Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of machine operation while doing both 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. Use the table of contents to help find adjustment procedures. This information may allow you to perform simple repairs yourself, reducing machine down time.

The information obtained after completing the operational checkout will allow you or your authorized dealer to pinpoint a specific test or repair needed to restore the machine to 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 this 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.

Locate the check to be performed at the top of the left column and read completely down the column before performing the check. Follow this sequence from left to right. In the far right column, if no problem is found, you will be instructed to go to next check. If a problem is indicated, you will be referred to either a group in this manual or to your authorized dealer for repair.

VD76477,00014A9 -19-19MAR07-1/1

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Display and Clear Trouble Codes

Always check for diagnostic trouble codes and correct them before performing the operational checkout.

Diagnostic trouble codes can be displayed by using two methods:

• Standard Display Monitor (SDM)
• Service Advisor

YES: Correct all diagnostics trouble codes before proceeding. See your authorized dealer.

NO: Proceed with operational checkout.

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Monitor Indicator Lights and Alarm Checks

YES: Go to next check.

NO: Check monitor/gauge fuse.

If STOP light stays ON and alarm sounds longer than three seconds, see your authorized dealer.

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

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TCL Switch Check

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Neutral Start Check

Move transmission control lever (TCL) lever to FORWARD "F" position and turn key switch to START position.

Move transmission control lever (TCL) lever to REVERSE "R" position and turn key switch to START position.

Did starting motor operate?

See your authorized dealer.

Go to next check.

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Start Circuit Check

Move transmission control lever (TCL) lever to NEUTRAL "N" position and turn key switch to START position.

Observe and listen to monitor as engine is cranking.

Did starting motor operate?
Did alarm sound?

LOOK: During engine cranking, were all indicator lights ON? Is STOP indicator ON?

Go to next check.

If engine turns but does not start, on machines (S.N. -880053) check fuel shut-off/start aid/reverse alarm fuses. On machines (S.N. 880054-) check fuel shut-off/start aid/reverse alarm fuse. If starting motor does not operate, check start fuse. See your authorized dealer. If indicator lights are NOT ON, check monitor/gauge fuse. See your authorized dealer.

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Backup Warning Alarm Check

Key switch ON.

Move transmission control lever (TCL) lever to reverse "R" position.

Does backup warning alarm sound?

Go to next check.

See your authorized dealer.

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Park Brake Indicator Check

IMPORTANT: If engine oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY, check oil level.

Engage park brake.

Put transmission control lever (TCL) lever in NEUTRAL "N" and start the engine.

Put transmission control lever (TCL) lever in FORWARD "F" position.

LOOK: Is STOP indicator ON? Does alarm sound? Are park brake and seat belt lights ON? Are all other indicator lights out?

Release park brake.

LOOK/LISTEN: Are park brake indicator and STOP lights out? Alarm will not sound.

Go to next check.

If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY and check oil level. See Check Engine Oil Level. (Section 3-4). If alternator indicator light is ON, increase engine speed to approximately 1/3 throttle and alternator light MUST go out. If no park brake light, see your authorized dealer.

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Hour Meter Circuit Check

IMPORTANT: If engine low oil pressure indicator light stays ON, STOP ENGINE IMMEDIATELY and check oil level.

Engage park brake.

Put transmission control lever (TCL) lever in NEUTRAL "N" and start the engine.

LOOK/LISTEN: Is hour meter indicator rotating?

Go to next check.

If park brake indicator light stays ON, see your authorized dealer. If no hour meter movement, see your authorized dealer.

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Engine Speed Hand Control Linkage Check (If Equipped)

Engage park brake.

Put transmission control lever (TCL) lever in NEUTRAL "N" and start engine.

Use a tachometer to check rpm.

Move hand throttle knob to fast idle position.

LOOK: Does tachometer read 900 + 25 - 0 rpm (slow idle) or 2350 + 50 - 0 rpm (fast idle?)

LOOK: Does speed control lever remain at selected position?

Check engine speed. See your authorized dealer.

Go to next check.

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Engine Speed Control Pedal Linkage Check

Engage park brake.

Put transmission control lever (TCL) lever in NEUTRAL "N" and start engine.

Use a tachometer to check rpm.

Depress speed control pedal.

LOOK: Does tachometer read 900 + 25 - 0 rpm (slow idle) or 2350 + 50 - 0 rpm (fast idle?)

Go to next check.

See your authorized dealer.

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Pedal Stop Check

Lift left and right brake pedals.

LOOK: Are brake pedals against pedal stop screws?

NOTE: This ensures that brake check valves are opened and brakes released.

Go to next check.

See your authorized dealer.

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Brake System Leakage Check

Depress and hold left brake pedal, then right brake pedal, using approximately 267 N (60 lb force).

LOOK: Brake pedal must NOT feel spongy (caused by air in system). Does pedal settle more than 25 mm (1.0 in.) per minute?

Go to next check.

See your authorized dealer.

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Brake Drag/Park Brake Capacity Check

Put seat belt on.

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

Lift bucket so it clears ground.

Shift transmission control lever (TCL) lever to NEUTRAL "N", differential lock control up, disengage park brake and release service brakes.

Let machine coast freely for several feet. Apply park brake.

LOOK: Did machine stop?

Release park brake.

LOOK: Did machine move or coast freely?

NOTE: If machine does not move freely on slope, drive the machine for five minutes. Feel axle housing area to locate which brake is dragging.

Go to next check.

See your authorized dealer.

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Steering Check

Raise loaded bucket to place added weight on front wheels.

Operate engine at slow idle.

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

LOOK: Did front wheels move smoothly in both directions?

LOOK: When steering wheel was stopped, did front wheels stop moving?

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

Go to next check.

See your authorized dealer.

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Steering Leakage Check

NOTE: Hydraulic oil must be at operating temperature.

Run engine at slow idle. Turn steering wheel until wheels are in maximum right turn position. Continue turning steering wheel, using approximately 11.3 N·m (100 lb-in.) force while counting steering wheel rpm.

Repeat leakage check, turning steering wheel to the left.

LOOK: Did steering wheel turn five rpm or less to the left or right? This represents acceptable steering wheel movement during normal operation.

Go to next check.

See your authorized dealer.

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Steering Priority Valve Check

Operate engine at slow idle.

Turn steering wheel to stop left and right. Note effort required to turn wheel.

Turn wheel to stop and apply constant pressure.

NOTE: The priority relief valve pressure must be set to the correct specification to obtain smooth steering.

LOOK/FEEL: Does wheel stop at both axle stops and require normal steering wheel effort?

Does engine rpm decrease when steering wheel is held against stop?

Go to next check.

Steers hard and no decrease in engine rpm. See your authorized dealer.

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Neutral Disconnect Circuit Check

CAUTION: Machine will move forward as transmission control lever (TCL) is moved and may cause injury to bystanders. Ensure machine has enough free space for this check.

Start engine, set idle speed at approximately 1/3 throttle.

Put transmission in fourth gear.

Release park brake and apply service brakes.

Shift transmission control lever (TCL) lever to forward "F" position.

When transmission control lever (TCL) lever is shifted to forward "F" position, can a noticeable drop in engine speed be heard?

Press Neutral Disconnect Switch on gear shift lever or loader control lever individually and note sound of engine.

Does engine rpm increase when the neutral solenoid switches are depressed?

Go to next check.

See your authorized dealer.

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Transmission Shift Linkage, Synchronizer and Noise Check

IMPORTANT: Press neutral disconnect switch on gear shift lever when shifting gears.

Run engine at approximately 1/2 throttle with transmission control lever (TCL) lever in FORWARD "F" position.

Shift transmission into each gear and drive for a short distance.

Can excessive gear noise be heard when shifting between gears?

Go to next check.

See your authorized dealer.

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Differential Lock Check

Raise rear of loader onto floor stands so rear wheels are off ground.

Unlock brake pedals. Turn mechanical front wheel drive (MFWD) switch OFF (if equipped).

Operate machine at approximately 1/2 throttle in 1st forward.

Depress differential lock control.

Apply one brake pedal.

LOOK: Both wheels must stop.

Go to next check.

See your authorized dealer.

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Differential Gear and Pinion Check

Shift transmission to first gear and operate engine at approximately 1/2 throttle.

Move transmission control lever (TCL) lever to FORWARD "F" position.

Steer machine in a maximum left turn and depress left brake pedal to stop the left wheel.

Steer machine in a maximum right turn and depress right brake pedal to stop the right wheel.

Can excessive gear noise be heard in the differential or pinion gear area?

Go to next check.

See your authorized dealer.

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Front Wheel Alignment (Toe-In) Check

Drive machine in fourth gear forward on a surface with loose material.

LOOK: Is material from behind front wheels thrown excessively inward or outward?

Go to next check.

If material is thrown, excessive tire wear will result. See Toe-In Check and Adjust. (Section 4-1.)

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Engine and Torque Converter Check (Without MFWD)

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

Shift transmission into fourth gear.

Move transmission control lever (TCL) lever to FORWARD "F" position.

Engage differential lock.

Increase engine speed to fast idle.

LOOK: Do rear wheels stall?

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

Go to next check.

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

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Transmission Hydraulic System Check

Run engine at approximately 1/2 throttle.

Shift transmission into third gear.

Move transmission control lever (TCL) lever to FORWARD "F" position.

Make several shifts from third forward to third reverse. Start counting the number of seconds when transmission control lever (TCL) lever is moved to opposite direction.

LOOK: Is shift from one direction to the other completed in three seconds?

NOTE: If longer in one direction ONLY, check the slower direction clutch pack.

Go to next check.

See your authorized dealer.

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MFWD Switch Check

Push switch and engage mechanical front wheel drive (MFWD).

LOOK: Does mechanical front wheel drive (MFWD) light in display monitor come ON when switch is pressed?

Push switch to disengage mechanical front wheel drive (MFWD).

LOOK: Is mechanical front wheel drive (MFWD) light in display monitor OFF with MFWD disengaged?

NOTE: Indicator light in mechanical front wheel drive (MFWD) switch will remain ON while MFWD is engaged. If MFWD is turned OFF while operating, light will go out but MFWD could stay engaged until load on drive train is released.

Go to next check.

See your authorized dealer.

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Engine and Torque Converter Check (With MFWD)

With loader bucket level and cutting edge at the centerline of front wheels, put machine against a dirt bank or immovable object.

Engage mechanical front wheel drive (MFWD) and differential lock.

Move shift lever to first gear.

Put transmission control lever (TCL) lever in FORWARD "F" position.

Increase engine speed to fast idle.

LOOK: Do both rear wheels and both front wheels turn?

Go to next check.

If all wheels stop, a torque converter or transmission control valve problem is indicated. If the front wheels stop, mechanical front wheel drive (MFWD) problem is indicated. See your authorized dealer.

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MFWD Gear and Pinion Check

Drive machine at transport speed with mechanical front wheel drive (MFWD) engaged, then disengaged.

Does mechanical front wheel drive (MFWD) "whine" when disengaged?

NOTE: It is normal for mechanical front wheel drive (MFWD) to "whine" when engaged.

Go to next check.

If mechanical front wheel drive (MFWD) whines when disengaged, check oil levels and fill to correct levels.

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Main Hydraulic Pump Performance Check

NOTE: If hydraulic oil is not at operating temperature, heat oil to 38-52°C (100-125°F).

Put loader bucket flat on ground.

Transmission in NEUTRAL "N", transmission control lever (TCL) in FORWARD "F".

Run engine at slow idle.

Measure cycle time to raise loader to maximum height (including bucket leveling).

LOOK: Does loader rise to maximum height in 15 seconds or less?

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

Go to next check.

If cycle time slow, see your authorized dealer.

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Loader Function Drift Check

NOTE: Cylinder oil temperature should be 38-52°C (100-125°F). If not, heat oil to specifications.

Position loader bucket cutting edge 50 mm (2.0 in.) off the ground.

Run engine at slow idle and observe bucket cutting edge.

LOOK: Does cutting edge touch ground within one minute?

Go to next check.

See your authorized dealer.

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Loader Boom Float Check

Put loader bucket at maximum height position with bucket dumped.

Run engine at approximately 1/2 throttle.

Move the loader control lever forward into boom float detent position. Remove hand from control lever.

LOOK: Does loader control lever remain in the boom float detent position?

Go to next check.

See your authorized dealer.

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Loader Return-to-Dig Check

Raise loader bucket to approximately 2/3 height position with bucket dumped.

Run engine at approximately 2/3 throttle.

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: Does the loader control lever disengage from the bucket rollback detent when the bucket is level?

LOOK: When the bucket is at ground level, bucket must be level and the bucket indicator pointer should be aligned with mark on the boom pivot. Alignment will vary according to each operator's eye level and preferences.

NOTE: Under low idle condition, 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.

See your authorized dealer.

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Bucket Leveling Linkage Check

NOTE: The loader bucket leveling feature functions during the boom rise cycle only. When bucket is lowered, the operator can manually level the bucket or use the return-to-dig.

Put loader bucket in the rollback position with the boom near 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: Does loader control lever move into the bucket dump position and the bucket dump function slowly activate? When the loader control lever moves to activate the bucket dump function, does the bucket position remain stationary the remainder of the loader boom rise cycle?

Go to next check.

See your authorized dealer.

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3-Point Hitch Hydraulic Function Check

Operate machine at approximately 1/3 throttle.

Operate controls to check each hitch cylinder function.

LOOK/FEEL: Does each cylinder extend smoothly?

LOOK/FEEL: Does each cylinder retract smoothly?

Go to next check.

See your authorized dealer.

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3-Point Hitch Down Force and Float Check

Put 305 mm (12 in.) high blocks under ends of the lower links.

With engine at slow idle, move the lift lever to the DOWN position.

LOOK: Does the lift cylinder down force relax the rear tire bulge without lifting the rear wheels off the ground?

Go to next step in this check.

See your authorized dealer.

Move the lift lever farther to FLOAT position.

LOOK: Does the tire bulge reappear?

Go to next check.

See your authorized dealer.

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PTO Function Check - If Equipped

Operate machine at approximately full throttle.

Operate control to check engagement function.

LOOK/LISTEN: Does PTO engage and disengage?

Does PTO engage and rotate smoothly?
Does PTO disengage and stop rotating?

Go to next check.

See your authorized dealer.

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Drive Light Check

Key switch in the ON position.

Push light rocker switch to middle position.

LOOK: Are two front lights, two red tail lights and gauge lights ON?

Go to next check.

Check fuse and bulbs. See your authorized dealer.

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Work Light Check

Key switch in the ON position.

Push light rocker switch to upper (WORK) position.

LOOK: Are two front lights, two red tail lights, gauge lights and two rear white lights (if equipped) ON?

Go to next check.

Check fuse and bulbs. See your authorized dealer.

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Turn Signal Check

Key switch in the ON position.

Push right side of turn signal rocker switch down.

LOOK: Is right amber light flashing? Does right indicator light on switch flash? Does left amber light remain on steady?

Push left side of turn signal rocker switch down.

LOOK: Is left amber light flashing? Does left indicator light on top of steering column flash? Does right amber light remain on steady?

Go to next check.

Check fuses and wiring. See your authorized dealer.

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Brake Light Switch Check

Key switch in the ON position.

Depress and hold left brake pedal, then right brake pedal.

LOOK: Rear brake light must come ON when either pedal is depressed with key switch in ON position.

Go to next check.

Check fuse and bulbs. See your authorized dealer.

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Warning Light Check

Key switch in the ON position.

Push bottom of warning light rocker switch in.

LOOK: Are both amber lights flashing? Are both turn signal indicators and light in warning light rocker switch flashing?

Go to next check.

Check fuses and wiring. See your authorized dealer.

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Horn Check

Key switch in the ON position.

Push horn button.

Did horn sound?

Go to next check.

Check fuses and wiring. See your authorized dealer.

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Seat Linkage Check

Move lever sideways.

Move seat forward and rearward and release lever.

LOOK: Does lever move freely and lock seat in desired position?

Go to next check.

Repair linkage. See your authorized dealer.

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Suspension Seat Height Adjustment Check

Turn knob or lift lever to raise or lower seat to desired position.

LOOK: Does seat move up or down and remain in desired position?

Go to next check.

See your authorized dealer.

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Suspension Seat Swivel Linkage Check

Pull lever forward. Swivel seat clockwise to stop and release lever.

Repeat steps to return seat to normal forward facing position.

LOOK: Does seat stop about 15 degrees clockwise from normal forward facing position?

FEEL: Does lever move freely and hold seat in positions?

Go to next check.

Lubricate linkage. See your authorized dealer.

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Suspension Seat Back Linkage Check

Turn lever to position seat back as desired.

FEEL: Does lever move freely and hold seat in desired positions?

Go to next check.

Lubricate linkage. See your authorized dealer.

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Check Periodic Maintenance Decal

Check periodic maintenance decal on right front frame.

LOOK: Is periodic maintenance decal legible?

Operational Checkout Complete.

Replace decal.

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