant recovery tank.

2. Add coolant, if necessary.


3-7-2 102703

PN=148


TX,75,JC2163 –19–20DEC01–1/2

Change Engine Oil and Replace Filter

T10

8430

B–U

N–0

8AP

R97

T10

6389

B–U

N–2

4JA

N97

A—Drain Valve

IMPORTANT: If fuel sulphur content exceeds 0.5percent, change engine oil at 1/2 thenormal interval.

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

1. Run engine to warm oil.


3. Lower equipment to ground.





7. Attach hose to drain valve (A). Allow oil to drain into acontainer. Dispose of waste oil properly.


3-7-3 102703

PN=149


TX,75,JC2163 –19–20DEC01–2/2

T11

1215

C–U

N–2

7AU

G97

A—Filler CapB—Filter

8. Turn filter (B) counterclockwise to remove.


NOTE: Before installing filter, to assure proper lubricationat start-up, fill the engine oil filter with engine oil.


11. Tighten 1/2—1 turn more.


13. Remove filler cap (A).

14. Fill engine with oil. See Diesel Engine Oil. (Section3-1.)

Engine Oil With Filter—Specification(S.N. —582360)—Capacity 20 L (21 qt).....................................................(S.N. 582361—)—Capacity 21 L (22 qt).....................................................


16. Start engine and run at slow idle.

17. Check that engine oil pressure light on monitor goesout and audible alarm stops immediately. If not, stopengine immediately and find cause.

18. Stop the engine. Check oil level. The engine is fullwhen oil level is in the cross hatched area on thedipstick.

19. Check for any leakage at filter. Tighten filter onlyenough to stop leakage.

3-7-4 102703

PN=150


TX,80,JC1821 –19–10OCT02–1/2

Grease Upper and Lower Drive Line SlidingJoints

T16

1066

B–U

N–2

9OC

T02

1—Frame Locking Bar

CAUTION: Prevent possible injury fromunexpected machine movement. Turn engine offand lower bucket to ground before lubricating.

Install frame lock bar using hole (1) for articulatedposition.

TX,80,JC1821 –19–10OCT02–2/2

T11

8182

–UN

–04N

OV

98

Lubricate until grease escapes around vent holes indrive shaft end. See Grease. (Section 3-1.)

NOTE: Grease daily when operating in deep mud,water, or snow.

3-8-1 102703

PN=151


TX,80,JC2164 –19–03SEP97–1/1

Check Air Intake Hoses

T11

1237

B–U

N–2

7AU

G97

A—Hose

Check hoses (A) for cracks.

Check hose clamps for tightness.

3-8-2 102703

PN=152


TX,75,DH1574 –19–28APR93–1/3

Check Battery Electrolyte Level andTerminals

TS

203

–UN

–23A

UG

88

CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level.

NEVER check battery charge by placing a metalobject across the posts. Use a voltmeter orhydrometer.

ALWAYS remove grounded (-) battery clampfirst and replace it last.

Sulfuric acid in battery electrolyte is poisonous.It is strong enough to burn skin, eat holes inclothing, and cause blindness if splashed intoeyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 15—30

minutes. Get medical attention immediately.

If acid is swallowed:

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.

3-8-3 102703

PN=153



TX,75,DH1574 –19–28APR93–2/3

T69

96D

B–U

N–0

9SE

P03

T69

96D

A–U

N–0

9SE

P03

A—Battery PostB—Fill TubeC—Electrolyte Level Range

IMPORTANT: If water is added to batteries duringfreezing weather, batteries must becharged after water is added to preventbatteries from freezing. Charge batteryusing a battery charger or by runningthe engine.

2. Fill each cell to within specified range with distilledwater. DO NOT overfill.

CAUTION: Prevent possible injury. ALWAYSremove grounded (-) battery clamp first andreplace it last.

3. Disconnect battery clamps, grounded clamp first.

TX,75,DH1574 –19–28APR93–3/3T

6758

AA

–UN

–21O

CT

88

A—Battery TerminalB—Lubricating Grease

4. Clean battery terminals (A) and clamps with a stiffbrush.

5. Apply lubricating grease (B) around battery terminalbase only.

6. Install and tighten clamps, grounded clamp last.

3-8-4 102703

PN=154


TX,80,JC2166 –19–31OCT02–1/1

Replace Primary Fuel Filter

T11

1238

C–U

N–2

7AU

G97

A—Filter Locking RingB—Sediment Bowl

1. Turn filter locking ring (A) counterclockwise to removefilter. Allow sediment to drain into a container. Disposeof waste properly.

2. Turn sediment bowl (B) counterclockwise to removefrom filter assembly.

3. Clean filter base.

4. Install new filter. (Follow instructions on filter.)

5. Install sediment bowl.

6. Bleed fuel system. See Bleeding Fuel System. (Section3-1.)

TX,80,JC2245 –19–29SEP97–1/1

Replace Final Fuel Filter

T11

1238

B–U

N–2

7AU

G97

A—Filter Locking Ring

1. Turn filter locking ring (A) counterclockwise to removefilter. Allow sediment to drain into a container. Disposeof waste properly.

2. Clean filter base.

3. Install new filter. (Follow instructions on filter.)

4. Bleed fuel system

3-8-5 102703

PN=155


TX,80,JC1825 –19–14JUN00–1/1

Replace Hydraulic System Return Filter

T13

1555

B–U

N–0

8JU

N00

Cover removed for clarity of photograph

A—Hydraulic System Return Filter

CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before changing filter.



3. Install new filter. Tighten filter 3/4 of a full turn afterseal contacts mounting base.

4. Fully loosen filter element. Repeat step 3.

5. Start engine. Check for leaks around filter base.Tighten filter only enough to stop leaks.

6. Stop engine. Check oil level.

TX,70,JC1851 –19–04FEB97–1/1

Grease Rear Oscillating Support Cover

T10

6389

C–U

N–3

1JA

N97

A—Lubrication Fitting


Lubricate point (A) with three shots of grease. See Grease(Section 3-1.)

Grease daily when operating in severe conditions such asdeep mud, water or snow.

3-8-6 102703

PN=156


CED,OUOE035,19 –19–03NOV98–1/1

Replace Hydraulic Reservoir Breather Filter

T11

8143

–UN

–02N

OV

98

A—Filter

Hydraulic reservoir breather filter is located on back sideof reservoir under the hood.


2. Install new filter and tighten until snug.

3-8-7 102703

PN=157


TX,80,JC1827 –19–10OCT02–1/3

Replace Transmission Oil Filter







CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before changing oil filter.






3-8-8 102703

PN=158


TX,80,JC1827 –19–10OCT02–2/3

T13

1555

C–U

N–1

4JU

N00

A—Transmission Oil Filter


10. Clean mounting surface. Apply thin film of oil togasket of new filter.


12. Tighten 3/4 of a full turn more.



TX,80,JC1827 –19–10OCT02–3/3

T10

6381

B–U

N–2

4JA

N97

A—Dipstick

15. Check oil level. Oil must be between marks ondipstick (A). Add oil if necessary.

16. Check for leaks around the filter base. Tighten filteronly enough to stop leaks.

3-8-9 102703

PN=159


CED,OUOE002,1730 –19–29OCT02–1/1

Check Park Brake Oil Level

T11

4802

–UN

–14A

PR

98T

1611

09–1

9–29

OC

T02

A—Plug

1. Remove plug (A). Check oil level.

IMPORTANT: Oil level must be at bottom of checkplug on the side of the park brake. Toomuch oil can cause overheating. Toolittle oil can cause bearing failure.

2. Add oil if necessary. Allow 2 minutes for oil to settle tobottom of level plug.

3. Check oil level and install plug.

3-8-10 102703

PN=160


TX,80,JC1828 –19–03SEP98–1/1

Check Front and Rear Differential Oil Level

T10

6373

B–U

N–2

9JA

N97

Left Front Differential Shown

A—Dipstick

NOTE: Dipsticks are located on left front and left rearaxle housing.

1. Clean area around dipstick

IMPORTANT: To properly check oil level, do notthread dipstick into dipstick port.

2. Remove dipstick (A).

3. Oil must be to FULL level on dipstick.

IMPORTANT: Each differential housing has threeseparate components. Allow 10 minutesfor oil to stabilize in each sump beforechecking.

4. If necessary, add oil. See Transmission, HydraulicSystem, Park Brake, and Differential Oil. (Section 3-1.)

NOTE: If axle is hot and dipstick too warm to hold withbare hands, the oil will expand and it is normal forit to be up to 25 mm (1 in.) above FULL mark. Donot adjust level. If oil level is above FULL mark,drain oil and check oil level.

5. Install dipstick.

3-8-11 102703

PN=161


TX,85,JC2168 –19–16SEP98–1/1

Clean Engine Crankcase Vent Tube

T11

1240

B–U

N–2

7AU

G97

A—Crankcase Vent Tube

Remove clamp at valve cover.

IMPORTANT: Do not pull on hose. Connector damagemay occur.

Remove crankcase vent tube (A) and clean.

TX,85,JC2169 –19–16SEP98–1/1

Replace Air Cleaner Dust Unloader Valve

T11

1210

C–U

N–2

7AU

G97

A—Dust Unloader Valve

NOTE: A missing, damaged, or hardened dust valve willcause the air filter elements to be ineffective.

Replace dust unloader valve (A).

TX,85,JC2170 –19–16SEP98–1/1

Replace Air Cleaner Elements

T11

7243

–UN

–16S

EP

98T

1172

44–U

N–1

6SE

P98

A—Primary ElementB—Secondary Element

1. Remove cover.

2. Remove primary element (A).

3. Remove secondary element (B).

4. Clean air cleaner canister.

5. Install new elements making sure secondary element iscentered in canister.

6. Install cover.

3-9-1 102703

PN=162


CED,OUOE002,1786 –19–16SEP98–1/1

Check Coolant

TS

281

–UN

–23A

UG

88T

1136

78–U

N–2

0FE

B98

T11

1110

–UN

–13A

UG

97

3-Way Test Kit

T11

1109

–UN

–13A

UG

97

CoolScan Plus

CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns.

Only remove filler cap when engine is cold orwhen cool enough to touch with bare hands.Slowly loosen cap to first stop to relievepressure before removing completely.

IMPORTANT: John Deere Liquid Coolant Conditionerdoes not protect against freezing.Coolant conditioner prevents rust,scale, and liner cavitation.

NOTE: Check coolant every 500 hours or 6 months, orwhen replacing 1/3 or more of coolant. Addcoolant conditioner as necessary.

1. Remove radiator cap (A) and test coolant solution. Useone of the following kits to check coolant.

• 3-WAY Heavy Duty Coolant Test Kit (TY16175)Coolant test strips provide an effective method tocheck freeze point and additive levels of enginecoolant. See your authorized dealer for 3-WAYHeavy Duty Coolant Test Kit and follow instructionson kit.

• CoolScan Plus

For a more thorough evaluation of coolant, performCoolScan Plus analysis, where available. See yourauthorized dealer for information about CoolScanPlus.

2. Add TY16004 John Deere Coolant Conditioner orequivalent non-chromatic conditioner/rust inhibitor asnecessary. Follow instructions on container for amount.

SpecificationCooling System—Capacity 22 L (23 qt) approximate.................................

3. Install cap.

CoolScan Plus is a trademark of Deere & Company.

3-9-2 102703

PN=163


CED,TX03679,5801 –19–19JUN00–1/1

Check Radiator Hoses

T11

1237

C–U

N–2

7AU

G97

Upper Radiator Hose Shown

1. Check upper (A) and lower radiator hoses for cracksand leaks. Replace if necessary.

2. Tighten clamps.

3-9-3 102703

PN=164


CED,OUOE002,1732 –19–10OCT02–1/3

Change Transmission Oil

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







CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before changing oil.




8. Turn key switch to “Off”. Let machine sit forapproximately 10 minutes.


3-9-4 102703

PN=165


CED,OUOE002,1732 –19–10OCT02–2/3

T10

6393

C–U

N–2

4JA

N97

A—Drain Plug

NOTE: Drain plug is magnetic. If an excessive amount ofmetal particles appear on plug, see your JohnDeere dealer.

9. Remove bottom guard, if equipped. Remove plug (A),located inside hole in bottom guard, to drain oil. Allowoil to drain into a container. Dispose of waste oilproperly.

10. Install drain plug.

CED,OUOE002,1732 –19–10OCT02–3/3T

1063

81B

–UN

–24J

AN

97

A—Dipstick

11. Remove transmission dipstick (A).

12. Fill transmission with oil. See Transmission, HydraulicSystem, Park Brake, and Differential Oil. (Section3-1.)

SpecificationTransmission Case and FilterOil—Capacity 27 L (29 qt)...........................................................................



15. Check oil level with oil at operating temperature. Oilmust be between marks on dipstick.

3-9-5 102703

PN=166


TX,85,JC1832 –19–14JUN00–1/1

Grease Frame Hinge Pivots

T10

6386

C–U

N–1

0MA

R97

Two Points


Lubricate each point with a minimum of three shots ofgrease and until grease escapes around the seals. SeeGrease. (Section 3-1.)

3-9-6 102703

PN=167


TX,85,JC1488 –19–03SEP98–1/1

Check Park Brake

T11

3486

–UN

–13F

EB

98

A—Park Brake Switch

1. Start engine.

CAUTION: Prevent possible injury from suddenmachine stop. Fasten seat belt for this check.

2. Fasten seat belt.

3. Move park brake switch (A) to OFF, and movetransmission control lever to 1st gear forward.

4. Drive machine at 3 mph and move park brake switchto ON. Machine must stop within 2 m (6 ft), andtransmission must shift to neutral.

5. If repair is necessary, see your authorized dealer.

3-9-7 102703

PN=168


CED,OUOE002,1733 –19–29OCT02–1/1

Change Park Brake Oil

T11

4802

–UN

–14A

PR

98T

1611

09–1

9–29

OC

T02

A—Plug

CAUTION: Prevent possible injury fromunexpected machine movement. Always installframe locking bar.

IMPORTANT: Oil must be at bottom of the check plugon the side of the park brake. Too muchoil can cause overheating; too little cancause bearing failure.

Park Brake Oil—SpecificationPark Brake Oil—Capacity 300 mL (10 oz).................................................

1. Remove plug (A).

2. Drain oil into a container. Dispose of waste oil properly.

3. Add John Deere HY-GARD oil. Allow oil to settle forapproximately 2 minutes after filling.

4. Drain or add oil if necessary.

5. Install plug.

HY-GARD is a trademark of Deere & Company.

3-9-8 102703

PN=169


TX03679,00017DD –19–08MAY01–1/1

Adjust Engine Valve Lash (Clearance)

See your authorized dealer.

3-10-1 102703

PN=170


TX,87,JC1834 –19–19OCT98–1/3

Change Hydraulic System Oil

T15

9423

I–U

N–1

7SE

P02


T15

6774

G–U

N–2

7JU

N02


A—Return-to-Carry SwitchB—Ride Control SwitchC—Pilot Enable/Boom Down Switch

1. Lower bucket to the ground.

2. Stop engine.

3. Turn key switch to “On.”

NOTE: Return-to-carry (B) must be OFF for float detent tooperate.

4. Move hydraulic control lever to float detent position.

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

5. Cycle ride control switch (C) from OFF to ON.

6. Push pilot enable/boom down switch (A) to releaseaccumulator pressure.

7. Turn key switch “Off”.

TX,87,JC1834 –19–19OCT98–2/3

T10

7063

–UN

–19F

EB

97

A—Filler Cap

8. Remove hydraulic reservoir filler cap (A).


3-11-1 102703

PN=171


TX,87,JC1834 –19–19OCT98–3/3

T10

7880

C–U

N–0

6MA

R97

T10

7064

–UN

–19F

EB

97

A—Drain ValveB—Sight Glass

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.


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

SpecificationHydraulic Reservoir and Filters—Capacity 117 L (31 gal)...............................................................................


14. Check oil level in sight glass (B). Oil should be inFULL range.

CED,OUO1021,184 –19–18MAR98–1/1

Clean Hydraulic System Strainer

T11

4483

–UN

–23M

AR

98

A—Filler CapB—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.

3-11-2 102703

PN=172


CED,OUOE002,1787 –19–03NOV98–1/2

Change Front and Rear Differential Oil

T11

7325

–UN

–22S

EP

98

A—HoseB—Screen Fitting

CAUTION: Prevent possible injury from hotspraying oil. Slowly loosen dipstick to relieveany air pressure.

NOTE: Axle Differential Recirculation Screen should alsobe cleaned at this time. See Clean AxleDifferential Recirculation Screen later in thissection.

1. Remove hose (A) and screen fitting (B). Allow oil todrain into a container. Dispose of waste oil properly.

2. Install screen fitting and hose.

SpecificationFront Differential Oil—Capacity 25 L (26 qt)...............................................Rear Differential Oil—Capacity 20 L (21 qt)...............................................

CED,OUOE002,1787 –19–03NOV98–2/2

T10

6373

B–U

N–2

9JA

N97

Left Front Differential Shown

A—Dipstick

3. Remove dipstick (A).

NOTE: Each differential housing has three separatecomponents. To expedite filling differential,remove right axle plug.

4. Add oil slowly through dipstick port on left front and leftrear differential.

IMPORTANT: To properly check oil level, do notthread dipstick into dipstick port.

5. Check oil level.

6. Install dipstick and tighten

3-11-3 102703

PN=173


CED,OUOE035,29 –19–05NOV98–1/1

Clean Axle Differential Recirculation Screen

T11

7325

–UN

–22S

EP

98

Front Differential Shown

T11

7326

–UN

–22S

EP

98

Rear Differential Shown

A—HoseB—Screen Fitting

1. Disconnect hose (A) and remove screen fitting (B).

2. Drain differential oil into a container. Dispose of wasteproperly. See Change Front and Rear Differential Oil inthis section.

NOTE: Fitting and screen are of a one piece design.Screen should be thoroughly cleaned and reused.

3. Clean screen with solvent.

4. Install screen fitting.

5. Install hose.

6. Refill differential with oil. See Change Front and RearDifferential Oil in this section.

3-11-4 102703

PN=174

Miscellaneous—Machine

TX,90,JC2246 –19–31OCT02–1/1

Draining the Cooling System

TS

281

–UN

–23A

UG

88T

1112

37C

–UN

–27A

UG

97

Upper Radiator Hose Shown

T11

1245

B–U

N–2

7AU

G97

T11

1243

B–U

N–0

3SE

P97

A—Radiator HoseB—Radiator Drain ValveC—Engine Drain Valve

CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns

Shut off engine. Only remove filler cap whencool enough to touch with bare hands. Slowlyloosen cap to first stop to relieve pressurebefore removing completely.

1. Check upper (A) and lower radiator hoses for cracksand leaks. Replace, if necessary.

2. Tighten clamps.

3. Check radiator, oil cooler, and air-to-air cooler for dirt,damage, leaks, and loose or broken mountings. Cleanradiator, oil cooler, and air-to-air cooler.

4. Connect a hose to drain valve (B) on radiator.

5. Turn drain valve counterclockwise to open. Allowcoolant to drain into a container. Dispose of usedcoolant properly.

6. Turn drain valve (C) counterclockwise to drain engineblock. Allow coolant to drain into a container. Disposeof used coolant properly.

4-1-1 102703

PN=175


CED,OUOE002,1788 –19–31OCT02–1/2

Filling the Cooling System

TS

281

–UN

–23A

UG

88

CAUTION: Prevent possible injury from hotspraying coolant. DO NOT remove radiator capunless the engine is cool. Then turn cap slowlyto the stop. Release pressure before removingcap.

SpecificationCooling System—Capacity 22 L (23 qt)......................................................

IMPORTANT: Use only permanent-type, low silicate,ethylene glycol base antifreeze incoolant solution. Other types ofantifreeze may damage cylinder seals.

FREEZING TEMPERATURES: Fill with permanent-type,low silicate, ethylene glycol antifreeze (without stop-leakadditive) and clean, soft water. Add TY16004 John DeereCoolant Conditioner or equivalent.


4-1-2 102703

PN=176


CED,OUOE002,1788 –19–31OCT02–2/2

T11

3678

–UN

–20F

EB

98

NOTE: All machines are shipped from the factory with a50-50 mixture for protection to -34°C (-30°F).Adjust mixture accordingly to provide freezeprotection for your machine.

FILL

• Fill radiator to the bottom of the radiator fill neck.• Fill the recovery tank to the FULL mark.

DEAERATION

The cooling system requires several warm-up and cooldown cycles to deaerate. It will NOT deaerate duringnormal operation. Only during warm-up and cool downcycles will the system deaerate.

• Start engine. Run engine until coolant reaches a warmtemperature.

• Stop engine. Allow coolant to cool.• Check coolant level at recovery tank.• Repeat Steps 1—3 until recovery tank coolant level is

repeatedly at the same level (stabilized).

NOTE: The level of the coolant in the cooling systemMUST BE repeatedly checked after all drain andrefill procedures to insure that all air is out of thesystem which allows the coolant level to stabilize.Check coolant level only when the engine is cold.

TX03679,00017F8 –19–13AUG01–1/1

Replacing Engine Vibration Damper

The engine vibration damper should be replaced every4500 hours or 5 years. See your authorized dealer.

4-1-3 102703

PN=177


HG31779,0000173 –19–29OCT02–1/1

Adjusting Pilot Controller Tower

T16

1077

B–U

N–2

9OC

T02

T16

1078

B–U

N–2

9OC

T02

1—Cap Screws (2 Used)2—Cap Screws (4 Used)

1. Remove two cap screws (1) from front load centerdoor. Open door.

2. Loosen four cap screws (2) under pilot controller tower.

3. Move tower to desired position.

4. Tighten cap screws (2).

SpecificationCap Screws—Torque 36.6 N•m (27 lb-ft)...................................................

5. Close front load center door. Install cap screws (1).

TX,90,JC1604 –19–04SEP96–1/1

Checking Fuel Tank Vent Hose

T10

3762

B–U

N–1

2DE

C96

A—Clamp

IMPORTANT: If fuel tank vent hose is plugged, thefuel tank could collapse.

1. Remove clamp (A).

2. Check hose for debris. If plugged, clean hose orreplace.

3. Install clamp.

4-1-4 102703

PN=178


TX,90,JC2176 –19–03SEP97–1/1

Bleeding Fuel System

T11

1238

E–U

N–2

7AU

G97

A—Bleed Screw (Final Fuel Filter)B—Bleed Screw (Primary Fuel Filter)C—Hand PrimerD—Primary Fuel FilterE—Drain Valve (Primary Fuel Filter)F—Drain Valve (Final Fuel Filter)G—Final Fuel Filter

1. Place container under filters (D and G).

2. Loosen bleed screw (A).

3. Pump hand primer (C) until bleed screw (A) has solidstream of fuel coming from it. Tighten bleed screw onfinal fuel filter (G).

4. Open bleed screw (B). Pump hand primer until bleedscrew has solid stream of fuel coming from it. Tightenbleed screw on primary fuel filter (D).


04T,90,C151 –19–20JUL92–1/1

Precautions for Alternator and Regulator

When batteries are connected, follow these rules:

1. Disconnect negative (-) battery cable when youwork on or near alternator or regulator.

2. DO NOT TRY TO POLARIZE ALTERNATOR ORREGULATOR.

3. Be sure alternator wires are correctly connectedBEFORE you connect batteries.

4. Do not ground alternator output terminal.

5. Do not disconnect or connect any alternator orregulator wires while batteries are connected orwhile alternator is operating.

6. Connect batteries or a booster battery in the correctpolarity (positive [+] to positive [+] and negative [-]to negative [-]).

7. Do not disconnect the batteries when engine isrunning and alternator is charging.

8. Disconnect battery cables before you connectbattery charger to the batteries. If machine hasmore than one battery, each battery must becharged separately.

4-1-5 102703

PN=179


TX03679,0001788 –19–11MAY01–1/3

Handling, Checking And Servicing BatteriesCarefully

TS

204

–UN

–23A

UG

88T

S20

3–U

N–2

3AU

G88

CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level.

Never check battery charge by placing a metalobject across the posts. Use a voltmeter orhydrometer.

Always remove grounded (-) battery clamp firstand replace it last.

Sulfuric acid in battery electrolyte is poisonous.It is strong enough to burn skin, eat holes inclothing, and cause blindness if splashed intoeyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 15—30

minutes. Get medical attention immediately.

If acid is swallowed:

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 relatedaccessories contain lead and lead compounds, chemicalsknown to the State of California to cause cancer andreproductive harm. Wash hands after handling.

4-1-6 102703

PN=180



TX03679,0001788 –19–11MAY01–2/3

If electrolyte spills on the floor, use one of the followingmixtures to neutralize the acid: 0.5 kg (1 lb) baking sodain 4 L (1 gal) water, or 0.47 L (1 pt) household ammoniain 4 L (1 gal) water.

IMPORTANT: Do not overfill the battery cells.

Check the specific gravity of electrolyte in each batterycell.

TX03679,0001788 –19–11MAY01–3/3

T85

402

–UN

–10N

OV

88

See your authorized dealer for JT05460 SERVICEGARDbattery and coolant tester. Follow directions included withthe tester.

A fully charged battery will have a corrected specificgravity reading of 1.260. If the reading is below 1.200,charge the battery.

SERVICEGARD is a trademark of Deere & Company

CED,OUOE002,1772 –19–15SEP98–1/1

Replacing Batteries

Your machine is equipped with a negative groundelectrical system. It uses two 12-volt batteries. If one ofthe two batteries fails, both batteries must be replaced.Use only batteries meeting following specifications.

SpecificationBattery—BCI Group 30H..............................................................................Cold Cranking Amps at -18°C(0°F) 625......................................................................................................Reserve Capacity at 25 amps 160 Minutes................................................

4-1-7 102703

PN=181


TX,90,JC1600 –19–29AUG96–1/1

Removing Batteries

T10

3150

C–U

N–1

2DE

C96

A—Positive (+) CableB—Negative (-) Cable

NOTE: Turn off master shut-off, if equipped, beforedisconnecting cables.

1. Remove left side battery cover.

CAUTION: To prevent injury from battery coversdropping, remove when servicing or replacingbatteries. Hinge is in place to aid in removalonly. Cover must not be held or propped openduring servicing.

CAUTION: To prevent injury from explosion orfire disconnect the left side battery firstregardless of which battery is being removed.

2. Disconnect negative (-) battery cable first, then positive(+) cable (A).

3. Remove nuts and washers (B) and hold down bracket.

4. Lift battery out of compartment.

4-1-8 102703

PN=182


HG31779,0000132 –19–20SEP02–1/2

Replacing Fuses

T10

3541

C–U

N–0

6JU

L00

One Lever Design

T16

0038

B–U

N–2

9OC

T02

Two Lever Design

A—Fuse Box


4-1-9 102703

PN=183


HG31779,0000132 –19–20SEP02–2/2

T159002

NotUsed

K31Ride Control

RelayAT162863

K25Drive Light

RelayAT162863

K27Hi-Beam Light

RelayAT162863

K23 LeftSignal/Flasher

RelayAT206685

K24 RightSignal/Flasher

RelayAT206685

K32Detent Enable

RelayAT162863

K28Brake Light

RelayAT162863

K17 Rear WiperReturn to Park

RelayAT162863

K18 Rear wiperIntermittent

RelayAT162863

K15 Front WiperReturn to Park

RelayAT162863

K16 Front WiperIntermittent

RelayAT162863

K13Return to Dig

RelayAT162863

K19Main Blower

RelayAT162863

K22Horn RelayAT162863

NotUsed

NotUsed

NotUsed

K21 SecondarySteering

(Relay Coil)Relay

AT162863

K4IgnitionRelay

AT162863

K10Back-Up

RelayAT162863

K6AccessoryRelay #2AT162863

K1Neutral Start

RelayAT162863

K5AccesoryRelay #1AT162863

K30 RideControl Boom

SolenoidRelay

AT162863

Rear Wiper Motor10 AMP Fuse

57M 7121P33 (ACC)

P34 (ACC)

J01 (ACC)

P32 (ACC)

P39 (ACC)

P42 (ACC)

P27 (ACC)

P45 (ACC)

P40 (BATT)

P37 (BATT)

P44 (BATT)

P35 (BATT)

A19 (ACC)

P01 (ST)

P36 (ACC)

P49 (ACC)

P48 (ACC)

P41 (ACC)

J07 (IGN)

P08 (IGN)

P24 (IGN)

P28 (IGN)

P10 (BATT)

P14 (BATT)

P16 (BATT)

P02 (BATT)

P11 (IGN)

P31 (12V BATT)

P47 (IGN)

P05 (IGN)

P25 (IGN)

P26 (IGN)

P04 (IGN)

Front Wiper Motor10 AMP Fuse

57M 7121

RideControl

7.5 AMP Fuse99M 7064

Power for PressureSwitches

5 AMP Fuse57M 7125

Tail & Marker Light7.5 AMP Fuse

99M 7064

Diff Lock, Pin Disc Solenoid

5 AMP Fuse57M 7125

Power for RockerSwitches

5 AMP Fuse57M 7125

Cab Work Light10 AMP CB

T103463

Drive & Hi-Beam Light10 AMP CB

T103463

Turn Signal/FlasherLight


Brake Light7.5 Amp Fuse

99M 7064

Spare15 AMP Fuse

99M 7065

PressurizerMotor


Neutral StartCircuit

5 AMP Fuse57M 7125

Horns7.5 AMP Fuse

99M 7064

SpareAccessory

5 AMP Fuse57M 7125

Seat Adjust,Lighter

10 AMP Fuse57M 7121

Rotary Beacon10 AMP Fuse

57M 7121

AlternatorExcitation


Engine ControllerSwitched

7.5 AMP FUSE99M 7065

Trans ControllerSwitched

5 AMP Fuse57M 7125

Pilot Enable7.5 AMP Fuse

99M 7064

Blower Motor25 AMP Fuse

99M 7069

Dome Light, Boom Down & Radio

Unswitched7.5 AMP Fuse

99M 7064

ConverterUnswitched

15 AMP Fuse99M 7065

Monitor & Trans ControllerUnswitched5 AMP Fuse

57M 7125

Power for BHKO, RTD, RTC Switch5 AMP Fuse

57M 7125

CCU 12VUnswitched5 AMP Fuse

57M 7125

SpareIgnition

5 AMP Fuse57M 7125

Monitor DisplaySwitched

5 AMP Fuse57M 7125

CCU 28 VSwitched


Park Brake,Back-up Alarm

5 AMP Fuse57M 7125

Start Aid,Converter & Sec. Strg

10 AMP Fuse57M 7121P06 (BATT)

Engine ControllerUnswitched

10 AMP Fuse57M 7121

NotUsed

NotUsed

NotUsed

NotUsed

F18

F17

F30

F10

F24

F14

F23

F29

F25

F22

F27

F35

F6

F20

F3

F21

F33

F32

F26

F1

F5

F12

F16

F19

F28

F31

F4

F15

F9

F34

F7

F11

F13

F2

T15

9002

–19–

24O

CT

02

IMPORTANT: Install fuses with correct amperagerating to prevent electrical systemdamage from overload.

The fuse box (A) is in the electrical load center on theright side (outside) of the cab. Both fuses and circuitbreakers are located in the load center.

4-1-10 102703

PN=184


TX,90,JC1936 –19–10MAR97–1/1

Fuse (Blade-Type) Color Codes

Amperage Rating Color

1 Black

3 Violet

4 Pink

5 Tan

7.5 Brown

10 Red

15 Light Blue

20 Yellow

25 Natural (White)

30 Light Green

4-1-11 102703

PN=185


TX,90,RR,1725 –19–11MAR94–1/1

Replacing Halogen Bulbs

T58

94A

G1

–UN

–17A

PR

89T

5894

AI1

–UN

–20O

CT

88T

6249

AU

–UN

–19O

CT

88

A—Flange NutB—Lock WasherC—HousingD—BulbE—GasketF—LensG—BezelH—Screw

IMPORTANT: To get the correct lighting pattern, lensmust be installed so the word "TOP" ison top when lamp is installed so widersection is on top when lamp isinstalled.

Before disassembling, remember how bezel and lens areinstalled with respect to mounting stud.

1. Remove four screws (H) to remove bezel (G) and lens(F).

2. Disconnect wiring lead and release retainer clip toremove bulb (D).

3. To disconnect ground wiring lead, push tab up, thenpull connector from terminal.

IMPORTANT: Do not touch the halogen bulb withbare hands. Oil and moisture maycause premature bulb failure. Cleanbulb using a soft, oil-free cloth andalcohol.

4. Install new bulb so square notch is aligned with squaretab on reflector back.

5. Install retainer clip into locking tabs on reflector back.

6. Connect wiring leads. Check wiring leads are free ofclip.

7. Install lens assembly (F) in housing (C) making surewires are not crimped, or keeping lens assembly fromseating on gasket.

8. Install bezel so wider section is on top. Sealing flangemust be inside housing on all four sides beforetightening screws.

9. Tighten screws alternately. Do not overtighten asscrews may strip out plastic.

4-1-12 102703

PN=186


TX,90,JC2178 –19–03SEP97–1/1

Engine Speeds

SpecificationEngine—Slow Idle Speed 900 ± 25 rpm....................................................Fast Idle Speed 2350 ± 25 rpm..................................................................

TX,90,JC1862 –19–17FEB97–1/1

Checking Neutral Start System

CAUTION: Avoid possible injury or death. DONOT attempt to start machine unless you aresitting in operator’s seat with the transmissioncontrol lever in neutral "N" position. DO NOTbypass or disable any of the starting systemparts.

Park brake is automatically applied whenengine stops and remains in park until the parkbrake switch is cycled.

Check the neutral start system to ENSURE that themachine:

1. WILL start with the transmission control lever in neutral"N" position.

2. WILL NOT start with the transmission control lever inforward "F" or reverse "R" position.

If starting system fails to operate correctly, have yourJohn Deere dealer repair the system immediately.

4-1-13 102703

PN=187


TX,90,JC2179 –19–03SEP97–1/1

Servicing Air Conditioning System

T11

1214

D–U

N–2

7AU

G97

A—Receiver Dryer Sight Glass

1. Check compressor clutch engagement.

2. Check evaporator core for clogging.

3. Check air intake filters for clogging.

4. Check blowers for proper operation.

5. Check the condenser core to see that it is not partiallyor completely plugged with dirt or trash. Clean withcompressed air or water when needed.

6. Run air conditioning system for several minutes.

7. Check sight glass (A) on receiver dryer (from outsideof cab). Bubbles must not be present in sight glass. Ifbubbles are present, see your authorized dealer forcharging the air conditioning system.

TX,90,JC1603 –19–29AUG96–1/1

Welding on Machine

IMPORTANT: Disconnect battery ground strap or turnbattery disconnect switch to "OFF" toprevent voltage spikes throughalternator or monitor.

Connect welder ground clamp close toeach weld area so electrical currentdoes not arc inside any bearings,bushings or pins.

NOTE: Machine is adequately grounded. It is notnecessary to disconnect any controllers(microprocessors).

4-1-14 102703

PN=188


CED,OUOE002,1738 –19–04SEP98–1/1

External Service Brake Inspection

T10

5193

B–U

N–0

2NO

V98

T11

7102

–UN

–10S

EP

98T

1171

03–U

N–2

3SE

P98

A—Feeler GaugeB—DisksC—DimensionD—Plates

Do first inspection at 5000 hours followed by 1000 hoursinspection intervals after the first 5000 hours inspection.

If the service brakes are subjected to severe duty, inspectmore frequently.

1. Remove plug from brake inspection port.

2. Start engine and run for 1 minute.

3. Stop and apply the brakes. Block pedal or havesomeone hold brakes on.

4. Using a tool (A), measure the thickness of disks (B) atdimension (C). Check dimension of two different disks.

SpecificationDisk—Thickness 2.92 mm (0.115 in.) new..................................................Thickness 2.22 mm (0.0874 in.) used

minimum.........................................................

5. If either of the disks thickness at dimension (C) is lessthan the minimum specification, the brake packs mustbe replaced.

4-1-15 102703

PN=189


TX,90,JC2277 –19–14OCT02–1/1

Checking Brake Accumulators

1. Start engine.

NOTE: If machine is equipped with return-to-carry, thereturn-to-carry switch must be in the “Off” position.

2. Lower boom by placing controller handle in “float”position.

3. Run engine for 1 minute at slow idle. Apply brakepedal four or five times.

4. Stop engine.

5. Turn key switch to “On” position.

NOTE: Accumulators are precharged and must bereplaced, not re-charged.

6. Apply brake pedal. The brake low pressure indicatorlight may come on after 18 to 35 full brakeapplications.

If brake light comes on with less than 18 applications,see your authorized dealer.

7. Repeat procedure three times to ensure accurateresults.

4-1-16 102703

PN=190


HG31779,0000181 –19–01NOV02–1/2

Checking Ride Control Accumulator—IfEquipped

X98

11–U

N–2

3AU

G88

T15

9423

Q–U

N–0

1NO

V02


T15

6774

H–U

N–2

7JU

N02



CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury. Avoidthe hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.Search for leaks with a piece of cardboard.Protect hands and body from high pressurefluids.

If an accident occurs, see a doctor immediately.Any fluid injected into the skin must besurgically removed within a few hours organgrene may result. Doctors unfamiliar withthis type of injury may call the Deere &Company Medical Department in Moline, Illinois,or other knowledgeable medical source.

CAUTION: The boom will jump upward duringthis check. Make sure area around bucket isclear.

1. Start engine.

2. Push ride control switch (A) to OFF position.

3. Raise boom to maximum height and hold control leverover relief for 2 seconds.

4. Lower boom and bucket to ground and stop engine.Put boom control lever in neutral.


4-1-17 102703

PN=191


HG31779,0000181 –19–01NOV02–2/2

T10

8328

C–U

N–2

7AU

G97

A—Accumulator

NOTE: When ride control switch is in “A” (automatic)position, ride control works at 6 km/h (3.7 mph) orabove.

5. Turn key switch to On.

6. Push ride control switch to center position. Switch willlight. Boom will jump upward, approximately 100 mm(4.0 in.) as accumulator (A) pressure is released.

7. If ride control accumulator has lost gas charge, seeyour authorized dealer.

To Discharge Accumulator

1. Turn key switch to “On”.

2. Push ride control switch to ON (center) position. Switchwill light.

NOTE: If ride control switch is already in the “On”position, it must be cycled to OFF then back toON (center) position.

3. Push pilot enable/boom down switch to boom lowerposition.

4. Hold hydraulic control lever in the boom float position.

4-1-18 102703

PN=192


TX,90,JC2181 –19–03SEP97–1/1

Transmission Oil Cooler, Hydraulic OilCooler, Air-To-Air Aftercooler, and RadiatorExternal Cleaning Procedure

T11

1246

B–U

N–2

7AU

G97

Shown With Air Conditioning

A—Cap Screw (3 used)

1. On machines equipped with air conditioning, removethree cap screws (A) and swing air conditioningcondenser forward for better access to coolers.

2. If dust or debris is light, clean coolers by blowing airthrough the fins. Do not exceed 6 bar (90 psi). Blow airstraight through fins to avoid bending them.

3. If air fails to clean the coolers, use a high-pressurewasher with soap and water not to exceed 48 bar (700psi). Direct water straight through fins to avoid bendingthem.

4-1-19 102703

PN=193


OUO1010,0000457 –19–01NOV02–1/2

Service Recommendations For STC1 Fittings

T13

4792

C–U

N–2

4OC

T00

1—Special Tool JDG13852—Shoulder Of Fitting3—Release Sleeve

STC fittings are used on this machine. The fittings aredesigned to allow the hydraulic hose to rotate as neededwhen the system is not pressurized. This prevents thehydraulic hoses from binding when components are putback to their operating position.

Fittings are easily disconnected using special tool,JDG1385 (1) (supplied in machine with Operator’sManual). The special tool has a different size slot cut intoeach end. The narrow slot is for -06 size fittings. The wideslot is for -08 size fittings. Use appropriate end of specialtool on fitting being disconnected. To connect fittings,simply push each half of fitting together.

IMPORTANT: DO NOT pry against release sleeve (3)or damage to fitting may result.

DO NOT force release sleeve beyondnormal range of travel, otherwise,release sleeve may fall off when hose isdisconnected. If this happens and fittingis connected without the release sleeveinstalled, fitting will not be able to bedisconnected again.

1. Disconnect STC type fittings:

a. Clean area around fitting, especially around therelease sleeve (3).

b. While keeping special tool JDG1385 (1)perpendicular to the fitting, insert tool betweenrelease sleeve (3) and shoulder (2).

c. Gently push, DO NOT PRY, release sleeve awayfrom shoulder to disconnect the fitting.

d. Pull hose to disconnect.

1STC is a registered trademark of the Aeroquip Corporation.

4-1-20 102703

PN=194



OUO1010,0000457 –19–01NOV02–2/2

T13

3922

–UN

–21S

EP

00

1—Release Sleeve2—Retaining Ring3—Female Half of STC Fitting4—O-Ring5—Backup Ring6—Male Half of STC Fitting

2. Inspect STC fittings:

a. Check seal mating surfaces for nicks, scratches, orflat spots.

b. Check O-ring (4), backup ring (5), and retaining ring(2) for wear or damage.

c. Make sure O-ring, backup ring, and retaining ringare in position before connecting fitting halvestogether.

3. Connect STC fittings:

a. Make sure fitting halves (3 and 6) are clean andfree of contaminates.

b. Make sure release sleeve (1) is on male half (6) offitting before connecting fitting halves together.

c. Push fitting halves together until a definite snap andsolid stop is felt.

d. Pull back on hose to make sure fitting halves arelocked together.

e. To prevent hoses from binding, move componentinto position before pressurizing hydraulic system.

TX,90,DH2537 –19–03SEP92–1/1

Do Not Service Control Valves, Cylinders,Pumps or Motors

Special tools and information are needed to servicecontrol valves, cylinders, pumps, or motors.

If these parts need service, see your authorized dealer.

4-1-21 102703

PN=195


T82,SKMA,AT –19–01AUG94–1/1

Hardware Torque Specifications

Check cap screws and nuts to be sure they are tight. Ifhardware is loose, tighten to torque shown on thefollowing charts unless a special torque is specified.

TX,90,JC1925 –19–03MAR97–1/1

Keep ROPS Installed Properly

TS

176

–UN

–23A

UG

88

CAUTION: Make certain all parts are reinstalledcorrectly if the roll-over protective structure(ROPS) is loosened or removed for any reason.Tighten mounting bolts to proper torque.

The protection offered by ROPS will beimpaired if ROPS is subjected to structuraldamage, is involved in an overturn incident, oris in any way altered. A damaged ROPS shouldbe replaced, not reused.

When installation of equipment on a machine necessitatesloosening or removing ROPS, mounting bolts must betightened.

SpecificationROPS Mounting Bolt—Torque 1150 N•m (850 lb-ft)..................................

4-1-22 102703

PN=196


DX,TORQ2 –19–01OCT99–1/1

Metric Bolt and Cap Screw Torque Values

TO

RQ

2–U

N–0

7SE

P99

Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)

M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)

M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)

M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)

M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)

M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)

M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)

M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)

M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)

M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)

M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)

M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)

M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)

M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)

M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)a "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.b "Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly startprocedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing whenfor general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximatelyreplace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,

not to the bolt head. Tighten toothed or serrated-type lock nuts to thefull torque value.

Fasteners should be replaced with the same or higher property class.If higher property class fasteners are used, these should only betightened to the strength of the original.

4-1-23 102703

PN=197


DX,TORQ1 –19–01OCT99–1/1

Unified Inch Bolt and Cap Screw Torque Values

TO

RQ

1A–U

N–2

7SE

P99

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings

Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)

1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)

5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)

3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)

7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)

1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)

9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)

5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)

3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)

7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)

1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)

1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)

1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)

1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)

1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,and for all other types of bolts and screws of any length.b "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.c "Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly startprocedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing whenfor general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximatelyreplace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,

not to the bolt head. Tighten toothed or serrated-type lock nuts to thefull torque value.

Fasteners should be replaced with the same or higher grade. Ifhigher grade fasteners are used, these should only be tightened tothe strength of the original.

4-1-24 102703

PN=198

Miscellaneous—Operational Checkout

HG31779,0000074 –19–02MAY02–1/1

Operational Checkout

Use this procedure to check all systems and functionson the machine. It is designed so you can make aquick check of the operation of the machine whiledoing a walk around inspection and performing specificchecks from the operator’s seat.

Should you experience a problem with your machine,you will find helpful diagnostic information in thischeckout that will pinpoint the cause. This informationmay allow you to perform a simple adjustment whichwill reduce the downtime of your machine. Use thetable of contents to help find adjustment procedures.

The information you provide after completing theoperational checkout will allow you or your authorizeddealer to pinpoint the specific test or repair workneeded to restore the machine to designspecifications.

A location will be required which is level and hasadequate space to complete the checks. No tools orequipment are needed to perform the checkout.

Complete the necessary visual checks (oil levels, oilcondition, external leaks, loose hardware, linkage,wiring, etc.) prior to doing the checkout. The machinemust be at operating temperature for many of thechecks.

Before starting this operational checkout, checkdiagnostic Service codes in monitor. These servicecodes must be corrected or cleared before starting thischeckout.

Start at the top of the left column and read completelydown column before performing check, follow thissequence from left to right. In the far right column, ifno problem is found (YES), you will be instructed to goto next check. If a problem is indicated (NO) or (NOTOK), you will be referred to either a section in thismanual or to your authorized dealer.

– – –1/1

Checking and Clearing Diagnostic Trouble Codes From Monitor

4-2-1 102703

PN=199


– – –1/1

Check Trouble Codes

T103702 –UN–13SEP96

T103152 –UN–09SEP96

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 pressSELECT to display service codes.

LOOK: Does display read “End”?

NOTE: Do NOT stop operating machine because servicecodes are displayed. The warning lights on dash willwarn you if machines requires maintenance. If servicecodes are displayed, record them.

YES: Go to BatteryCheck .

NO: Go to Check ServiceCodes .

– – –1/1

Clear Service Codes

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 SELECTfor three seconds to delete code.

NOTE: The service codes should disappear from window and next service codes bedisplayed or “End” displayed. If code can not be deleted, locate connector at sensorand disconnect it and reinstall it. Then repeat delete procedure. If code can not now bedeleted, 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?

YES: Go to BatteryCheck .

NO: See your authorizeddealer.

4-2-2 102703

PN=200


– – –1/1

Engine Off Checks

– – –1/1

Battery Check

T103154 –UN–10SEP96

Key OFF.

Press SELECT button and hold until battery volts aredisplayed.

LOOK: Does battery volts read a minimum of 24 volts?

YES: Go to next check .

NO: Check voltage oneach battery beforerecharging. If one batterywill not hold a charge,replace both batteries.

– – –1/1

Monitor Check Key switch ON.

Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges).

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 voltagereadings?

YES: Go to next check.


4-2-3 102703

PN=201


– – –1/1

Cab System Checks Check the following for proper working order.

• Seat adjustment• Seat belt• Tilt wheel counsel• Front and rear work lights• Front and rear drive lights• Turn signals• Dome light• Horn• Front and rear windshield wiper and washer• Four speed (five position) blower fan• Door and window latches• Side shield latches• Grill housing door latch• Radiator cap and fuel door checks• Cab mount ladder• Boom lock check• Service decal check


NO: Repair as needed.

– – –1/1

Neutral Start Check Move transmission control lever to 1st gear forward (1F), turn key switch to START.

LISTEN: Starting motor must not run.

NOTE: Gear display will not display “F” for forward or “R” for reverse until engine isstarted 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?


NO: Check neutral startfuse. If OK, see yourauthorized dealer.

– – –1/1

Backup Alarm Check

T106879 –UN–14FEB97

Move transmission control lever to reverse (R).

LISTEN: Does reverse alarm sound when lever is inreverse (R)?


NO: Check transmissioncontroller switched fuseand park brake andbackup alarm fuse. If OK,see your authorizeddealer.

4-2-4 102703

PN=202


– – –1/1

Diagnostic TroubleCodes (DTC)

Check Diagnostic Trouble Codes (DTC).

Record which (DTC) appear.

Clear (DTC).

If any (DTC) remain fix before continuing with checks, See Diagnostic Trouble CodesQuick Reference .

IF OK: Continue on withcheck.

– – –1/1

Engine Running Checks

– – –1/1

Monitor Check Key switch ON.

Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges).

LOOK/LISTEN: Do all lights come ON and does alarm sound?

Do Message Display and Basic Display windows have “8s” showing in every display?

Do all the gauge indicators point to approximately 12:00 O’ clock position?

Is backlighting of gauges ON?

After 4 seconds observe changes in Monitor.

LOOK: Do gauge indicators change from 12:00 O’clock to normal readings?

Does Message Display show John Deere?

LOOK: Does Basic Display change to show gear, rpm, hourmeter and battery voltagereadings?


NO: Check monitorswitched power fuse. IfOK, see your authorizeddealer.

4-2-5 102703

PN=203


– – –1/1

Park Brake Check

T103441 –UN–09SEP96

Release park brake by pushing park brake switch toOFF position.

LOOK: Does park brake indicator go off when brake isreleased? Will machine move if put into gear?

CAUTION: Seat belt must be worn during thischeck to prevent possible injury from suddenmachine stops.

Fasten seat belt.

Put transmission in 1st gear forward.

Drive machine at 3 MPH and push park brake switch toON.

LOOK/FEEL: Does machine come to a stop within 1meters (3 feet) when park brake is engaged at 3 MPH?Does transmission shift to neutral?



– – –1/1

Service Brake Check

T103453 –UN–05SEP96

DRIVE WORK 4-WAY NEUTRAL AUTO

A

A/C

ALPM1 2 3

4

5

CARRY BEACON DETACH RIDEPERFORMANCE MANAGEMENT

OFF

ON

LOADER HYDRAULICS

1

T140157 –UN–14AUG01

A—Left Service BrakeB—Right Service Brake1—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 puttransmission 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.


NO: Inspect for leaksunder machine oroverfilling of non-difflockaxle. See your authorizeddealer.

4-2-6 102703

PN=204


– – –1/1

Pilot Controller LockCheck

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)


NO: Check pilotenable/boom downswitch.

– – –1/1

Pilot Enable/Boom DownSolenoid Check

T107030 –UN–04FEB97

Raise Boom.

Stop Engine.

Turn key to ON position.

Move Pilot Enable/Boom Down Switch in DOWNposition.

CAUTION: Boom will quickly lower toground.

Move control lever to boom lower position.

LOOK: Does boom lower?


NO: Check boom downfuse (dome light will notwork if fuse is blown).

IF OK: Check boomdown solenoid.

4-2-7 102703

PN=205


– – –1/1

Pilot Control Valve BoomFloat Check

T107137 –UN–07FEB97

Run engine at slow idle.

Push Ride Control switch off.

Push Return-to-Carry switch off.

With the bucket partially dumped, lower boom to raisefront of machine.

Push control lever to the float detent position andrelease lever.

LOOK: Does front of machine lower to the ground andvalve remain in float position when lever is released?



– – –1/1

Pin Disconnect SystemCheck (If Equipped)

Run engine at slow idle.

Position bucket flat on the ground.

Push and hold Pin Disconnect Switch (DETACH).

LOOK: Does pin disconnect cylinder retract both pins while switch is pressed?


NO: Check differentiallock and pin disconnectfuse.

NO: Hold a screwdriverblade against the end ofthe pin disconnectsolenoid valve and checkfor magnetism with theswitch pushed, ifmagnetism switch is ok.

IF OK: See yourauthorized dealer.

4-2-8 102703

PN=206


– – –1/1

Ride Control CheckCAUTION: Boom will jump upward during this check. Make sure areaaround bucket is clear.

T107137 –UN–07FEB97

Push Ride Control Switch to OFF position.Raise boom to maximum height and hold control leverover relief for 2 seconds.

Lower boom and bucket to eye level. Observe loaderboom as ride control switch is switched to ON.

LOOK/FEEL: Does boom jump upward 30 cm (12 in) ormore?

Push Ride Control Switch to AUTO position. Switch willlight.

T107037 –UN–07FEB97

Raise boom to maximum height and hold control leverover relief for 2 seconds.

Lower boom and bucket to eye level and slowlyaccelerate to 5 mph while watching speedometer andbucket.

LOOK/FEEL: Does ride control come on atapproximately 3 mph and bucket raise slightly?


NO: Check ride controlfuse.

NO: Check ride controlboom solenoid. Checkride control On/Offsolenoid.

IF OK: Ride controlaccumulator chargepressure.

– – –1/1

Differential Lock Check

T103168 –UN–05SEP96

Park unit on a hard surface.

Release brakes.

Push Differential Lock Switch and steer unit left andright.

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 yourelease switch.

LOOK: Do front wheels rotate in opposite directions withdifferential lock switch released?

YES: Go to next check


4-2-9 102703

PN=207


– – –1/1

Clutch Cutoff Check Turn Clutch Cutoff Switch (NEUTRAL) on.

Apply brake.

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 yourloading needs by selecting one of three operating functions in the monitor.Transmission does not totally disengage, some effort to move by the machine can befelt. See your authorized dealer.



– – –1/1

Boom And BucketCylinder Drift Check

T6564NZ –UN–19OCT88

Set bucket flat on the ground and raise about 50 mm (2in.).

Stop engine. Observe bucket for 1 minute.

LOOK: Does bucket remain in position? Bucket shouldnot settle to the ground.

NOTE: Use good judgement to determine if the amountof drift is objectionable for your loader application.



4-2-10 102703

PN=208


– – –1/1

Automatic Shift AndSpeedometer Check

NOTE: In the AUTOMATIC mode, transmission will shift to highest gear selected asground 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 transmissionwill start in 1st when initially shifted from Neutral to Forward or Reverse. After the initialshift from Neutral, the transmission will downshift no lower than 2nd unless a high loadis encountered. Transmission will upshift or downshift as ground speed dictates.

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 speedwhen shifts are made until engaged in 4th gear. Reduce engine rpm to idle and notespeed 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-shiftsto 3rd then 4th. When transmission downshifts it returns to 2nd. Transmission will shiftat different speeds depending on machine loads. Use only as reference.


NO: Monitor isprogrammed for wrongtire size. See yourauthorized dealer.

4-2-11 102703

PN=209


– – –1/1

Transmission Shift ModeCheck

Turn Automatic Transmission Shift switch to OFF.

Press MENU until ACCESSORY shows in basic display, then press SELECT.

Accessory will display in Message Display Window and A 02 Quick Shift in BasicDisplay 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 gearthen 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 getDownshift 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?


LOOK/FEEL: Does transmission shift to and remain in 2nd gear?


LOOK/FEEL: Does transmission shift to and remain in 1st gear?


LOOK/FEEL: Does transmission stay in 1st gear?

NOTE: In DOWN ONLY mode pressing Quick Shift Switch will not change gears once1st gear is reached, unless a direction or gear change is made.



– – –1/1

Axle Disconnect Check(If Equipped)

T6601AA –UN–19OCT88

Operate machine in an open area away from bystanders.

With bucket partially dumped, lower boom to raise frontwheels off the ground.

Push Axle Disconnect Switch to ON position.

Watch front wheels while operating the machine inreverse. Front wheels must not rotate as machine movesbackwards.

LOOK: Do front wheels remain stationary while machinemoves backwards?


NO: Check differentiallock and pin disconnectfuse.

IF OK: See yourauthorized dealer.

4-2-12 102703

PN=210


– – –1/1

Steering Valve Check

T6471AQ –UN–19OCT88

Transmission in Neutral.

Run engine at low idle.

Remove foot from brake pedal.

Release park brake.

Turn steering wheel until machine frames contact rightand left frame stops.

LOOK: Does machine steer smoothly in both directions?

NOTE: It is normal for machine frames to drift away fromframe stops when steering wheel is released.

When steering wheel is stopped, frames must stop.

FEEL: Is excessive effort required to turn steeringwheel?

IF OK: Go to next check


4-2-13 102703

PN=211

Miscellaneous—Troubleshooting

HG31779,0000020 –19–16APR02–1/1

Troubleshooting Procedure

NOTE: Troubleshooting charts are arranged from thesimplest to verify, to least likely, more difficult toverify. When diagnosing a problem, use allpossible means to isolate the problem to a singlecomponent or system. Use the following steps todiagnose problems:

Step 1. Operational Checkout Procedure

Step 2. Troubleshooting Charts

Step 3. Adjustments

Step 4. See your authorized dealer.

4-3-1 102703

PN=212


TX17961,0000174 –19–03OCT02–1/3

Diagnostic Trouble Codes Quick Reference List

CCU SERVICE CODES

• F0275 CCU Power Dissipation Excessive

TRANSMISSION SYSTEM CODES:

• F0300 Oil Temperature High Long• F0305 TCU Output Speed Zero• F0306 TCU Voltage Low• F0307 TCU Voltage High• F0308 TCU Valve Solenoid Power• F0309 TCU Park Brake Solenoid Power• F0315 Oil Filter Circuit Short-to-Power• F0320 1st Gear Clutch Slippage• F0321 2nd Gear Clutch Slippage• F0322 3rd Gear Clutch Slippage• F0323 4th Gear Clutch Slippage• F0324 Forward Gear Clutch Slippage• F0325 Reverse Gear Clutch Slippage• F0330 Clutch Cut-Off Circuit Voltage Low• F0331 Clutch Cut-Off Circuit Voltage High• F0336 TCU Configuration Bad• F0337 TCU Memory Bad• F0339 Temperature Sensor Voltage Short-to-Ground• F0340 Temperature Sensor Voltage Short-to-Power• F0341 Output Speed Signal Bad• F0342 Output Speed Circuit Short-to-Ground• F0343 Output Speed Circuit Short-to-Power• F0344 Internal Clutch Speed Signal Bad• F0345 Internal Clutch Speed Circuit Short-to-Ground• F0346 Internal Clutch Speed Circuit Short-to-Power• F0347 Turbine Speed Signal Bad• F0348 Turbine Speed Circuit Short-to-Ground• F0349 Turbine Speed Circuit Short-to-Power• F0350 Input Speed Signal Bad• F0351 Input Speed Circuit Short-to-Ground• F0352 Input Speed Circuit Short-to-Power• F0353 FWD High Range Clutch Pack Solenoid

Open• F0354 FWD High Range Clutch Pack Solenoid Short

to Ground• F0355 FWD High Range Clutch Pack Solenoid Short

to Power• F0356 Third Speed Clutch Pack Solenoid Open

• F0357 Third Speed Clutch Pack SolenoidShort-to-Ground

• F0358 Third Speed Clutch Pack SolenoidShort-to-Power

• F0359 Second Speed Clutch Pack Solenoid Open• F0360 Second Speed Clutch Pack Solenoid

Short-to-Ground• F0361 Second Speed Clutch Pack Solenoid

Short-to-Power• F0362 First Speed Clutch Pack Solenoid Open• F0363 First Speed Clutch Pack Solenoid

Short-to-Ground• F0364 First Speed Clutch Pack Solenoid

Short-to-Power• F0365 Reverse Clutch Pack Solenoid Open• F0366 Reverse Clutch Pack Solenoid

Short-to-Ground• F0367 Reverse Clutch Pack Solenoid

Short-to-Power• F0368 FWD Low Range Clutch Pack Solenoid Open• F0369 FWD Low Range Clutch Pack Solenoid

Short-to-Ground• F0370 FWD Low Range Clutch Pack Solenoid

Short-to-Power• F0375 Gear Selector• F0377 Oil Temperature Circuit Short-to-Power• F0378 Oil Temperature Circuit Open• F0379 FNR Selector Switch Open• F0380 Oil Filter Restricted• F0384 Reverse Alarm Relay Short-to-Power• F0385 Reverse Alarm Relay Short-to-Ground• F0386 Reverse Alarm Relay Open• F0387 Park Brake Solenoid Short-to-Power• F0388 Park Brake Solenoid Short-to-Ground• F0389 Park Brake Solenoid Open• F0396 Oil Temperature High

ENGINE SYSTEM CODES:

• F0400 Oil Pressure Low Long• F0415 CCU Throttle Circuit Voltage Low• F0416 CCU Throttle Circuit Voltage High• F0423 Ambient Air Temperature Input Voltage High• F0424 Ambient Air Temperature Input Voltage Low

4-3-2 102703

PN=213



TX17961,0000174 –19–03OCT02–2/3

• F0425 Engine Coolant Temperature Input VoltageHigh

• F0426 Engine Coolant Temperature Input VoltageLow

• F0431 Cylinder #1 EI Circuit• F0432 Cylinder #2 EI Circuit• F0433 Cylinder #3 EI Circuit• F0434 Cylinder #4 EI Circuit• F0435 Cylinder #5 EI Circuit• F0436 Cylinder #6 EI Circuit• F0437 Fuel Temperature Input Voltage High• F0438 Fuel Temperature Input Voltage Too Low• F0439 Pump Control Valve #1 Error• F0440 Pump Control Valve #2 Error• F0441 Crank Position Input Missing• F0442 Crank Position Input Error• F0443 Pump Position Sensor Input Missing• F0444 Pump Position Sensor Input Error• F0445 Crank Position/Pump Position Timing

Moderately Out of Sync• F0450 Fuel Rail Pressure Input Voltage High• F0451 Fuel Rail Pressure Input Voltage Low• F0453 Water in Fuel Signal Voltage High• F0454 Water in Fuel Signal Voltage Low• F0455 Manifold Air Temperature Moderately High• F0456 Pump Control Valve #2 Fuel Flow Not

Detected• F0469 Pump Control Valve #1 Fuel Flow Not

Detected• F0470 Fuel Rail Pressure Control Error• F0471 Fuel Rail Pressure Sensor Supply Voltage

Low• F0478 Engine Oil Pressure Circuit Voltage Low• F0479 Engine Oil Pressure Circuit Voltage High• F0485 Water in Fuel Detected• F0499 Engine Oil Pressure Low• F0500 Engine Coolant Temperature High Long• F0515 Engine Air Filter Restriction Circuit• F0516 Engine Fuel Level Circuit Voltage Low• F0517 Engine Fuel Level Circuit Open• F0576 Engine Coolant Temperature Circuit Noisy• F0577 Engine Coolant Temperature Circuit

Short-to-Ground• F0578 Engine Coolant Temperature Circuit Open• F0580 Engine Air Filter Restricted• F0599 Engine Coolant Temperature High

STEERING SYSTEM CODES:

• F0998 Steering Pressure Circuit• F0999 Steering Pressure Low

BRAKE SYSTEM CODES:

• F1097 Service Brake Pressure Circuit• F1099 Service Brake Pressure Low

ELECTRICAL SYSTEM CODES:

• F1620 CCU Spare Relay #1 Short• F1621 CCU Spare Relay #3 Short• F1622 CCU Spare Relay #4 Short• F1623 CCU Spare Relay #5 Short• F1624 Air Preheat Driver Short Ground• F1625 Detent Enable Driver Short-to-Ground• F1626 Ride Control Boom Driver Short-to-Ground• F1628 Ride Control On Driver Short-to-Ground• F1629 Left Turn Driver Short-to-Ground• F1630 Right Turn Driver Short-to-Ground• F1633 Secondary Steering Driver Short-to-Ground• F1634 Rear Wiper Driver Short-to-Ground• F1635 Front Wiper Driver Short-to-Ground• F1636 CCU Relay Driver Overtemp• F1637 CCU Timer Reset• F1638 Proportional Fan Drive Solenoid Circuit Error• F1639 Reverse Fan Drive Solenoid Circuit Error• F1641 Drive Light Switch Circuit Open• F1644 MDU Memory Bad• F1645 CCU Memory Bad• F1647 Machine Odometer Bad• F1648 Machine Hourmeter Bad• F1649 CCU Hourmeter Bad• F1651 No ECU CAN Transmit• F1653 No CCU CAN Transmit• F1655 No TCU CAN Transmit• F1658 Power Voltage Balance• F1660 Alternator Voltage High• F1661 Alternator Voltage Low• F1662 Power Voltage High• F1663 Power Voltage Low• F1664 Brake Light Pressure Circuit• F1665 Drive Light Switch Circuit• F1667 Turn Switch Circuit Short

4-3-3 102703

PN=214



TX17961,0000174 –19–03OCT02–3/3

• F1668 Hazard Switch Circuit• F1671 Return to Carry Detent Solenoid Circuit Error• F1672 Boom Height Kickout Detent Solenoid Circuit

Error• F1699 Config Bad

HYDRAULIC SYSTEM CODES:

• F2100 Oil Temperature High Long• F3115 Oil Filter Restriction Circuit Short-to-Ground• F3150 Oil Filter Restriction Circuit Short-to-Power• F3160 Ride Control Circuit Short-to-Power• F3161 Ride Control Auto Circuit Short-to-Ground

• F3162 Ride Control On Circuit Short-to-Ground• F3163 Boom Position Voltage Low• F3164 Boom Position Sensor Voltage High• F3171 Hydraulic Oil Pressure Circuit Voltage Low• F3172 Hydraulic Oil Pressure Circuit Voltage High• F3173 Spin Control Mode Circuit• F3174 Spin Control Enable Circuit Short-to-Ground• F3175 Hydraulic Oil Temperature Circuit

Short-to-Ground• F3176 Hydraulic Oil Temperature Circuit Open• F3177 Hydraulic Oil Temperature Circuit Noisy• F3199 Hydraulic Oil Temperature High

4-3-4 102703

PN=215


TX17961,000000B –19–03OCT02–1/2

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 exhaustrestrictions.

Air heater not working If engine has an air heater, verify airheater operation in coldtemperatures.

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 asoff 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 airPower filters and fuel filters.

Fuel quality Check fuel quality.

Transmission problems Check for transmission problems.

Engine mechanical problems Check for engine mechanicalproblems.

Excessive load Check for excessive load on theengine.

Engine Emits Excessive White Fuel quantity and quality Check fuel quantity and quality.Exhaust Smoke

Low engine coolant temperature Check for extremely low enginecoolant temperature.

4-3-5 102703

PN=216



TX17961,000000B –19–03OCT02–2/2


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 airfilter.

Excessively loaded engine Check for excessively loadedengine.

Engine Will Not Crank Weak battery Replace battery.

Corroded or loose battery Clean battery terminals andconnections 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 qualityfuel of the proper grade.

Air leak on suction side of air intake Check hose and pipe connectionssystem for tightness; repair as required.

4-3-6 102703

PN=217


TX17961,000016A –19–03OCT02–1/3

Transmission


Transmission Clutch Slippage Low oil level See Transmission, HydraulicSystem, Park Brake, And DifferentialOil.

Wrong oil grade See Transmission, HydraulicSystem, Park Brake, And DifferentialOil.

Restricted Transmission pump Remove and clean screen.suction screen

Machine Will Not Move Diagnostic Trouble Code (DTC) Check Diagnostic Trouble Codes torelated 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 fullyreleased.

No power to transmission controller Check transmission controllerunit switched 5A fuse.

Check monitor and transmissioncontroller unswitched fuse.

Hydraulic failure of park brake Check operation of park brake.

Failed shift switch Check that display window showscorrect gear when shift switch ismoved.

Broken drive shafts Inspect drive shafts and universaljoints for external damage.

4-3-7 102703

PN=218



TX17961,000016A –19–03OCT02–2/3


Machine Does Not Engage In Clutch cutoff activated Check that brake pedal is fullyLow Gear released.

Shift switch problem Check Diagnostic Trouble Codes todefine problem. See Monitor DisplayUnit—User Diagnostics Menu.

Machine Will Not Shift Correctly Speed sensor disconnected or failed Check electrical connectors ontransmission 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 hydraulicpump 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 verifysender temperature.

Restricted air flow through oil cooler Check oil cooler and radiator foror 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 metaltransmission particles.

Damaged drive dampener Inspect drive dampener.

Driveline or park brake Inspect drive line and park brake.

4-3-8 102703

PN=219



TX17961,000016A –19–03OCT02–3/3


Foaming Oil Incorrect type of oil Check oil type. Change oil if needed.

High oil level Check oil level. Transmissionoverfilled or hydraulic pump sealleaking.

Low oil level Check oil level. Add oil if needed.

Oil Ejected From Dipstick Plugged breather Inspect breather on top oftransmission. 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 ordifferential 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. SeeChange Transmission Oil .

Aerated oil Check oil level. Add oil if needed.

4-3-9 102703

PN=220


TX17961,000016C –19–03OCT02–1/2

Differential And Axle


No differential Lock Operation Malfunction in electrical circuit With engine stopped and key switchon, activate differential lock andlisten for a click from solenoid valve.

Stuck differential lock solenoid valve With engine stopped and key switchon, activate differential lock andlisten 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 FrontChatters 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 switchon, activate differential lock andlisten for a click from solenoid valve.

Stuck differential lock solenoid valve With engine stopped and key switchon, activate differential lock andlisten for a click from solenoid valve.

Differential Low On Oil External leakage Inspect axle and differential forleaks.

Excessive Differential And/Or Low oil level in differential Check oil. Remove drain plug andAxle Noise inspect for metal particles in

differential case. See Check Frontand Rear Differential Oil Level .

Engaged differential lock Release lock.

If circuit remains pressurized, checkif foot switch is sticking. Remove andinspect.

Check solenoid valve for sticking.Remove and inspect valve.

4-3-10 102703

PN=221



TX17961,000016C –19–03OCT02–2/2


Oil Seeping From Outer Axle Dirt in face seal Inspect face seals.Seal

Overfilled differential Check differential lock oil returnsystem for excessive internalrestriction.

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 screenscreens plugged located in differential housing below

input yoke. See Clean AxleDifferential Recirculation Screen .

TX17961,000016D –19–03OCT02–1/1

Service Brake


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 andRear Differential Oil .

Wrong oil in hydraulic system Drain hydraulic reservoir anddifferentials. Refill with correct oil.See Change Front and RearDifferential Oil .

4-3-11 102703

PN=222


TX17961,000016E –19–03OCT02–1/1

Drive Line


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 andadjust as required. See Check ParkBrake 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 ofgrease.

4-3-12 102703

PN=223


TX17961,000016F –19–03OCT02–1/1

Park Brake


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 ParkBrake 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 FromFwd 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 wiresDoes Not Come On When Brake between brake indicator switch andApplied indicator on dash.

4-3-13 102703

PN=224


TX17961,0000170 –19–03OCT02–1/2

Hydraulic System


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. Tightenconnections. Replace O-rings and/orlines.

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.

4-3-14 102703

PN=225



TX17961,0000170 –19–03OCT02–2/2


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 andcylinders. 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 ofNot Retract pin disconnect solenoid valve and

check for magnetism with switchpushed.

Solenoid valve failure Remove and inspect.

Cylinder binding Inspect cylinder and adjust loads.

4-3-15 102703

PN=226


TX17961,0000171 –19–03OCT02–1/1

Steering


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.


Spongy or Soft Steering Air in oil Check for foamy oil.


Machine Turns in Opposite Lines to cylinders connected to Connect lines to correct ports.Direction wrong ports at steering valve.

4-3-16 102703

PN=227


TX17961,0000172 –19–03OCT02–1/2

Air Conditioning System


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)


4-3-17 102703

PN=228


TX17961,0000172 –19–03OCT02–2/2


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, replacecollapsed 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 compressorclutch.

Warm outside air leaking into cab Inspect, repair or replace door andwindow seals.

Heater valve remaining open Inspect, repair, adjust or replaceheater valve or cable.

System refrigerant (R134A) charge Inspect system for leaks.low

Evaporator fins frosting or freezing Freeze control switch capillary tubenot positioned correctly in evaporatorcore.

Air Conditioner Runs Constantly, Freeze control switch capillary tube Reposition capillary tube inToo 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.

4-3-18 102703

PN=229


TX17961,0000173 –19–03OCT02–1/1

Heater System


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, replacecollapsed collapsed hoses.

Heater core fins clogged with dirt or Clean heater fins.dust

Heater valve remaining closed Inspect, repair, adjust or replaceheater 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 (ifequipped).

4-3-19 102703

PN=230

Miscellaneous—Storage

TX,105,FF2313 –19–16NOV00–1/1

Prepare Machine For Storage

T58

13A

M–U

N–0

9FE

B89

1. Repair worn or damaged parts. Install new parts, ifnecessary, to avoid needless delays later.

2. Check primary air cleaner. Replace filter, if necessary.

IMPORTANT: High pressure washing greater than1379 kPa (13.8 bar) (200 psi) candamage freshly painted finishes. Paintshould be allowed to air dry for 30 daysminimum after receipt of machinebefore cleaning parts or machines withhigh pressure. Use low pressure washoperations 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 daysafter receipt of machine have elapsed. Paint areas toprevent rust. Replace decals, where needed.

4. Apply waste oil to track chains. Run machine back andforth several times. Park machine on a hard surface toprevent tracks from freezing to ground.

5. Store machine in a dry, protected place. If storedoutside, cover with a waterproof material.

IMPORTANT: LPS 3 Rust Inhibitor can destroypainted finish. DO NOT spray LPS 3Rust Inhibitor on painted areas.

6. Retract all hydraulic cylinders, if possible. If not, coatexposed cylinder rods with LPS 3 Rust Inhibitor.

7. Place a "DO NOT OPERATE" tag on the right controllever.

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.

4-4-1 102703

PN=231

Miscellaneous—Machine Numbers

TX,110,JC1841 –19–31JAN97–1/1

Record Product Identification Number (PIN)

T10

6371

B–U

N–2

4JA

N97

A—Product Identification Number

Purchase Date

NOTE: Record all 13 characters of the ProductIdentification Number.

TX,110,JC1995 –19–08APR97–1/1

Record Engine Serial Number

T10

8431

G–U

N–0

8AP

R97

A—Engine Serial Number

Engine Serial Number

CED,OUOE002,1740 –19–08SEP98–1/1

Record Transmission Serial Number

T11

7070

–UN

–11S

EP

98

A—Transmission Serial Number

Transmission Serial Number

Located near lower left corner of case.

TX,110,JC1859 –19–05FEB97–1/1

Record Hydraulic Pump Serial Number

T10

6391

B–U

N–2

4JA

N97

A—Hydraulic Pump Serial Number

Hydraulic Pump Serial Number

4-5-1 102703

PN=232

Miscellaneous—Machine Numbers

CED,OUOE002,1747 –19–09SEP98–1/1

Record Axle Serial Number

T11

7115

–UN

–10S

EP

98

A—Axle Serial Number

Axle Serial Number

4-5-2 102703

PN=233

Miscellaneous—Specifications

CED,OUOE002,1791 –19–30MAY00–1/2

624H/TC62H Specifications

T10

7472

–UN

–19F

EB

97

A—Bucket Hinge Height C—Dump Reach E—Wheelbase G—Machine Overall LengthB—Dump Height D—Machine Overall Height F—Machine-to-Ground

Clearance


A—Bucket Hinge Height 624H—3961 mm (13 ft 0.0 in.)TC62H—4005 mm (13 ft 2.0 in.)

B—Dump Height 624H—2834 mm (9 ft 4.0 in.)TC62H—2907 mm (9 ft 6.0 in.)

C—Dump Reach 624H—1062 mm (3 ft 6.0 in.)TC62H—1278 mm (4 ft. 2.0 in.)

D—Overall Machine Height 3300 mm (10 ft 10.0 in.)

E—Wheelbase Length 3030 mm (9 ft 11 in.)

4-6-1 102703

PN=234



CED,OUOE002,1791 –19–30MAY00–2/2


F—Machine-to-Ground Clearance 406 mm (16.0 in.)

G—Overall Machine Length 624H—7641 mm (25 ft 1.0 in.)TC62H—7671 mm (25 ft 2.0 in.)

Weight 624H—13 831 kg (30,492 lb)TC62H—13 849 kg (30,532 lb)

Counterweight 624H—509 kg (1,122 lb)TC62H—474 kg (1,045 lb)

NOTE: Specifications and design subject to changewithout notice. Wherever applicable,specifications are in accordance with SAEstandards. Except where otherwise noted,specifications are based on a machineequipped with all standard equipment, with 474

kg (1,045 lb) optional counterweight, ROPScab, diff lock front axle with standard rear axle,2 spool valve with two lever control, heaterand defroster, 79 kg (175 lb) operator and fullfuel tank.

4-6-2 102703

PN=235


CED,TX03679,5802 –19–21JUN00–1/1

624H High Lift Specifications

T13

1954

–UN

–22J

UN

00

A—Bucket Hinge Height C—Dump Reach E—Wheelbase G—Machine Overall LengthB—Dump Height D—Machine Overall Height F—Machine-to-Ground

Clearance


A—Bucket Hinge Height 4327 mm (14 ft 2.4 in.)

B—Dump Height 3224 mm (10 ft 7.0 in.)

C—Dump Reach 1125 mm (3 ft 8.3 in.)

D—Overall Machine Height 3300 mm (10 ft 10.0 in.)

E—Wheelbase Length 3030 mm (9 ft 11 in.)

F—Machine-to-Ground Clearance 406 mm (16.0 in.)

G—Overall Machine Length 8022 mm (26 ft 3.8 in.)Weight 13 648 kg (30,089 lb)Counterweight 509 kg (1,122 lb)

4-6-3 102703

PN=236


CED,OUOE002,1792 –19–20DEC01–1/1

Drain and Refill Capacities—624H/TC62H


Cooling System Capacity 22 L (23 qt)

Fuel Tank Capacity 265 L (70 gal)

Engine Crankcase and Filter Capacity (S.N. —582360) 20 L (21 qt)Capacity (S.N. 582361—) 21 L (22 qt)

Transmission Case and Filter Capacity 27 L (29 qt)

Front Differential Capacity 25 L (26 qt)

Rear Differential Capacity 20 L (21 qt)

Hydraulic Reservoir and Filters Capacity 117 L (31 gal)

Park Brake Capacity 0.300 L (10 oz)

4-6-4 102703

PN=237

Miscellaneous—Crime Prevention Tips

DX,CRPRV,A –19–03MAR93–1/1

Help Prevent Crime

TS

140

–19–

07O

CT

88

You can help take a bite out of crime by properlydocumenting ownership and discouraging theft.

DX,CRPRV,H –19–04JUN90–1/1

Record Identification Numbers

TS

156

–UN

–23M

AR

89

1. Mark your machines with your own unique numberingsystem.

2. Record the Product Identification Number (PIN) of theunit and also individual component identificationnumbers for engines, axles, pumps, etc. Include thePIN numbers on all documentation, such as insurance,financial, and warranty papers.

DX,CRPRV,I –19–04JUN90–1/1

Keep Proof of Ownership

TS

157

–UN

–23M

AR

89

1. Take color photographs from several angles of eachmachine.

2. Maintain an up-to-date inventory of all your machines.

3. Keep your documented identification numbers, colorphotographs, and inventory in a safe, secure location.

DX,CRPRV,J –19–04JUN90–1/1

Park Indoors Out of Sight

TS

158

–UN

–23M

AR

89

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.• Lock cab doors, windows, and vandal-proof devices.• Lock building.

4-7-1 102703

PN=238


DX,CRPRV,K –19–04JUN90–1/1

When Parking Outdoors

TS

144

–UN

–23A

UG

88

Make machines hard to move:

• Park in a well-lighted, fenced area.• Lower all equipment to the ground.• Remove ignition key.• Remove battery when unit is storage.• Lock cab doors, windows, and vandal-proof devices.

TX,120,DH1093 –19–16SEP92–1/1

Reduce Vandalism

T72

23B

B–U

N–2

2FE

B90

1. Install vandal-proof devices.

2. Participate in a neighborhood watch program. Takewritten notes of suspicious vehicles or persons andreport your findings to law enforcement agency.

3. Regularly verify that identification plates have not beenremoved. If they have, notify law enforcement agency.Order duplicate plates from your dealer.

4-7-2 102703

PN=239


DX,CRPRV,G –19–03MAR93–1/1

Report Thefts Immediately

TS

146

–UN

–09J

AN

89

1. Immediately notify your local law enforcement agencyand insurance agent.

2. Provide a complete description of the machine, all ofthe documented identification numbers and colorphotographs.

3. Request verification of the identification numbers afterthey have been entered with any regional or nationalcrime information center. Double check the numbers tobe sure they are correct.

4. Notify your John Deere dealer of the theft and requestthat its loss be posted with full description andidentification numbers.

4-7-3 102703

PN=240

IndexPage Page

A BleedFuel system . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5

BoomAccessory menuControl lever-one lever design . . . . . . . . . . 2-2-11Auto mode to first (A 03). . . . . . . . . . . . . . . 2-1-25Control lever-two lever design. . . . . . . . . . . 2-2-12Clutch Cutoff (A 01) . . . . . . . . . . . . . . . . . . 2-1-20Height kickout adjustment . . . . . . . . . . . . . . 2-2-18Hour meter mode (A 06) . . . . . . . . . . . . . . . 2-1-27

Boom LockJob timer mode (A 04) . . . . . . . . . . . . . . . . 2-1-26Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-4Metric units mode (A 07). . . . . . . . . . . . . . . 2-1-27

BrakeQuick shift mode (A 02) . . . . . . . . . . . . . . . 2-1-23Accumulator . . . . . . . . . . . . . . . . . . . . . . . . 4-1-16Stop watch mode (A 05) . . . . . . . . . . . . . . . 2-1-26

BrakesAccumulatorExternal inspection . . . . . . . . . . . . . . . . . . . 4-1-15Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-16

Break-in engine oil . . . . . . . . . . . . . . . . . . . . . . 3-1-3Acid burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-3BucketAdjustment

Control lever-one lever design . . . . . . . . . . 2-2-11Belt tension. . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-5Control lever-two lever design. . . . . . . . . . . 2-2-12Engine valve clearance . . . . . . . . . . . . . . . . 3-10-1

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-52Steering wheel tilt . . . . . . . . . . . . . . . . . . . . 2-1-49

Air CCleaner elements clean . . . . . . . . . . . . . . . . 3-3-4Cleaner elements replace . . . . . . . . . . . . . . . 3-9-1 CabCleaner unloader valve . . . . . . . . . . . . . . . . . 3-4-1 Fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3Conditioning control . . . . . . . . . . . . . . . . . . 2-1-48 Recirculating air filter . . . . . . . . . . . . . . . . . . 3-6-6Conditioning service . . . . . . . . . . . . . . . . . . 4-1-14 Cab fresh air filterInlet cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-4 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3Intake hose . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-2 Cab recirculating air filter

Air conditioning Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-6Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-17 Capacities, drain and refill

Air flow knob . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-49 624H/TC62H. . . . . . . . . . . . . . . . . . . . . . . . . 4-6-4Air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7 Control leverAir to air aftercooler Shifting transmission . . . . . . . . . . . . . . . . . . . 2-2-9

External cleaning . . . . . . . . . . . . . . . . . . . . 4-1-19 CoolantAlternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 3-1-7Axle Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-2

Clean recirculation screen. . . . . . . . . . . . . . 3-11-4 Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7Level radiator . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2Level recovery tank. . . . . . . . . . . . . . . . . . . . 3-4-1

CoolingDrain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1BSystem fill . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2

Coolscan Plus . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7Battery

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21Acid burns. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-3Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6Electrolyte level check. . . . . . . . . . . . . . . . . . 3-8-3Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-3 DHandling, checking, servicing . . . . . . . . . . . . 4-1-6Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-8 Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-2-1Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-7 Damper, engine vibrationTerminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-3 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3

Belt DiagnoseDrive Line Malfunctions. . . . . . . . . . . . . . . . 4-3-12Tension adjust . . . . . . . . . . . . . . . . . . . . . . . 3-3-5

Index-1 102703

PN=1

Index

Page Page

Diagnose malfunction Engine oil . . . . . . . . . . . . . . . . . . . . . . 3-5-1, 3-7-3Final fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-5Hydraulic system. . . . . . . . . . . . . . . . . . . . . 4-3-14

Transmission system . . . . . . . . . . . . . . . . . . 4-3-7 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-5Fuel drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-7Diesel engine oil . . . . . . . . . . . . . . . . . . . . . . . . 3-1-4

Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Hydraulic reservoir breather . . . . . . . . . . . . . 3-8-7Hydraulic return. . . . . . . . . . . . . . . . . . . . . . . 3-8-6Diesel fuel conditioner

Low sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Primary fuel drain and clean . . . . . . . . . . . . . 3-3-7Transmission oil . . . . . . . . . . . . . . . . . 3-5-5, 3-8-8Differential

Clean axle recirculation screen . . . . . . . . . . 3-11-4 Final fuel filterReplace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-5Lock pedal . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-18

Oil change . . . . . . . . . . . . . . . . . . . . . . . . . 3-11-3 Fire extinguisherCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-3Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5

Differential oil FrameMachine lock bar. . . . . . . . . . . . . . . . . . . . . . 3-2-3Check level . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-11

Differential/axle Front drivelineLubricate. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-10

Door FuelDiesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5

Locking open side. . . . . . . . . . . . . . . . . . . . 2-1-49 Filter change. . . . . . . . . . . . . . . . . . . . . . . . . 3-8-5Handling and storing . . . . . . . . . . . . . . . . . . . 3-1-2Drive belt

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-5 System bleed . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5Tank capacity . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5Dust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1Tank drain. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-6

Fuel tank vent hoseChecking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4

E Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-9

EngineAir heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7Boost starting . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 GCold weather warm-up . . . . . . . . . . . . . . . . . 2-2-8Coolant conditioner . . . . . . . . . . . . . . . . . . . . 3-9-2

GaugeOil change . . . . . . . . . . . . . . . . . . . . . 3-5-1, 3-7-3

Engine coolant temperature . . . . . . . . 2-1-3, 2-1-7Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-7Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1

Transmission oil temperature . . . . . . . 2-1-3, 2-1-7Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13

GreaseStarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2

Boom and cylinder pivots . . . . . . . . . . . . . . . 3-6-1Valve clearance adjust . . . . . . . . . . . . . . . . 3-10-1

Extreme pressure and multipurpose . . . . . . . 3-1-6Vent tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1

Frame hinge pivots . . . . . . . . . . . . . . . . . . . . 3-9-6Vibration damper, replace . . . . . . . . . . . . . . . 4-1-3

Oscillating rear axle . . . . . . . . . . . . . . . . . . . 3-6-3Engine oil

Steering cylinder pivots . . . . . . . . . . . . . . . . . 3-6-3Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3

Grille door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-4

Engine side shieldsOpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2

H

F Halogen bulbs . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12Heater

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-48FilterCab air recirculating . . . . . . . . . . . . . . . . . . . 3-6-6 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7

Engine air . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7Cab fresh air . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3

Index-2 102703

PN=2

Index

Page Page

Heater system Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1LiftingDiagnose malfunctions . . . . . . . . . . . . . . . . 4-3-19

Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-47 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-31LockHose

Air intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-2 Bar, machine frame. . . . . . . . . . . . . . . . . . . . 3-2-3Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1

Hoses Low sulfur diesel fuel conditioner . . . . . . . . . . . 3-1-1LubricantCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-3

Hydraulic Alternative. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2Oil change . . . . . . . . . . . . . . . . . . . . . . . . . 3-11-1

Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 LubricateBoom and cylinder pivots . . . . . . . . . . . . . . . 3-6-1Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5

Pump serial number . . . . . . . . . . . . . . . . . . . 4-5-2 Frame hinge pivots . . . . . . . . . . . . . . . . . . . . 3-9-6Front driveline . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1Reservoir breather filter. . . . . . . . . . . . . . . . . 3-8-7

Return filter . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6 Oscillating rear axle . . . . . . . . . . . . . . . . . . . 3-6-3Rear driveline . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1Hydraulic oil cooler

External cleaning . . . . . . . . . . . . . . . . . . . . 4-1-19 Rear oscillating support cover . . . . . . . . . . . . 3-8-6Rear steering cylinder pivots . . . . . . . . . . . . . 3-6-3Hydraulic pump

Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Steering cylinder pivots . . . . . . . . . . . . . . . . . 3-6-3Hydraulic system

Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . 4-3-14Suction strainer . . . . . . . . . . . . . . . . . . . . . . 3-11-2

M

MachineIFrame locking bar . . . . . . . . . . . . . . . . . . . . . 3-2-3

MaintenanceInch torque values . . . . . . . . . . . . . . . . . . . . . 4-1-24 Record keeping. . . . . . . . . . . . . . . . . . . . . . . 3-2-6Indicator Service intervals . . . . . . . . . . . . . . . . . . . . . . 3-2-8

Location . . . . . . . . . . . . . . . . . . . . . . . 2-1-3, 2-1-7 Metric torque values . . . . . . . . . . . . . . . . . . . . 4-1-23Receiver dryer . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . 3-1-2Secondary steering . . . . . . . . . . . . . . . . . . . 2-2-17 Monitor display unit

Inspection Accessory menu-auto mode to first (AExternal service brake. . . . . . . . . . . . . . . . . 4-1-15 03). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-25

Instruments Accessory menu-clutch cut-off (A 01) . . . . . 2-1-20Check before starting . . . . . . . . . . . . . . . . . . 2-2-2 Accessory menu-job timer mode (A 04) . . . 2-1-26

Accessory menu-metric units mode (A07). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-27

Accessory menu-quick shift mode (A 02) . . 2-1-23JAccessory menu-stop watch mode (A 05) . . 2-1-26Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6Digital display . . . . . . . . . . . . . . . . . . . . . . . 2-1-17Normal display . . . . . . . . . . . . . . . . . . . . . . 2-1-18User diagnostics menu-battery monitor (d

L 03). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-32User diagnostics menu-continuity check (d

02). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-30Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12Lever User diagnostics menu-engine sensors (d

04). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-33Boom control-one lever design . . . . . . . . . . 2-2-11Boom control-two lever design . . . . . . . . . . 2-2-12 User diagnostics menu-fuel sensor (d 07) . . 2-1-40

User diagnostics menu-hydraulic sensors (dBucket control-one lever design . . . . . . . . . 2-2-11Bucket control-two lever design. . . . . . . . . . 2-2-12 06). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-38

Index-3 102703

PN=3

Index

Page Page

User diagnostics menu-machine i.d. mode (d Pressure10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-41 Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-2

User diagnostics menu-service codes (d Tire, check . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-101). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-28 Product Identification Number. . . . . . . . . . . . . . 4-5-1

User diagnostics menu-transmission sensors (d Pump05). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21

QN

Neutral Quick shiftLock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-13Start system check . . . . . . . . . . . . . . . . . . . 4-1-13

RO

RadiatorOilCoolant level . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2Change differential . . . . . . . . . . . . . . . . . . . 3-11-3External cleaning . . . . . . . . . . . . . . . . . . . . 4-1-19Change engine . . . . . . . . . . . . . . . . . . 3-5-1, 3-7-3

Radiator hosesChange hydraulic . . . . . . . . . . . . . . . . . . . . 3-11-1Change park brake . . . . . . . . . . . . . . . . . . . . 3-9-8 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-3Change transmission . . . . . . . . . . . . . 3-5-3, 3-9-4 Rear drivelineCheck level park brake . . . . . . . . . . . . . . . . 3-8-10 Lubricate. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1Level engine . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Rear oscillating support coverLevel hydraulic system . . . . . . . . . . . . . . . . . 3-4-3 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6Level transmission . . . . . . . . . . . . . . . . . . . . 3-4-4 Lubricate. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6Specification differential . . . . . . . . . . . . . . . . 3-1-5 Rear steering cylinder pivotsSpecification hydraulic system . . . . . . . . . . . 3-1-5 lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-3Specification park brake . . . . . . . . . . . . . . . . 3-1-5 Receiver dryerSpecification transmission . . . . . . . . . . . . . . . 3-1-5 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2

Oilscan Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7 Recovery tankCoolant level . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1

Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5Return-to-carryP

Height kickout adjustment . . . . . . . . . . . . . . 2-2-19Return-to-dig circuitPark brake

Adjustment . . . . . . . . . . . . . . . . . . . 2-2-20, 2-2-22Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-8Ride controlCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-7

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . 4-1-17Diagnose malfunctions . . . . . . . . . . . . . . . . 4-3-13Switch . . . . . . . . . . . . . . . . . . . . . . . 2-2-14, 2-2-16Oil level check . . . . . . . . . . . . . . . . . . . . . . 3-8-10

RoadsOil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5Operating or traveling . . . . . . . . . . . . . . . . . . 1-3-5Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10

Roll-over protective structureSwitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10Torque value. . . . . . . . . . . . . . . . . . . . . . . . 4-1-22Pedal

ROPSDifferential lock . . . . . . . . . . . . . . . . . . . . . . 2-2-18Inpsect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-2Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6Pilot Controller Tower

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 Rust inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-2

Index-4 102703

PN=4

Index

Page Page

S StorageMachine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1

Storing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2SafetySuction strainerAdd cab guarding for special uses . . . . . . . . 1-2-2

Hydraulic system. . . . . . . . . . . . . . . . . . . . . 3-11-2Avoid unauthorized machine modifications . . 1-2-2SwitchFeatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1

Park brake . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10Follow safety instructions . . . . . . . . . . . . . . . 1-2-1Quick shift. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-13Inspect machine . . . . . . . . . . . . . . . . . . . . . . 1-2-3Ride control . . . . . . . . . . . . . . . . . . 2-2-14, 2-2-16Operate only if qualified . . . . . . . . . . . . . . . . 1-2-1

Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . 3-1-2Recognize safety information . . . . . . . . . . . . 1-2-1Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1Stay clear of moving parts . . . . . . . . . . . . . . 1-2-3Wear protective equipment . . . . . . . . . . . . . . 1-2-2

Seat TAdjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-52

Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-53 TireSecondary steering Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-17 Pressure check . . . . . . . . . . . . . . . . . . . . . . . 3-3-1Serial number Torque value

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Roll-over protective structure. . . . . . . . . . . . 4-1-22Hydraulic pump. . . . . . . . . . . . . . . . . . 4-5-1, 4-5-2 Wheel retaining cap screw . . . . . . . . . . . . . . 3-3-2Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Torque values

Service Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-24Interval . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1, 3-3-1 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-23

Service brakes Towing Procedure . . . . . . . . . . . . . . . . . . . . . 2-2-29External inspection . . . . . . . . . . . . . . . . . . . 4-1-15 Transmission

Service codes Oil change . . . . . . . . . . . . . . . . . . . . . 3-5-3, 3-9-4Quick reference list . . . . . . . . . . . . . . . . . . . . 4-3-2 Oil cooler external cleaning. . . . . . . . . . . . . 4-1-19

Service Doors Oil filter replace. . . . . . . . . . . . . . . . . . 3-5-5, 3-8-8Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-2 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-4

Service intervals Oil specification. . . . . . . . . . . . . . . . . . . . . . . 3-1-5Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-8 Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1

Shifting Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9 Traveling

Specifications On public roads. . . . . . . . . . . . . . . . . . . . . . . 1-3-5Cooling system . . . . . . . . . . . . . . . . . . . . . . . 3-9-2Differential oil . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-5

UTransmission oil . . . . . . . . . . . . . . . . . . . . . . 3-1-5624H high lift. . . . . . . . . . . . . . . . . . . . . . . . . 4-6-3

Unloader valve624H/TC62H. . . . . . . . . . . . . . . . . . . . . . . . . 4-6-1Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1Speed

Users diagnostics menuEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13Battery monitor (d 03) . . . . . . . . . . . . . . . . . 2-1-32Start aidContinuity check (d 02) . . . . . . . . . . . . . . . . 2-1-30Starting fluid-cold weather. . . . . . . . . . . . . . . 2-2-4Engine sensors (d 04). . . . . . . . . . . . . . . . . 2-1-33StartingFuel sensor (d 07) . . . . . . . . . . . . . . . . . . . 2-1-40The engine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2Hydraulic sensors (d 06) . . . . . . . . . . . . . . . 2-1-38Starting fluidMachine I.D. mode (d 10) . . . . . . . . . . . . . . 2-1-41Cold weather start aid . . . . . . . . . . . . . . . . . . 2-2-4Service codes (d 01). . . . . . . . . . . . . . . . . . 2-1-28Steering

Wheel tilt adjust . . . . . . . . . . . . . . . . . . . . . 2-1-49 Transmission sensors (d 05) . . . . . . . . . . . . 2-1-36

Index-5 102703

PN=5

Index

Page

V

ValveAir cleaner dust unloader . . . . . . . . . . . . . . . 3-4-1Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-21Dust unloader . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1

Vent tubeEngine crankcase . . . . . . . . . . . . . . . . . . . . . 3-9-1

W

Warm-upEngine, cold weather . . . . . . . . . . . . . . . . . . 2-2-8

WasherWindshield fluid level . . . . . . . . . . . . . . . . . . 3-2-5

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-14Wheel

Cap screw torque . . . . . . . . . . . . . . . . . . . . . 3-3-2Window

Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-51Sliding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-51

WindshieldWasher fluid . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5

3-Way Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7

Index-6 102703

PN=6

624h loader and tc62h tool carrier - moffat pipemoffatpipe.com/equipment-manuals/ldr 03 - jdtc62/ldr...

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