JOHN DEERE 120C (01) PDF MANUAL

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FREE ENGLISH JOHN DEERE 120C (01) PDF OWNER MANUAL

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JOHN DEERE 120C (01) PDF SUMMARY:

What should I do to learn how to operate and service my machine correctly?

READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage.

Where can I find safety signs on my machine?

Safety signs can be found installed in the cab on the hydraulic coupler, and on the hydraulic coupler itself, if equipped.

What should I check before starting work?

Review the operating precautions.
Use the seat belt when operating the machine, even during brief periods of use.

What safety and protective devices checks should I perform daily before starting?

Walk around the machine to clear all persons from the machine area.
Check the condition of guards, shields, and covers.

What overall machine checks should I perform daily before starting?

Check for worn or frayed electrical wires and loose or corroded connections.
Check for bent, broken, loose, or missing boom, bucket, sheet metal, and 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.
Check pedal and lever movement/clean out cab debris.
Check hydraulic oil level.
Check engine oil level.
Check/clean radiator and oil cooler outer fins.
Check coolant recovery tank level.

What should I do before starting the engine?

Turn the key switch to the ON position. All indicator lights will stay on for 3 seconds then go off except for the alternator voltage indicator, engine oil pressure indicator, and dig mode indicator, which will continue to stay on.

How do I start the engine?

Move the engine speed dial to the slow idle position.
Sound the horn to alert persons nearby.
Turn the key switch to START. (All indicator lights will stay on for approximately 3 seconds).
Release the key; the switch will return to the ON position.

IMPORTANT:

Prevent starter damage. Never operate the starter for more than 20 seconds at a time. If the engine fails to start, return the key switch to OFF. Wait for about 2 minutes, then try again. After a false start, DO NOT turn the key switch until the engine stops.
Prevent possible damage to the engine. If indicator lights do not go out after starting engine, IMMEDIATELY STOP THE ENGINE. Find and correct the problem.

What should I do after starting the engine?

After the engine is started, the indicator lights should go out. If they do not, stop the engine immediately. Find and correct the problem.

How do I warm the engine?

Run the engine at 1/3 speed for 30 seconds. Do not run the engine at fast or slow idle. Do not accelerate rapidly during warm-up.
Operate the machine at less-than-normal loads and speeds until the engine is at normal operating temperature.

How do I warm up the engine in cold weather?

Run engine at 1/2 speed for 5 minutes. Do not run at fast or slow idle.
Exercise travel and swing functions slowly, initially moving only short distances.
Operate boom, arm, and bucket functions by moving cylinders a short distance each direction for the first time.
Continue cycling cylinders by increasing the travel each cycle until full stroke is obtained.
Swing upperstructure so boom is perpendicular to tracks.
Keeping the angle between boom and arm 90—110°, fully actuate bucket close function (cylinder extend) and lower bucket to raise track off ground.
While rotating raised track in forward direction, actuate bucket curl function (cylinder extend) for 10 seconds and release for 5 seconds for a period of 2-1/2 minutes.
Repeat procedure with track rotating in reverse direction.
Lower machine to ground.
Repeat steps 5—9 on opposite track.
Operate all hydraulic functions to distribute warm oil in all cylinders, motors, and lines.
If hydraulic functions still move slowly, repeat steps 6 and 7.

How do I travel with the travel pedals and levers?

Keep bystanders clear of machine when traveling. The instructions below apply when the travel motors are to the rear of the machine. If the travel motors are to the front of the machine, the machine moves OPPOSITE to the direction described.

FORWARD TRAVEL: Push down on the front of both pedals or push both levers forward.
REVERSE TRAVEL: Push down on the rear of both pedals or pull both levers rearward.
NEUTRAL POSITION: Travel brakes will automatically stop and hold the machine.
RIGHT TURN: Push down on the front of the left pedal or push the left lever forward.
LEFT TURN: Push down on the front of the right pedal or push the 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.
TRAVELING DOWN A SLOPE: Operate control pedals or levers slowly when traveling down a slope.

How do I lock the hydraulic coupler to the attachment?

CAUTION: Make sure hydraulic coupler is attached correctly to attachment. The supplemental lock can be engaged with the attachment in an incorrect lock position. A visual check is required each time the lock operation is performed. Failure to do so could result in serious injury or death. CAUTION: Attaching the bucket in a reverse orientation on the hydraulic coupler is not recommended. When installed in the reverse orientation, the bucket or the lift hook interferes with the arm of the excavator when the bucket is in full curl position by extending the bucket cylinder. This is an inherent part of the design of the original equipment. Since the hydraulic coupler interacts with the arm at full curl position to unlock the supplemental lock, the hydraulic coupler will NOT operate properly when the bucket is attached in reverse orientation.

NOTE: A safety buzzer will sound to alert personnel the lock/unlock function has been activated.

Engage front hook (1) on pin (2). Toggle switch on control box should be in UNLOCK position.

NOTE: The hydraulic coupler must be held over relief in order to lock/unlock the hydraulic coupler cylinder.
Rotate to full-curl position. Move toggle switch to LOCK position. Hold in full-curl position for 5 seconds.
Slowly uncurl hydraulic coupler. Visually verify supplemental lock contacts locking plate. Visually verify lock plate is behind attachment pin. Toggle switch on the control box should be in the LOCK position.

NOTE: Do not operate attachment when the supplemental lock is used as the primary locking device. Doing so could result in hydraulic coupler failure.
Continue to slowly uncurl hydraulic coupler. Verify attachment is properly locked. Toggle switch on the control box should be in LOCK position.

How do I unlock the hydraulic coupler from the attachment?

Keep attachment close to ground. Toggle switch should be in LOCK position.

NOTE: The hydraulic coupler must be held over relief in order to unlock the hydraulic coupler cylinder.
Rotate hydraulic coupler to full-curl position to release supplemental lock. Toggle switch should be in LOCK position.

NOTE: A safety buzzer will sound to alert personnel the unlock function has been activated.
Move toggle switch to UNLOCK position. Hold in full-curl position for 5 seconds.
Slowly uncurl hydraulic coupler. Front hook (1) will release from pin (2). Toggle switch should be in UNLOCK position.

What should I be aware of regarding control lever pattern operation?

CAUTION: Never place any part of body beyond window frame to avoid serious crushing injury from boom. Boom could lower if the control lever is accidentally bumped or otherwise engaged. Immediately replace a missing or broken window.

Never place any part of the body beyond the window frame. Replace missing or broken windows immediately. CAUTION: Prevent injury from unexpected control lever function. Be aware of the control lever pattern used on the machine before operating.

What are the control lever patterns?

The machine comes equipped from the factory with the excavator control lever pattern and has the corresponding black-on-white labels installed on the left and right control consoles.

When changed to the backhoe control lever pattern the corresponding black-on-yellow labels must be installed on the left and right control consoles.

Check the pattern on the labels and then carefully operate the machine to verify that the correct labels are installed.

Is there a control pattern selector kit?

NOTE: A Control Pattern Selector Kit is available through parts, that when installed, changes the control lever pattern using a solenoid valve.

What happens when the control levers are released?

Control levers return to neutral when released. Functions will stop and remain positioned. Also the parking brake for swing and travel will engage.

What is the procedure to convert the control lever pattern?

Lower bucket to the ground.
Stop the engine. Remove the key from switch.

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. SLOWLY loosen hydraulic cap to relieve air pressure.
SLOWLY loosen hydraulic cap to relieve air pressure. (See Check Hydraulic Oil Level in section 3-4).
Remove panel on top of machine to access pilot signal manifold.

NOTE: DO NOT use manufacturer’s hose tags or markings on hose ends to identify hoses for this conversion procedure. The conversion must be done on the side of flow regulator valve that is connected to the pilot controllers.
Disconnect and connect hoses on the pilot controller side (FRONT) of the pilot signal manifold as follows:
- Switch hose to Port A (A) with hose to Port D (D).
- Switch hose to Port B (B) with hose to Port C ©.
Port designations (letters) are on the pilot signal manifold next to the ports. CAUTION: Prevent injury from unexpected control lever function. Install new labels on control consoles.
When changing to the backhoe control lever pattern, remove the old labels and install the black-on-yellow labels on the left and right control consoles near base of control levers. Labels are enclosed in Operator Manual package.

When changing to the excavator control lever pattern, remove the old labels and install the black-on-white labels on the left and right control consoles. Additional labels can be purchased from your authorized dealer. A control pattern selector kit is available through service parts. When installed, it changes the control lever pattern using a solenoid valve.

What are the operating tips for the backfill blade?

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.
Do not use the blade to stabilize machine.

What should I be careful of when operating in water and mud?

Be careful not to operate the machine in water or mud above the upper deck surface of the undercarriage, causing the swing bearing and rotary manifold to be submerged.

If the swing bearing and rotary manifold are submerged, remove cover from underneath center of machine. Remove drain plug (1) to drain water and mud. Clean swing gear area. Install plug and cover. Grease swing gear and swing bearing.

What is the procedure for driving up a steep or slippery slope?

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.

Wear seat belt.
Position undercarriage so travel motors will be on uphill end of machine.
Push bucket into the ground.
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.

What rules should I observe when lifting with the machine?

CAUTION: Lifting requires special care. Observe these rules when lifting with the 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

What is the procedure for lifting?

Use proper rigging to attach and stabilize loads.
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.
Check stability by carefully doing a trial lift:
- Raise load just off of ground
- Swing load all the way to one side
- Move load slowly away from machine
- Lower load immediately if machine is not stable

How do I lower the boom with the engine stopped?

Lower Boom With Engine Stopped

When an engine stops during operation, the boom cannot be lowered using the pilot controller because there is no pilot pressure oil to move the boom valve spool.

CAUTION: Prevent possible injury from unexpected machine movement. Clear all persons from the area before lowering the boom with the engine stopped.

Lift control valve access door.
Remove rubber caps (1) from the boom I section (2).
Turn nut (8) counterclockwise to remove.

IMPORTANT: Work on socket-head screw (7) before working on socket-head screw (6).
Turn socket-head screw (7) clockwise to the stop.
Turn nut (5) counterclockwise to loosen.
Turn socket-head screw (6) clockwise, while closely watching the boom lower. Adjust the boom lowering speed as required.
After the bucket is lowered to the ground, turn screws (6) and (7) counterclockwise to the stops. DO NOT remove snap ring (3) and washer (4).
Turn screw (7) clockwise 1/8 of a turn to loosen.
Tighten lock nuts (5) and (8)
Install rubber caps.

Specification Nut (5 and 8) Tool—Size 17 mm (Hex wrench) Socket-head screw (6 and 7) tool—Size 4 mm (Hex wrench) Nut (5 and 8)—Torque 19.5 N·m 14.4 lb-ft

What is the parking procedure?

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.

Park machine on a solid level surface.

During freezing weather, clean mud and dirt from tracks, rollers and track frames. If tracks are frozen in the ground, slowly raise the machine using boom to free the tracks. Move machine carefully.
Lower equipment to the ground.
Turn auto-idle/auto-acceleration switch OFF.

IMPORTANT: Turbocharger can be damaged if procedure to shut down engine is not done properly.
Run engine with engine speed dial at 1/3 position without load for 2 minutes.
Turn engine speed dial to slow idle position.
Turn key switch to OFF. Remove key from switch.
Pull pilot control shutoff lever to locked position.

IMPORTANT: Prevent cab electrical component damage from bad weather. Windows, roof vent, and cab door must be closed to prevent enter of rain.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.

What should I know about transporting the 120C Excavator when equipped with a long arm?

CAUTION: Prevent possible injury or machine damage from unexpected machine movement. Connect long arm to pin bore (B) only for machine transportation. When long arm is connected to pin bore (B), the working radius changes and the bucket will hit the cab.

Pin hole (B) is for transport only. Use pin hole (B) to make boom height lower than cab height. If necessary, remove bucket.

How do I convert the long arm machine from operating to transporting position?

Position the bucket cylinder with rod slightly retracted from the fully extended position.
Position the arm cylinder with rod slightly retracted from the fully extended position.
Lower the boom until the arm top comes into contact with the ground.

What rules should I observe when loading and unloading the machine for transport?

Loading And Unloading For Transport

CAUTION: Use extra care to prevent tipover 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.
Turn auto-idle/auto acceleration switch to OFF. Use low speed operating modes and move machine carefully.

What is the procedure for loading the machine for transport?

When loading machine, use bucket for support with angle (1) of arm to boom at 90°.

IMPORTANT: Prevent machine or trailer damage. DO NOT allow machine or bucket to impact trailer.
Position machine on trailer as shown. Fasten each corner of machine to trailer.
When unloading machine, use bucket for support with angle of arm to boom at 90°.

What is the procedure for towing?

CAUTION: Prevent possible injury from unexpected machine movement. Block both tracks when disconnecting travel gearboxes. When travel gearboxes are disconnected, machine has no brakes and can move. The machine will roll free on a slope or while being towed.

Block tracks.
Drain oil from each travel gearbox.
Remove cover from each gearbox.
Remove sun gear (1) from each gearbox.
Install cover. Fill gearbox with oil.

What should I be aware of when lifting the machine?

Lifting Machine

CAUTION: Prevent possible injury from unexpected 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. NOTE: The center of gravity (2) will vary depending on the kind of attachment. NOTE: Refer to decals on machine for correct lifting points (1). There are 2 lift points on each side of the undercarriage.

What is the procedure for lifting the machine?

Fully extended boom, arm, and bucket cylinders.
Position boom straight ahead of the upperstructure.
Turn key switch to OFF position. Remove key from key switch.
Pull pilot control shutoff lever to locked (UP) position.
Close and lock all doors and covers.
Route appropriate lifting device through lifting point (1) and under both sides of the track frame as illustrated.
Attach appropriate lifting device to crane.
Slowly lift machine.

What kind of diesel engine oil should I use?

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

John Deere Plus-50™ II oil is preferred. John Deere Plus-50™ is also recommended.

Other oils may be used if they meet one or more of the following:

John Deere Torq-Gard™
API Service Category CJ-4
API Service Category CI-4 PLUS
API Service Category CI-4
API Service Category CH-4
ACEA Oil Sequence E9
ACEA Oil Sequence E7
ACEA Oil Sequence E6
ACEA Oil Sequence E5
ACEA Oil Sequence E4

Multi-viscosity diesel engine oils are preferred.

What do I need to know about diesel fuel quality and fuel sulfur content?

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 10000 mg/kg (10000 ppm).

How often should I service the diesel engine oil and filter?

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 0.05% (500 mg/kg) is strongly recommended.
Use of diesel fuel with sulfur content 0.05% (500 mg/kg) to 0.50% (5000 mg/kg) may result in REDUCED oil 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.

What should I know about using biodiesel blends?

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.

Which oil types are included in the engine oil and filter service intervals?

John Deere Plus-50™ II and John Deere Plus-50 oils.
“Other Oils” include John DeereTorq-Gard Supreme™, API CJ-4, API CI-4 PLUS, API CI-4, API CH-4, ACEA E9, ACEA E7, ACEA E6, ACEA E5, ACEA E4, or ACEA E3 oils.

When is the 500 hour extended oil and filter change interval allowed?

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 0.05% (500 mg/kg)
Use of John Deere Plus-50™ II or John Deere Plus-50 oil
Use of an approved John Deere oil filter

Which coolants are preferred for a diesel engine?

The following pre-mix engine coolants are preferred:

John Deere COOL-GARD™II
John Deere COOL-GARD II PG

When should I use COOL-GARD II PG?

Use COOL-GARD II PG when a non-toxic coolant formulation is required.

What other engine coolant is recommended?

The following engine coolant is also recommended:

John Deere COOL-GARD II Concentrate in a 40—60% mixture of concentrate with quality water.

IMPORTANT: When mixing coolant concentrate with water, do not use less than 40% or greater than 60% concentration of coolant. Less than 40% gives inadequate additives for corrosion protection. Greater than 60% can result in coolant gelation and cooling system problems.

What other coolants may be used?

Other ethylene glycol or propylene glycol base coolants may be used if they meet one of the following specifications:

Pre-mix coolant meeting ASTM D6210 requirements
Coolant concentrate meeting ASTM D6210 requirements in a 40—60% mixture of concentrate with quality water
Pre-mix coolant meeting ASTM D3306 requirements
Coolant concentrate meeting ASTM D3306 requirements in a 40—60% mixture of concentrate with quality water

If coolant meeting one of these specifications is unavailable, use a coolant concentrate or pre-mix coolant that has a minimum of the following chemical and physical properties:

Is formulated with a nitrite-free additive package
Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion

What quality of water should I use?

How often should I drain diesel engine coolant?

Drain and flush the cooling system and refill with fresh coolant at the indicated interval, which varies with the coolant used.

When COOL-GARD II or COOL-GARD II PG is used, the drain interval is 6 years or 6000 hours of operation.

If a coolant other than COOL-GARD II or COOL-GARD II PG is used, reduce the drain interval to 2 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.

Do not use coolants that contain nitrites.

What should I know about 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.

What is John Deere COOL-GARD™ II Coolant Extender?

Some coolant additives gradually deplete during engine operation. For COOL-GARD™ II pre-mix and COOL-GARD II Concentrate, replenish coolant additives between drain intervals by adding COOL-GARD II Coolant Extender.

COOL-GARD II Coolant Extender should not be added unless indicated by COOL-GARD II Test Strips. These test strips provide a simple, effective method to check the freeze point, additive levels, and pH of your engine coolant.

Test the coolant solution at intervals of 12 months and whenever excessive coolant is lost through leaks or overheating.

IMPORTANT: Do not use COOL-GARD II Test Strips with COOL-GARD II PG.

COOL-GARD II Coolant Extender is a chemically matched additive system for use with all COOL-GARD II coolants.

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 can result in additive drop-out, gelation of the coolant, or corrosion of cooling system components.

Add the recommended concentration of COOL-GARD II Coolant Extender. DO NOT add more than the recommended amount.

What should I know about supplemental coolant additives?

Some coolant additives will gradually deplete during 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.

What should I do when operating in warm temperature climates?

John Deere engines are designed to operate using recommended engine coolants.

Always use a recommended engine coolant, even when operating in geographical areas where freeze protection is not required.

IMPORTANT: Water may be used as coolant in emergency situations only.

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended engine coolant as soon as possible.

What should I know 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.

What are the 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.

How do I replenish coolant additives?

Some coolant additives will gradually deplete during 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 should I 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 Premix and COOL-GARD II Concentrate and to provide optimum protection for up to six years or 6000 hours of operation.

Should I 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.

What water quality should I use?

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

How can I protect from freezing?

The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit.

DO NOT use a coolant-water mixture greater than 60% ethylene glycol or 60% propylene glycol.

How do I test diesel engine coolant?

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.

What are 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.

What should I do 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.

What should I do 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.

What is 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.

What kind of diesel fuel should I use?

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.

What are the required fuel properties?

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

Cetane number of 40 minimum. Cetane number greater than 47 is preferred, especially for temperatures below –20 °C (–4 °F) or elevations above 1675 m (5500 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 0.52 mm as measured by ASTM D6079 or ISO 12156-1. A maximum scar diameter of 0.45 mm is preferred.

What should I know about diesel fuel quality and sulfur content?

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).

What should I know about sulfur content for Interim Tier 4, Final Tier 4, Stage III B, and Stage IV Engines?

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

What should I know about 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—2000 mg/kg (1000—2000 ppm) REDUCES the oil and filter change interval.
BEFORE using diesel fuel with sulfur content greater than 2000 mg/kg (2000 ppm), contact your John Deere dealer.

What should I know about Sulfur Content for Tier 2 and Stage II Engines?

Use of diesel fuel with sulfur content less than 2000 mg/kg (2000 ppm) is RECOMMENDED.
Use of diesel fuel with sulfur content 2000—5000 mg/kg (2000—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.

How do I change the swing gearbox oil on a 120C?

Remove the plug mounted on the end of the drain pipe to drain oil into a container and dispose of the waste oil properly.
Install the plug.
Remove the filler cap and add oil.
Install the filler cap.
Check the oil level on the dipstick.

How do I replace the hydraulic oil tank filter?

Park the machine on a level surface with the arm cylinder fully retracted and the bucket cylinder fully extended.
Stop the engine.
Slowly loosen the cap to relieve pressure.
Hold down the filter cover against the light spring load when removing the last two cap screws.
Remove the spring, valve, and filter element.
Remove and discard the filter element and O-ring.
Install the filter element, valve, and spring.
Install the cover and tighten the cap screws to a torque of 49 N·m (36 lb-ft).
Tighten the cap.

What should I look for when inspecting the filter element?

Remove the element and inspect for metal particles and debris in the bottom of the filter canister. Excessive amounts of brass and steel particles can indicate a hydraulic pump, motor, or valve malfunction, or a malfunction in process. A rubber type of material can indicate a cylinder packing problem.

How do I clean the engine crankcase ventilation tube?

Clean the engine crankcase ventilation tube.

How do I replace the pilot system oil filter?

Slowly loosen the cap to relieve hydraulic pressure.
Remove the filter canister.
Remove the filter element.
Remove the O-ring.
Install a new O-ring and filter element.
Install the filter canister.
Tighten the hydraulic cap.

What is the torque specification for the filter canister?

The filter canister torque is 39 N·m (29 lb-ft).

How do I replace the air cleaner elements?

Loosen the clamps to remove the cover.
Remove the primary element.
Remove the secondary element.
Clean the inside of the filter canister.
Install the elements, making sure the secondary element is centered in the canister.
Install the cover and tighten the clamps.

How do I replace the air cleaner dust valve?

Replace the dust valve. NOTE: A missing, damaged, or hardened dust valve will cause the air filter elements to be ineffective.

How do I drain and flush the cooling system?

Check coolant hoses for cracks and leaks and replace if necessary.
Tighten clamps.
Check the radiator and oil cooler for dirt, grease, leaks, and loose or broken mountings. Clean radiator and oil cooler fins.
Release air to relieve pressure and remove the filler cap.
Turn the radiator drain valve counterclockwise to open the valve and allow the coolant to drain into a container. Dispose of waste coolant properly.
Turn the engine block drain valve counterclockwise to drain the engine block. Drain the coolant into a container and dispose of waste properly.

What should I avoid when servicing the cooling system?

Do not use cooling system sealing additives or antifreeze that contains sealing additives.
Do not mix ethylene glycol and propylene glycol base coolants.
Do not use coolants that contain nitrites.

What type of antifreeze should I use to refill the cooling system?

Use only permanent-type low silicate ethylene glycol base antifreeze in coolant solution. Other types of antifreeze may damage cylinder seals.
In freezing temperatures, fill with permanent-type, low silicate, ethylene glycol antifreeze (without stop-leak additive) and clean, soft water.
Fill the radiator to the bottom of the radiator fill neck.
Fill the recovery tank to the FULL mark.

How do I deaerate the cooling system?

The cooling system requires several warm-up and cool down cycles to deaerate and it will NOT deaerate during continuous operation. If necessary, fill the recovery tank to the FULL mark and install the recovery tank and radiator caps.

Where can I get the engine valve lash adjusted?

See your authorized dealer for engine valve clearance adjustment.

How do I change the travel gearbox oil?

Park the machine on level ground rotating the travel gearbox until the bottom of the oil level check plug is even with the horizontal centerline.
Stop the engine.
After the travel gearbox has cooled, slowly loosen the check plug to release pressure.
Remove the drain plug and allow the oil to drain into a container. Dispose of waste oil properly.
Wrap the threads of the drain plug with a sealing-type tape and install the plug. Tighten the plug to 49 N·m (430 lb-in).
Remove the oil fill plug.
Add oil until oil flows out of the oil level check plug hole.
Wrap the threads of the check plug and fill plug with sealing-type tape and install the plugs. Tighten the plugs to 49 N·m (36 lb-ft).
Change the oil of the second travel gearbox.

How do I change the hydraulic tank oil and clean the suction screen on a 120C?

Park the machine on a level surface with the upperstructure rotated 90° for easier access.
Position the machine with the arm cylinder fully retracted and the bucket cylinder fully extended.
Stop the engine.
Insert a 4 mm hex wrench into the hole and turn counterclockwise to release the locking pin.
Slowly turn the cap counterclockwise a few degrees to relieve pressure and remove the cap.
Remove the drain plug and allow the oil to drain into a container. Dispose of waste oil properly.
Remove the cover with the suction screen.
Clean the inside of the tank and suction screen.
Replace the hydraulic oil filter.
Replace the pilot system oil filter.
Install the suction screen with the cover. The suction screen must seal against the outlet pipe in the bottom of the tank. If necessary, loosen the nut to adjust the rod length.
Install the tank drain plug.
Add oil until it is between the marks on the sight glass.
Remove the air bleed plugs from the hydraulic pump and add oil until oil flows from the bleed holes.
Install the air bleed plugs in the hydraulic pump.
Check the oil level in the sight glass and add oil, if necessary. Install the tank cap and tighten the cap.
Purge air from the cylinders and swing motor by cycling hydraulic functions.

How do I change the hydraulic tank oil and clean the suction screen on a 160CLC?

Park machine on a level surface with the upperstructure rotated 90° for easier access.
Position machine with arm cylinder fully retracted and bucket cylinder fully extended.
Stop engine.
Insert 4 mm hex wrench into hole and turn counterclockwise to release locking pin.
Slowly turn cap counterclockwise a few degrees to relieve pressure and remove cap.
Remove drain plug and allow oil to drain into a container. Dispose of waste oil properly.
Remove cover with suction screen.
Clean inside of tank and suction screen.
Replace hydraulic oil filter.
Replace pilot system oil filter.
Install suction screen with cover. Suction screen must seal against outlet pipe in bottom of tank. If necessary, loosen nut to adjust suction screen rod length.
Install tank drain plug.
Add oil until it is between marks on sight glass.
Remove air bleed plug from top of hydraulic pump and add oil until oil flows from bleed hole.
Install air bleed plug in hydraulic pump.
Check oil level in sight glass. Add oil, if necessary. Install tank cap and tighten cap.
Purge air from cylinders and swing motor by cycling hydraulic functions.

What should I NOT do when servicing or adjusting injection nozzles or the high-pressure fuel pump?

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.

What should I avoid when handling, checking, and servicing batteries?

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 the grounded (-) battery clamp first and replace it last.
Filling batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added.
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.
Do not induce vomiting.
Do not overfill the battery cells.

What should I do if I spill acid on myself?

Flush contacted skin with water.
Apply baking soda or lime to the contacted area to help neutralize the acid.
Flush eyes with water for 15—30 minutes.
Get medical attention immediately.

What should I do if acid is swallowed?

Do not induce vomiting.
Drink large amounts of water or milk, but do not exceed 1.9 L (2 qts.).
Get medical attention immediately.

How do I neutralize 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.

How do I check the specific gravity of the battery electrolyte?

Check the specific gravity of electrolyte in each battery cell. A fully charged battery will have a corrected specific gravity reading of 1.260. If the reading is below 1.200, charge the battery.

What should I do before using a battery charger?

Do not charge a battery if the battery is frozen or it may explode. Warm battery to 16°C (60°F) before charging.
Turn off the charger before connecting or disconnecting it.
Disconnect the battery ground (-) clamp before you charge batteries in the machine to prevent damage to electrical components.
Ventilate the area where batteries are being charged.
Stop or cut back charging rate if battery case feels hot or is venting electrolyte. Battery temperature must not exceed 52°C (125°F).

Can I use a battery charger as a booster?

A battery charger may be used as a booster to start the engine. Do not use a battery charger as a booster if a battery has a 1.150 specific gravity reading or lower.

What should I do before using booster batteries on a 24-Volt system?

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

How do I use booster batteries on a 24-Volt system?

Connect one end of the positive cable to the positive terminal of the machine batteries and the other end to the positive terminal of the booster batteries.
Connect one end of the negative cable to the negative terminal of the booster batteries. Connect the other end of the negative cable to the machine frame as far away from the machine batteries as possible.
Start the engine.
Immediately after starting the engine, disconnect the end of the negative cable from the machine frame, then disconnect the other end of the negative cable from the negative terminal of the booster batteries.
Disconnect the positive cable from the booster batteries and machine batteries.

What are the battery specifications for replacing batteries in this machine?

Battery—Cold Cranking Amps At -18°C (0°F): 800
Battery—Minutes Reserve Capacity At 25 Amps: 180

What should I do if one battery in a 24-volt system has failed?

If one battery in a 24-volt system has failed but the other is still good, replace the failed battery with one of the same type. For example, replace a failed maintenance-free battery with a new maintenance-free battery.

How do I clean the machine regularly?

Remove any grease, oil, fuel, or debris build-up to avoid possible injury or machine damage. 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.

What pressure is considered high pressure when washing this machine?

High pressure washing (greater than 1379 kPa (13.8 bar) (20 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.

What should I avoid when using an electrical accessory?

Connecting a 12-volt accessory to one battery will cause one battery to overcharge, and the other battery to undercharge, causing battery failure.

How do I replace bucket teeth?

Use a hammer and drift to drive out the locking pin.
Remove the tooth.
Inspect the rubber pin lock for damage and replace if necessary.
If the rubber pin lock has moved, reposition it in the slot in the adapter tooth shank.
Position the new tooth over the tooth shank.
Drive the locking pin into the hole fully.

How do I replace a heavy-duty bucket tooth tip?

Clean the tooth and tooth tip.
Insert the lock removal tool under the U-shaped pin.
Remove the pin.
Turn the tooth tip counterclockwise and pull the tooth tip towards you to remove.
Clean the tooth shank.
Replace the U-shaped pin at the same time you replace the tooth tip.
Insert the tooth tip on the shank turning the tip clockwise.
Install the U-shaped pin. The side of the pin marked “FRONT” must face the tooth tip. Make sure the pin is firmly engaged over the tooth tip.

How do I adjust the bucket to arm joint?

Slide the O-ring out of the way.
Measure the distance between the bushing and the arm. This distance should not be adjusted below 0.5 mm (0.020 in).
Remove the plate.
Remove the shims according to the distance measured. This will allow the bushing to move to the right and take up the excessive play.
Install the plate and tighten the cap screws.
Slide the O-ring back into position.

How do I remove the bucket?

Lower the bucket to the ground.
Remove the snap rings and locking pins.
Slide the O-ring seals out of the way and remove the bucket pins.

How do I install track shoes?

Clean the mating surface of shoe and links and install the shoes.
Apply a light coating of oil to cap screw threads before installing.
Install nuts with the rounded corners against the milled surface of the link and the chamfered side is away from the link.
Tighten cap screws using a crisscross pattern, then repeat the torque pattern again.

What should I NOT do regarding torque values?

DO NOT use these values if a different torque value or tightening procedure is given for a specific application.

How do I troubleshoot problems with the machine?

Operational Checkout Procedure.
Troubleshooting charts.
Adjustments.
See your authorized dealer.

How do I prepare the machine for storage?

Repair worn or damaged parts and install new parts, if necessary, to avoid needless delays later.
Clean the primary air cleaner.
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 and replace decals, where needed.
Lubricate all grease points.
Remove batteries.
Remove seat cushion and other perishable items.
Remove keys and lock all covers and doors.

How do I handle, check, and service batteries?

Filling batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added.
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.

What should I do in the Operator Station Checks with the key switch on and the engine off?

Does the battery relay click?
Do the engine coolant temperature gauge and fuel gauge needles move to the right? YES: Go to next check.
Do all monitor indicators light and after 2—3 seconds only the alternator voltage indicator, engine oil pressure indicator, and dig mode indicator remain lit? NO: Check monitor fuse 1 in the fuse box.
Does the monitor display show 888888.8 for 2—3 seconds, then indicate machine hours? NO: Check and replace bulb if any bulb fails to come on. Go to your authorized dealer.

What should I check in the Operator Station with the Engine On?

Are all monitor indicator lights OFF after engine starts except for the dig mode indicator?
Is the coolant temperature gauge needle in the normal operating zone after a few minutes?
Does the fuel gauge indicate fuel level? YES: Go to next check.
Does the monitor display indicate machine hours? NO: Check alternator belt if alternator voltage indicator lights after engine starts. Go to your authorized dealer.

How do I check the Work Mode Circuit?

Auto-idle/auto-acceleration switch OFF. Pilot shutoff lever in LOCKED position. Push work mode selection switch to select desired work mode. YES: Go to next check. Do corresponding dig mode or attachment mode indicators light as switch is pushed? NO: Check fuse 1 in fuse box. Go to your authorized dealer.

How do I check the Engine Speed Dial?

Start engine. Auto-idle/auto-acceleration switch OFF. Move engine speed dial clockwise. Does engine speed increase? Move engine speed dial counterclockwise. YES: Go to next check. Does engine speed decrease? NO: Go to your authorized dealer.

How do I check the Auto-Idle/Auto-Acceleration Circuit?

Run engine at fast idle. Power mode switch in H/P mode. Auto-idle/auto-acceleration switch OFF. Pilot shutoff lever in UNLOCKED position. Move auto-idle/auto-acceleration switch to A/I. Does auto-idle indicator come on? Does engine speed decrease after 4 seconds? Slowly actuate any dig function control lever. Does engine speed return to fast idle? Move auto-idle/auto-acceleration switch to A/A. Do auto-idle and auto-acceleration indicators come on? Does engine speed decrease after 4 seconds? Slowly actuate any dig function control lever. YES: Go to next check. Does engine speed return to pre-set higher rpm? NO: Check fuse 1 in fuse box. Go to your authorized dealer.

How do I perform Pilot Shutoff Valve Checks?

Run engine at slow idle. Pilot shutoff lever in LOCKED (rearward) position. Actuate all dig and travel function controls. YES: Go to your authorized dealer. Do any dig or travel functions operate? NO: Continue check. Move pilot shutoff lever to UNLOCKED position (forward). Operate all dig and travel functions. YES: Go to next check. Do all functions operate? NO: Go to your authorized dealer.

How do I check the Pilot Controller Pattern?

Engine at slow idle. Operate machine in clear area. Move pilot shutoff lever to UNLOCKED position. Slowly move hydraulic levers to all positions on decals. Do bucket, boom, arm, and swing move as decals show? YES: Go to next test. See Section 2-2 for more detailed information. NO: Install decals for pattern (operator preference). Go to your authorized dealer.

How do I check the Swing Circuit Leakage?

Engine at slow idle. Position machine on a side hill or raise one side of the machine 300 mm (1 ft) with the boom and ease block under track. Raise bucket 300 mm (1 ft) off the ground at maximum reach. Bottom bucket cylinder and hold lever in the actuated position. NOTE: Actuating the bucket function releases the mechanical swing brake. YES: Go to next check. Does upperstructure move only slightly? NO: Go to your authorized dealer.

How do I check the Dig Function Drift?

Engine at slow idle. Fill bucket with dirt and position bucket at maximum reach with bucket 2 in. (50 mm) above ground. Observe bucket for 1 minute. YES: Go to your authorized dealer. Does bucket drift down to ground within 1 minute? NO: Go to next check.

How do I perform a Control Valve Lift Check Test?

Engine at slow idle. Position machine as illustrated. Slowly actuate pilot controller to lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder). YES: If functions move in opposite direction first, a leak within the cylinder or lift check valve is indicated. Go to your authorized dealer. Do functions move in opposite direction as control levers are moved, then change direction as levers are moved further? NO: Go to next check.

How do I perform Travel System Tracking Checks (Travel Only)?

Engine at fast idle. Travel speed switch in fast position. 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.) long between two points on track print. Measure and record greatest distance of mistrack between inside edge of track print and test line. Repeat procedure in reverse travel. YES: Go to next check. LOOK: Do both tracks move and machine does not mistrack excessively in forward or reverse? NO: Note which track does not move, or if machine mistracks note the mistrack pattern. Go to your authorized dealer.

How do I perform Travel System Tracking Checks (While Operating A Digging Function)?

Engine at fast idle. Travel speed switch in fast position. Drive machine at full speed forward on a flat and level area. After machine is moving, slowly move the arm control lever from neutral to full actuation to extend the arm. Does machine mistrack excessively when the arm is extended? YES: Go to your authorized dealer. NOTE: Machine will slow down during this test. NO: Go to next check.

How do I perform a Travel Speed Selection Check?

Engine at fast idle. Travel speed switch in fast position. Park machine on a level area. Move travel speed switch to slow speed position. YES: Go to next check. Does engine speed decrease? NO: Go to your authorized dealer.

How do I perform Cycle Times Check on a 120C?

Engine at fast idle. Auto-idle/auto-acceleration switch OFF. Travel speed switch in fast position. Record cycle time for each function. Does machine perform within specifications? NO: Go to your authorized dealer.

How do I perform Cycle Times Check on a 160CLC?

How do I perform Track Sag Roller And Idler Leakage Checks?

Swing upperstructure to side and raise track off ground. Operate track in reverse. Stop engine. Measure distance between top of track shoe to center of lower surface of track frame. Is track sag to specifications? NOTE: If track sag is less than specified, track chain wear will be accelerated. If it is less than specified on one side only, the machine may mistrack. Check rollers and idlers for oil leaks. Is oil leaking from rollers or idlers? Raise the other side of the machine and repeat checks. YES: Go to your authorized dealer for repair if oil leakage is noted from idlers or rollers. See Section 3-3 for more detailed information. NO: Go to next check.

How do I perform a Horn Circuit Check?

Key switch ON. Press horn button on top of left control lever. YES: Go to next check. Does horn sound? NO: Check fuse 14 in fuse box. Go to your authorized dealer.

How do I perform an Air Conditioner check?

Engine at fast idle. Turn air conditioner switch to ON position. Turn blower switch to high speed. Wait for any warm air in duct system to dissipate. Is air from ducts cool? YES: Check complete. See Section 2-1 for more detailed information. NO: Go to your authorized dealer.

How do I perform Miscellaneous Checks?

Does seat raise and lower easily?
Does seat angle change easily?
Does lever unlock easily and then lock to hold seat and consoles in position?
Does lever move easily to unlock seat support?
Does seat move forward and rearward easily?
Does lever lock seat support in position when released?
Does seat back tilt forward and rearward easily?
Does lever unlock and lock easily to hold seat back in position?

YES: Check complete. See Section 2-1 for more detailed information. NO: Inspect linkage.

How do I verify the Miscellaneous Machine Components?

Verify the following are working properly and all mounting brackets and hardware are tight:

All latches and locks.
Hood and access doors.
Hoses and clamps.
Fan shroud and fan guard YES: Check complete.
Fan direction NO: Repair or replace if necessary.

What should I do if the engine cranks but will not start or is hard to start?

Add fuel and bleed air if there is no fuel.
Use correct fuel if the wrong fuel was used.
Replace the fuel filter and bleed air if the fuel filter is clogged; clean the fuel tank inlet screen.
Check water separator if it is clogged or not primed.
Check, drain, and refill if there is water in the fuel.

What should I do if the engine is not developing full power?

Clean or replace filter elements if air filters are clogged.
Change the filter and bleed air if the fuel filter is clogged.
Change and bleed air if the water separator is clogged.
Drain the fuel tank, change the water separator, change the fuel filter, and bleed air; add clean fuel if the fuel is contaminated.
Use correct fuel if the wrong fuel was used.
Repair or replace the fuel line and bleed air if the fuel line is restricted.
Clean or install a new cap if there is a clogged vent in the fuel tank cap.

What should I do if the engine uses too much fuel?

Clean the air intake system if the air intake system is clogged or dirty. Use correct fuel if the wrong fuel was used.

What should I do if there is excessive black or gray exhaust smoke?

Use correct fuel if the wrong fuel was used.
Clean air intake and exhaust system if the air intake or exhaust system is clogged or dirty.

What should I do if the exhaust smoke is white?

Use correct fuel if the wrong fuel was used.
Run engine until warm if the engine is cold.

What should I do if the turbocharger is excessively noisy or vibrates?

Inspect and repair air leak in the engine, intake, or exhaust manifold.

What should I do if oil is dripping from the turbocharger adapter?

Check vent tube to ensure the tube is not clogged and clean if there is excessive crankcase pressure.
Remove and inspect/clean the turbocharger oil return line if there is carbon buildup where the line passes the exhaust manifold.

What should I do if nothing electrical works?

Recharge or replace the battery. Clean and tighten or replace batteries if there are loose or corroded connections and the batteries are undercharged.

What should I do if the alternator is noisy?

Replace the belt if the drive belt is worn.
Replace pulleys and belt if pulleys are worn.
Adjust the alternator mount if the pulley is misaligned.
Loosen alternator belts and turn the pulley by hand. If any roughness is felt, repair the alternator.

What should I do if no monitor panel indicators or gauges work?

Replace the fuse.

What should I do if individual indicators are not working in the monitor panel?

Replace the circuit board if an LED is not working.

What should I do if no switch panel switches or speed dial work?

Replace the fuse.

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