Operational Checkout

1 Checking and Clearing Diagnostic Service Codes From Monitor

Check Service Codes

With key switch ON and diagnostic service codes displayed. Press NEXT to view each service code and read explanation in message window (deluxe monitor only). Without deluxe monitor, refer to Troubleshooting chapter SERVICE CODES QUICK REFERENCE LIST for explanation of service codes. Record service codes. Press NEXT to move from one service code to the next. Press and hold SELECT for 5 seconds to delete each service code. When End appears, all service codes have been deleted. NOTE: Service codes will disappear from the window and the next service code will appear. "End" will appear if no more service codes exist. Repeat this procedure until "End" appears in Basic Display window. Press NEXT and "End" should still appear. Press MENU to return to operating display. LOOK: Are all the service codes deleted? Does "End" appear in Basic Display window?

YES: Go to first step of operational checkout. NO: Go next check.

Clear Service Codes

With key switch ON and diagnostic service codes menu (d 01) displayed. At d 01 menu press SELECT. First service code will be displayed with explanation in message window. Press SELECT again. The display window will show the hour meter reading at the first occurrence of the service code. Press NEXT. The display window will show the hour meter reading at the last occurrence of the service code and the total number of occurrences. Record all information given by monitor display. Press and hold SELECT for at least 5 seconds. NOTE: Audible beeps will alert the technician that a code is to be deleted. Service codes will disappear from the window and the next service code will appear. "End" will appear if no more service codes exist. Repeat this procedure until "End" appears in Basic Display window. Press NEXT and "End" should still appear. Press MENU to return to operating display. LOOK: Are all the service codes deleted? Does "End" appear in Basic Display window?

YES: Start operational checkout. NO: See your authorized dealer.

2 Monitor Indicator and Gauge Checks-Engine Off

Battery Check

Key switch OFF. Press SELECT button and hold until battery volts are displayed. LOOK: Does battery volts read a minimum of 25.2 volts? NOTE: The hour meter reading is also displayed and if you hold SELECT button down for 4 seconds the odometer reading will be displayed also.

YES: Go to next check. NO: Go to Monitor Display Unit-Menu Structure, Operator Station in Chapter 10. Check voltage on each battery before recharging. If one battery will not hold a charge, replace both batteries.

Monitor Bulb and Gauge Check

Turn key switch ON. Observe monitor and note changes for first 3 seconds. LOOK/LISTEN: Do all lights come ON and does alarm sound? Do Message Display and Basic Display windows have "8s" showing in every display? Do all the gauge indicators point to approximately 12:00 o' clock position? Is backlighting of gauges ON? After 4 seconds observe changes in monitor. LOOK: Do gauge indicators change from 12:00 o'clock to normal readings? Does Message Display window show John Deere? Does Basic Display window show correct machine model for 3 seconds? After 3 seconds observe Basic Display window. LOOK: Does Basic Display change to show gear, rpm, hour meter and battery voltage readings? NOTE: Hour meter only displays in hours, not in tenths of hour.

YES: Go to next check NO: Go to Monitor Display Unit-Menu Structure, Operator Station, Chapter 10.

Monitor Indicator Circuit and Key Switch Check

With key switch OFF and bucket on ground, push brake pedal 30-50 times. Turn key switch to accessory position. LOOK/LISTEN: Does accessory relay "click" but monitor does not come on? Turn key switch to ON. Does accessory relay "click" when key is turned to ON? NOTE: Click of relay will come from fuse block in right rear side of side console, it may be hard to hear if area is noisy. After 10 seconds: LOOK: Do the following indicators remain ON: Flashing STOP light, Engine Oil Pressure, Steering Pressure (if equipped), Park Brake and Brake Pressure? Go to next check See your authorized dealer.

3 Transmission Controls, Neutral Start and Reverse Warning Alarm Checks

4 Monitor Indicator and Gauge Checks-Engine Running

5 Brake System, Clutch Cut-Off, and Differential Lock Checks

6 Driving Checks

NOTE: Transmission oil must be at operating temperature for these checks.

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Transmission Oil Warm-Up Procedure Engine running Press MENU on monitor to get Diagnostic Menu (d) displayed. Press SELECT to get (d 01) displayed, then press NEXT until (d 05) is displayed. Press SELECT to get (d 051) transmission oil temperature. LOOK: Is transmission temperature in 120-150 °F (50-65 °C) range? Go to next check. Apply service brakes and release park brake. Push clutch cut-off switch to OFF position. Move transmission selector lever to 3rd speed. Increase engine speed to fast idle for 30 seconds. Move transmission control lever to neutral "N" position and run for 15 seconds. Repeat procedure until transmission temperature is in operating range.

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Transmission Noise Check Engine running. Run engine at approximately 1600 rpm. Drive machine with transmission in each forward and reverse speed. Is transmission quiet except for normal gear noise in all gears? LOOK/FEEL: Does engine speed remain almost constant as machine is shifted between gears? FEEL: Does transmission shift smoothly between gears and forward to reverse? Go to next check See your authorized dealer. See Transmission, Machine Will Not Shift Correctly, in Troubleshooting, Chapter 100.

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Transmission Shift Mode Check Engine running. Turn automatic transmission switch to OFF. Press MENU on monitor until Accessory (A) shows in Basic Display window, then press SELECT. Clutch Cut-Off will display in Message Display window. Press NEXT until A 02 is displayed. Press SELECT until Quick Shift 021 Down/Up displays, then press SELECT to enable Down/Up shift mode. Release park brake and shift to 3rd forward. Drive machine at approximately 1600 rpm and press quick shift switch once. LOOK/FEEL: Does transmission shift to and remain in 2nd gear? Press quick shift switch once more. LOOK/FEEL: Does transmission shift back to 3rd gear? NOTE: If quick shift switch is pressed twice, transmission will shift down one gear then immediately back up to where it was. Quick shift feature operates in all gears. In Basic Display window with Quick Shift 021 displayed press NEXT to get Down Only 022 to display. Press SELECT to enable Down Only shift mode. Release park brake and shift to 4th forward. Drive machine at approximately 1200 rpm and press quick shift switch once. LOOK/FEEL: Does transmission shift to and remain in 3rd gear? Press quick shift switch once more. LOOK/FEEL: Does transmission shift to and remain in 2nd gear? Press quick shift switch once more. LOOK/FEEL: Does transmission shift to and remain in 1st gear?

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Press quick shift switch once more. LOOK/FEEL: Does transmission stay in 1st gear? NOTE: In DOWN ONLY mode pressing quick shift switch will not change gears once 1st gear is reached, unless a direction or gear change is made. Go to next check. Check rocker, restriction, and radio switches 7.5A fuse. See your authorized dealer. See your authorized dealer.

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Forward, Reverse Clutch Pack Drag Check IMPORTANT: Transmission must be warmed up for this check. See Transmission Oil Warm-Up Procedure in this Chapter. Engine running. 1. Press MENU on monitor to get Diagnostic Mode (d) displayed on Basic Display window. 2. Press SELECT to get (d 01) displayed, then press NEXT until (d 05) is displayed. 3. Press SELECT, then NEXT to (d 054) Torque Output Speed. Press SELECT. 4. With machine on LEVEL hard surface, shift to 1st forward. Release park brake and service brakes. 5. Run engine at slow idle, do NOT put foot on accelerator. Observe Torque (converter) Output Speed and note rpm within 50m (50 yd) of machine travel. 6. Shift to 1st reverse and observe Torque (converter) Output Speed and highest rpm within 50 m (50 yd) of machine travel. 7. Repeat procedure in 2nd gear forward and reverse. LOOK/FEEL: Is Torque (converter) Output Speed within 400 rpm in each forward and reverse gear? NOTE: If output speed differential is greater than 400 rpm, drive the machine in the opposite direction across the test course to insure the surface is level. Some difference in rpm is normal. Machine has failed test only if rpm differential is excessive. Go to next check If Torque (converter) Output speed is excessively higher in one direction, opposite direction clutch pack drag is indicated. See your authorized dealer.

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1st, 2nd, and 3rd Speed Clutch Pack Drag Check Engine running. Stop machine on a level, hard surface. Push automatic transmission switch (A) to OFF position. Run engine at slow idle. Release park and service brakes. Put transmission in 1st forward, 2nd forward, then 3rd forward. Note machine movement. LOOK: Does machine roll ahead in each gear? NOTE: If machine rolls ahead in one gear but not the other two, drag is indicated in that clutch pack. Go to next check See your authorized dealer.

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Transmission Shift Modulation Check Engine running. Push clutch cut-off Switch to OFF position. Push automatic transmission switch (A) OFF. CAUTION: Fasten seat belt before performing this check. Machine will change directions abruptly! Shift transmission to 1st forward, increase engine speed to fast idle, shift from forward to reverse and reverse to forward several times, allowing machine to reach full speed in forward and reverse before changing directions. Repeat check in 2nd gear. LOOK: Does machine slow down and change direction smoothly? Drive machine in 2nd gear at fast idle, apply service brakes to slow engine down to 1800 rpm, then while still holding service brakes, shift to 1st gear. LOOK/FEEL: Does transmission shift smoothly without jerking? Go to next check. See Transmission Shifts Too Slow or Transmission Shifts Too Fast, Troubleshooting, in Chapter 100.

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Torque Converter Check Engine running and park brake released. Turn clutch cut-off switch to OFF. Transmission oil must be warm before performing this check. See Transmission Oil Warm-up Procedure in this chapter. Warm tramsnission oil to at least 83 °C (180 °F). Apply service brakes so machine does not move. Shift transmission to 3rd forward. Push accelerator pedal until it touches stop bolt. Record engine speed in basic display window. LOOK: Is torque converter stall speed within following range: Standard Cooling System No. 1 fuel: 1975-2175 rpm No. 2 fuel: 2000-2200 rpm High Ambient Cooling System No. 1 fuel: 1960-2140 rpm No. 2 fuel: 1985-2170 rpm Move transmission control lever to neutral "N" position and run for 15 seconds to cool oil. Go to next check. If speed is outside range, see your authorized dealer. See your authorized dealer.

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7 Hydraulic System Checks

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Pilot Controller Check Turn key switch to OFF position. Move control lever to all positions and then release. LOOK: Does lever return to neutral when released from all positions? Go to next check. See your authorized dealer.

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Pilot Controller Lock Check NOTE: Perform check in an open area, boom will raise during check. Start engine. Push pilot enable/boom down switch to LOCKED position. Move boom control lever to boom raise and hold. Move pilot enable/boom down switch to UNLOCK and observe boom. LOOK/FEEL: Does boom raise when switch is UNLOCKED? Move pilot enable/boom down switch to LOCKED position and observe boom. LOOK/FEEL: Does boom stop when switch is LOCKED? Go to next check. See your authorized dealer.

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Pilot Enable/Boom Down Solenoid (Key ON) Check Engine running. Raise boom to full height and roll bucket back half way. Stop engine. Turn key to ON position. Move pilot enable/boom down switch to LOWER position and hold it. Move control lever to bucket dump position. Move control lever to boom lower position. LOOK: Does bucket dump and boom lower? Go to next check Check pilot enable 7.5A fuse. See your authorized dealer.

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Pilot Enable/Boom Down Solenoid (Key OFF) Check Raise boom to full height and roll bucket back half way. Stop engine. With key switch OFF, move pilot enable switch to lower position and hold it. Move control lever to bucket dump position. Move control lever to boom lower position. LOOK: Does bucket dump and boom lower? Go to next check Check unswitched, boom down, radio and dome light 5A fuse. See your authorized dealer.

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Pilot Control Valve Boom Float Check Run engine at slow idle. Push ride control switch OFF. Push return-to-carry switch OFF. With the bucket partially dumped, lower boom to raise front of machine. Push control lever to the float detent position and release lever. LOOK: Does front of machine lower to the ground and valve remain in float position when lever is released? Go to next check. See your authorized dealer.

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Return-to-Dig Check Run engine at slow idle. Position bucket fully dumped just above ground level. Move control lever to return-to-dig detent position and release. LOOK: Does bucket rollback to the level position and control lever return to neutral? Go to next check Check BHKO and RTD 5A fuse, pilot enable/boom down switch and pilot enable 7.5A fuse. See your authorized dealer.

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Return-to-Carry Check Run engine at slow idle. With bucket flat on the ground, raise boom to full height. Move return-to-carry switch (A) to ON position. Move control lever to "float down" detent position and release. LOOK: Does boom lower and stop at the set carry position? NOTE: If Return-to-Carry is adjusted too far down, bucket may contact ground before control lever comes out of float. See Return-to-Carry Switch, Chapter 35. NOTE: Control lever will not stay in "boom float" position when boom is below return-to-carry kickout height. Go to next check Check BHKO and RTD 7.5A fuse. See your authorized dealer.

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Boom Height Kickout Check Run engine at slow idle. Position bucket flat on ground. Move control lever to boom raise detent position and release. LOOK: Does boom raise to the set height and stop? Does control lever return to neutral? Go to next check Check BHKO and RTD 7.5A fuse. See your authorized dealer. See your authorized dealer.

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Pin Disconnect System Check (if equipped) Run engine at slow idle. Position bucket flat on the ground. Push and hold pin disconnect switch (A). LOOK: Does pin disconnect cylinder retract both pins, while switch is pressed? Go to next check. Hold a screwdriver blade against the end of the pin disconnect solenoid valve and check for magnetism with the switch pushed. Check differential lock and pin disconnect 5A fuse. See your authorized dealer.

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Ride Control Check Push ride control switch to OFF position. CAUTION: Boom will jump upward during this check, Make sure area around bucket is clear. Raise boom to maximum height and hold control lever over relief for 2 seconds. Lower boom and bucket to eye level. Observe loader boom as ride control switch is switched to ON. LOOK/FEEL: Does boom jump upward 304 mm (12 in.) or more? Start engine. Push ride control switch to AUTO position. Raise boom to maximum height and hold control lever over relief for 2 seconds. Lower boom and bucket to eye level and slowly accelerate to 5 mph while watching speedometer and bucket. LOOK/FEEL: Does ride control indicator come on at approximately 3 mph and bucket raise slightly? NOTE: Ride control switch must be turned on every time key is turned on to activate ride control. Go to next check. Check ride control 7.5A fuse. See your authorized dealer.

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Hydraulic Oil Warm-Up Procedure IMPORTANT: Hydraulic oil temperature must be in 120-150 °F (50-65 °C) range to get accurate test results. Engine running Press MENU to get Diagnostic Mode (d) displayed. Press SELECT to get (d 01) displayed, then press NEXT until d 06 is displayed. Press SELECT get d 061 displayed to monitor hydraulic system oil temperature. LOOK: Is hydraulic temperature in 120-150 °F (50-65 °C) range? Go to next check. Release park brake. Run engine at fast idle. Hold bucket rollback lever and raise and lower the boom. Periodically cycle all hydraulic functions to distribute warm oil. Heat oil until hydraulic temperature has reached operating range.

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Hydraulic Oil Cool Down Procedure IMPORTANT: Hydraulic checks oil temperature must be below 220 °F (104 °C) to get accurate test results. Engine running Press MENU on monitor until Diagnostic Mode (d) is displayed. Press SELECT to get (d 01) displayed, then press NEXT until (d 06) is displayed. Press SELECT get (d 061) displayed to activate hydraulic system oil temperature. LOOK: Is hydraulic oil temperature below 220 °F (104 °C)? Go to next check. Operate engine at fast idle. Cycle loader boom and bucket cylinders full stoke until hydraulic oil temperature is below 220 °F (104 °C).

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Hydraulic Pump Performance Check Press MENU on monitor until Accessory Mode (A) is displayed then press SELECT. Press NEXT until (a 05) STOP WATCH is displayed then press SELECT. Press SELECT to start the stop watch and SELECT again to stop it. Press NEXT to reset the stop watch. Run engine at slow idle. Steer machine to either stop and hold steering wheel while boom is raising. With bucket flat on ground, actuate boom raise and press SELECT on monitor at the same time to measure boom raise time to full height. Press SELECT when boom stops to record time. LOOK: Does boom raise to full height in less than 20 seconds? NOTE: Repeat boom raise three times to get average time. Go to next check Go to Steering System Leakage Check in this group. See your authorized dealer.

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Control Valve Lift Check Run machine at slow idle. Turn ride control switch to OFF if equipped. With bucket partially dumped, lower boom to raise front of machine. Stop engine and turn key switch ON. Press pilot enable/boom down switch to Boom Down Position and hold. Slowly move boom control lever to boom lower position. Slowly move bucket control lever to bucket dump position. LOOK: Does boom remain stationary and not allow front wheels to drop to the ground. Start engine. Slowly move boom control lever to boom lower position. Slowly move bucket control lever to bucket dump position. LOOK: Does front of machine raise without dropping first? Go to next check. See your authorized dealer.

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Bucket Rollback Circuit Relief Valve Check Position bucket at a 45° angle against an immovable object. Engage transmission in third speed forward. Press accelerator to stop bolt and hold for 15 seconds. LOOK: Does bucket angle remain the same? Go to next check. See your authorized dealer.

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Bucket Dump Circuit Relief Valve Check CAUTION: Perform check in an open area away from other people. With bucket dumped at 45° raise front of machine off the ground. Drive the machine backwards with the front wheels off the ground while observing bucket angle. LOOK: Does bucket rollback less than 5-8 degrees? Go to next check. See your authorized dealer.

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Boom Down Check Valve Leakage Check Heat hydraulic oil to operating temperature. (See Hydraulic Oil Warm-Up Procedure in this group.) Position bucket flat on ground. Run engine at slow idle for two minutes. LOOK: Does bucket remain on the ground? Go to next check. See your authorized dealer.

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Boom and Bucket Cylinder Drift Check Set bucket flat on the ground and raise about 50 mm (2 in.). Stop engine. Observe bucket for 1 minute. LOOK: Does bucket remain in position? Bucket should not settle to the ground. NOTE: Use good judgement to determine if the amount of drift is objectionable for your loader application. Go to next check. See your authorized dealer.

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Axle Disconnect Check Operate machine in an open area away from bystanders. With bucket partially dumped, lower boom to raise front wheels off the ground. Push axle disconnect switch (A) to ON position. Watch front wheels while operating the machine in reverse. Front wheels must not rotate as machine moves backwards. LOOK: Do front wheels remain stationary while machine moves backwards? Go to next check. Check differential lock and pin disconnect 5A fuse. See your authorized dealer.

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8 Steering System Checks

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Steering Valve Check Transmission in neutral. Run engine at slow idle. Remove foot from brake pedal. Release park brake. Turn steering wheel until machine frames contact right and left frame stops. LOOK: Does machine steer smoothly in both directions? NOTE: It is normal for machine frames to drift away from frame stops when steering wheel is released. When steering wheel is stopped, frames must stop. FEEL: Is excessive effort required to turn steering wheel? Go to next check. Go to next check.

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Steering System Leakage Check Heat hydraulic oil to operating temperature. (See Hydraulic Oil Warm-Up Procedure in this group.) Run engine at fast idle. Turn steering wheel rapidly until machine frame contacts stop. Jerk steering wheel, and hold approximately 22 N (5 lb) force on steering wheel. Count steering wheel revolutions for 1 minute. Repeat test in opposite direction. LOOK: Does steering wheel rotate less than 5 rpm? NOTE: Steering wheel may rotate very little or even faster than specification. Use good judgement, excessive steering wheel rpm does not mean steering will be affected. A new valve may exceed specification and work for your application. Go to next check. See your authorized dealer.

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Secondary Steering System Check IMPORTANT: Do not operate secondary steering pump for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur. Park machine on a hard level surface with frames straight. Stop engine. Without starting engine, turn key switch to START position and release. Steer machine to right and left. LOOK: Does machine steer approximately half way to stops in both directions? Does light in monitor come ON and stay on until key is turned off? Go to next check. Check converter, secondary and start aid 7.5A fuse. See your authorized dealer. If secondary steering pump and motor operate, but machine steers slow, see your authorized dealer.

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Secondary Steering System Primary Check Valve Check Run engine at fast idle. Turn steering wheel rapidly until machine frame is against steering stop. Hold approximately 22 N (5 lb) force on steering wheel. Actuate a hydraulic function and hold over relief. Return control lever to neutral. FEEL: Is steering wheel "kickback" felt as hydraulic function is released? NOTE: Steering wheel "kickback" is normal on machines without secondary steering. Go to next check See your authorized dealer.

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9 Accessory Checks

NOTE: Engine OFF with key switch ON for these checks.

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Operating Lights Check Press drive light switch to middle position. Note light operation. LOOK: Do lights (B and I) come ON? Press drive light switch to top position Note light operation. LOOK: Do lights (A, B and I) come ON? Go to next check Check high beam/drive light fuse. See your authorized dealer.

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Work Light Check Push work light switch to ON position. Note light operation. LOOK: Do work lights (D and G) come on? Does work light indicator light in monitor come ON? Go to next check Check fuse. See your authorized dealer.

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4-Way Flasher Check Press 4-Way Flasher switch to ON position. Note light operation. LOOK: Are lights (A and I) flashing? Go to next check. Check left and right flasher 7.5A fuse, 4-way flasher light bulbs, and 4-way light switch. See your authorized dealer.

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Brake Light Check Start engine and run at slow idle for about 1 minute. Stop engine. Press either brake pedal (A or B) and observe brake lights (I). LOOK: Do both brake lights come on? NOTE: Brake light switch is a pressure switch in the brake valve. If brake accumulator is discharged, machine will need to be started for brake lights to come ON. Go to next check. Check brake light 7.5A fuse and check brake light bulbs.

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Horn Circuit Check Key switch ON. Push horn button. Does horn sound? Go to next check. Check horn 7.5A fuse.

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Start Aid System Check Start engine and run at slow idle. Push Start Aid Switch. Does engine speed increase slightly (25-50 rpm)? Go to next check Check for empty start aid can (A). Check converter, secondary steering and start aid 7.5A fuse.

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Air Heater Check NOTE: Air heater will not operate if battery voltage is below 20 volts. Air heater will not operate unless engine coolant temperature is below 10°C (50°F). Disconnecting the engine coolant temperature sensor harness connector will fool the CCU into thinking the coolant temperature is very low. Disconnect the sensor only during operational checkout procedures. CAUTION: If the engine coolant temperature sensor is disconnected, the air heater will operate when the key switch is ON. Damage to the engine or air heater may result if machine is operated with engine coolant temperature disconnected. To display coolant temperature: Turn key switch ON. Press MENU on monitor to display Diagnostic Mode (d). Press SELECT to display d 01. Press NEXT until d 04 is displayed. Press SELECT to display d 041 (Coolant Temperature). Note coolant temperature. If temperature is above 10°C (50°F) air heater will not operate. Key switch OFF. If coolant temperature is above 10°C (50°F), disconnect harness from engine coolant temperature sensor. NOTE: If battery voltage drops below 20 volts air heater may shut off early. Key switch ON and record length or time air heater stays ON. LOOK: Is engine preheat indicator ON?

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LOOK: Does air heater indicator (A) remain ON for about 10 seconds? Does engine air heater solenoid "Click" when air heater shuts OFF? CAUTION: Air heater housing will become HOT within a few seconds of operation. Hold hand close to housing, when feeling for heat, but DO NOT touch it. FEEL: Is air heater housing HOT? NOTE: If key switch is turned to START while air heater is ON, air heater will shut off. After engine starts air heater will come back ON for 30 seconds. When engine is running and air heater is ON, battery voltage indicator will come ON until batteries are recharged to about 26 volts. Reconnect harness to engine coolant temperature sensor after check is complete. Go to next check. See your authorized dealer. Check air heater fuse. See your authorized dealer.

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10 Cab Component and Vandal Protection Checks

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Windshield Washer and Wiper Check Turn front wiper switch knob clockwise to first position, then to second position. LOOK: Front wiper must operate at slow speed with switch in first detent and fast speed with switch in second position. Push front wiper switch knob to operate front windshield washer. LOOK: Does washer spray water on windshield? Turn front wiper switch knob counterclockwise to STOP front wiper. LOOK: Does front wiper park at side of windshield? Turn rear wiper switch to first detent position. NOTE: Rear wiper operates in a single speed only. LOOK: Does rear wiper operate? Push rear wiper switch to operate rear window washer. LOOK: Does washer spray water on rear window? Turn wiper off. LOOK: Does rear wiper park at side of rear window? Go to next check. Check Front Wiper 10A fuse and Rear Wiper 10A Fuse.

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Heater/Defroster Blower Check Turn blower speed switch knob (B) to low, medium, high and purge speeds. FEEL/LISTEN: Does blower have four speeds and OFF? Go to next check. Check Blower Motor 25A fuse and Pressurizer Motor 7.5A fuse. See your authorized dealer.

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Heater Functional Check Open heater shut-off valve. Start engine and run at fast idle until engine reaches operating temperature. Turn temperature control knob (A) to maximum heat position (fully clockwise). Turn blower speed knob to purge speed. FEEL: Does warm air come from ducts under the seat, operator air ducts around the monitor, and windshield defrost ducts below the windshield? Go to next check Check blower motor 25A fuse and pressurizer motor 7.5A fuse. See your authorized dealer.

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Air Conditioner Functional Check Start engine and run at fast idle. Push air conditioner switch (C) ON. Turn temperature control knob (A) to maximum cool setting (CCW). Turn blower speed knob (B) to purge position. Wait for any warm air in duct system to dissipate. FEEL: Does cool air come from ducts under the seat, operator air ducts around the monitor, and windshield defrost ducts below the windshield? Go to next check Check Blower Motor 25A fuse and Pressurizer Motor 7.5A fuse. See your authorized dealer.

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Dome Light Check Push dome light switch to on (A) position. LOOK: Does dome light come on? Push dome light switch to off (B) position. LOOK: Does dome light go off? Push dome light switch to door (C) position. Open and close cab door while observing dome light. LOOK: Does dome light go off when door is closed, and come on when door is opened? Go to next check. Check fuse and bulb. See your authorized dealer.

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Cab Door Latch Check Unlatch cab door using outside door latch by pushing latch button. Enter cab and close cab door. Unlatch cab door from inside by pushing inside door latch lever forward. FEEL: Does door unlatch easily using outside latch button? LOOK: Does door close tightly and compress seal all around door edge? FEEL: Does door unlatch easily using inside latch lever? Go to next check Adjust, repair or replace door latch or seal.

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Cab Door Hold-Open Latch Check Push door to full open position and push door into hold-open latch (B) to engage. LOOK: Does pin (A) fit into latch notch (B)? Does latch retain door? Does door contact rubber bumper (C) on cab? Go to next check Adjust rubber bumper. Adjust, repair or replace latch.

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Cab Door Release Check Release handle is located on the front panel of left console. Open door full open and push door into latch to engage. Pull handle up to release door from latch. LOOK/LISTEN: Does latch release door? Go to next check See your authorized dealer.

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Cab Door Lock Check Close cab door. Insert ignition key into slot in outside cab door handle button and turn counter clockwise to lock door latch. Push IN door latch button to verify latch is locked. Unlock cab door latch. LOOK: Does cab door handle button remain stationary when pushed IN with latch locked? FEEL: Does lock operate freely and does key slide into lock easily? Go to next check. Lubricate or repair lock.

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Cab Rear Side Windows Latch Check Inspect window seals. Pull forward on handle to open right side cab window. Push handle to close window. LOOK: Does latch hold window tightly closed? LOOK: Does window compress seals all around the frame without gaps between seal and frame? Pull forward on handle to open latch. LOOK: Does latch hold window open when in extended position? Go to next check See your authorized dealer.

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Cab Right Window Check Open window and push back to lock in open position. Inspect window seals. LOOK: Does latch hold window open? Push window latch (C) down to release and pull window closed. LOOK: Does window close securely? Does window compress seals all around the frame without gaps between seal and frame? Go to next check See your authorized dealer.

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Steering Column Adjustment Check Lift lever (A) and move steering wheel column to all positions. Release lever at each position. LOOK: When lever is released, does steering column lock securely in that position? Go to next check. Check and adjust lever linkage.

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Seat and Seat Belt Check IMPORTANT: Seat belt must be replaced every three years regardless of appearance. A date label is attached to each belt to determine its age. Adjust seat to all positions. Lock and unlock seat belt. LOOK/FEEL: Does seat adjust freely and remain locked in desired position? Does seat belt lock and hold securely? Inspect seat shell and suspension for cracks, damage or looseness. Inspect seat belt date label to determine how long belt has been on machine. LOOK: Has seat belt been on the machine less than three years? Go to next check Replace worn or broken suspension parts. Replace seat belt if worn. Replace seat belt every three years regardless of appearance. Replace seat belt anytime parts appear worn or broken.

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Storage Compartment and Operator Manual Check Unlock and open storage compartment under operators seat. Close and lock door. FEEL: Does storage compartment lock operate smoothly and hold door closed securely? LOOK: Does door open and close smoothly? LOOK: Is Operators Manual on shelf inside storage compartment? Go to next check. Lubricate hinges. Lubricate or repair lock. See your authorized dealer.

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Fresh Air Filter Door, Latch and Seals Check Lift lever (A) to unlock and open the fresh air filter door outside the cab. Close and lock door. LOOK: Does door open and close smoothly? LOOK: Does latch operate smoothly? LOOK: Are door seals in good condition? Go to next check. Lubricate hinges. Lubricate or repair latch. Replace door seal.

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Engine Side Panels and Latch Check Unlatch upper engine side panel by pulling latch handle (A). Open panel to full extent. Gas cylinder rod (B) will hold panel in open position. Close upper engine side panel. FEEL: Does upper engine side panel latch (A) operate freely and close securely? LOOK: Do panels open and close smoothly? LOOK: Does rod (B) hold the panel open and prevent the panel from closing? Are all parts free from damage? Repeat check on other side. Go to next check. Lubricate hinges. Repair or replace parts as needed.

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Lower Engine Side Shield Check Rotate lower engine side panel latch (A) counterclockwise to unlatch. LOOK: Does lower engine side panel latch operate freely and hold panel securely closed? Swing lower engine side panel down. Close lower engine side panel and rotate latch (A) clockwise to latch side panel closed. Repeat check on other side. Go to next check. Lubricate hinges. Repair or replace parts as needed.

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Engine Frame Mounting Step Check Check rubber step hangers (1) for damage or missing capscrews. LOOK: Are capscrews in place? Are rubber hangers in good condition? Go to next check. Repair or replace parts as needed.

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Radiator Cap Access Door Check Open and close access door on top of grille housing. LOOK: Does door move freely and is locking tab for padlock in good condition? Go to next check. Lubricate hinges. Repair door.

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Fuel Filler Access Door and Lock Check Insert ignition key in lock and turn clockwise to lock and counterclockwise to unlock. Open and close door. Inspect hinge for damage. LOOK: Does lock hold door securely closed? Are hinges in good condition and not damaged? Go to next check. Repair or replace damaged parts as needed.

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Cab Mount Step Check Inspect cab mounting step rubber hanger for missing hardware and damage. Inspect cab mounting steps for missing hardware and damage. LOOK: Is all hardware in place? Are mounting steps undamaged and in safe condition? Go to next check. Repair or replace damaged parts as needed

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Frame Locking Bar Check Install frame locking bar to lock frames and prevent steering action. LOOK: Do frame locking bar pins (A) go through locking bar (B) and machine frames easily? Do pin clips (C) go through pins easily, do retaining springs "snap" closed securely and show no signs of damage? Install frame locking bar in stored position. Install pins and clips to hold it position. LOOK: Does locking bar easily fit into the storage brackets? Do pins (B) easily go through the brackets and boom lock? Do the pin clips (A) go through pins easily, do retaining springs "snap" closed and show no signs of damage? Go to next check. Install new locking bar and pins.

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Boom Lock Check Raise boom far enough to install the boom lock. LOOK: Does boom lock fit over boom cylinder rod easily? Is boom lock in good condition, not bent or broken? Does tab on end of boom lock fit in opening of rod end clevis easily? Is the attaching handle installed and hand tightened in lower channel hole? Remove boom lock from cylinder and install it in the stored position. LOOK: Does attaching screw hold boom lock securely in the stored position when not in use? Go to next check. Install new boom lock.

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Service Decal Check Check service decal inside left engine shield door. LOOK: Is service decal legible? Operational checkout completed. Replace service decal.

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