JOHN DEERE 650H (01) PDF MANUAL

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How should I recognize safety information?

This is the safety alert symbol. When you see this symbol on your 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 your 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.

What should I do to follow safety instructions?

Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. Be sure all operators of this machine understand every safety message. Replace the operator’s manual and safety labels immediately if missing or damaged.

When should I operate the machine?

Do not operate this machine unless the operator’s manual has been read carefully, and you have been qualified by supervised training and instruction. The 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.

What protective equipment should I wear?

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.

What should I know about unauthorized machine modifications?

John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application, as these can create hazardous situations or hazardous performance. Non-John Deere Parts, or any damage or failures resulting from their use are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. This applies to all aspects of the machine, including electronic controls. Always contact an authorized dealer before making machine modifications that change the intended use, weight, or balance of the machine, or that alter machine controls, performance, or reliability.

How do I inspect the machine?

Inspect the 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.

How can I stay clear of moving parts?

Entanglements in moving parts can cause serious injury. Stop the engine before examining, adjusting, or maintaining any part of the 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.

How can I avoid high-pressure fluids?

This machine uses a high-pressure hydraulic system. Escaping fluid 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 the location of escaping fluid. Stop the engine and relieve pressure before disconnecting lines or working on the hydraulic system.
If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid 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.

How can I protect myself from exhaust fumes?

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes, or open doors and windows to bring outside air into the area.

How can I prevent fires?

Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel the machine while smoking or when near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease, and oil from accumulating in the 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 multi-purpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

How can I prevent battery explosions?

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

How should I handle chemical products safely?

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 the 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.

How should I dispose of waste properly?

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.

How should I prepare for emergencies?

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.

When should I add cab guarding?

Special work situations or machine attachments may expose the operator to intruding or flying objects. Using this machine in a forestry application or woods environment, or with attachments such as a winch, requires added guarding to protect the operator. Forestry protection packages or special screens should be installed when working in areas where logs or branches may strike the operator. A rear screen should always be used with a winch to protect against a snapping cable. Contact your authorized dealer for information on protective guarding before operating in any hazardous environment.

How do I start the machine only from the operator’s seat?

Avoid unexpected machine movement. Before starting the engine, sit in the operator’s seat. Ensure the park lock lever is in the “lock” position. Never attempt to start the engine from the ground or tracks. Do not attempt to start the engine by shorting across the starter solenoid terminals.

How can I prevent unintended machine movement?

Always move the park lock lever to the “lock” position before leaving the operator’s seat for any reason. Be careful not to accidentally actuate controls when co-workers are present. Engage park lock and lower work equipment to the ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator’s seat, or exiting the machine.

How can I avoid worksite hazards?

Avoid contact with gas lines, buried cables, and water lines. Call utility line location services to identify all underground utilities before starting work. Prepare the worksite properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move the machine 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 the machine in congested areas or where visibility is restricted. Always keep the signal person in view. Coordinate hand signals before starting the machine. Operate only on solid footing with strength sufficient to support the machine. Be especially alert when working near embankments or excavations. Avoid working under over-hanging embankments or stockpiles that could collapse under or on the machine. Reduce machine speed when operating with a tool on or near the 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.

How do I keep riders off the machine?

Only allow the operator on the machine. Riders are subject to injury. They may fall from the machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct the operator’s view or impair their ability to operate the machine safely.

How can I avoid backover accidents?

Before moving the machine, be sure all persons are clear of the machine path. Turn around and look directly for best visibility. Use a mirror to assist in checking behind the machine. Keep windows and mirrors clean and in good repair. Be certain the backup warning alarm is working properly. Use a signal person when backing if the view is obstructed or when in close quarters. Keep the signal person in view at all times. Use prearranged hand signals to communicate.

How can I avoid machine tip-over?

Use a 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 the truck is wide enough and secured on a firm, level surface. Use loading ramps and attach them properly to the 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 because the machine may slip sideways in these conditions. When traveling up or down steep slopes, keep the bucket or blade on the uphill side and just above ground level. Ensure solid footing. Use extra care when operating on stockpile materials or near banks or excavations that may cave in and cause the machine to tip or fall.

How do I park and prepare for service safely?

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

Park the machine on a level surface and lower the blade/bucket and attachments to the ground.
Place the park lock lever in the “lock” position. Stop the engine and remove the key.
Attach a “Do Not Operate” tag in an obvious place in the operator’s station.

Securely support the machine or attachment before working under it.

Do not support the machine with the blade/bucket or attachments.
Do not support the machine with cinder blocks or wooden pieces that may crumble or crush.
Do not support the machine with a single jack or other devices that may slip out of place.

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

How do I service the cooling system safely?

Explosive release of fluids from a pressurized cooling system can cause serious burns. Shut off the engine. Only remove the filler cap when cool enough to touch with bare hands. Slowly loosen the cap to the first stop to relieve pressure before removing completely.

Why is it important to remove paint before welding or heating?

To 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 the 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 the 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.

How do I make welding repairs safely?

Disable electrical power before welding. Turn off the main battery switch or disconnect the 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 the 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.

How do I drive metal pins safely?

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.

What does the winch oil pressure indicator on the instrument panel indicate?

The indicator will light and the STOP indicator will light when the oil pressure is too low. Immediately stop the engine and investigate the problem.

What does the check service code indicator on the instrument panel indicate?

If the indicator stays lit, there is an electrical problem in the transmission control system. It is not necessary to stop the machine. The transmission controller will automatically put the machine in an operational mode that will not harm the engine. The service code that is present is displayed in the transmission controller display window. This service code number pinpoints the problem and is a very important aid for your authorized dealer to quickly diagnose the problem. Always relay this code number to your dealer when reporting your problem.

When does the STOP indicator flash and alarm sound?

The STOP indicator flashes and the alarm sounds when:

Engine oil pressure is too low
Transmission oil temperature is excessively high
Engine coolant temperature is excessively high

If the engine coolant temperature indicator lights indicating that the temperature is excessively high, DO NOT stop the engine. Reduce the load and run the engine at fast idle for several minutes. Stop the engine and service the machine.

What should I do if the engine coolant temperature indicator lights up?

The indicator will light and stay lit when the coolant temperature is too high. The STOP indicator will light and the audible alarm will sound. Immediately take the load off the machine and run the engine at fast idle for several minutes. If the indicator continues to stay on after several minutes of idling, stop the engine and take corrective action.

What should I do if the engine oil pressure indicator lights up?

NOTE: It is normal for the light to come on at start-up and stay on for a few minutes.

The indicator will light and stay lit when the engine coolant temperature is too high. The STOP indicator will light and stay lit and the audible alarm will sound. Immediately park the machine in a safe environment, stop the engine, and take corrective action.

What should I do if the transmission oil temperature indicator lights up?

The indicator will light and stay lit when the transmission oil temperature is too high. The STOP indicator will light and the audible alarm will sound. Immediately park the machine in a safe environment, stop the engine, and take corrective action.

What should I do if the hydraulic oil filter restriction indicator lights up?

The indicator will light and stay lit when the hydraulic oil temperature is too high. The STOP indicator will light and the audible alarm will sound. Immediately park the machine in a safe environment, stop the engine, and take corrective action.

What does the fasten seat belt/park lock on indicator indicate?

The indicator will light when the key switch is “On” and the park lock lever is in the up (locked) position.

What does the transmission oil filter indicator mean?

The indicator will light when the transmission filter element is restricted. It is not necessary to stop operation, but the cause should be investigated as soon as possible. It is normal for this light to remain lit for several minutes after start-up in cold weather. In extremely cold weather, it is a good practice to operate at reduced engine speed so the light stays off.

What does the voltage indicator mean?

The indicator will light when the battery/alternator is below 12-volts. It is not necessary to stop operation, but the cause should be investigated as soon as possible.

What does the engine air filter restriction indicator mean?

The indicator will light when the engine air filter element is restricted. It is not necessary to stop operation, but the cause should be investigated as soon as possible.

What does the fuel gauge indicate?

The gauge will reflect the fuel level in the tank. The fuel level gauge needle will enter the red zone when the fuel level in the tank is too low.

What does the engine oil pressure gauge indicate?

After the engine is started, the gauge needle must point to the green zone immediately and not drop into the red zone after warm-up. If the gauge needle drops into the red zone, stop the engine. See your authorized dealer.

What does the engine coolant temperature gauge indicate?

When the engine coolant temperature is too high, the gauge needle will move to the red zone. Immediately take the load off the machine and run the engine at fast idle. If the gauge needle stays in the red zone after several minutes of idling, stop the engine. See your authorized dealer.

What does the transmission oil pressure gauge indicate?

IMPORTANT: If the needle remains in the red zone after warm-up or moves to the red zone while operating, power train damage may occur. See your authorized dealer to correct low pressure.

After the engine is started, the gauge needle must move above the “0” point within a few seconds. If not, stop the engine and see your authorized dealer.

How do I use the front and rear work lights switch?

Push the upper half of the switch to turn the front and rear work lights on. Push the lower half to turn the lights off.

What is the hour meter for?

Use to determine when your machine needs periodic maintenance.

How do I use the Under-Seat Heater ON/OFF Switch?

Push the upper half of the switch to turn the heater on. Push the lower half to turn the heater off.

What does the transmission speed setting gauge display indicate?

When the machine is started, the transmission gauge speed setting default range of SP1.6 will be displayed in the gauge window (1). The speed range is displayed as a two-digit value. The values can range from SP1.0 to SP3.0. When the transmission speed control button (located on the FNR lever) is pressed and held in the “Up” position, the range SP value can reach a maximum value of SP3.0. When the speed control button is held in the “Down” position, the value will decrease to a minimum of SP1.0.

How do I use the select button on the instrument panel?

With the key switch “On”, press and hold the select button to cycle between displays on the display window.

What displays are shown on the display window?

The display window has seven displays. Press and hold the select button to cycle between displays on the display window when the monitor panel is active:

Transmission Speed Setting
Tachometer
Hour Meter
Voltmeter
Temperature Light for Transmission Oil Temperature or Hydraulic Oil Temperature
Hydraulic Oil Temperature
Transmission Oil Temperature

What should I do if the engine coolant temperature gauge is too high?

What should I do if the engine oil pressure gauge drops into the red zone?

What does the fuel level gauge indicate?

The gauge will reflect the fuel level in the tank. The fuel level gauge needle will enter the red zone when the fuel level in the tank is too low.

What does the seat belt/park brake indicator mean?

The indicator will light when the key switch is “On” and the park lock lever is in the up (locked) position.

What does the engine alternator voltage indicator mean?

The indicator will light when the battery/alternator is below 12-volts. It is not necessary to stop operation, but the cause should be investigated as soon as possible.

What does the engine air filter restriction indicator mean?

The indicator will light when the engine air filter element is restricted. It is not necessary to stop operation, but the cause should be investigated as soon as possible.

What does the hydraulic oil filter indicator mean?

The indicator will light when the hydraulic filter element is restricted. It is not necessary to stop operation, but the cause should be investigated as soon as possible.

What does the hydraulic oil temperature indicator mean?

The indicator will light when the hydraulic oil temperature reaches 107° C (225° F) and stay lit until the temperature drops below 104° C (220° F). The display window will automatically default to the current temperature. It is not necessary to stop operation, but the temperature must be monitored. The STOP indicator will light and the audible alarm will sound when the hydraulic oil temperature reaches 112° C (235° F) until it drops below 110° C (230°F). Immediately park the machine in a safe environment, stop the engine, and investigate the problem.

What does the transmission oil filter indicator mean?

What does the transmission oil temperature indicator mean?

The indicator will light when the transmission oil temperature reaches 93°C (200° F) and stay lit until the temperature drops below 90° C (195° F). The display window will automatically default to the current temperature. Reduce the load and monitor the temperature. The STOP indicator will light and the audible alarm will sound when the transmission oil temperature reaches 95° C (205° F). Immediately take the load off the machine and run the engine at fast idle for several minutes. If the indicator continues to stay on after several minutes of idling, stop the engine and investigate the problem.

What does the check service code indicator mean?

If the service code indicator stays lit, there is an electrical problem in the transmission control system. It is not necessary to stop the machine. The transmission controller will automatically put the machine in an operational mode that will not harm the machine. The service code that is present is displayed in the transmission controller display window. This service code number pinpoints the problem and is a very important aid for your authorized dealer to quickly diagnose the problem. Always relay this code number to your dealer when reporting your problem. The service code indicator will go out when the machine is shut down.

When does the stop indicator flash and alarm sound?

The STOP indicator flashes and the alarm sounds when:

Engine oil pressure is too low
Transmission oil temperature is excessively high
Engine coolant temperature is excessively high
Hydraulic temperature is excessively high

How do I use the start aid button?

Press and hold the button when the engine is cold and cranking to inject starting fluid into the engine during cold weather start-up.

How do I use the front and rear work lights switch?

Push the upper half of the switch to turn the front and rear work lights on. Push the lower half to turn the lights off.

What does the transmission oil pressure gauge indicate?

IMPORTANT: If the needle remains in the red zone after warm-up or moves to the red zone while operating, power train damage may occur. See your authorized dealer to correct low pressure.

After the engine is started, the gauge needle must move above the “0” point within a few seconds. If not, stop the engine and see your authorized dealer.

How do I use the Under-Seat Heater ON/OFF Switch?

Push the upper half of the switch to turn the heater on. Push the lower half to turn the heater off.

What will appear in the transmission controller display window when an active service code is received by the transmission control unit?

The code will appear in the display window (A). See Transmission Controller Service Codes for an explanation of service codes (Section 4-3).

What does the Status Light (Red) on the Transmission Controller indicate?

Indicates an active service code.

What does the Power Light (Green) on the Transmission Controller indicate?

Indicates power is supplied to the transmission controller. Key ON or engine running.

What codes will be displayed in the Status Window during operation?

The following codes will be displayed in the window during operation:

PARK
RUN
PBrk
Neut

What does the PARK display indicate?

The display indicates the park lock lever is in the up (LOCKED) position. The machine can be started.

Key ON
FNR lever is NEUTRAL

PARK will be displayed until the park lock lever is in the down (UNLOCKED) position.

What does the RUN display indicate?

The display indicates the controller is operating, with the park lock lever in the down (UNLOCKED) position.

Engine running
Park lock lever lowered
FNR in NEUTRAL

To move the machine, move the FNR to forward or reverse. RUN will be displayed while the machine is being operated.

What does the PBrk display indicate?

The display indicates the following condition:

Key ON
Park lock lever lowered

The machine will not start until the park lock lever is raised to the up (LOCKED) position.

What does the Neut display indicate?

The display indicates the following condition:

Park lock lever can be up or down
Key ON, engine not running
FNR not in neutral

The machine will not start until the FNR is moved to neutral and the park lock lever is in the up (LOCKED) position.

Neut display also indicates the following condition:

Engine running
FNR lever moved to forward or reverse before moving park lock lever to down (UNLOCKED) position.

To move the machine, return the FNR lever to neutral and move the park lock lever down.

How do I use the air conditioning and cab heater?

IMPORTANT: Do not operate the air conditioner when the air temperature is below –1°C (30°F).

Check the refrigerant for proper charge before using the air conditioner. See Check Air Conditioner Refrigerant Level—If Equipped (Section 4-1).

Push the upper half of switch (A) up to turn the air conditioner on. Push the lower half of the switch to turn the heat on.
Turn the temperature control knob © clockwise to increase the temperature.
Turn the blower control knob (B) clockwise to increase the blower speed.
If the temperature in the cab becomes too cold, the temperature knob can be turned to add heat even though the air conditioner is on.
Move louvers (D) left or right to direct or restrict airflow.

How do I use the windshield wiper and washer controls?

Push switch (A) to operate the front and rear (if equipped) windshield wiper. Push switch (B) to operate the door wipers. Continue to push the switch(es) to operate the washer fluid.

Where is the windshield washer reservoir?

The windshield washer reservoir (A) is located in the right side service compartment.

How do I sound the horn?

Push the horn switch (A) to sound the horn.

Where is the auxiliary power outlet located?

A 12-volt auxiliary power outlet (A) (if equipped) is located above the fuse access panel.

How can the side windows be used as secondary exits?

To open windows, pull locking lever (B) down and squeeze two forward tabs (A). Slide the window forward to the desired position. Raise locking lever (B) to lock the window in place. To close, pull the locking lever down, squeeze the tabs, and slide the window rearward until the window latch engages.

How do I adjust the non-suspension seat?

Use the flip-out lever to turn the weight adjustment knob ©. Turn the knob clockwise for a firm ride and counterclockwise for a soft ride. Lift lever (B) to adjust the cushion position. Lift the seat fore-aft lever (A) to move the seat forward and rearward. Release the handle at one of several positions.

How do I adjust the suspension seat?

Use the flip-out lever to turn the weight adjustment knob (E). Turn the knob clockwise for a firm ride and counterclockwise for a soft ride. Lift lever (D) to adjust the cushion position. Lift the seat fore-aft lever (A) to move the seat forward and rearward. Release the lever at one of several positions. Remove your weight from the seat. Lift up lever © and move the seat to one of three positions for height adjustment. Move the seat to the mid-to-aft position. While sitting in the seat, turn the weight adjustment knob (E) to support weight. Check the weight indicator (B) for the appropriate weight setting and continue to turn until the yellow pointer inside the tube is flush with the tube opening. While sitting in the seat, lift lever (H) and allow the cushion to angle forward or lean backward into the desired position and release the handle. While sitting in the seat, rotate the lumbar support knob (F) to increase or decrease support to the lower back.

How do I adjust the armrest?

To adjust the armrest, loosen cap screws (A) and slide the armrest up or down.

What should I inspect on the seat belt?

The seat belt and mounting hardware must be inspected for wear or damage before operating the machine. Replace the belt or mounting hardware if worn or damaged. Replace the complete seat belt assembly every three years regardless of appearance. A date label, to determine the age of the belt, is attached to each belt.

What safety and protective devices checks should I make daily before starting the machine?

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

What overall machine checks should I make daily before starting the machine?

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.
Check engine coolant level in coolant recovery tank.
Check engine oil level.
Drain sediment from the water separator.
Check hydraulic system oil level.
Check transmission oil level.
Check air cleaner dust unloader valve.
Check track sag.
Grease dozer linkage.

How do I check the instruments before starting (earlier machines)?

CAUTION: Use a seat belt when you operate the machine to minimize the chance of injury from an accident such as an overturn.

Turn the key switch to the BULB CHECK position. All indicator lights must come on.
If the lights do not come on, check the bulbs.
Turn the key switch to ON.
The low voltage and engine oil pressure indicators must light and gauge needles must move a little.

How do you program the start of heating?

Three switch-on times within the following 24-hour period or one switch-on time in seven days can be stored in memory. Only one switch-on time can be activated at a time.

How do you activate the first memory?

Press (B) once. Memory display (L): 1 (default setting 12:00).

How do you activate the second memory?

Press (B) twice. Memory display (L): 2 (default setting 12:00).

How do you activate the third memory?

Press (B) once more. Memory display (L): 3 (default setting 12:00).

What does it mean if there is a neutral status?

No memory is activated.

How do you return to neutral status?

Press (B) repeatedly until the memory display disappears.

How do you program switch on heating within 24 Hours?

The correct program day is automatically displayed and no adjustment is necessary.

How do you set the program time?

Press (B) repeatedly until the desired memory display (L) flashes 1, 2, or 3.
Briefly press and release (D) or (E). The program time will flash.
Set the program time for heating using (D) or (E). Setting is only possible if the program time is flashing.
To select another memory, press (B).

How do you program switch on heating after 24 hours (maximum seven days)?

Press (B) repeatedly until the desired memory display (L) flashes 1, 2, or 3.
Briefly press and release (D) or (E). The program time will flash.
Set the program time for heating using (D) or (E). Setting is only possible if the program time is flashing.
To select another memory, press (B).

How do you set the program day?

The program day begins to flash approximately 5 seconds after the program time has been set.

Set the program day for heating using (D) or (E).
The program time and program day are stored when the time display disappears or when the current time appears.

What indicates that a memory has been activated?

The memory display (L) indicates the activated memory. The flashing heating-on symbol (K) also indicates that a memory has been activated.

How do you check activated memory?

The program time of the displayed memory is displayed for approximately five seconds. The display then disappears or the current time is displayed (if the time is ON). The program time display (J) and the program day (I) can then be called up by pressing (B) once for five seconds.

How is the temperature displayed?

If an ambient temperature sensor is connected and the time is activated, the temperature can be permanently displayed by pressing (A) once. If the time is OFF, the time temperature is displayed for 15 seconds by pressing (A) twice.

What should you do if a service code appears in the display window (F)?

Press © to turn heater off and on (twice maximum).
Check fuse (A).
Check exhaust tube (A) for blockage.
See your authorized dealer.

What is the proper procedure for using booster batteries with a 12-volt system?

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

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. Then connect the other end of the negative cable to the machine frame as far away from the machine batteries as possible.
Start engine.
Immediately after starting the engine, disconnect the end of the negative cable from the machine frame and 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 should you do to warm up the engine?

After the engine starts, run at 1/2 speed for 2 minutes. Do not run at fast or slow idle.
Operate the machine at less-than-normal loads and speeds until the engine is at normal operating temperature.

What should you do for cold weather warm-up?

NOTE: If hydraulic oil is cold, hydraulic functions move slowly. Do not attempt machine operations until hydraulic functions move at close-to-normal cycle times.

In extremely cold conditions, an extended warming-up period will be necessary.
Avoid sudden operation of hydraulic functions until the engine is thoroughly warmed up.
Remove ice, snow, and mud from machine before operation.

Run engine at 1/2 speed for 5 minutes.
Cycle all hydraulic functions to distribute warmed oil until all functions operate freely.

How do you drive the machine with a standard FNR lever (earlier machines)?

Start engine.
Move the engine speed control lever (A) to desired engine rpm.
Move the park lock lever (D) to down (unlocked) position. NOTE: Transmission lever adjusts travel speed.
Move the transmission speed control lever (B) to desired setting. Number “3” is high transmission speed and number “1” is low transmission speed. NOTE: Use decelerator pedal to adjust engine speed.
Depress decelerator pedal.
Move FNR lever © toward F to travel forward and toward R to travel in reverse. Move FNR lever in desired turning direction to steer.
Slowly release the decelerator to increase engine speed to the selected engine rpm.

How does the transmission speed reverse ratio knob work?

The reverse speed ratio knob (1) located to the left of FNR with Transmission Speed-In-Grip lever adjusts the reverse speed as a percentage of the transmission speed setting. The reverse speed percentage settings are 80%, 100%, 115%, and 130%.

Transmission speed reverse setting will not exceed transmission maximum speed of SP3.0 11 km/h (6.8 mph).
- Example: If transmission speed is SP3.0 and the reverse ratio knob is set at 80%, then the reverse speed would be equivalent to 8.7 km/h (5.4 mph).

How do you use the FNR with Transmission Speed In Grip (if equipped)?

Push the top of the FNR with transmission speed button (A) to increase transmission speed. Push the bottom of the switch to lower the machine transmission speed.
Push the horn button (B) to sound the machine horn when needed.
Turn the knob counter-clockwise to decrease machine transmission speed.
The FNR with Transmission Speed-In-Grip lever controls the direction (forward and reverse), steering (left turn, right turn), pivot turn, and counter-rotation.

How do you drive the machine using FNR with Transmission Speed In Grip (if equipped) for earlier machines?

Fasten seat belt.
Park lock lever (5) must be in locked position (up).
Place FNR (2) with Transmission Speed-In-Grip to “Neutral” position.
Move engine speed control lever (4) to low idle position.
Start engine. Speed gauge (6) will display SP1.6.
Depress decelerator pedal.
Move park lock lever to down (unlocked) position. Speed gauge will display default transmission setting SP1.6. NOTE: Transmission speed button and reverse speed ratio knob adjust travel speed and may be adjusted at any time.
Place FNR with Transmission Speed-In-Grip lever in desired position.
Press transmission speed button (1) to desired setting (SP1.0—SP3.0) as seen in gauge. The transmission speed range is pre-set for a startup speed range of SP1.6. The transmission speed range can vary depending on operator’s preference from SP1 to SP3 (machine speed can vary from 0 to 5 mph).
Adjust the reverse transmission speed ratio knob (3). (Reverse speed ratio of 80%, 100%, 115%, or 130% of transmission speed).
Slowly release decelerator pedal to move machine.
Move engine speed lever to a desired rpm setting.
Move FNR with Transmission Speed-In-Grip lever in desired turning direction to steer.

How do you drive the machine using FNR with Transmission Speed In Grip (if equipped) for later machines?

Fasten seat belt.
Park lock lever (5) must be in locked position (up).
Place FNR (2) with Transmission Speed-In-Grip to “Neutral” position.
Move engine speed control lever (4) to low idle position.
Start engine.
Depress decelerator pedal.
Move park lock lever to down (unlocked) position. Speed gauge will display default transmission setting SP1.6. NOTE: Transmission speed button and reverse speed ratio knob adjust travel speed and may be adjusted at any time.
Place FNR with Transmission Speed-In-Grip lever in desired position.
Press transmission speed button (1) to desired setting (SP1.0—SP3.0) as seen in display window. The transmission speed range is pre-set for a startup speed range of SP1.6. The transmission speed range can vary depending on operator’s preference from SP1 to SP3 (machine speed can vary from 0 to 5 mph).
Adjust the reverse transmission speed ratio knob (3). (Reverse speed ratio of 80%, 100%, 115%, or 130% of transmission speed).
Slowly release decelerator pedal to move machine.
Move engine speed lever to a desired rpm setting.
Move FNR with Transmission Speed-In-Grip lever in desired turning direction to steer.

How do you steer the machine?

Move the lever forward to move the machine forward.

Move the lever rearward to move the machine in reverse.
Movement of lever in range (A) (spring force) will slow one track to turn machine in desired direction.
Further movement to range (B) (no spring force) will stop one track to make a pivot turn in desired direction.
Continued movement in range © (increased spring force) will move one track forward and one track in reverse to counter-rotate machine in desired direction.

How do you steer using the FNR with Transmission Speed In Grip Lever (if equipped)?

The FNR (2) with Transmission Speed-In-Grip controls the direction (forward and reverse), the steering (left turn, right turn), pivot turn, and counter-rotation. Moving the FNR fully right or left will cause the machine to counter-rotate.

How do you use the engine speed control lever?

To increase engine speed, move engine speed control lever (A) rearward to position (B) (rabbit). To decrease engine speed, move lever forward to position © (turtle).

What travel speed is provided when using the FNR Transmission Speed In the Grip (if equipped)?

Hydrostatic dual path transmission provides variable travel speed (SP1.0—SP3.0) ranging from 0—11 km/h (0—6.8 mph) in forward or reverse. Reverse speed ratios of 80%, 100%, 115%, and 130% until maximum mph is reached, from 0—11 km/h (0—5 mph) in reverse. Transmission speed default speed of SP1.6 will be displayed by moving park lock lever or pushing FNR Speed in the grip button (1 and 3).

How do the foot pedals work?

NOTE: Release of brake pedal will allow machine to move.

Brake pedal (B) should not be used to stop machine during normal operating conditions. Pushing on brake pedal will stop machine abruptly. Travel will resume as pedal is released.
Pushing on decelerator pedal (A) will slow engine rpm and reduce machine ground speed.

How do you use the park lock lever?

When the park lock lever is in the up (locked) position (B), the FNR lever can move but will not operate the machine.

When the park lock lever is in the down (unlocked) position (A), the FNR lever can move the machine.
If the park lock lever is pulled down while the FNR lever is in forward or reverse, the machine will not move. Put the FNR lever in neutral, then raise and lower the park lever. The machine is now operable.

How do you stop the machine?

NOTE: Park brake automatically engages when the engine is not running.

Stop the machine by doing one of the following:
- Push the decelerator pedal.
- Push the brake pedal.
- Move the FNR lever to N.
- Push the park lock lever to the up (locked) position.
- As a last resort, drop the blade to stop the machine.

How do you park the machine?

Park the machine on a level surface.
Lower equipment to the ground.
Move FNR control lever (1) to N. NOTE: Park brake automatically engages when engine is not running or park lock lever is in up (locked) position.
Move park lock lever (3) to up (locked) position. IMPORTANT: To avoid damage to the turbocharger (if equipped), run the engine at 1/2 speed no load for two minutes.
Run the engine at 1/2 speed no load for 2 minutes.
Move the engine speed control lever (2) to slow idle position.
Turn the key switch to “Off” to stop the engine.
Remove the key from the switch.
Release hydraulic pressure by moving the control lever until the equipment does not move.
Turn the battery disconnect switch off.

What are the advantages of pitching the blade forward?

With the top of the blade pitched forward (A), the blade will not carry as much soil. The weight of the soil carried by the blade adds to the weight of the dozer and moves the balance of weight on the tracks forward. This can cause the front idlers of the crawler to sink in loose or soft soils.

When the idlers sink, the blade cuts unevenly into the soil.
With the blade forward, the dozer balance does not change as much with a full blade; therefore, the tendency for idlers to sink is reduced.
With the blade forward, there is less of a tendency for dirt to come over the back of the blade when dozing uphill.
It is also easier to drop dirt at the end of a push when dozing uphill or when dozing very sticky materials.

What are the advantages of pitching the blade back?

With the blade pitched back (B), the cutting edge lies more horizontally resulting in a heavier cut into soils. Having the cutting edge more horizontal also provides a smoother cut in heavy soils.

More soil is carried by the blade when it is pitched back. Carrying more soil on the blade adds to the weight of the dozer. This added weight can increase push force in heavy soils.
The soil carried by the blade also moves the balance of weight forward on the machine. In heavy soils, this can be an advantage because the increased weight can help keep the front of the machine down and keep the cutting edge penetrating during heavy cutting.

How do you change the pitch?

To determine which link is assembled to the blade, look at the right side of the pitch link (A). Cast into the link will be one of the following: FORWARD, MID, or BACK.

The standard pitch link is a universal (MID) position link.
There are two optional pitch links available.
- The FORWARD link performs better in sand, stone grading and has best visibility to cutting edge.
- The BACK link performs better in cutting, backfilling, and moving large quantities of material.

How do you operate the blade?

Move the control lever rearward to raise the blade. Move the control lever forward to lower the blade.

Move the lever to full forward detent for float position. This position allows the blade to follow the contour of the ground. Manually release lever from this position.

How do you tilt the blade?

Move the blade control lever left to tilt the blade left.

Move the blade control lever right to tilt the blade right.

How do you angle the blade?

Twist the lever to the right to angle the blade to the right.

Twist the lever to the left to angle the blade to the left.

How do you operate the winch (if equipped)?

Operate the winch only from operator’s station.
Before operating the winch, place the winch control in free spool to circulate oil through winch until transmission oil reaches operating temperature.
- Move the lever to the FREE SPOOL (A) position so the cable can be pulled out freely.
- Move the lever to the BRAKE OFF (B) position so the cable can be pulled out with tension.
- Move the lever to the BRAKE ON © position to hold the cable.
- Move the lever to the POWER IN (D) position to wind the cable on the drum.
- Move the lever to the POWER OUT (E) position (if equipped) to unwind cable from drum.

How do you fasten the cable to the winch drum for 4000S Series with maximum cable capacities?

To conform with certain state laws, the cable must be attached to the drum so that it can come loose if the cable is unwound from winch drum.

Attach cable to winch drum using one of the following methods:
- First Method—Breakaway Anchor:
  1. Attach a ferrule or cable clamp (A) to end of cable.
  2. Wrap cable around the drum and slide the ferrule or cable clamp under the cable and into slot in drum and secure with tab ©.
- Second Method—Fixed Anchor:
  1. Remove drum plug.
  2. Thread cable up through small hole and wrap cable around wedge (A). Insert cable back down through lower hole and pull wedge into drum (B).
- Third Method: IMPORTANT: If you unwind cable below one turn on drum, cable will come off drum.
  1. Remove drum plug (B).
  2. Thread cable up through small hole and insert cable back down through lower hole. Pull loop into drum.
  3. Adjust free spool drag to operator’s preference. NOTE: Factory free spool drag setting was done without cable; adjust free spool drag to operator’s preference when cable is added.

How do you perform winch free spool drag adjustment?

The winch drum drag can be adjusted to the operator’s preference.

Start engine.
Lower equipment to ground.
Engage park brake.
Place winch control handle in FREE SPOOL position.
Loosen nut (A).
Adjust slotted shaft to desired winch drum drag.
Tighten nut.

How do you load the machine on a trailer?

Keep the trailer bed clean.
Put chock blocks (A) against truck wheels.
Use a ramp or loading dock. Ramps must be strong enough, have a low angle, and be of correct height.
Fasten seat belt before starting engine.
Load and unload the machine on a level surface.
Drive the machine onto the ramps squarely.
The centerline of the machine should be over the centerline of the trailer.
Lower all equipment onto blocks.
Move FNR lever to N.
Move park lock lever to lock position. IMPORTANT: To avoid damage to turbocharger (if equipped), run engine at 1/2 speed no load for two minutes.
Run engine at 1/2 speed no load for 2 minutes.
Move engine speed control lever to slow idle position.
Turn key switch to “Off”. Stop engine.
Remove key from switch.
Release hydraulic pressure by moving control lever until equipment does not move.
Turn battery disconnect switch off.
Cover exhaust opening to prevent entry of wind and water. IMPORTANT: Fasten chains or cables to the machine frame or track chain links. Do not place chains or cables over or against hydraulic lines or hoses.
Fasten each corner of the machine to the trailer with a chain or cable.
- Front: Use towhook eye on bottom of the machine frame front end.
- Side: Use inside edge of track shoe.
- Rear: Use outer edge of track shoe or drawbar (if equipped).

How do you release the park brake to tow the machine?

Order CO2 Inflation Kit and attaching hardware through your authorized dealer.

Stop engine.
Move park lock lever down to unlocked position.
Remove rubber mat and floor plate from operator’s station. NOTE: Multi-function valves can be turned out using a 1 1/4 in. socket and a flexible head ratchet.
TO TOW MACHINE FORWARD: Both front and rear pump top multi-function relief valves (1) MUST be turned out (counterclockwise) 1/2 to 1 turn and the blade must be raised off the ground. (If engine will crank but will not start, the blade can be raised by cranking the engine while holding the blade raise function on the control valve).
- TO TOW MACHINE IN REVERSE: Both front and rear pump bottom multi-function valves (2) MUST be turned out (counterclockwise) 1/2 to 1 turn.
Disconnect quick coupler (3).
Assemble the CO2 Inflation Kit and attaching hardware.
Install CO2 assembly to hose coupler end. IMPORTANT: Release brakes using CO2 with a MINIMUM pressure of 200 psi and a MAXIMUM pressure of 400 psi. DO NOT exceed the limits of the charge pressure gauge on the dash. NOTE: The brakes initially start to release at approximately 150 psi and are fully released at approximately 190 psi. With the park lock lever down, monitor the pressure on the transmission oil pressure gauge on the instrument panel.
While sitting in the operator’s seat, watch the charge pressure gauge on dash when releasing brakes using CO2 assembly. Pressurize brake circuit to approximately 200 psi. IMPORTANT: DO NOT tow the machine faster than 2.4 km/h (1.5 mph) or extensive machine damage may result. NOTE: Engine does not have to be running to tow the machine.
Tow the machine.
After the machine is towed, step on the brakes to release pressure. Remove CO2 assembly and reconnect coupler. Tighten multi-function valve lock nut to 79 N·m (58 lb-ft). See your authorized dealer for repair.

What are the required fuel properties for diesel fuel?

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).

What type of diesel fuel should be used with 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.

What type of diesel fuel should be used with Tier 3 and Stage III A engines?

Use of diesel fuel with sulfur content less than 1000 mg/kg (1000 ppm) is RECOMMENDED.
Use of diesel fuel with sulfur content 1000–5000 mg/kg (1000–5000 ppm) REDUCES oil and filter change intervals.
BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John Deere dealer.

What type of diesel fuel should be used with 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.

What type of diesel fuel should be used with 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.

What should you do if the local fuel distributor will only supply low sulfur fuel?

Order and use John Deere PREMIUM DIESEL FUEL CONDITIONER.

What data does a fuel analysis program provide?

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.

How should you handle and store diesel fuel?

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.

What type of diesel engine oil is used for the engine break-in period?

New engines are filled at the factory with either John Deere Break-In™ or John Deere Break-In Plus™ Engine Oil. During the break-in period, add John Deere Break-In™ or Break-In Plus ™ Engine Oil, respectively, as needed to maintain the specified oil level.

Operate the engine under various conditions, particularly heavy loads with minimal idling, to help seat engine components properly.
If John Deere Break-In Engine Oil is used during the initial operation of a new or rebuilt engine, change the oil and filter at a maximum of 250 hours.
If John Deere Break-In Plus Engine Oil is used, change the oil and filter at a minimum of 100 hours and a maximum equal to the interval specified for John Deere Plus-50™ II or Plus-50 oil.
After engine overhaul, fill the engine with either John Deere Break-In™ or Break-In Plus™ Engine Oil.
If John Deere Break-In or Break-In Plus Engine Oil is not available, use an SAE 10W-30 viscosity grade diesel engine oil meeting one of the following and change the oil and filter at a maximum of 100 hours of operation:
- API Service Classification CE
- API Service Classification CD
- API Service Classification CC
- ACEA Oil Sequence E2
- ACEA Oil Sequence E1 IMPORTANT: Do not use Plus-50™ II, Plus-50 or engine oils meeting any of the following for the initial break-in of a new or rebuilt engine: API CJ-4 ACEA E9 API CI-4 PLUS ACEA E7 API CI-4 ACEA E6 API CH-4 ACEA E5 API CG-4 ACEA E4 API CF-4 ACEA E3 API CF-2 API CF These oils will not allow the engine to break in properly.
John Deere Break-In Plus™ Engine Oil can be used for all John Deere diesel engines at all emission certification levels.
After the break-in period, use John Deere Plus-50™ II, John Deere Plus-50, or other diesel engine oil as recommended in this manual.

What type of diesel engine oil should you use after the break-in period?

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
- API Service Category CG-4
- API Service Category CF-4
- ACEA Oil Sequence E9
- ACEA Oil Sequence E7
- ACEA Oil Sequence E6
- ACEA Oil Sequence E5
- ACEA Oil Sequence E4
- ACEA Oil Sequence E3
- ACEA Oil Sequence E2
If oils meeting API CG-4, API CF-4, or ACEA E2 are used, reduce the service interval by 50%.
Multi-viscosity diesel engine oils are preferred.

What type of oil should be used for track rollers, front idler, and carrier roller?

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

The following oils are preferred:
- John Deere GEAR LUBRICANT (SAE 80W90)
- John Deere EXTREME-GARD
The following oils are recommended:
- API Service Classification GL-5 gear oil (SAE 80W90)
- Arctic oils such as (MIL-L-10324A) may be used at temperatures below –30°C (–11°F).

What type of oil should be used for transmission and hydraulic systems?

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

The following oils are preferred:
- Plus-50™
- TORQ-GARD ™
Other oils may be used if they meet one or more of the following:
- API Service Classification CG-4
- API Service Classification CH-4

How do you drain the final fuel filter sediment?

Loosen drain valve (A). Drain liquid for several seconds or until water and sediment is removed.
Tighten drain valve.
Bleed fuel system. See Replace Final Fuel Filter. (Section 3-7.)

How do you check the final drives oil level?

Park machine on a level surface and turn engine off.
Remove oil level and filler plug (A). Oil MUST be within 13 mm (0.5 in.) of bottom of filler hole.
Add oil if needed. See Final Drive and Winch Oil. (Section 3-1.)
Install plug.

How do you change the engine oil and filter on 450H, 550H (earlier machines), and all 650H machines?

Run engine to warm oil. Stop engine.
Remove cap screws and remove oil pan access cover (located below engine).
Remove drain plug or open drain valve, if equipped, and allow oil to drain into a container. Dispose of waste oil properly.
Install drain plug.
Remove oil filter (A).
Apply thin film of oil to gasket of new filter.
Install new filter. Turn filter clockwise by hand until gasket touches mounting surface.
Tighten 1/2 turn more.
Fill engine with oil. See Diesel Engine Oil. (Section 3-1.) Specification Engine Oil (Including Filter)—Capacity…14 L (15 qt) Approximate
Run engine for 2 minutes and then stop engine. Check for leaks around filter and drain plug. Tighten enough only to stop leaks.
Check oil level.

How do you check the air intake hose?

Check hose (A) for cracks.
Check for loose hose clamps.
Replace damaged or missing parts.

How do you replace the final fuel filter?

Turn retaining ring (A) counterclockwise and remove filter element (B). Allow sediment to drain into a container. Dispose of waste properly.
Clean filter base (D).
Install new fuel element by aligning vertical locators (F) into slots (E) on filter base. Push filter element up firmly until filter snaps against base.
Turn retaining ring clockwise into filter base until retaining ring clicks tightly into place.
Loosen bleed screw (G) by turning knob counterclockwise.
Operate primer lever (H) until fuel flow from bleed screw is free of air bubbles.
Tighten bleed screw.
Push primer lever up as far as possible.

How do you replace the primary fuel filter?

Thoroughly clean primary fuel filter and water separator assembly and surrounding area.
Connect a drain line (A) to filter drain adapters and drain all fuel from filters.
Firmly grasp the retaining ring and rotate it counterclockwise 1/4 turn. Remove ring with filter element (B).
Inspect filter mounting base for cleanliness. Clean as required.
Install water separator bowl onto new filter element. Tighten securely.
Thoroughly inspect filter base seal ring. Replace as needed.
Install new filter element onto mounting base and position element using a slight rocking motion. Be sure element is properly indexed on mounting base.
Install retaining ring onto mounting base and tighten about 1/3 turn until ring “snaps” into the detent. DO NOT overtighten the retaining ring.
Open air bleed vent screw (D) two full turns by hand.
Pump the hand primer © on fuel filter until a noticeable amount of fuel and air comes out of vent opening. Continue pumping and close vent screw when fuel starts to flow.
Pump the hand primer several times until resistance is felt. Continue pumping and open air bleed vent screw again.
Close air bleed vent screw and pump the hand primer several times until resistance is felt again.

How do you check the coolant conditioner in the radiator?

Use caution and remove the filler cap only when the engine is cold or cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

How do you check the battery electrolyte level and terminals?

Remove hold-down clamps.
Remove battery covers.
Clean all excess dirt or debris from the top of battery(s) before removing cell caps.
Fill each cell to within specified range with distilled water. DO NOT overfill.
Disconnect battery clamps, grounded clamp first.
Clean battery terminals (A) and clamps with a stiff brush.
Apply lubricating grease around battery terminal base only.
Install and tighten clamps, grounded clamp last.
Install hold-down clamps.

How do you replace the winch oil filter?

The winch oil filter is located on the right side between winch and crawler (A).
Remove three cap screws from oil filter access cover.
Remove oil filter access cover.
Remove filter (B) by turning counterclockwise.
Apply a thin film of oil to gasket of new filter.
Install new filter.
Install oil filter access cover with three cap screws.
Check winch oil. See Check Winch Oil—If Equipped. (Section 3-4.)

How do you clean the engine crankcase ventilation tube?

Remove tube (1). Clean and install.

How do you change the final drives oil?

Remove drain plug (B) on each side of machine.
Drain all oil. Allow oil to drain into a container. Dispose of waste oil properly.
Install drain plugs.
Remove fill plugs (A).
Fill housing with oil until oil flows from fill plug opening. See Final Drive and Winch Oil. (Section 3-1.)
Install fill plugs.

How do you replace the air cleaner elements?

On earlier 450H machines: Remove cover by pulling yellow lever (A) out approximately 13 mm (1/2 in.) and rotating cover counterclockwise approximately 25 mm (1 in.).
On later 450H machines and all 550H and 650H machines: Unfasten latches (A). Remove cover.
Remove primary element (B).
Clean air cleaner housing.
Install new elements. Make sure elements are fully seated into housing.
On 450H machines: Install cover with the dust unloader valve in the 5 o’clock position and yellow lever pulled out. While firmly pushing cover onto housing, rotate cover clockwise approximately 25 mm (1 in.) until cover snaps into place. Push the yellow lever in to lock. On 550H and 650H machines: Install cover with the dust unloader valve in the 5 o’clock position. Latch three latches to secure cover.

How do you replace the dust unloader valve?

To remove the dust unloader valve, pry the collar of the unloader valve (1) from the tube of air cleaner housing. Install a new unloader valve by stretching the collar over the flange on the tube of the air cleaner housing. Be sure there are no gaps between the valve collar and the tube. The valve should remain closed above 1/3 engine speed.

How do you drain and refill the winch oil and replace the filter?

Remove three cap screws from oil filter access cover.
Remove oil filter access cover.
Remove drain plug (B). Allow oil to drain into container. Dispose of waste properly.
Install drain plug.
Apply a thin film of oil to gasket of new filter.
Install new filter.
Fill winch oil reservoir through fill port located at top of winch (E) with 34 L (9 gal) of oil. See Final Drive and Winch Oil. (Section 3-1.)
Add remaining 4 L (1 gal) of oil through dipstick fill port (D).
Check winch oil. See Check Winch Oil—If Equipped. (Section 3-4.)
Install oil filter access cover with three cap screws.

How do you clean or replace the winch hydraulic breather filter?

Loosen clamp cap screw.
Remove hose (1) from breather filter (2).
Using compressed air, clean filter. If filter can not be cleaned, replace filter.
Install hose end on filter making sure arrow points in same direction (toward reservoir).
Tighten clamp (3) with cap screw.

How do you change the hydraulic oil and filter?

The hydraulic reservoir, filter, and drain are located on the right side of the machine. Remove fill cap (A).
Remove hydraulic drain access panel (A).
Attach hose to drain valve (B), if equipped, or remove drain plug and route hose to container. Drain oil. Dispose of waste oil properly.
Remove filter (A) by turning counterclockwise.
Apply thin film of oil to gasket of new filter.
Install new filter. Turn filter clockwise by hand until gasket touches mounting surface.
Tighten an additional 1/2 turn.
Fill the reservoir with oil. See Transmission and Hydraulic Oil. (Section 3-1.) Specification Hydraulic Oil Reservoir—Capacity…32 L (8.5 gal) Approximate
Check O-ring on fill cap and install fill cap.
Start engine and run for 2 minutes. Stop engine and check for leaks around filter base. Tighten filter only enough to stop leaks.
Check oil level in sight tube (B). Oil level must be between the ADD and FULL marks on tube. If necessary, add more oil.

How do you change the transmission oil and filter?

Transmission hydrostatic reservoir, filter and drain are located on left side of machine. Remove fill cap (B).
Remove transmission drain access panel (A).
Attach hose to drain valve (B), if equipped, or remove drain plug and route hose to container. Drain oil. Dispose of waste oil properly.
Put shallow pan on battery cover to prevent oil from transmission filter from dripping on battery(ies).
Remove oil filter (A) by turning counterclockwise.
Apply a thin film of oil to gasket of new filter.
Install new filter. Turn filter clockwise by hand until gasket touches mounting surface.
Tighten additional 1/2 turn.
Fill reservoir with oil. See Transmission and Hydraulic Oil. (Section 3-1.) Specification Transmission Oil Reservoir—Capacity… 53 L (14 gal)
Check O-ring on fill cap and install fill cap.
Start engine and run for 2 minutes. Stop engine and check for leaks around filter base. Tighten filter only enough to stop leaks.
Check oil level in sight glass tube (B). Oil level should be between the ADD and FULL marks. Add oil if necessary.

How do you drain the cooling system?

Release pressure and then remove radiator cap (A).
Open radiator drain valve (A).
Open drain valve (B) to drain engine block.
Flush system using commercial product.
Close all drain valves.
Add new coolant. See Diesel Engine Coolant. (Section 3-1).

How do you fill the cooling system?

With engine COLD, coolant level must be between HOT and COLD marks on the recovery tank (A). If coolant is below COLD mark, add coolant to the recovery tank. If there is no coolant in the recovery tank, add coolant to the recovery tank and radiator.

How do you clean the engine air precleaner screen?

To clean the engine air screen (A), remove the hose clamp and bowl. Shake the bowl to remove debris.

How do you perform C-Frame Ball / Blade Socket Joint Adjustment?

Park machine on level surface. Lower blade to ground.
Remove cap screws (1) from socket retainers (2). Remove shims (3).
Install ball socket retainers without shims. Measure gap, remove ball socket retainers.
Install enough shims to fill gap, plus one extra shim.
Install ball socket retainers. Tighten cap screws to specification.

How do you clean a dusty primary element?

Tap the element with the palm of your hand, NOT ON A HARD SURFACE.
If this does not remove dust, use compressed air under 210 kPa (2.1 bar) (30 psi). Direct air up and down the pleats from inside to outside. Be careful not to make a break in the element.

What are some precautions for alternator and regulator?

When batteries are connected, follow these rules:

Disconnect negative (–) battery cable when you work on or near alternator or regulator.
DO NOT TRY TO POLARIZE ALTERNATOR OR REGULATOR.
Be sure alternator wires are correctly connected BEFORE you connect batteries.
Do not ground alternator output terminal.
Do not disconnect or connect any alternator or regulator wires while batteries are connected or while alternator is operating.
Connect batteries or a booster battery in the correct polarity (positive [+] to positive [+] and negative [–] to negative [–]).
Do not disconnect the batteries when the engine is running and the alternator is charging.
Disconnect battery cables before connecting a battery charger to the batteries.

How do you handle, check, and service batteries carefully?

Turn battery disconnect switch to “Off”.
Remove battery cover.
Disconnect negative battery cable(s) first then positive (+) cable(s).
Remove nuts to remove hold down frame(s).
Lift out battery/batteries.
Check cables and clamps for damage and wear.
Make certain that the battery/batteries are fully charged.
Set the battery/batteries in the compartment making sure they are level.
Install hold down frames.
Connect cables; positive then negative.
Install battery cover.
Turn battery disconnect switch to ON.

How do you drain the fuel tank sump?

Remove rear access panel (A).
Remove left fuel sump access panel (B). If equipped with winch, remove both left and right fuel sump access panels.
Attach hose to drain cock © and route through sump opening. Open drain cock for several seconds to drain water and sediment.
Close drain cock. Replace fuel sump panel(s) and tighten cap screws.
Install rear access panel, if removed. Tighten cap screws.

How do you clean the fresh cab air filter (if equipped)?

Loosen wing nuts (A) to remove access cover.
Remove filter holder from compartment. Remove filter element.
Tap filter on flat surface with dirty side down to loosen and remove large portions of dirt.
Install filter. Tighten wing nuts.

How do you clean the cab air recirculation filter (if equipped)?

Pull latch holding filter in place.
Remove filter (A).
Use compressed air under 210 kPa (2.1 bar) (30 psi). Direct air opposite to normal air flow.
Wash filter in warm, soapy water, rinse and dry.
If filter will not come clean, replace as necessary.
Fasten latch.

How do you check the air conditioner refrigerant level (if equipped)?

Remove left side access cover of air conditioning compartment.
Using a mirror (A), check the color of the sight glass (B) to see if the receiver/dryer is wet (pink) or dry (blue).
If wet (pink), see your authorized dealer within the next 100 machine hours to service the receiver/dryer.

How do you adjust the engine speed control lever tension on earlier machines?

Open the left rear service door.
Adjust lock nut (A) until a minimum of 31—40 N (7—9 lb) force is required to initiate movement in the forward direction using a spring scale placed just below the knob of the lever.

How do you perform a neutral start system check?

Move FNR lever to N.
Move park lock lever to down (unlocked) position (A).
Turn key switch to “Start” position. Starter must not engage. If the engine starts, see your authorized dealer.
Move park lock lever to up (locked) position (B).
Turn key switch to “Start” position. Starter should engage. If the engine does not start, see your authorized dealer.
Move FNR lever to F or R.
Turn key switch to “Start” position. Starter must not engage.
Move FNR lever to N.
Turn key switch to “Start” position. Starter should engage. If starter does not engage, see your authorized dealer.

How do you check track shoe cap screw torque?

Track shoe bolt torque should be periodically checked. If the cap screws do not meet the minimum torque specifications, remove the shoes and clean the mating surfaces of the shoes and links before tightening the bolts. Tighten cap screws to torque specification using a criss-cross pattern. Then repeat torque pattern again. Tighten cap screws using the torque-turn torque method.

What is the operational checkout?

Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of the operation of the machine while doing a walk-around inspection and performing specific checks from the operator’s seat.

How do you perform cooling system checks?

Radiator Cap, Coolant Level, Coolant Condition Checks

Open radiator cap. If the radiator is warmer than air temperature, a “whoosh” must be heard when the radiator cap is opened to the first stop position. If the vacuum release valve is plugged or spring corroded, replace the radiator cap.
The radiator cap must have a stop position and must be pushed down to turn to remove. The radiator cap must have a good seal and gasket. The seal must move freely and the spring must not be corroded.
Inspect coolant level and coolant condition. The coolant must not be oily, foamy, or rusty. If rust is in coolant, drain, flush, and replace coolant. If coolant is oily or foamy, see your authorized dealer. If the radiator is low and the coolant tank has coolant in it, check for an air leak on the recovery hose. See your authorized dealer.

How do you perform a radiator outside airflow check (blower fan)?

Start engine and run at fast idle.
Air flow must be brisk and even through the radiator (it is normal to have less airflow at the center of the fan).
Stop the engine.
Inspect fins for mud and debris.
Sides of the radiator must be free of mud, leaves, grass, and other debris. Clean the outside of the radiator. Fins must be straight and not broken or cracked. Straighten fins. Replace the radiator if severely damaged. See your authorized dealer.

How do you perform hose, clamp, and water pump checks?

Inspect all radiator and heater hoses for cracks or leaks. Radiator and heater hoses must NOT be brittle, show signs of leaks, or rub on adjacent parts. Replace damaged hoses. See your authorized dealer. Inspect all hose clamps. All hose clamps must be tight and perpendicular to the hose. Crooked clamps can cause damage and leaks. Straighten and tighten clamps. See your authorized dealer. Inspect water pump for leaks. The water pump must NOT show signs of leaks. Replace the water pump. See your authorized dealer.

How do you perform fan checks?

Remove the engine side shield. Inspect fan blades for damage. Fan blades must not have any nicks or bends. Check fan for correct installation. The cupped portion of the fan blades must be forward from the radiator. If blades are bent, replace the fan. If fan blades are nicked, repair. See your authorized dealer. If the fan is installed backward, about 50% of its capacity is lost. Remove and reinstall the fan. See your authorized dealer.

How do you perform fan shroud and fan guard checks?

Check fan to fan shroud clearance. The fan must be centered in the fan shroud. Adjust the fan shroud.

How do you check the start aid?

Open the right rear service door. Check the position of the canister (A) in the holder. Inspect the plastic line from the top of the starting aid to the air intake manifold. There must NOT be any kinks or breaks in the line and the ends must be installed securely. Replace the plastic line. See your authorized dealer. Check for a dot on the ether starting aid nozzle in the air intake manifold. The dot must be at the 12 o’clock position on the fitting of the air intake manifold. Adjust the fitting so the dot is in the correct position. Press and hold the starting aid button down to operate starting aid.

How do you perform a water separator trap check?

Open the rear right side service access door. Loosen the drain knob and drain fuel for several seconds or until water and sediment are removed. Fuel must flow from the drain tube. If there is no flow, remove and clean the valve. See your authorized dealer. Tighten the drain knob. Replace the valve. See your authorized dealer.

How do you check the fuel cap?

Remove the fuel cap. Note: Air “hiss” from the tank is normal when the cap is removed. Inspect the fuel cap seal. The seal on the fuel cap must NOT be damaged and the vents must be open. Replace the fuel cap.

How do you perform a fuel tank check?

Remove the fuel cap. Use a flashlight and inspect the bottom of the fuel tank by shining light through the fuel. There must NOT be any pieces of debris such as leaves in the bottom of the fuel tank that would restrict fuel flow. The fuel sender ball must be floating on fuel. Remove large pieces of debris through the filler neck.

How do you perform final fuel filter checks?

Remove the right side engine side shield. “Crack” open the bleed screw on the fuel filter and operate the hand primer on the fuel transfer pump. Fuel must come out of the bleed screw when the hand primer is operated. Tighten the bleed screw of the fuel filter and again operate the hand primer on the fuel pump. Resistance must be felt when fuel is being pumped and no resistance will be felt after the system is pumped up. Turn the fuel filter knob to drain sediment.

How do you perform a park lock/neutral start switch and reverse warning alarm check?

Park lock lever down. Turn key switch to “Start” position. Brake pedal will move UP and must travel to full up position. Engine must not crank. Depress brake pedal.
Park lock lever up and FNR lever in forward. Turn key switch to start position. Engine must not crank.
Move FNR lever to reverse and key switch to start. Engine must not crank and reverse warning alarm must sound. Reverse warning alarm must NOT sound.

How do you perform transmission filter restriction indicator, transmission oil temperature, and park brake indicator checks?

Key switch “On” to bulb check position. Transmission oil filter restriction light, hydraulic oil filter restriction light, transmission oil temperature light, fasten seat belt indicator, and park brake indicator on. Start engine and set at slow idle. Transmission oil filter and temperature indicators OFF, park brake indicator on. Lower park brake lever. Park brake indicator goes OFF. Check the bulb in monitor.

How do you perform a transmission gauge and charge pressure check?

Start the engine and position the engine speed control lever at slow idle. The needle must be in the green. Slowly increase engine speed to fast idle. The needle must gradually rise as speed increases. At fast idle, the needle must still be in the green with very minimal fluctuation. The transmission oil filter restriction indicator might stay on until the oil reaches operating temperature.

How do you perform a park brake valve leakage check?

Operate the machine for several minutes to heat the hydrostatic oil to normal operating temperature.
Position the engine speed control at slow idle with the park lock lever UP.
Observe the transmission pressure gauge while moving the park lock lever to the DOWN position. The brake pedal will move to the full UP position as the park brake lever is lowered. Pressure should drop as the park lock lever is moved DOWN, then return to the original value. Depress the brake pedal. Pressure should drop as the brake pedal is released, then return to the original value. Isolate park brakes, brake valve to locate leakage. See your authorized dealer.
Observe tracks for any creep or movement.

How do you perform a park brake operational check?

Operate the machine slowly in forward. Fully depress the park brake pedal and then release. Machine MUST STOP when the pedal is depressed and MUST MOVE when the pedal is released.

How do you perform steering checks?

Transmission speed control at minimum speed position or speed in grip (if equipped) at 1.0. Run the engine at approximately 1200 rpm. FNR to forward. Move the steer lever or speed in grip to the right-hand detent position. The right-hand track should stop and the transmission pressure should remain in the green. Move the steer lever to the maximum right-hand position. The right-hand track must counter-rotate and the transmission pressure should remain in the green. Repeat check for the left-hand track. If charge pressure is not in green, see your authorized dealer.

How do you perform a decelerator pedal check?

Start engine. Park lock lever down. Depress the decelerator pedal. Move the engine speed control lever to fast idle. Transmission speed control at maximum speed or speed in grip (if equipped) to 3.0. FNR in forward. Release the decelerator pedal. The machine must accelerate smoothly to maximum speed. If engine speed increases and the decelerator pedal moves up, see your authorized dealer.

How do you perform an FNR check?

Engine speed at 1500 rpm. Transmission speed control at position 1 1/2 or speed in grip (if equipped) to 2.0. Make several shifts from neutral to forward, neutral to reverse, and then forward to reverse. Observe how both tracks start to increase in speed. Both tracks must start at the same time and the machine should move forward or reverse in a straight line.

How do you perform a multi-function relief valve check (closed-loop system relief valve)?

Engine at fast idle. Transmission speed at 2 1/2 position or speed in grip (if equipped) to 2.5. Machine at operating temperature. Place the machine under a heavy load with the blade. The machine must push straight and the tracks maintain the same speed. The engine must not cycle as a heavy load is pushed.

How do you check the battery disconnect switch?

Turn the battery disconnect switch OFF. Turn the key switch “On”. Do indicator lights illuminate? Turn the battery disconnect switch ON. Turn the key switch “On”, but do not start the engine. Do indicator lights illuminate?

How do you check the hour meter circuit?

Start the engine. The hour meter must be rotating after 1/10 hour. Stop the engine, turn the key switch “On”. The hour meter must not rotate.

How do you check work lights?

Key switch “On”. Push work light switch on. Both front work lights and rear light must come on. Check wiring.

How do you perform a front/rear wiper and washer motor check (if equipped)?

Key switch “On”. Push rocker switch (A) to first detent, middle position. Both front/rear wiper motors should operate. Push the rocker switch all the way in and hold. Both front/rear wiper motors and the washer motor should operate. Check the fuse. See your authorized dealer.

How do you check the key switch, monitor, and bulb?

Turn the key switch “On”. Stop light, engine oil pressure light, volts, and fasten seat belt/park brake light will be ON. The warning alarm will sound. Turn the key switch between the “On” and “Start” position to check bulbs. Does the winch oil pressure (if equipped), check service code, stop, engine coolant, engine air filter, volts, transmission oil filter, engine oil pressure, transmission oil temperature, hydraulic oil filter, and fasten seat belt/park brake come on and the warning alarm sound?

How do you perform an alternator check?

Key ON. Is volts light on? Check and recharge batteries.

How do you check the neutral start switch?

Move FNR to NEUTRAL. Apply brakes. Turn key to START position. The machine must start. Park lock lever UP. Move FNR to neutral. Turn key to start position. The machine must start.

How do you check the start circuit?

Park lock lever UP and FNR in NEUTRAL. Starting motor must operate. Engine must start. During engine cranking, on the monitor indicator, all monitor functions must be ON and the alarm must BEEP. On the gauge package, low voltage and engine oil pressure indicators must be ON, fuel gauge needles moves to full and other gauge needles move slightly.

How do you perform a visual check of the hydraulic system?

Park the machine on a level surface. Lower all equipment to the ground. Hydraulic oil must be visible in the sight glass located inside the right rear access door. Hydraulic lines and fittings must not seep or leak oil. Cylinder seals must not seep or leak oil.

How do you perform a drift check of the hydraulic system?

Operate the engine at slow idle. Place the dozer blade 50 mm (2 in.) from the ground. The blade must NOT touch ground within two minutes. Determine if drift is excessive for your operation, see your authorized dealer.

How do you perform a control valve lift check test?

Raise the dozer approximately 305 mm (1.0 ft) above the ground. Stop the engine. Pull the blade lever control lever. The blade must not lower.
Start the engine and raise the front of the machine, tilt full right. Stop the engine. Push the blade level control lever to the power down position and tilt right. The machine must not lower.
Start the engine and tilt the blade full left. Stop the engine. Push the blade level control lever to tilt left. The machine must not lower.

How do you perform a blade float check?

Raise the front of the crawler off of the ground with the blade. Push the blade level control lever into float detent. The front of the crawler must lower to the ground. The blade level control lever must stay in the float detent position.

How do you check hydraulic pump performance?

Hydraulic oil must be at operating temperature 66°C (150°F).
Operate the engine at slow idle.
Place blade on the ground.
Record the time required to raise the blade. Check the oil level and condition. See Check Hydraulic Oil Level. (Section 3-4.) Maximum cycle time 7.5 seconds.

How do you perform a track roller check?

Have another person operate the machine in the forward direction. All rollers must turn but must NOT “wobble”.

How do you check seat controls?

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

How do you perform an air conditioner compressor check (if equipped)?

Is the drive belt tight?
Is the belt in good condition, NOT frayed, worn, or glazed?
Are the compressor mounting brackets in good condition, and bracket cap screws tight?
Is the belt pulley in good condition, NOT worn or grooved?
Are electrical connections to compressor clutch clean and tight?
Is the wiring to the compressor in good condition?
Turn the fan ON to check for interference to shroud due to damaged fan blades.
Check the wiring harness system for damage or cuts.
Is there any noise of fan blades to shroud?
Are air conditioner hoses protected by cordura sleeves in the engine compartment next to the fan shroud and alternator area?

How do you perform a cab door and window seals check?

Open and close the door and windows. Inspect seals.

Do the door and windows contact seals evenly?
Are seals in position and in good condition?
Are latches aligned with strikers?
Are the door latches and door hold-open latches easy to operate?

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