744j & 824j loaders (s.n. 590070—) · 744j&824jloaders (s.n.590070—) omt200785...

744J & 824J Loaders(S.N. 590070—)

*OMT200785*

OPERATOR'S MANUAL744J & 824J Loaders

OMT200785 ISSUE A3 (ENGLISH)

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,

birth defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects or other reproductive harm.

The State of California requires the above two warnings.

Additional Proposition 65 Warnings can be found in this manual.

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

DX,IFC7 -19-03APR09-1/1

VD76477,000104D -19-27JUN12-1/1

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 may alsobe available in other languages. (See your John Deeredealer to order.)

THIS MANUAL SHOULD BE CONSIDERED a permanentpart of your machine and should remain with the machinewhen you sell it.

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

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

WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.)in the Machine Numbers section. Accurately record allthe numbers to help in tracing the machine should it bestolen. Your dealer also needs these numbers when youorder parts. File the identification numbers in a secureplace off the machine.

WARRANTY is provided as part of John Deere's supportprogram for customers who operate and maintain their

equipment as described in this manual. The warranty isexplained on the warranty certificate or statement whichyou should have received from your dealer.

This warranty provides you the assurance that JohnDeere will back its products where defects appear withinthe warranty period. In some circumstances, John Deerealso provides field improvements, often without chargeto the customer, even if the product is out of warranty.Should the equipment be abused, or modified to changeits performance beyond the original factory specifications,the warranty will become void and field improvementsmay be denied. Setting fuel delivery above specificationsor otherwise overpowering machines will result in suchaction.

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

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

IMPORTANTWarranty will not apply to engine and drivetrain failuresresulting from unauthorized adjustments to this engine.

Unauthorized adjustments are in violation of the emissionsregulations applicable to this engine and may result insubstantial fines and penalties.

013013

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Introduction

VD76477,000104E -19-04JAN10-1/1

Emissions Control Warranty Statement—U.S. and Canada

TX1053039—19—19MAR10

013013

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Introduction

TX,II,FAX -19-10JUL01-1/1

Technical Information Feedback FormWe 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 Works

18600 South John Deere RoadAttn: Publications, Dept. 324Dubuque, IA 52004-0538USA

FAX NUMBER: 1-563-589-5800 (USA)

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

Email Address:

THANK YOU!

013013

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Contents

Page

Safety—Safety and Operator ConveniencesSafety and Operator Convenience Features .....1-1-1

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

Safety—Operating PrecautionsUse Steps and Handholds Correctly .................1-3-1Start Only From Operator's Seat .......................1-3-1Use and Maintain Seat Belt ...............................1-3-1Prevent Unintended Machine Movement ..........1-3-1Avoid Work Site Hazards...................................1-3-2Use Special Care When Operating Loader .......1-3-2Keep Riders Off Machine ..................................1-3-3Avoid Backover Accidents .................................1-3-3Avoid Machine Tip Over ....................................1-3-4Operating on Slopes..........................................1-3-4Operating or Traveling On Public Roads...........1-3-5Inspect and Maintain ROPS ..............................1-3-5Add and Operate Attachments Safely ...............1-3-5

Safety—Maintenance PrecautionsPark And Prepare For Service Safely................1-4-1Service Cooling System Safely .........................1-4-1Service Tires Safely...........................................1-4-2Remove Paint Before Welding or Heating.........1-4-2Make Welding Repairs Safely ...........................1-4-3Drive Metal Pins Safely .....................................1-4-3

Page

Safety—Safety SignsSafety Signs ......................................................1-5-1Replace Safety Signs ........................................1-5-3

Operation—Operator’s StationLevers................................................................2-1-1Pedals................................................................2-1-2CAN Monitor Unit (CMU) ...................................2-1-3Monitor Panel Functions ...................................2-1-4Switch Pad.........................................................2-1-6Switch and Accessory Functions ......................2-1-7Monitor Display Unit—Accessory Menu

Normal Display..............................................2-1-9Monitor Display Unit—Main Menu...................2-1-10Monitor Display Unit—Main Menu—Codes.....2-1-10Monitor Display Unit—Main

Menu—Codes—Active Codes ....................2-1-11Monitor Display Unit—Main

Menu—Codes—Stored Codes....................2-1-12Monitor Display Unit—Main

Menu—Machine Settings ............................2-1-12Monitor Display Unit—Main

Menu—Machine Settings—Quick Shift .......2-1-13Monitor Display Unit—Main

Menu—Machine Settings—Auto to 1st .......2-1-13Monitor Display Unit—Main

Menu—Machine Settings—Job Timer.........2-1-14Monitor Display Unit—Main

Menu—Machine Settings—Stopwatch........2-1-14Monitor Display Unit—Main

Menu—Diagnostics .....................................2-1-14Monitor Display Unit—Main

Menu—Diagnostics—Battery Monitor .........2-1-15Monitor Display Unit—Main

Menu—Diagnostics—Engine Sensors ........2-1-16Monitor Display Unit—Main

Menu—Diagnostics—Transmission ............2-1-17Monitor Display Unit—Main

Menu—Diagnostics—Hydraulic ..................2-1-18Monitor Display Unit—Main

Menu—Diagnostics—Machine....................2-1-18Monitor Display Unit—Main

Menu—Diagnostics—Machine Switches ....2-1-19Monitor Display Unit—Main

Menu—Diagnostics—Switch Module ..........2-1-20

Continued on next page

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

The right is reserved to make changes at any time without notice.COPYRIGHT © 2013DEERE & COMPANY

Moline, IllinoisAll rights reserved.

A John Deere ILLUSTRUCTION ® ManualPrevious Editions

Copyright © 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2010

i 013013

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Contents

Page

Monitor Display Unit—MainMenu—Diagnostics—Machine I.D. .............2-1-20

Monitor Display Unit—MainMenu—Monitor Settings..............................2-1-21

Monitor Display Unit—MainMenu—Monitor Settings—Units..................2-1-21

Monitor Display Unit—MainMenu—Monitor Settings—HideMain Menu ..................................................2-1-21

Monitor Display Unit—MainMenu—Monitor Settings—Backlighting.......2-1-22

Monitor Display Unit—MainMenu—Monitor Settings—LCD Contrast ....2-1-22

Horn Button .....................................................2-1-23Turn Signals ....................................................2-1-23Air Conditioning Controls and Heater

Operation ....................................................2-1-24Adjusting Steering Wheel Tilt ..........................2-1-24Adjusting Joystick Steering Arm Rest..............2-1-25Opening and Securing Side Door....................2-1-25Opening Side Window/Secondary Exit............2-1-27Opening Rear Side Window ............................2-1-27Adjusting Seat .................................................2-1-28

Operation—Operating the MachineInspect Machine Daily Before Starting ..............2-2-1Check Instruments Before Starting....................2-2-1Engine Break-In Period .....................................2-2-2Starting the Engine............................................2-2-2Starting Fluid—If Equipped (Cold

Weather Starting Aid)....................................2-2-4Engine Heater—If Equipped..............................2-2-5Using Coolant Heater—If Equipped ..................2-2-5Warm-Up ...........................................................2-2-5Cold Weather Warm-Up ....................................2-2-5Neutral Lock ......................................................2-2-6Shifting the Transmission ..................................2-2-6Shifting the Transmission—If Equipped

With Joystick Steering...................................2-2-7Joystick Steering Activation/Deactiva-

tion—If Equipped...........................................2-2-8Park Brake Switch .............................................2-2-9Boom and Bucket Control Lever—One

Lever Design ...............................................2-2-10Boom and Bucket Control Lever

Two Lever Design .......................................2-2-11Quick Shift Switch............................................2-2-12Ride Control—If Equipped...............................2-2-13Secondary Steering—If Equipped ...................2-2-14Differential Lock Switch ...................................2-2-15Boom Height Kickout Adjustment ....................2-2-15Return-to-Carry Kickout Adjustment................2-2-15Return-To-Dig Adjustment for Z-Bar

Linkage Only ...............................................2-2-16Using the Loader Bucket .................................2-2-17Backdragging...................................................2-2-18Fork Attachment ..............................................2-2-19Arm Attachment...............................................2-2-21

Page

Parking the Machine........................................2-2-22Parking the Machine—If Equipped

With Joystick Steering.................................2-2-22Loading Machine on a Trailer ..........................2-2-23Loading Machine on a Trailer—If

Equipped With Joystick Steering.................2-2-25Towing Procedure............................................2-2-27Lifting the Machine ..........................................2-2-28

Maintenance—MachineDiesel Fuel.........................................................3-1-1Lubricity of Diesel Fuel ......................................3-1-1Biodiesel Fuel ....................................................3-1-2Low Sulfur Diesel Fuel Conditioner ...................3-1-3Testing Diesel Fuel ............................................3-1-3Handling and Storing Diesel Fuel ......................3-1-3Minimizing the Effect of Cold Weather

on Diesel Engines .........................................3-1-4Alternative and Synthetic Lubricants .................3-1-5Diesel Engine Oil ...............................................3-1-5Diesel Engine Oil and Filter Service Intervals ...3-1-6Transmission, Hydraulic System, Park

Brake, and Differential Oil .............................3-1-7Grease...............................................................3-1-7Heavy Duty Diesel Engine Coolant ...................3-1-8

Maintenance—Periodic MaintenanceService Machine at Specified Intervals..............3-2-1Check Hour Meter Regularly .............................3-2-1Prepare Machine for Maintenance ....................3-2-2Locking Machine Frame ....................................3-2-3Boom Lock.........................................................3-2-3Opening Engine Side Shields and

Service Doors................................................3-2-4Opening Grille Door...........................................3-2-4Fuel Tank...........................................................3-2-5Check Windshield Washer Fluid Level ..............3-2-5Fluid Analysis Program Test Kits and

3-Way Coolant Test Kit..................................3-2-5Service Intervals ................................................3-2-6Required Parts...................................................3-2-8

Maintenance—As RequiredCheck Tire Pressure..........................................3-3-1Tire Pressures (744J) ........................................3-3-2Tire Pressures (824J) ........................................3-3-4Tighten Wheel Retainer Nuts ............................3-3-5Check Air Cleaner Elements .............................3-3-5Check Air Inlet Cover.........................................3-3-5Inspect Serpentine Belts....................................3-3-6Inspect External Seal.........................................3-3-6Drain Fuel Tank Sediment .................................3-3-7Inspect Fuel Filler Drain Hose and

Tank Breather Hose ......................................3-3-7Replace Primary and Final Fuel Filters .............3-3-8Replace In-Line Fuel Filter ................................3-3-9


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Drain Water Separator Bowl (744JS.N. 590070—601440, 824J S.N.590070—601506) .......................................3-3-10

Bleeding Fuel System (744J S.N.601441—, 824J S.N. 601507—) .................3-3-11

Check Cab Fresh Air Filter—If Equipped ........3-3-11Check Cab Recirculating Air Filter—If

Equipped .....................................................3-3-12

Maintenance—Every 10 Hours or DailyCheck Recovery Tank Coolant Level.................3-4-1Clean Air Cleaner Dust Unloader Valve ............3-4-1Check Engine Oil Level .....................................3-4-2Check Hydraulic Oil Level .................................3-4-2Check Transmission Oil Level ...........................3-4-3

Maintenance—Every 100 HoursGrease Loader Linkage and Cylinder

Pivots—If Equipped.......................................3-5-1Grease Front Steering Cylinder Pivots

744J (S.N. —612699), 824J (S.N.—612710) .....................................................3-5-2

Grease Rear Steering Cylinder Pivots744J (S.N. —612699), 824J (S.N.—612710) .....................................................3-5-2

Grease Oscillating Rear Axle ............................3-5-3

Maintenance—Initial Service - 250 HoursChange Engine Break-In Oil and

Replace Filter ................................................3-6-1Replace Hydraulic System Return Filters..........3-6-2Change Front and Rear

Differential/Axle Oil........................................3-6-2

Maintenance—Every 250 HoursGrease Front Driveline Sliding Joints ................3-7-1Check Radiator Coolant Level...........................3-7-2Take Engine Oil Sample ....................................3-7-2

Maintenance—Every 500 HoursGrease Rear Driveline Sliding Joint

and U-Joints ..................................................3-8-1Check Air Intake Hoses.....................................3-8-3Check Battery Electrolyte Level and Terminals ..3-8-4Change Engine Oil and Replace Filter ..............3-8-5Replace Hydraulic System Return Filters..........3-8-5Replace Primary and Final Fuel Filters

(744J S.N. 590070—601440, 824JS.N. 590070—601506) .................................3-8-6

Replace Primary and Final Fuel Filters(744J S.N. 601441—, 824J S.N.601507—) .....................................................3-8-7

Replace Hydraulic Reservoir Breather Filter .....3-8-8Check Park Brake Oil Level...............................3-8-8Check Front Differential/Axle Oil

Level—If Equipped With DifferentialLock Axle.......................................................3-8-9

Page

Check Rear Differential/Axle OilLevel—If Equipped With DifferentialLock Axle.....................................................3-8-10

Check Front Differential/Axle OilLevel—If Equipped With Standard Axle ......3-8-10

Check Rear Differential/Axle OilLevel—If Equipped With Standard Axle ......3-8-11

Take Fluid Samples .........................................3-8-11

Maintenance—Every 1000 HoursReplace Air Cleaner Dust Unloader Valve.........3-9-1Replace Air Cleaner Elements ..........................3-9-1Clean Engine Crankcase Vent Tube .................3-9-2Check Radiator Hoses.......................................3-9-2Replace In-Line Fuel Filter (744J

S.N. 590070—601440, 824J S.N.590070—601506) .........................................3-9-2

Replace In-Line Fuel Filter (744J S.N.601441—, 824J S.N. 601507—) ...................3-9-3

Replace Transmission Oil Filter.........................3-9-4Inspect and Clean Hydraulic Pump

Case Drain Fittings........................................3-9-5Grease Frame Hinge Pivots ..............................3-9-5Change Park Brake Oil......................................3-9-6

Maintenance—Every 2000 HoursCheck and Adjust Engine Valve Lash

and Electronic Injector Preload ...................3-10-1Re-Run Clutch Calibration...............................3-10-1Change Transmission Oil ................................3-10-2Change Front and Rear

Differential/Axle Oil......................................3-10-2Clean Axle Differential Recirculation

Screen—If Equipped ...................................3-10-3

Maintenance—Every 3000 HoursChange Hydraulic System Oil..........................3-11-1Clean Hydraulic System Strainer.....................3-11-2Replace Differential Lock Return

Filter(s)—If Equipped ..................................3-11-3

Maintenance—Every 4000 HoursReplace Engine Crankshaft Damper ...............3-12-1

Miscellaneous—MachineDraining the Cooling System.............................4-1-1Cooling System Fill and Deaeration

Procedure......................................................4-1-2Check Park Brake..............................................4-1-3Checking Fuel Tank Vent Hose .........................4-1-3Bleeding Fuel System (744J S.N.

590070—601440, 824J S.N.590070—601506) .........................................4-1-3

Bleeding Fuel System (744J S.N.601441—, 824J S.N. 601507—) ...................4-1-4

Cleaning Water Separator Bowl ........................4-1-4Checking Fire Extinguisher—If Equipped..........4-1-5


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Precautions for Alternator and Regulator ..........4-1-5Handling, Checking, and Servicing

Batteries Carefully.........................................4-1-6Using Booster Batteries—24-Volt System.........4-1-7Using Battery Charger .......................................4-1-8Batteries

Remove and Install .......................................4-1-9JDLink™ Machine Monitoring System

(MMS)—If Equipped......................................4-1-9JDLink™ Machine Monitoring System

(MMS) Direct Laptop Connection—IfEquipped .....................................................4-1-10

Replacing Fuses..............................................4-1-10Fuse (Blade-Type) Color Codes......................4-1-12Resetting Circuit Breakers...............................4-1-12Replacing Halogen Bulbs ................................4-1-13Checking Neutral Start System .......................4-1-14Servicing Air Conditioning System—If

Equipped .....................................................4-1-14Welding On Machine .......................................4-1-14External Service Brake Inspection...................4-1-14Checking Brake Accumulators ........................4-1-16Checking Ride Control Accumulator—If

Equipped .....................................................4-1-17Bleeding Brakes ..............................................4-1-18Radiator, Oil Cooler, and Charge Air Cooler

Cleaning Procedure ....................................4-1-19Service Recommendations For

Snap-To-Connect (STC®) Fittings ..............4-1-20Do Not Service Control Valves,

Cylinders, Pumps or Motors........................4-1-21Keep ROPS Installed Properly ........................4-1-21Hardware Torque Specifications......................4-1-21Metric Bolt and Screw Torque Values..............4-1-22Unified Inch Bolt and Screw Torque Values.....4-1-23

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

Miscellaneous—TroubleshootingTroubleshooting Procedure ...............................4-3-1Engine ...............................................................4-3-2Diagnose

Transmission System Malfunctions...............4-3-4Differential And Axle Malfunctions ................4-3-6Service Brake Malfunctions...........................4-3-7Drive Line Malfunctions.................................4-3-7Park Brake Malfunctions ...............................4-3-8Loader Hydraulic System Malfunctions.........4-3-9Steering Malfunctions..................................4-3-10

Air Conditioning System ..................................4-3-11Heater System.................................................4-3-12

Miscellaneous—StoragePrepare Machine For Storage ...........................4-4-1Monthly Storage Procedure...............................4-4-2

Miscellaneous—Machine NumbersRecord Product Identification Number (PIN) .....4-5-1

Page

Record Engine Serial Number...........................4-5-1Record Transmission Serial Number.................4-5-1Record Hydraulic Pump Serial Number.............4-5-2Keep Machines Secure .....................................4-5-2Keep Proof of Ownership ..................................4-5-2

Miscellaneous—Specifications744J Specifications............................................4-6-1Drain and Refill Capacities—744J.....................4-6-3824J Specifications............................................4-6-4Drain and Refill Capacities—824J.....................4-6-6

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Safety—Safety and Operator Conveniences

HG31779,000013B -19-18MAR08-1/1

Safety and Operator Convenience Features

TX1014200

5 6

7

12

1

23

4

108

911

1413

15

TX1014200—UN—22NOV06

Please remember, the operator is the key topreventing accidents.

1. ROPS , FOPS, and OPS. Structures designed to helpprotect the operator are certified to ISO, SAE, andOSHA. 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 flow foreffective window defogging/deicing.

3. Mirrors. Large exterior mirrors on both sides andan inside mirror offers operator a broad view of areabehind 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.Halogen drive andwork lights and high-visibility turn signals are standardequipment.

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

8. Handholds. Large, conveniently placed handholdsmake it easy to enter or exit the operator's station orservice area.

9. Horn. Standard horn is useful when driving orsignaling coworkers.

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

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

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

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

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

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

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Safety—General Precautions

TX03679,00016CC -19-03NOV08-1/1

TX03679,00016F9 -19-18OCT07-1/1

TX03679,00016FA -19-03NOV08-1/1

Recognize Safety InformationThis 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 —is used with the safety alert symbol. DANGER identifiesthe most 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.

T133555—UN—28AUG00

T133588—19—28AUG00

Follow Safety InstructionsRead the safety messages in this manual and onthe machine. Follow these warnings and instructionscarefully. Review them frequently. Keep safety signsin good condition. Replace missing or damaged safetysigns. Replacement safety signs are available from yourauthorized John Deere dealer.

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

T133556—UN—24AUG00

Operate Only If Qualified

Do not operate this machine unless you have read theoperator's manual carefully and you have been qualifiedby supervised training and instruction.

Familiarize yourself with the job site and your surroundingsbefore operating. Try all controls and machine functionswith the machine in an open area before starting to work.

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

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TX03679,00016D0 -19-03NOV08-1/1

AM40430,00000A9 -19-14JAN08-1/1

TX03679,00017C6 -19-18OCT07-1/1

Wear Protective EquipmentGuard 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 objectionableor uncomfortable loud noises.

TS206—UN—23AUG88

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deerereplacement parts to ensure machine performance.Never substitute genuine John Deere parts with alternateparts not intended for the application as these cancreate hazardous situations or hazardous performance.Non-John Deere Parts, or any damage or failures resultingfrom their use are not covered by any John Deere warranty.

Modifications of this machine, or addition of unapprovedproducts or attachments, may affect machine stability or

reliability, and may create a hazard for the operator orothers near the machine. The installer of any modificationwhich may affect the electronic controls of this machine isresponsible for establishing that the modification does notadversely affect the machine or its performance.

Always contact an authorized John Deere dealer beforemaking machine modifications that change the intendeduse, weight or balance of the machine, or that altermachine controls, performance or reliability.

Add Cab Guarding For Special UsesSpecial 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 authorizedJohn Deere dealer for information on devices intended toprotect the operator from falling or flying objects in specialwork situations.

T141893—UN—09JU

N11

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TX03679,0001734 -19-03NOV08-1/1

TX03679,00016D2 -19-03NOV08-1/1

DX,FLUID -19-12OCT11-1/1

Inspect MachineInspect machine carefully each day by walking around itbefore starting.

Keep all guards and shields in good condition and properlyinstalled. Fix damage and replace worn or broken partsimmediately. Pay special attention to hydraulic hoses andelectrical wiring.

T6607A

Q—UN—18OCT88

Stay Clear of Moving PartsEntanglements 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 guardor shield that has been removed for access as soon asservice or repair is complete. T1

33592—UN—12SEP01

Avoid High-Pressure FluidsInspect hydraulic hoses periodically – at least onceper year – for leakage, kinking, cuts, cracks, abrasion,blisters, corrosion, exposed wire braid or any other signsof wear or damage.

Replace worn or damaged hose assemblies immediatelywith John Deere approved replacement parts.

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed withina few hours or gangrene may result. Doctors unfamiliar

X9811

—UN—23AUG88

with this type of injury should reference a knowledgeablemedical source. Such information is available inEnglish from Deere & Company Medical Department inMoline, Illinois, U.S.A., by calling 1-800-822-8262 or +1309-748-5636.

1-2-3 013013

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TX03679,00016D3 -19-03NOV08-1/1

DX,AIR -19-17FEB99-1/1

Avoid High-Pressure OilsThis machine uses a high-pressure hydraulic system.Escaping oil 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 oil.Stop engine and relieve pressure before disconnectinglines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctorimmediately. Injected oil must be removed surgicallywithin hours or gangrene may result. Contact aknowledgeable medical source or the Deere & CompanyMedical Department in Moline, Illinois, U.S.A.

T133509—UN—17MAR06

T133840—UN—20SEP00

Work In Ventilated AreaEngine exhaust fumes can cause sickness or death. Ifit is necessary to run an engine in an enclosed area,remove the exhaust fumes from the area with an exhaustpipe extension.

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


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TX03679,00016F5 -19-03NOV08-1/1

TX03679,000174A -19-03NOV08-1/1

TX03679,00016D7 -19-03JAN07-1/1

Prevent FiresHandle 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, exhaust components, andelectrical wiring. Never store oily rags or flammablematerials inside a machine compartment.

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 amultipurpose fire extinguisher on or near the machine.Know how to use extinguisher properly.

T133552—UN—14SEP00

T133553 —UN—07SEP00

T133554 —UN—07SEP00

Prevent Battery ExplosionsBattery 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).


Handle Chemical Products SafelyExposure 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. Follow

T133580—UN—25AUG00

MSDS recommendations to handle chemical productssafely.

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TX03679,0001733 -19-03NOV08-1/1

TX03679,000174B -19-03NOV08-1/1

OUT4001,00000E3 -19-20AUG09-1/1

Dispose of Waste ProperlyImproper 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.

T133567—UN—25AUG00

Prepare for EmergenciesBe 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.


Clean Debris from MachineKeep engine compartment, radiator, batteries, hydrauliclines, exhaust components, fuel tank, and operator'sstation clean and free of debris.

Clean any oil spills or fuel spills on machine surfaces.

Temperature in engine compartment may go upimmediately after engine is stopped. BE ON GUARDFOR FIRES DURING THIS PERIOD.

Open access door(s) to cool the engine faster, and cleanengine compartment. T6

669A

G—UN—18OCT88

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PN=15

Safety—Operating Precautions

TX03679,00016F2 -19-15MAR07-1/1

TX03679,0001799 -19-22APR10-1/1

TX03679,00016DD -19-03NOV08-1/1

TX03679,00017C7 -19-08MAR07-1/1

Use Steps and Handholds CorrectlyPrevent falls by facing the machine when getting 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. T1

33468—UN—30AUG00

Start Only From Operator's SeatAvoid 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. T1

33715—UN—07SEP00

Use and Maintain Seat BeltUse 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 notcut or torn. Replace seat belt immediately if any part isdamaged or does not function properly.

The complete seat belt assembly should be replacedevery 3 years, regardless of appearance.

T133716—19—14SEP00

Prevent Unintended Machine MovementWhen coworkers 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.

T142001—UN—15MAY

01

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PN=16


VD76477,00014AE -19-08MAR07-1/1

TX03768,0000B70 -19-14MAY01-1/1

Avoid Work Site HazardsAvoid 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. Clearaway debris that could move unexpectedly if run over.

Avoid boom or attachment contact with overheadobstacles or overhead electrical lines. Never movemachine closer than 3 m (10 ft) plus twice the line insulatorlength 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 sufficientto support machine. Be especially alert working nearembankments or excavations.

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

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

T141894—UN—15JU

N01

T141670—UN—24APR01

T141672—UN—04MAY

01

Use Special Care When Operating LoaderNever 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 long tofit inside the bucket unless secured with an adequate chainor other device. Keep bystanders away from raised loads.

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.

T141957—UN—15MAY

01T141902—UN—07MAY

01

1-3-2 013013

PN=17


TX03679,000179B -19-20APR01-1/1

TX03679,000179C -19-20APR01-1/1

Keep Riders Off MachineOnly 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 abilityto operate machine safely.

T141671—UN—04MAY

01

Avoid Backover AccidentsBefore 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 is obstructedor when in close quarters. Keep signal person in view atall times. Use prearranged hand signals to communicate.

T141673—UN—04MAY

01

1-3-3 013013

PN=18


TX03679,000179D -19-02MAY01-1/1

TX03679,000179E -19-14MAY01-1/1

Avoid Machine Tip OverUse 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.

T133716—19—14SEP00

T141676—UN—04MAY

01T141672—UN—04MAY

01

Operating on SlopesAvoid 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. T1

41681—UN—30APR01

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PN=19


TX03679,00017C8 -19-02MAR07-1/1

TX03679,000179F -19-07SEP06-1/1

TX03679,00016F0 -19-24JAN07-1/1

Operating or Traveling On Public RoadsMachines 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 work machine.Check state and local regulations to assure compliance.Keep these devices clean and in working condition. T1

41891—UN—22MAY

01

Inspect and Maintain ROPS

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

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

If ROPS was loosened or removed for any reason, inspectit 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.

Add and Operate Attachments Safely

Always verify compatibility of attachments by contactingyour authorized dealer. Adding unapproved attachmentsmay affect machine stability or reliability, and may createa hazard for others near the machine.

Ensure that a qualified person is involved in attachmentinstallation. Add guards to machine if operator protection

is required or recommended. Verify that all connectionsare secure and attachment responds properly to controls.

Carefully read attachment manual and follow allinstructions and warnings. In an area free of bystandersand obstructions, carefully operate attachment to learn itscharacteristics and range of motion.

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PN=20

Safety—Maintenance Precautions

TX03679,00017A0 -19-25AUG10-1/1

DX,RCAP -19-04JUN90-1/1

Park And Prepare For Service SafelyWarn 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 inthe 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.

T133332—19—14DEC01


Service Cooling System SafelyExplosive 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.


1-4-1 013013

PN=21


DX,RIM -19-24AUG90-1/1

DX,PAINT -19-24JUL02-1/1

Service Tires SafelyExplosive separation of a tire and rim parts can causeserious injury or death.

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

Always maintain the correct tire pressure. Do not inflatethe tires above the recommended pressure. Never weldor heat a wheel and tire assembly. The heat can causean increase in air pressure resulting in a tire explosion.Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extensionhose long enough to allow you to stand to one side andNOT in front of or over the tire assembly. Use a safetycage if available.

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


Remove Paint Before Welding or HeatingAvoid 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 100 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.

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PN=22


TX03679,00016D5 -19-25APR08-1/1

TX03679,0001745 -19-03JAN07-1/1

Make Welding Repairs SafelyIMPORTANT: Disable electrical power before

welding. Turn off main battery switchor disconnect positive battery cable.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.

T133547—UN—31AUG00

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

Drive Metal Pins SafelyAlways wear protective goggles or safety glasses andother protective equipment before striking hardenedparts. 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. T1

33738—UN—14SEP00

1-4-3 013013

PN=23

Safety—Safety Signs

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

Safety Signs

T159570—19—30OCT02

Left Side Shown

1-5-1 013013

PN=24


HG31779,000013C -19-26SEP02-2/2

T159894—19—26SEP02

Right Side Shown

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PN=25


DX,SIGNS -19-18AUG09-1/1

Replace Safety SignsReplace missing or damaged safety signs. Use thisoperator’s manual for correct safety sign placement.

There can be additional safety information contained onparts and components sourced from suppliers that is notreproduced in this operator's manual.


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PN=26

Operation—Operator’s Station

VD76477,000105B -19-14SEP06-1/3

Continued on next page VD76477,000105B -19-14SEP06-2/3

Levers

T194168A

—UN—18SEP03

Single Lever with Auxiliary Control Design Shown with Joystick FNR

T194169A

—UN—18SEP03

Two Lever with Auxiliary Control Design

T195153A

—UN—25SEP03

2-1-1 013013

PN=27


VD76477,000105B -19-14SEP06-3/3

TX,10,JC1191 -19-18DEC06-1/1

NOTE: Joystick steering sensitivity changes with speed.Become familiar with steering at all speedsbefore operating in confined areas.

1—Column FNR2—Turn Signal

3—Joystick FNR - If Equipped

T213974A

—UN—29AUG05

Joystick Steering with FNR - If Equipped

PedalsAccelerator pedal (1): Depress to increase speed ofmachine.

Brake pedals (2 and 3): Depress left brake pedal (3) orright brake pedal (2) to stop machine.

NOTE: Brake pedals also serve as clutch cutoffpedals when clutch cutoff switch is in “clutchdisengaged” position.

Differential Lock Foot Switch (4)—If Equipped:Depress switch (4) to lock front axle differential. Releaseswitch to unlock differential.

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

TX1012982—UN—06OCT06

1—Accelerator2—Brake/Clutch Cutoff Pedal

3—Brake/Clutch Cutoff Pedal4—Differential Lock Foot

Switch—If Equipped

2-1-2 013013

PN=28


VD76477,000105C -19-20MAY10-1/1

CAN Monitor Unit (CMU)

1

4 6

987 151413121110

16 17 18 19 2120 22 23 24 25 26

5

2 3

TX1070946 TX1070946—UN—11FE

B10

1—Engine Coolant TemperatureGauge

2—Transmission OilTemperature Gauge

3—Hydraulic Oil TemperatureGauge

4—Engine Oil Pressure Gauge5—Display Window6—Fuel Gauge7—Engine Heater Indicator—If

Equipped8—Engine Air Filter Restriction

Indicator

9—Fasten Seat Belt Indicator10— Engine Alt Volts Indicator11— STOP Indicator12— Brake Pressure Indicator13— Hydraulic Oil Filter

Restriction Indicator14— Transmission Oil Filter

Indicator15— Park Brake Indicator

16— Left Turn Indicator17— Check Engine Indicator18— Ride Control Indicator19— Transmission Fault Indicator20— Joystick Steering - If

Equipped21— Service Required Indicator22— Secondary SteeringWarning

Indicator—If Equipped

23— Work Lights ON Indicator—IfEquipped

24— Hydraulic Coupler PinDisconnect Indicator—IfEquipped

25— Fuel Filter RestrictionIndicator

26— Right Turn Indicator

• MENU provides initial entry into machine settings,diagnostics, and monitor settings. Once a main menuhas been selected, pressing MENU again will return tothe Normal Display Mode Menu.• BACK will back out of a menu, one item each time thekey is pressed. The BACK key will eventually return tothe normal display.• NEXT will move to the next selection within a menu ormode. Press NEXT to cycle through all the possibleselections in a menu.

• SELECT toggles between the odometer, hour meter,and speedometer displays during normal operation.During menu modes, SELECT will activate the currentlychosen menu, provide additional information on codes,make selection, reset timers, or turn on/off stop watch.

2-1-3 013013

PN=29


Continued on next page VD76477,000105D -19-14SEP06-1/2

Monitor Panel Functions

NOTE: Monitor may not function in extremelycold conditions.

1—Engine Coolant Temperature Gauge: Indicator willlight, STOP indicator will flash and audible alarm will soundwhen pointer is in red zone. Stop machine and allowengine to cool. Shut off engine and take corrective action.

If pointer deflects to the far left side of the scale, electroniccommunication is lost or a sensor error is active. Indicatorwill not light.

2—Transmission Oil Temperature Gauge: If pointer is inred zone, indicator will light, STOP indicator will flash, andaudible alarm will sound indicating that the temperatureis too high. Stop machine and allow transmission to cool.Shut off engine and take corrective action.


3—Hydraulic Oil Temperature Gauge: Indicator will lightand service required indicator will light when pointer isin red zone. Stop work cycle and cycle loader functionswithout load to lower indicator reading. If indicator stillstays in red zone, stop machine and see your authorizeddealer.


4—Engine Oil Pressure Gauge:

IMPORTANT: Prevent possible engine damage. Ifengine oil pressure indicator light comeson while operating, stop machine. STOPENGINE IMMEDIATELY.

Indicator will flash, STOP indicator will flash, and alarmwill sound when engine oil pressure gauge indicates lowpressure. Stop machine. STOP ENGINE IMMEDIATELY.


NOTE: Extreme steep slope (off level) operationmay cause indicator to light.

5—Display Window: The display window has eightdisplays:

• Actual Gear• Requested Gear• FNR• Auto/Manual Transmission Mode• Tachometer• Hour Meter• Odometer• Speedometer

6—Fuel Gauge: Gauge will reflect fuel level in tank.Indicator will flash to indicate low level condition.


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

7—Engine Heater Indicator—If Equipped: If preheatis needed, Indicator will light when key switch isturned clockwise to the “On” position. Light will turnoff approximately 15-45 seconds depending on enginetemperature, indicating that preheating is completed.Light will turn off while cranking engine. Indicator will alsolight for approximately 15-45 seconds after engine isrunning, indicating post heat.

8—Engine Air Filter Restriction Indicator: Indicatorwill light and service required indicator will light when airelements are restricted.

9—Fasten Seat Belt Indicator: Indicator will light forthe first 5 seconds after the engine is started to warn theoperator to fasten seat belt.

10—Engine Alt Volts Indicator: Indicator will light andservice required indicator will light when alternator outputis below 24 volts with engine running or below 18 voltswhen engine is not running. Check battery charge underDiagnostics—Battery Monitor on digital display.

11—STOP Indicator:

CAUTION: Prevent possible injury or machinedamage. If STOP indicator flashes and alarmsounds, stop immediately and investigatecause of problem.

Indicator will light when a problem has developed.

12—Brake Pressure Indicator:

CAUTION: Prevent possible injury or machinedamage. If brake pressure indicator comes onwhile operating, stop machine immediately.

Indicator will flash, STOP indicator will flash, and alarm willsound when brake oil pressure is low or brake accumulatorhas lost its charge. Stop machine immediately and pushpark brake switch to ON.

Sensor failure will cause indicator light and caution lightto illuminate.

13—Hydraulic Oil Filter Restriction Indicator:

IMPORTANT: Prevent possible hydraulic pumpdamage. Change hydraulic oil filter as soonas possible when a problem occurs.

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PN=30


VD76477,000105D -19-14SEP06-2/2

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

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

14—Transmission Oil Filter Indicator: Indicator willlight and the service required indicator will light when thetransmission filter is restricted.

15—Park Brake Indicator: Indicator will light when parkbrake is engaged.

If transmission is shifted out of “Neutral” with enginerunning and park brake engaged, the STOP indicator willflash, park brake indicator will flash and alarm will sounduntil park brake is disengaged or transmission shiftedback to neutral.

16—Left Turn Indicator : Indicator will light when left turnsignal switch or 4-way flashers switch is engaged.

17—Check Engine Indicator: Indicator will flash whenexcessive water is present in final fuel filter or a fuelsystem failure has been detected. STOP indicator willflash, alarm will sound, and engine will derate to 50% offull power until water is drained.

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

18—Ride Control Indicator: Indicator will light when ridecontrol is activated.

19—Transmission Fault Indicator: Transmission faultindicator and service required indicator will light and stayon when a transmission clutch slippage service codehas been detected or if “limp home” mode has beenrequested. The transmission will shift to “Neutral” andthen machine can only be moved in “limp home” mode. Aservice code will be logged in Monitor Display Unit.

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

20—Joystick Steering Indicator: If equipped withjoystick steering, the joystick steering indicator will flashand beep when the joystick steering function is engaging

and disengaging. The icon will remain illuminated whilejoystick steering is active.

21—Service Required Indicator (Yellow): Indicator willlight when a problem is developing. It is not necessaryto stop the engine immediately, but the cause should beinvestigated as soon as possible.

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

22—Secondary Steering Warning Indicator—IfEquipped:

IMPORTANT: Prevent possible damage to secondarysteering system. Stop machine immediatelyif secondary steering indicator light and alarmcome on while operating. THE SECONDARYSTEERING SYSTEM IS NOT INTENDEDFOR CONTINUOUS USE.

Indicator will flash, STOP indicator will flash, and alarmwill sound when secondary steering system is activated.Stop machine immediately and take corrective action. Thesecondary steering system is not intended for continuoususe.

23—Cab Work Lights Indicator: Indicator will light whencab work lights switch is activated.

24—Hydraulic Coupler Pin Disconnect Indicator—IfEquipped: Indicator will light and alarm will sound everyten seconds when pin disconnect switch is activated toretract cylinders for removal of attachments.

25—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 and service required indicator will lightwhen fuel pressure drops below 300 kPa (43.5 psi).

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

26—Right Turn Indicator: Indicator will light when rightturn signal switch or 4-way flashers switch is engaged.

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PN=31


HG31779,00002BE -19-15SEP06-1/1

Switch Pad

T192095B

—UN—18SEP03

1—Not Used2—Drive, Tail and Marker Switch3—Automatic Transmission

Switch4—Ride Control Switch—If

Equipped5—Pilot Enable/Boom Down

Switch6—Cab Work Light Switch—If

Equipped

7—Beacon Switch—If Equipped8—Axle Disconnect Switch—If

Equipped9—Spin Control Switch—If

Equipped10— Clutch Cut-Off Switch11— Air Conditioning Switch—If

Equipped

12— Pin Disconnect Switch—IfEquipped

13— Reversing Cooling FanSwitch—If Equipped

14— Front Washer Switch15— Front Wiper Switch16— Return-to Dig Switch

17— Boom Height Kickout Switch18— Return-to-Carry Switch19— Rear Washer Switch20— Rear Wiper Switch

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PN=32


Continued on next page AM40430,000003D -19-09FEB05-1/2

Switch and Accessory Functions

1—Not Used

2—Drive and Marker Switch: The switch has threepositions:

• Press and release switch until one light is illuminated toturn on marker lights• Press and release switch until two lights are illuminatedto turn on drive lights and marker lights• Press and release switch until no lights are illuminatedto turn lights off

NOTE: When marker or drive lights are turned on,the backlighting of the switch pad will turn onand the intensity of the lights will be decreasedautomatically for nighttime operation.

When a communication fault occurs between theswitch pad and Flex Load Controller (FLC) or astuck button condition, the marker lights, drivelights, and backlighting turn on automatically.

3—Automatic Transmission Switch: Press and releaseswitch until light is illuminated. The transmission is nowin “Auto” mode. Move transmission lever to 3 or 4.Transmission will start in 2nd gear. As speed increases,transmission will automatically shift to 3rd and 4th gear.As load increases or speed decreases, transmission willautomatically shift to 3rd and 2nd gear.

NOTE: Transmission will start in first gear if ”Autoto 1st” mode is selected in Machine SettingsMenu on the display monitor.

Press and release switch until light is not illuminated. Thetransmission is now in manual mode.

4—Ride Control Switch—If Equipped: The switch hasthree positions:

• Press switch until one light is illuminated to turn ridecontrol on• Press switch until two lights are illuminated to “Auto”position that functions the same as the “On” positionwith one exception. The ride control is turned off whenground speed is approximately 6 km/h (3—1/2 mph)or less• Press switch until no lights are illuminated to turn ridecontrol off

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

• Press and hold switch while actuating boom down tolower boom with engine off and key switch on• Press and release switch until light is illuminated tounlock pilot controllers; normal operation• Press and release switch until light is not illuminated tolock pilot controllers; locks hydraulic controls

6—Cab Work Light Switch—If Equipped: The switchhas four positions:

• Press switch and release until one light is illuminatedto turn on front lights• Press switch and release until two lights are illuminatedto turn on front and rear lights• Press switch and release until three lights are illuminatedto turn on front, rear, and docking lights (if equipped)• Press switch and release until no lights are illuminatedto turn lights off

7—Beacon Switch—If Equipped: Press and releaseswitch until light is illuminated to turn beacon light on.Press and release switch until light is not illuminated toturn beacon light off.

8—Axle Disconnect Switch—If Equipped: Press andrelease switch until light is illuminated to disconnect frontaxle. Press and release switch until light is not illuminatedto connect front axle.

9—Spin Control Switch—If Equipped:The switch hasfour positions that reduce rim pull through reducing enginerpm when loading the bucket. For example, one out offour lights illuminated provides the minimum engine rpmdecrease. Four out of four lights illuminated provides themaximum engine rpm decrease.

10—Clutch Cut-Off Switch: This switch has fourpositions:

CAUTION: Prevent possible injury fromunexpected machine movement. When stoppingon inclines, press switch until no lights areilluminated to engage clutch cutoff beforereleasing left service brake. This will preventthe machine from rolling downhill duringtransmission re-engagement cycle.

NOTE: By turning one of these functions on, the othertwo are automatically turned off.

• Press and release switch until one light is illuminatedto turn on the Level Slope setting. On this setting theclutch releases with low brake pedal pressure.• Press and release switch until two lights are illuminatedto turn on Small Slope setting. On this setting the clutchreleases with medium brake pedal pressure.• Press and release switch until three lights areilluminated to turn on Steep Slope setting. On thissetting the clutch releases with high brake pressure.• Press and release switch until no lights are illuminatedto disable clutch cutoff.

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

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

2-1-7 013013

PN=33


AM40430,000003D -19-09FEB05-2/2

11—Air Conditioning Switch—If Equipped: Pressand release switch until light is illuminated to turn airconditioning on. Press and release switch until light is notilluminated to turn air conditioning off.

NOTE: Engine must be running and blower fan speedswitch must be on for air conditioning to function.

12—Pin Disconnect Switch—If Equipped: Press andhold switch for 2 seconds to retract cylinders for removalof attachments. The light will remain illuminated, the pindisconnect indicator will light, and the audible alarm willsound every ten seconds.

Press and release switch until light is not illuminated toextend cylinders for attachment.

13—Reversing Cooling Fan Switch—If Equipped:Every 30 minutes the radiator cooling fan will automaticallyreverse direction for 15 seconds without intervention fromthe operator. Press switch and hold for 2 seconds to turnon “Manual” mode to manually reverse the direction ofthe fan for 15 seconds.

NOTE: The reversing fan function shall not be reactivatedwithin one minute of its last completion (thistime includes “Automatic” cycle).

14—Front Washer Switch: Push switch to wash frontwindow. Pressing switch will also activate low speed frontwiper operation. After releasing washer switch the wiperblade will swipe three times and automatically turn off .

15—Front Wiper Switch: The switch has four positions:

• Press and release switch until one light is illuminatedfor intermittent front wiper operation• Press and release switch until two lights are illuminatedfor low speed front wiper operation• Press and release switch until three lights areilluminated for high speed front wiper operation• Press and release switch until no lights are illuminatedto turn front wipers off

16—Return-to-Dig Switch:The switch has threepositions:

• Press and release switch until one light is illuminated forbucket position on Powerllel linkage machines only.

• Press and release switch until two lights are illuminatedfor fork position on Powerllel linkage machines only.• Press and release switch until no lights are illuminatedto turn return-to-dig off for Z-Bar linkage machines.

17—Boom Height Kickout Switch: The switch has threepositions:

• Press and release switch until one light is illuminated toactivate boom height kickout. Pull boom lever to raisedetent position. Boom will kick out of detent positionwhen it reaches a preset height from ground.• While light is illuminated, press and hold switch to setboom height. Light will flash and audible alarm willsound to indicate position has been set.• Press and release switch until no light is illuminated todeactivate boom height kickout

18—Return-to-Carry Switch: The switch has threepositions:

• Press and release switch until one light is illuminatedto activate return-to-carry. Push boom lever to floatposition. Boom will kick out of float position when itreaches a preset distance from ground.• Press and hold switch to set return-to-carry height• Press and release switch until no light is illuminated todeactivate return-to-carry

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

19—Rear Washer Switch: Push switch to wash rearwindow. Pressing switch will also activate low speed rearwiper operation. After releasing washer switch the wiperblade will swipe five times and automatically turn off .

20—Rear Wiper Switch: The switch has four positions:

• Press and release switch until one light is illuminatedfor intermittent rear wiper operation• Press and release switch until two lights are illuminatedfor low speed rear wiper operation• Press and release switch until three lights areilluminated for high speed rear wiper operation• Press and release switch until no lights are illuminatedto turn rear wipers off

2-1-8 013013

PN=34


HG31779,0000320 -19-11AUG03-1/2

HG31779,0000320 -19-11AUG03-2/2

Monitor Display Unit—Normal DisplayWhen key switch is turned on, all lights on display monitorwill come on, all gauges will position gauge needle to the12 o'clock position, and alarm will sound.

The basic display window will show the bulb check mode.After bulb check mode, the stop indicator and engine oilpressure indicator will flash.

The machine model number will show in the basic displaywindow.

John Deere 724J

T195281—UN—13OCT03

744J Monitor Shown

Approximately five seconds later, the Normal display willbe shown.

The Actual Gear Display (1) shows the gear thetransmission has engaged when machine is not in neutral.When a transmission controller unit failure occurs, thisdisplay will show gear 1.

The FNR Display (2) shows the forward, neutral, reversestatus. When a transmission controller unit failure occurs,the FNR display will show neutral.

The Requested Gear Display (3) shows the requestedgear position of the shift lever or gear select.

The Transmission Mode Display (4) shows whether thetransmission is in "Auto" mode or “Manual” mode. Whena transmission controller unit failure occurs, this displaywill show manual mode.

The Tachometer Display (5) shows the engine revolutionsper minute to the nearest fifth of a rpm. When atransmission controller unit malfunction occurs, a "---" isdisplayed.

NOTE: Press SELECT or NEXT to toggle between theodometer, hour meter, and speedometer displays.

The Odometer Display (6) shows the odometer reading inmiles/km to the nearest tenth. The odometer is capableof displaying up to 99,999.9 total kilometers or 62137.1miles. The odometer runs only when the engine is on.

The Hour Meter Display (7) shows the machine hours tothe nearest tenth of an hour. The hour meter accumulates

4F2 3 4

AUTO ODM HOURS SPEED

rpm

323.3

9501

1

3

4

2 5

6 7 8

T194715—UN—17SEP03

1—Actual Gear Display2—FNR Display3—Requested Gear Display4—Transmission Mode Display

5—Tachometer Display6—Odometer Display7—Hour Meter Display8— Speedometer

hours only when the engine is on; and the icon flashesonce per second. The hour meter displays up to 99,999.9hours.

The Speedometer Display (8) will show speed in mph/kph.When a flex load controller failure occurs, a “- - -” isdisplayed.

2-1-9 013013

PN=35


HG31779,0000309 -19-11AUG03-1/1

HG31779,000030A -19-11AUG03-1/1

Monitor Display Unit—Main MenuThe Main Menu provides the capability to select the nextsub menus. The Main Menu is accessed by pressing theMENU key. The sub menus under Main Menu include:

• “Codes” menu allows service personnel or operator toview “active” or “stored” diagnostic trouble codes.• “Machine Settings” menu allows the operator to makechanges to various operating characteristics of themachine.• “Diagnostics” menu provides a limited set of tools, and isintended to be used by service personnel and machineoperator’s for diagnostic and troubleshooting functions.• “Monitor Settings” menu allows the operator to makechanges to various operating characteristics of themonitor.

1/4Main Menu 1-Codes 2-Machine Settings 3-Diagnostics 4-Monitor Settings

T194565—19—30SEP03

Monitor Display Unit—Main Menu—CodesThe Codes menu provides the capability to select the nextsub menus.

At the Main Menu with “1-Codes” highlighted, pressSELECT to display sub menu.

Codes 1-Active Codes 2-Stored Codes

1/2

T193353—19—22SEP03

2-1-10 013013

PN=36


HG31779,000030E -19-11AUG03-1/1

Monitor Display Unit—MainMenu—Codes—Active CodesThe Active Code sub menu will display up to twenty of thelatest Diagnostic Trouble Codes that are currently activeon the machine. As the diagnostic codes are resolved orfixed, the code will be removed from the active code list.

The following will be displayed:

• Text description of the DTC (Diagnostic Trouble Code)• Source controller of fault (ECU, CMU, FLC, SSM, orTCU)• SPN (Suspect Parameter Number)• FMI (Failure Mode Indicator)• Circuit information: fuse number, wire numbers,connector and pin numbers of source controller, andschematic section number

NOTE: Information on the circuit will vary basedupon diagnostic trouble code.

Press SELECT. An active diagnostic trouble code will bedisplayed.

Press SELECT to view occurrences.

Press SELECT again to view circuit information to helpdiagnose problem.

Press NEXT to display next active code.

Active Codes Right Turn Lts High Current �FLC 2370.6

1/3

T193355—19—30SEP03

Active Codes Fuse: F18 F28 Wires: M12 YEL M13 GRN P18 RED P28 RED CONN PIN: X23 25 X23 26 23 68 45�SECTION: SE23

2/3

T195057—19—07NOV03

2-1-11 013013

PN=37


HG31779,000030F -19-11AUG03-1/1

HG31779,000030B -19-08AUG03-1/1

Monitor Display Unit—MainMenu—Codes—Stored CodesThe Stored Code sub menu will display up to twenty ofthe latest diagnostic trouble codes that have occurred onthe machine. Each diagnostic trouble code will be savedin the order it occurred. If twenty codes exist and anotherDTC is present, the listing will be adjusted first in/first out.

The following will be displayed:

• Text description of the DTC (Diagnostic Trouble Code)• Source controller of fault (ECU, CMU, FLC, SSM, orTCU)• SPN (Suspect Parameter Number)• FMI (Failure Mode Indicator)• Value of sensor at time of fault (if applicable)• Current value of sensor (if applicable)• Hour meter reading at first and last occurrence• Total number of occurrences• Circuit information: fuse number, wire numbers,connector and pin numbers of source controller, andschematic section number

NOTE: Information on the circuit will vary basedupon diagnostic trouble code.

Press SELECT. A stored diagnostic trouble code will bedisplayed.

Press SELECT to view occurrences.

Press SELECT again to view circuit information to helpdiagnose problem.

Press NEXT to display next active code.

Stored Codes CAN Comm Lost for TCU�CMU 2003.9

2/3

T193356—19—08OCT03

Stored Codes Occurrences: 7

2/3

First:�118.0 hrs

Last:�119.5 hrs

T195058—19—23SEP03

Stored Codes Fuse: F18 F28 Wires: M12 YEL M13 GRN P18 RED P28 RED CONN PIN: X23 25 X23 26 23 68 45�SECTION: SE23

2/3

T195059—19—30SEP03

Monitor Display Unit—Main Menu—MachineSettingsThe Machine Settings menu allows the operator to makechanges to various operating conditions of the machine.The last selection of the machine settings will be storedand upon turning the ignition switch on, the last value willbe retrieved.

Press NEXT at Main Menu to highlight Machine Settings.

Press SELECT to display sub menu.

1/4Machine Settings 1-Quick Shift 2-Auto to 1st 3-Job Timer 4-Stopwatch

T193357—19—06OCT03

2-1-12 013013

PN=38


HG31779,0000310 -19-08AUG03-1/1

HG31779,0000311 -19-08AUG03-1/1

Monitor Display Unit—Main Menu—MachineSettings—Quick ShiftThe 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:When this function is turned On, each time the quick shiftswitch (at top of pilot controller handle) is pressed down,the transmission 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 causethe transmission 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:If the 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.

Quick Shift Down/Up Down Only

1/2

T193358—19—05AUG03

If the operator presses down on the quick shift switch whilean up shift is taking place, the transmission controller willcause the transmission to shift down to the previous gear.

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

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.

Press SELECT at Machine Settings menu.

If the display shows a checkmark next to Down/Up, theDown/Up function is on.

To turn on Down Only function and disable Down/Upfunction, press NEXT then press SELECT.

Press BACK to return to Machine Settings menu.

Monitor Display Unit—Main Menu—MachineSettings—Auto to 1stIn Auto to 1st mode, the transmission will shift to first gearif a high load is sensed while the transmission is actuallyin second gear. This shift change is made independentfrom 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 NEXT at Machine Settings menu to highlight Autoto 1st.

Press SELECT.

If Auto to 1st function is off, press NEXT then pressSELECT to turn Auto to 1st function on.

Auto to 1st Off On

1/2

T193359—19—05AUG03

2-1-13 013013

PN=39


HG31779,0000312 -19-08MAR07-1/1

HG31779,0000313 -19-08MAR07-1/1

HG31779,000030C -19-08AUG03-1/1

Monitor Display Unit—Main Menu—MachineSettings—Job TimerThe job timer is a resettable hour meter that can beused to time tasks to the nearest tenth of an hour. Themaximum capacity displayed is 999.9 hours. The jobtimer will stop and the value will be set to zero when itexceeds 999.9 hours. The job timer will run even whenthe Job Timer sub menu is not active. The job timer valuewill be stored when the ignition switch is turned off.

At Machine Settings menu, press NEXT to highlight JobTimer.

Press SELECT.

Press SELECT to reset the timer to zero.

Job Timer SELECT to Reset BACK to Exit

0.0 hours

T193360—19—05AUG03

Press BACK to exit.

Monitor Display Unit—Main Menu—MachineSettings—StopwatchThe stop watch is a resettable timer that is used tomeasure time in hours, minutes, seconds and tenths ofseconds. The maximum capacity displayed is 24:00:00:0hours. The stopwatch will stop and the value will be set tozero when it exceeds 24:00:00:0 hours. The stopwatchwill run even when the Stop Watch sub menu is not active.The stopwatch will be turned off and will reset to zerowhen the ignition switch is turned off.

At Machine Settings menu, press NEXT to highlight StopWatch.

Press SELECT.

Press SELECT again to start the timer when the stopwatchis off and has a value of zero.

Press SELECT to stop the timer when the stopwatch is on.

STOPWATCH SELECT on/off NEXT to reset BACK to Exit

00:00:00.0

T193361—19—30SEP03

Press NEXT to reset the timer.

Press BACK to exit.

Monitor Display Unit—MainMenu—DiagnosticsThe Diagnostics menu provides a limited set of tools andis intended for use by service personnel and machineoperators for diagnostic and troubleshooting functions.

Press NEXT at Main Menu to highlight Diagnostics.

Press SELECT to display sub menu.

1/8Diagnostics 1-Battery Monitor 2-Engine Sensors 3-Transmission 4-Hydraulic 5-Machine 6-Machine Switches 7-Switch Module 8-Machine I.D.

T193362—19—30SEP03

2-1-14 013013

PN=40


HG31779,0000314 -19-08AUG03-1/1

Monitor Display Unit—MainMenu—Diagnostics—Battery MonitorPress SELECT when “Battery Monitor” is highlighted toview the current voltage of the left and right batteries.

Press BACK to return to sub menu.

NOTE: If 12 volt center tap wire is not connected tothe right battery, left battery will display systemvoltage and right battery will display 0.0.

Battery Monitor Left Battery

Right Battery13.7�

13.7�

T193363—19—05AUG03

2-1-15 013013

PN=41


HG31779,0000315 -19-08AUG03-1/1

Monitor Display Unit—MainMenu—Diagnostics—Engine SensorsThis mode allows the technician to monitor all enginesensors that are accessible to the Engine Controller Unit(ECU).

Press NEXT at Diagnostics menu to highlight EngineSensors.

Press SELECT.

Press SELECT again at Display All sub menu to displayall data items. Continue to press SELECT or NEXT toscroll through the engine coolant temperature, engine oilpressure, throttle sensor, manifold air temperature, andfuel temperature displays.

OR

Press NEXT to highlight Coolant Temp.

Press SELECT.

Engine Coolant Temperature will be displayed in °C or°F (depending on setting selected in “Units” display in“Monitor Settings” menu.)

Press BACK.

Press NEXT to highlight Oil Pressure.

Press SELECT.

Engine Oil Pressure will be displayed in kPa or psi.

Press BACK.

Press NEXT to highlight Throttle Sensor.

Press SELECT.

Throttle Sensor voltage will be displayed as a percentage.

Press BACK.

Press NEXT to highlight MAT.

Press SELECT.

Intake Air Manifold Temperature will be displayed in °Cor °F.

Press BACK.

Press NEXT to highlight Fuel Temp.

Press SELECT.

Fuel Temperature will be displayed in °C or °F.

1/8Engine Sensors 1-Display All 2-Coolant Temp 3-Oil Pressure 4-Throttle Sensor 5-MAT 6-Fuel Temp 7-Fuel Pressure 8-MAP

T193364—19—01OCT03

Engine Sensors Coolant Temperature 141 F

1/7

T195234—19—30SEP03

Coolant Temp Display Shown

Press BACK.

NOTE: Fuel Pressure and MAP (Manifold Air Pressure)will not be displayed on menu if machine isnot equipped with sensor.

Press NEXT to highlight Fuel Pressure.

Fuel Pressure will be displayed in kPa or psi.

Press BACK.

Press NEXT to highlight MAP.

Press SELECT.

Manifold Air Pressure will be displayed in kPa or psi.

Press BACK twice to return to the Diagnostics menu.

2-1-16 013013

PN=42


HG31779,0000316 -19-08AUG03-1/1

Monitor Display Unit—MainMenu—Diagnostics—TransmissionThis mode allows the technician to monitor all transmissionsensors that are accessible to the Transmission Controller(TCU).

Press NEXT at Diagnostics Menu to highlightTransmission.

Press SELECT.

Press SELECT again at Display All sub menu to display alldata items. Continue to press SELECT or NEXT to scrollthrough the transmission oil temperature, torque converterinput speed, torque converter output speed, clutch speed,output shaft speed, and clutch cutoff voltage displays.

OR

Press NEXT to highlight Oil Temp.

Press SELECT.

Transmission Oil Temperature will be displayed in °C or °F.

Press BACK.

Press NEXT to highlight TC Input Speed.

Press SELECT.

Torque Converter Input Speed will be displayed in rpm.

Press BACK.

Press NEXT to highlight TC Output Speed.

Press SELECT.

Torque Converter Output Speed will be displayed in rpm.

Press BACK.

Press NEXT to highlight Clutch Speed.

1/7Transmission 1-Display All 2-Oil Temp 3-TC Input Speed 4-TC Output Speed 5-Clutch Speed 6-Output Shaft Spd 7-Clutch Cutoff V

T193372—19—01OCT03

Press SELECT.

Internal Clutch Speed will be displayed in rpm.

Press BACK.

Press NEXT to highlight Output Shaft Spd.

Press SELECT.

Output Shaft Speed will be displayed in rpm.

Press BACK.

Press NEXT to highlight Clutch Cutoff V.

Press SELECT.

Clutch Cut–off will be displayed in volts.

Press BACK to exit.

2-1-17 013013

PN=43


HG31779,0000317 -19-08AUG03-1/1

HG31779,0000318 -19-08AUG03-1/1

Monitor Display Unit—MainMenu—Diagnostics—HydraulicThis mode allows the technician to monitor hydraulicsensors that are accessible to the Flex Load Controller(FLC).

Press NEXT at Diagnostics Menu to highlight Hydraulic.

Press SELECT.

Press SELECT again at Display All sub menu to displayall data items. Continue to press SELECT or NEXT toscroll through the hydraulic oil temperature and hydraulicsystem pressure displays.

Press NEXT to highlight Oil Temp.

Press SELECT.

Hydraulic Oil Temperature will be displayed in °C or°F (depending on setting selected in “Units” display in“Monitor Settings” menu).

Press BACK.

Press NEXT to highlight Hyd Sys Press.

Hydraulic 1-Display All 2-Oil Temp 3-Hyd Sys Press

1/3

T193379—19—25JU

L03

Press SELECT.

Hydraulic System Pressure will be displayed in kPa or psi.

Press BACK twice to exit.

NOTE: Hydraulic system pressure will only be displayedon machines equipped with spin control.

Monitor Display Unit—MainMenu—Diagnostics—MachineThis mode allows the technician to monitor machinesensors that are accessible to the Flex Load Controller(FLC).

Press NEXT at Diagnostics Menu to highlight Machine.

Press SELECT.

Press SELECT again at Display All sub menu to displayall data items. Continue to press SELECT or NEXT toscroll through the boom height and fuel level displays.

OR

Press NEXT to highlight Boom Height.

Press SELECT.

Boom Height will be displayed as a percentage.

Press BACK.

NOTE: Bucket position will only be displayed on machineequipped with linkage coupler.

Press NEXT to highlight Bucket Position.

1/4Machine 1-Display All 2-Boom Height 3-Bucket Position�4-Fuel Level

T193382—19—04NOV03

Press SELECT.

Bucket Position will be displayed as a percentage.

Press NEXT to highlight Fuel Level.

Press SELECT.

Fuel Level will be displayed as a percentage of fuelremaining in tank.

Press BACK twice to exit.

2-1-18 013013

PN=44


HG31779,000031B -19-08AUG03-1/1

Monitor Display Unit—MainMenu—Diagnostics—Machine SwitchesThis mode allows the technician to monitor all machineswitches hardwired to the Flex Load Controller (FLC).

When a change occurs to the machine switch, the box tothe left of the machine switch description will change andthe audible alarm will sound.

“Off” indicates no signal present and “On” indicates asignal present to the FLC.

Machine Switches Hyd Oil Filt Res Brake Accum Chg Steering Press

1/4Off

Off

Off

Machine Switches Brake Light Ret to Dig Bkt Start Signal

2/4Off

Off

Off

Machine Switches 4 Way Flashers Blower� Front Wiper Park

3/4Off

Off

Off

Machine Switches Rear Wiper Park

4/4Off

T193385—19—15OCT03

2-1-19 013013

PN=45


HG31779,0000319 -19-25AUG10-1/1

HG31779,000031A -19-08AUG03-1/1

Monitor Display Unit—MainMenu—Diagnostics—Switch ModuleThis mode allows the technician to check continuityfunction of the Sealed Switch Module (SSM).

Pressing a switch on the SSM will change the status ofthe corresponding switch icon on the monitor.

When a change occurs to the SSM, the correspondingswitch icon will change and audible alarm will sound.

A blank square indicates no switch pressed.

“On” indicates switch pressed.

“?” indicates no CAN communication between the CanMonitor Unit (CMU) and Sealed Switch Module (SSM).

SSM Test

Press any Button..

T193389—19—22SEP03

Press BACK to return to previous screen.

Monitor Display Unit—MainMenu—Diagnostics—Machine I.D.This mode allows the service technician to view theversion of software and controller numbers.

Press NEXT to highlight CMU.

Press SELECT.

The box serial number, box part number, software partnumber and software version number for the CAN MonitorUnit will be displayed.

Press BACK.

Press NEXT to highlight FLC.

Press SELECT.

The box serial number, box part number, software partnumber and software version number for the FLC (FlexLoad Controller) will be displayed.

Press BACK.

Press NEXT to highlight SSM.

Press SELECT.

The box part number, software part number and softwareversion number for the SSM (Sealed Switch Module) willbe displayed.

Press BACK.

Press NEXT to highlight TCU.

Press SELECT.

The machine model, machine serial number, box partnumber and software version for the TCU (TransmissionControl Unit) will be displayed.

1/5Machine ID 1-CMU 2-FLC 3-SSM 4-TCU 5-Serial #

T193390—19—01OCT03

CMU�Serial #: 100040 Part #: AT226327�Software #: AT226948�Software Ver. 0.1.0.2

T193391—19—08OCT03

CMU Display Shown

Press BACK.

Press NEXT to highlight Serial #.

Press SELECT.

The machine serial number will be displayed.

2-1-20 013013

PN=46


HG31779,000030D -19-08AUG03-1/1

HG31779,000031C -19-08AUG03-1/1

HG31779,000031D -19-08AUG03-1/1

Monitor Display Unit—Main Menu—MonitorSettingsThe Monitor Settings Menu provides the capability toselect sub menus.

1/5Monitor Settings 1-Units 2-Backlighting 3-LCD Contrast

T193394—19—07NOV03

Monitor Display Unit—Main Menu—MonitorSettings—UnitsThis mode allows the technician to choose between metricand English unit displays.

When there is a checkmark next to English, all values willbe shown in English units. When there is checkmark nextto Metric, all values will be shown in metric.

Units English Metric

1/2

T193395—19—05AUG03

Monitor Display Unit—Main Menu—MonitorSettings—Hide Main MenuThis mode allows the operator or owner to hide all MainMenu functions and show only the Normal Display.

If Hide Main Menu is selected, the operator must accessthe Service Menu to get back into the menu.

Hide Main Menu Hide Main Menu Show Main Menu

1/2

T193396—19—05AUG03

2-1-21 013013

PN=47


HG31779,000031E -19-08AUG03-1/1

HG31779,000031F -19-08AUG03-1/1

Monitor Display Unit—Main Menu—MonitorSettings—BacklightingThis mode allows the operator to adjust the backlightingof the monitor. The backlight value is displayed inpercentage and is incremented by 1. The range ofadjustment is from 0 (no light) to 10 (brightest setting).The default backlight value is 10%.

Press NEXT to highlight Backlighting.

Press SELECT.

Press NEXT to increase backlighting by 1.

Press BACK to decrease backlighting by 1.

Press SELECT to store currently displayed value. Thestored value will be used as the default backlight valueuntil changed.

NOTE: Changing the backlight value without storingthe setting with the SELECT key will only affect

Backlighting BACK to decrease NEXT to increase SELECT to store

10

T193397—19—15OCT03

the backlighting until the key switch is turned off.The previously stored value will be used whenthe key switch is turned on again.

Press MENU to exit.

Monitor Display Unit—Main Menu—MonitorSettings—LCD ContrastThis mode allows the operator to adjust the contrastsetting of the monitor display. The range of adjustment isfrom 1 (lightest, or least contrast) to 9 (darkest, or mostcontrast). The default contrast value is 5.

Press NEXT at Monitor Settings menu to highlight LCDContrast.

Press SELECT.

Press NEXT to increase contrast by 1.

Press BACK to decrease contrast by 1.

Press SELECT to store currently displayed value. Thestored value will be used as default contrast value until itis changed.

NOTE: Changing the contrast without storing thesetting with the SELECT key will only affect the

LCD Contrast BACK to decrease NEXT to increase SELECT to store

9

T193398—19—22SEP03

contrast until the key switch is turned off. Thepreviously stored value will be used when thekey switch is turned on again.

Press MENU to exit.

2-1-22 013013

PN=48


VD76477,000105E -19-18SEP06-1/1

HG31779,00002CE -19-26JUN03-1/1

Horn Button

1—Horn Button

T192867A

—UN—18SEP03

Conventional Steering Horn Button

T214031C

—UN—07OCT05

Joystick Steering Horn Button - If Equipped

Turn SignalsPush turn signal lever (1) forward to signal a left turn. Pullturn signal lever rearward to signal a right turn.

1—Turn Signal Lever

T192869A

—UN—18SEP03

2-1-23 013013

PN=49


HG31779,00002C0 -19-23JUN03-1/1

HG31779,00002FD -19-07JUL03-1/1

Air Conditioning Controls and HeaterOperationIMPORTANT: Before you start air conditioner first

time in the season, check filters and condenser.Clean them if necessary. Check refrigerant level.

NOTE: Engine must be running and blower fan speedswitch must be on for air conditioning to function.

To Operate Air Conditioning—If Equipped:

Press air conditioning switch (1) until light is illuminated.

Turn temperature control knob (2) clockwise to increasetemperature.

Turn blower speed knob (3) clockwise to increase blowerspeed. (Knob also turns on heater blower.) Blower hasfour speeds.

To Operate Heater:

Air conditioning switch (1) should be in the “Off” position.

Temperature control knob (2) should be in the heatposition.

Turn blower speed knob (3) to desired blower speed.

1—Air Conditioning Switch2—Temperature Control Knob

3—Blower Speed Knob

T192344B

—UN—18SEP03

T194783A

—UN—18SEP03

Adjusting Steering Wheel TiltLift lever (1) to adjust steering column to desired tilt.Release lever.

1—Lever

T192870A

—UN—18SEP03

2-1-24 013013

PN=50


VD76477,000105F -19-15SEP06-1/1

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

Adjusting Joystick Steering Arm RestLoosen arm pad position adjustment knob (1) to movearm rest forward or backward and tighten when desiredposition is reached.

To raise or lower joystick arm rest, loosen arm pad heightadjustment knob (2) and tighten when desired height isreached.

NOTE: Arm pad height adjustment knob does nottighten the arm rest.

Lift joystick arm pad tilt lever (3) to tilt the joystick arm paduntil desired angle is reached.

To move the arm rest from side to side, lift lateraladjustment levers (4) until desired position is reached.

NOTE: Lateral adjustment levers can be pulled outwardto allow movement of arm rest.

Release hold-up lever (5) to tilt arm down to loweredposition.

IMPORTANT: If arm rest is loose when tiltingdownward, see your authorized dealer.

1—Arm Pad PositionAdjustment Knob

2—Arm Pad Height AdjustmentKnob

3—Arm Pad Tilt AdjustmentLever

4—Lateral Adjustment Levers5—Hold-Up Lever

T214157A

—UN—15SEP05

T214606C

—UN—10OCT05

Opening and Securing Side DoorTo open left side cab door from inside, push forward onlever (A).

A—Lever

T131654B

—UN—13JU

N00

2-1-25 013013

PN=51


CED,OUOE035,10 -19-14JUN00-2/2

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.

A—Outside LatchB—Notch

C—BumperD—Release Lever

T118147—UN—02NOV98

T160585B

—UN—17OCT02

2-1-26 013013

PN=52


HG31779,0000151 -19-15OCT02-1/1

TX,10,JC1589 -19-14JUN00-1/1

Opening Side Window/Secondary ExitNOTE: The cab right side window can be used

as a secondary exit.

Push up on lever (A) to open window.

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

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

A—LeverB—Outer Notch

C—Lever

T160249C

—UN—15OCT02

T103919B

—UN—12DEC96

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

A—Latch Tab

T131655B

—UN—19JU

N00

2-1-27 013013

PN=53


TX,10,JC1742 -19-04DEC96-1/1

Adjusting Seat

CAUTION: You can lose control of machine and beinjured if seat is loose. Be sure seat is properlylocked in position before operating the machine.

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

Lift fore-aft lever (H) to move seat forward and rearward.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 tilt knob (C) to tilt todesired 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 firmnessin ride, turn key to ON and push in on height/firmnessadjustment knob.

A—Lumbar Support LeverB—Armrest Height Adjustment

ScrewC—Armrest Adjustment KnobD—Backrest Tilt Adjustment

KnobE—Seat Height Adjustment

Lever

F—Weight Adjustment KnobG—Weight IndicatorH—Fore-Aft Adjustment LeverI— Height/Firmness

Adjustment Knob (Air RideSeat only)

T103679B

—UN—22NOV96

T105452—UN—26NOV96

2-1-28 013013

PN=54

Operation—Operating the Machine

TX,20,JC1199 -19-18JUL02-1/1

HG31779,00000B1 -19-18JUL02-1/1

Inspect Machine Daily Before StartingDo 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.

T103802—UN—18SEP96

A—Wheels (Front and Rear)B—Operator’s StationC—Air Inlet Cover

D—RadiatorE—Fuel Level (Monitor)F—Tires

Check Instruments Before StartingTurn key switch clockwise to “On” position. All lights ondisplay monitor will come on, all gauges will position gaugeneedle to the 12 o'clock position, and alarm will sound.

The basic display window will show the bulb check mode.After bulb check mode, the stop indicator and engine oilpressure indicator will flash.

OFF

ON

START

T195405—19—07OCT03

2-2-1 013013

PN=55


VD76477,00016F2 -19-22DEC10-1/1

Continued on next page VD76477,0001066 -19-15SEP06-1/2

Engine Break-In PeriodIMPORTANT: To avoid engine damage it is critical

to observe the engine break-in period. Extracare during the first 250 hours of operation willresult in more satisfactory long-term engineperformance and life. DO NOT exceed 250hours of operation with break-in oil.

1. Operate the machine at heavy or normal loads withminimal idling during the break-in period. During thefirst 20 hours, avoid prolonged periods of engine idlingor sustained maximum load operation. If engine willidle longer than 5 minutes, stop engine.

2. Check engine oil level more frequently during theengine break-in period.

IMPORTANT: DO NOT add make-up oil until theoil level is BELOW the ADD mark on the

dipstick. John Deere Break-In™ Engine Oilshould be used to make up any oil consumedduring the break-in period.

3. Change oil and oil filter after first 250 hours (maximum).Fill crankcase with the normal seasonal viscositygrade oil. See Maintenance—Machine. (Section 3-1.)

4. Watch coolant temperature gauge closely. If coolanttemperature rises above specified limits on the gauge,reduce load on engine. Unless temperature dropsquickly, stop the engine and determine the causebefore resuming operation. See Troubleshooting.(Section 4-3.)

5. Watch oil pressure gauge for pressure withinspecification.

6. Check serpentine belt for proper alignment andseating in pulley grooves.

Break-In is a trademark of Deere & Company.

Starting the Engine

CAUTION: Avoid possible injury or deathfrom a runaway machine.

DO NOT start engine by shorting acrossstarter terminals. Machine will start in gearif normal circuitry is bypassed.

NEVER start engine while standing on ground.Start engine only from operator’s seat, withFNR in “Neutral”. Engage park brake.

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

1. Fasten seat belt.

TS177—UN—11JAN89

2-2-2 013013

PN=56


VD76477,0001066 -19-15SEP06-2/2

2. Move FNR (1) to N.

NOTE: If starting the engine with FNR in F “Forward” orR “Reverse”, the transmission will not shift into F orR until the FNR is cycled through N “Neutral”.

3. Turn key switch to “On” position. Push horn buttonto sound horn to alert bystanders that machine willbe started.

IMPORTANT: The wait to start / start inhibit featurenotifies the operator not to start or preventsthe operator from cranking the machine formore than 30 seconds. After the engine hasbeen cranked for 30 seconds, the monitorwill display the “Wait to Start” message andthe starter will stop and cool for 60 seconds.The operator must wait 60 seconds after thekey switch has been removed from the startposition before attempting to start the engineagain. After the 60 second waiting period,the starter can be engaged.

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

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

4. Turn key switch to “Start” position. DO NOT 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, STOPTHE ENGINE. Find and correct the cause.

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

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

1—FNR

T194598A

—UN—18SEP03

Column FNR Shown

T194851A

—UN—18SEP03

T213837A

—UN—24AUG05

Joystick Steering FNR Shown - If Equipped

2-2-3 013013

PN=57


AM40430,0000041 -19-09FEB05-1/2

AM40430,0000041 -19-09FEB05-2/2

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

CAUTION: Prevent possible injury from explodingcontainer. Starting fluid is highly flammable. Keepcontainer away from heat, sparks, and open flame.Contents are pressurized. DO NOT puncture orincinerate container. Remove container frommachine if engine 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.


IMPORTANT: Excess starting fluid could damageengine; press starting aid button only whenengine is cold and cranking. Do not hold thestarting aid button for more than 5 seconds.Starting aid fluid is being injected into engineas long as you press button.

2. After one or two revolutions of engine crankshaft,press starting aid button (1) until engine starts. Crankengine for 20 seconds maximum, then allow 2 minutesbetween cranking periods.

REPLACING START AID CONTAINER

1. Loosen hose clamp (2).

2. Turn start aid container (3) 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 componentsfrom possible damage. Install starting aidplug in starting aid base.

Remove container from base and install plug (4) in base.

T192675A

—UN—18SEP03

T192875A

—UN—18SEP03

1—Starting Aid Button2—Hose Clamp

3—Start Aid Container4—Plug

2-2-4 013013

PN=58


HG31779,00002D1 -19-26JUN03-1/1

T82,25,C53 -19-19DEC06-1/1

TX,25,JC247 -19-29NOV94-1/1

TX,25,JC1942 -19-19NOV07-1/1

Engine Heater—If EquippedIMPORTANT: DO NOT USE ETHER WITH THIS

SYSTEM. Damage to your engine may occur.

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

1. Turn key switch to “On”. If engine temperature isbelow 10°C (50°F), engine heater indicator (1) willlight and stay on 0—30 seconds, depending on initialengine temperature. 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, heaterindicator 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.

T194774A

—UN—18SEP03

1—Engine Heater Indicator

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

Using Coolant Heater—If Equipped

CAUTION: Prevent property damage as a resultof possible fire from an overheated electrical

cord. Use a heavy-duty, grounded cord toconnect heater to electrical power.

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

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

Cold Weather Warm-Up

IMPORTANT: If hydraulic oil and transmission oilare cold, functions move slowly. Do notattempt normal machine operations untilhydraulic and transmission functions moveat close-to-normal cycle times.

NOTE: If machine is equipped with joystick steering, allowhydraulic oil temperature to reach at least 10°C(50°F) before activating joystick steering.

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 clutchcutoff 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.

2-2-5 013013

PN=59


HG31779,00002D2 -19-08FEB07-1/1

HG31779,00002D6 -19-26JUN03-1/1

Neutral Lock

CAUTION: Prevent possible injury fromunexpected machine movement. Alwaysmove transmission control lever (TCL) toneutral "N", and engage neutral lock beforestarting or dismounting.

Move neutral lock (1) to the locked position to engageneutral lock. Move lock to the unlocked position todisengage neutral lock.

1—Neutral Lock

T192873B

—UN—18SEP03

Shifting the TransmissionUnlock neutral lock (if equipped with column FNR).

Release park brake.

Change direction of machine by moving FNR (1) to F“Forward" or R “Reverse".

If equipped with column FNR, change speed of machineby rotating transmission control lever to desired gear. Ifequipped with joystick FNR, press button (2) to increasespeed. Press button (3) to decrease speed. Machinehas four forward gears and three reverse gears. Shiftingto 4th gear reverse will give same travel speed as 3rdgear reverse. Select a gear suitable to operating androad conditions.

When automatic transmission switch (4) is on,transmission will shift up or down as required tohighest gear selected. In automatic transmission mode,transmission starts out in 2nd gear.

1—FNR2— Increase Speed Button

3—Decrease Speed Button4—Automatic Transmission

Switch

T194598A

—UN—18SEP03

Column FNR Shown

T194597C

—UN—02OCT03

Joystick FNR ShownT192455D

—UN—02OCT03

2-2-6 013013

PN=60


VD76477,0001062 -19-15SEP06-1/1

Shifting the Transmission—If Equipped WithJoystick SteeringUnlock neutral lock (if equipped with column FNR).

Release park brake.

Change direction of machine by moving FNR (1) to F“Forward" or R “Reverse".

If equipped with column FNR, change speed of machineby rotating FNR lever to desired gear. If equipped withjoystick FNR, press button (2) to increase selected gear.Press button (3) to decrease selected gear. Sound hornby pressing the horn button (5). Machine has four forwardgears and three reverse gears. Shifting to 4th gearreverse will give same travel speed as 3rd gear reverse.Select a gear suitable to operating and road conditions.

When automatic transmission switch (4) is on,transmission will shift up or down as required tohighest gear selected. In automatic transmission mode,transmission may start in 1st or 2nd gear.

1—FNR2— Increase Selected Gear3—Decrease Selected Gear

4—Automatic TransmissionSwitch

5—Horn

T194598A

—UN—18SEP03

T214031A

—UN—09SEP05

Joystick Steering FNR Shown

T192455D

—UN—02OCT03

2-2-7 013013

PN=61


VD76477,0001064 -19-19NOV07-1/1

Joystick Steering Activation/Deactivation—IfEquippedJoystick steering is an option that allows the operatorto select direction, gear, sound the horn, and steer themachine from a single lever to the left of the operator'sseat. The armrest has an activation switch that enablesjoystick steering in the lowered position. The JoystickSteering activation switch is used to activate or deactivateJoystick Steering. In the active mode, the operator thencan use the joystick to steer the machine left or right.

NOTE: Joystick steering sensitivity changes with speed.Become familiar with steering at all speedsbefore operating in confined areas.

NOTE: Allow hydraulic oil temperature to reach at least10°C (50°F) before activating joystick steering.If attempting to activate joystick steering beforehydraulic oil reaches at least 10°C (50°F), thejoystick steering indicator will flash, the alarm willbeep, and the monitor will display the message“WARM UP HYDRAULICS TO OPERATE”.

Activate Joystick Steering

1. Ensure machine is stopped and move column FNR toNEUTRAL.

2. Release hold-up lever (1) and tilt arm down to loweredposition.

3. Activate joystick steering by pressing the joysticksteering activation switch (2). The joystick steeringindicator on the monitor will illuminate until joysticksteering is deactivated.

4. Release park brake.

NOTE: Monitor alarm will sound, joystick steeringicon will blink and joystick steering will remaininactive until park brake is released.

NOTE: When joystick steering is active and the steeringcolumn shifter is moved out of NEUTRAL while themachine is moving, the joystick steering FNR andgear up and gear down buttons will be deactivated,but the joystick steering lever will continue to steerthe machine. Once ground speed reaches zero,the joystick steering system will fully deactivate anddefault to the column shifter and steering wheel.

NOTE: When the joystick steering is enabled andthe park brake is on, the joystick steering iconon the monitor will blink.

NOTE: Joystick steering cannot be engaged whilemachine is moving.

T214606A

—UN—15SEP05

T214031B

—UN—13SEP05

1—Hold-Up Lever 2—Joystick SteeringActivation Switch

Deactivate Joystick Steering

Joystick steering may be deactivated by either of thefollowing methods:

• Press joystick steering activation switch and set parkbrake• Move left arm rest to raised position and set park brake

When joystick steering is deactivated, the FLC will turn offthe indicator light on the monitor.

2-2-8 013013

PN=62


HG31779,00002D3 -19-08FEB07-1/1

Park Brake Switch

CAUTION: Prevent possible injury or deathfrom machine runaway. Before disengagingpark brake, be sure engine is running andservice brakes are operational.

NOTE: Transmission clutches are disengaged whenpark brake is applied.

The park brake switch (1) has three positions:

• Park brake ON• Neutral, center detented position• Park brake release, momentary positionTo 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 (TCL) is in “Neutral”,park brake indicator will light.

If park brake is engaged when engine is runningand TCL is moved to F or R, park brakeindicator will flash, STOP indicator will flash,

T192869C

—UN—18SEP03

1—Park Brake Switch

and alarm will sound. Monitor display will read“N” until park brake is released.

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 starting engine.

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

2-2-9 013013

PN=63


MD04263,0000033 -19-19NOV08-1/1

Boom and Bucket Control Lever—One LeverDesignMove control lever forward (1) to lower boom, or rearward(4) to raise boom.

NOTE: Pilot enable/boom down switch (9) must bepushed and held down while moving control leverforward to lower boom with engine stopped.

Move control lever left (6) to roll back bucket, or right (3)to dump bucket.

Return-to-Carry (10): With Return-to-Carry switch on,push boom down lever to “Float” position (lever in fullforward detent position [2]). The boom will stop at a presetheight and lever will return to neutral position automatically.

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

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

Float (lever in full forward detent position [4]): This positionallows oil to flow in and out both ends of cylinders so thebucket can follow the contour of the ground. Manuallyrelease lever from this position.

Return-to-Dig (lever in full left detent position [7]): Bucketwill return to set dig position.

NOTE: RTD will return to the memory position settingof either the left memory position or right memoryposition, depending on which LED is illuminated.

Boom Height Kickout (lever in full rear detent position [5]):With the Boom Height Kickout switch on, lever will remainin this position until boom is at a preset height, then willreturn to neutral automatically.

DW1051735A

—UN—19NOV08

T192344E

—UN—18SEP03

1—Lower Boom2—Float3—Dump Bucket4—Raise Boom5—Boom Height Kickout

6—Rollback Bucket7—Return-to-Dig9—Pilot Enable/Boom Down

Switch10— Return-to-Carry Switch

Boom and bucket functions can be operatedsimultaneously by moving lever between positions. Forexample, to raise boom and roll back bucket, move leverbetween positions (4) and (6).

2-2-10 013013

PN=64


MD04263,0000034 -19-19NOV08-1/1

Boom and Bucket Control Lever—Two LeverDesignMove left control lever forward (1) to dump bucket, orrearward (2) to roll back bucket.

Return-to-Carry (10): With Return-to-Carry switch on,push boom down lever to “Float” position (lever in fullforward detent position [4]). The boom will stop at a presetheight and lever will return to neutral position automatically.

NOTE: Pilot enable/boom down switch (9) must bepushed and held down while moving control leverforward to lower boom with engine stopped.

Move right control lever forward (5) to lower boom orrearward (6) to raise boom.

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

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

Float (right lever in full forward detent position [4]): 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[3]): Bucket will return to set dig position.

NOTE: RTD will return to the memory position settingof either the left memory position or right memoryposition, depending on which LED is illuminated.

Boom Height Kickout (lever in full rear detent position [7]):With the Boom Height Kickout switch on, lever will remain

DW1051741A

—UN—19NOV08

T192344E

—UN—18SEP03

1—Dump Bucket2—Rollback Bucket3—Return-to-Dig4—Float5—Lower Boom

6—Raise Boom7—Boom Height Kickout9—Pilot Enable/Boom Down

Switch10— Return-to-Carry Switch

in this position until boom is at a preset height, then willreturn to neutral automatically.

2-2-11 013013

PN=65


HG31779,00002D7 -19-26JUN03-1/1

Quick Shift SwitchDown/Up

Press switch (1) to down shift from selected gear to nextlower gear when transmission is in gears 2—4. Pressagain to return to original gear.

NOTE: Machine can be programmed with QuickShift Mode in the Machine Settings Menufor down/up or down only.

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.

1—Switch

T194775A

—UN—18SEP03

Single Lever with Auxiliary Control Design Shown

T194778A

—UN—18SEP03

Two Lever with Auxiliary Control Design Shown

2-2-12 013013

PN=66


Continued on next page AM40430,00001BE -19-23MAY06-1/2

Ride Control—If Equipped

Ride control will improve machine ride and reduce tireflexing when traveling through rough terrain or at highspeeds. Ride control will also reduce material spillagefrom the bucket by cushioning boom movement.

The Ride Control Auto Speed set point is adjustable via themonitor with a range of adjustment from 3.0 km/h to 24.0km/h or 2.0 mph to 15.0 mph in increments of 0.5 units.The default Ride Control Speed set point value is 6.0 km/h.

“On” Position

NOTE: The “On” position has ride control on 100%of the time. It is best suited for fork andnon-bucket loading applications.

Once engine is running and the ride control switch (1)is cycled to the “On” position (left light illuminated), ridecontrol will remain on with or without the engine running.If key switch is turned “Off” and then “On” with ride controlswitch in “On” position, ride control is automatically turnedoff. Ride control will remain off until the ride control switchis cycled to “Off” then “On”.

“Auto” Position

NOTE: The “Auto” position is best suited for bucketloading applications since it will temporarilydisengage ride control to stop boom movementwhile crowding the pile for improved bucket loading.

With the ride control switch in the “Auto” position (bothlights illuminated), ride control will remain on as long asengine is running and ground speed is above the autospeed set point. The key switch will not turn off “Auto”ride control.

“Off” Position

Ride control is turned off (no lights illuminated).

T192456A

—UN—18SEP03

1—Ride Control Switch

Operating Ride Control

CAUTION: Prevent possible injury fromunexpected boom movement. The boom maymove up when ride control switch is turnedON. Clear all bystanders from area.

1. Make sure area around bucket is clear.

2. Start the engine.

Observe ride control switch:• If ride control switch light are not illuminated, cycleswitch to select “On” or “Auto” mode.• If switch left light is illuminated it is in “On” position,cycle switch to “Off” then “On” to activate ride control.• If switch has two lights illuminated it is in “Auto”position, ride control will automatically reactivateas soon as a ground speed greater than 6 km/h(3.5 mph) is reached and will operate until switchis turned “Off”.

2-2-13 013013

PN=67


AM40430,00001BE -19-23MAY06-2/2

AM40430,00002D5 -19-12JAN06-1/1

Discharging Ride Control Accumulator

1. Turn ride control “Off”.

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

3. Turn return-to-carry switch (1) “Off”.

4. Make sure area around bucket is clear.


5. Turn key switch to “On” without starting the engineand cycle ride control switch (2) to the “On” position(left light illuminated).

6. Press and hold the pilot enable/boom down switch (3)while holding the boom control in the float position for5 seconds.

T192464A

—UN—18SEP03

1—Return-to-Carry Switch2—Ride Control Switch

3—Pilot Enable/Boom DownSwitch

7. Turn key “Off”.

Secondary Steering—If EquippedIMPORTANT: Prevent possible damage to secondary

steering system. Stop machine immediatelyif steering pressure indicator light andaudible alarm come on while operating. THESECONDARY STEERING SYSTEM IS NOTINTENDED FOR CONTINUOUS USE.

NOTE: For optimum secondary steering performance,ensure electrical system and batteries areproperly maintained.

Steering pressure indicator (2) will flash, STOP indicator(1) will flash, and audible alarm will sound when secondarysteering system is activated. The light indicates lowhydraulic pressure resulting from mechanical malfunction,such as loss of engine power. An electrically driven pumpwill actuate to provide steering

The secondary steering system will function only whenkey switch is “On”.

T194774B

—UN—18SEP03

A—STOP Indicator B—Steering Pressure Indicator

NOTE: Secondary steering is activated if the engine dieswith key switch “On”. The secondary steering motorwill stop when the key switch is turned to “Off”.

2-2-14 013013

PN=68


TX,35,JC1943 -19-02SEP98-1/1

HG31779,0000307 -19-22JUL03-1/1

HG31779,0000308 -19-22JUL03-1/1

Differential Lock SwitchHold 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 when steering.

A—Switch

T113525—UN—13FE

B98

Boom Height Kickout Adjustment1. With engine running and pilot enable/boom down

switch (2) on, position boom in desired boom heightkickout position.

2. Press and release boom height kickout switch (1) toturn on function.

3. Press and hold boom height kickout switch untilaudible alarm sounds and light flashes.

NOTE: The boom height kickout position will remainthe same until a new position is set.

1—Boom Height KickoutSwitch


T192344C

—UN—07OCT03

Return-to-Carry Kickout Adjustment1. With engine running and pilot enable/boom down

switch (2) on, position boom in desired return-to-carryposition.

2. Press and release return-to-carry switch (1) to turnfunction on.

3. Press and hold return-to-carry switch until audiblealarm sounds.

NOTE: The return-to-carry position will remain thesame until a new position is set.

1—Return-to-Carry Switch 2—Pilot Enable/Boom DownSwitch

T192344K

—UN—07OCT03

2-2-15 013013

PN=69


CED,TX03679,5807 -19-18JUL02-1/1

Return-To-Dig Adjustment for Z-Bar Linkage Only

T131917—UN—12MAR09

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

C—Cap ScrewsD—Alignment Marks

E—Hex NutsF—Switch

NOTE: The machines hydraulic system must be atoperating temperatures and the boom and bucketcylinders should be cycled their full length 4 timesbefore setting return-to-dig to assure there iswarm hydraulic oil in the cylinders. Do not setreturn-to-dig with a cold hydraulic system!

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

NOTE: Engine speed should be approximately1500 to 1700 rpm.

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 but do not tighten. Adjust bar toalign marks on switch bracket and end of bar. Torquecap screws to 121 N·m (89 lb-ft).

SpecificationCap Screw—Torque....................................................................121 N·m

89 lb-ft

7. Loosen hex nuts (E) to switch bracket. Adjust air gap(A) between switch and adjustable bar to 5—8 mm(0.197— 0.315 in.). Torque hex nuts to 75 N·m (55lb-ft).

SpecificationAir Gap Between Switchand Bar—Distance.....................................................................5—8 mm

0.197— 0.315 in.Hex Screw—Torque......................................................................75 N·m

55 lb-ft

2-2-16 013013

PN=70


CED,OUO1021,168 -19-26FEB08-1/2

CED,OUO1021,168 -19-26FEB08-2/2

Using the Loader Bucket1. Place bucket in the return-to-dig position and lower

to ground.

NOTE: Bucket and boom can be positioned whilemachine is on-the-go.

2. Move transmission control lever to 1st or 2nd geardepending on ground condition.

3. Move forward into the material.

4. Raise and curl bucket to hold load.

EXCAVATING ON THE LEVEL: Position bucket at aslightly downward angle on ground (use bucket teeth forthis type of digging).

IMPORTANT: Prevent possible damage to thebellcrank linkage. DO NOT bulldoze with bucketin dump position. When dozing, keep bucketbottom parallel to the ground.

T7747B

B—UN—19MAY

92T7747B

C—UN—19MAY

92T7208A

R—UN—30JAN90

DOZING: With bucket parallel to ground, remove as littledirt as possible from the top surface. Let dirt spill frompartially dumped bucket to fill in low spots.

USING BOOM IN FLOAT POSITION: Place the boomin float position and bucket in return-to-dig position toprevent gouging the surface, as in cleaning concrete andsnow removal. Also use float position to avoid mixingsurface material with stockpile material.

DIGGING IN HARD, DENSE, OR TIGHTLY-PACKEDMATERIAL: To break material loose, use a gentleup-and-down motion of the bucket.

T7747B

D—UN—19MAY

92

2-2-17 013013

PN=71


CED,OUO1021,169 -19-17MAR98-1/1

BackdraggingLeveling and grading can be done with the boom in thefloat position by backdragging the loader bucket whiletraveling in reverse. (Float position allows the bucket tofollow contour of the ground.)

T7747B

G—UN—19MAY

92

2-2-18 013013

PN=72


Continued on next page CED,TX03679,5542 -19-03NOV99-1/2

Fork Attachment

T110742—UN—06AUG97

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 load positionedequally on forks. Continue to drive forward until load isagainst backrest of forks.

UNLOADING

• Always use a signal person if you cannot see theplacement area for the load. Make certain area is clearof all objects.• Lower load to ground and tilt forks to a level position.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 landing areaand ready to be set down.• If there is any indication of load instability during thelift such as movement, leaning, or swaying, stop liftingimmediately. Lower load and restock.• As load approaches desired height, slow the lift speedto a minimum. Continue the lift until load is slightlyhigher than the landing point.• After load is securely in place, retract forks clear of loadand lower forks to traveling height before moving.

DRIVING ON A SLOPE

CAUTION: Prevent possible injury from machinerollover, do not turn on slopes. Do not driveacross slopes under any circumstances.

Driving up or down slope WITH load on forks:

• Lower load near to ground.• Keep mast tilted back to retain load. Slowly drivestraight 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 less thanmast capacity or rated operating capacity of machine,whichever is less. (See Specifications chapter for machinelifting capacities.)

TRAVELING

• Operate machine controls from operator seat only.• While driving, carry load low for good visibility andmachine stability.• Downshift with care. A sudden deceleration could shiftor topple load.• A sudden reversal of travel direction could tip load orover turn the machine. Come to a gradual stop beforereversing directions.• Slow travel speed when making turns to avoid anoverturn.• Use low gear for hillside or ramp operation. Never coastdownhill with transmission in neutral. The machinecould go out of control and tip over.• Reduce speed when driving over rough terrain, carryinga heavy load, or working in a congested area. Avoidrocks, curbs, and ditches.

OPERATING TIPS

• Never use the fork attachment as a working platform.• 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. Neverclimb on the mast, boom, or attachments.• NEVER allow anyone to stand or pass under the raisedforks, 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 checked periodicallyto assure safe operation.

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

2-2-19 013013

PN=73


CED,TX03679,5542 -19-03NOV99-2/2

• Check for visibly bent forks and abrasions. If forks arebent more than 3°, replace forks. (Tapered forks are 90°nominal and standard forks are 87° nominal.) If a flatspot is clearly evident from abrasive wear, replace forks.• Inspect forks for cracks along the inside radius of heel.• Inspect hanger block welds for visible cracks.• Check to see that the spring loaded keeper, withwasher, is in position in the upper hanger block and thatthe keeper is functioning properly. (Spring in keepermust pull pin down into hanger block when pin is pulledout and released.)• Inspect hanger blocks for any sign of deformation,cracks, and wear.• Bent forks are not always detectable by sight. Removeforks and measure the interior angle of each fork todetect a bent fork.• Tapered tip forks have an interior angle of 90°. Standardsquare tip forks have an interior angle of 87°. If angleis bent more than 3°, replace fork.

FORK ADJUSTMENT

To change fork position:

CAUTION: To prevent injury, never stand underforks 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 fork byplacing a foot on tine and palm of other hand on topof fork. Alternately push fork with hand (top) and foot(lower) in a rocking motion until fork reaches desiredposition.

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

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

2-2-20 013013

PN=74


CED,TX03679,5543 -19-11DEC02-1/1

Arm Attachment

T110741—UN—06AUG97

LIFTING

CAUTION: Prevent possible injury. Nevermove the load suddenly. Never moveload over a person's head. DO NOT allowany person near load.

Keep all persons away from raised loaduntil blocks are supporting it or load issitting on the ground.

Check chart on the right window or liftingcapacity specification of this manual beforelifting with machine.

DO NOT use bucket function with arm attachment.

DO NOT lift with damaged or worn sling or chain.

1. Secure sling/chain tightly to load being lifted.

2. Coordinate hand signals with your signal man beforestarting.

3. Know location of all persons in working area.

4. Attach a hand line to load and make sure personholding it is away from load.

5. Before starting job, test your load.

• Park your machine close to load.• Attach load to machine.• Raise load 50 mm (2 in.) above the ground.• Swing the load all the way to one side.• While keeping load close to the ground, move itaway from machine.• If there is any indication of reduced stability of yourmachine, lower load to the ground.

6. Lift load only as high as necessary.

OPERATE ATTACHMENT SAFELY

An attachment may change the capabilities of yourmachine in any or all of these ways:

• Safe range of motion• Machine stability• Hydraulic performance• Engine performanceIn an area free of bystanders and obstructions, carefullyoperate the attachment to learn the available rangeof motion. Anticipate how objects manipulated by theattachment, or the attachment itself, may contact themachine, especially the operator's station.

See your dealer to match attachment demands tomachine performance.

2-2-21 013013

PN=75


HG31779,00002DB -19-26JUN03-1/1

VD76477,0001063 -19-15SEP06-1/1

Parking the Machine1. Park machine on a level surface.

2. Lower bucket to ground.

3. Move FNR (1) to N. If equipped with column FNR,engage neutral lock (2).

CAUTION: Prevent possible injury fromunexpected machine movement. Machine canunexpectedly roll or move under power, resultingin death or serious injury. Always turn engine offor push park brake switch to ON to hold 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.

1—FNR 2—Neutral Lock

T192873A

—UN—18SEP03

Column FNR Shown

T194597A

—UN—18SEP03

Joystick FNR Shown

Parking the Machine—If Equipped WithJoystick Steering1. Park machine on a level surface.



CAUTION: Prevent possible injury fromunexpected machine movement. Machine canunexpectedly roll or move under power, resultingin death or serious injury. Always turn engine offor push park brake switch to ON to hold machine.



5. Run engine at 1/2 speed without load for 2 minutesbefore stopping, to avoid damage to turbocharger.Release accelerator pedal to slow idle.




T192873A

—UN—18SEP03

T213974B

—UN—30AUG05


2-2-22 013013

PN=76


Continued on next page HG31779,00002DC -19-08MAR07-1/2

Loading Machine on a Trailer1. Keep the trailer bed clean. Put chock blocks against

trailer 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: Prevent possible injury from tipover.Position the machine so that its center line isover the center line of the truck bed. NEVERsteer the machine while on the ramp. If changingdirection is required on the ramp, unload themachine from the ramp, reposition the machineon the ground, then try loading again.

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

5. Lower all equipment onto blocks or trailer bed.


CAUTION: Prevent possible injury fromunexpected machine movement. Machine canunexpectedly roll or move under power, resultingin death or serious injury. Always turn off engineor push park brake switch to ON to hold machine.


8. Connect articulation locking bar.



T192873A

—UN—18SEP03

Column FNR Shown

T194597A

—UN—18SEP03

Joystick FNR Shown


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

2-2-23 013013

PN=77


HG31779,00002DC -19-08MAR07-2/2

12. Fasten the machine to the trailer with chains or cableswith appropriate load binders at the following tiedownpoints:

• Left Side and Right Side Rear Axle (1)• Left Side and Right Side Front Axle (2)

NOTE: If equipped with lift and tiedown eyes (3) onrear of the machine, use the lift and tiedowneyes as the tiedown points.

1—Left Side and Right SideRear Axle

2—Left Side and Right SideFront Axle

3—Lift and Tiedown Eye

T195631A

—UN—17OCT03

Left Rear Axle Shown

T195632A

—UN—17OCT03

Left Front Axle Shown

T195626A

—UN—16OCT03

2-2-24 013013

PN=78


Continued on next page VD76477,0001065 -19-08MAR07-1/2

Loading Machine on a Trailer—If EquippedWith Joystick Steering1. Keep the trailer bed clean. Put chock blocks against

trailer 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: Prevent possible injury from tipover.Position the machine so that its center line isover the center line of the truck bed. NEVERsteer the machine while on the ramp. If changingdirection is required on the ramp, unload themachine from the ramp, reposition the machineon the ground, then try loading again.

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

5. Lower all equipment onto blocks or trailer bed.


CAUTION: Prevent possible injury fromunexpected machine movement. Machine canunexpectedly roll or move under power, resultingin death or serious injury. Always turn off engineor push park brake switch to ON to hold machine.


8. Connect articulation locking bar.


T192873A

—UN—18SEP03

Column FNR Shown

T213974B

—UN—30AUG05




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

2-2-25 013013

PN=79


VD76477,0001065 -19-08MAR07-2/2

12. Fasten the machine to the trailer with chains or cableswith appropriate load binders at the following tiedownpoints:

• Left Side and Right Side Rear Counterweight (1)• Left Side and Right Side Loader Frame (2)• Mid-Frame Tiedowns (3)

NOTE: Rear tiedown locations are indicated by thecast-in tiedown symbols (4) and front and centertiedowns are indicated by tiedown decals.

1—Rear Tiedowns2—Front Tiedowns

3—Center Tiedowns4—Rear Cast-In Tiedown

Symbol

T215107A

—UN—26SEP05

T215109A

—UN—26SEP05

T215110A

—UN—26SEP05

Left Side Shown

T215483A

—UN—29SEP05

2-2-26 013013

PN=80


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

Towing Procedure

T138646—UN—20MAR01

1—Front Driveshaft2—Park Brake Fitting Plug

3—Park Brake Hose4—Telescoping Driveshaft

5—Rear Driveshaft

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

IMPORTANT: Engine cannot be started by towing.

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

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

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: Articulation locking bar is installed to preventweaving as machine is towed.

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

4. Move FNR to “Neutral” position. If equipped withcolumn FNR, engage neutral lock.

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. Goto Step 6.

6. Stop engine.

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

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

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

NOTE: Keep hydraulic hand operated pump filled with oil.

2-2-27 013013

PN=81


OUOE003,000009E -19-18JUL02-2/2

HG31779,0000164 -19-28OCT02-1/1

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

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

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

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

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

CAUTION: Prevent possible injury fromunexpected machine movement. Never

attempt to remove driveshafts withoutblocking front and rear tires.

11. Remove driveshafts if a hand operated pump is notavailable 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 for installationinformation.

Lifting the Machine

CAUTION: Prevent possible injury fromunexpected machine movement. Clear allbystanders from lifting area. Select correct liftingcable strength for weight of machine. Test lift byraising machine 0.3 m (1 ft) off the ground.

SpecificationMachine—744J—Ap-proximate Weight..................................................................... 23 360 kg

51,500 lbMachine—824J—Ap-proximate Weight..................................................................... 26 172 kg

57,700 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 machineas it is lifted.

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

5. Lift machine and swing to unloading area.

A—Cable

T7477AV—UN—19MAR91

2-2-28 013013

PN=82

Maintenance—Machine

DX,FUEL1 -19-11APR11-1/1

DX,FUEL5 -19-14APR11-1/1

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. Renewable diesel fuel produced byhydrotreating animal fats and vegetable oils is basicallyidentical to petroleum diesel fuel. Renewable diesel thatmeets EN 590 or ASTM D975 is acceptable for use at allpercentage mixture levels.

Required Fuel Properties

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

Cetane number of 43 minimum. Cetane number greaterthan 47 is preferred, especially for temperatures below–20°C (–4°F) or elevations above 1500 m (5000 ft.).

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

Fuel lubricity should pass a maximum scar diameter of0.45 mm as measured by ASTM D6079 or ISO 12156-1.

Diesel fuel quality and sulfur content must comply withall existing emissions regulations for the area in whichthe engine operates. DO NOT use diesel fuel with sulfurcontent greater than 10 000 mg/kg (10 000 ppm).

Sulfur content for Interim Tier 4 and Stage III B engines

• Use ONLY ultra low sulfur diesel (ULSD) fuel with amaximum of 15 mg/kg (15 ppm) sulfur content.

Sulfur Content for Tier 3 and Stage III A Engines

• Use of diesel fuel with sulfur content less than 1000mg/kg (1000 ppm) is RECOMMENDED• Use of diesel fuel with sulfur content 1000–5000 mg/kg(1000–5000 ppm) REDUCES oil and filter changeintervals.

• BEFORE using diesel fuel with sulfur content greaterthan 5000 mg/kg (5000 ppm), contact your John Deeredealer

Sulfur Content for Tier 2 and Stage II Engines

• Use of diesel fuel with sulfur content less than 500mg/kg (500 ppm) is RECOMMENDED.• Use of diesel fuel with sulfur content 500–5000 mg/kg(500–5000 ppm) REDUCES the oil and filter changeinterval• BEFORE using diesel fuel with sulfur content greaterthan 5000 mg/kg (5000 ppm), contact your John Deeredealer

Sulfur Content for Other Engines

• Use of diesel fuel with sulfur content less than 5000mg/kg (5000 ppm) is recommended.• Use of diesel fuel with sulfur content greater than 5000mg/kg (5000 ppm) REDUCES the oil and filter changeintervals.

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

IMPORTANT: Improper fuel additive usage maycause damage on fuel injection equipmentof diesel engines.

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States,Canada, and the European Union have adequate lubricityto ensure proper operation and durability of fuel injectionsystem components. However, diesel fuels manufacturedin some areas of the world may lack the necessary lubricity.

IMPORTANT: Make sure the diesel fuel usedin your machine demonstrates goodlubricity characteristics.

Fuel lubricity should pass a maximum scar diameter of0.45 mm as measured by ASTM D6079 or ISO 12156-1.

If fuel of low or unknown lubricity is used, add John DeereFuel-Protect Diesel Fuel Conditioner (or equivalent) atthe specified concentration.

Lubricity of Biodiesel Fuel

Fuel lubricity can improve significantly with biodieselblends up to B20 (20% biodiesel). Further increase inlubricity is limited for biodiesel blends greater than B20.

3-1-1 013013

PN=83


Continued on next page DX,FUEL7 -19-29AUG12-1/2

Biodiesel Fuel

Biodiesel fuel is comprised of mono-alkyl esters of longchain fatty acids derived from vegetable oils or animalfats. Biodiesel blends are biodiesel mixed with petroleumdiesel fuel on a volume basis.

Before using fuel containing biodiesel, review theBiodiesel Use Requirements and Recommendations inthis Operator’s Manual.

Environmental laws and regulations can encourage orprohibit the use of biofuels. Operators should consultwith appropriate governmental authorities prior to usingbiofuels.

All John Deere Engines with Exhaust Filter (Released2011 and After)

While 5% blends (B5) are preferred, biodieselconcentrations up to a 20% blend (B20) in petroleumdiesel fuel can be used. Biodiesel blends up to B20can be used ONLY if the biodiesel (100% biodiesel orB100) meets ASTM D6751, EN 14214, or equivalentspecification. Expect a 2% reduction in power and a 3%reduction in fuel economy when using B20.

Biodiesel concentrations above B20 can harm theengine’s emission control systems and should not beused. Risks include, but are not limited to, more frequentstationary regeneration, soot accumulation, and increasedintervals for ash removal.

John Deere approved fuel conditioners, which containdetergent and dispersant additives, are required whenusing B20, and are recommended when using lowerbiodiesel blends.

All John Deere Engines Excluding Exhaust Filter(Primarily Released Prior to 2012)

While 5% blends (B5) are preferred, biodieselconcentrations up to a 20% blend (B20) in petroleumdiesel fuel can be used. Biodiesel blends up to B20can be used ONLY if the biodiesel (100% biodiesel orB100) meets ASTM D6751, EN 14214, or equivalentspecification. Expect a 2% reduction in power and a 3%reduction in fuel economy when using B20.

These John Deere engines can operate on biodieselblends above B20 (up to 100% biodiesel). Operate atlevels above B20 ONLY if the biodiesel is permitted by lawand meets the EN 14214 specification (primarily availablein Europe). Engines operating on biodiesel blends aboveB20 might not fully comply with or be permitted by allapplicable emissions regulations. Expect up to a 12%reduction in power and an 18% reduction in fuel economywhen using 100% biodiesel.

John Deere approved fuel conditioners, which containdetergent and dispersant additives, are required whenusing B20, and are recommended when using lowerbiodiesel blends.

Biodiesel Use Requirements and Recommendations

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

Biodiesel users in the U.S. are strongly encouraged topurchase biodiesel blends from a BQ-9000 CertifiedMarketer and sourced from a BQ-9000 AccreditedProducer (as certified by the National Biodiesel Board).Certified Marketers and Accredited Producers can befound at the following website: http://www.bq9000.org.

Biodiesel contains residual ash. Ash levels exceeding themaximums allowed in either ASTM D6751 or EN14214can result in more rapid ash loading and require morefrequent cleaning of the Exhaust Filter (if present).

The fuel filter can require more frequent replacement,when using biodiesel fuel, particularly if switching fromdiesel. Check engine oil level daily prior to starting engine.A rising oil level can indicate fuel dilution of the engine oil.Biodiesel blends up to B20 must be used within 90 daysof the date of biodiesel manufacture. If used, biodieselblends above B20 must be used within 45 days from thedate of biodiesel manufacture.

When using biodiesel blends up to B20, the followingmust be considered:

• Cold weather flow degradation• Stability and storage issues (moisture absorption,microbial growth)• Possible filter restriction and plugging (usually a problemwhen first switching to biodiesel on used engines.)• Possible fuel leakage through seals and hoses(primarily an issue with older engines)• Possible reduction of service life of engine componentsRequest a certificate of analysis from your fuel distributorto ensure that the fuel is compliant with the specificationsprovided in this Operator’s Manual.

Consult your John Deere dealer for approved fuelconditioners to improve storage and performance withbiodiesel fuels.

The following must also be considered if using biodieselblends above B20:

• Possible coking or blocked injector nozzles, resulting inpower loss and engine misfire if John Deere approvedfuel conditioners are not used• Possible crankcase oil dilution (requiring more frequentoil changes)• Possible lacquering or seizure of internal components• Possible formation of sludge and sediments• Possible thermal oxidation of fuel at elevatedtemperatures• Possible compatibility issues with other materials(including copper, lead, zinc, tin, brass, and bronze)used in fuel handling equipment• Possible reduction in water separator efficiency• Possible damage to paint if exposed to biodiesel

3-1-2 013013

PN=84


DX,FUEL7 -19-29AUG12-2/2

TX,45,JC2126 -19-15AUG97-1/1

DX,FUEL6 -19-14APR11-1/1

DX,FUEL4 -19-14APR11-1/1

• Possible corrosion of fuel injection equipment• Possible elastomeric seal and gasket materialdegradation (primarily an issue with older engines)• Possible high acid levels within fuel system• Because biodiesel blends above B20 contain moreash, using blends above B20 can result in more rapidash loading and require more frequent cleaning of theExhaust Filter (if present)

IMPORTANT: Raw pressed vegetable oils areNOT acceptable for use as fuel in anyconcentration in John Deere engines. Theiruse could cause engine failure.

Low Sulfur Diesel Fuel ConditionerWhen possible, use existing fuel formulations for enginesused off-highway. This fuel will not require any additivesto provide good performance and engine reliability.However, many local fuel distributors will not carry bothlow and regular sulfur diesel fuels.

If the local fuel distributor will supply only low sulfur fuel,order and use John Deere PREMIUM DIESEL FUEL

CONDITIONER. It provides lubricating properties alongwith other useful benefits, such as cetane improver,anti-oxidant, fuel stabilizer, corrosion inhibitor and others.John Deere PREMIUM DIESEL FUEL CONDITIONER isspecifically for use with low sulfur fuels. Nearly all otherdiesel fuel conditioners only improve cold weather flow andstabilize long-term fuel storage. They do not contain thelubrication additives needed by rotary fuel injection pumps.

Testing Diesel FuelA fuel analysis program can help to monitor the qualityof diesel fuel. The fuel analysis can provide criticaldata such as cetane number, fuel type, sulfur content,water content, appearance, suitability for cold weather

operations, bacteria, cloud point, acid number, particulatecontamination, and whether the fuel meets specification.

Contact your John Deere dealer for more information ondiesel fuel analysis.

Handling and Storing Diesel Fuel

CAUTION: Reduce the risk of fire. Handle fuelcarefully. DO NOT fill the fuel tank when engineis running. DO NOT smoke while you fill thefuel tank or service the fuel system.

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

Keep all storage tanks as full as practicable to minimizecondensation.

Ensure that all fuel tank caps and covers are installedproperly to prevent moisture from entering. Monitor watercontent of the fuel regularly.

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

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

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

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

3-1-3 013013

PN=85


DX,FUEL10 -19-20APR11-1/1

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere diesel engines are designed to operateeffectively in cold weather.

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

Use Winter Grade Fuel

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

Cloud point is the temperature at which wax will begin toform in the fuel and this wax causes fuel filters to plug.Pour point is the lowest temperature at which movementof the fuel is observed.

NOTE: On average, winter grade diesel fuel has a lowerBtu (heat content) rating. Using winter grade fuelmay reduce power and fuel efficiency, but should notcause any other engine performance effects. Checkthe grade of fuel being used before troubleshootingfor low power complaints in cold weather operation.

Air Intake Heater

An air intake heater is an available option for someengines to aid cold weather starting.

Ether

An ether port on the intake is available to aid cold weatherstarting.

CAUTION: Ether is highly flammable. Do notuse ether when starting an engine equippedwith glow plugs or an air intake heater.

Coolant Heater

An engine block heater (coolant heater) is an availableoption to aid cold weather starting.

Seasonal Viscosity Oil and Proper CoolantConcentration

Use seasonal grade viscosity engine oil based on theexpected air temperature range between oil changesand a proper concentration of low silicate antifreeze asrecommended. (See DIESEL ENGINE OIL and ENGINECOOLANT requirements in this section.)

Diesel Fuel Flow Additive

Use John Deere Fuel-Protect Diesel Fuel Conditioner(winter formula), which contains anti-gel chemistry, orequivalent fuel conditioner to treat non-winter grade fuel(No. 2-D in North America) during the cold weatherseason. This generally extends operability to about 10°C(18°F) below the fuel cloud point. For operability at evenlower temperatures, use winter grade fuel.

IMPORTANT: Treat fuel when outside temperaturedrops below 0°C (32°F). For best results, usewith untreated fuel. Follow all recommendedinstructions on label.

BioDiesel

When operating with biodiesel blends, wax formation canoccur at warmer temperatures. Begin using John DeereFuel-Protect Diesel Fuel Conditioner (winter formula) at5°C (41°F) to treat biodiesel fuels during the cold weatherseason. Use B5 or lower blends at temperatures below0°C (32°F). Use only winter grade petroleum diesel fuelat temperatures below -10°C (14°F).

Winterfronts

Use of fabric, cardboard, or solid winterfronts is notrecommended with any John Deere engine. Their usecan result in excessive engine coolant, oil, and chargeair temperatures. This can lead to reduced engine life,loss of power and poor fuel economy. Winterfronts mayalso put abnormal stress on fan and fan drive componentspotentially causing premature failures.

If winterfronts are used, they should never totally closeoff the grill frontal area. Approximately 25% area in thecenter of the grill should remain open at all times. At notime should the air blockage device be applied directlyto the radiator core.

Radiator Shutters

If equipped with a thermostatically controlled radiatorshutter system, this system should be regulated in such away that the shutters are completely open by the time thecoolant reaches 93°C (200°F) to prevent excessive intakemanifold temperatures. Manually controlled systems arenot recommended.

If air-to-air aftercooling is used, the shutters must becompletely open by the time the intake manifold airtemperature reaches the maximum allowable temperatureout of the charge air cooler.

For more information, see your John Deere dealer.

3-1-4 013013

PN=86


AM40430,00000AA -19-03NOV08-1/1

DX,ENOIL7 -19-11APR11-1/1

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 in thismanual apply to both conventional and synthetic oils.

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

Avoid mixing different brands or types of oils. Oilmanufacturers blend base stock and additives tocreate their oils and to meet certain specifications andperformance requirements. Mixing different oils caninterfere with proper functioning of these formulations anddegrade lubricant performance.

Consult your authorized John Deere dealer to obtainspecific information and recommendations.

Diesel Engine Oil

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

John Deere Plus-50™ II oil is preferred.

John Deere Plus-50™ is also recommended.

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

• John Deere Torq-Gard™• API Service Category CJ-4• API Service Category CI-4 PLUS• API Service Category CI-4• API Service Category CH-4• ACEA Oil Sequence E9• ACEA Oil Sequence E7• ACEA Oil Sequence E6• ACEA Oil Sequence E5• ACEA Oil Sequence E4• ACEA Oil Sequence E3

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must complywith all existing emissions regulations for the area inwhich the engine operates.

DO NOT use diesel fuel with sulfur content greater than10 000 mg/kg (10 000 ppm).

SA

E 0

W-4

0

50 Co

40 Co

30 Co

20 Co

10 Co

0 C o

-10 Co

-20 Co

-30 Co

-40 Co

122 Fo

50 Fo

32 Fo

14 Fo

-4 Fo

-22 Fo

-40 Fo

104 Fo

68 Fo

86 Fo

SA

E 5

W-3

0

SA

E 1

0W-3

0

SA

E 1

0W-4

0

SA

E 1

5W-4

0

TS1689

—UN—18JU

L07

Oil Viscosities for Air Temperature Ranges

Plus-50 is a trademark of Deere & CompanyTorq-Gard is a trademark of Deere & Company

3-1-5 013013

PN=87


DX,ENOIL12 -19-03AUG09-1/1

Diesel Engine Oil and Filter Service Intervals

The oil and filter service intervals in the following tableshould be used as guidelines. Actual service intervalsalso depend on operation and maintenance practices. Itis suggested to use oil analysis to determine the actualuseful life of the oil and to aid in selection of the properoil and filter service interval.

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

Engine Oil and Filter Service IntervalsStandard Drain Oil Pan Extended Drain

Oil PanFuel Sulfur Less than 0.05% (500 mg/kg)Plus-50 375 hours 500 hoursOther Oils 250 hours 250 hoursFuel Sulfur 0.05 - 0.50% (500 - 5000 mg/kg)Plus-50 275 hours 400 hoursOther Oils 150 hours 150 hoursFuel Sulfur 0.50 - 1.00% (5000 - 10 000 mg/kg)Plus-50 187 hours 250 hoursOther Oils 125 hours 125 hoursThe service interval of “Other Oils” may be extended only if oil analysisis performed to determine the actual service life, to a maximum notto exceed that of Plus-50.

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

• Use of diesel fuel with sulfur content less than 0.05%(500 mg/kg) is strongly recommended.

• Use of diesel fuel with sulfur content 0.05% (500 mg/kg)to 0.50% (5000 mg/kg) may result in REDUCED oil andfilter change intervals as shown in the table.• BEFORE using diesel fuel with sulfur content greaterthan 0.50% (5000 mg/kg), contact your John Deeredealer.

IMPORTANT: When using biodiesel blends greaterthan B20, reduce the oil and filter serviceinterval by 50% or monitor engine oil basedon test results from Oilscan.

Oil types in the table include:

• John Deere Plus-50™ II and John Deere Plus-50 oils.• “Other Oils” include John DeereTorq-Gard Supreme™,API CJ-4, API CI-4 PLUS, API CI-4, API CH-4, ACEAE9, ACEA E7, ACEA E6, ACEA E5, ACEA E4, or ACEAE3 oils.

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

• Engine equipped with an extended draininterval oil pan• Use of diesel fuel with sulfur content lessthan 0.05% (500 mg/kg)• Use of John Deere Plus-50™ II or JohnDeere Plus-50 oil• Use of an approved John Deere oil filter

Plus-50 is a trademark of Deere & CompanyTorq-Gard Supreme is a trademark of Deere & Company

3-1-6 013013

PN=88


CED,TX03679,5800 -19-14JUN00-1/1

DX,GREA1 -19-14APR11-1/1

Transmission, Hydraulic System, Park Brake,and Differential OilUse 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-GARD1™oil when abiodegradable fluid is required.

TS1660

—UN—10OCT97

HY-GARD is a registered trademark of Deere & CompanyBIO-HY-GARD is a trademark of Deere & Company1 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.

GreaseUse grease based on NLGI consistency numbers and theexpected air temperature range during the service interval.

John Deere SD Polyurea Grease is preferred.

The following greases are also recommended:

• John Deere HD Lithium Complex Grease• John Deere HD Water Resistant Grease• John DeereGREASE-GARD™Other greases may be used if they meet the following:

• NLGI Performance Classification GC-LBIMPORTANT: Some types of grease thickeners are not

compatible with others. Consult your greasesupplier before mixing different types of grease.

TS1673

—UN—31OCT03

Greases for Air Temperature Ranges

GREASE-GARD is a trademark of Deere & Company

3-1-7 013013

PN=89


DX,COOL3 -19-14APR11-1/1

Heavy Duty Diesel Engine Coolant

The engine cooling system is filled to provide year-roundprotection against corrosion and cylinder liner pitting, andwinter freeze protection to -37°C (-34°F). If protection atlower temperatures is required, consult your John Deeredealer for recommendations.

The following engine coolants are preferred:

• John Deere COOL-GARD™ II Premix• John Deere COOL-GARD II PG Premix

Use John Deere COOL-GARD II PG Premix when anon-toxic coolant formulation is required.

Additional Recommended Coolants

The following engine coolant is also recommended:

• John Deere COOL-GARD II Concentrate in a 40–60%mixture of concentrate with quality water.

John Deere COOL-GARD II Premix, COOL-GARD II PGPremix, and COOL-GARD II Concentrate coolants do notrequire use of supplemental coolant additives.

Other Coolants

John Deere COOL-GARD II and COOL-GARD II PGcoolants might not be available in the geographical areawhere service is performed.

If these coolants are unavailable, use a coolantconcentrate or prediluted coolant intended for use withheavy duty diesel engines and with a minimum of thefollowing chemical and physical properties:

• Is formulated with a quality nitrite-free additive package.• Provides cylinder liner cavitation protection according toeither the John Deere Cavitation Test Method or a fleetstudy run at or above 60% load capacity• Protects the cooling system metals (cast iron, aluminumalloys, and copper alloys such as brass) from corrosion

The additive package must be part of one of the followingcoolant mixtures:

• ethylene glycol or propylene glycol base prediluted(40—60%) heavy duty coolant• ethylene glycol or propylene glycol base heavyduty coolant concentrate in a 40—60% mixture ofconcentrate with quality water

Water Quality

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycol andpropylene glycol base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealingadditives or antifreeze that containssealing additives.

Do not mix ethylene glycol and propyleneglycol base coolants.

Do not use coolants that contain nitrites.

COOL-GARD is a trademark of Deere & Company

3-1-8 013013

PN=90

Maintenance—Periodic Maintenance

VD76477,000146E -19-08MAR07-1/1

HG31779,00002DE -19-26JUN03-1/1

Service Machine at Specified IntervalsLubricate, make service checks and adjustments atintervals shown on the periodic maintenance chart (1) andon the following pages.

Service items at multiples of the original requirement.For example, at 500 hours also service those items (ifapplicable) listed under 250 hours, 100 hours, 50 hoursand 10 hours or daily.

IMPORTANT: See Operator's Manual service intervalssection or periodic maintenance chart onmachine for proper servicing.

NeverGrease™ Pin Joints do not require lubrication.Machines equipped with theNeverGrease™ Pin Jointoption still require some service maintenance points forgrease in specified areas. These are listed on the periodicmaintenance chart on the machine and in the operator'smanual listed under service intervals.

T146537B

—UN—10OCT01

1—Periodic Maintenance Chart

NeverGrease is a trademark of Deere & Company

Check Hour Meter RegularlyCheck hour meter display (1) to determine when yourmachine needs periodic maintenance.

Intervals on the periodic maintenance chart are foroperating in normal conditions. If you operate yourmachine in severe conditions, you should service it atSHORTER INTERVALS.

1—Hour Meter Display

4F2 3 4

AUTO ODM HOURS SPEED

rpm

323.3

9501

1

T193351—19—13OCT03

3-2-1 013013

PN=91


VD76477,000106C -19-15SEP06-1/1

Prepare Machine for MaintenanceBefore performing maintenance procedures given in thefollowing sections, and before leaving the operator’s seat,park the machine as described below unless anotherposition is specified in the procedure.

1. Lower equipment to ground.

If bucket needs to be off ground for maintenance, seeBoom Lock. (Section 3-2.)

2. Stop engine.

3. Turn key switch to “On”.

4. Press return-to-carry switch (1) to “Off” position, ifequipped.


5. Cycle ride control switch (2) from “OFF” (no lights)to “ON” (left light only illuminated), if equipped, todischarge ride control accumulator.

6. Press and hold pilot enable/boom down switch (3)while moving control lever forward to lower boom.

7. While still holding the pilot enable/boom down switch,put boom in float position for 5 seconds, then cycleeach hydraulic control lever to relieve pressure.


CAUTION: Prevent possible injury fromunexpected machine movement. Push parkbrake switch to ON to hold machine.


10. Turn key switch to “Off”. If maintenance must beperformed with engine running, do not leave machineunattended.

11. Turn battery disconnect switch OFF, if equipped.

1—Return-to-Carry Switch2—Ride Control Switch3—Pilot Enable/Boom Down

Switch

4—FNR5—Neutral Lock Lever

T192464A

—UN—18SEP03

T192873C

—UN—18SEP03

Column FNR Shown

T194851B

—UN—18SEP03

Joystick FNR Shown

T213837B

—UN—24AUG05

Joystick Steering FNR Shown - If Equipped

3-2-2 013013

PN=92


HG31779,0000171 -19-29OCT02-1/1

HG31779,0000172 -19-23MAY06-1/1

Locking Machine Frame

CAUTION: Prevent possible injury fromunexpected machine movement. Connectframe locking bar to both frames before youwork in frame 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 andend of locking bar. Install quick lock ring to securelocking bar in place.

1—Quick Lock Ring2—Locking Pin

3—Locking Bar

T161062B

—UN—29OCT02

T161061B

—UN—29OCT02

Boom Lock

CAUTION: Prevent possible crushing injuryfrom falling boom. Always install boom lockbefore working on or around this machinewith the boom 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. Perform the Prepare Machine for Maintenanceprocedure. (Section 3-2).

6. Before removing boom lock from cylinder, raise boomslightly to relieve pressure. Return boom lock tostorage position on side of machine and tighten handhold.

1—Boom Lock 2—Hand Bolt

T161064B

—UN—29OCT02

T161065B

—UN—29OCT02

3-2-3 013013

PN=93


TX,50,JC1806 -19-13OCT03-1/2

TX,50,JC1806 -19-13OCT03-2/2

HG31779,00002DF -19-26JUN03-1/1

Opening Engine Side Shields and ServiceDoors

CAUTION: Prevent possible injury from engineservice door closing. Always keep servicedoor in the open locked position whenservicing the engine area.

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

A—Latch

T106380B

—UN—24JAN97

2. Open service door to full extent. Gas cylinder (A) willhold door in place.

A—Cylinder

T131518B

—UN—07JU

N00

Opening Grille DoorPress down on release lever (1) to open grille door fully.Door will automatically lock open.

Rotate stop (2) to release door lock.

1—Release Lever 2—Stop

T139740C

—UN—10AUG01

T146005B

—UN—26SEP01

3-2-4 013013

PN=94


CED,OUOE002,1352 -19-01NOV02-1/1

CED,OUOE002,1462 -19-08MAY98-1/1

AM40430,00002FE -19-19OCT11-1/1

Fuel Tank

CAUTION: Handle fuel carefully. If the engine is hotor running, do not fill the fuel tank. Do not smokewhile you fill fuel tank or work on fuel system.

To avoid condensation, fill the fuel tank at the end of eachday’s operation.

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

Fuel Tank—Capacity....................................................................... 462 L122 gal

Check Windshield Washer Fluid LevelOpen lower left engine side shield.

Check fluid in windshield washer bottle (A).

During winter season, use all season windshield washerfluid which will not freeze.

A—Windshield Washer Bottle

T115303—UN—11MAY

98

Fluid Analysis Program Test Kits and 3-WayCoolant Test KitFluid Analysis Program Test Kits and the 3-Way CoolantTest Kit are John Deere fluid sampling products to help youmonitor machine maintenance and system condition. Theobjective of a fluid sampling program is to ensure machineavailability when you need it and to reduce repair costs byidentifying potential problems before they become critical.

Engine, hydraulic, power train, and coolant samplesshould be taken from each system on a periodic basis,usually prior to a filter and/or fluid change interval. Certainsystems require more frequent sampling. Consult yourauthorized John Deere dealer on a maintenance programfor your specific application. Your authorized John Deeredealer has the sampling products and expertise to assistyou in lowering your overall operating costs through fluidsampling.

TX1003513A

—UN—20FE

B06

Fluid Analysis Kits

3-2-5 013013

PN=95


Continued on next page CS58540,0000032 -19-21JAN13-1/2

Service IntervalsModel: 744J/824J Loaders PIN/Serial Number:Hour Meter Reading:

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

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

As Required□ Inspect tires and check pressure □ Inspect fuel filler drain hose and tank breather hose□ Tighten wheel retainer nuts □ Replace primary, final and inline fuel filters□ Clean or replace air cleaner elements □ Drain water separator bowl□ Check and clean air inlet cover □ Check and clean cab fresh air filter□ Inspect belts, A/C compressor and alternator □ Check and clean cab recirculating air filter

Every 10 Hours or Daily□ Check coolant recovery tank level □ Check hydraulic system oil level□ Clean or replace air cleaner dust unloader valve □ Check transmission oil level□ Check engine oil level □ Inspect external seal—if equipped

Every 100 Hours□ Grease loader linkage and cylinder pivots (if equipped) □ Grease oscillating rear axle□ Grease front and rear steering cylinder pivots 744J (S.N. —612699), 824J (S.N. —612710)

Initial Service—250 Hours1

□ Change engine break-in oil and replace filter □ Change front and rear differential/axle oil□ Replace hydraulic system return filter1Perform initial service once after the first 250 hours of operation.

Every 250 Hours□ Grease front driveline sliding joints □ Check radiator coolant level□ Take engine oil sample

Every 500 Hours□ Grease rear driveline sliding joints and driveline U-joints □ Replace hydraulic system return filter□ Check air intake hoses □ Replace hydraulic reservoir breather filter□ Check battery electrolyte level and terminals □ Check park brake oil level□ Replace primary and final fuel filters □ Check front and rear differential/axle oil level□ Change engine oil and replace filter □ Take transmission oil sample□ Take diesel fuel sample □ Take axle oil sample□ Take engine coolant sample □ Take hydraulic oil sample

Every 1000 Hours□ Replace air cleaner dust unloader valve □ Check radiator hoses□ Replace air cleaner elements □ Replace transmission oil filter□ Clean engine crankcase vent tube □ Grease frame hinge pivots□ Change in-line fuel filter □ Change park brake oil

Every 2000 Hours□ Check and adjust engine valve lash and electronic unit injector preload □ Re-run clutch calibration□ Drain and refill transmission oil (normal operation)2 □ Change front and rear differential/axle oil

3-2-6 013013

PN=96


CS58540,0000032 -19-21JAN13-2/2

□ Clean axle differential recirculation screen (if equipped)3 □ Clean magnetic axle oil drain plug□ Replace split seal—if equipped

Every 3000 Hours□ Change hydraulic system oil □ Replace differential lock return filters (if equipped)□ Clean hydraulic system fill strainer

Every 4000 Hours□ Replace engine crankshaft damper1Perform initial service once after the first 250 hours of operation.2Service intervals should be reduced in severe applications, which run the torque converter at high loads for more than approximately 25% of thetime. (Examples may include basement digging, land clearing, etc.)3Axle differential recirculation screen is equipped with the optional axle oil coolers.

3-2-7 013013

PN=97


Continued on next page CS58540,0000033 -19-30JAN13-1/2

Required PartsREQUIRED PARTS

Ensure 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.

Description PartNumber

InitialService1-

250Hours

Every250

Hours

Every500

Hours

Every1000Hours

Every2000Hours

Every3000Hours

Every4000Hours

Engine Oil Filter RE58935 1 1 1 1 1 1Primary Fuel Filter:744J (S.N. —044931)824J (S.N. —052220)

RE507284 1 1 1 1 1

744J (S.N. 044932—)824J(S.N. 052221—)

RE515345 1 1 1 1 1

Final Fuel Filter RE506428 1 1 1 1 1In-Line Fuel Filter AT223493 1 1 1 1Transmission Filter:744J/824J (S.N. —590067) AT147496 1 1 1 1744J/824J (S.N. 590068—) AT336140 2 2 2 2Hydraulic System Return Filter AT310905 2 2 2 2 2 2Air Filter (Primary) AT220822 1 1 1 1Air Filter (Secondary) AT203051 1 1 1 1Dust Unloader Valve R48568 1 1 1 1Hydraulic Reservoir Breather Filter AM39653 1 1 1 1 1Split Seals—If Equipped

• Boom to Bucket Joint AT341093 4 4 4

• Bucket to Bucket Link AT410593 2 2 2

• Bucket Link to Bellcrank AT410593 2 2 2

• Bellcrank to Boom AT341092 2 2 2

• Steering Cylinder T277557 4 4 4Differential Lock Return Filter(if equipped)

T19044 2

Engine Crankshaft Damper:744J/824J (S.N. —053079) RE65565 1744J/824J (S.N. 053080—) RE523267 1External Seal AT341092 As RequiredJohn Deere PLUS-50™ II Oil TY266744 38.0 L

(10.0 gal)38.0 L

(10.0 gal)38.0 L

(10.0 gal)38.0 L

(10.0 gal)38.0 L

(10.0 gal)38.0 L

(10.0 gal)HY-GARD™ Transmission and Hydraulic Oil:744J TY63544 92.0 L

(24.0 gal)0.6 L

(20.0 oz.)120.6 L(32.0 gal)

144.6 L(38.0 gal)

120.6 L(32.0 gal)

744J—With Optional Wide Axle TY63544 98.0 L(26.0 gal)

0.6 L(20.0 oz.)

126.6 L(34.0 gal)

144.6 L(38.0 gal)

126.6 L(34.0 gal)

824J TY63544 92.0 L(24.0 gal)

0.6 L(20.0 oz.)

120.6 L(32.0 gal)

144.6 L(38.0 gal)

120.6 L(32.0 gal)

Coolant Extender TY26603 As RequiredFluid Analysis Kits:5

Diesel Engine Oil AT346594 1 1 1 1 1 1Transmission Oil AT346594 1 1 1 1 1Axle Oil AT346594 2 2 2 2 2Hydraulic and Hydrostatic Oil AT346594 1 1 1 1 1Diesel Fuel AT180344 1 1 1 1 1Engine Coolant TY26873 1 1 1 1 1COOL-GARD™ II Test Strips TY26605 1 1 1 1 1

3-2-8 013013

PN=98


CS58540,0000033 -19-30JAN13-2/2

1Perform initial service once after the first 250 hours of operation.4For recommended oil type and oil viscosities based on operating temperatures, see Maintenance—Machine. (Section 3-1.)5Based on fluid analysis results, intervals may need to be adjusted for your operating conditions. Consult your local John Deere dealer.

PLUS-50 is a trademark of Deere & CompanyCOOL-GARD is a trademark of Deere & Company

3-2-9 013013

PN=99

Maintenance—As Required

CED,OUO1021,181 -19-17MAR98-1/1

Check Tire Pressure

CAUTION: Explosive separation of a tire and rimparts can cause serious injury or death.

Alwaysmaintain the correct tire pressure. DONOTinflate tires above the recommended pressure.

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 underinflated beforereinflating the tire. Damage to the rim and tiremay have developed. Call your authorized dealeror a qualified repair service to inspect the rim andtire assembly and make necessary repairs.

When inflating tires, use a clip-on chuck andextension hose long enough to allow you to standto one side and NOT in front of or over the tireassembly. Use a safety cage if available.

NEVER cut or weld on an inflated tire orrim assembly. Heat from welding couldcause an increase in pressure and mayresult in tire explosion.

Do not attempt to mount a tire if you do nothave the proper equipment and experience toperform the job. Have it done by your authorizeddealer 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.

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.

A—Pipe Cap


T108057B

—UN—12MAR97

T87502

—UN—21OCT88

3-3-1 013013

PN=100


Continued on next page TX,55,JC1225 -19-25JUN96-1/2

Tire Pressures (744J)The following tables indicate the recommended TirePressures (PSI) for 50,000 pound loader with 5.25 cubicyard bucket, handling 3400 pound per cubic yard material .

Recommended ply ratings for Bias Ply Tires and starratings for Radial Tires in parenthesis.

Addition of fluids, water and/or calcium chloride does notaffect recommended tire pressures.

To increase side-to-side stability, increase front tirepressures in 2 PSI increments.

To adjust fore-aft stability, increase or decrease rear tirepressures in 2 PSI increments.

See Tire Manufacturer's charts for detailed load, pressureand distance recommendations.

Bridgestone Firestone General GoodyearSize Front Rear P-

lyR-a-t-i-n-g

Front Rear P-lyR-a-t-i-n-g



23.5-25 L2, L2/E2,L2/E2/G2,L3, L3/E3,L3/E3/G3,L4, L5

475 kPa(4.75 bar)(69 psi)

241 kPa(2.41 bar)(35 psi)

24

475 kPa(4.75 bar)(69 psi)

241 kPa(2.41 bar)(35 psi)

24

475 kPa(4.75 bar)(69 psi)

241 kPa(2.41 bar)(35 psi)

24

482 kPa(4.82 bar)(70 psi)

241 kPa(2.41 bar)(35 psi)

24

26.5-25 L2, L2/E2,L2/E2/G2,L3, L3/E3,L3/E3/G3,L4, L5

324 kPa(3.24 bar)(47 psi)

172 kPa(1.72 bar)(25 psi)

20

324 kPa(3.24 bar)(47 psi)

158 kPa(1.58 bar)(23 psi)

20

324 kPa(3.24 bar)(47 psi)

158 kPa(1.58 bar)(23 psi)

20

310 kPa(3.10 bar)(45 psi)

158 kPa(1.58 bar)(23 psi)

20

29.5-25 L2, L2/E2,L2/E2/G2L3, L3/E3,L3/E3/G3

303 kPa(3.03 bar)(44 psi)

151 kPa(1.51 bar)(22 psi)

22

303 kPa(3.03 bar)(44 psi)

151 kPa(1.51 bar)(22 psi)

22

303 kPa(3.03 bar)(44 psi)

151 kPa(1.51 bar)(22 psi)

22

310 kPa(3.10 bar)(45 psi)

158 kPa(1.58 bar)(23 psi)

22

Bridgestone Firestone Goodyear MichelinSize Front Rear S-

t-arR-a-t-i-n-g

Front Rear S-tarR-at-in-g

Front Rear S-t-a-rR-a-t-i-n-g

Front Rear S-t-arR-a-t-i-n-g

23.5R25 L2, L2/E2,L2/E2/G2

524kPa(5.24 bar)(76 psi)

262 kPa(2.62 bar)(38 psi)

** 524kPa(5.24 bar)(76 psi)

262 kPa(2.62 bar)(38 psi)

** 552 kPa(5.52 bar)(80 psi)

276 kPa(2.76 bar)(40 psi)

** 352 kPa(3.52 bar)(51 psi)

200 kPa(2.00 bar)(29 psi)

*

L3, L3/E3,L3/E3/G3,L4, L5

524kPa(5.24 bar)(76 psi)

262 kPa(2.62 bar)(38 psi)

** 524kPa(5.24 bar)(76 psi)

262 kPa(2.62 bar)(38 psi)

** 552 kPa(5.52 bar)(80 psi)

276 kPa(2.76 bar)(40 psi)

** 303 kPa(3.03 bar)(44 psi)

200 kPa(2.00 bar)(29 psi)

*

750/65R25

L3 324 kPa(3.24 bar)(47 psi)

166 kPa(1.66 bar)(24 psi)

* 352 kPa(3.52 bar)(51 psi)

200 kPa(2.00 bar)(29 psi)

*

26.5R25 L2, L2/E2,L2/E2/G2

400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 413 kPa(4.13 bar)(60 psi)

206 kPa(2.06 bar)(30 psi)

*

L3, L3/E3,L3/E3/G3,L4, L5

400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 413 kPa(4.13 bar)(60 psi)

206 kPa(2.06 bar)(30 psi)

* 303 kPa(3.03 bar)(44 psi)

200 kPa(2.00 bar)(29 psi)

*

29.5R25 L2, L2/E2,L2/E2/G2

400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 379 kPa(3.79 bar)(55 psi)

193 kPa(1.93 bar)(28 psi)

*

3-3-2 013013

PN=101


TX,55,JC1225 -19-25JUN96-2/2

L3, L3/E3,L3/E3/G3

400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 379 kPa(3.79 bar)(55 psi)

193 kPa(1.93 bar)(28 psi)

* 352 kPa(3.52 bar)(51 psi)

200 kPa(2.00 bar)(29 psi)

*

800/65R25

L4T, E4T 324 kPa(3.24 bar)(47 psi)

166 kPa(1.66 bar)(24 psi)

*

NOTE: Tire shipping pressure may not be the sameas tire operating pressure. You may change tire

pressures to suit working condition according totire manufacturer’s recommendations

3-3-3 013013

PN=102


HG31779,0000150 -19-07OCT02-1/1

Tire Pressures (824J)The following tables indicate the recommended TirePressures (PSI) for 58,000 pound loader with 6.1 cubicyard bucket, handling 3400 pound per cubic yard material.

Recommended ply ratings for Bias Ply Tires and starratings for Radial Tires in parenthesis.

Addition of fluids, water and/or calcium chloride does notaffect recommended tire pressures.

To increase side-to-side stability, increase front tirepressures in 2 PSI increments.

To adjust fore-aft stability, increase or decrease rear tirepressures in 2 PSI increments.

See Tire Manufacturer's charts for detailed load, pressureand distance recommendations.

Bridgestone Firestone General GoodyearSize Front Rear P-

lyR-a-t-i-n-g




26.5-25 L2, L2/E2,L2/E2/G2,L3, L3/E3,L3/E3/G3,L4, L5

430 kPa(4.03 bar)(62 psi)

214 kPa(2.14 bar)(31 psi)

20

430 kPa(4.03 bar)(62 psi)

214 kPa(2.14 bar)(31 psi)

20

448 kPa(4.48 bar)(65 psi)

221 kPa(2.21 bar)(32 psi)

20

414 kPa(4.14 bar)(60 psi)

207 kPa(2.07 bar)(30 psi)

20

29.5-25 L2, L2/E2,L2/E2/G2,L3, L3/E3,L3/E3/G3

303 kPa(3.03 bar)(44 psi)

151 kPa(1.51 bar)(22 psi)

22

303 kPa(3.03 bar)(44 psi)

151 kPa(1.51 bar)(22 psi)

22

303 kPa(3.03 bar)(44 psi)

151 kPa(1.51 bar)(22 psi)

22

310 kPa(3.10 bar)(45 psi)

159 kPa(1.59 bar)(23 psi)

22

Bridgestone Firestone Goodyear MichelinSize Front Rear S-

t-arR-a-t-i-n-g

Front Rear S-tarR-at-in-g

Front Rear S-t-a-rR-a-t-i-n-g

Front Rear S-t-arR-a-t-i-n-g

26.5R25 L2, L2/E2,L2/E2/G2

476 kPa(4.76 bar)(69 psi)

241 kPa(2.41 bar)(35 psi)

* 476 kPa(4.76 bar)(69 psi)

241 kPa(2.41 bar)(35 psi)

* 483 kPa(4.83 bar)(70 psi)

241 kPa(2.41 bar)(35 psi)

*

L3, L3/E3,L3/E3/G3,L4, L5

476 kPa(4.76 bar)(69 psi)

241 kPa(2.41 bar)(35 psi)

* 476 kPa(4.76 bar)(69 psi)

241 kPa(2.41 bar)(35 psi)

* 483 kPa(4.83 bar)(70 psi)

241 kPa(2.41 bar)(35 psi)

* 448 kPa(4.48 bar)(65 psi)

228 kPa(2.28 bar)(33 psi)

*

29.5R25 L2, L2/E2,L2/E2/G2

400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 379 kPa(3.79 bar)(55 psi)

193 kPa(1.93 bar)(28 psi)

* *

L3, L3/E3,L3/E3/G3

400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 400 kPa4.00( bar)(58 psi)

200 kPa(2.00 bar)(29 psi)

* 379 kPa(3.79 bar)(55 psi)

193 kPa(1.93 bar)(28 psi)

* 352 kPa(3.52 bar)(51 psi)

200 kPa(2.00 bar)(29 psi)

*

800/65R25

L45, E4T 352 kPa(3.52 bar)(51 psi)

179 kPa(1.79 bar)(26 psi)

*

NOTE: Tire shipping pressure may not be the sameas tire operating pressure. You may change tire

pressures to suit working condition according totire manufacturer’s recommendations

3-3-4 013013

PN=103


CS58540,0000038 -19-21APR10-1/1

AM40430,00002CE -19-11JAN06-1/1

HG31779,00000A1 -19-21OCT02-1/1

Tighten Wheel Retainer NutsNOTE: Tighten nuts after first 10 hours, then again

after first 50 hours of loaded operation. After

that, tighten as required. Threads shouldbe clean and lightly oiled.

Item Measurement Specification

744J / 824J Wheel Nut Torque 950 N·m700 lb.-ft.

Check Air Cleaner Elements1. Open right service door.

2. Remove air inlet cover.

3. Pull primary element (A) straight back to remove.

4. Tap primary element with the palm of your hand, NOTON A HARD SURFACE.

CAUTION: Prevent possible injury from flyingchips if compressed air is more than 210 kPa(2.1 bar) (30 psi). Reduce compressed air to lessthan 210 kPa (2.1 bar) (30 psi) when using forcleaning purposes. Clear area of bystanders,guard against flying chips, and wear personalprotection equipment including eye protection.

5. If this does not remove dust, use compressed airunder 210 kPa (2.1 bar) (30 psi).

SpecificationCompressedAir—Pressure................................................................... Under 210 kPa

210 bar30 psi

T103190B

—UN—12DEC96

A—Primary Element

6. Direct air up and down from inside to outside. Becareful not to make a break in the element.

7. Reinstall primary element or replace elements asnecessary. See Replace Air Cleaner Elements.(Section 3-8.)

Check Air Inlet Cover1. Loosen hose clamp (A).

2. Remove air inlet cover (B).

3. Check cover for debris. Remove debris if necessary.

A—Hose Clamp B—Air Inlet Cover

T156026B

—UN—26JU

N02

3-3-5 013013

PN=104


OUOE003,00000B1 -19-14MAR01-1/1

ER93822,000010E -19-27FEB08-1/1

Inspect Serpentine Belts1. Check belts (1 and 2) regularly for wear, especially for

cracks at the bottom of grooves and for frayed edges.

IMPORTANT: If either belt is stretched to thepoint that the belt tensioner is against itsstop, belt must be replaced.

2. If necessary, replace belt.

3. Remove lower fan guard.

NOTE: Alternator belt requires a 1/2 inch square drivetool and fan belt requires a 3/4 inch squaredrive tool to release belt tension.

4. Hold tension adjuster assembly away from belt whileremoving old belt and installing new belt.

5. Install fan guard.

1—Belt 2—Belt

T139776B

—UN—20MAR01

Inspect External SealCheck external seals (1) for wear. If damaged or missing,replace seal.

To remove damaged seal:

1. Loosen and remove nut (3) from seal bolt assembly.

2. Remove washer (4) from seal bolt assembly.

3. Remove remaining bolt (2) and washer from seal.

4. Open seal and remove from around boss.

To replace seal:

1. Open seal and place around boss.

2. Place washer onto bolt.

3. Place bolt into seal opening.

4. Place washer onto bolt end protruding from sealopening

5. Place and tighten nut around open end of seal boltassembly.

1—External Seal (4 used)2—Bolt (4 used)

3—Nut (4 used)4—Washer (8 used)

TX1037267A

—UN—26FE

B08

External Seal Locations

TX1037266A

—UN—25FE

B08

3-3-6 013013

PN=105


OUOE003,00000B2 -19-08MAR07-1/1

TX03679,000180D -19-24SEP01-1/1

Drain Fuel Tank SedimentNOTE: Drain valve is located at the bottom of the fuel

tank to the left of machine center line.

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

2. Drain water and sediment into a container.

3. Tighten drain valve.

4. Install cover and tighten cap screws.

5. Dispose of waste properly.

1—Cap Screw (2 used)2—Rock Guard Cover

(Optional)

3—Drain Valve

T139780B

—UN—20MAR01

T139781B

—UN—20MAR01

Inspect Fuel Filler Drain Hose and TankBreather HoseInspect hoses for cracks or wear. Tighten clamps ifnecessary.

1—Tank Breather Hose 2—Fuel Filler Drain Hose

T145905B

—UN—24SEP01

3-3-7 013013

PN=106


Continued on next page AM40430,00002D0 -19-26FEB08-1/2

Replace Primary and Final Fuel Filters

CAUTION: If engine has been running, engineand fuel filter housing may be hot.

1. Clean entire top area of fuel filter assembly to keepdebris from entering fuel system.

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

NOTE: Relieve vacuum in filter housing by operating handprimer until fuel filter “pops up”. If filter does not“pop up” after about 30 strokes of primer, insert asmall screwdriver as shown to carefully pry underfilter flange to relieve vacuum in the housing.

3. Remove filter element as shown. Hold filter suspendedstraight up in top of housing to drain fuel from filter.

4. Dispose of used filter properly.

5. Drain fuel from water separator bowl.

NOTE: If sediment in bowl cannot be flushed out bypumping primer, remove bowl to clean.

6. Clean sediment from water separator bowl. See CleanWater Separator Bowl. (Section 3-3.)

1—Cap

T144885C

—UN—16AUG01

RG10303—UN—27MAY

04RG10304—UN—02SEP99

3-3-8 013013

PN=107


AM40430,00002D0 -19-26FEB08-2/2

AM40430,00000BF -19-11JAN06-1/1

IMPORTANT: Fuel level below the MIN indication mayresult in trapped air in the filter causing theengine to stall and not restart without additionalsystem purging. Fuel level above the MAXindication may cause fuel to overflow from thefilter housing during insertion of filter element.

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

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

9. Install fuel filter cap and hand tighten.

10. Pump primer at least 20 strokes.

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

RG10305—UN—02SEP99

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

B—Minimum Level 127 mm (5in.) From Top of Housing

Replace In-Line Fuel Filter1. Park machine.

2. Open left side service door.

3. Remove side panel.

4. Loosen and slide hose clamps away from fuel filter(1). Remove hoses.

5. Remove fuel filter.

6. Install new filter.

7. Install hoses and tighten clamps.

8. Install side panel and close service door.

T212127A

—UN—10JU

N05

1— In-Line Fuel Filter

3-3-9 013013

PN=108


AM40430,00002F1 -19-20JAN06-1/2

AM40430,00002F1 -19-20JAN06-2/2

Drain Water Separator Bowl (744J S.N.590070—601440, 824J S.N. 590070—601506)IMPORTANT: Use the least amount of force

necessary with strap wrench when removingand installing separator bowl to preventplastic bowl from cracking.

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

2. Drain fuel from separator bowl.

3. Position a strap wrench (1) as close as possible to topedge of separator bowl. While applying pressure withstrap wrench, grip bowl and twist with other hand, asshown, to remove bowl.

4. Clean water separator bowl.

5. Install separator bowl and tighten by hand until sealmakes contact.

SpecificationWater SeparatorBowl-to-FilterHousing—Torque.............................................................................6 N·m

55 lb-in.

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

T212336A

—UN—21JU

N05

1—Strap Wrench

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

8. Pump primer until fuel is within 6 inches of filtercanister top.

9. Press filter to seal.

10. Install filter cap.


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

1—Maximum Level 63 mm(2-1/2 in.) From Top ofHousing (New filter)

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

T212338A

—UN—21JU

N05

3-3-10 013013

PN=109


AM40430,00002F2 -19-19JAN06-1/1

Continued on next page CED,OUO1021,94 -19-18JUL02-1/2

Bleeding Fuel System (744J S.N. 601441—,824J S.N. 601507—)NOTE: This procedure should be performed after each fuel

filter change and when the engine has run out of fuel.

1. With key switch ON, engage fuel primer pump byturning toggle switch (1) on. Let pump run for fiveminutes.

2. After five minutes, start the engine while the primeris still on.

3. Run engine for five minutes.

4. Turn fuel primer toggle switch off.

NOTE: When fuel primer pump is engaged, enginewill not exceed 1000 rpm's.

T213714C

—UN—24AUG05

1—Fuel Primer Toggle Switch

Check Cab Fresh Air Filter—If Equipped1. Open cab fresh air filter door by pulling up on lever (A)

to the left of the operator’s seat.

A—Lever

T105479B

—UN—12DEC96

3-3-11 013013

PN=110


CED,OUO1021,94 -19-18JUL02-2/2

AM40430,00002D1 -19-11JAN06-1/1

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

NOTE: If operating in dusty conditions, cab fresh air filtershould be checked and cleaned as necessary.

3. Release clips.

4. Remove filter. Replace if damaged.

5. Clean filter in one of these ways:


• 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.

T117050—UN—10SEP98

A—Knob

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

Check Cab Recirculating Air Filter—IfEquippedNOTE: The cab recirculating air filter is located

next to the seat.

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

2. Remove filter.


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.

T159520B

—UN—18SEP02

1—Wing Bolt

4. Install filter.

5. Install grille.

3-3-12 013013

PN=111

Maintenance—Every 10 Hours or Daily

OUOE003,00000B4 -19-14MAR01-1/1

HG31779,0000136 -19-25SEP02-1/1

Check Recovery Tank Coolant LevelWith 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 water. DO NOT remove radiator filler capunless engine is cool. Then turn cap slowly to thestop. Release all pressure before you remove cap.

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

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.

T139808B

—UN—20MAR01

T6274A

Q—UN—18OCT88

Clean Air Cleaner Dust Unloader ValveIMPORTANT: A missing, damaged, or hardened dust

unloader valve will make the dust cup precleanerineffective, causing very short element life. Valveshould suck closed above 1/3 engine speed.

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

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

A—Dust Valve

T139810B

—UN—20MAR01

3-4-1 013013

PN=112


OUOE003,00000B6 -19-31OCT02-1/1

CED,OUOE012,290 -19-10JUL01-1/1

Check Engine Oil LevelIMPORTANT: If oil level is low, the engine can be

damaged. DO NOT operate the engine whenoil 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.

1. Park machine on a level surface.

2. Engage park brake.

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

4. BEFORE THE ENGINE IS STARTED: The engineis full when oil level is in the cross hatched area. Itis acceptable 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 (2) to add oil. SeeDiesel Engine Oil. (Section 3-1.)

T144885G

—UN—10OCT01

1—Dipstick 2—Filler Cap

Check Hydraulic Oil LevelIMPORTANT: Prevent possible hydraulic pump

damage. DO NOT operate engine withoutoil 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.

A—Filler Cap B—Sight GlassT101195—UN—19FE

B97

3-4-2 013013

PN=113


HG31779,000012F -19-20SEP02-1/1

Check Transmission Oil LevelIMPORTANT: Prevent possible transmission

damage. DO NOT operate engine whentransmission oil level is low.

1. Before starting engine, check oil level on sight gauge(1). If oil level is higher than the sight gauge, there issufficient oil to start the engine.

2. If necessary, add oil at filler tube (2). SeeTransmission, Hydraulic System, Park Brake, andDifferential Oil. (Section 3-1.)

3. Start engine.

4. Engage service brakes. Move clutch cut-off switch todisengaged position.

5. Move auto transmission switch to “Off” position.Release park brake.

6. Move transmission control lever to 3rd speed forward"3F" position.

Operate engine at fast idle for 30 seconds. 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).

7. Move transmission control lever to neutral "N", andengage neutral lock. Lower all equipment to ground.


9. Release service brakes.

10. Allow 2 minutes for oil level to stabilize.

11. Check oil level with engine at slow idle. With oil atnormal operating temperature, oil level should bebetween HOT marks on sight gauge.

12. If necessary, add oil. See Transmission, HydraulicSystem, Park Brake, and Differential Oil. (Section 3-1.)

1—Sight Gauge 2—Filler TubeT159631B

—UN—20SEP02

T161201—19—01NOV02

3-4-3 013013

PN=114

Maintenance—Every 100 Hours

VD76477,0001470 -19-08MAR07-1/1

Grease Loader Linkage and Cylinder Pivots—If Equipped

T139815B

—UN—20MAR01

Four Points

T101199—UN—21MAY

96

Three Points, Right Side Shown

CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before lubricating.

NOTE: NeverGrease™ Pin Joints do notrequire lubrication.

Lower bucket flat on ground.

Lubricate following 13 points until grease escapes aroundseals. See Grease. (Section 3-1.)

Lubricate bucket/working attachment hinge pins every 10hours when operating in severe conditions such as deepmud, water, or snow.

T101200—UN—19MAY

98

Six Points, Right Side Shown

NeverGrease is a trademark of Deere & Company

3-5-1 013013

PN=115


VD76477,0001471 -19-28MAR07-1/1

VD76477,0001473 -19-28MAR07-1/1

Grease Front Steering Cylinder Pivots744J (S.N. —612699), 824J (S.N. —612710)


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.

A—Left Steering Cylinder(Head End)

B—Right Steering Cylinder(Head End)

T101202—UN—21MAY

96

Two Points, Left Side Shown

T102520—UN—03SEP96

Grease Rear Steering Cylinder Pivots744J (S.N. —612699), 824J (S.N. —612710)


Lubricate each point with 10 shots of grease. See Grease.(Section 3-1.) Grease daily when operating in severeconditions such as deep mud, water, or snow.

T114501—UN—24MAR98

Four Points

3-5-2 013013

PN=116


VD76477,0001472 -19-01MAR07-1/1

Grease Oscillating Rear Axle


Lubricate each point with 10 shots of grease. See Grease.(Section 3-1.) Grease daily when operating in severeconditions such as deep mud, water, or snow.

A—Rear Axle Front OscillatingPivot

B—Rear Axle Rear OscillatingPivot

T103215—UN—03SEP96

3-5-3 013013

PN=117

Maintenance—Initial Service - 250 Hours

AM40430,00002D2 -19-09APR10-1/2

AM40430,00002D2 -19-09APR10-2/2

Change Engine Break-In Oil and ReplaceFilterNOTE: Perform this service after the first 250 hours of

operation and at 500 hour intervals thereafter.

1. Run engine to warm oil.


3. Lower equipment to ground.

4. Move transmission control lever to N. Engage neutrallock.

CAUTION: Prevent possible injury fromunexpected machine movement. Machinecan unexpectedly roll or move under power,resulting in death or serious injury. Alwaysengage park brake to hold machine.



NOTE: Oil drain hose is located at lower left frontcorner of fuel tank mount.

T139286B

—UN—27MAR01

1—Drain Valve T-Handle

7. Turn T-handle (1) on drain valve counterclockwise.Allow oil to drain into a container. Dispose of wasteoil properly.

8. Turn filter (1) counterclockwise to remove.

9. Clean mounting surface. Apply thin film of oil to gasketof new filter.

NOTE: Before installing filter, to ensure 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—3/4 turn more.


13. Remove filler cap (2).

14. Fill engine with oil. Approximate oil capacity with filteris 38 L (10 gal). See Diesel Engine Oil. (Section 3-1.)


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.

T144885F

—UN—16AUG01

1—Filter 2—Filler Cap

19. Check for any leakage at filter. Tighten filter onlyenough to stop leakage.

3-6-1 013013

PN=118


AM40430,00002D3 -19-11JAN06-1/1

Continued on next page VD76477,00004F4 -19-19APR10-1/2

Replace Hydraulic System Return FiltersNOTE: Perform this service after the first 250 hours of

operation and at 500 hour intervals thereafter.

CAUTION: Prevent possible injury fromunexpected machine movement. Install framelocking bar before changing filters.

1. Turn filters (1) counterclockwise to remove.


3. Install new filters. Tighten each filter 3/4—1 full turnafter seal contacts mounting base.

4. Fully loosen each filter element. Repeat step 3.

5. Start engine. Check for leaks around each filter base.Tighten filters only enough to stop leaks.

6. Stop engine. Check oil level.

T139860B

—UN—20MAR01

1—Hydraulic System ReturnFilter (2 used)

Change Front and Rear Differential/Axle OilNOTE: Perform this service at the first 250 hours of

operation and then at 2000 hour intervals thereafter.

CAUTION: Prevent possible injury from hotspraying oil. Slowly loosen dipstick torelieve any air pressure.

NOTE: The axle drain plug is magnetized and shouldbe cleaned when changing differential/axle oil.Axle differential recirculation screens (if equipped)should also be cleaned at this time. See Clean AxleDifferential Recirculation Screen in this section.

1. Remove drain plug (A). Allow oil to drain into acontainer. Dispose of waste oil properly.

NOTE: It is normal for differential lock axles to befilled approximately 1—2 L (1—2 qt) abovebrake inspection plug.

2. Install drain plug.

3. Remove service door (B) and open lower left engineside panel.

T101208—UN—03SEP96

Front Differential Shown

A—Drain Plug B—Service Door

3-6-2 013013

PN=119


VD76477,00004F4 -19-19APR10-2/2

4. Remove dipsticks and dipstick tubes.

5. Add oil slowly through port on front differential (C) andrear differential (D).

Specification744J—Differential Oil(Each)............................................................................................. 46.0 L

(12.0 gal)744J—With OptionalWide Axle—DifferentialOil (Each)....................................................................................... 49.0 L

(13.0 gal)824J—Differential Oil(Each)............................................................................................. 46.0 L

(12.0 gal)

NOTE: Each differential housing has three sumps. Fillcenter housing slowly so oil drains into all sumps.

6. Install dipstick tubes. Check oil level at dipsticks.

7. Repeat steps 4 and 5 until FULL mark on dipstick isreached.

8. Install dipstick tubes and dipsticks.

9. Install service door and engine side panel.

C—Dipstick D—Dipstick

T101209—UN—21MAY

96

Front Differential

T105480B

—UN—12DEC96

Rear Differential

3-6-3 013013

PN=120


HG31779,0000174 -19-29OCT02-1/2

HG31779,0000174 -19-29OCT02-2/2

Grease Front Driveline Sliding Joints

CAUTION: Prevent possible injury fromunexpected machine movement. Turn engine offand lower bucket to ground before lubricating.

NOTE: To prevent plug loss, lubricate the machinewhen it is fully articulated or half articulated andNOT in the straight position.

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

1—Frame Locking Bar

T161066B

—UN—29OCT02

T102891—UN—03SEP96

Lubricate until grease escapes around vent holes in driveshaft end. See Grease. (Section 3-1.) NOTE: Grease daily when operating in deep

mud, water, or snow.

3-7-1 013013

PN=121


CED,OUO1021,97 -19-18JUL02-1/1

OUT4001,000039B -19-14MAR12-1/1

Check Radiator Coolant Level

CAUTION: Prevent possible injury from hotspraying coolant. DO NOT remove radiatorfiller cap unless engine is cool. Then turn capslowly to the stop. Release air to relieve allpressure before you remove cap.

1. Slowly remove cap. Coolant level must be at bottomof the filler neck.

NOTE: If radiator coolant level is low, check for leakson radiator cap, and hose connections betweenradiator and coolant recovery tank.

2. Add coolant, if necessary.


T6642E

K—UN—01NOV88

Take Engine Oil SampleSee your authorized dealer.

3-7-2 013013

PN=122


Continued on next page HG31779,0000157 -19-22OCT02-1/2

Grease Rear Driveline Sliding Joint andU-Joints

CAUTION: Prevent possible injury fromunexpected machine movement. Turn engine offand lower bucket to ground before lubricating.

Install frame locking bar (1) using hole for articulatedposition.

1—Frame Locking Bar

T161066B

—UN—29OCT02

3-8-1 013013

PN=123


HG31779,0000157 -19-22OCT02-2/2

T103426—UN—03SEP96

T102890—UN—09AUG96

Six Points


IMPORTANT: Potential U-joint damage may occur ifgrease does not purge from each cap.

Lubricate each point until grease purges from each cap.Lubricate daily or every 10 hours when operating in deepmud, water, or snow.

3-8-2 013013

PN=124


OUOE003,00000BA -19-10OCT01-1/2

OUOE003,00000BA -19-10OCT01-2/2

Check Air Intake HosesAir Intake Hose

Check air intake hose (1) for cracks. Replace asnecessary.

Tighten clamps.

1—Air Intake Hose

T139808C

—UN—15AUG01

Charge Air Cooler Hoses

Check connections and tubes between the turbochargercompressor outlet and the charge air cooler and alsobetween the engine intake manifold and the charge aircooler for cracks or leaks.

T139838

T139838—UN—20MAR01

3-8-3 013013

PN=125


Continued on next page TX,75,DH1574 -19-28APR93-1/3

Check Battery Electrolyte Level andTerminals

CAUTION: Battery gas can explode. Keep sparksand flames away from batteries. Use a flashlightto check battery electrolyte level.

NEVER check battery charge by placinga metal object across the posts. Use avoltmeter or hydrometer.

ALWAYS remove grounded (-) battery clampfirst and replace it last.

Sulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin,eat holes in clothing, and cause blindnessif splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when

electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help

neutralize the acid.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, butdo not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

1. Remove battery box cover.

3-8-4 013013

PN=126


TX,75,DH1574 -19-28APR93-2/3

TX,75,DH1574 -19-28APR93-3/3

VD76477,000043B -19-19APR06-1/1

VD76477,000043C -19-19APR06-1/1

IMPORTANT: If water is added to batteries duringfreezing weather, batteries must be chargedafter water is added to prevent batteries fromfreezing. Charge battery using a batterycharger or by running the engine.

2. Fill each cell to within specified range with distilledwater. DO NOT overfill.

CAUTION: Prevent possible injury. ALWAYSremove grounded (-) battery clamp firstand replace it last.

3. Disconnect battery clamps, grounded clamp first.

A—Battery PostB—Fill Tube

C—Electrolyte Level Range

T6996D

B—UN—10FE

B89

T6996D

A—UN—10FE

B89

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.

A—Battery Terminal B—Lubricating Grease

T6758A

A—UN—21OCT88

Change Engine Oil and Replace FilterSee Change Engine Break-In Oil and Replace Filter(Section 3-5).

Replace Hydraulic System Return FiltersSee Replace Hydraulic System Return Filters (Section3-5).

3-8-5 013013

PN=127


AM40430,00002EB -19-20JAN06-1/4

AM40430,00002EB -19-20JAN06-2/4

Continued on next page AM40430,00002EB -19-20JAN06-3/4

Replace Primary and Final Fuel Filters(744J S.N. 590070—601440, 824J S.N.590070—601506)

CAUTION: If engine has been running, engineand fuel filter housing may be hot.

1. Clean entire top area of fuel filter assembly to keepdebris from entering fuel system.

1—Cap

T144885C

—UN—16AUG01

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

NOTE: Relieve vacuum in filter housing by operating handprimer until fuel filter “pops up”. If filter does not“pop up” after about 30 strokes of primer, insert asmall screwdriver as shown to carefully pry underfilter flange to relieve vacuum in the housing.

RG10303—UN—27MAY

04

3. Remove filter element as shown. Hold filter suspendedstraight up in top of housing to drain fuel from filter.


5. Drain fuel from water separator bowl.

NOTE: If sediment in bowl cannot be flushed out bypumping primer, remove bowl to clean.

6. Clean sediment from water separator bowl. See CleanWater Separator Bowl. (Section 3-3.)

RG10304—UN—02SEP99

3-8-6 013013

PN=128


AM40430,00002EB -19-20JAN06-4/4

AM40430,00002EC -19-19JAN06-1/1

IMPORTANT: Fuel level below the MIN indication mayresult in trapped air in the filter causing theengine to stall and not restart without additionalsystem purging. Fuel level above the MAXindication may cause fuel to overflow from thefilter housing during insertion of filter element.

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

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



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

RG10305—UN—02SEP99

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

B—Minimum Level 127 mm (5in.) From Top of Housing

Replace Primary and Final Fuel Filters (744JS.N. 601441—, 824J S.N. 601507—)NOTE: Perform this service at 500 hour intervals when

operating in normal conditions. When operatingin dry and/or dusty conditions, fuel filters shouldbe check and cleaned as necessary.

NOTE: Dispose of waste properly.

1. Thoroughly clean primary fuel filter (1) and final fuelfilter (2) and surrounding area.

2. Remove cap (3) from primary fuel filter housing.

3. Remove primary filter element and hold filtersuspended straight up on top of housing to drain fuelfrom filter.


5. Drain fuel from water separator bowl (4).

6. Carefully insert new (dry) filter into filter housing.


8. Rotate final fuel filter (3) counterclockwise and remove.

9. Clean filter base.

10. Install final fuel filter element.


12. Start engine and run for five minutes to bleed air outof fuel system.


T213469A

—UN—08SEP05

T213714A

—UN—08SEP05

1—Primary Fuel Filter2—Final Fuel Filter3—Cap

4—Water Separator Bowl5—Fuel Primer Pump Toggle

Switch


3-8-7 013013

PN=129


OUOE003,00000BE -19-14MAR01-1/1

HG31779,000016B -19-28OCT02-1/1

Replace Hydraulic Reservoir Breather FilterHydraulic reservoir breather filter is located on back sideof reservoir under the hood.



1—Hydraulic ReservoirBreather Filter

T139861B

—UN—07SEP01

Check Park Brake Oil LevelNOTE: Park brake oil should be changed every 500 hours

for applications running in deep water, mud or snow.

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. Too littleoil 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.

T114802—UN—14APR98

A—Plug

3-8-8 013013

PN=130


DW90712,00000F0 -19-03APR06-1/2

DW90712,00000F0 -19-03APR06-2/2

Check Front Differential/Axle Oil Level—IfEquipped With Differential Lock Axle


NOTE: Each differential housing has three sumps. Fillcenter housing slowly to let oil drain into all sumps.If machine has been driven, allow time for oil tostabilize in each sump before checking.

1. Remove service door (B).


T101208—UN—03SEP96

2. Clean area surrounding dipstick.

3. Remove dipstick (C). Oil must be to FULL mark ondipstick. If not, install dipstick and tighten.

4. Start engine.

5. Hold down differential lock pedal for 1 minute withengine running at slow idle.

6. Stop engine.

7. Slowly remove dipstick. Oil must be to FULL mark ondipstick. If not, install dipstick and repeat steps 3—5until oil is to FULL mark.

8. If necessary, add oil to hydraulic reservoir. SeeTransmission, Hydraulic System, Park Brake, andDifferential Oil . (Section 3-1.)

NOTE: If differential housing is overfilled, install dipstickand tighten. Start engine and run at high idle underload for several minutes. Turbo boost pressure todifferential should return excess oil to hydraulicreservoir. Check differential oil level.

If oil level has lowered, continue to operatemachine. Oil level will stabilize.

If oil level remains overfilled or increases,see your authorized dealer.

T101209—UN—21MAY

96

C—Dipstick

3-8-9 013013

PN=131


DW90712,00000F1 -19-03APR06-1/1

Continued on next page DW90712,00000F2 -19-03APR06-1/2

Check Rear Differential/Axle Oil Level—IfEquipped With Differential Lock Axle


NOTE: Each differential housing has three sumps. Fillcenter housing slowly to let oil drain into all sumps.If machine has been driven, allow time for oil tostabilize in each sump before checking.

1. Remove lower left engine side panel.

2. Clean area surrounding dipstick.

3. Remove dipstick (D). Oil must be to FULL mark ondipstick. If not, install dipstick and tighten.

4. Start engine.

5. Hold down differential lock pedal for 1 minute withengine running at slow idle.

6. Stop engine.

7. Slowly remove dipstick. Oil must be to FULL mark ondipstick. If not, install dipstick and repeat steps 3—5until oil is to FULL mark.

8. If necessary, add oil to hydraulic reservoir. SeeTransmission, Hydraulic System, Park Brake, andDifferential Oil. (Section 3-1.)

T105480B

—UN—12DEC96

D—Dipstick

NOTE: If differential housing is overfilled, install dipstickand tighten. Start engine and run at high idle underload for several minutes. Turbo boost pressure todifferential should return excess oil to hydraulicreservoir. Check differential oil level.

If oil level has lowered, continue to operatemachine. Oil level will stabilize.

If oil level remains overfilled or increases,see your authorized dealer.

Check Front Differential/Axle Oil Level—IfEquipped With Standard AxleNOTE: Each differential housing has three sumps. Fill

center housing slowly to let oil drain into all sumps.If machine has been driven, allow time for oil tostabilize in each sump before checking.

1. Remove service door (B).

2. Clean area around dipstick.


T101208—UN—03SEP96

3-8-10 013013

PN=132


DW90712,00000F2 -19-03APR06-2/2

DW90712,00000F3 -19-03APR06-1/1

CS58540,0000060 -19-10JUN10-1/1

3. Remove dipstick (C).

4. Oil must be to FULL level on dipstick.

NOTE: Remove complete dipstick tube assemblyfor ease of filling.


NOTE: If axle is hot and dipstick too warm to hold withbare hands, the oil will expand and it is normalfor it to be up to 25 mm (1 in.) above FULL mark.Do not adjust level. If oil level is above FULLmark, see your authorized dealer.

6. Install dipstick.

C—Dipstick

T101209—UN—21MAY

96

Check Rear Differential/Axle Oil Level—IfEquipped With Standard AxleNOTE: Each differential housing has three sumps. Fill

center housing slowly to let oil drain into all sumps.If machine has been driven, allow time for oil tostabilize in each sump before checking.

1. Remove lower left engine side panel.

2. Clean area around dipstick.

3. Remove dipstick (D).

NOTE: Remove complete dipstick tube assemblyfor ease of filling.

4. Oil must be to FULL level on dipstick.


NOTE: If axle is hot and dipstick too warm to hold withbare hands, the oil will expand and it is normalfor it to be up to 25 mm (1 in.) above FULL mark.

T105480B

—UN—12DEC96

D—Dipstick

Do not adjust level. If oil level is above FULLmark, see your authorized dealer.

6. Install dipstick.

Take Fluid SamplesSee your authorized dealer for taking the following fluidsamples:

• Hydraulic Oil

• Transmission Oil• Axle Oil• Coolant• Diesel Fuel

3-8-11 013013

PN=133


HG31779,0000138 -19-25SEP02-1/1

HG31779,00000A6 -19-08JUL02-1/1

Replace Air Cleaner Dust Unloader ValveNOTE: A missing, damaged, or hardened dust valve will

cause the air filter elements to be ineffective.

Replace dust unloader valve (1).

1—Dust Unloader Valve

T139810B

—UN—20MAR01

Replace Air Cleaner Elements1. Remove cover.

2. Remove primary element (A).

3. Remove secondary element (B).

4. Clean inside of air cleaner canister.

5. Install new elements making sure secondary elementis centered in canister.

6. Install cover.

A—Primary Element B—Secondary Element

T103190B

—UN—12DEC96

T103189B

—UN—12DEC96

3-9-1 013013

PN=134


OUOE003,00000C2 -19-14MAR01-1/1

TX03679,00017FA -19-15AUG01-1/1

AM40430,00002ED -19-20JAN06-1/1

Clean Engine Crankcase Vent TubeRemove clamp at valve cover.

Remove hose (1). Clean hose.

IMPORTANT: Do not pull on hose. Connectordamage may occur.

1—Engine Crankcase VentHose

T139861C

—UN—07SEP01

Check Radiator HosesCheck hoses (1) for cracks and leaks. Replace ifnecessary.

Tighten clamps.

1—Radiator Hoses

T144860C

—UN—05SEP01

Replace In-Line Fuel Filter (744J S.N.590070—601440, 824J S.N. 590070—601506)1. Park machine.








T212127A

—UN—10JU

N05

1— In-Line Fuel Filter

3-9-2 013013

PN=135


AM40430,00002EE -19-19JAN06-1/1

Replace In-Line Fuel Filter (744J S.N.601441—, 824J S.N. 601507—)NOTE: Perform this service at 500 hour intervals when

operating in normal conditions. When operatingin dry and/or dusty conditions, fuel filters shouldbe check and cleaned as necessary.

1. Park machine.








9. Start engine and run for five minutes to bleed air outof fuel system.




T213477A

—UN—11AUG05

T213714D

—UN—12SEP05

1— In-line Fuel Filter 2—Toggle Switch

3-9-3 013013

PN=136


HG31779,000014B -19-07OCT02-1/2

HG31779,000014B -19-07OCT02-2/2

Replace Transmission Oil Filter1. Operate machine under load until transmission oil

reaches normal operating temperature.


3. Stop engine.



6. Install new filter. Turn filter clockwise by hand untilgasket touches mounting surface.

7. Tighten 1/2 to 3/4 turn more.

8. Start engine and run for 2 minutes.

9. Move transmission control lever to neutral "N", andengage neutral lock.

1—Transmission Oil Filter

T139862—UN—20MAR01

10. Check oil level. Oil must be between HOT marks onsight gauge (B). Add oil if necessary.

11. Check for leaks around the filter base. Tighten filteronly enough to stop leaks.

B—Sight Gauge

T159631C

—UN—20SEP02

3-9-4 013013

PN=137


ER93822,0000074 -19-03NOV08-1/1

CED,OUO1021,115 -19-13OCT03-1/1

Inspect and Clean Hydraulic Pump CaseDrain Fittings1. Drain hydraulic reservoir (1).

2. Remove hoses (2) from reservoir.

3. Remove screen fittings (3) from hoses.

4. Inspect fittings for damage. Replace, if necessary.

5. Clean fittings and allow to dry prior to returning fittingsto hoses.

6. Reattach hoses to hydraulic reservoir.

7. Refill hydraulic reservoir.

32

1

23

TX1033283—UN—11DEC07

1—Hydraulic reservoir2—Hoses

3—Fittings

Grease Frame Hinge Pivots


Lubricate each point with a minimum of three shots ofgrease and until grease escapes from around the seals.See Grease. (Section 3-1.)

T113669—UN—18FE

B98

Two Points

3-9-5 013013

PN=138


AM40430,00002D4 -19-08APR10-1/1

Change Park Brake OilNOTE: Park brake oil should be changed at every

500 hours for applications running in deepwater, mud or snow.

IMPORTANT: Oil must be at level mark. Toomuch oil can cause overheating; too littlecan cause bearing failure.

SpecificationPark BrakeOil—Capacity..................................................................................... .6 L

20 oz

1. Remove plug (B).

2. Drain oil into a container. Dispose of waste oil properly.

3. Install plug.

4. Remove plug (A) and add oil. See Transmission,Hydraulic System, Park Brake, and Differential Oil.(Section 3-1.) Allow oil to settle for approximately 2minutes after filling.

T104817—UN—07NOV96

A—Plug B—Plug

5. Drain or add oil if necessary.

6. Install plug.

3-9-6 013013

PN=139


TX03679,00017EF -19-08FEB07-1/1

HG31779,000032E -19-07NOV03-1/1

Check and Adjust Engine Valve Lash andElectronic Injector PreloadSee your authorized dealer.

Re-Run Clutch CalibrationSee your authorized dealer.

3-10-1 013013

PN=140


DW90712,00000F8 -19-19APR10-1/1

VD76477,0000444 -19-30JAN13-1/1

Change Transmission Oil

Operation* John Deere HY-GARD™ - Oils meetingJDM J20C

John Deere Low Viscosity HY-GARD™ - Oils meetingJDM J20D

Normal 2000 hrs 1500 hrsSevere 1500 hrs 1000 hrs*Most applications would be considered "normal" operation. Service intervals should be reduced in severe applications which run the torqueconverter at high load more than approximately 25% of the time. (Examples may include basement digging, land clearing, etc.)

1. Operate machine under load until transmission oilreaches normal operating temperature.



4. Move transmission control lever to neutral “N”. Engageneutral lock.

CAUTION: Prevent possible injury fromunexpected machine movement. Machinecan unexpectedly roll or move under power,resulting in death or serious injury. Alwaysengage park brake to hold machine.


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 STOP. Let machine sit forapproximately 10 minutes.

9. Remove bottom guard, if equipped. Remove plug(A), located inside hole in bottom guard, to drain oil.Allow oil to drain into a container. Dispose of wasteoil properly.

10. Install drain plug.

11. Fill transmission with oil at filler tube (B). SeeTransmission, Hydraulic System, Park Brake, andDifferential Oil. (Section 3-1.)

T103344B

—UN—12DEC96

T159631D

—UN—07OCT02

A—PlugB—Filler Tube

C—Sight Gauge

SpecificationTransmissionOil—Capacity (IncludesFilter).............................................................................................. 28.0 L

(30.0 qt)

12. Start engine and run for 2 minutes.

13. Move transmission control lever to N and engageneutral lock.

14. Check oil level with oil at operating temperature. Oilmust be between marks on sight gauge (C).

Change Front and Rear Differential/Axle OilSee Change Front and Rear Differential/Axle Oil. (Section3-6.)

3-10-2 013013

PN=141


DW90712,00000FD -19-11APR06-1/1

Clean Axle Differential RecirculationScreen—If Equipped1. Disconnect hose (A) and remove screen fitting (B).

2. Drain differential oil into a container. Dispose of wasteproperly.

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.

A—Hose B—Screen Fitting

T117325—UN—22SEP98

Front Differential Shown

T117326—UN—22SEP98

Rear Differential Shown

3-10-3 013013

PN=142


HG31779,00000B9 -19-18JUL02-1/4

HG31779,00000B9 -19-18JUL02-2/4

Continued on next page HG31779,00000B9 -19-18JUL02-3/4

Change Hydraulic System Oil1. Lower bucket to ground.

2. Stop engine.

3. Turn key switch to “On”.

NOTE: Return-to-carry (1) must be OFF for floatdetent to operate.

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 (2) from OFF to ON.

6. Push pilot enable/boom down switch (3) to releaseaccumulator pressure.

T192344L

—UN—13OCT03

1—Return-to-Carry Switch2—Ride Control Switch


7. Turn key switch “Off”.

8. Remove hydraulic reservoir filler cap (A).

A—Hydraulic Reservoir FillerCap

T107063—UN—19FE

B97

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. Approximate capacity is 144 L (38 gal).See Transmission, Hydraulic System, Park Brake, andDifferential Oil. (Section 3-1.)

SpecificationHydraulicReservoir—Capacity....................................................................... 144 L

38 gal

T103644B

—UN—12DEC96

A—Reservoir Drain Valve

3-11-1 013013

PN=143


HG31779,00000B9 -19-18JUL02-4/4

HG31779,00002F5 -19-26JUN03-1/1

13. Install filler cap (A).

14. Check oil level in sight glass (B). Oil should be inFULL range.


B—Sight Glass

T101195—UN—19FE

B97

Clean Hydraulic System Strainer1. Remove hydraulic reservoir filler cap (A).

2. Remove snap ring.

3. Remove strainer (B) and clean with solvent.

4. Install strainer and snap ring.

5. Replace cap.

A—Filler Cap B—StrainerT114483—UN—23MAR98

3-11-2 013013

PN=144


TX,87,JC1495 -19-09AUG96-1/2

TX,87,JC1495 -19-09AUG96-2/2

Replace Differential Lock Return Filter(s)—IfEquipped1. Remove hydraulic reservoir filler cap (A).

2. Remove cap screws from reservoir cover (B) andremove cover.

3. Remove hydraulic strainer (C).


B—Reservoir Cover

C—Hydraulic Strainer

T101287—UN—21MAY

96

4. Turn filter(s) (D) counterclockwise to remove.

5. Install new filter(s). Turn filter(s) clockwise by handuntil tight.

6. Inspect cover gasket (E). Replace if necessary.

7. Install cover, cap screws, and filler cap.

D—Differential Lock ReturnFilter(s)

E—Cover Gasket

T101288—UN—21MAY

96

3-11-3 013013

PN=145


ER93822,00000E6 -19-21JAN13-1/1

Replace Engine Crankshaft DamperThe crankshaft damper assembly is not repairable andshould be replaced every five years or 4500 hours,

whichever occurs first, or whenever crankshaft isreplaced. See your authorized John Deere dealer.

3-12-1 013013

PN=146

Miscellaneous—Machine

Continued on next page OUOE003,00000C4 -19-31OCT02-1/2

Draining the Cooling System

CAUTION: Explosive release of fluids frompressurized cooling system can causeserious burns

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 hoses (2) for cracks and leaks. Replace ifnecessary.

2. Tighten clamps.

3. Check radiator, oil cooler, and charge air cooler fordirt, damage, leaks, and loose or broken mountings.Clean radiator, oil cooler, and charge air cooler fins.

4. Install hose or drain valve (3) and place in container.

5. Turn drain valve counterclockwise to open. Allowcoolant to drain into a container. Approximate coolingsystem capacity is 38 L (40 qt). Dispose of usedcoolant properly.

1—Engine Coolant Drain Valve2—Hose (2 used)

3—Radiator Drain Valve


T144860B

—UN—16AUG01

T138034C

—UN—20MAR01

4-1-1 013013

PN=147


OUOE003,00000C4 -19-31OCT02-2/2

OUOE003,00000C5 -19-19APR10-1/1

6. Turn drain valve (1) counterclockwise to drain engineblock. Allow coolant to drain into a container. Disposeof used coolant properly.

1—Drain Valve

T144885H

—UN—12OCT01

Cooling System Fill and Deaeration Procedure

IMPORTANT: Use only permanent-type low silicateethylene glycol base antifreeze in coolantsolution. Other types of antifreeze maydamage 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.

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.

1. Start engine. Run engine until coolant reaches a warmtemperature.

2. Stop engine. Allow coolant to cool.

3. Check coolant level at recovery tank.

4. Repeat steps 1—3 until recovery tank coolant level isrepeatedly 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.

5. If necessary, fill recovery tank to FULL mark. Coolingsystem capacity is approximately 38 L (40 qt).

SpecificationCooling System—Capac-ity.................................................................................................... 38.0 L

(10.0 gal)

6. Install recovery tank and radiator caps.

Coolant level must be at bottom of filler neck.

4-1-2 013013

PN=148


TX,85,JC1488 -19-12JAN06-1/1

HG31779,0000154 -19-18OCT02-1/1

AM40430,00002EF -19-20JAN06-1/1

Check Park Brake1. 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.

T115292—UN—11MAY

98

A—Park Brake Switch

Checking Fuel Tank Vent HoseIMPORTANT: If fuel filler drain hose is clogged,

the fuel tank could collapse.

1. Remove clamp (A).

2. Check hose for debris. If clogged, clean hose orreplace.

3. Install clamp.

A—Clamp

T115326—UN—11MAY

98

Bleeding Fuel System (744J S.N.590070—601440, 824J S.N. 590070—601506)NOTE: Under normal conditions, fuel system bleeding

is not required. Priming system with hand primer(B) is normally sufficient. If necessary to bleedthe system, use the following procedure.

1. Drain water and contaminates from clear waterseparator sediment bowl by opening drain valve (C)and operating primer (B) until bowl is clear of water.

2. Attach an open line to diagnostic port (A) and placeend of line in suitable container for diesel fuel.

3. Pump hand primer (B) until a steady flow of fuel(without bubbles) comes out of line.

NOTE: It can take up to 200 strokes until fuelcomes out steadily.

4. Disconnect line from diagnostic port (A).5. Pump hand primer (B).

NOTE: If engine has been run out of fuel, 200strokes will be necessary.

RG10309—UN—02SEP99

Bleed Fuel System

A—Diagnostic PortB—Hand Primer

C—Water Drain Valve

6. Start engine and run for five minutes.

NOTE: If engine does not start after 20 seconds ofcranking, pump hand primer an additional 100strokes, and attempt to start engine again.

4-1-3 013013

PN=149


AM40430,00002F0 -19-19JAN06-1/1

Continued on next page HG31779,00001A4 -19-25NOV02-1/2

Bleeding Fuel System (744J S.N. 601441—,824J S.N. 601507—)NOTE: This procedure should be performed after each fuel

filter change and when the engine has run out of fuel.


2. After five minutes, start the engine while the primeris still on.

3. Run engine for five minutes.



T213714C

—UN—24AUG05

1—Fuel Primer Toggle Switch

Cleaning Water Separator BowlIMPORTANT: Use the least amount of force

necessary with strap wrench when removingand installing separator bowl to preventplastic bowl from cracking.

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

2. Drain fuel from separator bowl.

3. Position a strap wrench (A) as close as possible to topedge of separator bowl. While applying pressure withstrap wrench, grip bowl and twist with other hand, asshown, to remove bowl.

4. Clean water separator bowl.

5. Install separator bowl and tighten by hand until sealmakes contact.

SpecificationWater SeparatorBowl-to-FilterHousing—Torque.............................................................................6 N·m

55 lb-in.

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

RG10351—UN—13SEP99

A—Strap Wrench

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

4-1-4 013013

PN=150


HG31779,00001A4 -19-25NOV02-2/2

CED,OUO1021,79 -19-12MAR98-1/1

04T,90,C151 -19-20JUL92-1/1

8. Pump primer until fuel is within 6 inches of filtercanister top.

9. Press filter to seal.

10. Install filter cap.


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

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

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

RG10305—UN—02SEP99

Checking Fire Extinguisher—If EquippedIMPORTANT: Dry powder has a tendency to pack

in the 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 orreplaced after any use.

A—Fire Extinguisher

T113598—UN—17FE

B98

Precautions for Alternator and Regulator

When batteries are connected, follow these rules:

1. Disconnect negative (-) battery cable when you workon 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 or whilealternator is operating.

6. Connect batteries or a booster battery in the correctpolarity (positive [+] to positive [+] and negative [-] tonegative [-]).

7. Do not disconnect the batteries when engine isrunning and alternator is charging.

8. Disconnect battery cables before you connect batterycharger to the batteries. If machine has more than onebattery, each battery must be charged separately.

4-1-5 013013

PN=151


Continued on next page TX03679,0001788 -19-23AUG12-1/2

Handling, Checking, and Servicing BatteriesCarefully

CAUTION: Battery gas can explode. Keep sparksand flames away from batteries. Use a flashlightto check battery electrolyte level.

Never check battery charge by placinga metal object across the posts. Use avoltmeter or hydrometer.

Always remove grounded (-) battery clampfirst, and replace it last.

Sulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin,eat holes in clothing, and cause blindnessif splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when

electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush contacted skin with water.2. Apply baking soda or lime to contacted

area to help neutralize the acid.3. Flush 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 qts.).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.

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.


Exploding Battery Gas


Battery Electrolyte

IMPORTANT: Do not overfill the battery cells.

Check the specific gravity of electrolyte in each battery cell.

4-1-6 013013

PN=152


TX03679,0001788 -19-23AUG12-2/2

OUT4001,0000058 -19-02JUL09-1/1

See your authorized dealer for JT05460SERVICEGARD™ battery and coolant tester. Followdirections included with the tester.

A fully charged battery will have a corrected specificgravity reading of 1.260. If the reading is below 1.200,charge the battery.

T85402

—UN—10NOV88

Battery and Coolant Tester

SERVICEGARD is a trademark of Deere & Company

Using Booster Batteries—24-Volt SystemBefore 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. Keep flamesor sparks away from the battery area. Make surethe batteries are charged in a well ventilated area.

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

1. Connect one end of the positive cable to the lug onstarter (1) and the other end to the positive terminal ofbooster batteries (2).

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 (3) 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 lug on starter.

1—Lug on Starter2—Booster Batteries

3—Machine Frame


TX1014128—UN—16NOV06

TX1015327A

—UN—21NOV06

4-1-7 013013

PN=153


OUT4001,0000239 -19-03JAN12-1/1

Using Battery Charger

CAUTION: Prevent possible injury from explodingbattery. Do not charge a battery if the batteryis frozen or it may explode. Warm battery to16°C (60°F) before charging.

Turn off charger before connecting ordisconnecting it.

IMPORTANT: Do not use battery charger as abooster if a battery has a 1.150 specificgravity reading or lower.

Disconnect battery ground (-) clamp beforeyou charge batteries in the machine to preventdamage to electrical components.

A battery charger may be used as a booster to start engine.

Ventilate the area where batteries are being charged.

Stop or cut back charging rate if battery case feels hot,or is venting electrolyte. Battery temperature must notexceed 52°C (125°F).


Prevent Battery Explosions

N36890—UN—07OCT88

Charger

4-1-8 013013

PN=154


OUOE003,00000C6 -19-15MAR01-1/1

VD76477,0001541 -19-20JUL12-1/1

Removing and Installing Batteries

CAUTION: To prevent injury from batterycovers dropping, remove when servicing orreplacing batteries. Hinge is in place to aidin removal only. Cover must not be held orpropped open during servicing.

NOTE: Your machine is equipped with a negativeground electrical system. It uses two 12-voltbatteries. If one of the two batteries fails, bothbatteries must be replaced.

IMPORTANT: Turn off master shut-off beforedisconnecting cables.

1. Remove left side battery cover.

CAUTION: To prevent injury from explosion or fire,disconnect the left side battery first regardlessof which battery is being removed.

2. Disconnect negative (-) battery cable (2) first, thenpositive (+) battery cable (1).

3. Remove nuts (3), washers, and hold-down bracket (4).

4. Lift battery out of compartment.

5. Remove right side battery cover.

6. Disconnect both battery cables.

7. Remove nuts (6), washers, and hold-down bracket (7).

8. Replace parts as necessary.

9. Install left side battery. Connect cables.

10. Install right side battery. Connect positive (+) batterycable, then negative (-) battery cable.

11. Install battery covers.

T139946B

—UN—20MAR01

Battery—Left Side

T139927B

—UN—20MAR01

Battery—Right Side

1—Positive (+) Battery Cable2—Negative (-) Battery Cable3—Nut (2 used)4—Hold-Down Bracket

5—Battery Cable (2 used)6—Nut (2 used)7—Hold-Down Bracket

JDLink™ Machine Monitoring System(MMS)—If EquippedJDLink™ is an equipment monitoring and informationdelivery system. JDLink™ automatically collects andmanages information about where and how construction

and forestry equipment is being used, as well as criticalmachine health data and service status.

For more information, see your authorized dealer or visitwww.deere.com (browse to Construction, Services andSupport, JDLink™).

JDLink is a trademark of Deere & Company

4-1-9 013013

PN=155


OUT4001,00002FA -19-08MAY08-1/1

Continued on next page OUT4001,00002D9 -19-05JUL07-1/3

JDLink™ Machine Monitoring System (MMS)Direct Laptop Connection—If Equipped• The direct laptop connector is located in the front rightservice door (1).• To download machine data using the JDLink™ MMSDirect:- Install the JDLink™ MMS Direct Cable by insertingthe Ethernet connector into the laptop.

- Connect the JDLink™ MMS Direct Cable to thevehicle 4-pin DEUTSCH connector (2).

- Launch JDLink™ MMS Direct Software.• Contact your authorized John Deere dealer to obtainthe JDLink™ MMS Direct Kit (AT347680), whichincludes the JDLink™ MMS Direct Cable (AT335476)and software.

NOTE: On equipment using the JDLink™ Direct system,there is no nightly upload to a remote serverand thus, the information is only stored in onelocation—the controller. Without downloadingthe controller data on a regular basis, the datacould be lost if the controller fails.

To obtain the most detailed machine data onyour laptop, perform a machine data downloadevery 1000 hours or less.

1—Front Right Service Door 2—4-pin Deutsch Connector

TX1025832A

—UN—08MAY

08TX

1025833A

—UN—08MAY

08


Replacing FusesThe fuse block is located in the load center. Remove fusepanel cover (1) to access fuse panel.

IMPORTANT: Install fuse with correct amperagerating to prevent electrical system damagefrom overload.

1—Fuse Panel Cover

T195538A

—UN—16OCT03

4-1-10 013013

PN=156


Continued on next page OUT4001,00002D9 -19-05JUL07-2/3

T192491—UN—12SEP03

4-1-11 013013

PN=157


OUT4001,00002D9 -19-05JUL07-3/3

04T,90,J22 -19-25AUG10-1/1

04T,90,C155 -19-12JUL01-1/1

F1—Flashers (5A)F2—Brake Light Pressure Switch

(5A)F3— (ECU) Engine Control Unit

Battery Power (10A)F4—Converter Battery Power

(15A)F5—Blower Motor (25A)F8—Electric Adjust Seat (10A)F9—Converter Ignition Power

(10A)F10— (ECU) Engine Control Unit

Ignition Power (5A)F11— Restriction Switch/Radio

Ignition Power (10A)F13— (CMU) Can Monitor Unit,

(SSM) Sealed SwitchModule, Ignition Power(10A)

F15— (FLC) Flex Load ControllerIgnition Power (5A)

F16— Spare Igntion Power (15A)F17— JDLink™ Unswitched

Power Fuse (15A) — IfEquipped

F18— (TCU) TransmissionControl Unit Battery power(5A)

F19— Horn (5A)F20— Spare Battery Power (5A)F21— (FLC) Flex Load Controller

Battery Power (10A)F23— Brake/Steering Pressure

Switch (5A)F28— (TCU) Transmission

Control Unit Ignition power(5A)

F29— Joystick Steering IgnitionPower (5A)

F31— JDLink™ Switched PowerFuse (5A) — If Equipped

F32— Park Brake ReleaseSwitch/Backup Alarm (5A)

F33— Pressurizer Motor (10A)F34— (CMU) Can Monitor Unit

Battery Power (5A)F38— Differential Lock Foot

Switch (5A)F40— Transmission Output

Speed Sensor (5A)F41— Start Relay (5A)F46— Start Aid Solenoid Switch

(5A)

F49— Radio, DiagnosticConnector, Dome LightBattery Power (10A)

F53— Alternator Excitation (5A)F55— Rear Wiper Motor (10A)F56— Front Wiper Motor (10A)K1—Horn RelayV2—Start Aid Solenoid Diode

(3A)V3—Ignition Relay (3A)V4—Start Relay (3A)V5—Alternator Excitation (3A)V7—Reverse Polarity (3A)


Fuse (Blade-Type) Color CodesAmperage Rating Color

1 Black3 Violet4 Pink5 Tan

7-1/2 Brown10 Red15 Light Blue20 Yellow25 Natural (White)30 Light Green

Resetting Circuit BreakersAir conditioning system contains two circuit breakers.If circuit breakers open because of a short circuit oroverloading, air conditioner will shut off.

Turn off air conditioning switch. Wait a couple of minutesbefore restarting, to allow a cooling off period. Circuitbreaker will reset itself. If circuit breaker opens repeatedly,see your authorized dealer.

4-1-12 013013

PN=158


TX,90,RR,1725 -19-11MAR94-1/2

TX,90,RR,1725 -19-11MAR94-2/2

Replacing Halogen BulbsIMPORTANT: To get the correct lighting pattern, lens

must be installed so the word “TOP” is ontop when lamp is installed so wider sectionis on top when lamp is installed.

Before disassembling, remember how bezel and lens areinstalled with respect to mounting stud.

T5894A

G1—UN—17APR89

T5894A

I1—UN—20OCT88

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 may causepremature bulb failure. Clean bulb using asoft, oil-free cloth and alcohol.

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. Sealingflange must be inside housing on all four sides beforetightening screws.

T6249A

U—UN—19OCT88

A—Flange NutB—Lock WasherC—HousingD—Bulb

E—GasketF—LensG—BezelH—Screw

9. Tighten screws alternately. Do not overtighten asscrews may strip out plastic.

4-1-13 013013

PN=159


TX,90,JC1862 -19-18MAY05-1/1

OUOE003,00000C8 -19-15MAR01-1/1

TX,90,JC1603 -19-29AUG96-1/1

Continued on next page VD76477,0001479 -19-08MAR07-1/3

Checking Neutral Start System

CAUTION: Avoid possible injury or death. DO NOTattempt to start machine unless you are sittingin operator’s seat with the FNR in neutral "N"position with park brake applied. DO NOT bypassor disable any of the starting system parts.

Check the neutral start system to ENSURE that themachine:

1. WILL start with the FNR in neutral "N" position.

2. WILL start with the FNR in forward "F" or reverse "R"position, but will not move until it has been cycledback to “N”.

If starting system fails to operate correctly, have yourJohn Deere dealer repair the system immediately.

Servicing Air Conditioning System—If Equipped

1. Check compressor belt.

2. Check compressor clutch engagement.

3. Check evaporator core for clogging.

4. Check air intake filters for clogging.

5. Check blowers for correct operation.

6. Check the condenser core to see that it is not partiallyor completely clogged with dirt or trash. Clean withcompressed air or water when needed.

7. Run air conditioning system for several minutes.

Welding On MachineIMPORTANT: Disconnect battery ground strap or turn

battery disconnect switch to “OFF” to preventvoltage spikes through alternator or monitor.

Connect welder ground clamp close to eachweld area so electrical current does not arcinside any bearings, bushings or pins.

NOTE: Machine is adequately grounded. It isnot necessary to disconnect any controllers(microprocessors).

External Service Brake Inspection

CAUTION: Prevent possible injury fromhot spraying oil. Slowly loosen plug torelieve any air pressure.

Prevent possible crushing injury from heavycomponent. If machine is equipped withbottom guards see your authorized dealerfor brake inspection.

IMPORTANT: Check both front and rear axleduring each inspection.

Perform first inspection at 5000 hours followed by1000 hour inspection intervals after the first 5000 hourinspection.

If the service brakes are subjected to severe duty, inspectmore frequently.

1. Remove brake inspection port plugs (A).

TX1020129A

—UN—02MAR07

A—Port Plugs

4-1-14 013013

PN=160


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VD76477,0001479 -19-08MAR07-3/3

2. Inspect the brake linings (A) on brake disk.

A—Brake Lining

T6138A

Z—UN—07MAY

08

3. Remove axle housing and replace brake disc if oilgrooves (B) on facing material are no longer visible.

4. If further inspection of brake elements or replacementof brake linings is necessary, see your authorizeddealer.

B—Oil Grooves

T8137A

C—UN—03DEC93

4-1-15 013013

PN=161


OUOE003,00000C9 -19-15MAR01-1/2

OUOE003,00000C9 -19-15MAR01-2/2

Checking Brake Accumulators

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury.Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure. Searchfor leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately.Any fluid injected into the skin must be surgicallyremoved within a few hours or gangrenemay result. Doctors unfamiliar with thistype of injury may call the Deere & CompanyMedical Department in Moline, Illinois, or otherknowledgeable medical source.

1. Start engine.

2. Run engine for one minute at slow idle. Apply brakepedal four or five times.

X9811

—UN—23AUG88

3. Stop engine.

4. Turn key switch to ON position.

NOTE: Accumulators are precharged and must bereplaced, not recharged.

5. Apply brake pedal. The brake low pressure indicatorlight may come on after three to four full brakeapplications. The indicator light will stay on 2—3seconds after each application and then go off. Aftersix to seven applications, indicator light will stay on.

If brake light comes onwith less than three applications,individual accumulators (1) should be replaced.

6. Repeat procedure three times to ensure accurateresults.

1—Brake Accumulator (2 used)

T139953B

—UN—20MAR01

4-1-16 013013

PN=162


Continued on next page OUOE003,00000CA -19-13OCT03-1/2

Checking Ride Control Accumulator—IfEquipped

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury.Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure. Searchfor leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately.Any fluid injected into the skin must besurgically removed within a few hours organgrene may result.

CAUTION: The boom will jump upward during thischeck. Make sure area around bucket is clear.

1. Start engine.

2. Push ride control switch (1) to “Off” position.

3. Raise boom to maximum height and hold control leverover relief for two seconds.

4. Lower boom and bucket to ground and stop engine.Put boom control lever in neutral.

X9811

—UN—23AUG88

T192456A

—UN—18SEP03

1—Ride Control Switch

4-1-17 013013

PN=163


OUOE003,00000CA -19-13OCT03-2/2

Continued on next page TX,DH,114 -19-06JUN91-1/2

NOTE: When ride control switch is in “A” (automatic)position, ride control works at 6 km/h (3.7mph) or above.

5. Push ride control switch to center position. Boomwill jump upward, approximately 100 mm (4.0 in.) asaccumulator (A) pressure is released.

6. If ride control accumulator has lost gas charge, seeyour authorized dealer.

A—Accumulator

T114389—UN—20MAR98

Bleeding Brakes

CAUTION: Escaping fluid under pressure canpenetrate skin causing serious injury. Relievepressure before disconnecting hydraulic or otherlines. Tighten all connections before applyingpressure. Keep hands and body away frompinholes and nozzles which eject fluids underhigh pressure. Use a piece of cardboard or paperto search for leaks. Do not use your hand.

If ANY fluid is injected into skin, it mustbe surgically removed within a few hoursby a doctor familiar with this type of injuryor gangrene may result.

NOTE: Two people are required to bleed brake systemoil, one to operate brake valve and the otherto open and close bleed screws.

1. Install frame locking bar.

X9811

—UN—23AUG88

2. Start engine and run at slow idle.

3. Push and hold brake pedal down until brake bleedingprocedure is complete.

4-1-18 013013

PN=164


TX,DH,114 -19-06JUN91-2/2

OUOE003,00000D7 -19-19MAR01-1/1

4. Put a clear plastic tube on bleed screw (A) to routeflow to hydraulic reservoir filler tube or to a container.

5. Open one bleed screw on differential and axleassembly until hydraulic oil starts to flow. Close bleedscrew when oil is free of air.

6. Repeat steps 2—4 for each bleed screw (two bleedscrews on each differential).

7. Release brake pedal and stop engine.

8. Check hydraulic oil level. See Check Hydraulic OilLevel in Maintenance—Every 10 Hours or Dailychapter.

A—Bleed Screw

T103358B

—UN—12DEC96

Radiator, Oil Cooler, and Charge Air CoolerExternal Cleaning Procedure1. If dust or debris is light, clean oil cooler by blowing air

through the fins. Do not exceed 6 bar (90 psi). Blowair straight through fins to avoid bending them.

2. If air fails to clean the oil cooler, use a high-pressurewasher with soap and water. Direct water straightthrough fins to avoid bending them.

SpecificationWater—Pressure........................................................... 48 bar maximum

700 psi

1—Charge Air Cooler2—Hydraulic Oil Cooler

3—Radiator4—Transmission Oil Cooler

T160597—UN—17OCT02

4-1-19 013013

PN=165


OUO1010,0000457 -19-05DEC11-1/2

OUO1010,0000457 -19-05DEC11-2/2

Service Recommendations For Snap-To-Connect (STC®) Fittings

Snap-To-Connect (STC®) fittings are used on thismachine. The fittings are designed to allow the hydraulichose to rotate as needed when the system is notpressurized. This prevents the hydraulic hoses frombinding when components are put back to their operatingposition.

Fittings are easily disconnected using special tool,JDG1385 STC Fitting Release Tool (1) (supplied inmachine with Operator's Manual). The special tool has adifferent size slot cut into each end. The narrow slot isfor -06 size fittings. The wide slot is for -08 size fittings.Use appropriate end of special tool on fitting beingdisconnected. To connect fittings, simply push each halfof fitting together.

IMPORTANT: DO NOT pry against release sleeve(3) or damage to fitting may result.

DO NOT force release sleeve beyond normalrange of travel, otherwise, release sleeve mayfall off when hose is disconnected. If thishappens and fitting is connected without therelease sleeve installed, fitting will not beable to be disconnected again.

1. Disconnect STC type fittings:

a. Clean area around fitting, especially around therelease sleeve (3).

T134792C

—UN—24OCT00

STC Fitting and JDG1385 STC Fitting Release Tool

1—JDG1385 STC FittingRelease Tool

2—Shoulder

3—Release Sleeve

b. While keeping JDG1385 STC Fitting Release Tool(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.

Snap-To-Connect (STC) is a trademark of Eaton Corp.

2. Inspect STC fittings:

a. Check seal mating surfaces for nicks, scratches,or flat spots.

b. Check O-ring (4), backup ring (5), and retaining ring(2) for wear or damage.

c. Make sure O-ring, backup ring, and retaining ring arein position before connecting fitting halves together.

3. Connect STC fittings:

a. Make sure fitting halves (3 and 6) are clean andfree of contaminants.

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.

T133922—UN—21SEP00

STC Fitting Cross Section

1—Release Sleeve2—Retaining Ring3—Female Half of STC Fitting

4—O-Ring5—Backup Ring6—Male Half of STC Fitting

4-1-20 013013

PN=166


TX,90,DH2537 -19-03SEP92-1/1

04T,90,MM8 -19-30NOV11-1/1

T82,SKMA,AT -19-01AUG94-1/1

Do Not Service Control Valves, Cylinders,Pumps or MotorsSpecial tools and information are needed to servicecontrol valves, cylinders, pumps, or motors.

If these parts need service, see your authorized dealer.

Keep ROPS Installed Properly

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,or is in any way altered. A damaged ROPSshould be replaced, not reused.

When installation of equipment on a machine necessitatesloosening or removing ROPS, mounting bolts must betightened to 620 N·m (457 lb.-ft).

SpecificationROPS MountingBolts—Torque..............................................................................620 N·m

457 lb.-ft.


ROPS Maintenance

Hardware Torque SpecificationsCheck cap screws and nuts to be sure they are tight.If hardware is loose, tighten to torque shown on thefollowing charts unless a special torque is specified.

4-1-21 013013

PN=167


DX,TORQ2 -19-12JAN11-1/1

Metric Bolt and Screw Torque ValuesTS1670 —UN—01MAY03

4.84.8 8.8 9.8 10.9 12.9 12.9

12.912.910.99.88.84.8

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9Bolt or ScrewSize Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172

N·m lb.-ft. N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35

N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70

N·m lb.-ft.M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

Torque values listed are for general use only, based on the strength ofthe bolt or screw. DO NOT use these values if a different torque value ortightening procedure is given for a specific application. For stainless steelfasteners or for nuts on U-bolts, see the tightening instructions for thespecific application. Tighten plastic insert or crimped steel type lock nutsby turning the nut to the dry torque shown in the chart, unless differentinstructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Alwaysreplace shear bolts with identical property class. Replace fasteners withthe same or higher property class. If higher property class fasteners areused, tighten these to the strength of the original. Make sure fastenerthreads are clean and that you properly start thread engagement. Whenpossible, lubricate plain or zinc plated fasteners other than lock nuts,wheel bolts or wheel nuts, unless different instructions are given for thespecific application.

a“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.b“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.

4-1-22 013013

PN=168


DX,TORQ1 -19-12JAN11-1/1

Unified Inch Bolt and Screw Torque ValuesTS1671 —UN—01MAY03

SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2Bolt or ScrewSize Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150

N·m lb.-ft. N·m lb.-ft.5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26

N·m lb.-ft. N·m lb.-ft.3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46

N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74

N·m lb.-ft.1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 1159/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 1655/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 2253/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 4007/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 6401 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 13501-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 19201-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 25001-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

Torque values listed are for general use only, based on the strength of the boltor screw. DO NOT use these values if a different torque value or tighteningprocedure is given for a specific application. For plastic insert or crimped steeltype lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see thetightening instructions for the specific application. Shear bolts are designed to failunder predetermined loads. Always replace shear bolts with identical grade.

Replace fasteners with the same or higher grade. If highergrade fasteners are used, tighten these to the strength of theoriginal. Make sure fastener threads are clean and that youproperly start thread engagement. When possible, lubricateplain or zinc plated fasteners other than lock nuts, wheel boltsor wheel nuts, unless different instructions are given for thespecific application.

aGrade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6in. (152 mm) long, and for all other types of bolts and screws of any length.b“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.c“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.

4-1-23 013013

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Miscellaneous—Operational Checkout

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VD76477,0001068 -19-15SEP06-2/32


Operational Checkout

Use this procedure to check all systems and functionson the machine. It is designed so you can make a quickcheck of the operation of the machine while doing a walkaround inspection and performing specific checks fromthe operator’s seat.

Should you experience a problem with your machine, youwill find helpful diagnostic information in this checkoutthat will pinpoint the cause. This information may allowyou to perform a simple adjustment which will reduce thedowntime of your machine. Use the table of contents tohelp find adjustment procedures.

The information you provide after completing theoperational checkout will allow you or your authorizeddealer to pinpoint the specific test or repair work neededto restore the machine to design specifications.

A location will be required which is level and has adequatespace to complete the checks. No tools or equipment areneeded 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 machine must be atoperating temperature for many of the checks.

Before starting this operational checkout, check diagnosticService codes in monitor. These service codes must becorrected or cleared before starting this checkout.

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, if noproblem is found (YES), you will be instructed to go tonext check. If a problem is indicated (NO) or (NOT OK),you will be referred to either a section in this manual orto your authorized dealer.

•1 Engine Off Checks

Battery Check

65.125.0

T194308 —UN—11SEP03Key OFF.Press SELECT button and hold until battery volts are displayed. YES: Go to next check.LOOK: Does battery volts read a minimum of 24 volts? NO: See Monitor Display

Unit—Diagnostics Menu.Check voltage on eachbattery before recharging.

If one battery will not holda charge, replace bothbatteries.

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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 the LCD display show John Deere and the model number?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. YES: Go to next check.LOOK: Do gauge indicators change from 12:00 O’clock to normal readings?Does the LCD show gear, engine speed, and hourmeter/speedometer/odometer?

NO: Check CMU / SSMignition power 5 A fuse.

Cab System Checks Check the following for proper working order:

• Seat Adjustment• Seat Belt• Tilt Wheel Counsel

• Front and rear work lights

• Drive and marker 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

• Fuel fill cap and fuel door

• Cab Mount Ladder

• Boom Lock check YES: Go to next check.

• Service Decal check NO: Go to specificproblem.

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PN=171


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Transmission Gear ShiftSwitch And Neutral LockLatch Checks

A

T194310 —UN—11SEP03Push automatic transmission switch to OFF position (LED unlit).Move transmission gear shift to Forward (F), Neutral and Reverse (R) positions.LISTEN/LOOK: Does switch move into Forward, Neutral and Reverse positions.Does switch stay in detented positions?Does Backup alarm sound when in Reverse?NOTE: Neutral lock only applies to steering column mounted shifter switch.Put neutral lock in LOCKED position.Apply slight effort to move lever into forward (F) and reverse (R).LOOK: Does neutral lock stay engaged and lever stay in neutral?Put neutral lock in UNLOCK position.NOTE: The following check applies only to steering column mounted shifter switch.Twist lever to shift into each gear 1st, 2nd, 3rd and 4th.LOOK: Does gear number align with pointer in each detented position?Does twist handle remain in detented positions?Does LCD display indicate correct gear and “N” position? (1 N, 2 N, 3 N and 4 N)NOTE: The following checks applied only to hydraulic control lever

mounted shift controls.YES: Go to next check.

Press the up-shift button and down-shift button on the control lever. NO: If lever does not moveor lock properly, replacelever.

LOOK: Does LCD display indicate correct gear and “N” position? (1 N, 2 N, 3 N and 4 N) NO: If gears do not changeon monitor, see yourauthorized dealer.

Neutral Start Check Move FNR to 1st gear forward (1F) of to 1st gear reverse (1R), turn key switch to START.LOOK/LISTEN: Does engine start?Does LCD display indicate a neutral gear selection?

YES: Go to next check.

NOTE: Gear display will not display “F” for forward or “R” for reverse until shifteris cycled back to neutral and park brake released.

NO: See your authorizeddealer.

•2 Engine Running Checks

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Monitor Check Start Engine.Observe CMU and check bulbs, indicators and gauges.LOOK/LISTEN: Do all lights illuminate?Does monitor alarm sound?Is backlighting of gauges ON?


After 4 seconds observe changes in Monitor. NO: Check CMU / SSMignition power 5 A fuse(F13).

LOOK: Do gauges show normal readings?Does home screen change to show gear, rpm, and hourmeter/speedometer/odometer?Does engine speed read idle speed?Does seat belt indicator go OFF 5 seconds after engine starts?

IF OK: Check appropriatediagnostic item ondiagnostics menu.

Park Brake Check

T103441 —UN—09SEP96Release park brake by pushing park brake switch to OFF position.LOOK: Does park brake indicator go off when brake is released? Will machine move ifput into gear?

CAUTION: Seat belt must be worn during this check to preventpossible injury from sudden machine stops.

Fasten seat belt.Place transmission in 1st gear forward.Drive machine at 3 MPH and push park brake switch to ON. YES: Go to next check.LOOK/FEEL: Does machine come to a stop within 1 meters (3 feet) when park brakeis engaged at 3 MPH? Does transmission shift to neutral? Does alarm sound?

NO: If machine doesnot stop within specifieddistance, see yourauthorized dealer.

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VD76477,0001068 -19-15SEP06-11/32


Service Brake Check Move each pedal with hand to check “free travel.” YES: Go to next check.FEEL: Does each pedal have about 6 mm (0.25 in.) free travel? NO: Inspect for debris

under brake pedal. Inspectbrake pedal linkage fordamage.

T194311 —UN—11SEP03Push clutch cutoff switch until function is OFF (LEDs unlit).Fully apply either service brake pedal.Push park brake switch to OFF.Put transmission in 2nd forward.Increase engine speed to high idle.LOOK: Does machine remain stationary or move very slowly? YES: Go to next check.Repeat check three times to ensure accurate results. NO: See your authorized

dealer.

Pilot Controller LockCheck

T194312 —UN—11SEP03

T103429 —UN—09SEP96Press pilot enable/boom down switch to lock the pilot controls (LED unlit).Hold control lever in boom raise position.Press pilot enable/boom down switch to unlock the pilot controls (LED illuminated).LOOK: Does boom raise when pilot controls are unlocked?Press pilot enable/boom down switch to lock the pilot controls (LED unlit) and observeboom.LOOK: Does boom stop when controls are locked?Unlock pilot controls and check all hydraulic functions.

• Boom Up/Down

• Bucket Roll/Dump• Auxiliary functions (if equipped)• Steering (Left and Right)

• Pin Disconnect (if equipped) YES: Go to next check.LOOK: Do all equipped hydraulic functions operate correctly? NO: See your authorized

dealer.

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Pilot Enable/Boom DownSolenoid Check

T194312 —UN—11SEP03Raise boom.Stop engine.Turn key to ON position.Press and hold Pilot Enable/Boom Down Switch.

CAUTION: Boom will quickly lower to ground.Move control lever to boom lower position. YES: Go to next check.LOOK: Does boom lower? NO: See your authorized

dealer.

Service Brake PressureSwitch And BrakeAccumulator Precharge

T194312 —UN—11SEP03Stop engine.Turn key to ON position.Press and hold Pilot Enable/Boom Down Switch and cycle hydraulic control lever in alldirections 20 times to bleed charge pressure from PRV/brake accumulator.Press brake pedal and record number of applications until brake pressure indicatorcomes on.Continue pushing brake pedal and counting applications until brake lights fail to come on. YES: Go to next check.LOOK: Are at least 12 brake pedal applications needed before brake pressureindicator comes on?

NO: If brake oil pressureindictor does not come on,see your authorized dealer.

LOOK: Are at least 30 brake pedal applications needed before brake lights fail tocome on?

NO: If brake lights failto come on, see yourauthorized dealer.

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Pilot Control Valve BoomFloat Check

T194313 —UN—11SEP03 T194315 —UN—11SEP03

Run engine at idle.Turn ride control off.Turn return-to-carry off.With the bucket partially dumped, lower boom to raise front of machine.Push control lever to the float detent position and release lever. YES: Go to next check.LOOK: Does front of machine lower to the ground and valve remain in float positionwhen lever is released?


Return-to-Dig Check

T194314 —UN—11SEP03Raise the boom to about eye level.Fully dump the bucket.Verify that return-to-dig function is turned on.Place controller in the bucket load detent position. YES: Go to next check.LOOK/FEEL: Does pilot controller detent? NO: Verify that the sensor

is adjusted correctly. SeeReturn-to-Dig Adjustment.

LOOK: Does bucket travel stop upon reaching dig position? NO: See your authorizeddealer.

Return-to-Carry Check

T194315 —UN—11SEP03Fully raise boom.Place bucket in dig position.Verify that the return-to-carry function is turned on.Place controller in the boom down detent position.LOOK/FEEL: Does pilot controller detent? YES: Go to next check.LOOK: Does boom travel stop upon reaching carry position? NO: Verify that the sensor

is adjusted correctly. Seeyour authorized dealer.

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Boom Height KickoutCheck

T194316 —UN—11SEP03Lower boom to the ground.Place bucket in dig position.Verify that boom height kickout function is turned on.Place controller in the boom up detent position.LOOK/FEEL: Does pilot controller detent? YES: Go to next check.LOOK: Does boom travel stop before reaching full height? NO: Verify that the sensor

is adjusted correctly. Seeyour authorized dealer.

Pin Disconnect SystemCheck (If Equipped)

T194317 —UN—11SEP03Run engine at slow idle.Position bucket flat on the ground.Push and hold pin disconnect switch on the sealed switch module (SSM). YES: Go to next check.LOOK: Does pin disconnect cylinder retract both pins while switch is pressed? NO: See your authorized

dealer.

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Ride Control Check

T194313 —UN—11SEP03

CAUTION: Boom will jump upward during this check. Makesure area around bucket is clear.

Press ride control switch on SSM to enable ride control manual mode. Left LED willilluminate.Raise boom to maximum height and hold control lever over relief for 2 seconds.Lower boom and bucket to eye level. Observe loader boom as Ride Control Switchis switched to ON.LOOK/FEEL: Does boom jump upward 30 cm (12 in) or more?Press ride control switch on the SSM once more to enable auto mode. Right LEDwill illuminate.Raise boom to maximum height and hold control lever over relief for 2 seconds.Lower boom and bucket to eye level and slowly accelerate to 5 mph while watchingspeedometer and bucket.


LOOK/FEEL: Does ride control come on at approximately 3 mph and bucket raiseslightly?


Differential Lock Check

T103168 —UN—05SEP96Park unit on a hard surface.Release brakes.Push differential lock switch and steer unit left and right.Release switch and steer unit left and right.LOOK: Do front wheels slide with differential lock on?NOTE: It is normal to get a "clunk" sound when you release switch. YES: Go to next check.LOOK: Do front wheels rotate in opposite directions with differential lock switchreleased?


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Clutch Cutoff Check

T194311 —UN—11SEP03Press clutch cutoff switch to enable clutch cutoff at any slope. LED(s) will illuminate.Apply brake.Increase engine rpm to 1500.Press clutch cutoff switch until clutch cutoff is turned off. All LEDs will be off.LISTEN/LOOK: Does engine rpm drop? YES: Go to next check.FEEL: Can you feel machine pull through brakes? NO: See your authorized

dealer.

Boom And BucketCylinder Drift Check

T6564NZ —UN—19OCT88Set bucket flat on the ground and raise about 50 mm (2 in.).Stop engine. Observe bucket for 1 minute.LOOK: Does bucket remain in position? Bucket should not settle to the ground. YES: Go to next check.NOTE: Use good judgement to determine if the amount of drift is objec-

tionable for your loader application.NO: See your authorizeddealer.

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PN=179



Automatic Shift AndSpeedometer Check

NOTE: In the AUTOMATIC mode, transmission will shift to highest gear selectedas ground speed increases, or will down shift to 2nd as ground speeddecreases. Transmission will never shift to 1st gear. In AUTO MODE TOFIRST the transmission will start in 1st when initially shifted from Neutral toForward or Reverse. After the initial shift from Neutral, the transmission willdownshift no lower than 2nd unless a high load is encountered. Transmissionwill upshift or downshift as ground speed dictates.

A

T194310 —UN—11SEP03Press automatic transmission switch to place transmission in automatic mode. LEDis illuminated.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?

744J, 824JShift MPH Km/H2nd-3rd 6 93rd-4th 10 164th-3rd 7 113rd-2nd 4 6


NOTE: In 4th Forward automatic the transmission starts out in 2nd gear and upshifts to3rd then 4th. When transmission downshifts it returns to 2nd. Transmission willshift at different speeds depending on machine loads. Use only as reference.


4-2-11 013013

PN=180



Transmission ShiftMode Check

A

T194310 —UN—11SEP03Press automatic transmission switch to place transmission in manual mode. LED is off.Press MENU to bring up themain menu, select Machine Settings (2), then Quick Shift (1).Press SELECT to set quick shift in Down/Up mode.Release park brake and shift to 3rd forward.Drive machine at approximately 1600 rpm and press Quick Shift Switch once.LOOK/FEEL: Does transmission shift to and remain in 2nd gear?Press Quick Shift Switch once more.LOOK/FEEL: Does transmission shift back to 3rd gear?NOTE: If Quick Shift Switch is pressed twice, transmission will shift down one gear then

immediately back up to where it was. Quick Shift feature operates in all gears.PressMENU to bring up themain menu, select Machine Settings (2), then Quick Shift (1).Press NEXT to highlight Down Only then press SELECT to set quick shift in Downonly mode.Release park brake and shift to 4th forward.Drive machine at approximately 1200 rpm and press Quick Shift Switch once.LOOK/FEEL: Does transmission shift to and remain in 3rd gear?Press Quick Shift Switch once more.LOOK/FEEL: Does transmission shift to and remain in 2nd gear?Press Quick Shift Switch once more.LOOK/FEEL: Does transmission shift to and remain in 1st gear?Press Quick Shift Switch once more. YES: Go to next check.LOOK/FEEL: Does transmission stay in 1st gear? NO: Check restriction

switch / radio ignition power10 A fuse (F11).

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.


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Axle Disconnect Check(If Equipped)

T6601AA —UN—19OCT88

T194318 —UN—11SEP03Operate machine in an open area away from bystanders.With bucket partially dumped, lower boom to raise front wheels off the ground.Press Axle Disconnect Switch on Sealed Switch Module (SSM) to disconnect axle.Watch front wheels while operating the machine in reverse. Front wheels must notrotate as machine moves backwards.


LOOK: Do front wheels remain stationary while machine moves backwards? NO: See your authorizeddealer.

Transmission ShiftModulation Check

T194311 —UN—11SEP03Press clutch cutoff switch to turn off clutch cutoff (all LEDs off).Press automatic transmission switch to place transmission in manual mode. LED is off.

CAUTION: Fasten seat belt before performing this check. Machinewill change directions abruptly!

Shift transmission to 1st forward, increase engine speed to fast idle, shift from forwardto reverse and reverse to forward several times, allowing machine to reach full speed inforward and reverse before changing directions. Repeat check in 2nd gear.LOOK: Does machine slow down and change direction smoothly?Drive machine in 2nd gear at high idle, apply service brakes to slow engine down to1800 rpm, then while still holding service brakes, shift to 1st gear.


FEEL: Does transmission shift smooth without jerking? NO: See your authorizeddealer.

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Torque Converter andEngine Power Check

T194311 —UN—11SEP03

T106883 —UN—14FEB97Release park brake.Press clutch cutoff switch to turn off clutch cutoff (all LEDs off).Apply service brakes so machine does not move.Shift transmission to 3rd forward.Push accelerator pedal until it touches stop bolt. Record engine speed in basic displaywindow.LOOK: Is torque converter stall speed within following range:

• No. 1 fuel: 1880—1980 rpm

• No. 2 fuel: 1930—2030 rpm YES: Go to next check.Move FNR to neutral "N" position and run for 15 seconds to cool oil. NO: If stall speed is outside

range, see your authorizeddealer.

Steering Valve Check

T6471AQ —UN—19OCT88Transmission in Neutral.Run engine at low idle.Remove foot from brake pedal.Release park brake.Turn steering wheel until machine frames contact right and left frame stops.LOOK: Does machine steer smoothly in both directions?NOTE: It is normal for machine frames to drift away from frame stops

when steering wheel is released.When steering wheel is stopped, frames must stop. YES: Go to next check.FEEL: Is excessive effort required to turn steering wheel? NO: See your authorized

dealer.

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VD76477,0001068 -19-15SEP06-31/32

VD76477,0001068 -19-15SEP06-32/32

Joystick Steering Check(If Equipped) CAUTION: Joystick steering sensitivity changes with speed. Become

familiar with steering at all speeds before operating in confined areas.Return column shifter to neutral.Lower arm left hand arm rest.LISTEN: Does monitor alarm beep?Press joystick activation switch to activate joystick steering.LOOK/LISTEN: Does joystick steering indicator flash on monitor? Does monitoralarm sound?NOTE: Joystick steering will not activate if park brake is applied.Press gear up and gear down buttons.LOOK: Does monitor display show gear selection as buttons are pressed?Press horn button.LISTEN: Does horn sound?Move joystick left and right.LOOK/FEEL: Does machine move smoothly left and right?Press joystick steering FNR selector to Forward and Reverse.LOOK/FEEL: Does machine move forward and backward?Select 1st forward and shift column shifter to 1st reverse. YES: Go to next check.LOOK/FEEL: Does joystick steering deactivate and column shifter selection overridejoystick steering gear selection?

NO: Joystick steering doesnot operate. Check JoystickSteering Ignition Power 5 AFuse.

Check Flex Load Controllerand Transmission ControlUnit Circuits.

Check steering systemhydraulics.

Secondary SteeringSystem Check (IfEquipped)

IMPORTANT: Do not operate secondary steering pump for more than 15 secondswith the steering in neutral or damage to the pump and motor can occur.

Park unit on a hard level surface with engine running and machine frames straight.Remove ECU ignition power fuse (F10).Secondary steering will activate.Steer unit to right and left. YES: Go to next check.LOOK: Does machine steer approximately half way to stops in both directions? Doeslight in monitor come on and stay on until key is turned off?


Diagnostic TroubleCodes Check

Check Diagnostic Trouble Codes. Diagnostic Trouble Codes can be displayed usingSERVICE ADVISOR™ system or machine CAN monitor unit (CMU).Display diagnostic trouble codes using machine CMU:Press MENU to reach main menu. Press SELECT to view code menu, then selectActive Codes or Stored Codes. Press NEXT to view the next code or press SELECTto view more information on that code.If any codes appear, see Diagnostic Trouble Codes. IFOK: Operational

Checkout complete.

SERVICE ADVISOR is a trademark of Deere & Company

4-2-15 013013

PN=184

Miscellaneous—Troubleshooting

HG31779,0000020 -19-06MAY10-1/1

Troubleshooting ProcedureNOTE: Troubleshooting charts are arranged from the

simplest to verify, to least likely, more difficultto verify. When diagnosing a problem, useall possible means to isolate the problem to asingle component or system. Use the followingsteps to diagnose problems:

Step 1. Operational Checkout Procedure

Step 2. Troubleshooting Charts

Step 3. Adjustments

Step 4. See your authorized John Deere dealer.

4-3-1 013013

PN=185


Continued on next page TX17961,000000B -19-03OCT02-1/2

EngineSymptom 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 cold temperatures.

Engine Misfires/Runs Irregularly Intake manifold air leaks Check for intake manifold air leaks

Mechanical problems Check for mechanical problems.

Transmission problems Check for transmission problems.

Engine accessories cycling on and off Check engine accessories, such asA/C, cycling on and off.

Electronic interference Check for improperly installed radios,etc.

Engine Does Not Develop FullPower

Restricted or plugged air and fuelfilters

Check for restricted or plugged air andfuel 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 WhiteExhaust Smoke

Fuel quantity and quality Check fuel quantity and quality.

Low engine coolant temperature Check for extremely low enginecoolant temperature.

Engine Emits Excessive Black OrGray Smoke

Fuel quantity and quality Check fuel quantity and quality.

Restricted or plugged air filter Check for restricted or plugged airfilter.

Excessively loaded engine Check for excessively loaded engine.

Engine Will Not Crank Weak battery Replace battery.

4-3-2 013013

PN=186


TX17961,000000B -19-03OCT02-2/2

Symptom Problem Solution

Corroded or loose battery connections Clean battery terminals andconnections.

Defective main switch or start safetyswitch

Repair switch as required.

Starter solenoid defective Replace solenoid.

Starter defective Replace starter.

Start circuit defective Check wiring, fuses, and relays.

Engine is seized Check by rotating engine by hand.

Engine Idles Poorly Poor fuel quality Drain fuel and replace with quality fuelof the proper grade.

Air leak on suction side of air intakesystem

Check hose and pipe connections fortightness; repair as required.

4-3-3 013013

PN=187


Continued on next page TX17961,000016A -19-21JAN13-1/2

TransmissionSymptom Problem Solution

Transmission Clutch Slippage Low oil level See Transmission, Hydraulic System,Park Brake, And Differential Oil.

Wrong oil grade See Transmission, Hydraulic System,Park Brake, And Differential Oil.

Restricted Transmission pump suctionscreen

Remove and clean screen.

Machine Will Not Move Diagnostic Trouble Code (DTC)related problem

See your authorized dealer.

Applied park brake (electrical problem) Check park brake fuse.

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 control unit Check transmission control switched5A fuse.

Check monitor and transmissioncontrol 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.

Machine Does Not Engage Clutch cutoff activated Check that brake pedal is fullyreleased.

Shift switch problem Check Diagnostic Trouble Codes todefine problem.

Machine Will Not Shift Correctly Speed sensor disconnected or failed Check electrical connectors ontransmission speed sensors.

Low oil level Add oil.

Transmission Shifts Too Slow Low oil level (aeration of oil) Add oil.

Restricted transmission pump suctionscreen

Remove and clean suction screen.

Transmission Hydraulic SystemOverheats

High oil level Check transmission oil level.

4-3-4 013013

PN=188


TX17961,000016A -19-21JAN13-2/2


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 lubelines

Check cooler lines.

Malfunction in temperature gauge orsender

Install temperature sensor to verifytemperature.

Restricted air flow through oil cooleror radiator

Check oil cooler and radiator fordebris. Clean if needed.

Excessive Transmission Noise(under load or no load)

Worn parts or damaged intransmission

Inspect suction screen for metalparticles.

Damaged drive damper Inspect drive damper.

Driveline or park brake Inspect drive line and park brake.

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.

Failed universal joints on transmissiondrive shaft or differential drive shafts

Check universal joints.

Damaged drive damper. Inspect drive damper.

Machine Lacks Power AndAcceleration

Incorrect transmission oil Drain transmission oil and refill. SeeChange Transmission Oil.

Aerated oil Check oil level. Add oil if needed.

4-3-5 013013

PN=189


Continued on next page TX17961,000016C -19-03OCT02-1/2

Differential And AxleSymptom Problem Solution

No differential Lock Operation Malfunction in electrical circuit With engine stopped and key switchon, activate differential lock and listenfor a click from solenoid valve.

Stuck differential lock solenoid valve With engine stopped and key switchon, activate differential lock and listenfor a click from solenoid valve.

Excessive leakage in differential lockpiston seals

Check differential oil level.

Differential Lock Slips Or ChattersWhen Engaged

Axle oil broken down Change axle oil. See Change Frontand Rear Differential Oil.

Excessive leakage differential lockpiston seals

Check differential oil level.

Differential Lock Will Not Release Stuck foot switch Inspect.

Malfunction in electrical circuit With engine stopped and key switchon, activate differential lock and listenfor a click from solenoid valve.

Stuck differential lock solenoid valve With engine stopped and key switchon, activate differential lock and listenfor a click from solenoid valve.

Differential Low On Oil External leakage Inspect axle and differential for leaks.

Excessive Differential And/Or AxleNoise

Low oil level in differential Check oil. Remove drain plugand inspect for metal particles indifferential case. See Check Frontand Rear Differential Oil Level.

Engaged differential lock Release lock.

If circuit remains pressurized, check iffoot switch is sticking. Remove andinspect.

Check solenoid valve for sticking.Remove and inspect valve.

Oil Seeping From Outer Axle Seal Dirt in face seal Inspect face seals.

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.

4-3-6 013013

PN=190


TX17961,000016C -19-03OCT02-2/2

TX17961,000016D -19-03OCT02-1/1

TX17961,000016E -19-03OCT02-1/1


Overfilled differential Check oil level. Drain oil if needed.

Axle recirculation motor dual pumpscreens plugged

Inspect axle recirculation filter screenlocated in differential housing belowinput yoke. See Clean Axle DifferentialRecirculation Screen.

Service BrakeSymptom Problem Solution

Poor or No Brakes Axle overheated Check axle temperature.

Brake disks worn or warped Inspect service brake pads.

Aggressive Brakes Clutch cutoff mode set to steep slope Press clutch cutoff switch until “Off”position.

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 correctoil. See Change Front and RearDifferential Oil.

Drive LineSymptom Problem Solution

Excessive Drive Line Vibration OrNoise

Lack of lube in park brake Inspect park brake oil level and adjustas required. See Check Park BrakeOil Level.

Bent drive shaft Inspect all drive shafts.

Loose yoke retaining nuts (drive shaftswobble at high speed)

Inspect. Replace.

Rear axle oscillating support Inspect.

Lack of lubrication Lubricate with proper grade of grease.

4-3-7 013013

PN=191


TX17961,000016F -19-03OCT02-1/1

Park BrakeSymptom Problem Solution

Brake Will Not Hold Breather plugged Inspect and clean breather.

Malfunctioning park brake solenoid Inspect.

Brake Overheats Overfilled with oil Adjust oil level. See Check ParkBrake Oil Level.

Breather plugged Inspect and clean breather.

Park Brake Indicator In MonitorComes On When Shifting From Fwdto Rev (All Other Gears OK)

Low oil level Check oil level. Add oil if needed.

Cold oil Warm oil.

Park Brake Light Comes On ForEach Shift

Cold oil Warm oil.

Park Brake Indicator In MonitorDoes Not Come On When BrakeApplied

Faulty wiring or switch Inspect for loose or broken wiresbetween brake indicator switch andindicator on dash.

4-3-8 013013

PN=192


Continued on next page TX17961,0000170 -19-03OCT02-1/2

Hydraulic SystemSymptom Problem Solution

No Hydraulic Functions Pilot enable switch OFF Turn switch ON

Pilot enable switch failed Check pilot enable switch.

Slow Hydraulic Functions Cold oil Warm oil.

Slow engine speed Check fast idle speed.

Suction line air leak Check for foamy oil.

Low oil supply Add recommended oil.

Wrong oil viscosity Use recommended oil.

Blocked or damaged line Inspect lines.

Noisy Hydraulic Pump Low oil supply or wrong viscosity Fill reservoir with recommended oil.

Plugged or pinched suction line Clean or replace line.

Air in oil Check for foamy oil. Tightenconnections. Replace O-rings and/orlines.

Loose or missing hydraulic line clamps Tighten or replace clamps.

Hydraulic lines in contact with frame Inspect and repair.

Boom Float Function Does NotWork

Return-to-carry switch ON Turn switch OFF.

One Hydraulic Function Does NotWork

Blockage in oil lines or valve Inspect lines for damage.

Function Drifts Down Leaking cylinders Check cylinder leakage.

Boom lower solenoid valve Check Solenoid.

Leaking loader control valve Replace valve section.

BoomDown Does NotWork (EngineOff)

Pilot enable/boom down switch notheld down

Push and hold pilot enable/boomdown switch as loader control lever ismoved.

Boom down solenoid failed Replace solenoid.

Pilot enable/boom down switch failed. Replace switch.

Oil Overheats Low oil viscosity in hot weather Use recommended oil.

Cylinder Leakage Check cylinder leakage.

4-3-9 013013

PN=193


TX17961,0000170 -19-03OCT02-2/2

VD76477,000106B -19-15SEP06-1/1


Restriction in oil lines or loader valve Inspect for dented or kinked lines.

Hydraulic Oil Foams Low oil level Add recommended oil.

Wrong oil Change to recommended oil.

Water in oil Drain oil from reservoir and cylinders.Fill with recommended oil.

Loose or faulty suction lines (air leakin system)

Tighten or install new lines.

Pin Disconnect Cylinders Will NotRetract

Electrical circuit failure Hold a screwdriver against end of pindisconnect solenoid valve and checkfor magnetism with switch pushed.

Solenoid valve failure Remove and inspect.

Cylinder binding Inspect cylinder and adjust loads.

SteeringSymptom Problem Solution

No Steering Functions Frame locking bar in place Pin locking bar in unused position.

Low oil level Add recommended oil.

Pinched steering line Inspect and repair line.

No Joystick Steering Functions Check for Diagnostics Trouble Codes(DTC) in CAN Monitor Unit (CMU)


Check joystick steering valveoperating pressure


Check for load sense signal on port LX If pressure present check orbitalsteering valve.

Failed joystick steering valve See your authorized dealer.

Erratic Steering Air in oil Check for foamy oil.


Spongy or Soft Steering Air in oil Check for foamy oil.


Machine Turns in OppositeDirection

Lines to cylinders connected to wrongports at steering valve.

Connect lines to correct ports.

4-3-10 013013

PN=194


Continued on next page TX17961,0000172 -19-03OCT02-1/2

Air Conditioning SystemSymptom Problem Solution

Air Conditioning System Does NotOperate

FLC ignition power 5A fuse (F15) Replace fuse.

FLC battery power 10A fuse (F21) Replace fuse.

Blower motor 25A fuse (F5) Replace fuse.

Pressurizer motor 10A fuse (F33) Replace fuse.

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 binary pressure switch (B50) Check switch.

A/C compressor clutch solenoid (Y16) Check clutch operation.

Air Conditioner Does Not CoolInterior of Cab

Fresh air filter clogged Clean or replace filter.

Condenser fins clogged with debris Clean condenser fins.

Recirculating air filter clogged Clean or replace filter.

Compressor pulley worn Replace pulley.

Refrigerant hose kinked, pinched orcollapsed

Re-route or re-index hoses, replacekinked or collapsed hoses.

Heater or evaporator core fins cloggedwith dirt or dust

Clean heater or evaporator core fins.

Pressurizer blower motor failed oroperating too slowly

Check motor speed.

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) chargelow

Inspect system for leaks.

4-3-11 013013

PN=195


TX17961,0000172 -19-03OCT02-2/2

TX17961,0000173 -19-03OCT02-1/1


Evaporator fins frosting or freezing Freeze control switch capillary tubenot positioned correctly in evaporatorcore.

Air Conditioner Runs Constantly,Too Cold

Freeze control switch capillary tubenot positioned in evaporator correctly

Reposition capillary tube in evaporatorcore

Interior Windows Continue To Fog Fresh air filter clogged Clean or replace filter.

A/C system off Turn A/C (ON/OFF) switch ON.

Heater SystemSymptom Problem Solution

Heater System Does Not Operate Blower motor fuse Replace fuse.

Blower speed switch Check switch.

Heater Does Not Warm Interior OfCab

Fresh air filter clogged Clean or replace filter.

Recirculating air filter clogged Clean or replace filter.

Heater hose kinked, pinched orcollapsed

Re-route or re-index hoses, replacecollapsed hoses.

Heater core fins clogged with dirt ordust

Clean heater fins.

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 Fog Fresh air filter clogged Clean or replace filter.

A/C system off (if equipped) Turn A/C ON/OFF switch ON (ifequipped).

4-3-12 013013

PN=196

Miscellaneous—Storage

ER93822,00000E7 -19-18MAR08-1/1

Prepare Machine For StorageIMPORTANT: Avoid machine damage, do not use

biodiesel during machine storage. Whenusing biodiesel blends, switch to petroleumdiesel for long term storage.

1. Before storage, operate engine on at least onecomplete tank of petroleum diesel fuel to purge thefuel system. Ensure that the fuel tank is full duringstorage to prevent water build up due to condensation.

NOTE: For blends up to and including B20, it isrecommended that biodiesel be used within threemonths of its manufacture. For blends greaterthan B20, it is recommended that the biodieselbe used within 45 days. The poor oxidationstability characteristic of biodiesel can result inlong-term storage problems. John Deere does notrecommend using biodiesel in engines poweringstandby applications or vehicles operating on aseasonal basis. Consult your John Deere dealer orfuel supplier for additives to improve fuel storageand performance of biodiesel fuels. These additivesmust be added to the biodiesel close to its timeof production for them to be effective.

2. Repair worn or damaged parts. Install new parts, ifnecessary, to avoid needless delays later.

3. Check primary air cleaner. Replace filter, if necessary.

IMPORTANT: High pressure washing greater than1379 kPa (13.8 bar) (200 psi) can damagefreshly painted finishes. Paint should beallowed to air dry for 30 days minimum afterreceipt of machine before cleaning parts ormachines with high pressure.

4. Wash the machine. Use spray pressure less than1379 kPa (13.8 bar) (200 psi) on new machines duringfirst 30 days. Paint areas as required to prevent rust.Replace decals where needed.

5. Fill fuel tank, to prevent condensation.

T5813A

M—UN—09FE

B89

6. Run machine back and forth several times. Parkmachine on a hard surface to prevent tires fromfreezing to ground.

7. 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 3 RustInhibitor on painted areas.

8. Retract all hydraulic cylinders, if possible. If not, coatexposed cylinder rods with LPS ® 3 Rust Inhibitor.

9. Lubricate all grease points.

10. Turn key to ON position; DO NOT START engine.

11. Press and hold pilot enable/boom down switch, thenmove all hydraulic control levers to relieve pressure.

12. Turn key to OFF position.

13. Place "DO NOT OPERATE" tag on control lever.

14. Remove batteries.

15. Remove seat cushion and other perishable items.

16. Remove keys and lock all covers and doors.

LPS is a trademark of the Holt Lloyd Corporation.

4-4-1 013013

PN=197

Miscellaneous—Storage

VD76477,00016A3 -19-13JUN11-1/2

VD76477,00016A3 -19-13JUN11-2/2

Monthly Storage Procedure

CAUTION: Prevent possible injury or deathfrom asphyxiation. Engine exhaust fumescan cause sickness or death. Start engineONLY in a well-ventilated area.

1. Drain water and sediment from fuel tank when airtemperature is above freezing.

2. Remove LPS 3® Rust Inhibitor from cylinder rods witha cleaning solvent.

T6191A

A—UN—18OCT88

LPS 3 Rust Inhibitor is a trademark of Illinois Tool Works.

IMPORTANT: Prevent possible engine damage.During cold temperatures, check fluidity ofengine oil on dipstick. If the oil appears waxyand/or jelly-like rather than liquid, DO NOTattempt to start engine. Use external heat sourceto warm the crankcase until oil appears fluid.

3. Check all fluid levels. If low, check for leaks and addoil as required.

4. Check belts.

5. Check condition of all hoses and connections.

6. Check battery electrolyte level. Charge and installbattery.

7. For machines with tires, check condition of tires andtire pressure.

For machines with tracks, check condition of tracksand track sag.

On crawler machines with non sealed-and-lubricatedtrack chains, apply oil to the pin-to-bushing joints. Runmachine back and forth several times.

8. Park machine on a hard surface to prevent tracks fromfreezing to ground.

9. Fill fuel tank.

10. Pre-lubricate turbocharger bearings, if equipped:

a. Disconnect fuel shutoff fuse.

b. Crank engine for 10 seconds.

c. Connect fuel shutoff fuse.

11. Inspect engine compartment, and remove any foreignmaterial that may have accumulated. Start engine and

T6181A

U—UN—18OCT88

run until it reaches operating temperature. Run at 1/2speed for five minutes. Do not run at fast or slow idle.

• If engine fails to start or runs poorly after starting,change fuel filter(s). Bleed fuel system.

12. Operate all controls, levers, seat adjustments, etc.

CAUTION: Prevent possible injury fromunexpected machine movement. Clear thearea of all persons before running machinethrough the operation procedure.

13. Make sure the area is clear to allow for movement.Cycle all hydraulic functions several times. Checkcondition of all hoses and connections.

14. Park the machine with cylinder rods retracted, ifpossible. Turn key switch to OFF.

15. Apply LPS 3 Rust Inhibitor to exposed cylinder rodareas.

4-4-2 013013

PN=198

Miscellaneous—Machine Numbers

TX,110,JC1733 -19-03DEC96-1/1

TX,110,JC1582 -19-20AUG96-1/1

TX,110,JC1583 -19-20AUG96-1/1

Record Product Identification Number (PIN)Purchase Date

NOTE: Record all 13 characters of the ProductIdentification Number (A).

T105500B

—UN—12DEC96

Record Engine Serial NumberEngine Serial Number (A)

T103191B

—UN—12DEC96

Record Transmission Serial NumberTransmission Serial Number (A)

Located on right side of transmission case, near lowerright corner of case.

T103192B

—UN—12DEC96

4-5-1 013013

PN=199

Miscellaneous—Machine Numbers

TX,110,JC1523 -19-12AUG96-1/1

DX,SECURE2 -19-18NOV03-1/1

DX,SECURE1 -19-18NOV03-1/1

Record Hydraulic Pump Serial NumberHydraulic Pump Serial Number (A)

T103357B

—UN—12DEC96

Keep Machines Secure1. Install vandal-proof devices.2. When machine is in storage:

- Lower equipment to the ground- Set wheels to widest position to make loading moredifficult

- Remove any keys and batteries3. When parking indoors, put large equipment in front of

exits and lock your storage buildings.4. When parking outdoors, store in a well-lighted and

fenced area.5. Make note of suspicious activity and report any thefts

immediately to law enforcement agencies.6. Notify your John Deere dealer of any losses.

TS230—UN—24MAY

89

Keep Proof of Ownership1. Maintain in a secure location an up-to-date inventory

of all product and component serial numbers.2. Regularly verify that identification plates have not

been removed. Report any evidence of tampering tolaw enforcement agencies and order duplicate plates.

3. Other steps you can take:- Mark your machine with your own numbering system- Take color photographs from several angles of eachmachine

TS1680

—UN—09DEC03

4-5-2 013013

PN=200

Miscellaneous—Specifications

Continued on next page TX,115,JC1524A -19-08MAR07-1/2

744J Specifications

T102977—UN—16AUG96

A—Bucket Hinge Height 4281mm (14 ft 0.6 in.)

B—Dump Height 3042 mm (9 ft10 in.)

C—Dump Reach 1270 mm (4 ft 2in.)

D—Overall Height 3520 mm (11 ft6.6 in.)

E—Wheelbase 3400 mm (11 ft 2in.)

F—Ground Clearance 465 mm(18.3 in.)

G—Overall Length 8586 m (28 ft2 in.)


Bucket Hinge-To-Ground Height Distance 4281 mm14 ft 0.6 in.

Bucket Dump-To-Ground Height Distance 3042 mm9 ft 10 in.

Bucket Dump-To-Tire Reach Distance 1270 mm4 ft 2 in.

Machine Overall Height 3520 mm11 ft 6.6 in.

Machine Wheelbase Length 3400 mm11 ft 2 in.

Machine Ground Clearance 465 mm18.3 in.

Machine Overall Length 8403 m28 ft 2 in.

4-6-1 013013

PN=201


TX,115,JC1524A -19-08MAR07-2/2


Machine Operating Weight 23 360 kg51 500 lb

Assumed Operator Weight 79 kg175 lb

NOTE: Specifications and design subject to changewithout notice. Wherever applicable, specificationsare in accordance with SAE standards. Exceptwhere otherwise noted, specifications are based ona machine equipped with all standard equipment,

with 566 kg (1248 lb) optional counterweight, ROPScab, diff lock front axle with standard rear axle,2 spool valve with two lever control, heater anddefroster, 79 kg (175 lb) operator and full fuel tank.


John Deere 6125ATurbocharged AndAftercooled Diesel Engine:

Gear 1: Power 240 hp @ 2000 rpm

Gears 2-4: Power 260 hp @ 2000 rpm

Piston Displacement Distance 12.5 L766 cu in.

Air Cleaner w/Safety Element AndRestriction Indicator

Type Dual stage dry type with restrictionindicator

Electrical System Voltage 24 volt with 80-amp alternator

Cold Cranking Capacity At -18°C(0°F)

Current 950 amps

Reserve Capacity Time 190 min.

Torque Converter Type Single phase, single stageTransmission

Countershaft Type Computer controlled powershiftForward Travel:

1 Speed 7.4 km/h4.6 mph




Reverse Travel:




NOTE: All travel speeds are with 26.5—25 20PR (L3) tires.

4-6-2 013013

PN=202


VD76477,00004F3 -19-19APR10-1/1

Drain and Refill Capacities—744JItem Measurement Specification

Cooling system Capacity 38.0 L10.0 gal

Fuel tank Capacity 462.0 L122.0 gal

Engine crankcase and filter Capacity 38.0 L10.0 gal

Transmission case and filter Capacity 28.0 L30.0 qt

Front differential Capacity 46.0 L12.0 gal

Rear differential Capacity 46.0 L12.0 gal

Front differential—With OptionalWide Axle

Capacity 49.0 L13.0 gal

Rear differential—With OptionalWide Axle

Capacity 49.0 L13.0 gal

Hydraulic reservoir and filters Capacity 144.0 L38.0 gal

Park brake Capacity .6 L20.0 oz

4-6-3 013013

PN=203


Continued on next page TX,115,JC1560A -19-27SEP01-1/2

824J Specifications

T103085—UN—16AUG96

A—Bucket Hinge Height 4510mm (14 ft 10 in.)

B—Dump Height 3202 mm (10 ft6 in.)

C—Dump Reach 1260 mm (4 ft 1in.)

D—Overall Height 3520 mm (11 ft6.6 in.)

E—Wheelbase 3400 mm (11 ft 2in.)

F—Ground Clearance 465 mm(18.3 in.)

G—Overall Length 8825 mm (28ft 11 in.)


Bucket Hinge Height 4281 mm14 ft 10 in.

Dump Height 3202 mm10 ft 6 in.

Dump Reach Distance 1260 mm4 ft 1 in.

Overall Height 3520 mm11 ft 6.6 in.

Wheelbase Distance 3400 mm11 ft 2 in.

Ground Clearance 465 mm18.3 in.

Overall Length 8991 mm29 ft 6 in.

4-6-4 013013

PN=204


TX,115,JC1560A -19-27SEP01-2/2


Standard Operating Weight 23 450 kg57 710 lb

Assumed Operator Weight 79 kg175 lb

NOTE: Specifications and design subject to changewithout notice. Wherever applicable, specificationsare in accordance with SAE standards. Exceptwhere otherwise noted, specifications are based ona machine equipped with all standard equipment,

with 566 kg (1248 lb) optional counterweight, ROPScab, diff lock front axle with standard rear axle,2 spool valve with two lever control, heater anddefroster, 79 kg (175 lb) operator and full fuel tank.


John Deere 6125ATurbocharged AndAftercooled Diesel Engine:

Engine: Net Rated Power 275 hp @ 2000 rpm

Piston Displacement Distance 12.5 L766 cu in.

Air Cleaner w/Safety Element AndRestriction Indicator

Type Dual stage dry type with restrictionindicator

Electrical System Voltage 24 volt with 80-amp alternator

Cold Cranking Capacity At -18°C(0°F)

Current 950 amps

Reserve Capacity Time 190 min.

Torque Converter Type Single phase, single stage

Transmission Type Countershaft, computer controlledpowershift

Forward Travel:





Reverse Travel:




NOTE: All travel speeds are with 26.5—25 tires.

4-6-5 013013

PN=205


AM40430,00002E4 -19-19APR10-1/1

Drain and Refill Capacities—824JItem Measurement Specification

Cooling system Capacity 38.0 L10.0 gal

Fuel tank Capacity 462.0 L122.0 gal

Engine crankcase and filter Capacity 38.0 L10.0 gal

Transmission case and filter Capacity 28.0 L30.0 qt

Front differential Capacity 46.0 L12.0 gal

Rear differential Capacity 46.0 L12.0 gal

Hydraulic reservoir and filters Capacity 144.0 L38.0 gal

Park brake Capacity .6 L20.0 oz

4-6-6 013013

PN=206

Index

Page

A

AccumulatorBrakeCheck ............................................................... 4-1-16

Ride control.......................................................... 4-1-17Acid burns.................................................................. 3-8-4AdjustmentSeat...................................................................... 2-1-28Steering wheel tilt................................................. 2-1-24

AirCharge cooler hoseCheck ................................................................. 3-8-3

Cleaner elementsReplace .............................................................. 3-3-5

Cleaner elements replace...................................... 3-9-1Cleaner unloader valve .......................................... 3-4-1Conditioning systemService ............................................................. 4-1-14

Inlet cover .............................................................. 3-3-5Intake hoseCheck ................................................................. 3-8-3

Air conditioningControl ................................................................. 2-1-24Diagnose malfunctions......................................... 4-3-11

Air heater ................................................................... 2-2-5Alternator ................................................................... 4-1-5Arm restJoystick steering .................................................. 2-1-25

AttachmentsAdding safely ......................................................... 1-3-5Operating safely..................................................... 1-3-5

AxleClean recirculation screen ................................... 3-10-3

B

Backdragging........................................................... 2-2-18BatteriesUsing battery charger............................................. 4-1-8

BatteryAcid burns.............................................................. 3-8-4Booster................................................................... 4-1-7Electrolyte level check ........................................... 3-8-4Explosion ............................................................... 3-8-4Handling, checking, and servicing ......................... 4-1-6Remove and install ................................................ 4-1-9Terminals................................................................ 3-8-4

Battery explosionsPrevent................................................................... 1-2-5

BeltSerpentineInspect................................................................ 3-3-6

BleedBrake.................................................................... 4-1-18

Bleeding fuel system ...........................3-3-11, 4-1-3, 4-1-4

Page

Bolt and screw torque valuesMetric ................................................................... 4-1-22Unified inch .......................................................... 4-1-23

BoomControl lever-one lever design............................. 2-2-10Control lever-two lever design ............................. 2-2-11Height kickout adjustment.................................... 2-2-15

Boom LockStorage .................................................................. 3-2-3

BrakeAccumulatorCheck ............................................................... 4-1-16

Bleed.................................................................... 4-1-18External inspection............................................... 4-1-14Park, change oil ..................................................... 3-9-6Park, check ............................................................ 4-1-3

BucketControl lever-one lever design............................. 2-2-10Control lever-two lever design ............................. 2-2-11

C

CabFresh air filter ....................................................... 3-3-11Recirculating air filter ........................................... 3-3-12

Cab fresh air filterClean.................................................................... 3-3-11

Cab recirculating air filterClean.................................................................... 3-3-12

Charge air coolerCleaning procedure.............................................. 4-1-19

Checklist .................................................................... 3-2-6Chemical productsHandling................................................................. 1-2-5

Circuit breaker ......................................................... 4-1-12CleanFittingsHydraulic pump case drain................................. 3-9-5

Cleaning procedureCharge air cooler ................................................. 4-1-19Oil cooler.............................................................. 4-1-19Radiator ............................................................... 4-1-19

Control leverShifting transmission....................................2-2-6, 2-2-7

CoolantDiesel engine ......................................................... 3-1-8Drain ...................................................................... 4-1-1Fill procedure ......................................................... 4-1-2Heater .................................................................... 2-2-5Level radiator ......................................................... 3-7-2Level recovery tank................................................ 3-4-1Sample................................................................. 3-8-11

Crankshaft damper replacement ............................. 3-12-1Cylinder ................................................................... 4-1-21PivotFront steering, lubricate...................................... 3-5-2

Pivots, lubricate...................................................... 3-5-1


Index-1 013013

PN=1

Index

Page

D

Daily inspection ......................................................... 2-2-1Damper replacement, crankshaft ............................ 3-12-1DiagnoseDrive Line Malfunctions.......................................... 4-3-7

Diagnose malfunctionHydraulic system.................................................... 4-3-9Transmission system ............................................. 4-3-4

Diagnose malfunctionsTroubleshooting procedure .................................... 4-3-1

Diesel fuel........................................................3-1-1, 3-1-2Sample................................................................. 3-8-11

Diesel fuel conditionerLow sulfur............................................................... 3-1-3

Diesel fuel, testingTesting Diesel Fuel................................................. 3-1-3

DifferentialClean axle recirculation screen............................ 3-10-3FrontOil level, check ................................................... 3-8-9

Front (standard axle)Oil level check .................................................. 3-8-10

Front and rearOil change ..............................................3-6-2, 3-10-2

Lock foot switch ..................................................... 2-1-2Lock pedal............................................................ 2-2-15Lock return filter(s), replace ................................. 3-11-3Oil specification...................................................... 3-1-7RearOil level check .................................................. 3-8-10

Rear (standard axle)Oil level check .................................................. 3-8-11

Differential/axleDiagnose malfunctions........................................... 4-3-6

DiggingLoader bucket ...................................................... 2-2-17

DoorGrille....................................................................... 3-2-4Locking open side................................................ 2-1-25

Drive lineU-JointsLubricate............................................................. 3-8-1

DrivelineFront sliding joints, lubricate .................................. 3-7-1

Driving metal pins ...................................................... 1-4-3Dust valve.................................................................. 3-9-1

E

Effect of Cold Weather on Diesel EnginesDiesel Engines, Cold Weather Effect..................... 3-1-4

ElectricalFuse Specifications.............................................. 4-1-10

ElementAir cleanerReplace .............................................................. 3-3-5

Emergency preparation ............................................. 1-2-6

Page

Emissions control warranty statement............................ -3EngineAir heater ............................................................... 2-2-5Boost starting......................................................... 4-1-7Break-in.................................................................. 2-2-2Check and adjust valve lash ................................ 3-10-1Cold weather warm-up........................................... 2-2-5Crankshaft damper replacement.......................... 3-12-1Oil change....................................................3-6-1, 3-8-5Oil level .................................................................. 3-4-2Serial number......................................................... 4-5-1Starting................................................................... 2-2-2Vent tube................................................................ 3-9-2

Engine oilSample................................................................... 3-7-2

Engine side shieldsOpening ................................................................. 3-2-4

ExplosionBattery.................................................................... 1-2-5

F

FeaturesOperator convenience............................................ 1-1-1Safety..................................................................... 1-1-1

FilterCab air recirculating ............................................. 3-3-12Cab fresh air ........................................................ 3-3-11Differential lock return, replace ............................ 3-11-3Engine oil, replace .......................................3-6-1, 3-8-5Fuel ........................................................................ 3-8-7Fuel (water separator)Replace ....................................................3-3-8, 3-8-6

Fuel, In-LineReplace ......................................... 3-3-9, 3-9-2, 3-9-3

Hydraulic reservoir breather, replace..................... 3-8-8Hydraulic return, replace..............................3-6-2, 3-8-5Transmission oil ..................................................... 3-9-4

Fire extinguisherCheck..................................................................... 4-1-5

Fire prevention........................................................... 1-2-5FittingsHydraulic pump case drainClean.................................................................. 3-9-5Inspect................................................................ 3-9-5

Fluid analysis test kit ................................................. 3-2-5FrameMachine lock bar.................................................... 3-2-3

Front drivelineLubricate ................................................................ 3-7-1

FuelDiesel ...........................................................3-1-1, 3-1-2FilterReplace ....................................................3-3-8, 3-8-6

Filter change .......................................................... 3-8-7Handling and storing.............................................. 3-1-3Lubricity.................................................................. 3-1-1Tank ....................................................................... 3-2-5Tank drain .............................................................. 3-3-7


Index-2 013013

PN=2

Index

Page

Fuel filterChange .................................................................. 3-8-7

Fuel systemBleeding...........................................3-3-11, 4-1-3, 4-1-4

Fuel tankVent hoseCheck ................................................................. 4-1-3

FuseBlade typeColor codes ...................................................... 4-1-12

Color codes.......................................................... 4-1-12Specification......................................................... 4-1-10

G

GaugeEngine coolant temperature................................... 2-1-3Fuel ........................................................................ 2-1-3Transmission oil temperature................................. 2-1-3

Grease....................................................................... 3-1-7Alternative and synthetic lubricants ....................... 3-1-5Boom and cylinder pivots....................................... 3-5-1Frame hinge pivots ................................................ 3-9-5Oscillating rear axle ............................................... 3-5-3Rear steering cylinder pivots.................................. 3-5-2Steering cylinder pivots.......................................... 3-5-2

Grille door .................................................................. 3-2-4

H

Halogen bulbs.......................................................... 4-1-13Handhold Use............................................................ 1-3-1HardwareTorque specifications ........................................... 4-1-21

Hardware torque valuesMetric ................................................................... 4-1-22Unified inch .......................................................... 4-1-23

HazardsAvoiding ................................................................. 1-3-2

HeaterControl ................................................................. 2-1-24Coolant................................................................... 2-2-5Engine air............................................................... 2-2-5

Heater systemDiagnose malfunctions......................................... 4-3-12

High-pressure oilsAvoid ...................................................................... 1-2-4

Horn button.............................................................. 2-1-23HoseAir IntakeCheck ................................................................. 3-8-3

Charge air coolerCheck ................................................................. 3-8-3

CoolantCheck ................................................................. 4-1-1

Fuel filler drain hoseInspect................................................................ 3-3-7

Radiator ................................................................. 3-9-2

Page

Tank breather hoseInspect................................................................ 3-3-7

HydraulicOil change............................................................ 3-11-1Oil level .................................................................. 3-4-2Oil specification...................................................... 3-1-7PumpCase drain fittings............................................... 3-9-5

Pump serial number............................................... 4-5-2Reservoir breather filter, replace............................ 3-8-8Return filter, replace.....................................3-6-2, 3-8-5

Hydraulic systemMalfunctions........................................................... 4-3-9Suction strainer .................................................... 3-11-2

I

IndicatorLocation ................................................................. 2-1-3Secondary steering.............................................. 2-2-14

InspectExternal Seal.......................................................... 3-3-6FittingsHydraulic pump case drain................................. 3-9-5

InstrumentsCheck before starting............................................. 2-2-1

J

JDLink........................................................................ 4-1-9Laptop connection................................................ 4-1-10

JDLink fusesUnswitched and switched .................................... 4-1-10

JoystickSteeringActivate............................................................... 2-2-8

Joystick steeringArm rest ............................................................... 2-1-25Shifting transmission.............................................. 2-2-7

Jump starting............................................................. 4-1-7

L

Lamps...................................................................... 4-1-13LeverBoom control-one lever design ............................ 2-2-10Boom control-two lever design............................. 2-2-11Bucket control-one lever design........................... 2-2-10Bucket control-two lever design........................... 2-2-11Loader.................................................................... 2-1-1

LiftingMachine ............................................................... 2-2-28

Loader linkageLubricate ................................................................ 3-5-1

Loading machine on a trailer ................................... 2-2-23Loading machine on trailerUsing joystick steering ......................................... 2-2-25


Index-3 013013

PN=3

Index

Page

LockBar, machine frame................................................ 3-2-3Neutral ................................................................... 2-2-6

Low sulfur diesel fuel conditioner .............................. 3-1-3LubricantsAlternative and synthetic lubricants ....................... 3-1-5

LubricateBoom and cylinder pivots....................................... 3-5-1Drive line U-joints................................................... 3-8-1Frame hinge pivots ................................................ 3-9-5Front driveline ........................................................ 3-7-1Oscillating rear axle ............................................... 3-5-3Rear steering cylinder pivots.................................. 3-5-2Steering cylinder pivots.......................................... 3-5-2

Lubrication................................................................. 3-2-1Lubricity of diesel fuel ................................................ 3-1-1

M

MachineFrame locking bar .................................................. 3-2-3Service................................................................... 3-2-1

Machine modificationsAvoid ...................................................................... 1-2-2

MaintenancePreparing machine................................................. 3-2-2Record ................................................................... 3-2-6

Metal pins .................................................................. 1-4-3Metric bolt and screw torque values ........................ 4-1-22Monitor display unitCheck..................................................................... 3-2-1Normal display ....................................................... 2-1-9

Motor ....................................................................... 4-1-21

N

NeutralLock ....................................................................... 2-2-6Start system check............................................... 4-1-14

NeverGrease™ pin joints ................................3-2-1, 3-5-1

O

OilAlternative and synthetic lubricants ....................... 3-1-5Axle sample ......................................................... 3-8-11Change engine.............................................3-6-1, 3-8-5Check level park brake .......................................... 3-8-8Differential, front and rear, change.............3-6-2, 3-10-2Engine sample ....................................................... 3-7-2Front differential (standard axle) level check ....... 3-8-10Front differential level check .................................. 3-8-9Hydraulic sample ................................................. 3-8-11Hydraulic, change ................................................ 3-11-1Level engine........................................................... 3-4-2Level hydraulic system........................................... 3-4-2Level transmission ................................................. 3-4-3Park brake, change................................................ 3-9-6

Page

Rear differential (standard axle) level check........ 3-8-11Rear differential level check................................. 3-8-10Specification differential ......................................... 3-1-7Specification hydraulic system............................... 3-1-7Specification park brake......................................... 3-1-7Specification transmission ..................................... 3-1-7Transmission sample ........................................... 3-8-11Transmission, change.......................................... 3-10-2

Oil coolerCleaning procedure.............................................. 4-1-19

P

Park brakeChange oil.............................................................. 3-9-6Check..................................................................... 4-1-3Diagnose malfunctions........................................... 4-3-8Oil level check........................................................ 3-8-8Oil specification...................................................... 3-1-7Operation ............................................................... 2-2-9Switch .................................................................... 2-2-9

Parking MachineUsing joystick steering ......................................... 2-2-22

PedalDifferential lock .................................................... 2-2-15

PedalsAccelerator............................................................. 2-1-2Brake...................................................................... 2-1-2

PivotsOscillating rear axle, lubricate................................ 3-5-3Rear steering, cylinder lubricate ............................ 3-5-2

Prepare Machine for Maintenance ............................ 3-2-2Product Identification Number ................................... 4-5-1PumpHydraulicCase drain fittings............................................... 3-9-5

Service................................................................. 4-1-21

Q

Quick shiftSwitch .................................................................. 2-2-12

R

RadiatorCleaning procedure.............................................. 4-1-19Coolant level .......................................................... 3-7-2

Radiator hoses .......................................................... 3-9-2Recovery tankCoolant level .......................................................... 3-4-1

Regulator ................................................................... 4-1-5Return-to-carryHeight kickout adjustment.................................... 2-2-15

Return-to-dig circuitAdjustment ........................................................... 2-2-16

Ride controlAccumulator check............................................... 4-1-17


Index-4 013013

PN=4

Index

Page

Switch .................................................................. 2-2-13RoadsOperating or traveling ............................................ 1-3-5

Roll-over protective structureTorque values....................................................... 4-1-21

ROPSInspect ................................................................... 1-3-5Maintain ................................................................. 1-3-5

S

SafetyAdd cab guarding for special uses......................... 1-2-2Clean debris from machine.................................... 1-2-6Features................................................................. 1-1-1Follow safety instructions....................................... 1-2-1Inspect machine..................................................... 1-2-3Operate only if qualified ......................................... 1-2-1Operator's seat ...................................................... 1-3-1Recognize safety information................................. 1-2-1Signs...................................................................... 1-5-1Stay clear of moving parts ..................................... 1-2-3Wear protective equipment .................................... 1-2-2

Safety, Avoid High-Pressure FluidsAvoid High-Pressure Fluids ................................... 1-2-3

SealExternalInspect................................................................ 3-3-6

SeatAdjust ................................................................... 2-1-28

Seat beltUse and maintenance............................................ 1-3-1

Secondary steeringOperation ............................................................. 2-2-14

Serial numberEngine.................................................................... 4-5-1Hydraulic pump...................................................... 4-5-2Transmission.......................................................... 4-5-1

Serpentine beltInspect ................................................................... 3-3-6

ServiceInterval ................................................................... 3-3-1Machine ................................................................. 3-2-1Safely park and prepare......................................... 1-4-1

Service DoorsOpening ................................................................. 3-2-4

Service interval checklist ........................................... 3-2-6Service record ........................................................... 3-2-6ShiftingTransmission................................................2-2-6, 2-2-7Joystick steering................................................. 2-2-7

Snap-to-connect (STC) fittingsService recommendations ................................... 4-1-20

SpecificationFuse..................................................................... 4-1-10

SpecificationsDifferential oil ......................................................... 3-1-7Hardware torque .................................................. 4-1-21Hydraulic oil ........................................................... 3-1-7

Page

Park brake.............................................................. 3-1-7Transmission oil ..................................................... 3-1-7

StartingThe engine............................................................. 2-2-2

Starting fluidIf equipped ............................................................. 2-2-4

STC fittingsService recommendations ................................... 4-1-20

SteeringJoystickActivate............................................................... 2-2-8Arm rest............................................................ 2-1-25

Wheel tilt adjust.................................................... 2-1-24Steps Use.................................................................. 1-3-1StorageMachine ................................................................. 4-4-1Monthly .................................................................. 4-4-2

Storing fuel ................................................................ 3-1-3Suction strainerHydraulic system.................................................. 3-11-2

SwitchDifferential lock ...................................................... 2-1-2Park brake.............................................................. 2-2-9Quick shift ............................................................ 2-2-12Ride control.......................................................... 2-2-13

Switch pad................................................................. 2-1-6

T

TirePressure check ...................................................... 3-3-1

Torque chartsMetric ................................................................... 4-1-22Unified inch .......................................................... 4-1-23

Torque specificationsHardware ............................................................. 4-1-21

Torque valuesRoll-over protective structure ............................... 4-1-21Wheel retaining cap screw..................................... 3-3-5

Towing Procedure.................................................... 2-2-27TransmissionOil change............................................................ 3-10-2Oil filter, replace ..................................................... 3-9-4Oil level .................................................................. 3-4-3Oil specification...................................................... 3-1-7Serial number......................................................... 4-5-1Shifting.........................................................2-2-6, 2-2-7

TravelingOn public roads...................................................... 1-3-5

Troubleshooting procedure........................................ 4-3-1

U

Unified inch bolt and screw torque values ............... 4-1-23Unloader valveAir cleaner.............................................................. 3-4-1


Index-5 013013

PN=5

Index

Page

V

ValveAir cleaner dust unloader ....................................... 3-4-1Control ................................................................. 4-1-21Dust unloader......................................................... 3-9-1

Valve lash, engineCheck and adjust ................................................. 3-10-1

Vent tubeEngine crankcase .................................................. 3-9-2

VibrationCrankshaft damper replacement.......................... 3-12-1

W

Warm-upEngine, cold weather ............................................. 2-2-5

Warranty statementEmissions control........................................................ -3

Page

WasherWindshield fluid level ............................................. 3-2-5

Waste disposal .......................................................... 1-2-6Water separatorBowl, clean.................................................3-3-10, 4-1-4Replace........................................................3-3-8, 3-8-6

Welding.................................................................... 4-1-14Welding repairs.......................................................... 1-4-3WheelCap screw torque................................................... 3-3-5

WindowOpening ............................................................... 2-1-27Sliding .................................................................. 2-1-27

WindshieldWasher fluid ........................................................... 3-2-5

Work site hazardsAvoid ...................................................................... 1-3-2

Index-6 013013

PN=6

Index

Index-7 013013

PN=7

Index

Index-8 013013

PN=8

744j & 824j loaders (s.n. 590070—) · 744j&824jloaders (s.n.590070—) *omt200785*...

Documents

744j & 824j loaders (s.n. 590070—) · 744j&824jloaders (s.n.590070—) omt200785...