ADT 01 - JD250D - English

250D and 300D
Articulated Dump Trucks
*OMT201340*
(Serial No. 200537 - 609165)
OPERATOR'S MANUAL
250D and 300D Articulated Dump Trucks
OMT201340 ISSUE G2
(ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
The State of California requires the above two warnings.
Additional Proposition 65 Warnings can be found in this manual.
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Introduction
READ THIS MANUAL carefully to learn how to operate
and service your machine correctly. Failure to do so
could result in personal injury or equipment damage. This
manual and safety signs on your machine may also be
available in other languages. (See your authorized dealer
to order.)
THIS MANUAL SHOULD BE CONSIDERED a permanent
part of your machine and should remain with the machine
when you sell it.
MEASUREMENTS in this manual are given in both
metric and customary U.S. unit equivalents. Use only
correct replacement parts and fasteners. Metric and inch
fasteners may require a specific metric or inch wrench.
RIGHT-HAND AND LEFT-HAND sides are determined by
facing in the direction of forward travel.
WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.)
in the Machine Numbers chapter. Accurately record all
the numbers to help in tracing the machine should it be
stolen. Your dealer also needs these numbers when you
order parts. File the identification numbers in a secure
place off the machine.
WARRANTY is provided as part of John Deere’s support
program for customers who operate and maintain their
equipment as described in this manual. The warranty is
explained on the warranty certificate which you should
have received from your dealer.
This warranty provides you the assurance that John
Deere will back its products where defects appear within
the warranty period. In some circumstances, John Deere
also provides field improvements, often without charge
to the customer, even if the product is out of warranty.
Should the equipment be abused, or modified to change
its performance beyond the original factory specifications,
the warranty will become void and field improvements
may be denied. Setting fuel delivery above specifications
or otherwise overpowering machines will result in such
action.
THE TIRE MANUFACTURER'S warranty supplied with
your machine may not apply outside the U.S.
Continued on next page
CED,TX14740,6463 -19-18DEC01-1/2
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Introduction
EMISSIONS CONTROL WARRANTY STATEMENT FOR
NEW JOHN DEERE CONSTRUCTION EQUIPMENT (U.S. AND CANADA)
To determine if the engine in your machine qualifies for the additional warranties set forth below, look for the "Engine Information"
label located on your engine. If you reside in the United States and the engine label states: "Engine conforms to
US EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control Warranty
Statement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy duty
non road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement."
U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT
Warranties stated on this certificate refer only to emissions-related
parts and components of your engine. The complete machine
warranty, less emisions-related parts and components, is
provided separately as "John Deere "Secure Warranty" For New
Construction Products."
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and John Deere are
pleased to explain the emission control system on your new
engine. In California, new heavy-duty engines must be designed,
built and equipped to meet the State's stringent anti-smog
standards. John Deere must warrant the emission control system
on your engine for the periods of time listed below provided there
has been no abuse, neglect, or improper maintenance of your
machine.
Your emissions control system includes:
Fuel Metering System
Fuel Injection System
Air Induction System
Intake Manifold
Turbocharger System
Charge Air Cooling System
Miscellaneous Items used in Above Systems
Where a warrantable condition exists, i.e. failure due to defect in
John Deere-supplied material and/or workmanship, John Deere
will repair your heavy-duty engine at no cost to you including
diagnosis, parts and labor
JOHN DEERE'S WARRANTY COVERAGE:
The emission control system of your heavy-duty engine is
warranted for five years or 3000 hours of operation, whichever
occurs first. If any emission-related part on your engine is
defective, the part will be repaired or replaced by John Deere.
Warranties stated on this certificate refer only to emissions-related
parts and components of your engine. The complete machine
warranty, less emissions-related parts and components, is
provided separately as the "John Deere "Secure Warranty" For
New Construction Products."
OWNER'S WARRANTY RESPONSIBILITIES:
As the heavy-duty engine owner, you are responsible for the
performance of the required maintenance as outlined in the
Operator's Manual. John Deere recommends that you retain all
receipts covering maintenance on your heavy-duty engine, but
John Deere cannot deny warranty solely for the lack of receipts
or for your failure to ensure the performance of all scheduled
maintenance.
However, as the heavy-duty engine owner, you should be aware
that John Deere may deny you warranty coverage if your heavyduty engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of
any other fuel may result in your engine no longer operating in
compliance with California's emissions requirements.
You are responsible for initiating the warranty process. The CARB
suggests that you present your machine to the nearest authorized
John Deere dealer as soon as a problem is suspected. The
warranty repairs should be completed by the service dealer as
expeditiously as possible.
If you have any questions regarding your warranty rights and
responsibilities, you should contact John Deere at 1-319-2925400, or the State of California Air Resources Board, Mobile Source
Operation Division, PO Box 8001, El Monte, CA 91731-2900
The warranty period begins on the date the machine is delivered
to an ultimate purchaser, or when otherwise put into service.
John Deere warrants to the ultimate purchaser and each
subsequent purchaser that the engine is designed, built and
equipped so as to conform with all applicable regulations adopted
by the Air Resources Board, and that it is free from defects in
materials and workmanship which would cause the failure of a
warranted part.
Any warranted part which is scheduled for replacement as
required maintenance by the operator's manual is warranted by
John Deere for the period of time prior to the first scheduled
replacement point for that part. If the part fails prior to the first
scheduled replacement point, the part shall be repaired or
replaced under warranty. Any such part repaired or replaced
under warranty is warranted for the remainder of the period prior
to the first scheduled replacement point for that part.
Any warranted part which is not scheduled for replacement as
required maintenance, or which is scheduled only for regular
inspection to the effect of repairing or replacing as necessary, is
warranted for the warranty period.
Repair or replacement of a warranted part will be performed at no
charge to you by an authorized John Deere dealer. You will not
be charged for diagnostic labor which leads to the determination
that a warranted part is defective, if the diagnostic work is
performed by a John Deere dealer.
John Deere is liable for damages to other engine components
caused by failure under warranty of any warranted part.
John Deere is NOT liable for travel or mileage on extended
emissions warranty service calls.
Any replacement part may be used in the performance of any
maintenance or repairs, and such use will not reduce the warranty
obligations of John Deere. However, the use of add-on or
modified parts are grounds for disallowing a warranty claim.
T132126 —19—28JUN00
Emissions control-related parts and components are warranted
by John Deere for five years or 3000 hours of operation, whichever
occurs first. John Deere further warrants that the engine covered
by this warranty was designed, built, and equipped so as to
conform at the time of sale with all U.S. emissions standards at
the time of manufacture, and that it is free of defects in materials
and workmanship which would cause it not to meet these
standards within the period of five years or 3000 hours of
operations, whichever occurs first.
CED,TX14740,6463 -19-18DEC01-2/2
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Introduction
Technical Information Feedback Form
We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO:
John Deere Dubuque Works
18600 South John Deere Road
Attn: Publications, Dept. 324
Dubuque, IA 52004-0538
USA
FAX NUMBER: 1-563-589-5800 (USA)
Publication Number:
Page Number:
Ideas, Comments:
Name:
Phone:
Email Address:
THANK YOU!
TX,TM,FAX -19-03JUL01-1/1
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Contents
Page
Page
Operator Control Functions ...............................2-1-3
Instrument Panel ...............................................2-1-4
Instrument Panel Functions...............................2-1-5
Heater and Air Conditioner Controls..................2-1-6
Steering Column Lever......................................2-1-7
Circuit Breaker Compartment ............................2-1-8
Operator Seat and Instructional Seat ................2-1-9
Air Suspension Seat—If Equipped ..................2-1-10
Seat Belt ..........................................................2-1-10
Battery Disconnect Switch and Battery
Circuit Breakers...........................................2-1-11
Miscellaneous Equipment................................2-1-12
Monitor Display Unit—Default Display Menu...2-1-14
Monitor Display Unit—Menu Function .............2-1-16
Safety—Safety Features
Safety Features .................................................1-1-1
Safety—General Precautions
Recognize Safety Information ...........................1-2-1
Follow Safety Instructions..................................1-2-1
Operate Only If Qualified ...................................1-2-1
Wear Protective Equipment...............................1-2-1
Avoid Unauthorized Machine Modifications.......1-2-2
Inspect Machine ................................................1-2-2
Stay Clear of Moving Parts................................1-2-2
Avoid High-Pressure Oils ..................................1-2-3
Beware of Exhaust Fumes ................................1-2-3
Prevent Fires .....................................................1-2-4
Prevent Battery Explosions ...............................1-2-4
Handle Chemical Products Safely .....................1-2-4
Dispose of Waste Properly ................................1-2-5
Prepare for Emergencies...................................1-2-5
Operation—Operating the Machine
Before Starting Work .........................................2-2-1
Operator's Daily Machine Check
Before Starting ..............................................2-2-1
Starting Engine ..................................................2-2-2
Replace Start Aid Can .......................................2-2-3
Driving Machine.................................................2-2-3
Steering Machine...............................................2-2-4
Shifting Transmission ........................................2-2-5
Using Range Hold .............................................2-2-6
Using Inter-Axle Lock ........................................2-2-6
Slowing and Stopping the Machine ...................2-2-7
Operating on a Hill.............................................2-2-8
Off-Road Operation ...........................................2-2-8
Loading and Unloading Dump Body..................2-2-9
Freeing Stuck Machine....................................2-2-10
Parking the Machine........................................2-2-10
Towing the Machine.........................................2-2-11
Releasing Park Brake for Towing ....................2-2-12
Mechanically Releasing Park Brake ................2-2-12
Machine Lifting Points .....................................2-2-13
Loading and Unloading Machine from Trailer ..2-2-14
Lock All Compartments ...................................2-2-15
Safety—Operating Precautions
Use Steps and Handholds Correctly .................1-3-1
Start Only From Operator's Seat .......................1-3-1
Use and Maintain Seat Belt ...............................1-3-1
Prevent Unintended Machine Movement ..........1-3-1
Avoid Work Site Hazards...................................1-3-2
Keep Riders Off Machine ..................................1-3-2
Avoid Backover Accidents .................................1-3-2
Avoid Machine Tip Over ....................................1-3-3
Operating on Slopes..........................................1-3-3
Operating Or Traveling On Public Roads ..........1-3-3
Inspect and Maintain ROPS ..............................1-3-4
Add and Operate Attachments Safely ...............1-3-4
Safety—Maintenance Precautions
Park And Prepare For Service Safely................1-4-1
Service Tires Safely...........................................1-4-1
Service Cooling System Safely .........................1-4-2
Remove Paint Before Welding or Heating.........1-4-2
Make Welding Repairs Safely ...........................1-4-2
Drive Metal Pins Safely .....................................1-4-3
Maintenance—Machine
Diesel Fuel.........................................................3-1-1
Low Sulfur Diesel Fuel Conditioner ...................3-1-1
Testing Diesel Fuel ............................................3-1-1
Handling and Storing Diesel Fuel ......................3-1-2
Diesel Engine Oil ...............................................3-1-2
Diesel Engine Oil and Filter Service Intervals ...3-1-3
Hydraulic Oil ......................................................3-1-4
Safety—Safety Signs
Safety Signs ......................................................1-5-1
Operation—Operator’s Station
Operator Controls ..............................................2-1-1
Continued on next page
Original Instructions. All information, illustrations and specifications in this
manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2012
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual
Previous Editions
Copyright © 2004, 2005, 2006, 2007, 2008, 2009
i
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Contents
Page
Page
Transmission and Transfer Case Oil .................3-1-4
Axle Gear Oil .....................................................3-1-5
Diesel Engine Coolant .......................................3-1-5
Grease...............................................................3-1-6
Oil Filters ...........................................................3-1-6
Lubricant Storage ..............................................3-1-6
Alternative And Synthetic Lubricants.................3-1-7
Lubricate Oscillation Tube, Articulation
Joints, Steering Cylinder Rod Ends,
and Oscillation Tube Through Drive
Shaft Bearings...............................................3-6-5
Check Transmission Oil Level ...........................3-6-6
Clean and Inspect Hydraulic Reservoir
Breather ........................................................3-6-7
Replace In-line Fuel Filter (S.N. 201015—).......3-6-7
Replace Fuel Filters (S.N.—201014).................3-6-8
Replace Final Fuel Filter (S.N. 201015—).........3-6-8
Check Coolant Conditioner in Radiator .............3-6-9
Maintenance—Periodic Maintenance
Service Your Machine at Specified Intervals .....3-2-1
Use Correct Fuels and Lubricants .....................3-2-1
Prepare Machine for Maintenance ....................3-2-1
Install Dump Body Prop.....................................3-2-2
Install Articulation Safety Lock Bar ....................3-2-2
Lower and Raise Bottom Guard ........................3-2-2
Relieve Pneumatic Pressure .............................3-2-3
Tilt Cab ..............................................................3-2-4
Maintenance and Repair Record
Keeping System ............................................3-2-5
Fluid Analysis Program Test Kits and
3-Way Coolant Test Kit..................................3-2-5
Maintenance and Repair Record
Keeping System ............................................3-2-6
Maintenance—Every 1000 Hours
Check Axle Oil Levels........................................3-7-1
Check Final Drive Oil Levels .............................3-7-1
Replace Hydraulic Reservoir Breather ..............3-7-2
Check and Adjust Bin Shock Pad......................3-7-3
Grease Prop Shaft Slip Joint .............................3-7-3
Maintenance—Every 2000 Hours
Adjust Engine Valve Clearance .........................3-8-1
Change Transmission Oil ..................................3-8-1
Replace Transmission Oil Filter.........................3-8-2
Change Transfer Case Oil.................................3-8-3
Change Axle Oil.................................................3-8-3
Change Final Drive Oil ......................................3-8-4
Replace Pneumatic System Dryer-Filter ...........3-8-4
Maintenance—As Required
Service Engine Air Intake System .....................3-3-1
Inspect and Clean Cooling Systems..................3-3-2
Clean, Inspect, and Replace—Transmission, Transfer Case, and Axle
Breathers.......................................................3-3-3
Inspect Tires, Check Pressure ..........................3-3-4
Drain Fuel Filters (S.N.—201014) .....................3-3-6
Drain Fuel Filters (S.N. 201015—) ....................3-3-6
Inspect Serpentine Belt .....................................3-3-6
Maintenance—Every 4000 Hours
Change Hydraulic Oil.........................................3-9-1
Replace Hydraulic Suction Screen ....................3-9-2
Replace Pneumatic Block Silencer Filter...........3-9-2
Maintenance—Every 4500 Hours
Replace Engine Crankshaft Dampener ...........3-10-1
Maintenance—Every 10 Hours or Daily
Check Engine Coolant Level .............................3-4-1
Check Engine Oil Level .....................................3-4-1
Check Transfer Case Oil Level..........................3-4-2
Check Hydraulic Oil Level .................................3-4-2
Grease Dump Body Pivot Pins ..........................3-4-3
Lubricate Tailgate Pivots—If Equipped..............3-4-3
Maintenance—Every 5000 Hours
Drain, Flush and Refill Engine Cooling
System ........................................................3-11-1
Miscellaneous—Machine
Do Not Service Control Valves,
Cylinders, Pumps or Motors..........................4-1-1
Do Not Service Injection Nozzles ......................4-1-1
Bleeding Fuel System........................................4-1-1
Check Engine Air Intake System .......................4-1-2
Check Brake Accumulators ...............................4-1-3
Check Wheel Nuts.............................................4-1-3
Lubricate Hinges................................................4-1-3
Using Booster Batteries—24-Volt System .........4-1-3
Using Battery Charger .......................................4-1-4
Handling, Checking And Servicing
Batteries Carefully.........................................4-1-5
Replace Batteries ..............................................4-1-6
Replace Front Turn Signal Bulb,
Headlight Bulb, and Front Park Light Bulb ....4-1-7
Adjust Headlights...............................................4-1-9
Maintenance—Initial Service - 100 Hours
Change Engine Oil and Replace Filter ..............3-5-1
Replace Hydraulic System Oil Return Filter ......3-5-2
Replace Primary Fuel Filter (S.N. 201015—) ....3-5-3
Change Transfer Case Oil.................................3-5-3
Change Axle Oil.................................................3-5-4
Change Final Drive Oil ......................................3-5-4
Maintenance—Every 500 Hours
Check Park Brake Pad Wear.............................3-6-1
Check Dry Caliper Service Brake Pad Wear .....3-6-1
Check Front Axle Suspension Struts.................3-6-2
Inspect, Clean, and Replace Cab Air Filter .......3-6-3
Check Batteries, Clean and Tighten Terminals ..3-6-4
Continued on next page
ii
080112
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Contents
Page
Replace Backup Light and Work
Light—If Equipped.......................................4-1-10
Replace Tail and Brake Light and Rear
Turn Signal ..................................................4-1-10
Replace Dome Light Bulb and Circuit
Breaker Compartment Light Bulb................4-1-11
Clean The Machine Regularly .........................4-1-11
Unified Inch Bolt and Screw Torque Values.....4-1-12
Metric Bolt and Screw Torque Values..............4-1-13
Imperial and SAE (Inch) Cap Screw
and Nut Torque Values................................4-1-14
Metric Cap Screw and Nut Torque Values.......4-1-15
Welding on Machine ........................................4-1-16
Miscellaneous—Operational Checkout
Operational Checkout........................................4-2-1
Miscellaneous—Troubleshooting
Using Troubleshooting Charts ...........................4-3-1
Engine ...............................................................4-3-2
Transmission .....................................................4-3-4
Axle....................................................................4-3-5
Tires...................................................................4-3-6
Brakes ...............................................................4-3-6
Hydraulic System...............................................4-3-7
Instruments and Controls ..................................4-3-7
Electrical System ...............................................4-3-8
Rear Frame and Cab.........................................4-3-9
MDU Displayed Service Codes .......................4-3-10
Miscellaneous—Storage
Prepare Machine for Storage ............................4-4-1
Miscellaneous—Serial Numbers
Record Product Identification Number (PIN) .....4-5-1
Record Engine Serial Number...........................4-5-1
Record Transmission Serial Number.................4-5-1
Front Axle Serial Number ..................................4-5-2
Middle Axle Serial Number ................................4-5-2
Rear Axle Serial Number...................................4-5-2
Miscellaneous—Specifications
250D Articulated Dump Truck Specifications ....4-6-1
300D Articulated Dump Truck Specifications ....4-6-5
250D and 300D Engine Specifications ..............4-6-8
250D and 300D Travel Speeds .........................4-6-9
250D and 300D Drain and Refill Capacities ......4-6-9
iii
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Contents
iv
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Safety—Safety Features
Safety Features
1
16
15
14
4
12
2
8
13
5
T147632 —UN—19NOV01
11
3
10
6
7
9
T147632
Please remember, the operator is the key to
preventing accidents.
1. ROPS/FOPS Cab Protection. Structures designed to
help protect the operator are certified to ISO, SAE,
and OSHA. Enclosures also deflect sun and rain.
2. Cab with Heater/Defroster. Cab ventilation system
circulates both outside and inside air through filters for
a clean working environment. Built in defroster vents
direct air flow for effective window defogging/deicing.
3. Dump Body Service Lock. A mechanical lock is
provided for working on or around this machine with
the dump body raised.
4. Stop/Backup Lights. Highly visible lights are
standard equipment.
5. Backup Alarm. Alerts bystanders when reverse travel
direction is selected by operator.
6. Independent Parking Brake. Is air released/spring
applied and engages whenever the key switch is
turned off.
7. Articulation Locking Bar. A self-storing mechanical
lock is provided for transport or service.
8. Secondary Steering. Ground driven, continuously in
operation. Secondary steering indicator light will light.
9. Horn. Standard horn is useful when driving or
signalling co-workers.
10. Halogen Lights and Turn Signals. High intensity
halogen drive/work lights and high-visibility turn
signals are standard equipment.
11. Engine Fan Guard. A secondary fan guard inside
the engine compartment helps prevent contact with
rotating fan blades.
12. Bypass Start Protection. Shielding over the starter
terminals helps prevent dangerous bypass starting.
13. Transmission Retarder. Engages whenever the truck
is in motion and the operator lets up on the accelerator.
14. Seatbelt Retractors. Help keep belts clean and
convenient to use.
15. Mirrors. Large exterior mirrors on both sides offer the
operator a view of activity behind him.
16. Large Windshield Wiper With Washer. Extra long
wiper cleans large windshield area.
TX14740,0000002 -19-27JUL12-1/1
1-1-1
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Safety—General Precautions
Recognize Safety Information
T133555 —UN—28AUG00
This is the safety alert symbol. When this symbol is
noticed on the machine or in this manual, be alert for
the potential of personal injury.
Follow the precautions and safe operating practices
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION —
is used with the safety alert symbol. DANGER identifies
the most serious hazards.
T133588 —19—28AUG00
On the machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.
TX03679,00016CC -19-03JAN07-1/1
Follow Safety Instructions
Read the safety messages in this manual and on the
machine. Follow these warnings and instructions carefully.
Review them frequently.
Keep safety signs in good condition.
Be sure all operators of this machine understand every
safety message. Replace operator's manual and safety
signs immediately if missing or damaged. Replacement
safety signs are available from your authorized dealer.
Be sure new equipment components and repair parts
include the current safety signs.
TX14740,0000019 -19-10JAN07-1/1
Operate Only If Qualified
Do not operate this machine unless the operator's manual
has been read carefully, and you have been qualified by
supervised training and instruction.
Operator should be familiar with the job site and
surroundings before operating. Try all controls and
machine functions with the machine in an open area
before starting to work.
Know and observe all safety rules that may apply to every
work situation and work site.
TX03679,00016FA -19-03JAN07-1/1
Wear Protective Equipment
Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
TS206 —UN—23AUG88
Wear close fitting clothing and safety equipment
appropriate to the job.
TX03679,00016D0 -19-03JAN07-1/1
1-2-1
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Safety—General Precautions
Avoid Unauthorized Machine Modifications
John Deere recommends using only genuine John Deere
replacement parts to ensure machine performance.
Never substitute genuine John Deere parts with alternate
parts not intended for the application as these can
create hazardous situations or hazardous performance.
Non-John Deere Parts, or any damage or failures resulting
from their use are not covered by any John Deere warranty.
Modifications of this machine, or addition of unapproved
products or attachments, may affect machine stability
or reliability, and may create a hazard for the operator
or others near the machine. The installer of any
modification which may affect this machine is responsible
for establishing that the modification does not adversely
affect the machine or its performance. This applies to all
aspects of the machine, including electronic controls.
Always contact an authorized dealer before making
machine modifications that change the intended use,
weight or balance of the machine, or that alter machine
controls, performance or reliability.
AM40430,0000084 -19-01OCT07-1/1
Inspect Machine
Keep all guards and shields in good condition and properly
installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and
electrical wiring.
T6607AQ —UN—18OCT88
Inspect machine carefully each day by walking around it
before starting.
TX03679,0001734 -19-03JAN07-1/1
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard
or shield that has been removed for access as soon as
service or repair is complete.
T133592 —UN—12SEP01
Stay Clear of Moving Parts
TX03679,00016D2 -19-03JAN07-1/1
1-2-2
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Safety—General Precautions
Avoid High-Pressure Oils
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
T133840 —UN—20SEP00
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
T133509 —UN—17MAR06
This machine uses a high-pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
TX03679,00016D3 -19-03NOV08-1/1
Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in an enclosed space, provide
adequate ventilation. Use an exhaust pipe extension to
remove the exhaust fumes or open doors and windows to
bring outside air into the area.
T133546 —UN—24AUG00
Beware of Exhaust Fumes
TX03679,00016D4 -19-03NOV08-1/1
1-2-3
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Safety—General Precautions
T133552 —UN—14SEP00
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
materials inside a machine compartment.
T133553 —UN—07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
T133554 —UN—07SEP00
TX03679,00016F5 -19-03NOV08-1/1
Prevent Battery Explosions
Battery gas can explode. Keep sparks, lighted matches,
and open flame away from the top of battery.
TS204 —UN—23AUG88
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TX03679,000174A -19-03NOV08-1/1
Handle Chemical Products Safely
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
T133580 —UN—25AUG00
Exposure to hazardous chemicals can cause serious
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
MSDS recommendations to handle chemical products
safely.
TX03679,00016D7 -19-03JAN07-1/1
1-2-4
080112
PN=13
Safety—General Precautions
Improper disposal of waste can threaten the environment.
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants can damage the atmosphere.
Government regulations may require using a certified
service center to recover and recycle used refrigerants.
T133567 —UN—25AUG00
Dispose of Waste Properly
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your dealer for
more information.
TX03679,0001733 -19-03NOV08-1/1
Prepare for Emergencies
Be prepared if an emergency occurs or a fire starts.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
TS291 —UN—23AUG88
Keep a first aid kit and fire extinguisher handy.
TX03679,000174B -19-03NOV08-1/1
1-2-5
080112
PN=14
Safety—Operating Precautions
Use Steps and Handholds Correctly
T133468 —UN—30AUG00
Prevent falls by facing the machine when getting on and
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,00016F2 -19-15MAR07-1/1
T133715 —UN—07SEP00
Start Only From Operator's Seat
Avoid unexpected machine movement. Start engine only
while sitting in operator's seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,0001799 -19-22APR10-1/1
Use and Maintain Seat Belt
T133716 —19—14SEP00
Use seat belt when operating machine. Remember to
fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not
cut or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every 3 years, regardless of appearance.
TX03679,00016DD -19-03NOV08-1/1
Be careful not to accidentally actuate controls when
co-workers are present.
Ensure dump body is lowered during work interruptions.
Place transmission control in neutral, engage park brake
and stop engine before allowing anyone to approach the
machine.
Follow these same precautions before standing up,
leaving the operator's seat, or exiting the machine.
P
T143805 —UN—20JUL01
Prevent Unintended Machine Movement
TX14740,0001D31 -19-22JUN01-1/1
1-3-1
080112
PN=15
Safety—Operating Precautions
Avoid Work Site Hazards
Avoid contact with gas lines, buried cables and water
lines. Call utility line location services to identify all
underground utilities before starting work.
T143350 —UN—06JUL01
Prepare work site properly. Avoid operating near
structures or objects that could fall onto the machine. Clear
away debris that could move unexpectedly if run over.
Avoid boom or attachment contact with overhead
obstacles or overhead electrical lines. Never move
machine closer than 3 m (10 ft) plus twice the line insulator
length to overhead wires.
T143748 —UN—20JUL01
Keep bystanders clear at all times. Use barricades or a
signal person to keep vehicles and pedestrians away. Use
a signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient
to support machine. Be especially alert working near
embankments or excavations.
Avoid working under over-hanging embankments or
stockpiles that could collapse under or on machine.
Reduce machine speed when operating with tool on or
near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc.). At high speeds
hitting obstacles (rocks, uneven concrete or manholes)
can cause a sudden stop. Always wear your seatbelt.
VD76477,0001583 -19-06JUL07-1/1
Keep Riders Off Machine
Only allow operator on machine except when necessary
for instruction or short periods of observation.
Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects. They also may obstruct operator’s view or impair
his ability to operate machine safely.
T143354 —UN—06JUL01
Use seat belt at all times.
Use the instructional seat only to accommodate trainers
or persons needing to observe machine operation for
short periods.
TX14740,0001D33 -19-23SEP10-1/1
Before moving machine, be sure all persons are clear
of machine path. Where conditions permit, raise dump
body for better visibility to the rear. Use mirrors to assist in
checking all around machine. Keep windows and mirrors
clean, adjusted, and in good repair.
Be certain backup alarm is working properly.
Use a signal person when backing if view is obstructed
or when in close quarters. Keep signal person in view at
all times. Use prearranged hand signals to communicate.
T143356 —UN—06JUL01
Avoid Backover Accidents
TX14740,0001D34 -19-22JUN01-1/1
1-3-2
080112
PN=16
Safety—Operating Precautions
Use extra care when dump body is raised. Machine
stability is greatly reduced when dump body is raised.
Drive slowly. Avoid sharp turns and uneven ground.
Be careful on slopes and soft, rocky, or frozen ground.
Traction and stability are reduced by slopes and adverse
terrain. Avoid piles of dirt and banks or excavations that
may cave in and cause the machine to tip or fall.
Do not overload the machine. Oversize loads reduce
machine stability, increase tire flex, and erode travel
surfaces. Braking capability and brake life are also
reduced.
If machine tips, carefully inspect brake and hydraulic lines,
electrical wiring, and machine structure before operating.
T144185 —UN—23JUL01
Use seat belt at all times. Do not jump if the machine
tips. You will be unlikely to jump clear and the machine
may crush you.
T133716 —19—14SEP00
Avoid Machine Tip Over
TX14740,0001D3E -19-20JUL01-1/1
Operating on Slopes
Check service brake condition frequently when operating
on slopes.
Select low gear speed before starting down slope. The
maximum slope you can operate on will be limited by
ground conditions and the load being handled.
Use transmission retarder and service brakes, to control
speed. Sudden brake application with a loaded dump
body could cause loss of machine control.
T143361 —UN—27JUN01
Avoid sideslope travel whenever possible.
TX14740,0000003 -19-24JAN03-1/1
Machines that work near vehicle traffic or travel slower
than normal highway speeds must have proper lighting
and markings to assure they are visible to other drivers.
Mirrors are especially important for the operator when on
roadways.
Install additional lights, beacons, slow moving vehicle
(SMV) emblems, or other devices and use as required to
make the machine visible and identify it as a work machine.
Check state and local regulations to assure compliance.
Keep these devices clean and in working condition.
T141891 —UN—22MAY01
Operating Or Traveling On Public Roads
TX03679,00017C8 -19-30APR01-1/1
1-3-3
080112
PN=17
Safety—Operating Precautions
Inspect and Maintain ROPS
A damaged roll-over protective structure (ROPS) should
be replaced, not reused.
The protection offered by ROPS will be impaired if ROPS
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting.
If ROPS was loosened or removed for any reason, inspect
it carefully before operating the machine again.
To maintain the ROPS:
• Replace missing hardware using correct grade
hardware.
• Check hardware torque.
• Check isolation mounts for damage, looseness or wear;
replace them if necessary.
• Check ROPS for cracks or physical damage.
TX03679,000179F -19-07SEP06-1/1
Add and Operate Attachments Safely
Always verify compatibility of attachments by contacting
your authorized dealer. Adding unapproved attachments
may affect machine stability or reliability, and may create
a hazard for others near the machine.
Ensure that a qualified person is involved in attachment
installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections
are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all
instructions and warnings. In an area free of bystanders
and obstructions, carefully operate attachment to learn its
characteristics and range of motion.
TX03679,00016F0 -19-24JAN07-1/1
1-3-4
080112
PN=18
Safety—Maintenance Precautions
Park And Prepare For Service Safely
• Park machine on a level surface.
• Lower dump body unless raised position is required
for service.
• Engage park brake.
• Stop engine and remove key.
• Attach a “Do Not Operate” tag in an obvious place in
the operator's station.
• Install the articulation safety locking bar.
• Install service locks if dump body or cab are raised for
T133332 —19—14DEC01
Warn others of service work. Always park and prepare
your machine for service or repair properly.
service.
Securely support machine before working under it.
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TS229 —UN—23AUG88
Install wheel chocks to ensure machine cannot move
backward or forward during service.
TX14740,0001D36 -19-22JUN01-1/1
Service Tires Safely
Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
TS211 —UN—23AUG88
Check wheels for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.
DX,RIM -19-24AUG90-1/1
1-4-1
080112
PN=19
Safety—Maintenance Precautions
Service Cooling System Safely
Explosive release of fluids from pressurized cooling
system can cause serious burns.
TS281 —UN—23AUG88
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
DX,RCAP -19-04JUN90-1/1
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
TS220 —UN—23AUG88
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area
•
•
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding
will take place.
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT -19-24JUL02-1/1
Make Welding Repairs Safely
Avoid welding or heating near pressurized fluid lines.
Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.
Use a qualified welding technician for structural repairs.
T133547 —UN—31AUG00
IMPORTANT: Disable electrical power before
welding. Turn off main battery switch
or disconnect positive battery cable.
Separate harness connectors to engine and
vehicle microprocessors.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
TX03679,00016D5 -19-25APR08-1/1
1-4-2
080112
PN=20
Safety—Maintenance Precautions
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened
parts. Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
T133738 —UN—14SEP00
Drive Metal Pins Safely
TX03679,0001745 -19-03JAN07-1/1
1-4-3
080112
PN=21
Safety—Safety Signs
Safety Signs
CAUTION
This instructional seat has been provided only
for training operators or to diagnose machine
problems. Keep all other riders off this
machine. Always wear your seat belt.
Torque all wheel nuts to 650 N.m
[480 LB.FT.] after the first
5 hours and then again after
50 hours. Repeat this procedure
if wheels are changed.
CAUTION
AVOID DEATH OR SERIOUS INJURY
*READ AND UNDERSTAND OPERATOR'S MANUAL BEFORE OPERATING
THIS MACHINE.
*OPERATE ONLY FROM THE OPERATOR'S SEAT.
*BEFORE LEAVING SEAT: LOWER BODY TO FRAME REST.
PLACE TRANSMISSION IN NEUTRAL.
APPLY PARK BRAKE.
STOP ENGINE (TURN KEY SWITCH TO OFF).
*DO NOT PERMIT RIDERS.
*AVOID CONTACT WITH OVERHEAD OBSTACLES WHEN OPERATING OR
HAULING THE TRUCK.
*USE EXTRA CARE TO AVOID TIP-OVER WHEN DUMPER BODY IS RAISED.
WARNING
AVOID SERIOUS
INJURY
Block wheels to
prevent machine
movement before
deactivating park
brake for towing.
WARNING
SPRING UNDER
PRESSURE
Read the manual
before carrying out
maintenance in this
area
WARNING
COMPRESSED AIR
RESERVOIR
Avoid injury, drain
completely before carrying
out maintenance.
Typical working pressure:
800 kPa (116 PSI).
WARNING
WARNING
WARNING
HIGH PRESSURE
HYDRAULICS
See manual for correct
maintenance procedure.
Typical working
pressure: 8000 kPa
(1160 PSI).
AVOID INJURY
Ensure propshaft
guards are in
place at all times
T148212
Continued on next page
1-5-1
T148212 —19—21NOV01
Ensure that the cab
support is properly
engaged before
carrying out any
maintenance in this
area.
OUO1043,0000DF4 -19-30OCT01-1/2
080112
PN=22
T164920 —19—03FEB03
Safety—Safety Signs
OUO1043,0000DF4 -19-30OCT01-2/2
1-5-2
080112
PN=23
Operation—Operator’s Station
T147633B —UN—08NOV01
Operator Controls
1— Dome Light Switch
2— Headlight Switch
3— Warning Lights Switch
4— Rear View Mirrors Defrost
Switch—If Equipped
5— Air Vent (6 used)
6— Instrument Panel
12— Park Brake Lever
13— Dump Body Control Lever
14— Gearshift Control
15— Ash Tray (2 used)
16— Steering Wheel
17— Cigarette Lighter
18— Telescopic Steering Adjust
Lever
7— Inter-Axle Lock Switch
8— Range Hold Switch
9— Start Aid Switch
10— Rear View Mirrors
Adjustment Controls—If
Equipped
11— Transmission Torque
Retarder Control Lever
Continued on next page
2-1-1
19— Key Switch
20— Steering Column Lever
21— Tilt Steering Adjust Lever
22— Service Brake Pedal
23— Accelerator Pedal
OUO1043,0000DF5 -19-30OCT01-1/2
080112
PN=24
T142703C —UN—15NOV01
Operation—Operator’s Station
24— Operator's Manual
Compartment
25— Dome Light
26— Radio—If Equipped
27— Circuit Breaker
Compartment Latch
28— Circuit Breaker
Compartment
29— Visor
30— Heater and Air Conditioner
Control Panel
OUO1043,0000DF5 -19-30OCT01-2/2
2-1-2
080112
PN=25
Operation—Operator’s Station
Operator Control Functions
1. Dome Light Switch: Push lower half of switch to turn
dome light ON. Push upper half of switch to turn dome
light OFF.
2. Headlight Switch:
CAUTION: Prevent possible injury from
unexpected machine movement. DO
NOT leave machine unattended with
engine running.
NOTE: The parking lights, tail lights, and instrument
panel lighting will light when headlight switch is
in center position with key switch ON or OFF.
The headlights will light only when switch is
in down position with key switch ON.
3.
4.
5.
6.
7.
require, to adjust the percentage of torque retarder
applied when accelerator pedal is released.
12. Park Brake Lever:
The headlight switch is a 3-position switch used to
control headlights, tail lights and park lights.
- Upper half of switch pushed—lights OFF
- Lower half of switch pushed to first detent—park
lights, tail lights, and instrument panel lighting ON
- Lower half of switch pushed to furthest
position—headlights ON
Warning Lights Switch: Push lower half of switch to
turn warning lights ON. Push upper half of switch to
turn warning lights OFF.
Rear View Mirrors Defrost Switch (If Equipped):
Push lower half of switch to turn mirror defrosters ON.
Push upper half of switch to turn mirror defrosters OFF.
Air Vent (6 Used): Adjust air vents to control air flow
in the cab.
Instrument Panel: Contains instruments and
indicators.
Inter-Axle Lock Switch:
IMPORTANT: The inter-axle lock must only be
used when ground conditions are very poor.
DO NOT use on graded or tarred surfaces.
Reduce engine speed (accelerator pedal less than
10% depressed) and push lower half of switch to
engage inter-axle lock. Push upper half of switch to
disengage inter-axle lock.
8. Range Hold Switch: Push lower half of switch to
turn range hold ON. Push upper half of switch to turn
range hold OFF.
9. Start Aid Switch:
IMPORTANT: Never operate starter motor for more
than 17 seconds at a time. If engine fails to
start after 2 or 3 tries, return key switch to
OFF. Wait for about 1 minute, then try again.
IMPORTANT: Prevent damage to engine. Use
start aid when temperatures are below 0°C
(32°F) and only when engine is COLD.
If temperature is below 0°C (32°F) and engine is
COLD, press start aid switch while starting engine.
10. Rear View Mirrors Adjustment Controls (If
Equipped): Select left or right side mirror. Adjust
mirror, up, down, left or right, to operator's preference.
11. Transmission Torque Retarder Control Lever:
Move lever forward or rearward, as driving conditions
If the operator must leave machine with
engine running, the operator MUST shift the
transmission to neutral (N), engage the park
brake, chock wheels and take all other steps
necessary to prevent machine from moving.
IMPORTANT: After releasing park brake, wait
until park brake indicator on instrument
panel goes out before driving.
Lift and push lever forward to release park brake. Pull
lever rearward until it locks into place to engage park
brake.
13. Dump Body Control Lever:
NOTE: The dump body control lever is spring-loaded
and will return to center position when released.
Pull lever rearward to raise dump body. Push lever
forward to lower dump body. Push lever forward to
detent for dump body float.
14. Transmission Control Panel: Selects travel direction
and maximum gear.
15. Ash Tray: Ash trays are provided for operator
convenience.
16. Steering Wheel: Turn steering wheel to control
machine steering.
17. Cigarette Lighter: Cigarette lighter is provided for
operator convenience.
18. Telescopic Steering Adjust Lever: Loosens
telescopic steering clamp to allow steering column to
be pulled out or pushed in to operator preference.
19. Key Switch: Insert key and turn to start engine.
20. Steering Column Lever: Steering column lever
controls horn, windshield wiper/washers, turn
indicators and headlight beam intensity.
21. Tilt Steering Adjust Lever: Loosens tilt steering
clamp to allow steering column to be tilted up or down
to operator preference.
22. Service Brake Pedal: Push pedal to engage service
brakes.
23. Accelerator Pedal: Push pedal to increase speed.
Release pedal to slow machine. Retarder will engage,
as necessary, when pedal is released.
24. Operator's Manual Compartment: Store operator's
manual in the operator's manual compartment.
25. Dome Light: Provides operator with light in the cab.
26. Radio (If Equipped): Provided for operator
convenience.
27. Circuit Breaker Compartment Latch: Push latch
button to open circuit breaker compartment.
Continued on next page
2-1-3
TX14740,0000008 -19-06FEB03-1/2
080112
PN=26
Operation—Operator’s Station
28. Circuit Breaker Compartment: Open circuit breaker
compartment door to access machine circuit breakers.
29. Visor: Lower and adjust visor as necessary.
30. Heater and Air Conditioner Control Panel: Use
heater and air conditioner control panel to control cab
temperature.
TX14740,0000008 -19-06FEB03-2/2
Instrument Panel
1
9
10
11
12
14
EMERGENCY
STEERING
ENGINE
FAULT
COOLANT
LEVEL
COLD
START
8
4
3
2
PARK
BRAKE
15
BRAKE
PRESSURE
16
BRAKE
TEMP
n/min
BATTERY
CHARGE
5
RETARDER
6
13
TRANSMISSION
FAULT
21
7
ENGINE OIL
PRESSURE
30
COOLANT
TEMP
20
31
29
40
20
27
TRANS OIL
TEMP
DIFF
LOCK
19
AUTO
20
MENU
23
BACK
24
40
70
0
n/min
50
NEXT
80
0
22
60
30
mph
10
INTER-AXLE
DIFF LOCK
18
50
km/h
10
AIR
PRESSURE
BIN
UP
17
HYDRAULIC
TEMP
25
30
28
T142483 —UN—03OCT01
FUEL
SELECT
26
volts
MILES / Km
T142483
1— Cold Start Indicator
2— Coolant Level Indicator
3— Engine Service Indicator
(Marked Engine Fault)
4— Secondary Steering Indicator
(Marked Emergency Steering)
5— Battery Charge Indicator
6— Transmission Retarder
Indicator
7— Transmission Service
Indicator (Marked
Transmission Fault)
8— Left Turn Indicator
9— Service Required Indicator
10— High Beam Indicator
11— Engine Overspeed Indicator
12— Right Turn Indicator
13— Message Display
14— Park Brake Indicator
15— Brake Oil Pressure Indicator
16— Brake Temperature Indicator
17— Hydraulic Oil Temperature
Indicator
18— Dump Body Raised Indicator
(Marked Bin Up)
19— Inter-Axle Lock Indicator
(Marked Inter-Axle Diff Lock)
20— Differential Lock Indicator
(Marked Diff Lock)—Not
Used
21— Data Display
22— Menu Button
23— Back Button
24— Next Button
25— Select Button
26— Fuel Gauge
27— Speedometer
28— Transmission Oil
Temperature Gauge
29— Coolant Temperature Gauge
30— Air Pressure Gauge
31— Engine Oil Pressure Gauge
OUO1043,0000DD0 -19-27JUL01-1/1
2-1-4
080112
PN=27
Operation—Operator’s Station
Instrument Panel Functions
1. Cold Start Indicator: Indicator lights when key switch
is turned clockwise to ON position. Indicator will go out
after 20 seconds, depending on engine temperature,
indicating that preheating is completed.
2. Coolant Level Indicator:
IMPORTANT: If low coolant level indicator lights,
stop machine and shut down engine
immediately to prevent engine damage.
NOTE: Low engine coolant level indicator will flash
briefly during start-up when ignition key is
turned to the ON position.
Indicator lights when engine coolant level is low.
3. Engine Service Indicator (Marked Engine Fault):
Engine service indicator lights and stays lit when an
engine service code has been detected.
4. Secondary Steering Indicator (Marked Emergency
Steering):
IMPORTANT: If there is an engine or main pump
malfunction, the ground-driven secondary
steering system will enable operator to
steer machine to a controlled stop.
Indicator will light when secondary steering system is
activated. Stop machine and take corrective action.
Secondary steering system is ground driven and not
intended for continuous use.
5. Battery Charge Indicator: Indicator lights when
alternator output is low.
6. Transmission Retarder Indicator: Indicator lights
when transmission retarder is engaged.
7. Transmission Service Indicator (Marked
Transmission Fault): Transmission service indicator
lights and stays lit when a transmission clutch slippage
service code has been detected.
8. Left Turn Indicator: Indicator lights when left turn
indicator is switched ON.
9. Service Required Indicator: Indicator lights if
service is required. It is not necessary to stop engine
immediately, but cause should be investigated and
corrected as soon as possible.
10. High Beam Indicator: Indicator lights when headlight
high beams are ON.
11. Engine Overspeed Indicator:
14. Park Brake Indicator: Indicator lights when park
brake is engaged and transmission control lever is in
neutral.
15. Brake Oil Pressure Indicator: Indicator lights when
brake oil pressure is low or brake accumulator has lost
its charge. Stop machine immediately and engage
park brake. Take corrective action.
16. Brake Temperature Indicator: Indicator lights when
brake temperature is too high.
17. Hydraulic Oil Temperature Indicator: Indicator
lights when hydraulic oil temperature exceeds 104°C
(220°F). If hydraulic oil temperature is too high, stop
work. Allow engine to operate at high idle for 3
minutes and allow oil to cool. If indicator stays on, stop
machine and see your authorized dealer.
18. Dump Body Raised Indicator (Marked Bin Up):
Indicator lights when body is raised off the frame.
19. Inter-Axle Lock Indicator (Marked Inter-Axle Diff
Lock): Indicator lights when inter-axle lock is engaged.
20. Differential Lock Indicator (Marked Diff Lock): Not
used.
21. Data Display: Displays machine information.
22. Menu Button: Used to navigate through Monitor
Display Unit.
23. Back Button: Used to navigate through Monitor
Display Unit.
24. Next Button: Used to navigate through Monitor
Display Unit.
25. Select Button: Used to navigate through Monitor
Display Unit.
26. Fuel Gauge: Gauge indicates fuel level in tank.
Always fill fuel tank at end of day to eliminate
condensation in fuel tank.
27. Speedometer: Speedometer indicates travel speed in
kilometers per hour (km/hr) or miles per hour (mph).
28. Transmission Oil Temperature Gauge:
IMPORTANT: DO NOT exceed maximum
transmission operating temperature of 145°C
(293°F) to avoid damage to the transmission.
Gauge indicates temperature of transmission oil.
Normal operating temperature is indicated by green
zone. If indicator points to red zone, allow transmission
to cool.
29. Coolant Temperature Gauge:
IMPORTANT: To prevent machine damage,
DO NOT operate machine when engine
coolant temperature is high.
IMPORTANT: If engine overspeed indicator
lights, reduce engine speed immediately
using the service brake.
DO NOT exceed 2800 rpm or serious engine
or transmission damage may occur.
Indicator lights when engine speed exceeds 2800 rpm.
12. Right Turn Indicator: Indicator lights when right turn
indicator is switched ON.
13. Message Display: Displays machine information for
operator.
Gauge indicates temperature of engine coolant.
Normal operating temperature is indicated by the
green zone. If indicator points to red zone, stop
machine and allow engine to cool.
30. Air Pressure Gauge:
CAUTION: To prevent personal injury or
machine damage, DO NOT operate machine
when air pressure is low.
Continued on next page
2-1-5
OUO1043,0000DAE -19-06FEB03-1/2
080112
PN=28
Operation—Operator’s Station
Gauge indicates system air pressure. Normal
operating pressure is indicated by the green zone. If
indicator points to red zone, stop machine and take
corrective action.
31. Engine Oil Pressure Gauge:
Gauge indicates engine oil pressure. Normal operating
pressure is indicated by the green zone. If indicator
points to red zone, stop machine and take corrective
action.
IMPORTANT: To prevent machine damage,
DO NOT operate machine when engine
oil pressure is low.
OUO1043,0000DAE -19-06FEB03-2/2
Heater and Air Conditioner Controls
T143696B —UN—05JUL01
1. Air Conditioner Switch: Push lower half of switch to
turn air conditioner or defrost ON. Push upper half of
switch to turn air conditioner or defrost OFF.
2. Temperature Control Knob: Turn counterclockwise
for cooler air. Turn clockwise for warmer air.
3. Blower Speed Control Knob: Turn blower speed
control knob to adjust blower speed.
4. Air Flow Control Knob: Turn knob to defrost, low,
high or divided flow.
5. Recirculating Air Switch: Push lower half of switch
to recirculate air. Push the upper half of the switch
for fresh air.
1— Air Conditioner Switch
2— Temperature Control Knob
3— Blower Speed Control Knob
4— Air Flow Control Knob
5— Recirculating Air Switch
OUO1043,0000DC9 -19-03JUL01-1/1
2-1-6
080112
PN=29
Operation—Operator’s Station
Steering Column Lever
1. High Beam Headlight: Push lever forward to high
beam headlight position (1).
2. Low Beam Headlight: Move lever to center dim
headlight position (2).
T143150B —UN—20JUN01
3. Flash-to-Pass Headlight: Pull lever rearward to
flash-to-pass headlight position (3). Lever will return
to dim headlight position when released.
4. Horn Button: Push to sound horn.
5. Windshield Washer Button: With key switch in ON
or ACCESSORY position, push to activate windshield
washer.
6. Intermittent Windshield Wiper: With key switch in
ON or ACCESSORY position, turn steering column
lever forward to intermittent wiper position (6).
Intermittent wiper time interval can be adjusted using
the monitor display unit (MDU).
7. Windshield Wiper Off: Turn steering column lever
forward or rearward, as necessary, to windshield wiper
OFF position (7) to turn wiper OFF.
8. Low Speed Windshield Wiper: With key switch in
ON or ACCESSORY position, turn steering column
lever rearward to low speed windshield wiper position
(8) to activate low speed windshield wiper.
9. High Speed Windshield Wiper: With key switch in
ON or ACCESSORY position, turn steering column
lever rearward to high speed windshield wiper position
(9) to activate high speed windshield wiper.
1— High Beam HeadLight
Position
2— Low Beam HeadLight
Position
3— Flash-to-Pass Headlight
Position
4— Horn Button
5— Windshield Washer Button
6— Intermittent Windshield
Wiper Position
7— Windshield Wiper Off
Position
8— Low Speed Windshield
Wiper Position
9— High Speed Windshield
Wiper Position
10— Right Turn Indicator
Position
11— Left Turn Indicator
Position
11. Left Turn Indicator: Push steering column lever
down to left turn indicator position (11) to activate left
turn indicator.
10. Right Turn Indicator: Lift steering column lever up to
right turn indicator position (10) to activate right turn
indicator.
OUO1043,0000DB4 -19-20JUN01-1/1
2-1-7
080112
PN=30
Operation—Operator’s Station
T143685B —UN—05JUL01
T148487B —UN—29NOV01
Circuit Breaker Compartment
1— 15 Amp Circuit Breaker
(F1)—Park Lights, Interior
Lights, Brake Lights,
Hazards/Indicators, Voltage
Regulator
2— 30 Amp Circuit Breaker
(F2)—Battery Supply to Fuses
F12, F13, F18, F19, F20, and
F21
3— 20 Amp Circuit Breaker
(F3)—Ignition Supply to
Fuses F11, F14, F15, and F16
4— 30 Amp Circuit Breaker
(F4)—Back Up Lights,
Headlights, Work Lights, and
Rotating Beacon
5— 25 Amp Circuit Breaker
(F5)—Air Conditioner,
Headlights Relay
6— 15 Amp Circuit Breaker
(F6)—Gear Hold, Bin Down
Latch Solenoid, Park Brake
Solenoid, CTD Solenoid,
Automatic Greaser, and Fan
Drive Solenoid
7— 25 Amp Circuit Breaker
(F7)—Seat Pump, Wiper
Motor, Mirror Defrost,
Electrical Mirrors,
Washer Motor, Horn
Solenoid/Electrical Horn
8— 25 Amp Circuit Breaker
(F8)—Cold Start
The circuit breaker panel consists of 9 circuit breakers
which provide electrical overload protection for the
identified circuits. Push circuit breaker button to reset a
tripped circuit breaker.
9— 15 Amp Circuit Breaker
(F9)—Bin Float Solenoid,
Neutral Relay, Start Relay,
MDU/CCU Power Relay
10— 10 Amp Fuse
(F11)—Transmission,
Engine Brake, and Voltage
Regulator
11— 10 Amp Fuse
(F12)—Transmission
12— 5 Amp Fuse
(F13)—MDU/CCU (Battery to
Relay), Hazard Input to CCU
13— 5 Amp Fuse (F14)—Alternator D+
14— 10 Amp Fuse (F15)—CCU
Program, MDU Program,
Diagnostic
15— 20 Amp Fuse (F16)—Engine
16— 10 Amp Fuse (F17)—Reverse
Camera, FM Radio—If
Equipped
17— 5 Amp Fuse (F19)—MDU
18— 10 Amp Fuse
(F20)—Diagnostic
19— 10 Amp Fuse (F21)—Battery
Balancer, Accessory,
Battery Balancer Enable
20— 15 Amp Fuse (F22)—2-Way
Radio
The fuse block consists of 11 fuses which provide
overload protection for the identified circuits. Replace
fuses as necessary.
TX14740,0000009 -19-27JAN03-1/1
2-1-8
080112
PN=31
Operation—Operator’s Station
Operator Seat and Instructional Seat
CAUTION: Use seat belt to prevent personal
injury. Check condition of seat belt and
mounting hardware before operating machine.
Replace seat belt at least every 3 years,
regardless of condition.
Seat belt must fit snugly over abdomen. Seat belt
extends as necessary to fit comfortably.
6. Fore/Aft Adjustment Lever: Lift and hold seat
cushion adjustment lever and adjust seat cushion angle
as desired. Release lever to lock seat into position.
7. Instructional Seat: The instructional seat is
non-adjustable and is equipped with a seat belt.
1— Backrest Angle Adjustment
Knob
2— Weight Adjustment Lever
3— Seat Height Adjustment
Lever
4— Arm Rest Angle Adjustment
Knob
5— Seatbelt
6— Fore/Aft Adjustment Lever
7— Instructional Seat
T143728B —UN—24AUG01
1. Backrest Adjustment Knob: Turn knob to move
backrest to desired position.
2. Weight Adjustment Lever: Use adjustment lever to
obtain the most comfortable seat suspension.
3. Seat Height Adjustment Lever: Pull and hold
adjustment lever up to obtain the most comfortable
driving position.
4. Arm Rest Angle Adjustment Knob: The arm rests
may be lifted to allow easier access to seat and then
lowered for driver comfort. To adjust angle of arm
rests, turn arm rest angle adjustment knob under
arm rest clockwise or counterclockwise until the most
comfortable position is reached.
5. Seat Belt:
T144959B —UN—24AUG01
The operator's seat is fully adjustable to suit operator's
height, weight and reach.
OUO1043,0000DD1 -19-06FEB03-1/1
2-1-9
080112
PN=32
Operation—Operator’s Station
Air Suspension Seat—If Equipped
The operator's seat is fully adjustable to suit operator's
height, weight and reach.
1. Fore/Aft Adjustment Lever:Lift to move seat forward
or rearward. Release lever to lock seat into position.
2. Air/Height Lever:Lift and hold air/height lever to
obtain the most comfortable driving position.
3. Lumbar:Push lumbar support button to adjust seat
back lumbar support to the most comfortable position.
4. Armrest Height:The armrests may be lifted to allow
easier access to seat and then lowered for driver
comfort.
5. Backrest Tilt:Lift seat back tilt lever to adjust seat
back tilt. Release lever to lock seat back into position.
6. Fore/Aft Cushion Lock:Adjust cushion to improve
operator comfort.
7. Ride Control/Stiffness:Adjust seat to improve overall
ride control and to reduce stiffness.
5— Backrest Tilt
6— Fore/Aft Cushion Lock
7— Ride Control/Stiffness
T213148A —UN—02AUG05
1— Fore/Aft Adjustment Lever
2— Air/Height Lever
3— Lumbar
4— Armrest Height
AM40430,00000F4 -19-01AUG05-1/1
Seat Belt
Seat belt and mounting hardware must be inspected for
wear or damage before operating the machine. Replace
the belt or mounting hardware if worn or damaged.
Replace the complete seat belt assembly every three
years regardless of appearance.
VD76477,0001581 -19-06JUL07-1/1
2-1-10
080112
PN=33
Operation—Operator’s Station
Battery Disconnect Switch and Battery
Circuit Breakers
T147634B —UN—09NOV01
The battery disconnect switch (4) is located inside the
battery compartment.
IMPORTANT: Always turn battery disconnect switch
OFF when engine is stopped and machine
is left unattended. If switch is left ON for
long periods while engine is stopped, the
batteries may become discharged.
IMPORTANT: Always turn battery disconnect switch
OFF before any maintenance or repair is
performed on machine's electrical system or
any welding work is performed.
T147883B —UN—09NOV01
The battery disconnect switch is used to isolate electrical
power from batteries to machine.
The battery disconnect switch has 2 positions, OFF and
ON.
Three circuit breakers are located in the battery
compartment to protect the machine's electrical circuits
from a possible overload condition or problem from
batteries.
• The main circuit breaker (3) (marked Ignition) is rated
at 60 amps.
• The battery balancer circuit breaker (2) (marked 12 V)
is rated at 20 amps.
• The purging units, fuel filter and coolant level switch
circuit breaker (1) is rated at 20 amps.
1— 20 Amp Circuit
Breaker—Purging Units,
Fuel Filter, and Coolant
Level Switch
2— 20 Amp Circuit
Breaker—Battery Balancer
(Marked 12 V)
3— 60 Amp Circuit
Breaker—Main (Marked
Ignition)
4— Battery Disconnect Switch
OUO1043,0000DF7 -19-30OCT01-1/1
2-1-11
080112
PN=34
Operation—Operator’s Station
Miscellaneous Equipment
High beam and low beam headlights (1) are controlled
using the steering column lever.
Tail, brake and park lights (4) light when brake pedal is
depressed or when accelerator pedal is released and
torque retarder is activated.
Turn indicator lights (2 and 3) light when warning lights or
turn signals are turned ON.
T147635B —UN—29NOV01
Lights
Back-up lights (5) light when machine transmission is
shifted to reverse.
4— Tail, Brake and Park Light
(2 used)
5— Back Up Light (3 used)
T147636B —UN—09NOV01
1— Headlight and Front Park
Light (2 used)
2— Front Turn Indicator Light
(2 used)
3— Rear Turn Indicator Light (2
used)
TX14740,000000A -19-27JAN03-1/6
Secondary Exit
If necessary, use the secondary exit tool (1) to break the
glass of the right-side window.
T143573B —UN—06JUL01
1— Secondary Exit Tool
TX14740,000000A -19-27JAN03-2/6
12-Volt Accessory Outlet
The 12-volt accessory outlet is used to power operator
accessories, as necessary.
T144144B —UN—19JUL01
1— 12-Volt Accessory Outlet
Continued on next page
2-1-12
TX14740,000000A -19-27JAN03-3/6
080112
PN=35
Operation—Operator’s Station
Storage Compartment
Store items in compartment located behind the operator's
seat to keep them clean and dry.
T144275B —UN—27JUL01
1— Storage Compartment
TX14740,000000A -19-27JAN03-4/6
Wheel Wrench and Brace
NOTE: Brace is also used as cab tilt pump handle.
1— Wheel Wrench
T143737B —UN—06JUL01
The wheel wrench (1) and brace (2) are located at rear
of cab, behind the operator's seat and are secured in
position by 2 plates.
2— Brace
TX14740,000000A -19-27JAN03-5/6
Windshield Washer Reservoir
The windshield washer reservoir (1) is located at front of
cab under hood.
T143736B —UN—06JUL01
To fill reservoir:
1. Tilt hood.
2. Remove filler cap (2) and fill reservoir with washer
cleaning fluid.
3. Install cap. Ensure that electrical connection and fluid
delivery hose are also secure.
4. Close hood.
1— Windshield Washer
Reservoir
2— Filler Cap
TX14740,000000A -19-27JAN03-6/6
2-1-13
080112
PN=36
Operation—Operator’s Station
1. Message Display: When key switch is turned ON or
machine is started, the default menu will be displayed.
The default menu can be configured to suit the
operator. The information on the bottom row can be
changed by pressing the NEXT button.
When other menus are selected or service codes
are detected, message display will show relevant,
descriptive information.
2. Gear Display: When machine is in neutral (N), the
gear display will show “0”. When machine is in drive
(D), gear display will show the current of 6 forward
gears that the machine is in. When machine is in
reverse (R), the gear display will display “1”; there is
only a single reverse gear.
3. Drive/Neutral/Reverse Display: When machine is in
drive (D), display will show “F”. When machine is in
neutral (N), display will show “N”. When machine is in
reverse (R), display will show “R”.
4. NEXT Button: To change the information shown in the
information display, press and hold NEXT button for 3
beeps to access default menu. Once default menu is
accessed, push NEXT button repeatedly until message
display (1) shows that desired default information
is being shown in information display (5). Once
default screen has been changed, the selected default
information will be displayed any time the key switch is
turned to the ON position or the machine is started.
5. Information Display: Information displayed varies,
depending on which default display is currently
T144175 —UN—09OCT01
Monitor Display Unit—Default Display Menu
1— Message Display
2— Gear Display
3— Drive/Neutral/Reverse
Display
4— NEXT Button
selected. When ignition is switched OFF and then ON
again, the last selected information will be displayed.
6. Tachometer Display: Displays current engine speed
rpm.
7. Hour Meter Display: Displays the machine hours in
whole hour increments. The hour meter accumulates
hours only when the engine is running.
Continued on next page
2-1-14
5— Information Display
6— Tachometer Display
7— Hour Meter Display
OUO1043,0000DCC -19-19JUL01-1/3
080112
PN=37
T143037 —UN—11OCT01
Operation—Operator’s Station
Default Menu Function
Default Menu
Description
Machine Model
Message display shows machine model number. Data display shows machine system voltage in volts.
Bin Tip Counter
Data display shows number of times dump body was tipped since bin tip counter was last reset.
Trip Distance
Data display shows distance machine traveled, in kilometers or miles, since counter was last reset.
Trip Time
Data display shows machine operation time since counter was last reset.
Trip Fuel
Data display shows machine fuel consumption rate since trip fuel counter was last reset.
Odometer
Odometer displays total distance machine has travelled in kilometers or miles. Odometer cannot be reset.
Lockup Clutch
Data display shows ON/OFF status of lock up clutch.
Transmission Temperature
Data display shows transmission oil temperature in °C or °F.
Return Temperature
Data display shows transmission return oil temperature in °C or °F.
Retarder Torque
Data display shows transmission torque as a percentage of available torque.
Engine Temperature
Data display shows engine temperature in °C or °F.
Engine Oil Pressure
Data display shows engine oil pressure in bar or psi.
Engine Oil Level
Data display shows engine oil level as a percentage.
Fuel Consumption
Data display shows fuel consumption in L/h or gal/h.
Actual Torque
Data display shows machine torque as a percentage of available torque.
Engine Retarder Torque
Data display shows engine brake torque as a percentage of available torque.
Fuel Level
Data display shows fuel supply in L or gal.
System Air Pressure
Data display shows system air pressure in bar or psi.
Continued on next page
2-1-15
OUO1043,0000DCC -19-19JUL01-2/3
080112
PN=38
Operation—Operator’s Station
Default Menu Function
Default Menu
Description
Hydraulic Temperature
Data display shows hydraulic oil temperature in °C or °F.
Brake Temperature
If machine is equipped with wet brakes, data display shows wet brake temperature in °C or °F.
OUO1043,0000DCC -19-19JUL01-3/3
1. Message Display: Shows description of current menu
screen selected.
2. Menu Display: Shows which menu is currently
selected.
3. Sub Menu Display: Shows which sub menu is
currently selected.
4. Sub Sub Menu Display: Shows which sub sub menu
is currently selected.
5. Information Display: Information displayed varies,
depending on which menu screen is currently selected.
6. MENU Button: Push to advance through 5 menus (A,
B, C, D, and E) and the default menu.
Push MENU at any time while navigating through a
menu to return to default data display.
7. BACK Button: Push to return to the next higher
menu. For example, if navigating in the A 01 sub
menu level, pressing BACK will return the MDU data
display to the A menu of the top menu level.
8. NEXT Button: Push to advance from one menu to
the next in the same sub menu level or sub sub menu
level. For example, if navigating in the A 01 sub level,
push NEXT button once to go to the A 02 menu.
9. SELECT Button: Push to access the menu below the
currently shown menu. For example, if sub level menu
T144178 —UN—24JUL01
Monitor Display Unit—Menu Function
1— Message Display
2— Menu Display
3— Sub Menu Display
4— Sub Sub Menu Display
5— Information Display
A 01 is currently displayed, press SELECT to display
the A 011 sub sub level.
Continued on next page
2-1-16
6— MENU Button
7— BACK Button
8— NEXT Button
9— SELECT Button
OUO1043,0000DB5 -19-21JUN01-1/12
080112
PN=39
T143038 —UN—11OCT01
Operation—Operator’s Station
Continued on next page
2-1-17
OUO1043,0000DB5 -19-21JUN01-2/12
080112
PN=40
T143039 —UN—22OCT01
Operation—Operator’s Station
Continued on next page
2-1-18
OUO1043,0000DB5 -19-21JUN01-3/12
080112
PN=41
T143040 —UN—11OCT01
Operation—Operator’s Station
Continued on next page
2-1-19
OUO1043,0000DB5 -19-21JUN01-4/12
080112
PN=42
T143744 —UN—11OCT01
Operation—Operator’s Station
Continued on next page
2-1-20
OUO1043,0000DB5 -19-21JUN01-5/12
080112
PN=43
T143041 —UN—22OCT01
Operation—Operator’s Station
Continued on next page
2-1-21
OUO1043,0000DB5 -19-21JUN01-6/12
080112
PN=44
T143042 —UN—11OCT01
Operation—Operator’s Station
Continued on next page
2-1-22
OUO1043,0000DB5 -19-21JUN01-7/12
080112
PN=45
Operation—Operator’s Station
Menu Functions
Menu
A
00
Counters
A
01
Trip Information
Menu displays trip counter information since counters were last reset.
A
011
Trip Distance
Data display shows distance machine traveled, in kilometers or miles, since trip distance
counter was last reset.
A
011
1
Press SELECT for longer than 3 beeps to reset trip distance counter.
A
012
A
013
A
014
A
02
A
03
B
00
Reset
Trip Time
Data display shows machine operation time since trip time counter was last reset.
A
012
1
Press SELECT for longer than 3 beeps to reset trip time counter.
Reset?
Trip Fuel
Data display shows machine fuel consumption rate since trip fuel counter was last reset.
A
013
1
Reset?
Press SELECT for longer than 3 beeps to reset trip fuel counter.
Reset All Trip Data?
Press SELECT for longer than 3 beeps to reset all trip counters.
Bin Tip Counter
Data display shows number of times dump body was tipped since bin tip counter was
last reset.
A
021
Press SELECT for longer than 3 beeps to reset bin tip counter.
Reset?
Odometer
Actual Values
B
01
Engine Values
B
011
B
02
Engine Oil Pressure
Odometer displays distance machine has traveled in kilometers or miles. Odometer
cannot be reset.
Menu displays machine sensor information.
Menu displays engine sensor information.
Data display shows engine oil pressure in bar or psi.
B
012
Engine Coolant Temperature
Data display shows engine coolant temperature in °C or °F.
B
013
Throttle Position
Data display shows throttle position as a percentage of full throttle.
B
014
Actual Torque
Data display shows actual engine torque as a percentage.
B
015
Engine Retarder Torque
Data display shows engine brake as a percentage.
B
016
Engine Oil Level
Data display shows engine oil level as a percentage of full.
B
017
Fuel Consumption
Data display shows fuel consumption in L/h or gal/h.
Transmission Values
B
021
B
03
Description
Menu displays counter information and allows counters to be reset.
Transmission Temperature
Menu displays transmission sensor information.
Data display shows transmission temperature in °C or °F.
B
022
Lock-Up Clutch
Data display shows ON/OFF status of lock-up clutch.
B
023
Current Gear
Data display shows the currently activated travel gear.
B
024
Retarder Torque
Data display shows actual transmission retarder torque as a percentage.
B
025
Retarder Oil Temperature
Data display shows retarder oil temperature in °C or °F.
Vehicle Values
Menu displays miscellaneous machine sensor information.
Continued on next page
2-1-23
OUO1043,0000DB5 -19-21JUN01-8/12
080112
PN=46
Operation—Operator’s Station
Menu Functions
Menu
B
031
C
00
Air Pressure
B
032
Fuel Level
Data display shows fuel supply in L or gal.
B
033
Bin Position
Data display shows body position as a percentage of body in full up position.
B
034
Hydraulic Temperature
Data display shows hydraulic oil temperature in °C or °F.
B
035
Brake Temperature
If machine is equipped with wet brakes, data display shows wet brake temperature in
°C or °F.
B
036
Inter-Axle Lock
Data display shows ON/OFF status of differential lock.
This menu is used to display service codes and diagnose inputs and outputs of CCU.
Diagnostics
C
01
C
02
Actual Service Codes
Menu displays CCU service code. If service code appears, see Service Codes in
Miscellaneous—Troubleshooting section.
C
011
Data display shows first active service code. See Service Codes in
Miscellaneous—Troubleshooting section.
Service Code 1
C
012
Service Code 2
Data display shows second active service code. See Service Codes in
Miscellaneous—Troubleshooting section.
C
01X
Service Code X
Continue to press NEXT button to advance through all active service codes.
C
01Y
End
Continue to press NEXT button until END is displayed on message display. Press NEXT
button again to return to first active service code.
Stored Service Codes
C
021
C
03
Description
Data display shows system air pressure in bar or psi.
Clear Service Codes?
Menu displays CCU service code. If service code appears, see Service Codes in
Miscellaneous—Troubleshooting section.
Press SELECT for longer than 3 beeps to reset trip time counter.
C
022
ECU/TCU/CCU Service Code
Data display shows first stored service code. See Service Codes in
Miscellaneous—Troubleshooting section.
C
02X
ECU/TCU/CCU Service Code X
Continue to press NEXT button to advance through maximum of 5 stored service codes.
C
02Y
End
Continue to press NEXT button until END is displayed on data display. Press NEXT
button again to return to “CLEAR FAULT CODES?” display.
CCU Inputs
Menu displays ON/OFF status of CCU digital inputs.
C
031
Low Coolant Level
C
032
Park Brake
C
033
Latch Control
C
034
Coldstart
C
035
Inter-Axle Lock Dash Switch
C
036
Left Indicator
C
037
Right Indicator
C
038
Hazards
C
039
Intermittent Wipers
C
031
0
Start Signal
Data display indicates if key switch is in START position. ON indicates key switch is in
START position; OFF indicates key is not in start position.
C
031
1
Ignition
Data display indicates if key switch is in RUN position. ON indicates key switch is in RUN
position; OFF indicates key is not in RUN position.
Data display shows ON/OFF status of low coolant level sensor.
Data display shows ON/OFF status of pressure switch controlling park brake light.
Data display shows ON/OFF status of park brake lever.
Data display shows ON/OFF status of machine coldstart function.
Data display shows ON/OFF status of inter-axle lock dash switch.
Data display shows ON/OFF status of left turn indicator input from steering column switch.
Data display shows ON/OFF status of right turn indicator input from steering column switch.
Data display shows ON/OFF status of hazard switch.
Data display shows ON/OFF status of intermittent wiper input from steering column switch.
Continued on next page
2-1-24
OUO1043,0000DB5 -19-21JUN01-9/12
080112
PN=47
Operation—Operator’s Station
Menu Functions
Menu
C
04
C
05
D
00
C
031
2
Brake
C
031
3
Gear Hold
Data display indicates ON/OFF status of range hold rocker switch.
CCU Analog Inputs
Menu displays CCU analog inputs in milivolts for analog sensors as measured at CCU
input.
C
041
Bin Position
Data display shows milivolts of at bin position sensor at CCU input and the associated
value of bin position as a percentage of full tip value.
C
042
Air Pressure
Data display shows milivolts of air pressure sensor as measured at CCU input and the
air pressure value in bar or psi.
C
043
Hydraulic Temperature
Data display shows milivolts of hydraulic temperature sensor as measured at CCU input
and temperature value in °C or °F.
C
044
Wet Brake Temperature
Data display shows milivolts of wet brake temperature sensor as measured at CCU
input and temperature value in °C or °F.
C
045
Battery Voltage
C
046
Fuel Level
CCU Outputs
C
051
Intermittent Wipers
C
052
Left Indicator
C
053
Right Indicator
C
054
Inter-Axle Lock
C
055
Park Brake
C
056
Overspeed
C
057
Hydraulic Cutout
C
058
Brake
C
059
Bin Float
C
051
0
Purging Unit
C
051
1
Engine Running
Data display shows milivolts of fuel level sensor as measured at CCU input and fuel
level value in L or gal.
Menu displays CCU analog output signal ON/OFF status.
Data display shows CCU intermittent wiper output signal ON/OFF status.
Data display shows CCU left turn indicator output signal ON/OFF status.
Data display shows CCU right turn indicator output signal ON/OFF status.
Data display shows CCU inter-axle lock output signal ON/OFF status.
Data display shows CCU park brake output signal ON/OFF status.
Data display shows CCU overspeed output signal ON/OFF status.
Data display shows CCU hydraulic cutout output signal ON/OFF status.
Data display shows CCU brake light output signal ON/OFF status, activated with engine
brake and transmission retarder.
Data display shows CCU bin float output signal ON/OFF status.
Data display shows CCU engine run output signal ON/OFF status.
Wiper Intermittent Timing
D
011
Data display shows both single battery voltage and 2 battery voltage in volts.
Data display shows CCU purging unit output signal ON/OFF status.
Machine Configuration
D
01
Description
Data display indicates if brake pedal is being depressed. ON indicates brake pedal is
being depressed. OFF indicates brake pedal is not being depressed.
3 Seconds
Menu displays the current machine settings and allows them to be adjusted, if necessary.
Menu displays current setting of intermittent wipers and allows setting to be changed.
Press NEXT as necessary to advance through screens, until desired intermittent wiper
time interval is displayed. When desired interval is displayed, press SELECT for longer
than 3 beeps to activate that interval.
D
012
4 seconds
Press NEXT as necessary to advance through screens, until desired intermittent wiper
time interval is displayed. When desired interval is displayed, press SELECT for longer
than 3 beeps to activate that interval.
D
01
XX
XX Seconds
Press NEXT as necessary to advance through screens, until desired intermittent wiper
time interval is displayed. When desired interval is displayed, press SELECT for longer
than 3 beeps to activate that interval.
Continued on next page
2-1-25
OUO1043,0000DB5 -19-21JUN01-10/12
080112
PN=48
Operation—Operator’s Station
Menu Functions
Menu
D
012
0
D
02
Menu allows tire size to be selected to reflect tire size installed on machine.
NOTE: Value shown in data display is dynamic rolling radius of tire in mm.
Press NEXT as necessary to advance through screens, until machine tire size is displayed.
When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.
D
023
734
Press NEXT as necessary to advance through screens, until machine tire size is displayed.
When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.
D
02
XX
XXX
Press NEXT as necessary to advance through screens, until machine tire size is displayed.
When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.
D
021
7
YYY
Press NEXT as necessary to advance through screens, until machine tire size is displayed.
When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.
Imperial/English Units
ON
OFF
E
02
Menu allows operator to determine whether measurements will be displayed in
Imperial/English units or metric units.
Press SELECT for 3 beeps to display Imperial/English units.
Press SELECT for 3 beeps to display metric units.
Bin Tip Angle
Menu allows operator to set bin full down and bin full up positions. Also allows operator
to determine bin tip counter parameters.
D
041
With machine body in the full down position, press SELECT for longer than 3 beeps to set
the zero position. Display will change to show 0%.
Set Zero
D
042
Set Full Tip
With machine body in the full up position, press SELECT for longer than 3 beeps to set
the zero position. Display will change to show 100%.
D
043
Set Low Bin Counter Trigger
Before setting low bin count trigger, set zero and full tip values.
Low bin counter trigger default is body raised 10%.
To set low bin counter trigger, raise body to desired low bin counter trigger height. Data
display will show current bin height percentage. Press SELECT for 12 beeps to set
low bin counter trigger.
D
04
Set High Bin Counter Trigger
Before setting high bin count trigger, set zero and full tip values.
High bin counter trigger default is body raised 70%.
To set high bin counter trigger, raise body to desired high bin counter trigger height. Data
display will show current bin height percentage. Press SELECT for 12 beeps to set
high bin counter trigger.
Machine Identification
E
01
Press NEXT as necessary to advance through screens, until machine tire size is displayed.
When tire size is displayed, press SELECT for longer than 12 beeps to select that interval.
714
D
032
E
00
647
D
022
D
031
D
04
Description
Press NEXT as necessary to advance through screens, until desired intermittent wiper
time interval is displayed. When desired interval is displayed, press SELECT for longer
than 3 beeps to activate that interval.
Tire Size
D
021
D
03
20 Seconds
Menu displays machine identification information.
Menu displays engine control unit (ECU) identification information.
ECU
E
011
EN XXXXXX
E
012
Software Version
Message display shows ECU part number.
Data display shows current ECU software version.
E
013
Hardware Version
Data display shows current ECU hardware version.
E
014
Serial Number
Message display shows ECU serial number.
E
015
Engine Hours
Data display shows engine hours logged on current ECU.
Menu displays transmission control unit (TCU) identification information.
TCU
E
021
TN XXXXXX
E
022
Software Version
E
023
Hardware Version
Message display shows TCU part number.
Data display shows current TCU software version.
Data display shows current TCU hardware version.
Continued on next page
2-1-26
OUO1043,0000DB5 -19-21JUN01-11/12
080112
PN=49
Operation—Operator’s Station
Menu Functions
Menu
E
024
E
03
E
04
Serial Number
Description
Message display shows TCU serial number.
Menu displays monitor display unit (MDU) identification information.
MDU
E
031
VIN AEB XXXXX
E
032
Software Version
Message display shows the vehicle identification number of the machine.
Data display shows current MDU software version information.
E
033
Hardware Version
Data display shows current MDU hardware version.
E
034
Serial Number
Data display shows MDU serial number.
E
035
Engine Hours
Data display shows MDU hours on current MDU.
Menu displays chassis control unit (CCU) identification information.
CCU
E
041
VIN AEB XXXXXX
E
042
Software Version
Message display shows the vehicle identification number of the machine.
Data display shows current CCU software version information.
E
043
Hardware Version
Data display shows current CCU hardware version.
E
044
Serial Number
Message display shows CCU serial number.
E
045
Engine Hours
Data display shows CCU hours on current CCU.
OUO1043,0000DB5 -19-21JUN01-12/12
2-1-27
080112
PN=50
Operation—Operating the Machine
Before Starting Work
T133556 —UN—24AUG00
Review the operating precautions in the Safety
Section of this manual.
Use seat belt when operating your machine.
Remember to fasten seat belt even during brief periods
of use.
TX03679,0001780 -19-02NOV00-1/1
Operator's Daily Machine Check Before Starting
Safety and Protective Devices Checks
Check for bent, broken, loose or missing sheet metal.
Walk around machine to clear all persons from machine
area before starting machine.
Check for loose or missing hardware.
Check back-up alarm, horn, turn signals and lights for
correct operation.
Check for oil leaks, missing or loose hose clamps, kinked
hoses and lines or hoses that rub against each other or
other parts.
Check condition of guards, shields and covers.
Check brake accumulators precharge.See Check Brake
Accumulators. (Section 4-1.)
Overall Machine Checks
Check for worn or frayed electrical wires and loose or
corroded connections.
OUO1043,0000DC2 -19-28JUN01-1/1
2-2-1
080112
PN=51
Operation—Operating the Machine
Starting Engine
Before Starting the Engine
1. Turn battery disconnect switch to the ON position.
2. Fasten seat belt.
TS175 —UN—23AUG88
3. Turn key switch to ON position (1) and verify that the
following happens during 3-second bulb check:
• All indicators will light or flash.
• All gauges and speedometer move to center position.
• Warning alarm sounds.
• All segments of MDU LCDs will display.
• All segments of transmission control LED display
and mode button indicator will light.
T143521B —UN—03JUL01
After 3 seconds all gauges, LCD and LED displays
will return to normal operation mode and warning
alarm will silence. All indicators, except for secondary
steering (marked emergency steering), battery charge
and park brake indicators, will go out.
Air pressure indicator may also remain lit, depending
on system air pressure. Cold start indicator may also
remain lit, depending on ambient temperature.
Starting the Engine
1. Press horn button to sound horn and alert bystanders
that machine will be started.
CAUTION: Prevent possible injury from
unexpected machine movement. If hydraulic oil
is cold, hydraulic functions move slowly. DO NOT
attempt normal machine operation until hydraulic
functions move at close-to-normal cycle times.
IMPORTANT: Never operate starter motor for more
than 17 seconds at a time. If engine fails to
start after 2 or 3 tries, return key switch to OFF.
Wait for about 1 minute, then try again.
After a false start, do not turn key switch until
engine stops or starter may be damaged.
Engine will not start by towing or pushing.
Permanent damage to transmission will result.
IMPORTANT: Prevent damage to engine. Use start
aid when temperatures are below 0°C (32°F)
and only when engine is COLD.
1— Key Switch ON Position
2— Key Switch START Position
engine is COLD, press start aid switch while starting
engine.
3. Allow engine to idle until secondary steering (marked
emergency steering) and air pressure indicators go out.
Warming the Engine
IMPORTANT: Allow engine to idle at least 1/2
minute. Do not run engine at fast idle or under
heavy load until engine oil, transmission and
hydraulic oils have warmed up to normal
operating temperatures.
Operate machine at less than normal loads and at slow
idle speed until engine warms up.
2. Turn key switch to START position (2) and hold until
engine starts. If temperature is below 0°C (32°F) and
OUO1043,0000E40 -19-13NOV01-1/1
2-2-2
080112
PN=52
Operation—Operating the Machine
Replace Start Aid Can
TS281 —UN—23AUG88
CAUTION: Prevent possible injury from exploding
container. Starting fluid is highly flammable. Keep
container away from heat, sparks and open flame.
Contents are pressurized. DO NOT puncture or
incinerate container. Remove can from machine
if engine does not need starting fluid.
IMPORTANT: Remove can from container and
install container upside-down to protect start
aid components from dust.
1. Open hood.
2. Loosen clamp (1).
T148320B —UN—26NOV01
3. Turn start aid can (2) counterclockwise to remove
from base.
4. Remove safety cap and spray button from new start
aid can.
5. Install new start aid can. Hand tighten.
6. Tighten clamp.
7. Close hood.
1— Clamp
2— Start Aid Can
OUO1043,0000E42 -19-15NOV01-1/1
Driving Machine
IMPORTANT: Avoid serious transmission damage.
Never maintain a stall condition for more
than 30 seconds at one time because of the
rapid rise in oil temperature.
Before driving on public roads, check state and local laws
that apply to tractors, self-propelled machines, and towed
equipment. Additional lights, mirrors, SMV emblems, or
reflectors may be required.
Operate the machine in accordance with site and road
regulations.
Always adjust machine speed to road and traffic conditions.
When driving through a bend, do not drive too fast,
especially while transporting a load. If road is slippery, the
operator could lose control.
Do not use inter-axle lock when operating on smooth,
graded surfaces.
Due to weight of machine, allow for long braking
distances, especially on slippery roads.
OUO1043,0000E44 -19-27NOV01-1/1
2-2-3
080112
PN=53
Operation—Operating the Machine
Steering Machine
Normal Steering
NOTE: There is no self-centering function with normal
steering. The machine must be straightened by
turning steering wheel to the straight-ahead position.
Normal steering is operational when engine is running.
NOTE: If there is an engine or main pump malfunction,
the ground-driven secondary steering system will
allow operator to steer machine to a safe stop.
When engine or main pump malfunctions, the secondary
steering indicator (marked emergency steering) will flash.
The machine's secondary steering system is ground
driven and will not operate when machine is stopped.
Secondary Steering
NOTE: There is no secondary steering when
machine is traveling in reverse. Machine
must be traveling forward for the secondary
steering system to operate.
OUO1043,0000DB9 -19-27APR11-1/1
2-2-4
080112
PN=54
Operation—Operating the Machine
Shifting Transmission
IMPORTANT: When transmission sump oil
temperature is below 7°C (19°F), only neutral,
reverse and second gears are available.
T147638B —UN—26NOV01
IMPORTANT: When transmission sump oil
temperature is above 128°C (262°F), the TCU
will restrict the use of higher gears.
NOTE: With dump body in raised position, transmission
will not shift beyond first gear from neutral. If already
in gear, transmission can downshift but not upshift.
The transmission has 6 forward gears and 1 reverse gear
with automatic lock-up in all gears.
The transmission can be operated as a fully automatic
transmission. All automatic gear shifting is controlled
by the transmission control unit (TCU). Gear shifting
is dependent upon engine speed (rpm) and operating
conditions.
1— 1st Gear
2— 2nd Gear
3— 3rd Gear
4— Drive Gear
Shifting Transmission
5— Neutral
6— Reverse Gear
7— Gearshift Control
Move gear shift control to drive gear (D) to revert to
normal operation, allowing the machine to shift through
the full range of gears.
IMPORTANT: Stop machine before shifting from
a forward gear to reverse gear.
Downshift or Reverse Inhibitor
1.
With engine running, park brake engaged, and
gearshift control in neutral (N) (5) apply service brake.
2. Select drive (D) (4) or reverse (R) (6) using gearshift
control (7).
3. Release park brake.
NOTE: Shifting from neutral (N) to drive (D) or reverse
(R) is inhibited when engine speed is above 1100
rpm. Before shifting to drive (D) or reverse (R)
engine speed must be below 1100 rpm.
Although there is no speed limitation on upshifting, there
is on downshifting and shifts from neutral to drive or
reverse. If a downshift or neutral-to-gear shift is selected
when engine speed is too high, the TCU will prevent the
shift until neutral is selected or engine speed is reduced.
4. Release service brake and increase engine speed.
When transmission is in drive (D), the transmission will
sequentially select the next gear as machine speed
increases and downshift as machine speed decreases.
Accelerator Control
Gear Pre-Selection
CAUTION: To avoid injury or property damage
caused by sudden movement of machine, do
not make shift from neutral (N) to drive (D) or
reverse (R) while pressing accelerator.
NOTE: The transmission will shift to gear above
pre-selected gear, up to gear 6, if an engine
overspeed condition occurs.
A lower drive gear (1st gear (1), 2nd gear (2) or 3rd gear
(3) may be pre-selected to match anticipated driving
conditions, giving the operator better control on slick or icy
roads and on downgrades. Pre-selecting a gear limits
the maximum attainable gear to the gear selected. For
example, if gear 3 is pre-selected, gear 4, gear 5 and
gear 6 will not be attained unless an overspeed condition
occurs.
Downshifting to a lower gear increases engine braking.
The selection of a lower gear often prevents cycling
between that gear and the next higher gear on a series of
up-and-down grades.
NOTE: Shifting from neutral (N) to drive (D) or reverse
(R) is inhibited when engine speed is above 1100
rpm. Before shifting to drive (D) or reverse (R)
engine speed must be below 1100 rpm.
Shifting transmission from neutral (N) to reverse (R) or
drive (D) is not allowed if engine speed is above 1100
rpm. If shift is attempted while engine speed is above
1100 rpm, release accelerator and allow engine speed to
drop below 1100 rpm, then attempt shift again.
The position of the accelerator pedal influences the timing
at which automatic shifting occurs. When the pedal is
fully depressed, upshifts will occur automatically at fast
engine speeds.
Continued on next page
2-2-5
OUO1043,0000DF8 -19-30OCT01-1/2
080112
PN=55
Operation—Operating the Machine
A partially depressed accelerator pedal position will cause
upshifts to occur at slow engine speeds.
OUO1043,0000DF8 -19-30OCT01-2/2
Using Range Hold
T147639B —UN—26NOV01
Under certain conditions, such as driving uphill, the
transmission may start shift cycling or “gear hunting”, i.e.,
the transmission changes up and down between 2 gears
at short intervals. This is because power is insufficient for
operating in the higher gear but is sufficient for upshifting
from the lower gear.
NOTE: The MDU will display the actual gear that
the machine is in at anytime.
When this condition occurs, press lower half of range
hold switch (1) to turn range hold ON. The transmission
will hold the gear that it is in at the time the range hold
switch is turned ON. Normal downshifting will occur, but
transmission will NOT upshift to a higher gear until either
the range hold switch is turned OFF or an overspeed
condition occurs.
When level ground is reached, press upper half of range
hold switch to switch range hold OFF. When range hold
1— Range Hold Switch
2— Gearshift Display Window
switch is turned OFF, normal automatic operation mode
will continue.
OUO1043,0000DF9 -19-30OCT01-1/1
Using Inter-Axle Lock
T143346B —UN—28JUN01
IMPORTANT: The inter-axle lock must only be used
when ground conditions are very poor and
not on graded or tarred surfaces.
The inter-axle lock can be engaged while machine is
moving.
To engage inter-axle lock, reduce engine speed
(accelerator pedal less than 10% depressed), press lower
half of inter-axle lock switch (1) and ensure that inter-axle
lock indicator (2) lights.
To disengage inter-axle lock, press upper half of inter-axle
lock switch.
1— Inter-Axle Lock Switch
2— Inter-Axle Lock Indicator
OUO1043,0000E41 -19-13NOV01-1/1
2-2-6
080112
PN=56
Operation—Operating the Machine
Slowing and Stopping the Machine
During normal operation, stop machine using service
brakes. When machine is stopped for more than a few
seconds, engage park brake.
T143568B —UN—06JUL01
CAUTION: Use a combination of downshifting
and braking while going downhill.
Under normal driving conditions, the transmission prevents
automatic upshifting above the lower gear selected.
However, during downhill operation, if engine governed
speed is exceeded in the lower gear, the transmission
may upshift to the next higher gear. This will reduce
braking. Apply service brakes to prevent exceeding
engine governed speed in the lower gear selected.
1— Transmission Retarder
Lever
Remove foot from accelerator pedal to use engine as a
braking force. The transmission will start to downshift.
Use service brakes to slow machine if machine is
exceeding maximum speed for held gear.
Transmission Retarder Lever
Position
Engine braking provides good speed control for traveling
downhill. When machine is fully loaded, or slope is steep,
it may be desirable to preselect a lower gear before
reaching gradient. Downshifting to a lower gear increases
engine braking and helps the operator maintain control
of machine.
Using Transmission Retarder to Slow Machine
The transmission retarder is automatically engaged when
the accelerator pedal is completely released.
The retarder indicator light on the dash will light whenever
the transmission retarder engages.
Using transmission retarder lever (1), select a level of
retardation between 0 and 6 depending on the amount of
retardation required for the operating conditions, with the
0 position having the least amount of retardation, 0%, and
6 having the maximum amount of retardation, 100%. The
level of retardation can be changed while the machine is
moving or stationary.
When brake pedal is applied and transmission retarder
lever is set in positions 0, 1, 2, or 3, the transmission
retarder will apply 50% retardation. When brake pedal is
applied and transmission retarder lever is set in positions
4, 5, or 6, the transmission retarder will apply retardation
indicated by lever setting.
0
0%
1
12%
2
24%
3
39%
4
57%
5
76%
6
100%
Service Brakes
CAUTION: Prevent possible injury from loss of
service brakes. Use transmission retarder in
conjunction with service brakes.
1. Release accelerator pedal.
NOTE: When brake pedal is applied and transmission
retarder lever is set in positions 0, 1, 2, or
3, the transmission retarder will apply 50%
retardation. When brake pedal is applied and
transmission retarder lever is set in positions
4, 5, or 6, the transmission retarder will apply
retardation indicated by lever setting.
2. Depress service brake pedal.
To resume driving, release service brake pedal. The
transmission will automatically select the lowest gear.
Continued on next page
2-2-7
Percentage of Retardation
TX14740,0000012 -19-06FEB03-1/2
080112
PN=57
Operation—Operating the Machine
Park Brake
T147640B —UN—08NOV01
NOTE: Park brake will engage when key is turned to
OFF position. If engine is stopped while park
brake is not engaged, then when engine is started,
park brake lever must be moved to the engaged
position before park brake can be released.
NOTE: The park brake should be engaged only when
machine is completely stationary.
1. Stop machine using service brake pedal.
2. Move park brake lever rearward until it locks in place
to engage park brake.
1— Park Brake Lever
3. Release service brake.
4. Select neutral (N) on gearshift control.
TX14740,0000012 -19-06FEB03-2/2
Operating on a Hill
Uphill Operation
The machine operates in full automatic mode and the
transmission will select the correct gear for traveling uphill.
Engage inter-axle lock to allow for even traction when
operating on slippery roads.
Shift cycling or “gear hunting” on certain uphill applications
can be eliminated by correct use of range hold switch.
Release accelerator pedal to reduce brake pad wear
when driving downhill.
Slow down before going downhill so the transmission
automatically selects a low gear.
Engage inter-axle lock to improve traction and braking
effect when traveling on icy or other slippery conditions.
Downhill Operation
Set retarder for desired operation.
TX14740,000000B -19-27JAN03-1/1
Off-Road Operation
Do not operate too close to quarry edges, ramp edges,
pier edges or soft edges that may collapse under the
machine weight.
Use the articulation steering combined with inter-axle lock
to negotiate difficult ground conditions.
Engage inter-axle lock during off-road operation when
there is a risk of wheels slipping.
OUO1043,0000E46 -19-27NOV01-1/1
2-2-8
080112
PN=58
Operation—Operating the Machine
Loading and Unloading Dump Body
CAUTION: DO NOT operate dump body control
lever unless transmission is in neutral (N) (or
dumping in 1st or reverse). This practice can
effect machine stability and could cause damage
to machine and/or personal injury.
CAUTION: Serious injury or death can result from
contact with electric lines. Never move any part
of the machine or load closer to electric line than
3 m (10 ft) plus twice the line insulator length.
Back up to a loading machine in a single, straight position
so that you can maintain eye contact at all times with the
operator of the loading machine.
Steer machine so that it stays straight. This gives a clear
and unobstructed vision through rear view mirrors. It may
be difficult to observe the spotter and the loading machines
if machine is articulated and not in straight-ahead position
Stop machine on a firm, level surface.
Lower the dump body fully.
Do not overload machine.
Be sure there is sufficient space for machine before
entering confined areas.
Keep bystanders clear of machine loading or unloading
area.
Do not operate too closely to quarry edges, ramp edges,
quay edges and soft edges that may collapse under
machine weight.
Be aware of other machines and personnel when entering
or leaving loading or dumping area.
Loading
If a spotter is present, follow only his instructions.
Load machine evenly. An uneven load will cause tire and
axle damage.
Unloading
If a spotter is present, follow only his instructions.
Back up to unloading site in a single, straight position so
you can maintain eye contact at all times with the spotter.
Steer machine so it stays straight. You must have clear
and unobstructed vision through rear view mirrors. If
machine is articulated and not in straight-ahead position,
it may be difficult to observe the spotter and the dumping
action.
OUO1043,0000DBF -19-06FEB03-1/1
2-2-9
080112
PN=59
Operation—Operating the Machine
Freeing Stuck Machine
Turning Machine Free
IMPORTANT: If the ground is soft, give constant
attention to rear chassis angle. If rear
chassis starts to lean sideways excessively,
stop machine immediately.
1. Select neutral (N) on gearshift control.
2. Engage inter-axle lock.
IMPORTANT: If the wheels are stuck and not turning,
do not apply full power for more than 30
seconds in either drive (D) or reverse (R)
or transmission will overheat.
If transmission overheats, select neutral (N) on gear shift
control and operate engine at 1500 rpm until it cools (2—3
minutes).
If machine is stuck in deep sand, snow or mud, it may be
possible to rock it out as follows:
3. Select drive (D) on gearshift control.
4. Drive off slowly, keeping engine speed constant.
5. Turn steering wheel one way and then the other to
assist with traction until machine is free and can be
operated normally.
1. Select drive (D) on gearshift control and apply steady,
light throttle (NOT full throttle).
2. When vehicle has rocked forward as far as it will go,
apply service brakes.
3. Allow engine to return to slow idle.
Rocking Machine Free
CAUTION: Prevent injury or property damage
caused by sudden movement of machine. DO
NOT shift from neutral (N) to drive (D) or reverse
(R) when accelerator is depressed.
If shifting while pressing accelerator, the transmission
will engage only if accelerator is released in the next 3
seconds causing transmission to remain in neutral (N).
Avoid this condition by making shifts from neutral (N) to
drive (D) or reverse (R) only when accelerator is released.
4. Select reverse (R) on gearshift control.
5. Release service brakes and apply a steady, light
throttle and allow machine to rock in reverse (R) as
far as it will go.
6. Apply and hold service brake and allow engine to
return to slow idle.
7. Repeat procedure.
OUO1043,0000E47 -19-27NOV01-1/1
Parking the Machine
1. Unload machine and lower dump body to fully-lowered
position.
5. Allow engine to idle for 2 minutes before stopping
engine. This allows turbocharger to cool down and
receive proper lubrication and for all oil temperatures
to stabilize.
2. Stop machine on firm, level ground.
6. Move all switches to OFF position.
3. Engage park brake.
7. Turn key switch to OFF.
4. Select neutral (N) on gearshift control.
8. If machine is to be parked overnight, turn battery
disconnect switch to OFF and lock cab door, fuel cap
and compartments.
IMPORTANT: DO NOT stop engine immediately after
bringing machine to a halt. Allow engine to
idle for 2 minutes before stopping engine.
This allows turbocharger to cool down and
receive proper lubrication, and for all oil
temperatures to stabilize.
If storing longer than overnight, see Prepare Machine for
Storage in Miscellaneous—Storage section.
OUO1043,0000DC5 -19-28JUN01-1/1
2-2-10
080112
PN=60
Operation—Operating the Machine
Towing the Machine
Towing a Machine with Inoperable Engine
CAUTION: Prevent possible injury from
unexpected machine movement. Always
chock wheels to prevent machine from rolling
before releasing park brake.
Ensure brake system of the towing machine
is sufficient to hold the combined weight of
towing machine and disabled machine.
To prevent damage to transmission, disconnect
front and middle drive shafts before towing.
Removing front and middle drive shafts
renders park brake inoperable.
NOTE: The park brake may be released mechanically but
steering system will remain inoperative. Articulation
can be obtained only by disconnecting steering
cylinder hydraulic supply hoses.
With engine stopped, the machine hydraulic and
pneumatic systems are inoperable, so there is no powered
steering or braking system.
Disconnect front and middle drive shafts before towing.
See Releasing Park Brake for Towing in this section.
With brakes released and drive shafts disconnected, the
towing machine must be capable of steering and stopping
disabled machine.
Do not exceed 2 km/h (1—2 mph).
If the problem is in the transmission, DO NOT run engine,
as the engine is directly coupled to the transmission.
Refer to Towing a Machine with Inoperable Engine in this
procedure.
If the problem is in the transfer case, select neutral (N) on
gearshift control, and disconnect drive shaft connecting
transfer case to front differential and drive shaft connecting
transfer case to through drive.
If the problem does not affect the braking system, release
the park brake.
Towing a Machine with Inoperable Steering
NOTE: If park brake was mechanically released and
driveshafts remain connected for towing, secondary
steering system may remain operable.
Use this procedure in conjunction with relevant Operable
Engine or Inoperable Engine towing procedures. If
machine must articulate while being towed and the
steering system is inoperable, disconnect as follows:
1. Remove supply hoses from the T-pieces on left-hand
steering cylinder.
NOTE: Some oil spillage will be unavoidable. Clean
up any oil spillage as soon as possible.
Dispose of waste oil properly.
2. Block off 2 supply hoses using suitable plugs.
3. Loop 2 steering cylinder T-pieces together using a
suitable hose.
Towing a Machine with an Operable Engine
Operator must steer machine if there is no steering
problem and engine can be run.
OUO1043,0000DC6 -19-07FEB03-1/1
2-2-11
080112
PN=61
Operation—Operating the Machine
Releasing Park Brake for Towing
T147641B —UN—08NOV01
CAUTION: Machine will roll freely when drive
shafts are disconnected. To prevent injury, chock
wheels and connect machine to towing vehicle
before disconnecting drive shafts.
IMPORTANT: To prevent damage to transmission,
disconnect front axle and middle axle
drive shafts when towing a machine with
an inoperable engine.
1. Chock wheels and connect machine to towing vehicle
prior to disconnecting drive shafts.
Front Axle Drive Shaft
T147642B —UN—08NOV01
2. Remove U-joint cap screws (1) and disconnect front
axle drive shaft (2) at rear of front axle. Move drive
shaft aside and support to allow front axle drive shaft
yoke to turn freely.
3. Remove U-joint cap screws (3) and disconnect middle
axle drive shaft (4) at front of middle axle. Move drive
shaft aside and support to allow middle axle drive
shaft yoke to turn freely.
1— U-joint Cap Screw (4 used)
2— Front Axle Drive Shaft
3— U-joint Cap Screw (4 used)
4— Middle Axle Drive Shaft
Middle Axle Drive Shaft
OUO1043,0000DFB -19-30OCT01-1/1
Mechanically Releasing Park Brake
T147643B —UN—08NOV01
CAUTION: Machine will roll freely when park
brake is released. To prevent injury, chock
wheels before releasing park brake.
1. Chock tires to prevent machine rollaway.
2. Remove release stud (1), nut (2) and washer (3) from
storage position (4).
3. Install release stud in hole at rear of park brake
actuator housing and rotate clockwise a 1/4 turn to
lock into place.
4. Install washer and nut onto release stud and tighten
until park brake releases.
1— Release Stud
2— Nut
3— Washer
4— Release Stud Storage
Location
OUO1043,0000DFC -19-30OCT01-1/1
2-2-12
080112
PN=62
Operation—Operating the Machine
T143386 —UN—28JUN01
Machine Lifting Points
T143386
Lifting the Machine
4. Attach lifting beam to a crane.
IMPORTANT: Install the articulation safety lock
bar prior to lifting machine.
5. Raise the lifting beam until all the play in chain is
removed.
NOTE: The machine lifting points are indicated
on machine.
IMPORTANT: Move crane slowly to prevent excessive
swinging of lifted machine.
1. Park the machine next to the crane.
NOTE: Lifting beam must be at least 1032 cm
(406 in.) in length.
2. Engage park brake.
6. Lower lifting beam until the chain can be removed
from the machine.
IMPORTANT: To prevent damage to hood, use a
nylon sling for front lifting points.
3. Attach chains or straps to the lifting beam and the
machine.
IMPORTANT: The crane must be able to carry total
machine weight, 20 400 kg (44 500 lb) for 250D
and 21 800 kg (48 100 lb) for 300D.
7. Raise the lifting beam with chains and move it away
from machine.
8. Chock all wheels.
9. Secure machine to the trailer of transporting vehicle
with chains.
MD04263,00000C3 -19-30JAN09-1/1
2-2-13
080112
PN=63
Operation—Operating the Machine
Loading and Unloading Machine from Trailer
Loading Machine on Trailer
2. Drive machine onto the trailer slowly, following the
instructions of the spotter.
• Always use the aid of spotters when loading machine
3. Engage park brake.
•
4. Chock all wheels.
•
•
•
onto the transporting vehicle.
Be sure the transporting vehicle is capable of safely
carrying machine.
When driving the machine onto other transportation
vehicles, do not install the articulation lock bar until the
machine is secured.
When machine is lifted onto the transportation vehicle,
install the articulation locking bar.
Chock wheels when securing the machine to the
transporting vehicle.
1. Position transporting trailer against the loading ramp.
NOTE: The 250D and 300D machines have 6
tie-down points, two in the front, two in the
middle and two in the rear.
5. Secure machine to the trailer of transporting vehicle
with chains, using machine tie-down points (1).
6. Move vehicles mirrors inward to the sides of machine.
7. Drive transporting vehicle away slowly.
1
1
TX1022448 —UN—10MAY07
1
TX1022448
Right Side Shown
1— Tie-Down Points (6 Points
Total)
IMPORTANT: Avoid sudden machine movement and
machine damage; install the articulation
locking bar.
2. If driving machine off transporting vehicle, remove
articulation locking bar.
3. Release park brake.
Machine Tie-Down Points
4. If lifting machine off transporting vehicle, install the
articulation locking bar.
1. Unloading Machine from Trailer
Disconnect chains securing machine to transporting
vehicle.
5. Always use the aid of spotters when unloading
machine from transporting vehicle.
VD76477,000150B -19-15MAY07-1/1
2-2-14
080112
PN=64
Operation—Operating the Machine
Lock All Compartments
Your machine is equipped with locks on cab door, battery
compartment, fuel cap, storage compartments, and hood
access door. One key will fit all locks. Use these locks to
help safeguard your machine.
OUO1043,0000DCE -19-23JUL01-1/1
2-2-15
080112
PN=65
Maintenance—Machine
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended. Renewable diesel fuel produced by
hydrotreating animal fats and vegetable oils is basically
identical to petroleum diesel fuel. Renewable diesel that
meets EN 590 or ASTM D975 is acceptable for use at all
percentage mixture levels.
Sulfur Content for Tier 3 and Stage III A Engines
• Use of diesel fuel with sulfur content less than 1000
mg/kg (1000 ppm) is RECOMMENDED
• Use of diesel fuel with sulfur content 1000–5000 mg/kg
(1000–5000 ppm) REDUCES oil and filter change
intervals.
• BEFORE using diesel fuel with sulfur content greater
than 5000 mg/kg (5000 ppm), contact your John Deere
dealer
Sulfur Content for Tier 2 and Stage II Engines
Required Fuel Properties
• Use of diesel fuel with sulfur content less than 500
In all cases, the fuel shall meet the following properties:
• Use of diesel fuel with sulfur content 500–5000 mg/kg
Cetane number of 43 minimum. Cetane number greater
than 47 is preferred, especially for temperatures below
–20°C (–4°F) or elevations above 1500 m (5000 ft.).
Cold Filter Plugging Point (CFPP) should be at least 5°C
(9°F) below the expected lowest temperature or Cloud
Point below the expected lowest ambient temperature.
Fuel lubricity should pass a maximum scar diameter of
0.45 mm as measured by ASTM D6079 or ISO 12156-1.
Diesel fuel quality and sulfur content must comply with
all existing emissions regulations for the area in which
the engine operates. DO NOT use diesel fuel with sulfur
content 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 a
maximum of 15 mg/kg (15 ppm) sulfur content.
mg/kg (500 ppm) is RECOMMENDED.
•
(500–5000 ppm) REDUCES the oil and filter change
interval
BEFORE using diesel fuel with sulfur content greater
than 5000 mg/kg (5000 ppm), contact your John Deere
dealer
Sulfur Content for Other Engines
• Use of diesel fuel with sulfur content less than 5000
mg/kg (5000 ppm) is recommended.
• Use of diesel fuel with sulfur content greater than 5000
mg/kg (5000 ppm) REDUCES the oil and filter change
intervals.
IMPORTANT: Do not mix used diesel engine oil or any
other type of lubricating oil with diesel fuel.
IMPORTANT: Improper fuel additive usage may
cause damage on fuel injection equipment
of diesel engines.
DX,FUEL1 -19-11APR11-1/1
Low Sulfur Diesel Fuel Conditioner
When possible, use existing fuel formulations for engines
used off-highway. This fuel will not require any additives
to provide good performance and engine reliability.
However, many local fuel distributors will not carry both
low and regular sulfur diesel fuels.
If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere PREMIUM DIESEL FUEL
CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
anti-oxidant, fuel stabilizer, corrosion inhibitor and others.
John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other
diesel fuel conditioners only improve cold weather flow and
stabilize long-term fuel storage. They do not contain the
lubrication additives needed by rotary fuel injection pumps.
CED,OUO1021,174 -19-17MAR98-1/1
Testing Diesel Fuel
A fuel analysis program can help to monitor the quality
of diesel fuel. The fuel analysis can provide critical
data such as cetane number, fuel type, sulfur content,
water content, appearance, suitability for cold weather
operations, bacteria, cloud point, acid number, particulate
contamination, and whether the fuel meets specification.
Contact your John Deere dealer for more information on
diesel fuel analysis.
DX,FUEL6 -19-14APR11-1/1
3-1-1
080112
PN=66
Maintenance—Machine
Handling and Storing Diesel Fuel
CAUTION: Reduce the risk of fire. Handle fuel
carefully. DO NOT fill the fuel tank when engine
is running. DO NOT smoke while you fill the
fuel tank or service the fuel system.
Fill the fuel tank at the end of each day's operation to
prevent water condensation and freezing during cold
weather.
Keep all storage tanks as full as practicable to minimize
condensation.
Ensure that all fuel tank caps and covers are installed
properly to prevent moisture from entering. Monitor water
content of the fuel regularly.
When using biodiesel fuel, the fuel filter may require more
frequent replacement due to premature plugging.
Check engine oil level daily prior to starting engine. A
rising oil level may indicate fuel dilution of the engine oil.
IMPORTANT: The fuel tank is vented through the
filler cap. If a new filler cap is required, always
replace it with an original vented cap.
When fuel is stored for an extended period or if there is a
slow turnover of fuel, add a fuel conditioner to stabilize the
fuel and prevent water condensation. Contact your fuel
supplier for recommendations.
DX,FUEL4 -19-14APR11-1/1
104o F
John Deere Plus-50™ is also recommended.
30 o C
86 o F
20 o C
68 o F
10 o C
50 o F
0o C
32 o F
-10 o C
14 o F
-20 o C
-4 o F
-30 o C
-22 o F
-40 o C
-40 o F
Other oils may be used if they meet one or more of the
following:
• 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
TS1689 —UN—18JUL07
40 o C
SAE 5W-30
John Deere Plus-50™ II oil is preferred.
SAE 10W-30
122o F
SAE 15W-40
50 o C
SAE 10W-40
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
SAE 0W-40
Diesel Engine Oil
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply
with all existing emissions regulations for the area in
which the engine operates.
Oil Viscosities for Air Temperature Ranges
DO NOT use diesel fuel with sulfur content greater than
10 000 mg/kg (10 000 ppm).
Plus-50 is a trademark of Deere & Company
Torq-Gard is a trademark of Deere & Company
DX,ENOIL7 -19-11APR11-1/1
3-1-2
080112
PN=67
Maintenance—Machine
Diesel Engine Oil and Filter Service Intervals
The oil and filter service intervals in the following table
should be used as guidelines. Actual service intervals
also depend on operation and maintenance practices. It
is suggested to use oil analysis to determine the actual
useful life of the oil and to aid in selection of the proper
oil and filter service interval.
Oil and filter service intervals are based on a combination
of oil pan capacity, type of engine oil and filter used, and
sulfur content of the diesel fuel.
Engine Oil and Filter Service Intervals
Standard Drain Oil Pan
Fuel Sulfur
Extended Drain
Oil Pan
375 hours
500 hours
Other Oils
250 hours
250 hours
Fuel Sulfur
275 hours
400 hours
Other Oils
150 hours
150 hours
Fuel Sulfur
0.50 - 1.00% (5000 - 10 000 mg/kg)
Plus-50
187 hours
250 hours
Other Oils
125 hours
125 hours
IMPORTANT: When using biodiesel blends greater
than B20, reduce the oil and filter service
interval by 50% or monitor engine oil based
on test results from Oilscan.
Oil types in the table include:
API CJ-4, API CI-4 PLUS, API CI-4, API CH-4, ACEA
E9, ACEA E7, ACEA E6, ACEA E5, ACEA E4, or ACEA
E3 oils.
0.05 - 0.50% (500 - 5000 mg/kg)
Plus-50
•
to 0.50% (5000 mg/kg) may result in REDUCED oil and
filter change intervals as shown in the table.
BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 mg/kg), contact your John Deere
dealer.
• John Deere Plus-50™ II and John Deere Plus-50 oils.
• “Other Oils” include John DeereTorq-Gard Supreme™,
Less than 0.05% (500 mg/kg)
Plus-50
• Use of diesel fuel with sulfur content 0.05% (500 mg/kg)
NOTE: The 500 hour extended oil and filter change interval
is only allowed if all the following conditions are met:
• Engine equipped with an extended drain
interval oil pan
The service interval of “Other Oils” may be extended only if oil analysis
is performed to determine the actual service life, to a maximum not
to exceed that of Plus-50.
Diesel fuel sulfur level will affect engine oil and filter
service intervals. Higher fuel sulfur levels reduce oil and
filter service intervals as shown in the table.
• Use of diesel fuel with sulfur content less
than 0.05% (500 mg/kg)
• Use of John Deere Plus-50™ II or John
Deere Plus-50 oil
• Use of an approved John Deere oil filter
• Use of diesel fuel with sulfur content less than 0.05%
(500 mg/kg) is strongly recommended.
Plus-50 is a trademark of Deere & Company
Torq-Gard Supreme is a trademark of Deere & Company
DX,ENOIL12 -19-03AUG09-1/1
3-1-3
080112
PN=68
Maintenance—Machine
T122287 —19—14JUL99
Hydraulic Oil
Depending on the expected air temperature range
between oil changes, use oil viscosity shown on the
temperature chart above.
• John Deere HY-GARD® Hydraulic Oils.
• John Deere Low Viscosity HY-GARD® Hydraulic Oils.
• You may also use other oils meeting John Deere
Standard J20C, or J20D.
The following oils are preferred:
HY-GARD is a trademark of Deere & Company
OUO1043,0000DFD -19-30OCT01-1/1
T164955 —19—04FEB03
Transmission and Transfer Case Oil
Use only Allison/Castrol TransSynd™ or Castrol
Transmax Z or S oils.
TX14740,000001B -19-03FEB03-1/1
3-1-4
080112
PN=69
Maintenance—Machine
104˚F
30˚C
86˚F
20˚C
68˚F
10˚C
50˚F
0˚C
32˚F
-10˚C
14˚F
-20˚C
-4˚F
-30˚C
-22˚F
-40˚C
-40˚F
TX1024300 —UN—31MAY07
40˚C
SAE 140
122˚F
SAE 90
•
•
•
JDM J11F
ZF TE-ML-05C
ZF TE-ML-05D
50˚C
SAE 75W
Other oils may be used if they meet the following:
SAE 75W-80 LS
Additive
SAE 75W-90
• John Deere GEAR LUBRICANT with Limited Slip
SAE 80W-140
The following oil is preferred:
SAE 80W-90 LS
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
SAE 85W-140 LS
Axle Gear Oil
VD76477,000152D -19-24MAY07-1/1
Diesel Engine Coolant
The engine cooling system is filled to provide year-round
protection against corrosion and cylinder liner pitting, and
winter freeze protection to -37°C (-34°F).
The following engine coolant is preferred for service:
• John Deere COOL-GARD Prediluted Coolant
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
base engine coolant concentrate.
IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
sealing additives.
The following engine coolant is also recommended:
• John Deere COOL-GARD Coolant Concentrate in a 40
to 60% mixture of concentrate with quality water.
Coolant Drain Intervals
• ASTM D5345 (prediluted coolant)
• ASTM D4985 (coolant concentrate) in a 40 to 60%
Drain the factory fill engine coolant, flush the cooling
system, and refill with new coolant after the first 8 years
or 8000 hours of operation. Subsequent drain intervals
are determined by the coolant used for service. At each
interval, drain the coolant, flush the cooling system, and
refill with new coolant.
Coolants meeting these specifications require use of
supplemental coolant additives, formulated for heavy-duty
diesel engines, for protection against corrosion and
cylinder liner erosion and pitting.
When John Deere COOL-GARD is used, the drain interval
may be extended to 5 years or 5000 hours of operation,
provided that the coolant is tested annually AND additives
are replenished, as needed, by adding a supplemental
coolant additive.
Other low silicate ethylene glycol base coolants for
heavy-duty engines may be used if they meet one of the
following specifications:
mixture of concentrate with quality water
A 50% mixture of ethylene glycol engine coolant in water
provides freeze protection to -37°C (-34°F). If protection at
lower temperatures is required, consult your John Deere
dealer for recommendations.
If COOL-GARD is not used, the drain interval is reduced
to 2 years or 2000 hours of operation.
OUO1043,0000DF2 -19-29OCT01-1/1
3-1-5
080112
PN=70
Maintenance—Machine
T144281 —19—03AUG01
Grease
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
• SAE Multipurpose EP grease containing 3-to-5%
The following greases are preferred:
• John Deere MOLY HIGH TEMPERATURE EP GREASE
Molybdenum Disulfide
OUO1079,0000429 -19-26JUL01-1/1
Oil Filters
Use filters meeting John Deere performance
specifications.
Filtration of oils is critical to proper operation and
lubrication.
Always change filters regularly as specified in this manual.
DX,FILT -19-18MAR96-1/1
Lubricant Storage
Your equipment can operate at top efficiency only when
clean lubricants are used.
Use clean containers to handle all lubricants.
Store lubricants and containers in an area protected from
dust, moisture, and other contamination. Store containers
on their side to avoid water and dirt accumulation.
Make certain that all containers are properly marked to
identify their contents.
Properly dispose of all old containers and any residual
lubricant they may contain.
DX,LUBST -19-11APR11-1/1
3-1-6
080112
PN=71
Maintenance—Machine
Alternative And Synthetic Lubricants
Conditions in certain geographical areas may require
lubricant recommendations different from those printed
in this manual. Some John Deere brand coolants and
lubricants may not be available in your location.
Synthetic lubricants may be used if they meet the
performance requirements as shown in this manual.
The temperature limits and service intervals shown in this
manual apply to both conventional and synthetic oils.
IMPORTANT: Avoid mixing different brands or types
of oils. Oil manufacturers engineer their oils to
meet certain specifications and performance
requirements. Mixing different oil types can
degrade lubricant and machine performance.
Consult your authorized dealer to obtain specific
information and recommendations.
Re-refined base stock products may be used if the
finished lubricant meets the performance requirements.
TX14740,0001C42 -19-17APR06-1/1
3-1-7
080112
PN=72
Maintenance—Periodic Maintenance
Service Your Machine at Specified Intervals
Lubricate, make service checks, and make adjustments at
intervals shown on the periodic maintenance chart and on
the following pages.
Perform service on items at multiples of the original
requirement. For example, at 2000 hours also service
those items (if applicable) listed under 1000 hours, 500
hours, and 10 hours or daily.
OUO1079,00003BF -19-18JUN01-1/1
Use Correct Fuels and Lubricants
IMPORTANT: To prevent machine damage, use
correct fuels and lubricants when servicing your
machine. (See Maintenance—Machine section.)
OUO1079,00003C0 -19-18JUN01-1/1
Prepare Machine for Maintenance
Before performing maintenance on machine:
9. If servicing the pneumatic system, relieve pneumatic
pressure. See Relieve Pneumatic Pressure in this
section.)
1. Unload dump body.
2. Wash machine.
3. Park machine on firm, level ground. Steer machine
to straighten frames.
4. Install articulation safety lock bar. See Install
Articulation Safety Lock Bar in this section.
5. Fully lower dump body, unless specifically instructed
otherwise in a maintenance procedure. If dump body
must be raised, install dump body prop. See Install
Dump Body Prop in this section.
6. Stop engine and engage park brake.
7. Remove key from key switch and attach a DO NOT
OPERATE sign to steering wheel.
8. Relieve hydraulic pressure:
a. Turn steering wheel back and forth 3 times.
b. If dump body is fully lowered, hydraulic pressure
is automatically relieved. If dump body is raised
and dump body prop is installed, move dump body
control lever forward and rearward 3 times to ensure
that the weight of the dump body is securely settled
onto the dump body prop.
CAUTION: Prevent possible injury from
unexpected machine movement. Prevent
rollaway. Install wheel chocks on at least one axle.
10. Install wheel chocks to ensure that machine cannot
move backward or forward during service.
CAUTION: Prevent possible injury. Be careful
when working with hot equipment and
fluids. Hot equipment and fluids can cause
burns to unprotected skin.
11. Allow time for the engine and all fluids to cool, unless
specifically instructed otherwise in a maintenance
procedure.
NOTE: The air conditioning system is charged with gas
under pressure. Air conditioning service should be
performed only by a qualified technician with proper
equipment. (See your authorized dealer.)
OUO1079,00003BD -19-07FEB03-1/1
3-2-1
080112
PN=73
Maintenance—Periodic Maintenance
Install Dump Body Prop
T143166B —UN—21JUN01
CAUTION: Prevent possible injury from
unexpected machine movement. When the dump
body is raised to perform maintenance tasks,
the dump body prop must be installed.
NOTE: Operate the dump body control lever in the
operator's station to raise and lower the dump body.
1. Raise dump body high enough to allow dump body
prop (1) to be fully raised.
2. Use handle (4) to raise dump body prop. Ensure that
stop bolt (3) is in firm contact with stop (2).
CAUTION: Prevent possible injury from
unexpected machine movement. Check to
ensure that the dump body prop is seated
securely in retaining cup.
1— Dump Body Prop
2— Stop
3— Stop Bolt
4— Handle
5— Retaining Cup
3. Lower dump body until dump body prop is seated
securely in retaining cup (5).
4. Relieve hydraulic pressure before servicing machine.
OUO1079,00003C9 -19-07FEB03-1/1
Install Articulation Safety Lock Bar
1. Steer machine to straighten articulation joint.
2. Stop engine and engage park brake.
T147644B —UN—09NOV01
3. Remove keys from key switch and attach a DO NOT
OPERATE sign to steering wheel.
4. Remove pin (3) from articulation safety lock bar (2)
and storage location (1).
5. Swing articulation safety bar rearward to locked
position. Ensure that holes line up on locking lug (4).
6. Install pin through articulation safety lock bar and
locking lug.
1— Storage Location
2— Articulation Safety Lock
Bar
3— Pin
4— Locking Lug
OUO1043,0000DFE -19-30OCT01-1/1
Lower and Raise Bottom Guard
Lift bottom guard into place and install cap screws to raise
bottom guards.
1— Front Bottom Guard Cap
Screw
2— Front Bottom Guard
3— Rear Bottom Guard Cap
Screw
4— Rear Bottom Guard
T147645B —UN—19NOV01
Remove front bottom guard cap screws (1) to lower front
bottom guard (2) or remove rear bottom guard cap screws
(3) to rear bottom guard lower rear bottom guard (4).
OUO1043,0000DFF -19-30OCT01-1/1
3-2-2
080112
PN=74
Maintenance—Periodic Maintenance
Relieve Pneumatic Pressure
1— Pneumatic Reservoir
T148041B —UN—15NOV01
Push and hold stem of drain valve (2) on pneumatic
reservoir (1). Air will discharge through drain valve under
pressure. Hold stem until “hiss” stops completely.
2— Drain Valve
OUO1043,0000E00 -19-30OCT01-1/1
3-2-3
080112
PN=75
Maintenance—Periodic Maintenance
Tilt Cab
Raising Cab
T147647B —UN—08NOV01
1. Park the machine on level ground with dump body
lowered. Engage park brake. Turn ignition switch
OFF. Turn battery disconnect switch OFF.
2. Move mirrors to normal operating position. Ensure
that no people or loose objects are inside cab or on
right-side platform. Close cab door and right-side
compartment access door securely.
3. Open hood.
Left-Rear Cab Mount Shown
4. Remove cab mounting cap screws, washers, and nuts
(1) from left-front and left-rear cab mounts.
5. Rotate pump valve lever (8) counterclockwise to raise
position.
NOTE: Pump handle is stored on floor of cab, to
left of operator's seat.
T147648B —UN—08NOV01
6. Remove pump handle (6) from storage position. Insert
pump handle into pump socket (5).
7. Operate pump using long, firm strokes to raise the
cab. When cab is fully raised, support pin (3) must line
up with detent slot (2) at top of support strut (4).
CAUTION: Prevent possible injury from
unexpected machine movement. DO NOT
work under the raised cab unless the support
strut is properly engaged.
Cab Shown Lowered
8. While pushing support strut handle (7) toward
machine, slowly rotate pump valve lever clockwise to
lower position. Cab will begin to “float” down. Support
pin MUST be seated securely in detent slot at top of
support strut.
1— Cab Mounting Cap Screw,
Washer, and Nut (4 used)
2— Detent Slot
3— Support Pin
4— Support Strut
5— Pump Socket
6— Pump Handle
7— Support Strut Handle
8— Pump Valve Lever
3. While pulling support strut handle away from machine,
slowly rotate pump valve lever clockwise to lower
position. Allow cab to lower until cab mounts are at
rest.
9. Rotate pump valve lever counterclockwise to raise
position.
Lowering Cab
CAUTION: Avoid possible injury from crushing
and pinching. Use proper tools when installing
cab mounting hardware. DO NOT grasp cab
mounts with bare hands when support strut
is not securely engaged.
1. Ensure that no people or foreign objects are present
under the cab, and that the cab's movement is not
obstructed.
2. Operate pump to raise cab fully. Support pin must
slide free of detent slot at top of support strut.
NOTE: Install new mounting hardware when
cab is lowered.
CAUTION: Prevent possible injury from
unexpected machine movement. Cab will
“float” down when pump valve lever is rotated
clockwise. Stay clear of cab while lowering.
4. Install new cab mounting cap screws, washers, and
nuts on left-side cab mounts. Tighten to specification.
Cab—Specification
Mounting Cap
Screws—Torque......................................................... 210 N·m (155 lb-ft)
NOTE: Support strut handle must be pulled away from
machine while cab is lowered, or support pin will
engage secondary detent position on support strut.
5. Remove pump handle from pump socket. Install pump
handle in storage position.
Continued on next page
3-2-4
OUO1043,0000E01 -19-07FEB03-1/2
080112
PN=76
Maintenance—Periodic Maintenance
Maintenance and Repair Record Keeping
System
The checklist in this section summarizes scheduled
maintenance, and parts and oil required at each
maintenance interval.
Use the checklist to:
• Remind you to perform machine maintenance at
specified intervals to minimize downtime.
• Calculate cost of machine operation and ownership
allowing you to make better job estimates.
• Place yourself in a stronger position at trade-in time.
• Satisfy your SECURE contract requirements.
As maintenance is performed, check off each item on the
list and record date and hour meter reading.
T7511CO —UN—27JUN91
Do not tear out or mark on checklist in this section; keep it
to make extra copies.
TX,50,FF2898 -19-27SEP07-1/1
Fluid Analysis Program Test Kits and 3-Way
Coolant Test Kit
Engine, hydraulic, power train, and coolant samples
should be taken from each system on a periodic basis,
usually prior to a filter and/or fluid change interval. Certain
systems require more frequent sampling. Consult your
authorized John Deere dealer on a maintenance program
for your specific application. Your authorized John Deere
dealer has the sampling products and expertise to assist
you in lowering your overall operating costs through fluid
sampling.
TX1003513A —UN—20FEB06
Fluid Analysis Program Test Kits and the 3-Way Coolant
Test Kit are John Deere fluid sampling products to help you
monitor machine maintenance and system condition. The
objective of a fluid sampling program is to ensure machine
availability when you need it and to reduce repair costs by
identifying potential problems before they become critical.
Fluid Analysis Kits
AM40430,00002FE -19-19OCT11-1/1
3-2-5
080112
PN=77
Maintenance—Periodic Maintenance
Maintenance and Repair Record Keeping
System
SERVICE INTERVALS
Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 2000
hours, also service those items (if applicable) listed under 1000 hours, 500 hours, and 10 hours or daily.
As Required
• Check and clean engine air cleaner and pre-cleaner bowl
• Check tire pressure
• Replace primary and secondary air cleaner filters
• Drain sediment from water separator and clean strainer
• Check and clean cooling system
• Inspect belt
• Check and clean axle, transmission and transfer case breathers
Every 10 Hours or Daily
• Check engine coolant level
• Check transfer case oil level
• Check engine oil level
• Check hydraulic system oil level
• Check transmission for leaks
• Grease dump body pivot pins
• Grease tailgate pivots-if equipped
• Grease steering cylinder rod ends
• Grease oscillation joint and thru drive bearing
• Grease articulation joints
Initial Service - 100 Hours*
*Perform initial service once after the first 100 hours of operation
• Change engine oil and replace filter
• Change transfer case oil
• Replace hydraulic system return filter
• Change axle oil
• Replace primary fuel filter
• Change final drive oil
Model: 250D and 300D Articulated Dump Truck
Customer:
Delivery Date:
PIN/Serial Number:
OIL SAMPLING
Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form: 500, 1000, 2000, 4000
hours. Maintenance recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you supply.
Regular oil sampling will extend the operational life of your machine’s systems.
Every 250 Hours
□ Take diesel engine oil sample
□ Take hydraulic oil sample
Every 500 Hours
□ Change engine oil and replace filter
□ Check transmission oil level
□ Check park brake pad wear
□ Check and clean hydraulic breather
□ Check service brake pad wear
□ Grease steering cylinder rod ends
□ Check suspension strut height, leakage, and boot condition
□ Replace in-line fuel filter strainer
□ Clean or replace cab air filter
□ Replace primary fuel filter
□ Check battery electrolyte level; clean and tighten terminals
□ Replace final fuel filter
□ Take transfer case oil sample
□ Take engine coolant sample
□ Take final drive oil sample
□ Take diesel fuel sample
□ Take transmission oil sample
□ Take axle oil sample
Every 1000 Hours
□ Check axle and final drive oil levels
□ Check and adjust bin shock pad
□ Replace hydraulic breather filter
□ Grease prop shaft slip joint
Every 2000 Hours
□ Check and adjust engine valve clearance
□ Drain and refill axle and final drive oil
□ Drain and refill transmission oil
□ Replace pneumatic system air dryer filter
□ Replace transmission filters
□ Replace hydraulic system return filter
□ Drain and refill transfer case oil
Every 4000 Hours
□ Drain and refill hydraulic tank
□ Replace pneumatic block silencer filters
□ Replace hydraulic suction screen
Every 4500 Hours
□ Replace engine torsional damper
Every 5000 Hours
Continued on next page
3-2-6
MD04263,000005A -19-26DEC08-1/3
080112
PN=78
Maintenance—Periodic Maintenance
□ Drain, flush and refill engine cooling system
REQUIRED PARTS
Ensure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated
parts are also on hand, i.e., filter O-rings.
Item
Part
Number
Initial
Service 100 Hours
Engine Oil Filter
Kit
RE509672
Every 500
Hours
Every 1000 Every 2000 Every 4000
Hours
Hours
Hours
Every 4500
Hours
Every 5000
Hours
1
1
1
1
1
1
1
Primary Fuel
TT206616
Filter (S.N.
200537--201014)
1
1
1
1
1
1
1
10 Micron
Primary Fuel
Filter (S.N.
201015—)
RE522687
1
1
1
1
1
1
1
Final Fuel Filter
(S.N.—201014)
RE522372
1
1
1
1
1
1
2 Micron Final
Fuel Filter (S.N.
201015—)
RE522688
1
1
1
1
1
1
In-Line Fuel Filter AT223493
(S.N. 201015—)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Transmission Oil
Filter
Every 250
Hours
TTZF21042
4
Pneumatic
AT252831
System Air Dryer
Filter
Hydraulic System TT220735
Return Filter
Hydraulic
Reservoir
Breather Filter
TT220010
Cab Air Filter
TT226019
1
1
1
Hydraulic Suction TT210497
Screen
1
Pneumatic Block TT226348
Silencer Filters
2
Engine Torsional
Damper
RE500934
Transmission,
Transfer Case
and Axle
Breather Filter
AT253791
As required
Air Cleaner
Primary Element
TT220725
As required
Air Cleaner
Secondary
Element
TT220747
As required
Coolant
Conditioner
TY16004
As required
PLUS-50™
Engine Oil
TY6389*
HY-GARD™
Hydraulic Oil
TY6354*
Allison/Castrol
TransSynd
Transmission Oil
TY25007*
4.7 L (5.0 qt)
27 L (7.1
gal)
27 L (7.1 gal)
API GL-5 Gear
Oil with Limited
Slip Additive
TY25050*
90 L (24 gal)
90 L (24
gal)
90 L (24 gal)
1
1
1
1
1
25.5 L (6.7
gal)
25.5 L (6.7
gal)
25.5 L (6.7
gal)
25.5 L (6.7
gal)
25.5 L (6.7
gal)
25.5 L (6.7
gal)
25.5 L (6.7
gal)
79 L (21 gal)
Pre-diluted
TY16036
Radiator Coolant
26.5 L (7 gal)
Continued on next page
3-2-7
MD04263,000005A -19-26DEC08-2/3
080112
PN=79
Maintenance—Periodic Maintenance
REQUIRED PARTS
Fluid Analysis Kits
•Diesel Engine
Oil
AT317904
1
1
1
1
1
1
1
•Hydraulic Oil
AT303189
1
1
1
1
1
1
1
•Transmission Oil AT303189
1
1
1
1
1
1
•Transfer Case
Oil
AT303189
1
1
1
1
1
1
•Axle Oil
AT303189
3
3
3
3
3
3
•Final Drive Oil
AT303189
6
6
6
6
6
6
•DieselScan™
AT180344
1
1
1
1
1
1
•COOLSCAN
PLUS™
AT183016
1
1
1
1
1
1
3 Way Heavy
Duty Coolant
Test
TY16175
1
1
1
1
*For oil type and oil viscosities based on operating
temperatures see Maintenance-Machine. (Section 3-1).
PLUS-50 is a trademark of Deere & Company
HY-GARD is a trademark of Deere & Company
DieselScan is a trademark of Deere & Company
COOLSCAN PLUS is a trademark of Deere & Company
MD04263,000005A -19-26DEC08-3/3
3-2-8
080112
PN=80
Maintenance—As Required
Service Engine Air Intake System
1. Empty the precleaner bowl.
b. Remove precleaner bowl (3). Empty precleaner
bowl and wipe clean with a lint-free cloth.
c. Install precleaner bowl and lid. Tighten wing nut.
2. Check service indicator (4). If window shows a red
flag, service air cleaner filter elements.
a. Unfasten clasps (5) and remove air cleaner cover
(6).
T147649B —UN—09NOV01
a. Loosen wing nut (1) and remove lid (2).
NOTE: At minimum, secondary element must be replaced
every third time primary element is replaced.
c. Remove and inspect secondary element (8).
Replace, if necessary.
d. Wipe dust from air cleaner housing (9) with a
lint-free cloth. Squeeze unloader valve to empty
air cleaner housing of dust and debris. Inspect air
cleaner housing for damage.
T147650B —UN—09NOV01
b. Remove and inspect primary element (7). Replace,
if necessary.
f. Install primary element, ensuring that it is firmly and
evenly seated.
g. Install air cleaner cover and fasten clasps.
3. Press top of service indicator to reset flag.
1— Wing Nut
2— Lid
3— Precleaner Bowl
4— Service Indicator
5— Clasp (4 used)
6— Air Cleaner Cover
7— Primary Element
8— Secondary Element
9— Air Cleaner Housing
T147651B —UN—09NOV01
e. Install secondary element, ensuring that it is firmly
and evenly seated.
OUO1043,0000E03 -19-30OCT01-1/1
3-3-1
080112
PN=81
Maintenance—As Required
Inspect and Clean Cooling Systems
Inspect Cooling Systems
1. Inspect components of cooling system for damage.
2. Inspect hoses and clamps for damage and tightness.
T147907B —UN—15NOV01
3. Inspect mountings and hardware for damage and
tightness.
4. Inspect fins for damage and cleanliness. Ensure
that there is no restriction to air flow. Clean cooling
systems, if necessary.
Clean Cooling Systems
1. Turn battery disconnect switch OFF.
2. Remove cap screws, lock nuts (1) and fan guard (2).
IMPORTANT: Use a pressure washer and a mild
detergent that is not caustic to aluminum
when cleaning cooling systems.
Do not spray cooling system fins at an
angle. Fins may bend.
T148541C —UN—28NOV01
3. Raise hood and wash front cooling system, spraying
from rear face (3) to front face. Keep cooling system
free of debris and obstructions which may restrict air
flow.
4. Install fan guard, cap screws and lock nuts.
5. Open battery compartment door.
6. Spray outer face of transmission cooler (4). Keep
cooling system free of debris and obstructions which
may restrict air flow.
7. Turn battery disconnect switch ON and close hood
and battery compartment door.
1— Lock Nut (6 used)
2— Fan Guard
3— Rear Face of Cooling
System
4— Outer Face of Transmission
Cooler
OUO1043,0000E05 -19-30OCT01-1/1
3-3-2
080112
PN=82
Maintenance—As Required
Clean, Inspect, and Replace—Transmission,
Transfer Case, and Axle Breathers
T147909B —UN—15NOV01
IMPORTANT: DO NOT spray steam, water or cleaning
solution directly at breathers. Spray could
be forced into housings.
NOTE: Breathers should be checked daily in adverse
working conditions. The amount of dust and
dirt encountered will determine the frequency
of breather cleaning.
The cab must be tilted to access the transmission
breather cap and front axle breather.
Located Under Hydraulic Reservoir
1. Clean dirt, dust, and debris from each breather (1—5)
and from surrounding areas.
T147908B —UN—15NOV01
IMPORTANT: DO NOT crush or damage breathers
during removal. Foreign matter may
enter housings.
2. Inspect each breather for clogging, damage, and
proper installation. If necessary, remove clogged
breather(s) from machine and clean with water. Dry
thoroughly before reinstalling. Replace any breather
that appears damaged or cannot be unclogged.
Tighten to specification.
Breather—Specification
Tightening—Torque................................... 12—16 N·m (106—142 lb-in.)
Located Under Cab
3. Inspect axle breather hoses for clogging, damage, and
proper installation.
1— Transfer Case Breather
2— Transmission Breather Cap
3— Front Axle Breather
T147910B —UN—15NOV01
If necessary, clear breather hose(s). Replace any
breather hose that appears damaged or cannot be
unclogged.
4— Middle Axle Breather
5— Rear Axle Breather
Located Above Rear Axles
OUO1043,0000E06 -19-30OCT01-1/1
3-3-3
080112
PN=83
Maintenance—As Required
Inspect Tires, Check Pressure
TX1021707 —19—20APR07
CAUTION: Prevent possible injury from tire
blowout. Ensure that tires are properly inflated.
Improperly inflated tires can cause excessive
heat build-up, excessive or uneven tire wear,
or rim damage, resulting in blowouts.
NOTE: Shipping pressure may not be the same
as operating pressure. You may change tire
pressures to suit working condition according to
tire manufacturer’s recommendations.
Maximum Permissible Differences in Tire Diameters
1. Ensure that valve caps are installed.
2. Check for wear and cuts to tires. Consult your
authorized dealer if in doubt about the serviceability
of a damaged tire.
3. Check tire pressures.
IMPORTANT: In the interest of the drivetrain reliability
in the 6x6 ADT's, the maximum permissible
difference in tire diameter across axles and
between axles is 2%. Failure to adhere to this
recommendation could result in premature
drivetrain failure. Only factory approved tire
sizes are to be used on all machines. Should
retreaded tires be used, it is important to ensure
that the original tire diameter is maintained
and or falls within the 2% guideline.
Tires—250D
23.5 R 25—Michelin XADN—Specification
Front Axle
Tires—Pressure........................................................................... 250 kPa
2.50 bar
36 psi
Middle Axle
Tires—Pressure........................................................................... 303 kPa
3.03 bar
44 psi
Rear Axle
Tires—Pressure........................................................................... 275 kPa
2.75 bar
44 psi
23.5 R 25—Goodyear RL2+—Specification
Front Axle
Tires—Pressure........................................................................... 269 kPa
2.69 bar
39 psi
Middle Axle
Tires—Pressure........................................................................... 317 kPa
3.17 bar
46 psi
Rear Axle
Tires—Pressure........................................................................... 317 kPa
3.17 bar
46 psi
23.5 R 25—Bridgestone VLT—Specification
Front Axle
Tires—Pressure........................................................................... 352 kPa
3.52 bar
51 psi
Middle Axle
Tires—Pressure........................................................................... 400 kPa
4 bar
58 psi
Rear Axle
Tires—Pressure........................................................................... 400 kPa
4 bar
58 psi
23.5 R 25—Continental STL3/STL2+—Specification
Front Axle
Tires—Pressure........................................................................... 324 kPa
3.24 bar
47 psi
Middle Axle
Tires—Pressure........................................................................... 372 kPa
3.72 bar
54 psi
Rear Axle
Tires—Pressure........................................................................... 372 kPa
3.72 bar
54 psi
23.5 R 25—Yokohama RB31—Specification
Front Axle
Tires—Pressure........................................................................... 352 kPa
3.52 bar
51 psi
Middle Axle
Tires—Pressure........................................................................... 400 kPa
4 bar
58 psi
Rear Axle
Tires—Pressure........................................................................... 400 kPa
4 bar
58 psi
23.5 R 25—Pirelli RM94—Specification
Front Axle
Tires—Pressure........................................................................... 325 kPa
3.25 bar
47 psi
Continued on next page
3-3-4
VD76477,000047C -19-20APR07-1/3
080112
PN=84
Maintenance—As Required
Middle Axle
Tires—Pressure........................................................................... 350 kPa
3.50 bar
51 psi
Rear Axle
Tires—Pressure........................................................................... 350 kPa
3.50 bar
51 psi
23.5 R 25—Toyo T-331—Specification
Front Axle
Tires—Pressure........................................................................... 325 kPa
3.25 bar
47 psi
Middle Axle
Tires—Pressure........................................................................... 375 kPa
3.75 bar
54 psi
Rear Axle
Tires—Pressure........................................................................... 375 kPa
3.75 bar
54 psi
23.5 R 25—Triangle TB516—Specification
Front Axle
Tires—Pressure........................................................................... 325 kPa
3.25 bar
47 psi
Middle Axle
Tires—Pressure........................................................................... 375 kPa
3.75 bar
54 psi
Rear Axle
Tires—Pressure........................................................................... 375 kPa
3.75 bar
54 psi
Tires—300D
23.5 R 25—Michelin XADN—Specification
Front Axle
Tires—Pressure........................................................................... 275 kPa
2.75 bar
40 psi
Middle Axle
Tires—Pressure........................................................................... 375 kPa
3.75 bar
54 psi
Rear Axle
Tires—Pressure........................................................................... 375 kPa
3.75 bar
54 psi
750/65R25—Michelin XAD65-1—Specification
Front Axle
Tires—Pressure........................................................................... 250 kPa
2.50 bar
36 psi
Middle Axle
Tires—Pressure........................................................................... 275 kPa
2.75 bar
40 psi
Rear Axle
Tires—Pressure........................................................................... 275 kPa
2.75 bar
40 psi
23.5 R 25—Goodyear RL2+—Specification
Front Axle
Tires—Pressure........................................................................... 300 kPa
3.00
44 psi
Middle Axle
Tires—Pressure........................................................................... 380 kPa
3.8 bar
55 psi
Rear Axle
Tires—Pressure........................................................................... 380 kPa
3.8 bar
55 psi
23.5 R 25—Bridgestone VLT—Specification
Front Axle
Tires—Pressure........................................................................... 375 kPa
3.75 bar
54 psi
Middle Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
Rear Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
23.5 R 25—Continental STL3/STL2+—Specification
Front Axle
Tires—Pressure........................................................................... 350 kPa
3.5 bar
51 psi
Middle Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
Rear Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
23.5 R 25—Yokohama RB31—Specification
Front Axle
Tires—Pressure........................................................................... 375 kPa
3.75 bar
54 psi
Middle Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
Rear Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
23.5 R 25—Pirelli RM94—Specification
Front Axle
Tires—Pressure........................................................................... 350 kPa
3.50 bar
Continued on next page
VD76477,000047C -19-20APR07-2/3
3-3-5
080112
PN=85
Maintenance—As Required
51 psi
Middle Axle
Tires—Pressure........................................................................... 400 kPa
4.0 bar
58 psi
Rear Axle
Tires—Pressure........................................................................... 400 kPa
4.0 bar
58 psi
23.5 R 25—Toyo T-331—Specification
Front Axle
Tires—Pressure........................................................................... 350 kPa
3.50 bar
51 psi
Middle Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
Rear Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
23.5 R 25—Triangle TB516—Specification
Front Axle
Tires—Pressure........................................................................... 350 kPa
3.50 bar
51 psi
Middle Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
Rear Axle
Tires—Pressure........................................................................... 450 kPa
4.5 bar
65 psi
VD76477,000047C -19-20APR07-3/3
Drain Fuel Filters (S.N.—201014)
1. Open hood.
T165115B —UN—11FEB03
2. Loosen drain valve (1). Drain liquid for several
seconds or until water and sediment is removed.
3. Tighten drain valve.
1— Drain Valve
TX14740,0000180 -19-21JUL04-1/1
Drain Fuel Filters (S.N. 201015—)
1. Open hood.
T201824A —UN—22JUL04
2. Loosen drain valves (1). Drain liquid for several
seconds or until water and sediment is removed.
3. Tighten drain valves.
1— Drain Valve
TX14740,000017C -19-21JUL04-1/1
Inspect Serpentine Belt
Inspect serpentine belt for wear, fraying, splitting,
cracking, damage, dirt, and debris.
Replace serpentine belt, if necessary. (See your
authorized dealer.)
OUO1079,00003FF -19-19JUL01-1/1
3-3-6
080112
PN=86
Maintenance—Every 10 Hours or Daily
Check Engine Coolant Level
CAUTION: Explosive release of fluids from
pressurized cooling system can cause
serious burns.
TS281 —UN—23AUG88
Remove filler cap only when engine is cold or
when cool enough to touch with bare hands.
Slowly loosen fill cap to first stop to relieve
pressure before removing completely.
IMPORTANT: If this machine is factory filled
with Caltex extended life coolant, Deere
COOL-GARD® coolant can be used at top-off.
1. Check coolant level in expansion tank (1). Remove
filler cap (2), or shine light through tank so coolant level
is visible. Cold coolant should not be below the ADD
mark. Hot coolant should not be above FULL mark.
T147658B —UN—09NOV01
NOTE: If expansion tank is overfilled while engine is cold,
expansion tank will overflow and excess coolant
will purge during machine operation.
IMPORTANT: When the system needs top-off the
first time, add two pints (32 oz) of John
Deere Coolant Conditioner. Finish topping-off
with JD COOL-GARD.
2. Add coolant at fill port, if necessary.
1— Expansion Tank
2— Filler Cap
COOL-GARD is a trademark of Deere & Company
TX14740,000001C -19-08AUG05-1/1
Check Engine Oil Level
1. Park machine on level ground.
2. Allow time for engine to cool and oil to settle in oil pan.
Open hood.
3. Remove dipstick (1) and wipe clean with a lint-free
cloth.
4. Insert dipstick until fully seated.
T147659B —UN—19NOV01
NOTE: Check engine oil level with engine cold
1— Dipstick
Continued on next page
3-4-1
OUO1043,0000E0A -19-30OCT01-1/2
080112
PN=87
Maintenance—Every 10 Hours or Daily
5. Remove dipstick and check oil level. Oil level should
be in the full mark (2).
6. If oil level is in low mark (1), add oil as necessary.
2— Full Mark
T148256B —UN—19NOV01
1— Low Mark
OUO1043,0000E0A -19-30OCT01-2/2
Check Transfer Case Oil Level
2. Add or drain oil, if necessary. See Change Transfer
Case Oil. Section 3-8.)
1— Sight Glass
T147662B —UN—19NOV01
1. Check oil level at sight glass (1). Oil level should be
to middle of sight glass.
OUO1043,0000E0C -19-30OCT01-1/1
Check Hydraulic Oil Level
1. Fully lower the dump body.
2. Check oil level in sight glass (1). Oil level must be
visible.
3. If no oil is visible in sight glass, add oil to hydraulic oil
reservoir. If sight glass is completely filled with oil, drain
excess oil. See Change Hydraulic Oil . (Section 3-9.)
T147663B —UN—19NOV01
IMPORTANT: Prevent damage to hydraulic system
components. DO NOT run engine without
oil in hydraulic oil reservoir.
1— Sight Glass
OUO1043,0000E0D -19-30OCT01-1/1
3-4-2
080112
PN=88
Maintenance—Every 10 Hours or Daily
Grease Dump Body Pivot Pins
T148150B —UN—08JAN02
Apply grease to lubrication fittings (9) and (10) until it
escapes at joints. See Grease. (Section 3-1.)
AM40430,00000E9 -19-29JUL05-1/1
Lubricate Tailgate Pivots—If Equipped
Add 1 shot of grease at each lubrication fitting (1).
T148411B —UN—26NOV01
1— Lubrication Fitting—Tailgate Pivot (2 used)
OUO1043,0000E13 -19-30OCT01-1/1
3-4-3
080112
PN=89
Maintenance—Initial Service - 100 Hours
Change Engine Oil and Replace Filter
T147664B —UN—19NOV01
NOTE: Perform this service after the first 100 hours of
operation and at 500 hour intervals thereafter.
CAUTION: Be careful when draining hot
engine oil. Hot engine oil can cause burns
to unprotected skin.
NOTE: The engine oil will drain easier when
engine is warm.
1. Run engine to warm oil slightly. Stop engine.
2. Open hood. Remove engine oil dipstick and fill cap.
3. Lower rear bottom guard. See Lower and Raise
Bottom Guard. (Section 3-2.)
T147665B —UN—19NOV01
4. Install hose to drain valve with a hose clamp. Put end
of hose into a container.
NOTE: Dispose of waste properly.
5. Loosen nut (2) and loosen valve stem (1). Drain oil
into container.
Engine—Specification
Oil—Capacity............................................................ 25.5 L approximate
6.7 gal
6. Tighten valve stem and tighten nut. Remove hose
clamp (4) and hose (5). Wipe excess oil from drain
valve (3).
1— Valve Stem
2— Nut
3— Drain Valve
4— Hose Clamp
5— Hose
6— Filter
7. Clean dirt and debris from engine oil filter cap and
surrounding area.
11. Install engine oil dipstick and fill cap.
8. Remove engine oil filter (6).
12. Start engine and let it run at slow idle for 1 minute.
Check for oil leaks at engine oil filter and drain valve.
Tighten only enough to stop leaks.
9. Lubricate seal ring on new filter with a small amount
of clean engine oil. Fill filter with clean engine oil and
install to filter head. Hand-tighten.
13. Check engine oil level.
14. Raise rear bottom guard.
IMPORTANT: Do not overfill the engine with oil.
10. Add oil at fill port. Do not overfill. See Diesel Engine
Oil. (Section 3-1.)
TX14740,0000011 -19-29JUL05-1/1
3-5-1
080112
PN=90
Maintenance—Initial Service - 100 Hours
Replace Hydraulic System Oil Return Filter
T147657B —UN—13NOV01
NOTE: Perform this service after the first 100 hours of
operation and at 2000 hour intervals thereafter.
In dry and/or dusty conditions, this service may
need to be performed every 1000 hours.
1. Remove nuts (2) and clamp (3) from dump body
heater support and pipe, if equipped.
2. Remove cap screws (1) and access cover (4).
3. Turn hydraulic reservoir breather (2) counterclockwise
and remove from machine.
4. Clean area around return filter cover (3).
T147656C —UN—13NOV01
CAUTION: Avoid personal injury. Remove return
filter cover carefully. Spring is under load.
5. Remove filter cover. Loosen and remove opposite
sets of cap screws (5) in sequence, to keep spring
load distributed evenly. Hold filter cover securely in
place while removing last 2 cap screws and washers,
then release slowly to relieve spring load.
6. Inspect filter cover seal ring for damage and wear.
Replace, if necessary.
7. Grasp spring and remove spring and return filter
assembly.
T143811C —UN—13NOV01
8. Clean filter seat. Do not allow dirt, debris, or foreign
objects to fall into hydraulic reservoir.
9. Remove retaining screw (7). Remove element (8).
10. Inspect shoulder seal ring (9) and face seal ring (10)
for damage and wear. Replace, if necessary.
IMPORTANT: Use only recommended filters which
have correct micron filtration rating for the
hydraulic system. (See your authorized dealer.)
11. Install new element. Install retaining screw. Ensure
that element is centered on face seal ring.
12. Install spring and filter element assembly. Ensure that
shoulder seal ring is properly seated in filter seat.
13. Install filter cover and cap screws. Ensure that filter
cover is free of dirt and debris before installing. Tighten
opposite cap screws and washers in sequence,
to ensure that filter cover seal ring is compressed
uniformly.
1— Cap Screw (4 used)
2— Nut—If Equipped (2 used)
3— Dump Body Heater Pipe
Clamp—If Equipped
4— Access Cover
5— Filter Cover Cap Screw
6— Filter Cover
7— Retaining Screw
8— Element
9— Shoulder Seal Ring
10— Face Seal Ring
15. Install clamp and nuts to dump body heater support
and pipe, if equipped.
14. Install access cover and cap screws.
OUO1043,0000E20 -19-13JUN06-1/1
3-5-2
080112
PN=91
Maintenance—Initial Service - 100 Hours
Replace Primary Fuel Filter (S.N. 201015—)
NOTE: Perform this service after the first 100 hours of
operation and at 500 hour intervals thereafter.
T213129A —UN—02AUG05
1. Disconnect the WIF sensor connector (1).
2. Turn primary fuel filter (2) counterclockwise to remove.
Allow sediment to drain into a container. Dispose of
waste properly.
3. Clean filter base.
4. Install new filter. (Follow instructions on filter.)
5. Install sensor connector.
1— Sensor Connector
2— Primary Fuel Filter
6. Bleed fuel system. See Bleeding Fuel System.
Section 4-1.)
3— Final Fuel Filter
AM40430,00000EB -19-29JUL05-1/1
Change Transfer Case Oil
NOTE: Perform this service after the first 100 hours of
operation and at 2000 hour intervals thereafter.
T147975B —UN—19NOV01
1. Remove fill plug and sealing ring (1). Clean fill plug
and sealing ring. Inspect sealing ring. Replace sealing
ring, if necessary.
NOTE: Dispose of waste properly.
2. Put a container under drain plug (2). Remove drain
plug and drain oil into container.
Transfer Case—Specification
Oil—Capacity................................................................................... 4.7 L
5.0 qt
3. Clean drain plug thoroughly.
T147662C —UN—19NOV01
4. Install drain plug. Tighten to specification.
Transfer Case—Specification
Drain Plug and Fill Plug
Tightening—Torque............................................................... 25—32 N·m
38—45 lb-ft
5. Add oil at fill port. Do not overfill. Oil level should be to
middle of sight glass (3).
6. Install fill plug and sealing ring.
7. Start engine. Drive machine in low gears for 1 minute.
Stop engine.
1— Fill Plug and Sealing Ring
2— Drain Plug
3— Sight Glass
8. Check for leaks at drain plug. Tighten only enough to
stop leaks.
9. Check oil level at sight glass. Oil level should be to
middle of sight glass. Add more oil, if necessary.
OUO1043,0000E1C -19-29JUL05-1/1
3-5-3
080112
PN=92
Maintenance—Initial Service - 100 Hours
Change Axle Oil
NOTE: Perform this service after the first 100 hours of
operation and at 2000 hour intervals thereafter.
T147833B —UN—18DEC01
NOTE: Perform this procedure for each axle. The
procedure is the same for all axles.
1. Clean axle housing around check and fill plug (1) and
drain plug (2).
NOTE: Dispose of waste properly.
2. Remove axle drain plug (2) from axle housing and
allow oil to drain into a container. For middle axle,
remove adapter case drain plug (3).
Axle—Specification
Oil (Each)—Capacity...................................................................... 21.9 L
5.8 gal
1— Check and Fill Plug
2— Axle Drain Plug
3— Adapter Case Drain Plug
(Middle Axle Only)
5. Install check and fill plug.
3. Clean drain plug(s) and install in axle housing.
4. Add oil at check and fill port. See Axle and Final Drive
Oil. (Section 3-1.)
OUO1043,0000E1D -19-29JUL05-1/1
Change Final Drive Oil
NOTE: Perform this service after the first 100 hours of
operation and at 2000 hour intervals thereafter.
NOTE: Perform this procedure for each final drive. The
procedure is the same for all final drives.
1. Rotate wheel until drain plug (1) is at lowest point.
NOTE: Dispose of waste properly.
2. Remove drain plug from final drive and allow oil to
drain into a container.
T147834B —UN—13NOV01
Final Drive—Specification
Oil (Each)—Capacity........................................................................ 4.0 L
4.2 qt
3. Clean drain plug of oil and debris. Install drain plug
tightly.
4. Remove check and fill plug (2) and fill final drive with
clean oil, until oil flows from the check and fill port.
See See Axle and Final Drive Oil. (Section 3-1.)
1— Drain Plug
5. Install check and fill plug.
2— Check and Fill Plug
OUO1043,0000E1E -19-29JUL05-1/1
3-5-4
080112
PN=93
Maintenance—Every 500 Hours
Check Park Brake Pad Wear
1.
Raise the dump body and install the dump body prop.
2. Measure thickness of park brake pads.
3. If either of the brake pads has worn to minimum
specified thickness, both brake pads must be replaced.
(See your authorized dealer.)
T124415B —UN—09SEP99
Park Brake—Specification
Pad—Thickness............................................................3.0 mm minimum
0.12 in. minimum
OUO1079,00003CD -19-19MAY06-1/1
Check Dry Caliper Service Brake Pad Wear
NOTE: If operating in wet or muddy conditions, check
wear indicators every 250 hours.
T148251B —UN—26NOV01
1. Remove cap screws (2) and upper brake shield (1).
2. Inspect brake pads (3) for wear. If pads are not within
specification, see your authorized dealer.
Service Brakes—Specification
Pad—Thickness............................................... 3 mm (0.12 in.) Minimum
3. Install upper brake shield and cap screws.
250D Shown; 300D Similar
4. Repeat procedure for each wheel.
3— Brake Pad (2 used)
T148252B —UN—26NOV01
1— Upper Brake Shield
2— Cap Screw (2 used)
OUO1043,0000E0F -19-30OCT01-1/1
3-6-1
080112
PN=94
Maintenance—Every 500 Hours
Check Front Axle Suspension Struts
NOTE: If operating in wet or muddy conditions, check
front axle suspension struts every 250 hours.
NOTE: Struts must be checked at ambient temperatures,
i.e. when the machine has not been operating
during the work shift.
1. Park machine on a level surface with an empty bin
and install articulation lock.
A
2. Clean boot and surrounding area. Inspect boot for
damage. Replace if necessary.
TX1008608 —UN—07JUN06
3. From a stand still and with the articulation lock
installed, drive straight forward aggressively for
approximately 5-10 m (16-33 ft.) and bring the
machine to a stand still using the service brakes.
4. Reverse the machine gently and bring the machine
back to it's original position without applying any
brakes.
5. Repeat steps 3 and 4.
6. Once the machine has come to a stop, apply the park
brake and switch off the engine.
7. Measure height from the centerline of the top mounting
location to the centerline of the bottom mounting
location. If height is not within specification, see your
authorized dealer.
A—Height
Suspension Strut—Specification
Centerline to
Centerline—Height...................................................................... 646 mm
25.4 in.
VD76477,000046A -19-13JUN06-1/1
3-6-2
080112
PN=95
Maintenance—Every 500 Hours
Inspect, Clean, and Replace Cab Air Filter
1. Open storage compartment door (1).
T143532B —UN—06JUL01
2. Turn latches (2) 1/4-turn counterclockwise. Open
access door (3).
3. Remove element (4). Inspect element for dust, debris,
moisture, and damage.
a. Replace element, if damaged.
CAUTION: Use compressed air regulated to 207
kPa (30 psi) to clean filter. If high pressure
compressed air is used, filter may be damaged
or personal injury may result.
T143533B —UN—06JUL01
b. Clean element, if necessary. Remove large debris
by hand, then spray compressed air through
element in direction opposite normal air flow.
c. If element is moist, allow to dry before reinstalling.
Do not apply heat to element.
4. Install element. Ensure that “air flow” decal is at top,
and arrows on decal point toward front of machine.
5. Close access door. Turn latches 1/4-turn clockwise.
Ensure latches are secure.
6. Close storage compartment door.
1— Storage Compartment Door
2— Latch (2 used)
3— Access Door
4— Element
OUO1079,00003DE -19-02JUL01-1/1
3-6-3
080112
PN=96
Maintenance—Every 500 Hours
Check Batteries, Clean and Tighten Terminals
1. Open hood. Open battery compartment door (1).
T148322B —UN—26NOV01
2. Push top access door latch (2) inward and open top
access door.
3. Clean debris from battery compartment.
4. Inspect circuit breaker box (3) and battery disconnect
switch (4) for damage and secure installation. Tighten
mounting hardware, if necessary. Replace damaged
components. (See your authorized dealer.)
5. Inspect batteries and cables for damage. Replace, if
necessary. See Replace Batteries. (Section 4-1.)
6. Inspect and clean terminals (6). Ensure that posts are
secure in battery housings. Ensure that cables are
securely installed on posts.
T148323B —UN—26NOV01
7. Ensure that mounting bracket assemblies (5) are
secure. Tighten nuts, if necessary.
8. Check battery charge indicator (7) (if equipped) on
each battery. The colors displayed are as follows:
• Green—Battery is fully charged.
• Black—Battery charge is low and must be charged.
See Using Battery Charger. (Section 4-1.)
Battery must be
replaced.
• Yellow—Battery life has expired.
Outer Battery
9. Check electrolyte level if battery has level check/fill
plugs.
1— Battery Compartment Door
2— Top Access Door Latch
3— Circuit Breaker Box
4— Battery Disconnect Switch
T148324B —UN—26NOV01
10. Start engine. After bulb check, verify that battery
charge indicator on instrument panel is not lit. Verify
battery voltages on monitor display unit.
5— Mounting Bracket
Assembly (2 used)
6— Terminal (4 used)
7— Battery Charge Indicator (2
used) (If Equipped)
Inner Battery
OUO1043,0000E11 -19-08AUG05-1/1
3-6-4
080112
PN=97
Maintenance—Every 500 Hours
Lubricate Oscillation Tube, Articulation
Joints, Steering Cylinder Rod Ends, and
Oscillation Tube Through Drive Shaft
Bearings
Add grease at each lubrication fitting (1—7) until grease
escapes from joint. See Grease. (Section 3-1.)
T149788C —UN—01AUG05
5— Lubrication Fitting—Left
Steering Cylinder Rod End
6— Lubrication Fitting—Oscillation Tube
7— Lubrication Fitting—Oscillation Tube Through Drive
Shaft Rear Bearing
T213218A —UN—03AUG05
1— Lubrication Fitting—Upper
Articulation Joint
2— Lubrication Fitting—Oscillation Tube Through Drive
Shaft Front Bearing
3— Lubrication Fitting—Lower
Articulation Joint
4— Lubrication Fitting—Right
Steering Cylinder Rod End
AM40430,00000EC -19-29JUL05-1/1
3-6-5
080112
PN=98
Maintenance—Every 500 Hours
Check Transmission Oil Level
NOTE: To obtain the most accurate transmission oil level
readings, check transmission oil dipstick with engine
running, transmission in neutral, transmission oil
warm and machine parked on level ground.
T201846A —UN—22JUL04
1. Park machine on level ground and engage park brake.
2. Select neutral (N) and run engine at slow idle.
3. Raise cab.
4. Remove transmission dipstick (1) from fill tube. Turn
handle counterclockwise to loosen. Wipe oil from
dipstick and fill tube.
5. Fully insert transmission dipstick into fill tube. Remove
transmission dipstick and read oil level. Repeat.
STOP
HOT
• Checking cold, engine not running—Oil level must
be at or near STOP mark on dipstick.
• Checking cold, engine running—Oil level must be
between lines of COLD mark.
• Checking hot, engine running—Oil level must be
T148377
COLD
T148377 —19—21NOV01
NOTE: STOP and COLD marks indicate sufficient
oil levels for running machine. Check oil level
with transmission oil at operating temperature
for accurate reading.
between lines of HOT mark.
6. Add or drain transmission oil, as necessary. See
Change Transmission Oil . (Section 3-8.)
1— Transmission Dipstick
7. Fully insert transmission dipstick into fill tube. Turn
handle clockwise to tighten.
8. Lower cab.
TX14740,0000182 -19-22JUL04-1/1
3-6-6
080112
PN=99
Maintenance—Every 500 Hours
Clean and Inspect Hydraulic Reservoir
Breather
T147657B —UN—13NOV01
1. Remove nuts (2) and clamp (3) from dump body
heater support and pipe.
2. Remove access panel cap screws (1) and access
panel (4).
IMPORTANT: DO NOT spray steam, water or cleaning
solution directly at hydraulic reservoir breather.
Spray could be forced into hydraulic reservoir.
NOTE: Hydraulic reservoir breather should be checked
daily in adverse working conditions. The amount
of dust and dirt encountered will determine the
frequency of breather cleaning.
T147656B —UN—13NOV01
3. Clean dirt, dust, and debris from hydraulic reservoir
breather (5) and from surrounding area.
4. Inspect hydraulic reservoir breather for clogging,
damage, and proper installation.
Replace hydraulic reservoir breather if it appears
damaged or cannot be unclogged. See Replace
Hydraulic Reservoir Breather, (Section 3-9.)
5. Install access panel and cap screws.
6. Install clamp and nuts to dump body heater support
and pipe.
1— Access Panel Cap Screw (4
used)
2— Nut (2 used)
3— Clamp
4— Access Panel
5— Hydraulic Reservoir
Breather
OUO1043,0000E07 -19-30OCT01-1/1
Replace In-line Fuel Filter (S.N. 201015—)
1. Open hood.
T201828A —UN—22JUL04
2. Loosen and slide hose clamps away from in-line fuel
filter (1). Remove hoses.
3. Remove filter.
4. Install new filter.
5. Install hoses and tighten clamps.
TX14740,000017F -19-21JUL04-1/1
3-6-7
080112
PN=100
Maintenance—Every 500 Hours
Replace Fuel Filters (S.N.—201014)
1. Disconnect the WIF sensor connector (2).
T165115C —UN—11FEB03
2. Turn filter (1) counterclockwise to remove. Allow
sediment to drain into a container. Dispose of waste
properly.
3. Turn sediment bowl (3) counterclockwise to remove
from filter assembly.
4. Clean filter base.
5. Install new filter. (Follow instructions on filter.)
6. Install sediment bowl.
7. Install sensor connector.
1— Filter
2— Sensor Connector
8. Bleed fuel system. See Bleeding Fuel System.
(Section 4-1.).
3— Sediment Bowl
TX14740,0000181 -19-21JUL04-1/1
Replace Final Fuel Filter (S.N. 201015—)
1. Disconnect the WIF sensor connector (1).
T213129A —UN—02AUG05
2. Turn final fuel filter (3) counterclockwise to remove.
Allow sediment to drain into a container. Dispose of
waste properly.
3. Clean filter base.
4. Install new filter. (Follow instructions on filter.)
5. Install sensor connector.
6. Bleed fuel system. See Bleeding Fuel System.
(Section 4-1.).
1— Sensor Connector
2— Primary Fuel Filter
3— Final Fuel Filter
AM40430,00000ED -19-29JUL05-1/1
3-6-8
080112
PN=101
Maintenance—Every 500 Hours
Check Coolant Conditioner in Radiator
CAUTION: Explosive release of fluids
from pressurized cooling system can
cause serious burns.
TS281 —UN—23AUG88
Remove fill cap only when engine is cold or
when cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve pressure
before removing completely.
IMPORTANT: John Deere Liquid Coolant Conditioner
does not protect against freezing. Coolant
conditioner prevents rust, scale, and
liner cavitation.
T147658B —UN—09NOV01
NOTE: If Caltex coolant has been replaced with
Deere COOL-GARD coolant, add coolant
conditioner as necessary.
1. Remove fill cap (2) and test coolant solution in
expansion tank (1). For Caltex coolant, use an
appropriate test device to measure the specific
gravity of coolant solution. If Caltex coolant has been
replaced with Deere COOL-GARD, use one of the
following kits to check coolant:
• 3-WAY Heavy Duty Coolant Test Kit (TY16175) (For
T111110 —UN—13AUG97
use with Deere COOL-GARD coolant.)
Coolant test strips provide an effective method to
check freeze point and additive levels of engine
coolant. See your authorized dealer for 3-WAY
Heavy Duty Coolant Test Kit and follow instructions
on kit.
• CoolScan Plus (For use with Deere COOL-GARD
coolant.)
For a more thorough evaluation of coolant, perform
CoolScan Plus analysis, where available. See your
authorized dealer for information about CoolScan
Plus.
3-Way Test Kit
IMPORTANT: To prevent machine damage, ensure
that all coolant additives are compatible with
coolant system is currently filled with.
T111109 —UN—13AUG97
2. Add coolant conditioner or equivalent non-chromatic
conditioner/rust inhibitor, as necessary. Follow
instructions on container for amount.
3. Install fill cap.
1— Expansion Tank
2— Fill Cap
CoolScan Plus
OUO1043,0000E19 -19-30OCT01-1/1
3-6-9
080112
PN=102
Maintenance—Every 1000 Hours
Check Axle Oil Levels
NOTE: The procedure is the same for all 3 axles.
T147833C —UN—13NOV01
1. Clean axle housing around check and fill plug (1).
2. Remove check and fill plug from axle housing.
3. Oil must be level with bottom of check and fill port.
4. Add oil through check and fill port, if necessary. See
Change Axle Oil. (Section 3-8.)
5. Install check and fill plug.
1— Check and Fill Plug
OUO1043,0000E16 -19-30OCT01-1/1
Check Final Drive Oil Levels
NOTE: Perform this procedure for each final drive. The
procedure is the same for all final drives.
T123135B —UN—29JUL99
1. Rotate wheel until check plug (1) is in a horizontal
position.
2. Remove check plug and check oil level. Oil level must
be even with bottom edge of check port.
3. If necessary, add oil. See Change Final Drive Oil.
(Section3-8.)
4. Install check plug tightly.
1— Check Plug
OUO1043,0000E17 -19-30OCT01-1/1
3-7-1
080112
PN=103
Maintenance—Every 1000 Hours
Replace Hydraulic Reservoir Breather
1. Remove nuts (2) and clamp (3) from dump body
heater support and pipe, if equipped.
2. Remove cap screws (1) and access panel (4).
3. Turn hydraulic reservoir breather (5) counterclockwise
and remove from machine.
T147657B —UN—13NOV01
NOTE: Hydraulic reservoir breather should be replaced
at scheduled intervals, or whenever found to
be damaged or clogged.
4. Install new hydraulic reservoir breather. Hand-tighten.
5. Install access panel and cap screws.
1— Cap Screw (4 used)
2— Nut—If Equipped (2 used)
3— Dump Body Heater Pipe
Clamp—If Equipped
T147656B —UN—13NOV01
6. Install clamp and nuts to dump body heater support
and pipe, if equipped.
4— Access Cover
5— Hydraulic Reservoir
Breather
OUO1043,0000E18 -19-07FEB03-1/1
3-7-2
080112
PN=104
Maintenance—Every 1000 Hours
Check and Adjust Bin Shock Pad
IMPORTANT: Before starting procedure, make sure
bin pads and chassis are clean of debris and
that the bin pivots do not show any signs
of excessive play or movement.
1. Ensure bin is completely empty.
2. Remove bin float relay from relay/fuse panel.
3. Lift the bin until all pads are off of the chassis.
4. Lower the bin until either the left or the right rear pad
just contacts the chassis.
NOTE: If both pads contact the chassis at the same time
or within 1 mm of each other the side-to-side rear
pad spacing is acceptable. If the pads contact the
chassis more than 1 mm apart, shims need to be
added to the pad that contacts the chassis last.
T213202A —UN—02AUG05
5. Reinstall the bin float relay.
6. Lift the bin and allow it to float onto the rear pads.
7. Measure the gaps between the front pads and the
chassis. If either of the front pad gaps are smaller
than 3 mm, both left and right rear pads should have
an equal number of shims added to lift the front pads.
For gaps that are larger than 3 mm, shims should be
added to the front pads to meet the specification.
Specification
250D and 300D Bin
Shock Pads—Distance.................................................................... 3 mm
1— Rear Bin Pads
2— Front Bin Pads
VD76477,000045F -19-15MAY06-1/1
Grease Prop Shaft Slip Joint
Add grease at lubrication fitting (1) until grease escapes
at joint. See Grease. (Section 3-1.)
T213146A —UN—02AUG05
1— Lubrication fitting
AM40430,00000F3 -19-29JUL05-1/1
3-7-3
080112
PN=105
Maintenance—Every 2000 Hours
Adjust Engine Valve Clearance
See your authorized dealer for engine valve clearance
adjustment.
OUO1079,00003BC -19-13JUN01-1/1
NOTE: It is not necessary to change transmission oil until a
contaminated OILSCAN PLUS® sample is indicated.
Draw sample from transmission oil at drain plug. For
convenience, install a sampling valve in drain port.
NOTE: Dispose of waste properly.
1. Remove drain plug (1) and drain oil into a container.
2. Remove drain plug (2) and drain oil into a container.
Transmission—Specification
Oil Pan—Capacity.......................................................................... 21.8 L
5.8 gal
T147672B —UN—21NOV01
Change Transmission Oil
4. Replace transmission oil filters. See Replace
Transmission Oil Filters in this section.
5. Remove dipstick (3) and add oil at fill tube (4). See
Transmission and Transfer Case Oil. Section 3-1.)
6. Check transmission oil level.
1— Drain Plug
2— Drain Plug
3— Dipstick
4— Fill Tube
T147661C —UN—21NOV01
3. Install drain plugs.
OILSCAN PLUS is a trademark of Deere & Company
OUO1043,0000E1A -19-01AUG05-1/1
3-8-1
080112
PN=106
Maintenance—Every 2000 Hours
Replace Transmission Oil Filter
T148394B —UN—21NOV01
NOTE: Perform this service at every 2000 hours in
normal operating conditions. In dry and dusty
operating conditions, this service may need to be
performed as often as every 1000 hours.
1. Drain transmission oil. See Change Transmission Oil
in this section.
2. Put a container under filter assembly.
3. Remove cap screws (1) and filter assembly (2). Drain
oil into container. Dispose of waste properly.
4. Remove filter element (3). Discard old element.
5. Install new filter element.
6. Replace filter cover o-ring.
T148546B —UN—28NOV01
7. Install filter cover and cap screws. Tighten to
specification.
Transmission—Specification
Oil Filter Cap
Screw—Torque............................................................... 25 N·m (18 lb-ft)
8. Fill transmission oil. See Change Transmission Oil
in this section.
9. Check transmission oil level.
1— Cap Screw (4 used)
2— Filter Cover
3— Filter Element
OUO1043,0000E1B -19-08AUG05-1/1
3-8-2
080112
PN=107
Maintenance—Every 2000 Hours
Change Transfer Case Oil
T147975B —UN—19NOV01
NOTE: Perform this service at every 2000 hours in
normal operating conditions. In dry and dusty
operating conditions, this service may need to be
performed as often as every 1000 hours.
1. Remove fill plug and sealing ring (1). Clean fill plug
and sealing ring. Inspect sealing ring. Replace sealing
ring, if necessary.
NOTE: Dispose of waste properly.
2. Put a container under drain plug (2). Remove drain
plug and drain oil into container.
Transfer Case—Specification
Oil—Capacity.......................................................................4.7 L (5.0 qt)
T147662C —UN—19NOV01
3. Clean drain plug thoroughly.
4. Install drain plug. Tighten to specification.
Transfer Case—Specification
Drain Plug and Fill Plug
Tightening—Torque......................................... 25—32 N·m (38—45 lb-ft)
5. Add oil at fill port. Do not overfill. Oil level should be to
middle of sight glass (3).
6. Install fill plug and sealing ring.
7. Start engine. Drive machine in low gears for 1 minute.
Stop engine.
8. Check for leaks at drain plug. Tighten only enough to
stop leaks.
1— Fill Plug and Sealing Ring
2— Drain Plug
3— Sight Glass
9. Check oil level at sight glass. Oil level should be to
middle of sight glass. Add more oil, if necessary.
OUO1043,0000E1C -19-30OCT01-1/1
Change Axle Oil
T147833B —UN—18DEC01
NOTE: Perform this service at every 2000 hours in
normal operating conditions. In dry and dusty
operating conditions, this service may need to be
performed as often as every 1000 hours.
NOTE: Perform this procedure for each axle. The
procedure is the same for all axles.
1. Clean axle housing around check and fill plug (1) and
drain plug (2).
NOTE: Dispose of waste properly.
2. Remove axle drain plug (2) from axle housing and
allow oil to drain into a container. For middle axle,
remove adapter case drain plug (3).
Axle—Specification
Oil (Each)—Capacity........................................................ 21.9 L (5.8 gal)
3. Clean drain plug(s) and install in axle housing.
1— Check and Fill Plug
2— Axle Drain Plug
3— Adapter Case Drain Plug
(Middle Axle Only)
4. Add oil at check and fill port. See Axle and Final Drive
Oil. (Section 3-1.)
5. Install check and fill plug.
OUO1043,0000E1D -19-08AUG05-1/1
3-8-3
080112
PN=108
Maintenance—Every 2000 Hours
Change Final Drive Oil
NOTE: Perform this service at every 2000 hours in
normal operating conditions. In dry and dusty
operating conditions, this service may need to be
performed as often as every 1000 hours.
NOTE: Perform this procedure for each final drive. The
procedure is the same for all final drives.
1. Rotate wheel until drain plug (1) is at lowest point.
NOTE: Dispose of waste properly.
T147834B —UN—13NOV01
2. Remove drain plug from final drive and allow oil to
drain into a container.
Final Drive—Specification
Oil (Each)—Capacity............................................................4.0 L (4.2 qt)
3. Clean drain plug of oil and debris. Install drain plug
tightly.
4. Remove check and fill plug (2) and fill final drive with
clean oil, until oil flows from the check and fill port.
See See Axle and Final Drive Oil. (Section 3-1.)
1— Drain Plug
2— Check and Fill Plug
5. Install check and fill plug.
OUO1043,0000E1E -19-08AUG05-1/1
Replace Pneumatic System Dryer-Filter
1. Relieve pneumatic pressure.
T147646C —UN—09NOV01
2. Remove old element (1) from head (2). Discard old
element.
3. Inspect O-ring on head. Clean or replace O-ring, if
necessary.
4. Apply thin layers of oil to O-ring on head and O-ring
on new element.
5. Install new element. Tighten until O-rings make
contact, then tighten an additional 1/2-turn.
6. Start engine and let it run. When pneumatic system
has reached normal operating pressure, stop engine
and check for air leaks at head and element. Tighten
element only enough to stop leaks.
1— Element
2— Head
OUO1043,0000E1F -19-30OCT01-1/1
3-8-4
080112
PN=109
Maintenance—Every 4000 Hours
NOTE: Perform this service at every 4000 hours in
normal operating conditions. In dry and/or dusty
operating conditions, this service may need to be
performed as often as every 2000 hours.
1. Install a drain hose and clamp to drain valve (3).
NOTE: Dispose of waste properly.
2. Loosen nut (1) and valve stem (2) to open drain valve.
Drain hydraulic oil.
T147782B —UN—13NOV01
Change Hydraulic Oil
Hydraulic System—Specification
Reservoir Oil—Capacity................................................................. 78.8 L
20.8 gal
4. Remove fill cap (4). Fill hydraulic reservoir with new
hydraulic oil. See Hydraulic Oil. (Section 3-1.)
5. Install fill cap.
6. Check for leaks at drain valve. Tighten plug only
enough to stop leaks.
1— Nut
2— Valve Stem
T147784B —UN—13NOV01
3. Tighten valve stem and nut to close drain valve.
Remove drain hose and clamp from drain valve.
3— Drain Valve
4— Fill Cap
OUO1043,0000E21 -19-29JUL05-1/1
3-9-1
080112
PN=110
Maintenance—Every 4000 Hours
Replace Hydraulic Suction Screen
1
1. Drain oil from hydraulic reservoir.
Specification
Reservoir Oil—Capacity................................................................. 78.8 L
20.8 gal
2
2. Remove external hydraulic reservoir cover (1).
3. Remove internal hydraulic reservoir cover (2).
4. Remove suction screen from fitting (3).
3
5. Clean magnet (4) as necessary.
6. Insert new suction screen into fitting.
4
7. Replace reservoir covers (1 and 2).
8. Fill hydraulic reservoir and check hydraulic oil level.
3— Fitting
4— Magnet
T213160 —UN—08AUG05
1— External Hydraulic
Reservoir Cover
2— Internal Hydraulic
Reservoir Cover
AM40430,0000106 -19-08AUG05-1/1
Replace Pneumatic Block Silencer Filter
1. Park machine and turn engine off.
3. Thread bin tip lever exhaust silencer (1) out with a
wrench and insert new silencer.
4. Thread park brake lever exhaust silencer (2) out with
a wrench and insert new silencer.
1— Bin Tip Lever Exhaust
Silencer
2— Park Brake Exhaust
Silencer
T213145A —UN—02AUG05
2. Open hood and locate pneumatic manifold on the right
hand side.
AM40430,00000F0 -19-29JUL05-1/1
3-9-2
080112
PN=111
Maintenance—Every 4500 Hours
Replace Engine Crankshaft Dampener
The crankshaft dampener assembly is not repairable
and should be replaced every four years or 4000
hours, whichever occurs first, or whenever crankshaft is
replaced. See your authorized John Deere dealer.
CED,TX03768,2668 -19-11NOV09-1/1
3-10-1
080112
PN=112
Maintenance—Every 5000 Hours
Drain, Flush and Refill Engine Cooling
System
T147658B —UN—09NOV01
IMPORTANT: If this machine is factory filled with
Caltex extended life coolant which is good
for 5000 operating hours, this coolant can
be topped off with the Deere COOL-GARD
coolant. When system needs to be refilled,
it is recommended to drain and refill cooling
system with Deere COOL-GARD coolant.
1. Open hood. Remove fill cap (2) from expansion tank
(1).
2. Lower front bottom guard. See Lower and Raise
Bottom Guard. (Section 3-2.)
T147677B —UN—19NOV01
3. Attach drain hose and hose clamp to drain valve
nozzle (3).
NOTE: Dispose of waste properly.
4. Loosen nut (5) and valve stem (4) to open drain valve
(6). Drain engine coolant into a container.
Engine—Specification
Coolant—Capacity......................................................................... 26.5 L
7.0 gal
5. Tighten valve stem to close drain valve. Do not
overtighten. Remove hose clamp and hose.
IMPORTANT: Engine coolant is often sold in
concentrated form, and must be mixed with
water to obtain correct specific gravity. Verify
correct mixture before filling.
6. Add new engine coolant at expansion tank fill port.
Do not overfill.
7. With fill cap NOT installed, start engine. Run engine
at slow idle for 3 minutes to purge air pockets from
engine cooling system. Stop engine.
1— Expansion Tank
2— Fill Cap
3— Valve Nozzle
4— Valve Stem
5— Nut
6— Drain Valve
9. Raise front bottom guard.
10. Check coolant level in expansion tank. Cold coolant
should not be below the ADD mark. Hot coolant
should not be above FULL mark. Add more coolant, if
necessary.
11. Install fill cap securely.
8. Check for leaks at drain valve. Tighten only enough to
stop leaks.
AM40430,00000F2 -19-08AUG05-1/1
3-11-1
080112
PN=113
Miscellaneous—Machine
Do Not Service Control Valves, Cylinders,
Pumps or Motors
If these parts need service, see your authorized dealer.
Special tools and information are needed to service
control valves, cylinders, pumps, or motors.
TX,90,FF3114 -19-18NOV92-1/1
• Poor quality fuel
• Excessive idling
Do Not Service Injection Nozzles
IMPORTANT: Do not service or remove injection
nozzles. The service life of the injection
nozzles may be shortened by:
If injection nozzles are not working correctly or are dirty,
the engine will not run normally. (See your authorized
dealer for service.)
• Overheating
• Improper operation
TX,90,FF3116 -19-18NOV92-1/1
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury. Relieve
pressure before disconnecting fuel or other
lines. Tighten all connections before applying
pressure. Keep hands and body away from
pinholes and nozzles that eject fluids under high
pressure. Use a piece of cardboard or paper to
search for leaks. Do not use your hand.
If ANY fluid is injected into the skin, a
doctor familiar with this type of injury must
surgically remove it within a few hours or
gangrene may result.
X9811 —UN—23AUG88
Bleeding Fuel System
Whenever the fuel system has been opened up for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
Continued on next page
4-1-1
TX14740,000017E -19-21JUL04-1/2
080112
PN=114
Miscellaneous—Machine
1. Open drain valves (2) to drain water and contaminates
from filters.
Loosen diagnostic port (1) located on back filter to
allow air and fuel to escape. Attach a hose and bleed
fuel into suitable container.
T201826A —UN—22JUL04
2.
3. Close drain valves.
4. Unlock and operate hand primer (3) until a steady flow
of fuel (without bubbles) flows out of hose. This could
take 270-330 strokes until fuel flow is free of bubbles.
5. Continue to pump hand primer while tightening
diagnostic port to specification below.
Two Fuel Filter System Shown
Specification
Diagnostic
Port—Torque.................................................................................14 N·m
20 lb-ft
T159635B —UN—20SEP02
6. Start engine and run at 1200-1500 RPM for 3-5
minutes.
7. If engine fails to start, loosen high pressure fuel line
fittings (4). Pump hand primer until steady flow of fuel
escapes the fuel pump. This could take an additional
90-120 fuel line fittings to specification below and lock
hand primer.
Specification
High Pressure Fuel
Lines—Torque...............................................................................27 N·m
20 lb-ft
1— Drain Valves
2— Diagnostic Port
3— Hand Primer
4— High Pressure Fuel Line
Fittings
8. Crank engine up to 15 seconds. If engine does not
start, wait 15 seconds and then crank for an additional
15 seconds. If engine starts, run at 1200-1500 RPM
for 3-5 minutes.
TX14740,000017E -19-21JUL04-2/2
Check Engine Air Intake System
1. Check air cleaner assembly for damage to precleaner
(1) and air cleaner housing (2).
3. Check rubber elbows (4), clamps (5), and pipes (6) for
tightness, cracks, or damage.
1— Precleaner
2— Air Cleaner Housing
3— Service Indicator
4— Rubber Elbow (4 used)
5— Clamp (12 used)
6— Pipe (3 used)
T147679B —UN—09NOV01
2. Check that service indicator (3) is not showing a red
flag. If red flag is shown, service air cleaner and reset
service indicator.
OUO1043,0000E24 -19-30OCT01-1/1
4-1-2
080112
PN=115
Miscellaneous—Machine
Check Brake Accumulators
3. Turn key switch to OFF position to stop engine.
1. Start engine and wait until main pump has fully
charged the accumulators.
4. Turn key switch to ON position and wait for bulb check
to complete.
2. Press brake pedal repeatedly to make the main
pump recharge the accumulators several times. Stop
pushing pedal while in the middle of a recharge cycle,
to ensure brakes are not consuming oil after main
pump stops.
5. Press brake pedal repeatedly, counting the number
of strokes before the brake indicator lights. Machine
must allow 8 strokes of the brake pedal before brake
pressure indicator on instrument panel lights. If it does
not, see your authorized dealer.
OUO1043,0000E25 -19-30OCT01-1/1
Check Wheel Nuts
Ensure that wheel nuts are tight. Torque to specification.
IMPORTANT: Check torque on wheel nuts after the first
5 hours of use and again after 50 hours of use any
time a wheel has been removed and reinstalled.
Wheel—Specification
Nut—Torque............................................................... 650 N·m (480 lb-ft)
OUO1043,0000DF0 -19-25OCT01-1/1
Lubricate Hinges
• Battery compartment door hinges
• Hood hinges
• Bottom guard hinge
Lubricate the following with powdered graphite:
• Cab door hinges
OUO1043,0000E48 -19-27NOV01-1/1
Using Booster Batteries—24-Volt System
T7233JN —UN—21MAY90
Before boost starting, machine must be properly shutdown
to prevent unexpected machine movement when engine
starts.
CAUTION: An explosive gas is produced while
batteries are in use or being charged. Keep flames
or sparks away from the battery area. Make sure
the batteries are charged in a well ventilated area.
IMPORTANT: The machine electrical system is a
24-volt negative (-) ground. Connect two 12-volt
booster batteries together as shown for 24-volts.
1. Connect one end of the positive cable to the positive
terminal of the machine batteries (A) and the other end
to the positive terminal of the booster batteries (B).
Booster Batteries, 2-Battery Application
A—Machine Battery (2 used)
B—Booster Battery (2 used)
2. Connect one end of the negative cable to the negative
terminal of the booster batteries. Connect the other
end of the negative cable to the machine frame as far
away from the machine batteries as possible.
4. Immediately after starting engine disconnect the end
of the negative cable from the machine frame. Then
disconnect the other end of the negative cable from
the negative terminal of the booster batteries.
3. Start engine.
5. Disconnect positive cable from booster batteries and
machine batteries.
OUT4001,0000238 -19-12MAR12-1/1
4-1-3
080112
PN=116
Miscellaneous—Machine
Using Battery Charger
TS204 —UN—23AUG88
CAUTION: Prevent possible injury from exploding
battery. Do not charge a battery if the battery
is frozen or it may explode. Warm battery to
16°C (60°F) before charging.
Turn off charger before connecting or
disconnecting it.
IMPORTANT: Do not use battery charger as a
booster if a battery has a 1.150 specific
gravity reading or lower.
Disconnect battery ground (-) clamp before
you charge batteries in the machine to prevent
damage to electrical components.
Prevent Battery Explosions
A battery charger may be used as a booster to start engine.
Ventilate the area where batteries are being charged.
N36890 —UN—07OCT88
Stop or cut back charging rate if battery case feels hot,
or is venting electrolyte. Battery temperature must not
exceed 52°C (125°F).
Charger
OUT4001,0000239 -19-03JAN12-1/1
4-1-4
080112
PN=117
Miscellaneous—Machine
Handling, Checking And Servicing Batteries
Carefully
TS204 —UN—23AUG88
CAUTION: Battery gas can explode. Keep sparks
and flames away from batteries. Use a flashlight
to check battery electrolyte level.
Never check battery charge by placing
a metal object across the posts. Use a
voltmeter or hydrometer.
Always remove grounded (-) battery clamp
first and replace it last.
Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness
if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a 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:
TS203 —UN—23AUG88
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but
do not exceed 1.9 L (2 quarts).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
If electrolyte spills on the floor, use one of the following
mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda
in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in
4 L (1 gal) water.
IMPORTANT: DO NOT overfill the battery cells.
Check the specific gravity of electrolyte in each battery cell.
Continued on next page
4-1-5
TX03679,0001788 -19-16NOV00-1/2
080112
PN=118
Miscellaneous—Machine
See your John Deere dealer for JT05460
SERVICEGARD™ battery and coolant tester. Follow
directions included with the tester.
T85402 —UN—10NOV88
A fully charged battery will have a corrected specific
gravity reading of 1.260. If the reading is below 1.200,
charge the battery.
SERVICEGARD is a trademark of Deere & Company
TX03679,0001788 -19-16NOV00-2/2
Replace Batteries
1. Open hood. Open side access door (1).
T148322B —UN—26NOV01
2. Push top access door latch (2) inward and open top
access door.
3. Turn battery disconnect switch (4) OFF.
4. Clean debris from battery compartment.
IMPORTANT: Ensure that all cables are reconnected
properly. Note all connections while removing
batteries, to prevent incorrect connections
while installing batteries.
T147883B —UN—09NOV01
5. Disconnect all cables from battery terminals, beginning
with outer battery negative (—) terminal. For each
terminal, lift rubber terminal cover, remove nut, and
remove washer and ring connector(s) from terminal.
Move all cables aside.
6. Remove outer battery from machine, then remove
inner battery.
a. Loosen nuts and washers on mounting bracket
assembly. Remove mounting bracket assembly
from machine.
b. Lift battery from machine through side access door.
7. Install new inner battery. Turn battery so positive (+)
terminal faces front of machine. Install and tighten
mounting bracket assembly.
8. Install new outer battery. Turn battery so negative (—)
terminal faces left side of machine. Install and tighten
mounting bracket assembly.
9. Install all cables, beginning at inner battery positive (+)
terminal. For each terminal, install ring connector(s),
washer, and nut. Pull rubber terminal cover over
terminal.
1— Side Access Door
2— Top Access Door Latch
3— Circuit Breaker Box
4— Battery Disconnect Switch
10. Turn battery disconnect switch ON.
11. Start engine. After bulb check, verify that battery
charge indicator on instrument panel is not lit. Verify
battery voltages on monitor display unit.
TX14740,0000013 -19-27JAN03-1/1
4-1-6
080112
PN=119
Miscellaneous—Machine
Replace Front Turn Signal Bulb, Headlight
Bulb, and Front Park Light Bulb
T143214B —UN—28JUN01
IMPORTANT: Prevent bulb damage. Use a clean
cloth or tissue paper to handle bulbs. If
touched, clean glass thoroughly with rubbing
alcohol and clean, lint-free cloth. DO NOT use
a halogen bulb that is not clean.
1. Remove cap screws (1) and headlight grille (3) from
headlight assembly.
2. Remove screws (2) securing headlight assembly to
fender.
3. Swing headlight assembly out of fender.
1— Cap Screw (2 used)
2— Screw (2 used)
3— Headlight Grille—If
Equipped
OUO1079,00003D3 -19-20JUN01-1/3
4. Replace front turn signal bulb, if necessary:
b. Squeeze tabs (4) and remove front turn signal bulb
from headlight assembly.
c. Install new front turn signal bulb.
d. Connect wire leads.
4— Tab (2 used)
5— Front Turn Signal Bulb
6— Wire Lead (2 used)
Continued on next page
4-1-7
T143218B —UN—28JUN01
a. Disconnect wire leads (6) from front turn signal bulb
(5).
OUO1079,00003D3 -19-20JUN01-2/3
080112
PN=120
Miscellaneous—Machine
5. Replace headlight bulb, if necessary:
a. Disconnect connector (7) from headlight bulb (9).
T143212B —UN—28JUN01
b. Squeeze retaining clips (8) to unfasten. Swing
retaining clips downward.
c. Remove headlight bulb from headlight assembly.
d. Install new headlight bulb.
e. Swing retaining clips upward. Squeeze retaining
clips to fasten.
f. Connect connector to headlight bulb.
6. Replace front park light bulb, if necessary:
a. Disconnect wire leads (11) from front park light bulb
(10).
7— Connector
8— Retaining Clips (2 used)
9— Headlight Bulb
10— Front Park Light Bulb
11— Wire Lead (2 used)
b. Twist front park light bulb counterclockwise to
unfasten. Remove from headlight assembly.
c. Install new front park light bulb. Twist clockwise to
fasten.
d. Connect wire leads to front park light bulb.
8. Install screws to secure headlight assembly to fender.
9. Adjust headlights. See Adjust Headlights in this
section.
10. Install headlight grille and cap screws.
7. Swing headlight assembly into fender.
OUO1079,00003D3 -19-20JUN01-3/3
4-1-8
080112
PN=121
Miscellaneous—Machine
Adjust Headlights
T143221 —UN—14AUG01
1
2
T143221
1— Horizontal Adjustment Screw 2— Vertical Adjustment Screw
The headlights must be adjusted to correct height so that
the operator can safely operate the machine at night or in
poor light conditions.
When properly adjusted, headlight beams are parallel,
angled neither right nor left, and low beams are angled
downward at a 1% grade.
5. Use string line and tape to mark wall at center point
between headlights.
6. Measure left and right on wall and mark wall at centers
of headlights.
1. Verify that the tires are at the correct pressure.
7. Activate low-beam headlights. Turn vertical adjustment
screw (2) to aim each headlight so the center of each
beam is 5 cm (2 in.) lower than the tape mark.
2. Drive machine onto a level surface, directly facing
a vertical wall with frames steered straight. Stop
machine with headlights 5.0 m (16.4 ft) from wall.
8. Activate high-beam headlights. Adjust horizontal
adjustment screw (1) to aim each headlight directly
toward tape mark.
3. Measure width between centers of headlights. Mark
grille with tape at center point.
4. Measure height from ground to center point between
headlights.
OUO1079,00003D4 -19-21JUN01-1/1
4-1-9
080112
PN=122
Miscellaneous—Machine
Replace Backup Light and Work Light—If
Equipped
1. Remove screws (1).
T143353B —UN—28JUN01
2. Remove bezel (2), lamp (3), and rubber seal (4) from
housing (5).
3. Disconnect wire lead (7) from connector (8).
4. Disconnect connector from terminal (6).
5. Remove bezel and rubber seal from lamp. Discard
lamp.
Shown Removed from Machine for Clarity of Photo
6. Install rubber seal and bezel on new lamp.
7. Connect connector to terminal.
1— Screw (2 used)
2— Bezel
3— Lamp
4— Rubber Seal
8. Connect wire lead to connector.
9. Install rubber seal, lamp, and bezel in housing.
5— Housing
6— Terminal
7— Wire Lead
8— Connector
10. Install screws.
11. Adjust position of light for best illumination. If housing
is loose, tighten mounting hardware (not shown).
OUO1079,00003D5 -19-22JUN01-1/1
Replace Tail and Brake Light and Rear Turn
Signal
IMPORTANT: DO NOT use excessive force when
removing lamp, or plastic or rubber may
become damaged.
2. Pry gently around edges of lamp (3) to remove from
rubber seal (4).
3. Disconnect connector (5). Discard lamp.
T147680B —UN—19NOV01
1. Remove cap screws (1) and protective grille (2).
4. Connect connector to new lamp.
5. Install lamp in rubber seal. Index lamp so “TOP”
marking is at top. Push lamp into rubber seal with firm,
even pressure. Ensure that lamp is securely seated.
1— Cap Screws (3 used)
2— Protective Grille
3— Lamp
T143366C —UN—19NOV01
6. Install protective grille and cap screws.
4— Rubber Seal
5— Connector
OUO1043,0000E3F -19-06NOV01-1/1
4-1-10
080112
PN=123
Miscellaneous—Machine
Replace Dome Light Bulb and Circuit Breaker
Compartment Light Bulb
T143363B —UN—28JUN01
IMPORTANT: DO NOT use excessive force
when removing lens cover, or plastic
may become damaged.
1. Pry gently along edges of lens cover to remove.
2. Remove and replace dome light bulb (1) or fuse
compartment light bulb (2).
3. Install lens cover. Push with gentle, even pressure
until lens cover “snaps” into place. Lens cover should
rock back and forth between 3 detent positions.
1— Dome Light Bulb
Lens Cover Removed for Clarity of Photo
2— Circuit Breaker
Compartment Light Bulb
OUO1079,00003D6 -19-22JUN01-1/1
Clean The Machine Regularly
Remove any grease, oil, fuel, or debris build-up to avoid
possible injury or machine damage.
High pressure washing (greater than 1379 kPa (13.8
bar) (200 psi) can damage freshly painted finishes. Paint
should be allowed to air dry for 30 days minimum after
receipt of machine before cleaning with high pressure. Use
low pressure wash operations until 30 days have elapsed.
T6642EJ —UN—18OCT88
IMPORTANT: Directing pressurized water at
electronic/electrical components or connectors,
bearings and hydraulic seals, fuel injection
pumps or other sensitive parts and components
may cause product malfunctions. Reduce
pressure and spray at a 45 to 90 degree angle.
Do not spray oil cooler fins at an angle. Fins may bend.
TX03679,00017E5 -19-06FEB03-1/1
4-1-11
080112
PN=124
Miscellaneous—Machine
Unified Inch Bolt and Screw Torque Values
TS1671 —UN—01MAY03
Bolt or Screw
Size
1/4
5/16
3/8
7/16
SAE Grade 2a
SAE Grade 1
b
c
Lubricatedb
Dry
Lubricated
SAE Grade 5, 5.1 or 5.2
Dryc
Lubricatedb
Dryc
SAE Grade 8 or 8.2
Lubricatedb
Dryc
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
3.7
33
4.7
42
6
53
7.5
66
9.5
84
12
106
13.5
120
17
150
N·m
lb.-ft.
N·m
lb.-ft.
28
20.5
35
26
7.7
13.5
68
120
22
194
N·m
lb.-ft.
9.8
86
12
106
15.5
137
17.5
155
22
194
27
240
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
28
20.5
35
26
44
32.5
lb.-in.
19.5
172
25
221
N·m
lb.-ft.
N·m
lb.-ft.
35
26
44
32.5
49
36
63
46
56
41
70
52
80
59
100
74
1/2
34
25
42
31
53
39
67
49
85
63
110
80
120
88
155
115
9/16
48
35.5
60
45
76
56
95
70
125
92
155
115
175
130
220
165
5/8
67
49
85
63
105
77
135
100
170
125
215
160
240
175
305
225
3/4
120
88
150
110
190
140
240
175
300
220
380
280
425
315
540
400
7/8
190
140
240
175
190
140
240
175
490
360
615
455
690
510
870
640
1
285
210
360
265
285
210
360
265
730
540
920
680
1030
760
1300
960
1-1/8
400
300
510
375
400
300
510
375
910
670
1150
850
1450
1075
1850
1350
1-1/4
570
420
725
535
570
420
725
535
1280
945
1630
1200
2050
1500
2600
1920
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2140
1580
2700
2000
3400
2500
1-1/2
990
730
1250
930
990
730
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
Torque values listed are for general use only, based on the strength of the bolt
or screw. DO NOT use these values if a different torque value or tightening
procedure is given for a specific application. For plastic insert or crimped steel
type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the
tightening instructions for the specific application. Shear bolts are designed to fail
under predetermined loads. Always replace shear bolts with identical grade.
Replace fasteners with the same or higher grade. If higher
grade fasteners are used, tighten these to the strength of the
original. Make sure fastener threads are clean and that you
properly start thread engagement. When possible, lubricate
plain or zinc plated fasteners other than lock nuts, wheel bolts
or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with JDM F13C, 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.
b
DX,TORQ1 -19-12JAN11-1/1
4-1-12
080112
PN=125
Miscellaneous—Machine
Metric Bolt and Screw Torque Values
TS1670 —UN—01MAY03
Bolt or Screw
Size
M6
M8
M10
4.8
8.8
9.8
10.9
12.9
12.9
4.8
8.8
9.8
10.9
12.9
12.9
Class 4.8
Lubricateda
Class 8.8 or 9.8
Dryb
Lubricateda
Class 10.9
Dryb
Lubricateda
Class 12.9
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
4.7
42
6
53
8.9
79
11.3
100
13
115
16.5
146
15.5
137
19.5
172
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
32
23.5
40
29.5
37
27.5
47
35
63
46
80
59
75
55
95
70
11.5
102
14.5
128
22
194
27.5
243
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
29
21
43
32
55
40
lb.-in.
23
204
N·m
lb.-ft.
M12
40
29.5
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14
63
46
80
59
120
88
150
110
175
130
220
165
205
150
260
190
M16
100
74
125
92
190
140
240
175
275
200
350
255
320
235
400
300
M18
135
100
170
125
265
195
330
245
375
275
475
350
440
325
560
410
M20
190
140
245
180
375
275
475
350
530
390
675
500
625
460
790
580
M22
265
195
330
245
510
375
650
480
725
535
920
680
850
625
1080
800
M24
330
245
425
315
650
480
820
600
920
680
1150
850
1080
800
1350
1000
M27
490
360
625
460
950
700
1200
885
1350
1000
1700
1250
1580
1160
2000
1475
M30
660
490
850
625
1290
950
1630
1200
1850
1350
2300
1700
2140
1580
2700
2000
M33
900
665
1150
850
1750
1300
2200
1625
2500
1850
3150
2325
2900
2150
3700
2730
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2770
4750
3500
Torque values listed are for general use only, based on the strength of
the bolt or screw. DO NOT use these values if a different torque value or
tightening procedure is given for a specific application. For stainless steel
fasteners or for nuts on U-bolts, see the tightening instructions for the
specific application. Tighten plastic insert or crimped steel type lock nuts
by turning the nut to the dry torque shown in the chart, unless different
instructions are given for the specific application.
Shear bolts are designed to fail under predetermined loads. Always
replace shear bolts with identical property class. Replace fasteners with
the same or higher property class. If higher property class fasteners are
used, tighten these to the strength of the original. Make sure fastener
threads are clean and that you properly start thread engagement. When
possible, lubricate plain or zinc plated fasteners other than lock nuts,
wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C, 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.
DX,TORQ2 -19-12JAN11-1/1
4-1-13
080112
PN=126
Miscellaneous—Machine
T121289 —19—16SEP99
Imperial and SAE (Inch) Cap Screw and Nut Torque Values
CED,OUO1032,2601 -19-01SEP99-1/1
4-1-14
080112
PN=127
Miscellaneous—Machine
T121288 —19—16SEP99
Metric Cap Screw and Nut Torque Values
CED,OUO1032,2602 -19-01SEP99-1/1
4-1-15
080112
PN=128
Miscellaneous—Machine
Welding on Machine
T147681B —UN—26NOV01
IMPORTANT: Disconnect battery ground strap or turn
battery disconnect switch to OFF to prevent
voltage spikes through alternator or monitor.
To prevent voltage spikes through
microprocessors, disconnect harness
connectors from the following controllers:
• Chassis Control Unit (CCU) (1)
• Transmission Control Unit (TCU) (2)
• Engine Control Unit (ECU) (3)
• Battery Balancer (4)
• Monitor Display Unit (MDU)
Connect welder ground clamp close to
each weld area so electrical current does
not arc inside any bearings.
1— Chassis Control Unit (CCU)
2— Transmission Control Unit
(TCU)
3— Engine Control Unit (ECU)
4— Battery Balancer
OUO1043,0000E29 -19-30OCT01-1/1
4-1-16
080112
PN=129
Miscellaneous—Operational Checkout
Operational Checkout
A location will be required which is level and has adequate
space to complete the checks. No tools or equipment are
needed to perform the checkout.
Use this procedure to check all systems and functions
on the machine. It is designed so you can make a quick
check of machine operation while performing specific
checks from the operator's seat.
Should you experience a problem with the machine, you
will find helpful diagnostic information in this checkout that
will pinpoint the cause. This information may allow you to
perform a simple adjustment which will reduce the down
time of the machine. Use the table of contents to help
find adjustment procedures.
The information provided, after completing the operational
checkout, will allow you to pinpoint a specific test or repair
needed to restore the machine to design specifications.
Complete the necessary visual checks (oil levels, oil
condition, external leaks, loose hardware, linkage, wiring,
etc.) prior to doing the checkout. The machine must be at
operating temperature for many of the checks.
Start at the top of the left column and read completely
down column before performing check. Follow this
sequence from left to right. In the far right column, if
no problem is found, you will be instructed to go to next
check. If a problem is indicated, you will be referred either
to a section in this manual for a specific procedure or to
your authorized dealer.
OUO1043,0000E2A -19-30OCT01-1/15
Operator Station Checks—Key Switch ON, Engine Stopped
OUO1043,0000E2A -19-30OCT01-2/15
Gauges and Indicator
Lights Check
T144013B —UN—17JUL01
1— ON Position
With battery disconnect switch ON, turn key switch to ON position (1).
LOOK/LISTEN: Does the following happen?
• All indicators light or flash.
• All gauges and speedometer move to center position.
• All segments of MDU LCDs will display.
• All segments of transmission control LED display and mode button indicator will light.
• Warning alarm sounds.
YES: Go to next check.
NOTE: Warning alarm will sound until air pressure reaches normal operating pressure. NO: Check circuit
breakers. Reset if tripped.
Cold start indicator will remain lit for a maximum of 20 seconds in
low ambient temperature conditions.
LOOK/LISTEN: After 3 seconds, do all gauges, LCD and LED displays return to normal IF OK: Check indicator
operation mode and warning alarm silences? Do all indicators, except for secondary
bulbs. Replace if necessary.
steering (marked emergency steering), battery charge and park brake indicators go out?
Air pressure indicator may also remain lit, depending on system air pressure. Cold start IF OK: See your authorized
indicator may also remain lit, depending on ambient temperature.
dealer.
OUO1043,0000E2A -19-30OCT01-3/15
Operator Station Checks—Key Switch ON, Engine Running
Continued on next page
4-2-1
OUO1043,0000E2A -19-30OCT01-4/15
080112
PN=130
Miscellaneous—Operational Checkout
Key Switch Start Check
T144013C —UN—26JUL01
1— OFF Position
2— ON Position
3— START Position
Turn key switch to ON position (2).
Turn key switch to START position (3).
IMPORTANT: DO NOT hold start switch for more than 17 seconds. If the
engine does not start during this period, turn key switch to OFF
position (1). Wait 1 minute and try again.
YES: Go to next check.
LISTEN: Starter motor will start the engine.
NO: Check battery
disconnect switch.
Run engine for a few seconds then turn key switch to OFF position.
NO: Check battery.
LISTEN: Engine must stop immediately when key switch is turned OFF.
NO: See your authorized
dealer.
Continued on next page
4-2-2
OUO1043,0000E2A -19-30OCT01-5/15
080112
PN=131
Miscellaneous—Operational Checkout
Gauges and Indicators
Checks
6
1
3
BATTERY
CHARGE
EMERGENCY
STEERING
ENGINE
FAULT
COOLANT
LEVEL
COLD
START
PARK
BRAKE
BRAKE
PRESSURE
BRAKE
TEMP
n/min
RETARDER
TRANSMISSION
FAULT
ENGINE OIL
PRESSURE
888888888888
30
COOLANT
TEMP
20
40
60
30
mph
10
INTER-AXLE
DIFF LOCK
AUTO
8888
40
70
0
TRANS OIL
TEMP
8
50
km/h
20
10
AIR
PRESSURE
BIN
UP
DIFF
LOCK
MENU
BACK
n/min
50
NEXT
80
0
HYDRAULIC
TEMP
88888
FUEL
88888.8
SELECT
volts
MILES / Km
4
5
2
T144018
T144018 —UN—21AUG01
1— Park Brake Indicator
2— RPM Display of MDU
3— Engine Oil Pressure Gauge
4— Air Pressure Gauge
5— Transmission Oil Temperature Gauge
6— Coolant Temperature Gauge
Start the engine.
NOTE: Warning alarm will sound until air pressure reaches normal operating pressure.
Transmission temperature gauge (5) will not begin to indicate temperature
until transmission temperature is close to operating temperature.
LOOK: Do all the indicators, except park brake indicator (1), go out after the engine
starts?
LOOK: Does the MDU display engine RPM (2)?
Observe engine oil pressure gauge (3).
LOOK: Does needle of gauge indicate pressure is increasing to normal (green)?
Observe air pressure gauge (4) immediately after the engine is started.
LOOK: Does needle of gauge indicate pressure is increasing to normal (green)?
Observe coolant temperature gauge (6) immediately after the engine is started.
YES: Go to next check.
LOOK: Does needle of gauge indicate temperature is increasing to normal (green)?
NO: See your authorized
dealer.
OUO1043,0000E2A -19-30OCT01-6/15
Brake Accumulator Check Ensure brake accumulators are fully charged by pressing brake pedal repeatedly to
make pump recharge accumulators several times.
Stop pumping during a recharge cycle to ensure brakes are not using oil after pump
stops.
Stop engine.
Turn key switch to ON position and wait until warning indicator goes out.
Press brake pedal repeatedly. Count the number of applications the brake pedal is
pressed before brake pressure indicator lights.
YES: Start machine and go
to next check.
FEEL/LOOK: Does machine allow 8 full applications before brake pressure indicator
lights?
NO: See your authorized
dealer.
Continued on next page
4-2-3
OUO1043,0000E2A -19-30OCT01-7/15
080112
PN=132
Miscellaneous—Operational Checkout
Service Brake Check
NOTE: Perform this check in an open area where machine can travel at full speed.
Drive machine slowly.
Push brake pedal to stop machine.
Release brake pedal.
LOOK/FEEL: Does brake pedal push easily without binding?
LOOK/FEEL: Does brake pedal return to the released position so brakes are not
dragging?
LOOK/FEEL: Do brakes stop machine in a reasonable distance without pulling to one
side or making noises?
Operate machine at full speed.
Release accelerator and apply service brakes to stop machine.
YES: Go to next check.
LOOK/FEEL: Do brakes stop machine in a reasonable distance without pulling to one
side or making noises?
NO: See your authorized
dealer.
OUO1043,0000E2A -19-30OCT01-8/15
Park Brake Check
CAUTION: Machine will stop abruptly during this check. Fasten
seat belt. Perform check in an open area.
NOTE: Park brake will not release if air pressure is below 410 kPa (4.1 bar) (60 psi).
T147682B —UN—19NOV01
1— Park Brake Lever
Start engine.
Lift park brake lever (1) and move forward.
NOTE: Park brake will apply at any speed. Apply only when moving slowly.
Drive machine at slow idle in 1st gear.
With machine moving 5 km/h (3 mph) or less, pull park brake lever rearward until it
locks into position.
YES: Continue check.
FEEL: Does park brake indicator come ON, park brake engage and machine stop?
NO: See your authorized
dealer.
With the engine running, transmission in neutral (N) and park brake ON, lift park brake
lever and move forward.
Shift transmission to drive (D).
Slowly increase engine speed.
LOOK/FEEL: Does machine move when engine speed is just above slow idle?
Return engine to slow idle.
YES: Go to next check.
Shift transmission to neutral (N).
NO: See your authorized
dealer.
Continued on next page
4-2-4
OUO1043,0000E2A -19-30OCT01-9/15
080112
PN=133
Miscellaneous—Operational Checkout
Steering Check
Move machine to an open area and park on a hard, level surface.
Turn inter-axle lock switch to OFF position.
Release park brake.
Release service brakes.
Run engine at slow idle.
Turn steering wheel fully left then fully right.
YES: Continue with check.
FEEL: Does machine turn both directions smoothly?
NO: If steering is jerky or
steering wheel is hard to
turn, see your authorized
dealer.
Run engine at fast idle.
Turn steering wheel fully left then fully right.
YES: Go to next check.
FEEL: Does machine turn both directions smoothly?
NO: If steering is jerky or
steering wheel is hard to
turn, see your authorized
dealer.
OUO1043,0000E2A -19-30OCT01-10/15
Dump Body Raise and
Lower Checks
CAUTION: Ensure there is at least 7.6 m (25 ft) clearance above machine.
DO NOT perform this check within 4 m (13.1 ft) of a high voltage power line.
T144028B —UN—17JUL01
1— Dump Body Control Lever
Perform this check in an open area away from other people.
Position the machine straight.
CAUTION: Clear all personnel from behind machine. Some material
may slide out of dump body as it is raised.
CAUTION: Ensure area above dump body is clear of obstructions and power
lines. Height of raised dump body is 7226 mm (23 ft 8.5 in.).
Ensure the dump body is empty.
Operate the engine at 1500 rpm.
Pull dump body control lever rearward to raise dump body.
When dump body is almost completely up, reduce engine speed to slow idle.
YES: Continue check.
LOOK: Does dump body raise to full height smoothly?
NO: See your authorized
dealer.
Release dump body control lever.
YES: Continue check.
LOOK/FEEL: Does dump body control lever return to neutral position?
NO: See your authorized
dealer.
Push dump body control lever to full forward detent dump body float position and
release lever.
LOOK/FEEL: Does control lever return to neutral position?
YES: Go to next check.
LOOK: Does dump body lower to full down position smoothly?
NO: See your authorized
dealer.
Continued on next page
4-2-5
OUO1043,0000E2A -19-30OCT01-11/15
080112
PN=134
Miscellaneous—Operational Checkout
YES: Continue with check.
Lights Check
T147683B —UN—09NOV01
T147684B —UN—09NOV01
1— Front Turn Indicator Light (2 used)
2— Front Parking Light (2 used)
3— Headlight (2 used)
4— Rear Turn Indicator Light (2 used)
5— Tail, Brake and Parking Light (2 used)
6— Backup Light (2 used)
Push lower half of headlight switch to first ON position.
LOOK: Are front parking lights (2) and tail, brake and parking lights (5) ON?
NO: See your authorized
dealer.
Push lower half of headlight switch to second position ON.
YES: Continue with check.
LOOK: Are headlights (3) ON?
NO: See your authorized
dealer.
Push steering column lever forward.
YES: Continue with check.
LOOK: Are high beam headlights and high beam indicator ON?
NO: See your authorized
dealer.
With headlight switch in the OFF position, have a helper push the brake pedal.
YES: Continue with check.
LOOK: Are tail, brake and parking lights (5) ON?
NO: See your authorized
dealer.
NOTE: Hazard lights will operate with the key switch in OFF position.
Press lower half of hazard switch.
YES: Continue with check.
LOOK: Do turn indicators (1 and 4) flash?
NO: See your authorized
dealer.
CAUTION: Perform check in an open area. Machine may move unexpectedly.
Park brake ON.
Push and hold service brake.
Shift transmission into reverse (R).
Have a helper look at backup lights (6).
YES: Go to next check.
LOOK: Are backup lights ON?
NO: See your authorized
dealer.
OUO1043,0000E2A -19-30OCT01-12/15
Miscellaneous Checks
Continued on next page
4-2-6
OUO1043,0000E2A -19-30OCT01-13/15
080112
PN=135
Miscellaneous—Operational Checkout
Dump Body Warming
System Check—If
Equipped
YES: Go to next check.
CAUTION: Engine exhaust flows through tubes in sides of
dump body. Tubes may be hot.
Check dump body warming system.
NO: Check to see that
tubes aren't plugged.
FEEL: Do tubes in sides of dump body warm as engine temperature increases to
normal?
NO: See your authorized
dealer.
OUO1043,0000E2A -19-30OCT01-14/15
Service Decal Check
Check all service and safety decals, ensure they are in place and in readable condition. YES: Operational checkout
complete.
NO: Replace safety
decals. See your authorized
dealer.
OUO1043,0000E2A -19-30OCT01-15/15
4-2-7
080112
PN=136
Miscellaneous—Troubleshooting
Using Troubleshooting Charts
Step 1. Operational Checkout Procedure.
NOTE: Troubleshooting charts are arranged from the
most likely, simplest to verify, to least likely, more
difficult to verify. When diagnosing a problem,
use all possible means to isolate the problem to
a single component or system. Use the following
steps to diagnose problems:
Step 2. Troubleshooting charts.
Step 3. Adjustments.
Step 4. See your authorized dealer.
CED,TX14740,6388 -19-21APR99-1/1
4-3-1
080112
PN=137
Miscellaneous—Troubleshooting
Engine
Symptom
Problem
Solution
Starter Motor Turns Engine Too
Slowly
Battery undercharged
Check battery charge. Charge or
replace battery.
Loose or dirty battery terminals
Tighten or clean battery terminals.
Faulty engine ground connection
Repair, clean or tighten the
connection.
Incorrect grade of engine oil
Change oil.See Change Engine Oil
and Replace Filter. (Section 3-6.)
Engine Hard Starting when Cold
Engine starter motor turns engine too Check battery charge. Charge or
slowly
replace battery.
Incorrect use of cold start function
Instruct operator on correct use.
Engine Turns, but Does Not Start
Insufficient fuel in fuel tank
Fill fuel tank and bleed fuel system.
See Bleeding Fuel System. (Section
3-6.)
Engine Difficult to Start (Hot or
Cold)
Starter motor turns too slowly
Check the battery charge. Charge or
replace battery.
Air in fuel system
Bleed fuel system. See Bleeding Fuel
System. (Section 3-6.)
Restricted air inlet
Service air filter system. See Service
Engine Air Intake System. (Section
3-3.)
Restricted exhaust system
Locate and repair restriction.
Engine Cuts Out Soon After Starting Insufficient fuel in fuel tank
Engine Overheating
Fill fuel tank and bleed fuel system.
See Bleeding Fuel System. (Section
3-6.)
Air in fuel system
Bleed fuel system. See Bleeding Fuel
System (Section 3-6.)
Blocked fuel tank air vent
Clean air vent and bleed fuel system.
See Bleeding Fuel System (Section
3-6.)
Blocked fuel filters
Replace fuel filters. See Replace Final
Fuel Filter. (Section 3-6.)
Air filter restriction
Service air filter system. See Service
Engine Air Intake System. (Section
3-3.)
Engine coolant level too low
Fill radiator. See Check Engine
Coolant Level. Section 3-4.)
Continued on next page
4-3-2
OUO1043,0000E2B -19-30OCT01-1/3
080112
PN=138
Miscellaneous—Troubleshooting
Symptom
Problem
Solution
Drive belt slipping
Inspect, adjust or replace drive belt.
See Inspect Serpentine Belt. (Section
4-1.)
Radiator cap not sealing or worn
Replace cap.
Blocked radiator
Clean radiator. See Inspect and Clean
Cooling Systems. (Section 3-3.)
Air intake is blocked
Clean as necessary.
Engine Knocking
Incorrect fuel grade
Drain and refill. See Bleeding Fuel
System. (Section 3-6.)
Loss of Power
Air filter restriction
Service air filter system. See Service
Engine Air Intake System. (Section
3-3.)
Excessive Fuel Consumption
External fuel tank leak
Check fuel tank, fuel lines and filter
for leaks and/or damage. See your
authorized dealer.
Low operating temperature
Check and repair cooling system. See
Check Engine Coolant Level. (Section
3-4.)
Air filter restriction
Service air filter system. See Service
Engine Air Intake System. (Section
3-3.)
Low Engine Oil Pressure
Incorrect grade of oil used
See Fuels and Lubricants section.
Abnormal Oil Consumption
Engine overfilled
Drain to proper level. Check drained
oil to ensure there are no other oils in
oil.
Engine oil leaks
Locate and repair oil leaks.
Incorrect grade of engine oil
See Fuels and Lubricants section.
Engine oil level too low
Fill to correct level. See Check Engine
Oil Level. (Section 3-4.)
Oil Pressure Too High
Incorrect engine oil used
Drain engine sump. See Change
Engine Oil and Replace Filter.
(Section 3-6.)
Engine Oil Sludge
Incorrect grade of oil used
Drain engine sump. See Change
Engine Oil and Replace Filter(Section
3-6.)
Engine operating temperature too
high or too low
Check and correct cooling system.
Continued on next page
4-3-3
OUO1043,0000E2B -19-30OCT01-2/3
080112
PN=139
Miscellaneous—Troubleshooting
Symptom
Problem
Solution
Oil in service for too long
Change oil and oil filters. See Change
Engine Oil and Replace Filter.
(Section 3-6.)
Loose components (e.g., alternator,
etc.)
Tighten all components including
engine mounts and exhaust system.
Worn or damaged engine mountings
Check and replace engine mounting.
Air inlet system restricted
Service and repair inlet system. See
Service Engine Air Intake System.
(Section 3-3.)
Incorrect grade of fuel
Drain and fill fuel tank. See Bleeding
Fuel System. (Section 3-6.)
Blue Smoke from Exhaust
Engine oil level too high
Drain to correct level.
White Smoke from Exhaust
Engine running too cold
Check cooling system.
Water in fuel supply
Clean fuel system. See Bleeding Fuel
System . (Section 3-6.)
Excessive Vibration at Any Speed
Black Smoke from Exhaust
OUO1043,0000E2B -19-30OCT01-3/3
Transmission
Symptom
Problem
Solution
Low Clutch Pressure
Low oil level
Fill transmission. See Check
Transmission Oil Level. (Section 3-4.)
Low Converter Charging Pump
Output
Low oil level
Fill transmission. See Check
Transmission Oil Level. (Section 3-4.)
Suction screen blocked
Clean suction screen.
Low oil level
Fill transmission. See Check
Transmission Oil Level. (Section 3-4.)
Transmission Overheats
OUO1043,0000DDB -19-08AUG01-1/1
4-3-4
080112
PN=140
Miscellaneous—Troubleshooting
Axle
Symptom
Problem
Solution
Final Drive Leaking Oil
Loose or damaged oil plugs
Tighten or replace oil plugs.
Oil level too high
Drain oil to correct level.
Final drive bolts loose
Tighten final drive bolts to correct
torque.
Axle breather blocked
Check axle breather
Noisy Final Drive
Low oil level in final drive
Fill final drive. See Check Axle Oil
Levels. (Section 3-7.)
Final Drive Overheating
Oil level too high
Drain oil to correct level.
Oil level too low
Fill final drive.See Check Axle Oil
Levels (Section 3-7.)
Differential Assembly Leaking Oil
Bolts loose on main housing
Tighten bolts to correct torque.
Differential Assembly Noisy
Oil level too low
Fill the differential. See Check Axle
Oil Levels (Section 3-7.)
Differential Assembly Overheating
Oil level too high
Drain oil to correct level.
Oil level too low
Fill the differential. See Check Axle
Oil Levels (Section 3-7.)
Axle breather blocked
Clean axle breather. (See
Clean, Inspect, and Replace
Breathers—Transmission, Transfer
Case, and Axles in Maintenance—As
Required section.)
OUO1043,0000E2C -19-30OCT01-1/1
4-3-5
080112
PN=141
Miscellaneous—Troubleshooting
Tires
Symptom
Problem
Solution
Tires Wearing in Tread Center
Tires over-inflated
Reduce tire pressure to correct level.
See Inspect Tires, Check Pressure.
(Section 3-3,)
Tires Wearing on Both Sides of
Tread
Tires under-inflated
Reduce tire pressure to correct level.
See Inspect Tires, Check Pressure
(Section 3-3.)
Rapid Tire Wear
Excessive speed
Follow proper safe driving procedures.
Poor road surface conditions
Recommend road surface
maintenance.
Excessive speed
Follow proper safe driving procedures.
Tire Component Heat Separation
OUO1043,0000DD9 -19-08AUG01-1/1
Brakes
Symptom
Problem
Solution
Poor or No Service Brakes
Service Brake Pedal
Check brake pedal for obstructions
around and under pedal. Check that
pedal can be pushed to the end of its
stroke and it returns to the released
position.
Worn brake pads
Replace brake pads.
Service Brake Pads and Disks
Wearing Excessively
Driving technique—constantly using
service brakes to slow machine.
Allow torque retarder to slow the
machine.
Increased Stopping Distance
Worn brake pads
Replace brake pads.
Oil or grease on brake pads
Replace brake pads.
Squealing Noise from Brakes when Brake pads glazed
Applied
Brake disks warped or scored
Replace brake pads.
Brakes Do Not Fully Release
Replace brake caliper.
Brake caliper pistons sticking
Inspect brake disks for damage.
TX14740,000000C -19-27JAN03-1/1
4-3-6
080112
PN=142
Miscellaneous—Troubleshooting
Hydraulic System
Symptom
Problem
Solution
Pump Not Delivering Hydraulic Oil
Hydraulic oil level in reservoir is too
low
Fill hydraulic reservoir. See Check
Hydraulic Oil Level. (Section 3-4.)
Outlet hose from tank to pump is
blocked
Check suction strainer for blockages.
Clean if necessary.
Hydraulic oil viscosity and type is
incorrect
Drain and fill hydraulic system. See
Change Hydraulic Oil. (Section 3-9.)
Pump intake is partially blocked
Check suction strainer for blockages.
Clean if necessary.
Breather is blocked
Replace breather filter. See Replace
Hydraulic Reservoir Breather.
(Section 3-9.)
Pump Making Noise
OUO1043,0000E2E -19-30OCT01-1/1
Instruments and Controls
Symptom
Problem
Solution
Gauge Not Working Properly
Circuit breaker tripped
Investigate cause and correct problem.
Switch Not Working Properly
Circuit breaker tripped
Investigate cause and correct problem.
Warning Light Not Working
Warning light bulb
Replace bulb.
Circuit breaker tripped
Investigate cause and correct problem.
OUO1043,0000DD6 -19-08AUG01-1/1
4-3-7
080112
PN=143
Miscellaneous—Troubleshooting
Electrical System
Symptom
Problem
Solution
Indicator light bulb
Alternator Charge Indicator Does
Not Illuminate when Master Switch
Is in ON Position
Poor battery connections
Alternator Charge Indicator
Illuminated when Engine Is ON
Battery cells dry
Batteries Do Not Hold Charge
Replace bulb.
Clean and check battery connections.
Check battery electrolyte level. Add
water, if necessary.
Short running time with lights on
Remove batteries and charge or
replace.
Batteries are low on charge
Charge or replace batteries
Batteries defective or damaged
Replace batteries.
Battery terminals loose or damaged
Tighten or clean battery terminals.
Circuit breaker tripped
Investigate and correct problem.
Headlight bulb defective
Replace bulb. See Replace Front
Turn Signal Bulb, Headlight Bulb, and
Front Park Light Bulb. (Section 4-1.)
Only High Beam or Low Beam
Comes On
Headlight bulb defective
Replace bulb. See Replace Front
Turn Signal Bulb, Headlight Bulb, and
Front Park Light Bulb (Section 4-1.)
One Headlight Does Not Come On
(High or Low Beam)
Headlight bulb defective
Replace bulb. See Replace Front
Turn Signal Bulb, Headlight Bulb, and
Front Park Light Bulb. (Section 4-1.)
High Beam Indicator Light Does
Not Come On when High Beam Is
Selected
Indicator bulb defective
Replace bulb. See Replace Front
Turn Signal Bulb, Headlight Bulb, and
Front Park Light Bulb. (Section 4-1.)
Tail Lights Do Not Come On
Tail light bulb defective
Replace bulb. See Replace Tail and
Brake Light and Rear Turn Signal.
(Section 4-1.)
Stop Lights Do Not Come On
Stop light bulb defective
Replace bulb. See Replace Tail and
Brake Light and Rear Turn Signal
(Section 4-1.)
Turn Signal and Horn Do Not Work
Circuit breaker tripped
Investigate and correct cause.
Right Turn Signal Does Not Work
Turn signal light bulb defective
Replace bulb. See Replace Tail and
Brake Light and Rear Turn Signal
(Section 4-1.)
Starter Motor Does Not Turn or
Turns Very Slowly
Headlights Do Not Work
Continued on next page
4-3-8
OUO1043,0000DD5 -19-08AUG01-1/2
080112
PN=144
Miscellaneous—Troubleshooting
Symptom
Problem
Solution
Left Turn Signal Does Not Work
Turn signal light bulb defective
Replace bulb. See Replace Tail and
Brake Light and Rear Turn Signal.
(Section 4-1.)
Windshield Wiper Does Not Work
Circuit breaker tripped
Investigate and correct cause.
OUO1043,0000DD5 -19-08AUG01-2/2
Rear Frame and Cab
Symptom
Problem
Solution
Excessive Cab Movement while
Machine Is Operating
Loose or missing mounting bolt(s) or
mounts
Tighten or replace mounting bolts or
mounts.
A Smear Remains on the
Windshield when the Windshield
Wiper Is in Operation
Wiper blade damaged
Replace the wiper blade.
Oil or grease on windshield
Clean windshield
Obstruction in seat runner
Remove obstruction.
Lack of lubricant
Lubricate seat runners.
Seat Is Difficult to Adjust
Loose or missing retaining bolts
Excessive Movement of the Wing
Mirrors while Machine Is Operating
Damaged wing mirror arm
Wing Mirror Difficult to View
Tighten or replace retaining bolts.
Replace wing mirror arm.
Incorrect adjustment
Adjust as necessary.
Wing mirror cracked
Replace mirror.
NOTE: If any other problems are encountered which
require special tools or machine knowledge,
see your authorized dealer.
OUO1043,0000DD4 -19-08AUG01-1/1
4-3-9
080112
PN=145
Miscellaneous—Troubleshooting
MDU Displayed Service Codes
T146103B —UN—05OCT01
The MDU displayed service codes are shown as a
combination of two numbers, one above the other, on the
data display. In the MDU Displayed Service Codes table,
the two numbers will be shown separated by a decimal
point, with the first number being the bottom number (2)
on the data display and the second number being the top
number (1) on the data display. For example, the service
code shown in the figure would be shown in the table as
1702.4.
1— Top Number
Continued on next page
4-3-10
2— Bottom Number
TX14740,0000001 -19-24JAN03-1/4
080112
PN=146
Miscellaneous—Troubleshooting
MDU Displayed Service Codes
Service
Code
Service Code Name
Engine Control Unit (ECU) Codes
91.3
Primary Throttle Input Voltage High
91.4
Primary Throttle Input Voltage Low
91.8
Primary Throttle has Abnormal Pulse Width or Frequency
94.3
Fuel Rail Pressure Voltage High
94.4
Fuel Rail Pressure Voltage Low
94.10
Fuel Rail Pressure Dropping Too Fast
94.17
At Starting, 10 Mpa of Rail Pressure Not Attained After
Cranking Engine a Short Time.
97.3
Water in Fuel Voltage High
97.4
Water in Fuel Voltage Low
97.31
Water in Fuel
100.1
Engine Oil Pressure Extremely Low
100.3
Engine Oil Pressure Input Voltage High
100.4
Engine Oil Pressure Input Voltage Low
105.3
Manifold Air Temperature Voltage High
105.4
Manifold Air Temperature Voltage Low
105.16
Manifold Air Temperature Voltage High—Moderately
Severe
110.0
Engine Coolant Temperature Extremely High
110.3
Engine Coolant Temperature Input Voltage High
110.4
Engine Coolant Temperature Input Voltage Low
110.16
Engine Coolant Temperature Moderately High
158.17
ECU Cannot Power Down
174.3
Fuel Temperature Input Voltage High
174.4
Fuel Temperature Input Voltage Low
174.16
Fuel Temperature Moderately High
190.0
Engine Overspeed
611.3
Short-To-Battery on Injector Lines
611.4
Short-To-Ground on Injector Lines
620.3
Accelerator Pedal Position Sensor Input Voltage High
620.4
Accelerator Pedal Position Sensor Input Voltage Low
627.1
All Injector Currents Are Out of Specification
629.13
Engine Control Unit (ECU) Internal Malfunction
636.2
Noise Detected On Engine Position Sensor in High
Pressure Pump
636.8
Missing Signal From Engine Position Sensor in High
Pressure Pump
636.10
Signal From Engine Position Sensor in High Pressure
Pump Does Not Have Proper Pulse Pattern
637.2
Noise Detected On Engine Position Sensor on Crank
Shaft
637.7
Relationship Between the Two Engine Position Signals
is Incorrect
637.8
Missing Signal From Engine Position Sensor on Crank
Shaft
637.10
Signal From Engine Position Sensor on Crank Shaft
Does Not Have Proper Pulse Pattern
639.13
CAN Data Link Malfunction
651.5
Current to the Injector in Cylinder #1 is Less Than
Expected
651.6
Current to the Injector in Cylinder #1 Increases Too
Rapidly
651.7
Injector Fuel Flow at Cylinder #1 is Less Than Expected
652.5
Current to the Injector in Cylinder #2 is Less Than
Expected
652.6
Current to the Injector in Cylinder #2 Increases Too
4-3-11
Rapidly
652.7
Injector Fuel Flow at Cylinder #2 is Less Than Expected
Continued on next page
TX14740,0000001 -19-24JAN03-2/4
080112
PN=147
Miscellaneous—Troubleshooting
Continued on next page
4-3-12
TX14740,0000001 -19-24JAN03-3/4
080112
PN=148
Miscellaneous—Storage
Prepare Machine for Storage
1. Repair worn or damaged parts. Install new parts, if
necessary, to avoid needless delays later.
2. Wash the machine. [Use low pressure wash
operations (less than 1379 kPa (13.8 bar) (200 psi)
until 30 days after receipt of machine.] Paint areas to
prevent rust. Replace decals, where needed.
3. Fill fuel tank, to prevent condensation.
4. Park machine on a hard surface to prevent tires from
freezing to ground.
IMPORTANT: LPS 3 ® Rust Inhibitor can destroy
painted finish. DO NOT spray LPS 3 Rust
Inhibitor on painted surfaces.
5. Fully lower dump body. Install articulation safety lock
bar. Coat exposed steering cylinder rods with LPS
3 Rust Inhibitor.
T5813AM —UN—09FEB89
IMPORTANT: High pressure washing [greater than
1379 kPa (13.8 bar) (200 psi)] can damage freshly
painted finishes. Paint should be allowed to
air dry for 30 days minimum after receipt of
machine before cleaning parts or machine
with high pressure. Use low pressure wash
operations until 30 days have elapsed.
7. Remove batteries.
8. Store machine in a dry, protected place. If stored
outside, cover with a waterproof material.
IMPORTANT: Prevent possible machine damage
from unauthorized persons operating
machine. Attach a "DO NOT OPERATE"
tag to steering wheel.
9. Put a "DO NOT OPERATE" tag on the steering wheel.
10. Close all vent louvers in the cab.
11. Remove keys and lock all covers and doors.
6. Apply grease at all lubrication fittings.
LPS 3 Rust Inhibitor is manufactured by Holt Lloyd Corporation.
OUO1079,0000415 -19-23JUL01-1/1
4-4-1
080112
PN=149
Miscellaneous—Serial Numbers
Record Product Identification Number (PIN)
PIN (1)
Purchase Date
T147685B —UN—15NOV01
NOTE: Record all 13 characters of the Product
Identification Number.
OUO1043,0000E30 -19-30OCT01-1/1
Record Engine Serial Number
T147686B —UN—15NOV01
Engine Serial Number (1)
OUO1043,0000E31 -19-30OCT01-1/1
Record Transmission Serial Number
T147687B —UN—15NOV01
Transmission Serial Number (1)
OUO1043,0000E32 -19-30OCT01-1/1
4-5-1
080112
PN=150
Miscellaneous—Serial Numbers
Front Axle Serial Number
T147688B —UN—15NOV01
Front Axle Serial Number (1)
OUO1043,0000E33 -19-30OCT01-1/1
Middle Axle Serial Number
T147689B —UN—15NOV01
Middle Axle Serial Number (1)
OUO1043,0000E34 -19-30OCT01-1/1
Rear Axle Serial Number
T147690B —UN—15NOV01
Rear Axle Serial Number (1)
OUO1043,0000E35 -19-30OCT01-1/1
4-5-2
080112
PN=151
Miscellaneous—Specifications
250D Articulated Dump Truck Specifications
7
10
11
1
6
2
3
8
5
12
4
16
14
15
17
13
18
19
23
20
21
24
9
T147691
Continued on next page
4-6-1
T147691 —UN—13NOV01
22
MD04263,00000C4 -19-30JAN09-1/3
080112
PN=152
Miscellaneous—Specifications
1— Height, Machine
Overall—Dumped
2— Height, Top of Dump Body
Side—Lowered
3— Height, Dump Body
Lip—Lowered
4— Height, Dump Body
Lip—Dumped
5— Clearance, Articulation
Pivot-to-Ground
6— Height, Machine
Overall—Lowered
7— Angle, Maximum Dump Body
8— Angle, Maximum Approach
9— Angle, Maximum Articulation
10— Length, Dump Body Overall
11— Length, Maximum Dump
Body Load
12— Protrusion, Dump Body
Rear Edge
13— Length, Dump Body
Lip-to-Rear Axle
Centerline—Lowered
14— Length, Rear Axle
Centerline-to-Middle Axle
Centerline
15— Length, Middle Axle
Centerline-to-Front Axle
Centerline—Articulation
Frames Straightened
NOTE: Specifications and design subject to change
without notice. Whenever applicable, specifications
are in accordance with SAE standards. Except
Item
16— Length, Articulation
Pivot-to-Front Axle
Centerline
17— Length, Front Axle
Centerline-to-Front of
Machine
18— Length, Machine
Overall—Lowered,
Articulation Frames
Straightened
19— Width, Dump Body Overall
20— Clearance, Minimum
Tire-to-Tire
21— Width, Tire Tread
Centerline-to-Tire Tread
Centerline
22— Width, Tires Overall
23— Radius, Inside Turning
24— Radius, Outside Turning
where otherwise noted, specifications are based on
a machine equipped with all standard equipment,
79 kg (175 lb) operator, and full fuel tank.
Measurement
Specification
1—Machine Overall—Dumped
Height
6128 mm
20 ft 1 in.
2—Top of Dump Body
Side—Lowered
Height
2629 mm
8 ft 7 in.
3—Dump Body Lip—Lowered
Height
1897 mm
6 ft 3 in.
4—Dump Body Lip—Dumped
Height
588 mm
1 ft 1 in.
5—Articulation Pivot-to-Ground
Clearance
447 mm
1 ft 6 in.
6—Machine Overall—Lowered
Height
3556 mm
11 ft 8 in.
7—Maximum Dump Body
Angle
70°
8—Maximum Approach
Angle
30°
9—Maximum Articulation
Angle
45°
10—Dump Body Overall
Length
5390 mm
17 ft 8 in.
11—Maximum Dump Body Load
Length
5242 mm
16 ft 10 in.
12—Dump Body Rear Edge
Protrusion
509 mm
1 ft 8 in.
13—Dump Body Lip-to-Rear Axle
Centerline—Lowered
Length
1316 mm
4 ft 4 in.
14—Rear Axle Centerline-toMiddle Axle Centerline
Length
1670 mm
5 ft 8 in.
15—Middle Axle Centerline-toFront Axle Centerline—Articulation
Frames Straightened
Length
4177 mm
13 ft 8 in.
16—Articulation Pivot-to-Front Axle Length
Centerline
1363 mm
4 ft 5 in.
250D Articulated Dump Truck
Dimensions
Continued on next page
4-6-2
MD04263,00000C4 -19-30JAN09-2/3
080112
PN=153
Miscellaneous—Specifications
Item
Measurement
Specification
17—Front Axle Centerline-to-Front
of Machine
Length
2337 mm
7 ft 8 in.
18—Machine Overall—Lowered,
Articulation Frames Straightened
Length
9501 mm
31 ft 2 in.
19—Dump Body Overall
Width
2758 mm
9 ft 1 in.
20—Minimum Tire-to-Tire
Clearance
1570 mm
5 ft 2 in.
21—Tire Tread Centerline-to-Tire
Tread Centerline
Width
2225 mm
7 ft 4 in.
22—Tires Overall
Width
2880 mm
9 ft 5 in.
23—Inside Turning
Radius
4167 mm
13 ft 8 in.
24—Outside Turning
Radius
7935 mm
26 ft
250D Articulated Dump Truck
Weight
20 400 kg
44 500 lb
250D Dump Body—Dump
Cycle Time
11.9 seconds
250D Dump Body—Lower
Cycle Time
6 seconds
250D Specifications
MD04263,00000C4 -19-30JAN09-3/3
4-6-3
080112
PN=154
Miscellaneous—Specifications
4-6-4
080112
PN=155
Miscellaneous—Specifications
300D Articulated Dump Truck Specifications
7
10
11
1
6
2
3
8
5
12
4
16
14
15
17
13
18
19
23
20
21
24
9
T147691
Continued on next page
4-6-5
T147691 —UN—13NOV01
22
MD04263,00000C5 -19-30JAN09-1/3
080112
PN=156
Miscellaneous—Specifications
1— Height, Machine
Overall—Dumped
2— Height, Top of Dump Body
Side—Lowered
3— Height, Dump Body
Lip—Lowered
4— Height, Dump Body
Lip—Dumped
5— Clearance, Articulation
Pivot-to-Ground
6— Height, Machine
Overall—Lowered
7— Angle, Maximum Dump Body
8— Angle, Maximum Approach
9— Angle, Maximum Articulation
10— Length, Dump Body Overall
11— Length, Maximum Dump
Body Load
12— Protrusion, Dump Body
Rear Edge
13— Length, Dump Body
Lip-to-Rear Axle
Centerline—Lowered
14— Length, Rear Axle
Centerline-to-Middle Axle
Centerline
15— Length, Middle Axle
Centerline-to-Front Axle
Centerline—Articulation
Frames Straightened
NOTE: Specifications and design subject to change
without notice. Whenever applicable, specifications
are in accordance with SAE standards. Except
Item
16— Length, Articulation
Pivot-to-Front Axle
Centerline
17— Length, Front Axle
Centerline-to-Front of
Machine
18— Length, Machine
Overall—Lowered,
Articulation Frames
Straightened
19— Width, Dump Body Overall
20— Clearance, Minimum
Tire-to-Tire
21— Width, Tire Tread
Centerline-to-Tire Tread
Centerline
22— Width, Tires Overall
23— Radius, Inside Turning
24— Radius, Outside Turning
where otherwise noted, specifications are based on
a machine equipped with all standard equipment,
79 kg (175 lb) operator, and full fuel tank.
Measurement
Specification
1—Dump Body Backsplash—Dumped
Height
6207 mm
20 ft 4 in.
2—Top of Dump Body
Side—Lowered
Height
2756 mm
9 ft
3—Dump Body Lip—Lowered
Height
1928 mm
6 ft 4 in.
4—Dump Body Lip—Dumped
Height
526 mm
1 ft 8 in.
5—Articulation Pivot-to-Ground
Clearance
447 mm
1 ft 5 in.
6—Machine Overall—Lowered
Height
3556 mm
11 ft 8 in.
7—Maximum Dump Body
Angle
70°
8—Maximum Approach
Angle
30°
9—Maximum Articulation
Angle
45°
10—Dump Body Overall
Length
5500 mm
18 ft
11—Maximum Dump Body Load
Length
5242 mm
17 ft 1 in.
12—Dump Body Rear Edge
Protrusion
565 mm
1 ft 10 in.
13—Dump Body Lip-to-Rear Axle
Centerline—Lowered
Length
1392 mm
4 ft 7 in.
14—Rear Axle Centerline-toMiddle Axle Centerline
Length
1670 mm
5 ft 6 in.
15—Middle Axle Centerline-toFront Axle Centerline—Articulation
Frames Straightened
Length
4177 mm
13 ft 8 in.
16—Articulation Pivot-to-Front Axle Length
Centerline
1363 mm
4 ft 5 in.
300D Articulated Dump Truck
Dimensions
Continued on next page
4-6-6
MD04263,00000C5 -19-30JAN09-2/3
080112
PN=157
Miscellaneous—Specifications
Item
Measurement
Specification
17—Front Axle Centerline-to-Front
of Machine
Length
2337 mm
7 ft 8 in.
18—Machine Overall—Lowered,
Articulation Frames Straightened
Length
9577 mm
31 ft 5 in.
19—Dump Body Overall
Width
2990 mm
9 ft 10 in.
20—Minimum Tire-to-Tire
Clearance
1390 mm
4 ft 7 in.
21—Tire Tread Centerline-to-Tire
Tread Centerline
Width
2176 mm
7 ft 2 in.
22—Tires Overall
Width
2960 mm
9 ft 8 in.
23—Inside Turning
Radius
4122 mm
13 ft 6 in.
24—Outside Turning
Radius
7980 mm
26 ft 2 in.
300D Articulated Dump Truck
Weight
21 800 kg
48 100 lb
300D Dump Body—Dump
Cycle Time
11.9 seconds
300D Dump Body—Lower
Cycle Time
6 seconds
300D Specifications
MD04263,00000C5 -19-30JAN09-3/3
4-6-7
080112
PN=158
Miscellaneous—Specifications
250D and 300D Engine Specifications
Item
Measurement
Specification
Model
Configuration
Aspiration
Injection Type
Gross Power
Deere 6081H
In-line 6 Cylinder
Turbocharged and Intercooled
Direct
200 kW @ 2000 rpm
268 hp
1100 N·m @ 1200—1400 rpm
810 lb-ft
250D Engine
Specifications
Gross Torque
Idle Speed
High Idle Speed
Displacement
800 ± 20 rpm
2620 ± 50 rpm
8.1 L
494 in3
Oil Pressure
138 kPa @ Low Idle
1.38 bar
20 psi
400 kPa @ High Idle
4.0 bar
58 psi
300D Engine
Specifications
Model
Configuration
Deere 6081H
In-line 6 Cylinder
Aspiration
Injection Type
Gross Power
Idle Speed
Turbocharged and Intercooled
Direct
215 kW @ 2200 rpm
288 hp
1100 N·m @ 1200—1600 rpm
810 lb-ft
800 ± 20 rpm
High Idle Speed
Displacement
2620 ± 50 rpm
8.1 L (494 in3)
Oil Pressure
138 kPa @ Low Idle
1.38 bar
20 psi
Gross Torque
400 kPa @ High Idle
4.0 bar
58 psi
TX14740,000000D -19-01AUG05-1/1
4-6-8
080112
PN=159
Miscellaneous—Specifications
250D and 300D Travel Speeds
Item
Measurement
Specification
1st Forward
Speed
6.7 km/hr
4.2 mph
2nd Forward
Speed
10.8 km/hr
6.7 mph
3rd Forward
Speed
18.5 km/hr
11.5 mph
4th Forward
Speed
26.2 km/hr
16.3 mph
5th Forward
Speed
37.2 km/hr
23.1 mph
6th Forward
Speed
50.4 km/hr
31.3 mph
1st Reverse
Speed
7.9 km/hr
4.9 mph
250D and 300D Travel Speeds
OUO1043,0000E39 -19-01AUG05-1/1
250D and 300D Drain and Refill Capacities
Item
Measurement
Specification
Capacity
340 L
90 gal
Oil
Capacity
25.5 L
6.7 gal
Coolant
Capacity
26.5 L
7.0 gal
Capacity
21.8 L
5.8 gal
Capacity
4.7 L
5.0 qt
Capacity
21.9 L
5.8 gal
Capacity
4.0 L
4.2 qt
Capacity
78.8 L
20.8 gal
Fuel System
Tank Fuel
Engine
Transmission
Oil
Transfer Case
Oil
Axle
Oil (Each)
Final Drive
Oil (Each)
Hydraulic System
Reservoir Oil
OUO1043,0000E3A -19-01AUG05-1/1
4-6-9
080112
PN=160
Index
Page
Page
Accelerator pedal
Location ................................................................. 2-1-1
Air conditioner
Condenser, inspect and clean................................ 3-3-2
Controls.................................................................. 2-1-6
Filter ....................................................................... 3-6-3
Air pressure
Gauge function....................................................... 2-1-5
Gauge location....................................................... 2-1-4
Air suspension
Seat...................................................................... 2-1-10
Air, engine intake
Inspect ................................................................... 4-1-2
Service ................................................................... 3-3-1
Air, pneumatic system
Dryer-filter .............................................................. 3-8-4
Relieve pressure .................................................... 3-2-3
Articulation safety lock bar......................................... 3-2-2
Attachments
Adding safely ......................................................... 1-3-4
Operating safely..................................................... 1-3-4
Axle
Breather ................................................................. 3-3-3
gear oil ................................................................... 3-1-5
Oil
Change.....................................................3-5-4, 3-8-3
Check level......................................................... 3-7-1
Serial number, front axle ........................................ 4-5-2
Serial number, middle axle..................................... 4-5-2
Serial number, rear axle......................................... 4-5-2
Suspension struts, inspect ..................................... 3-6-2
Troubleshooting ..................................................... 4-3-5
Bleed
Fuel system............................................................ 4-1-1
Body raise and lower checks..................................... 4-2-5
Body warming system check ..................................... 4-2-7
Bolt and screw torque values
Metric ................................................................... 4-1-13
Unified inch .......................................................... 4-1-12
Boost starting............................................................. 4-1-3
Bottom guard ............................................................. 3-2-2
Brake accumulator check .......................................... 4-2-3
Brake accumulators................................................... 4-1-3
Brake oil pressure indicator
Location ................................................................. 2-1-4
Brake pedal
Location ................................................................. 2-1-1
Brake temperature indicator
Location ................................................................. 2-1-4
Brake, dry caliper
Pad wear................................................................ 3-6-1
Brake, park
Pad wear................................................................ 3-6-1
Brake, wet disk
Oil, cooling
Specifications ..................................................... 3-1-4
Brakes
Park........................................................................ 2-2-8
Service ................................................................... 2-2-7
Transmission retarder, using.................................. 2-2-7
Troubleshooting ..................................................... 4-3-6
Breather
Hydraulic reservoir
Clean and inspect............................................... 3-6-7
Replace .............................................................. 3-7-2
Transmission, transfer case, axles ........................ 3-3-3
B
C
Back button
Location ................................................................. 2-1-4
Batteries
Disconnect switch ................................................ 2-1-11
Using battery charger............................................. 4-1-4
Battery
Booster batteries.................................................... 4-1-3
Inspect, clean, tighten terminals ............................ 3-6-4
Replace, two-battery machines.............................. 4-1-6
Safety..................................................................... 4-1-5
Battery charge indicator
Location ................................................................. 2-1-4
Battery explosions
Prevent................................................................... 1-2-4
Before starting engine ............................................... 2-2-1
Before starting work................................................... 2-2-1
Belt, serpentine.......................................................... 3-3-6
Bin
Shock pad .............................................................. 3-7-3
Cab
Filter, air ................................................................. 3-6-3
Tilt .......................................................................... 3-2-4
Cab tilt pump handle
Location ............................................................... 2-1-13
Charge air cooler
Inspect and clean................................................... 3-3-2
Chemical products
Handling................................................................. 1-2-4
Circuit breaker compartment
Location ................................................................. 2-1-1
Circuit breakers
Battery balancer................................................... 2-1-11
Identification........................................................... 2-1-8
Main ..................................................................... 2-1-11
Purging units, fuel filter and coolant level switch.. 2-1-11
Cold start indicator
Location ................................................................. 2-1-4
Controls
Functions ............................................................... 2-1-3
Locations................................................................ 2-1-1
A
Continued on next page
Index-1
080112
PN=1
Index
Page
Page
Seat........................................................................ 2-1-9
Coolant
Capacity, drain and refill......................................... 4-6-9
Coolant level indicator
Location ................................................................. 2-1-4
Coolant temperature guage
Location ................................................................. 2-1-4
Coolant, engine
Change ................................................................ 3-11-1
Check condition ..................................................... 3-6-9
Check level ............................................................ 3-4-1
Specifications......................................................... 3-1-5
Crankshaft dampener replacement ......................... 3-10-1
Cylinder, do not service ............................................. 4-1-1
Troubleshooting ..................................................... 4-3-2
Valve clearance...................................................... 3-8-1
Engine overspeed indicator
Location ................................................................. 2-1-4
Engine service indicator
Location ................................................................. 2-1-4
Ether Aid
Replace.................................................................. 2-2-3
Exhaust fumes........................................................... 1-2-3
Explosion
Battery.................................................................... 1-2-4
D
Dampener replacement, crankshaft ........................ 3-10-1
Data display
Location ................................................................. 2-1-4
Defrost controls ......................................................... 2-1-6
Diesel fuel.................................................................. 3-1-1
Diesel fuel, testing
Testing Diesel Fuel................................................. 3-1-1
Dome light
Location ................................................................. 2-1-1
Dome light switch
Location ................................................................. 2-1-1
Driving machine......................................................... 2-2-3
Driving metal pins ...................................................... 1-4-3
Dump body
Pivot pins ............................................................... 3-4-3
Dump body control lever
Location ................................................................. 2-1-1
Dump body prop ........................................................ 3-2-2
Dump body raised indicator
Location ................................................................. 2-1-4
E
Electrical system
Troubleshooting ..................................................... 4-3-8
Emergency preparation ............................................. 1-2-5
Engine
Coolant
Change............................................................. 3-11-1
Check level......................................................... 3-4-1
Specifications ..................................................... 3-1-5
Coolant conditioner ................................................ 3-6-9
Crankshaft dampener replacement...................... 3-10-1
Filter, air
Check ................................................................. 4-1-2
Service ............................................................... 3-3-1
Filter, oil.................................................................. 3-5-1
Oil
Change............................................................... 3-5-1
Check level......................................................... 3-4-1
Serial number......................................................... 4-5-1
Starting................................................................... 2-2-2
F
Filter
Cab air ................................................................... 3-6-3
Engine air intake ..........................................3-3-1, 4-1-2
Engine oil ............................................................... 3-5-1
Final fuel ................................................................ 3-6-8
Fuel ........................................................................ 3-6-8
Fuel drain ............................................................... 3-3-6
Hydraulic breather
Clean and inspect............................................... 3-6-7
Replace .............................................................. 3-7-2
Hydraulic return...................................................... 3-5-2
Pneumatic block silencer ....................................... 3-9-2
Pneumatic dryer-filter............................................. 3-8-4
Primary fuel............................................................ 3-5-3
Transmission.......................................................... 3-8-2
Final drive
Oil
Change.....................................................3-5-4, 3-8-4
Check levels ....................................................... 3-7-1
Fire prevention........................................................... 1-2-4
Fluid analysis test kit ................................................. 3-2-5
Freeing stuck machine ............................................ 2-2-10
Fuel
Capacity ................................................................. 4-6-9
Diesel ..................................................................... 3-1-1
Do not service injection nozzles............................. 4-1-1
Filter replace ................................................3-5-3, 3-6-8
Gauge function....................................................... 2-1-5
Gauge location....................................................... 2-1-4
Handling and storing .............................................. 3-1-2
Low sulfur conditioner ............................................ 3-1-1
System bleed ......................................................... 4-1-1
Use correct fuels and lubricants............................. 3-2-1
Fuses
Identification........................................................... 2-1-8
G
Gauges
Functions ............................................................... 2-1-5
Locations................................................................ 2-1-4
Gauges and indicator lights check............................. 4-2-1
Gauges and indicators checks .................................. 4-2-3
Gearshift control
Location ................................................................. 2-1-1
Continued on next page
Index-2
080112
PN=2
Index
Page
Page
Grease
Alternative and synthetic lubricants ....................... 3-1-7
Cylinder pins, oscillation tube, articulation
joints, oscillation tube through drive shaft
bearings ............................................................... 3-6-5
Dump body pivot pins ............................................ 3-4-3
Hinges.................................................................... 4-1-3
Prop shaft slip joint................................................. 3-7-3
Specifications......................................................... 3-1-6
Tailgate pivots ........................................................ 3-4-3
Use correct fuels and lubricants............................. 3-2-1
In-line fuel
Filter replace .......................................................... 3-6-7
Inch torque values
Cap screw and nut ............................................... 4-1-14
Indicator
Air cleaner service .......................................3-3-1, 4-1-2
Injection nozzle, do not service ................................. 4-1-1
Inspect machine ........................................................ 1-2-2
Instructional seat ....................................................... 2-1-9
Instrument panel
Functions ............................................................... 2-1-5
Location .......................................................2-1-1, 2-1-4
Instruments and controls
Troubleshooting ..................................................... 4-3-7
Inter-axle lock ............................................................ 2-2-6
Inter-axle lock indicator
Location ................................................................. 2-1-4
Inter-axle lock switch
Location ................................................................. 2-1-1
H
Handhold Use............................................................ 1-3-1
Hardware torque values
Metric ................................................................... 4-1-13
Unified inch .......................................................... 4-1-12
Headlight
Intensity controls .................................................... 2-1-7
Headlight switch
Location ................................................................. 2-1-1
Heater
Controls.................................................................. 2-1-6
Heater and air conditioner control panel
Location ................................................................. 2-1-1
High beam indicator
Location ................................................................. 2-1-4
High-pressure oils
Avoid ...................................................................... 1-2-3
Hill
Operation ............................................................... 2-2-8
Hinges ....................................................................... 4-1-3
Horn button................................................................ 2-1-7
Hydraulic
Filter, breather
Inspect and clean ............................................... 3-6-7
Replace .............................................................. 3-7-2
Filter, return............................................................ 3-5-2
Oil
Change............................................................... 3-9-1
Check level......................................................... 3-4-2
Specifications ..................................................... 3-1-4
Suction screen ....................................................... 3-9-2
Hydraulic oil temperature indicator
Location ................................................................. 2-1-4
Hydraulic system
Troubleshooting ..................................................... 4-3-7
I
Identification
Axle serial number, front ........................................ 4-5-2
Axle serial number, middle..................................... 4-5-2
Axle serial number, rear ......................................... 4-5-2
Engine serial number ............................................. 4-5-1
Product identification number ................................ 4-5-1
Transmission serial number................................... 4-5-1
J
Jump starting ............................................................. 4-1-3
K
Key switch
Location ................................................................. 2-1-1
L
Lever
Steering column ..................................................... 2-1-7
Lifting points ............................................................ 2-2-13
Light
Backup light, replace............................................ 4-1-10
Circuit breaker compartment light, replace .......... 4-1-11
Dome light, replace .............................................. 4-1-11
Headlight, adjust .................................................... 4-1-9
Headlight, replace .................................................. 4-1-7
Park light, front, replace ......................................... 4-1-7
Park light, rear, replace ........................................ 4-1-10
Tail and brake light, replace ................................. 4-1-10
Turn signal, front, replace ...................................... 4-1-7
Turn signal, rear, replace ..................................... 4-1-10
Work light, replace ............................................... 4-1-10
Lights
Locations.............................................................. 2-1-12
Loading and unloading dump body
Operation ............................................................... 2-2-9
Loading machine on trailer ...................................... 2-2-14
Lock ......................................................................... 2-2-15
Lubricant Storage
Storage, Lubricant.................................................. 3-1-6
Lubricants
Alternative and synthetic lubricants ....................... 3-1-7
Grease ................................................................... 3-1-6
Hydraulic and wet disk brake cooling oil ................ 3-1-4
Continued on next page
Index-3
080112
PN=3
Index
Page
Page
Transmission and transfer case oil ........................ 3-1-4
Lubricate
Cylinder pins, oscillation tube, articulation
joints, oscillation tube through drive shaft
bearings ............................................................... 3-6-5
Dump body pivot pins ............................................ 3-4-3
Hinges.................................................................... 4-1-3
Tailgate pivots ........................................................ 3-4-3
Use correct fuels and lubricants............................. 3-2-1
Engine
Change............................................................... 3-5-1
Check level......................................................... 3-4-1
Final drive
Change.....................................................3-5-4, 3-8-4
Check levels ....................................................... 3-7-1
Hydraulic
Change............................................................... 3-9-1
Check level......................................................... 3-4-2
Specifications ..................................................... 3-1-4
Pressure gauge function ........................................ 2-1-5
Pressure gauge location ........................................ 2-1-4
Transfer case
Change.....................................................3-5-3, 3-8-3
Check level......................................................... 3-4-2
Specifications ..................................................... 3-1-4
Transmission
Change............................................................... 3-8-1
Check condition.................................................. 3-8-1
Check level......................................................... 3-6-6
Specifications ..................................................... 3-1-4
Wet disk brake cooling
Specifications ..................................................... 3-1-4
Oil filters..................................................................... 3-1-6
Oil gear
axle ........................................................................ 3-1-5
Operation
Freeing stuckmachine.......................................... 2-2-10
Hill .......................................................................... 2-2-8
Loading and unloading dump body........................ 2-2-9
Off-road.................................................................. 2-2-8
Parking machine .................................................. 2-2-10
Towing with inoperable engine............................. 2-2-11
Towing with inoperable steering........................... 2-2-11
Towing with operable engine................................ 2-2-11
Operation qualification............................................... 1-2-1
Operator controls
Functions ............................................................... 2-1-3
Locations................................................................ 2-1-1
Operator's manual compartment
Location ................................................................. 2-1-1
Outlet
Accessory, 12-volt................................................ 2-1-12
M
Machine
Clean regularly..................................................... 4-1-11
Driving.................................................................... 2-2-3
Lifting points......................................................... 2-2-13
Loading onto trailer .............................................. 2-2-14
Shifting ................................................................... 2-2-5
Slowing and stopping............................................. 2-2-7
Steering.................................................................. 2-2-4
Storage .................................................................. 4-4-1
Machine inspection.................................................... 1-2-2
Maintenance
Prepare machine.................................................... 3-2-1
Record keeping...................................................... 3-2-5
Schedule and record.............................................. 3-2-6
Menu button
Location ................................................................. 2-1-4
Message display
Location ................................................................. 2-1-4
Metal pins .................................................................. 1-4-3
Metric bolt and screw torque values ........................ 4-1-13
Metric torque values
Cap screw and nut ............................................... 4-1-15
Monitor display unit (MDU)
Default display menu ........................................... 2-1-14
Menu function ...................................................... 2-1-16
Service codes ...................................................... 4-3-10
Motor, do not service ................................................. 4-1-1
Moving parts
Safety..................................................................... 1-2-2
Servicing ................................................................ 1-2-2
N
P
Next button
Location ................................................................. 2-1-4
O
Off-road
Operation ............................................................... 2-2-8
Oil
Alternative and synthetic lubricants ....................... 3-1-7
Axle
Change.....................................................3-5-4, 3-8-3
Check level......................................................... 3-7-1
Capacities, drain and refill...................................... 4-6-9
Park brake
Using...................................................................... 2-2-8
Park brake check....................................................... 4-2-4
Park brake lever
Location ................................................................. 2-1-1
Parking light check .................................................... 4-2-6
Parking machine...................................................... 2-2-10
Parts catalog
Location ............................................................... 2-1-13
Pneumatic
Dryer-filter .............................................................. 3-8-4
Relieve pressure .................................................... 3-2-3
Continued on next page
Index-4
080112
PN=4
Index
Page
Page
Pneumatic block silencer
Filter ....................................................................... 3-9-2
Pneumatic pressure
Gauge function....................................................... 2-1-5
Gauge location....................................................... 2-1-4
Power supply, 12V................................................... 2-1-12
Pre-start inspection.................................................... 2-2-1
Prepare machine for maintenance ............................ 3-2-1
Pressure, tires ........................................................... 3-3-4
Product identification number .................................... 4-5-1
Prop shaft
Slip joint ................................................................. 3-7-3
Protective equipment................................................. 1-2-1
Pump, do not service................................................. 4-1-1
Seat
Air suspension ..................................................... 2-1-10
Belt....................................................................... 2-1-10
Controls.................................................................. 2-1-9
Instructional............................................................ 2-1-9
Seat belt
Use and maintenance ............................................ 1-3-1
Secondary exit......................................................... 2-1-12
Secondary steering.................................................... 2-2-4
Secondary steering indicator
Location ................................................................. 2-1-4
Select button
Location ................................................................. 2-1-4
Serial number
Axle, front............................................................... 4-5-2
Axle, middle ........................................................... 4-5-2
Axle, rear................................................................ 4-5-2
Engine.................................................................... 4-5-1
Product................................................................... 4-5-1
Transmission.......................................................... 4-5-1
Serpentine belt .......................................................... 3-3-6
Service
Do not service control valves, cylinders,
pumps or motors .................................................. 4-1-1
Do not service injection nozzles............................. 4-1-1
Service brake
Using...................................................................... 2-2-7
Service brake pedal
Location ................................................................. 2-1-1
Service brake pedal check ........................................ 4-2-4
Service codes
Monitor display unit (MDU) .................................. 4-3-10
Service decal check................................................... 4-2-7
Service lock
Articulation safety lock bar ..................................... 3-2-2
Cab support strut ................................................... 3-2-4
Dump body prop .................................................... 3-2-2
Service required indicator
Location ................................................................. 2-1-4
Service your machine at specified intervals .............. 3-2-1
Shock pad
Bin.......................................................................... 3-7-3
Slowing machine ....................................................... 2-2-7
Specifications
250D cycle times.................................................... 4-6-3
250D dimensions ................................................... 4-6-1
250D drain and refill capacities.............................. 4-6-9
250D engine........................................................... 4-6-8
250D tire pressure and radius................................ 3-3-4
250D weight ........................................................... 4-6-3
300D cycle times.................................................... 4-6-7
300D dimensions ................................................... 4-6-5
300D drain and refill capacities.............................. 4-6-9
300D engine........................................................... 4-6-8
300D tire pressure and radius................................ 3-3-4
300D weight ........................................................... 4-6-7
Coolant, engine............................................3-1-5, 3-6-9
Lubricants
Grease................................................................ 3-1-6
R
Radiator
Coolant
Change............................................................. 3-11-1
Check condition.................................................. 3-6-9
Check level......................................................... 3-4-1
Specifications ..................................................... 3-1-5
Inspect and clean................................................... 3-3-2
Radius, tires............................................................... 3-3-4
Range hold ................................................................ 2-2-6
Range hold switch
Location ................................................................. 2-1-1
Rear frame and cab
Troubleshooting ..................................................... 4-3-9
Rear view mirrors adjustment switch
Location ................................................................. 2-1-1
Rear view mirrors defrost swtich
Location ................................................................. 2-1-1
Replace
Start Aid Can.......................................................... 2-2-3
Reservoir
Windshield washer............................................... 2-1-13
Riders
Keeping off machine .............................................. 1-3-2
Roads
Operating or traveling ............................................ 1-3-3
Rocking machine free.............................................. 2-2-10
ROPS
Inspect ................................................................... 1-3-4
Maintain ................................................................. 1-3-4
Rust inhibitor.............................................................. 3-6-9
S
Safety
Operator's seat ...................................................... 1-3-1
Safety equipment....................................................... 1-2-1
Safety features .......................................................... 1-1-1
Safety information
Recognizing ........................................................... 1-2-1
Safety instructions ..................................................... 1-2-1
Safety signs ............................................................... 1-5-1
Safety symbols .......................................................... 1-2-1
Continued on next page
Index-5
080112
PN=5
Index
Page
Page
Hydraulic and wet disk brake cooling oil ............ 3-1-4
Transmission and transfer case oil..................... 3-1-4
Travel speeds ........................................................ 4-6-9
Speed
Machine travel speeds ........................................... 4-6-9
Speedometer
Function ................................................................. 2-1-5
Locations................................................................ 2-1-4
Start Aid
Replace.................................................................. 2-2-3
Start aid switch
Location ................................................................. 2-1-1
Start switch check...................................................... 4-2-2
Starting
Engine.................................................................... 2-2-2
Steering ..................................................................... 2-2-4
Steering check........................................................... 4-2-5
Steering column
Lever ...................................................................... 2-1-7
Steering column lever
Location ................................................................. 2-1-1
Steering wheel
Location ................................................................. 2-1-1
Steps Use .................................................................. 1-3-1
Stopping machine...................................................... 2-2-7
Storage
Machine ................................................................. 4-4-1
Storing fuel ................................................................ 3-1-2
Suction screen
Replace.................................................................. 3-9-2
Switch
Battery disconnect ............................................... 2-1-11
Range hold............................................................. 2-2-6
Transfer case
Breather ................................................................. 3-3-3
Oil
Change.....................................................3-5-3, 3-8-3
Check level......................................................... 3-4-2
Specifications ..................................................... 3-1-4
Transmission
Breather ................................................................. 3-3-3
Cooler, inspect and clean....................................... 3-3-2
Filters ..................................................................... 3-8-2
Oil
Change............................................................... 3-8-1
Check condition.................................................. 3-8-1
Check level......................................................... 3-6-6
Specifications ..................................................... 3-1-4
Serial number......................................................... 4-5-1
Shifting ................................................................... 2-2-5
Temperature gauge function .................................. 2-1-5
Temperature gauge locations................................. 2-1-4
Troubleshooting ..................................................... 4-3-4
Transmission retarder
Using...................................................................... 2-2-7
Transmission retarder indicator
Location ................................................................. 2-1-4
Transmission service indicator
Location ................................................................. 2-1-4
Transmission torque retarder control lever
Location ................................................................. 2-1-1
Transporting
Lifting points......................................................... 2-2-13
Loading machine on trailer................................... 2-2-14
Travel speed.............................................................. 4-6-9
Traveling
On public roads...................................................... 1-3-3
Troubleshooting
Axle ........................................................................ 4-3-5
Brakes.................................................................... 4-3-6
Electrical system .................................................... 4-3-8
Engine.................................................................... 4-3-2
Hydraulic system.................................................... 4-3-7
Instruments and controls........................................ 4-3-7
Rear frame and cab ............................................... 4-3-9
Tire......................................................................... 4-3-6
Transmission.......................................................... 4-3-4
Turn indicator
Controls.................................................................. 2-1-7
Turn indicators
Location ................................................................. 2-1-4
Turning machine free............................................... 2-2-10
T
Telescopic steering adjust lever
Location ................................................................. 2-1-1
Tilt cab ....................................................................... 3-2-4
Tilt steering adjust lever
Location ................................................................. 2-1-1
Tire
Pressure and radius, 250D .................................... 3-3-4
Pressure and radius, 300D .................................... 3-3-4
Size, pressure, and radius ..................................... 3-3-4
Troubleshooting ..................................................... 4-3-6
Wheel nut torque.................................................... 4-1-3
Wheel wrench and brace location........................ 2-1-13
Torque
Cap screw and nut, inch ...................................... 4-1-14
Cap screw and nut, metric ................................... 4-1-15
Wheel nuts ............................................................. 4-1-3
Torque charts
Metric ................................................................... 4-1-13
Unified inch .......................................................... 4-1-12
Towing
Inoperable engine ................................................ 2-2-11
Inoperable steering .............................................. 2-2-11
Operable engine .................................................. 2-2-11
U
Unified inch bolt and screw torque values ............... 4-1-12
V
Valve
Engine valve clearance.......................................... 3-8-1
Valve, do not service ................................................. 4-1-1
Continued on next page
Index-6
080112
PN=6
Index
Page
Page
Vibration
Crankshaft dampener replacement...................... 3-10-1
Welding.................................................................... 4-1-16
Welding repairs.......................................................... 1-4-2
Wheel nut torque ....................................................... 4-1-3
Wheel wrench and brace......................................... 2-1-13
Windshield washer reservoir ................................... 2-1-13
Windshield wiper
Controls.................................................................. 2-1-7
W
Warning light switch
Location ................................................................. 2-1-1
Waste disposal .......................................................... 1-2-5
Index-7
080112
PN=7
Index
Index-8
080112
PN=8