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.

Should you experience a problem with your machine, you will find helpful diagnostic information in this checkout that will pinpoint the cause. This information may allow you to perform a simple adjustment which will reduce the downtime of your machine. Use the table of contents to help find adjustment procedures.

The information you provide after completing the operational checkout will allow you or your authorized dealer to pinpoint the specific test or repair work needed to restore the machine to design specifications.

A location will be required which is level and has adequate space to complete the checks. No tools or equipment are needed to perform the checkout.

Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) prior to doing the checkout. The machine must be at operating temperature for many of the checks.

Start at the top of the left column and read completely down column before performing check, follow this sequence from left to right. In the far right column, if no problem is found (OK), you will be instructed to go to next check. If a problem is indicated (NOT OK), you will be referred to either a section in this manual or to your authorized dealer.

TX,95,BG591 -19-21JAN97-1/1

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Gauges, Indicators and FNR Range Lever Check

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Start Circuit Check

Apply park brake.

Move FNR range lever to neutral position and turn key to START position.

LOOK: During engine cranking, all eight indicator lights must be on. On machines (S.N. -872256), SERVICE REQUIRED INDICATOR light must light and STOP must flash . On machines (S.N. 872257- ), SERVICE REQUIRED INDICATOR light and STOP must be on.

Starting motor must operate and engine must start.

NOTE: It is normal for stop indicator and park brake light to come ON as engine slows, but must go OFF when engine has stopped.

Turn key switch to OFF position.

Go to next check.

If engine turns but does not start, check fuel shut-off fuse.

Check fuel supply.

If starting motor does not operate, check FNR fuse and start relay fuse.

See your authorized dealer.

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Monitor Indicator Light and Alarm Check

Turn key switch to BULB CHECK position.

LOOK: On machines (S.N. -872256), all monitor indicators and SERVICE REQUIRED INDICATOR light must be on, STOP must flash and alarm must "BEEP". On machines (S.N. 872257-), all monitor indicators , SERVICE REQUIRED INDICATOR light and STOP must be on, and alarm must "BEEP".

Starting motor must NOT operate.

Go to next check.

Check monitor fuse.

If motor starts and bulb check position is OK, key switch failed or there is a short in the wiring. See your authorized dealer.

See your authorized dealer.

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Monitor Indicator Light Check

Turn key switch to OFF position.

LOOK: All lights must go out.

Go to next check.

Park brake and engine oil indicator lights stay on for 3 to 5 seconds after key switch is OFF.

Check for "open" in charging circuit. See your authorized dealer.

If park brake engine oil and alternator indicators stay on, see your authorized dealer.

See your authorized dealer.

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Engine Low Oil Pressure and Alternator Low Voltage Indicator Light Check

Turn key switch to BULB CHECK position then back to ON position.

LOOK: Only engine low oil pressure and alternator low voltage indicators must be on. On machines (S.N. -872256), STOP light must flash, seat belt light must be on and alarm must "BEEP". On machines (S.N. 872257- ), STOP and seat belt lights must be on and alarm must "BEEP"

No engine low pressure indicator light. See your authorized dealer.

No alternator low voltage indicator light. See your authorized dealer.

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FNR Range Lever Check

Move the FNR range lever to forward, reverse, then neutral position.

Twist range handle on FNR lever.

FEEL: Can detents be felt in forward, neutral and reverse?

Can four gear ranges be felt when twisting range handle?

LOOK: FNR range lever must align with neutral position to quadrant when in neutral (center) detent position.

LOOK: Does pointer on range handle line up with correct gear number on FNR range handle?

Go to next check.

See your authorized dealer.

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FNR Range Lever Neutral Start Switch and Reverse Warning Alarm Check

NOTE: On machines (S.N. -872256), neutral start switch is part of FNR circuit and is not on transmission spool. Reverse warning alarm is powered by FNR switch and reverse relay.

Put transmission in neutral.

Move FNR range lever to forward position and turn key to START position.

Move FNR range lever to reverse position and turn key to START position.

Starting motor must NOT operate.
Reverse warning alarm must sound when FNR range lever is in reverse position.

Go to next check.

See your authorized dealer.

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Park Brake Indicator and Tachometer/Hour Meter Circuit Check

IMPORTANT: If engine low oil pressure indicator light stays ON, stop engine immediately and check oil level.

Apply park brake.

Put FNR range lever in neutral position.

Move FNR range lever to 1st gear position.

LOOK: On machines (S.N. -872256), park brake indicator and STOP indicator lights must be on and flashing, all other lights must go out. On machines (S.N. 872257- ), park brake indicator and STOP indicator lights must be on, all other lights must go out. Alarm must "BEEP".

Go to next step in this check.

If engine low oil pressure indicator light stays on, stop engine immediately and check oil level. See Fuels and Lubricants chapter.

If alternator indicator light is on, increase engine speed to 1200 rpm and alternator light must go out. See your authorized dealer.

If no park brake light, see your authorized dealer.

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NOTE: Hour meter turns very slowly (one tenth hour every six minutes).

LOOK: Hour meter indicator (A) must rotate every 3 seconds.

LOOK: Tachometer must indicate rpm.

Release park brake.

LOOK: Park brake indicator and STOP light must go out. Alarm must stop "BEEPING".

Go to next check.

If no hour meter or tachometer movement, see your authorized dealer.

If park brake light stays ON, see your authorized dealer.

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Engine Speed Control Lever Linkage Check

Apply park brake.

Move FNR range lever to neutral.

Operate engine at slow idle.

Make note of rpm on tachometer.

Move speed control lever to fast idle position.

LOOK: Speed control lever must remain at selected position.

LOOK: Tachometer must read:

(S.N. -830204)

• 850 ± 50 rpm slow idle
• 2375 ± 50 rpm fast idle.

(S.N. 830205- )

• 900 ± 25 rpm slow idle
• 2375 ± 25 rpm fast idle

Go to next check.

Tighten speed control lever nut. See Adjust Engine Speed Control Lever Tension in Maintenance-As Required chapter.

Check injection pump override linkage. See your authorized dealer.

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Engine Speed Control Pedal Linkage Check

Depress speed control pedal.

Engine speed must be the same as with speed control lever in fast idle position.

Go to next check.

Adjust speed control linkage override. See your authorized dealer.

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Start Aid Check-If Equipped

Operate engine at slow idle.

Push start aid button once.

Engine speed must increase then return to slow idle.

Go to next check.

Check can contents by shaking.

Check fuse. See your authorized dealer.

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Service Brake System Check

Start engine.

Unlock brake pedals.

Set engine at 1200 rpm.

Move FNR range lever to 2nd gear.

After machine has moved for 3 seconds, depress and hold left brake pedal.

Repeat procedure for right brake pedal.

FEEL: Brake should stop tire rotation.

LOOK: Machine should surge to the side that the brake pedal is depressed.

Continue check.

Excessive leakage in brake system. See your authorized dealer.

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Service Brake Equalization Check (S.N. 872257- )

Park machine on inclined surface.

Lock service brake pedals together.

Park brake OFF.

Allow machine to coast forward.

Slowly apply service brakes to stop machine.

LOOK: Does front of machine pull to either left or right when service brakes are applied?

Go to next step in this check.

See your authorized dealer.

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Service Brake Retraction Check

Park machine on inclined surface.

Lock service brakes together.

Park brake OFF.

Shift FNR range lever to neutral.

Release service brakes.

LOOK: Does front of machine pull to the side when service brakes are released?

Go to next step in this check.

See your authorized dealer.

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Service Brake Pressure Indicator and Brake Accumulator Precharge (S.N. 872257- )

NOTE: Axles and hydraulic oil must be at operating temperature.

Stop engine.

Key switch ON. DO NOT start engine. Press right brake pedal and record number of applications until brake pressure indicator comes ON.

LOOK: Are at least 6 brake pedal applications needed before brake pressure indicator comes ON?

Repeat procedure for left brake pedal.

Go to next check.

If fewer than 7 brake pedal applications are required to turn brake pressure indicator ON, accumulator charge pressure may be low. See your authorized dealer.

If brake oil pressure indicator does not come ON, see your authorized dealer.

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Pedal Stop Check

Stop engine.

Release pedal latch.

Depress and release each brake pedal.

LOOK: Brake pedals must move freely and return to the up position. Both pedals must be even with each other in the up position.

Go to next step in this check.

Brake return passage may be closed. See your authorized dealer.

Lift each pedal.

FEEL: For machines (S.N. -872256), pedals must have approximately 6 mm (0.25 in.) free-travel above the rest position.

For machines (S.N. 872257- ), pedals must have no free-travel above the rest position.

Go to next check.

See your authorized dealer.

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Brake System Leakage Check

Start engine and run for 10 seconds.

Unlock brake pedals.

Run engine at slow idle. Depress and hold right brake pedal.

Release brake pedal.

Engine speed will not decrease as pedal is depressed.
There must NOT be any noticeable engine speed change when pedal is released or depressed.

LOOK: Rear brake light must come "on" when either pedal is depressed.

Repeat for left pedal.

Go to next check.

Excessive leakage in brake system. See your authorized dealer.

Inspect horn, brake, light fuse.

See your authorized dealer.

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Brake Pedal Latch Check

Latch the brake pedals together.

Kick each brake pedal three times.

LOOK: Latch must move freely and stay in desired position.

Go to next check.

Repair latch. See your authorized dealer.

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Park Brake Check

CAUTION: Prevent possible injury from unexpected machine movement. Fasten seat belt before doing this check.

Fasten seat belt.

Start machine on dry hard pavement.

Disengage MFWD (if equipped). Raise loader bucket to transport height, stabilizers fully up, and backhoe off the ground.

Move the park brake switch (B) to the OFF position.

Move the FNR range lever to 2nd gear, forward position.

Operate engine at 1000 rpm and drive approximately 7 m (20 ft) before moving the park brake switch to the "ON" position.

LOOK: The machine must stop within 2 m (6 ft).

LOOK: On machines (S.N. -872256), park brake switch light (B) will be ON. On machines (S.N. 872257- ), park brake indicator in monitor will be on.

FEEL: Transmission must shift into neutral.

Go to next check.

For machines (S.N. -872256), adjust park brake. See Check and Adjust Park Brake (S.N. -872256) in Maintenance-Every 1000 Hours chapter. For machines (S.N. 872257- ), see your authorized dealer for adjustment.

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Brake Drag Check

Engine on.

Position machine on a gradual grade with front of machine downhill.

Lift buckets so they clear ground.

Shift FNR range lever to neutral, differential lock pedal up, disengage park brake and release service brakes.

LOOK: Machine must move freely down slope.

CAUTION: Prevent possible injury from machine unexpected movement. Apply park brake, lower equipment, shut engine off, and block wheels before servicing machine.

Go to next check.

Brakes dragging. See your authorized dealer.

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Steering System Operational Check

Operate engine at approximately 1000 rpm.

Turn steering wheel from full left to full right several times.

LOOK: Front wheels must move smoothly in both directions.

LOOK: When steering wheel is stopped, front wheels must stop moving.

NOTE: Internal leakage or sticking steering valve spool can cause wheels to continue to move after steering wheel is stopped.

Go to next check.

Check hydraulic oil level. See Check Hydraulic Reservoir Oil Level in Maintenance-Every 250 Hours chapter.

See your authorized dealer.

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Steering System Leakage Check

NOTE: Hydraulic oil must be at operating temperature for this test.

Run engine at approximately 1000 rpm. Turn steering wheel until wheels are against stop. Continue turning steering wheel, using approximately 11.3 N·m (100 lb-in.) force.

Specification

Steering Wheel -Torque

11.3 N·m (100 lb-in.)

Repeat leakage check turning steering wheel to the left.

LOOK: Steering wheel should turn approximately 5 rpm, left or right.

NOTE: Use good judgment. Excessive steering wheel rpm does not mean steering performance will be affected.

Go to next check.

See your authorized dealer.

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Steering Priority Valve Check

Operate engine at slow idle.

Turn steering wheel left to right and note effort needed to turn wheel.

Operate the loader raise function and turn steering wheel at the same time. Note effort needed to turn the steering wheel.

FEEL: Effort to turn steering wheel must NOT increase when turning the wheel while a hydraulic function is activated.

Go to next check.

If steering wheel effort is more or wheel will not turn as hydraulic function is activated, a problem is indicated in steering priority valve. See your authorized dealer.

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Steering Priority Valve Pressure Check

Put front wheels on dirt or gravel.

Raise rear of machine so tires are just off ground using stabilizers.

Operate engine at approximately 1000 rpm.

Starting with front wheels in the straight ahead position, turn steering wheel to the left and right while raising loader.

LOOK: Wheels must turn to the left and to the right while loader is being raised.

Go to next check.

If front wheels do not turn in either direction, pressure setting is too low. See your authorized dealer.

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Clutch Disconnect Check

CAUTION: Machine should try to move forward as clutch is applied.

Release park brake.

Apply and hold service brakes.

Start engine, set engine speed at approximately 1200 rpm.

Put transmission in 2nd gear.

Shift FNR range lever to forward position.

Press loader lever switch on loader control and note sound of engine.

When FNR range lever is shifted to forward, a noticeable drop in engine speed should be heard.
Engine rpm must increase when the loader lever switch is pressed.

Go to next check.

See your authorized dealer.

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Transmission Warm-Up Procedure

CAUTION: Machine will try to move forward during this procedure. Use service brakes plus park brake to hold machine stationary.

IMPORTANT: Transmission oil must be at correct level and operating temperature.

Start engine.

Release park brake.

Latch service brakes together and hold during torque converter stalls.

Move FNR range lever to forward position.

Put transmission in 4th gear.

IMPORTANT: Limit stalls to 30 seconds to prevent localized overheating of torque converter.

Increase engine speed to fast idle and stall torque converter for 30 seconds. Move FNR range lever to neutral position for 15 seconds to let temperature stabilize.

Repeat stall four times to bring transmission to operating temperature.

NOTE: Cold ambient temperatures will require more stalls to get transmission to operating temperature. If transmission oil temperature light comes ON during procedure, stop stall procedure and put FNR range lever in neutral.

Go to next check.

Repeat warm-up procedure.

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Transmission Shift Check

Position machine on hard level surface.

Run engine at approximately 1500 rpm.

Shift transmission into all of the 4 forward and 2 reverse speeds, driving a short distance in each speed.

FEEL: FNR range lever must move freely into each speed. On machines (S.N. -872256), there must be 4 forward and 2 reverse speeds. On machines (S.N. 872257-), there must be 4 forward and 3 reverse speeds.

LOOK: The FNR range lever must stop at each detent.

Excessive gear and transmission noise must not be heard in any gear.

NOTE: When shifting to 3rd and 4th, it is normal for torque converter to slip but machine must not stop.

Go to next check.

See your authorized dealer.

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Front Wheel (Toe-In) Alignment Check

Drive machine in 4th forward on a surface with loose material such as gravel.

LOOK: Material behind front tires must not be thrown excessively inward or outward.

Go to the next check.

If material is thrown, excessive tire wear will result. See Check and Adjust Toe-In in Maintenance chapter.

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Engine and Transmission Check

Position machine with loader bucket at ground level against a dirt bank or immovable object.

Shift transmission into 1st gear.

Apply differential lock.

Move FNR range lever to forward position. Increase engine speed to fast idle.

LOOK: Engine must NOT stall.

LOOK: Rear wheels must NOT stall.

NOTE: This test will give a general indication of engine and transmission performance.

If loader bucket is positioned above the centerline of front axle and ground conditions are soft, the engine can be stalled due to the weight transferred to rear wheels and tractive conditions. The preceding situations should not be confused with low engine power.

Go to next check.

If engine stalls, check if fuel supply shut-off is closed. Check for restricted fuel or air filter.

If the wheels can be easily stalled, see your authorized dealer.

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Transmission Shift Modulation Check

Raise rear of machine off ground using stabilizers.

MFWD OFF.

Park brake OFF.

Engine speed at 1500 rpm.

Shift machine from neutral to 1st forward.

Twist FNR lever handle to shift from 1st forward to 2nd forward.

Continue to twist FNR lever handle until 4th forward. Allow machine to come up to speed before making each sequential shift.

Repeat for reverse.

Does machine shift smoothly with no clunking or jerking of power train?

Go to next check.

See your authorized dealer.

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B3, C2 Accumulator Check (S.N. -872256)

Perform this check on dirt or loose gravel surface.

Operate machine at approximately 1500 rpm in 1st gear forward.

Shift to 2nd gear and observe rear tires.

LOOK: Rear wheels must not spin (lose traction) as machine comes up to speed.

FEEL: Machine must not "jerk" aggressively during this shift.

NOTE: A "clunk" sound will be heard if shift is too aggressive.

Go to next check.

Too aggressive shifts or "clunk" sound. See your authorized dealer.

Slow shifts, check oil level. See your authorized dealer.

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C1, B1, B2 Accumulator Check (S.N. -872256)

Operate machine on hard surface such as compacted clay or road.

Operate machine at approximately 1500 rpm in 2nd forward.

Make several forward to reverse shifts. Count the number of seconds (one thousand one-one thousand two, etc.) required for machine to change direction and get up to speed.

LOOK/FEEL: Machine must change direction within 1-1/2 seconds and be up to speed in 3 seconds.

Go to next check.

Slow shifts can be caused by low oil level or restricted filter. See your authorized dealer.

Too fast shifts or "clunk" sound. See your authorized dealer.

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C1 Clutch, B1, B2 Brake Drag Check (S.N. -872256)

Raise wheels off ground with stabilizers and loader bucket.

Release park brake.

Shift transmission to 2nd forward.

Adjust engine speed to 1000 rpm.

Move FNR range lever to neutral position.

LOOK: Both rear wheels must stop.

NOTE: If wheels turn, apply service brakes until wheels stop and note change in rpm on tachometer.

If depressing brake pedal causes rpm to drop enough that difference can be seen on tachometer (15 rpm), it indicates warped disks in that pack. Lube oil does not affect these "drag" checks because they are done at operating temperature and at slow idle. If "drag" is caused by lube oil within the transmission clutches and brakes, "drag" will increase when oil is cold. When engine speed is increased to 1500 rpm or higher, "drag" is reduced because lube relief valve opens and returns excessive cold oil to sump. It is normal for wheels to "creep" with cold oil as engine speed is increased but to stop moving at speeds above 2000 rpm. If "drag" is caused by warped clutch or brake disks or plates, "drag" will be seen at any oil temperature and will increase proportionally as engine speed is increased.

Go to next check.

See your authorized dealer.

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C2 Clutch, B3 Brake Drag Check (S.N. -872256)

Raise wheels off ground with stabilizers and loader bucket.

Release park brake.

Shift transmission to 1st forward.

Adjust engine speed to 1000 rpm per tachometer.

Shift transmission to 2nd forward.

LOOK: Wheels must increase in speed but engine rpm must return to 1000 rpm.

Go to next check.

See your authorized dealer.

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Differential Lock Check

Raise wheels off ground with stabilizers and loader bucket.

Unlock brake pedals. Turn MFWD switch (if equipped) off.

Operate machine at approximately 1500 rpm in 1st forward.

Depress differential lock pedal or switch.

Apply one brake pedal until engine rpm drops.

LOOK/FEEL: Both wheels must turn at same speed.

Release differential lock pedal or switch.

LOOK: Pedal or switch must return to up position and engine speed must return to 1500 rpm.

Release brake pedal and move transmission control levers to neutral.

Reduce engine speed to slow idle.

Depress differential lock pedal or switch and note engine rpm change.

LOOK/LISTEN: Must hear/see only slight decrease in engine rpm as the pedal is depressed.

Go to next check.

See your authorized dealer.

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Differential Gear and Pinion Noise Check

NOTE: Hold the wheel being braked stationary during this check or brake chatter could be confused with differential gear noise.

Raise wheels off ground with stabilizers and loader bucket.

Operate engine at approximately 1500 rpm in 1st forward.

LOOK: Both wheels must turn at same speed.

Depress right brake pedal until wheel stops. Observe left wheel.

LOOK: Wheel being braked must stop and opposite wheel must increase in speed.

Release right brake and depress left brake pedal until wheel stops. Observe right wheel.

LOOK: Wheel being braked must stop and opposite wheel must increase in speed.

No excessive gear noise must be heard in the differential or pinion gears.

Go to next check.

See your authorized dealer.

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MFWD Clutch Drag Check

Raise machine off ground with stabilizers and loader bucket.

Shift transmission to 2nd gear and FNR range lever to forward position.

Run engine speed at 1000 rpm.

Check that MFWD control is disengaged (switch up/light off).

Lower front wheels to ground and raise bucket above ground.

LOOK: MFWD indicator light must be off.

LOOK: Front wheels may turn while wheels are off ground but must stop when lowered to ground. Rear wheels must continue to turn.

Go to next check.

If light is on, check fuse.

If rear wheels stop, MFWD control valve problem or clutch "drag" is indicated. Repeat check using 1st gear.

If front wheels turn, or rear wheels stall, MFWD solenoid valve problem is indicated. See your authorized dealer.

If front wheels remain stopped, see your authorized dealer.

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MFWD Limited-Slip Differential and Solenoid Valve Check

Shift transmission to 1st reverse.

Apply MFWD and drive machine.

Run engine at approximately 1200 rpm.

Turn steering wheel for a full left or right turn and observe the front tires.

LOOK: Observe how the front tires attempt to slide sideways (side load) and the amount of tire scuffing. MFWD indicator lights must be on.

Disengage MFWD switch.

LOOK: Tire side loading and scuffing must stop when MFWD is disengaged.

LOOK: MFWD indicator light (A) in switch must be off.

NOTE: If tires attempt to slide sideways and tire scuffing is seen with MFWD applied, limited-slip differential is working and power is being transmitted to MFWD.

Go to next check.

If tires do not attempt to slide sideways and tire scuffing is not seen with MFWD applied, see your authorized dealer.

Repair limited-slip in MFWD differential. See your authorized dealer.

If light stays on, inspect fuse.

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MFWD Gear and Pinion Noise Check

Drive machine at transport speed with MFWD applied, then disengaged.

MFWD must NOT "whine" when disengaged.

Go to next check.

If MFWD "whines", check oil levels and fill to specification. See Fuels and Lubricants chapter.

Check backlash. See your authorized dealer.

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Hydraulic Pump Performance Check

NOTE: If hydraulic oil is not at operating temperature, heat hydraulic oil until loader and backhoe cylinders feel warm to touch using following procedure:

Cover front of radiator to stop air flow.

Activate backhoe boom down function and run engine at 2000 rpm.

NOTE: Activating boom down may load engine, boom down relief valve is set too high or hydraulic pump stand-by pressure too low.

Operate all functions periodically to distribute heated oil to all cylinders.

Lower stabilizers.

Put backhoe at maximum reach with bucket fully dumped at ground level.

Run engine at 2000 rpm.

Measure cycle time by simulating loading the bucket, retracting the dipperstick and raising the boom to the boom cylinder cushion. Do not time boom cylinder through cushion.

LOOK/LISTEN: Boom down must reduce engine rpm.

NOTE: Take the average cycle time for at least three complete cycles. This average cycle time will give a general indication of hydraulic pump performance.

LOOK: The maximum cycle time is 11.5 seconds.

Go to next check.

See your authorized dealer.

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Hydraulic System Charge and Return System Check

Raise machine with stabilizers until wheels are 150 mm (6.0 in.) off ground.

Fully extend dipperstick, putting bucket in loaded position and lower boom until dipperstick is 45° to the ground.

Slowly retract dipperstick. Bucket must clear ground.

Fully extend dipperstick.

Run engine at 1200 rpm.

Retract dipperstick while holding control valve fully open.

LOOK: Dipperstick can slow down, but must NOT stop moving during test.

Go to next check.

See your authorized dealer.

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Hydraulic Control Valve Lift Check Test

Raise loader until bucket is 1 m (3 ft) off ground with the bucket level.

Position backhoe at maximum reach with bottom of bucket level with ground, 1 m (3 ft) off ground.

Stop the engine.

Activate each function one at a time:

• Loader boom raise
• Loader bucket rollback
• Backhoe boom up
• Dipperstick extend
• Backhoe bucket dump

LOOK: These functions must NOT move when the control lever is activated.

NOTE: It is normal for a function to jump upward but must not lower.

Go to next check.

See your authorized dealer.

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Backhoe Circuit Leakage Checks

Put backhoe in transport position and set boom and swing lock.

Retract extendible dipperstick (if equipped).

Raise stabilizers to full down position.

Run engine at slow idle.

Fully activate functions one at a time:

• Boom up
• Bucket load
• Dipperstick retract
• Extendible dipperstick retract (if equipped)
When these functions are activated, NO decrease in engine rpm must be noted.

Fully activate functions one at a time:

• Boom down
• Swing left, then right
Boom down may cause rpm to decrease since relief valve setting is below standby pressure.

LOOK/LISTEN: Swing left and right may cause rpm to decrease slightly because relief valve setting is close to standby pressure.

NOTE: If boom down does not decrease engine rpm, check main pump standby pressure.

Pressure seal passages are used in boom valve and leakage return passages are used in swing valve. When boom down or swing functions are bottomed and control valves are "metered", rpm will decrease and leakage within circuit will be apparent. This is normal.

Go to next step in this check.

See your authorized dealer.

Raise stabilizer to maximum up position, extend dipperstick to maximum reach, extend extendible dipperstick (if equipped) and put bucket in dump position 1 m (3 ft) off ground.

Fully activate functions, one at a time:

• Extend dipperstick
• Extend extendible dipperstick (if equipped)
• Bucket dump
When these functions are activated, NO decrease in engine rpm must be noted.

Go to next check.

See your authorized dealer.

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Loader Circuit Leakage Check

Raise loader to full height, bucket in dump position.

Run engine at slow idle.

Fully activate functions one at a time:

• Loader boom up
• Bucket dump

Put bucket in rollback position and lower loader to full down position.

Fully activate functions, one at a time:

• Loader boom down
• Bucket rollback
When functions are activated, engine rpm must NOT decrease.

NOTE: Leakage return passages are used in boom valve. When boom cylinders are retracted and valve is "metered", rpm will decrease and leakage within circuit will be apparent. This is normal.

Go to next check.

See your authorized dealer.

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Cylinder Cushion Check

Run engine at slow idle.

Lower stabilizers to the ground.

Lower backhoe boom 45° outward.

Fully activate functions, one at a time:

• Backhoe swing left and right
• Backhoe boom raise
• Dipperstick retract
Note sound and speed as cylinders near the end of their stroke.

LOOK: Speed of cylinder rod must decrease near the end of its stroke.

Must hear oil flowing through orifice as cylinder rod nears the end of its stroke.

Go to next check.

See your authorized dealer.

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Backhoe and Loader Function Drift Check

FEEL: Backhoe cylinder must be warm to touch 38-52°C (100-125°F). If cylinders are not warm, heat hydraulic oil.

Raise machine off ground with stabilizers.

Position backhoe bucket at a 45° angle to the ground. Lower boom until bucket cutting edge is 50 mm (2.0 in.) off ground.

Position loader bucket at the same angle and distance from ground as backhoe bucket.

Run engine at slow idle and observe bucket cutting edges.

LOOK: If bucket cutting edges touch the ground within one minute, leakage is indicated in the crowd cylinder, bucket or boom cylinders, or control valves.

Go to next check.

See your authorized dealer.

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Loader Boom Float and Return-to-Dig Check

Put loader at maximum height position with bucket dumped.

Run engine at approximately 2000 rpm.

Move the loader control lever forward into boom float detent position, and at the same time into bucket rollback detent position. Remove hand from control lever.

LOOK: Loader control lever must remain in the boom float detent position.

Go to next step in this check.

If lever jumps out of detent, inspect detent spring and balls. See your authorized dealer.

LOOK: Loader control lever must disengage from the bucket rollback detent when the bucket is level.

Go to next step in this check.

See Adjusting Loader Bucket Level Indicator and Return-to-Dig Switch in Operating the Machine chapter.

LOOK: When the bucket is at ground level, bucket must be level and the bucket indicator pointer must be aligned with mark on the boom pivot.

NOTE: When return-to-dig is used with loader boom in full up position, the bucket leveling linkage will move the bucket control valve out of return-to-dig position before bucket is actually level.

Go to next check.

Adjust linkage as necessary. See Adjusting Loader Bucket Level Indicator and Return-to-Dig Switch in Operating the Machine chapter.

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Bucket Leveling Linkage Check

NOTE: The loader bucket leveling feature functions during the boom raise cycle only.

Put bucket in the rollback position with the boom near the ground level.

Raise the loader and at the same time, hold the control lever in the bucket rollback position.

Observe bucket and loader control lever as the loader rises.

LOOK/FEEL: Loader control lever must move into the bucket dump position and the bucket dump function must slowly activate. When the loader control lever moves to activate the bucket dump function, the bucket position must remain stationary the remainder of the loader boom raise cycle.

Go to next check.

See Adjusting Loader Bucket Self-Leveling Linkage in Operating the Machine chapter.

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All Lines and Hoses

Engine OFF.

Inspect all lines and hoses.

Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts or "weather checked"?

Are hose and line connections clean NOT showing signs of leakage, such as oil or dust accumulation at fittings?

All hose and line clamps must be in place and tight. Clamps must have rubber inserts or cushions in place to prevent clamps from crushing or wearing into hoses or lines?

Check complete.

Reposition hoses or lines and tighten or replace clamps. Tighten fittings or replace O-rings in fittings. Replace hoses or lines as required.

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Air Conditioner Compressor Check

Inspect compressor.

Is compressor drive belt tight?

Is belt in good condition, NOT frayed, worn or glazed?

Is compressor belt pulley in good condition, NOT worn or grooved?

Are compressor mounting brackets in good condition, and bracket cap screws tight?

Are electrical connections to compressor clutch clean and tight? Is wiring to compressor in good condition?

Check complete.

Repair or replace components as required. See your authorized dealer.

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Condenser Check

Engine OFF.

Inspect condenser cores.

Is condenser core free of dirt or debris?

Does condenser show signs of leakage, dust accumulation or oily areas?

Are condenser fins straight, not bent or damaged?

Inspect engine fan.

Are fan blades in good condition, not worn, bent, broken or missing?

Check complete.

Clean, repair or replace condenser core. Replace engine fan. See your authorized dealer.

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Evaporator Check

Remove seat and heater/blower cover.

Is ice forming on evaporator core?

Is fan motor failing or fan blades damaged?

Is freeze switch sensing tube properly positioned?

Is heater temperature balance control misadjusted or damaged?

Is evaporator drain tubes plugged?

Check complete.

See your authorized dealer.

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Evaporator Core Check

Engine OFF.

Inspect core.

Are fins straight?

Is evaporator core free of dirt and debris?

Check complete.

Repair, replace or clean evaporator. See your authorized dealer.

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A/C Freeze Switch Sensing Tube Check

Engine OFF.

Inspect A/C freeze switch sensing tube.

Is sensing tube straight, NOT kinked or broken?

Is sensing tube inserted into evaporator core and secured in place?

Check complete.

See your authorized dealer.

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Expansion Valve Check

Is expansion valve outlet line free of frost?

Is insulating tape wound tightly around outlet line and is tape in good condition?

Check complete.

See your authorized dealer.

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Cab Door and Window Seals Check

Open and close door and windows. Inspect seals.

Do door and windows contact seals evenly?

Are seals in position and in good condition?

Check complete.

Adjust door and windows to close against seals properly. Replace seals as necessary. See your authorized dealer.

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Blower Motor Check (S.N. -816286)

Engine OFF.

Key switch ON.

Turn blower switch (A) to LOW, MEDIUM and HIGH.

Does fan have three speeds?

Does air exit from ducts?

Check complete.

See your authorized dealer.

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Heater (S.N. -816286)

Start engine and allow to warm several minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high speed.

Does warm air exit from ducts?

Check complete.

See your authorized dealer.

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Air Conditioner (S.N. -816286)

Start engine and run at fast idle.

Turn air conditioner switch (A) to ON position.

Turn blower switch (B) to high speed.

Wait several minutes for any warm air in duct system to escape.

Is air from ducts cool?

Check complete.

See your authorized dealer.

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Blower Motor Check (S.N. 816287- )

Engine OFF. Key switch ON.

Turn blower switch (A) to position 1, 2, 3 and 4.

Does fan have four speeds?

Does air exit from ducts?

Check complete.

See your authorized dealer.

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Heater (S.N. 816287- )

Start engine and allow to warm several minutes.

Turn heater temperature switch (A) to maximum heat. Turn blower switch (B) to high speed.

Does warm air exit from ducts?

Check complete.

See your authorized dealer.

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Air Conditioner (S.N. 816287- )

Start engine and run at fast idle.

Turn air conditioner switch (A) to ON position.

Turn blower switch (B) to high speed.

Wait for any warm air in duct system to dissipate.

Is air from ducts cool?

Check complete.

See your authorized dealer.

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Compressor Clutch Check

Engine OFF.

Key switch ON.

Blower switch on LOW.

Air conditioner switch ON.

Does compressor clutch "click" as switch is pushed?

Check complete.

See your authorized dealer.

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Radiator Cap, Coolant Level, Coolant Condition Checks

CAUTION: DO NOT remove radiator cap unless engine is cool. Turn cap slowly to stop. Release all pressure before removing cap.

Open radiator cap.

If radiator is warmer than air temperature, a "whoosh" must be heard when radiator cap is opened to first stop position.

FEEL: The radiator cap must have a stop position and must be pushed down to turn to remove.

Inspect coolant level and coolant condition.

LOOK: The radiator cap must have a good seal and gasket. The seal must move freely and the spring must not be corroded.

LOOK: The vacuum release valve (center of cap rubber seal) must move freely and holes must not be plugged.

LOOK: The coolant must not be oily, foamy or rusty.

Check complete.

If vacuum release valve is plugged or spring corroded, replace radiator cap.

If coolant is oily or foamy, see your authorized dealer.

If rust is in coolant, see Draining the Cooling System in Maintenance chapter.

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Hose and Water Pump Check

Inspect all radiator and heater hoses and water pump for cracks or leaks.

LOOK: Radiator hoses must not be brittle or show signs of leaks.

Check all hose clamps.

LOOK: All hose clamps must be tight.

Squeeze lower radiator hose.

FEEL: Lower hose must have wire insert.

LOOK: Water pump must not show any signs of leaks.

Check complete.

Replace defective hoses, tighten clamps as necessary. See your authorized dealer.

See your authorized dealer.

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Fan and Fan Shroud Check

Inspect fan and shroud clearance.

inspect fan blades for damages.

Check fan belts for wear.

LOOK: Fan blades must not have any nicks or bends.

LOOK: Make sure there is no oil or grease on fan belt or pulleys.

LOOK: Inside surface of fan belt must not have any cracks or contact bottom of pulley groove.

NOTE: If the fan blade has been installed backwards about 50% of its capacity is lost.

LOOK: Cupped portion of fan blades must be away from radiator.

Check complete.

See your authorized dealer.

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Start Aid Checks (S.N. -872256)

Remove right engine side shield.

Check position of lower can holder.

LOOK: If can is missing, lower portion of holder must be upside down to seal opening in upper holder.

Inspect plastic line from top of starting aid to air intake manifold.

LOOK: There must NOT be any kinks or breaks in line and ends must be installed securely.

Check for arrow on either starting aid nozzle in air intake manifold.

NOTE: It may be necessary to scrape paint from nozzle.

LOOK: Arrow must be pointed AGAINST air flow of air intake manifold.

Check complete.

Reposition lower holder.

Replace plastic line.

Turn nozzle until arrow is in correct position (pointing AGAINST incoming air flow).

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Start Aid Checks (S.N. 872257- )

Remove right engine side shield.

Check to be sure ether aid can (B) is tight and clamp (A) is tight

LOOK: If can is missing, cap (D) must be installed into base (C).

Inspect plastic line from top of starting aid to air intake manifold.

LOOK: There must NOT be any kinks or breaks in line and ends must be installed securely.

Check for red dot on either starting aid nozzle in air intake manifold.

NOTE: It may be necessary to scrape paint from nozzle.

LOOK: Red dot must be on the top side of nozzle so that the nozzle is pointed AGAINST air flow (of air intake manifold.

Check complete.

Reposition lower holder.

Replace plastic line.

Turn nozzle until red dot is in correct position (on top of nozzle).

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Exhaust Smoke Check

NOTE: Engine must be at operating temperature before performing this check.

Run engine at fast idle.

Operate a hydraulic function over relief to load engine.

Observe exhaust smoke.

LOOK: Exhaust smoke must NOT be excessive or blue in color.

NOTE: Excessive black smoke is caused by lack of sufficient air to the engine. Excessive white smoke when engine is cold can be caused by a cold engine, dirty nozzles, or both. Excessive blue smoke can be caused by worn or damaged rings or cylinder liners.

Check complete.

See your authorized dealer.

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Engine Oil Level Check

Perform this check with engine OFF.

Remove dipperstick and check oil level.

LOOK: Oil must be between add and full marks.

NOTE: If oil level is high, check for fuel in oil. Drain a small quantity of oil and check for antifreeze. If oil level is low check for oil leaks or oil seal problems in engine.

Remove dipperstick and check condition of oil. Clean oil from dipperstick with finger and thumb.

LOOK: Oil must NOT be milky, grainy or contain fuel oil or antifreeze.

Check complete.

Add or replace oil. See Fuels and Lubricants chapter.

See your authorized dealer.

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Engine Fuel System Inspection Checks

Engine off, speed control lever at fast idle position.

Inspect fuel drain, cap strainer and inside fuel tank (with flashlight).

Operate pump primer by hand.

Inspect all fuel lines, line clamps and speed control linkage stop.

Inside of fuel tank must NOT contain any foreign matter.

LOOK: No fuel leakage must be noted at any of the fuel line connections. The injection line rubber clamps must be in position and NO wiring banded to the injection lines.

Check complete.

If air "hissing" from tank or enters tank when cap is removed, replace fuel cap.

If excessive debris is found in the bottom of the fuel line, observe flow. If flow is restricted, clean tank. See your authorized dealer.

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Engine Speed Check (Tachometer Installed)

Start engine, run at slow idle, and record rpm.

Increase engine speed to fast idle with speed control pedal and record rpm.

LOOK: Slow idle must be 850 ± 50 rpm (S.N. -830204). Slow idle must be 900 ± 25 rpm (S.N. 830205- ).

LOOK: Fast idle must be 2375 ± 50 rpm (S.N. -830204). Fast idle must be 2375 ± 25 rpm (S.N. 830205- ).

NOTE: Override adjustment is 6 mm (0.25 in.).

Check complete.

Check spring loaded injection pump lever override. See Adjust Engine Speed Control Linkage in Maintenance-Every 1000 Hours chapter.

See your authorized dealer.

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Engine Power Check (S.N. -830204)

NOTE: Engine and transmission must be at operating temperature using No. 2 fuel.

Start engine.

Hold service brake.

Put transmission in fourth gear.

Operate engine at fast idle.

Record minimum engine rpm.

Repeat check several times to determine average rpm.

LOOK: Minimum engine speed is 1800 rpm.

Check complete.

RPM too low. Inspect air and fuel filters.

See your authorized dealer.

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Engine Power Check (S.N. 830205- )

NOTE: Engine and transmission must be at operating temperature using No. 2 fuel.

Start engine.

Hold service brake.

Put transmission in fourth gear.

Operate engine at fast idle.

Record minimum engine rpm.

Repeat check several times to determine average rpm.

LOOK: Minimum engine speed is 1875 rpm.

Check complete.

RPM too low. Inspect air and fuel filters.

See your authorized dealer.

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Engine Blow-By Check

Run engine at fast idle and check blow-by tube.

LOOK: Fumes should be barely visible at the blow-by tube at fast idle with no load.

NOTE: Excessive blow-by indicates that piston rings and cylinder liners do not seal off the combustion chamber. This is a comparative check that requires some experience to determine excessive blow-by.

Check complete.

See your authorized dealer.

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Loose or Worn Engine Parts

Run engine at slow idle.

Depress brake pedals.

Shift to first forward.

Knock or rattling noise must not be heard from engine.

Check complete.

See your authorized dealer.

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Front Light Switch

Turn key switch to ON position.

Push front light rocker switch to middle position.

LOOK: Two front lights, two red tail lights and gauge lights must come on.

Push front light rocker switch in completely.

LOOK: All four front lights, two red tail lights and gauge lights must come on.

Go to next check.

Check fuse and bulbs.

See your authorized dealer.

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Rear Light Switch Check

Turn key switch to ON position.

Push side console rear light rocker switch in.

LOOK: Rear light(s) must come on.

Go to next check.

Check fuse and bulbs.

Check switch. See your authorized dealer.

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Turn Signal Check

Turn key switch to ON position.

Push down right side of turn signal switch.

LOOK: Right front and right rear amber lights must flash. Right indicator light on top of steering column must flash. Left front and left rear amber lights, and left indicator light on top of steering column will stay completely lit.

Push down left side of turn signal switch.

LOOK: Left front and left rear amber lights must flash. Left indicator light on top of steering column must flash. Right front and right rear amber lights, and right indicator light on top of steering column will stay completely lit.

Go to next check.

Check fuses and wiring. See your authorized dealer.

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4-Way Flasher

Key switch may be ON or OFF.

Push bottom of warning light rocker switch in.

LOOK: Both front and rear amber lights must come ON. Both turn signal indicators and light in warning light rocker switch must flash.

Go to next check.

Check fuses and bulbs.

Check 4-way flasher switch. See your authorized dealer.

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Horn Circuit Check

Turn key switch to ON position.

Push horn button.

Horn must sound.

Go to next check.

Check fuse.

Check horn switch. See your authorized dealer.

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Start Aid Check-If Equipped

Operate engine at slow idle.

Push start aid button once.

Engine speed must increase then return to slow idle.

Go to next check.

Check can contents by shaking or weight.

Check fuel shut-off/start aid/reverse alarm fuse.

See your authorized dealer.

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Left Cab Door Latch and Opener Check-If Equipped

Unlatch door.

Observe door as it opens.

Pull door closed and latch it.

FEEL: Cab door latch must work freely.

LOOK: Door cylinder must push door open.

LOOK: Cab door must contact door stop bumper before door cylinder bottoms.

Go to next check.

Adjust cab door. See your authorized dealer.

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Right Cab Door Latch and Opener Check-If Equipped

Unlatch door and pull door open.

Close and latch door.

FEEL: Cab door latch must work freely.

Go to next check.

Adjust door. See your authorized dealer.

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Rear Window Latch and Opener Checks-If Equipped

Squeeze latches on both sides of middle rear window. Lower window to rubber bumpers.

Push latch releases on upper rear window.

Observe window as it opens.

Push window up and into window catches and note fit.

Observe cylinders while closing window. Raise middle window and push into latches.

LOOK: Window latches and hinges must move freely.

LOOK: The gas-filled cylinders must slowly assist raising the window to open position. Cylinders must not be at end of travel when closing window.

LOOK: The window catches must hold and not bow the window in the up position.

Go to next check.

See your authorized dealer.

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Rear Windshield Wiper Check-If Equipped

Turn key to ON position.

Push rear wiper rocker switch to first detent, middle position.

Push rear wiper rocker switch all the way in.

LOOK: Rear wiper must operate and have two speeds.

LOOK: Wipers must return to park position.

Go to next check.

Check fuse.

Check rear wiper. See your authorized dealer.

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Front Windshield Wiper Check-If Equipped

Turn key switch to ON position.

Push front wiper rocker switch to first detent, middle position.

Push front wiper switch all the way in.

LOOK: Both front wipers must operate and have two speeds.

LOOK: Wipers must return to park position.

Go to next check.

Check fuse.

Check front wiper. See your authorized dealer.

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Front Windshield Washer Check-If Equipped

Turn key switch to ON position.

Push windshield washer rocker switch in.

LOOK: Fluid must spray on both front windows. Rocker switch must return to OFF position.

Go to next check.

Check fluid level, and fluid lines for blockage.

See your authorized dealer.