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250D and 300D Articulated Dump Trucks (Serial No. 609166-

)

OPERATOR’S MANUAL 250D and 300D Articulated Dump Trucks OMT224115 Issue K7 (ENGLISH)

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. If this product contains a gasoline engine:

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

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

Introduction 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.

VD76477,00010A3 –19–05OCT06–1/1

IMPORTANT Warranty will not apply to engine and drivetrain failures resulting from unauthorized adjustments to this engine. Unauthorized adjustments are in violation of the emissions regulations applicable to this engine and may result in substantial fines and penalties.

VD76477,000104D –19–13JUN07–1/1

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Emissions Control Warranty Statement EMISSIONS CONTROL WARRANTY STATEMENT FOR NEW JOHN DEERE CONSTRUCTION EQUIPMENT (U.S. AND CANADA) To determine if the engine in your machine qualifies for the additional warranties set forth below, look for the "Engine Information" label located on your engine. If you reside in the United States and the engine label states: "Engine conforms to US EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control Warranty Statement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy duty non road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement." U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT

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

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.

–19–28JUN00

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."

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.

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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.

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

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

FAX NUMBER:

563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one) Poor 1

Fair 2

Good 4

Very Good 6

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Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU!

TX,TM,FAX –19–03JUL01–1/1 110807

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Page

Safety—Safety and Operator Conveniences Safety and Operator Conveniences . . . . . . . . . 1-1-1

Safety—Safety Signs Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1

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 . . . . . . . . . . . . . . . 1-2-2 Avoid Unauthorized Machine Modifications. . . . 1-2-2 Inspect Machine . . . . . . . . . . . . . . . . . . . . . . . . 1-2-2 Stay Clear of Moving Parts. . . . . . . . . . . . . . . . 1-2-3 Avoid High-Pressure Fluids . . . . . . . . . . . . . . . 1-2-3 Avoid High-Pressure Oils . . . . . . . . . . . . . . . . . 1-2-4 Beware of Exhaust Fumes . . . . . . . . . . . . . . . . 1-2-4 Prevent Fires . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5 Prevent Battery Explosions. . . . . . . . . . . . . . . . 1-2-5 Handle Chemical Products Safely. . . . . . . . . . . 1-2-6 Dispose of Waste Properly . . . . . . . . . . . . . . . . 1-2-6 Prepare for Emergencies . . . . . . . . . . . . . . . . . 1-2-6

Operation—Operator’s Station Operator Controls . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Operator Control Functions . . . . . . . . . . . . . . . 2-1-3 Sealed Switch Module (SSM) . . . . . . . . . . . . . . 2-1-4 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . 2-1-7 Instrument Panel Functions . . . . . . . . . . . . . . . 2-1-8 Radio Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-1-10 Steering Column Lever. . . . . . . . . . . . . . . . . . 2-1-11 Operator Seat and Instructional Seat . . . . . . . 2-1-12 Battery Disconnect Switch and Battery Circuit Breakers . . . . . . . . . . . . . . . . . . . . . 2-1-14 Miscellaneous Equipment . . . . . . . . . . . . . . . . 2-1-15 Monitor Display Unit (MDU)—Default Display Menus . . . . . . . . . . . . . . . . . . . . . . 2-1-18 Monitor Display Unit (MDU)—Main Menu . . . . 2-1-21 Monitor Display Unit (MDU)—Counters . . . . . 2-1-22 Monitor Display Unit (MDU)—Actual Values . . 2-1-25 Monitor Display Unit (MDU)—Diagnostics. . . . 2-1-28 Monitor Display Unit (MDU)—Machine Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-33 Monitor Display Unit (MDU)—Machine ID. . . . 2-1-39 Monitor Display Unit (MDU)—Service Mode . . 2-1-39

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 . . . . . 1-3-2 Avoid Work Site Hazards . . . . . . . . . . . . . . . . . 1-3-3 Keep Riders Off Machine . . . . . . . . . . . . . . . . . 1-3-4 Avoid Backover Accidents . . . . . . . . . . . . . . . . 1-3-4 Avoid Machine Tip Over . . . . . . . . . . . . . . . . . . 1-3-5 Operating on Slopes. . . . . . . . . . . . . . . . . . . . . 1-3-5 Operating or Traveling on Public Roads . . . . . . 1-3-6 Inspect and Maintain ROPS . . . . . . . . . . . . . . . 1-3-6 Add and Operate Attachments Safely. . . . . . . . 1-3-6 Prevent Unintended Detonation of Explosive Devices . . . . . . . . . . . . . . . . . . . . . 1-3-7

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 . . . . . . . . . . . . . . . . . . . 2-2-4 Warming Hydraulic System. . . . . . . . . . . . . . . . 2-2-5 Driving Machine . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Steering Machine . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Shifting Transmission . . . . . . . . . . . . . . . . . . . . 2-2-7 Using Range Hold . . . . . . . . . . . . . . . . . . . . . 2-2-10 Using Inter-Axle Lock . . . . . . . . . . . . . . . . . . . 2-2-11 Slowing and Stopping the Machine. . . . . . . . . 2-2-12 Operating on a Hill . . . . . . . . . . . . . . . . . . . . . 2-2-14 Off-Road Operation . . . . . . . . . . . . . . . . . . . . 2-2-15

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. . . . . . . . . . . . . . 1-4-3 Drive Metal Pins Safely . . . . . . . . . . . . . . . . . . 1-4-3

Continued on next page

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT  2007 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright  2003, 2004, 2005, 2006

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Loading and Unloading Bin . . . . . . . . . . . . . . 2-2-16 Freeing Stuck Machine. . . . . . . . . . . . . . . . . . 2-2-17 Parking the Machine. . . . . . . . . . . . . . . . . . . . 2-2-18 Towing the Machine . . . . . . . . . . . . . . . . . . . . 2-2-19 Removing Drive shafts for Towing . . . . . . . . . 2-2-20 Mechanically Releasing Park Brake . . . . . . . . 2-2-21 Machine Lifting Points . . . . . . . . . . . . . . . . . . 2-2-22 Loading and Unloading Machine from Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-23 Lock All Compartments . . . . . . . . . . . . . . . . . 2-2-24

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 Check Transmission . . . . . . . . . . . . . . . . . . . . . 3-4-2 Grease Bin Pivot Pins . . . . . . . . . . . . . . . . . . . 3-4-3 Lubricate Tailgate Pivots—If Equipped . . . . . . . 3-4-3 Maintenance—Initial Service - 100 Hours Change Engine Oil and Replace Filter . . . . . . . 3-5-1 Replace Primary Fuel Filter . . . . . . . . . . . . . . . 3-5-2 Replace Secondary Fuel Filter . . . . . . . . . . . . . 3-5-3 Change Transfer Case Oil . . . . . . . . . . . . . . . . 3-5-4 Change Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . 3-5-5 Change Final Drive Oil . . . . . . . . . . . . . . . . . . . 3-5-6 Replace Hydraulic System Oil Return Filter . . . 3-5-7

Maintenance—Machine Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1 Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2 Low Sulfur Diesel Fuel Conditioner. . . . . . . . . . 3-1-3 Testing Diesel Fuel. . . . . . . . . . . . . . . . . . . . . . 3-1-4 Handling and Storing Diesel Fuel . . . . . . . . . . . 3-1-4 Diesel Engine Oil and Filter Service Intervals . . 3-1-5 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-7 Transmission and Transfer Case Oil . . . . . . . . 3-1-8 Axle Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-8 Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . 3-1-9 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-10 Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-10 Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . 3-1-11 Alternative and Synthetic Lubricants. . . . . . . . 3-1-11

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 Change Engine Oil and Replace Filter . . . . . . . 3-6-3 Inspect, Clean, and Replace Cab Air Filter . . . . 3-6-4 Check Batteries, Clean and Tighten Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-5 Lubricate Oscillation Tube, Articulation Joints, Steering Cylinder Rod Ends, and Oscillation Tube Through Drive Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-6 Check Transmission Oil Level . . . . . . . . . . . . . 3-6-6 Clean and Inspect Hydraulic Reservoir Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-8 Replace In-line Fuel Filter. . . . . . . . . . . . . . . . . 3-6-9 Replace Secondary Fuel Filter . . . . . . . . . . . . . 3-6-9 Replace Primary Fuel Filter . . . . . . . . . . . . . . 3-6-10 Check Coolant Conditioner in Radiator. . . . . . 3-6-11

Maintenance—Periodic Maintenance Service Your Machine at Specified Intervals. . . 3-2-1 Use Correct Fuels and Lubricants . . . . . . . . . . 3-2-1 Prepare Machine for Maintenance . . . . . . . . . . 3-2-2 Install Bin Support Rod. . . . . . . . . . . . . . . . . . . 3-2-3 Install Articulation Locking Bar . . . . . . . . . . . . . 3-2-3 Lower and Raise Bottom Guard . . . . . . . . . . . . 3-2-4 Relieve Pneumatic Pressure. . . . . . . . . . . . . . . 3-2-4 Tilt Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-5 Maintenance and Repair Record Keeping System . . . . . . . . . . . . . . . . . . . . . . 3-2-8 Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit . . . . . . . . . . . . . . . . . 3-2-9 Maintenance and Repair Record Keeping System . . . . . . . . . . . . . . . . . . . . . 3-2-10

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 . . . . . . . . . . . . . . 3-7-4

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 . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Inspect Serpentine Belt . . . . . . . . . . . . . . . . . . 3-3-9

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 . . . . . . . . . . . . . . . . . . . . . . . . 3-8-4 Continued on next page

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Change Final Drive Oil . . . . . . . . . . . . . . . . . . . 3-8-5 Replace Pneumatic System Dryer-Filter . . . . . . 3-8-6 Replace Hydraulic System Oil Return Filter . . . 3-8-7

Clean The Machine Regularly . . . . . . . . . . . . 4-1-21 Unified Inch Bolt and Screw Torque Values . . 4-1-22 Metric Bolt and Screw Torque Values. . . . . . . 4-1-23 Imperial and SAE (Inch) Cap Screw and Nut Torque Values . . . . . . . . . . . . . . . . . . . 4-1-24 Metric Cap Screw and Nut Torque Values . . . 4-1-25 Welding on Machine . . . . . . . . . . . . . . . . . . . . 4-1-26

Maintenance—Every 3000 Hours Replace Hydraulic Suction Screen . . . . . . . . . . 3-9-1 Maintenance—Every 4000 Hours Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . 3-9-1 Replace Pneumatic Block Silencer Filter . . . . . 3-9-2

Miscellaneous—Operational Checkout Operational Checkout . . . . . . . . . . . . . . . . . . . . 4-2-1 Operator Station Checks—Key Switch ON, Engine Stopped . . . . . . . . . . . . . . . . . . . . . . 4-2-1 Operator Station Checks—Key Switch ON, Engine Running . . . . . . . . . . . . . . . . . . . . . . 4-2-2 Miscellaneous Checks . . . . . . . . . . . . . . . . . . . 4-2-8

Maintenance—Every 4500 Hours Replace Engine Crankshaft Dampener. . . . . . 3-10-1

Maintenance—Every 5000 Hours Drain, Flush and Refill Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11-1

Miscellaneous—Troubleshooting Using Troubleshooting Charts . . . . . . . . . . . . . 4-3-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-5 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . 4-3-9 Instruments and Controls . . . . . . . . . . . . . . . . . 4-3-9 Electrical System . . . . . . . . . . . . . . . . . . . . . . 4-3-10 Rear Frame and Cab . . . . . . . . . . . . . . . . . . . 4-3-12

Maintenance—Every 6000 Hours Replace Universal Joints . . . . . . . . . . . . . . . . 3-13-1

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. . . . . . . . . . . . . . . . . . . . 4-1-2 Check Engine Air Intake System . . . . . . . . . . . 4-1-2 Check Brake Accumulators . . . . . . . . . . . . . . . 4-1-3 Check Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . 4-1-3 Lubricate Hinges . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 JDLink Machine Monitoring System (MMS)—If Equipped . . . . . . . . . . . . . . . . . . . 4-1-4 JDLink Machine Monitoring System (MMS) Direct Laptop Connection—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Fuse and Relay Compartment (S.N. — XXXXXX) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5 Fuse and Relay Compartment (S.N. XXXXXX—). . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-8 Using Battery Charger . . . . . . . . . . . . . . . . . . 4-1-12 Using Booster Batteries—24-Volt System. . . . 4-1-13 Handling, Checking And Servicing Batteries Carefully . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-14 Replace Batteries . . . . . . . . . . . . . . . . . . . . . . 4-1-16 Replace Front Turn Signal Bulb, Headlight Bulb, and Front Park Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-17 Adjust Headlights . . . . . . . . . . . . . . . . . . . . . . 4-1-19 Replace Backup Light and Work Light—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-20 Replace Tail and Brake Light and Rear Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-20 Replace Dome Light Bulb. . . . . . . . . . . . . . . . 4-1-21

Miscellaneous—Storage Prepare Machine for Storage . . . . . . . . . . . . . . 4-4-1 Monthly Storage Procedure . . . . . . . . . . . . . . . 4-4-2 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 . . . . . . . . . . . . . . . . . 4-5-1 Middle Axle Serial Number . . . . . . . . . . . . . . . . 4-5-2 Rear Axle Serial Number . . . . . . . . . . . . . . . . . 4-5-2 Miscellaneous—Specifications 250D Articulated Dump Truck Specifications . . 4-6-2 300D Articulated Dump Truck Specifications . . 4-6-6 250D and 300D Engine Specifications . . . . . . . 4-6-9 250D and 300D Travel Speeds . . . . . . . . . . . 4-6-10 250D and 300D Drain and Refill Capacities . . 4-6-11

iii

110807

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Contents

110807

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Safety—Safety and Operator Conveniences Safety and Operator Conveniences 1

16 15

2 8

–UN–19NOV01

10 7

T147632

6 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. Pressurized Cab with Heater/Defroster. Positive pressure 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. Bin Service Lock. A mechanical lock is provided for working on or around this machine with the bin 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.

CS33148,0000D3E –19–20SEP06–1/1

1-1-1

110807

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Safety—General Precautions Recognize Safety Information –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.

T133555

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

–19–28AUG00

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

T133588

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.

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.

Keep safety signs in good condition. 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 –19–05OCT07–1/1

1-2-1

110807

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Safety—General Precautions

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

–UN–23AUG88

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

TS206

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.

TX03679,00016D0 –19–03JAN07–1/1

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. 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

T6607AQ

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.

–UN–18OCT88

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

TX03679,0001734 –19–03JAN07–1/1

1-2-2

110807

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Safety—General Precautions

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

Entanglements in moving parts can cause serious injury.

–UN–12SEP01

Stay Clear of Moving Parts

TX03679,00016D2 –19–03JAN07–1/1

Avoid High-Pressure Fluids

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

–UN–23AUG88

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

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

DX,FLUID –19–03MAR93–1/1

1-2-3

110807

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Safety—General Precautions

Avoid High-Pressure Oils

T133509 T133840

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

–UN–20SEP00

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.

–UN–17MAR06

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.

TX03679,00016D3 –19–01OCT07–1/1

If you must operate in a building, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

T133546

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

–UN–24AUG00

Beware of Exhaust Fumes

TX03679,00016D4 –19–03JAN07–1/1

1-2-4

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Safety—General Precautions

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.

T133552 T133554

–UN–07SEP00

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

–UN–07SEP00

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

T133553

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

–UN–14SEP00

Prevent Fires

TX03679,00016F5 –19–08MAR07–1/1

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

–UN–23AUG88

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

TS204

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

TX03679,000174A –19–03JAN07–1/1

1-2-5

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Safety—General Precautions

Handle Chemical Products Safely

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

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.

TX03679,00016D7 –19–18OCT07–1/1

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

T133567

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.

–UN–25AUG00

Dispose of Waste Properly

Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your dealer for more information.

TX03679,0001733 –19–28NOV06–1/1

Prepare for Emergencies Be prepared if an emergency occurs or a fire starts.

TS291

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B –19–31JAN07–1/1

1-2-6

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Safety—Operating Precautions

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.

T133468

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

–UN–30AUG00

Use Steps and Handholds Correctly

TX03679,00016F2 –19–25JAN07–1/1

T133715

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.

–UN–07SEP00

Start Only From Operator’s Seat

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

TX03679,0001799 –19–03JAN07–1/1

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.

T133716

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

–19–14SEP00

Use and Maintain Seat Belt

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

TX03679,00016DD –19–20MAR07–1/1

1-3-1

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Safety—Operating Precautions

Prevent Unintended Machine Movement –UN–28JUN06

Be careful not to accidentally actuate controls when co-workers are present.

TX1009522A

Ensure bin 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.

SJ25320,000009A –19–02AUG06–1/1

1-3-2

110807

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Safety—Operating Precautions

Avoid Work Site Hazards

–UN–06JUL01

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

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.

T143748

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.

–UN–20JUL01

T143350

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 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.

VD76477,000108E –19–27SEP06–1/1

1-3-3

110807

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Safety—Operating Precautions

Keep Riders Off Machine

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

Only allow operator on machine except when necessary for instruction or short periods of observation.

–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 –19–22JUN01–1/1

T143356

Before moving machine, be sure all persons are clear of machine path. Where conditions permit, raise bin 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.

–UN–06JUL01

Avoid Backover Accidents

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.

SJ25320,00000A6 –19–02AUG06–1/1

1-3-4

110807

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Safety—Operating Precautions

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.

T144185

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.

T133716

Use extra care when bin is raised. Machine stability is greatly reduced when bin is raised. Drive slowly. Avoid sharp turns and uneven ground.

–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.

–19–14SEP00

Avoid Machine Tip Over

If machine tips, carefully inspect brake and hydraulic lines, electrical wiring, and machine structure before operating.

SJ25320,00000A7 –19–02AUG06–1/1

Operating on Slopes

Check service brake condition frequently when operating on slopes.

T143361

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.

–UN–27JUN01

Avoid sideslope travel whenever possible.

Use the transmission retarder, and service brakes to control speed. Sudden brake application with a loaded bin could cause loss of machine control.

SJ25320,00001CC –19–15SEP06–1/1

1-3-5

110807

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Safety—Operating Precautions

Operating or Traveling on Public Roads

T141891

–UN–22MAY01

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

MM61211,00015BD –19–08AUG06–1/1

Inspect and Maintain ROPS A damaged roll-over protective structure (ROPS) should be replaced, not reused. The protection offered by ROPS will be impaired 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.

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.

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

TX03679,000179F –19–07SEP06–1/1

Add and Operate Attachments Safely Always verify compatibility of attachments by 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.

MM61211,00015BE –19–08AUG06–1/1

1-3-6

110807

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Safety—Operating Precautions

TX1023216

Avoid serious injury or death from an explosion hazard. Deactivate all cellular or radio frequency devices on equipment stored or operating in an area, such as a blasting zone, where the use of radio transmitting devices are prohibited.

–UN–07MAY07

Prevent Unintended Detonation of Explosive Devices

VD76477,0001543 –19–07JUN07–1/1

1-3-7

110807

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Safety—Maintenance Precautions Park and Prepare for Service Safely

T133332

• Park machine on a level surface. • Lower bin 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 locking bar. • Install service locks if bin or cab is raised for service.

–19–14DEC01

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

Securely support machine before working under it.

TS229

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

–UN–23AUG88

Install wheel chocks to ensure machine cannot move backward or forward during service.

SJ25320,00000A9 –19–08AUG06–1/1

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.

TS211

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

–UN–23AUG88

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

DX,RIM –19–24AUG90–1/1

1-4-1

110807

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Safety—Maintenance Precautions

Service Cooling System Safely

TS281

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.

–UN–23AUG88

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

DX,RCAP –19–04JUN90–1/1

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

• 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.

TS220

Remove paint before heating:

–UN–23AUG88

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

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

1-4-2

110807

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Safety—Maintenance Precautions

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.

T133547

IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.

–UN–31AUG00

Make Welding Repairs Safely

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

TX03679,00016D5 –19–12SEP07–1/1

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

T133738

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.

–UN–14SEP00

Drive Metal Pins Safely

TX03679,0001745 –19–17JUL07–1/1

1-4-3

110807

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Safety—Safety Signs Safety Signs

CAUTION This instructional seat has been provided for training operators and machine diagnostics only. No passengers permitted during operational use of this machine. Always wear the safety belt provided.

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 Ensure that the cab support is properly engaged before carrying out any maintenance in this area.

WARNING

HIGH PRESSURE HYDRAULICS See manual for correct maintenance procedure. Typical working pressure: 8000 kPa (1160 PSI).

TX1011468

AVOID INJURY Ensure propshaft guards are in place at all times

–19–22AUG06

208046

WARNING

TX1011468

Continued on next page

1-5-1

CS33148,0000D3D –19–11SEP06–1/2 110807

PN=24

Safety—Safety Signs

WARNING Crushing injury may result in hinge area if machine is turned. Make sure people are clear of machine before starting engine or moving steering wheel. Attach locking bar before performing service near center of machine or transporting on a truck.

WARNING

DANGER Avoid crushing Do not jump if machine tips

To avoid injury or death, install bin support pole before carrying out any maintenance in this area

USE SEAT BELT

WARNING STAY CLEAR OPERATOR MAY REVERSE THE MACHINE.

DANGER Start only from seat in park or neutral. Starting in gear kills.

DANGER Serious injury or death can result from contact with electric lines. Never move any part of unit or load closer than: 3m[10FT] plus twice the line insulator length to an electric line.

WARNING WARNING

–19–15SEP06

Avoid injury from escaping fluid. Refer to manual for correct removal, installation and maintenance procedure. Typical working pressure: 4800 kPa (700 PSI).

AVOID INJURY Keep clear of rotating fan blades

TX1011870

207331

PRESSURISED GAS

TX1011870

CS33148,0000D3D –19–11SEP06–2/2

1-5-2

110807

PN=25

Operation—Operator’s Station

TX1011251A

–UN–17AUG06

Operator Controls

1—Air Vent (5 used) 2—12-Volt Accessories Socket 3—Diagnostic Connection 4—Radio 5—Steering Column Lever 6—Tilt Steering Adjust Lever

7—Monitor Display Unit (MDU) 8—Telescopic Steering Adjust Lever 9—Key Switch 10—Sealed Switch Module (SSM)

11—Park Brake Switch 12—Mirror Adjustment Control (If Equipped) 13—Gearshift Control 14—Bin Control Lever 15—Four-Way Flasher Switch

Continued on next page

2-1-1

16—Cooler Box 17—Cigarette Lighter 18—Ashtray 19—Accelerator Pedal 20—Service Brake Pedal 21—Fuse Panel Compartment

RK98916,0000024 –19–15SEP06–1/2

110807

PN=26

TX1009606A

–UN–06JUL06

Operation—Operator’s Station

22—Speaker (2 used)

23—Dome Light and Switch

24—Visor

RK98916,0000024 –19–15SEP06–2/2

2-1-2

110807

PN=27

Operation—Operator’s Station

Operator Control Functions 1. Air Vent (5 used)—controls and directs air flow in the cab. 2. 12-Volt Accessories Socket—allows use of 12V accessory. 3. Diagnostic Connection—to hook up diagnostic troubleshooting tool. 4. Radio—is provided for operator convenience. 5. Steering Column Lever—controls horn, turn indicators, and headlight beam intensity. 6. Tilt Steering Adjust Lever—loosens tilt steering clamp to allow steering column to be tilted up or down to operator preference. 7. Monitor Display Unit (MDU)—contains instruments and indicators. 8. Telescopic Steering Adjust Lever—allows steering column to be pulled out or pushed in to operator preference. 9. Key Switch—turn to start engine. 10. Sealed Switch Module (SSM)—contains heating and air conditioning switches, wiper switches, lighting switches, transmission and differential control switches. CAUTION: DO NOT leave machine unattended with engine running. Avoid serious injury or death from unexpected machine movement. 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.

11. Park Brake Switch—push on the top side of switch to release park brake; Push on the bottom side of switch to engage park brake. 12. Mirror Adjustment Control (if equipped)—select left or right side mirror. Adjust mirror up, down, left, or right, to operator preference. 13. Gearshift Control—selects travel direction and maximum gear. 14. Bin Control Lever—raises or lowers bin. Pull lever to raise bin; push lever to lower bin. NOTE: The bin control lever is spring-loaded and will return to center position when released. 15. Four-Way Flasher Switch—push switch to turn four-way flasher lights ON; push switch again to turn four-way flasher lights OFF. 16. Cooler Box—provided to store items for operator convenience. 17. Cigarette Lighter—provided for operator convenience. 18. Ashtray—provided for operator convenience. 19. Accelerator Pedal—push pedal to increase speed; release pedal to slow machine. Retarder will engage, as necessary, when pedal is released. 20. Service Brake Pedal—push pedal to engage service brakes. 21. Fuse Panel Compartment—to access machine fuses. 22. Speaker—used with radio for operator convenience. 23. Dome Light and Switch—illuminates interior of cab. Push to activate light. 24. Visor—can be lowered and adjusted as necessary.

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PN=28

Operation—Operator’s Station

TX1010643A

–UN–28JUL06

Sealed Switch Module (SSM)

1—Air Conditioner Switch 2—Recirculating Air Switch 3—Blower Speed Switch 4—Not Used 5—Inter-axle Lock Switch 6—Temperature Control DOWN Switch

7—Temperature Control UP Switch 8—Air Flow Control Switch 9—Not Used 10—Range Hold Switch 11—Bin Maximum Position Switch

12—Beacon Light Switch 13—Headlight Switch 14—Retarder DOWN Switch 15—Retarder UP Switch 16—Bin Production Switch

1. Air Conditioner Switch—turns air conditioner on and off. 2. Recirculating Air Switch—selects between fresh air from outside (LED off) and recirculated air in cab (LED on). 3. Blower Speed Switch—increases or decreases the blower speed. • Low speed (one LED). • Medium speed (two LEDs). • Maximum speed (three LEDs). 4. Not Used

17—Electric Mirror Defrost Switch 18—Work Light Switch 19—Rear Wiper Switch 20—Front Wiper Switch

5. Inter-axle Lock Switch—used to improve traction. 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 inter-axle lock switch and ensure that inter-axle lock LED is on. To disengage inter-axle lock, press inter-axle lock switch again. 6. Temperature Control DOWN Switch—decreases temperature in the cab. • Blue—Cold. • Orange—Medium. • Red—Hot (heater).

Continued on next page

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RK98916,0000026 –19–06JUL07–1/3 110807

PN=29

Operation—Operator’s Station • Headlights, park lights, and taillights (two LEDs)

NOTE: The color of the LED above the temperature control switch indicates the temperature setting.

14. Retarder DOWN Switch—decreases the amount of retardation. • 15% retardation (no LEDs). • 25% retardation (one LED). • 35% retardation (two LEDs). • 45% retardation (three LEDs). • 60% retardation (four LEDs). • 75% retardation (five LEDs). • 100% retardation (six LEDs).

7. Temperature Control UP Switch—increases temperature in the cab. 8. Air Flow Control Switch—controls the air flow inside cab. • Defrost (one LED). • Defrost and lower vents (two LEDs). • Middle vents (three LEDs). • Middle and lower vents (four LEDs). 9. Not Used 10. Range Hold Switch—when the switch is pushed, the transmission will hold the gear that it is in at the time of the switch being activated. Normal downshifting will occur, but the transmission will not upshift to a higher gear until the switch is turned off (except in overspeed conditions). When the switch is activated, the gear shift display screen on the gear shift control will display the gear number that the transmission will be “held” in. 11. Bin Maximum Position Switch—activates the production limit bin settings set in monitor display unit (MDU). When switch is pushed, production limit setting (as a percentage) will appear on MDU and all four LEDs will come on. IMPORTANT: Machine must be in bin restriction or load spreading mode to enable production limit bin settings. If all four LEDs do not come on at the same time after switch is pushed, machine is not in bin restriction or load spreading mode. For more information, see Monitor Display Unit (MDU)—Machine Config in this section. 12. Beacon Light Switch—activates the flashing beacon (if equipped). 13. Headlight Switch—activates the headlights, park lights, and taillights. • Park lights and taillights (one LED).

NOTE: There are seven available retarder positions. Each position increases the degree of retardation to a maximum of 100% retardation, when all six LED’s are illuminated. 15. Retarder UP Switch—increases the amount of retardation. • 15% retardation (no LEDs) • 25% retardation (one LED) • 35% retardation (two LEDs) • 45% retardation (three LEDs) • 60% retardation (four LEDs) • 75% retardation (five LEDs) • 100% retardation (six LEDs) 16. Bin Production Switch—selects one of the following four features: • Hard stop (first LED). • Drive line assist (second LED). • Hard stop and drive line assist (first and second LEDs). a. Hard Stop—abruptly stops bin at 100% position. b. Drive Line Assist—when bin control lever is pulled back, the park brake will be applied, neutral gear will be requested, and 100% engine speed will be requested (returning to idle speed at 100% bin position). c. Auto Discharge—not used. 17. Electric Mirror Defrost Switch—defrosts the electric mirrors (if equipped).

Continued on next page

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PN=30

Operation—Operator’s Station 18. Work Light Switch—operates the work lights on the cab. • Front work lights (one LED). • Front and rear work lights (two LEDs). 19. Rear Wiper Switch—activates rear wiper (if equipped). • Intermittent operation (one LED). • Slow speed operation (two LEDs). • High speed operation (three LEDs).

20. Front Wiper Switch—operates same as rear wiper switch. • Intermittent operation (one LED). • Slow speed operation (two LEDs). • High speed operation (three LEDs). NOTE: To activate washer, push and hold switch. Washer will be activated for as long as the switch is pushed.

NOTE: To activate washer, push and hold switch. Washer will be activated for as long as the switch is pushed.

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PN=31

Operation—Operator’s Station

TX1009527

–UN–29JUN06

Instrument Panel

1—Coolant Temperature Gauge 2—Speedometer 3—Message Display 4—Engine RPM Gauge 5—Fuel Gauge 6—Transmission Oil Temperature Gauge 7—Cold Start Indicator (not used) 8—Left Turn Indicator

9—Coolant Level Indicator 10—Tire Pressure Indicator 11—Engine Service Indicator (Engine Fault) 12—Transmission Service Indicator (Transmission Fault) 13—Secondary Steering Indicator (Emergency Steering) 14—Retarder Indicator

15—Service Required Indicator 16—Engine Air Filter Indicator (not used) 17—Battery Charge Indicator 18—High Beam Indicator 19—Bin Raised Indicator (Bin Up) 20—Engine Overspeed Indicator 21—Inter-axle Lock Indicator (Interaxle Diff Lock)

22—Differential Lock Indicator (not used) 23—Brake Oil Pressure Indicator 24—High Speed Indicator (not used) 25—Right Turn Indicator 26—Hydraulic Indicator 27—Brake Temperature Indicator (not used) 28—Park Brake Indicator

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PN=32

Operation—Operator’s Station

Instrument Panel Functions IMPORTANT: Prevent machine damage. DO NOT operate machine when engine coolant temperature is high.

IMPORTANT: Prevent machine damage. If low coolant level indicator is on, shut down engine immediately.

1. Coolant Temperature Gauge—displays temperature of engine coolant. Normal operating temperature is indicated by green zone. When gauge is in red zone, indicator will come on, and audible alarm will sound. Stop operation and, with engine running at slow idle, allow to cool. If temperature continues to increase, stop engine immediately. 2. Speedometer—displays travel speed in kilometers per hour (km/h) and miles per hour (mph). 3. Message Display—displays machine information for operator. 4. Engine RPM Gauge—displays engine rpm. If engine is over 2800 rpm, indicator will come on, audible alarm will sound, and service required indicator will flash. 5. Fuel Gauge—displays fuel level in tank. Indicator will come on, and low fuel message will appear on monitor.

9. Coolant Level Indicator—when coolant level is low, indicator comes on, audible alarm will sound, and service required indicator will flash. 10. Tire Pressure Indicator— if equipped with the tire pressure monitoring system, indicator lights when there is a 10-15% tire pressure reduction in any tire. Check tire pressure. 11. Engine Service Indicator (Engine Fault)— service indicator comes on and stays on when an engine service code has been detected. 12. Transmission Service Indicator (Transmission Fault)—lights and stays lit when a transmission clutch slippage service code has been detected.

NOTE: Always fill fuel tank at end of day to prevent condensation in fuel tank.

IMPORTANT: DO NOT exceed maximum transmission operating temperature of 145°C (293°F) to avoid damage to the transmission. 6. Transmission Oil Temperature Gauge—indicates temperature of transmission oil. Normal operating temperature is indicated by green zone. If gauge is in red zone, indicator will come on, and audible alarm will sound. Stop machine immediately. 7. Cold Start Indicator (not used). 8. Left Turn Indicator—comes on when left turn signal is switched ON.

NOTE: 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. 13. Secondary Steering Indicator (Emergency Steering)—comes on when secondary steering system is activated. Stop machine and take corrective action. Secondary steering system is ground-driven and not intended for continuous use. 14. Retarder Indicator—comes on when engine or transmission retarder is engaged. 15. Service Required Indicator—comes on if service is required, should be investigated and corrected as soon as possible. 16. Engine Air Filter Indicator (not used). 17. Battery Charge Indicator—comes on when alternator output is low. 18. High Beam Indicator—comes on when headlight high beams are ON. 19. Bin Raised Indicator (Bin Up)—comes on when bin is raised off the frame.

Continued on next page

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PN=33

Operation—Operator’s Station

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. 20. Engine Overspeed Indicator—comes on when engine speed exceeds 2800 rpm. 21. Inter-axle Lock Indicator (Interaxle Diff Lock)— comes on when inter-axle lock is engaged. 22. Differential Lock Indicator (not used). 23. Brake Oil Pressure Indicator—comes on when brake oil pressure is low or brake accumulator has lost its charge. Stop machine immediately. Push park brake switch ON and take corrective action. 24. High Speed Indicator (not used).

25. Right Turn Indicator—comes on when right turn signal is switched ON. 26. Hydraulic Indicator—comes on and audible alarm will sound when hydraulic oil temperature is too high or hydraulic filter element is restricted. For high hydraulic oil temperature, stop work and place transmission in neutral. Allow engine to operate at 1500 rpm for 3 minutes and allow oil to cool. For a restricted hydraulic filter, replace as soon as possible when a problem occurs. If indicator stays on, see your authorized dealer. NOTE: Cold oil may cause hydraulic oil filter restriction indicator to light until oil is warm. 27. Brake Temperature Indicator (not used). 28. Park Brake Indicator—comes on when park brake is engaged and transmission control lever is in neutral.

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PN=34

Operation—Operator’s Station

Radio Controls 1. Power Button—with key switch in the ON or ACCESSORY position, push to turn radio ON or OFF. Pushing the audio button will also turn the radio ON.

TX1009737A

2. Release Button—push to release control panel. 3. CD Eject Button—push to eject CD. 4. Volume Control—increase the volume by pressing the UP arrow button; decrease the volume by pressing the DOWN arrow button. 5. CD Slot—insert CD into slot. 6. Audio Button—to adjust the bass, treble, balance and fader settings and sound preset. 7. Menu Scan Button—press to access the menu or scan function. Short press: Menu , to open the basic settings menu. Long press: Scan, to start scan function. 8. Tune Button—press the LEFT arrow or RIGHT arrow button to manually change station. 9. X Bass Button—press to adjust the X bass function. 10. Display Button—press to display the time. 11. Preset Button—press any of the six preset buttons for preset stations. 12. AM/FM Select Button—press to access AM or FM stations.

–UN–10JUL06

NOTE: The faceplate is factory set to be non-removable. Contact DTAC if the radio face plate needs to be removable.

1—Power Button 2—Release Button 3—CD Eject Button 4—Volume Control 5—CD Slot 6—Audio Button 7—Menu Scan Button 8—Tune Button 9—X Bass Button 10—Display Button 11—Preset Button (6 used) 12—AM/FM Select Button 13—SRC Button

NOTE: FM1 and FM2 bands are the same. This allows for twelve FM preset stations instead of six. 13. SRC Button—push to select the CD, radio, CD changer or AUX sources.

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PN=35

Operation—Operator’s Station

Steering Column Lever 1. High Beam Headlight—push lever forward to high beam headlight position (1).

–UN–10JUL06

2. Low Beam Headlight—move lever to center dim headlight position (2).

TX1009738A

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. Right Turn Indicator—lift steering column lever up to right turn indicator position (4) to activate right turn signal. 5. Left Turn Indicator—push steering column lever down to left turn indicator position (5) to activate left turn signal. 6. Horn Button—push to sound horn.

1—High Beam Headlight Position 2—Low Beam Headlight Position 3—Flash-to-Pass Headlight Position 4—Right Turn Indicator Position 5—Left Turn Indicator Position 6—Horn Button

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PN=36

Operation—Operator’s Station

Operator Seat and Instructional Seat CAUTION: Check condition of seat belt and mounting hardware before operating machine. Replace seat belt at least every three years, regardless of condition. The operator seat is fully adjustable to suit the operator’s height, weight and reach.

TX1009739A

–UN–10JUL06

1. Fore/Back Adjustment Lever—lift to move seat forward or backward. 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—may be lifted to allow easier access to seat and then lowered for operator comfort. 5. Backrest Tilt—seat back tilt lever to adjust seat back tilt. Lift the release lever to lock seat back into position. 6. Fore/Back Cushion Lock—to adjust cushion to improve operator comfort. 7. Ride Control/Stiffness—adjust seat to improve overall ride control and to reduce stiffness. 8. Instructional Seat—is non-adjustable and is equipped with a seat belt.

–UN–10JUL06

An optional leather and cloth seat with heat and high back is available.

TX1009742A

1—Fore/Back Adjustment Lever 2—Air/Height Lever 3—Lumbar 4—Armrest Height 5—Backrest Tilt 6—Fore/Back Cushion Lock 7—Ride Control/Stiffness 8—Instructional Seat

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110807

PN=37

Operation—Operator’s Station To activate the heat feature use the 3-position seat heater switch.

TX1026458

–UN–16JUL07

• Press the upper half of the seat heater switch to turn both the seat and back heat on. • Press the lower half of the seat heater switch to turn the back heat on. • Place the switch in the middle position to turn heat off completely.

Seat Heater Switch

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PN=38

Operation—Operator’s Station

Battery Disconnect Switch and Battery Circuit Breakers

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

TX1011252A

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. The battery disconnect switch should also be turned OFF if machine is left unattended. If switch is left ON for long periods, batteries may become discharged.

–UN–17AUG06

The battery disconnect switch (4) is located inside the battery compartment.

1—20-Amp Circuit Breaker—Battery Balancer 2—20-Amp Circuit Breaker—Cold Start Aid and Unloader Valve Heater 3—60-Amp Circuit Breaker—Main 4—Battery Disconnect Switch

The battery disconnect switch has two 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) is rated at 60 amps. • The battery balancer circuit breaker (1) is rated at 20 amps. • The cold start aid and unloader valve heater (2) are rated at 20 amps.

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PN=39

Operation—Operator’s Station

Miscellaneous Equipment Lights—high beam and low beam headlights (1) are controlled using the steering column lever. See Steering Column Lever. (Section 2-1.)

–UN–25SEP01

Brake lights (5) light when brake pedal is depressed or when accelerator pedal is released and torque retarder and exhaust brake are activated.

T143574B

Turn indicator lights (2 and 4) light when four-way flasher lights or turn signals are turned on. Backup lights (6 and 7) light when machine transmission is shifted to reverse.

TX1009607A

–UN–29JUN06

1—Headlight and Front Park Light (2 used) 2—Front Turn Indicator Light (2 used) 3—Work Light—If Equipped (2 used) 4—Rear Turn Indicator Light (2 used) 5—Tail, Brake and Park Light (2 used) 6—Backup Light (3 used) 7—Articulation Backup Light

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–UN–29JUN06

Secondary Exit—if necessary, use the secondary exit tool (1) to break the glass of the right-side window and cut seat belt.

TX1009552A

1—Secondary Exit Tool

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PN=40

Operation—Operator’s Station 12-Volt Accessory Outlet—accessory outlet is used to power operator accessories, as necessary.

TX1009553A

–UN–29JUN06

1—12-Volt Accessory Outlet

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Operator’s Manual Compartment—to store Operator’s Manual in compartment located behind the operator seat to keep it clean and dry.

TX1010034A

–UN–11JUL06

1—Compartment

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Cab Tilt Pump Handle—is located in the cab by the operator seat and secured in position with two plates.

TX1009554A

–UN–29JUN06

1—Cab Tilt Pump Handle

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110807

PN=41

Operation—Operator’s Station Windshield Washer Reservoir—is located at front of the cab under the hood.

–UN–29JUN06

To fill reservoir: 1. Tilt hood.

TX1009557A

2. Remove filler cap (2) and fill windshield washer reservoir (1) with washer cleaning fluid. 3. Install cap. Ensure that electrical connection and fluid delivery hose are also secure. 1—Windshield Washer Reservoir 2—Filler Cap

4. Close hood.

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PN=42

Operation—Operator’s Station

NOTE: The operator can choose one of five default display menus. To change the default display menu, press the SELECT button. To change the information within the display menu, press the NEXT button. 1. Default Display Menu 1—allows the operator to view machine information.

TX1011255

DEERE 250D

RPM –UN–08SEP06

Monitor Display Unit (MDU)—Default Display Menus

1 Default Display Menu 1

Pressing the NEXT button will change the information in the machine data display (1).

1—Machine Data Display

The following information can be displayed using the machine data display: • Bin Tip Count—amount of times the bin is tipped. • Trip Odo—trip odometer measures trip distance. • Trip Time—trip time. • Trip Fuel—fuel used per hour. • Trip Load (not used). • Odometer—distance of total miles driven. • Lock Up (CTH)—amount of clutch lock up. • Current Gear—shows current gear. • Sump Oil—oil temperature. • Ret Oil Temp—retarder oil temperature. • Retr Torq—amount of retarder torque. • Eng Coolant—engine coolant temperature. • Eng Oil—engine oil pressure. • Boost Press—turbo boost pressure. • Eng Oil Lvl—percent of engine oil level. • Fuel Economy—fuel used per hour of use. • Eng Torq—percent of engine torque. • Eng Ret Torq—percent of engine retarder torque. • Fuel—amount of fuel in tank. • Air Pressure—amount of air pressure in system. • HydTemp—temperature of hydraulic fluid. • Brake temp—temperature of brake fluid. • Payload (not used). • Time—current time. • Date—current date.

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PN=43

Operation—Operator’s Station

Gear Display—displays selected gear range. When machine is in neutral, gear display (2) will show “0”. When machine is in drive, the gear display will show a number from “1” to “6”, indicating which forward gear the machine is in; there are six forward gears. When the machine is in reverse, the gear display will show “1”; there is only a single reverse gear.

rpm

0.0 ODM HOURS SPEED

–UN–08SEP06

TX1011775

2. Default Display Menu 2—allows the operator to view selected gear, current engine speed, machine hours, travel speed, and distance machine has traveled.

Default Display Menu 2

Drive/Neutral/Reverse Display—when machine is in drive, “F” will be displayed on drive/neutral/reverse display (3). When machine is in neutral, “N” will be displayed. When machine is in reverse, “R” will be displayed.

2—Gear Display 3—Drive/Neutral/Reverse Display 4—Engine Speed Display 5—Hours 6—Odometer 7—Speed

Engine Speed Display—current engine speed is displayed on engine speed display (4). Machine Hours—when Hours (5) is highlighted, the machine total hours to the nearest tenth of an hour are displayed. The hour meter accumulates hours only when the engine is on. The hour meter displays up to 99,999.9 hours. Pressing the NEXT button will highlight the travel Speed display. Travel Speed—when SPEED (7) is highlighted, the travel speed of the machine is displayed to the nearest tenth. Odometer—when ODM (6) is highlighted, the distance the machine has traveled in kilometers or miles since the odometer’s last reset is displayed.

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PN=44

Operation—Operator’s Station

Pressing the NEXT button will change the information in the machine data display (1).

1—Machine Data Display 2—Gear 3—Drive/Neutral/Reverse 4—Tachometer (RPM) 5—Hours 7—Speed 8—Odometer

0RPM DEERE 250D 0.0 HRS

0.0 ODO 8

–UN–08SEP06

0 MPH

TX1011835

3. Default Display Menu 3—allows the operator to view selected gear, current engine speed, machine hours, travel speed, distance machine has traveled, and machine information.

Default Display Menu 3

RK98916,000002F –19–21SEP06–3/5

0 0

RPM

0.0 ODO

0.0 HRS

–UN–08SEP06

MPH

TX1011776

4. Default Display Menu 4—-allows the operator to view selected gear, current engine speed, machine hours, travel speed, and distance machine has traveled.

Default Display Menu 4

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PN=45

Operation—Operator’s Station

MPH

0.0 HRS

0.0

ODO

RPM

–UN–08SEP06

TX1011836

5. Default Display Menu 5—allows the operator to view selected gear, current engine speed, machine hours, travel speed, distance machine has traveled, and machine information.

Default Display Menu 5

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Monitor Display Unit (MDU)—Main Menu

1. Counters—displays a counter meter that can be reset and is used to keep track of certain tasks. The counter value will be stored when the ignition switch is turned off. 2. Actual Values—displays machine sensor information. 3. Diagnostics—menu provides a limited set of tools, and is intended to be used by service personnel and machine operators for diagnostic and troubleshooting functions. 4. Machine Config—menu allows the operator to make changes to various operating characteristics of the machine. 5. Machine ID—displays machine identification information. 6. Service Mode—a troubleshooting aid for service personnel only.

1/6

–19–31JUL06

Service Mode is for service personnel only.

Main Menu 1-Counters 2-Actual Values 3-Diagnostics 4-Machine Config 5-Machine ID 6-Service Mode

TX1010762

NOTE: Main Menu has six categories. Pressing NEXT will highlight the next category. Press SELECT to enter that highlighted category. Press BACK to exit Main Menu.

1—Counters 2—Actual Values 3—Diagnostics 4—Machine Config 5—Machine ID 6—Service Mode (service personnel only)

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PN=46

Operation—Operator’s Station

Monitor Display Unit (MDU)—Counters NOTE: Pressing NEXT will highlight the next category. Press SELECT to enter that highlighted category. Press BACK to return to the previous screen.

1/3

Counters—displays Trip Information, Bintip Count, and Service Information and allows counters to be reset.

TX1009421

NOTE: Pressing NEXT will highlight the next category. Press SELECT to enter that highlighted category. Press BACK to return to the previous screen.

–19–01AUG06

Counters 1–Trip Info 2–Bintip Count 3–Service

1. Trip Info—displays trip distance, trip time, trip fuel and trip load counters. 1—Trip Info 2—Bintip Count 3—Service

RK98916,0000031 –19–21SEP06–1/7

Trip Distance Total: 000.0 mi Trip: 000.0 mi

1/4

TX1010765

Press SELECT to Reset

–19–01AUG06

• Trip Distance—displays total distance machine traveled, in kilometers or miles, and distance machine traveled since counter was last reset. To reset Trip counter, press and hold SELECT until 3 beeps are heard. Press NEXT to advance the menu.

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PN=47

Operation—Operator’s Station

Trip Time Total: Trip:

2/4 0.0 hrs 0.0 hrs

TX1010766

Press SELECT to Reset

–19–01AUG06

• Trip Time—displays machine operation time since counter was last reset. To reset Trip Time counter, press and hold SELECT until 3 beeps are heard. Press NEXT to advance the menu.

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Trip Fuel Total: Trip:

3/4 0.0 gal/h 0.0 gal/h

TX1010767

Press SELECT to Reset

–19–01AUG06

• Trip Fuel—displays fuel consumption, in L/h or gal/h, since counter was last reset. To reset Trip Fuel counter, press and hold SELECT until 3 beeps are heard. Press NEXT to advance the menu.

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PN=48

Operation—Operator’s Station • Trip Load (not used)

4/4 0.0 T 0.0 T

TX1010768

Press SELECT to Reset

–19–01AUG06

Trip Load Total: Trip:

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Bintip Count Total: 000.0 Trip: 0.0

1/1

TX1010760

Press SELECT to Reset

–19–31JUL06

2. Bintip Count—displays number of times the bin was tipped since counter was last reset. To reset Bintip counter, press and hold SELECT until 3 beeps are heard.

RK98916,0000031 –19–21SEP06–6/7

3. Service—displays last service interval and next service interval.

1/1 0.0 hrs .

–19–01AUG06

Service Last: Next:

TX1009400

NOTE: The Service menu can be reset only by a service technician and in service mode only.

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PN=49

Operation—Operator’s Station

Monitor Display Unit (MDU)—Actual Values

Actual Values 1–Engine Values 2–Trans Values 3–Vehicle Values

1/3

TX1009402

1. Engine Values—displays the following engine information. • Engine Torq—displays machine torque as a percentage of available torque. • Req Eng Torq—displays the requested engine torque. • Req RPM—displays the requested engine rpm. • Engine Ret Torq—displays engine retarder torque. • Ret Control Mode—to adjust the percentage of torque retarder applied when accelerator pedal is released. • Req Ret Torq—displays requested retarder torque. • Engine Oil Temp—displays engine oil temperature in °C or °F. • Engine Coolant Temp—displays engine coolant temperature in °C or °F. • Intake Manifold—displays engine intake manifold temperature in °C or °F. • Fuel Temp (not used). • Eng Oil Pressure—displays engine oil pressure in bar or psi. • Boost Pressure—displays boost pressure in bar or psi. • Engine Oil Level—displays engine oil level as a percentage. • Fuel Consump—displays fuel consumption in L/h or gal/h. • Throttle Position—displays a number that represents a percentage of pedal position of the throttle from 0—100%. • Kick Down • Ref Ret Torq—displays reference retarder torque.

–19–01AUG06

Actual Values—displays engine, transmission, and vehicle values.

1—Engine Values 2—Trans Values 3—Vehicle Values

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Operation—Operator’s Station

1/3

TX1010018

Actual Values 1–Engine Values 2–Trans Values 3–Vehicle Values

–19–01AUG06

2. Trans Values—displays the following transmission information. • Ret Torq—transmission retarder torque. • Ret Control Mode—retarder control mode. • Req Ret Torq—the percentage of the torque retarder, which is selected by the retarder switch on the SSM. • Output Speed—output speed at transmission. • Selected Gear—gear that has been selected from the transmission shift control. • Current Gear—currently activated travel gear. • Lock-Up Clutch—status of ON/OFF. • Shift Program • Sump Oil Temp—transmission oil temperature in °C or °F. • Ret Oil Temp—transmission return oil temperature in °C or °F. • Ref Ret Torq—reference retarder torque.

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Operation—Operator’s Station

1/3 –19–01AUG06

Actual Values 1–Engine Values 2–Trans Values 3–Vehicle Values

TX1010021

3. Vehicle Values—displays the following vehicle information. • Aircon Air Temp—air conditioner temperature in °C or °F. • Cab Temp—inside cab temperature in °C or °F. • Req Cab Temp—temperature setting for cab temperature in °C or °F. • Battery 24V—available voltage in 24V circuit, displayed in mv. • Battery 12V—available voltage in 12V circuit, displayed in mv. • Bin Position— bin position as a percentage of bin in full-up position. • Bin Lever Position—position of the bin lever. • Left Height (not used). • Right Height (not used). • Artic Angle (not used). • Air Pressure—display shows system air pressure in bar or psi. • Wet Brake Temp (not used). • Hyd Temp—hydraulic oil temperature in °C or °F. • Fuel Level—remaining fuel supply as a percentage. • Fuel—remaining fuel supply in L or gal.

RK98916,0000032 –19–21SEP06–3/3

2-1-27

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Operation—Operator’s Station

Monitor Display Unit (MDU)—Diagnostics

1/9 Diagnostics 1–Actual Faults 2–Stored Faults 3–CCU Diagnostics 4–OEU Outputs 5–MDU Diagnostics 6–OBW Diagnostics 7–MM Diagnostics 8–CAN Diagnostics 9–TPM Diagnostics

–19–31JUL06 TX1010762

1—Actual Faults 2—Stored Faults 3—CCU Diagnostics 4—OEU Outputs 5—MDU Diagnostics 6—OBW Diagnostics 7—MM Diagnostics 8—CAN Diagnostics 9—TPM Diagnostics

–19–01AUG06

1. Actual Faults—displays active diagnostic trouble codes. If service code appears, see your authorized dealer.

1/6

TX1010727

Main Menu 1-Counters 2-Actual Values 3-Diagnostics 4-Machine Config 5-Machine ID 6-Service Mode

Diagnostics—displays information used to display service codes and diagnose inputs and outputs of CCU.

VD76477,0001537 –19–06JUL07–1/7

2. Stored Faults—displays diagnostic trouble codes. If a service code appears, see your authorized dealer.

1/1 0000.00 0 0.0

TX1010759

SELECT for Detail

–19–31JUL06

Stored Faults MDU Occur Count: Mach hrs Last:

NOTE: Stored faults can be cleared only in service mode.

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2-1-28

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PN=53

Operation—Operator’s Station

CCU Diagnostics 1-CCU Inputs 2-CCU Analog 3-CCU Outputs

CCU Inputs—displays On/Off status of CCU inputs.

TX1010822

• Start Signal (On/Off) • Brake Light Switch (On/Off) • Hazard Dash Switch (On/Off) • Park Brake Dash Switch (On/Off) • Front Wiper Park Signal (On/Off) • Front Two-Speed Switch (not used) • Rear Wiper Park Signal (not used) • Rear Two-Speed Switch (not used) • Two-Speed Press (not used) • Mid Two-Speed Switch (not used) • Scraper Dash Switch (not used) • IDL Pressure Switch • Horn Switch (On/Off) • Aircon Thermo Switch (On/Off) • Bonnet Fan Temp Switch (not used) • Hardware Detect (On/Off) • SSM

1/3 –19–01AUG06

3. CCU Diagnostics—displays CCU monitored input, analog and output signals. • CCU Inputs • CCU Analog • CCU Outputs

CCU Analog—displays CCU analog inputs in millivolts for analog sensors as measured at CCU input. • Bin Position (%) • Bin Position (mV) • Bin Lever Position (%) • Bin Lever Position (mV) • Air Pressure (bar or psi) • Air Pressure (mV) • Hydraulic Temp (°C or °F) • Hydraulic Temp (mV) • Battery 24V (mV) • Battery 12V (mV) • Articulation Angle (%) (not used) • Articulation Angle (mV) (not used) • Left Height (in.or mm) (not used) • Left Height (mV) (not used) • Right Height (in.or mm) (not used) • Right Height (mV) (not used) • Aircon Air Temp (°C or °F)

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Operation—Operator’s Station • Aircon Air Temp (mV) • Cab Temp (°C or °F) • Cab Temp (mV) • Wet Brake Temp (°C or °F) (not used) • Wet Brake Temp (mV) (not used) CCU Outputs—displays CCU analog output signal On/Off status. • Articulation Rev Light (not used) • Brake Light (On/Off) • Left Indicator Light (On/Off) • Right Indicator Light (On/Off) • Headlight Dips • Headlight Brights • Park Lights • Reverse • Work Lights (not used) • Flashing Beacon (not used) • Front Wiper Lo Speed • Rear Wiper Lo Speed (not used) • Front Wiper Hi Speed (On/Off) • Rear Wiper Hi Speed (not used) • Front Washer Pump (On/Off) • Rear Washer Pump (not used) • Bin Up Solenoid • Bin Down Solenoid • Bin Pressure Reduction (On/Off) • Bin Lever Latch (On/Off) • Horn/Hooter (On/Off) • Park Brake Solenoid (On/Off) • Overspeed Control (On/Off) • IDL Solenoid (On/Off) • CTD Solenoid (On/Off) (not used) • Pneumatic Blow Off (On/Off) • Mirror Heating (On/Off) • Hydraulic Cut Solenoid (On/Off) • D Plus (On/Off) • A/C Clutch Solenoid (On/Off) • Recirculation Flap (%) 4. OEU Outputs—displays OEU monitored outputs. • Fan Cut Solenoid (On/Off) (not used) • Fan Low Solenoid (On/Off) (not used) • Fan Medium Solenoid (On/Off) (not used) • Gear Hold Control (On/Off) (not used)

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Operation—Operator’s Station • Left Strut Up (%) (not used) • Left Strut Down (%) (not used) • Right Strut Up (%) (not used) • Right Strut Down (%) (not used) • Two-Speed Solenoid (not used) • Automatic Neutral (On/Off) (not used) • Pre-Sel Sec Gear (On/Off) • Unladed (On/Off) • Blower Speed 1 • Blower Speed 2 • Blower Speed 3 • JD Starter • Feet Actuator (%) • Mid/Demist Actuator (%) • Heater Valve Actuator (%) • Load Light Yellow (not used) • Load Light Green (not used) • Load Light Red (not used) • Bonnet Fan 1 (not used) • Bonnet Fan 2 (not used) 5. MDU Diagnostics—displays monitor display unit (MDU) monitored inputs and outputs. • Fuel Level (%) • Fuel Level (mV) • Hydraulic Filter Switch (On/Off) • Hydraulic Level Switch (On/Off) • CTD Switch (On/Off) (not used) • E/Steering Switch (On/Off) • H/Light Bright Switch (On/Off) • H/Light Dip Switch (On/Off) • Engine Coolant Level Switch (On/Off) • Cold Start Switch (On/Off) • Engine Filter Switch (On/Off) • Transmission Filter Switch (On/Off) • Low Brake Pressure Switch (On/Off) • Park Brake Pressure (On/Off) 6. OBW Diagnostics (not used) 7. MM Diagnostics (not used)

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Operation—Operator’s Station

CAN Diagnostic 1-CAN Stats 2-RX CAN Mess

CAN Stats:

TX1010823

• Bus Load • Tx Count • Rx Count • Error/sec • Total Errors • Bus Off Errors • Stuff Errors • Form Errors • Ack Errors • Bit1 Errors • Bit0 Errors • Crc Errors • Reset Errors (press SELECT to reset CAN errors)

1/2 –19–01AUG06

8. CAN Diagnostics—displays CAN monitored statistics and RX CAN messages. • CAN Stats • RX Can Messages

RX Can Messages: • CCU • TCU • ECU • GEAR • SSM • OEU • ECU RET • TCU RET 9. TPM Diagnostics—displays tire information including: • Tire Temperature • Gauge Pressure • Comp Set Pressure • Tire ID

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1/6 Del izg Temp neum Atico 84 F Manometro 55psi Pres reg comp 57psi ID Neum Atico 110542

Use the NEXT button to change to the next screen. • Left Front • Right Front • Left Middle • Right Middle • Left Rear • Right Rear

TX1024471

NOTE: When the tire pressure is below the appropriate level the tire pressure indicator on the instrument panel will light.

–19–01OCT07

Operation—Operator’s Station

VD76477,0001537 –19–06JUL07–7/7

Machine Config—data displays the current machine configuration settings and allows user to view and change the following seven submenus, if necessary.

Config mAquina 1/13 1 - Ajustes monitor 2 - Cadencia limpia 3 - Funcion arrastre 4 - Opciones prod 5 - Ajustes caja 6 - Tam neum Atico

TX1025830

1—Monitor Settings 2—Wiper Timing 3—Scraper Function (not used) 4—Prod Options 5—Bin Settings 6—TPM Config 7—Sus Setup (not used)

–19–01OCT07

Monitor Display Unit (MDU)—Machine Config

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Operation—Operator’s Station

Monitor Settings 1–Language 2–Units 3–Backlighting 4–Time Offset 5–LCD Contrast

TX1010113

1—Language 2—Units 3—Backlighting 4—Time Offset 5—LCD Contrast

1/5

–19–01AUG06

Monitor Settings—displays the current monitor settings and allows user to view and change the following five submenus if necessary.

VD76477,0001576 –19–10JUL07–2/11

1/4 –19–17AUG06

Language English German French Spanish

TX1010844

1. Language—allows user to change the language of monitor display. ❒ English—menu language will be set to English. ❒ German—menu language will be set to German. ❒ French—menu language will be set to French. ❒ Spanish—menu language will be set to Spanish.

VD76477,0001576 –19–10JUL07–3/11

1/2

TX1010934

Units Metric Imperial

–19–03AUG06

2. Units—allows user to switch units of measure from metric to imperial on the monitor display. ❒ Metric—all units will be metric units. ❒ Imperial—all units will be standard/English units.

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Backlighting MENU to Exit BACK to Decrease NEXT to Increase SELECT to Store

NOTE: To adjust the following screens, press BACK to decrease, and NEXT to increase. Hold SELECT until 3 beeps are heard to store. Press MENU to return to the previous screen. 3. Backlighting—allows user to change the backlighting of the monitor display.

TX1010758

–19–31JUL06

Operation—Operator’s Station

VD76477,0001576 –19–10JUL07–5/11

4. Time Offset—allows user to offset monitor time setting.

MENU to Exit BACK to Decrease NEXT to Increase SELECT to Store

TX1010828

0 hrs

–19–01AUG06

Time Offset

VD76477,0001576 –19–10JUL07–6/11

5. LCD Contrast—allows user to adjust the contrast of the LCD display.

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2-1-35

TX1010783

MENU to Exit BACK to Decrease NEXT to Increase SELECT to Store

–19–01AUG06

LCD Contrast

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PN=60

Operation—Operator’s Station

Config mAquina 1/13 1 - Ajustes monitor 2 - Cadencia limpia 3 - Funcion arrastre 4 - Opciones prod 5 - Ajustes caja 6 - Tam neum Atico

TX1025830

Scraper Function (Not used)

–19–01OCT07

Wiper Timing—can be adjusted in one-second increments and up to twenty-second intervals.

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Operation—Operator’s Station Prod Options—allows user to switch from Bin Restriction to Load Spreading.

3 - Speed Limit

–UN–05JUL07

– Bin Restriction—allows use of Production Limit function. – Load Selection (not used) – Load Spreading—allows operator to raise and lower the bin in gears 1-4 • Engine Limit—allows operator to change engine rpm limit. • Speed Limit—allows operator to set speed limit.

–19–01OCT07

IMPORTANT: When machine is in Load Selection mode, the Production Limit function will not operate.

1/3

TX1025834

Opciones prod 1 - e-Bin 2 - Engine Limit

• e-Bin

TX1026009A

Pressing the bin maximum position switch (1) with all of the LEDs off will cause all 4 LEDs to flash indicating that load spreading is active. The operator will be allowed to raise the bin while the vehicle is in gears 1-4 (no higher) and the LEDs are flashing. Pressing the bin maximum position switch while the LEDs are flashing will de-activate the feature and thus revert to the standard bin features. 1—Bin Maximum Position Switch

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Operation—Operator’s Station Bin Settings—menu allows user to restrict the maximum bin position.

Bin Settings 1-Production Limit

–19–01AUG06

IMPORTANT: Machine must be in Bin Restriction or Load Spreading mode for Production Limit function to operate.

1/1

TX1010754

• Production Limit—restricts bin position based on a percentage of maximum bin position (ex., a production limit of 60% will restrict bin position to 60% of maximum position when function is active). NOTE: To adjust the Production Limit screen, press BACK to change place holders and NEXT to increase. To store, push and hold SELECT until 3 beeps are heard. Press MENU to return to the previous screen.

VD76477,0001576 –19–10JUL07–10/11

Config TPM 1 - Config CIP

This menu option should only be used during the initial set up of the tire pressure mounting system.

2 - Trazado manual 3 - Trazado auto

Sus Setup(Not Used)

TX1025837

NOTE: When the tire pressure is below the appropriate level the tire pressure indicator on the instrument panel will light.

–19–01OCT07

TPM Config (If Equipped)

VD76477,0001576 –19–10JUL07–11/11

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Operation—Operator’s Station

Monitor Display Unit (MDU)—Machine ID

1. ECU—engine control unit (ECU) identification information. 2. TCU—transmission control unit (TCU) identification information. 3. MDU—monitor display unit (MDU) identification information. 4. CCU—chassis control unit (CCU) identification information. 5. OEU—output expansion unit (OEU) identification information. 6. SSM—sealed switch module (SSM) identification information. 7. MMU (not used) 8. OBW (not used) 9. TPM (optional)

1/6

–19–31JUL06

Machine ID—displays machine identification information.

Main Menu 1-Counters 2-Actual Values 3-Diagnostics 4-Machine Config 5-Machine ID 6-Service Mode

TX1010762

NOTE: Press NEXT to highlight the next category. Press SELECT to enter that highlighted category. Press BACK to return to the previous screen.

RK98916,0000035 –19–05JUL07–1/1

Monitor Display Unit (MDU)—Service Mode

–19–31JUL06

1/6

TX1010762

Main Menu 1-Counters 2-Actual Values 3-Diagnostics 4-Machine Config 5-Machine ID 6-Service Mode

“Service Mode” Is a troubleshooting aid for service personnel only.

RK98916,0000036 –19–24AUG06–1/1

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Operation—Operating the Machine Before Starting Work –UN–24AUG00

Review the operating precautions in the Safety Section of this manual.

T133556

Use seat belt when operating your machine. Remember to fasten seat belt even during brief periods of use.

CS33148,0000CAC –19–11AUG06–1/1

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 condition of guards, shields and covers.

Check for oil leaks, missing or loose hose clamps, kinked hoses and lines or hoses that rub against each other or other parts. 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.

CS33148,0000CAD –19–11AUG06–1/1

2-2-1

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Operation—Operating the Machine

Starting Engine Before Starting the Engine 1. Turn battery disconnect switch to the ON position. –UN–23AUG88

2. Fasten seat belt.

TS175

3. Turn key switch to ON position (1) and verify that the following happens during 3-second bulb check:

–UN–27JUL06

• 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.

TX1010705A

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.

1—Key Switch ON Position 2—Key Switch START Position

Starting the Engine 1. Press horn button to sound horn and alert bystanders that machine will be started.

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2-2-2

CS33148,0000CAE –19–18SEP06–1/2

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PN=66

Operation—Operating the Machine

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. 2. Turn key switch to START position (2) and hold until engine starts. If temperature is below 0°C (32°F) and engine is COLD, press start aid switch (if equipped) 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.

CS33148,0000CAE –19–18SEP06–2/2

2-2-3

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PN=67

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). 3. Turn start aid can (2) counterclockwise to remove from base. 4. Remove safety cap and spray button from new start aid can. –UN–29AUG06

5. Install new start aid can. Hand tighten. 6. Tighten clamp.

TX1011672A

7. Close hood. 1—Clamp 2—Start Aid Can

SJ25320,000018C –19–18SEP06–1/1

2-2-4

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Operation—Operating the Machine

Warming Hydraulic System NOTE: The monitor can be used to display hydraulic oil temperature. See Monitor Display Unit— Actual Values. (Section 2-1.) IMPORTANT: If machine temperature is below — 18°C (0°F), start procedure with engine running at 1/2 speed. Failure to do this could cause pump cavitation. Once oil temperature is above —18°C (0°F) the engine speed can be increased to fast idle. Below —18°C (0°F) an extended warm-up period may be necessary. Hydraulic function will move slowly and lubrication of parts may not be adequate with cold oil. Do not attempt normal machine operation until hydraulic functions move at or close to normal cycle times. Operate functions slowly and avoid sudden movements until engine and hydraulic oils are thoroughly warmed. Operate a function by moving it a short distance in each direction. Continue operating the function, increasing the distance traveled in each cycle until full stroke is reached. For faster warm-up, restrict air flow through oil cooler using cardboard or other similar material. Use correct viscosity hydraulic oil to minimize warm-up period. See Hydraulic Oil. (Section 3-1.)

CAUTION: Avoid possible serious injury from machine movement during warm-up procedure. Clear the area of all bystanders before doing the warm-up procedure. 2. Clear the area of all bystanders to allow for machine movement. 3. Start engine. Do not accelerate engine rapidly during warm-up. Run engine at 1/2 speed for approximately five minutes before operating any functions. 4. Engage park brake. IMPORTANT: Holding a function over relief for more than 10 seconds can cause damage to control valve. 5. Operate steering and bin raise and lower functions over relief to heat hydraulic system. 6. Once oil temperature is above —18°C (0°F), increase engine speed to fast idle. 7. Stop periodically and operate all hydraulic functions to distribute the heated oil.

1. Display hydraulic oil temperature using MDU. See Monitor Display Unit—Actual Values. (Section 2-1.)

RK98916,0000047 –19–20SEP06–1/1

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Operation—Operating the Machine

Driving Machine Always adjust machine speed to road and traffic conditions.

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.

When driving through a bend, do not drive too fast, especially while transporting a load. If road is slippery, the operator could lose control.

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.

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.

Operate the machine in accordance with site and road regulations.

CS33148,0000CB1 –19–11AUG06–1/1

Steering Machine steering system will enable operator to steer machine to a safe stop.

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.

When engine or main pump malfunctions, the secondary steering indicator (emergency steering) will flash. The machine’s secondary steering system is ground driven and will not operate when machine is stopped.

Secondary Steering NOTE: If there is an engine or main pump malfunction, the ground-driven secondary

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PN=70

Operation—Operating the Machine

Shifting Transmission not shift beyond second gear. With bin raised 15% or less, transmission will not shift beyond third gear.

IMPORTANT: When transmission sump oil temperature is below 7°C (19°F), only neutral, reverse and second gears are available.

The transmission has six forward gears and one reverse gear with automatic lock-up in all gears.

IMPORTANT: When transmission sump oil temperature is above 128°C (262°F), the TCU will restrict the use of higher gears. NOTE: With bin raised 50% or more , transmission will not shift beyond first gear. with bin raised more than 15% but less than 50% transmission will

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.

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Operation—Operating the Machine Shifting Transmission IMPORTANT: Stop machine before shifting from a forward gear to reverse gear.

–UN–17AUG06

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).

TX1011257A

3. Release park brake. 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.

1—1st Gear 2—2nd Gear 3—3rd Gear 4—Drive Gear 5—Neutral 6—Reverse Gear 7—Gearshift Control

Gear Pre-Selection 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. Move gear shift control to drive gear (D) to revert to normal operation, allowing the machine to shift through the full range of gears.

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2-2-8

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PN=72

Operation—Operating the Machine Downshift or Reverse Inhibitor NOTE: Shifting from neutral (N) to drive (D) or reverse (R) is inhibited when engine speed is above 900 rpm. Before shifting to drive (D) or reverse (R) engine speed must be below 900 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. Accelerator Control 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: Shifting from neutral (N) to drive (D) or reverse (R) is inhibited when engine speed is above 900 rpm. Before shifting to drive (D) or reverse (R) engine speed must be below 900 rpm. Shifting transmission from neutral (N) to reverse (R) or drive (D) is not allowed if engine speed is above 900 rpm. If shift is attempted while engine speed is above 900 rpm, release accelerator and allow engine speed to drop below 900 rpm, then attempt shift again. The position of the accelerator pedal influences the timing at which automatic shifting occurs.

CS33148,0000CB3 –19–15SEP06–3/3

2-2-9

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Operation—Operating the Machine

Using Range Hold

TX1011256A

When this condition occurs, press 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.

–UN–17AUG06

Under certain conditions, such as driving uphill, the transmission may start shift cycling or gear hunting, the transmission changes up and down between two 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.

1—Range Hold Switch

NOTE: The MDU will display the actual gear that the machine is in at any time. When range hold switch is turned off, normal automatic operation mode will continue. When level ground is reached, press range hold switch to switch range hold off.

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Operation—Operating the Machine

Using Inter-Axle Lock

–UN–29JUN06

IMPORTANT: The inter-axle lock must be used only when ground conditions are very poor and not on graded or tarred surfaces.

TX1009560A

NOTE: When the inter-axle lock is ON, a buzzer will sound once every 60 seconds and “IDL Is Active” will display on the message display. The inter-axle lock is used to improve traction. To engage inter-axle lock, reduce engine speed (accelerator pedal less than 10% depressed), press inter-axle lock switch (1) and ensure that inter-axle lock indicator lights.

1—Inter-Axle Lock Switch

When the inter-axle lock collar is engaged, the planetary goes into a lockup configuration and torque is 1:1 front and rear. With the inter-axle lock in lockup, both axles turn at the same speed and equal power is sent to all three axles. To disengage inter-axle lock, press inter-axle lock switch again.

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Operation—Operating the Machine

Slowing and Stopping the Machine decreased to less than 2600 rpm. Then the accelerator pedal is reactivated, giving the accelerator pedal (and operator) control of the electronic throttle again.

During normal operation, stop machine using service brakes. When machine is stopped for more than a few seconds, engage park brake. IMPORTANT: Use a combination of downshifting and braking while going downhill. NOTE: When the engine speed exceeds 2800 rpm, a condition known as “engine overspeed” occurs. During an engine overspeed condition, the transmission retarder will go to 100 % retardation. Engine overspeed condition will automatically deactivate the accelerator pedal, thus removing the accelerator pedal from the electronic throttle control circuit. During this time, the electronic throttle control will go to slow idle regardless of the position of the accelerator pedal. The engine overspeed condition exists until engine speed has

Remove foot from accelerator pedal to use engine as a braking force. The transmission will start to downshift and the transmission retarder will be applied to the setting selected on the SSM. Use service brakes and/or transmission retarder to slow machine if machine is exceeding maximum speed for held gear. Transmission retardation provides good speed control for traveling downhill. When machine is fully loaded, or slope is steep, it may be desirable to pre-select a lower gear before reaching gradient. Downshifting to a lower gear increases engine braking and helps the operator maintain control of machine.

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Operation—Operating the Machine Using Transmission Retarder to Slow Machine—the transmission retarder is automatically engaged when the accelerator pedal is completely released. –UN–29JUN06

The retarder indicator on the monitor panel will come on whenever the transmission retarder engages.

TX1009558A

Using transmission retarder switch (1), select a level of retardation between 0 and 6, depending on the amount of retardation required for the operating conditions. The 0 position has the least amount of retardation (15%) and 6 has the maximum amount of retardation (100%). The level of retardation can be changed while the machine is moving or stationary.

1—Transmission Retarder Switch

Full retardation (100%) is applied whenever the service brake pedal is pressed, regardless of retarder position. Transmission Retarder Position

Percentage of Retardation

15%

25%

35%

45%

60%

75%

100%

1. Applying Service Brake—release accelerator pedal. IMPORTANT: When operating machines , excessive use of service brakes will result in brake components overheating, which in extreme circumstances could result in a brake assembly problem. NOTE: When operating in 2nd gear or higher, the transmission retarder are activated when accelerator is released. NOTE: When service brake pedal is pressed, transmission retarder is automatically applied at 100%. 2. Depress service brake pedal. To resume driving, release service brake pedal. The transmission will automatically select the lowest gear.

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Operation—Operating the Machine

–UN–28JUN06

NOTE: Park brake will engage when key is turned to OFF position. If engine is stopped while park brake is not engaged, when engine is started, park brake switch must be moved to the engaged position before park brake can be released.

TX1009564A

1. Applying Park Brake—stop machine using service brake pedal. NOTE: The park brake should be engaged only when machine is completely stationary. 2. Push the park brake switch on the bottom to engage park brake.

1—Park Brake Lever

3. Release service brake. 4. Select neutral “N” on gearshift control.

RK98916,000003D –19–21SEP06–3/3

Operating on a Hill Release accelerator pedal to reduce brake pad wear when driving downhill.

Uphill Operation The machine operates in full automatic mode and the transmission will select the correct gear for traveling uphill.

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.

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. Downhill Operation Set retarder for desired operation.

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Operation—Operating the Machine

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.

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Operation—Operating the Machine

Loading and Unloading Bin IMPORTANT: DO NOT operate bin control lever unless transmission is in neutral “N” (or dumping in 1st or reverse while moving). Running the engine above slow idle with the transmission in gear and service brakes applied could cause damage to machine and/or personal injury. If the engine is above slow idle while in gear with service brakes applied for more than 15 seconds, the transmission controller will automatically limit the engine to 1000 rpm for 30—40 seconds to keep the transmission from overheating. 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. 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 close 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. 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 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 bin fully. Do not overload machine. Load machine evenly. An uneven load will cause tire and axle damage. NOTE: If the transmission is in 4th gear or higher, will not allow the bin to be raised, if the transmission is in 3rd gear, will only allow the bin to be raised to 15%, 2nd gear to 50% and 1st gear has no limit. Bin can be fully raised. 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. Avoid backing into material pile. Excessive material buildup in bin pivot area may cause tip cylinder damage. If machine is stopped while unloading, place transmission in neutral “N” before increasing engine speed above slow idle.

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Operation—Operating the Machine

Freeing Stuck Machine Turning Machine Free

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.

IMPORTANT: If the ground is soft, give constant attention to rear chassis angle. If rear chassis starts to lean sideways excessively, stop machine immediately.

If transmission overheats, select neutral (N) on gear shift control and operate engine at 1500 rpm until it cools (2—3 minutes).

1. Select neutral (N) on gearshift control. 2. Engage inter-axle lock.

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. 1. Select drive (D) on gearshift control and apply steady, light throttle (NOT full throttle).

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.

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 4. Select reverse (R) on gearshift control. 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.

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.

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Operation—Operating the Machine

Parking the Machine 1. Unload machine and lower bin to fully-lowered position. 2. Stop machine on firm, level ground. 3. Engage park brake. 4. Select neutral (N) on gearshift control. 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. 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. 6. Move all switches to OFF position. 7. Turn key switch to OFF. 8. If machine is to be parked overnight, turn battery disconnect switch to OFF and lock cab door, fuel cap and compartments. If storing longer than overnight, see Prepare Machine for Storage in Miscellaneous—Storage section.

CS33148,0000CBB –19–25AUG06–1/1

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Operation—Operating the Machine

Towing the Machine Towing a Machine with Inoperable Engine CAUTION: Always chock wheels to prevent machine from rolling before releasing park brake. Injury or death from being crushed by machine due to unexpected movement may result. Ensure brake system of the towing machine is sufficient to hold the combined weight of towing machine and disabled machine.

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.

To prevent damage to transmission, disconnect front and middle drive shafts before towing. Removing front and middle drive shafts renders park brake inoperable. See Releasing Park Brake for Towing. (Section 2-2.)

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.

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.

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:

With engine stopped, the machine hydraulic and pneumatic systems are inoperable, so there is no powered steering or braking system.

1. Remove supply hoses from the T-pieces on left-hand steering cylinder.

Disconnect front and middle drive shafts before towing. See Releasing Park Brake for Towing. (Section 2-2.)

NOTE: Some oil spillage will be unavoidable. Clean up any oil spillage as soon as possible. Dispose of waste oil properly.

With brakes released and drive shafts disconnected, the towing machine must be capable of steering and stopping the disabled machine. Do not exceed 2 km/h (1—2 mph).

2. Block off the two supply hoses using suitable plugs. 3. Loop the two 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.

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Operation—Operating the Machine

Removing Drive shafts for Towing

–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.

T147641B

IMPORTANT: To prevent damage to transmission, disconnect front axle and middle axle drive shafts when towing a machine with an inoperable engine. Front Axle Drive Shaft

1. Chock wheels and connect machine to towing vehicle prior to disconnecting drive shafts.

–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.

T147642B

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. Middle Axle Drive Shaft 1—U-joint Cap Screw (4 used) 2—Front Axle Drive Shaft 3—U-joint Cap Screw (4 used) 4—Middle Axle Drive Shaft

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Operation—Operating the Machine

Mechanically Releasing Park Brake

–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.

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.

T147643B

2. Remove release stud (1), nut (2) and washer (3) from storage position (4).

1—Release Stud 2—Nut 3—Washer 4—Release Stud Storage Location

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Operation—Operating the Machine

T143386

–UN–28JUN01

Machine Lifting Points

T143386

Lifting the Machine IMPORTANT: Install the articulation safety lock bar prior to lifting machine. NOTE: The machine lifting points are indicated on machine. 1. Park the machine next to the crane. 2. Engage park brake. IMPORTANT: To prevent truck from oscillating, use four individual chains or straps when lifting. To prevent damage to hood, use a nylon sling for front lifting points.

IMPORTANT: The crane must be able to carry total machine weight, 18 298 kg (40 340 lb) for 250D and 19 190 kg (42 300 lb) for 300D. 4. Attach lifting beam to a crane. 5. Raise the lifting beam until all the play in chain is removed. IMPORTANT: Move crane slowly to prevent excessive swinging of lifted machine. NOTE: Lifting beam must be at least 1032 cm (406 in.) in length. 6. Lower lifting beam until the chain can be removed from the machine.

3. Attach chains or straps to the lifting beam and the machine.

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PN=86

Operation—Operating the Machine 7. Raise the lifting beam with chains and move it away from machine.

9. Secure machine to the trailer of transporting vehicle with chains.

8. Chock all wheels. CS33148,0000CBF –19–15SEP06–2/2

Loading and Unloading Machine from Trailer Loading Machine on Trailer • Always use the aid of spotters when loading machine 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. 2. Drive machine onto the trailer slowly, following the instructions of the spotter. 3. Engage park brake. 4. Chock all wheels. 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.

Continued on next page

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Operation—Operating the Machine

TX1022448

–UN–10MAY07

TX1022448 Right Side Shown 1—Tie-Down Points (6 Points Total)

2. If driving machine off transporting vehicle, remove articulation locking bar.

IMPORTANT: Avoid sudden machine movement and machine damage; install the 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.

VD76477,000150A –19–15MAY07–2/2

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. CS33148,0000CC1 –19–11AUG06–1/1

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Maintenance—Machine Diesel Fuel

Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).

• Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates. Ask your retailer what sulfur content he is providing. • Use of diesel fuel with sulfur content less than 0.10% (1000 ppm) is STRONGLY recommended. • Use of diesel fuel with sulfur content 0.10% (1000 ppm to 0.50% (5000 ppm) may result in REDUCED oil and filter change intervals. . Use condition based maintenance to determine what your oil change interval should be. (See Diesel Engine Oil and Filter Service Intervals). • BEFORE using diesel fuel with sulfur content greater than 0.50% (5000 ppm), contact your John Deere dealer. • If you must use diesel fuel with sulfur content greater than 1.0%, reduce your oil change intervals. Use condition based maintenance to determine what your oil change interval should be.

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C (9°F) below the expected low temperature.

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

Fuel lubricity should pass a minimum level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

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

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

Sulfur content:

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Maintenance—Machine

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

Biodiesel is a fuel comprised of mono-alkyl esters of long chain fatty acids derived from vegetable oils or animal fats. Biodiesel blends are biodiesel mixed with petroleum diesel fuel on a volume basis. Biodiesel users in the U.S. are strongly encouraged to purchase biodiesel blends from a BQ-9000 Certified Marketer and sourced from a BQ-9000 Accredited Producer (as certified by the National Biodiesel Board). Certified Marketers and Accredited Producers can be found at the following website: http://www.bq-9000.org. While 5% blends are preferred (B5), biodiesel concentrations up to a 20% blend (B20) in petroleum diesel fuel can be used in all John Deere engines. Biodiesel blends up to B20 can be used ONLY if the biodiesel (100% biodiesel or B100) meets ASTM D6751 (US), EN 14214 (EU), or equivalent specification. Expect a 2% reduction in power and a 3% reduction in fuel economy when using B20.

The petroleum diesel portion of biodiesel blends must meet the requirements of ASTM D975 (US) or EN 590 (EU) commercial standards. Biodiesel blends up to B20 must be used within 90 days of the date of biodiesel manufacture. Biodiesel blends from B21 to B100 must be used within 45 days of the date of biodiesel manufacture.

When using biodiesel fuel, the engine oil level must be checked daily. If oil becomes diluted with fuel, shorten oil change intervals. Refer to Diesel Engine Oil and Filter Service Intervals for more details regarding biodiesel and engine oil change intervals. The following must be considered when using biodiesel blends up to B20:

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

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

• Cold weather flow degradation • Stability and storage issues (moisture absorption, oxidation, microbial growth) • Possible filter restriction and plugging (usually a problem when first switching to biodiesel on used engines.) • Possible fuel leakage through seals and hoses • Possible reduction of service life of engine components The following must also be considered when using biodiesel blends above B20. • Possible coking and/or blocked injector nozzles, resulting in power loss and engine misfire if John Deere approved fuel conditioners containing detergent/dispersant additives are not used • Possible crankcase oil dilution, requiring more frequent oil changes • Possible corrosion of fuel injection equipment • Possible lacquering and/or seizure of internal components • Possible formation of sludge and sediments • Possible thermal oxidation of fuel at elevated temperatures • Possible elastomer seal and gasket material degradation ( primarily an issue with older engines)

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PN=90

Maintenance—Machine • Possible compatibility issues with other materials (including copper, lead, zinc, tin, brass, and bronze) used in fuel systems and fuel handling equipment • •Possible reduction in water separator efficiency • •Potential high acid levels within fuel system • •Possible damage to paint if exposed to biodiesel

IMPORTANT: Raw pressed vegetable oils are NOT acceptable for use as fuel in any concentration in John Deere engines. Their use could cause engine failure.

DX,FUEL7 –19–04OCT07–2/2

Low Sulfur Diesel Fuel Conditioner When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulfur diesel fuels. If the local fuel distributor will supply only low sulfur fuel, order and use John Deere PREMIUM DIESEL FUEL CONDITIONER. It provides lubricating properties along with other useful benefits, such as cetane improver, anti-oxidant, fuel stabilizer, corrosion inhibitor and others. John Deere PREMIUM DIESEL FUEL CONDITIONER is specifically for use with low sulfur fuels. Nearly all other diesel fuel conditioners only improve cold weather flow and stabilize long-term fuel storage. They do not contain the lubrication additives needed by rotary fuel injection pumps.

TX,45,JC2126 –19–15AUG97–1/1

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Maintenance—Machine

Testing Diesel Fuel DIESELSCAN is a John Deere fuel analysis program that can be used to monitor the quality of your fuel. The DIESELSCAN analysis verifies fuel type, cleanliness, water content, suitability for cold weather operation, and whether the fuel meets specifications. Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

DX,FUEL6 –19–14NOV05–1/1

Handling and Storing Diesel Fuel CAUTION: 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.

When using bio-diesel 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.

Monitor water content of the fuel regularly.

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Maintenance—Machine

Diesel Engine Oil and Filter Service Intervals The oil and filter service intervals in the table below should be used as guidelines because actual service intervals also depend on operation and maintenance practices. It is suggested that oil analysis be used prior to each oil change to be certain the proper oil and filter service interval is selected.

Oil and filter change intervals are based on oil pan capacity, type of oil and filter used, and sulfur content of the diesel fuel. Refer to the following table for oil and filter service intervals.

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Maintenance—Machine Oil and Filter Service Intervals Standard Oil Pan a

Fuel Sulfur Level

Fuel Sulfur Level:

Extended Drain Oil Pan b

Less than 1000 ppm (0.10%)

With Standard Oil

250 hours

With Premium Oil

375 hours

500 hours

Use condition based maintenance - sample oil at normal interval

Fuel Sulfur Level

1000 to 5000 ppm (0.10 to 0.50%)

With Standard Oil

150 hours

With Premium Oil

250 hours

Use condition based maintenance - sample oil at 150 hour interval

Download latest Exhaust Gas Recirculation (ERG) dynamic cleaning software

Exhaust Gas Recirculation (EGR) R&R inspect and clean at 2000 hour interval

Use premium oil

Know what sulfur level you are fueling with - sample fuel at 500 hour interval

Fuel Sulfur Level

5000 to 10,000 ppm (0.50 to 1.00%)

With Standard Oil

100 hours

With Premium Oil

150 hours

Use condition based maintenance - sample oil at 100 hour interval

Download latest Exhaust Gas Recirculation (ERG) dynamic cleaning software

The level of sulfur will directly relate to the level of contaminants in the oil and exhaust which if left unattended could lead to intake components (valves, ports, etc.) being caked with soot, stuck Exhaust Gas Recirulation (EGR) valves, Exhaust Gas Recirulation (EGR) system corrosion downstream of cooler, and accelerated cylinder and bearing wear. Bearing wear becomes more critical as oil Total Base Number (TBN) is depleted. In order to minimize the effect of high sulfur fuels on the internal components of our engines the following recommendations are being shared. • Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates. Ask your retailer what sulfur content he is providing. • Use of diesel fuel with sulfur content less than 0.10% (1000 ppm) is STRONGLY recommended. • Use of diesel fuel with sulfur content 0.10% (1000 ppm to 0.50% (5000 ppm) may result in REDUCED oil and filter change intervals. . Use condition based maintenance to determine what your oil change interval should be. (see chart). • BEFORE using diesel fuel with sulfur content greater than 0.50% (5000 ppm), contact your John Deere dealer. • If you must use diesel fuel with sulfur content greater than 1.0%, reduce your oil change intervals. Use condition based maintenance to determine what your oil change interval should be. Oil types (premium or standard) are as follows:

Exhaust Gas Recirculation (EGR) R&R inspect and clean at 500 hour interval

Inspect/cycle Variable Geometry Turbos (VGT) linkage at 500 hour interval

Use premium oil

Know what sulfur level you are fueling with - sample fuel at 500 hour interval

a Oil pans with option codes 1909, 1914, 1915 or 1916 (lower power levels) <200 HP

b Oil pans with option codes 1911 or 1916 (higher power levels) > 200 HP

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PN=94

Maintenance—Machine • “Premium Oils” include John Deere PLUS-50, ACEA E6, or ACEA E7 oils, and assume the use of a specified John Deere oil filter.

• “Standard Oils” include John Deere TORQ-GARD SUPREME, API CI-4 PLUS, API CI-4, ACEA E4, or ACEA E5 oils.

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

VD76477,000104C –19–14SEP06–3/3

T122287

–19–14JUL99

Hydraulic Oil

Depending on the expected air temperature range between oil changes, use oil viscosity shown on the temperature chart above. The following oils are preferred:

• 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.

HY-GARD is a trademark of Deere & Company

CS33148,0000CC7 –19–20SEP06–1/1

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Maintenance—Machine

T164955

–19–04FEB03

Transmission and Transfer Case Oil

Use only Allison/Castrol TransSynd or Castrol Transmax Z or S oils.

CS33148,0000CC8 –19–18SEP06–1/1

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

–UN–31MAY07

104˚F

TX1024300

40˚C

SAE 140

122˚F

SAE 90

50˚C

SAE 75W

• JDM J11F • ZF TE-ML-05C • ZF TE-ML-05D

SAE 75W-80 LS

Other oils may be used if they meet the following:

SAE 80W-90 LS

• John Deere GEAR LUBRICANT with Limited Slip Additive

SAE 75W-90

The following oil is preferred:

SAE 80W-140

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

SAE 85W-140 LS

Axle Gear Oil

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Maintenance—Machine

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).

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.

The following engine coolant is preferred for service:

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.

• John Deere COOL-GARDCOOL-GARD Prediluted Coolant The following engine coolant is also recommended: • John Deere COOL-GARD Coolant Concentrate in a 40 to 60% mixture of concentrate with quality water

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

Other low silicate ethylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications: • ASTM D5345 (prediluted coolant) • ASTM D4985 (coolant concentrate) in a 40 to 60% mixture of concentrate with quality water 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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. If COOL-GARDCOOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.

COOL-GARD is a trademark of Deere & Company

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Maintenance—Machine

T144281

–19–03AUG01

Grease

• SAE Multipurpose EP grease containing 3 to 5% Molybdenum Disulfide • John Deere MOLY HIGH TEMPERATURE EP GREASE

Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following greases are preferred:

CS33148,0000CCB –19–29AUG06–1/1

Oil Filters Filtration of oils is critical to proper operation and lubrication. Always change filters regularly as specified in this manual. Use filters meeting John Deere performance specifications.

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Maintenance—Machine

Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used.

Make certain that all containers are properly marked to identify their contents.

Use clean containers to handle all lubricants.

Properly dispose of all old containers and any residual lubricant they may contain.

Whenever possible, 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.

CS33148,0000CCD –19–11AUG06–1/1

Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual. Some John Deere brand coolants and lubricants may not be available in your location. Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

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.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils. Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

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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.

CS33148,0000CCF –19–29AUG06–1/1

Use Correct Fuels and Lubricants IMPORTANT: To prevent machine damage, use correct fuels and lubricants when servicing your machine. (See Maintenance—Machine section.)

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Maintenance—Periodic Maintenance

Prepare Machine for Maintenance Before performing maintenance on machine:

CAUTION: Avoid serious injury or death from being crushed by machine moving unexpectedly. To prevent rollaway, install wheel chocks on one axle.

1. Unload bin. 2. Wash machine. 3. Park machine on firm, level ground. Steer machine to straighten frames.

10. Install wheel chocks to ensure that machine cannot move backward or forward during service. CAUTION: Be careful when working with hot equipment and fluids. Hot equipment and fluids can cause burns to unprotected skin.

4. Install articulation locking bar. See Install Articulation Locking Bar. (Section 3-2.) 5. Fully lower bin, unless specifically instructed otherwise in a maintenance procedure. If bin must be raised, install bin support rod. See Install Bin Support Rod. (Section 3-2.)

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

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 three times. b. If bin is fully lowered, hydraulic pressure is automatically relieved. If bin is raised and bin support rod is installed, move bin control lever forward and rearward 3 times to ensure that the weight of the bin is securely settled onto the bin support rod.

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.)

9. If servicing the pneumatic system, relieve pneumatic pressure. See Relieve Pneumatic Pressure. (Section 3-2.)

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Maintenance—Periodic Maintenance

Install Bin Support Rod

–UN–21JUN01

CAUTION: Avoid serious injury or death from crushing. Always use the bin support rod when performing maintenance.

T143166B

NOTE: Operate the bin control lever in the operator’s station to raise and lower the bin. 1. Raise bin high enough to allow bin support rod (1) to be fully raised. Bin Support Rod

2. Use handle (4) to raise bin support rod. Ensure that stop bolt (3) is in firm contact with stop (2). CAUTION: Avoid serious injury or death from crushing. Check to ensure that the bin support rod is seated securely in retaining cup.

1—Bin Support Rod 2—Stop 3—Stop Bolt 4—Handle 5—Retaining Cup

3. Lower bin until bin support rod is seated securely in retaining cup (5). 4. Relieve hydraulic pressure before servicing machine.

RK98916,000003F –19–17AUG06–1/1

Install Articulation Locking Bar 1. Steer machine to straighten articulation joint.

–UN–09NOV01

2. Stop engine and engage park brake. 3. Remove keys from key switch and attach a DO NOT OPERATE sign to steering wheel.

T147644B

4. Remove pin (3) from articulation locking bar (2) and storage location (1). 5. Swing articulation locking bar rearward to the locked position. Ensure that holes line up on locking lug (4). 6. Install pin through articulation locking bar and locking lug.

1—Storage Location 2—Articulation Locking Bar 3—Pin 4—Locking Lug

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Maintenance—Periodic Maintenance

Lower and Raise Bottom Guard

T147645B

Lift bottom guard into place and install cap screws to raise bottom guards.

–UN–19NOV01

Remove front bottom guard cap screws (1) to lower front bottom guard (2), or remove rear bottom guard cap screws (3) to lower rear bottom guard (4).

1—Front Bottom Guard Cap Screw (2 used) 2—Front Bottom Guard 3—Rear Bottom Guard Cap Screw (2 used) 4—Rear Bottom Guard

CS33148,0000CD4 –19–29AUG06–1/1

Relieve Pneumatic Pressure 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.

TX1011388A

–UN–21AUG06

1—Pneumatic Reservoir (2 used) 2—Drain Valve (2 used)

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Maintenance—Periodic Maintenance

Tilt Cab Raising Cab 1. Park the machine on level ground with bin 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.

Continued on next page

3-2-5

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Maintenance—Periodic Maintenance 4. Remove cab mounting cap screws, washers, and nuts (1) from left-front and left-rear cab mounts.

–UN–22JUN01

5. Rotate pump valve lever (8) counterclockwise to the raise position. NOTE: Pump handle is stored on floor of cab, to left of operator seat.

T142966B

6. Remove pump handle (6) from storage position. Insert pump handle into pump socket (5). Left-Rear Cab Mount Shown

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).

–UN–05JUL06

CAUTION: Avoid serious injury or death from crushing. DO NOT work under the raised cab unless the support strut is properly engaged.

TX1009663A

8. While pushing support strut handle (7) toward machine, slowly rotate pump valve lever clockwise to the 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

9. Rotate pump valve lever counterclockwise to the raise position. Lowering Cab 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.

Continued on next page

3-2-6

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Maintenance—Periodic Maintenance

CAUTION: Avoid possible injury from crushing. Cab will “float” down when pump valve lever is rotated clockwise. Stay clear of cab while lowering. 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. 3. While pulling support strut handle away from machine, slowly rotate pump valve lever clockwise to the lower position. Allow cab to lower until cab mounts are at rest. 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. NOTE: Install new mounting hardware when cab is lowered. 4. Install new cab mounting cap screws, washers, and nuts on left-side cab mounts. Tighten to specification. Specification Cab Mounting Cap Screws— Torque .......................................................................................... 210 N•m 155 lb-ft

5. Remove pump handle from pump socket. Install pump handle in storage position.

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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.

T7511CO

Do not tear out or mark on checklist in this section; keep it to make extra copies.

–UN–27JUN91

As maintenance is performed, check off each item on the list and record date and hour meter reading.

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Maintenance—Periodic Maintenance

Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit

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.

T111410

–UN–16SEP97

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 dealer on a maintenance program for your specific application. Your dealer has the sampling products and expertise to assist you in lowering your overall operating costs through fluid sampling.

3-Way Coolant Test Kit

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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 precleaner bowl

• Check tire pressure

• Replace primary and secondary air cleaner filters

• Drain sediment from water separator; clean strainer

• Check and clean cooling system (radiator, charge air cooler, A/C condenser, transmission)

• Inspect belt

• Check and clean axle, transmission and transfer case breathers

Every 10 Hours or Daily

• Check engine coolant level

• Check transmission for leaks

• Check engine oil level

• Grease bin pivot pins

• Check transfer case oil level

• Grease tailgate pivots-if equipped

• Check hydraulic system oil level

Initial Service —100 Hours*

• Change engine oil and replace filter

• Change axle oil

• Replace primary fuel filter

• Change final drive oil

• Replace secondary fuel filter

• Replace hydraulic system return filter

• Change transfer case oil

•*Perform initial service once after the first 100 hours of operation

Continued on next page

3-2-10

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Maintenance—Periodic Maintenance Model: 250D and 300D Artculated Dump Truck

Customer:

PIN / Serial Number:

Delivery Date: OIL SAMPLING

Oil samples should be taken from each system prior to its recommended drain/charge interval indicated on this form: 500, 1000, 2000, 4000 hours. Maintenance recommendations supplied by OILSCAN PLUS will be provided based upon the oil analysis and operating information you supply. Regular oil sampling will extend the operational life of your machine’s systems. Every 250 Hours ❒ Take engine oil sample, 250 hours (recommended), 500 hours (maximum)

❒ Take hydraulic oil sample

Every 500 Hours

❒ Check park brake pad wear

❒ Check and clean hydraulic breather

❒ Check service brake pad wear

❒ Replace secondary fuel filter

❒ Grease oscillation joint and thru drive bearing

❒ Replace in-line fuel filter strainer

❒ Check suspension strut height, leakage, and boot condition

❒ Replace primary fuel filter

❒ Change engine oil and replace filter

❒ Take axle oil sample

❒ Clean or replace cab air filter

❒ Take transfer case oil sample

❒ Check battery electrolyte level; clean and tighten terminals

❒ Take final drive oil sample

❒ Grease articulation joints and steering rod ends

❒ Take diesel fuel sample

❒ Check transmission oil level

❒ Take engine coolant sample

❒ Check coolant conditioner in radiator

❒ Take transmission oil sample

❒ Take engine oil sample, 250 hours (recommended), 500 hours (maximum)

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

OILSCAN PLUS is a trademark of Deere & Company

Continued on next page

3-2-11

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Maintenance—Periodic Maintenance Every 3000 Hours ❒ Replace hydraulic suction screen Every 4000 Hours ❒ Drain and refill hydraulic tank

❒ Replace pneumatic block silencer filters Every 4500 Hours

❒ Replace engine crankshaft dampener Every 5000 Hours ❒ Drain, flush and refill engine cooling system

Every 6000 Hours

❒ Replace universal joints

Continued on next page

3-2-12

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Maintenance—Periodic Maintenance 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, e.g., filter O-rings. Item

Part Number

Initial Every Service— 250 100 Hours Hours

Every 500 Hours

Every 1000 Hours

Every 2000 Hours

Every 3000 Hours

Every 4000 Hours

Every 4500 Hours

Every 5000 Hours

Every 6000 Hours

Engine Oil Filter Kit

RE509672

Primary and Secondary Fuel Filters (Kit)

RE525523

In-Line Fuel Filter

AT223493

Transmission Oil Filter

TTZF210424

Pneumatic System Air Dryer Filter

AT252831

Hydraulic System Return Filter

TT222389

Hydraulic Reservoir Breather Filter

AT252815

Cab Air Filter

TT226019

Hydraulic Suction Screen

TT210497

Pneumatic Block Silencer Filters

TT226831

Engine Torsional Damper

RE522932

Engine Crankshaft Dampener

R57604

Universal Joint

TT206765

Universal Joint

TT207990

Transmission, Transfer Case and Axle Breather Filter

AT253791

As required

Air Cleaner Primary Element

AT308575

As required

Air Cleaner Secondary Element

TT220747

As required

Coolant Conditioner

TY16004

As required

Continued on next page

3-2-13

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Maintenance—Periodic Maintenance REQUIRED PARTS PLUS-50 Engine Oil

TY6389*

32 L (8.5 gal)

HY-GARD Hydraulic Oil (J20C)

TY6354*

Allison/Castrol TransSynd Transmission Oil

TY25007*

4.7 L (5.0 qt)

27.0 L (7.1 gal)

API GL-5 Gear Oil with Llimited Slip Additive

TY25050*

90 L (24 gal)

Pre-diluted Radiator Coolant

TY16036

79 L (21 gal)

33 L (8.7 gal)

Fluid Analysis Kits

•Diesel Engine Oil

AT317904

•Hydraulic Oil

AT303189

•Transmission Oil

AT303189

•Transfer Case Oil

AT303189

•Axle Oil

AT303189

•Final Drive Oil

AT303189

•DieselScan

AT180344

•COOLSCAN PLUS

AT183016

3-Way Heavy Duty Coolant Test

TY16175

*For recommended 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

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Maintenance—As Required Service Engine Air Intake System 1. Empty the precleaner bowl. –UN–18AUG06

a. Loosen wing nut (1) and remove lid (2).

TX1011347A

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).

–UN–09NOV01

b. Remove and inspect primary element (7). Replace, if necessary.

T147650B

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.

–UN–09NOV01

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. e. Install secondary element, ensuring that it is firmly and evenly seated.

T147651B

f. Install primary element, ensuring that it is firmly and evenly seated. g. Install air cleaner cover and fasten clasps. 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

3. Press top of service indicator to reset flag.

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Maintenance—As Required

Inspect and Clean Cooling Systems Inspect Cooling Systems

SJ25320,000014E –19–23AUG06–1/2

1. Inspect components of cooling system for damage. 2. Inspect hoses and clamps for damage and tightness. –UN–18AUG06

3. Inspect mountings and hardware for damage and tightness.

TX1011346A

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).

1—Lock Nut (6 used) 2—Fan Guard 3—Rear Face of Cooling System

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. 3. Raise hood and wash front cooling system, spraying from rear face (3) to front face. Keep cooling system free of debris and obstructions that may restrict air flow. 4. Install fan guard, cap screws and lock nuts. 5. Open battery compartment door. 6. Spray outer face of cooler. Keep cooling system free of debris and obstructions that may restrict air flow. 7. Turn battery disconnect switch ON, and close hood and battery compartment door.

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Maintenance—As Required

Clean, Inspect, and Replace—Transmission, Transfer Case, and Axle Breathers

–UN–15NOV01

IMPORTANT: DO NOT spray steam, water or cleaning solution directly at breathers. Spray could be forced into housings.

The cab must be tilted to access the transmission breather cap and front axle breather.

T147909B

NOTE: Breathers should be checked daily in adverse working conditions. The amount of dust and dirt encountered will determine the frequency of breather cleaning. Located Under Hydraulic Reservoir

1. Clean dirt, dust, and debris from each breather (1—5) and from surrounding areas.

T147908B

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.

–UN–15NOV01

IMPORTANT: DO NOT crush or damage breathers during removal. Foreign matter may enter housings.

Located Under Cab

–UN–23AUG06

Breather—Specification Tightening—Torque ................................................................. 12—16 N•m 106—142 lb-in.

TX1011541A

3. Inspect axle breather hoses for clogging, damage, and proper installation. If necessary, clear breather hose(s). Replace any breather hose that appears damaged or cannot be unclogged. 1—Transfer Case Breather 2—Transmission Breather Cap 3—Front Axle Breather 4—Middle Axle Breather 5—Rear Axle Breather

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Maintenance—As Required

Inspect Tires, Check Pressure 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. 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.

Continued on next page

3-3-4

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Maintenance—As Required

TX1021707

–19–20APR07

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.

Maximum Permissible Differences in Tire Diameters

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

Continued on next page

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PN=118

Maintenance—As Required 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 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

Continued on next page

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PN=119

Maintenance—As Required 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

Continued on next page

3-3-7

VD76477,00014F5 –19–20APR07–4/6 110807

PN=120

Maintenance—As Required 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 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

Continued on next page

3-3-8

VD76477,00014F5 –19–20APR07–5/6 110807

PN=121

Maintenance—As Required Rear Axle Tires—Pressure............................................................ 450 kPa 4.5 bar 65 psi

VD76477,00014F5 –19–20APR07–6/6

Drain Fuel Filters 1. Open hood. –UN–22AUG06

2. Loosen drain valves (1). Drain liquid for several seconds or until water and sediment is removed.

TX1011481A

3. Tighten drain valves. 1—Drain Valve

SJ25320,000016C –19–29AUG06–1/1

Inspect Serpentine Belt Inspect serpentine belt for wear, fraying, splitting, cracking, damage, dirt, and debris.

Replace serpentine belt, if necessary. (See your authorized dealer.) CS33148,0000CE0 –19–11AUG06–1/1

3-3-9

110807

PN=122

Maintenance—Every 10 Hours or Daily Check Engine Coolant Level

–UN–23AUG88

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

TS281

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. 1. Check coolant level in expansion tank (1). Cold coolant should not be below the ADD mark. Hot coolant should not be above the FULL mark.

–UN–21AUG06

NOTE: If expansion tank is overfilled while engine is cold, expansion tank will overflow and excess coolant will purge during machine operation.

TX1011380A

IMPORTANT: When the system needs top-off the first time, add two pints (32 oz) of John Deere Coolant Conditioner. 2. Add coolant at fill port, if necessary. 1—Expansion Tank 2—Filler Cap

SJ25320,000014F –19–15SEP06–1/1

Check Engine Oil Level 1. Park machine on level ground. –UN–18AUG06

NOTE: Check engine oil level with engine cold.

TX1011344A

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. 1—Dipstick

Continued on next page

3-4-1

SJ25320,0000150 –19–23AUG06–1/2 110807

PN=123

Maintenance—Every 10 Hours or Daily 5. Remove dipstick and check oil level. Oil level should be in the full mark (2).

–UN–19NOV01

6. If oil level is in low mark (1), add oil as necessary.

T148256B

1—Low Mark 2—Full Mark

SJ25320,0000150 –19–23AUG06–2/2

Check Transfer Case Oil Level 1. Check oil level at sight glass (1). Oil level should be to middle of sight glass. –UN–19NOV01

2. Add or drain oil, if necessary. See Change Transfer Case Oil. Section 3-8.)

T147662B

1—Sight Glass

CS33148,0000CE3 –19–11AUG06–1/1

Check Hydraulic Oil Level

–UN–19NOV01

IMPORTANT: Prevent damage to hydraulic system components. DO NOT run engine without oil in hydraulic oil reservoir. 1. Fully lower the bin.

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

2. Check oil level in sight glass (1). Oil level must be visible.

1—Sight Glass

CS33148,0000CE4 –19–20SEP06–1/1

Check Transmission Visually inspect transmission for leaking and damage.

SJ25320,00001CE –19–18SEP06–1/1

3-4-2

110807

PN=124

Maintenance—Every 10 Hours or Daily

Grease Bin Pivot Pins

TX1011345A

–UN–18AUG06

Apply grease to lubrication fittings (9) and (10) until it escapes at joints. See Grease. (Section 3-1.)

SJ25320,0000151 –19–24AUG06–1/1

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)

CS33148,0000CE6 –19–11AUG06–1/1

3-4-3

110807

PN=125

Maintenance—Initial Service - 100 Hours Change Engine Oil and Replace Filter

–UN–21AUG06

NOTE: Perform this service after the first 100 hours of operation and at 500 hour intervals thereafter. NOTE: The engine oil will drain easier when engine is warm.

TX1011465A

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.)

–UN–21AUG06

4. Install hose to drain valve with a hose clamp. Put end of hose into a container. NOTE: Dispose of waste properly.

TX1011466A

5. Turn drain valve shutoff (2) counterclockwise. Drain oil into container. Engine—Specification Oil—Capacity .................................................................. 32 L approximate 8.5 gal 1—Drain End of Valve 2—Drain Valve Shutoff 3—Drain Valve 4—Filter Cover

6. Tighten drain valve shutoff clockwise. Remove hose clamp and hose. Wipe excess oil from drain valve (3). 7. Clean dirt and debris from engine oil filter cap and surrounding area. 8. Remove engine oil filter cover (4). Remove and replace filter and seal ring. 9. Install oil filter cover. IMPORTANT: Do not overfill the engine with oil. 10. Add oil at fill port. Do not overfill. See Diesel Engine Oil. (Section 3-1.) 11. Install engine oil dipstick and fill cap. 12. Start engine and let it run at slow idle for one minute. Check for oil leaks at engine oil filter and drain valve. Tighten only enough to stop leaks.

Continued on next page

3-5-1

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PN=126

Maintenance—Initial Service - 100 Hours 13. Check engine oil level. 14. Raise rear bottom guard.

SJ25320,000016A –19–22AUG06–2/2

Replace Primary Fuel Filter

3. Turn primary fuel filter housing (3) counterclockwise to remove. Allow sediment to drain into a container. Dispose of waste properly. 4. Remove primary fuel filter (4), discard primary fuel filter housing seal.

TX1011394A

2. Turn Primary Fuel Filter Drain (2) counterclockwise to drain.

–UN–21AUG06

1. Disconnect the WIF sensor connector (1).

5. Install new filter and seal (Follow instructions on filter.)

TX1011460A

7. Bleed fuel system. See Bleeding Fuel System. (Section 4-1.).

–UN–21AUG06

6. Install sensor connector.

1—Sensor Connector 2—Primary Fuel Filter Drain 3—Primary Fuel Filter Housing 4—Primary Fuel Filter 5—Primary Fuel Filter Housing Seal

SJ25320,000016B –19–28AUG06–1/1

3-5-2

110807

PN=127

Maintenance—Initial Service - 100 Hours

Replace Secondary Fuel Filter

–UN–21AUG06

1. Turn drain (2) counterclockwise and drain secondary fuel filter. Allow sediment to drain into a container. Dispose of waste properly. 2. Turn filter (1) counterclockwise to remove.

TX1011397A

3. Clean filter base. 4. Install new filter. (Follow instructions on filter.) 5. Bleed fuel system. See Bleeding Fuel System. (Section 4-1.)

1—Secondary Filter 2—Secondary Filter Drain

SJ25320,000015B –19–20SEP06–1/1

3-5-3

110807

PN=128

Maintenance—Initial Service - 100 Hours

Change Transfer Case Oil NOTE: Perform this service after the first 100 hours of operation and at 2000 hour intervals thereafter. –UN–19NOV01

1. Remove fill plug and sealing ring (1). Clean fill plug and sealing ring. Inspect sealing ring. Replace sealing ring, if necessary.

T147975B

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

–UN–19NOV01

3. Clean drain plug thoroughly. 4. Install drain plug. Tighten to specification.

5. Add oil at fill port. Do not overfill. Oil level should be to middle of sight glass (3).

T147662C

Transfer Case—Specification Drain Plug and Fill Plug Tightening—Torque ................................................................. 25—32 N•m 38—45 lb-ft 1—Fill Plug and Sealing Ring 2—Drain Plug 3—Sight Glass

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. 9. Check oil level at sight glass. Oil level should be to middle of sight glass. Add more oil, if necessary.

CS33148,0000CEA –19–11AUG06–1/1

3-5-4

110807

PN=129

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. –UN–18DEC01

NOTE: Perform this procedure for each axle. The procedure is the same for all axles.

T147833B

1. Clean axle housing around check and fill plug (1) and drain plug (2). NOTE: Dispose of waste properly. 1—Check and Fill Plug 2—Axle Drain Plug 3—Adapter Case Drain Plug (Middle Axle Only)

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. 4. Add oil at check and fill port. See Axle and Final Drive Oil. (Section 3-1.) 5. Install check and fill plug.

CS33148,0000CEB –19–11AUG06–1/1

3-5-5

110807

PN=130

Maintenance—Initial Service - 100 Hours

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.

–UN–13NOV01

2. Remove drain plug from final drive and allow oil to drain into a container.

T147834B

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.

CS33148,0000CEC –19–11AUG06–1/1

3-5-6

110807

PN=131

Maintenance—Initial Service - 100 Hours

Replace Hydraulic System Oil Return Filter

–UN–21AUG06

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.

TX1011390A

1. Remove nuts (2) and clamp (3) from bin heater support and pipe, if equipped. 2. Remove cap screws (1) and access cover (4). 3. Turn hydraulic reservoir breather counterclockwise and remove from machine. 4. Clean area around return filter cover (6).

–UN–13NOV01

CAUTION: Avoid personal injury. Remove return filter cover carefully. Spring is under load.

T147656C

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 two cap screws and washers, then release slowly to relieve spring load. 6. Inspect filter cover seal ring for damage and wear. Replace, if necessary.

–UN–13NOV01

7. Grasp spring and remove spring and return filter assembly.

T143811C

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.

1—Cap Screw (4 used) 2—Nut—If Equipped (2 used) 3—Bin 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

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. Be sure that element is centered on face seal ring.

Continued on next page

3-5-7

SJ25320,0000179 –19–21SEP06–1/2 110807

PN=132

Maintenance—Initial Service - 100 Hours 12. Install spring and filter element assembly. Be sure that shoulder seal ring is properly seated in filter seat. 13. Install filter cover and cap screws. Be sure 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. 14. Install access cover and cap screws. 15. Install clamp and nuts to bin heater support and pipe, if equipped.

SJ25320,0000179 –19–21SEP06–2/2

3-5-8

110807

PN=133

Maintenance—Every 500 Hours Check Park Brake Pad Wear 1. Raise the bin and install the bin prop. 2. Measure thickness of park brake pads.

–UN–05JUL06

3. If either of the brake pads has worn to minimum specified thickness, both brake pads must be replaced. (See your authorized dealer.)

TX1009659A

Specification Pad—Thickness.............................................................. 3.0 mm minimum 0.12 in. minimum

SJ25320,0000152 –19–17AUG06–1/1

Check Dry Caliper Service Brake Pad Wear NOTE: If operating in wet or muddy conditions, check wear indicators every 250 hours. –UN–26NOV01

1. Remove cap screws (2) and upper brake shield (1).

T148251B

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 250D Shown; 300D Similar

3. Install upper brake shield and cap screws. 4. Repeat procedure for each wheel.

T148252B

–UN–26NOV01

1—Upper Brake Shield 2—Cap Screw (2 used) 3—Brake Pad (2 used)

CS33148,0000CEE –19–11AUG06–1/1

3-6-1

110807

PN=134

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.

–UN–07JUN06

2. Clean boot and surrounding area. Inspect boot for damage. Replace if necessary.

4. Reverse the machine gently and bring the machine back to it’s original position without applying any brakes.

TX1008608

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.

A—Height

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. Suspension Strut—Specification Centerline to Centerline—Height................................................... 646 mm 25.4 in.

CS33148,0000CEF –19–24APR07–1/1

3-6-2

110807

PN=135

Maintenance—Every 500 Hours

Change Engine Oil and Replace Filter

–UN–21AUG06

NOTE: Perform this service after the first 100 hours of operation and at 500 hour intervals thereafter. NOTE: The engine oil will drain easier when engine is warm.

TX1011465A

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.)

–UN–21AUG06

4. Install hose to drain valve with a hose clamp. Put end of hose into a container. NOTE: Dispose of waste properly.

TX1011466A

Continued on next page

3-6-3

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PN=136

Maintenance—Every 500 Hours 13. Check engine oil level. 14. Raise rear bottom guard.

SJ25320,000017A –19–23AUG06–2/2

Inspect, Clean, and Replace Cab Air Filter 1. Open storage compartment door (1).

–UN–06JUL01

2. Turn latches (2) 1/4-turn counterclockwise. Open access door (3).

T143532B

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.

–UN–06JUL01

b. Clean element, if necessary. Remove large debris by hand, then spray compressed air through element in direction opposite normal air flow.

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.

T143533B

c. If element is moist, allow to dry before reinstalling. Do not apply heat to element.

1—Storage Compartment Door 2—Latch (2 used) 3—Access Door 4—Element

6. Close storage compartment door.

CS33148,0000CF0 –19–11AUG06–1/1

3-6-4

110807

PN=137

Maintenance—Every 500 Hours

Check Batteries, Clean and Tighten Terminals

3. Clean debris from battery compartment. 4. Inspect circuit breaker box (2) and battery disconnect switch (3) for damage and secure installation. Tighten mounting hardware, if necessary. Replace damaged components. (See your authorized dealer.)

TX1011377A

2. Remove screws (4); lift and remove top access cover.

–UN–18AUG06

1. Open hood. Open battery compartment door (1).

7. Ensure that mounting bracket assembly (5) is secure. Tighten nuts, if necessary. 8. Check electrolyte level if battery has level check/fill plugs.

TX1011378A

6. Inspect and clean terminals (6). Ensure that posts are secure in battery housings. Ensure that cables are securely installed on posts.

–UN–18AUG06

5. Inspect batteries and cables for damage. Replace, if necessary. See Replace Batteries. (Section 4-1.)

–UN–18AUG06

9. Start engine. After bulb check, verify that battery charge indicator on instrument panel is not lit. Verify battery voltages on monitor display unit.

TX1011379A

1—Battery Compartment Door 2—Circuit Breaker 3—Battery Disconnect Switch 4—Top Access Cover Screw (8 used) 5—Mounting Bracket Assembly 6—Terminal (4 used)

SJ25320,0000153 –19–23AUG06–1/1

3-6-5

110807

PN=138

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.)

T213218A

–UN–03AUG05

T149788C

–UN–01AUG05

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 5—Lubrication Fitting—Left Steering Cylinder Rod End 6—Lubrication Fitting—Oscillation Tube 7—Lubrication Fitting—Oscillation Tube Through Drive Shaft Rear Bearing

CS33148,0000CF2 –19–11AUG06–1/1

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.

2. Select neutral (N) and run engine at slow idle. 3. Raise cab.

1. Park machine on level ground and engage park brake.

Continued on next page

3-6-6

SJ25320,0000174 –19–22AUG06–1/2

110807

PN=139

Maintenance—Every 500 Hours 4. Remove transmission dipstick (1) from fill tube (2). Turn handle counterclockwise to loosen. Wipe oil from dipstick and fill tube.

TX1011486A

–UN–22AUG06

NOTE: STOP and COLD marks indicate sufficient oil levels for running machine. Check oil level with transmission oil at operating temperature for accurate reading. 5. Fully insert transmission dipstick into fill tube. Remove transmission dipstick and read oil level. Repeat.

HOT

6. Add or drain transmission oil, as necessary. See Change Transmission Oil . (Section 3-8.) 7. Fully insert transmission dipstick into fill tube. Turn handle clockwise to tighten.

T148377

8. Lower cab.

COLD

T148377

STOP

–19–21NOV01

• 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 between lines of HOT mark.

1—Transmission Dipstick 2—Fill Tube

SJ25320,0000174 –19–22AUG06–2/2

3-6-7

110807

PN=140

Maintenance—Every 500 Hours

Clean and Inspect Hydraulic Reservoir Breather

–UN–21AUG06

1. Remove nuts (2) and clamp (3) from bin heater support and pipe.

TX1011390A

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.

–UN–13NOV01

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

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.)

1—Access Panel Cap Screw (4 used) 2—Nut (2 used) 3—Clamp 4—Access Panel 5—Hydraulic Reservoir Breather

5. Install access panel and cap screws. 6. Install clamp and nuts to bin heater support and pipe.

SJ25320,0000158 –19–22AUG06–1/1

3-6-8

110807

PN=141

Maintenance—Every 500 Hours

Replace In-line Fuel Filter 1. Open hood. –UN–20MAR07

2. Loosen and slide hose clamps away from in-line fuel filter (1). Remove hoses.

TX1020624A

3. Remove filter. 4. Install new filter. 5. Install hoses and tighten clamps.

SJ25320,0000156 –19–14MAR07–1/1

Replace Secondary Fuel Filter

–UN–21AUG06

1. Turn drain (2) counterclockwise and drain secondary fuel filter. Allow sediment to drain into a container. Dispose of waste properly. 2. Turn filter (1) counterclockwise to remove.

TX1011397A

3. Clean filter base. 4. Install new filter. (Follow instructions on filter.) 5. Bleed fuel system. See Bleeding Fuel System. (Section 4-1.)

1—Secondary Filter 2—Secondary Filter Drain

SJ25320,000015B –19–20SEP06–1/1

3-6-9

110807

PN=142

Maintenance—Every 500 Hours

Replace Primary Fuel Filter

3. Turn primary fuel filter housing (3) counterclockwise to remove. Allow sediment to drain into a container. Dispose of waste properly. 4. Remove primary fuel filter (4), and discard primary fuel filter housing seal (5).

TX1011394A

2. Turn primary fuel filter drain (2) counterclockwise to drain.

–UN–21AUG06

1. Disconnect the WIF sensor connector (1).

5. Install new filter and seal. (Follow instructions on filter.)

TX1011460A

7. Bleed fuel system. See Bleeding Fuel System. (Section 4-1.)

–UN–21AUG06

6. Install sensor connector.

1—Sensor Connector 2—Primary Fuel Filter Drain 3—Primary Fuel Filter Housing 4—Primary Fuel Filter 5—Primary Fuel Filter Housing Seal

SJ25320,0000157 –19–28AUG06–1/1

3-6-10

110807

PN=143

Maintenance—Every 500 Hours

Check Coolant Conditioner in Radiator

–UN–23AUG88

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

TS281

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.

–UN–21AUG06

1. Remove fill cap (2) and test coolant solution in expansion tank (1). Deere COOL-GARD, use one of the following kits to check coolant:

TX1011380A

• 3-WAY Heavy Duty Coolant Test Kit (TY16175) (For 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.

T111110

–UN–13AUG97

• 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. IMPORTANT: To prevent machine damage, ensure that all coolant additives are compatible with coolant system is currently filled with.

3-Way Test Kit

2. Add coolant conditioner or equivalent non-chromatic conditioner/rust inhibitor, as necessary. Follow instructions on container for amount.

T111109

–UN–13AUG97

1—Expansion Tank 2—Fill Cap

CoolScan Plus

Continued on next page

3-6-11

SJ25320,0000155 –19–15SEP06–1/2 110807

PN=144

Maintenance—Every 500 Hours 3. Install fill cap.

SJ25320,0000155 –19–15SEP06–2/2

3-6-12

110807

PN=145

Maintenance—Every 1000 Hours Check Axle Oil Levels NOTE: The procedure is the same for all 3 axles.

–UN–13NOV01

1. Clean axle housing around check and fill plug (1). 2. Remove check and fill plug from axle housing.

T147833C

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.) 1—Check and Fill Plug

5. Install check and fill plug.

CS33148,0000CF9 –19–11AUG06–1/1

Check Final Drive Oil Levels NOTE: Perform this procedure for each final drive. The procedure is the same for all final drives. –UN–29JUL99

1. Rotate wheel until check plug (1) is in a horizontal position.

T123135B

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. (Section 3-8.) 1—Check Plug

4. Install check plug tightly.

CS33148,0000CFA –19–14SEP06–1/1

3-7-1

110807

PN=146

Maintenance—Every 1000 Hours

1. Remove nuts (2) and clamp (3) from bin 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.

TX1011390A

NOTE: Hydraulic reservoir breather should be replaced at scheduled intervals, or whenever found to be damaged or clogged.

–UN–21AUG06

Replace Hydraulic Reservoir Breather

4. Install new hydraulic reservoir breather. Hand-tighten.

6. Install clamp and nuts to bin heater support and pipe, if equipped.

T147656B

1—Cap Screw (4 used) 2—Nut—If Equipped (2 used) 3—Bin Heater Pipe Clamp—If Equipped 4—Access Panel 5—Hydraulic Reservoir Breather

–UN–13NOV01

5. Install access panel and cap screws.

SJ25320,000015C –19–22AUG06–1/1

3-7-2

110807

PN=147

Maintenance—Every 1000 Hours

Check and Adjust Bin Shock Pad NOTE: For accurate measurements, 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, before starting procedure. 1. Be sure bin is completely empty. 2. Remove bin sensor linkage rod (3). 3. Move sensor arm (4) forward as shown. 4. Lift bin until all pads are off the chassis.

T213202A

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, add shims to the pad that contacts the chassis last.

–UN–02AUG05

5. Lower bin until either the left or right rear pad just contacts the chassis.

6. Attach bin sensor linkage rod.

Specification 250D and 300D Bin Shock Pads—Distance ............................................................................ 5—8 mm

TX1011695A

–UN–30AUG06

1—Rear Bin Pads 2—Front Bin Pads 3—Bin Sensor Linkage 4—Sensor Arm

TX1011694A

8. Measure the gaps between the front pads and the chassis. If either of the front pad gaps is smaller than specifications, add an equal number of shims to both left and right rear pads to lift the front pads. For gaps that are larger than specifications, add shims to the front pads to meet specifications.

–UN–30AUG06

7. Lift bin and allow it to float onto rear pads.

SJ25320,000015D –19–01SEP06–1/1

3-7-3

110807

PN=148

Maintenance—Every 1000 Hours

Grease Prop Shaft Slip Joint

–UN–02AUG05

Add grease at lubrication fitting (1) until grease escapes at joint. See Grease. (Section 3-1.)

T213146A

1—Lubrication fitting

CS33148,0000CFD –19–11AUG06–1/1

3-7-4

110807

PN=149

Maintenance—Every 2000 Hours Adjust Engine Valve Clearance See your authorized dealer for engine valve clearance adjustment. CS33148,0000CFE –19–11AUG06–1/1

Change Transmission Oil

–UN–22AUG06

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.

TX1011485A

1. Tilt cab. See Tilt Cab. (Section 3-2.) 2. Loosen dipstick (3) from fill tube (2) by turning counterclockwise. NOTE: Dispose of waste properly. 3. Remove drain plug (1) and drain oil into a container.

–UN–22AUG06

4. Install drain plug.

TX1011486A

Specification Transmission Oil Pan—Capacity...................................................... 21.8 L (5.8 gal)

5. Replace transmission oil filters. See Replace Transmission Oil Filters. (Section 3-8.) 1—Drain Plug 2—Fill Tube 3—Dipstick

6. Remove dipstick (3) and add oil at fill tube (2). See Transmission and Transfer Case Oil. (Section 3-1.) 7. Check transmission oil level. See Check Transmission Oil Level. (Section 3-6.)

OILSCAN PLUS is a trademark of Deere & Company

SJ25320,0000171 –19–29AUG06–1/1

3-8-1

110807

PN=150

Maintenance—Every 2000 Hours

Replace Transmission Oil Filter

–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.

T148394B

1. Drain transmission oil. See Change Transmission Oil. (Section 3-8.) 2. Put a container under filter assembly. 3. Remove cap screws (1) and filter cover (2). Drain oil into container. Dispose of waste properly. 4. Remove filter element (3). Discard old element.

–UN–28NOV01

5. Install new filter element. 6. Replace filter cover o-ring.

Specification Transmission Oil Filter cover Cap Screw—Torque ............................................................................... 25 N•m 18 lb-ft

T148546B

7. Install filter cover and cap screws. Tighten to specification.

1—Cap Screw (4 used) 2—Filter Cover 3—Filter Element

8. Fill transmission oil. See Change Transmission Oil. (Section 3-8.) 9. Check transmission oil level. See Check Transmission Oil Level. (Section 3-6.)

CS33148,0000D00 –19–14SEP06–1/1

3-8-2

110807

PN=151

Maintenance—Every 2000 Hours

Change Transfer Case Oil

–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.

T147975B

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.

–UN–19NOV01

Transfer Case—Specification Oil—Capacity ..................................................................................... 4.7 L 5.0 qt

3. Clean drain plug thoroughly.

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).

T147662C

4. Install drain plug. Tighten to specification.

1—Fill Plug and Sealing Ring 2—Drain Plug 3—Sight Glass

CS33148,0000D01 –19–14SEP06–1/1

3-8-3

110807

PN=152

Maintenance—Every 2000 Hours

Change Axle Oil

–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.

T147833B

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). 1—Check and Fill Plug 2—Axle Drain Plug 3—Adapter Case Drain Plug (Middle Axle Only)

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. 4. Add oil at check and fill port. See Axle and Final Drive Oil. (Section 3-1.) 5. Install check and fill plug.

CS33148,0000D02 –19–14SEP06–1/1

3-8-4

110807

PN=153

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.

–UN–13NOV01

NOTE: Dispose of waste properly. 2. Remove drain plug from final drive and allow oil to drain into a container.

3. Clean drain plug of oil and debris. Install drain plug tightly.

T147834B

Final Drive—Specification Oil (Each)—Capacity .......................................................................... 4.0 L 4.2 qt

1—Drain Plug 2—Check and Fill Plug

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.) 5. Install check and fill plug.

CS33148,0000D03 –19–14SEP06–1/1

3-8-5

110807

PN=154

Maintenance—Every 2000 Hours

Replace Pneumatic System Dryer-Filter 1. Relieve pneumatic pressure. –UN–21AUG06

2. Remove old element (1) from head (2). Discard old element.

TX1011415A

3. Inspect O-ring on head. Clean or replace O-ring, if necessary. 4. Apply thin layer of oil to O-ring on head and to O-ring on new element. 1—Element 2—Head

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.

SJ25320,000015F –19–22AUG06–1/1

3-8-6

110807

PN=155

Maintenance—Every 2000 Hours

Replace Hydraulic System Oil Return Filter

–UN–21AUG06

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.

TX1011390A

–UN–13NOV01

CAUTION: Avoid personal injury. Remove return filter cover carefully. Spring is under load.

T147656C

–UN–13NOV01

7. Grasp spring and remove spring and return filter assembly.

T143811C

Continued on next page

3-8-7

SJ25320,0000177 –19–24AUG06–1/2 110807

PN=156

Maintenance—Every 2000 Hours 12. Install spring and filter element assembly. Be sure that shoulder seal ring is properly seated in filter seat. 13. Install filter cover and cap screws. Be sure 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. 14. Install access cover and cap screws. 15. Install clamp and nuts to bin heater support and pipe, if equipped.

SJ25320,0000177 –19–24AUG06–2/2

3-8-8

110807

PN=157

Maintenance—Every 3000 Hours Replace Hydraulic Suction Screen 1 1. Drain oil from hydraulic reservoir. Specification Reservoir Oil—Capacity ................................................................... 78.8 L 20.8 gal

2. Remove external hydraulic reservoir cover (1). 3. Remove internal hydraulic reservoir cover (2).

3 4. Remove suction screen from fitting (3).

5. Clean magnet (4) as necessary. 6. Insert new suction screen into fitting. 7. Replace reservoir covers (1 and 2).

–UN–08AUG05

8. Fill hydraulic reservoir and check hydraulic oil level.

T213160

1—External Hydraulic Reservoir Cover 2—Internal Hydraulic Reservoir Cover 3—Fitting 4—Magnet

SJ25320,0000175 –19–22AUG06–1/1

3-9-1

110807

PN=158

Maintenance—Every 4000 Hours Change Hydraulic Oil

–UN–13NOV01

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).

T147782B

NOTE: Dispose of waste properly. 2. Loosen nut (1) and valve stem (2) to open drain valve. Drain hydraulic oil. Specification Reservoir Oil—Capacity ................................................................... 78.8 L 20.8 gal

–UN–13NOV01

3. Tighten valve stem and nut to close drain valve. Remove drain hose and clamp from drain valve.

T147784B

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 3—Drain Valve 4—Fill Cap

SJ25320,000018B –19–28AUG06–1/1

3-9-1

110807

PN=159

Maintenance—Every 4000 Hours

Replace Pneumatic Block Silencer Filter

TX1011686

–UN–29AUG06

TX1011686 1—Exhaust Silencer (3 used)

2—Exhaust Silencer (2 used)

1. Park machine and turn engine off.

4. Remove C-clips and exhaust silencers (1) from manifold; insert new exhaust silencers with C-clips.

CAUTION: Prevent possible injury. Discharge pneumatic system completely before removing any filter or components. 2. Discharge air pressure from pneumatic system by pulling drain plug ring on air reservoir. See Relieve Pneumatic Pressure. (Section 3-2.)

5. Remove lines and fittings, and remove pneumatic exhaust silencer filters (2). 6. Install new pneumatic exhaust silencer filters, and install fittings and lines.

3. Open hood and locate pneumatic manifold on the right-hand side.

CS33148,00013EA –19–11SEP06–1/1

3-9-2

110807

PN=160

Maintenance—Every 4500 Hours Replace Engine Crankshaft Dampener The crankshaft dampener assembly is not repairable and should be replaced every five years or 4500 hours, whichever occurs first, or whenever crankshaft is replaced. See your authorized dealer.

CS33148,0000D08 –19–07NOV07–1/1

3-10-1

110807

PN=161

Maintenance—Every 5000 Hours Drain, Flush and Refill Engine Cooling System

–UN–21AUG06

1. Open hood. Remove fill cap (2) from expansion tank (1).

TX1011380A

2. Lower front bottom guard. See Lower and Raise Bottom Guard. (Section 3-2.) 3. Attach clear hose and hose clamp to drain valve (3). NOTE: Dispose of waste properly. 4. Drain coolant From radiator block into a container.

–UN–23AUG06

Specification Engine Coolant—Capacity .................................................................. 33 L (8.7 gal)

5. Tighten drain valve. Do not overtighten.

TX1011495A

6. Remove hose clamp and hose. 7. Attach clear hose and hose clamp to drain valve (4). 8. Drain coolant From engine block into a container. 9. Tighten drain valve. Do not overtighten.

–UN–23AUG06

10. Remove hose clamp and hose.

TX1011500A

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. 11. Add new engine coolant at expansion tank fill port. Do not overfill.

1—Expansion Tank 2—Fill Cap 3—Drain Valve (radiator) 4—Drain Valve (engine block)

12. Check for leaks at drain valve. Tighten only enough to stop leaks. 13. 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. 14. Raise front bottom guard.

Continued on next page

3-11-1

SJ25320,0000173 –19–15SEP06–1/2 110807

PN=162

Maintenance—Every 5000 Hours 15. 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. 16. Install fill cap securely.

SJ25320,0000173 –19–15SEP06–2/2

3-11-2

110807

PN=163

Maintenance—Every 6000 Hours Replace Universal Joints The universal joints are not repairable and should be replaced every 6000 hours (See your authorized dealer.) SJ25320,0000176 –19–24AUG06–1/1

3-13-1

110807

PN=164

Miscellaneous—Machine Do Not Service Control Valves, Cylinders, Pumps or Motors Special tools and information are needed to service control valves, cylinders, pumps, or motors. If these parts need service, see your authorized dealer.

CS33148,0000D0A –19–11AUG06–1/1

Do Not Service Injection Nozzles IMPORTANT: Do not service or remove injection nozzles. The service life of the injection nozzles may be shortened by: • Overheating • Improper operation • Poor quality fuel • Excessive idling If injection nozzles are not working correctly or are dirty, the engine will not run normally. (See your authorized dealer for service.)

CS33148,0000D0B –19–11AUG06–1/1

4-1-1

110807

PN=165

Miscellaneous—Machine

Bleeding Fuel System 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. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

NOTE: Whenever the fuel system has been opened up for service (lines disconnected or filters removed), or if machine has run out of fuel, it will be necessary to bleed air from the system. 1. Turn key to the ON position. 2. Wait two minutes. 3. Turn key to the OFF position. 4. Turn key back to the ON position. 5. Wait two minutes. 6. Start engine.

SJ25320,0000169 –19–18AUG06–1/1

Check Engine Air Intake System

2. Check that service indicator (3) is not showing a red flag. If red flag is shown, service air cleaner and reset service indicator.

TX1011491A

3. Check rubber elbows (4), clamps (5), and pipes (6) for tightness, cracks, or damage.

–UN–23AUG06

1. Check air cleaner assembly for damage to precleaner (1) and air cleaner housing (2).

1—Precleaner 2—Air Cleaner Housing 3—Service Indicator 4—Rubber Elbow (2 used) 5—Clamp (6 used) 6—Pipe (2used)

SJ25320,0000172 –19–23AUG06–1/1

4-1-2

110807

PN=166

Miscellaneous—Machine

Check Brake Accumulators 1. Start engine and wait until main pump has fully charged the accumulators. 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. 3. Turn key switch to the off position to stop engine. 4. Turn key switch to the on position and wait for bulb check to complete. 5. Press brake pedal repeatedly, counting the number of strokes before the brake indicator lights. 6. Machine must allow six strokes of the brake pedal before brake pressure indicator on instrument panel lights. If it does not, see your authorized dealer.

SJ25320,0000161 –19–31AUG06–1/1

Check Wheel Nuts 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. Ensure that wheel nuts are tight. Torque to specification. Wheel—Specification Nut—Torque ................................................................................. 650 N•m 480 lb-ft

CS33148,0000D0F –19–14SEP06–1/1

4-1-3

110807

PN=167

Miscellaneous—Machine

Lubricate Hinges • Battery compartment door hinges • Hood hinges • Bottom guard hinge

Lubricate the following with powdered graphite: • Cab door hinges

CS33148,0000D10 –19–11AUG06–1/1

JDLink Machine Monitoring System (MMS)—If Equipped JDLink is an equipment monitoring and information delivery system. JDLink automatically collects and manages information about where and how construction and forestry equipment is being used, as well as critical machine health data and service status. There are two ways to identify if machine is equipped with JDLink: 1. Check for the JDLink fuse in the designated fuse location. (See section 4-1.) 2. Check that the JDLink controllers are installed. See your authorized dealer. CAUTION: Avoid serious injury or death from an explosion hazard. This machine is equipped with a radio frequency device. Do not store or operate in an area, such as a blasting zone, where the use of cellular phones or radio frequency devices are prohibited. To deactivate the system, remove the JDLink unswitched power fuse. For more information visit www.deere.com, browse to Construction, Services and Support, JD Link.

JDLink is a trademark of Deere & Company

VD76477,0001541 –19–18OCT07–1/1

4-1-4

110807

PN=168

Miscellaneous—Machine

JDLink Machine Monitoring System (MMS) Direct Laptop Connection—If Equipped

TX1025657A

–UN–27JUN07

• The direct laptop connector is located in the fuse box on the front left side of operators cab. • To download machine data using the JDLink MMS Direct: – Install the JDLink MMS Direct cable by inserting the Ethernet connector into the laptop. – Connect the JDLink MMS Direct cable to the vehicle 4-pin Deutsch connector (1). – Launch JDLink MMS Direct Software. • Contact your authorized dealer to obtain the JDLink MMS Direct Kit (AT347680), which includes the JDLink MMS Direct cable (AT335476) and software.

1—4-pin Deutsch Connector

NOTE: On equipment using the JDLink Direct system, there is no nightly upload to a remote server and thus, the information is only stored in one location—the controller. Without downloading the controller data on a regular basis, the data could be lost if the controller were to fail. To obtain the most detailed machine data on your laptop, you must perform a machine data download every 1000 hrs or less.

JDLink is a trademark of Deere & Company

OUT4001,00002F9 –19–26JUN07–1/1

Fuse and Relay Compartment (S.N. — XXXXXX) The relay panel consists of four relays. The fuse block consists of fuses, which provide overload protection for the identified circuits. Replace fuses as necessary.

Continued on next page

4-1-5

VD76477,00016EA –19–07NOV07–1/3

110807

PN=169

Miscellaneous—Machine

K15 R1 - 12V SUPPLY

X13 S1 - STUD 1

R2 - GEAR HOLD

BATTERY POWER

87a 85

FUSE AND RELAY LAYOUT

87a

F1 F2 F3

10A

FUSE 7

10A

FUSE 6

20A

FUSE 5

20A

FUSE 3

FUSE 4

F11 F12 F13 F14

F44

10A

SPARE 4

10A

SPARE 3

10A

SPARE 2

SPARE 1

10A

FUSE 10

10A

10A 10A

F45

FUSE 45

10A

F46

FUSE 46

10A

F47

FUSE 47

FUSE 15

10A FUSE 16

40A FUSE 17

10A FUSE 18

20A FUSE 19

30A FUSE 20

20A FUSE 21

20A

IGNITION

F15 F16 F17

F18 F19 F20 F21

FUSE 22

10A FUSE 23

25A FUSE 24

15A FUSE 25

20A FUSE 26

30A FUSE 27

20A FUSE 28

20A

IGNITION

F22 F23 F24

F25 F26 F27 F28

FUSE 29

10A FUSE 30

25A FUSE 31

15A FUSE 32

10A FUSE 33

10A FUSE 34

10A FUSE 35

IGNITION

F36

F29

F48

SPARE 5

FUSE 36

10A

F30

FUSE 37

10A

F31

FUSE 38

10A

F32

FUSE 39

10A

F33

F37

F38

F39

10A FUSE 41

10A

F35

ZF EOL

X14

F40

FUSE 40

F34

DIODE 1

S2 - STUD 2

F41

IGNITION POWER

X274

10A

TX1011045

IGNITION

10A

–UN–23AUG06

86 87

FUSE 9

FUSE 8

86 87

10A FUSE 44

87a

BATTERY

F43

FUSE 43

F8 F9 F10

87a

10A

R4 - OVERSPEED

10A

R3 - AUTO NEUTRAL

FUSE 2

FUSE 1

BATTERY

TX1011045 Fuse and Relay Layout

Continued on next page

4-1-6

VD76477,00016EA –19–07NOV07–2/3

110807

PN=170

Miscellaneous—Machine F1—TCU Unswitched Power 10 Amp Fuse F2—ECU Unswitched Power 10 Amp Fuse F3—OEU 20 Amp Fuse F4—Coldstart Engine On Signal, Left Tun Light, and Right Turn Light 20 Amp Fuse (marked as CCU2) F5—Not Used F6—Battery Balancer 10 Amp Fuse F7—Diagnostic Connector Unswitched Power 10 Amp Fuse F8—MDU 10 Amp Fuse F9—Not Used F10—Dome Light, Service Brake Light Switch, and 4-Way Flasher Switch 10 Amp Fuse F11—Spare 10 Amp Fuse F12—Spare 10 Amp Fuse F13—Spare 10 Amp Fuse F14—Spare 10 Amp Fuse F15—TCU Switched Power 10 Amp Fuse F16—Coldstart 40 Amp Fuse F17—ECU Switched Power 10 Amp Fuse F18—Range Hold and Blower Speed Low 20 Amp Fuse (marked as OEU Output Driver Supply 3) F19—Not Used F20—Automatic Neutral Relay, Engine Overheat/Preselect 2nd, and Blower Speed Medium 20 Amp Fuse (marked as OEU Output Driver Supply 4)

F21—Blower Speed High 20 Amp Fuse (marked as OEU Output Driver Supply 5) F22—OEU Ignition Status 10 Amp Fuse F23—Fan Low Solenoid and Fan Medium Solenoid 25 Amp Fuse (marked as OEU Output Driver Supply 2) F24—Heater Valve, Floor Vent Actuator, and Middle Vent/Defrost Actuator 15 Amp Fuse (marked as OEU Output Driver Supply 1) F25—Bin Pressure Reduction Solenoid, Inter-Axle Lock Solenoid, Front Wiper Low Speed, and Rear Wiper Low Speed 20 Amp Fuse (marked as CCU2 Output Driver Supply 3) F26—Park Lights and Work Lights 30 Amp Fuse (marked as CCU2 Output Driver Supply 6) F27—Rear Wiper High Speed, Differential Lock Solenoid, Air System Drain Solenoid, Bin Lever Detent Magnet, and Backup Lights 20 Amp Fuse (marked as CCU2 Output Driver Supply 4)

F28—Horn, Headlights (Low and High Beam), and Flashing Beacon Light 20 Amp Fuse (marked as CCU2 Output Driver Supply 5) F29—CCU Ignition Status 10 Amp Fuse F30—Park Brake Solenoid, Overspeed Control, Front Washer Pump, Front Wiper High Speed, and Artic Reverse Light 25 Amp Fuse (marked as CCU2 Output Driver Supply 2) F31—Hydraulic Cut-Off Solenoid, A/C Clutch Solenoid, Mirror Heating, and Recirculation Vent Actuator 15 Amp Fuse (marked as CCU2 Output Driver Supply 1) F32—Diagnostic Connector Switched Power 10 Amp Fuse F33—MDU Ignition Status 10 Amp Fuse F34—Not Used F35—Mirror Electrical 10 Amp Fuse F36—Hardware Detection, Park Brake Switch, and Park Brake Pressure Switch 10 Amp Fuse F37—12 Volt Supply Relay, Front Wiper Park Signal, Headlight Switch, Rear Wiper Motor Park Signal 10 Amp Fuse

F38—Service Brake Pressure Switch and Secondary Steering 10 Amp Fuse F39—Not Used F40—Electrical Seat 10 Amp Fuse F41—Not Used F43—12 Volt Radio (Switched) 10 Amp Fuse F44—Not Used F45—12 Volt Power Socket and 12 Volt Cigarette Lighter 10 Amp Fuse F46—CCU 12 Volt Input 10 Amp Fuse F47—12 Volt Radio (Unswitched) 10 Amp Fuse F48—Not Used K1—Neutral Start Relay (marked as R3) K6—Engine Overspeed Relay (marked as R4) K15—12 Volt Supply Relay (marked as R1) K8—Range Hold Relay (marked as R2) V3—Alternator Excitation Diode (3 Amp) X13—Unswitched Power Terminal (marked as Stud 1) X14—Switched Power Terminal (marked as Stud 2) X274—Not Used

VD76477,00016EA –19–07NOV07–3/3

4-1-7

110807

PN=171

Miscellaneous—Machine

Fuse and Relay Compartment (S.N. XXXXXX—) The relay panel consists of four relays. The fuse block consists of fuses, which provide overload protection for the identified circuits. Replace fuses as necessary.

Continued on next page

4-1-8

VD76477,00016E9 –19–08NOV07–1/4

110807

PN=172

Miscellaneous—Machine

4-1-9

110807

PN=173

Miscellaneous—Machine

K15 R1 - SPARE

S1 - STUD 1

F1 F2 F3

87a

BATTERY POWER

R3 - AUTO NEUTRAL

R4 - OVERSPEED

10A

25A

FUSE 7

25A

FUSE 6

20A

FUSE 5

FUSE 4

20A

FUSE 3

F8 F9 F10

F11 F12 F13 F14

F44

10A 10A

10A

SPARE 4

10A

SPARE 3

SPARE 2

15A

SPARE 1

10A

FUSE 10

FUSE 9

10A

FUSE 8

BATTERY

87a

10A FUSE 44

87a

F43

FUSE 43

F45

FUSE 45

10A

F46

FUSE 46

10A

F47

FUSE 47

FUSE 15

10A FUSE 16

40A FUSE 17

10A FUSE 18

20A FUSE 19

30A FUSE 20

20A FUSE 21

20A

IGNITION

F15 F16 F17

F18 F19 F20 F21

FUSE 22

10A FUSE 23

25A FUSE 24

15A FUSE 25

20A FUSE 26

30A FUSE 27

20A FUSE 28

20A

IGNITION

F22

F23

F24

F25 F26

F27 F28

FUSE 29

10A FUSE 30

25A FUSE 31

15A FUSE 32

10A FUSE 33

10A FUSE 34

10A FUSE 35

IGNITION

F29

10A

F30

FUSE 37

10A

F31

FUSE 38

10A

F32

FUSE 39

10A

F33

10A

F36

SPARE

F37

SPARE

FUSE 36

F38

F48

10A

15A

F39

F40

X14

FUSE 40

10A

F34

FUSE 41

10A

F35

10A

F41

S2 - STUD 2 IGNITION POWER

X274

15A

TX1031773

IGNITION

–19–08NOV07

10A

FUSE 2

BATTERY

FUSE 1

87a

86 87

X13

R2 - GEAR HOLD

FUSE AND RELAY LAYOUT

TX1030827 Continued on next page

4-1-10

VD76477,00016E9 –19–08NOV07–2/4

110807

PN=174

Miscellaneous—Machine F1—TCU Unswitched Power 10 Amp Fuse F2—ECU Unswitched Power 20 Amp Fuse F3—OEU 20 Amp Fuse F4—Coldstart Engine On Signal, Left Tun Light, and Right Turn Light 20 Amp Fuse (marked as CCU2) F5—Spare 25 Amp Fuse F6—Battery Balancer 25 Amp Fuse F7—Diagnostic Connector Unswitched Power 10 Amp Fuse F8—MDU 10 Amp Fuse F9—Spare 10 Amp Fuse F10—Dome Light, Service Brake Light Switch, and 4-Way Flasher Switch 10 Amp Fuse F11—Spare 15 Amp Fuse F12—Spare 10 Amp Fuse F13—Spare 10 Amp Fuse F14—Spare 10 Amp Fuse

F15—TCU Switched Power 10 Amp Fuse F16—Coldstart 40 Amp Fuse F17—ECU Switched Power 10 Amp Fuse F18—Range Hold and Blower Speed Low 20 Amp Fuse (marked as OEU Output Driver Supply 3) F19—Starter Solenoid 30 Amp Fuse (marked as OEU Output Driver Supply 6) F20—Automatic Neutral Relay, Engine Overheat/Preselect 2nd, and Blower Speed Medium 20 Amp Fuse (marked as OEU Output Driver Supply 4) F21—Blower Speed High 20 Amp Fuse (marked as OEU Output Driver Supply 5) F22—OEU Ignition Status 10 Amp Fuse F23—Fan Low Solenoid and Fan Medium Solenoid 25 Amp Fuse (marked as OEU Output Driver Supply 2) F24—Heater Valve, Floor Vent Actuator, and Middle Vent/Defrost Actuator 15 Amp Fuse (marked as OEU Output Driver Supply 1) F25—Bin Pressure Reduction Solenoid, Inter-Axle Lock Solenoid, Front Wiper Low Speed, and Rear Wiper Low Speed 20 Amp Fuse (marked as CCU2 Output Driver Supply 3) F26—Park Lights and Work Lights 30 Amp Fuse (marked as CCU2 Output Driver Supply 6)

JDLink is a trademark of Deere & Company

F27—Rear Wiper High Speed, Differential Lock Solenoid, Air System Drain Solenoid, Bin Lever Detent Magnet, and Backup Lights 20 Amp Fuse (marked as CCU2 Output Driver Supply 4) F28—Horn, Headlights (Low and High Beam), and Flashing Beacon Light 20 Amp Fuse (marked as CCU2 Output Driver Supply 5) F29—CCU Ignition Status 10 Amp Fuse F30—Park Brake Solenoid, Overspeed Control, Front Washer Pump, Front Wiper High Speed, and Artic Reverse Light 25 Amp Fuse (marked as CCU2 Output Driver Supply 2) F31—Hydraulic Cut-Off Solenoid, A/C Clutch Solenoid, Mirror Heating, and Recirculation Vent Actuator 15 Amp Fuse (marked as CCU2 Output Driver Supply 1) F32—Diagnostic Connector Switched Power 10 Amp Fuse F33—MDU Ignition Status 10 Amp Fuse F34—Spare 10 Amp Fuse F35—Mirror Electrical 10 Amp Fuse F36—Hardware Detection, Park Brake Switch, Park Brake Pressure Switch, and JDLink Switched Power 10 Amp Fuse

Continued on next page

4-1-11

F37—12 Volt Supply Relay, Front Wiper Park Signal, Headlight Switch, Rear Wiper Motor Park Signal 10 Amp Fuse F38—Service Brake Pressure Switch and Secondary Steering 10 Amp Fuse F39—Auto Greaser Ign. Supply 10 Amp Fuse F40—Electrical Seat 10 Amp Fuse F41—On-Board Weighing, Tire Pressure Monitoring 10 Amp Fuse (marked as OBW, TPM) F43—12 Volt Radio (Switched) 10 Amp Fuse F44—12 Volt Two-Way Radio and Reverse Monitor 10 Amp Fuse F45—12 Volt Power Socket and 12 Volt Cigarette Lighter 10 Amp Fuse F46—CCU 12 Volt Input 10 Amp Fuse F47—12 Volt Radio (Unswitched) 10 Amp Fuse F48—Spare 10 Amp Fuse K1—Neutral Start Relay (marked as R3) K6—Engine Overspeed Relay (marked as R4) K8—Range Hold Relay (marked as R2) K15—Spare (marked as R1) V3—Spare 15 Amp Fuse X13—Unswitched Power Terminal (marked as Stud 1) X14—Switched Power Terminal (marked as Stud 2) X274—Spare 15 Amp Fuse

VD76477,00016E9 –19–08NOV07–3/4 110807

PN=175

Miscellaneous—Machine JDLink In-Line Fuse (If Equipped) 1. Turn machine off. –UN–27JUN07

2. Open battery compartment door on front left-side of machine to access the 10 Amp JDLink unswitched power in-line fuse (1).

TX1025654A

NOTE: JDLink unswitched power in-line fuse (F55) will be labeled with a tag and will be on the red wire. 3. To deactivate the JDLink Machine Monitoring System, remove the unswitched power in-line fuse. 1—JDLink Unswitched Power In-Line Fuse (10 Amp)

4. Close battery compartment door.

JDLink is a trademark of Deere & Company

VD76477,00016E9 –19–08NOV07–4/4

Using Battery Charger

–UN–23AUG88

CAUTION: Disconnect battery ground before you charge batteries in the machine to prevent damage to electrical components.

TS204

A battery may explode if charged when it is frozen. Warm battery to 16°C (60°F) before charging. A battery charger may be used as a booster to start engine. IMPORTANT: Do not use battery charger as a booster if a battery has a 1.150 specific gravity reading or lower. Turn off charger before connecting or disconnecting it.

CS33148,0000D11 –19–11AUG06–1/1

4-1-12

110807

PN=176

Miscellaneous—Machine

Using Booster Batteries—24-Volt System

–UN–23AUG88

Before boost starting, machine must be properly shut down and secured to prevent unexpected machine movement when engine starts.

TS204

CAUTION: An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from 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 2 12-volt booster batteries together in series as shown for 24-volts.

–UN–21MAY90

1. Connect one end of positive cable to positive terminal of machine batteries and other end to positive terminal of booster batteries.

T7233JN

2. Connect one end of negative cable to negative terminal of booster batteries. Connect other end of negative cable to machine frame as far away from machine batteries as possible. A—Machine Batteries B—Booster Batteries

3. Start engine. 4. Immediately after starting engine, disconnect end of negative cable from machine frame. Then disconnect other end of negative cable from negative terminal of booster batteries. 5. Disconnect positive cable from booster batteries and machine batteries.

OUT4001,0000301 –19–11JUL07–1/1

4-1-13

110807

PN=177

Miscellaneous—Machine

Handling, Checking And Servicing Batteries Carefully

–UN–23AUG88

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

TS204

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:

–UN–23AUG88

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.

TS203

If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts). 3. Get medical attention immediately. WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Continued on next page

4-1-14

CS33148,0000D12 –19–11AUG06–1/3 110807

PN=178

Miscellaneous—Machine If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in 4 L (1 gal) water. IMPORTANT: DO NOT overfill the battery cells. Check the specific gravity of electrolyte in each battery cell.

CS33148,0000D12 –19–11AUG06–2/3

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

CS33148,0000D12 –19–11AUG06–3/3

4-1-15

110807

PN=179

Miscellaneous—Machine

Replace Batteries 1. Open hood. Open battery compartment door (1). –UN–18AUG06

2. Remove screws (4) ; lift and remove top access cover. 3. Turn battery disconnect switch (3) OFF.

TX1011377A

4. Clean debris from battery compartment. IMPORTANT: Be sure that all cables are reconnected properly. Note all connections while removing batteries, to prevent incorrect connections while installing batteries.

–UN–18AUG06

5. Disconnect all cables from battery terminals, beginning with battery negative (—) terminal. For each terminal (6), lift rubber terminal cover, remove nut, and remove washer and ring connector(s) from terminal. Move all cables aside.

TX1011378A

6. Loosen nuts and washers on mounting bracket assembly (5). Remove mounting bracket assembly from machine. Lift batteries from machine through top access opening. 7. Install new batteries. Install and tighten mounting bracket assembly.

–UN–18AUG06

8. Install all cables, beginning at battery positive (+) terminal. For each terminal, install ring connector(s), washer, and nut. Pull rubber terminal cover over terminal.

10. Start engine. After bulb check, verify that battery charge indicator on instrument panel is not lit. Verify battery voltages on monitor display unit. 11. Install top access cover and screws.

TX1011379A

9. Turn battery disconnect switch ON.

1—Battery Compartment Door 2—Circuit Breaker 3—Battery Disconnect Switch 4—Top Access Cover Screw (8 used) 5—Mounting Bracket Assembly 6—Terminal (4 used)

SJ25320,0000160 –19–24AUG06–1/1

4-1-16

110807

PN=180

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 a 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. 1—Cap Screw (2 used) 2—Screw (2 used) 3—Headlight Grille (if equipped)

2. Remove screws (2) securing headlight assembly to fender. 3. Swing headlight assembly out of fender.

Continued on next page

4-1-17

SJ25320,0000162 –19–17AUG06–1/2

110807

PN=181

Miscellaneous—Machine 4. Replace front turn signal bulb, if necessary: a. Squeeze tabs (4) and remove front turn signal bulb (5) from headlight assembly. b. Install new front turn signal bulb. 5. Replace headlight bulb, if necessary: –UN–05JUL06

a. Push retainer (6) inward and rotate counterclockwise, releasing retainer from slots in headlight assembly.

c. Install new headlight bulb and park light bulb if needed. d. Align retainer with slots in headlight assembly, push inward and rotate.

TX1009689A

b. Remove headlight bulb (8) and park light bulb (7) from headlight assembly.

4—Tab (2 used) 5—Front Turn Signal Bulb 6—Retainer 7—Park Light Bulb 8—Headlight Bulb

6. Swing headlight assembly into fender. 7. Install screws to secure headlight assembly to fender. 8. Adjust headlights. 9. Install headlight grille and cap screws.

SJ25320,0000162 –19–17AUG06–2/2

4-1-18

110807

PN=182

Miscellaneous—Machine

Adjust Headlights

–UN–14AUG01

T143221

2 T143221

1—Horizontal Adjustment Screw

2—Vertical Adjustment Screw

5. Use string line and tape to mark wall at center point between headlights.

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. 1. Verify that the tires are at the correct pressure. 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.

6. Measure left and right on wall and mark wall at centers of headlights. 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. 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.

CS33148,0000D15 –19–11AUG06–1/1

4-1-19

110807

PN=183

Miscellaneous—Machine

Replace Backup Light and Work Light—If Equipped

–UN–05JUL06

1. Remove screws (1). 2. Remove bezel (2) and lamp (3) from housing.

TX1009687A

3. Disconnect wire lead (5) from connector. 4. Remove bulb (4) from lamp. 5. Install new bulb. 1—Screw (4 used) 2—Bezel 3—Lamp 4—Bulb 5—Wire Lead

6. Connect wire lead to connector. 7. Install lamp and bezel in housing. 8. Install screws. 9. Adjust position of light for best illumination. If housing is loose, tighten mounting hardware (not shown).

SJ25320,0000163 –19–18AUG06–1/1

Replace Tail and Brake Light and Rear Turn Signal

–UN–25JUN01

IMPORTANT: DO NOT use excessive force when removing lamp, or plastic or rubber may become damaged. 1. Remove light guard if equipped.

3. Disconnect connector (3). Discard lamp.

T143366B

2. Pry gently around edges of lamp (1) to remove from rubber seal (2). 1—Lamp 2—Rubber Seal 3—Connector

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.

SJ25320,0000164 –19–17AUG06–1/1

4-1-20

110807

PN=184

Miscellaneous—Machine

Replace Dome Light Bulb

–UN–27JUL06

IMPORTANT: DO NOT use excessive force when removing dome light assembly, or plastic may become damaged.

TX1010704A

1. Pry gently along short edges of dome light assembly to release clips and remove. 2. Remove retainer (2) on back side of dome light assembly and replace dome light bulb (1). 3. Install dome light assembly with even pressure until it snaps into place.

1—Dome Light Bulb 2—Retainer

SJ25320,0000165 –19–24AUG06–1/1

Clean The Machine Regularly

T6642EJ

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.

–UN–18OCT88

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. Do not spray oil cooler fins at an angle. Fins may bend.

CS33148,0000D19 –19–11AUG06–1/1

4-1-21

110807

PN=185

Miscellaneous—Machine

Unified Inch Bolt and Screw Torque Values TS1671 –UN–01MAY03

Bolt or

SAE Grade 2a

SAE Grade 1 b

Screw

Lubricated

Size

Dry

Lubricated

SAE Grade 5, 5.1 or 5.2 c

Dry

Lubricated

SAE Grade 8 or 8.2 Lubricatedb

Dry

Dryc

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

1/4

3.7

4.7

7.5

9.5

106

13.5

120

150

N•m

lb-ft

N•m

lb-ft

5/16

7.7

9.8

106

15.5

137

19.5

172

221

20.5

N•m

lb-ft

N•m

lb-ft

32.5

100

115

3/8

7/16

13.5

120

194

N•m

lb-ft

17.5

155

194

240

N•m

lb-ft

N•m

lb-ft

N•m

lb-ft

20.5

32.5

1/2

110

120

155

9/16

35.5

125

155

115

175

130

220

165

5/8

105

135

100

170

125

215

160

240

175

305

225

3/4

120

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

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.

b “Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C zinc flake coating.

“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.

CS33148,0000D1A –19–11AUG06–1/1

4-1-22

110807

PN=186

Miscellaneous—Machine

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

TS1670

4.8

–UN–01MAY03

Metric Bolt and Screw Torque Values

Bolt or

Class 4.8 a

Class 8.8 or 9.8 b

Lubricated

Dry

Lubricated

Class 12.9 b

Lubricateda

Dry

Dryb

Screw

Lubricated

Size

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

N•m

lb-in

4.7

8.9

11.3

100

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

11.5

102

14.5

128

194

27.5

243

23.5

29.5

27.5

N•m

lb-ft

N•m

lb-ft

N•m

lb-ft

M10

Dry

Class 10.9 b

204

N•m

lb-ft

M12

29.5

110

140

105

130

165

120

M14

120

150

110

175

130

220

165

205

150

260

190

M16

100

125

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 zinc flake coating. b

“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.

CS33148,0000D1B –19–11AUG06–1/1

4-1-23

110807

PN=187

Miscellaneous—Machine

T121289

–19–16SEP99

Imperial and SAE (Inch) Cap Screw and Nut Torque Values

CS33148,0000D1C –19–11AUG06–1/1

4-1-24

110807

PN=188

Miscellaneous—Machine

T121288

–19–16SEP99

Metric Cap Screw and Nut Torque Values

CS33148,0000D1D –19–11AUG06–1/1

4-1-25

110807

PN=189

Miscellaneous—Machine

Welding on Machine

–UN–23AUG06

IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF to prevent voltage spikes through alternator or monitor.

• Chassis Control Unit (CCU) (1) • Transmission Control Unit (TCU) (2) • Engine Control Unit (ECU) (3) • Battery Balancer (4) • Monitor Display Unit (MDU)

TX1011516A

To prevent voltage spikes through microprocessors, disconnect harness connectors from the following controllers: 1—Chassis Control Unit (CCU) 2—Transmission Control Unit (TCU) 3—Engine Control Unit (ECU) 4—Battery Balancer

Connect welder ground clamp close to each weld area so electrical current does not arc inside any bearings.

CS33148,0000D1E –19–22AUG06–1/1

4-1-26

110807

PN=190

Miscellaneous—Operational Checkout Operational Checkout Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of machine operation while 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 that will reduce the down time of the machine. Use the table of contents to help find adjustment procedures. After the operational checkout is completed, the information provided will allow you to pinpoint a specific test or repair needed to restore the machine to design specifications. A location will be required that is level and has adequate space to complete the checks. No tools or equipment are needed to perform the checkout. 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 the column before performing the check. Follow this sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to the 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.

SJ25320,0000166 –19–29AUG06–1/1

Operator Station Checks—Key Switch ON, Engine Stopped

– – –1/1

4-2-1

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PN=191

Miscellaneous—Operational Checkout Gauges and Indicator Lights Check

TX1010708A –UN–27JUL06

Key Switch

1—ON Position

YES: Go to next check.

With battery disconnect switch ON, turn key switch to ON position (1). LOOK/LISTEN: Does the following happen?

NO: Check circuit breakers. Reset if tripped.

• All indicators light or flash. • All gauges and speedometer move to center position. • All segments of MDU LCDs display. • All segments of transmission control LED display and mode button indicator light. • Warning alarm sounds.

IF OK: Check indicator bulbs. Replace if necessary. IF OK: See your authorized dealer.

NOTE: Warning alarm will sound until air pressure reaches normal operating pressure. 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 operation mode and warning alarm silences? Do all indicators, except for secondary 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 indicator may also remain lit, depending on ambient temperature.

– – –1/1

Operator Station Checks—Key Switch ON, Engine Running

– – –1/1

1—ON Position 2—START Position 3—OFF Position

Key Switch Start Check

Turn key switch to ON position (1). Turn key switch to START position (2).

TX1010709A –UN–27JUL06

Key Switch

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 (3). Wait 1 minute and try again.

YES: Go to next check. NO: Check battery disconnect switch. NO: Check battery. NO: See your authorized dealer.

LISTEN: Starter motor will start the engine. Run engine for a few seconds, then turn key switch to OFF position. LISTEN: Engine must stop immediately when key switch is turned OFF.

– – –1/1

4-2-2

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PN=192

Miscellaneous—Operational Checkout Gauges and Indicators Checks

YES: Go to next check. NO: See your authorized dealer.

TX1010040 –UN–02AUG06

1—Park Brake Indicator 2—RPM Display of MDU 3—Main Warning Lamp 4—Coolant Temperature Gauge 5—Transmission Oil 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 main warning lamp (3). LOOK: Does main warning lamp go out after the engine starts? Observe coolant temperature gauge (4) immediately after the engine is started. LOOK: Does needle of gauge indicate temperature is increasing to normal (green)?

– – –1/1

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Miscellaneous—Operational Checkout Brake Accumulator Check

Ensure brake accumulators are fully charged by pressing brake pedal repeatedly to make pump recharge accumulators several times.

YES: Start machine and go to next check.

Stop pumping during a recharge cycle to ensure brakes are not using oil after pump stops.

NO: See your authorized dealer.

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. FEEL/LOOK: Does machine allow two full applications before brake pressure indicator lights?

– – –1/1

Service Brake Check

NOTE: Perform this check in an open area where machine can travel at full speed.

YES: Go to next check.

Drive machine slowly.

NO: See your authorized dealer.

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. LOOK/FEEL: Do brakes stop machine in a reasonable distance without pulling to one side or making noises? – – –1/1

4-2-4

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Miscellaneous—Operational Checkout Park Brake Check

YES: Continue check. CAUTION: Machine will stop abruptly during this check. Fasten seat belt. Perform check in an open area.

NO: See your authorized dealer.

NOTE: Park brake will not release if air pressure is below 410 kPa (4.1 bar) (60 psi). 1—Park Brake Switch Start engine. Push park brake switch (1) and move forward. NOTE: Park brake will apply at any speed. Apply only when moving slowly. TX1010017A –UN–11JUL06

Drive machine at slow idle in 1st gear. With machine moving 5 km/h (3 mph) or less, push park brake switch to ON position. FEEL: Does park brake indicator come ON, park brake engage and machine stop?

With the engine running, transmission in neutral (N) and park brake ON, push park brake switch to ON position.

YES: Go to next check. NO: See your authorized dealer.

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. Shift transmission to neutral (N).

– – –1/1

Steering Check

Move machine to an open area and park on a hard, level surface.

YES: Continue with check.

Push inter-axle lock switch to OFF position. NO: If steering is jerky or steering wheel is hard to turn, see your authorized dealer.

Release park brake. Release service brakes. Run engine at slow idle. Turn steering wheel fully left, then fully right. FEEL: Does machine turn both directions smoothly?

Run engine at fast idle.

YES: Go to next check.

Turn steering wheel fully left, then fully right.

NO: If steering is jerky or steering wheel is hard to turn, see your authorized dealer.

FEEL: Does machine turn in both directions smoothly?

– – –1/1

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PN=195

Miscellaneous—Operational Checkout Bin Raise and Lower Checks

YES: Continue check.

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.

NO: See your authorized dealer.

1—Bin Control Lever Perform this check in an open area away from other people. Position the machine straight.

TX1010085A –UN–11JUL06

CAUTION: Clear all personnel from behind machine. Some material may slide out of bin as it is raised.

CAUTION: Ensure area above bin is clear of obstructions and power lines. Height of raised bin is 7.23m (23 ft 8.5 in.). Ensure the bin is empty. Operate the engine at 1500 rpm. Pull bin control lever rearward to raise bin. When bin is almost completely up, reduce engine speed to slow idle. LOOK: Does bin rise to full height smoothly?

Release bin control lever.

YES: Continue check.

LOOK/FEEL: Does bin control lever return to neutral position?

NO: See your authorized dealer.

Push bin control lever to full forward detent bin float position and release lever.

YES: Go to next check.

LOOK/FEEL: Does control lever return to neutral position?

NO: See your authorized dealer.

LOOK: Does bin lower to full down position smoothly?

– – –1/1

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Miscellaneous—Operational Checkout YES: Continue with check.

Lights Check

NO: See your authorized dealer.

T147683B –UN–09NOV01

TX1010011A –UN–11JUL06

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 headlight switch to the first ON position. Switch located in SSM. LOOK: Are front parking lights (2) and tail, brake and parking lights (5) ON?

Push headlight switch to the second ON position.

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.

YES: Continue with check.

Press hazard switch on. LOOK: Do turn indicators (1 and 4) flash?

NO: See your authorized dealer. – – –1/2

4-2-7

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PN=197

Miscellaneous—Operational Checkout YES: Go to next check. CAUTION: Perform check in an open area. Machine may move unexpectedly.

NO: See your authorized dealer.

Park brake ON. Push and hold service brake. Shift transmission into reverse (R). Have a helper look at backup lights (6). LOOK: Are backup lights ON?

–19– –2/2

Miscellaneous Checks

– – –1/1

Bin Warming System Check—If Equipped

YES: Go to next check. CAUTION: Engine exhaust flows through tubes in sides of bin. Tubes may be hot.

NO: Check to see that tubes aren’t plugged.

Check bin warming system. FEEL: Do tubes in sides of bin warm as engine temperature increases to normal?

NO: See your authorized dealer.

– – –1/1

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. – – –1/1

4-2-8

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PN=198

Miscellaneous—Troubleshooting Using Troubleshooting Charts 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 1. Operational Checkout Procedure. Step 2. Troubleshooting charts. Step 3. Adjustments. Step 4. See your authorized dealer.

SJ25320,000017D –19–29AUG06–1/1

4-3-1

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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 starter motor turns engine too slowly

Check battery charge. Charge or 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 4-1.)

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 4-1.)

Restricted air inlet

Service air filter system. See Service Engine Air Intake System. (Section 3-3.)

Restricted exhaust system

Locate and repair restriction.

Engine Hard Starting when Cold

Continued on next page

4-3-2

SJ25320,000017E –19–20SEP06–1/4

110807

PN=200

Miscellaneous—Troubleshooting Symptom

Problem

Solution

Engine Cuts Out Soon After Starting

Insufficient fuel in fuel tank

Fill fuel tank and bleed fuel system. See Bleeding Fuel System. (Section 4-1.)

Air in fuel system

Bleed fuel system. See Bleeding Fuel System. (Section 4-1.)

Blocked fuel tank air vent

Clean air vent and bleed fuel system. See Bleeding Fuel System. (Section 4-1.)

Blocked fuel filters

Replace fuel filters. See Replace Secondary 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.)

Drive belt slipping

Inspect, adjust or replace drive belt. See Inspect Serpentine Belt. (Section 3-3.)

Radiator cap worn or not sealing

Replace cap.

Blocked radiator

Clean radiator. See Inspect and Clean Cooling Systems. (Section 3-3.)

Blocked air intake

Clean as necessary.

Engine Knocking

Incorrect fuel grade

Drain and refill fuel tank. See Bleeding Fuel System. (Section 4-1.)

Loss of Power

Air filter restriction

Service air filter system. See Service Engine Air Intake System. (Section 3-3.)

Engine Overheating

Continued on next page

4-3-3

SJ25320,000017E –19–20SEP06–2/4

110807

PN=201

Miscellaneous—Troubleshooting Symptom

Problem

Solution

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 is free of contaminants.

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.

Oil in service for too long

Change oil and oil filters. See Change Engine Oil and Replace Filter. (Section 3-6.)

Loose components (alternator, etc.)

Tighten all components, including engine mounts and exhaust system.

Worn or damaged engine mountings

Check and replace engine mounting.

Continued on next page

SJ25320,000017E –19–20SEP06–3/4

Excessive Vibration at Any Speed

4-3-4

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Miscellaneous—Troubleshooting Symptom

Problem

Solution

Black Smoke from Exhaust

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 4-1.)

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 4-1.)

SJ25320,000017E –19–20SEP06–4/4

Transmission Symptom

Problem

Solution

Low Clutch Pressure

Low oil level

Fill transmission. See Check Transmission Oil Level. (Section 3-6.)

Low Converter Charging Pump Output

Low oil level

Fill transmission. See Check Transmission Oil Level. (Section 3-6.)

Suction screen blocked

Clean suction screen.

Low oil level

Fill transmission. See Check Transmission Oil Level. (Section 3-6.)

Transmission Overheating

SJ25320,000017F –19–31AUG06–1/1

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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.

Loose Final drive bolts

Tighten final drive bolts to correct torque.

Blocked axle breather

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.)

Blocked axle breather

Clean axle breather. See Clean, Inspect, and Replace— Transmission, Transfer Case, and Axle Breathers. (Section 3-3.)

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4-3-6

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PN=204

Miscellaneous—Troubleshooting

Tires Symptom

Problem

Solution

Tires Wearing in Tread Center

Tires overinflated

Reduce tire pressure to correct level. See Inspect Tires, Check Pressure. (Section 3-3.)

Tires Wearing on Both Sides of Tread

Tires underinflated

Increase 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

SJ25320,0000181 –19–31AUG06–1/1

4-3-7

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PN=205

Miscellaneous—Troubleshooting

Brakes Symptom

Problem

Solution

Poor or No Service Brakes

Service brake pedal

Check for obstructions around and under brake pedal. Check that pedal can be pushed to the end of its stroke and return 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.

Brake pads glazed

Replace brake pads.

Brake disks warped or scored

Inspect brake disks for damage.

Brake caliper pistons sticking

Replace brake caliper.

Squealing Noise from Brakes when Applied

Brakes Do Not Fully Release

SJ25320,0000182 –19–31AUG06–1/1

4-3-8

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PN=206

Miscellaneous—Troubleshooting

Hydraulic System Symptom

Problem

Solution

Pump Not Delivering Hydraulic Oil

Hydraulic oil level in reservoir too low

Fill hydraulic reservoir. See Check Hydraulic Oil Level. (Section 3-4.)

Blocked outlet hose from tank to pump

Check suction strainer for blockages. Clean if necessary.

Incorrect hydraulic oil viscosity and type

Drain and fill hydraulic system. See Change Hydraulic Oil. (Section 3-9.)

Pump intake partially blocked

Check suction strainer for blockages. Clean if necessary.

Blocked breather

Replace breather filter. See Replace Hydraulic Reservoir Breather. (Section 3-7.)

Pump Making Noise

SJ25320,0000183 –19–31AUG06–1/1

Instruments and Controls Symptom

Problem

Solution

Gauge Not Working Properly

Fuse blown

Investigate cause and correct problem.

Switch Not Working Properly

Fuse blown

Investigate cause and correct problem.

Warning Light Not Working

Fuse blown

Investigate cause and correct problem.

SJ25320,0000184 –19–25AUG06–1/1

4-3-9

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PN=207

Miscellaneous—Troubleshooting

Electrical System Symptom

Problem

Solution

Alternator Charge Indicator Does Not Illuminate when Master Switch Is in ON Position

Monitor display unit

See your authorized Dealer.

Alternator Charge Indicator Illuminated when Engine Is ON

Poor battery connections

Clean and check battery connections.

Batteries Do Not Hold Charge

Battery cells dry

Check battery electrolyte level. Add water, if necessary.

Short running time with lights on

Remove batteries and charge or replace.

Three second delay if going from key off directly to cranking

Wait for bulb check to finish.

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.

Fuse blown

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.)

Starter Motor Does Not Turn or Turns Very Slowly

Headlights Do Not Work

Continued on next page

4-3-10

SJ25320,0000185 –19–15SEP06–1/2 110807

PN=208

Miscellaneous—Troubleshooting Symptom

Problem

Solution

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

Fuse blown

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.)

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

Fuse blown

Investigate and correct cause.

Windshield Wiper Does Not Park

Park Fuse 37

Investigate and correct cause.

SJ25320,0000185 –19–15SEP06–2/2

4-3-11

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PN=209

Miscellaneous—Troubleshooting

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.

Smear Remains on Windshield when the Windshield Wiper Is in Operation

Wiper blade damaged

Replace wiper blade.

Oil or grease on windshield

Clean windshield.

Obstruction in seat runner

Remove obstruction.

Lack of lubricant

Lubricate seat runners.

Excessive Movement of Wing Mirrors while Machine Is Operating

Loose or missing retaining bolts

Tighten or replace retaining bolts.

Wing Mirror Difficult to View

Damaged wing mirror arm

Replace wing mirror arm.

Incorrect adjustment

Adjust as necessary.

Wing mirror cracked

Replace mirror.

Seat Is Difficult to Adjust

NOTE: If any other problems are encountered that require special tools or machine knowledge, see your authorized dealer.

SJ25320,0000186 –19–31AUG06–1/1

4-3-12

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Miscellaneous—Storage Prepare Machine for Storage 1. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later.

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. 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. Ensure tires are properly inflated. 5. 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. 6. Fully lower bin. Install articulation locking bar. Coat exposed steering cylinder rods with LPS 3 Rust Inhibitor. 7. Apply grease at all lubrication fittings. 8. Remove batteries or disconnect terminals from batteries. 9. Store machine in a dry, protected place.

LPS 3 Rust Inhibitor is manufactured by Holt Lloyd Corporation.

Continued on next page

4-4-1

VD76477,00015C9 –19–13AUG07–1/2

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PN=211

Miscellaneous—Storage IMPORTANT: Prevent possible machine damage from unauthorized persons operating machine. Attach a DO NOT OPERATE tag to steering wheel. 10. Put a DO NOT OPERATE tag on the steering wheel. 11. Close all vent louvers in the cab. 12. Remove keys and lock all covers and doors.

VD76477,00015C9 –19–13AUG07–2/2

Monthly Storage Procedure

–UN–18OCT88

CAUTION: Prevent possible injury or death from asphyxiation. Engine exhaust fumes can cause sickness or death. Start engine ONLY in a well-ventilated area.

T6191AA

1. Drain water and sediment from fuel tank when air temperature is above freezing. 2. Remove LPS 3 Rust Inhibitor from cylinder rods with a cleaning solvent.

LPS 3 Rust Inhibitor is manufactured by Holt Lloyd Corporation.

Continued on next page

4-4-2

VD76477,00016A3 –19–22OCT07–1/3

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PN=212

Miscellaneous—Storage

–UN–18OCT88

IMPORTANT: Prevent possible engine damage. During cold temperatures, check fluidity of engine oil on dipstick. If the oil appears waxy and/or jelly-like rather than liquid, DO NOT attempt to start engine. Use external heat source to warm the crankcase until oil appears fluid.

T6181AU

3. Check all fluid levels. If low, check for leaks and add oil as required. 4. Check belts. 5. Check condition of all hoses and connections. 6. Check battery electrolyte level. Charge and install battery. 7. For machines with tires, check condition of tires and tire pressure. For machines with tracks, check condition of tracks and track sag. 8. Fill fuel tank. 9. Pre-lubricate turbocharger bearings, if equipped: a. Disconnect fuel shutoff fuse. b. Crank engine for 10 seconds. c. Connect fuel shutoff fuse. 10. Start engine and run until it reaches operating temperature. Run at 1/2 speed for five minutes. Do not run at fast or slow idle. • If engine fails to start or runs poorly after starting, change fuel filter(s). Bleed fuel system. 11. Operate all controls, levers, seat adjustments, etc.

Continued on next page

4-4-3

VD76477,00016A3 –19–22OCT07–2/3 110807

PN=213

Miscellaneous—Storage

CAUTION: Prevent possible injury from unexpected machine movement. Clear the area of all persons before running machine through the operation procedure. 12. Make sure the area is clear to allow for movement. Cycle all hydraulic functions several times. Check condition of all hoses and connections. 13. Park the machine with cylinder rods retracted, if possible. Turn key switch to OFF. 14. Apply LPS 3 Rust Inhibitor to exposed cylinder rod areas.

VD76477,00016A3 –19–22OCT07–3/3

4-4-4

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PN=214

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.

CS33148,0000D2B –19–11AUG06–1/1

Record Engine Serial Number

TX1011479A

–UN–23AUG06

Engine Serial Number (1)

CS33148,0000D2C –19–24AUG06–1/1

Record Transmission Serial Number

T147687B

–UN–15NOV01

Transmission Serial Number (1)

CS33148,0000D2D –19–11AUG06–1/1

Front Axle Serial Number

T147688B

–UN–15NOV01

Front Axle Serial Number (1)

CS33148,0000D2E –19–11AUG06–1/1

4-5-1

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PN=215

Miscellaneous—Serial Numbers

Middle Axle Serial Number

TX1011480A

–UN–23AUG06

Middle Axle Serial Number (1)

CS33148,0000D2F –19–24AUG06–1/1

Rear Axle Serial Number

T147690B

–UN–15NOV01

Rear Axle Serial Number (1)

CS33148,0000D30 –19–11AUG06–1/1

4-5-2

110807

PN=216

Miscellaneous—Specifications

4-6-1

110807

PN=217

Miscellaneous—Specifications

250D Articulated Dump Truck Specifications

11 1

6 2

5 12

16 14

20 21

T147691

–UN–13NOV01

T147691

Continued on next page

4-6-2

CS33148,0000D31 –19–06SEP06–1/4 110807

PN=218

Miscellaneous—Specifications 1—Height, Machine Overall— Dumped 2—Height, Top of Bin Side— Lowered 3—Height, Bin Lip—Lowered 4—Height, Bin Lip—Dumped 5—Clearance, Articulation Pivot-to-Ground 6—Height, Machine Overall— Lowered 7—Angle, Maximum Bin 8—Angle, Maximum Approach

9—Angle, Maximum Articulation 10—Length, Bin Overall 11—Length, Maximum Bin Load 12—Protrusion, Bin Rear Edge 13—Length, Bin 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 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

specifications are based on a machine equipped with all standard equipment, 79 kg (175 lb) operator, and full fuel tank.

NOTE: Specifications and design subject to change without notice. Whenever applicable, specifications are in accordance with SAE standards. Except where otherwise noted, Item

19—Width, Bin 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

Measurement

Specification

1—Machine Overall—Dumped

Height

6126 mm 20 ft 1 in.

2—Top of Bin Side—Lowered

Height

2629 mm 8 ft 6 in.

3—Bin Lip—Lowered

Height

1970 mm 6 ft 6in.

4—Bin Lip—Dumped

Height

661 mm 2 ft 2in.

5—Articulation Pivot-to-Ground

Clearance

525 mm 1 ft 9 in.

6—Machine Overall—Lowered

Height

3425 mm 11 ft 3 in.

7—Maximum Bin

Angle

70°

8—Maximum Approach

Angle

30°

9—Maximum Articulation

Angle

45°

10—Bin Overall

Length

5390 mm 17 ft 8 in.

250D Articulated Dump Truck Dimensions

Continued on next page

4-6-3

CS33148,0000D31 –19–06SEP06–2/4 110807

PN=219

Miscellaneous—Specifications

Item

Measurement

Specification

11—Maximum Bin Load

Length

5128 mm 16 ft 10 in.

12—Bin Rear Edge

Protrusion

509 mm 1 ft 8 in.

13—Bin Lip-to-Rear Axle Centerline—Lowered

Length

1316 mm 4 ft 4 in.

14—Rear Axle Centerline-to-Middle Axle Centerline

Length

1670 mm 5 ft 6 in.

15—Middle Axle Centerline-to-Front 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.

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—Bin Overall

Width

2758 mm 9 ft 6in.

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 3in.

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

Continued on next page

4-6-4

CS33148,0000D31 –19–06SEP06–3/4 110807

PN=220

Miscellaneous—Specifications

Item

Measurement

Specification

250D Articulated Dump Truck

Weight

18 298 kg 40 340 lb

250D Bin—Dump

Cycle Time

11.9 seconds

250D Bin—Lower

Cycle Time

6 seconds

250D Specifications

CS33148,0000D31 –19–06SEP06–4/4

4-6-5

110807

PN=221

Miscellaneous—Specifications

300D Articulated Dump Truck Specifications

11 1

6 2

5 12

16 14

20 21

T147691

–UN–13NOV01

T147691

Continued on next page

4-6-6

CS33148,0000D32 –19–18AUG06–1/4 110807

PN=222

specifications are based on a machine equipped with all standard equipment, 79 kg (175 lb) operator, and full fuel tank.

NOTE: Specifications and design subject to change without notice. Whenever applicable, specifications are in accordance with SAE standards. Except where otherwise noted, Item

Measurement

Specification

1—Bin Backsplash—Dumped

Height

6207 mm 20 ft 4 in.

2—Top of Bin Side—Lowered

Height

2756 mm 9 ft

3—Bin Lip—Lowered

Height

2005 mm 6 ft 6 in.

4—Bin Lip—Dumped

Height

603 mm 1 ft 10 in.

5—Articulation Pivot-to-Ground

Clearance

525 mm 1 ft 7 in.

6—Machine Overall—Lowered

Height

3425 mm 11 ft 3 in.

7—Maximum Bin

Angle

70°

8—Maximum Approach

Angle

30°

9—Maximum Articulation

Angle

45°

10—Bin Overall

Length

5500 mm 18 ft

300D Articulated Dump Truck Dimensions

Continued on next page

4-6-7

CS33148,0000D32 –19–18AUG06–2/4 110807

PN=223

Miscellaneous—Specifications

Item

Measurement

Specification

11—Maximum Bin Load

Length

5242 mm 17 ft 1 in.

12—Bin Rear Edge

Protrusion

565 mm 1 ft 10 in.

13—Bin Lip-to-Rear Axle Centerline—Lowered

Length

1392 mm 4 ft 7 in.

14—Rear Axle Centerline-to-Middle Axle Centerline

Length

1670 mm 5 ft 6 in.

15—Middle Axle Centerline-to-Front 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.

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—Bin 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.

Continued on next page

4-6-8

CS33148,0000D32 –19–18AUG06–3/4 110807

PN=224

Miscellaneous—Specifications

Item

Measurement

Specification

300D Articulated Dump Truck

Weight

18 200 kg 40 100 lb

300D Bin—Dump

Cycle Time

11.9 seconds

300D Bin—Lower

Cycle Time

6 seconds

300D Specifications

CS33148,0000D32 –19–18AUG06–4/4

250D and 300D Engine Specifications Item

Measurement

Specification

Model Configuration Aspiration Injection Type Gross Power

Deere 6090H In-line 6 Cylinder Turbocharged and Intercooled Direct 214 kW @ 2000 rpm 287 hp 1100 N•m @ 1200—1600 rpm 810 lb-ft 780 - 820 rpm 2350 - 2450 rpm 9.0 L 549 in3 172 kPa @ Low Idle 1.72 bar 25 psi 400 kPa @ High Idle 4.0 bar 58 psi

250D and 300D Engine Specifications

Gross Torque Idle Speed High Idle Speed Displacement Oil Pressure

CS33148,0000D33 –19–13SEP06–1/1

4-6-9

110807

PN=225

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

CS33148,0000D34 –19–11AUG06–1/1

4-6-10

110807

PN=226

Miscellaneous—Specifications

250D and 300D Drain and Refill Capacities Item

Measurement

Specification

Capacity

305 L 81 gal

Oil

Capacity

32 L 8.45 gal

Coolant

Capacity

33 L 8.7 gal

Capacity

21.8L 5.8 gal

Capacity

4.7 L 5 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

VD76477,000108D –19–27SEP06–1/1

4-6-11

110807

PN=227

Miscellaneous—Specifications

4-6-12

110807

PN=228

Index Page

A Acid burns . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12 Air conditioner Condenser, inspect and clean. . . . . . . . . . . . 3-3-2 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-4 Air pressure Gauge function . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Gauge location . . . . . . . . . . . . . . . . . . . . . . . 2-1-7 Air, engine intake Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 Air, pneumatic system Dryer-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6 Relieve pressure . . . . . . . . . . . . . . . . . . . . . . 3-2-4 Articulation Locking bar . . . . . . . . . . . . . . . . . . 3-2-3 Axle Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-3 gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-8 Oil Change . . . . . . . . . . . . . . . . . . . . . . 3-5-5, 3-8-4 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1 Serial number, front axle . . . . . . . . . . . . . . . . 4-5-1 Serial number, middle axle . . . . . . . . . . . . . . 4-5-2 Serial number, rear axle . . . . . . . . . . . . . . . . 4-5-2 Suspension struts, inspect . . . . . . . . . . . . . . 3-6-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-6

B Batteries disconnect switch . . . . . . . . . . . . . . . . . . . . 2-1-14 Battery Acid burns. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12 Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12 Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-12 Inspect, clean, tighten terminals . . . . . . . . . . 3-6-5 Replace, two-battery machines . . . . . . . . . . 4-1-16 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-14 Battery explosions Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5 Before starting engine . . . . . . . . . . . . . . . . . . . 2-2-1 Before starting work . . . . . . . . . . . . . . . . . . . . . 2-2-1 Belt, serpentine . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Bin Bin pivot pins . . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 Pivot pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 Shock pad. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-3 Bin support rod. . . . . . . . . . . . . . . . . . . . . . . . . 3-2-3 Bleed fuel system . . . . . . . . . . . . . . . . . . . . . . . 4-1-2

Page

Body raise and lower checks . . . . . . . . . . . . . . 4-2-6 Body warming system check . . . . . . . . . . . . . . 4-2-8 Boost starting . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13 Bottom guard . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-4 Brake accumulator check . . . . . . . . . . . . . . . . . 4-2-4 Brake accumulators . . . . . . . . . . . . . . . . . . . . . 4-1-3 Brake, dry caliper Pad wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-1 Brake, park Pad wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-1 Brakes Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-8 Breather Hydraulic reservoir Clean and inspect . . . . . . . . . . . . . . . . . . . 3-6-8 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Transmission, transfer case, axles . . . . . . . . 3-3-3

C Cab Filter, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-4 tilt service lock . . . . . . . . . . . . . . . . . . . . . . . 3-2-5 Charge air cooler Inspect and clean . . . . . . . . . . . . . . . . . . . . . 3-3-2 Chemical products Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6 Circuit breakers battery balancer . . . . . . . . . . . . . . . . . . . . . 2-1-14 main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14 purging units, fuel filter and coolant level switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14 Controls Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3 Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Coolant Capacity, drain and refill . . . . . . . . . . . . . . . 4-6-11 Coolant, engine Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11-1 Check condition . . . . . . . . . . . . . . . . . . . . . 3-6-11 Check level . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-1-9 Coolscan Plus . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-9 Crankshaft dampener replacement . . . . . . . . . 3-10-1 Cylinder, do not service . . . . . . . . . . . . . . . . . . 4-1-1

D Dampener replacement, crankshaft . . . . . . . . 3-10-1

Index-1

110807

PN=1

Index

Page

Default display menus monitor display unit (MDU) . . . . . . . . . . . . . 2-1-18 Diagnostics monitor display unit (MDU) . . . . . . . . . . . . . 2-1-28 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . 3-1-1, 3-1-2 Diesel fuel conditioner Low sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3 Driving machine . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Driving metal pins. . . . . . . . . . . . . . . . . . . . . . . 1-4-3

Engine air intake . . . . . . . . . . . . . . . . . 3-3-1, 4-1-2 Engine oil . . . . . . . . . . . . . . . . . . . . . . 3-5-1, 3-6-3 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5-3, 3-6-9 Fuel drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Hydraulic breather Clean and inspect . . . . . . . . . . . . . . . . . . . 3-6-8 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Hydraulic return. . . . . . . . . . . . . . . . . . 3-5-7, 3-8-7 Pneumatic block silencer . . . . . . . . . . . . . . . 3-9-2 Pneumatic dryer-filter . . . . . . . . . . . . . . . . . . 3-8-6 Primary fuel . . . . . . . . . . . . . . . . . . . 3-5-2, 3-6-10 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 3-8-2 Final drive Oil Change . . . . . . . . . . . . . . . . . . . . . . 3-5-6, 3-8-5 Check levels . . . . . . . . . . . . . . . . . . . . . . . 3-7-1 Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5 Freeing stuck machine . . . . . . . . . . . . . . . . . . 2-2-17 Fuel Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-11 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1, 3-1-2 Do not service injection nozzles . . . . . . . . . . 4-1-1 Filter replace . . . . . . . . . 3-5-2, 3-5-3, 3-6-9, 3-6-10 Gauge function . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Gauge location . . . . . . . . . . . . . . . . . . . . . . . 2-1-7 Handling and storing . . . . . . . . . . . . . . . . . . . 3-1-4 Use correct fuels and lubricants . . . . . . . . . . 3-2-1 Fuel system, bleed . . . . . . . . . . . . . . . . . . . . . . 4-1-2 Fuse compartment . . . . . . . . . . . . . . . . . . . . 4-1-5, 4-1-8

E Electrical system Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-3-10 Emergency preparation . . . . . . . . . . . . . . . . . . 1-2-6 Emissions Control Warranty Statement Engine Battery boost starting . . . . . . . . . . . . . . . . . 4-1-13 Coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11-1 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 3-1-9 Coolant conditioner . . . . . . . . . . . . . . . . . . . 3-6-11 Crankshaft dampener replacement . . . . . . . 3-10-1 Filter, air Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-1 Filter, oil . . . . . . . . . . . . . . . . . . . . . . . 3-5-1, 3-6-3 Oil Change . . . . . . . . . . . . . . . . . . . . . . 3-5-1, 3-6-3 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1 Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-2 Valve clearance . . . . . . . . . . . . . . . . . . . . . . 3-8-1 Engine oil Service Intervals . . . . . . . . . . . . . . . . . . . . . . 3-1-5 Engine values, transmission values, vehicle values monitor display unit (MDU) . . . . . . . . . . . . . 2-1-25 Equipment miscellaneous . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 Ether Aid Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-4 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4 Explosion Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5

F Filter Cab air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-4

G Gauges Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7 Gauges and indicator lights check . . . . . . . . . . 4-2-2 Gauges and indicators checks . . . . . . . . . . . . . 4-2-3 Grease Alternative and synthetic lubricants . . . . . . . 3-1-11 Bin pivot pins . . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 Cylinder pins, oscillation tube, articulation joints, oscillation tube through drive shaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-6 Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 Prop shaft slip joint . . . . . . . . . . . . . . . . . . . . 3-7-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 3-1-10 Tailgate pivots. . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 Use correct fuels and lubricants . . . . . . . . . . 3-2-1

Index-2

110807

PN=2

Index

Page

Inter-axle lock . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-11

Handhold use . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1 Headlight Intensity controls . . . . . . . . . . . . . . . . . . . . . 2-1-11 High-pressure oils Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4 Hill Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14 Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 Horn operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11 Hydraulic Filter, breather Inspect and clean . . . . . . . . . . . . . . . . . . . 3-6-8 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-2 Filter, return . . . . . . . . . . . . . . . . . . . . 3-5-7, 3-8-7 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 3-1-7 Suction screen . . . . . . . . . . . . . . . . . . . . . . . 3-9-1 Hydraulic system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-9 Warming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5

I Identification Axle serial number, front . . . . . . . . . . . . . . . . 4-5-1 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 In-line fuel Filter replace . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-9 Inch torque values Cap screw and nut . . . . . . . . . . . . . . . . . . . 4-1-24 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 operator seat. . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 Instrument panel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7 Instruments and controls Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-9

J JDLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 Laptop connection. . . . . . . . . . . . . . . . . . . . . 4-1-5 JDLink fuse Switched power. . . . . . . . . . . . . . . . . . . . . . . 4-1-8 JDLink in-line fuse Unswitched power. . . . . . . . . . . . . . . . . . . . . 4-1-8 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13

L Lever Steering column . . . . . . . . . . . . . . . . . . . . . 2-1-11 Lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22 Light Backup light, replace. . . . . . . . . . . . . . . . . . 4-1-20 compartment light, replace . . . . . . . . . . . . . 4-1-21 Dome light, replace . . . . . . . . . . . . . . . . . . . 4-1-21 Headlight, adjust . . . . . . . . . . . . . . . . . . . . . 4-1-19 Headlight, replace . . . . . . . . . . . . . . . . . . . . 4-1-17 Park light, front, replace . . . . . . . . . . . . . . . 4-1-17 Park light, rear, replace. . . . . . . . . . . . . . . . 4-1-20 Tail and brake light, replace . . . . . . . . . . . . 4-1-20 Turn signal, front, replace . . . . . . . . . . . . . . 4-1-17 Turn signal, rear, replace . . . . . . . . . . . . . . 4-1-20 Work light, replace . . . . . . . . . . . . . . . . . . . 4-1-20 Loading and unloading bin Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-16 Loading machine on trailer . . . . . . . . . . . . . . . 2-2-23 Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-24 Low sulfur diesel fuel conditioner . . . . . . . . . . . 3-1-3 Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-11 Lubricants Alternative and synthetic lubricants . . . . . . . 3-1-11 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-10 Hydraulic and wet disk brake cooling oil . . . . 3-1-7 Transmission and transfer case oil . . . . . . . . 3-1-8 Lubricate Cylinder pins, oscillation tube, articulation joints, oscillation tube through drive shaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-6 Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-4 Tailgate pivots. . . . . . . . . . . . . . . . . . . . . . . . 3-4-3 Use correct fuels and lubricants . . . . . . . . . . 3-2-1

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Machine Clean regularly . . . . . . . . . . . . . . . . . . . . . . 4-1-21 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Lifting points . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22 Loading onto trailer . . . . . . . . . . . . . . . . . . . 2-2-23 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7 Slowing and stopping . . . . . . . . . . . . . . . . . 2-2-12 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1 Machine ID monitor display unit (MDU) . . . . . . . . . . . . . 2-1-39 Machine inspection. . . . . . . . . . . . . . . . . . . . . . 1-2-2 Main menu monitor display unit (MDU) . . . . . . . . . . . . . 2-1-21 Maintenance Prepare machine. . . . . . . . . . . . . . . . . . . . . . 3-2-2 Record keeping. . . . . . . . . . . . . . . . . . . . . . . 3-2-8 Schedule and record. . . . . . . . . . . . . . . . . . 3-2-10 Metal pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3 Metric torque values Cap screw and nut . . . . . . . . . . . . . . . . . . . 4-1-25 Miscellaneous equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 Monitor display unit (MDU) Actual values . . . . . . . . . . . . . . . . . . . . . . . 2-1-25 Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-22 Default display menus. . . . . . . . . . . . . . . . . 2-1-18 diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-28 Machine configuration . . . . . . . . . . . . . . . . . 2-1-33 machine ID . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-39 main menu . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-21 service mode . . . . . . . . . . . . . . . . . . . . . . . 2-1-39 Motor, do not service . . . . . . . . . . . . . . . . . . . . 4-1-1 Moving parts Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3

Engine Change . . . . . . . . . . . . . . . . . . . . . . 3-5-1, 3-6-3 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1 Final drive Change . . . . . . . . . . . . . . . . . . . . . . 3-5-6, 3-8-5 Check levels . . . . . . . . . . . . . . . . . . . . . . . 3-7-1 Hydraulic Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 3-1-7 Pressure gauge function . . . . . . . . . . . . . . . . 2-1-8 Pressure gauge location . . . . . . . . . . . . . . . . 2-1-7 Transfer case Change . . . . . . . . . . . . . . . . . . . . . . 3-5-4, 3-8-3 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 3-1-8 Transmission Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-1 Check condition . . . . . . . . . . . . . . . . . . . . . 3-8-1 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-6-6 Specifications . . . . . . . . . . . . . . . . . . . . . . 3-1-8 Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-10 Oil gear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-8 Oilscan Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-9 Operation Freeing stuckmachine . . . . . . . . . . . . . . . . . 2-2-17 Hill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14 Loading and unloading bin . . . . . . . . . . . . . 2-2-16 Off-road . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15 Parking machine . . . . . . . . . . . . . . . . . . . . . 2-2-18 radio controls . . . . . . . . . . . . . . . . . . . . . . . 2-1-10 Operation qualification . . . . . . . . . . . . . . . . . . . 1-2-1 Operator controls Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3 Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Operator seat instructional. . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12

Off-road Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15 Oil Alternative and synthetic lubricants . . . . . . . 3-1-11 Axle Change . . . . . . . . . . . . . . . . . . . . . . 3-5-5, 3-8-4 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-7-1 Capacities, drain and refill. . . . . . . . . . . . . . 4-6-11

Park brake check . . . . . . . . . . . . . . . . . . . . . . . 4-2-5 Parking light check . . . . . . . . . . . . . . . . . . . . . . 4-2-7 Parking machine. . . . . . . . . . . . . . . . . . . . . . . 2-2-18 Pneumatic Dryer-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8-6 Relieve pressure . . . . . . . . . . . . . . . . . . . . . . 3-2-4 Pneumatic block silencer Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-2

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Pneumatic pressure Gauge function . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Gauge location . . . . . . . . . . . . . . . . . . . . . . . 2-1-7 Pre-start inspection. . . . . . . . . . . . . . . . . . . . . . 2-2-1 Prepare machine for maintenance . . . . . . . . . . 3-2-2 Pressure, tires . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-4 Prevent unintended detonation of explosive devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-7 Product identification number . . . . . . . . . . . . . . 4-5-1 Prop shaft Slip joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-4 Protective equipment . . . . . . . . . . . . . . . . . . . . 1-2-2 Pump, do not service . . . . . . . . . . . . . . . . . . . . 4-1-1

Safety equipment . . . . . . . . . . . . . . . . . . . . . . . 1-2-2 Safety information Recognizing . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . 1-2-1 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1 Sealed switch module (SSM) . . . . . . . . . . . . . . 2-1-4 Seat belt Use and maintenance . . . . . . . . . . . . . . . . . . 1-3-1 Secondary steering. . . . . . . . . . . . . . . . . . . . . . 2-2-6 Serial number Axle, front . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Axle, middle . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-2 Axle, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Serpentine belt . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9 Service Do not service control valves, cylinders, pumps or motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1 Do not service injection nozzles . . . . . . . . . . 4-1-1 Service brake pedal check . . . . . . . . . . . . . . . . 4-2-4 Service decal check . . . . . . . . . . . . . . . . . . . . . 4-2-8 Service intervals Engine oil and filter . . . . . . . . . . . . . . . . . . . . 3-1-5 Service lock Articulation locking bar . . . . . . . . . . . . . . . . . 3-2-3 Bin support rod . . . . . . . . . . . . . . . . . . . . . . . 3-2-3 service mode monitor display unit (MDU) . . . . . . . . . . . . . 2-1-39 Service your machine at specified intervals . . . 3-2-1 Shock pad Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7-3 Slowing machine . . . . . . . . . . . . . . . . . . . . . . 2-2-12 Specifications Coolant, engine. . . . . . . . . . . . . . . . . 3-1-9, 3-6-11 Lubricants Grease . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-10 Hydraulic and wet disk brake cooling oil . . 3-1-7 Transmission and transfer case oil . . . . . . 3-1-8 Travel speeds . . . . . . . . . . . . . . . . . . . . . . . 4-6-10 250D cycle times . . . . . . . . . . . . . . . . . . . . . 4-6-5 250D dimensions . . . . . . . . . . . . . . . . . . . . . 4-6-2 250D drain and refill capacities . . . . . . . . . . 4-6-11 250D engine . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-9 250D tire pressure and radius. . . . . . . . . . . . 3-3-4 250D weight . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-5 300D cycle times . . . . . . . . . . . . . . . . . . . . . 4-6-9 300D dimensions . . . . . . . . . . . . . . . . . . . . . 4-6-6 300D drain and refill capacities . . . . . . . . . . 4-6-11 300D engine . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-9

R Radiator Coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11-1 Check condition . . . . . . . . . . . . . . . . . . . . 3-6-11 Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-4-1 Specifications . . . . . . . . . . . . . . . . . . . . . . 3-1-9 Inspect and clean . . . . . . . . . . . . . . . . . . . . . 3-3-2 Radio controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-10 Radius, tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-4 Range hold. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10 Rear frame and cab Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-3-12 Relay compartment . . . . . . . . . . . . . . . . . . . . 4-1-5, 4-1-8 Relay compartment fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5, 4-1-8 Replace Start Aid Can . . . . . . . . . . . . . . . . . . . . . . . . 2-2-4 Roads Operating or traveling . . . . . . . . . . . . . . . . . . 1-3-6 Rocking machine free. . . . . . . . . . . . . . . . . . . 2-2-17 ROPS Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6 Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6 Rust inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . 3-6-11

S Safety Operator’s seat . . . . . . . . . . . . . . . . . . . . . . . 1-3-1 Welding repairs . . . . . . . . . . . . . . . . . . . . . . . 1-4-3 Safety and operator conveniences . . . . . . . . . . 1-1-1

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300D tire pressure and radius. . . . . . . . . . . . 3-3-4 300D weight . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-9 Speed Machine travel speeds . . . . . . . . . . . . . . . . 4-6-10 Speedometer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-8 Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-7 Start Aid Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-4 Start switch check . . . . . . . . . . . . . . . . . . . . . . 4-2-2 Starting Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-13 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6 Steering check . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-5 Steering column Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11 Steps use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1 Stopping machine. . . . . . . . . . . . . . . . . . . . . . 2-2-12 Storage Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-1 Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4-2 Storing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-4 Storing lubricants . . . . . . . . . . . . . . . . . . . . . . 3-1-11 Suction screen Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9-1 Switch battery disconnect . . . . . . . . . . . . . . . . . . . . 2-1-14 range hold. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10

Check level . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 Specifications . . . . . . . . . . . . . . . . . . . . . . 3-1-8 Transmission Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-3 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-2 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 . . . . . . . . . . . . . . . . . . . . . . 3-1-8 Serial number . . . . . . . . . . . . . . . . . . . . . . . . 4-5-1 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7 Temperature gauge function . . . . . . . . . . . . . 2-1-8 Temperature gauge locations . . . . . . . . . . . . 2-1-7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-5 Transporting Lifting points . . . . . . . . . . . . . . . . . . . . . . . . 2-2-22 Loading machine on trailer . . . . . . . . . . . . . 2-2-23 Travel speed . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-10 Traveling On public roads. . . . . . . . . . . . . . . . . . . . . . . 1-3-6 Trip info, bintip, service monitor display unit (MDU) . . . . . . . . . . . . . 2-1-22 Troubleshooting Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-8 Electrical system . . . . . . . . . . . . . . . . . . . . . 4-3-10 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-2 Hydraulic system. . . . . . . . . . . . . . . . . . . . . . 4-3-9 Instruments and controls . . . . . . . . . . . . . . . . 4-3-9 Rear frame and cab . . . . . . . . . . . . . . . . . . 4-3-12 Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-7 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 4-3-5 Turn indicator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11 Turning machine free . . . . . . . . . . . . . . . . . . . 2-2-17

T Tilt cab cab support strut . . . . . . . . . . . . . . . . . . . . . . 3-2-5 Tire Pressure and radius, 250D . . . . . . . . . . . . . . 3-3-4 Pressure and radius, 300D . . . . . . . . . . . . . . 3-3-4 Size, pressure, and radius . . . . . . . . . . . . . . 3-3-4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-3-7 Wheel nut torque . . . . . . . . . . . . . . . . . . . . . 4-1-3 Torque Cap screw and nut, inch . . . . . . . . . . . . . . . 4-1-24 Cap screw and nut, metric . . . . . . . . . . . . . 4-1-25 Wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3 Towing Inoperable engine . . . . . . . . . . . . . . . . . . . . 2-2-19 Transfer case Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-3 Oil Change . . . . . . . . . . . . . . . . . . . . . . 3-5-4, 3-8-3

V Valve Engine valve clearance . . . . . . . . . . . . . . . . . 3-8-1 Valve, do not service . . . . . . . . . . . . . . . . . . . . 4-1-1 Vibration Crankshaft dampener replacement . . . . . . . 3-10-1

W Warming Hydraulic system. . . . . . . . . . . . . . . . . . . . . . 2-2-5

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Index

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Warranty Statement Emissions Control Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-26 Wheel nut torque . . . . . . . . . . . . . . . . . . . . . . . 4-1-3 250D specifications Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-2 Drain and refill capacities . . . . . . . . . . . . . . 4-6-11 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-9 Tire pressure and radius . . . . . . . . . . . . . . . . 3-3-4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-5 3-way coolant test kit . . . . . . . . . . . . . . . . . . . . 3-2-9 300D specifications Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-9 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-6 Drain and refill capacities . . . . . . . . . . . . . . 4-6-11 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-9 Tire pressure and radius . . . . . . . . . . . . . . . . 3-3-4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6-9

Index-7

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Index

Index-8

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