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 perfume 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 the 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.
Cooling System Checks
1 Radiator Cap, Coolant Level, Coolant Condition Checks
Action:
CAUTION: DO NOT remove radiator cap unless engine is cool. Then
turn cap slowly to the stop. Release all pressure before you remove
cap.
Open radiator cap.
ENGLISH If radiator is warmer than air temperature, a "whoosh" must be heard when radiator cap is opened to first stop position.
ENGLISH The radiator cap must have a stop position and must be pushed down to turn to remove.
Inspect coolant level, coolant condition.
ENGLISH The radiator cap must have a good seal and gasket. The seal must move freely and the spring must not be corroded.
ENGLISH The coolant must not be oily, foamy, or rusty.
Result:
OK: Check complete.
NOT OK: If vacuum release valve is plugged or spring corroded, replace radiator cap.
NOT OK: If coolant is oily or foamy, see your authorized dealer.
NOT OK: If rust in coolant, drain, flush and replace coolant, see Service the Cooling System in this manual.
NOT OK: If radiator is low and coolant tank has coolant in it, check for air leak on recovery hose. See your authorized dealer.
2 Radiator Outside Air Flow Check (Blower Fan)
Action:
CAUTION: Keep park lock lever in full down (locked) position
during this check to prevent movement of unit.
Start engine. Run at fast idle.
ENGLISH Air flow must be brisk and even through radiator.
NOTE: It is normal to have less air flow at center of fan.
Stop engine.
Inspect fins for mud and debris.
ENGLISH Sides of radiator must be free of mud, leaves, grass, and other debris.
Inspect radiator for bent or damaged fins.
ENGLISH Fins must be straight and not broken or cracked.
Result:
OK: Check complete.
NOT OK: Clean outside of radiator.
NOT OK: Straighten fins. Replace radiator if severely damaged. See your authorized dealer.
3 Hose, Clamps, and Water Pump Checks
Action:Inspect all radiator and heater hoses for cracks or leaks.
Inspect all hose clamps.
Inspect water pump for leaks.
ENGLISH Radiator and heater hoses must NOT be brittle, show signs of leaks, or rub on adjacent parts.
ENGLISH All hose clamps must be tight and perpendicular to the hose. Crooked clamps can cause damage and leaks.
ENGLISH Water pump must NOT show signs of leaks.
Result:
OK: Check complete.
NOT OK: Replace damaged hoses. See your authorized dealer.
NOT OK: Straighten and tighten clamps. See your authorized dealer.
NOT OK: Replace water pump. See your authorized dealer.
4 Fan Checks
Action:
T6558AN-UN-23AUG93
Open engine compartment door.
Inspect fan blades for damage.
ENGLISH Fan blades must not have any nicks or bends.
Check fan for correct installation.
ENGLISH Cupped portion of fan blades must be forward from radiator.
NOTE: If fan is installed backwards, about 50% of its capacity is lost.
Result:
OK: Check complete.
NOT OK: If blades are bent, replace fan. If fan blades are nicked, repair. See your authorized dealer.
NOT OK: Remove and reinstall fan. See your authorized dealer.
5 Fan Shroud and Fan Guard Checks
Action:Check fan to fan shroud clearance.
Inspect fan guard.
ENGLISH Fan must be centered in fan shroud.
ENGLISH Guard must NOT be bent or damaged, all mounting brackets must be intact and all hardware must be tight.
Result:
OK: Check complete.
NOT OK: Adjust fan shroud to center fan. See your authorized dealer.
NOT OK: Repair or replace guard. Tighten hardware. See your authorized dealer.
6 Belt Checks
Action:Inspect condition of V-belt(s).
ENGLISH There must NOT be any oil or grease on fan belt or pulley.
ENGLISH Inside surface of belt must NOT have any cracks.
ENGLISH Fan belt must not squeal when engine is stopped.
Result:
OK: Check complete.
NOT OK: Replace fan belt. See Inspect V-Belt in Maintenance—As Required chapter.
Air System Check
1 Air Filter Restriction Indicator Check
Action:
T117820-UN-25NOV98
The air restriction indicator is located on the control panel.
Run engine at slow idle.
Remove pre-cleaner cover.
Slowly partially cover air cleaner intake.
ENGLISH Air restriction indicator must light.
Result:
OK: Check complete.
NOT OK: Check air restriction indicator sensor circuit. See your authorized dealer.
Lubrication System Checks
1 Engine Oil Level Check
Action:Perform these checks with engine OFF.
Remove dipstick and check oil level.
ENGLISH Oil must be between add and full marks.
NOTE: If oil level is high, check for fuel in oil. Also, drain a small quantity of oil and check for anti-freeze. If oil level is low, check for oil leaks or oil seal problems in engine.
Remove dipstick and check condition of oil. Clean off oil from dipstick with finger or thumb.
ENGLISH Oil must NOT be milky, grainy, contain fuel or anti-freeze.
Result:
OK: Check complete.
NOT OK: Add or replace oil. (See Fuels and Lubricants chapter.)
NOT OK: Replace oil. (See Change Engine Oil and Filter in Maintenance—Every 250 Hours chapter.)
Fuel System Checks
1 Fuel Water Separator Trap Check
Action:Open left side engine compartment door.
Loosen drain knob and drain fuel for several seconds or until water and sediment are removed.
ENGLISH Fuel must flow from drain.
Tighten drain knob.
Result:
OK: Check complete.
NOT OK: No flow, remove and clean valve. See your authorized dealer.
NOT OK: Replace valve. See your authorized dealer.
2 Fuel Cap
Action:Remove fuel cap.
NOTE: Air "hiss" from tank is normal when cap is removed.
Inspect fuel cap seal.
ENGLISH Seal on fuel cap must NOT be damaged and vents must be open.
Result:
OK: Check complete.
NOT OK: Replace fuel cap.
3 Final Fuel Filter Checks
Action:Open left side engine compartment door.
Loosen bleed screw on final fuel filter and operate hand primer on fuel transfer pump.
ENGLISH Fuel must come out of bleed screw when hand primer is operated.
Tighten bleed screw of fuel filter and again operate hand primer on fuel pump.
ENGLISH Resistance must be felt when fuel is being pumped and no resistance will be felt after system is pumped up.
Turn fuel filter knob to drain sediment.
Result:
OK: Check complete.
NOT OK: Be certain fuel filter is clean. If not, replace filter and recheck fuel pump. (See Replace Final Fuel Filter in Maintenance—Every 1000 Hours chapter.)
Engine Speed and Performance Checks
1 Engine Crankcase Ventilation Tube Check
Action:Run engine at fast idle and check engine crankcase ventilation tube.
ENGLISH Fumes should be barely visible at the engine crankcase breather at fast idle no load.
NOTE: Excessive blow-by indicates that piston rings and cylinder liners do not seal off the combustion chamber. This is a visual check that requires some experience to determine excessive blow-by.
Result:
OK: Check complete.
NOT OK: If fumes are visible, see your authorized dealer.
Transmission Checks
1 Park Lock/Neutral Start Switch and Reverse Warning Alarm Check
Action:NOTE: If park lock lever is up, engine will not start.
Park lock lever up.
Turn key switch to start position.
ENGLISH Engine must not crank.
Park lock lever down and FNR lever in forward.
Turn key switch to start position.
ENGLISH Engine must not crank.
Move FNR lever to reverse and key switch to start.
ENGLISH Engine must not crank and reverse warning alarm must sound.
Result:
OK: Check complete.
NOT OK: See your authorized dealer.
2 Transmission Hydraulic Oil Pressure Indicator, Charge Indicator, Park Brake Indicator, and Cab Warning Light Check
Action:Key switch ON to bulb check position.
ENGLISH Transmission hydaulic oil pressure indicator, charge indicator , park brake indicator and cab warning light ON.
Start engine and set at slow idle.
ENGLISH Transmission hydaulic oil pressure indicator, charge indicator and cab warning light OFF, park brake indicator ON.
Raise park lock lever and move FNR lever.
ENGLISH Park brake indicator goes OFF.
Result:
OK: Check complete.
NOT OK: Check bulb in monitor. See your authorized dealer.
3 Brake Pedal Operational Check
Action:Operate machine slowly in forward. Fully depress brake pedal and then release.
ENGLISH Machine MUST STOP when the pedal is depressed and will move when pedal is released.
Result:
OK: Check complete.
NOT OK: See your authorized dealer.
4 Park Brake Operational Check
Action:
CAUTION: Pushing hard on brake pedal will stop machine abruptly.
Operate machine slowly in forward. Fully depress brake pedal and then release.
ENGLISH Machine MUST STOP when the pedal is depressed and park brake indicator must light.
Operate machine slowly in forward. Depress park brake switch.
ENGLISH Machine MUST STOP when the pedal is depressed and park brake indicator must light.
Operate machine slowly in forward. Move FNR lever back to neutral.
ENGLISH Machine MUST STOP and park brake indicator must light after 5 seconds.
Result:
OK: Check complete.
NOT OK: See your authorized dealer.
5 Steering Checks
Action:Run engine at 1/2 speed. Right steering pedal fully depressed and FNR lever slowly forward.
ENGLISH Tracks should move in opposite directions.
Run engine at 1/2 speed. Left steering pedal fully depressed and FNR lever slowly forward.
ENGLISH Tracks should move in opposite directions.
Move FNR lever forward and slowly depress right steering pedal.
ENGLISH Both tracks should move and machine should angle to the right.
Move FNR lever forward and slowly depress left steering pedal.
ENGLISH Both tracks should move and machine should angle to the left.
Result:
OK: Check complete.
NOT OK: See your authorized dealer.
6 Forward-Neutral-Reverse Lever Control Check
Action:Engine at 1/2 speed. Make several shifts from neutral to forward, neutral to reverse and then forward to reverse.
ENGLISH Observe how both tracks start to increase in speed. Both tracks must start at the same time and machine should move forward or reverse in a straight line.
Result:
OK: Check complete.
NOT OK: See your authorized dealer.
Key Switch, Control Panel , Battery, And Hour Meter Checks
1 Hour Meter Circuit Check
Action:Start engine.
ENGLISH Hour meter must be rotating after 1/10 hour.
Stop engine, turn key ON.
ENGLISH Hour meter must not rotate.
Result:
OK: Go to next check.
NOT OK: See your authorized dealer.
2 Flood Light Check
Action:Key ON.
Push work light switch ON.
ENGLISH Both front flood lights and flood lights must come ON.
Result:
OK: Go to next check.
NOT OK: Replace bulbs. (See Replacing Flood Light Bulbs in Maintenance chapter.)
NOT OK: Check wiring. See your authorized dealer.
3 Wiper and Washer Motor Checks
Action:
T138479D-UN-28FEB01
Push rocker switch (A) to first detent, middle position.
ENGLISH Front wiper motor should operate.
Push rocker switch all the way in and hold.
ENGLISH Both front wiper motor and washer motor should operate.
Push rocker switch (B) to first detent, middle position.
ENGLISH Rear wiper motor should operate.
Push rocker switch all the way in and hold.
ENGLISH Both rear wiper motor and washer motor should operate.
Result:
OK: Go to next check.
NOT OK: Check fuse. See your authorized dealer.
4 Key Switch, Control Panel, and Bulb Check
Action:Turn key switch ON.
Cab warning light, transmission hydraulic oil pressure indicator, charge indicator, and park brake indicator will be ON. The warning alarm will sound.
ENGLISH Cab warning light, transmission hydraulic oil pressure indicator, charge indicator, and park brake indicator will be ON. The warning alarm will sound.
Result:
OK: Go to next check.
NOT OK: See your authorized dealer.
5 Alternator Check
Action:Key ON.
Start engine.
ENGLISH Is charge indicator lit?
Result:
OK: See your authorized dealer.
OK: Check and recharge batteries. (See Service Batteries Carefully in Maintenance chapter.)
NOT OK: Go to next check.
Reverse Warning Alarm Checks (With Engine Off)
1 Reverse Warning Alarm Check
Action:Key ON, engine OFF.
Pull park lock lever up (unlocked).
Move FNR lever to reverse.
ENGLISH Reverse warning alarm must sound in reverse.
Result:
OK: Go to next check.
NOT OK: See your authorized dealer.
Neutral Start Switch and Start Circuit Checks
1 Neutral Start Switch Check
Action:Park lock lever down.
Move FNR lever to NEUTRAL.
Turn key to START position.
ENGLISH Does machine start?
Result:
OK: If machine starts, go to next check.
NOT OK: If machine does not start, see your authorized dealer.
Action:
Park lock lever down.
Move FNR lever to forward or reverse.
Turn key to start position.
ENGLISH Starting motor MUST NOT operate.
Result:
OK: If starting motor does not operate, go to next check.
NOT OK: If starting motor operates, see your authorized dealer.
2 Start Circuit Check
Action:Park lock lever down and FNR lever in NEUTRAL.
Turn key to START position.
ENGLISH Starting motor must operate.
ENGLISH Engine must start.
Result:
OK: Go next check.
NOT OK: Starting motor did not turn. See your authorized dealer.
NOT OK: Starting motor turns, but engine does not start. See your authorized dealer.
NOT OK: See your authorized dealer.
Engine Speed Control Lever and Brake Checks
1 Engine Speed Control Lever Linkage Check
Action:Start engine.
Move lever to fast idle then to slow idle.
ENGLISH Lever must move with some resistance.
ENGLISH Lever must hold at any position.
Depress brake pedal and move lever slowly back and forth several times.
ENGLISH Linkage must not catch or bind.
ENGLISH Engine speed must not increase.
Result:
OK: Go to next check.
NOT OK: See your authorized dealer.
Undercarriage Checks
1 Track Sag Roller and Idler Leakage Checks
Action:
T119010-UN-14DEC98
Measure track sag at longest span of unsupported track.
ENGLISH Track sag must be 30-40 mm (1.18-1.57 in).
Inspect rollers and front idler.
ENGLISH No oil seepage must be noted from roller or idlers.
Result:
OK: Go to next check.
NOT OK: Adjust track sag. (See Adjust Track Sag in Maintenance—As Required chapter.)
NOT OK: Repair or replace roller or idler. See your authorized dealer.
2 Sprocket Wear Check
Action:
T6484AY-UN-19OCT88
Inspect drive sprocket.
ENGLISH Sprocket root wear must NOT be excessive.
NOTE: Do not evaluate sprocket by condition of tooth tip.
Tooth tip wear does not affect sprocket operation if it does not extend into the bushing contact area.
NOTE: Reverse drive side wear is generally more than forward drive side wear.
Result:
OK: Go to next check.
NOT OK: See your authorized dealer.
3 Grouser Wear, Bent Track Shoe, and Loose Hardware Checks
Action:Inspect for worn grousers, bent track shoes and loose shoe hardware.
ENGLISH Grouser bars must NOT be worn excessively and track shoes must NOT be bent and hardware must be tight.
NOTE: Excessive grouser wear weakens track shoes and may result in track shoes bending.
Result:
OK: Go to next check.
NOT OK: If shoe hardware is loose, remove shoe and clean joint before tightening. (See Checking Track Shoe Cap Screw Torque in Maintenance chapter.)
4 Track Roller Check
Action:Have another person operate machine in forward direction.
ENGLISH All rollers must turn but must NOT "wobble".
Result:
OK: Go to next check.
NOT OK: Repair. See your authorized dealer.
5 Track Link Roller and Front Idler Wear Checks
Action:Inspect track links for pin boss wear.
ENGLISH Link pin boss areas must NOT indicate contact with roller flanges or track guides.
NOTE: Some contact or wear is normal. Excessive contact or wear indicates excessive rail wear.
Inspect front idler flanges.
ENGLISH Idler flanges must NOT contact bushings.
NOTE: Idler contact with bushings indicates excessive chain rail wear and idler tread surface wear.
Result:
OK: Go to next check.
NOT OK: See your authorized dealer.
Accessory Checks
1 Seat Belt Check
Action:Inspect seat belt for damage.
ENGLISH Seat belt must not be cut.
Install and adjust seat belt.
ENGLISH Seat belt must adjust easily and must lock.
Result:
OK: Go to next check.
NOT OK: Replace belt. See your authorized dealer.
2 Vandal Protection Checks
Action:The vandal cover (if equipped) can be locked with the machine key.
Check locks on following with machine key:
- Engine Compartment Doors
- Cab Doors
- Tool Compartment Doors
- Fuel Tank Cap
ENGLISH Padlock must fit freely and must secure opening when in place.
Result:
OK: Go to next check.
NOT OK: Repair lock or tabs. See your authorized dealer.
3 Periodic Maintenance Decal Check
Action:Check periodic maintenance decal on inside of left-side engine compartment door.
ENGLISH Periodic maintenance decal must be legible.
Result:
OK: Operational Checkout completed.
NOT OK: Replace decal.
Blower/Heater/Air Conditioning Component Operational Checks—If Equipped
1 Visual Inspection of All Lines and Hoses
Action: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.
Result:
OK: Check complete.
NOT OK: Reposition hoses or lines and tighten or replace clamps. Tighten fittings or replace O-rings in fittings. Replace hoses or lines as required. See your authorized dealer.
2 Air Conditioner Compressor Check—If Equipped
Action:Inspect compressor and belt.
ENGLISH Is drive belt tight?
ENGLISH Is belt in good condition, NOT frayed, worn or glazed?
ENGLISH Are compressor mounting brackets in good condition, and bracket cap screws tight?
ENGLISH Is belt pulley in good condition, NOT worn or groved?
ENGLISH Are electrical connections to compressor clutch clean and tight? Is wiring to compressor in good condition?
Turn fan ON to check for interference to shroud due to damaged fan blades.
Check wiring harness system for damage or cuts.
ENGLISH Is there any noise of fan blades to shroud?
ENGLISH Are air conditioner hoses protected by cordura sleeves in engine compartment next to fan shroud and alternator area?
Result:
OK: Check complete.
NOT OK: Repair or replace components as required. See your authorized dealer.
3 Cab Door and Window Seals Check
Action:Open and close door and windows. Inspect seals.
ENGLISH Do door and windows contact seals evenly?
ENGLISH Are seals in position and in good condition?
ENGLISH Are latches aligned with strikers?
ENGLISH Are the door latches and door hold-open-latches easy to operate?
Result:
OK: Check complete.
NOT OK: Adjust door and windows to close against seals properly. Replace seals as necessary. See your authorized dealer.
4 Heater Blower Motor Check
Action:Engine OFF. Key switch to Accessory position.
Turn heater blower switch to each position.
ENGLISH Does air exit all eight heater vents?
Result:
OK: Check complete.
NOT OK: Check fuse. Replace.
NOT OK: Check wiring harness. See your authorized dealer.
5 Heater Check
Action:Start engine and allow to reach operating temperature.
Turn heater temperature control (C) to maximum heat. Turn heater blower switch (B) to position high Speed position.
ENGLISH Does warm air exit from ducts?
Result:
OK: Check complete.
NOT OK: Check coolant level. (See Check Coolant Level in Maintenance—Every 10 Hours or Daily chapter.)
NOT OK: Check heater hose shut-off valve is open. (See See heating and Air Conditioning Controls in Operator's Station chapter.)
NOT OK: Check wiring harness. See your authorized dealer.
6 Air Conditioner Compressor Clutch Check
Action:Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner ON.
ENGLISH Does compressor clutch "click" as air conditioner button is pushed?
Result:
OK: Check complete.
NOT OK: Replace compressor clutch. See your authorized dealer.
7 Air Conditioner Check
Action:Start engine and run at fast idle.
Push air conditioner button on control panel to turn air conditioner on.
Turn blower speed control knob to position high speed position.
Wait for any warm air in duct system to dissipate.
ENGLISH Is air from ducts cool?
Result:
OK: Check complete.
NOT OK: See your authorized dealer.
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