OMT223334 - John Deere 27D Compact Excavator Operator's Manual

Print
27D
Excavator
Copyright 2013 © Deere & Company. THIS DATA IS THE PROPERTY OF DEERE & COMPANY. ALL
USE AND/OR REPRODUCTION NOT SPECIFICALLY AUTHORIZED BY DEERE & COMPANY IS
PROHIBITED.
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.
Emission Control Statement

Technical Information Feedback Form
Section 1-1 - Safety—Safety and Operator Convenience

Safety and Operator Convenience Features
Section 1-2 - Safety—General Precautions

Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Add Cab Guarding for Special Uses
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Work In Ventilated Area
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Section 1-3 - Safety—Operating Precautions

Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Use Special Care When Lifting Objects
Add and Operate Attachments Safely
Section 1-4 - Safety—Maintenance Precautions
Park and Prepare for Service Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Section 1-5 - Safety—Safety Signs

Safety Signs
Section 2-1 - Operation—Operator Station

Monitor Panel and Functions (S.N. —255551)
Monitor Panel and Functions (S.N. 255551— )
Switch Panel—Cab
Switch Panel—Canopy
Pedals and Levers
Engine Speed Control Lever
Pilot Control Shutoff Lever
Setting Trip Meters
Door Release Lever—If Equipped
Front (Secondary Exit) Window—If Equipped
Secondary Exit Tool—If Equipped
Opening Rear Window—If Equipped
Opening Right Side Window—If Equipped
Adjusting Operator Seat
Toolbox and Operator’s Manual Compartment
Section 2-2 - Operation—Operating the Machine

Before Starting Work
Operator's Daily Machine Check Before Starting
Starting the Engine
Starting the Engine in Cold Weather
Checking Instruments After Starting
Cold Weather Warm-Up
Travel Pedals and Levers
Control Lever Pattern Operation
Control Lever Pattern Conversion
Multi-Function Control Lever—If Equipped
Boom-Swing Pedal
Auxiliary Pedal
Positioning Auxiliary Line Selector Valve
Operating Backfill Blade
Operating Tips—Backfill Blade
Operating in Water and Mud
Selecting Correct Track
Driving Up a Steep or Slippery Slope
Lowering Boom With Engine Stopped
Parking
Loading and Unloading for Transport
Towing Machine a Short Distance
Lifting
Lifting Machine
Section 3-1 - Maintenance—Machine
Diesel Fuel
Lubricity of Diesel Fuel
Handling and Storing Diesel Fuel
Biodiesel Fuel
Testing Diesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Alternative and Synthetic Lubricants
Diesel Engine Oil
Diesel Engine Oil and Filter Service Intervals
Hydraulic Oil
Travel Gearbox Oil
Grease
Light Duty Diesel Engine Coolant (for diesel engines without wet sleeve cylinder liners)
Drain Intervals for Diesel Engine Coolant
John Deere COOL-GARD™ II Coolant Extender
Supplemental Coolant Additives
Operating in Warm Temperature Climates
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender
Testing Diesel Engine Coolant
Section 3-2 - Maintenance—Periodic Maintenance

Service Machine at Specified Intervals
Check the Hour Meter Regularly
Preparing Machine for Maintenance
Engine Access Door
Maintenance Access Cover
Tilting the Operator Station
Fuel Tank
Checking Washer Fluid Level
Hydraulic Breaker and Crusher Attachments
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit
Service Intervals
Required Parts
Section 3-3 - Maintenance—As Required

Cleaning Air Cleaner Element
Cleaning Radiator Core and Oil Cooler
Check Coolant
Section 3-4 - Maintenance—Every 10 Hours or Daily

Checking Engine Oil Level
Checking Hydraulic Oil Tank Level
Draining Fuel Tank Sump
Draining Water Separator
Checking Recovery Tank Coolant Level
Checking Bucket Teeth
Checking Track Sag—Rubber Track
Checking Track Sag—Steel Track—If Equipped
Track Sag General Information
Adjusting Track Sag
Seat Belt
Section 3-5 - Maintenance—First 50, Then Every 100 Hours
Lubricate Bucket and Link Pins
Grease Front Joint Pins
Inspect Fan Belt, Check and Adjust Tension
Section 3-6 - Maintenance—Every 250 Hours

Grease Swing Bearing
Checking Travel Gearbox Oil Level
Draining Hydraulic Oil Tank Sump
Replacing Hydraulic Oil Tank Filter
Take Engine Oil Sample

Changing Engine Oil and Replacing Filter
Lubricate Swing Bearing Gear
Lubricate Control Lever Universal Joint
Replacing Final Fuel Filter
Lubricate Blade Pins
Replacing Air Cleaner Element
Take Fluid Samples

Changing Travel Gearbox Oil
Replacing Pilot System Oil Filter
Checking and Adjusting Engine Valve Lash (Clearance)
Checking Starter and Alternator
Check Coolant

Draining Cooling System
Cooling System Fill and Deaeration
Changing Hydraulic Tank Oil and Cleaning Suction Screen

Section 4-1 - Miscellaneous—Machine

Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump
Do Not Service Control Valves, Cylinders, Pumps, or Motors
Precautions for Alternator and Regulator
Handling, Checking, and Servicing Batteries Carefully
Using Booster Batteries—12-Volt System
Using Battery Charger
Replacing the Battery
Welding On Machine
Bleed Hydraulic System
Clean Machine Regularly
12-Volt Auxiliary Power Outlet
Connecting and Disconnecting Auxiliary Lines
Replacing Fuses
Cleaning Heating and Air Conditioning Filter Screens—If Equipped
Installing Bucket With Quick Coupler
Checking Track Shoe Hardware
Rubber Track Care
Removing and Installing Rubber Track
Converting the Track
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Section 4-2 - Miscellaneous—Operational Checkout

Operational Checkout
Section 4-3 - Miscellaneous—Troubleshooting

Using Troubleshooting Charts
Engine
Electrical System
Hydraulic System
Section 4-4 - Miscellaneous—Storage

Prepare Machine for Storage
Monthly Storage Procedure
Section 4-5 - Miscellaneous—Serial Numbers

Record Product Identification Number (PIN)
Record Engine Serial Number
Keep Proof of Ownership
Keep Machines Secure
Section 4-6 - Miscellaneous—Specifications

Engine Specifications
Drain and Refill Capacities
Machine Specifications
Working Ranges
Excavator Lift Capacity
(Blade on the Ground With Standard Boom and Canopy)
(Blade on the Ground With Long Arm and Canopy)
(Blade on the Ground With Standard Boom and Cab)
(Blade on the Ground With Long Arm and Cab)
OMT223334
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 the electronic controls of this machine is
responsible for establishing that the modification does not
adversely affect the machine or its performance.
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.
AM40430,00000A9-19-20090820
Avoid Unauthorized Machine Modifications 1

OMT223334
Fluid Analysis Program Test Kits and

3-Way Coolant Test Kit
TX1003513A-UN-20FEB06
Fluid Analysis Kits
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.
Engine, hydraulic, power train, and coolant samples should

be taken from each system on a periodic basis, usually
prior to a filter and/or fluid change interval. Certain
systems require more frequent sampling. Consult your
authorized John Deere dealer on a maintenance program
for your specific application. Your authorized John Deere
dealer has the sampling products and expertise to assist
you in lowering your overall operating costs through fluid
sampling.
AM40430,00002FE-19-20111019
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 2
OMT223334
T205087-UN-01DEC04
1 - Radiator Filler Cap
Drain and flush cooling system using commercial products.
1. Check coolant hoses for cracks and leaks. Replace

if necessary.
2. Tighten clamps.
3. Check radiator and oil cooler for dirt, grease,
leaks, and loose or broken mountings. Clean
radiator and oil cooler fins.
4. CAUTION: Prevent possible injury from hot
spraying water. DO NOT remove radiator filler
cap unless engine is cool. Then turn cap slowly to
the stop.
Slowly turn radiator filler cap (1) to release

pressure. Remove cap.
5.
T205089-UN-01DEC04
Drain Valve
1 - Radiator Drain Valve
Turn radiator drain valve (1) counterclockwise to

open valve. Allow coolant to drain into a
container. Dispose of waste coolant properly.
6. Close drain valves.

7. IMPORTANT: Avoid mixing different brands or
types of coolant. Coolant manufacturers engineer
their coolants to meet certain specifications and
performance requirements. Mixing different
coolant types can degrade coolant and machine
performance.
John Deere COOL-GARD II Pre-Mix coolant is

recommended when adding new coolant to cooling
system. Follow directions on container for correct
Draining Cooling System 3

OMT223334
mixture ratio.
Fill with proper coolant. See Light Duty Engine

Coolant. (Section 3-1.)
Item Measurement Specification

Cooling System Capacity 5.2 L 5.5 qt
(S.N. —254999)
(S.N. 255000— )
COOL-GARD is a trademark of
Deere & Company CC28724,0000095-19-20090831

OMT223334

IMPORTANT: John Deere COOL-GARD II Pre-Mix
coolant is recommended when adding new coolant to
cooling system.
Follow directions on container for correct mixture ratio.
Use only permanent-type low silicate ethylene glycol base

antifreeze in coolant solution. Other types of antifreeze
may damage cylinder seals.
John Deere COOL-GARD II Pre-Mix coolant is

recommended when adding new coolant to cooling system.
Follow directions on container for correct mixture ratio.
FREEZING TEMPERATURES: Fill with permanent-type,

low silicate, ethylene glycol antifreeze (without stop-leak
additive) and clean, soft water. Add John Deere
COOL-GARD II Coolant Extender as required.
Fill
Fill radiator to the bottom of the radiator fill neck and fill
recovery tank to the FULL mark.
Deaeration
The cooling system requires several warm-up and cool

down cycles to deaerate. It will NOT deaerate during
normal operation. Only during warm-up and cool down
cycles will the system deaerate.
1. Start engine. Run engine until coolant reaches a

warm temperature.
2. Stop engine. Allow coolant to cool.
3. Check coolant level at recovery tank.
4. Repeat steps 1—3 until recovery tank coolant level
is repeatedly at the same level (stabilized).
5. NOTE: The level of the coolant in the cooling
system MUST BE repeatedly checked after all
drain and refill procedures to ensure that all air is
out of the system which allows the coolant level to
stabilize. Check coolant level only when the
engine is cold.
If necessary, fill recovery tank to FULL mark.

6. Install recovery tank and radiator caps.
Cooling System Fill and Deaeration 5

OMT223334
Deere & Company CC28724,0000096-19-20090831
Deaeration 6
OMT223334
Required Parts
REQUIRED PARTS
Ensure machine performance and availability; use only genuine
John Deere parts. Verify part numbers are current and that any
associated parts are also on hand, i.e., filter O-rings.
Every Every Every Every Every
Part
Description 250 500 1000 2000 6000
Number
Hours Hours Hours Hours Hours
Engine Oil M801002 1 1 1
1
Filter
Hydraulic
System Return AT308568 1 1 1 1 1
Oil Filter
O-Ring for
4621929 1 1 1 1 1
AT308568
Fuel Filter MIU800645 1 1 1
1
Element
Air Filter RG60690 1 1 1
1
Primary
Pilot Control 4294130 1 1
1
Oil Filter
Engine Rocker
Arm Cover M811429 1 1 1
Gasket
Fuel and Water
Separator M811032 1 1 1
Element
Heating and Air
Conditioning
4641220 As Required
Filter Screen
(rear)
Heating and Air
Conditioning
4641221 As Required
Filter Screen
(front)
Heating and Air
Conditioning
4641222 As Required
Filter Screen
(top)
Hydraulic
System Suction 4617513 As Required
Oil Filter
7.2 L 7.2 L 7.2 L 7.2 L
PLUS-50 Oil TY6389*
(7.6 qt) (7.6 qt) (7.6 qt) (7.6 qt)
0.6 L 0.6 L 0.6 L
API GL-5 Gear
TY6296*
Oil (0.63 (0.63 (0.63
qt) qt) qt)
Hitachi SUPER EX 46HN Hydraulic Oil
Required Parts 7
OMT223334
35 L 35 L
(S.N.
2908-050*
—254999) (9.2 (9.2
gal) gal)
32 L 32 L 32 L
(S.N.
2908-050*
255000—) (8.5 (8.5 (8.5
gal) gal) gal)
COOL-GARD II Pre-Mix
5.2 L
(S.N.
TY26575
—254999)
(5.5 qt)
5.0 L
(S.N.
TY26575
255000—)
(5.3 qt)
Coolant TY26603
As Needed
Extender
Fluid Analysis Kits
□ Diesel Engine AT317904 1 1 1
1 1
Oil
□ Hydraulic Oil AT303189 1 1 1 1
□ Travel
AT303189 2 2 2 2
Gearbox Oil
□
AT180344 1 1 1 1
DIESELSCAN
COOLSCAN AT183016 1 1 1
1
PLUS Kit
COOL-GARD
TY26605 1 1 1
II Test Strips
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
Deere & Company
COOLSCAN PLUS is a trademark

of Deere & Company CC28724,000017D-19-20091006
Required Parts 8
OMT223334
T205831-UN-07DEC04
Right Side Shown - 10 Points
Lubricate bucket and link pins until grease escapes from

joints. (See Section 3-1.) Lubricate every 10 hours when
working in mud and water.
CED,TX14740,6379-19-20120228
Lubricate Bucket and Link Pins 9

OMT223334
T122095-UN-30JUN99
1 - Rear Window Latch (2 used)
Lift up on latches (1) to unlock. Push latch joints to open

window. Lock latches in place.
CED,TX14740,6400-19-19990507
Opening Rear Window—If Equipped 10

OMT223334

See your authorized dealer for inspection and repair.
CED,TX14740,6412-19-19990510
Checking Starter and Alternator 11

OMT223334

Check bucket teeth for wear. Replace tooth if tooth wear is
below 65 mm (2.6 in.)
CAUTION: Guard against injury from flying pieces of

metal; wear goggles or safety glasses.
NOTE: Alternate buckets may use different tooth

assemblies.
CED,TX14740,6421-19-20020703
Checking Bucket Teeth 12

OMT223334
Checking and Adjusting Engine Valve

Lash (Clearance)
See your authorized dealer for inspection and repair.
CED,TX14740,6434-19-19990610
Checking and Adjusting Engine Valve Lash (Clearance) 13

OMT223334
Opening Right Side Window—If

Equipped
T122098-UN-30JUN99
Slide front pane to the rear and/or rear pane to the front to
open and/or close the window.
CED,TX14740,6439-19-19990611
Opening Right Side Window—If Equipped 14

OMT223334

IMPORTANT: Use only permanent-type low silicate
ethylene glycol base antifreeze in coolant solution. Other
types of antifreeze may damage cylinder seals.
FREEZING TEMPERATURES: Fill with permanent-type,

low silicate, ethylene glycol antifreeze (without stop-leak
additive) and clean, soft water.
Fill
Fill radiator to the bottom of the radiator fill neck and fill
recovery tank to the FULL mark.
Deaeration
The cooling system requires several warm-up and cool

down cycles to deaerate. It will NOT deaerate during
normal operation. Only during warm-up and cool down
cycles will the system deaerate.
1. Start engine. Run engine until coolant reaches a

warm temperature.
2. Stop engine. Allow coolant to cool.
3. Check coolant level at recovery tank.
4. Repeat Steps 1—3 until recovery tank coolant
level is repeatedly at the same level (stabilized).
5. NOTE: The level of the coolant in the cooling
system MUST BE repeatedly checked after all
drain and refill procedures to insure that all air is
out of the system which allows the coolant level to
stabilize. Check coolant level only when the
engine is cold.
If necessary, fill recovery tank to FULL mark.

6. Install recovery tank and radiator caps.
CED,TX14740,6458-19-19990626
Cooling System Fill and Deaeration 15

OMT223334

The rubber track uses a different track adjuster than that
used for the steel track.
CAUTION: Prevent possible injury from high-pressure

grease. DO NOT attempt to disassemble the track adjuster
before converting the track. See your authorized dealer.
Change the track adjuster whenever converting the track.

See your authorized dealer for correct track adjuster.
CED,TX14740,6459-19-20060418
Deaeration 16
OMT223334

(Blade on the Ground With Standard
Boom and Canopy)
Rubber Track
Load Radius
At Maximum
1.5 m 3m
Reach
5 ft 10 ft
Load Side Front Side Front Side Front @m
Point
Height @ft
ft
453 787 232 395 4.48
1.5 m kg kg* kg kg* m
5 ft 998 1735 512 870 14 ft

lb lb* lb lb* 8 in.
4.20
409 1158 249 488
m
0 kg kg* kg kg*
13 ft
Ground 902 2554 549 1076
10
lb lb* lb lb*
in.
1329 1650 416 870
-1.5 m kg kg* kg kg*
-5 ft 2930 3637 917 1917

lb lb* lb lb*
Steel Track
Load Radius
At Maximum
1.5 m 3m
Reach
5 ft 10 ft
Point
Height @ft
ft
471 787 244 395 4.48
5 ft 1038 1735 537 870 14 ft

lb lb* lb lb* 8 in.
0
Converting the Track 17

OMT223334
Ground 427 1158 261 488 4.20

kg kg* kg kg* m
941 2554 575 1076 13 ft

lb lb* lb lb* 10 in.
1378 1650 434 870
-5 ft 3038 3637 956 1917

lb lb* lb lb*
NOTE: Ratings are at bucket lift hook, using standard
counterweight, situated on firm, level, uniform supporting
surface.
Figures do not exceed 87 percent of hydraulic capacity or

75 percent of weight needed to tip machine. Figures
marked with an (*) are hydraulically limited capacities.
Remaining figures are stability-limited capacities.
DW90712,00000F4-19-20090109
Excavator Lift Capacity(Blade on the Ground With StandardBoom and Canopy) 18

OMT223334

(Blade on the Ground With Standard
Boom and Cab)
Rubber Track
Load Radius
At Maximum
1.5 m 3m
Reach
5 ft 10 ft
Point
Height @ft
ft
484 787 252 395 4.48
5 ft 1066 1735 555 870 14 ft

lb lb* lb lb* 8 in.
440 1158 269 488 4.20
0 kg kg* kg kg* m
Ground 970 2554 594 1076 13 ft

1414 1650 447 870
-5 ft 3117 3637 985 1917

lb lb* lb lb*
Steel Track
Load Radius
At Maximum
1.52 m 3m
Reach
5 ft 10 ft
Point
Height @ft
ft
501 787 263 395 4.48
5 ft 1105 1735 579 870 14 ft

lb lb* lb lb* 8 in.
0 458 1158 282 488 4.20
kg kg* kg kg* m
Excavator Lift Capacity (Blade on the Ground With Standard Boom and Cab) 19
OMT223334
Ground 1009 2554 621 1076 13 ft

1463 1650 464 870
-5 ft 3226 3637 1024 1917

lb lb* lb lb*
NOTE: Ratings are at bucket lift hook, using standard
counterweight, situated on firm, level, uniform supporting
surface.

marked with an (*) are hydraulically-limited capacities.
DW90712,00000F5-19-20090109
Excavator Lift Capacity (Blade on the Ground With Standard Boom and Cab) 20
OMT223334

(Blade on the Ground With Long Arm
and Cab)
IMPORTANT: Using the Long Arm requires additional
counterweight.
Rubber Track
Load Radius
At Maximum
1.5 m 3m
Reach
5 ft 10 ft
Point
Height @ft
ft
506 487 236 364 4.72
5 ft 1116 1456 520 802 15 ft

lb lb* lb lb* 6 in.
453 433 249 452 4.48
0 kg kg* kg kg* m
Ground 998 2455 548 996 14 ft

lb lb* lb lb* 8 in.
1423 1668 448 1012
-5 ft 3137 3678 988 2231

lb lb* lb lb*
Steel Track
Load Radius
1.52 m 3m At Maximum
Reach
5 ft 10 ft
Point
Height @ft
ft
1.52 m 592 661 286 364 4.72
kg kg* kg kg* m
5 ft
Excavator Lift Capacity (Blade on the Ground With Long Arm and Cab) 21
OMT223334
1306 1457 631 802 15 ft

lb lb* lb lb* 6 in.
538 1113 302 452 4.48
0 kg kg* kg kg* m
Ground 1186 2453 665 996 14 ft

lb lb* lb lb* 8 in.
1659 1668 534 1011
-5 ft 3657 3678 1177 2228

lb lb* lb lb*
NOTE: Ratings are at bucket lift hook, situated on firm,
level, uniform supporting surface.

marked with an (*) are hydraulically-limited capacities.
DW90712,00000F6-19-20090109
Excavator Lift Capacity (Blade on the Ground With Long Arm and Cab) 22
OMT223334
Connecting and Disconnecting

Auxiliary Lines
NOTE: The right and left side is determined while the
operator is sitting in the seat facing forward - looking at the
boom and arm.
This procedure will reduce amount of effort to make the

connection and disconnection of auxiliary lines.
1. Move the bucket clamp (thumb) to the storage

position (up) with 1 inch of cylinder rod exposed.
NOTE: If the rod is completely bottomed out this

procedure will not work.
2. Turn the machine off.
3. Switch the flow selector valve to the hammer
mode. (Left side of machine.)
4. Disconnect the LEFT side hydraulic quick coupler.
5. Disconnect the RIGHT side hydraulic quick
coupler.
6. Change the attachment. (Once the attachment is in
place-shut the machine off.)
7. Connect the RIGHT side hydraulic coupler.
8. Connect the LEFT side hydraulic coupler.
9. Switch the flow selector valve, if necessary for the
particular type of attachment.
10. Operate the machine.
DW90712,0000102-19-20070130
Connecting and Disconnecting Auxiliary Lines 23

OMT223334

See Replacing Hydraulic Oil Tank Filter (Section 3-6.)
DW90712,0000104-19-20091006
Replacing Hydraulic Oil Tank Filter 24

OMT223334
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.
In extremely cold conditions, an extended warm-up period

will be necessary. Under such conditions, the radiator and
oil cooler should be covered to maintain correct operating
temperature.
Avoid sudden operation of all functions until the engine

and hydraulic oil are thoroughly warm.
1. Run engine at 1/2 speed for 5 minutes. Do not run

at fast or slow idle.
2. CAUTION: Prevent possible injury from
unexpected machine movement. Clear the area of
all persons before running your machine through
the warm-up procedure. If machine is inside a
building, warm the travel circuit first and move the
machine to a clear area outside. Cold oil will cause
machine functions to respond slowly.
Exercise travel and swing functions slowly,

initially moving for only short distances.
3. Operate boom, arm, and bucket functions by
moving cylinders a short distance in each direction
for the first time.
4. Continue cycling cylinders by increasing cylinder
extension until full stroke is obtained.
5. IMPORTANT: Holding function actuated for more
than 30 seconds can cause damage from hot spots
in the control valve.
Actuate bucket curl function (cylinder extend) for

10 seconds and release for 5 seconds for a period
of 2-1/2 minutes.
6. Repeat procedure with bucket dump function.
7. Operate all hydraulic functions to distribute warm
oil in all cylinders, motors, and lines.
8. If hydraulic functions still move slowly, repeat
steps 5 and 6.
DW90712,0000105-19-20060418
Cold Weather Warm-Up 25

OMT223334
Changing Engine Oil and Replacing

Filter
See Changing Engine Oil and Replacing Filter Section 3-5.
DW90712,0000110-19-20060426
Changing Engine Oil and Replacing Filter 26

OMT223334
Hydraulic Oil
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.
TX1079198-UN-24JUN10
Use oil viscosity based on the expected air temperature

range during the period between oil changes.
The following oil is preferred:
2000 hour change interval:
• Super EX 46HN Hitachi excavator oil from John Deere
1000 hour change interval:
The following products can be used provided a complete

hydraulic system flush has been performed. Contact your
dealer for this procedure.
Biodegradable Hydraulic Oil:
Use only Exxon Mobil EAL Envirosyn 46H Synthetic

Esther Oil when a biodegradable oil is required. (Contact
your John Deere dealer for Registration and Routine Oil
Analysis to meet warranty requirements.)
DW90712,0000141-19-20120227
Hydraulic Oil 27
OMT223334
CAUTION: Avoid injury! Prevent injury from an

explosion:
Starting fluid is highly flammable; DO NOT use any type

of starting fluid. An electric air preheater may ignite
starting fluid.
1. IMPORTANT: DO NOT use ether or any other

type of starting fluid on engines equipped with an
electric preheater system.
In extremely cold climates, set the engine control

lever (5) to the fast idle position to start engine.
After the engine is started, gradually reduce engine
speed and perform warm-up procedure at the
medium speed range.
NOTE: Engine will not start unless pilot control

shutoff lever is in locked (rearward) position.
T204921-UN-03DEC04
T217414-UN-08DEC05
T217415-UN-08DEC05
1 - HEAT
2 - OFF
3 - ON
4 - START
5 - Engine Speed Control Lever
Starting the Engine in Cold Weather 28

OMT223334
6 - Preheat Indicator
Move engine speed control lever (5) halfway

between slow and fast idle in cold weather.
2. Turn and hold the key switch in HEAT position

(1). In cold weather the engine preheat indicator
(6) on monitor will light.
3. Sound horn to alert persons nearby.
4. IMPORTANT: Prevent starter damage. Never
operate starter for more than 15 seconds at a time.
If engine fails to start, return key switch to OFF.
Wait about 30 seconds, then try again. After a false
start, do not turn key switch until engine stops.
When the engine preheat indicator light (6) goes

out after 15 seconds, immediately turn key switch
to START (4). Release key; switch will return to
ON (3) position.
5. Allow sufficient time for warm-up operation to be
completed.
DW90712,000018E-19-20060706
Starting the Engine in Cold Weather 29

OMT223334
CAUTION: Prevent possible injury from machine

rollover. Use this technique only on a short slope. Machine
depends on support of boom/arm/bucket during entire
procedure until machine reaches top of slope.
Repositioning the bucket during this procedure is NOT
recommended. DO NOT swing upperstructure during this
procedure. DO NOT reposition bucket during this
procedure.
1. Wear seat belt.

2. Position undercarriage so travel motors will be on
uphill end of machine.
3. Push bucket into the ground.
4. When boom is on uphill end of machine: Pull
machine using boom and arm cylinder to help
travel motors.
When boom is on downhill end of machine: Push

machine using boom and arm cylinder to help
travel motors.
DW90712,000018F-19-20070130
Driving Up a Steep or Slippery Slope 30

OMT223334

(Blade on the Ground With Long Arm
and Canopy)
IMPORTANT: Using the Long Arm requires additional
counterweight.
Rubber Track
Load Radius
At Maximum
1.5 m 3m
Reach
5 ft 10 ft
Point
Height @ft
ft
544 661 258 364 4.72
5 ft 1199 1457 568 802 15 ft

lb lb* lb lb* 6 in.
489 1112 271 451 4.48
0 kg kg* kg kg* m
Ground 1079 2453 599 996 14 ft

lb lb* lb lb* 8 in.
1524 1649 485 1011
-5 ft 3361 3678 1070 2228

lb lb* lb lb*
Steel Track
Load Radius
At Maximum
1.5 m 3m
Reach
5 ft 10 ft
Point
Height @ft
ft
1.5 m 562 661 268 364 4.72
kg kg* kg kg* m
5 ft
Excavator Lift Capacity (Blade on the Ground With Long Arm and Canopy) 31
OMT223334
1238 1457 591 802 15 ft

lb lb* lb lb* 6 in.
508 1113 283 452 4.48
0 kg kg* kg kg* m
Ground 1119 2453 623 996 14 ft

lb lb* lb lb* 8 in.
1574 1649 503 1011
-5 ft 3470 3635 1109 2228

lb lb* lb lb*
NOTE: Ratings are at bucket lift hook, situated on firm,
level, uniform supporting surface.

marked with an (*) are hydraulically limited capacities.
DW90712,000030A-19-20090109
Excavator Lift Capacity (Blade on the Ground With Long Arm and Canopy) 32
OMT223334
TS220-UN-15APR13
Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove the
exhaust fumes from the area with an exhaust pipe
extension.
If you do not have an exhaust pipe extension, open the

doors and get outside air into the area.
DX,AIR-19-19990217
Work In Ventilated Area 33

OMT223334

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.
Consult your John Deere dealer to obtain information and

recommendations.
Synthetic lubricants may be used if they meet the

performance requirements as shown in this manual.
The temperature limits and service intervals shown in this

manual apply to both conventional and synthetic
lubricants.
Re-refined base stock products may be used if the finished

lubricant meets the performance requirements.
DX,ALTER-19-20110411
Alternative and Synthetic Lubricants 34

OMT223334
Drain Intervals for Diesel Engine

Coolant
Drain and flush the cooling system and refill with fresh
coolant at the indicated interval, which varies with the
coolant used.
John Deere COOL-GARD II Premix, COOL-GARD II

PG Premix and COOL-GARD II Concentrate are
maintenance free coolants for up to six years or 6000 hours
of operation, provided that the cooling system is topped off
using only John Deere COOL-GARD II Premix or
COOL-GARD II PG Premix.
Test the coolant condition annually with Coolant Test

Strips designed for use with John Deere COOL-GARD II
coolants. If the test strip chart indicates that additive is
required, add John Deere COOL-GARD II Coolant
Extender as directed.
If John Deere COOL-GARD™ II Premix, COOL-GARD

II PG Premix, or COOL-GARD II Concentrate is used, but
the coolant is not tested OR additives are not replenished
by adding John Deere COOL-GARD II Coolant Extender,
the drain interval is four years or 4000 hours of operation.
This drain interval only applies to COOL-GARD II
coolants that have been maintained within a 40—60%
mixture of concentrate with quality water.
If a coolant other than COOL-GARD II, or COOL-GARD

II PG is used, reduce the drain interval to two years or
2000 hours of operation.
Deere & Company DX,COOL11-19-20110414
Drain Intervals for Diesel Engine Coolant 35

OMT223334
John Deere COOL-GARD™ II Coolant

Extender
Some coolant additives will gradually deplete during
engine operation. For John Deere COOL-GARD II
Premix, COOL-GARD II PG Premix, and COOL-GARD
II Concentrate, replenish coolant additives between drain
intervals by adding John Deere COOL-GARD II Coolant
Extender.
John Deere COOL-GARD II Coolant Extender should not

be added unless indicated by coolant testing.
John Deere COOL-GARD II Coolant Extender is a

chemically matched additive system for use with all John
Deere COOL-GARD II coolants. John Deere
COOL-GARD II Coolant Extender is not intended for use
with nitrite-containing coolants.
IMPORTANT: Do not add a supplemental coolant additive

when the cooling system is drained and refilled with any of
the following:
• John Deere COOL-GARD II

• John Deere COOL-GARD II PG
The use of non-recommended supplemental coolant

additives may result in additive drop-out, gelation of the
coolant, or corrosion of cooling system components.
Add the recommended concentration of John Deere

COOL-GARD II Coolant Extender. DO NOT add more
than the recommended amount.
John Deere COOL-GARD™ II Coolant Extender 36

OMT223334
Additional Information About Diesel

Engine Coolants and John Deere
COOL-GARD™ II Coolant Extender
Engine coolants are a combination of three chemical
components: ethylene glycol (EG) or propylene glycol
(PG) antifreeze, inhibiting coolant additives, and quality
water.
Coolant Specifications
John Deere COOL-GARD II Premix either EG or PG, are

fully formulated coolants that contain all three components
in their correct concentrations. DO NOT add an initial
charge of John Deere COOL-GARD II Coolant Extender
to COOL-GARD II Premix. DO NOT add any other
supplemental coolant additive or water to COOL-GARD II
Premix.
John Deere COOL-GARD II Concentrate contains both

ethylene glycol and inhibiting coolant additives. Mix this
product with quality water, but DO NOT add an initial
charge of John Deere COOL-GARD II Coolant Extender
or any other supplemental coolant additive.
Replenish Coolant Additives

engine operation. Periodic replenishment of inhibitors is
required, even when John Deere COOL-GARD II Premix
or COOL-GARD II Concentrate is used. Follow the
recommendations in this manual for the use of John Deere
COOL-GARD II Coolant Extender.
Why use John Deere COOL-GARD II Coolant

Extender?
Operating without proper coolant additives will result in

increased corrosion, cylinder liner erosion and pitting, and
other damage to the engine and cooling system. A simple
mixture of ethylene glycol or propylene glycol and water
will not give adequate protection.
John Deere COOL-GARD II Coolant Extender is a

chemically matched additive system designed to fortify the
proprietary additives used in John Deere COOL-GARD II
37
OMT223334
Premix and COOL-GARD II Concentrate and to provide

optimum protection for up to six years or 6000 hours of
operation.
Avoid Automotive-type Coolants
Never use automotive-type coolants (such as those meeting

ASTM D3306). These coolants do not contain the correct
additives to protect heavy-duty diesel engines. Do not treat
an automotive engine coolant with supplemental coolant
additives because the high concentration of additives can
result in additive fallout.
Water Quality
Water quality is important to the performance of the

cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol and
propylene glycol base engine coolant concentrate.All water
used in the cooling system should meet the following
minimum specifications for quality:
Chlorides <40 mg/L

Sulfates <100 mg/L
Total dissolved solids <340 mg/L
Total hardness <170 mg/L
pH 5.5 to 9.0
Freeze Protection
The relative concentrations of glycol and water in the

engine coolant determine its freeze protection limit.
Ethylene Glycol Freeze Protection Limit

40% -24°C (-12°F)
50% -37°C (-34°F)
60% -52°C (-62°F)
Propylene Glycol Freeze Protection Limit
40% -21°C (-6°F)
50% -33°C (-27°F)
60% -49°C (-56°F)
DO NOT use a coolant-water mixture greater than 60%
ethylene glycol or 60% propylene glycol.
Why use John Deere COOL-GARD II CoolantExtender? 38

OMT223334
Light Duty Diesel Engine Coolant (for

diesel engines without wet sleeve
cylinder liners)
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). If protection at
lower temperatures is required, consult your John Deere
dealer for recommendations.
The following engine coolants are preferred:
• John Deere COOL-GARD™ II Premix

• John Deere COOL-GARD II PG Premix
Use John DeereCOOL-GARD II PG Premix when a

non-toxic coolant formulation is required.
Additional Recommended Coolants
The following engine coolant is also recommended:
• John Deere COOL-GARD II Concentrate in a

40—60% mixture of concentrate with quality
water.
Other Coolants
Other ethylene glycol or propylene glycol base coolants

may be used if they meet one of the following
specifications:
• ASTM D3306 prediluted (50%) coolant

• ASTM D3306 coolant concentrate in a 40—60%
mixture of concentrate with quality water
If these coolants are unavailable, use an engine coolant

concentrate or prediluted coolant with a minimum of the
following chemical and physical properties:
• Is formulated with a quality nitrite-free additive

package.
• Protects the cooling system metals (cast iron,
aluminum alloys, and copper alloys such as brass)
from corrosion.
The coolant concentrate or prediluted coolant shall be of a

quality that is suitable for all-aluminum engines.
Freeze Protection 39
OMT223334
Water Quality
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.
Coolant Drain Intervals
Drain and flush the cooling system and refill with fresh
coolant at the indicated interval, which varies with the
coolant used.
When John Deere COOL-GARD II is used, the drain

interval is six years or 6000 hours of operation.
When John Deere COOL-GARD II PG is used, the drain

interval is five years or 5000 hours of operation.
If a coolant other than COOL-GARD II or COOL-GARD

II PG is used, reduce the drain interval to two years or
2000 hours of operation.
IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains sealing additives.
Do not mix ethylene glycol and propylene glycol base

coolants.
Water Quality 40
OMT223334

engine operation. For nitrite-containing coolants, replenish
coolant additives between drain intervals by adding a
supplemental coolant additive as determined necessary by
coolant testing.
John Deere Liquid Coolant Conditioner is recommended as

a supplemental coolant additive for nitrite-containing
coolants.
John Deere Liquid Coolant Conditioner is not designed for

use with John Deere COOL-GARD II Premix,
COOL-GARD II PG Premix, or COOL-GARD II
Concentrate.
IMPORTANT: Do not add a supplemental coolant additive

when the cooling system is drained and refilled with any of
the following:
• John Deere COOL-GARD II

• John Deere COOL-GARD II PG
If other coolants are used, consult the coolant supplier and

follow the manufacturer's recommendation for use of
supplemental coolant additives.
The use of non-recommended supplemental coolant

additives may result in additive drop-out and gelation of
the coolant.
Add the manufacturer's recommended concentration of

supplemental coolant additive. DO NOT add more than the
recommended amount.
Coolant Drain Intervals 41

OMT223334
Operating in Warm Temperature

Climates
John Deere engines are designed to operate using glycol
base engine coolants.
Always use a recommended glycol base engine coolant,

even when operating in geographical areas where freeze
protection is not required.
John Deere COOL-GARD II Premix is available in a

concentration of 50% ethylene glycol. However, there are
situations in warm temperature climates where a coolant
with lower glycol concentration (approximately 20%
ethylene glycol) has been approved. In these cases, the low
glycol formulation has been modified to provide the same
level of corrosion inhibitor as John Deere COOL-GARD II
Premix (50/50).
IMPORTANT: Water may be used as coolant in

emergency situations only.
Foaming, hot surface aluminum and iron corrosion,

scaling, and cavitation will occur when water is used as the
coolant, even when coolant conditioners are added.
Drain cooling system and refill with recommended glycol

base engine coolant as soon as possible.
Supplemental Coolant Additives 42

OMT223334

Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect the
engine and cooling system against freezing, corrosion, and
cylinder liner erosion and pitting.
Test the coolant solution at intervals of 12 months or less

and whenever excessive coolant is lost through leaks or
overheating.
Coolant Test Strips
Coolant test strips are available from your John Deere

dealer. These test strips provide a simple, effective method
to check the freeze point and additive levels of your engine
coolant.
When Using John Deere COOL-GARD II
John Deere COOL-GARD II Premix , COOL-GARD II

PG Premix and COOL-GARD II Concentrate are
maintenance free coolants for up to six years or 6000 hours
of operation, provided that the cooling system is topped off
using only John Deere COOL-GARD II Premix or
COOL-GARD II PG premix. Test the coolant condition
annually with coolant test strips designed for use with John
Deere COOL-GARD II coolants. If the test strip chart
indicates that additive is required, add John Deere
COOL-GARD II Coolant Extender as directed.
Add only the recommended concentration of John Deere

COOL-GARD II Coolant Extender. DO NOT add more
than the recommended amount.
When Using Nitrite-Containing Coolants
Compare the test strip results to the supplemental coolant

additive (SCA) chart to determine the amount of inhibiting
additives in your coolant and whether more John Deere
Liquid Coolant Conditioner should be added.
Add only the recommended concentration of John Deere

Liquid Coolant Conditioner. DO NOT add more than the
recommended amount.
Operating in Warm TemperatureClimates 43

OMT223334
Coolant Analysis
For a more thorough evaluation of your coolant, perform a

coolant analysis. The coolant analysis can provide critical
data such as freezing point, antifreeze level, pH, alkalinity,
nitrite content (cavitation control additive), molybdate
content (rust inhibitor additive), silicate content, corrosion
metals, and visual assessment.
Contact your John Deere dealer for more information on

coolant analysis.
Coolant Analysis 44
OMT223334
Diesel Engine Oil
TS1691-UN-18JUL07
Oil Viscosities for Air Temperature Ranges

John Deere Plus-50 II oil is preferred.
John Deere Plus-50™ is also recommended.
Other oils may be used if they meet one or more of the

following:
• John Deere Torq-Gard

• API Service Category CJ-4
• API Service Category CI-4 PLUS
• API Service Category CI-4
• ACEA Oil Sequence E9
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply

with all existing emissions regulations for the area in
which the engine operates.
DO NOT use diesel fuel with sulfur content greater than 10

000 mg/kg (10 000 ppm).
Plus-50 is a trademark of Deere &

Company
Torq-Gard is a trademark of Deere

& Company DX,ENOIL11-19-20110411
Diesel Engine Oil 45

OMT223334
Diesel Engine Oil and Filter Service

Intervals
The oil and filter service intervals in the following table should
be used as guidelines. Actual service intervals also depend on
operation and maintenance practices. It is suggested to use oil
analysis to determine the actual useful life of the oil and to aid
in selection of the proper oil and filter service interval.
Oil and filter service intervals are based on a combination of oil

pan capacity, type of engine oil and filter used, and sulfur
content of the diesel fuel.
Diesel fuel sulfur level will affect engine oil and filter service
intervals. Higher fuel sulfur levels reduce oil and filter service
intervals as shown in the table.
• Use of diesel fuel with sulfur content less than 0.10%

(1000 mg/kg) is strongly recommended.
• Use of diesel fuel with sulfur content 0.10% (1000
mg/kg) to 0.50% (5000 mg/kg) may result in
REDUCED oil and filter change intervals as shown in
the table.
• BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 mg/kg), contact your John Deere
dealer.
• DO NOT use diesel fuel with sulfur content greater than
1.00% (10 000 mg/kg).
IMPORTANT: When using biodiesel blends greater than B20,

reduce the oil and filter service interval by 50% or monitor
engine oil based on test results from Oilscan.
Oil types in the table include:
• John Deere Plus-50 II and John Deere Plus-50

• “Other Oils” include John Deere Torq-Gard Supreme,
API CJ-4, API CI-4 PLUS, API CI-4, ACEA E9,
ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils.
Use of lower specification oils in Tier 3 engines may result in

premature engine failure.
NOTE: The 500 hour extended oil and filter change interval is
only allowed if all the following conditions are met:
• Engine equipped with an extended drain interval oil pan

• Use of diesel fuel with sulfur content less than 0.50%
(5000 mg/kg)
• Use of John Deere Plus-50™ II or John Deere Plus-50
oil
• Use of an approved John Deere oil filter
John Deere Plus-50 II oil is preferred. 46

OMT223334
U.S. Tier 3 and EU

U.S. Tier 3 and EU Stage III
Stage III A -
A - PowerTech Plus
PowerTech
Oil Pan Size (L/kW) Oil Pan Size (L/kW)
Greater Greater Greater Greater Greater Greater Greater
Oil pan than or than or than or than or than or than or than or
capacity equal equal equal equal equal equal equal
to 0.10 to 0.12 to 0.14 to 0.22 to 0.10 to 0.12 to 0.14
Fuel Less than 0.10% (1000
Less than 0.10% (1000 mg/kg)
Sulfur mg/kg)
375 500 500 500 375 500 500
Plus-50
hours hours hours hours hours hours hours
Other 250 250 250 250 250 250 250
Oils hours hours hours hours hours hours hours
Fuel 0.10 - 0.20% (1000 - 2000 0.10 - 0.20% (1000 -
Sulfur mg/kg) 2000 mg/kg)
300 300 500 500 300 400 500
Plus-50
Other 200 200 250 250 200 200 250
Fuel 0.20 - 0.50% (2000 - 5000 0.20 - 0.50% (2000 -
Sulfur mg/kg) 5000 mg/kg)
250 250 300 500 275 350 500
Plus-50
Other 150 150 200 250 150 175 250
Fuel 0.50 - 1.00% (5000 - 10 000 0.50 - 1.00% (5000 -
Sulfur mg/kg) 10 000 mg/kg)
Contact John Deere Dealer
187 250 250
Plus-50 (dealer refers to DTAC
hours hours hours
solutions)
Contact John Deere Dealer
Other 125 125 125
(dealer refers to DTAC
Oils hours hours hours
solutions)
The service interval of “Other Oils” may be extended only if oil
analysis is performed to determine the actual service life, to a
maximum not to exceed that of Plus-50.
Plus-50 is a trademark of Deere &

Company
Torq-Gard Supreme is a trademark

of Deere & Company
PowerTech Plus is a trademark of

Deere & Company
PowerTech is a trademark of Deere

& Company DX,ENOIL13-19-20090803
Diesel Engine Oil and Filter ServiceIntervals 47

OMT223334
X9811-UN-23AUG88
Inspect hydraulic hoses periodically – at least once per

year – for leakage, kinking, cuts, cracks, abrasion, blisters,
corrosion, exposed wire braid or any other signs of wear or
damage.
Replace worn or damaged hose assemblies immediately

with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands

and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available in English
from Deere & Company Medical Department in Moline,
Illinois, U.S.A., by calling 1-800-822-8262 or +1
309-748-5636.
DX,FLUID-19-20111012
Avoid High-Pressure Fluids 48

OMT223334
Minimizing the Effect of Cold Weather

on Diesel Engines
John Deere diesel engines are designed to operate
effectively in cold weather.
However, for effective starting and cold weather operation,

a little extra care is necessary. The information below
outlines steps that can minimize the effect that cold
weather may have on starting and operation of your engine.
See your John Deere dealer for additional information and
local availability of cold weather aids.
Use Winter Grade Fuel
When temperatures fall below 0°C (32°F), winter grade

fuel (No. 1-D in North America) is best suited for cold
weather operation. Winter grade fuel has a lower cloud
point and a lower pour point.
Cloud point is the temperature at which wax will begin to

form in the fuel and this wax causes fuel filters to plug.
Pour point is the lowest temperature at which movement
of the fuel is observed.
NOTE: On average, winter grade diesel fuel has a lower

Btu (heat content) rating. Using winter grade fuel may
reduce power and fuel efficiency, but should not cause any
other engine performance effects. Check the grade of fuel
being used before troubleshooting for low power
complaints in cold weather operation.
Air Intake Heater
An air intake heater is an available option for some engines

to aid cold weather starting.
Ether
An ether port on the intake is available to aid cold weather

starting.
CAUTION: Ether is highly flammable. Do not use

ether when starting an engine equipped with glow plugs or
an air intake heater.
Minimizing the Effect of Cold Weather on Diesel Engines 49

OMT223334
Coolant Heater
An engine block heater (coolant heater) is an available

option to aid cold weather starting.
Seasonal Viscosity Oil and Proper Coolant

Concentration
Use seasonal grade viscosity engine oil based on the

expected air temperature range between oil changes and a
proper concentration of low silicate antifreeze as
recommended. (See DIESEL ENGINE OIL and ENGINE
COOLANT requirements in this section.)
Diesel Fuel Flow Additive
Use John Deere Fuel-Protect Diesel Fuel Conditioner

(winter formula), which contains anti-gel chemistry, or
equivalent fuel conditioner to treat non-winter grade fuel
(No. 2-D in North America) during the cold weather
season. This generally extends operability to about 10°C
(18°F) below the fuel cloud point. For operability at even
lower temperatures, use winter grade fuel.
IMPORTANT: Treat fuel when outside temperature drops

below 0°C (32°F). For best results, use with untreated fuel.
Follow all recommended instructions on label.
BioDiesel
When operating with biodiesel blends, wax formation can

occur at warmer temperatures. Begin using John Deere
Fuel-Protect Diesel Fuel Conditioner (winter formula) at
5°C (41°F) to treat biodiesel fuels during the cold weather
season. Use B5 or lower blends at temperatures below 0°C
(32°F). Use only winter grade petroleum diesel fuel at
temperatures below -10°C (14°F).
Winterfronts
Use of fabric, cardboard, or solid winterfronts is not

recommended with any John Deere engine. Their use can
result in excessive engine coolant, oil, and charge air
temperatures. This can lead to reduced engine life, loss of
power and poor fuel economy. Winterfronts may also put
abnormal stress on fan and fan drive components
Coolant Heater 50
OMT223334
potentially causing premature failures.
If winterfronts are used, they should never totally close off

the grill frontal area. Approximately 25% area in the center
of the grill should remain open at all times. At no time
should the air blockage device be applied directly to the
radiator core.
Radiator Shutters
If equipped with a thermostatically controlled radiator

shutter system, this system should be regulated in such a
way that the shutters are completely open by the time the
coolant reaches 93°C (200°F) to prevent excessive intake
manifold temperatures. Manually controlled systems are
not recommended.
If air-to-air aftercooling is used, the shutters must be

completely open by the time the intake manifold air
temperature reaches the maximum allowable temperature
out of the charge air cooler.
For more information, see your John Deere dealer.
DX,FUEL10-19-20110420
Winterfronts 51
OMT223334
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low

temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are

recommended. Renewable diesel fuel produced by
hydrotreating animal fats and vegetable oils is basically
identical to petroleum diesel fuel. Renewable diesel that
meets EN 590 or ASTM D975 is acceptable for use at all
percentage mixture levels.
Required Fuel Properties
In all cases, the fuel shall meet the following properties:
Cetane number of 43 minimum. Cetane number greater

than 47 is preferred, especially for temperatures below
–20°C (–4°F) or elevations above 1500 m (5000 ft.).
Cold Filter Plugging Point (CFPP) should be at least 5°C

(9°F) below the expected lowest temperature or Cloud
Point below the expected lowest ambient temperature.
Fuel lubricity should pass a maximum scar diameter of

0.45 mm as measured by ASTM D6079 or ISO 12156-1.
Diesel fuel quality and sulfur content must comply with

all existing emissions regulations for the area in which the
engine operates. DO NOT use diesel fuel with sulfur
content greater than 10 000 mg/kg (10 000 ppm).
Sulfur content for Interim Tier 4 and Stage III B

engines
• Use ONLY ultra low sulfur diesel (ULSD) fuel

with a maximum of 15 mg/kg (15 ppm) sulfur
content.
Sulfur Content for Tier 3 and Stage III A Engines
• Use of diesel fuel with sulfur content less than

1000 mg/kg (1000 ppm) is RECOMMENDED
• Use of diesel fuel with sulfur content 1000–5000
mg/kg (1000–5000 ppm) REDUCES oil and filter
Radiator Shutters 52
OMT223334
change intervals.
• BEFORE using diesel fuel with sulfur content

greater than 5000 mg/kg (5000 ppm), contact your
John Deere dealer
Sulfur Content for Tier 2 and Stage II Engines
• Use of diesel fuel with sulfur content less than 500

mg/kg (500 ppm) is RECOMMENDED.
• Use of diesel fuel with sulfur content 500–5000
mg/kg (500–5000 ppm) REDUCES the oil and
filter change interval
• BEFORE using diesel fuel with sulfur content
greater than 5000 mg/kg (5000 ppm), contact your
John Deere dealer
Sulfur Content for Other Engines
• Use of diesel fuel with sulfur content less than

5000 mg/kg (5000 ppm) is recommended.
• Use of diesel fuel with sulfur content greater than
5000 mg/kg (5000 ppm) REDUCES the oil and
filter change intervals.
IMPORTANT: Do not mix used diesel engine oil or any

other type of lubricating oil with diesel fuel.
IMPORTANT: Improper fuel additive usage may cause

damage on fuel injection equipment of diesel engines.
DX,FUEL1-19-20110411
Sulfur Content for Tier 3 and Stage III A Engines 53

OMT223334
CAUTION: Reduce the risk of fire. Handle fuel

carefully. DO NOT fill the fuel tank when engine is
running. DO NOT smoke while you fill the fuel tank or
service the fuel system.
Fill the fuel tank at the end of each day's operation to

prevent water condensation and freezing during cold
weather.
Keep all storage tanks as full as practicable to minimize

condensation.
Ensure that all fuel tank caps and covers are installed
properly to prevent moisture from entering. Monitor water
content of the fuel regularly.
When using biodiesel fuel, the fuel filter may require more
frequent replacement due to premature plugging.
Check engine oil level daily prior to starting engine. A

rising oil level may indicate fuel dilution of the engine oil.
IMPORTANT: The fuel tank is vented through the filler

cap. If a new filler cap is required, always replace it with
an original vented cap.
When fuel is stored for an extended period or if there is a

slow turnover of fuel, add a fuel conditioner to stabilize the
fuel and prevent water condensation. Contact your fuel
supplier for recommendations.
DX,FUEL4-19-20110414
Sulfur Content for Other Engines 54

OMT223334

Most diesel fuels manufactured in the United States,
Canada, and the European Union have adequate lubricity
to ensure proper operation and durability of fuel injection
system components. However, diesel fuels manufactured in
some areas of the world may lack the necessary lubricity.
IMPORTANT: Make sure the diesel fuel used in your

machine demonstrates good lubricity characteristics.
Fuel lubricity should pass a maximum scar diameter of

0.45 mm as measured by ASTM D6079 or ISO 12156-1.
If fuel of low or unknown lubricity is used, add John Deere

Fuel-Protect Diesel Fuel Conditioner (or equivalent) at the
specified concentration.
Lubricity of Biodiesel Fuel
Fuel lubricity can improve significantly with biodiesel

blends up to B20 (20% biodiesel). Further increase in
lubricity is limited for biodiesel blends greater than B20.
DX,FUEL5-19-20110414
Handling and Storing Diesel Fuel 55

OMT223334
Testing Diesel Fuel

A fuel analysis program can help to monitor the quality of
diesel fuel. The fuel analysis can provide critical data such
as cetane number, fuel type, sulfur content, water content,
appearance, suitability for cold weather operations,
bacteria, cloud point, acid number, particulate
contamination, and whether the fuel meets specification.
Contact your John Deere dealer for more information on

diesel fuel analysis.
DX,FUEL6-19-20110414
Lubricity of Diesel Fuel 56

OMT223334
Biodiesel Fuel
Biodiesel fuel is 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.
Before using fuel containing biodiesel, review the

Biodiesel Use Requirements and Recommendations in this
Operator’s Manual.
Environmental laws and regulations can encourage or

prohibit the use of biofuels. Operators should consult with
appropriate governmental authorities prior to using
biofuels.
All John Deere Engines with Exhaust Filter (Released

2011 and After)
While 5% blends (B5) are preferred, biodiesel

concentrations up to a 20% blend (B20) in petroleum
diesel fuel can be used. Biodiesel blends up to B20 can be
used ONLY if the biodiesel (100% biodiesel or B100)
meets ASTM D6751, EN 14214, or equivalent
specification. Expect a 2% reduction in power and a 3%
reduction in fuel economy when using B20.
Biodiesel concentrations above B20 can harm the engine’s

emission control systems and should not be used. Risks
include, but are not limited to, more frequent stationary
regeneration, soot accumulation, and increased intervals
for ash removal.
John Deere approved fuel conditioners, which contain

detergent and dispersant additives, are required when using
B20, and are recommended when using lower biodiesel
blends.
All John Deere Engines Excluding Exhaust Filter

(Primarily Released Prior to 2012)
While 5% blends (B5) are preferred, biodiesel

concentrations up to a 20% blend (B20) in petroleum
diesel fuel can be used. Biodiesel blends up to B20 can be
used ONLY if the biodiesel (100% biodiesel or B100)
meets ASTM D6751, EN 14214, or equivalent
specification. Expect a 2% reduction in power and a 3%
reduction in fuel economy when using B20.
These John Deere engines can operate on biodiesel blends

above B20 (up to 100% biodiesel). Operate at levels above
B20 ONLY if the biodiesel is permitted by law and meets
the EN 14214 specification (primarily available in Europe).
Testing Diesel Fuel 57

OMT223334
Engines operating on biodiesel blends above B20 might

not fully comply with or be permitted by 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, which contain

detergent and dispersant additives, are required when using
B20, and are recommended when using lower biodiesel
blends.
Biodiesel Use Requirements and Recommendations
The petroleum diesel portion of all biodiesel blends must

meet the requirements of ASTM D975 (US) or EN 590
(EU) commercial standards.
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.bq9000.org.
Biodiesel contains residual ash. Ash levels exceeding the

maximums allowed in either ASTM D6751 or EN14214
can result in more rapid ash loading and require more
frequent cleaning of the Exhaust Filter (if present).
The fuel filter can require more frequent replacement,

when using biodiesel fuel, particularly if switching from
diesel. Check engine oil level daily prior to starting engine.
A rising oil level can indicate fuel dilution of the engine
oil. Biodiesel blends up to B20 must be used within 90
days of the date of biodiesel manufacture. If used,
biodiesel blends above B20 must be used within 45 days
from the date of biodiesel manufacture.
When using biodiesel blends up to B20, the following must

be considered:
• Cold weather flow degradation

• Stability and storage issues (moisture absorption,
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
(primarily an issue with older engines)
• Possible reduction of service life of engine
components
Request a certificate of analysis from your fuel distributor

to ensure that the fuel is compliant with the specifications
Biodiesel Fuel 58
OMT223334
provided in this Operator’s Manual.
Consult your John Deere dealer for approved fuel

conditioners to improve storage and performance with
biodiesel fuels.
The following must also be considered if using biodiesel

blends above B20:
• Possible coking or blocked injector nozzles,

resulting in power loss and engine misfire if John
Deere approved fuel conditioners are not used
• Possible crankcase oil dilution (requiring more
frequent oil changes)
• Possible lacquering or seizure of internal
components
• Possible formation of sludge and sediments
• Possible thermal oxidation of fuel at elevated
temperatures
• Possible compatibility issues with other materials
(including copper, lead, zinc, tin, brass, and
bronze) used in fuel handling equipment
• Possible reduction in water separator efficiency
• Possible damage to paint if exposed to biodiesel
• Possible corrosion of fuel injection equipment
• Possible elastomeric seal and gasket material
degradation (primarily an issue with older engines)
• Possible high acid levels within fuel system
• Because biodiesel blends above B20 contain more
ash, using blends above B20 can result in more
rapid ash loading and require more frequent
cleaning of the Exhaust Filter (if present)
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,FUEL7-19-20120829
Biodiesel Fuel 59
OMT223334
Grease
TS1674-UN-31OCT03
Greases for Air Temperature Ranges
Use grease based on NLGI consistency numbers and the

expected air temperature range during the service interval.
John Deere HD Moly Grease is preferred.
Other greases may be used if they meet the following:
• NLGI Performance Classification GC-LB with

3–5% molybdenum disulfide
IMPORTANT: Some types of grease thickeners are not

compatible with others. Consult your grease supplier
before mixing different types of grease.
DX,GREA4-19-20110414
Grease 60
OMT223334
Remove Paint Before Welding or

Heating
TS220-UN-15APR13
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by

welding, soldering, or using a torch.
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from

area to be affected by heating. If paint cannot be
removed, wear an approved respirator before
heating or welding.
• If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator.
• If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow fumes
to disperse at least 15 minutes before welding or
heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT-19-20020724
Remove Paint Before Welding or Heating 61

OMT223334
TS281-UN-15APR13
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop to
relieve pressure before removing completely.
DX,RCAP-19-19900604
Service Cooling System Safely 62

OMT223334
TS1680-UN-09DEC03
1. Maintain in a secure location an up-to-date

inventory of all product and component serial
numbers.
2. Regularly verify that identification plates have not
been removed. Report any evidence of tampering
to law enforcement agencies and order duplicate
plates.
3. Other steps you can take:
♦ Mark your machine with your own
numbering system
♦ Take color photographs from several
angles of each machine
DX,SECURE1-19-20031118
Keep Proof of Ownership 63

OMT223334
TS230-UN-24MAY89
1. Install vandal-proof devices.

2. When machine is in storage:
♦ Lower equipment to the ground
♦ Set wheels to widest position to make
loading more difficult
♦ Remove any keys and batteries
3. When parking indoors, put large equipment in
front of exits and lock your storage buildings.
4. When parking outdoors, store in a well-lighted and
fenced area.
5. Make note of suspicious activity and report any
thefts immediately to law enforcement agencies.
6. Notify your John Deere dealer of any losses.
DX,SECURE2-19-20031118
Keep Machines Secure 64

OMT223334
TS1671-UN-01MAY03
Bolt or SAE Grade 1 SAE Grade 21 SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Screw Lubricated 2 Dry 3 Lubricated2 Dry3 Lubricated4 Dry 3 Lubricated2 Dry3
Size
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N˙m lb.-ft. N˙m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N˙m lb.-ft. N˙m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N˙m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the Replace fasteners with the same or higher grade. If
strength of the bolt or screw. DO NOT use these values if a higher grade fasteners are used, tighten these to the
different torque value or tightening procedure is given for a strength of the original. Make sure fastener threads
specific application. For plastic insert or crimped steel type are clean and that you properly start thread
lock nuts, for stainless steel fasteners, or for nuts on U-bolts, engagement. When possible, lubricate plain or zinc
see the tightening instructions for the specific application. plated fasteners other than lock nuts, wheel bolts or
Shear bolts are designed to fail under predetermined loads. wheel nuts, unless different instructions are given for
Always replace shear bolts with identical grade. the specific application.
1 Grade 2 applies for hex cap screws DX,TORQ1-19-20110112
(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.
2 “Lubricated” means coated with a
lubricant such as engine oil,

fasteners with phosphate and oil
coatings, or 7/8 in. and larger
fasteners with JDM F13C, F13F or
F13J zinc flake coating.
3 “Dry” means plain or zinc plated
Unified Inch Bolt and Screw Torque Values 65

OMT223334
without any lubrication, or 1/4 to 3/4

in. fasteners with JDM F13B, F13E
or F13H zinc flake coating.
4 “Lubricated” means coated with a

coatings, or 7/8 in. and larger
Unified Inch Bolt and Screw Torque Values 66

OMT223334
TS1670-UN-01MAY03
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricated1 Dry2 Lubricated1 Dry2 Lubricated1 Dry3 Lubricated1 Dry2
Size
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N˙m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based
Shear bolts are designed to fail under predetermined loads.
on the strength of the bolt or screw. DO NOT use
Always replace shear bolts with identical property class.
these values if a different torque value or tightening
Replace fasteners with the same or higher property class. If
procedure is given for a specific application. For
higher property class fasteners are used, tighten these to the
stainless steel fasteners or for nuts on U-bolts, see
strength of the original. Make sure fastener threads are clean
the tightening instructions for the specific
and that you properly start thread engagement. When
application. Tighten plastic insert or crimped steel
possible, lubricate plain or zinc plated fasteners other than
type lock nuts by turning the nut to the dry torque
lock nuts, wheel bolts or wheel nuts, unless different
shown in the chart, unless different instructions are
instructions are given for the specific application.
given for the specific application.
1 “Lubricated” means coated with a DX,TORQ2-19-20110112

coatings, or M20 and larger
without any lubrication, or M6 to

M18 fasteners with JDM F13B, F13E
without any lubrication, or M6 to
Metric Bolt and Screw Torque Values 67

OMT223334
M18 fasteners with JDM F13B, F13E

Metric Bolt and Screw Torque Values 68

OMT223334
Service Intervals
Model: 27D PIN/Serial Number:
Hour Meter Reading:
SERVICE INTERVALS
Service your machine at intervals shown on this chart.
Also, perform service on items at multiples of the original
requirement. For example, at 500 hours also service those
items (if applicable) listed under 250 hours, 100 hours, 50
hours and 10 hours or daily.
FLUID SAMPLING
Fluid samples should be taken from each system at its
recommended change interval prior to actually draining
the fluid. Regular oil sampling will extend the operational
life of your machine.
As Required
□ Drain fuel tank sump □ Replace rubber crawler
□ Replace bucket □ Clean cab floor
□ Add coolant extender as
□ Check and replace
indicated by COOL-GARD II
seat belt
test strips
Every 10 Hours or Daily

□ Grease front end pin □ Grease bucket and link pins
joints
□ Check engine oil
□ Check hydraulic oil level
level
□ Check hoses and □ Check water separator
lines for leaks or
looseness
□ Drain water □ Check seat belt
separator
□ Check fuel hoses for
□ Check coolant level
leaks, cracks, etc.
□ Check bucket teeth □ Check track sag
□ Check bucket hook □ Check air conditioner (if
(if equipped) equipped)
After First 50 Hours

□ Check and adjust fan □ Check tightening torque of bolts
belt tension and nuts
Every 100 Hours

□ Grease front joint
□ Grease bucket and link pins
pins
□ Check and adjust fan
belt tension
Service Intervals 69
OMT223334
Every 250 Hours

□ Grease swing □ Check hoses and lines for cracks and
bearing gear bends
□ Check gear oil
□ Check fuel hoses for cracks and bends
level
□ Drain hydraulic
□ Clean air cleaner element
tank sump
□ Replace
hydraulic filter □ Take engine oil sample
element
□ Check tightening torque of bolts and nuts
Every 500 Hours

□ Grease front
□ Replace fuel filter
end pin joints
□ Grease blade
□ Clean radiator core
pins
□ Grease swing □ Clean air conditioner recirculation
internal gear filter
□ Grease control
lever universal □ Take diesel fuel sample
joint
□ Change engine
oil and replace
filter □ Take gear oil sample
□ Replace
hydraulic filter □ Take engine coolant sample
element
□ Take hydraulic reservoir oil sample
Every 1000 Hours

□ Change
□ Check starter and alternator
transmission oil
□ Replace pilot
□ Check and adjust valve clearance
filter element
□ Check fuel
□ Measure engine compression pressure
injection nozzles
□ Replace fuel
and water
separator □ Check coolant
Every 2000 Hours

□ Change
hydraulic oil;
□ Check injection timing
clean suction
screen
□ Check radiator cap
□ Drain, flush, and refill radiator coolant

For recommended oil type and oil viscosities based on
operating temperatures, see Maintenance-Machine.
OMT223334
(Section 3-1).
Deere & Company JH91824,000058F-19-20091006
OMT223334
Check Coolant
CAUTION:
TS281-UN-15APR13
T205085-UN-01DEC04
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Remove radiator filler cap (1) only when engine is cold or

when cool enough to touch with bare hands. Slowly loosen
cap to relieve pressure before removing completely.
IMPORTANT: John Deere COOL-GARD II Coolant

Extender does not protect against freezing. Coolant
extender prevents rust, scale, and liner cavitation.
NOTE: Check coolant every 1000 hours or 1 year, or when

replacing 1/3 or more of coolant. Add coolant extender as
indicated by John Deere COOL-GARD II test strips.
1. Remove radiator filler cap and test coolant

solution. Use one of the following kits to check
coolant.
♦ COOL-GARD II Test Strips
Coolant test strips provide an effective

method to check freeze point and additive
levels of engine coolant. See your
authorized dealer for COOL-GARD II test
strips and follow instructions on kit.
♦ COOLSCAN PLUS
For a more thorough evaluation of coolant,

perform COOLSCAN PLUS analysis,
where available. See your authorized
dealer for information about COOLSCAN
PLUS.
Check Coolant 72
OMT223334
2. Add John Deere COOL-GARD II Coolant

Extender as necessary. Follow instructions on
container for amount.

3. Install radiator filler cap.
Deere & Company
COOLSCAN PLUS is a
trademark of Deere & Company JH91824,00005B2-19-20090831
Check Coolant 73
OMT223334
Take Fluid Samples

See your authorized dealer for taking the following fluid
samples:
• Hydraulic Oil
• Coolant
• Diesel Fuel
• Travel Gear Oil
JH91824,00005B3-19-20091006
Take Fluid Samples 74

OMT223334
John Deere Operator Manual View

Use the links to your left to navigate this Operator Manual
John Deere Operator Manual View 75

OMT223334
Monitor Panel and Functions (S.N.

—255551)
T216977-UN-04NOV05
1 - Coolant Temperature Gauge
2 - Fuel Gauge
3 - Monitor Display
4 - SET Switch
5 - DISPLAY SELECT Switch
6 - Fast Travel Mode Indicator
7 - Engine Preheat Indicator
8 - Alternator Voltage Indicator
9 - Low Fuel Level Indicator
10 - High Coolant Temperature Indicator
11 - Engine Oil Pressure Indicator
12 - System Failure Indicator
1. Coolant Temperature Gauge: When the first three

segments come ON, the coolant temperature is normal.
NOTE: When the coolant temperature is lower than 20°C

(68°F), the first segment will flash.
2. Fuel Gauge and Fuel Level Indicator: When the fuel

level is low, the first segment flashes, indicating the fuel
tank is almost empty. Add fuel before gauge reaches “E.”
NOTE: When the key switch is OFF, continuously

pressing display select switch (5) for more than 0.5
seconds will display the fuel level.
3. Monitor Display: Three modes are available: hour

meter, trip meter 1 and trip meter 2. To change mode, press
Monitor Panel and Functions (S.N. —255551) 76

OMT223334
DISPLAY SELECT switch (5) until desired mode is

displayed. Hour meter is the default display. The
right-hand number on the hour meter indicates tenths of an
hour (six minutes).
4. SET Switch: Used to set trip meters.
5. DISPLAY SELECT Switch: Used to change

information shown in monitor display.
6. Fast Travel Mode Indicator: When fast travel mode is

selected on travel speed control switch, fast travel mode
indicator will light.
7. Engine PreHeat Indicator: Yellow indicator will light

when key switch is held in the HEAT position. Indicator
will go out after 15 seconds, indicating that preheating is
completed. Start engine immediately after light goes out.
8. Alternator Voltage Indicator: Indicator will light with

no or low alternator output.
9. Low Fuel Level Indicator: When the fuel level

indicator flashes while machine is operating on level
ground, fuel level is extremely low (approximately 6.5 L
[1.7 gal]). Refuel as soon as possible.
10. Engine Coolant Temperature Gauge and Engine

Coolant Temperature Indicator: Coolant temperature is
normal when the gauge segments remain in the white
range.
The monitor alarm sounds and the gauge segments in the

red range come ON when coolant temperature rises
extremely high. Reduce load immediately and run engine
at slow idle. Inspect for debris around radiator. Check for
low coolant in the radiator recovery tank.
11. Engine Oil Pressure Indicator:
IMPORTANT: Avoid engine damage. If engine oil

pressure light comes on while operating, stop engine
immediately.
Indicator will light and alarm will sound when engine oil
pressure is low. Stop engine immediately.
NOTE: Cold oil, low oil level, or extreme off-level

operation may cause indicator to light.
12. System Failure Indicator: The indicator will come

ON or flash when an abnormality is found in the system.
Contact your authorized dealer as soon as possible.

OMT223334
MB60223,00002CD-19-20120829

OMT223334
Monitor Panel and Functions (S.N.

255551— )
TX1096536A-UN-25AUG11
Monitor Panel (S.N. 280539— )
2 - Fuel Gauge
3 - Hour Meter
4 - Overheat Indicator
6 - Alternator Indicator
7 - Auto Idle Indicator
10 - Preheat Indicator
1. Coolant Temperature Gauge:

When the first three segments are illuminated, the coolant
temperature is normal.

(68°F), the first segment flashes.
2. Fuel Gauge:
Position of segment illumination indicates fuel level. Add
fuel before only the “E” segment of the gauge is
illuminated and/or the Low Fuel Level Indicator (5) is
illuminated.
IMPORTANT: Avoid machine damage. If all segments of

the fuel gauge are illuminated and flashing, immediately
contact your authorized John Deere dealer.
Monitor Panel and Functions (S.N. 255551— ) 79

OMT223334
3. Hour Meter:
Numbers to the left of the decimal point indicate total
accumulated operation hours since the machine began
working. The number to the right of the decimal point
indicates tenths of an hour (six minutes).
4. Overheat Indicator:
If the temperature of the coolant is extremely hot, this
indicator illuminates and a buzzer activates. Immediately
stop machine operation and reduce engine speed to slow
idle speed to reduce coolant temperature.
5. Low Fuel Level Indicator:

If this indicator illuminates while on level ground, the
amount of fuel remaining in the fuel tank is 10.0 L (2.6
gal) or less. Add fuel to the fuel tank as soon as safely
possible.
6. Alternator Indicator:
This indicator illuminates when little or no alternator
output exists. If this indicator illuminates, examine
components of the electrical system such as the alternator
and/or battery.
7. Auto Idle Indicator:

This indicator illuminates when the auto-idle switch on the
switch panel is activated.
8. Fast Travel Mode Indicator:

This indicator illuminates when the fast mode side (rabbit)
of the travel mode switch has been pressed.
9. System Failure Indicator:

This indicator will illuminate and/or flash when there is a
strong possibility of an irregularity in the engine control
system.
IMPORTANT: Avoid machine damage. If system failure

indicator is illuminated, contact your authorized John
Deere dealer immediately.
10. Preheat Indicator:

This indicator illuminates when the machine determines
that preheating is required.
11. Engine Oil Pressure Indicator:

This indicator illuminates red when low engine oil pressure
is present. The engine oil pressure warning buzzer
activates simultaneously with indicator.
IMPORTANT: Avoid machine damage. If engine oil

pressure indicator is illuminated, stop the engine
immediately. Examine the engine oil pressure system and
engine oil level for the presence of irregularities.

OMT223334
MB60223,00002CE-19-20120829

OMT223334
Switch Panel—Cab
T216978-UN-04NOV05
Cab Machines
1 - Work Light Switch
2 - Travel Speed Control Switch
3 - Wiper and Washer Switch
4 - Travel Alarm Cancel Switch
5 - Upper Vent and Defrost Button
6 - Upper and Lower Vents and Defrost Button
7 - Lower Vent Button
8 - Air Conditioner ON/OFF Button
9 - Temperature Control—Lower Button
10 - Temperature Control—Raise Button
11 - Blower Speed Button
12 - Heater and Air Conditioner Power Button
1. Work Light Switch: Press the upper half of switch to

turn work lights ON. Press the lower half of switch to turn
work lights OFF.
2. Travel Speed Control Switch: Press the upper half of

switch (rabbit) to select the fast travel mode. As load
increases, travel speed decreases. Press the lower half of
switch (turtle) to select slow travel mode.
3. Wiper and Washer Switch: Push switch to operate

wiper continuously. Press and hold down switch to activate
washer.
NOTE: Make sure the upper front window is fully secure.

Wiper will not operate if window is not in proper position.
Switch Panel—Cab 82
OMT223334
4. Travel Alarm Cancel Switch: The travel alarm sounds

when a travel lever is operated and will continue as long as
the tracks are moving. When travel motion stops, the travel
alarm switch is reset. Press the travel alarm cancel switch
to shut alarm off.
5. Upper Vent and Defrost Button: Push button to direct

air flow to upper vents and upper front window.
6. Upper and Lower Vents and Defrost Button: Push

button to direct air flow to upper and lower vents and
upper front window.
7. Lower Vent Button: Push button to direct air flow to

lower vents.
8. Air Conditioner ON/OFF Button: Push button to turn

air conditioning ON. Indicator will light. Push button again
to turn air conditioning OFF. Heating and air conditioner
power button (12) must also be ON.
9. Temperature Control—Lower Button: Push button to

lower temperature.
10. Temperature Control—Raise Button: Push button to

raise temperature.
11. Blower Speed Buttons: Push upper button to increase

blower speed. Push lower button to decrease blower speed.
12. Heater and Air Conditioner Power Button: Push

button to turn power to heater ON or OFF. Indicator above
button will light when power is ON. Push button again to
turn heater OFF. To operate air conditioning, heater and air
conditioner power button and air conditioner ON/OFF
button (8) must be on.
MM61211,0000976-19-20051213
Switch Panel—Cab 83
OMT223334
T216979-UN-04NOV05
Canopy Machines
1. Work Light Switch: Press the upper half of switch to

turn work lights ON. Press the lower half of switch to turn
work lights OFF.
2. Travel Speed Control Switch: Press the upper half of

switch (rabbit) to select the fast travel mode. As load
increases, travel speed decreases. Press the lower half of
switch (turtle) to select slow travel mode.
3. Travel Alarm Cancel Switch: The travel alarm sounds

when a travel lever is operated and will continue as long as
the tracks are moving. When travel motion stops, the travel
alarm switch is reset. Press the travel alarm cancel switch
to shut alarm off.
MM61211,0000977-19-20051103
Switch Panel—Canopy 84
OMT223334
Pedals and Levers
T216986A-UN-07NOV05
1 - Left Control Lever
2 - Auxiliary Pedal—If Equipped
3 - Left Travel Lever
4 - Right Travel Lever
5 - Boom Swing Pedal
6 - Right Control Lever/Horn (located on top of lever)
7 - Blade Control Lever
8 - Pilot Control Shutoff Lever
MM61211,0000979-19-20051213
Pedals and Levers 85

OMT223334
T216987A-UN-07NOV05
Use the engine speed control lever (1) to adjust engine

speed.
Pull lever back to increase speed.
Push lever forward to decrease speed.
MM61211,000097A-19-20051104
Engine Speed Control Lever 86

OMT223334
Setting Trip Meters

NOTE: Trip meters are preset to 10,000 hours at the
factory.
Trip meters can be set to notify the operator that a certain

number of operation hours have passed. There are two
meters, TRIP 1 and TRIP 2, and each one is set
individually.
To Set Trip Meters
1.
T216988-UN-07NOV05
T205888-UN-07DEC04
T205889-UN-07DEC04
1 - DISPLAY SELECT Switch
2 - SET Switch
3 - TRIP 1 (trip meter 1)
4 - TRIP 2 (trip meter 2)
Turn key switch ON.
2. Press DISPLAY SELECT switch (1) to display

either trip meter 1 (3) or trip meter 2 (4).
3. Press SET switch (2) to select number of hours.
The available hour settings are:
Setting Trip Meters 87

OMT223334
♦ 50
♦ 100
♦ 150
♦ 200
♦ 250
♦ 300
♦ 400
♦ 500
♦ 750
♦ 1000
♦ 1250
♦ 1500
♦ 2000
♦ 2500
♦ 3000
4. Press DISPLAY SELECT switch (1) to set the trip

meter hours.
5. When set hours reach zero, the trip meter display
will flash. If trip meter is not reset at that time, the
trip meter hours will continue to display the
operation hours with a minus (-) sign until trip
meter is reset.
MM61211,000097B-19-20051213
To Set Trip Meters 88

OMT223334
Toolbox and Operator’s Manual

Compartment
T216989-UN-08NOV05
Canopy Machines
T217413-UN-08DEC05
1 - Tool Box—Canopy Machines
2 - Operator’s Manual Compartment
Store operator’s manual in compartment (2) behind the

seat.
MM61211,000097C-19-20051104
Toolbox and Operator’s Manual Compartment 89

OMT223334

IMPORTANT: Prevent possible damage to engine. If
indicator lights do not go out after starting engine,
IMMEDIATELY STOP THE ENGINE. Find and correct
the problem.
T216991-UN-08NOV05
1 - Engine Coolant Temperature Gauge
3 - Alternator Indicator
After the engine is started, the alternator indicator light (3)

and engine oil pressure indicator light (2) should go out. If
they do not, stop the engine immediately. Find and correct
the problem.
Engine coolant temperature gauge (1) should be in the

white zone.
MM61211,000097D-19-20060418
Checking Instruments After Starting 90

OMT223334
Using Booster Batteries—12-Volt

System
TS204-UN-15APR13
T204924-UN-07DEC04
1 - Machine Ground
Before boost starting, machine must be properly shut down

to prevent unexpected machine movement when engine
starts.
CAUTION: Prevent possible injury from exploding

battery. An explosive gas is produced while battery is in
use or being charged. Keep flames or sparks away from the
battery area. Make sure the battery is charged in a
well-ventilated area.
IMPORTANT: The machine electrical system is a 12-volt

negative (-) ground. Use only 12-volt booster batteries.
1. Connect one end of the positive cable to the

positive terminal of the machine battery and
connect the other end to the positive terminal of
the booster batteries.
2. Connect one end of the negative cable to the
negative terminal of the booster batteries. Connect
the other end of the negative cable to the machine
ground (1) as far away from the machine battery as
possible.
3. Start engine.
4. Immediately after starting engine disconnect end
of the negative cable from the machine. Then
disconnect the other end of the negative cable from
the negative terminal of the booster batteries.
5. Disconnect positive cable from booster batteries
and machine battery.
MM61211,000097E-19-20051213
Using Booster Batteries—12-Volt System 91

OMT223334
T216992-UN-08NOV05
Excavator Control Lever Pattern
T216993-UN-08NOV05
Backhoe Control Lever Pattern
T204931-UN-07DEC04
Boom, Arm, Bucket Movement
1 - Arm Out
2 - Arm In
3 - Swing Left
4 - Swing Right
5 - Boom Down
6 - Boom Up
7 - Bucket Load
8 - Bucket Dump
CAUTION: Never place any part of body beyond the

operator station to avoid serious crushing injury from
boom. Boom could lower if the control lever is
accidentally bumped or otherwise engaged. Immediately
Control Lever Pattern Operation 92

OMT223334
replace a missing or broken window (if equipped).
Never place any part of the body beyond the operator

station. Replace missing or broken windows (if equipped)
immediately.
CAUTION: Prevent injury from unexpected control

lever function. Be aware of the control lever pattern used
on the machine before operating.
A label showing each control lever pattern operation is

provided on the operator's right.
Check the pattern on the label and then carefully operate

the machine to verify that the selected pattern is correct.
(See Control Lever Pattern Conversion in this section.)
Control levers return to neutral when released. Functions

will stop and remain positioned. The parking brake for
swing and travel will also engage.
MM61211,000097F-19-20051213
Control Lever Pattern Operation 93

OMT223334
Boom-Swing Pedal
CAUTION: Avoid injury from unexpected machine

movement. Keep boom-swing pedal locked during travel
and when not in use.
T216995-UN-08NOV05
Unlocked Position
T216996-UN-08NOV05
Locked Position
T120779-UN-14APR99
1 - Boom-Swing Pedal
2 - Pedal Cover
3 - Swing Left
4 - Swing Right
1. Lift pedal cover (2) to unlock boom-swing pedal

(1).
2. Push on left side of pedal to swing left (3).
3. Push on right side of pedal to swing right (4).
4. Lower pedal cover to lock boom-swing pedal
when not in use.
MM61211,0000980-19-20051104
Boom-Swing Pedal 94
OMT223334
Positioning Auxiliary Line Selector

Valve
IMPORTANT: Prevent possible machine damage. Stop the
engine and move pilot control shutoff lever to locked
(rearward) position before moving the selector valve.
T216997-UN-08NOV05
T205137A-UN-10DEC04
1 - Selector Valve Plug
2 - OPEN/CLOSE (for double actuating cylinder

attachment)
3 - ON/OFF (for single actuating cylinder attachment)
1. Park machine on a level surface.

2. Lower attachments to the ground.
3. Stop engine.
4. Remove plug (1) to access selector valve. Selector
valve must be positioned according to the type of
attachment to be operated:
♦ Position 2: Operating a crusher or other

double actuating cylinder attachment
requiring two actions such as
OPEN/CLOSE operation.
♦ Position 3: Operating a breaker or other
single actuating cylinder attachment
requiring only ON/OFF operation.
MM61211,0000981-19-20051213
Positioning Auxiliary Line Selector Valve 95

OMT223334
T216998-UN-08NOV05
T205092-UN-01DEC04
1 - Blade Lever
2 - Blade Raise
3 - Blade Lower
Pull blade lever (1) rearward to raise blade (2).
Push blade lever forward to lower blade (3).
When the blade lever is released, it automatically returns to

neutral, keeping the blade in position until the lever is
moved again.
MM61211,0000982-19-20051104
Operating Backfill Blade 96

OMT223334
T121704-UN-08JUN99
1 - Upper Track Shoe Surface
Be careful not to operate the machine in water or mud

above the upper track shoe surface (1), causing the swing
bearing and rotary manifold to be submerged.

Upper Track Distance 485 mm 19 in.
Shoe Surface
(Operable Water
Depth)
If the swing bearing and rotary manifold are submerged,
remove cover from underneath center of machine. Remove
drain plug to drain water and mud.
Clean swing gear area. Install plug and cover. Grease

swing bearing and grease swing bearing gear. (See
Sections 3-6 and 3-7.)
MM61211,0000983-19-20051213
Operating in Water and Mud 97

OMT223334
Lifting Machine
T217418-UN-12DEC05
1 - Boom Eye
2 - Blade Eye

machine movement when lifting the machine. Check lifting
capacity of crane before lifting the excavator. Lift load
only as high as necessary.
Keep all people clear of raised load.
1. Swing the upperstructure so the blade is positioned

to the rear.
2. Fully retract the blade cylinder.
3. Fully extend the boom, arm, and bucket cylinders.
4. Position the boom straight ahead of the
upperstructure.
5. Turn key switch to OFF. Remove key from switch.
6. Pull the pilot control shut-off lever to the locked
position.
7. Attach cables to the eye plates, one on the boom
and two on the blade.
8. Slowly lift the machine.

Excavator Operating 2800 kg 6160 lb
Weight—Canopy
MM61211,0000984-19-20051104
Lifting Machine 98
OMT223334
T216999-UN-07NOV05
1 - Hour Meter
Check the hour meter (1) to determine when your machine

needs periodic maintenance.
Intervals on the periodic maintenance chart are for

operating in normal conditions. If you operate your
machine in difficult conditions, you should service it at
SHORTER INTERVALS.
MM61211,0000985-19-20060418
Check the Hour Meter Regularly 99

OMT223334

1.
T204972-UN-29NOV04
T204973-UN-29NOV04
1 - Release Button
2 - Maintenance Access Cover
3 - Wire
4 - Rod
5 - Rod Holder
6 - Bracket
Push button (1) to release maintenance access

cover (2) latch.
2. Lift cover slowly. Wire (3) will act as a stop.

3. CAUTION: Prevent injury from unexpected
component movement. Always engage rod (4) in
bracket (6) when working in maintenance
compartment.
Remove one end of rod (4) from rod holder (5) and
insert into bracket (6).
MM61211,0000986-19-20051104
Maintenance Access Cover 100

OMT223334

IMPORTANT: Avoid machine damage. Do not use
another method of tilting the operator station.
Avoid damaging the tilt mechanism or operator station.

Raise and lower the operator station slowly.
Tilting Operator Station
1. Park machine on level surface with pilot shut-off

lever in the locked position.
2. Close cab door, and windows, if equipped.
3.
T205418-UN-09DEC04
Tilting Position
Move boom directly in front of operator station

and retract all cylinders.
4.
T205611-UN-07DEC04
T205612-UN-07DEC04
Canopy Machines
T205613-UN-07DEC04
Cab Machines
Tilting the Operator Station 101

OMT223334
1 - Panel Cap Screw (2 used)
2 - Panel
3 - Operator Station Platform Cap Screw (2 used)
4 - Operator Station Mounting Cap Screw (3 used)
Loosen panel cap screws (1) and raise panel (2).

Tighten screws to hold panel in place.
5. IMPORTANT: Avoid damaging operator station

platform. Do not remove operator station platform
cap screws (3).
Remove three operator station mounting cap

screws (4) from rear of operator station.
6. IMPORTANT: Avoid potential machine damage.
Avoid contact between operator station and hoses,
swing casting, or boom while tilting the operator
station.
T217001A-UN-07NOV05
1 - Tilt Screw
2 - Disk
3 - Tilt Stop Decal
4 - Tilt Stop Line
Turn tilt screw (1) clockwise to raise operator

station. Stop rotating tilt screw when disk (2) is at
tilt stop line (4).
7. If access to the interior of the cab is required, open

cab door and ensure both door latches are engaged.
Lowering Operator Station
1. IMPORTANT: Prevent damage to the cab door.

Cab door must be closed before lowering operator
station.
Tilting Operator Station 102

OMT223334
Turn tilt screw counterclockwise slowly until

operator station is completely lowered. Do not
over-tighten tilt screw.
2. Install operator station mounting cap screws in rear
of operator station. Tighten to specification.

Operator Station Torque 90 N˙m 66 lb-ft
Tilt Cap Screws
3. Loosen panel cap screws and lower panel. Tighten
cap screws.
MM61211,0000987-19-20051104
Lowering Operator Station 103

OMT223334
Fuel Tank
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.
To avoid condensation, fill the fuel tank at the end of each

day’s operation.

Fuel Tank Capacity 40.0 L 10.6 gal
MM61211,0000988-19-20051107
Fuel Tank 104

OMT223334
T123610-UN-17AUG99
T205083-UN-29NOV04
1 - Air Cleaner Element
2 - Clamp (2 used)
3 - Cover
4 - Dust Unloader Valve
5 - Air Filter Restriction Indicator
1. Loosen clamps (2) to remove cover (3).

2. Remove element (1).
3. Tap element with the palm of your hand, NOT ON
A HARD SURFACE.
4. CAUTION: Prevent possible injury from flying
chips if compressed air is more than 210 kPa (2.1
bar) (30 psi). Reduce compressed air to less than
210 kPa (2.1 bar) (30 psi) when using for cleaning
purposes. Clear area of bystanders, guard against
flying chips, and wear personal protection
equipment including eye protection.
If this does not remove dust, use compressed air

under 210 kPa (2.1 bar) (30 psi).
5. Direct air up and down from inside to outside. Be
careful not to make a break in the element.
6. Install element.
7. Install cover with dust unloader valve (4) pointing
down and tighten clamps.
8. Check air filter restriction indicator (5). If
necessary, replace element. See Replacing Air
Cleaner Element. (Section 3-7.)
MM61211,000098A-19-20051107
Cleaning Air Cleaner Element 105

OMT223334

IMPORTANT: Prevent damage to hydraulic system
components. Do not run engine without oil in hydraulic
tank.
Avoid mixing different brands or types of oils. Oil

manufacturers engineer their oils to meet certain
performance.
This excavator is factory filled with 46HN extended life

zinc-free hydraulic oil. Avoid servicing this excavator with
products that do not meet this specification. If oils have
been mixed or if alternate service oils are desired, the
complete hydraulic system needs to be totally flushed by
an authorized dealer.
1.
T205418-UN-09DEC04
Park machine on a level surface and position

machine with cylinders fully retracted.
2.
T204977-UN-29NOV04
Oil Sight Gauge
1 - Hydraulic Oil Sight Gauge
Stop engine.
3. Check oil level on hydraulic oil sight gauge (1) on

hydraulic tank. Oil must be between marks on
window.
If necessary, add oil.

4. To add oil: Open maintenance access cover.
5. CAUTION: Avoid injury. High-pressure
release of oil from pressurized system can cause
Checking Hydraulic Oil Tank Level 106

OMT223334
serious burns or penetrating injury. Relieve

pressure by SLOWLY loosening cap (2).
T204980-UN-30NOV04
Hydraulic Oil Filler Cap
2 - Hydraulic Oil Filler Cap
Slowly turn cap (2) counterclockwise a few

degrees to relieve pressure. Remove cap.
6. Add oil. See Hydraulic Oil. (See Section 3-1.)

7. Install filler cap.
MM61211,000098B-19-20090106
Checking Hydraulic Oil Tank Level 107

OMT223334
Checking Track Sag—Steel Track—If

Equipped
T204987-UN-30NOV04
T204988-UN-30NOV04
1 - Boom-to-Arm Angle
2 - Track Frame-to-Track Shoe Distance
1. Rotate upperstructure 90° and lower bucket to

raise track off ground.
2. Keep the angle (1) between boom and arm
90—110° and position the bucket’s round side on
the ground.
unexpected machine movement. Place blocks
under machine frame to support machine while
measuring track sag.
Place blocks under machine frame to support

machine.
4. Rotate track forward two full rotations and then in
reverse two full rotations.
5. Stop engine.
6. Measure distance (2) at middle track roller from
bottom of track frame to top surface of track shoe.

Track Sag 120—140 mm
4.7—5.5 in.
7. If not to specification, adjust track sag. See
Adjusting Track Sag.
8. Repeat check on other side of machine.
MM61211,000098C-19-20051107
Checking Track Sag—Steel Track—If Equipped 108

OMT223334
T205002-UN-30NOV04
One Point
T205003-UN-30NOV04
One Point
T205004-UN-30NOV04
One Point
T205006-UN-30NOV04
Two Points
T205007-UN-30NOV04
Two Points
T205008-UN-30NOV04
One Point
Grease Front Joint Pins 109

OMT223334
T205009-UN-30NOV04
One Point
Add grease until grease escapes from joints. Grease every

10 hours when working in mud and water. (See Section
3-1.)
MM61211,000098D-19-20051107
Grease Front Joint Pins 110

OMT223334
Inspect Fan Belt, Check and Adjust

Tension
1.
T217426A-UN-09DEC05
T205324-UN-09DEC04
T205323-UN-09DEC04
1 - Fan Pulley
2 - Alternator
3 - Fan Belt Deflection
4 - Adjustment Cap Screw (3 used)
Check belt regularly for wear. Replace if

necessary.
2. Check belt tension with belt tension gauge at

midway between alternator (2) and fan pulley (1).

Belt Deflection 7—9 mm at 98 N
0.27—0.35 in. at
22 lb-ft
3. If deflection is not within specifications, loosen
cap screws (4) for adjusting strap.
4. Move alternator (2) until tension is correct.
5. Tighten cap screws.
MM61211,000098E-19-20051107
Inspect Fan Belt, Check and Adjust Tension 111

OMT223334
CAUTION: High-pressure release of oil from

pressurized system can cause serious burns or penetrating
injury. The hydraulic tank is pressurized. Slowly loosen
cap to release pressure.
1.
T205034-UN-30NOV04
1 - Hydraulic Tank Cap
Slowly loosen cap (1) to release pressure.
2.
T217005A-UN-07NOV05
2 - Hydraulic Sump Drain Plug
Loosen drain plug (2) for several seconds to drain

water and sediment into a container. Do not
remove plug completely. Dispose of waste
properly.
3. Tighten drain plug.
MM61211,000098F-19-20060418
Draining Hydraulic Oil Tank Sump 112

OMT223334
T123610-UN-17AUG99
T205083-UN-29NOV04
1 - Air Cleaner Element
2 - Clamp (2 used)
3 - Cover
4 - Dust Unloader Valve
5 - Air Filter Restriction Indicator
1. Loosen clamps (2) to remove cover (3).

2. Remove element (1).
3. Install new element.
4. Install cover with dust unloader valve (4) pointing
down and tighten clamps.
5. Check air filter restriction indicator (5).
MM61211,0000991-19-20051107
Replacing Air Cleaner Element 113

OMT223334

1.
T121260-UN-22APR99
Two Places
1 - Fill Plug
2 - Check Plug
3 - Drain Plug
Park the machine on level ground, rotating travel

gearbox until positioned as shown.
2. Stop engine.
3. CAUTION: High-pressure release of oil from
pressurized system can cause serious burns. Wait
for travel gearbox oil to cool. Keep body and face
away from check plug. Gradually loosen fill plug
to release pressure.
After travel gearbox has cooled, slowly loosen fill

plug (1) to release pressure.
4. Remove drain plug (3). Allow oil to drain into a
container. Dispose of waste oil properly. Install
plug.
5. Remove oil fill plug.
6. Remove check plug (2).
7. Add oil to fill plug hole until oil flows out of oil
level check plug hole. See Hydraulic Oil. (See
Section 3-1.)

Travel Gearbox Oil Capacity 0.6 L 0.63 qt
(each)
8. Install plugs.
9. Repeat steps 4—8 for other travel gearbox.
MM61211,0000992-19-20090106
Changing Travel Gearbox Oil 114

OMT223334
T205034-UN-30NOV04
Hydraulic Tank Cap
T205033-UN-30NOV04
T205032-UN-30NOV04
2 - Pilot Filter Access Panel
3 - Screw (3 used)
1. Open maintenance access cover.

pressurized system can cause serious burns or
penetrating injury. The hydraulic tank is
pressurized. Slowly loosen cap to release pressure.
Slowly loosen hydraulic tank cap (1) to release

pressure.
3. NOTE: Pilot filter access panel (2) is under the left
rear of machine.
Remove screws (3) from pilot filter access panel.

4.
T121925-UN-22JUN99
1 - Filter Case
2 - Filter Element
Replacing Pilot System Oil Filter 115

OMT223334
3 - O-Ring
4 - Filter Head
Turn filter case (1) counterclockwise to remove

from filter head (4).
5. Pull down on filter element (2) while moving it

back and forth to remove.
6. Remove and discard O-ring (3).
7. Apply a thin film of clean oil to new O-ring and
install in filter head.
8. Install new filter element by moving it back and
forth while pushing it upward.
9. Install filter case.
10. Install hydraulic oil cap.
11. IMPORTANT: Avoid hydraulic pump damage.
Hydraulic system must be bled whenever the pilot
oil filter is changed.
Bleed hydraulic system. See Bleeding Hydraulic

System. (Section 4-1.)
12. Install pilot filter access cover.
MM61211,0000993-19-20060418
Replacing Pilot System Oil Filter 116

OMT223334
T205087-UN-01DEC04
1 - Radiator Cap
Drain and flush cooling system using commercial products.
1. Check coolant hoses for cracks and leaks. Replace

if necessary.
2. Tighten clamps.
3. Check radiator and oil cooler for dirt, grease,
leaks, and loose or broken mountings. Clean
radiator and oil cooler fins.
4. CAUTION: Prevent possible injury from hot
spraying water. DO NOT remove radiator filler
cap unless engine is cool. Then turn cap slowly to
the stop.
Slowly turn radiator cap (1) to release pressure.

Remove cap.
5.
T205089-UN-01DEC04
Drain Valve
1 - Radiator Drain Valve
Turn radiator drain valve (1) counterclockwise to

open valve. Allow coolant to drain into a
container. Dispose of waste coolant properly.
6. Close drain valves.

7. IMPORTANT: Avoid mixing different brands or
types of coolant. Coolant manufacturers engineer
their coolants to meet certain specifications and
performance requirements. Mixing different
coolant types can degrade coolant and machine
performance.
Fill with proper coolant. (See Section 3-1.)

OMT223334

(S.N. —254999)
(S.N. 255000— )
MM61211,0000994-19-20081222

OMT223334
Changing Hydraulic Tank Oil and

Cleaning Suction Screen
NOTE: Change original Hitachi factory fill hydraulic oil
after first 2000 hours. Change every 1000 hours if using
any of the other recommended hydraulic oils.
IMPORTANT: Prevent damage to hydraulic system

components. DO NOT run engine without oil in the tank.
Avoid mixing different brands or types of oils. Oil

manufacturers engineer their oils to meet certain
performance.

1.
T205418-UN-09DEC04
Park machine on surface with arm cylinder fully

retracted and bucket cylinder fully extended.
Lower bucket and blade to ground.
2. Stop engine.
3. Remove cover above hydraulic oil tank.
T205034-UN-30NOV04
Hydraulic Tank Cap
Changing Hydraulic Tank Oil and Cleaning Suction Screen 119

OMT223334
Slowly loosen hydraulic tank cap (1) to release

pressure. Remove cap.
5. Drain oil using a suction pump.

6.
T217005A-UN-07NOV05
Drain Plug (S.N. —254999)
TX1052954-UN-11DEC08
Drain Plug (S.N. 255000— )
2 - Drain Plug
Remove or loosen drain plug (2) on bottom of

hydraulic oil tank. Allow remaining oil to drain
into a container. Dispose of waste oil properly.
7. Tighten drain plug (S.N. 255000— ).

8.
T204999-UN-29NOV04
Exploded View
1 - Cover
2 - Rod Support
3 - Rod

OMT223334
4 - Suction Filter
Remove cover (1) with O-ring.
9. Remove suction filter (4) with rod (3).

10. Clean inside of tank and suction filter.
11. Replace hydraulic oil tank filter. (See Section 3-7.)
12. Install suction filter with rod.
13. Install drain plug (S.N. —254999).
14. Install cover so rod is securely inserted into
support (2) on cover.
15. Secure cover with screws.
16.
T204977-UN-29NOV04
1 - Sight Gauge
Add oil until it is between marks on sight gauge

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

Hydraulic Tank Oil Capacity 35 L 9.2 gal.
(S.N. —254999)
Hydraulic Tank Oil Capacity 32 L 8.5 gal.
(S.N. 255000— )

Hydraulic system must be bled whenever the
hydraulic oil is changed.
Bleed hydraulic system. See Bleeding Hydraulic

MM61211,0000995-19-20081222

OMT223334
Cleaning Heating and Air Conditioning

Filter Screens—If Equipped
1.
T205901A-UN-09DEC04
T217013A-UN-08NOV05
T217012A-UN-08NOV05
1 - Floor Mat
2 - Floor Panel Cap Screw (3 used)
3 - Air Conditioning Filter Screen (3 used)
Remove floor mat (1).
2. Remove floor panel cap screws (2).

3. Remove floor panel assembly.
4. Remove three filter screens (3). Wipe off or rinse
with warm water.
5. Install filter screens.
6. Install floor panel assembly.
7. Install floor panel cap screws.
8. Install floor mat.
MM61211,0000998-19-20051108
Cleaning Heating and Air Conditioning Filter Screens—If Equipped 122

OMT223334
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 doing a walk around inspection
and performing specific checks from the operators seat.
Should you experience a problem with your 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 yourself which will
reduce the down time of your machine. Use the table of
contents to help find adjustment procedures.
The information you provide after completing the

operational checkout will allow you or your authorized
dealer to pinpoint a specific test or repair needed to restore
the machine to design specifications.
A location will be required which is level and has adequate

space to complete the checks. No tools or equipment are
needed to perform the checkout.
Complete the necessary visual checks (oil levels, oil

condition, external leaks, loose hardware, linkage, wiring,
etc.) prior to doing the checkout. The machine must be at
operating temperature for many of the checks.
Start at the top of the left column and read completely

down column before performing check. Follow this
sequence from left to right. In the far right column, if no
problem is found, you will be instructed to go to next
check. If a problem is indicated, you will be referred to
either a section in this manual or to your authorized dealer
for repair.
Operator Station Checks—Key Switch

ON, Engine OFF
1 Monitor and Gauge Circuit Check
Action:
T216977-UN-04NOV05
Operational Checkout 123

OMT223334
2 - Fuel Gauge
3 - Monitor Display
4 - Set Switch
5 - Display Select Switch
7 - Engine Pre-Heat Indicator
NOTE: Monitor alarm is not checked during this

procedure.
If engine coolant temperature is below 20°C (68°F), the

first segment will flash. Run engine a few minutes to warm
coolant before check.
Engine OFF.
Key switch ON.
ENGLISH Do engine coolant temperature gauge (1) and

fuel gauge (2) segments come on?
ENGLISH Do all monitor lights come on, and after 2—3

seconds, only the alternator indicator and engine oil
pressure indicator light remain on?
Result:
YES: Go to next check.
NO: Check fuse F9.
Go to your authorized dealer.
2 Engine Pre-Heat Circuit Check
Action:
Operator Station Checks—Key SwitchON, Engine OFF 124

OMT223334
T204921-UN-03DEC04
T102341-UN-29AUG96
1 - HEAT
2 - OFF
3 - ON
4 - START
Turn and hold the key switch in HEAT position (1).
ENGLISH Does the engine pre-heat indicator light come

ON and then go OFF?
ENGLISH Does the engine pre-heat indicator go OFF

after 15 seconds?
Result:
NO: Check fuse F9.
3 Travel Lever and Pedal Neutral Check
Action:
T121794-UN-16JUN99
Engine OFF.
Push each travel lever forward, then release.
Pull each travel lever rearward, then release.
ENGLISH Does each lever have equal effort to operate

forward and reverse?

OMT223334
ENGLISH Does each lever return to neutral at the same

time when released?
Result:
NO: Go to your authorized dealer.
4 Light Circuit Check
Action:
T216979-UN-04NOV05
Canopy Machine Shown
NOTE: All accessories are powered from the fuse block. If

any accessories do not function, check fuses in fuse block.
Turn key switch ON.
Push work light switch (1) to turn on work lights.
ENGLISH Are the work lights on the boom and left front
corner of upperstructure ON?
Push work light switch to turn off the work lights.
ENGLISH Do all the lights go OFF?
Result:
NO: Check fuse F5.
5 Wiper Circuit Check—Cab Only
Action:

OMT223334
T217016-UN-08NOV05
NOTE: Ensure upper front window is fully down and

latched in place. Wiper interlock switch will prevent
operation if window is not in place.
Key switch ON.
Push wiper switch (1) to turn on the wiper.
ENGLISH Does wiper operate continuously?
Push wiper switch to turn off wiper.
ENGLISH Does wiper arm stop in park position at left side

of window?
Result:
NO: Check fuse F6.
6 Washer Circuit Check—Cab Only
Action:
T217016-UN-08NOV05
NOTE: Ensure upper front window is fully down and

latched in place. Wiper interlock switch will prevent
operation if window is not in place.
Key switch ON.
Push wiper and washer switch (1) to activate washer

motor.

OMT223334
ENGLISH Does washer motor operate?
Push wiper and washer switch to turn on the wiper and

activate the washer.
ENGLISH Do the washer motor and the wiper operate?
Result:
YES: Go to next check
NO: Check fuse F6.
7 Horn Circuit Check
Action:
Key switch OFF.
Push horn button on top of right control lever.
ENGLISH Does horn sound?
Result:
NO: Check fuse F1.
Operational Checks—Engine ON
1 Monitor and Gauge Circuit Check
Action:
T216977-UN-04NOV05
2 - Fuel Gauge
3 - Monitor Display
Operational Checks—Engine ON 128

OMT223334
4 - Set Switch
5 - Display Select Switch
7 - Engine Pre-Heat Indicator
Start engine.
ENGLISH Do alternator voltage (8) and engine oil

pressure (11) indicators go OFF after engine starts?
ENGLISH Do all monitor indicators remain OFF after

engine starts?
IMPORTANT: Stop the engine if alternator or engine oil

pressure indicators do not go OFF, or a monitor indicator
comes ON after engine starts.

(68°F), the first segment will flash.
ENGLISH Are coolant temperature gauge (1) segments in

normal operating zone after a few minutes?
ENGLISH Does fuel gauge (2) indicate fuel level?
Result:
NO: Check fluid levels.
Check fuses F11 and F9.
See Inspect Fan Belt, Check and Adjust Tension to adjust

belt tension. (Section 3-5.)
2 Heater and Air Conditioning Circuit Check—If

Equipped

OMT223334
Action:
T217015-UN-09NOV05
1 - Upper Vent and Defrost Button
2 - Upper and Lower Vents and Defrost Button
3 - Lower Vent Button
4 - Blower Speed—Raise Button
5 - Heater and Air Conditioning ON Button
6 - Blower Speed—Lower Button
7 - Temperature Control—Raise Button
8 - Temperature Control—Lower Button
9 - Air Conditioning ON/OFF Button
Engine running and at normal operating temperature.
Push heater and air conditioning ON button (5). Indicator

next to button will light.
Push blower speed—raise button (4) to all three speeds.
ENGLISH Does blower motor have three speeds?
Result:
NO: Check fuse F7.
Action:
Push blower speed—raise button (4) to highest speed.
Push upper vent and defrost button (1).
ENGLISH Does air flow through upper vents?
Push upper and lower vents and defrost button (2).
ENGLISH Does air flow through upper and lower vents?

OMT223334
Push lower vent button (3).
ENGLISH Does air flow through lower vent?
Result:
NO: Check fuse F7.
Action:
With heater and air conditioning ON button on (5), push
temperature control—raise button (7) to warmest position.
ENGLISH Does warm air flow from vents?
Turn air conditioning ON/OFF button (9) on. Indicator

next to button will light.
Move temperature control—lower button (8) to coolest

position.
ENGLISH Does cool air flow from vents?
Result:
NO: Check fuses F2 and F7.
3 Pilot Control Shut-Off Switch Check
Action:
T205926-UN-10DEC04

machine movement. Machine will move during this check.
Make sure area is clear and large enough to operate all
machine functions. Keep bystanders clear of the area.
Run engine at slow idle.
Pilot control shut-off lever in LOCKED (rearward)

position (1).
Actuate all dig and travel function controls.

OMT223334
ENGLISH Do any dig or travel functions operate?
Result:
YES: Go to your authorized dealer.
NO: Go to next step in this check.
Action:
T205927-UN-10DEC04
Move pilot control shut-off lever to UNLOCKED position

(forward) (1).
Actuate all dig and travel functions.
ENGLISH Do all functions operate?
Result:
4 Travel Alarm Circuit Check
Action:

Engine running.
Pilot control shut-off lever in UNLOCKED position

(forward).
Push travel levers or pedals forward for forward travel.
ENGLISH Does travel alarm sound?
Pull levers or push travel pedals rearward for reverse

travel.
ENGLISH Does travel alarm sound?
Pilot control shut-off lever in UNLOCKED position

(forward).
Push travel levers or pedals forward for forward travel.

OMT223334
Press and release the travel alarm cancel switch.
ENGLISH Does the travel alarm stop?
Result:
NO: Check fuses F8 and F9.
5 Hydraulic Oil Tank Pressurization Check
Action:
Engine running.
Raise boom to full height, then lower boom to ground.
Engine OFF.
Slowly loosen cap on hydraulic oil tank.
ENGLISH Is air heard escaping?
IMPORTANT: Avoid pump damage. The pressurized

hydraulic oil tank creates pressure at the inlet to the
hydraulic pumps. If filler cap does not seal, hydraulic
pumps could cavitate and be damaged.
Result:
NO: Replace cap.
6 Pilot Controller Pattern Check—SAE Backhoe

Pattern
Action:
T205929-19-15DEC04
T205091-UN-01DEC04

OMT223334
1 - Pilot Control Pattern Lever Selector
2 - Excavator Position
3 - Backhoe Position
4 - Excavator Pattern
5 - Backhoe Pattern

Operate machine in clear area.
Move pilot control pattern lever selector (1) to backhoe

position (3).
Push pilot shut-off lever to UNLOCKED position. Slowly

move control levers to all backhoe positions (5) on decal.
ENGLISH Do bucket, boom, arm, and swing move as

shown on decals?
Result:
NO: Check pilot controller pattern conversion valve

position.
7 Pilot Controller Pattern Check—ISO Excavator

Pattern
Action:
T205929-19-15DEC04
T205091-UN-01DEC04

OMT223334
1 - Pilot Control Pattern Lever Selector
4 - Excavator Pattern
5 - Backhoe Pattern

Operate machine in clear area.
Move pilot control pattern lever selector (1) to excavator

position (2).
Push pilot shut-off lever to UNLOCKED position. Slowly

move control levers to all excavator positions (4) on decal.
ENGLISH Do bucket, boom, arm, and swing move as

shown on decals?
Result:
NO: Check pilot controller pattern conversion valve

position.
8 Swing Dynamic Braking Check
Action:
T6479AY-UN-19OCT88

Position upperstructure with boom in front.
Extend arm and curl the bucket. Lower boom so bucket

OMT223334
pivot pin is at the same level as boom-to-main frame pin.
Run engine at fast idle.
Actuate swing control valve to full stroke. Swing around

90 degrees (1/4 turn) and then release lever.
ENGLISH Does upperstructure stop within 45 degrees (1/8

turn) after releasing lever?
Repeat procedure in opposite direction.
Result:
9 Dig Function Drift Check
Action:
T6290AF-UN-19OCT88

Fill bucket with dirt. Position bucket at maximum reach

with bucket 50 mm (2 in.) above ground.
Observe bucket for 1 minute.
ENGLISH Does bucket drift down to ground within 1

minute?
Result:
NO: Go to next check.
10 Travel System Tracking Check
Action:

OMT223334
T216979-UN-04NOV05

Engine at fast idle.
Press upper half (rabbit) of travel speed control switch (2).
TX1120481-UN-17AUG12
Tracking Check
5 - Distance of Mistrack
6 - Acceleration and Deceleration Zone (approximately):

3—5 m (10—16 ft.)
7 - Test Line (distance): 20 m (66 ft.)
8 - Track Print
Operate machine at full travel forward speed on a flat and

level surface approximately 30 m (99 ft.).
NOTE: When machine mistracks right, hydraulic pump 1

circuit oil flow may be less than specification. When
machine mistracks left, hydraulic pump 2 circuit oil flow
may be less than specification.
Observe direction of mistrack.
Create a straight test line 20 m (66 ft.) (7) long between

OMT223334
two points on track print (8).
Measure and record greatest distance of mistrack (5)

between inside edge of track print and test line.
Repeat procedure in reverse travel.
ENGLISH Does machine mistrack excessively?
Result:
11 Travel System Tracking Checks While Operating a

Dig Function
Action:
T216979-UN-04NOV05

Engine at fast idle.
Press upper half (rabbit) of travel speed control switch (2).
Travel machine at full speed forward on a flat and level

area.
NOTE: Machine will slow down during this test.
After machine is moving, slowly move the arm control

lever from neutral to full actuation to extend the arm.
ENGLISH Does machine mistrack excessively when the

arm is extended?

OMT223334
Result:
12 Travel Speed Change Check
Action:
T216979-UN-04NOV05

Run engine at fast idle.
Ensure travel speed control switch (2) is in slow speed

(turtle).
Actuate travel function to full speed forward.
Push travel speed control switch (2) to fast speed (rabbit).
ENGLISH Does machine travel speed increase?
Result:
13 Blade Function Check
Action:


OMT223334
Pull blade control lever rearward.
ENGLISH Does blade rise?
Release lever.
ENGLISH Does lever return to neutral and the blade stop?
Push lever forward.
ENGLISH Does blade lower?
Release lever.
ENGLISH Does lever return to neutral and the blade stop?
Result:
YES: Operational checkout complete.
MM61211,0000999-19-20120912

OMT223334
T205429A-UN-29NOV04
Top of Engine Shown
1 - Engine Serial Number
Engine Serial Number (1)
MM61211,000099A-19-20051108
Record Engine Serial Number 141

OMT223334

Yanmar 3TNV88 Type 4 Cycle Water
Cooled
MM61211,000099B-19-20051214
Engine Specifications 142

OMT223334

Fuel Tank Capacity 40 L 10.6 gal
(S.N. —254999)
(S.N. 255000— )
Engine Oil Capacity, 7.2 L 7.6 qt
Including Filter
Change
Hydraulic Tank Oil Capacity 35 L 9.2 gal
(S.N. —254999)
Hydraulic Tank Oil Capacity 32 L 8.5 gal
(S.N. 255000— )
Travel Gearbox Oil Capacity 0.6 L 0.63 qt
(each)
MM61211,000099C-19-20081222
Drain and Refill Capacities 143

OMT223334
T205725-UN-07DEC04
1 - Overall Upperstructure Width
2 - Machine Height
3 - Rear End Swing Radius
4 - Minimum Ground Clearance
5 - Counterweight Clearance
6 - Engine Cover Height
7 - Undercarriage Length
8 - Undercarriage Width
9 - Sprocket Center to Idler Center
10 - Track Shoe Width
NOTE: Specifications and design are subject to change

without notice. Wherever applicable, specifications are in
accordance with PCSA and SAE standards. Except where
otherwise noted, these specifications are based on a
machine equipped with 300 mm (12 in.) shoes, 1.17 m (3 ft
10 in.) arm, 0.09 m3 (0.12 yd3) bucket, full fuel tank 79 kg
(175 lb) operator standard counterweight 292 kg (644 lb),
and standard equipment.

1—Overall Distance 1,550 mm 5 ft
Upperstructure 1 in.
Width
2—Machine Transport 2,460 mm 8 ft
Height Height—Canopy 1 in.
3—Rear End Distance—Standard 775 mm 2 ft 7
Swing Radius Counterweight in.
Distance
Machine Specifications 144

OMT223334
4—Minimum 320 mm 1 ft 6
Ground Clearance in.
5—Counterweight Distance 560 mm 1 ft
Clearance 10 in.
6— Engine Cover Height 1420 mm 4 ft
8 in.
7—Undercarriage Length 1950 mm 6 ft
5 in.
8—Undercarriage Width 1550 mm 5 ft
1 in.
9—Sprocket Distance 1490 mm 4 ft
Center to Idler 11 in.
Center
10—Track Shoe Width 300 mm 12 in.

Machine with Operating 2800 kg 6,160 lb
Standard Arm Weight—Canopy
and Standard
Counterweight
Machine with Operating 3,010 kg 6620 lb
Long Arm and Weight—Canopy
Additional
Counterweight
MM61211,000099D-19-20051215
Machine Specifications 145

OMT223334
Working Ranges
T121258-UN-22APR99
1 - Maximum Digging Reach
2 - Maximum Digging Depth
3 - Maximum Cutting Height
4 - Maximum Dumping Height
5 - Transport Height
6 - Overall Transport Length
7 - Minimum Swing Radius
8 - Blade Bottom Highest Position (above ground level)
9 - Blade Bottom Lowest Position (below ground level)
10 - Boom Offset (left)
11 - Boom Offset (right)

1—Maximum Digging Distance—Canopy 4670 mm 15
Reach or Cab ft 4 in.
2—Maximum Digging Canopy or Cab 2590 mm 8 ft
Depth 6 in.
3—Maximum Cutting Canopy 5760 mm 18
Height ft 11 in.
4—Maximum Canopy 4080 mm 13
Dumping Height ft 5 in.
5—Machine—Rubber Transport 2460 mm 8 ft
Track Height—Canopy 1 in.
6—Machine Transport 4200 mm 13
Length—Canopy ft 9 in.
or Cab
Working Ranges 146

OMT223334
7—Minimum Swing Radius—Canopy 1960 mm 6 ft

5 in.
8—Blade Bottom Distance 360 mm 1 ft
Highest Position 2 in.
(above ground level)
9—Blade Bottom Distance 315 mm 1 ft
Lowest Position
(below ground level)
10—Offset Distance Maximum 640 mm 2 ft
(right) Distance—Canopy 1 in.
11—Offset Distance Maximum Distance 705 mm 2 ft
(left) 4 in.
MM61211,000099E-19-20090106
Working Ranges 147

OMT223334
T217139-UN-16NOV05
T217140-UN-16NOV05
1 - Boom Up Circuit Relief Valve
2 - Adjusting Screw
3 - Nut
When the engine stops during operation, the boom cannot

be lowered using the pilot controller because there is no
pilot pressure to move the boom valve spool.
1. Remove cover for access to boom up circuit relief

valve (1).
2. Make an alignment mark on the adjusting screw
(2), nut (3), and relief valve body.
3. Loosen nut using a 14 mm wrench.
unexpected machine movement. Clear all persons
from the area before lowering the boom.
Loosening the boom up circuit relief valve

adjusting screw more than two turns may result in
the release of the pilot spring and oil from the
circuit relief valve.
Slowly turn the adjusting screw out approximately

1-1/2 turns to lower the boom.
5. After bucket is on the ground, turn the adjusting
screw in to its original setting. Hold the screw and
tighten the nut.
MM61211,00009F2-19-20060418
Lowering Boom With Engine Stopped 148

OMT223334

Special work situations or machine attachments may create
an environment where special additional guarding is
needed to protect the operator.
Special screens or guarding should be installed to prevent

machine damage. Contact your authorized dealer for
information on devices intended to provide protection in
special work situations.
MM61211,0000A54-19-20070125
Add Cab Guarding for Special Uses 149

OMT223334
Safety and Operator Convenience

Features
T217409-UN-07DEC05
Canopy Model Shown
Please remember that the operator is the key to

preventing accidents.
1. ROPS/TOPS/FOPS. A protective structure protects the

operator of the compact excavator.
2. Seat belt. A seat belt is provided for the operator.
3. Pilot Control Shutoff. A lever near the cab exit reminds

the operator to deactivate hydraulic functions before
leaving the machine and prevents engine startup unless
lever is in locked position.
4. Handholds. Large, conveniently placed handholds make

it easy to enter or exit the operator's station or service area.
5. Swing Brake. Swing brake is engaged when the pilot

control shutoff lever is raised. Helps secure upperstructure
when transporting the machine.
6. Travel Alarm. Alerts bystanders of machine movement

when traveling.
7. Fan Guard. A fan guard inside the engine compartment

helps prevent contact with the fan blades.
8. Horn. Standard horn is useful when driving or signaling

co-workers.
9. Cab with Heater/Defroster/Air Conditioner.

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.
MM61211,0000A56-19-20051214
Safety and Operator Convenience Features 150

OMT223334
T134986-UN-31OCT00
T133650-UN-27SEP00
T133549-UN-24AUG00
Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all
underground utilities before you dig.
Prepare work site properly. Avoid operating near

structures or objects that could fall onto the machine. Clear
away debris that could move unexpectedly if run over.
Avoid boom or arm contact with overhead obstacles or

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

away from raised booms, attachments, and unsupported
loads. Avoid swinging or raising booms, attachments, or
loads over or near personnel. 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. When working close to an excavation,
position travel motors away from the hole.
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 seat belt.
MM61211,0000A57-19-20090107
Avoid Work Site Hazards 151

OMT223334
T204926-UN-07DEC04
T204927-UN-07DEC04
1 - Forward Travel
2 - Neutral Position
3 - Reverse Travel

machine movement. Keep bystanders clear of machine
when traveling.
The instructions below apply when the upperstructure is

facing forward and travel motors are to the rear of the
machine. If the upperstructure is rotated to the rear and the
travel motors are to the front of the machine, the machine
moves OPPOSITE to the direction described.
NOTE: Unfold foot pedals before using.
FORWARD TRAVEL: Push down on front (1) of both

pedals or push both levers forward (1).
REVERSE TRAVEL: Push down on rear (3) of both

pedals or pull both levers rearward (3).
NEUTRAL POSITION (2): Travel brakes will

automatically stop and hold the machine.
RIGHT TURN: Push down on front of left pedal or push

left lever forward.
LEFT TURN: Push down on front of right pedal or push

right lever forward.
SHORT TURN (COUNTER-ROTATE): Push down the

front of one pedal and the rear of the other or push one
lever forward and pull the other rearward.
Travel Pedals and Levers 152

OMT223334
CAUTION: Prevent possible injury from machine

tipping. Operate control pedals or levers slowly when
traveling down a slope.
TRAVELING DOWN A SLOPE: Operate control pedals

or levers slowly when traveling down a slope.
COLD WEATHER OPERATION: Travel pedal and lever

dampers are provided for smooth control. In extremely
cold weather, pedal or lever effort will increase. Operate
pedals or levers several times with pilot control shutoff
lever in locked position.
MM61211,0000A59-19-20051213
Travel Pedals and Levers 153

OMT223334
Travel Gearbox Oil
TS1653-UN-14MAR96

The following oils are preferred:
• John Deere GL-5 GEAR LUBRICANT

• John Deere EXTREME-GARD
Other oils may be used if they meet API Service

Classification GL-5.
EXTREME-GARD is a
trademark of Deere &
Company. MM61211,0000A5C-19-20051207
Travel Gearbox Oil 154

OMT223334
T121880-UN-18JUN99
1. Rotate upperstructure so front of upperstructure is

over travel motors (180°).
2. Lower the bucket and blade to raise both tracks off
ground.
3. Raise pilot control shut-off lever to locked
position.

machine.
5. Lower pilot control shut-off lever to unlocked
position.
6. Rotate track so track joint is positioned at the
upper center of the track.
7. Stop engine.
8.
T121709-UN-10JUN99
T217423-UN-09DEC05
Track Sag Distance
1 - Track Sag Distance
Measure distance (1) from bottom of center roller

to inner ridge of rubber track.

Track Sag 10—15 mm
0.4—0.6 in.
Checking Track Sag—Rubber Track 155

OMT223334
9. If not to specification, adjust track sag. See

Adjusting Track Sag.
10. Repeat check on other side of machine.
MM61211,0000A5D-19-20051207
Checking Track Sag—Rubber Track 156

OMT223334

To maximize undercarriage life, keep track sag within
specification. Tracks may require adjustment several times
during a working day due to changing soil type and
moisture content.
Adjust tracks in the actual operating conditions.
TIGHT TRACK: Packing causes a tight track. If material

packs in the undercarriage, adjust tracks with the material
packed in the components.
While the track spring will recoil and the machine can
continue to operate with a tight track, continued operation
will result in excessive pin and bushing wear, sprocket
popping, tooth tip wear, and excessive loads on the entire
undercarriage and travel drive system.
Machine productivity and fuel consumption are also

adversely affected because increased horsepower is needed
to move the machine.
LOOSE TRACK: A loose track has more side to side

motion, increasing side wear on the links, rollers and front
idler. An excessively loose track will slap at high ground
speeds, resulting in high impact loads on the sprocket
teeth, bushings, and carrier rollers.
MM61211,0000A5E-19-20051207
Track Sag General Information 157

OMT223334

1.
T121259-UN-22APR99
1 - Fill Plug
2 - Check Plug
Park the machine on level ground rotating travel

gearbox until positioned as shown.
2. Lower bucket and blade to the ground.

3. Run engine at slow idle speed without load for 5
minutes.
5. Pull pilot control shut-off lever to locked position.
6. CAUTION: High pressure release of oils from
pressurized system can cause serious burns. Wait
for travel gearbox oil to cool. Keep body and face
away from check plug. Gradually loosen check
plug to release air to relieve pressure.
After travel gearbox has cooled, slowly loosen fill

plug (1) to release air to relieve pressure.
7. Remove check plug (2). Oil must be to bottom of
hole.
8. If necessary, add oil until oil flows out of oil level
check plug hole. (See Section 3-1.)
9. Install plugs.
10. Check second travel gearbox oil level.
MM61211,0000A5F-19-20060418
Checking Travel Gearbox Oil Level 158

OMT223334
T204990-UN-30NOV04
1. Rotate upperstructure so front of upperstructure is

over travel motors (180°).
2. Lower the bucket and blade to raise both tracks off
ground.

machine.
high-pressure grease. DO NOT remove grease
fitting (1) from valve (2).
T204989-UN-30NOV04
T204991-UN-30NOV04
1 - Grease Fitting
2 - Valve
3 - Bleed Hole
4 - Steel Pipe
To loosen track, slowly turn valve (2)

counterclockwise. Grease will escape through the
bleed hole (3).
5. CAUTION: Prevent potential injury from front

idler. This procedure will require additional help.
Do not stand in front of idler during removal of
Removing and Installing Rubber Track 159

OMT223334
track. Front idler may come off unexpectedly.
Insert two or three steel pipes (4) into gaps among

lower rollers, track frame, and rubber track. Rotate
track slowly in reverse to lift track off idler. Pry
track off idler.
6. Install the rubber track on the sprocket first.
Position the other end of the rubber track on the
front idler.
7. While rotating the sprocket in reverse, push on the
rubber track to force it on the idler.
8.
T204992-UN-30NOV04
4 - Steel Pipe
Insert a steel pipe (4) into gaps among lower

rollers, track frame, and rubber track and rotate
slowly in reverse to force the rubber track onto the
idler.
9. Check that the rubber track is correctly engaged

with the sprocket and idler.
10. Adjust track sag. See Adjusting Track Sag.
(Section 3-4.)
11. Lower the machine to the ground.
MM61211,0000A60-19-20051207
Removing and Installing Rubber Track 160

OMT223334
Hydraulic System
Symptom Problem Solution

No Hydraulic Low hydraulic oil Add oil.
Functions
Clogged suction Clean.
filter
Hydraulic Low oil level Fill tank to full
Functions Are mark.
Slow or Have
Little or No
Power
Wrong oil Use correct oil.
Suction screen Inspect and clean.
clogged
Hydraulic tank Replace cap.
cap
Hydraulic Oil Wrong oil Use correct oil.
Overheats
Clogged radiator Clean and
or oil cooler straighten fins.
Radiator screen Remove and
clogged clean.
Clogged filters Install new
filters.
Low oil level Fill tank to full
mark.
Contaminated oil Drain oil and
refill.
Oil Foams High or low oil Correct level.
level
Water in oil Change oil.
Kinks or dents in Check lines.
oil lines
No Swing Pilot control Inspect and
Function hoses pinched or correct.
kinked
Swing Function Lack of grease Fill with grease.
Is "Jerky"
Slow Travel Fuse Replace fuse F8.
Speed only
Pilot controller Inspect and
hoses pinched or correct.
kinked
Hydraulic System 161

OMT223334
Travel Is "Jerky" Track sag Adjust tension.

adjustment
Rocks or mud Remove and
jammed in track repair.
frame
Engine Stops Water separator Drain.
When Travel Or clogged
Control Lever
Moved
NOTE: If any other problems are encountered which
require special tools or machine knowledge to correct, see
your authorized dealer.
MM61211,0000A61-19-20060418
Hydraulic System 162

OMT223334
Front (Secondary Exit) Window—If

Equipped
Open
1.
T205344-UN-09DEC04
T205345-UN-09DEC04
T205346-UN-09DEC04
1 - Window Lock Pin (2 used)
2 - Handhold (2 used)
3 - Cab Frame Lock Pin (2 used)
Pull lock pins (1) down to release window.
2. Grasp the handholds (2).

unexpected rapid window movement. Ensure cab
frame lock pins (3) are fully engaged.
Pull window up and back until the frame lock pins

(3) latch into the cab frame boss holes.
Close

unexpected rapid window movement. Front
window can come down forcefully. Close window
only when sitting on operator’s seat. Guide
window down slowly.
Front (Secondary Exit) Window—If Equipped 163

OMT223334
Unlatch cab frame lock pins from cab frame boss

holes.
2. Slide window down slowly using handholds.
3. Push on handholds until window lock pins (1) are
locked in place.
MM61211,0000A63-19-20051207
Close 164
OMT223334
Starting the Engine

1. NOTE: Engine will not start unless pilot control
shut-off lever is in locked (rearward) position.
T204921-UN-03DEC04
1 - HEAT
2 - OFF
3 - ON
4 - START
Turn the key switch to ON (3).
2. Sound horn to alert persons nearby.

3. Move the engine speed control lever to slow idle.
4. IMPORTANT: Prevent starter damage. Never
operate starter for more than 15 seconds at a time.
If engine fails to start, return key switch to OFF.
Wait about 30 seconds, then try again. After a false
start, do not turn key switch until engine stops.
Turn key switch to START (4). Release key;

switch will return to ON position.
MM61211,0000A65-19-20051207
Starting the Engine 165

OMT223334

• Use blade only for moving loose material and for
backfilling.
• Load the blade evenly.
• Do not use blade to dig.
• Do not run the machine into a load.
• Lower the blade to the ground.
MM61211,0000A66-19-20051207
Operating Tips—Backfill Blade 166

OMT223334
T217416-UN-08DEC05
CAUTION: Avoid possible injury from unexpected

machine movement. Use extra care to prevent tip over or
unexpected movement when loading and unloading
machine for transport. Observe these rules when loading
and unloading machine:
• Always wear seat belt.

• Locate trailer on a level and stable surface. Chock
trailer wheels.
• Use loading ramps. Keep ramps at a low angle and
firmly attached to trailer.
1. When loading machine, use bucket for support

with angle of arm to boom at 90°.
2. IMPORTANT: Prevent machine or trailer damage.
DO NOT allow machine or bucket to impact
trailer.
Position machine on trailer (centerline of machine

over centerline of trailer).
3. Lower the bucket and fasten machine to trailer at
the blade and track frame. Do not allow cables to
come into direct contact with rubber tracks.
4. When unloading machine, use bucket for support
with angle of arm to boom at 90°.
MM61211,0000A67-19-20051213
Loading and Unloading for Transport 167

OMT223334

machine movement if controls are moved by another
person. Lubricating swing bearing gear and rotating the
upperstructure must be done by one person.
Each time you leave the operators station:
• Lower the bucket to the ground

• Stop the engine
• Raise the pilot control shut-off lever to the locked
position.
T204996-UN-30NOV04

3. Lubricate swing bearing with 2—3 shots of grease
at grease fitting. (See Section 3-1.)
4. Start engine. Raise bucket several inches off the
ground and rotate upperstructure 90 degrees (1/4
turn).
5. Repeat steps 2—4 seven times. It is not necessary
to start the engine the last time.
NOTE: Grease the swing bearing gear at 500 hours.
MM61211,0000A69-19-20051208
Grease Swing Bearing 168

OMT223334

Your machine has one 12-volt battery with negative (-)
ground. Battery must meet or exceeds the specifications
below.

Battery Cold Cranking 350 amps
Amps At -18°C
(0°F)
Replace the failed battery with one of the same type. For
example, replace a failed maintenance-free battery with a
new maintenance-free battery. Different types of batteries
may have different rates of charge. This difference could
overload the battery and cause it to fail.
MM61211,0000A6A-19-20051208
Replacing the Battery 169

OMT223334
Safety Signs
T205161-19-21DEC04
T217441-19-11JUL06
MM61211,0000A6B-19-20080125
Safety Signs 170

OMT223334
Operator's Daily Machine Check Before

Starting
T123629-UN-17AUG99
1 - Check Pedal and Lever Movement, clean cab of any

debris
2 - Check Hydraulic Tank Oil Level
3 - Check Coolant Recovery Tank Level
4 - Check/Clean Radiator and Oil Cooler Outer Fins
5 - Check Engine Oil Level
Safety and Protective Devices Checks
Walk around machine to clear all persons from machine

area before starting machine.
Check condition of guards, shields, and covers.
Overall Machine Checks
Check for worn or frayed electrical wires and loose or

corroded connections.
Check for bent, broken, loose, or missing boom, bucket,

sheet metal, track parts.
Check for loose or missing hardware.
Check for oil leaks, missing or loose hose clamps, kinked

hoses, and lines or hoses that rub against each other or
other parts.
MM61211,0000A6D-19-20060418
Operator's Daily Machine Check Before Starting 171

OMT223334
T121986-UN-24JUN99
CAUTION: Prevent possible injury from tow line

breaking. Do not tow machine with damaged chains,
frayed cables, slings, straps or wire tow lines.
Always wear gloves when handling cables, straps, or wire

tow lines.
Attach tow line to track frame of machine being towed,

and of towing machine. Slowly tow machine.
MM61211,0000A6E-19-20051213
Towing Machine a Short Distance 172

OMT223334
Lifting
CAUTION: Prevent possible injury when lifting.

Observe these rules when lifting with your machine:
• Never use machine to lift people.

• Do not exceed lift capacity limits.
• Keep everyone clear of raised loads.
• Never attach sling or chain to bucket teeth.
• Use tether lines to guide loads.
• Use hand signals to communicate with others.
1. Use proper rigging to attach and stabilize loads.

2. Without bucket loop: Curl bucket and retract arm.
Fasten sling or chain to bucket pivot pin.
With bucket loop: Curl bucket and retract arm.

Fasten sling or chain to bucket loop.
3. Check stability by carefully doing a trial lift:
♦ Raise load just off the ground

♦ Swing load all the way to one side
♦ Move load slowly away from machine
♦ Lower load immediately if machine is not
stable
MM61211,0000A6F-19-20051213
Lifting 173
OMT223334
T204913-UN-03DEC04
Locked Position Shown
1 - Pilot Control Shutoff Lever
2 - Console
3 - Pilot Control Lever
The pilot control shutoff lever (1) shuts off hydraulic pilot
pressure to all pilot control valves. When pilot control
shutoff lever is in locked (up) position, the machine will
not move if a pilot control lever (3) or pedal is accidentally
moved.
IMPORTANT: Prevent possible console or control lever

damage. Only use the pilot control shutoff lever to raise or
lower console (2).
Pilot control shutoff lever is linked to the console latch

mechanism. Raise and lower console using pilot control
shutoff lever.
Always pull pilot control shutoff lever up to locked

position when stopping the engine or leaving the operator’s
station.
NOTE: After moving pilot control shutoff lever to

unlocked position, check that no activators move when all
control levers and pedals are in neutral before starting
operation.
Engine will not start unless pilot control shutoff lever is in

locked position. Slowly lower lever to unlocked position
before starting operation.
OU90V02,0000142-19-20090106
Pilot Control Shutoff Lever 174

OMT223334
Multi-Function Control Lever—If

Equipped
TX1054235-UN-09JAN09
TX1054236-UN-09JAN09
1 - Multi-Function Right Control Lever
2 - Slide Switch
3 - Switch
1. Move slide switch (2) of multi-function right

control lever (1) to the right or left to operate
front-end attachment such as hydraulic breaker.
2. When switch (3) of right control lever is pushed, it
operates the same as when slide switch is moved to
the left. (This switch operation is convenient for
using hydraulic breaker.)
In case slide switch and switch are pushed simultaneously,

switch operation has priority.
OU90V02,000014A-19-20090109
Multi-Function Control Lever—If Equipped 175

OMT223334
T205343-UN-09DEC04
T204914-UN-21DEC04
1 - Outer Latch
2 - Outer Latch
3 - Door Release Lever
IMPORTANT: Prevent machine damage from swinging

door. Ensure door is latched securely in both outer latches
(1 and 2) if operating with door open.
The cab door can be locked in the open position. Open the
door all the way until it locks in both latches (1 and 2) on
the side of the cab.
To release the door from locked position, push down on

door release lever (3).
OUO1032,0001572-19-20041116
Door Release Lever—If Equipped 176

OMT223334
T204915-UN-03DEC04
1 - Secondary Exit Tool
NOTE: Use tool (1) to break window. Always keep tool in

machine.
If the cab door does not open, exit in the following manner:
1. Open the front window. Exit through the window.

2. CAUTION: Protect your eyes and face from
broken glass and debris.
If the front window is difficult to open, break the

window glass with the secondary exit tool (1). Exit
through the broken window.
3. If exiting through the front window is not possible,
break the rear window glass with the secondary
exit tool. Exit through the broken window.
NOTE: A secondary exit kit is also offered

through your authorized dealer.
OUO1032,0001573-19-20041116
Secondary Exit Tool—If Equipped 177

OMT223334
T204918-UN-03DEC04
1 - Seat Fore-Aft Adjustment
Move lever (1) to the right and hold to slide the seat
forward or rearward. Release lever to lock.
OUO1032,0001574-19-20041116
Adjusting Operator Seat 178

OMT223334
Auxiliary Pedal
T204935-UN-07DEC04
1 - Pedal Cover
2 - Auxiliary Pedal
1. CAUTION: Avoid injury from unexpected

machine movement. Keep pedal cover in locked
position when not using auxiliary pedal.
Lift pedal cover (1) to unlock auxiliary pedal (2).

2. Push on the right or left side of the auxiliary pedal
to operate the front-end attachment. (See
Positioning Auxiliary Line Selector Valve below
for single and double activation.)
3. Lower pedal cover to lock auxiliary pedal.
OUO1032,000157B-19-20041116
Auxiliary Pedal 179

OMT223334
Parking
IMPORTANT: During freezing weather, prevent damage
to undercarriage components from frozen mud and dirt.
Machine must be parked on a solid level surface to prevent
tracks freezing in the ground.
T204913-UN-03DEC04
Lever in Locked Position
1 - Pilot Control Shut-Off Lever
2 - Console
3 - Pilot Control Levers

2. Lower the bucket and blade to the ground.
minutes.
5. Pull pilot control shutoff lever (1) to locked
position.
6. Close windows and cab door, if equipped.
7. Lock all access doors and compartments.
OUO1032,000157E-19-20070125
Parking 180
OMT223334
Engine Access Door

component movement. Always keep access door in the
locked position when servicing the engine area.
T204970-UN-07DEC04
T204971-UN-07DEC04
1 - Engine Access Door
2 - Locking Arm
3 - Stopper
1. Pull latch to unlock engine access door (1).

2. Raise door and lock stopper (3) securely into
locking arm (2).
3. To close, raise door slightly and push on locking
arm to release stopper. Lower door and latch
securely.
OUO1032,0001580-19-20041116
Engine Access Door 181

OMT223334
T205077-UN-29NOV04
1 - Washer Fluid Reservoir
Check level in washer fluid reservoir (1).
OUO1032,0001583-19-20041116
Checking Washer Fluid Level 182

OMT223334

IMPORTANT: Prevent engine damage. Do not run engine
when oil level is below MIN. level on dipstick.
T204975-UN-29NOV04
T204976-UN-29NOV04
1 - Dipstick
2 - Filler Cap
The most accurate oil level reading is obtained when the

engine is cold before starting the engine for the day’s
operation.
1. Make sure dipstick (1) is fully seated.

2. Remove dipstick to check oil level.
BEFORE THE ENGINE IS STARTED: The

engine is full when oil level is between MIN. and
MAX levels on dipstick.
AFTER THE ENGINE HAS BEEN RUN: Allow

the oil to drain into the oil pan for 10 minutes
before checking the oil level. Ten minutes after
shutdown the engine oil level must be above the
cross-hatch area.
3. If necessary, remove filler cap (2) to add oil. (See
Section 3-1.)
OUO1032,0001585-19-20051208
Checking Engine Oil Level 183

OMT223334

NOTE: Fuel tank drain valve (1) is located under machine
directly below fuel tank.
T204985-UN-30NOV04
1 - Fuel Tank Drain Valve
1. Open drain valve (1) for several seconds to drain

water and sediment into a container. Dispose of
waste properly.
2. Close drain valve.
OUO1032,0001587-19-20041116
Draining Fuel Tank Sump 184

OMT223334
TX1053012-UN-12DEC08
Water Separator (S.N. —254999)
TX1052932-UN-11DEC08
Water Separator (S.N. 255000— )
1 - Air Bleed Plug
2 - Water Separator
3 - Drain Valve
1. Open engine access door to access water separator

(2).
2. Open drain valve (3) for several seconds to drain
water and sediment into a container. If water is
difficult to drain, loosen air bleed plug (1).
3. Dispose of waste properly.
4. Close drain valve.
5. Close access door.
OUO1032,0001588-19-20081211
Draining Water Separator 185

OMT223334
Adjusting Track Sag

IMPORTANT: Prevent possible damage to track
components. DO NOT use the grease fitting on the track
adjusting cylinder for lubrication. Use this fitting ONLY
for track adjustment.
T204989-UN-30NOV04
T121713-UN-10JUN99
Steel Track Shown
1 - Grease Fitting
2 - Valve
3 - Bleed Hole
4 - Access Hole
To tighten track, connect a grease gun to grease fitting (1)

(located through access hole [4] in track frame). Add
grease until sag is within recommended limits.
CAUTION: Prevent possible serious injury from

high-pressure grease penetrating your skin. Do not remove
grease fitting (1) from valve (2). If grease does not escape
immediately from the vent hole when check valve is
loosened, slowly drive machine in forward and reverse
direction until grease escapes. DO NOT disassemble parts
until you know the correct procedure and have the correct
tools. See your authorized John Deere dealer.
If an accident occurs, see a doctor immediately. Any oil

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury may call Deere & Company Medical
Department in Moline, Illinois, or other knowledgeable
medical source.
To loosen, slowly turn valve (2) counterclockwise; grease

will escape through the bleed hole (3).
Adjusting Track Sag 186

OMT223334
When amount of track sag is satisfactory, turn valve

clockwise to tighten.
OUO1032,000158B-19-20060718
Adjusting Track Sag 187

OMT223334

machine movement if controls are moved by another
person. Lubricating swing bearing gear and rotating the
upperstructure must be done by one person.
Each time you leave the cab:
• Lower the bucket to the ground

• Stop the engine
• Pull the pilot control shutoff lever to the locked
position.
1.
T205010-UN-30NOV04
Apply grease to grease fitting.
2. IMPORTANT: If water or mud is found in swing

gear area, see Operating in Water and Mud.
(Section 2-2.)
In order to apply grease evenly to the swing gear,

raise the bucket approximately 200 mm (8 in.) off
the ground, swing upperstructure four 90° intervals
and apply grease at each interval. Add grease as
required. (See Section 3-1.)
OUO1032,0001593-19-20120228
Lubricate Swing Bearing Gear 188

OMT223334
Lubricate Control Lever Universal

Joint
T205011-UN-30NOV04
T205012-UN-30NOV04
Four Points
1 - Boot
2 - Screw (2 used)
3 - Bracket
1. Lift boot (1). Remove screws (2).

2. Remove bracket (3).
3. Lubricate points shown.
4. Install bracket and screws.
5. Install boot.
OUO1032,0001594-19-20120228
Lubricate Control Lever Universal Joint 189

OMT223334

1.
T205024-UN-30NOV04
1 - Fuel Shut-Off Valve
2 - Final Fuel Filter
Turn fuel shutoff valve (1) to OFF.
2. Remove fuel filter (2). Dispose of waste properly.

3. Clean mounting surface for fuel filter.
4. Add a small amount of fuel to new filter and
install.
5. Turn fuel shutoff valve to ON.
6. Turn the key switch to ON for 10—15 seconds to
engage automatic bleeding. Do not start engine.
7. Start engine. Stop engine. Check for fuel leakage.
OUO1032,0001595-19-20070125
Replacing Final Fuel Filter 190

OMT223334
T205163-UN-09DEC04
Four Points
Lubricate blade pins until grease escapes from joint. See

Grease. (Section 3-1.)
OUO1032,0001596-19-20120228
Lubricate Blade Pins 191

OMT223334

Perform the hydraulic system bleeding procedure
every time you change the hydraulic filter, pilot
system oil filter, or change hydraulic tank oil.
Do not operate any hydraulic function, including

unlocking pilot control shutoff lever, until you
complete steps 1—5 in this procedure.
T205418-UN-09DEC04
Turn engine speed control knob to slow idle

position.
2. Start engine. Run for 5—10 seconds to ensure oil

flow to hydraulic pump. Stop engine.
3. Check the hydraulic oil level at the sight gauge.
Add hydraulic oil if necessary. (See Section 3-1.)
4. Start the engine again. Confirm oil level is above
minimum point in hydraulic oil sight gauge. Run
engine for approximately one minute to circulate
oil through the system.
5. Stop engine and check hydraulic oil level. Add
more oil if necessary.
6. Start engine again. Operate each cylinder and
swing motor repeatedly for 10—15 minutes to
purge air from hydraulic system.
7. Park machine on a level surface and position
machine with cylinders fully retracted.
8. Stop engine. Check hydraulic oil level. Add oil if
necessary.
OUO1032,0001599-19-20060418
Bleed Hydraulic System 192

OMT223334
T205080-UN-10DEC04
1 - 12-Volt Auxiliary Power Outlet
A 12-volt auxiliary power outlet (1) is provided for service

and maintenance.
OUO1032,000159A-19-20041116
12-Volt Auxiliary Power Outlet 193

OMT223334
T205091-UN-01DEC04
1 - Control Pattern Selector Lever
The machine pilot control levers can be changed from the

standard “Excavator” control pattern to a “Backhoe”
control pattern. To change control pattern:

minutes.
3. Turn key switch to OFF to stop engine. Remove
key from switch.
4. Pull pilot shutoff lever up to the locked position.
5. Selector lever (1) is located under seat. Open panel
to access selector lever.
6. Rotate selector lever to desired control pattern
position. (Lever must be aligned with arrow on
selected control pattern and detented in order to
function as expected.)
7. Close panel.
8. Verify selected pattern is visible through sight
hole.
OUO1032,000159D-19-20070125
Control Lever Pattern Conversion 194

OMT223334
CAUTION: Prevent possible injury from flying chips if

compressed air is more than 210 kPa (2.1 bar) (30 psi).
Reduce compressed air to less than 210 kPa (2.1 bar) (30
psi) when using for cleaning purposes. Clear area of
bystanders, guard against flying chips, and wear personal
protection equipment including eye protection.
Clean the radiator core and oil cooler with compressed air
or water. Blow air straight through fins to avoid bending
them.
OUO1032,000159E-19-20041117
Cleaning Radiator Core and Oil Cooler 195

OMT223334
T123697B-UN-19AUG99
Machine Shown with Optional Thumb Attachment
T123698B-UN-19AUG99
1 - Arm Pivot Pin
2 - Bucket Ears
3 - Bucket Cylinder
4 - Square Pin Boss
5 - Bucket Ears
1. Position bucket and machine on a flat level

surface.
2. Slowly lower boom and maneuver arm to insert
arm pivot pin (1) into open end of bucket ears (2).
3. Extend bucket cylinder (3) until the square pin
boss (4) rests on the flat surface of bucket ears (5).
4.
T130378C-UN-11JUL00
1 - Wedge Bar
Installing Bucket With Quick Coupler 196

OMT223334
2 - Lynch Pins
3 - Cap Screw
Install bucket or attachment and wedge bar (1).

Two lynch pins (2) are installed on rear of
mechanical quick coupler.
5. Tighten cap screw (3) to specification.

Cap Screw Torque 135 N˙m 100
lb-ft
OUO1032,00015A6-19-20041119
Installing Bucket With Quick Coupler 197

OMT223334

1.
T47764-UN-09NOV88
T5813AM-UN-09FEB89
Repair worn or damaged parts. Install new parts, if

necessary, to avoid needless delays later.
2. Clean primary air cleaner.

3. 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 machines with
high pressure. Use low pressure wash operations
until 30 days have elapsed.
Wash the machine. Use low-pressure wash

operations (less than 1379 kPa [13.8 bar] [200 psi]
until 30 days after receipt of machine have
elapsed. Paint areas to prevent rust. Replace
decals, where needed.
4. Steel tracks: Apply waste oil to track chains. Run
machine back and forth several times. Park
machine on a hard surface to prevent tracks from
freezing to ground.
5. Store machine in a dry, protected place. If stored
outside, cover with a waterproof material.
6. IMPORTANT: LPS 3 Rust Inhibitor can destroy
painted finish. DO NOT spray LPS 3 Rust
Inhibitor on painted areas.
Retract all hydraulic cylinders, if possible. If not,

coat exposed cylinder rods with LPS ® 3 Rust
Inhibitor.
7. Place a "DO NOT OPERATE" tag on the right
control lever.
8. Lubricate all grease points.
9. Remove battery.
10. Remove perishable items.
11. Remove keys and lock all covers and doors.
Prepare Machine for Storage 198

OMT223334
LPS is a trademark of the Holt

Lloyd Corporation. OUO1032,00015A7-19-20060418
Prepare Machine for Storage 199

OMT223334
Record Product Identification Number

(PIN)
T205214A-UN-24NOV04
1 - Product Identification Number
Purchase Date
PIN
NOTE: Record all 13 characters of the Product

Identification Number.
OUO1032,00015AA-19-20041124
Record Product Identification Number (PIN) 200

OMT223334
Engine

Engine Cranks No fuel Add fuel.
But Will Not
Start Or Hard To
Start
Wrong fuel Use correct fuel.
Fuel filter Replace filter.
clogged Bleed air.
Water separator Check water
clogged or not separator.
primed
Water in fuel Check, drain fuel
tank , and refill.
Leaks in fuel Check fuel
system system
connections. See
your authorized
dealer.
Contaminated Drain tank. Add
fuel clean fuel. Check
water separator.
Air in fuel system Bleed air.
Low battery Charge or install
power new battery.
Slow cranking Clean and tighten
speed (poor battery and starter
electrical connections.
connection)
Wrong engine oil Use correct oil.
Air filter clogged Clean or replace
element.
Starter Replace starter.
Engine Knocks, Air filter clogged Clean or replace
Runs Irregularly, element.
Or Stops
Fuel filter Replace filter.
clogged Bleed air.
Water separator Check water
clogged separator.
Air in water Bleed air from
separator fuel system.
Engine oil level Add oil.
low
Engine 201
OMT223334
Contaminated Drain tank. Add

fuel clean fuel.
Replace water
separator.
Air in fuel system Bleed air from
fuel system.
Coolant Check for proper
temperature low thermostat
temperature and
operation.
Replace if
necessary.
Injection pump See your
authorized dealer.
Engine Starts But No fuel flow to Check and
Will Not engine replace fuse F9.
Continue To Run
Engine Not Air filters Clean or replace
Developing Full clogged filter element.
Power
Fuel filter Change filter.
clogged Bleed air.
Water separator Change.
Contaminated Drain tank.
fuel Change water
separator, change
fuel filter, bleed
air. Add clean
fuel.
Fuel line clogged Repair or replace
fuel line. Bleed
air.
Clogged vent in Clean or install
fuel tank cap new cap.
Exhaust Install new
restriction muffler.
Wrong valve Check and adjust
clearance valves.
Engine Overheats Coolant level low Add coolant to
recovery tank.
Remove cap
when cool. Check
coolant level in
radiator.
Radiator screen Remove and
clogged clean screen.
Engine 202
OMT223334
Radiator core or Clean radiator

oil cooler core and oil cooler.
clogged
Air filter clogged Clean or replace
element. Check
inlet screen.
Radiator cap Go to your
authorized dealer.
Fan on Install fan
backwards correctly.
Cooling system Flush cooling
passages clogged system.
Low Engine Oil Oil level low Add oil.
Pressure
Oil filter clogged Install new oil
filter.
Oil leaks Go to your
authorized dealer.
Engine Check cooling
temperature too system.
high
Engine Uses Too Wrong oil Use correct oil.
Much Oil
Oil leaks Check engine oil
drain plug.
Engine Check cooling
temperature too system.
high
Air cleaner Clean element or
clogged install new
element.
Engine Uses Too Clogged or dirty Clean air intake
Much Fuel air intake system system.
Excessive Black Wrong fuel Use correct fuel.
Or Gray Exhaust
Smoke
Clogged or dirty Clean air intake
air intake or and exhaust
exhaust system system.
Exhaust Smoke Is Wrong fuel Use correct fuel.
White
Cold engine Run engine until
warm.
OUO1032,00015BB-19-20080606
Engine 203
OMT223334
Electrical System

Nothing Works Battery Recharge or
replace.
Battery Loose or Clean and tighten
Undercharged corroded connections or
connections replace battery.
Battery Will Not Loose or Clean and
Take A Charge corroded tighten.
connections
Low battery Replace battery.
power
Battery Uses Too Cracked battery Replace battery.
Much Water case
High ambient Refill with water.
temperature
Cracked Battery No battery hold Replace battery
Case down clamp and install hold
down clamp.
Loose battery Replace battery
hold down clamp and install hold
down clamp.
Frozen battery Replace battery.
Keep battery
fully charged in
cold weather.
Low Battery Low water level Add water.
Output
Dirty or wet Clean and wipe
battery top, battery top dry.
causing discharge
Corroded or loose Clean and tighten
battery cables battery cables.
Broken battery Wiggle battery
post post by hand. If
post wiggles or
turns, replace
battery.
Starter Will Not Battery Recharge or
Turn undercharged or replace battery.
dead
Battery cables Clean
making poor connections.
connections
Starter Repair or replace
starter.
Electrical System 204

OMT223334
Starter pinion Repair or replace

jammed in starter or ring
flywheel gear gear.
Starter Turns But Starter Repair or replace
Will Not Crank starter.
Engine
Engine Cranks Battery cables Inspect and
Slowly damaged or replace cables.
broken internally
Battery or starter Clean and tighten
cable connections connections.
loose or corroded
Battery Recharge or
discharged or will replace battery.
not hold a charge
Starter Repair or replace
starter.
Low battery Recharge or
voltage replace battery.
Starter Continues Starter Repair or replace
To Run After starter.
Engine Starts
Key switch Disconnect
malfunction battery ground.
See your
authorized dealer.
Charging Loose or glazed Check belt.
Indicator Light alternator belt Replace if glazed.
On, Engine
Running
Excessive Remove
electrical load accessories or
from added install higher
accessories output alternator.
Loose or Inspect, clean, or
corroded tighten electrical
electrical connections.
connections on
battery, ground
strap, starter, or
alternator
Battery voltage Charge or replace
low battery.
Noisy Alternator Worn drive belt Replace belt.
Worn pulleys Replace pulleys
and belt.
Pulley misaligned Adjust alternator
mount.

OMT223334
Alternator Loosen alternator

bearing belts. Turn pulley
by hand. If any
roughness is felt,
repair alternator.
No Monitor Panel Fuse Replace fuse F2
Indicators or or F9.
Gauges Work
Individual Bulb Replace bulb.
Indicators Not
Working In
Monitor Panel
No Switch Panel Fuse Replace fuses F2
Switches Work or F9.
Angle Blade Drift Angle blade Check lever
Too Great moves when switches.
blade is not
operated Check relays and
fuses.
Check solenoids.
Angle Blade Not One side of angle Check lever
Operated blade does not switches.
work
Check relays and
fuses.
Check solenoids.
Angle Blade One side of angle Check lever
Moves Slowly blade does not switches.
work
Check relays and
fuses.
Check solenoids.
OUO1032,00015BC-19-20081217

OMT223334
Welding On Machine
IMPORTANT: Disconnect battery ground strap to prevent
voltage spikes through alternator or monitor.
Disable electrical power before welding. Disconnect

positive battery cable. Separate harness connectors to
engine and vehicle microprocessors.
Do not weld within 12 inches of electronic components.

Remove electronic components if necessary.
Connect welder ground clamp close to each weld area so

electrical current does not arc inside any bearings.
OUO1032,00015C0-19-20041208
Welding On Machine 207

OMT223334
T120806-UN-14APR99
Before moving machine, be sure all persons are clear of

both travel and swing paths. Turn around and look
directly for best visibility. Keep windows clean, adjusted,
and in good repair.
Be certain travel 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.
OUO1032,00015D0-19-20070125
Avoid Backover Accidents 208

OMT223334
T133547-UN-15APR13
IMPORTANT: Disable electrical power before welding.

Turn off main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and vehicle
microprocessors.
Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
OUO1032,00015DD-19-20091006
Make Welding Repairs Safely 209

OMT223334

IMPORTANT: Avoid damaging tracks. Using rubber
tracks or rubber pads on rough ground may result in pads
being damaged.
Rubber tracks and rubber pads are designed for flat, hard
surfaces only. Do not use on rough ground such as rocks,
sand or gravel.
Check track shoe bolts periodically for tightness.
OUO1032,00015DF-19-20070125
Selecting Correct Track 210

OMT223334
T132126-19-28JUN00
OUO1065,000006C-19-20080108
Emission Control Statement 211

OMT223334
Check Coolant
See Check Coolant. (Section 3-3.)
OUT4001,0000365-19-20110412
Check Coolant 212

OMT223334

See your authorized dealer.
OUT4001,000039B-19-20120314
Take Engine Oil Sample 213

OMT223334
Replacing Fuses
T205082-UN-01DEC04
1 - Fuse Panel
The fuse panel (1) is located under the seat. Lower cover to
access.
TX1032415-UN-17JAN08
T205683A-UN-03DEC04
Main Power Fuse
1 - F1—25 Amp—Horn, Fuel Shut-Off Pull-In Coil
2 - F2—5 Amp—Monitor, A/C Controller (if equipped),

Radio (if equipped)—Unswitched
3 - F3—5 Amp—Pilot Shut-Off Switch, Safety Start
4 - F4—10 Amp—Auxiliary Power Outlet
5 - F5—20 Amp—Work Lights
6 - F6—10 Amp—Wiper Motor (if equipped), Washer

Switch (if equipped), and Dome Light (if equipped)
7 - F7—25 Amp—Radio (if equipped), A/C Controller (if

equipped), A/C Torque Control Relay, Blower Motor (if
equipped)
8 - F8—20 Amp—Travel Speed Selector Switch, Travel

Alarm Controller, Travel Alarm
Replacing Fuses 214

OMT223334
9 - F9—10 Amp—Monitor Power Supply, Monitor Alarm,

Starter Interlock Relay, Alternator Excite, Fuel Shut-Off
Solenoid Hold-In Coil, Fuel Pump, Travel Alarm
10 - F10—5 Amp—Safety Start Relay
11 - F11—65 Amp—Main Power Fuse
12 - F12—5 Amp—Glow Plug Power Fuse (S.N.

225112— )
IMPORTANT: Install fuse with correct amperage rating to

prevent electrical system damage from overload.
Fuse (Blade-Type) Color Codes
Amperage Rating Color

1 Black
3 Violet
4 Pink
5 Tan
7-1/2 Brown
10 Red
15 Light Blue
20 Yellow
25 Natural (white)
30 Light Green
SJ25320,000071A-19-20080118
Fuse (Blade-Type) Color Codes 215

OMT223334
CAUTION:
TS204-UN-15APR13
Prevent possible injury from exploding battery. Do not

charge a battery if the battery is frozen or it may explode.
Warm battery to 16°C (60°F) before charging.
IMPORTANT: Disconnect battery ground before you

charge batteries in the machine to prevent damage to
electrical components.
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.
A battery charger may be used as a booster to start engine.
T82,EXMA,G-19-19920803
Using Battery Charger 216

OMT223334
Precautions for Alternator and

Regulator
When batteries are connected, follow these rules:
1. Disconnect negative (-) battery cable when you

work on or near alternator or regulator.
2. Be sure alternator wires are correctly connected
BEFORE you connect batteries.
3. Do not ground alternator output terminal.
4. Do not disconnect or connect any alternator or
regulator wires while batteries are connected or
while alternator is operating.
5. Connect batteries or a booster battery in the correct
polarity (positive [+] to positive [+] and negative
[-] to negative [-]).
6. Do not disconnect the batteries when engine is
running and alternator is charging.
7. Disconnect battery cables before you connect
battery charger to the batteries.
T82,EXMA,I-19-20060418
Precautions for Alternator and Regulator 217

OMT223334
Print
27D
Excavator
Copyright 2013 © Deere & Company. THIS DATA IS THE PROPERTY OF DEERE & COMPANY. ALL
USE AND/OR REPRODUCTION NOT SPECIFICALLY AUTHORIZED BY DEERE & COMPANY IS
PROHIBITED.
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.

Section 1-1 - Safety—Safety and Operator Convenience

Safety and Operator Convenience Features
Section 1-2 - Safety—General Precautions

Avoid Unauthorized Machine Modifications
Inspect Machine
Prevent Fires
Section 1-3 - Safety—Operating Precautions

Prevent Unintended Machine Movement
Print 218
OMT223334
Section 1-4 - Safety—Maintenance Precautions

Remove Paint Before Welding or Heating
Section 1-5 - Safety—Safety Signs

Safety Signs
Section 2-1 - Operation—Operator Station

Monitor Panel and Functions (S.N. —255551)
Monitor Panel and Functions (S.N. 255551— )
Switch Panel—Cab
Pedals and Levers
Setting Trip Meters
Front (Secondary Exit) Window—If Equipped
Opening Right Side Window—If Equipped
Toolbox and Operator’s Manual Compartment
Section 2-2 - Operation—Operating the Machine

Operator's Daily Machine Check Before Starting
Starting the Engine
Multi-Function Control Lever—If Equipped
Boom-Swing Pedal
Auxiliary Pedal
Positioning Auxiliary Line Selector Valve
Section 1-3 - Safety—Operating Precautions 219

OMT223334
Parking
Lifting
Lifting Machine
Section 3-1 - Maintenance—Machine

Diesel Fuel
Biodiesel Fuel
Testing Diesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Diesel Engine Oil
Diesel Engine Oil and Filter Service Intervals
Hydraulic Oil
Travel Gearbox Oil
Grease
Light Duty Diesel Engine Coolant (for diesel engines without wet sleeve cylinder liners)
Drain Intervals for Diesel Engine Coolant
John Deere COOL-GARD™ II Coolant Extender
Operating in Warm Temperature Climates
Section 3-2 - Maintenance—Periodic Maintenance

Engine Access Door
Fuel Tank
Hydraulic Breaker and Crusher Attachments
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit
Service Intervals
Required Parts
Section 3-3 - Maintenance—As Required

Check Coolant
Section 3-4 - Maintenance—Every 10 Hours or Daily

Section 2-2 - Operation—Operating the Machine 220

OMT223334
Checking Recovery Tank Coolant Level
Checking Track Sag—Steel Track—If Equipped
Adjusting Track Sag
Seat Belt
Section 3-5 - Maintenance—First 50, Then Every 100 Hours

Inspect Fan Belt, Check and Adjust Tension


Changing Engine Oil and Replacing Filter
Lubricate Control Lever Universal Joint
Take Fluid Samples

Checking and Adjusting Engine Valve Lash (Clearance)
Check Coolant

Changing Hydraulic Tank Oil and Cleaning Suction Screen

Section 3-4 - Maintenance—Every 10 Hours or Daily 221

OMT223334
Section 4-1 - Miscellaneous—Machine

Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump
Do Not Service Control Valves, Cylinders, Pumps, or Motors
Precautions for Alternator and Regulator
Handling, Checking, and Servicing Batteries Carefully
Using Booster Batteries—12-Volt System
Welding On Machine
Connecting and Disconnecting Auxiliary Lines
Replacing Fuses
Cleaning Heating and Air Conditioning Filter Screens—If Equipped
Rubber Track Care
Section 4-2 - Miscellaneous—Operational Checkout

Section 4-3 - Miscellaneous—Troubleshooting

Engine
Electrical System
Hydraulic System
Section 4-4 - Miscellaneous—Storage

Section 4-5 - Miscellaneous—Serial Numbers

Record Product Identification Number (PIN)
Section 4-6 - Miscellaneous—Specifications

Working Ranges
Section 4-1 - Miscellaneous—Machine 222

OMT223334
(Blade on the Ground With Standard Boom and Canopy)
(Blade on the Ground With Long Arm and Canopy)
(Blade on the Ground With Standard Boom and Cab)
(Blade on the Ground With Long Arm and Cab)
Section 4-6 - Miscellaneous—Specifications 223

OMT223334
T133555-UN-15APR13
T133588-19-28AUG00
This is the safety alert symbol. When this symbol is

noticed on the machine or in this manual, be alert for
the potential of personal injury.
Follow the precautions and safe operating practices

highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION

— is used with the safety alert symbol. DANGER
identifies the most serious hazards.
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-19-20070103
Recognize Safety Information 224

OMT223334
TS206-UN-15APR13
Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.
Wear close fitting clothing and safety equipment

appropriate to the job.
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.
TX03679,00016D0-19-20070103
Wear Protective Equipment 225

OMT223334
T133592-UN-15APR13
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or

shield that has been removed for access as soon as service
or repair is complete.
TX03679,00016D2-19-20070103
Stay Clear of Moving Parts 226

OMT223334
T133509-UN-15APR13
T133840-UN-20SEP00
This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin causing
serious injury.
Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting lines
or working on hydraulic system.
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.
TX03679,00016D3-19-20081103
Avoid High-Pressure Oils 227

OMT223334
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.
If uncertain about safe handling or use of these chemical

products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,00016D7-19-20070103
Handle Chemical Products Safely 228

OMT223334
T133716-19-17APR13
Use seat belt when operating machine. Remember to

fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not cut or

torn. Replace seat belt immediately if any part is damaged
or does not function properly.
The complete seat belt assembly should be replaced

every 3 years, regardless of appearance.
TX03679,00016DD-19-20081103
Use and Maintain Seat Belt 229

OMT223334
T133716-19-17APR13
T133545-UN-15SEP00
T133803-UN-27SEP00
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.
Load and unload from trucks or trailers carefully. Be

sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Avoid trucks with steel beds because tracks slip more
easily on steel.
Be careful on slopes. Use extra care on soft, rocky or

frozen ground. Machine may slip sideways in these
conditions. When traveling up or down slopes, keep the
bucket on uphill side and just above ground level.
Be careful with heavy loads. Using oversize buckets or

lifting heavy objects reduces machine stability. Extending
a heavy load or swinging it over side of undercarriage may
cause machine to tip.
Ensure solid footing. Use extra care when operating near

banks or excavations that may cave-in and cause machine
to tip or fall.
TX03679,00016DF-19-20070103
Avoid Machine Tip Over 230

OMT223334
T133839-UN-27SEP00
Never use this machine to lift people.
Never lift a load above another person. Keep bystanders

clear of all areas where a load might fall if it breaks free.
Do not leave the seat when there is a raised load.
Do not exceed lift capacity limits posted on machine and in

this manual. Extending heavy loads too far or swinging
over undercarriage side may cause machine to tip over.
Use proper rigging to attach and stabilize loads. Be sure

slings or chains have adequate capacity and are in good
condition. Use tether lines to guide loads and prearranged
hand signals to communicate with co-workers.
TX03679,00016E1-19-20070103
Use Special Care When Lifting Objects 231

OMT223334
T133332-19-17APR13
TS229-UN-23AUG88
Warn others of service work. Always park and prepare

your machine for service or repair properly.
• Park machine on a level surface and lower

equipment and attachments to the ground.
• Place pilot shutoff lever in “lock” position. Stop
engine and remove key.
• Attach a “Do Not Operate” tag in an obvious place
in the operator's station.
Securely support machine or attachment before working

under it.
• Do not support machine with boom, arm, or other

hydraulically actuated attachments.
• Do not support machine with cinder blocks or
wooden pieces that may crumble or crush.
• Do not support machine with a single jack or other
devices that may slip out of place.
Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people whenever
the engine must be running for service work.
TX03679,00016E9-19-20070103
Park and Prepare for Service Safely 232

OMT223334

Always verify compatibility of attachments by contacting
your authorized dealer. Adding unapproved attachments
may affect machine stability or reliability and may create a
hazard for others near the machine.
Ensure that a qualified person is involved in attachment

installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections
are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all

instructions and warnings. In an area free of bystanders and
obstructions, carefully operate attachment to learn its
characteristics and range of motion.
TX03679,00016F0-19-20070212
Add and Operate Attachments Safely 233

OMT223334
T133468-UN-15APR13
Prevent falls by facing the machine when getting on and

off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present

slippery conditions. Keep steps clean and free of grease or
oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,00016F2-19-20130424
Use Steps and Handholds Correctly 234

OMT223334
Prevent Fires
T133552-UN-15APR13
T133553-UN-07SEP00
T133554-UN-07SEP00
Handle Fuel Safely: Store flammable fluids away from

fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease and

oil from accumulating in engine compartment, around fuel
lines, hydraulic lines, exhaust components, and electrical
wiring. Never store oily rags or flammable materials inside
a machine compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses

immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a

multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
TX03679,00016F5-19-20081103
Prevent Fires 235

OMT223334
T133556-UN-24AUG00
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
labels immediately if missing or damaged.
TX03679,00016F9-19-20070103
Follow Safety Instructions 236

OMT223334

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-19-20070103
Operate Only If Qualified 237

OMT223334
T133567-UN-25AUG00
Improper disposal of waste can threaten the environment.

Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into

any water source.
Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your authorized
dealer for more information.
TX03679,0001733-19-20070103
Dispose of Waste Properly 238

OMT223334
Inspect Machine
T6607AQ-UN-15APR13
Inspect machine carefully each day by walking around it

before starting.
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.
TX03679,0001734-19-20070103
Inspect Machine 239

OMT223334
T133738-UN-15APR13
Always wear protective goggles or safety glasses and other

protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and bucket
teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and

object to prevent chipping.
TX03679,0001745-19-20070103
Drive Metal Pins Safely 240

OMT223334
TS204-UN-15APR13
Battery gas can explode. Keep sparks, lighted matches, and

open flame away from the top of battery.
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).
TX03679,000174A-19-20081103
Prevent Battery Explosions 241

OMT223334
TS291-UN-15APR13
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.
TX03679,000174B-19-20070103
Prepare for Emergencies 242

OMT223334
T133556-UN-24AUG00
Reading Operator's Manual
Review the operating precautions. See

Safety-Operating Precautions. (Section 1-3.)
Use seat belt when operating machine. Remember to

fasten seat belt even during brief periods of use.
TX03679,0001780-19-20120821
Before Starting Work 243

OMT223334
Handling, Checking, and Servicing

Batteries Carefully
CAUTION:
TS204-UN-15APR13
Exploding Battery Gas
TS203-UN-23AUG88
Battery Electrolyte
Battery gas can explode. Keep sparks and flames away

from batteries. Use a flashlight to check battery electrolyte
level.
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
Always remove grounded (-) battery clamp first and

replace it last.
Sulfuric acid in battery electrolyte is poisonous. It is strong

enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
Handling, Checking, and Servicing Batteries Carefully 244

OMT223334
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 15—30 minutes.
Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not
exceed 1.9 L (2 quarts).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
If electrolyte spills on the floor, use one of the following

mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in
4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in 4
L (1 gal) water.
IMPORTANT: Do not overfill the battery cells.
Check the specific gravity of electrolyte in each battery

cell.
T85402-UN-10NOV88
Battery and Coolant Tester
See your authorized dealer for JT05460 SERVICEGARD

battery and coolant tester. Follow directions included with
the tester.
A fully charged battery will have a corrected specific

gravity reading of 1.260. If the reading is below 1.200,
charge the battery.
SERVICEGARD is a trademark
of Deere & Company TX03679,0001788-19-20130305
Handling, Checking, and Servicing Batteries Carefully 245

OMT223334
T133715-UN-15APR13
Avoid unexpected machine movement. Start engine only

while sitting in operator's seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not

attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,0001799-19-20100422
Start Only From Operator's Seat 246

OMT223334
T6642EJ-UN-18OCT88
Remove any grease, oil, fuel, or debris build-up to avoid

possible injury or machine damage.
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.
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.
TX03679,00017E0-19-20130305
Clean Machine Regularly 247

OMT223334
Seat Belt
Seat belt and mounting hardware must be inspected for
wear or damage before operating the machine. Replace the
belt or mounting hardware if worn or damaged.
Replace the complete seat belt assembly every 3 years

regardless of appearance.
TX,10,DH3548-19-20080429
Seat Belt 248

OMT223334

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 500 hours also service those
items (if applicable) listed under 250 hours, 100 hours, 50
hours, and 10 hours or daily.
TX14740,0001C9F-19-20070717
Service Machine at Specified Intervals 249

OMT223334

Tracks shoes should be checked periodically for loose or
missing cap screws and nuts. For shoes with missing or
loose cap screws and nuts, remove shoes and clean the
mating surface of shoes and links before tightening cap
screws and nuts. The cap screws should be replaced
because they have been stretched to yield previously.
Operating a machine with loose shoes can cause the cap

screws and holes in the shoes and links to wear making it
difficult to keep the shoes tight. Loose shoes can also cause
hardware failure and loss of shoes.
1. Clean the mating surface of shoe and links. Install

shoes.
2. Apply a light coating of oil to cap screw threads
before installing.
3. Install nuts with the rounded corners against milled
surface of link and chamfered side is away from
link.
Check that nuts are square with the milled surface

of link and there is full contact between nut and
milled surface. As necessary, hold the nut so it
does not turn.
4. Starting at any cap screw, tighten all cap screws in
sequence to the torque specification, then 1/2 turn
(180°) more.
TX14740,0001CFC-19-20020123
Checking Track Shoe Hardware 250

OMT223334
T120807-UN-14APR99
Only allow operator on machine.
Riders are subject to injury. They may fall from machine,

be caught between machine parts, or be struck by foreign
objects.
Riders may obstruct operator’s view or impair his ability to

operate machine safely.
TX14740,0001E7A-19-20020319
Keep Riders Off Machine 251

OMT223334
T121197-UN-21APR99
Before performing maintenance procedures given in the

following sections and before leaving the operator’s seat,
position machine as shown below unless another position
is specified in the procedure.
1. Park machine on a level surface as shown.

2. Stop engine.
3. Move pilot control shutoff lever to locked
(rearward) position.
TX14740,0001E83-19-20070125
Preparing Machine for Maintenance 252

OMT223334
Rubber Track Care

machine movement. A machine with rubber track is less
stable than a machine with steel shoes, as the edge of the
rubber track may bend when bucket is loaded, especially
when digging over the side.
When you drive the machine:
• Do not operate on sharp, rocky, uneven

surfaces. NOTE: The rubber track has a thin
rubber film on its inner surface when it is new. It is
normal for the film to come off when track rubs
against rollers.
• Keep the rubber track free of oil, gasoline, etc.
Avoid traveling on oil to reduce the chance of
slipping.
• If machine is parked or stored for more than 90
days, park in an area out of direct sunlight.
• When transporting a machine with rubber tracks,
always fasten the right and left track frames
securely to the trailer. Do not allow tie down
chains to come into direct contact with rubber
track pads.
TX,55,DH5376-19-20070125
Rubber Track Care 253

OMT223334
Do Not Service Control Valves,

Cylinders, Pumps, or Motors
Special tools and information are needed to service control
valves, cylinders, pumps, or motors.
If these parts need service, see your authorized dealer.
TX,90,FF3114-19-20070103
Do Not Service Control Valves, Cylinders, Pumps, or Motors 254

OMT223334
Do Not Service or Adjust Injection

Nozzles or High Pressure Fuel Pump
If injection nozzles are not working correctly or are dirty,
the engine will not run normally. (See your authorized
dealer for service.)
Changing the injection pump in any way not approved by

the manufacturer will end the warranty. (See your copy of
the John Deere warranty on this machine.)
Do not service an injection pump that is not operating

correctly. (See your authorized injection pump service
center.)
TX,90,FF3116-19-20060907
Do Not Service or Adjust Injection Nozzles or High Pressure Fuel Pump 255
OMT223334

NOTE: Troubleshooting charts are arranged from the
simplest to verify, to least likely, more difficult to verify.
When diagnosing a problem, use all possible means to
isolate the problem to a single component or system. Use
the following steps to diagnose problems:
Step 1. Operational Checkout Procedure.
Step 2. Troubleshooting charts.
Step 3. Adjustments.
Step 4. See your authorized dealer.
TX,FF,105-19-20020227
Using Troubleshooting Charts 256

OMT223334

We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works

18600 South John Deere Road
Attn: Publications, Dept. 324
Dubuque, IA 52004-0538
USA
FAX NUMBER: 1-563-589-5800 (USA)
Publication Number:
Page Number:
Ideas, Comments:
Technical Information Feedback Form 257

OMT223334
Name:
Phone:
Email Address:
THANK YOU!
TX,TM,FAX-19-20010703
Technical Information Feedback Form 258

OMT223334

NOTE: Perform this service at the first 250 hours of
operation and then at 500 hour intervals thereafter.
1.
T205418-UN-09DEC04
Park machine on a level surface with arm cylinder

fully retracted and bucket cylinder fully extended.
Lower bucket and blade to ground.
2.
T205001-UN-30NOV04
1 - Cap Screw (4 used)
2 - Cover
3 - O-Ring
4 - Spring
5 - Valve
6 - Filter Element
Stop engine.

Slowly loosen hydraulic oil tank cap to release

hydraulic pressure. Remove cap.

OMT223334
4. Hold down filter cover (2) against light spring load

when removing cap screws (1).
5. Remove O-ring (3), spring (4), valve (5), and filter
element (6).
NOTE: Remove element and inspect for metal

particles and debris in bottom of filter can.
Excessive amounts of brass and steel particles can
indicate a hydraulic pump, motor, or valve
malfunction, or a malfunction in process.
Rubber-type material can indicate a cylinder
packing problem.
6. Discard element and O-ring.
7. Install new filter element, valve, and spring.
8. Fill new filter with oil. See Hydraulic Oil. (Section
3-1.)
9. Install cover and new O-ring.
10. Install cap screws.

Cap Screw Torque 49 N˙m 36 lb-ft
Hydraulic system must be bled whenever the
hydraulic oil filter is changed.
Bleed hydraulic system. See Bleed Hydraulic

VD76477,0000059-19-20090109

OMT223334
Checking Recovery Tank Coolant

Level
T205085-UN-01DEC04
Recovery Tank
2 - Recovery Tank
With the engine cold, coolant level must be between the

FULL and LOW marks on the recovery tank (2).
If coolant is below the LOW mark, add coolant to the

recovery tank.
CAUTION: Prevent possible injury from hot spraying

water. DO NOT remove radiator filler cap (1) unless
engine is cool. Then turn cap slowly to the stop. Release all
pressure before you remove cap.

coolant. Coolant manufacturers engineer their coolants to
meet certain specifications and performance requirements.
Mixing different coolant types can degrade coolant and
machine performance.
If recovery tank is empty, check for leaks. Repair as

required. Add coolant to the radiator then the recovery
tank.
NOTE: If recovery tank is full and radiator is low, check

for leaks in radiator cap and hose connections between
radiator and coolant recovery tank.
Coolant level must be at bottom of the radiator filler neck.
VD76477,00000BB-19-20050719
Checking Recovery Tank Coolant Level 261

OMT223334
Hydraulic Breaker and Crusher

Attachments
oils. Oil manufacturers engineer their oils to meet certain
performance.

Hydraulic breaker or crusher operation subjects the

machine’s hydraulic system to possible contamination and
accelerated deterioration. The hydraulic return filter and
hydraulic oil must be replaced more often to prevent
damage to hydraulic pumps and other hydraulic
components. Use of different attachments may shorten oil
change interval. Use this table for reference.
Bucket, Breaker, and Crusher Attachments

Attachment Percentage of Hydraulic Hydraulic Oil
Operating Return Filter Change
Time Change Interval
Interval
Bucket 100% 500 hours 2000 hours
Breaker or
100% 250 hours 1000 hours
Crusher
VD76477,00000C8-19-20060418
Hydraulic Breaker and Crusher Attachments 262

OMT223334
Prevent Unintended Machine

Movement
T216779-UN-22NOV05
Be careful not to accidentally actuate control levers when

coworkers are present. Pull pilot shutoff lever to locked
(UP) position during work interruptions. Pull pilot shutoff
lever to locked (UP) position and stop engine before
allowing anyone to approach machine.
Always lower work equipment to the ground and pull pilot

shutoff lever to locked (UP) position before standing up or
leaving the operator's seat. Stop engine before exiting.
VD76477,000036D-19-20110419
Prevent Unintended Machine Movement 263

OMT223334
T6191AA-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.
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.
3. 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-UN-18OCT88
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.
On crawler machines with non

sealed-and-lubricated track chains, apply oil to the
pin-to-bushing joints. Run machine back and forth
several times.
8. Park machine on a hard surface to prevent tracks
from freezing to ground.
9. Fill fuel tank.
10. Pre-lubricate turbocharger bearings, if equipped:
Monthly Storage Procedure 264

OMT223334
a. Disconnect fuel shutoff fuse.

b. Crank engine for 10 seconds.
c. Connect fuel shutoff fuse.
11. Inspect engine compartment, and remove any
foreign material that may have accumulated. 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.
12. Operate all controls, levers, seat adjustments, etc.

unexpected machine movement. Clear the area of
all persons before running machine through the
operation procedure.
Make sure the area is clear to allow for movement.

Cycle all hydraulic functions several times. Check
condition of all hoses and connections.
14. Park the machine with cylinder rods retracted, if
possible. Turn key switch to OFF.
15. Apply LPS 3 Rust Inhibitor to exposed cylinder
rod areas.
LPS 3 Rust Inhibitor is a

trademark of Illinois Tool
Works. VD76477,00016A3-19-20110613
Monthly Storage Procedure 265

OMT223334 - John Deere 27D Compact Excavator Operator's Manual

Uploaded by

Copyright:

Available Formats

OMT223334 - John Deere 27D Compact Excavator Operator's Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

OMT223334 - John Deere 27D Compact Excavator Operator's Manual

Uploaded by

Copyright:

Available Formats

Print

Emission Control Statement

Section 1-1 - Safety—Safety and Operator Convenience

Section 1-2 - Safety—General Precautions

Section 1-3 - Safety—Operating Precautions

Section 1-5 - Safety—Safety Signs

Section 2-1 - Operation—Operator Station

Section 2-2 - Operation—Operating the Machine

Section 3-2 - Maintenance—Periodic Maintenance

Section 3-3 - Maintenance—As Required

Section 3-4 - Maintenance—Every 10 Hours or Daily

Section 3-6 - Maintenance—Every 250 Hours

Section 3-7 - Maintenance—Every 500 Hours

Section 3-8 - Maintenance—Every 1000 Hours

Section 3-9 - Maintenance—Every 2000 Hours

Section 3-10 - Maintenance—Every 6000 Hours

Section 4-1 - Miscellaneous—Machine

Section 4-2 - Miscellaneous—Operational Checkout

Section 4-3 - Miscellaneous—Troubleshooting

Section 4-4 - Miscellaneous—Storage

Section 4-5 - Miscellaneous—Serial Numbers

Section 4-6 - Miscellaneous—Specifications

Avoid Unauthorized Machine

Modifications of this machine, or addition of unapproved

Always contact an authorized dealer before making

Avoid Unauthorized Machine Modifications 1

Fluid Analysis Program Test Kits and

Fluid Analysis Kits

Fluid Analysis Program Test Kits and the 3-Way Coolant

Engine, hydraulic, power train, and coolant samples should

Draining Cooling System

1 - Radiator Filler Cap

Drain and flush cooling system using commercial products.

1. Check coolant hoses for cracks and leaks. Replace

Slowly turn radiator filler cap (1) to release

1 - Radiator Drain Valve

Turn radiator drain valve (1) counterclockwise to

6. Close drain valves.

John Deere COOL-GARD II Pre-Mix coolant is

Draining Cooling System 3

Fill with proper coolant. See Light Duty Engine

Item Measurement Specification

Draining Cooling System 4

Cooling System Fill and Deaeration

Follow directions on container for correct mixture ratio.

Use only permanent-type low silicate ethylene glycol base

John Deere COOL-GARD II Pre-Mix coolant is

FREEZING TEMPERATURES: Fill with permanent-type,

The cooling system requires several warm-up and cool

1. Start engine. Run engine until coolant reaches a

If necessary, fill recovery tank to FULL mark.

Cooling System Fill and Deaeration 5

PLUS-50 is a trademark of Deere &

COOLSCAN PLUS is a trademark

Lubricate Bucket and Link Pins

Right Side Shown - 10 Points

Lubricate bucket and link pins until grease escapes from

Lubricate Bucket and Link Pins 9

Opening Rear Window—If Equipped

1 - Rear Window Latch (2 used)

John Deere COOL-GARD II Pre-Mix coolant is

John Deere COOL-GARD II Pre-Mix coolant is