160GLC and 180GLC Excavator(PIN: 1FF160GX …moffatpipe.com/Equipment-Manuals/EXC 12 - JD160GLC/EXC...

160GLC and 180GLCExcavator

(PIN: 1FF160GX_ _E055001— )(PIN: 1FF180GX_ _E020001— )

*OMT306200* OPERATOR'S MANUAL

160GLC and 180GLC Excavator(PIN: 1FF160GX_ _E055001— )(PIN: 1FF180GX_ _E020001— )OMT306200 ISSUE H4 (ENGLISH)

CALIFORNIAProposition 65 Warning

Diesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,

birth defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects or other reproductive harm.

The State of California requires the above two warnings.

Additional Proposition 65 Warnings can be found in this manual.

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

VD76477,00004EB -19-07JUL14-1/1

Foreword

READ THIS MANUAL carefully to learn how to operateand service your machine correctly. Failure to do socould result in personal injury or equipment damage. Thismanual and safety signs on your machine may also beavailable in other languages; see your John Deere dealerto order.

THIS MANUAL SHOULD BE CONSIDERED a permanentpart of your machine and should remain with the machinewhen you sell it.

MEASUREMENTS in this manual are given in bothmetric and customary U.S. unit equivalents. Use onlycorrect replacement parts and fasteners. Metric and inchfasteners may require a specific metric or inch wrench.

RIGHT-HAND AND LEFT-HAND sides are determined byfacing in the direction of forward travel.

WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.)in the Machine Numbers section. Accurately record all thenumbers to help in tracing the machine if machine is everstolen. Your dealer also needs these numbers when youorder parts. File the identification numbers in a secureplace off the machine.

WARRANTY is provided as part of John Deere's supportprogram for customers who operate and maintain theirequipment as described in this manual. The warranty isexplained on the warranty certificate or statement whichyou should have received from your dealer.

This warranty provides you the assurance that JohnDeere will back its products where defects appear withinthe warranty period. In some circumstances, John Deerealso provides field improvements, often without chargeto the customer, even if the product is out of warranty.Should the equipment be abused, or modified to changeits performance beyond the original factory specifications,the warranty will become void and field improvementsmay be denied. Setting fuel delivery above specificationsor otherwise overpowering machines will result in suchaction.

If you are not the original owner of this machine, it is inyour interest to contact your local John Deere dealer toinform them of this unit's serial number. This will help JohnDeere notify you of any issues or product improvements.

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Manual Identification—READ THIS FIRST!IMPORTANT: Use only supporting manuals

designated for your specific machine. Ifincorrect manual is chosen, improper servicemay occur. Verify product identification number(PIN) when choosing the correct manual.

Choosing the Correct Supporting Manuals

John Deere excavators are available in different machineconfigurations based on the various markets into whichthey are sold. Different supporting manuals exist fordifferent machine configurations.

When necessary, product identification numbers are listedon the front covers of excavator manuals. These numbersare used to identify the correct supporting manual for yourmachine.

Product Identification Number

The product identification number (PIN) plate (1) is locatedon the front, right corner of the cab. Each machine has a17-character PIN (2) shown on PIN plate.

TX1160624—UN—13MAY

14

PIN Plate Location—Early Production

TX1156411—UN—27MAR14

PIN Plate Location—Late Production

TX1160834—UN—16MAY

14

Example of PIN Plate

TX1160690—UN—16MAY

14

Example of PIN Plate

1—PIN Plate 2—17-Character PIN

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The PIN identifies the producing factory, machine modelnumber, machine option, year of manufacture, engineemission level, and machine serial number.

The following is an example for a machine that meetsInterim Tier 4 and Stage III B emission levels:

17-Character PIN Examples1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 171 F F 1 6 0 G X _ _ E 0 5 5 0 0 1

• (1—3) World Code: Identifies location where machineis manufactured.

1FF .................. World Code (manufacturing location)1DW ............. Davenport Works1T8 ............... Thibodaux Works1T0 ............... Dubuque Works1FF ............... Deere—Hitachi (Kernersville, NC, USA)1F9 ............... Deere—Hitachi (Indaiatuba, São Paulo, Brazil)

• (4—8) Machine Model Identifier: Identifies modelnumber.

160G ................ Machine Model Identifier

NOTE: Characters 7—8 identify series and majormachine configuration options. These characterswill change from one machine to another.

X ..................... Machine Option CodeX .................. Base MachineR ................. HYEX Military Excavators

• (9) Check Letter: This is a random character assignedby the factory. This is not used in machine identification.

_ ..................... Check Letter (variable)

• (10) Manufacturing Year Code: Identifies year ofmachine manufacture.

_ ..................... Manufacturing Year Code (variable)B .................. 2011C ................. 2012D ................. 2013E .................. 2014

• (11) Engine Emission Code: Represents engineemission certification.

E ..................... Engine Emission CodeC ................. Tier 2 and Stage IID ................. Tier 3 and Stage III AE .................. Interim Tier 4 and Stage III BF .................. Final Tier 4 and Stage IV

• (12—17) Machine Serial Number: Identifies machineserial number. This character will change from onemachine to another.

055001 ............. Machine Serial Number

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OUT4001,0000A72 -19-21MAY14-3/3

VD76477,000104D -19-27JUN12-1/1

Engine Model Number Identification

The engine serial number plate (3) is located on theengine behind the open crankcase ventilation (OCV) filter.Each engine has a 9-character engine model number (4)shown on this plate.

Engine Emissions Level Identification

The 9-character engine model number corresponds to aspecific engine emissions level.

Engine Model Number Engine Emissions Level4045HT068 Interim Tier 4/Stage III B4045HT065 Tier 3/Stage III A

3—Engine Serial Number Plate 4—9-Character Engine ModelNumber

TX1105031—UN—07JAN12

Engine Serial Number Plate Location

DEERE & COMPANY MOLINE, ILLINOIS MADE IN MEXICO

4045HT068

*PE4045R123456*Engine Serial Number

3 4

TX1100222—UN—03NOV11

Engine Serial Number Plate (Interim Tier 4/Stage III B)

DEERE & COMPANY MOLINE, ILLINOIS MADE IN MEXICO

4045HT065

*PE4045R123456*Engine Serial Number

3 4

TX1100776—UN—11NOV11

Engine Serial Number Plate (Tier 3/Stage III A)

IMPORTANTWarranty will not apply to engine and drivetrain failuresresulting from unauthorized adjustments to this engine.

Unauthorized adjustments are in violation of the emissionsregulations applicable to this engine and may result insubstantial fines and penalties.

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EPA Non-road Emissions Control Warranty Statement—Compression Ignition

DXLOGOV1 —UN—28APR09

U.S. AND CANADA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS

To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the "Emissions Control Information" labellocated on the engine. If the engine is operated in the United States or Canada and the Emissions Control information label states: "This enginecomplies with US EPA regulations for nonroad and stationary diesel engines”, or “This engine conforms to US EPA nonroad compression-ignitionregulations”, refer to the "U.S. and Canada Emission Control Warranty Statement." If the engine is operated in California, and the label states: "Thisengine complies with US EPA and CARB regulations for nonroad diesel engines”, or “This engine conforms to US EPA and California nonroadcompression-ignition emission regulations”, also refer to the "California Emission Control Warranty Statement.”

Warranties stated on this certificate refer only to emissions-related parts and components of your engine. The complete engine warranty, lessemissions-related parts and components, is provided separately. If you have any questions about your warranty rights and responsibilities,you should contact John Deere at 1-319-292-5400.

JOHN DEERE'S WARRANTY RESPONSIBILITY

John Deere warrants to the ultimate purchaser and each subsequent purchaser that this off-road diesel engine including all parts of itsemission-control system was designed, built and equipped so as to conform at the time of the sale with Section 213 of the Clean Air Act and is freefrom defects in materials and workmanship which would cause the engine to fail to conform with applicable US EPA regulations for a period of fiveyears from the date the engine is placed into service or 3,000 hours of operation, whichever first occurs.

Where a warrantable condition exists, John Deere will repair or replace, as it elects, any part or component with a defect in materials orworkmanship that would increase the engine’s emissions of any regulated pollutant within the stated warranty period at no cost to you, includingexpenses related to diagnosing and repairing or replacing emission-related parts. Warranty coverage is subject to the limitations and exclusionsset forth herein. Emission- related components include engine parts developed to control emissions related to the following:Air-Induction SystemFuel SystemIgnition SystemExhaust Gas Recirculation Systems

Aftertreatment DevicesCrankcase Ventilation ValvesSensorsEngine Electronic Control Units

EMISSION WARRANTY EXCLUSIONS

John Deere may deny warranty claims for malfunctions or failures caused by:

• Non-performance of maintenance requirements listed in the Operator’s Manual• The use of the engine/equipment in a manner for which it was not designed• Abuse, neglect, improper maintenance or unapproved modifications or alterations• Accidents for which it does not have responsibility or by acts of God

The off-road diesel engine is designed to operate on diesel fuel as specified in the Fuels, Lubricants and Coolants section in the Operators Manual.Use of any other fuel can harm the emissions control system of the engine/equipment and is not approved for use.

To the extent permitted by law John Deere is not liable for damage to other engine components caused by a failure of an emission-relatedpart, unless otherwise covered by standard warranty.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTYOF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THEPROVISIONS OF MATERIAL AND SERVICES AS SPECIFIED HEREIN. WHERE PERMITTED BY LAW, NEITHER JOHN DEERE NOR ANYAUTHORIZED JOHN DEERE ENGINE DISTRIBUTOR, DEALER, OR REPAIR FACILITY OR ANY COMPANY AFFILIATED WITH JOHNDEERE WILL BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Emission_CI_EPA (18Dec09)

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DX,EMISSIONS,EPA -19-12DEC12-2/2

TS1721

—UN—15JU

L13

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CARB Non-road Emissions Control Warranty Statement—Compression Ignition

DXLOGOV1 —UN—28APR09

CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS

To determine if the John Deere engine qualifies for the additional warranties set forth below, look for the “Emission Control Information” label locatedon the engine. If the engine is operated in the United States or Canada and the engine label states: “This engine complies with US EPA regulationsfor nonroad and stationary diesel engines”, or “This engine complies with US EPA regulations for stationary emergency diesel engines”, refer to the“U.S. and Canada Emission Control Warranty Statement.” If the engine is operated in California, and the engine label states: “This engine complieswith US EPA and CARB regulations for nonroad diesel engines” also refer to the “California Emissions Control Warranty Statement.”

Warranties stated on this certificate refer only to emissions-related parts and components of your engine. The complete engine warranty, lessemission-related parts and components, is provided separately. If you have any questions about your warranty rights and responsibilities,you should contact John Deere at 1-319-292-5400.

CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT:

The California Air Resources Board (CARB) is pleased to explain the emission-control system warranty on 2013 through 2015 off-road dieselengines. In California, new off-road engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. John Deeremust warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect orimproper maintenance of your engine.

Your emission control system may include parts such as the fuel injection system and the air induction system. Also included may be hoses, belts,connectors and other emission-related assemblies.

John Deere warrants to the ultimate purchaser and each subsequent purchaser that this off-road diesel engine was designed, built, and equippedso as to conform at the time of sale with all applicable regulations adopted by CARB and is free from defects in materials and workmanship whichwould cause the failure of a warranted part to be identical in all material respects to the part as described in John Deere's application for certificationfor a period of five years from the date the engine is delivered to an ultimate purchaser or 3,000 hours of operation, whichever occurs first for allengines rated at 19 kW and greater. In the absence of a device to measure hours of use, the engine shall be warranted for a period of five years.

EMISSIONS WARRANTY EXCLUSIONS:

John Deere may deny warranty claims for failures caused by the use of an add-on or modified part which has not been exempted by the CARB. Amodified part is an aftermarket part intended to replace an original emission-related part which is not functionally identical in all respects and whichin any way affects emissions. An add-on part is any aftermarket part which is not a modified part or a replacement part.

In no event will John Deere, any authorized engine distributor, dealer, or repair facility, or any company affiliated with John Deere be liablefor incidental or consequential damage.

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JOHN DEERE'S WARRANTY RESPONSIBILITY:

Where a warrantable condition exists, John Deere will repair or replace, as it elects, your off-road diesel engine at no cost to you, includingdiagnosis, parts or labor. Warranty coverage is subject to the limitations and exclusions set forth herein. The off-road diesel engine is warrantedfor a period of five years from the date the engine is delivered to an ultimate purchaser or 3,000 hours of operation, whichever occurs first.The following are emissions-related parts:

Air Induction System

• Intake manifold• Turbocharger• Charge air cooler

Fuel Metering system

• Fuel injection system

Exhaust Gas Recirculation

• EGR valve

Catalyst or Thermal Reactor Systems

• Catalytic converter• Exhaust manifold

Emission control labels

Particulate Controls

• Any device used to capture particulateemissions• Any device used in the regeneration of thecapturing system• Enclosures and manifolding• Smoke Puff Limiters

Positive Crankcase Ventilation (PCV) System

• PCV valve• Oil filler cap

Advanced Oxides of Nitrogen (NOx) Controls

• NOx absorbers and catalysts

SCR systems and urea containers/dispensingsystems

Miscellaneous Items used in Above Systems

• Electronic control units, sensors, actuators,wiring harnesses, hoses, connectors, clamps,fittings, gasket, mounting hardware

Any warranted emissions-related part scheduled for replacement as required maintenance is warranted by John Deere for the period of time priorto the first scheduled replacement point for the part. Any warranted emissions-related part not scheduled for replacement as required maintenanceor scheduled only for regular inspection is warranted by John Deere for the stated warranty period.

OWNER'S WARRANTY RESPONSIBILITIES:

As the off-road diesel engine owner you are responsible for the performance of the required maintenance listed in your Operator’s Manual. JohnDeere recommends that the owner retain all receipts covering maintenance on the off-road diesel engine, but John Deere cannot deny warrantysolely for the lack of receipts or for the owner’s failure to ensure the performance of all scheduled maintenance. However, as the off-road dieselengine owner, you should be aware that John Deere may deny you warranty coverage if your off-road diesel engine or a part has failed due toabuse, neglect, improper maintenance or unapproved modifications.

The off-road diesel engine is designed to operate on diesel fuel as specified in the Fuels, Lubricants and Coolants section in the Operators Manual.Use of any other fuel may result in the engine no longer operating in compliance with applicable emissions requirements.

The owner is responsible for initiating the warranty process, and should present the machine to the nearest authorized John Deere dealer as soonas a problem is suspected. The warranty repairs should be completed by the authorized John Deere dealer as quickly as possible.

Emissions regulations require the customer to bring the unit to an authorized servicing dealer when warranty service is required. As a result, JohnDeere is NOT liable for travel or mileage on emissions warranty service calls.

Emission_CI_CARB (19Sep12)

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TS1722

—UN—17DEC12

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DX,EMISSIONS,CARB -19-12DEC12-4/4

TS1723

—UN—15JU

L13

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MM16284,000196F -19-07JUL14-1/1

FCC Notifications to User

FCC Notification

These devices comply with Part 15 of the FCC Rules.Operation is subject to the following two conditions: (1)These devices may not cause harmful interference, and(2) these devices must accept any interference received,including interference that may cause undesired operation.

These devices must be operated as supplied by JohnDeere Ag Management Solutions. Any changes ormodifications made to these devices without the expressedwritten approval of John Deere Ag Management Solutionsmay void the user’s authority to operate these devices.

Modular Telematics Gateway and Satellite Module

This equipment has been tested and found to comply withthe limits for Class B digital devices, pursuant to part 15of the FCC Rules. These limits are designed to providereasonable protection against harmful interference in a

residential installation. This equipment generates, uses,and can radiate radio frequency energy, and if not installedand used in accordance with the instructions, may causeharmful interference to radio communications. However,no guarantee shall be made that interference will not occurin a particular installation. If this equipment does causeharmful interference to radio or television reception, whichcan be determined by turning the equipment off and on,the user is encouraged to try to correct the interference byone or more of the following measures:

• Reorient or relocate the receiving antenna.• Increase the separation between the equipment andreceiver.• Connect the equipment into an outlet on a circuitdifferent from that to which the receiver is connected.• Consult the dealer or an experienced radio/TVtechnician for help.

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Service ADVISOR™ Remote (SAR)—SOFTWARE TERMS AND CONDITIONS

IMPORTANT -- READ CAREFULLY: THIS SOFTWARELICENSE AGREEMENT IS A LEGAL CONTRACTBETWEEN YOU AND THE LICENSOR ("LICENSOR")IDENTIFIED BELOW AND GOVERNS YOUR USE OFTHE SOFTWARE DELIVERED TO YOUR MACHINE(THE “MACHINE”).

BY INDICATING YOUR ACCEPTANCE ON A DISPLAYON THE MACHINE, BY INSTALLING SOFTWARETO THE MACHINE, OR USING SOFTWARE ON THEMACHINE, YOU ARE ACCEPTING AND AGREEING TOTHE TERMS OF THIS LICENSE AGREEMENT WITHRESPECT TO THE SOFTWARE (THE "Software") THATIS DELIVERED TO YOURMACHINE. YOU AGREE THATTHIS SOFTWARE LICENSE AGREEMENT, INCLUDINGTHE WARRANTY DISCLAIMERS, LIMITATIONS OFLIABILITY AND TERMINATION PROVISIONS BELOW,IS BINDING UPON YOU, AND UPON ANY COMPANYON WHOSE BEHALF YOU USE THE SOFTWAREAS WELL AS THE EMPLOYEES OF ANY SUCHCOMPANY (COLLECTIVELY REFERRED TO AS"YOU" IN THIS SOFTWARE LICENSE AGREEMENT).IF YOU DO NOT AGREE TO THE TERMS OF THISAGREEMENT, OR IF YOU ARE NOT AUTHORIZEDTO ACCEPT THESE TERMS ON BEHALF OF YOURCOMPANY OR ITS EMPLOYEES, PLEASE CLICK THE[Decline] ICON ON THE DISPLAY ON THE MACHINETO DECLINE THESE TERMS AND CONDITIONS.THIS LICENSE AGREEMENT REPRESENTS THEENTIRE AGREEMENT CONCERNING THE SOFTWAREBETWEEN YOU AND THE LICENSOR.

1. Delivery of Software. Software may be delivered toyour Machine by Licensor wirelessly or via an agent ofLicensor, such as a dealer. If it is delivered wirelessly,you may be responsible for any data transmission feesincurred due to such delivery.

2. License. Licensor hereby grants to you, and youaccept, a nonexclusive license to use the Software inmachine-readable, object code form, only as authorizedin this License Agreement and the applicable provisionsof the Operators' Manuals, which you agree to reviewcarefully prior to using the Software. The Software maybe used only on the Machine to which it was initiallydelivered. You agree that you will not assign, sublicense,transfer, pledge, lease, rent, or share your rights underthis License Agreement, except that you may permanentlytransfer all of your rights under this License Agreementin connection with the sale of the Machine on which theSoftware covered by this Agreement is installed.

3. Licensor's Rights. You acknowledge and agree thatthe Software is proprietary to Licensor and is protectedunder copyright law. You further acknowledge and agreethat all right, title, and interests in and to the Software,including associated intellectual property rights, are andshall remain with Licensor. This License Agreement doesnot convey to you any title or interest in or to the Software,but only a limited right of use revocable in accordancewith the terms of this License Agreement. You agree

that you will not: (a) reverse assemble, reverse compile,modify, or otherwise translate the Software, or attempt todefeat the copyright protection and application enablingmechanisms therein; (b) copy or reproduce the Software;or, (b) remove or obliterate any copyright, trademark orother proprietary rights notices from the Software. Youalso agree not to permit any third party acting under yourcontrol to do any of the foregoing.

4. License Fees. The license fees paid by you, if any, arepaid in consideration of the licenses granted under thisLicense Agreement.

5. Limited Warranty. Licensor warrants, for yourbenefit alone and not for the benefit of any other party,that during the "Warranty Period" defined below, theSoftware will operate substantially in accordance with theapplicable functional specifications ("Specifications")set forth in the Operators' Manuals. If, prior to expirationof the Warranty Period, the Software fails to performsubstantially in accordance with the Specifications, youmay return the Machine to the place of purchase forrepair or replacement of the non-performing Software.The Warranty Period is ninety (90) days from the date ofinstallation of the Software or the duration of the warrantyperiod of the component of the Machine on which theSoftware is installed, whichever is longer. The SoftwareWarranty Period does not affect the warranty period of theMachine itself or any component thereof.

6. DISCLAIMER OF WARRANTIES. YOU HEREBYAGREE THAT THE LIMITED WARRANTY PROVIDEDABOVE (THE "LIMITED WARRANTY") CONSTITUTESYOUR SOLE AND EXCLUSIVE REMEDY FOR ANYPROBLEM WHATSOEVER WITH THE SOFTWARE.EXCEPT AS PROVIDED IN THE LIMITED WARRANTY,THE SOFTWARE IS LICENSED “AS IS,” ANDLICENSOR, ITS AFFILIATES AND THIRD PARTYSUPPLIERS EXPRESSLY DISCLAIM AND YOUEXPRESSLY WAIVE, RELEASE AND RENOUNCE ALLWARRANTIES ARISING BY LAW OR OTHERWISEWITH RESPECT TO THE SOFTWARE, INCLUDING,BUT NOT LIMITED TO: ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE; ANY IMPLIED WARRANTY ARISINGFROM COURSE OF PERFORMANCE, COURSE OFDEALING OR TRADE USAGE; ANY WARRANTY OFTITLE OR NON-INFRINGEMENT; AND, ANY OTHERWARRANTY ARISING UNDER ANY THEORY OFLAW, INCLUDING TORT, NEGLIGENCE, STRICTLIABILITY, CONTRACT OR OTHER LEGAL OREQUITABLE THEORY. NO REPRESENTATION OROTHER AFFIRMATION OF FACT INCLUDING, BUT NOTLIMITED TO, STATEMENTS REGARDING SUITABILITYFOR USE, SHALL BE DEEMED TO BE A WARRANTYBY LICENSOR OR ANY OF ITS AFFILIATES OR THIRDPARTY SUPPLIERS. LICENSOR DOES NOT WARRANTTHAT THE SOFTWARE IS ERROR-FREE OR WILLOPERATE WITHOUT INTERRUPTION.

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7. LIMITATION OF LIABILITY. EXCEPT AS SETFORTH IN THE LIMITED WARRANTY, UNDER NOCIRCUMSTANCES SHALL LICENSOR, ITS AFFILIATESOR ITS THIRD PARTY SUPPLIERS BE LIABLE TOYOU OR TO ANY THIRD PARTIES FOR DIRECT,INDIRECT, INCIDENTAL OR CONSEQUENTIALDAMAGES OF ANY KIND, INCLUDING ANY LOSSOR DAMAGE CAUSED BY THE SOFTWARE; ANYPARTIAL OR TOTAL FAILURE OF THE SOFTWARE;PERFORMANCE, NONPERFORMANCE OR DELAYSIN CONNECTION WITH ANY INSTALLATION,MAINTENANCE, WARRANTY OR REPAIRS OF THESOFTWARE, DAMAGES FOR CROP LOSS, DAMAGETO LAND, LOST PROFITS, LOSS OF BUSINESS ORLOSS OF GOODWILL, LOSS OF USE OF EQUIPMENTOR SERVICES OR DAMAGES TO BUSINESS ORREPUTATION ARISING FROM THE PERFORMANCEOR NON-PERFORMANCE OF ANY ASPECT OF THISAGREEMENT, WHETHER IN CONTRACT, TORT OROTHERWISE, AND WHETHER OR NOT LICENSOR,ITS AFFILIATES OR ITS THIRD PARTY SUPPLIERSHAVE BEEN ADVISED OF THE POSSIBILITY OFSUCH DAMAGES. IN NO EVENT SHALL LICENSOR’SCUMULATIVE LIABILITY TO YOU OR TO ANY OTHERPARTY FOR ANY LOSSES OR DAMAGES RESULTINGFROM ANY CLAIMS, LAWSUITS, DEMANDS, ORACTIONS ARISING FROM OR RELATING TO USE OFTHE SOFTWARE EXCEED YOUR TOTAL PAYMENTFOR THE MACHINE AND FOR THE LICENSE OF THESOFTWARE.

8. Termination of License. Licensor may terminate thelicense granted under this Agreement upon written noticeof termination provided to you if you violate any materialterm of this Agreement pertaining to your use of theSoftware or Licensor's rights, including, without limitation,the provisions of Sections 2 and 3 above.

9. Compliance with Law. You agree that you will use theSoftware in accordance with United States law and thelaws of the country in which you are located, as applicable,including foreign trade control laws and regulations. TheSoftware may be subject to export and other foreigntrade controls restricting re-sales and/or transfers toother countries and parties. By accepting the terms ofthis Agreement, you acknowledge that you understandthat the Software may be so controlled, including, butnot limited to, by the Export Administration Regulationsand/or the foreign trade control regulations of the TreasuryDepartment of the United States. Any other provisionof this Agreement to the contrary notwithstanding, youagree that the Software will not be resold, re-exported orotherwise transferred. The Software remains subject toapplicable U.S. laws.

10. Indemnification. You agree to defend, indemnifyand hold Licensor, its affiliates and third party supplier,and their, officers, directors, employees, agents andrepresentatives (each an "Indemnified Party"), harmless

from and against all claims, demands proceedings,injuries, liabilities, losses, or costs and expenses (includingreasonable legal fees) brought by any third party againstany such persons arising from or in connection with youruse of the Software, regardless of whether such lossesare caused, wholly or partially, by any negligence, breachof contract or other fault of an Indemnified Party.

11. Costs of Litigation. If any claim or action is broughtby either party to this License Agreement against the otherparty regarding the subject matter hereof, the prevailingparty shall be entitled to recover, in addition to any otherrelief granted, reasonable attorney fees and expensesof litigation.

12. Severability and Waiver. Should any term of thisAgreement be declared void or unenforceable by anycourt of competent jurisdiction, such declaration shallhave no effect on the remaining terms hereof. The failureof either party to enforce any rights granted hereunderor to take action against the other party in the event ofany breach hereunder shall not be deemed a waiverby that party as to subsequent enforcement of rights ofsubsequent actions in the event of future breaches.

13. Language Clause. If you are a resident of Canadaat the time you accept this Agreement, then the partieshereby acknowledge that they have required thisAgreement, and all other documents relating hereto,be drawn up in the English language only. Les partiesreconnaissent avoir demandé que le présent contrat ainsique toute autre entente ou avis requis ou permis à êtreconclu ou donné en vertu des stipulations du présentcontrat, soient rédigés en langue anglaise seulement. Ifyou are a resident of any country other than the UnitedStates, Canada, Great Britain, Australia or New Zealandthen you agree as follows: there may be a translatedversion of this Agreement. If there is an inconsistencyor contradiction between the translated version and theEnglish version of this Agreement, the English version ofthis Agreement shall control.

14. Assignment by Licensor. Licensor may assign thisAgreement without your prior consent to any companyor entity affiliated with Licensor, or by an assignmentassociated with a corporate restructuring, merger oracquisition.

15. Governing Law and Forum. This Agreement willbe governed by and construed in accordance with thesubstantive laws identified in the table in Section 18, belowThe respective courts of the venue identified in the tablein Section 18, below, for the location of the Machine shallhave non-exclusive jurisdiction over all disputes relatingto this Agreement. This Agreement will not be governedby the conflict of law rules of any jurisdiction or the UnitedNations Convention on Contracts for the International Saleof Goods, the application of which is expressly excluded.

16. Specific Exceptions.

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16.1 Limited Warranty for Users Residing in EuropeanEconomic Area Countries or Switzerland. If youobtained the Software in any European Economic Areacountry or Switzerland, and you usually reside in suchcountry, then Section 6 does not apply, instead, Licensorwarrants that the Software provides the functionalitiesset forth in the Operators Manuals (the "agreed uponfunctionalities") for the Warranty Period. As usedin this Section, "Warranty Period" means one (1)year. Non-substantial variation from the agreed uponfunctionalities shall not be considered and does notestablish any warranty rights. THIS LIMITED WARRANTYDOES NOT APPLY TO SOFTWARE PROVIDED TOYOU FREE OF CHARGE, FOR EXAMPLE, UPDATES,OR SOFTWARE THAT HAS BEEN ALTERED BY YOU,TO THE EXTENT SUCH ALTERATIONS CAUSED ADEFECT. To make a warranty claim, during the WarrantyPeriod you must return, at our expense, the Software andproof of purchase to the location where you obtained it.If the functionalities of the Software vary substantiallyfrom the agreed upon functionalities, Licensor is entitled-- by way of re-performance and at its own discretion --to repair or replace the Software. If this fails, you areentitled to a reduction of the purchase price (reduction)or to cancel the purchase agreement (rescission). Forfurther warranty information, please contact Licensor atthe address listed in Section 18.

16.2 Limitation of Liability for Users Residing inEuropean Economic Area Countries or Switzerland.

(a) If you obtained the Software in any EuropeanEconomic Area country or Switzerland, and you usuallyreside in such country, then Sections 7 and 10 do notapply, Instead, Licensor's statutory liability for damagesshall be limited as follows: (a) Licensor shall be liable onlyup to the amount of damages as typically foreseeableat the time of entering into this Agreement in respectof damages caused by a slightly negligent breach of amaterial contractual obligation and (b) Licensor shall

not be liable for damages caused by a slightly negligentbreach of a non-material contractual obligation.

(b) The aforesaid limitation of liability shall not apply to anymandatory statutory liability, in particular, to liability underthe German Product Liability Act, liability for assuming aspecific guarantee or liability for culpably caused personalinjuries.

(c) You are required to take all reasonable measures toavoid and reduce damages, in particular to make back-upcopies of the Software and your computer data subject tothe provisions of this Agreement.

17. Representations of Licensee. BY ACCEPTINGTHIS AGREEMENT, YOU: (A) ACKNOWLEDGETHAT YOU HAVE READ AND UNDERSTAND THISAGREEMENT; (B) REPRESENT THAT YOU HAVE THEAUTHORITY TO ENTER INTO THIS AGREEMENT; (C)AGREE THAT THIS AGREEMENT IS ENFORCEABLEAGAINST YOU AND ANY LEGAL ENTITY THATOBTAINED THE SOFTWARE AND ON WHOSE BEHALFIT IS USED; AND, (D) AGREE TO PERFORM THEOBLIGATIONS OF THIS AGREEMENT.

18. Identification of Licensor and Notices. TheLicensor is the entity identified in the table below. Allnotices to Licensor shall be sent by certified or registeredmail to the corresponding address for the Licensor givenbelow. In each case a copy of the notice shall also besent to John Deere Intelligent Solutions Group, ATTN:Legal, 4140 114th Street Urbandale, IA 50322 U.S.A. Allnotices to Licensor shall be effective upon receipt. Allnotices required to be given to you shall, in Licensor’s solediscretion, either be sent via certified or registered mailto the address given to Licensor in connection with yourpurchase of the Machine. Either method of notificationused by Licensor shall be effective upon dispatch. Youagree to notify Licensor of any change in your address inthe manner set forth above.

Place of Purchase Address Governing Law VenueUnited States of America John Deere Shared Services, Inc.

One John Deere PlaceMoline, IL 61265 U.S.A.

State of Illinois, USA Rock Island County, Illinois, USA

Argentina Industrias John Deere Argentina, S.A.Casilla de Correo 80Rosario (Santa Fe), 2000, Argentina

Province of Santa Fe, Argentina Province of Santa Fe, Argentina

Australia or New Zealand John Deere Limited (Australia)P.O. Box 2022Crestmead, Queensland, Australia 4132

State of Queensland, Australia State of Queensland, Australia

Canada John Deere Limited295 Hunter RoadP.O. Box 1000Grimsby, ON L9K 1M3

Province of Ontario, Canada Province of Ontario, Canada

Chile John Deere Water, S.A.Cerro Santa Lucia 9990Quilicura, Santiago, Chile

Province of Santiago, Chile Province of Santiago, Chile

Mexico Industrias John Deere, S.A. de C.V.Boulevard Diaz Ordaz #500Garza GarciaNuevo Leon 66210, Mexico

State of Nuevo Leon, Mexico State of Nuevo Leon, Mexico

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Introduction

OUT4001,00006C5 -19-08NOV10-4/4

TX,TM,FAX -19-03JUL01-1/1

Europe ETICStrassburgerallee 567657 Kaiserslautern, Germany

Federal Republic of Germany Kaiserslautern, Germany

Other The John Deere entity identifiedfor the location of your Machineon www.JDLink.com.

The John Deere entity identifiedfor the location of your Machineon www.JDLink.com.

The John Deere entity identifiedfor the location of your Machineon www.JDLink.com.

Technical Information Feedback FormWe need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.SEND TO: John Deere Dubuque Works

18600 South John Deere RoadAttn: Publications, Dept. 324Dubuque, IA 52004-0538USA

FAX NUMBER: 1-563-589-5800 (USA)

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

Email Address:

THANK YOU!

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Contents

Page

Safety—Safety and Operator ConveniencesSafety and Operator Convenience Features .....1-1-1

Safety—General PrecautionsRecognize Safety Information ...........................1-2-1Follow Safety Instructions..................................1-2-1Operate Only If Qualified ...................................1-2-1Wear Protective Equipment...............................1-2-2Avoid Unauthorized Machine Modifications.......1-2-2Control Pattern Selector—If Equipped ..............1-2-2Add Cab Guarding for Special Uses..................1-2-2Inspect Machine ................................................1-2-3Stay Clear of Moving Parts................................1-2-3Avoid High-Pressure Fluids ...............................1-2-3Avoid High-Pressure Oils ..................................1-2-4Work In Ventilated Area.....................................1-2-4Avoid Static Electricity Risk When Refueling.....1-2-5Prevent Fires .....................................................1-2-5Prevent Battery Explosions ...............................1-2-6Handle Chemical Products Safely .....................1-2-6Dispose of Waste Properly ................................1-2-6Exhaust Filter Ash Handling and Disposal ........1-2-7Prepare for Emergencies...................................1-2-7Clean Debris from Machine...............................1-2-7

Safety—Operating PrecautionsUse Steps and Handholds Correctly .................1-3-1Start Only From Operator's Seat .......................1-3-1Use and Maintain Seat Belt ...............................1-3-1Prevent Unintended Machine Movement ..........1-3-1Avoid Work Site Hazards...................................1-3-2Keep Riders Off Machine ..................................1-3-2Avoid Backover Accidents .................................1-3-3Inspect and Maintain ROPS ..............................1-3-3Avoid Machine Tip Over ....................................1-3-4Use Special Care When Lifting Objects ............1-3-4Use Special Care When Operating ...................1-3-4Travel Safely......................................................1-3-5Prevent Acid Burns............................................1-3-5Add and Operate Attachments Safely ...............1-3-5

Safety—Maintenance PrecautionsPark and Prepare for Service Safely .................1-4-1Service Cooling System Safely .........................1-4-1Remove Paint Before Welding or Heating.........1-4-2Make Welding Repairs Safely ...........................1-4-2

Page

Drive Metal Pins Safely .....................................1-4-2Clean Exhaust Filter Safely ...............................1-4-3

Safety—Safety SignsSafety Signs ......................................................1-5-1Hydraulic Coupler Safety Signs—If

Equipped .....................................................1-5-14

Operation—Operator's StationPedals, Levers, and Panels...............................2-1-1Switch Panel......................................................2-1-2Switch Panel Functions .....................................2-1-3Rear Left Panel..................................................2-1-4Horn...................................................................2-1-4Power Dig Button...............................................2-1-4Pilot Shutoff Lever .............................................2-1-5Left Console ......................................................2-1-5Travel Alarm and Travel Alarm Cancel Switch ..2-1-5Seat Heater Switch—If Equipped......................2-1-6Reversing Fan Switch—If Equipped..................2-1-6Right Console ....................................................2-1-6Exhaust Filter Parked Cleaning Switch .............2-1-7Right Enable Switch ..........................................2-1-7Service ADVISOR™ Remote (SAR) Switch......2-1-8Cab Heater and Air Conditioner ........................2-1-9Selecting Display Between Celsius and

Fahrenheit ...................................................2-1-10Operating the AM/FM Radio............................2-1-11Fire Extinguisher Mounting Location ...............2-1-12Secondary Exit Tool.........................................2-1-12Cab Dome Light Switch ...................................2-1-13Opening Upper Front (Secondary Exit)

Window .......................................................2-1-13Removing and Storing the Lower Front

Window .......................................................2-1-14Opening Cab Door Window.............................2-1-14Opening and Closing the

Polycarbonate Type Roof Exit Cover ..........2-1-15Adjusting the Mechanical Suspension Seat ....2-1-15Adjusting the Air Suspension Seat—If

Equipped .....................................................2-1-16Adjusting Pilot Control Lever Console Height ..2-1-16

Operation—Monitor OperationMonitor...............................................................2-2-1Monitor Functions..............................................2-2-2

Continued on next page

Original Instructions. All information, illustrations and specifications in thismanual are based on the latest information available at the time of publication.

The right is reserved to make changes at any time without notice.COPYRIGHT © 2014DEERE & COMPANY

Moline, IllinoisAll rights reserved.

A John Deere ILLUSTRUCTION ® ManualPrevious Editions

Copyright © 2012, 2013

i 081214

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Contents

Page

Monitor Start-Up ................................................2-2-3Main Menu.........................................................2-2-4Main Menu—Alarm List .....................................2-2-5Main Menu—Air Conditioner ...........................2-2-11Main Menu—Radio..........................................2-2-13Main Menu—Work Mode.................................2-2-14Main Menu—Setting Menu..............................2-2-15Main Menu—Setting Menu—Date and Time...2-2-16Main Menu—Setting Menu—Attach-

ment Name Input.........................................2-2-16Main Menu—Setting Menu—Auto Shutdown ..2-2-17Main Menu—Setting Menu—Auto

Exhaust Filter Cleaning ...............................2-2-18Main Menu—Setting Menu—Sub

Meter Selection ...........................................2-2-19Main Menu—Setting Menu—Rear

View Camera Monitor..................................2-2-20Main Menu—Setting Menu—Display

Item Selection .............................................2-2-21Main Menu—Setting Menu—Bright-

ness Adjustment..........................................2-2-21Main Menu—Setting Menu—Language ..........2-2-21Main Menu—Setting Menu—Unit Selection ....2-2-22Main Menu—Setting Menu—Main

Menu Sequence Change ............................2-2-22Main Menu—Information Menu .......................2-2-23Main Menu—Information Menu—Operation....2-2-24Main Menu—Information

Menu—Maintenance ...................................2-2-25Main Menu—Information

Menu—Troubleshooting ..............................2-2-25Main Menu—Information Menu—Monitoring...2-2-26

Operation—Operating the MachineBefore Starting Work .........................................2-3-1Operator's Daily Machine Check

Before Starting ..............................................2-3-1Engine Break-In Period .....................................2-3-2Starting Engine..................................................2-3-3Cold Weather Start Aid......................................2-3-4Cold Weather Warmup ......................................2-3-5Travel Pedals and Levers..................................2-3-6Exhaust Filter.....................................................2-3-7Exhaust Filter Parked Cleaning.........................2-3-9Service ADVISOR™ Remote (SAR)

Software Delivery Process ..........................2-3-10Service ADVISOR™ Remote (SAR)

Operation ....................................................2-3-11Locking the Hydraulic Coupler to the

Attachment—If Equipped ............................2-3-13Unlocking the Hydraulic Coupler From

the Attachment—If Equipped ......................2-3-15Control Lever Pattern Operation......................2-3-16Mechanical Control Lever Pattern

Selector—If Equipped .................................2-3-17Control Lever Pattern Conversion ...................2-3-18Operating in Water and Mud ...........................2-3-19

Page

Driving Up a Steep or Slippery Slope..............2-3-19Lifting...............................................................2-3-19Lower Boom With Engine Stopped..................2-3-20Parking the Machine........................................2-3-21Loading and Unloading for Transport ..............2-3-22Towing Machine...............................................2-3-23Lifting the Machine ..........................................2-3-23

Maintenance—MachineDiesel Fuel.........................................................3-1-1Diesel Fuel Specifications .................................3-1-1Lubricity of Diesel Fuel ......................................3-1-2Handling and Storing Diesel Fuel ......................3-1-2Biodiesel Fuel ....................................................3-1-3Testing Diesel Fuel ............................................3-1-4Fuel Filters.........................................................3-1-4Minimizing the Effect of Cold Weather

on Diesel Engines .........................................3-1-5Alternative and Synthetic Lubricants .................3-1-6Mixing of Lubricants...........................................3-1-6Lubricant Storage ..............................................3-1-6John Deere Break-In Plus™ Engine Oil ............3-1-7Diesel Engine Oil—Interim Tier 4 and

Stage III B Engines .......................................3-1-8Engine Oil and Filter Service Intervals

— Interim Tier 4, Final Tier 4, StageIIIB, and Stage IV Engines ............................3-1-9

Oil Filters ...........................................................3-1-9Hydraulic Oil ....................................................3-1-10Swing Gear Case and Travel Gear

Case Oils.....................................................3-1-11Pump Drive Gear Case Oil ..............................3-1-11Track Adjuster, Working Tool Pivot,

Swing Bearing, and Swing BearingGear Grease ...............................................3-1-12

Diesel Engine Coolant (engine withwet sleeve cylinder liners) ...........................3-1-13

Drain Intervals for Diesel Engine Coolant........3-1-14John Deere COOL-GARD™ II Coolant

Extender......................................................3-1-14Supplemental Coolant Additives......................3-1-15Operating in Warm Temperature Climates ......3-1-15Additional Information About Diesel

Engine Coolants and John DeereCOOL-GARD™ II Coolant Extender ...........3-1-16

Testing Diesel Engine Coolant.........................3-1-17Disposing of Coolant .......................................3-1-17

Maintenance—Periodic MaintenanceService Machine at Specified Intervals..............3-2-1Check the Hour Meter Regularly .......................3-2-1Prepare Machine for Maintenance ....................3-2-2Open Access Doors for Service ........................3-2-3Open Engine Cover for Service.........................3-2-3Fuel Tank...........................................................3-2-3Hydraulic Breaker and Crusher Attachments ....3-2-4


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Contents

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Fluid Analysis Program Test Kits and3-Way Coolant Test Kit..................................3-2-4

Service Intervals ................................................3-2-5Required Parts...................................................3-2-7

Maintenance—As RequiredRemove and Clean Fuel Tank Inlet Screen.......3-3-1Check Windshield Washer Fluid Level ..............3-3-1Check and Clean Air Cleaner Dust

Unloader Valve..............................................3-3-1Check and Adjust Track Sag .............................3-3-2Clean Rear Camera Lens—If Equipped............3-3-3Check Coolant ...................................................3-3-4Service Exhaust Filter........................................3-3-5

Maintenance—10 Hours or DailyCheck Engine Oil Level .....................................3-4-1Check Engine Coolant Level .............................3-4-2Check Hydraulic Tank Oil Level.........................3-4-3Lubricate Hydraulic Coupler—If Equipped ........3-4-4

Maintenance—Every 50 Hours or WeeklyDrain Water and Sediment from Fuel

Tank Sump ....................................................3-5-1Drain Primary Fuel Filter and Water Separator ..3-5-1Drain Final Fuel Filter ........................................3-5-2Drain Auxiliary Fuel Filter and Water

Separator—If Equipped.................................3-5-2

Maintenance—Every 100 HoursLubricate Working Tool Pivots ...........................3-6-1Inspect and Re-Torque Track Hardware............3-6-2

Maintenance—Every 250 HoursCheck Swing Gear Case Oil Level ....................3-7-1Drain Water and Sediment from

Hydraulic Tank...............................................3-7-2Check Pump Drive Gear Case Oil Level ...........3-7-3Check Battery Electrolyte Level and Terminals ..3-7-4Check Travel Gear Case Oil Level ....................3-7-6Take Engine Oil Sample ....................................3-7-6

Maintenance—Every 500 HoursLubricate Front End Pin Joints ..........................3-8-1Lubricate Swing Bearing....................................3-8-2Lubricate Swing Bearing Gear...........................3-8-2Replace Primary Fuel Filter and Water

Separator ......................................................3-8-3Replace Final Fuel Filter....................................3-8-4Replace Auxiliary Fuel Filter and Water

Separator—If Equipped.................................3-8-5Check Air Intake Hoses.....................................3-8-5Drain and Refill Engine Oil and Replace Filter ..3-8-6Clean Cab Fresh Air and Cab

Recirculating Air Filters .................................3-8-7Take Fluid Samples ...........................................3-8-7

Page

Maintenance—Every 1000 HoursDrain and Refill Swing Gear Case Oil ...............3-9-1Replace Hydraulic Tank Oil Filter ......................3-9-2Replace Pilot Oil Filter .......................................3-9-3Drain and Refill Pump Drive Gear Case Oil ......3-9-4Remove and Clean Open Crankcase

Ventilation (OCV) Hose .................................3-9-4Inspect Serpentine Belt .....................................3-9-5Replace Air Cleaner Elements ..........................3-9-6Replace Air Cleaner Dust Unloader Valve.........3-9-6Check Coolant ...................................................3-9-7

Maintenance—Every 2000 HoursCheck and Adjust Engine Valve Lash..............3-10-1Drain and Refill Travel Gear Case Oil .............3-10-1Replace Open Crankcase Ventilation

(OCV) Filter .................................................3-10-1

Maintenance—Every 5000 HoursDrain and Refill Hydraulic Tank Oil ..................3-11-1Replace Hydraulic Tank Vent Cap Filter ..........3-11-3

Maintenance—Every 6000 HoursDrain Cooling System......................................3-12-1Cooling System Fill and Deaeration

Procedure....................................................3-12-2

Miscellaneous—MachineBleed Fuel System ............................................4-1-1Clean Radiator, Oil Cooler, Charge Air

Cooler, and Fuel Cooler ................................4-1-1Do Not Service or Adjust Injection

Nozzles or High-Pressure Fuel Pump...........4-1-2Do Not Service Control Valves,

Cylinders, Pumps, or Motors.........................4-1-2Precautions for Alternator and Regulator ..........4-1-2Handling, Checking, and Servicing

Batteries Carefully.........................................4-1-3Using Battery Charger .......................................4-1-4Using Booster Batteries—24-Volt System.........4-1-5Replacing Batteries ...........................................4-1-5Fluid Sampling Test Ports—If Equipped............4-1-6Welding On Machine .........................................4-1-6Clean the Machine Regularly ............................4-1-7Adding 12—Volt Accessories ............................4-1-7JDLink™ Machine Monitoring System

(MMS)—If Equipped......................................4-1-7Replacing Fuses................................................4-1-8Replacing Bucket Teeth...................................4-1-11Replacing Bucket Tooth

Tip—Heavy-Duty Bucket .............................4-1-13Replacing Bucket Teeth—TK Series ...............4-1-13Removing the Bucket ......................................4-1-14Track Sag General Information .......................4-1-14Check Track Shoe Hardware ..........................4-1-14


iii 081214

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Contents

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Hardware Torque Specifications......................4-1-14Unified Inch Bolt and Screw Torque Values.....4-1-15Metric Bolt and Screw Torque Values..............4-1-16

Miscellaneous—Operational CheckoutOperational Checkout........................................4-2-1

Miscellaneous—TroubleshootingTroubleshooting Procedure ...............................4-3-1Engine ...............................................................4-3-2Hydraulic System...............................................4-3-5Electrical System...............................................4-3-7

Miscellaneous—StoragePrepare Machine for Storage ............................4-4-1Monthly Storage Procedure...............................4-4-2

Miscellaneous—Machine NumbersRecord Product Identification Number (PIN) .....4-5-1Record Engine Serial Number...........................4-5-1Record Travel Motor Serial Numbers ................4-5-2Record Swing Motor Serial Number ..................4-5-2Record Hydraulic Coupler Serial

Number—If Equipped....................................4-5-3Hydraulic Pump Serial Number .........................4-5-3Keep Proof of Ownership ..................................4-5-4Keep Machines Secure .....................................4-5-4

Miscellaneous—Specifications160GLC Engine Specifications..........................4-6-1180GLC Engine Specifications..........................4-6-1160GLC and 180GLC Drain and Refill

Capacities .....................................................4-6-2160GLC Machine Specifications .......................4-6-3180GLC Machine Specifications .......................4-6-5160GLC Working Ranges..................................4-6-7180GLC Working Ranges..................................4-6-9160GLC Lift Capacity—Arm: 2.60 m (8

ft. 6 in.); Bucket: 528 kg (1164 lb.);Shoe: 600 mm (24 in.) ................................4-6-11

160GLC Lift Capacity—Arm: 2.60 m (8ft. 6 in.); Bucket: 528 kg (1164 lb.);Shoe: 700 mm (28 in.) ................................4-6-12

160GLC Lift Capacity—Arm: 3.10 m(10 ft. 2 in.); Bucket: 528 kg (1164lb.); Shoe: 600 mm (24 in.) .........................4-6-13





Page




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Safety—Safety and Operator Conveniences

OUT4001,0000A68 -19-04JAN12-1/1

Safety and Operator Convenience Features

TX1101571

11

9

10

14

8

7

313

1

212

54

6

15

TX1101571—UN—13NOV12

Excavator Safety and Operator Convenience Features

Please remember that the operator is the key topreventing accidents.

1. Seat belt with Retractors. Seat belt retractors helpkeep belts clean and convenient to use.

2. Window Guarding. The stationary window with barsprevent contact with a moving boom.

3. Rearview Mirrors. Rearview mirrors offer the operatora view of activity along side of the excavator.

4. Secondary Exit. The front window provides a largeexit path if the cab door is blocked in an emergencysituation. The rear window is an alternate secondary exit,a secondary exit tool is also provided.

5. Pilot Shutoff Lever. A lever near the cab exit remindsthe operator to deactivate hydraulic functions beforeleaving the machine.

6. Steps. Wide, slip-resistant steps make entry and exiteasier. Steps also provide a place to clean shoes.

7. Handholds. Large, conveniently placed handholdsmake it easy to enter or exit the operator's station orservice area.

8. Swing Brake. Swing brake engages automaticallywhen the swing is not operated. Helps secureupperstructure when transporting the machine.

9. Bypass Start Protection. Shielding over the starterhelps prevent dangerous bypass starting.

10. Travel Alarm. Alerts bystanders of forward or reversemachine movement.

11. Engine Fan Guard. A fan guard inside the enginecompartment helps prevent contact with the hydraulicallydriven fan.

12. Horn. Standard horn is useful when driving orsignaling coworkers.

13. Cab with Heater, Defroster, and Air Conditioner.Ventilation system circulates both outside and inside airthrough filters for a clean working environment. Builtin defroster vents direct air flow for effective windowdefogging/deicing. Air conditioner provides a comfortable,temperature-controlled working environment.

14. Counterweight Mirror. The counterweight mirroroffers the operator a view directly behind the excavator.

15. ROPS and FOPS. Integrated rollover protectivestructure (ROPS) and falling object protective structure(FOPS) are designed to protect the operator. Theenclosed lockable cabin also provides protection from theweather and reduces vandalism.

1-1-1 081214

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Safety—General Precautions

TX,RECOGNIZE -19-28JUN10-1/1

TX,FOLLOW -19-20JAN11-1/1

TX,QUALIFIED -19-18JAN11-1/1

Recognize Safety InformationThis is the safety alert symbol. When you see thissymbol on your machine or in this manual, be alertfor the potential of personal injury.

Follow the precautions and safe operating practiceshighlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION —is used with the safety alert symbol. DANGER identifiesthe most serious hazards.

On your machine, DANGER signs are red in color,WARNING signs are orange, and CAUTION signs areyellow. DANGER and WARNING signs are located nearspecific hazards. General precautions are on CAUTIONlabels.

T133555—UN—15APR13

T133588—19—28AUG00

Follow Safety InstructionsCarefully read all safety messages in this manual and onyour machine safety signs. Keep safety signs in goodcondition. Replace missing or damaged safety signs. Usethis operator’s manual for correct safety sign placement.Be sure that new equipment components and repair partsinclude the current safety signs. Replacement safetysigns are available from your John Deere dealer.

There can be additional safety information contained onparts and components sourced from suppliers that is notreproduced in this operator's manual.

Learn how to operate the machine and how to use controlsproperly. Do not let anyone operate without instruction.

Keep your machine in proper working condition.Unauthorized modifications to the machine could impairthe function or safety and affect machine life.

TS201—UN—15APR13

If you do not understand any part of this manual and needassistance, contact your John Deere dealer.

Operate Only If QualifiedDo not operate this machine unless the operator's manualhas been read carefully, and you have been qualified bysupervised training and instruction.

Operator should be familiar with the job site andsurroundings before operating. Try all controls and

machine functions with the machine in an open areabefore starting to work.

Know and observe all safety rules that may apply to everywork situation and work site.

1-2-1 081214

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TX,WEAR,PE -19-22SEP10-1/1

AM40430,00000A9 -19-20AUG09-1/1

DB84312,00000A5 -19-04JAN12-1/1

TX,CABGUARD -19-12FEB13-1/1

Wear Protective EquipmentGuard against injury from flying pieces or metal or debris;wear goggles or safety glasses.

Wear close fitting clothing and safety equipmentappropriate to the job.

Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.

Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionable oruncomfortable loud noises. Radio or music headphonesare not suitable to use for hearing protection.


Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deerereplacement parts to ensure machine performance.Never substitute genuine John Deere parts with alternateparts not intended for the application as these cancreate hazardous situations or hazardous performance.Non-John Deere parts, or any damage or failures resultingfrom their use are not covered by any John Deere warranty.

Modifications of this machine, or addition of unapprovedproducts or attachments, may affect machine stability or

reliability, and may create a hazard for the operator orothers near the machine. The installer of any modificationwhich may affect the electronic controls of this machine isresponsible for establishing that the modification does notadversely affect the machine or its performance.

Always contact an authorized dealer before makingmachine modifications that change the intended use,weight or balance of the machine, or that alter machinecontrols, performance or reliability.

Control Pattern Selector—If EquippedThis machine may be equipped with a control patternselector valve. Ensure all personnel are clear of machine

and area is large enough to operate machine functions.Verify the machine response to each control movement.

Add Cab Guarding for Special UsesSpecial work situations or machine attachments couldcreate an environment with falling or flying objects.Working near an overhead bank, demolition work, usinga hydraulic hammer or winch, working in a forestryapplication or wooded area, or working in a wastemanagement application, for example, could requireadded guarding to protect the operator.

Additional level II FOPS (falling object protectivestructure), forestry protection packages, and specialscreens or guarding should be installed when fallingor flying objects could enter or damage the machine.A rear screen should always be used with a winch toprotect against a snapping cable. Before operating in anyspecial work environments, follow the operator protectionrecommendations of the manufacturer of any specializedattachment or equipment. Contact your authorized JohnDeere dealer for information on protective guarding.

1-2-2 081214

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TX,INSPECT -19-08SEP10-1/1

TX,MOVING,PARTS -19-20JAN11-1/1

DX,FLUID -19-11DEC12-1/1

Inspect MachineInspect machine carefully each day by walking around itbefore starting.

Keep all guards and shields in good condition and properlyinstalled. Fix damage and replace worn or broken partsimmediately. Pay special attention to hydraulic hoses andelectrical wiring.

T6607A

Q—UN—15APR13

Stay Clear of Moving PartsEntanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting, or maintainingany part of machine with moving parts.

Keep guards and shields in place. Replace any guardor shield that has been removed for access as soon asservice or repair is complete. T1

33592—UN—15APR13

Avoid High-Pressure FluidsEscaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed withina few hours or gangrene may result. Doctors unfamiliarwith this type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.

X9811

—UN—23AUG88

1-2-3 081214

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TX,HPOILS -19-20JAN11-1/1

DX,AIR -19-17FEB99-1/1

Avoid High-Pressure OilsThis machine uses a high-pressure hydraulic system.Escaping oil under pressure can penetrate the skincausing serious injury.

Never search for leaks with your hands. Protect hands.Use a piece of cardboard to find location of escaping oil.Stop engine and relieve pressure before disconnectinglines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctorimmediately. Injected oil must be removed surgicallywithin hours or gangrene could result. Contact aknowledgeable medical source or the Deere & CompanyMedical Department in Moline, Illinois, U.S.A.

T133509—UN—15APR13

T133840—UN—20SEP00

Work In Ventilated AreaEngine exhaust fumes can cause sickness or death. Ifit is necessary to run an engine in an enclosed area,remove the exhaust fumes from the area with an exhaustpipe extension.

If you do not have an exhaust pipe extension, open thedoors and get outside air into the area.


1-2-4 081214

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DX,FUEL,STATIC,ELEC -19-12JUL13-1/1

TX,PREVENT,FIRE -19-20JAN11-1/1

Avoid Static Electricity Risk When RefuelingThe removal of sulfur and other compounds in Ultra-LowSulfur Diesel (ULSD) fuel decreases its conductivity andincreases its ability to store a static charge.

Refineries may have treated the fuel with a staticdissipating additive. However, there are many factors thatcan reduce the effectiveness of the additive over time.

Static charges can build up in ULSD fuel while it is flowingthrough fuel delivery systems. Static electricity dischargewhen combustible vapors are present could result in afire or explosion.

Therefore, it is important to ensure that the entire systemused to refuel your machine (fuel supply tank, transferpump, transfer hose, nozzle, and others) is properlygrounded and bonded. Consult with your fuel or fuelsystem supplier to ensure that the delivery system is incompliance with fueling standards for proper groundingand bonding practices.

RG22142—UN—17MAR14

RG21992—UN—21AUG13

Prevent FiresHandle Fuel Safely: Store flammable fluids away fromfire hazards. Never refuel machine while smoking or whennear sparks or flame.

Clean Machine Regularly: Keep trash, debris, greaseand oil from accumulating in engine compartment, aroundfuel lines, hydraulic lines, exhaust components, andelectrical wiring. Never store oily rags or flammablematerials inside a machine compartment.

Maintain Hoses and Wiring: Replace hydraulic hosesimmediately if they begin to leak, and clean up any oilspills. Examine electrical wiring and connectors frequentlyfor damage.

Keep A Fire Extinguisher Available: Always keep amultipurpose fire extinguisher on or near the machine.Know how to use extinguisher properly.

T133552—UN—15APR13

T133553 —UN—07SEP00

T133554 —UN—07SEP00

1-2-5 081214

PN=26


DX,SPARKS -19-03MAR93-1/1

DX,MSDS,NA -19-03MAR93-1/1

DX,DRAIN -19-03MAR93-1/1

Prevent Battery ExplosionsKeep sparks, lighted matches, and open flame away fromthe top of battery. Battery gas can explode.

Never check battery charge by placing a metal objectacross the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).


Handle Chemical Products SafelyDirect exposure to hazardous chemicals can causeserious injury. Potentially hazardous chemicals used withJohn Deere equipment include such items as lubricants,coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specificdetails on chemical products: physical and health hazards,safety procedures, and emergency response techniques.

Check the MSDS before you start any job using ahazardous chemical. That way you will know exactly whatthe risks are and how to do the job safely. Then followprocedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemicalproducts used with John Deere equipment.)

TS1132

—UN—15APR13

Dispose of Waste ProperlyImproperly disposing of waste can threaten theenvironment and ecology. Potentially harmful waste usedwith John Deere equipment include such items as oil, fuel,coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

Do not pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants escaping into the air candamage the Earth’s atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.

TS1133

—UN—15APR13

1-2-6 081214

PN=27


TX,ASH,DISP -19-20JAN11-1/1

DX,FIRE2 -19-03MAR93-1/1

TX,DEBRIS -19-20JAN11-1/1

Exhaust Filter Ash Handling and Disposal

CAUTION: Under federal, state, and local laws orregulations, exhaust filter ash can be classifiedas a hazardous waste. Hazardous waste mustbe disposed of in accordance with all applicablefederal, state, and local laws or regulations

governing hazardous waste disposal. Only aqualified service provider should remove ash fromthe exhaust filter. Personal protective equipmentand clothing, maintained in a sanitary and reliablecondition, should be used when handling andcleaning exhaust filter. See your authorized dealerfor exhaust filter ash handling and disposal.

Prepare for EmergenciesBe prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.


Clean Debris from MachineKeep engine compartment, radiator, batteries, hydrauliclines, exhaust components, fuel tank, and operator'sstation clean and free of debris.

Clean any oil spills or fuel spills on machine surfaces.

Temperature in engine compartment could go upimmediately after engine is stopped. BE ON GUARDFOR FIRES DURING THIS PERIOD.

Open access door(s) to cool the engine faster, and cleanengine compartment. T6

669A

G—UN—15APR13

1-2-7 081214

PN=28

Safety—Operating Precautions

TX,STEPS -19-09FEB11-1/1

TX,SOFOS -19-20JAN11-1/1

TX,SEAT,BELT -19-20JAN11-1/1

VD76477,000036D -19-19APR11-1/1

Use Steps and Handholds CorrectlyPrevent falls by facing the machine when you get on andoff. Maintain 3-point contact with steps and handrails.Never use machine controls as handholds.

Use extra care when mud, snow, or moisture presentslippery conditions. Keep steps clean and free of greaseor oil. Never jump when exiting machine. Never mount ordismount a moving machine. T1

33468—UN—15APR13

Start Only From Operator's SeatAvoid unexpected machine movement. Start engine onlywhile sitting in operator's seat. Ensure that all controls andworking tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do notattempt to start engine by shorting across the startersolenoid terminals. T1

33715—UN—15APR13

Use and Maintain Seat BeltUse seat belt when operating machine. Remember tofasten seat belt when loading and unloading from trucksand during other uses.

Examine seat belt frequently. Be sure that webbing is notcut or torn. Replace seat belt immediately if any part isdamaged or does not function properly.

The complete seat belt assembly should be replacedevery three years, regardless of appearance.

T133716—19—17APR13

Prevent Unintended Machine MovementBe careful not to accidentally actuate control levers whencoworkers are present. Pull pilot shutoff lever to locked(UP) position during work interruptions. Pull pilot shutofflever to locked (UP) position and stop engine beforeallowing anyone to approach machine.

Always lower work equipment to the ground and pull pilotshutoff lever to locked (UP) position before standing up orleaving the operator's seat. Stop engine before exiting.

T216779—UN—22NOV05

1-3-1 081214

PN=29


TX03679,0001748 -19-09JUL12-1/1

TX03679,0001726 -19-03JAN07-1/1

Avoid Work Site HazardsAvoid contact with gas lines, buried cables and waterlines. Call utility line location services to identify allunderground utilities before you dig.

Prepare work site properly. Avoid operating nearstructures or objects that could fall onto the machine. Clearaway debris that could move unexpectedly if run over.

Avoid boom or arm contact with overhead obstaclesor overhead electrical lines. Never move any part ofmachine or load closer than 3 m (10 ft.) plus twice the lineinsulator length to overhead wires.

Keep bystanders clear at all times. Keep bystandersaway from raised booms, attachments, and unsupportedloads. Avoid swinging or raising booms, attachments, orloads over or near personnel. Use barricades or a signalperson to keep vehicles and pedestrians away. Use asignal person if moving machine in congested areas orwhere visibility is restricted. Always keep signal person inview. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient tosupport machine. When working close to an excavation,position travel motors away from the hole.

Reduce machine speed when operating with tool on ornear ground when obstacles may be hidden (e.g., duringsnow removal or clearing mud, dirt, etc). At high speeds,hitting obstacles (rocks, uneven concrete or manholes)can cause a sudden stop. Always wear your seat belt.

T134986—UN—31OCT00

T133650—UN—27SEP00

T133549—UN—24AUG00

Keep Riders Off MachineOnly allow operator on machine.

Riders are subject to injury. They may fall from machine,be caught between machine parts, or be struck by foreignobjects.

Riders may obstruct operator’s view or impair his abilityto operate machine safely.

T7273A

H—UN—08JU

N90

1-3-2 081214

PN=30


TX,AVOID,BACKOVER -19-25OCT10-1/1

TX,ROPS -19-20JAN11-1/1

Avoid Backover AccidentsBefore moving machine, be sure that all persons areclear of machine path. Turn around and look directly forbest visibility. Use mirrors to assist in checking all aroundmachine. Keep windows and mirrors clean, adjusted, andin good repair.

Be certain reverse warning alarm is working properly.

Use a signal person when backing if view is obstructedor when in close quarters. Keep signal person in view atall times. Use prearranged hand signals to communicate.

Do not rely on the rear camera and radar object detectionsystems to determine if personnel are behind the machine.The system has limitations due to maintenance practices,environmental conditions, and operating range.

PC10857X

W—UN—15APR13

Inspect and Maintain ROPSA damaged rollover protective structure (ROPS) shouldbe replaced, not reused.

The protection offered by ROPS could be impaired ifROPS is subjected to structural damage, is involved inan overturn incident, or is in any way altered by welding,bending, drilling, or cutting.

If ROPS was loosened or removed for any reason, inspectit carefully before operating the machine again.

To maintain the ROPS:

• Replace missing hardware using correct gradehardware.• Check hardware torque.• Check isolation mounts for damage, looseness, orwear; replace them if necessary.• Check ROPS for cracks or physical damage.

1-3-3 081214

PN=31


TX03679,00016DF -19-03JAN07-1/1

TX03679,00016E1 -19-03JAN07-1/1

DB84312,00000CA -19-11APR14-1/1

Avoid Machine Tip OverUse seat belt at all times.

Do not jump if the machine tips. You will be unlikely tojump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Besure truck is wide enough and on a firm level surface.Use loading ramps and attach them properly to truck bed.Avoid trucks with steel beds because tracks slip moreeasily on steel.

Be careful on slopes. Use extra care on soft, rockyor frozen ground. Machine may slip sideways in theseconditions. When traveling up or down slopes, keep thebucket on uphill side and just above ground level.

Be careful with heavy loads. Using oversize buckets orlifting heavy objects reduces machine stability. Extendinga heavy load or swinging it over side of undercarriagemay cause machine to tip.

Ensure solid footing. Use extra care when operatingnear banks or excavations that may cave-in and causemachine to tip or fall.

T133716—19—17APR13

T133545—UN—15SEP00

T133803—UN—27SEP00

Use Special Care When Lifting ObjectsNever use this machine to lift people.

Never lift a load above another person. Keep bystandersclear of all areas where a load might fall if it breaks free.Do not leave the seat when there is a raised load.

Do not exceed lift capacity limits posted on machine andin this manual. Extending heavy loads too far or swingingover undercarriage side may cause machine to tip over.

Use proper rigging to attach and stabilize loads. Be sureslings or chains have adequate capacity and are in goodcondition. Use tether lines to guide loads and prearrangedhand signals to communicate with co-workers.

T133839—UN—27SEP00

Use Special Care When OperatingNever use the attachment to lift people. Do not allowanyone to ride on attachment or use it as a workplatform.

Operate carefully with raised loads. Raising the loadreduces machine stability, especially on side slopes or anunstable surface. Drive and turn slowly with a raised load.

Be careful when lifting loads. Never attempt to lift loadstoo heavy for your machine. Assure machine stability andhydraulic capability with a test lift before attempting othermaneuvers. Keep bystanders away from raised loads.

1-3-4 081214

PN=32


CN93077,00000B3 -19-14FEB13-1/1

DX,POISON -19-21APR93-1/1

TX,ATTACH -19-20JAN11-1/1

Travel SafelyNOTE: When working on steep slopes, travel as straight

up and down as possible to prevent roll-over.

DO NOT PARK ON A HILLSIDE OR AN INCLINE.

Always park the machine on level ground.

Know the location of bystanders before moving themachine.

Always keep the reverse warning alarm in workingcondition. The alarm warns bystanders when the machinestarts to move in reverse.

Use a signal person when moving the machine incongested areas. Coordinate hand signals before startingthe machine.

T6964A

D—UN—20DEC88

Travel Safely

Prevent Acid BurnsSulfuric acid in battery electrolyte is poisonous. It is strongenough to burn skin, eat holes in clothing, and causeblindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize the acid.3. Flush your eyes with water for 15—30 minutes. Get

medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.2. Drink large amounts of water or milk, but do not

exceed 2 L (2 quarts).3. Get medical attention immediately.

TS203—UN—23AUG88

Add and Operate Attachments SafelyAlways verify compatibility of attachments by contactingyour authorized dealer. Adding unapproved attachmentscould affect machine stability or reliability and could createa hazard for others near the machine.

Ensure that a qualified person is involved in attachmentinstallation. Add guards to machine if operator protection

is required or recommended. Verify that all connectionsare secure and attachment responds properly to controls.

Carefully read attachment manual and follow allinstructions and warnings. In an area free of bystandersand obstructions, carefully operate attachment to learn itscharacteristics and range of motion.

1-3-5 081214

PN=33

Safety—Maintenance Precautions

OUT4001,000089A -19-30JAN12-1/1

TX,SURGE -19-19JAN11-1/1

Park and Prepare for Service SafelyWarn others of service work. Always park and prepareyour machine for service or repair properly.

• Park machine on a level surface and lower equipmentto the ground.• Place pilot shutoff lever in locked (UP) position. Stopengine and remove key.• Attach a “Do Not Operate” tag in an obvious place inthe operator's station.

Securely support machine or attachment before workingunder it.

• Do not support machine with any hydraulically actuatedequipment.• Do not support machine with cinder blocks or woodenpieces that may crumble or crush.• Do not support machine with a single jack or otherdevices that may slip out of place.

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

T133332—19—17APR13


Service Cooling System SafelyExplosive release of fluids from pressurized coolingsystem can cause serious burns.

Do not service radiator through the radiator cap. Only fillthrough the surge tank filler cap. Shut off engine. Onlyremove surge tank filler cap when cool enough to touchwith bare hands. Slowly loosen cap to relieve pressurebefore removing completely.


1-4-1 081214

PN=34


DX,PAINT -19-24JUL02-1/1

MB60223,0000212 -19-04FEB14-1/1

TX,PINS -19-20JAN11-1/1

Remove Paint Before Welding or HeatingAvoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from areato be affected by heating. If paint cannot be removed,wear an approved respirator before heating or welding.• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

Do not use a chlorinated solvent in areas where weldingwill take place.


Do all work in an area that is well ventilated to carry toxicfumes and dust away.

Dispose of paint and solvent properly.

Make Welding Repairs SafelyIMPORTANT: Disable electrical power before welding.

Turn off main battery switch and disconnectpositive and negative battery cables.

Do not weld or apply heat on any part of a reservoir ortank that has contained oil or fuel. Heat from welding andcutting can cause oil, fuel, or cleaning solution to creategases which are explosive, flammable, or toxic.

Avoid welding or heating near pressurized fluid lines.Flammable spray may result and cause severe burns ifpressurized lines fail as a result of heating. Do not let heatgo beyond work area to nearby pressurized lines.

Remove paint properly. Do not inhale paint dust or fumes.Use a qualified welding technician for structural repairs.

T133547—UN—15APR13

Avoid Heating Near Pressurized Fluid Lines

Make sure there is good ventilation. Wear eye protectionand protective equipment when welding.

Drive Metal Pins SafelyAlways wear protective goggles or safety glasses andother protective equipment before striking hardenedparts. Hammering hardened metal parts such as pins andbucket teeth could dislodge chips at high velocity.

Use a soft hammer or a brass bar between hammer andobject to prevent chipping. T1

33738—UN—15APR13

1-4-2 081214

PN=35


DX,EXHAUST,FILTER -19-12JAN11-1/1

Clean Exhaust Filter SafelyDuring exhaust filter cleaning operations, the enginemay run at elevated idle and hot temperatures for anextended period of time. Exhaust gases and exhaustfilter components reach temperatures hot enough to burnpeople, or ignite or melt common materials.

Keep machine away from people, animals, or structureswhich may be susceptible to harm or damage from hotexhaust gases or components. Avoid potential fire orexplosion hazards from flammable materials and vaporsnear the exhaust. Keep exhaust outlet away from peopleand anything that can melt, burn, or explode.

Closely monitor machine and surrounding area forsmoldering debris during and after exhaust filter cleaning.

Adding fuel while an engine is running can create a fireor explosion hazard. Always stop engine before refuelingmachine and clean up any spilled fuel.

Always make sure that engine is stopped while haulingmachine on a truck or trailer.

Contact with exhaust components while still hot can resultin serious personal injury.

Avoid contact with these components until cooled to safetemperatures.

If service procedure requires engine to be running:

• Only engage power-driven parts required by serviceprocedure• Ensure that other people are clear of operator stationand machine

Keep hands, feet, and clothing away from power-drivenparts.

Always disable movement (neutral), set the parking brakeor mechanism and disconnect power to attachments ortools before leaving the operator’s station.

Shut off engine and remove key (if equipped) beforeleaving the machine unattended.



TS1693

—UN—09DEC09

TS1695

—UN—07DEC09

1-4-3 081214

PN=36

Safety—Safety Signs

Continued on next page MB60223,00002BC -19-12AUG14-1/29

Safety SignsEarly Production (S.N. —XXXXXX)

TX1162553—UN—09JU

N14

Safety Signs

1—CAUTION, Alternate ControlPatterns—If Equipped

2—CAUTION, Operate MachineSafely

3—CAUTION, Do Not Open Hot

4—DANGER, Start Only FromSeat

5—WARNING, Stay Clear6—WARNING, Rotating Fan

Blade7—WARNING, Pressurized

System

8—WARNING, Avoid SeriousCrushing Injury From Boom

9—CAUTION, Avoid Injury FromSlip or Fall

10— DANGER, Electric Lines

11— CAUTION, Prevent Injury12— WARNING, Avoid Machine

Tipover

1-5-1 081214

PN=37


MB60223,00002BC -19-12AUG14-2/29


1. CAUTION, Alternate Control Patterns—If Equipped

Alternate control patterns are available for thisbackhoe. Always verify control response beforeoperating.

This safety label is located inside the cab on theright-side window.

TX1104371—19—12APR12

CAUTION, Alternate Control Patterns—If Equipped

2. CAUTION, Operate Machine Safely

AVOID DEATH OR SERIOUS INJURY - Read andunderstand Operator’s Manual before operating thismachine.

• Read and understand the Operator's Manual andsafety manual prior to operating this machine.• Controls may be changed for attachment or operatorpreference. Verify control pattern before operating.• Before leaving the operator’s station:- Always lower working tools to the ground.- Engage hydraulic control lockout lever.- Stop engine unless service procedure requiresengine to be running.

- Do not leave machine running unattended.• Keep riders off machine.• Avoid contact between boom/attachments andoverhead obstacles when operating or haulingmachine.• Keep bystanders clear of machine.• Upperstructure position affects travel direction.Operate pedals or levers to determine traveldirection before moving the machine.• Avoid tipping - Do not lift or move objects thatexceed machine stability.• Avoid parking machine on an incline.This safety label is located inside the cab on theright-side window.

TX1104372—19—12APR12

CAUTION, Operate Machine Safely

1-5-2 081214

PN=38


MB60223,00002BC -19-12AUG14-4/29

MB60223,00002BC -19-12AUG14-5/29


3. CAUTION, Do Not Open Hot

Release internal pressure by pressing air breatherbutton prior to removing reservoir cap.

This safety label is located on top of the hydraulicreservoir.

TX1104377—19—12APR12

CAUTION, Do Not Open Hot

4. DANGER, Start Only From Seat

Start only from seat in park or neutral. Starting in gearkills.

This safety message is positioned on the starter insidethe engine compartment.

TX1099889—19—05DEC11

DANGER, Start Only From Seat

5. WARNING, Stay Clear

Operator may swing or reverse machine.

This safety label is located at the rear of the machineon each side of the counterweight.

TX1104370—19—19DEC12

WARNING, Stay Clear

1-5-3 081214

PN=39


MB60223,00002BC -19-12AUG14-7/29

MB60223,00002BC -19-12AUG14-8/29


6. WARNING, Rotating Fan Blade

Avoid injury, keep clear of rotating fan blade.

This safety label is located on top of the engine.

TX1103569—19—16DEC11

WARNING, Rotating Fan Blade

7. WARNING, Pressurized System

Hot coolant can cause serious burns, injury or death.To open the cooling system filler cap, stop the engineand wait until the cooling system components arecool. Loosen the cooling system pressure cap slowlyin order to relieve the pressure.

This safety label is located on the surge tank cap.

TX1099924—UN—24OCT11

WARNING, Pressurized System

8. WARNING, Avoid Serious Crushing Injury FromBoom

Never place any part of body beyond window bars orframe. It could be crushed by the boom if boom controllever is accidentally bumped or otherwise engaged.

DO NOT remove window bars. If window is missing orbroken, replace immediately.


TX1104373—19—12APR12

WARNING, Avoid Serious Crushing Injury From Boom

1-5-4 081214

PN=40


MB60223,00002BC -19-12AUG14-10/29

MB60223,00002BC -19-12AUG14-11/29


9. CAUTION, Avoid Injury From Slip or Fall

DO NOT use as a handhold.

Window handle will move with the front window.

This safety label is located inside the cab on thehandle of the front window.

TX1104375—19—12APR12

CAUTION, Avoid Injury From Slip or Fall

10.DANGER, Electric Lines

Serious injury or death can result from contact withelectric lines.

Never move any part of unit or load closer to electricline than 3 M [10 ft.] plus twice the line insulator length.


TX1104374—19—19DEC12

DANGER, Electric Lines

11. CAUTION, Prevent Injury

To prevent injury from the front window falling, lockwindow in place with the lock pin.


TX1104376—19—12APR12

CAUTION, Prevent Injury

1-5-5 081214

PN=41



12.WARNING, Avoid Machine Tipover

Machine is less stable with boom and arm removed.

• Travel and swing very slowly.• Use extreme care when loading.- Avoid counter-rotation.- Do not swing counterweight beyond edge of truckbed.

• Keep counterweight pointed uphill on inclines.This safety label is located outside the left front servicedoor.

TX1111959—19—12APR12

WARNING, Avoid Machine Tipover

1-5-6 081214

PN=42



Late Production (S.N. XXXXXX— )

TX1162551—UN—10JU

N14

Safety Signs

1—Protective StructureCertification

2—CAUTION, Avoid Injury FromSlip or Fall

3—CAUTION, Do Not Open Hot4—DANGER, Start Only From

Seat

5—WARNING, Stay Clear6—WARNING, Rotating Fan

Blade7—WARNING, Pressurized

System8—WARNING, Avoid Machine

Tipover9—DANGER, Electric Lines

10— CAUTION, Operate MachineSafely

11— WARNING, Avoid SeriousCrushing Injury From Boom

12— CAUTION, Alternate ControlPatterns—If Equipped

13— CAUTION, Prevent Injury14— CAUTION, Pinch Point15— IMPORTANT, Secondary Exit

1-5-7 081214

PN=43


MB60223,00002BC -19-12AUG14-15/29

MB60223,00002BC -19-12AUG14-16/29


1. Protective Structure Certification

Any alteration or modification to this structure voidsthe certification.

Always wear seat belt when moving.

This safety label is located inside the cab on the leftfront ROPS post or on the right front corner of theoutside cab.

TX1156960—UN—07APR14

Protective Structure Certification

2. CAUTION, Avoid Injury From Slip or Fall

DO NOT use as a handhold.

Window handle will move with the front window.

This safety label is located inside the cab on thehandle of the front window.

TX1104375—19—12APR12

CAUTION, Avoid Injury From Slip or Fall

3. CAUTION, Do Not Open Hot

Release internal pressure by pressing air breatherbutton prior to removing reservoir cap.

This safety label is located on top of the hydraulicreservoir.

TX1104377—19—12APR12

CAUTION, Do Not Open Hot

1-5-8 081214

PN=44


MB60223,00002BC -19-12AUG14-18/29

MB60223,00002BC -19-12AUG14-19/29


4. DANGER, Start Only From Seat

Start only from seat in park or neutral. Starting in gearkills.

This safety message is positioned on the starter insidethe engine compartment.

TX1099889—19—05DEC11

DANGER, Start Only From Seat

5. WARNING, Stay Clear

Operator may swing or reverse machine.

This safety label is located at the rear of the machineon each side of the counterweight.

TX1104370—19—19DEC12

WARNING, Stay Clear

6. WARNING, Rotating Fan Blade

Avoid injury, keep clear of rotating fan blade.

This safety label is located on top of the engine.

TX1103569—19—16DEC11

WARNING, Rotating Fan Blade

1-5-9 081214

PN=45


MB60223,00002BC -19-12AUG14-21/29

MB60223,00002BC -19-12AUG14-22/29


7. WARNING, Pressurized System

Hot coolant can cause serious burns, injury or death.To open the cooling system filler cap, stop the engineand wait until the cooling system components arecool. Loosen the cooling system pressure cap slowlyin order to relieve the pressure.

This safety label is located on the surge tank cap.

TX1099924—UN—24OCT11

WARNING, Pressurized System

8. WARNING, Avoid Machine Tipover

Machine is less stable with boom and arm removed.

• Travel and swing very slowly.• Use extreme care when loading.- Avoid counter-rotation.- Do not swing counterweight beyond edge of truckbed.

• Keep counterweight pointed uphill on inclines.This safety label is located outside the left front servicedoor.

TX1111959—19—12APR12

WARNING, Avoid Machine Tipover

9. DANGER, Electric Lines

Serious injury or death can result from contact withelectric lines.

Never move any part of unit or load closer to electricline than 3 M [10 ft.] plus twice the line insulator length.


TX1104374—19—19DEC12

DANGER, Electric Lines

1-5-10 081214

PN=46


MB60223,00002BC -19-12AUG14-24/29


10.CAUTION, Operate Machine Safely

AVOID DEATH OR SERIOUS INJURY - Read andunderstand Operator’s Manual before operating thismachine.

• Read and understand the Operator's Manual andsafety manual prior to operating this machine.• Controls may be changed for attachment or operatorpreference. Verify control pattern before operating.• Before leaving the operator’s station:- Always lower working tools to the ground.- Engage hydraulic control lockout lever.- Stop engine unless service procedure requiresengine to be running.

- Do not leave machine running unattended.• Keep riders off machine.• Avoid contact between boom/attachments andoverhead obstacles when operating or haulingmachine.• Keep bystanders clear of machine.• Upperstructure position affects travel direction.Operate pedals or levers to determine traveldirection before moving the machine.• Avoid tipping - Do not lift or move objects thatexceed machine stability.• Avoid parking machine on an incline.This safety label is located inside the cab on theright-side window.

TX1104372—19—12APR12

CAUTION, Operate Machine Safely

11.WARNING, Avoid Serious Crushing Injury FromBoom

Never place any part of body beyond window bars orframe. It could be crushed by the boom if boom controllever is accidentally bumped or otherwise engaged.

DO NOT remove window bars. If window is missing orbroken, replace immediately.


TX1104373—19—12APR12

WARNING, Avoid Serious Crushing Injury From Boom

1-5-11 081214

PN=47


MB60223,00002BC -19-12AUG14-26/29

MB60223,00002BC -19-12AUG14-27/29


12.CAUTION, Alternate Control Patterns—If Equipped

Alternate control patterns are available for thisbackhoe. Always verify control response beforeoperating.


TX1104371—19—12APR12

CAUTION, Alternate Control Patterns—If Equipped

13.CAUTION, Prevent Injury

To prevent injury from the front window falling, lockwindow in place with the lock pin.


TX1104376—19—12APR12

CAUTION, Prevent Injury

14.CAUTION, Pinch Point

Avoid personal injury when operating seat fore-aftlever.

This safety label is located on the front of seat pedestal.

TX1157159—UN—04APR14

CAUTION, Pinch Point

1-5-12 081214

PN=48


MB60223,00002BC -19-12AUG14-29/29

15. IMPORTANT, Secondary Exit

Use tool to break window. Always keep tool in machine.

This safety label is located inside the cab on the leftROPS post.

TX1156964—19—04APR14

IMPORTANT, Secondary Exit

1-5-13 081214

PN=49


DB84312,00000D6 -19-14FEB12-1/1

Hydraulic Coupler Safety Signs—If EquippedInstall these safety decals to the right window inside thecab and on the hydraulic coupler.

TX1105472—19—13JAN12

Hydraulic Coupler Safety Signs

1-5-14 081214

PN=50

Operation—Operator's Station

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Pedals, Levers, and Panels

1—Left Pilot Control Lever (3button lever optional)/HornButton (bottom button ontop of lever)

2—Left Travel Pedal3—Left Travel Lever4—Right Travel Lever5—Right Travel Pedal6—Right Pilot Control

Lever/Power Dig Button(bottom button on top oflever)

7—Monitor8—Switch Panel9—Key Switch

10— Right Console11— Operator's Seat12— Cab Door Release Lever13— Pilot Shutoff Lever14— Rear Deck15— Lighter/Accessory Power

Port16— Fuse Box Cover17— Left Console18— Storage Compartment

TX1086605—UN—10JAN11

Pedals, Levers and Panels

TX1086606—UN—10JAN11

Fuse Box and Left Console

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PN=51


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Switch Panel

1—Back Button2—Home Button3—Monitor Dial4—Temperature Control/Mode

Switch5—Blower Speed Switch6—Radio Tuning Switch7—Radio Power and Volume

Switch8—Engine Speed Dial

9—Auto-Idle Switch10— Travel Speed Switch11— Power Mode Button12— Work Light Switch13— Windshield Wiper and

Washer Switch14— Key Switch15— Keypad

TX1086613—UN—10JAN11

Switch Panel

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PN=52


Continued on next page OUT4001,000073C -19-28FEB12-1/2

Switch Panel Functions

1. Back Button (for monitor use)—press button toreturn to the previous menu.

2. Home Button (for monitor use)—press button toreturn to the default screen when in any of the monitormenus. If key switch is OFF, press and hold button tocheck hour meter and fuel amount on monitor.

3. Monitor Dial (for monitor use)—press dial to go fromthe default screen to the main menu screen. Rotate dialto highlight desired menu function on the monitor. Pressdial to select desired screen information or to confirmdesired action.

4. Temperature Control/Mode Switch—press switchto toggle between different air vent settings. The airconditioner display on the monitor will show the differentsettings each time the switch is pressed. There are fourdifferent settings:

• Air flows out of front vent and the defroster vents.• Air flows out of front, rear, and the defroster vents.• Air flows out of front, rear, foot, and the defroster vents.• Air flows out of foot vents.Rotate switch counterclockwise for cooler air setting andclockwise for warmer air setting. Temperature settingwill change on the air conditioner display as the switchis rotated either way.

5. Blower Speed Switch—press switch while airconditioner is OFF and it turns to AUTO mode(blower speed setting and air flow setting are selectedautomatically). Temperature control/mode switch can berotated to operator's preferred cab degree setting. Blowerspeed and air flow settings adjust automatically to reachdesired cab temperature and maintain it.

If blower speed switch is rotated or temperaturecontrol/mode switch is pressed while in AUTO mode,AUTO mode is cancelled and all settings need to beadjusted by the operator as needed.

If blower speed switch is pressed while air conditioneris ON, it will turn the air conditioner OFF. (This switchmust be ON to operate the ON/OFF function of the airconditioner in the monitor menu.)

Rotate switch to adjust the blower speed to desired settingwhen not in AUTO mode.

6. Radio Tuning Switch—press switch to toggle betweenAM and FM frequency. Rotate switch to tune in desiredradio station.

7. Radio Power and Volume Switch—press switch toturn radio ON or OFF. Rotate switch to adjust the volumeto desired setting.

8. Engine Speed Dial—turn dial clockwise to increaseengine speed or counterclockwise to decrease enginespeed.

9. Auto-Idle Switch—turn switch to select between A/ION or A/I OFF.

With engine on, move auto-idle switch to A/I ON and theengine speed dial to above the auto-idle speed. Auto-idleindicator will appear on monitor when auto-idle is on.The engine will run at the engine speed dial setting for4 seconds and then the auto-idle system will slow theengine to auto-idle engine speed. When any control leveris operated, engine speed increases to engine speed dialsetting. When control levers are placed back in neutralposition, auto-idle circuit automatically slows the engine toauto-idle engine speed after 4 seconds.

Turn auto-idle switch to A/I OFF and set engine speeddial to improve machine control in difficult work areas,loading, and unloading. Auto-idle indicator will disappearon monitor.

10. Travel Speed Switch—turn switch to select betweenfast (rabbit) or slow (turtle) speed travel.

11. Power Mode Button—press button to select differentengine speed modes:

• ECO (Economy) Mode—use to improve fuel efficiencyand reduce noise level with a small difference in enginespeed.• PWR (Power) Mode—use when general digging work isneeded.• H/P (High Power) Mode—use when more flow is desiredfor booming up or rolling in the arm in excavation work.

12. Work Light Switch—has three positions:

• 1st Position—drive light on base of machine turns ON.Switch panel will also illuminate.• 2nd Position—boom work light turns ON along with thedrive light and switch panel. The monitor also changesto night mode.• OFF—work lights and switch panel illumination will turnOFF.

13. Windshield Wiper and Washer Switch—has 5operating positions:

NOTE: The wiper does not operate unless the upperfront window is completely closed.

• OFF—wiper stops operating and is retracted.• INT (slow)—wiper operates intermittently at 8 secondintervals.• INT (medium)—wiper operates intermittently at 6second intervals.• INT (fast)—wiper operates intermittently at 3 secondintervals.• ON—wiper operates continuously.

Push and hold switch to squirt fluid on windshield. Ifswitch is held more than 2 seconds, the wiper operatesuntil the switch is released. Do not hold down switch formore than 20 seconds.

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OUT4001,000073D -19-02APR11-1/1

14. Key Switch—has 4 positions:

• OFF• ACC• ON• START15. Keypad—has a few different applications:

• Use numbers 0—9 to enter password at machine startup, if equipped.• Press keypad numbers 1—8 while the radio is ON toswitch between programmed stations.• When work light switch is on position 2, the monitorchanges to night mode display (background lighting isdimmed). Press and hold the number 0 on keypad tochange monitor back to daytime mode display.

Rear Left PanelLighter (1): For operator convenience. Can also be usedas an electrical port for 24-volt appliances only.

Accessory Power Port (2): 12-volt, 5-amp electrical portprovided for service and maintenance.

1—Lighter 2—Accessory Power Port

TX1085863A

—UN—14DEC10

Rear Left Panel

HornHorn button (1) is located on top of left control lever.

1—Horn Button

TX1086237A

—UN—27DEC10

Horn Button

Power Dig ButtonThe power dig button (1) is located on the right pilotcontrol lever. Press and hold down power dig button foran 8 second increase in hydraulic power. Release buttonto reset power dig function.

Power dig is automatically activated when the followingconditions are met:

• Boom up• No arm in• High delivery pressure1—Power Dig Button

TX1086698A

—UN—08JAN11

3 Button Pilot Control Lever Shown

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Pilot Shutoff LeverThe pilot shutoff lever (1) shuts off hydraulic pilot pressureto all pilot control valves. When pilot shutoff lever is inlocked (UP) position, the machine will not move if a leveror pedal is accidentally moved. Engine will not start withpilot shutoff lever in the unlocked (DOWN) position.

Always pull pilot shutoff lever to locked (UP) position whenyou stop the engine or leave the operator’s station.

Push pilot shutoff lever forward to unlocked (DOWN)position to operate machine.

1—Pilot Shutoff Lever

TX1086699A

—UN—08JAN11

Lever in Locked (UP) Position

Left ConsoleNOTE: There are standard and optional switches on

the left console. Before using the switches on theleft console, be aware of what kind of optionaldevices are equipped on the machine.

Raise the armrest when operating the switches.

1—Reversing Fan Switch—IfEquipped

2—Seat Heater Switch—IfEquipped

3—Travel Alarm Cancel Switch

TX1086700A

—UN—08JAN11

Left Console

Travel Alarm and Travel Alarm Cancel SwitchNOTE: If alarm is not operating during normal transport,

or if alarm sounds when engine is running andmachine is stationary, see your authorized dealer.

The travel alarm sounds when a travel pedal or leveris activated and will continue as long as the tracks aremoving. When travel motion stops, the travel alarm switchis reset.

After the initial 13 second alarm, alarm can be silenced bydepressing the right half of the travel alarm cancel switch(1), located on the left console.

1—Travel Alarm Cancel Switch

TX1001227—UN—14DEC05

Travel Alarm Cancel Switch

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Seat Heater Switch—If EquippedSeat heater switch is located on the left console.

Use switch to turn seat heater ON or OFF.

When seat heater is ON, it will automatically cyclebetween 10°C and 20°C (50°F and 68°F).

1—Seat Heater Switch

TX1090148A

—UN—31MAR11

Seat Heater Switch

Reversing Fan Switch—If EquippedNOTE: The reversing fan function shall not be

reactivated within 1 minute of its last completion(this time includes AUTO cycle).

The reversing fan switch is located on the left console.

The reversing fan switch has three positions:

• AUTO: Every 60 minutes the radiator cooling fan willautomatically reverse direction for 30 seconds withoutintervention from the operator when engine rpm isabove auto-idle speed.• OFF: Fan resumes normal operation.• MANUAL: When pressed and held for 3 seconds, thefan will reverse direction for 30 seconds when rightportion of switch is pressed.

TX1000844A

—UN—29NOV05

Reversing Fan Switch

Right Console

1—Exhaust Filter ParkedCleaning Switch

2—Right Enable Switch

3—Service ADVISOR™Remote (SAR) Switch

TX1089996A

—UN—28MAR11

Right Console

Service ADVISOR is a trademark of Deere & Company

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PN=56


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OUT4001,0000747 -19-11JAN11-1/1

Exhaust Filter Parked Cleaning Switch

CAUTION: Servicing machine during exhaustfilter parked cleaning can result in seriouspersonal injury. Avoid exposure and skin contactwith hot gases and components.

During exhaust filter parked cleaning, the enginemay run at elevated idle and hot temperaturesfor an extended period of time. Exhaust gasesand exhaust filter components may reachtemperatures hot enough to burn people andignite or melt common materials.

Avoid death or serious injury from machinemovement. Do not leave running machineunattended during exhaust filter cleaning.

IMPORTANT: Avoid machine damage. Alwayspark machine in a safe location and checkfor adequate fuel level before beginningexhaust filter parked cleaning.

The exhaust filter parked cleaning switch (1) is locatedon the right console.

Before starting the parked cleaning process, the machineneeds to be in a predetermined safe state. This safe stateincludes three conditions:

• Machine is parked in a safe place with the frontattachment lowered to the ground• Pilot shutoff lever is in locked (UP) position• Engine speed dial is set to slow idle

An exhaust filter alarm indicator will appear on the monitorto inform the operator when a parked cleaning needs to

TX1086795A

—UN—11JAN11



take place or the operator can check the restriction levelbar graph in the monitor. See Main Menu—InformationMenu—Monitoring. (Section 2-2.)

Once the safe state conditions are met, press and holdthe right half of exhaust filter parked cleaning switch for 3seconds to begin a parked cleaning procedure.

Monitor will show a progress screen during the cleaningand will prompt the operator when the cleaning iscomplete.

For more information, see Exhaust Filter Parked Cleaning.(Section 2-3.)

Right Enable SwitchThe right enable switch (1) is located on the right console.

Press right half of switch to enable auxiliary functions onthe right pilot control lever.

Press left half of switch to disable auxiliary functions onthe right pilot control lever.

1—Right Enable Switch

TX1086796A

—UN—11JAN11

Right Enable Switch

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PN=57


OUT4001,0000748 -19-22JAN11-1/1

Service ADVISOR™ Remote (SAR) SwitchThe Service ADVISOR™ Remote (SAR) switch (1) allowsoperator to accept or decline software updates availableto the machine when prompted by an alarm on themonitor. LEDs on the SAR switch will illuminate when thealarm appears. The left LED will be red and the right LEDwill be green.

Press left side of SAR switch (red LED) to DECLINEinstallation (2) of software updates.

Press right side of SAR switch (green LED) to ACCEPTinstallation (3) of software updates.

For more information on SAR functionality, see ServiceADVISOR™ Remote (SAR) Software Delivery Processand Service ADVISOR™ Remote (SAR) SoftwareOperation. (Section 2-3.)

TX1086797A

—UN—21JAN11

Service ADVISOR™ Remote Switch


2—DECLINE Installation

3—ACCEPT Installation


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PN=58


Continued on next page OUT4001,0000741 -19-28FEB12-1/2

Cab Heater and Air ConditionerCab Heater Operation:

AUTO operation—

1. Press blower speed switch (1) while air conditioner isOFF and it turns to AUTO mode (blower speed settingand air flow setting are selected automatically).

2. Rotate temperature control/mode switch (2) toreach operator's preferred cab degree heat setting.Temperature setting will change on the air conditionerdisplay on the monitor as the switch is rotated eitherway. Blower speed and air flow settings adjustautomatically to reach desired cab temperature andmaintain it.

Manual operation—

1. Press blower speed switch (1) while air conditioner isOFF and it turns to AUTO mode. Rotate blower speedswitch either way to cancel AUTO mode and set theblower speed manually to desired speed setting.

2. Rotate temperature control/mode switch (2) toreach operator's preferred cab degree heat setting.Temperature setting will change on the air conditionerdisplay on the monitor as the switch is rotated eitherway.

3. Press temperature control/mode switch to togglebetween different air vent options. The air conditionerdisplay on the monitor will show the different settingseach time the switch is pressed. There are fourdifferent settings:- Air flows out of front vent and the defroster vents.- Air flows out of front, rear, and the defroster vents.- Air flows out of front, rear, foot, and the defrostervents.

- Air flows out of foot vents.

NOTE: Usually the cab heater turns the dehumidifierfunction OFF. To turn ON the dehumidifier function,turn the air conditioner ON from the monitor menu.See Main Menu—Air Conditioner. (Section 2-2.)

Defroster Operation

1. Press blower speed switch (1) while air conditioner isOFF and it turns to AUTO mode. During cold weatherseason when starting the engine, the engine coolanttemperature and air temperature in the cab are low.The heater/air conditioner unit controls the blow rateto the minimum in order to restrict cool air from flowinginto the cab.

2. Rotate temperature control/mode switch (2) toreach operator's preferred cab degree heat setting.Temperature setting will change on the air conditionerdisplay on the monitor as the switch is rotated eitherway.

3. Set the circulation mode to fresh air using the monitormenu. SeeMain Menu—Air Conditioner. (Section 2-2.)

4. Once AUTO mode is operating and cab starts to heatup, press temperature control/mode switch to cancelAUTO mode and toggle between different air ventoptions. The air conditioner display on the monitor

TX1086733A

—UN—11JAN11

Cab Heater and Air Conditioner Operation

1—Blower Speed Switch 2—Temperature Control/ModeSwitch

will show the different settings each time the switch ispressed. For best defrosting results, select either:- Air flows out of front vent and the defroster vents.- Air flows out of front, rear, and the defroster vents.

5. Control air flow direction by adjusting the vents in thecab to blow towards the windows.

6. Rotate temperature control/mode switch as needed tocontrol preferred air temperature.

7. Rotate blower speed switch as needed to set preferredfan speed.

Air Conditioner Operation

NOTE: During off season, operate the air conditioner atleast once a month for several minutes with theengine running at slow idle to protect each part ofthe air conditioner compressor from lack of lubricant.

AUTO operation—

1. Press blower speed switch (1) while air conditioner isOFF and it turns to AUTO mode (blower speed settingand air flow setting are selected automatically).

2. Rotate temperature control/mode switch (2) to reachoperator's preferred cab degree cold air setting.Temperature setting will change on the air conditionerdisplay on the monitor as the switch is rotated eitherway. Blower speed and air flow settings adjustautomatically to reach desired cab temperature andmaintain it.

Manual operation—

1. Press blower speed switch (1) while air conditioner isOFF and it turns to AUTO mode. Rotate blower speed

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switch either way to cancel AUTO mode and set theblower speed manually to desired speed setting.

2. Turn the air conditioner ON from the monitor menu.See Main Menu—Air Conditioner. (Section 2-2.)

3. Rotate temperature control/mode switch to reachoperator's preferred cab degree cold air setting.Temperature setting will change on the air conditionerdisplay on the monitor as the switch is rotated eitherway.

4. Press temperature control/mode switch to togglebetween different air vent options. The air conditionerdisplay on the monitor will show the different settings

each time the switch is pressed. There are fourdifferent settings:

NOTE: If lower front window becomes cloudy,close the defroster vents.

- Air flows out of front vent and the defroster vents.- Air flows out of front, rear, and the defroster vents.- Air flows out of front, rear, foot, and the defrostervents.

- Air flows out of foot vents.

Selecting Display Between Celsius andFahrenheitThe cab temperature (1) is always shown in the airconditioner display on the monitor. Temperature displaycan be changed between degrees Celsius (°C) andFahrenheit (°F) using the Unit Selection menu. Formore information, see Main Menu—Setting Menu—UnitSelection. (Section 2-2.)

Degrees Celsius (°C) can be set in a range from18°C—32°C.

Degrees Fahrenheit (°F) can be set in a range from63°F—91°F.

1—Cab Temperature

TX1087258A

—UN—24JAN11

Air Conditioner Display on the Monitor

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Operating the AM/FM RadioPress the radio power and volume switch (1) to turn ONthe radio. Rotate the radio power and volume switch todesired volume setting. Treble and base settings areavailable through the monitor menu. For more information,see Main Menu—Radio. (Section 2-2.)

Press the radio tuning switch (2) to toggle between AMor FM frequency. Rotate radio tuning switch to tuneradio to desired AM or FM station. To find the clearestreception stations for the area, use the seek functionthat is available through the monitor menu. For moreinformation, see Main Menu—Radio. (Section 2-2.)

Press buttons 1—8 on the keypad (3) to move betweenpreset memory radio stations. Radio display (4) onmonitor shows the station and frequency setting thatcorresponds with each keypad button.

NOTE: Presetting memory radio stations can also bedone using the monitor menu. Stations can beautomatically selected for the area using the autopreset option in the monitor menu. For moreinformation, see Main Menu—Radio. (Section 2-2.)

To preset memory radio stations or to change previouslyset stations using the keypad, tune radio to desired stationsetting. Press and hold one of the keypad buttons (1to 8) for more than 1 second. Setting is stored to thatcorresponding button. Repeat procedure for seven otherdesired stations.

1—Radio Power and VolumeSwitch

2—Radio Tuning Switch

3—Keypad4—Radio Display

TX1087264A

—UN—24JAN11

Radio Controls on Switch Panel

TX1087265A

—UN—24JAN11

Radio Display on Monitor

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Fire Extinguisher Mounting LocationMOUNTING LOCATION:

The designated fire extinguisher mounting location (1) isinside the cab on the left rear side.

USE:

NOTE: All fire extinguishers do not operate the same.Read operating instructions on canister.

The portable fire extinguisher is used to aid in theextinguishing of small fires. Refer to individualmanufacturer’s instructions and proper fire fightingprocedures before the need to use the fire extinguisherarises. See Prevent Fires. (Section 1-2.)

MAINTENANCE:

IMPORTANT: Avoid possible machine damage.Check gauge (if equipped) on fire extinguisher.If fire extinguisher is not fully charged,recharge or replace it according to themanufacturer’s instructions.

Inspect and maintain the fire extinguisher following themanufacturer’s recommendations and all local, regionaland national regulations.

TX1086294—UN—03JAN11

Fire Extinguisher Mounting Location

1—Fire Extinguisher MountingLocation

Secondary Exit ToolIMPORTANT: For secondary exit of machine, use

the secondary exit tool to break window.Always keep tool inside cab.

Secondary exit tool (1) is located on the left side postinside the cab.

1—Secondary Exit Tool

TX1085781A

—UN—13DEC10

Secondary Exit Tool

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Cab Dome Light SwitchThe cab dome light is located on the right side of cab roof.There are three operating positions:

• ON (1): The cab light turns ON and stays ON untilswitch is moved to the OFF position.

NOTE: The cab light will NOT turn ON if the keyswitch is in OFF position.

• Cab door—middle position (2): The cab light turnsON when the door is opened. When the cab door isclosed or cab door is left in the open position, the cablight turns OFF automatically after 30 seconds.

NOTE: The cab light will turn ON if the keyswitch is in OFF position.

• OFF (3): The cab light turns OFF and stays OFF untilswitch is moved to the cab door—middle position orON position.

TX1086802A

—UN—11JAN11

Cab Dome Light Switch

1—ON2—Cab Door—Middle Position

3—OFF

Opening Upper Front (Secondary Exit)WindowNOTE: The wiper cannot operate with the upper front

window open. The washer can operate withthe upper front window open.

1. Park machine on a solid, level surface.

2. Lower equipment to the ground.

3. Stop engine and pull pilot shutoff lever to locked (UP)position.

4. Lift the lock pin (1) up, slide inward, then down intonotch.

5. Pull the lock release bar (2) toward operator.

6. While holding the lower handle on the window, pullwindow up and guide all the way back on track until itclicks into position.

CAUTION: Prevent possible injury from windowclosing unexpectedly. Always lock the pinin the cab frame boss hole.

7. Slide the lock pin into the cab frame boss hole androtate downward into the lock position.

CAUTION: Prevent possible injury when closingthe upper front window. Upper front window

TX1087290A

—UN—25JAN11

Upper Front Window

1—Lock Pin 2—Lock Release Bar

comes down forcefully. Close window onlywhen sitting in operator’s seat.

8. To close upper front window, unlock pin and pull lockrelease bar down. Hold lower handle on the windowand guide window down the track slowly until it clicksinto position. Install lock pin.

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Removing and Storing the Lower FrontWindowNOTE: In cold weather, some operators may choose

to work with the upper front window open andthe lower front window in place. This providesexcellent visibility and tends to hold the heat beingcirculated around the operator’s feet.

Upper front window must be opened and locked inposition before lower front window can be removed.

1. While pulling in on window, raise window to remove.

2. Store window in rear storage area of cab behindoperator’s seat. Install window in lower protectors (1)first.

3. Slide window into the upper left protector (2).

4. Push right fastener (3) up and slide window underfastener.

5. Release fastener to secure window in storage position.

1—Lower Protector (2 used)2—Upper Left Protector

3—Right Fastener

T136266—UN—18DEC00

Removing and Storing the Lower Front Window

TX1087294A

—UN—25JAN11

Storage Area for Lower Front Window

Opening Cab Door WindowTo open cab window, pinch latch (1) and slide rear paneforward.

1—Latch

T214915—UN—17NOV05

Cab Window Latch

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Opening and Closing the PolycarbonateType Roof Exit CoverIMPORTANT: Replace the polycarbonate type

roof with a new one every 5 years, even ifundamaged. In case it was remarkably damagedor has received severe shock loads, replace iteven if it has not been in use for 5 years.

When cleaning the polycarbonate type roof,use a neutral detergent. If acidic or alkalinedetergent is used, the polycarbonate type roofmay become discolored or crack.

Keep organic solvent away from polycarbonatetype roof. Failure to do so may causethe polycarbonate type roof to becomediscolored or crack.

Opening the Roof Exit Cover:

1. Move lock levers (1) toward center of roof exit.

2. Push on handle (2) to open roof exit cover.

TX1087303A

—UN—25JAN11

Roof Exit Cover

1—Lock Lever (2 used) 2—Handle

Closing the Roof Exit Cover:

Hold handle and pull roof exit cover down until leverslock in position.

Adjusting the Mechanical Suspension SeatWhile sitting on seat, push down on seat angle lever (1) toadjust seat to desired angle. Release lever.

Pull up on seat fore-aft handle (2) to unlock seat. Slide seatto desired distance from control levers. Release handle.

Turn weight adjustment knob (3) to adjust seat to weightof operator.

Squeeze lumbar ball (4) to add air for firmness to lowerbackrest area. Press button on bottom of lumbar ball torelease air and decrease firmness.

Pull up on backrest lever (5) to release backrest lock.Move backrest to desired position. Release lever.

Pull headrest (6) upward or push downward to desiredheight. Move headrest to desired angle.

Pull up on armrest (7) to move it out of the way whenexiting the cab.

Turn armrest dial (8) to adjust angle of armrest.

Pull seat and console handle (9) up toward operator. Slideentire seat and consoles to desired distance from travelpedals and levers. Release handle.

1—Seat Angle Lever2—Seat Fore-Aft Handle3—Weight Adjustment Knob4—Lumbar Ball5—Backrest Lever

6—Headrest7—Armrest8—Armrest Dial9—Seat and Console Handle

TX1000836A

—UN—29NOV05

Mechanical Suspension Seat

T140133—UN—02MAY

01

Adjusting The Seat

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Adjusting the Air Suspension Seat—IfEquippedWhile sitting on seat, push down on seat angle lever (1) toadjust seat to desired angle. Release lever.

Pull up on seat fore-aft handle (2) to unlock seat. Slide seatto desired distance from control levers. Release handle.

Pull out firmness button (3) to decrease seat firmness.With key switch in the ON position, press in and holdfirmness button to increase seat firmness.

Pull up on backrest lever (4) to release backrest lock.Move backrest to desired position. Release lever.

Squeeze lumbar ball (5) to add air for firmness to lowerbackrest area. Press button on bottom of lumbar ball torelease air and decrease firmness.

Pull headrest (6) upward or push downward to desiredheight. Move headrest to desired angle.

Pull up on armrest (7) to move it out of the way whenexiting the cab.

Turn armrest dial (8) to adjust angle of armrest.

Pull seat and console handle (9) up toward operator. Slideentire seat and consoles to desired distance from travelpedals and levers. Release handle.

1—Seat Angle Lever2—Seat Fore-Aft Handle3—Firmness Button4—Backrest Lever5—Lumbar Ball

6—Headrest7—Armrest8—Armrest Dial9—Seat and Console Handle

TX1087310A

—UN—25JAN11

Air Suspension Seat

T140133—UN—02MAY

01

Adjusting The Armrest

Adjusting Pilot Control Lever Console Height

CAUTION: Avoid possible crushing injuryfrom console unexpectedly dropping. Beforeloosening the cap screws, support the console.

1. Ensure engine is OFF and pilot shutoff lever is inlocked (UP) position.

2. Remove right console holding cap screws (1).

3. Loosen cap screw (2) and adjust the pilot control leverconsole height relative to the cab floor.

4. Install holding cap screws in holes for desired consoleheight and tighten.

5. Tighten cap screw.Specification

Cap Screws—Torque....................................................................50 N·m36.9 lb.-ft.

TX1087326A

—UN—25JAN11

Right Side of Seat Shown

1—Holding Cap Screw (2 used) 2—Cap Screw

Repeat procedure for left console.

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Operation—Monitor Operation

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Monitor

TX113016424.0˚C 81.3

10:00 ECO

ST MHz

VOL FM

50.0h AM

A/I A/S

F

E

C

H

CH1 12

14

11

8

720

412 151617 3

619

518

10913

TX1130164—UN—25JAN13

Monitor

1—Work Mode Indicator2—Exhaust Filter Indicator3—Power Mode Indicator4—Hour Meter and Clock5—Not Used6—Engine Preheat Indicator7—Seat Belt Indicator8—Fuel Gauge9—Fuel Mark10— Sub Meter11— Radio Display

12— Air Conditioner Display13— Coolant Temperature Mark14— Coolant Temperature

Gauge15— Auxiliary Indicator16— Auxiliary Indicator17— Auxiliary Indicator18— Travel Speed Indicator19— Auto Shutdown Indicator20— Auto-Idle Indicator21— Alarm Indicators

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Alarm Indicators

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Continued on next page OUT4001,000071B -19-25JAN13-1/2

Monitor Functions

1. Work Mode Indicator: Displays icon for the currentattachment being used (digging mode, breaker, pulverizer,crusher, vibrating hammer, grapple, clamshell, or others).For more information, see Main Menu—Work Mode inthis section.

2. Exhaust Filter Indicator: Displays condition of theexhaust filter. Two different indicators could appear here:

• Exhaust Filter Cleaning Indicator appears whenexhaust temperature is high during an auto or parkedcleaning.

NOTE: The exhaust filter auto cleaning disabledindicator will display on the monitor when thekey switch is in ON position. Once the engineis started, the indicator will disappear unlessexhaust filter auto cleaning has been disabledby the operator through the monitor.

• Exhaust Filter Auto Cleaning Disabled Indicatorappears when exhaust filter auto cleaning has beendisabled by the operator. For more information, seeMain Menu—Setting Menu—Exhaust Filter in thissection.

3. Power Mode Indicator: Displays a power modeselected from the switch panel (ECO, PWR, or H/P). Formore information, see Switch Panel Functions. (Section2-1.)

4. Hour Meter and Clock: Displays total machineoperation hours counted since the machine startedworking in the unit of hours (h). One digit after the decimalpoint indicates tenths of an hour (6 minutes).

Clock indicates present time.

5. Not Used.

6. Engine Preheat Indicator:

IMPORTANT: Prevent engine damage. Do notuse ether in this machine.

If preheating is required, the engine preheat indicator isautomatically lit. If preheating is not required, this indicatorwill not display.

7. Seat Belt Indicator: Displays when key switch is ON,and disappears 5 seconds after the engine starts.

8. Fuel Gauge: Displays remaining fuel amount asindicated by the needle. Fuel machine before needlereaches E.

9. Fuel Mark: If fuel sensor is malfunctioning, color ofthe fuel mark changes and the needle disappears. If theharness between the fuel sensor and the monitor unit isbroken, the needle disappears but the fuel mark colordoes not change.

10. Sub Meter: Displays fuel consumption or breakerhours depending on what is set in the monitor. For more

TX1086447 —UN—05JAN11

Exhaust Filter Cleaning Indicator

TX1086347 —UN—06JAN11

Exhaust Filter Auto CleaningDisabled Indicator

information, see Main Menu—Setting Menu—Sub MeterSelection in this section.

11. Radio Display: Shows current radio station,frequency, and volume setting.

12. Air Conditioner Display: Shows blower fan speed,selected air vent, and temperature setting.

13. Coolant Temperature Mark: If coolant temperaturesensor is malfunctioning, color of the coolant temperaturemark changes and the needle disappears. If the harnessbetween the coolant temperature sensor and the monitorunit is broken, the needle disappears but the coolanttemperature mark color does not change.

14. Coolant Temperature Gauge:

IMPORTANT: Possible engine damage may occur. Ifneedle points to RED zone, idle engine to bringback to BLUE zone before stopping engine. Ifneedle continues to rise, stop engine.

Displays engine coolant temperature. Needle should bearound the center of the scale during operation.

15. Auxiliary Indicator: Displays optional auxiliary dataindicator.



18. Travel Speed Indicator: Displays travel speedselected from the switch panel (rabbit—fast speed travelor turtle—slow speed travel).

19. Auto Shutdown Indicator: Displays if auto shutdownwas selected by operator from the menu screen. Formore information, see Main Menu—Setting Menu—AutoShutdown in this section.

20. Auto-Idle Indicator: Displays if auto-idle mode isturned ON from the switch panel. For more information,see Switch Panel Functions. (Section 2-1.)

21. Alarm Indicators: Displays if an abnormality occurs.If six or more alarms are generated, the indicators canbe scrolled through using the monitor dial on the switchpanel. For more information, see Main Menu—Alarm Listin this section.

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OUT4001,000071C -19-28FEB12-1/1

Monitor Start-UpNOTE: Start the engine after the default screen

is displayed.

NOTE: The exhaust filter auto cleaning disabled indicatorwill display on the monitor when the key switch is inON position. Once the engine is started, the indicatorwill disappear unless exhaust filter auto cleaning hasbeen disabled by the operator through the monitor.

When the key switch is turned to the ON position, thesystem starting screen (1) displays for about 2 secondsand then the default screen (2) is displayed.

1—System Starting Screen 2—Default Screen

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—UN—28DEC10

System Starting Screen

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—UN—28DEC10

Default Screen

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OUT4001,000071D -19-03JAN11-1/1

Main MenuWhen the default screen (5) is displayed, press themonitor dial (2) on the switch panel to display the MainMenu screen (1).

The Main Menu screen displays submenus which can beselected to view diagnostic information or change variousoperating characteristics of the machine or the monitor.

NOTE: Translations shown on screen may be abbreviated.

The submenus under Main Menu that appear on monitorinclude:

NOTE: Alarm List ONLY appears as a submenuif there is an actual alarm.

• Alarm List—provides detailed information of generatedalarms.• Air Conditioner—provides air conditioner functions.• Radio—provides radio functions.• Work Mode—provides front attachment functions.• Setting Menu—allows operator to change variousmonitor and machine functions.• Information Menu—allows operator to view operatinghours, maintenance items, troubleshooting (diagnostictrouble codes [DTCs]), engine speed, and exhaust filteraccumulation.

NOTE: The Alarm List will always be displayed first onthe Main Menu if there is an actual alarm. AirConditioner, Radio, and Work Mode submenuscan be ordered in the sequence that is preferredaccording to how often they are used. Forchanging the order sequence of these submenus,see Main Menu—Setting Menu—Main MenuSequence Change in this section.

Rotate monitor dial to highlight desired submenu. Pressdial button to display chosen submenu.

Press Back button (3) to return to previous screen.

Press Home button (4) to return to default screen.

1—Main Menu Screen2—Monitor Dial3—Back Button

4—Home Button5—Default Screen

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—UN—28DEC10

Default Screen

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—UN—28DEC10

Main Menu Screen

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Switch Panel

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Continued on next page DB84312,000002D -19-02OCT12-1/24

Main Menu—Alarm ListThe Alarm List menu will always appear as the firstsubmenu under Main Menu, but ONLY if there is an actualalarm generated. If there is more than one alarm, a listwill be displayed. If there are no alarms, Alarm List willnot appear as a submenu.



• Alarm List• Air Conditioner• Radio• Work Mode• Setting Menu• Information Menu

At Main Menu screen (1) with Alarm List highlighted, pressmonitor dial (2) to view generated alarms.

If there is more than one alarm, rotate monitor dial tohighlight a particular alarm. Press monitor dial to viewdetailed information about that alarm and how to rectifythe problem.

When an alarm indicator appears on the monitor display,an alarm light (5) is also illuminated on the bottom of themonitor to alert the operator.




4—Home Button5—Alarm Light

TX1086306A

—UN—28DEC10

Main Menu Screen

TX1086272A

—UN—27DEC10

Switch Panel

TX1086914A

—UN—13JAN11

Alarm Light

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Possible alarm indicators that could appear are:

•Exhaust Filter Alarms—The same exhaust filter alarmsymbol appears, but the condition of the alarm is different.If the alarm symbol is:

• Illuminated and yellow—Exhaust filter is restricted andat HIGH soot level. Enable auto cleaning, disableauto-idle, and operate machine normally or movemachine to safe area and perform a parked cleaning.• Blinking and yellow—Exhaust filter is restricted and atVERY HIGH soot level. The warning alarm will alsoilluminate yellow. Immediately move machine to safearea and perform a parked cleaning.• Blinking and red—Exhaust filter is very restrictedand at SERVICE soot level. The warning alarm

TX1086346 —UN—06JAN11

Exhaust Filter Alarm

will also illuminate red. Immediately park machine,stop the engine, and a service cleaning will need tobe performed. For service cleaning, contact yourauthorized John Deere dealer.

For more information on exhaust filter, see Exhaust Filter.(Section 2-3.)

•Exhaust Filter Auto Cleaning Disabled Alarm—Autocleaning is disabled and exhaust filter needs to be cleaned.Move machine to safe area and perform a parked cleaning.

TX1086347 —UN—06JAN11

Exhaust Filter Auto Cleaning Disabled Alarm

•Exhaust Filter Error Alarm—There is a system orhardware error causing the exhaust filter cleaning to abort.See your authorized dealer.

TX1086356 —UN—06JAN11

Exhaust Filter Error Alarm

•Engine Oil Level Alarm—Check engine oil level andrefill oil.

TX1086348 —UN—06JAN11

Engine Oil Level Alarm

•Engine Oil Pressure Alarm—Engine oil pressure hasdecreased. Immediately stop engine. Check engine oilsystem and oil level.

TX1086353 —UN—06JAN11

Engine Oil Pressure Alarm

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•Engine Start Disabled Alarm—Engine will not start dueto pilot shutoff lever being lowered.

TX1086354 —UN—06JAN11

Engine Start Disabled Alarm

•Engine Overheat Alarm—Engine coolant temperaturehas abnormally increased. Stop operation. Run the engineat slow idle speed or lower the coolant temperature.

TX1086350 —UN—06JAN11

Engine Overheat Alarm

•Warning Alarm—An abnormal condition has beendetected. Alarm will either be red or yellow depending onseverity of problem. Contact your authorized John Deeredealer.

TX1086352 —UN—06JAN11

Warning Alarm

•Programming Alarm—If this Service ADVISOR™Remote (SAR) programming alarm appears on themonitor, different conditions may exist depending on thecolor. If this alarm is:

• YELLOW—Service ADVISOR™ Remote (SAR)software update is ready to install.• RED—SAR programming is in process. Do not turnOFF machine power until programming is complete.

TX1087187 —UN—21JAN11

Programming Alarm

• GREEN—SAR programming is complete and cyclemachine power to complete the process.


•Program Failure Alarm—This alarm will appear alongwith a red warning alarm. A problem occurred duringthe Service ADVISOR™ Remote (SAR) programmingprocess. Contact your authorized John Deere dealer.

TX1087189 —UN—21JAN11

Program Failure Alarm

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•Unable to Program Alarm—This alarm will appearalong with a yellow warning alarm. A condition exists thatwill not allow the transfer of new Service ADVISOR™Remote (SAR) software to happen. Retry programming orcontact your authorized John Deere dealer.

TX1087190 —UN—21JAN11

Unable to Program Alarm

•Coolant Level Alarm—Check coolant level and refillcoolant.

TX1086349 —UN—06JAN11

Coolant Level Alarm

•Engine Air Filter Restriction Alarm—Air filter elementsare clogged. Clean or replace air filter elements.

TX1086365 —UN—06JAN11

Engine Air Filter Restriction Alarm

•Boost Temperature Alarm—Engine intake airtemperature has abnormally increased. Stop operation.Check charge air cooler for clogging and intake air pipingfor disconnection.

TX1086355 —UN—06JAN11

BOOST

Boost Temperature Alarm

•Hydraulic Oil Overheat Alarm—Hydraulic oiltemperature has abnormally increased. Stop operation,check hydraulic oil level, and check for leaks.

TX1086351 —UN—06JAN11

Hydraulic Oil Overheat Alarm

•Hydraulic Oil Filter Restriction Alarm—Hydraulic oilfilter is clogged. Replace filter.

TX1086364 —UN—06JAN11

Hydraulic Oil Filter Restriction Alarm

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•Hydraulic Oil Cooling System Alarm—Hydraulic oilcooling system is abnormal. Contact your authorizedJohn Deere dealer.

TX1086357 —UN—06JAN11

Hydraulic Oil Cooling System Alarm

•Alternator Alarm—Electrical system is abnormal.Contact your authorized John Deere dealer.

TX1086358 —UN—06JAN11

Alternator Alarm

•Fuel Level Alarm—Fuel level is low. Refill fuel tank assoon as possible.

TX1086362 —UN—06JAN11

Fuel Level Alarm

•Fuel Temperature Alarm—Fuel temperature hasabnormally increased. Stop operation. Check fuel coolerfor any malfunction such as clogging.

TX1086363 —UN—06JAN11

Fuel Temperature Alarm

•Fuel Filter Restriction Alarm—Fuel filter is clogged.Clean or replace fuel filter elements.

TX1086366 —UN—06JAN11

Fuel Filter Restriction Alarm

•System Failure Alarm—Satellite communication systemis abnormal. Contact your authorized John Deere dealer.

TX1086367 —UN—06JAN11

System Failure Alarm

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•Pilot Shutoff Lever Alarm—Pilot shutoff lever system isabnormal. Contact your authorized John Deere dealer.

TX1086368 —UN—06JAN11

Pilot Shutoff Lever Alarm

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Main Menu—Air Conditioner

TX1086306A

—UN—28DEC10

Main Menu Screen

TX1086272A

—UN—27DEC10

Switch Panel

The Air Conditioner menu allows operator to turn the airconditioner ON or OFF and set the circulation air mode torecirculating cab air or fresh air.




At Main Menu screen (1), rotate monitor dial (2) tohighlight Air Conditioner. Press monitor dial to displayAir Conditioner menu.

Air Conditioner menu items include:

□ (Cab recirculating air mode symbol is displayed.)Rotate monitor dial to highlight the cab recirculatingair mode symbol. Press monitor dial to turn ON thecab recirculating air mode. The color of the precedingsquare will turn green and a recirculating air icon (5) willappear in the air conditioner display in the lower leftcorner of the monitor. Press monitor dial again to turnOFF the recirculating air mode and switch to fresh airmode. The color of the preceding square will be grayand a fresh air icon (6) will appear in the air conditionerdisplay in the lower left corner of the monitor.

TX1086310A

—UN—28DEC10

Circulating Air Icon

TX1086311A

—UN—28DEC10

Fresh Air Icon


4—Home Button5—Recirculating Air Icon6—Fresh Air Icon

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□A/C

NOTE: Blower speed switch on switch panel needs tobe ON in order to operate the ON/OFF functionof the air conditioner in the monitor menu.

Rotate monitor dial to highlight A/C. Press monitordial to turn ON the air conditioner. The color of thepreceding square will turn green and an air conditionericon (7) will appear in the air conditioner display in thelower left corner of the monitor. Press monitor dialagain to turn OFF the air conditioner. The color of thepreceding square will be gray and air conditioner iconwill disappear.

If an exclamation mark appears on the monitor,communication between the air conditioner and themonitor is abnormal. See your authorized dealer.



TX1086312A

—UN—28DEC10

Air Conditioner Icon

7—Air Conditioner Icon

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Main Menu—RadioThe Radio menu allows operator to set preferred radiostations and adjust the tone settings.




At Main Menu screen (1), rotate monitor dial (2) tohighlight Radio. Press monitor dial to display Radio menu.

Radio menu items include:

• CH1 AM _ _ _ _ kHz• CH2 AM _ _ _ _ kHz• CH3 AM _ _ _ _ kHz• CH4 AM _ _ _ _ kHz• CH5 FM _ _ _ ._ MHz• CH6 FM _ _ _ ._ MHz• CH7 FM _ _ _ ._ MHz• CH8 FM _ _ _ ._ MHz

NOTE: Presetting memory radio stations can also bedone using the keypad on switch panel. SeeOperating the AM/FM Radio. (Section 2-1.)

Press radio tuning switch (5) to toggle between AM orFM frequency. Tune radio to desired AM or FM stationby rotating the radio tuning switch. When desired stationis found, rotate monitor dial to highlight CH1. Press andhold monitor dial for more than 1 second. Current stationis set. Repeat procedure for seven additional AM or FMstations using CH2 through CH8. Once the stations arestored, operator can select these programmed stationsby using keys 1—8 on the switch panel keypad (6).• <<Rotate monitor dial to highlight <<. Press monitor dialto seek next lower frequency station. Continue to pressmonitor dial to seek next lower frequency station untildesired station is found.• >>Rotate monitor dial to highlight >>. Press monitor dial toseek next higher frequency station. Continue to pressmonitor dial to seek next higher frequency station untildesired station is found.• TONERotate monitor dial to highlight TONE. Press monitordial to adjust tone. (Backlighting will turn orange.)Rotate monitor dial clockwise to boost treble. Rotatemonitor dial counterclockwise to boost base. Pressmonitor dial again to store changes.

TX1086306A

—UN—28DEC10

Main Menu Screen

TX1086274A

—UN—27DEC10

Switch Panel


4—Home Button5—Radio Tuning Switch6—Keypad

• AUTO PRESETRotate monitor dial to highlight AUTO PRESET. Pressmonitor dial to start auto preset process. The AUTOPRESET scans reception frequency and allocatesstations to CH1 to CH8. AM frequency stations will bepreset to CH1 to CH4 and FM frequency stations will bepreset to CH5 to CH8. Operating the radio during thescan stops the AUTO PRESET process.

If an exclamation mark appears in the radio display onthe monitor, communication between the radio and themonitor is abnormal. See your authorized dealer.



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Main Menu—Work ModeThe Work Mode menu allows operator to select frontattachment.




At Main Menu screen (1), rotate monitor dial (2) tohighlight Work Mode. Press monitor dial to display WorkMode menu.

Work Mode menu items include:

NOTE: This list of front attachments are examplesonly. Personalized list of front attachments canbe entered in monitor through the AttachmentName Input screen. See Main Menu—SettingMenu—Attachment Name Input in this section.

• Bucket (bucket icon will also be shown)• Breaker 1 (breaker icon will also be shown)Type-A• Breaker 2 (breaker icon will also be shown)Type-B• Pulverizer 1 (pulverizer icon will also be shown)• Crusher 1 (crusher icon will also be shown)• Grapple 1 (grapple icon will also be shown)

Rotate monitor dial to highlight desired front attachment.Press monitor dial to select the desired attachment foroperation.

—If Bucket work mode was selected, screen will revertback to the default screen and a bucket icon displays onmonitor in the upper left corner.

—If any other work mode is selected, the followinginformation is displayed:

• Maximum Pump Flow Rate..........XXX.XX gpm• Maximum Engine Speed.................XXXX min-¹• Selector Valve................................O/T or C/V• 2 Pumps Combined Flow.........OFF/ON• Breaker Relief Pressure.........OFF/ON

TX1086306A

—UN—28DEC10

Main Menu Screen

TX1086272A

—UN—27DEC10

Switch Panel

1—Main Menu Screen2—Monitor Dial

3—Back Button4—Home Button

•If adjustments need to be made to this information, seeyour authorized dealer. If information is correct andready for operation, rotate monitor dial to highlight thecheckmark ( ) and press monitor dial. Screen will revertback to the default screen and selected attachment icondisplays on monitor in the upper left corner.



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Main Menu—Setting MenuThe Setting Menu allows operator to change variousmonitor and machine functions.




At Main Menu screen (1), rotate monitor dial (2) to highlightSetting Menu. Press monitor dial to display Setting Menu.

Setting Menu items include:

• Date and Time• Attachment Name Input• Auto Shutdown• Auto Exhaust Filter Cleaning• Sub Meter Selection• Rear View Camera Monitor• Display Item Selection• Brightness Adjustment• Language• Unit Selection• Main Menu Sequence Change

Rotate monitor dial to highlight a Setting submenu. Pressmonitor dial to display chosen Setting submenu.



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—UN—28DEC10

Main Menu Screen

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—UN—27DEC10

Switch Panel



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Main Menu—Setting Menu—Date and TimeThe Date and Time menu provides the capability tochange the date and time settings. Year/month/day formatand 24h/12h display mode can also be changed.

At Setting Menu, rotate monitor dial to highlight Date andTime. Press monitor dial to display Date and Time menu.

Date and Time menu items include:

• Time Setting(present time is displayed here)- Hour- Minute-Rotate monitor dial to highlight Time Setting. Pressmonitor dial to display Time Setting screen. Rotatemonitor dial to highlight Hour and press monitor dial.(Backlighting will turn orange.) Rotate monitor dial toadjust the hour setting. (Rotate clockwise to incrementnumber and counterclockwise to decrement number.)Press monitor dial when desired hour setting is reached.Rotate monitor dial to highlight Minute and press monitordial. (Backlighting will turn orange.) Rotate monitordial to adjust the minute setting. (Rotate clockwise toincrement number and counterclockwise to decrementnumber.) Press monitor dial when desired minutesetting is reached. Rotate monitor dial to highlight checkmark ( ). Press monitor dial to store the Time Settings.• Date Setting- Year- Month- Day-Rotate monitor dial to highlight Date Setting. Pressmonitor dial to display Date Setting screen. Rotate

monitor dial to highlight Year and press monitor dial.(Backlighting will turn orange.) Rotate monitor dial toadjust the year setting. (Rotate clockwise to incrementnumber and counterclockwise to decrement number.)Press monitor dial when desired year setting is reached.Rotate monitor dial to highlight Month and press monitordial. (Backlighting will turn orange.) Rotate monitordial to adjust the month setting. (Rotate clockwise toincrement number and counterclockwise to decrementnumber.) Press monitor dial when desired monthsetting is reached. Rotate monitor dial to highlight Dayand press monitor dial. (Backlighting will turn orange.)Rotate monitor dial to adjust the day setting. (Rotateclockwise to increment number and counterclockwise todecrement number.) Press monitor dial when desiredday setting is reached. Rotate monitor dial to highlightcheck mark ( ). Press monitor dial to store the DateSettings.• Display Form- Time- DateRotate monitor dial to highlight Display Form. Pressmonitor dial to display Display Form screen. Rotatemonitor dial to highlight Time and press monitor dial.Press monitor dial to switch between 12h or 24hsettings. When desired time setting is reached, rotatemonitor dial to highlight Date and press monitor dial.Press monitor dial to switch between YYYY/MM/DD,MM/DD/YYYY, or DD/MM/YYYY settings.

Press Back button to return to previous screen.

Press Home button to return to default screen.

Main Menu—Setting Menu—AttachmentName InputTheAttachment Name Inputmenu provides the capabilityto personalize front attachment with a specific name.

At Setting Menu, rotate monitor dial to highlightAttachment Name Input. Press monitor dial to displayAttachment Name Input menu. Rotate monitor dial tohighlight desired attachment name. Press monitor dial todisplay name change screen. To add specific informationto the attachment name, rotate monitor dial either way tohighlight a character, then press the monitor dial. After

inputting new name, rotate monitor dial to highlight SETon bottom right corner of monitor. Press monitor dial tofinalize the setting.

NOTE: To delete the last entered character, rotate monitordial to highlight BS on bottom left corner of monitorand then press monitor dial. To delete all enteredcharacters, rotate monitor dial to highlight ALLCLEAR and then press monitor dial.



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Main Menu—Setting Menu—Auto ShutdownThe Auto Shutdown menu provides the capability toturn on this feature and set a desired time for machineshutdown to take place.

At Setting Menu, rotate monitor dial to highlight AutoShutdown. Press monitor dial to display Auto Shutdownmenu.

Auto Shutdown menu items include:

NOTE: When auto shutdown is ON, the color of thepreceding square is green and A/S will appear onthe default screen. When auto shutdown is OFF,the color of the preceding square is gray.

□ON (Enable)Rotate monitor dial to highlight ON (Enable). Pressmonitor dial to turn the auto shutdown function ON.Press monitor dial again to turn the auto shutdownfunction OFF.

NOTE: Setting Time minute increment needs to beset before enabling auto shutdown.

Setting TimeRotate monitor dial to highlight Setting Time and pressmonitor dial. (Backlighting will turn orange.) Rotatemonitor dial to adjust the auto shutdown acting time.Auto shutdown can be set to activate after 1, 2, 3, 4,5, 7, 10, 15, 20, 25, or 30 minute increments. Pressmonitor dial to store desired time setting.

NOTE: Thirty seconds before the engine stops, themonitorwill display Engine Shutdown Soon message.



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Main Menu—Setting Menu—Auto ExhaustFilter Cleaning

CAUTION: Servicing machine during exhaustfilter auto cleaning can result in serious personalinjury. Avoid exposure and skin contact withhot gases and components.

During exhaust filter auto cleaning, the enginemay run at elevated idle and hot temperaturesfor an extended period of time. Exhaust gasesand exhaust filter components may reachtemperatures hot enough to burn people andignite or melt common materials.

NOTE: Disabling auto exhaust filter cleaning is notpreferred. Whenever possible, auto cleaning shouldbe enabled to keep soot buildup to a minimumand to increase overall machine uptime.

If operating in conditions where it may be unsafe forelevated exhaust temperatures, auto cleaning of theexhaust filter can be disabled.

The Auto Exhaust Filter Cleaning menu allows theoperator to enable or disable the auto cleaning functionfor the exhaust filter.

At Setting Menu, rotate monitor dial to highlight AutoExhaust Filter Cleaning. Press monitor dial to displayAuto Exhaust Filter Cleaning menu:

NOTE: When auto cleaning is disabled, the colorof the preceding square is green and exhaustfilter auto cleaning disabled indicator (1) willappear on the default screen.

When auto cleaning is enabled, the color ofthe preceding square is gray and an exhaustfilter cleaning indicator (2) will appear on thedefault screen when an auto or parked cleaningprocedure is taking place.

The exhaust filter auto cleaning disabled indicatorwill display on the monitor when the key switch isin ON position. Once the engine is started, the

TX1086450—UN—06JAN11

Exhaust Filter Auto Cleaning Disabled Indicator

TX1086451—UN—06JAN11

Exhaust Filter Cleaning Indicator

1—Exhaust Filter AutoCleaning Disabled Indicator

2—Exhaust Filter CleaningIndicator

indicator will disappear unless exhaust filter autocleaning has been disabled by the operator.

□OFF (Disable)

Press monitor dial to turn OFF (disable) auto cleaning.Press monitor dial again to enable auto cleaning.



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Main Menu—Setting Menu—Sub MeterSelectionNOTE: Only one sub meter can be selected at a time.

When one of the selections is ON, the color ofthe preceding square is green.

The Sub Meter Selection menu provides the capabilityto add a meter on the fuel gauge for fuel consumptionor breaker hours.

At Setting Menu, rotate monitor dial to highlight SubMeter Selection. Press monitor dial to display Sub MeterSelection menu.

Sub Meter Selection menu items include:

□OFFRotate monitor dial to highlight OFF. Press monitor dialto turn OFF any meters.

□ Fuel Consumption IndicatorRotate monitor dial to highlight Fuel ConsumptionIndicator. Press monitor dial to turn ON the fuelconsumption indicator (1). (Fuel consumption will bedisplayed on the fuel gauge on the default screen.)

□Breaker Hour MeterRotate monitor dial to highlight Breaker Hour Meter.Press monitor dial to turn ON the breaker hour meter(2). (Breaker hours will be displayed on the fuel gaugeon the default screen.)



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—UN—28DEC10

Fuel Consumption Indicator

TX1086326A

—UN—28DEC10

Breaker Hour Meter

1—Fuel Consumption Indicator 2—Breaker Hour Meter

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Main Menu—Setting Menu—Rear ViewCamera Monitor

CAUTION: The rear view camera image isdesigned to supplement other safety practicesand is not intended to be the sole methodof collision avoidance. Always be alert andaware of the surroundings when operatingthis machine to avoid possible injury ordeath to operator or others.

NOTE: When the rear view camera mode is enabled,the color of the preceding square is green andrear view image (1) is continuously displayedon the default screen.

NOTE: For a clear image, clean lens and monitorbefore operating the machine. The monitorand camera lens surface is a resin product.Lightly wipe the surface with a wet, clean cloth.Never use an organic solvent.

The Rear View Camera Monitor menu provides thecapability to turn the camera ON or OFF so the viewbehind the machine is shown on the monitor.

At Setting Menu, rotate monitor dial to highlight Rear ViewCamera Monitor. Press monitor dial to display Rear ViewCamera Monitor menu.

□ON (Enable)Press monitor dial to turn ON (enable) the rear viewcamera mode on the monitor. Press monitor dial againto disable rear view camera mode.

Never attempt to change the mounting position of therear view camera (2). If rear view camera monitor is notoperating properly, see your authorized dealer.



TX1086330A

—UN—28DEC10

Rear View Image

TX1086331A

—UN—28DEC10

Camera

1—Rear View Image 2—Rear View Camera

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OUT4001,000072F -19-28FEB12-1/1

OUT4001,000072C -19-28APR14-1/1

OUT4001,000072D -19-28APR14-1/1

Main Menu—Setting Menu—Display ItemSelectionNOTE: Only one display item can be selected at a

time. When one of the selections is ON, the colorof the preceding square is green.

The Display Item Selection menu provides the capabilityto change what appears on the default screen.

At Setting Menu, rotate monitor dial to highlight DisplayItem Selection. Press monitor dial to display Display ItemSelection menu.

Display Item Selection menu items include:

□ LogoRotate monitor dial to highlight Logo. Press monitor dialto have manufacturer logo (1) appear on default screen.

□Operational InformationRotate monitor dial to highlight Operational Information.Press monitor dial to have operational information (2)appear on default screen.

□OFF (Disable)Rotate monitor dial to highlight OFF (Disable). Pressmonitor dial to turn OFF any images.



1—Manufacturer Logo 2—Operational Information

TX1086332A

—UN—28DEC10

Manufacturer Logo

TX1086333A

—UN—28DEC10

Operational Information

Main Menu—Setting Menu—BrightnessAdjustmentThe Brightness Adjustment menu allows operator toadjust the brightness of the monitor for better viewing.

At Setting Menu, rotate monitor dial to highlight BrightnessAdjustment. Press monitor dial to display BrightnessAdjustment menu.

Rotate monitor dial clockwise for lighter image andcounterclockwise for darker image.



Main Menu—Setting Menu—LanguageThe Language menu allows operator to change thelanguage text that appears on the monitor to a specificpreference.

At Setting Menu, rotate monitor dial to highlight Language.Press monitor dial to display Language menu. A list ofdifferent languages appears.

NOTE: Only one language can be selected at a time.When one of the selections is ON, the color ofthe preceding square is green.

Rotate monitor dial to highlight desired language andpress monitor dial to store setting.



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OUT4001,000072E -19-28APR14-1/1

OUT4001,0000730 -19-28APR14-1/1

Main Menu—Setting Menu—Unit SelectionThe Unit Selection menu allows operator to change theunit system that appears on the monitor to either USor Metric and change temperature display reading onthe monitor between degrees Celcius (°C) or degreesFarenheit (°F).

At Setting Menu, rotate monitor dial (2) to highlight UnitSelection. Press monitor dial to display Unit Selectionmenu.

Unit Selection menu items include:

• UnitRotate monitor dial to highlight Unit and press monitordial. Press monitor dial to change setting between USor Metric.• °C/°F(Blower Must Be ON)

NOTE: Before changing °C or °F, turn the blowerfan ON by pressing the blower speed switch(1) on the switch panel.

Rotate monitor dial to highlight °C/°F and press monitordial. After displaying Wait message, temperaturereading is changed from previous setting in lower leftcorner of the screen on the air conditioner display.Press monitor dial again to change temperature readingback to opposite setting.


TX1086278A

—UN—27DEC10

Switch Panel

1—Blower Speed Switch2—Monitor Dial



Main Menu—Setting Menu—Main MenuSequence ChangeThe Main Menu Sequence Change menu providesthe capability to change the sequence order of some ofthe submenus under the Main Menu according to howfrequently they are used.

At Setting Menu, rotate monitor dial to highlight MainMenu Sequence Change. Press monitor dial to displayMain Menu Sequence Change menu.

Main Menu Sequence Change menu items include:

• Air Conditioner• Radio• Work Mode

Rotate monitor dial to highlight the submenu that ispreferred to be shown first. Press monitor dial to changethe submenu sequence.



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OUT4001,0000722 -19-28APR14-1/1

Main Menu—Information MenuThe Information Menu provides operating hourinformation, maintenance items, troubleshooting(diagnostic trouble codes [DTCs]), engine speed, andrestriction level in the exhaust filter.




At Main Menu screen (1), rotate monitor dial (2) tohighlight Information Menu. Press monitor dial to displayInformation Menu.

Information Menu items include:

• Operation• Maintenance• Troubleshooting• MonitoringPress Back button (3) to return to previous screen.




TX1086306A

—UN—28DEC10

Main Menu Screen

TX1086272A

—UN—27DEC10

Switch Panel

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PN=89


OUT4001,0000731 -19-28APR14-1/1

Main Menu—Information Menu—OperationThe Operation menu provides fuel consumption andoperating hours of the breaker, front attachment, tracks,and overall machine hours.

At Information Menu, rotate monitor dial to highlightOperation. Press monitor dial to display Operation menu.

NOTE: Total fuel consumption and fuel consumptionrate depend on the operating environment andthe operation method of machine.

Operation menu items include:

• Fuel ConsumptionRotate monitor dial to highlight Fuel Consumption. Pressmonitor dial to display Fuel Consumption information:- Machine Operation Hours ............... XX h- Fuel Consumption ............................ XX L- Average Fuel Consumption Rate....XX.X L/hPress monitor dial to return to the previous menu. Toreset fuel consumption data, rotate monitor dial tohighlight CLEAR in the bottom right corner of screenand press monitor dial.

• Breaker OperationRotate monitor dial to highlight Breaker Operation.Press monitor dial to display Breaker Operationinformation:- Operating Time ........................XXXXXX.X h- Machine Operation Hours ............XXXX.X h- Operation Ratio................................XXX.X %Press monitor dial to return to the previous menu. Toreset breaker operating data, rotate monitor dial tohighlight CLEAR in the bottom right corner of screenand press monitor dial.

• Attachment OperationRotate monitor dial to highlight Attachment Operation.Press monitor dial to display Attachment Operationinformation:- Operating Time ...........................XXXX.X hPress monitor dial to return to the previous menu.To reset attachment operating hours, rotate monitordial to highlight CLEAR in the bottom right corner ofscreen and press monitor dial.

• Travel OperationRotate monitor dial to highlight Travel Operation. Pressmonitor dial to display Travel Operation information:- Operating Time ...........................XXXX.X hPress monitor dial to return to the previous menu. Toreset travel operating hours, rotate monitor dial tohighlight CLEAR in the bottom right corner of screenand press monitor dial.

• Actual OperationNOTE: The actual operation time includes the

front attachment operation and the traveloperation hours.

Rotate monitor dial to highlight Actual Operation. Pressmonitor dial to display Actual Operation information:- Operating Time ...........................XXXX.X hPress monitor dial to return to the previous menu. Toreset actual operating hours, rotate monitor dial tohighlight CLEAR in the bottom right corner of screenand press monitor dial.



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DB84312,000002E -19-28APR14-1/1

OUT4001,0000733 -19-28APR14-1/1

Main Menu—InformationMenu—MaintenanceThe Maintenance menu provides the capability to notifythe operator when the next maintenance item is due,shows hours remaining until next maintenance interval,and allows the interval hours to be reset.

At Information Menu, rotate monitor dial to highlightMaintenance. Press monitor dial to display Maintenancemenu.

Maintenance menu items include:

• Engine Oil• Engine Oil Filter• Hydraulic Oil• Pilot Hydraulic Oil Filter• Hydraulic Oil Full-Flow Filter• Pump Transmission Oil• Travel Reduction Gear Oil• Swing Reduction Gear Oil• Swing Bearing Grease• Air Cleaner Element• Fuel Filter• Air Conditioner Filter• Exhaust Filter• User Setting 1• User Setting 2• Maintenance Notice...........ON or OFF

Rotate monitor dial to highlight Maintenance Notice.Press monitor dial to turn Maintenance Notice ON. Pressmonitor dial again to turn Maintenance Notice OFF.

If Maintenance Notice is ON, a message is displayed onthe monitor for 10 seconds (when the key switch is ON)

if any of the maintenance items listed come due for achange. Press the Home button on switch panel to deletethe notification.

If Maintenance Notice is OFF, no notification is displayedon the monitor.

To check if a maintenance item is due for a change,rotate monitor dial through list to reach specific item andhighlight. If a wrench symbol appears next to the item,service is due. Press monitor dial to display the followinginformation for each item:

• Previous Maintenance(date is displayed).............X.X h• Remains...........................XXX.X h• Maintenance Interval......XXX.X h

Press monitor dial to return to previous menu with nochanges.

To reset remaining time data, rotate monitor dial tohighlight RESET at the bottom center of monitor andpress monitor dial. The value of remaining hours is resetto that of change interval. The previous maintenance dateand hours are updated with current date and time.

To change the maintenance interval, rotate monitordial to highlight the wrench with the clock next to it at thebottom right corner of monitor and press monitor dial.(Backlighting will turn orange for Maintenance Interval.)Rotate monitor dial to adjust the time for scheduled hourmaintenance. Press monitor dial to store the change.



Main Menu—InformationMenu—TroubleshootingThe Troubleshooting menu provides access to view anydiagnostic trouble codes (DTCs) generated by a controller.

At Information Menu, rotate monitor dial to highlightTroubleshooting. Press monitor dial to beginTroubleshooting data. After displaying Wait message, thescreen displays controller troubleshooting menu:

• Engine (00)• Main (00)

• Monitor (00)• Information (00)

The amount of currently generated DTCs are displayed atthe right side of each item in parenthesis. Rotate monitordial to highlight an item displaying DTCs. Press monitordial to display the actual DTC numbers. Up to 20 DTCscan be displayed.



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OUT4001,0000734 -19-28APR14-1/1

Main Menu—Information Menu—MonitoringThe Monitoring menu provides access to view enginespeed and restriction level in the exhaust filter.

At Information Menu, rotate monitor dial to highlightMonitoring. Press monitor dial to display Monitoring menu:

• Actual Engine Speed...........XXXX min-¹• Exhaust Filter Restriction Level....(displays a bargraph)There are five segments to the bar graph to indicate therestriction status of the exhaust filter.

- If any of the first three segments of the bar graphdisplay a block, auto cleaning needs to be enabled.

- If the fourth or fifth segment also displays a block, aparked cleaning needs to be initiated by the operator.An exhaust filter alarm indicator will also appear onthe monitor.



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PN=92

Operation—Operating the Machine

TX03679,0001780 -19-21AUG12-1/1

DB84312,00000C4 -19-22FEB12-1/1

Before Starting WorkReview the operating precautions. SeeSafety-Operating Precautions. (Section 1-3.)

Use seat belt when operating machine. Remember tofasten seat belt even during brief periods of use.

T133556—UN—24AUG00

Reading Operator's Manual

Operator's Daily Machine Check BeforeStartingSafety and Protective Devices Checks

Walk around machine to clear all persons from machinearea before starting machine.

Clear all steps and walking surfaces.

Check condition of guards, shields, and covers.

Overall Machine Checks

Check for worn or frayed electrical wires and loose orcorroded connections.

Inspect machine for bent, broken, or loose parts.

Check for loose or missing hardware.

Check for oil leaks, missing or loose hose clamps, kinkedhoses, and lines or hoses that rub against each other orother parts.

1—Check Pedal and LeverMovement/Clean Out CabDebris

2—Check Hydraulic Oil Level3—Check Surge Tank Level

4—Check Engine Oil Level5—Check/Clean Radiator and

Oil Cooler Outer Fins

1

2

5

3

4

TX1000291—UN—15NOV05

Inspect Machine Daily

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OUT4001,00005FE -19-10DEC10-1/1

Engine Break-In PeriodIMPORTANT: To avoid engine damage it is critical

to observe the engine break-in period. Extracare during the first 500 hours of operationwill result in more satisfactory long-termengine performance and life. DO NOT exceed500 hours of operation with John DeereBreak-In Plus™ engine oil.

This machine is factory filled with John Deere Break-InPlus engine oil.

1. Operate the machine at heavy or normal loads withminimal idling during the break-in period. During thefirst 20 hours, avoid prolonged periods of engine idlingor sustained maximum load operation. If engine willidle longer than 5 minutes, stop engine.

IMPORTANT: DO NOT add make-up oil until the oillevel is BELOW the ADD mark on the dipstick.John Deere Break-In Plus oil should be usedto make up any oil consumed during thebreak-in period. See John Deere Break-InPlus Engine Oil. (Section 3-1.)

If John Deere Break-In Plus Engine Oil isnot available, use a 10W-30 diesel engine

oil meeting one of the following during theinitial 250 hours of operation:

• API Service Category CJ-4• ACEA Oil Sequence E9• ACEA Oil Sequence E6

2. Check engine oil level more frequently during theengine break-in period.

3. Change oil and oil filter after first 500 hours of operation(maximum). Fill crankcase with the normal seasonalviscosity grade oil. See Diesel Engine Oil—InterimTier 4 and Stage III B Engines. (Section 3-1.)

4. Watch coolant temperature gauge closely. If coolanttemperature rises above specified limits on the gauge,reduce load on engine. Unless temperature dropsquickly, stop the engine and determine the causebefore resuming operation. See Troubleshooting.(Section 4-3.)

5. Watch oil pressure gauge for pressure withinspecification.

6. Check belt for proper alignment and seating in pulleygrooves.

Break-In Plus is a trademark of Deere & Company

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OUT4001,000084C -19-19MAR12-1/1

Starting EngineIMPORTANT: Prevent possible damage to engine.

Temperatures below -20°C (-4°F) require anadditional warmup period. See Cold WeatherWarmup in this section.

Before Starting the Engine

Turn key switch to ON position. The system startingscreen (1) displays for about 2 seconds and then thedefault screen (2) is displayed.

IMPORTANT: Prevent possible damage to engine.Wait until engine preheat indicator (4) is nolonger illuminated before starting the engine.

Starting the Engine

1. Move pilot shutoff lever to the locked (UP) position tostart machine.

2. Move engine speed dial (3) to slow idle position.

3. Sound horn to alert persons nearby.

IMPORTANT: Prevent starter damage. Never operatestarter for more than 10 seconds at a time.If engine does not start, return key switchto OFF. Wait for more than 30 seconds, thentry again. After a false start, DO NOT turnkey switch until engine stops.

4. Turn key switch to START. Release the key switchimmediately after the engine has started. Switch willreturn to ON position.

After Starting Check

IMPORTANT: Prevent possible damage to engine.If alarm indicators remain illuminated afterstarting engine, IMMEDIATELY STOP THEENGINE. Find and correct the problem. SeeMain Menu—Alarm List. (Section 2-2.)

After the engine is started, check that no alarm indicatorsare shown on display.

Warming The Engine

1. Run engine at 1/3 speed for 30 seconds. Do not runengine at fast or slow idle. Do not accelerate rapidlyduring warmup.

2. Operate machine at less-than-normal loads andspeeds until engine is at normal operating temperature.

TX1086287A

—UN—28DEC10

System Starting Screen

TX1090660—UN—11APR11

Default Screen

TX1086455A

—UN—04JAN11

Engine Speed Dial

1—System Starting Screen2—Default Screen

3—Engine Speed Dial4—Engine Preheat Indicator

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PN=95


ER79617,0000DC8 -19-28JAN11-1/1

Cold Weather Start Aid

CAUTION: Ether is highly flammable. Donot use ether when starting an engineequipped with glow plugs.

IMPORTANT: Prevent possible damage to theengine. The diesel fired coolant heater isrequired for temperatures -20°C (-4°F) andbelow. See your authorized dealer.

IMPORTANT: Prevent possible damage to engine.Temperatures below -20°C (-4°F) require anadditional warmup period. See Cold WeatherWarmup in this section.

This machine is equipped with glow plugs. Glow plugsare automatically controlled by the engine controller whenthe key is turned ON. Do not start engine until the enginepreheat indicator disappears on the monitor.

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PN=96


ER79617,0000DC6 -19-09JAN12-1/1

Cold Weather Warmup

CAUTION: Prevent possible injury fromunexpected machine movement. If hydraulic oilis cold, hydraulic functions move slowly. DO NOTattempt normal machine operation until hydraulicfunctions move at close-to-normal cycle times.

IMPORTANT: Prevent possible damage to theengine. The diesel fired coolant heater isrequired for temperatures -20°C (-4°F) andbelow. See your authorized dealer.

IMPORTANT: Prevent possible damage to engine.Temperatures below -20°C (-4°F) require adiesel fired coolant heater warmup period. At-20°C (-4°F) the engine requires 1 hour warmupperiod. Temperatures below -20°C (-4°F) requireadditional warmup period. See table below.

Diesel Fired Coolant Heater Warmup PeriodTemperature Required Warmup Period Before

Operation-20°C (-4°F) 1 Hour-21°C (-5°F) 1 Hour-22°C (-7°F) 2 Hours-23°C (-9°F) 2 Hours-24°C (-11°F) 2 Hours-25°C (-13°F) 2 Hours-26°C (-14°F) 2 Hours-27°C (-16°F) 2 Hours-28°C (-18°F) 2 Hours-29°C (-20°F) 3 Hours-30°C (-22°F) 4 Hours-31°C (-23°F) 5 Hours-32°C (-25°F) 6 Hours-33°C (-27°F) 7 Hours-34°C (-29°F) 8 Hours-35°C (-31°F) 9 Hours-36°C (-32°F) 10 Hours-37°C (-34°F) 11 Hours-38°C (-36°F) 12 Hours-39°C (-38°F) 13 Hours-40°C (-40°F) 14 Hours

In extremely cold conditions, an extended warmup periodwill be necessary.

Avoid sudden operation of all functions until the engineand hydraulic oil are thoroughly warm.

1. If temperature is below 0°C (32°F), engine willstart at 800 rpm and ramp to 1200 rpm after 30

seconds. Engine will maintain 1200 rpm until hydraulictemperature reaches 2°C (35.6°F) or 15 minutes,whichever comes first.

2. Run engine at 1/2 speed for 5 minutes. Do not runat fast or slow idle.

CAUTION: Prevent possible injury fromunexpected machine movement. Clear the area ofall persons before running your machine throughthe warmup procedure. If machine is inside abuilding, warm the travel circuit first and movethe machine to a clear area outside. Cold oil willcause machine functions to respond slowly.

3. Actuate travel and swing functions slowly, initiallymoving only short distances.

4. Operate boom, arm, and bucket functions by movingcylinders a short distance each direction for the firsttime.

5. Continue cycling cylinders by increasing the traveleach cycle, until full stroke is obtained.

6. Swing upperstructure so boom is perpendicular totracks.

CAUTION: Prevent possible injury from machinesliding backwards. Keep angle betweenboom and arm 90—110°.

7. Keeping the angle between boom and arm 90—110°,fully actuate bucket close function (cylinder extend)and lower bucket to raise track off ground.

IMPORTANT: Holding function actuated for morethan 10 seconds can cause damage fromhot spots in the control valve.

8. While rotating raised track in forward direction, actuatebucket curl function (cylinder extend) for 10 secondsand release for 5 seconds for a period of 2-1/2 minutes.

9. Repeat procedure with track rotating in reversedirection.

10. Lower machine to ground.

11. Repeat steps 6—10 on opposite track.

12. Operate all hydraulic functions to distribute warm oilin all cylinders, motors, and lines.

13. If hydraulic functions still move slowly, repeat steps7 and 8.

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ER79617,0000E31 -19-21AUG12-1/1

Travel Pedals and Levers

CAUTION: Prevent possible injury fromunexpected machine movement. Keepbystanders clear of machine when traveling.

Keep bystanders clear of machine when traveling.

The instructions below apply when the travel motors (4)are to the rear of the machine. If the travel motors are tothe front of the machine, the machine moves OPPOSITEto the direction described.

FORWARD TRAVEL (1): Push down on front of bothpedals or push both levers forward.

REVERSE TRAVEL (2): Push down on rear of bothpedals or pull both levers rearward.

NEUTRAL POSITION (3): Travel brakes will automaticallystop and hold the machine.

RIGHT TURN: Push down on front of left pedal or pushleft lever forward.

LEFT TURN: Push down on front of right pedal or pushright lever forward.

SHORT TURN (COUNTER-ROTATE): Push down thefront of one pedal and the rear of the other or push onelever forward and pull the other rearward.

CAUTION: Prevent possible injury from machinetipping. Operate control pedals or levers slowlywhen traveling down a slope.

TRAVELING DOWN A SLOPE: Operate control pedals orlevers slowly when traveling down a slope.

T137492—UN—25JAN01

Travel Pedals and Levers

1—Forward Travel2—Reverse Travel

3—Neutral Position4—Travel Motor (2 used)

COLD WEATHER OPERATION: Travel pedal and leverdampers are provided for smooth control. In extremelycold weather, pedal or lever effort will increase. Operatepedals or levers several times with pilot shutoff lever in thelocked (UP) position.

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Continued on next page DB84312,000002F -19-23AUG12-1/2

Exhaust FilterThe exhaust filter is a critical component in the engine'semissions control system, which is required to meetgovernmental emissions regulations. The exhaust filtercaptures soot and ash to prevent its release into theatmosphere. The soot and ash must be eliminated fromthe exhaust filter to keep it functioning properly. Theprocess of eliminating collected soot is called exhaustfilter cleaning. There are three types of exhaust filtercleaning available to the operator:

• NATURAL/PASSIVE• AUTO• PARKEDThere are five soot levels to describe the amount ofrestriction in the exhaust filter. These levels determine thetype of cleaning that is required:

• LOW• MODERATE• HIGH• VERY HIGH• SERVICETo observe the current restriction status of the exhaustfilter, an exhaust filter restriction level bar graph islocated in the Information Menu for viewing at any time.For more information, see Main Menu—InformationMenu—Monitoring. (Section 2-2.)

Auto cleaning is able to activate (if not disabled by theoperator) when the exhaust filter restriction is anywherebetween LOW and HIGH soot levels. Auto cleaning is nolonger available if exhaust filter restriction reaches VERYHIGH or SERVICE soot levels.

Parked cleaning can only be initiated when the exhaustfilter restriction reaches HIGH or VERY HIGH soot levels.

If exhaust filter restriction reaches SERVICE soot level,contact your authorized dealer.

In addition to the cleaning procedures, the exhaust filteralso requires maintenance at every 5000 hours to removeaccumulated ash, which is a noncombustible result ofadditives used in crankcase lubrication oils and the fuel.Ash removal CANNOT be performed by the operator.For more information on exhaust filter ash removal, seeService Exhaust Filter. (Section 3-3.)

NOTE: Unnecessary idling can cause exhaust filtersoot to accumulate more quickly. For the bestpossible exhaust filter operation which requiresthe least amount of operator interaction, idlingshould be kept to a minimum.

Natural/Passive Cleaning

During normal machine operation, the exhaust heat willnaturally clean the soot build up in the exhaust filter.

Auto Cleaning

CAUTION: Servicing machine during exhaustfilter auto cleaning can result in serious personalinjury. Avoid exposure and skin contact withhot gases and components.

During exhaust filter auto cleaning, the enginemay run at elevated idle and hot temperaturesfor an extended period of time. Exhaust gasesand exhaust filter components may reachtemperatures hot enough to burn people andignite or melt common materials.

With auto cleaning enabled, exhaust filter cleaning isautomatically performed as needed, with no interactionfrom the operator. An exhaust filter cleaning indicatorwill illuminate on the default screen of the monitor whenthe system is actively performing an exhaust filter autocleaning. Machine can be operated as normal. When theexhaust filter auto cleaning process has completed itscycle, the cleaning indicator will automatically turn off.

NOTE: Disabling exhaust filter auto cleaning is notpreferred. Whenever possible, auto cleaning shouldbe enabled to keep soot buildup to a minimumand to increase overall machine uptime.

If operating in conditions where it may be unsafe forelevated exhaust temperatures, auto cleaning can bedisabled through the monitor. For more information, seeMain Menu—Setting Menu—Auto Exhaust Filter Cleaning.(Section 2-2.) If auto cleaning is disabled by the operator,an exhaust filter auto cleaning disabled indicator willappear on the default screen of the monitor and remainson until auto cleaning is enabled again. If filter restrictionreaches the HIGH soot level with auto cleaning disabled,an exhaust filter alarm indicator will appear on the defaultscreen of the monitor to alert the operator to enable autocleaning or to initiate a parked cleaning. Operator cancheck the restriction level bar graph in the monitor at anytime. See Main Menu—Information Menu—Monitoring.(Section 2-2.)

Parked Cleaning




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DB84312,000002F -19-23AUG12-2/2


Parked cleaning is a process that allows the system toclean the exhaust filter. It is most commonly initiatedafter extended operation with exhaust filter auto cleaningdisabled or frequent engine shutdowns have occurredwhile the auto cleaning process was active. (For moredetailed information, see Exhaust Filter Parked Cleaningin this section.)

During the cleaning process, the engine speed will becontrolled automatically and the machine must remainparked to complete the procedure. Complete cleaningtime takes less than 45 minutes, but will vary on severalcriteria including fuel type, oil type, duty cycle, ambienttemperature, and the number of previously abortedexhaust filter cleaning requests.

Parked cleaning can only be initiated if the filter restrictionis at HIGH or VERY HIGH soot levels. It is prompted byan exhaust filter alarm indicator appearing on the monitor.If exhaust filter alarm indicator is illuminated and yellow,filter restriction is at a HIGH soot level and auto cleaningneeds to be enabled or a parked cleaning should be donesoon. If exhaust filter alarm indicator is blinking and yellowalong with the warning alarm indicator, filter restriction isat a VERY HIGH soot level and a parked cleaning shouldbe done immediately.

Machine needs to be in a predetermined safe state. Thissafe state includes three conditions:

• machine is parked in a safe place with the frontattachment lowered to the ground• pilot shutoff lever is in locked (UP) position• engine speed dial is set to slow idle

Once the exhaust filter parked cleaning switch is pressedand held for 3 seconds, a parked cleaning progress

screen appears on monitor. Progress status is displayedby a bar graph. The cleaning process will continue untilone of the following conditions exist:

• there is no soot restriction in the exhaust filter• 45 minutes has elapsed causing a timeout• operator cancels the parked cleaning procedure bylowering the pilot shutoff lever or increasing enginespeed• parked cleaning is aborted due to a system malfunction• engine runs out of fuel• engine is shut off by operator (not recommended)IMPORTANT: Avoid engine damage. If machine will

NOT be returning to operation immediately after aparked cleaning procedure, allow the engine andexhaust filter time to return to normal operatingtemperatures BEFORE stopping engine.

The exhaust filter cleaning indicator will be illuminatedon the monitor during the parked cleaning. When parkedcleaning procedure is complete, engine will automaticallyreturn to slow idle and exhaust filter cleaning indicator willturn off. Machine is ready to return to operation.

Avoid disabling the auto cleaning process unlessabsolutely necessary. Repeated disabling of the autocleaning process or ignoring prompts to perform a parkedcleaning procedure, will cause engine power limitationsand can eventually lead to dealer required servicecleaning.

Ash Removal

The exhaust filter cleaning procedures listed previously,clean the soot from the machine's exhaust filter. Theexhaust filter also traps ash deposits over time whichare not removed during an exhaust filter cleaning. Whenthe exhaust filter has run several thousand hours, theseash deposits can restrict engine performance and mustbe removed. For more information on ash removal, seeService Exhaust Filter. (Section 3-3.)

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Continued on next page DB84312,0000030 -19-09JAN12-1/2

Exhaust Filter Parked Cleaning





The exhaust filter parked cleaning process allows thesystem to clean the exhaust filter when the filter restrictionis at HIGH or VERY HIGH soot levels. It is most commonlyinitiated after extended operation with exhaust filter autocleaning disabled or frequent engine shutdowns haveoccurred while the auto cleaning process was active.Operator can check the restriction level bar graph inthe monitor at any time. See Main Menu—InformationMenu—Monitoring. (Section 2-2.)

Before starting the parked cleaning process, the machineneeds to be in a predetermined safe state. This safe stateincludes three conditions:

• machine is parked in a safe place with the frontattachment lowered to the ground• pilot shutoff lever is in locked (UP) position• engine speed dial is set to slow idle

An exhaust filter alarm indicator (1) on the monitor willinform the operator when a parked cleaning needs to takeplace.

• If the alarm indicator is illuminated yellow, exhaust filterrestriction is at HIGH soot level and an exhaust filterparked cleaning should be done soon.• If the alarm indicator is illuminated yellow and blinking,exhaust filter restriction is at VERY HIGH soot leveland an exhaust filter parked cleaning should be doneimmediately. Warning alarm indicator will also beilluminated.

Before starting the parked cleaning process, make surethe machine is in a safe state as listed previously. Oncethese conditions are met, press and hold the exhaustfilter parked cleaning switch (3) on the right console for 3seconds.

NOTE: If the safe state conditions are NOT met and theexhaust filter parked cleaning switch is pressed and

TX1086513—UN—06JAN11

Parked Cleaning Start Screen

TX1086512A

—UN—04JAN11


TX1086514—UN—06JAN11

Parked Cleaning Progress Screen

1—Exhaust Filter AlarmIndicator

2—Parked Cleaning StartScreen


4—Exhaust Filter CleaningIndicator

5—Parked Cleaning ProgressScreen

6—Bar Graph

held, a parked cleaning start screen (2) appearson the monitor. Move the pilot shutoff lever tolocked (UP) position and set engine speed dialto slow idle. Press and hold the parked cleaningswitch again for 3 seconds to begin the exhaustfilter parked cleaning process.

Exhaust filter cleaning indicator (4) will illuminate onthe monitor and a parked cleaning progress screen (5)appears. Progress status is displayed on the bar graph (6).

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DB84312,0000030 -19-09JAN12-2/2

OUT4001,000075A -19-26JAN11-1/1

During the cleaning process, the engine speed will becontrolled automatically and the machine must remainparked to complete the procedure. Complete cleaningtime takes less than 45 minutes, but will vary on severalcriteria including fuel type, oil type, duty cycle, ambienttemperature, and the number of previously abortedexhaust filter cleaning requests. Exhaust combustion maytemporarily emit white smoke during the cleaning process.

The cleaning process will continue until one of thefollowing conditions exist:

• 45 minutes has elapsed causing a timeout• pilot shutoff lever is moved• engine speed dial is moved• parked cleaning is aborted due to a system fault• engine runs out of fuel• engine is shut off by operator (not recommended)If any of these conditions happen during the parkedcleaning process, the process will be cancelled and amessage will be displayed on the monitor informing theoperator. The condition will need to be amended and

the parked cleaning process must be started over. Fora system fault, see your authorized dealer.

IMPORTANT: Avoid engine damage. If machine willNOT be returning to operation immediately after aparked cleaning procedure, allow the engine andexhaust filter time to return to normal operatingtemperatures BEFORE stopping engine.

NOTE: If machine needs to be operated during theparked cleaning procedure, press the exhaustfilter parked cleaning switch again. The processwill be cancelled and a message will be displayedon the monitor informing the operator. Machineoperation can resume, but a parked cleaning mustbe performed as soon as possible.

When there is no soot restriction in the exhaust filter,the parked cleaning procedure is complete. Enginewill automatically return to slow idle and exhaust filtercleaning indicator will turn off. A message will appear onthe monitor stating Exhaust Filter Cleaning Complete andthe machine is ready to return to operation.

Service ADVISOR™ Remote (SAR) SoftwareDelivery ProcessTheory of Operation

Service ADVISOR™ is a diagnostic tool used by JohnDeere dealers to perform diagnostics as well as updatesto machine settings and software. Dealers can accessdiagnostic trouble codes and diagnostic addresses,create readings and recordings, and program controllers.This technology consists of both software and hardware.Technicians attend a minimum of 8 hours of training tobecome certified in utilizing this tool.

Service ADVISOR Remote (SAR) is a function of ServiceADVISOR. It allows the dealer technician to connect toa SAR-enabled machine via the JDLink™ network toremotely access diagnostic trouble code information andrecord diagnostic data, as well as program controllers.

Similar to software (payload) updates in the computerindustry, SAR enables John Deere to remotely deliverupdated software via the JDLink hardware on board.Remote programming gives John Deere the ability toupdate software to enhance the performance of themachine. This capability can be used to reprogram mostmachine controllers. The user actively participates withthe dealer in this process by installing the software update.

NOTE: Some vehicle controllers may not be compatiblefor SAR reprogramming.

For more information about Service ADVISOR Remote,consult your local John Deere dealer.

Vehicle Reprogramming

NOTE: Factory setting is set to always acceptsoftware downloads.

Normal machine operation can continue duringthe software download process.

Customer will be notified by John Deere or a John Deeredealer of pending software updates with appropriateinstallation instructions via letter or phone.

Customer can determine the appropriate time and placeto install the new software on the machine. For moreinformation, see Service ADVISOR™ Remote (SAR)Operation in this section.

Once the customer initiates installation of the software,SAR will start and manage the installation of the newpayload to the appropriate machine controllers.

NOTE: Software download speed capability dependson JDLink cellular coverage.

Service ADVISOR is a trademark of Deere & CompanyJDLink is a trademark of Deere & Company

2-3-10 081214

PN=102


Continued on next page OUT4001,0000778 -19-28JAN11-1/3

Service ADVISOR™ Remote (SAR) Operation

The flex power controller (FPC) will interface withJDLink™ and the monitor to communicate the availabilityof software updates and programming progress. TheService ADVISOR™ Remote (SAR) switch (1) is wireddirectly to the FPC and allows the operator to acceptor decline available updates. Alarm indicators on thedisplay are controlled through diagnostic trouble codes(DTCs) originating from the FPC. The FPC will create theDTCs under certain conditions, which will then promptthe monitor to display operator instructions. It will benecessary to interact with your John Deere dealer ortechnician for needed information.

NOTE: The programming alarm indicator is used fordifferent purposes, but the color of the alarmindicator changes for each purpose.

When a software update is available to install, a yellowprogramming alarm will appear on the monitor, along witha message stating:

SOFTWARE UPDATE READY

NOTE: Alarm List ONLY appears as a submenu ifthere is an actual alarm.

The Alarm List submenu under the Main Menu will giveinstructions to guide the operator through the process.For viewing alarm instructions, see Main Menu—AlarmList. (Section 2-2.)

Park machine and stop engine. Installation of the softwarecan only process if the engine is not running and pilotshutoff lever is in locked (UP) position.

NOTE: Before installing software, make sure theSOFTWARE TERMS AND CONDITIONS havebeen read. (Find SOFTWARE TERMS ANDCONDITIONS at the beginning of this manual.)

LEDs on the SAR switch will illuminate when this alarmappears. The left LED will be red and the right LED willbe green.

Press and hold the right side of SAR switch (green LED)for 3 seconds to begin programming installation. Press leftside of SAR switch (red LED) to cancel software updateand wait until the next power cycle.

TX1086797A

—UN—21JAN11

Service ADVISOR™ Remote SwitchTX1087187 —UN—21JAN11

Programming Alarm


2—DECLINE Software Updates

3—ACCEPT Software Updates

If operator chooses to install the new update, theprogramming alarm will remain on the monitor, but thecolor will change to red and the message will state:

PROGRAMMING IN PROCESS

Green LED on SAR switch will blink while programmingis taking place.

DO NOT turn OFF machine power until the programmingis complete.

Once programming is completed, programming alarm willturn green and the message will state:

PROGRAMMING COMPLETED

Cycle machine power to complete the installation process.

JDLink is a trademark of Deere & CompanyService ADVISOR is a trademark of Deere & Company

2-3-11 081214

PN=103


OUT4001,0000778 -19-28JAN11-2/3

OUT4001,0000778 -19-28JAN11-3/3

If a problem occurs during the programming process, ared program failure alarm will appear on the monitor alongwith a red warning alarm. The message on the monitorwill state:

PROGRAM FAILURE

If these alarms appear, contact your authorized dealerfor solutions.

TX1087189 —UN—21JAN11

Program Failure Alarm

TX1086352 —UN—06JAN11

Warning Alarm

If conditions exist that will not allow the transfer of newsoftware to happen, a red unable to program alarmappears on the monitor along with a yellow warning alarm.The message on the monitor will state:

UNABLE TO REPROGRAM DEVICE

Make sure the engine is stopped and pilot shutoff leveris in locked (UP) position. Press and hold the right sideof SAR switch (green LED) again for 3 seconds to retryprogramming or contact your authorized John Deeredealer.

TX1087190 —UN—21JAN11

Unable to Program Alarm

TX1086352 —UN—06JAN11

Warning Alarm

2-3-12 081214

PN=104


Continued on next page OUT4001,0000866 -19-23AUG12-1/2

Locking the Hydraulic Coupler to the Attachment—If Equipped

TX1017664A

—UN—17JAN07

Front Hook on Hydraulic Coupler

TX1017662A

—UN—17JAN07

Hydraulic Coupler Pin

CAUTION: Prevent possible injury or death fromunexpected hydraulic coupler movement. Makesure hydraulic coupler is attached correctlyto attachment. The supplemental lock can beengaged with the attachment in an incorrectlock position. A visual check is required eachtime the lock operation is performed.

CAUTION: Avoid personal injury. Preventinjury from hydraulic coupler movement. Keepbystanders clear of machine.

IMPORTANT: Prevent possible hydraulic couplerdamage from incorrect installation. Attachingthe bucket in a reverse orientation on thehydraulic coupler is not recommended.When installed in the reverse orientation,the bucket or the lift hook interferes withthe arm of the excavator when the bucket isin full-curl position by extending the bucketcylinder. This is an inherent part of thedesign of the original equipment.

Since the hydraulic coupler interacts withthe arm at full-curl position to unlock thesupplemental lock, the hydraulic coupler willNOT operate properly when the bucket isattached in reverse orientation.

NOTE: The safety buzzer located on the hydraulic couplercontrol box (3) will sound to alert personnel thelock/unlock function has been activated.

1. Engage front hook (1) on pin (2). Switch on controlbox should be in UNLOCK position.

NOTE: The hydraulic coupler must be held over relief inorder to lock/unlock the hydraulic coupler cylinder.

2. Rotate to full-curl position. Press switch to LOCKposition. Hold in full-curl position for 5 seconds.

3. Slowly uncurl hydraulic coupler. Visually verifysupplemental lock contacts locking plate. Visually

TX1017663A

—UN—17JAN07

Bucket Rotated to Full-Curl Position

TX1090672A

—UN—11APR11

Hydraulic Coupler Control Box

1—Front Hook2—Pin

3—Hydraulic Coupler ControlBox

verify lock plate is behind attachment pin. Switch onthe control box should be in the LOCK position.

2-3-13 081214

PN=105


OUT4001,0000866 -19-23AUG12-2/2

IMPORTANT: Prevent possible damage to thehydraulic coupler. Do not operate attachmentwhen the supplemental lock is used as theprimary locking device. Doing so could resultin hydraulic coupler malfunction.

4. Continue to slowly uncurl hydraulic coupler. Verifyattachment is properly locked. Switch on the controlbox should be in LOCK position.

2-3-14 081214

PN=106


Continued on next page OUT4001,0000867 -19-19MAR12-1/2

Unlocking the Hydraulic Coupler From the Attachment—If Equipped

TX1017663A

—UN—17JAN07

Bucket Rotated to Full-Curl Position

TX1017662A

—UN—17JAN07

Hydraulic Coupler Pin

CAUTION: Prevent possible injury or death fromunexpected hydraulic coupler movement. Makesure hydraulic coupler is attached correctlyto attachment. The supplemental lock can beengaged with the attachment in an incorrectlock position. A visual check is required eachtime the lock operation is performed.

CAUTION: Avoid personal injury. Preventinjury from hydraulic coupler movement. Keepbystanders clear of machine.

IMPORTANT: Prevent possible hydraulic couplerdamage from incorrect installation. Attachingthe bucket in a reverse orientation on thehydraulic coupler is not recommended.When installed in the reverse orientation,the bucket or the lift hook interferes withthe arm of the excavator when the bucket isin full-curl position by extending the bucketcylinder. This is an inherent part of thedesign of the original equipment.

Since the hydraulic coupler interacts withthe arm at full-curl position to unlock thesupplemental lock, the hydraulic coupler willNOT operate properly when the bucket isattached in reverse orientation.

1. Keep attachment close to ground. Switch should be inLOCK position.

NOTE: The hydraulic coupler must be held over relief inorder to unlock the hydraulic coupler cylinder.

2. Rotate hydraulic coupler to full-curl position to releasesupplemental lock. Switch should be in LOCK position.

NOTE: The safety buzzer located on the hydraulic couplercontrol box (3) will sound to alert personnel thelock/unlock function has been activated.

3. Press switch to UNLOCK position. Hold in full-curlposition for 5 seconds.

TX1017664A

—UN—17JAN07

Front Hook on Hydraulic Coupler

TX1090672A

—UN—11APR11

Hydraulic Coupler Control Box

1—Front Hook2—Pin

3—Hydraulic Coupler ControlBox

2-3-15 081214

PN=107


OUT4001,0000867 -19-19MAR12-2/2

OUT4001,0000868 -19-24AUG12-1/1

4. Slowly uncurl hydraulic coupler. Front hook (1) willrelease from pin (2). Switch should be in UNLOCKposition.

Control Lever Pattern Operation

CAUTION: Avoid personal injury from unexpectedmachine movement. Never place any part ofbody beyond window frame to avoid seriouscrushing injury from boom. Boom could lowerif the control lever is accidentally bumpedor otherwise engaged. Immediately replacea missing or broken window.

Prevent injury from unexpected control leverfunction. Be aware of the control lever patternused on the machine before operating.

The machine comes equipped from the factory with theexcavator control lever pattern. A label, with both theexcavator and backhoe control lever patterns, is installedon the right cab window.

Check the patterns on the label, and then carefully operatethe control levers to verify the pattern on machine.

To change the pattern from excavator to backhoe, seeControl Lever Pattern Conversion in this section.

NOTE: A control pattern selector is an available field kit,that when installed, allows operator to change thecontrol lever pattern using a mechanical valve.

Control levers return to neutral when released. Functionswill stop and remain positioned. The parking brake forswing and travel will engage.

1—Arm Out2—Arm In3—Swing Left4—Swing Right

5—Boom Down6—Boom Up7—Bucket Curl8—Bucket Dump

T137500—UN—25JAN01

Excavator Control Lever Pattern

T137498—UN—25JAN01

Backhoe Control Lever Pattern

T137499—UN—25JAN01

Boom, Arm, Bucket Movement

2-3-16 081214

PN=108


DB84312,000003F -19-23NOV11-1/1

Mechanical Control Lever PatternSelector—If EquippedThe machine pilot control levers can be changed from thestandard EXCAVATOR control pattern (1) to a BACKHOEcontrol pattern (2). To change control pattern:

1. Park machine on a level surface.

2. Run engine at slow idle speed without load for 3minutes.

3. Place pilot shutoff lever in the locked (UP) position.

4. Turn key switch to OFF position to stop engine.Remove key from switch.

5. Open the left service door to access the mechanicalcontrol lever pattern selector.

6. Remove tie band (3).

7. Remove locking screw (4).

8. Turn selector lever to the standard EXCAVATORcontrol pattern or BACKHOE control pattern.

9. Install tie band.

TX1102031A

—UN—29NOV11

Mechanical Control Lever Pattern Selector

1—EXCAVATOR ControlPattern

2—BACKHOE Control Pattern

3—Tie Band4—Locking Screw

2-3-17 081214

PN=109


MM16284,0001B12 -19-22AUG13-1/1

Control Lever Pattern Conversion1. Park and prepare machine for service.

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

2. Release hydraulic oil tank pressure by pushingpressure release button on top of hydraulic oil tank.

NOTE: When going from excavator to backhoe pattern,moving boom up (A) hose to arm in (D) port,a fabricated hose size -6 JIC male x femaleapproximately 150 mm (6 in.) long, is needed.

3. Switch pilot line boom up (A) with arm in (D) port.Switch pilot line boom down (B) with arm out (C) port.

4. To view control lever patterns, see Control LeverPattern Operation in this section.

EXCAVATOR PATTERNPILOT SIGNAL MANIFOLD

FUNCTIONS PILOT CONTROLVALVE SIDE

CONTROLVALVE SIDE

BUCKET DUMP H 8BOOM DOWN B 2BUCKET CURL G 7BOOM UP A 1

Right

SWING RIGHT F 6ARM OUT C 3

SWING LEFT E 5Left

ARM IN D 4NOTE: LETTERS AND NUMBERS ARE ONTHE HOUSINGS NEXT TO THE PORTS

B

A

D

C

41

TX1137117—UN—17JU

N13

Pilot Control Valve Side

41— Pilot Signal Manifold (pilotcontrol valve side)

A—Boom UpB—Boom Down

C—Arm OutD—Arm In

BACKHOE PATTERNPILOT SIGNAL MANIFOLD

FUNCTIONS PILOT CONTROLVALVE SIDE

CONTROLVALVE SIDE

BUCKET DUMP H 8ARM OUT C 3

BUCKET CURL G 7ARM IN D 4

Right

SWING RIGHT F 6BOOM DOWN B 2SWING LEFT E 5

Left

BOOM UP A 1NOTE: LETTERS AND NUMBERS ARE ONTHE HOUSINGS NEXT TO THE PORTS

2-3-18 081214

PN=110


ER79617,0000DB3 -19-27MAY11-1/1

VD76477,00001F4 -19-09JAN12-1/1

ER79617,0000DD6 -19-19MAR12-1/1

Operating in Water and MudBe careful not to operate the machine in water or mudabove the upper deck surface of the undercarriage,causing the swing bearing and rotary manifold to besubmerged.

If the swing bearing and rotary manifold are submerged,remove cover from underneath center of machine.Remove drain plug (1) to drain water and mud.

Clean swing gear area. Install plug and cover. Lubricateswing gear and swing bearing.

1—Drain Plug

TX1086781A

—UN—11JAN11

Drain Plug (view from underneath)

Driving Up a Steep or Slippery Slope

CAUTION: Prevent possible injury from machineroll-over. Use this technique only on a short slope.Machine depends on support of boom/arm/bucketduring entire procedure until machine reachestop of slope. Repositioning the bucket duringthis procedure is NOT recommended. DO NOTswing upperstructure during this procedure. DONOT reposition bucket during this procedure.

1. Wear seat belt.

2. Position undercarriage so travel motors will be onuphill end of machine.

3. Push bucket into the ground.

4. When boom is on uphill end of machine; pull machineusing boom and arm cylinder to help travel motors.

When boom is on downhill end of machine; pushmachine using boom and arm cylinder to help travelmotors.

Lifting

CAUTION: Avoid possible injury from unexpectedmachine movement. Lifting requires special care.Observe these rules when lifting with themachine:

• Never use machine to lift people.• Do not exceed lift capacity limits.• Keep everyone clear of raised loads.• Never attach sling or chain to bucket teeth.• Use tether lines to guide loads.• Use hand signals to communicate with others.

NOTE: For buckets without a loop, see yourauthorized dealer.

1. Use proper rigging to attach and stabilize loads.

2. Curl bucket and retract arm. Fasten sling or chain tobucket loop (1).

3. Check stability by carefully doing a trial lift:

• Raise load just off of ground.• Swing load all the way to one side.• Move load slowly away from machine.• Lower load immediately if machine is not stable.

TX1087169A

—UN—20JAN11

Bucket Loop

1—Bucket Loop

2-3-19 081214

PN=111


DB84312,0000088 -19-04MAR14-1/1

Lower Boom With Engine StoppedWhen an engine stops during operation, the boom cannotbe lowered using the pilot controller because there is nopilot pressure oil to move the boom valve spool.

CAUTION: Prevent possible injury fromunexpected machine movement. Clear allpersons from the area before lowering theboom with the engine stopped.

1. Remove control valve access cover.

CAUTION: To avoid injury from escaping oilunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

IMPORTANT: Never loosen screw more than twoturns as screw may come off.

2. Loosen nut (1). Loosen boom manual lower screw(2) 1/2 turn. The boom will start to lower. Theboom lowering speed can be somewhat adjusted byloosening screw more.

3. After the bucket is lowered to the ground, tightenscrew, then nut to specifications.

SpecificationHex Key Wrench—Size................................................................... 4 mmScrew—Torque.............................................................................7.0 N·m

5.2 lb.-ft.Nut (1)—Torque..........................................................................13.0 N·m

9.4 lb.-ft.

1—Nut 2—Boom Manual Lower Screw

X9811

—UN—23AUG88

Lower Boom with Engine Stopped

TX1000642—UN—29NOV05

Control Valve-Right Side Shown

2-3-20 081214

PN=112


ER79617,0000DCF -19-09JAN12-1/1

Parking the Machine

IMPORTANT: During freezing weather, preventdamage to undercarriage components fromfrozen mud and dirt. Machine must beparked on a solid level surface to preventtracks freezing in the ground.

1. Park machine on a solid level surface.

During freezing weather, clean mud and dirt fromtracks, rollers and track frames. Clean the steps andwalkways after parking the machine.

If tracks are frozen in the ground, slowly raise themachine using boom to free the tracks. Move machinecarefully.


3. Turn auto-idle switch (1) to the A/I OFF position.

IMPORTANT: Turbocharger can be damagedif procedure to shutdown engine is notdone properly.

4. Run engine with engine speed dial (2) at 1/3 positionwithout load for 2 minutes.

5. Turn engine speed dial to slow idle position.

6. Turn key switch (3) to the OFF position. Remove keyfrom switch.

7. Place pilot shutoff lever (4) to locked (UP) position.

IMPORTANT: Prevent cab electrical componentdamage from bad weather. Windows, roofvent, and cab door must be closed toprevent rain from entering.

8. Close windows, roof vent, and cab door.

9. Lock all access doors and compartments.

TX1087012A

—UN—18JAN11

Switch Panel

TX1087013A

—UN—18JAN11

Pilot Shutoff Lever

1—Auto-Idle Switch2—Engine Speed Dial

3—Key Switch4—Pilot Shutoff Lever

2-3-21 081214

PN=113


ER79617,0000D83 -19-19MAR12-1/1

Loading and Unloading for Transport

CAUTION: Use extra care to prevent tipoveror unexpected movement when loading andunloading machine for transport. Observe theserules when loading and unloading machine:

• Keep the trailer bed clean.• Locate trailer on a level and stable surface.• Chock trailer wheels.• Always wear seat belt.• Use loading ramps. Keep ramps at a lowangle and firmly attached to trailer.• Turn auto-idle switch to the A/I OFF position.Use slow speed operating modes andmove machine carefully.

1. When loading machine, use bucket for support withangle of arm to boom at 90° (1).

IMPORTANT: Prevent machine or trailer damage. DONOT allow machine or bucket to impact trailer.

2. Position machine on trailer as shown. Fasten machineto trailer at designated tie down (2) areas.

3. When unloading machine, use bucket for support withangle of arm to boom at 90°.

1—90° Arm to Boom 2—Tie Down (4 used)

T137507—UN—25JAN01

Loading Machine On A Trailer

T7405B

J—UN—29NOV90

Moving Machine On Trailer

TX1086371A

—UN—03JAN11

Tie Downs (front side shown)

T137505—UN—25JAN01

Unloading Machine From A Trailer

2-3-22 081214

PN=114


ER79617,0000A94 -19-09JAN12-1/1

JS93577,00008EC -19-02APR14-1/1

Towing Machine

CAUTION: Prevent possible injury fromunexpected machine movement. Blockboth tracks when disconnecting travelgear cases. When travel gear cases aredisconnected, machine has no brakes andcan move. The machine will roll free on aslope or while being towed.

1. Block tracks.

2. Drain oil from each travel gear case.

3. Remove cover from each gear case.

4. Remove sun gear (1) from each gear case.

5. Install cover. Fill gear case with oil.

T137511—UN—25JAN01

Sun Gear

1—Sun Gear

Lifting the Machine

CAUTION: Prevent possible injury fromunexpected machine movement when liftingthe machine. Check lifting capacity of cranebefore lifting the excavator. Lift load onlyas high as necessary.

Keep all people clear of raised load.

NOTE: The center of gravity (2) will vary dependingon the kind of attachment.

NOTE: Refer to decals on machine for correct liftpoints (1). There are 2 lift points on eachside of the undercarriage.

1. Fully extend boom, arm, and bucket cylinders.

2. Position boom straight ahead of the upperstructure.

3. Turn key switch to OFF. Remove key from switch.

4. Pull pilot control shutoff lever to locked position.

5. Route appropriate lifting device through lifting points (1)and under both sides of the track frame as illustrated.

6. Attach appropriate lifting device to crane.

7. Slowly lift machine.

TX1156707—UN—27MAR14

Lifting Machine

1—Lifting Points2—Center of Gravity

3—Support Bar

Specification160GLC —ApproximateWeight...................................................................................... 18 017 kg

39 685 lb.

Specification180GLC—ApproximateWeight...................................................................................... 20 120 kg

44 317 lb.

2-3-23 081214

PN=115

Maintenance—Machine

DX,FUEL1 -19-17JUN13-1/1

OUT4001,000060A -19-10JAN12-1/1

Diesel Fuel

Consult your local fuel distributor for properties of thediesel fuel available in your area.

In general, diesel fuels are blended to satisfy the lowtemperature requirements of the geographical area inwhich they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 arerecommended. Renewable diesel fuel produced byhydrotreating animal fats and vegetable oils is basicallyidentical to petroleum diesel fuel. Renewable diesel thatmeets EN 590 or ASTM D975 is acceptable for use at allpercentage mixture levels.

Required Fuel Properties

In all cases, the fuel shall meet the following properties:

Cetane number of 43 minimum. Cetane number greaterthan 47 is preferred, especially for temperatures below–20 °C (–4 °F) or elevations above 1500 m (5000 ft.).

Cold Filter Plugging Point (CFPP) should be at least 5°C (9 °F) below the expected lowest temperature or CloudPoint below the expected lowest ambient temperature.

Fuel lubricity should pass a maximum scar diameter of0.52 mm as measured by ASTM D6079 or ISO 12156-1.A maximum scar diameter of 0.45 mm is preferred.

Diesel fuel quality and sulfur content must comply withall existing emissions regulations for the area in whichthe engine operates. DO NOT use diesel fuel with sulfurcontent greater than 10000 mg/kg (10000 ppm).

Sulfur content for Interim Tier 4, Final Tier 4,Stage III B, and Stage IV Engines

• Use ONLY ultra low sulfur diesel (ULSD) fuel with amaximum of 15 mg/kg (15 ppm) sulfur content.

Sulfur Content for Tier 3 and Stage III A Engines

• Use of diesel fuel with sulfur content less than 1000mg/kg (1000 ppm) is RECOMMENDED.• Use of diesel fuel with sulfur content 1000—2000 mg/kg(1000—2000 ppm) REDUCES the oil and filter changeinterval.

• BEFORE using diesel fuel with sulfur content greaterthan 2000 mg/kg (2000 ppm), contact your John Deeredealer.

Sulfur Content for Tier 2 and Stage II Engines

• Use of diesel fuel with sulfur content less than 2000mg/kg (2000 ppm) is RECOMMENDED.• Use of diesel fuel with sulfur content 2000—5000 mg/kg(2000—5000 ppm) REDUCES the oil and filter changeinterval.• BEFORE using diesel fuel with sulfur content greaterthan 5000 mg/kg (5000 ppm), contact your John Deeredealer.

Sulfur Content for Other Engines

• Use of diesel fuel with sulfur content less than 5000mg/kg (5000 ppm) is RECOMMENDED.• Use of diesel fuel with sulfur content greater than 5000mg/kg (5000 ppm) REDUCES the oil and filter changeinterval.

IMPORTANT: Do not mix used diesel engine oil or anyother type of lubricating oil with diesel fuel.

Improper fuel additive usage may cause damageon fuel injection equipment of diesel engines.

Diesel Fuel SpecificationsThe engine in this machine is designed to operate onlywith ultra low sulfur diesel (ULSD) fuel. Use of fuelother than ULSD will reduce the efficiency and durabilityof the engine, will harm and permanently damage the

engine’s advanced emissions control systems, reducefuel economy, and possibly prevent the engine fromrunning at all. Emission-related warranties are likely tobe rendered void by the use of fuel that does not meetthese specifications.

3-1-1 081214

PN=116


DX,FUEL5 -19-07FEB14-1/1

DX,FUEL4 -19-15FEB13-1/1

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States,Canada, and the European Union have adequate lubricityto ensure proper operation and durability of fuel injectionsystem components. However, diesel fuels manufacturedin some areas of the world may lack the necessary lubricity.

IMPORTANT: Make sure the diesel fuel usedin your machine demonstrates goodlubricity characteristics.

Fuel lubricity should pass a maximum scar diameter of0.52 mm as measured by ASTM D6079 or ISO 12156-1.A maximum scar diameter of 0.45 mm is preferred.

If fuel of low or unknown lubricity is used, add John DeereFuel-Protect Diesel Fuel Conditioner (or equivalent) atthe specified concentration.

Lubricity of BioDiesel Fuel

Fuel lubricity can improve significantly with BioDieselblends up to B20 (20% BioDiesel). Further increase inlubricity is limited for BioDiesel blends greater than B20.

Handling and Storing Diesel Fuel

CAUTION: Reduce the risk of fire. Handle fuelcarefully. DO NOT fill the fuel tank when engineis running. DO NOT smoke while you fill thefuel tank or service the fuel system.

Fill the fuel tank at the end of each day's operation toprevent water condensation and freezing during coldweather.

Keep all storage tanks as full as practicable to minimizecondensation.

Ensure that all fuel tank caps and covers are installedproperly to prevent moisture from entering. Monitor watercontent of the fuel regularly.

When using BioDiesel fuel, the fuel filter may require morefrequent replacement due to premature plugging.

Check engine oil level daily prior to starting engine. Arising oil level may indicate fuel dilution of the engine oil.

IMPORTANT: The fuel tank is vented through thefiller cap. If a new filler cap is required, alwaysreplace it with an original vented cap.

When fuel is stored for an extended period or if there is aslow turnover of fuel, add a fuel conditioner to stabilize thefuel and prevent water condensation. Contact your fuelsupplier or John Deere dealer for recommendations.

3-1-2 081214

PN=117


OUT4001,0000671 -19-29MAR11-1/1

Biodiesel Fuel

Biodiesel is a fuel comprised of monoalkyl esters of longchain fatty acids derived from vegetable oils or animalfats. Biodiesel blends are biodiesel mixed with petroleumdiesel fuel on a volume basis.

Before using fuel containing biodiesel review the BiodieselUse Requirements and Recommendations in thisOperator’s Manual.

Environmental laws / regulations may encourage orprohibit the use of biofuels. Operators should consultwith appropriate governmental authorities prior to usingbiofuels.

US / Canada

While 5% blends are preferred (B5), biodieselconcentrations up to a 20% blend (B20) in petroleumdiesel fuel can be used in all John Deere engines.Biodiesel blends up to B20 can be used ONLY if thebiodiesel (100% biodiesel or B100) meets ASTM D6751(US), EN 14214 (EU), or equivalent specification. Expecta 2% reduction in power and a 3% reduction in fueleconomy when using B20.

Biodiesel concentrations above B20 may harm theengine’s emission control systems and should not beused in the US and Canada. Risks may include, butnot be limited to, more frequent exhaust filter parkedcleanings, soot accumulation, and increased intervals forash removal.

Biodiesel users in the U.S. are strongly encouragedto purchase biodiesel blends from a BQ9000 CertifiedMarketer and sourced from a BQ9000 AccreditedProducer (as certified by the National Biodiesel Board).Certified Marketers and Accredited Producers can befound at the following website: http://www.bq9000.org.

Other regions

John Deere engines can operate on biodiesel blendsbelow and above B20 (up to 100% biodiesel). Operateat levels above B20 ONLY if the biodiesel meets theEN 14214 specification (primarily available in Europe).Engines operating on biodiesel blends above B20 maynot fully comply with all applicable emissions regulations.Expect up to a 12% reduction in power and an 18%reduction in fuel economy when using 100% biodiesel.John Deere approved fuel conditioners containingdetergent/dispersant additives are required.

Biodiesel Use Requirements

The petroleum diesel portion of all biodiesel blends mustmeet the requirements of ASTM D975 (US) or EN 590(EU) commercial standard.

When using biodiesel fuel, the fuel filter may require morefrequent replacement due to premature plugging. Checkengine oil level daily prior to starting engine. A rising oillevel may indicate fuel dilution of the engine oil.

John Deere approved fuel conditioners containingdetergent/dispersant additives are required when usingB20 blends and recommended when using lower biodieselblends. Biodiesel blends up to B20 must be used within90 days of the date of biodiesel manufacture. Biodieselblends above B20 must be used within 45 days from thedate of biodiesel manufacture.

Biodiesel Use Recommendations

When using biodiesel blends up to B20 the following mustbe considered:

• Cold weather flow degradation

• Stability and storage issues (moisture absorption,oxidation, microbial growth)

• Possible filter restriction and plugging (usually a problemwhen first switching to biodiesel on used engines)

Request a certificate of analysis from your fuel distributorto ensure that the fuel is compliant with the specificationsprovided in this Operator’s Manual.

Consult your John Deere dealer for approved fuelconditioners to improve storage and performance withbiodiesel fuels.

The following must also be considered when usingbiodiesel blends above B20:

• Possible coking and/or blocked injector nozzles,resulting in power loss and engine misfire if JohnDeere approved fuel conditioners containingdetergent/dispersant additives are not used

• Possible crankcase oil dilution, requiring more frequentoil changes

• Possible lacquering and/or seizure of internalcomponents

• Possible formation of sludge and sediments• Possible thermal oxidation of fuel at elevatedtemperatures

• Possible compatibility issues with other materials(including copper, lead, zinc, tin, brass, and bronze)used in fuel handling equipment

• Possible reduction in water separator efficiency• Possible damage to paint if exposed to biodieselIMPORTANT: Raw pressed vegetable oils are

NOT acceptable for use as fuel in anyconcentration in John Deere engines. Theiruse could cause engine failure.

3-1-3 081214

PN=118


DX,FUEL6 -19-14APR11-1/1

DX,FILT2 -19-14APR11-1/1

Testing Diesel FuelA fuel analysis program can help to monitor the qualityof diesel fuel. The fuel analysis can provide criticaldata such as cetane number, fuel type, sulfur content,water content, appearance, suitability for cold weather

operations, bacteria, cloud point, acid number, particulatecontamination, and whether the fuel meets specification.

Contact your John Deere dealer for more information ondiesel fuel analysis.

Fuel FiltersThe importance of fuel filtration cannot be overemphasizedwith modern fuel systems. The combination of increasinglyrestrictive emission regulations and more efficient enginesrequires fuel system to operate at much higher pressures.Higher pressures can only be achieved using fuel injectioncomponents with very close tolerances. These close

manufacturing tolerances have significantly reducedcapacities for debris and water.

John Deere brand fuel filters have been designed andproduced specifically for John Deere engines.

To protect the engine from debris and water, alwayschange engine fuel filters as specified in this manual.

3-1-4 081214

PN=119


DB84312,0000035 -19-08MAY12-1/1

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere diesel engines are designed to operateeffectively in cold weather.

However, for effective starting and cold weather operation,a little extra care is necessary. The following informationoutlines steps that can minimize the effect that coldweather may have on starting and operation of yourengine. See your John Deere dealer for additionalinformation and local availability of cold weather aids.

Use Winter Grade Fuel

When temperatures fall below 0°C (32°F), winter gradefuel (No. 1D in North America) is best suited for coldweather operation. Winter grade fuel has a lower cloudpoint and a lower pour point.

Cloud point is the temperature at which wax will begin toform in the fuel and this wax causes fuel filters to plug.Pour point is the lowest temperature at which movementof the fuel is observed.

NOTE: On an average, winter grade diesel fuel has a lowerBTU (heat content) rating. Using winter grade fuelmay reduce power and fuel efficiency, but should notcause any other engine performance effects. Checkthe grade of fuel being used before troubleshootingfor low power complaints in cold weather operation.

Air Intake Heater

An air intake heater is an available option for someengines to aid cold weather starting.

CAUTION: Ether is highly flammable. Do notuse ether when starting an engine equippedwith glow plugs or an air intake heater.

Coolant Heater

An engine block heater (coolant heater) is an availableoption to aid cold weather starting.

Seasonal Viscosity Oil and Proper CoolantConcentration

Use seasonal grade viscosity engine oil based on theexpected air temperature range between oil changesand a proper concentration of low silicate antifreeze asrecommended. (See Diesel Engine Oil and Heavy DutyDiesel Engine Coolant in this section.)

Diesel Fuel Flow Additive

Use John Deere PREMIUM DIESEL FUELCONDITIONER (winter formula), which contains antigel

chemistry, or equivalent fuel conditioner to treat non-wintergrade fuel (No. 2D in North America) during the coldweather season. This generally extends operabilityto about 10°C (18°F) below the fuel cloud point. Foroperability at even lower temperatures, use winter gradefuel.

IMPORTANT: Treat fuel when outside temperaturedrops below 0°C (32°F). For best results, usewith untreated fuel. Follow all recommendedinstructions on label.

BioDiesel

When operating with biodiesel blends, wax formationcan occur at warmer temperatures. Begin using JohnDeere PREMIUM BIODIESEL FUEL CONDITIONER(winter formula) at 5°C (41°F) to treat biodiesel fuelsduring the cold-weather season. Use B5 or lower blendsat temperatures below 0°C (32°F). Use only winter gradepetroleum diesel fuel at temperatures below -10°C (14°F).In colder weather, engines operating with biodiesel mayhave more frequent parked cleanings, soot accumulation,and increased intervals for ash removal from the exhaustfilter.

Winterfronts

Use of fabric, cardboard, or solid winterfronts is notrecommended with any John Deere engine. Their usecan result in excessive engine coolant, oil, and chargeair temperatures. This can lead to reduced engine life,loss of power and poor fuel economy. Winterfronts mayalso put abnormal stress on fan and fan drive componentspotentially causing premature failures. If winterfronts areused, they should never totally close off the grill frontalarea. Approximately 25% area in the center of the grillshould remain open at all times. At no time should the airblockage device be applied directly to the radiator core.

Radiator Shutters

If equipped with a thermostatically controlled radiatorshutter system, this system should be regulated in such away that the shutters are completely open by the time thecoolant reaches 93°C (200°F) to prevent excessive intakemanifold temperatures. Manually controlled systemsare not recommended. If air-to-air aftercooling is used,the shutters must be completely open by the time theintake manifold air temperature reaches the maximumallowable temperature out of the charge air cooler. Formore information, see your John Deere dealer.

3-1-5 081214

PN=120


DX,ALTER -19-11APR11-1/1

DX,LUBMIX -19-18MAR96-1/1

DX,LUBST -19-11APR11-1/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may requirelubricant recommendations different from those printed inthis manual.

Some John Deere brand coolants and lubricants may notbe available in your location.

Consult your John Deere dealer to obtain information andrecommendations.

Synthetic lubricants may be used if they meet theperformance requirements as shown in this manual.

The temperature limits and service intervals shown inthis manual apply to both conventional and syntheticlubricants.

Re-refined base stock products may be used if thefinished lubricant meets the performance requirements.

Mixing of Lubricants

In general, avoid mixing different brands or types of oil.Oil manufacturers blend additives in their oils to meetcertain specifications and performance requirements.

Mixing different oils can interfere with the properfunctioning of these additives and degrade lubricantperformance.

Consult your John Deere dealer to obtain specificinformation and recommendations.

Lubricant Storage

Your equipment can operate at top efficiency only whenclean lubricants are used.

Use clean containers to handle all lubricants.

Store lubricants and containers in an area protected fromdust, moisture, and other contamination. Store containerson their side to avoid water and dirt accumulation.

Make certain that all containers are properly marked toidentify their contents.

Properly dispose of all old containers and any residuallubricant they may contain.

3-1-6 081214

PN=121


OUT4001,000067D -19-31MAR11-1/1

John Deere Break-In Plus™ Engine Oil

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

Operate the engine under various conditions, particularlyheavy loads with minimal idling, to help seat enginecomponents properly.

Change the oil and filter at 250 hours maximum forBreak-In Oil or 500 hours maximum for Break-In Plus Oilduring the initial operation of a new or rebuilt engine.

After engine overhaul, fill the engine with either JohnDeere Break-In or Break-In Plus Engine Oil.

If John Deere Break-In or Break-In Plus Engine Oil is notavailable, use a 10W-30 diesel engine oil meeting one ofthe following during the first 250 hours of operation:

• API Service Classification CE• API Service Classification CD• API Service Classification CC• ACEA Oil Sequence E2• ACEA Oil Sequence E1

IMPORTANT: Do not use Plus-50™ II, Plus-50, orengine oils meeting any of the following for theinitial break-in of a new or rebuilt engine:

API CJ-4 ACEA E9API CI-4 PLUS ACEA E7API CI-4 ACEA E6API CH-4 ACEA E5API CG-4 ACEA E4API CF-4 ACEA E3API CF-2API CF

These oils will not allow the engine tobreak in properly.

John Deere Break-In Plus Engine Oil can be used for allJohn Deere diesel engines at all emission certificationlevels.

After the break-in period, use John Deere Plus-50 II, JohnDeere Plus-50, or other diesel engine oil as recommendedin this manual.

Break-In is a trademark of Deere & Company.Break-In Plus is a trademark of Deere & CompanyPlus-50 is a trademark of Deere & Company.

3-1-7 081214

PN=122


VD76477,00004E6 -19-23MAY12-1/1

Diesel Engine Oil—Interim Tier 4 and StageIII B EnginesUse oil viscosity based on the expected air temperaturerange during the period between oil changes.

John Deere Plus-50™ II is the recommendedengine oil.

Extended service intervals may apply when John DeerePlus-50 II engine oil is used. Refer to the engine oil draininterval table and consult your John Deere dealer for moreinformation.

If John Deere Plus-50 II engine oil is not available, engineoil meeting one or more of the following may be used:

• API Service Category CJ-4• ACEA Oil Sequence E9• ACEA Oil Sequence E6

DO NOT use engine oil containing more than 1.0%sulfated ash, 0.12% phosphorus, or 0.4% sulfur.

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must complywith all existing emissions regulations for the area inwhich the engine operates.

IMPORTANT: Use only ultra low sulfur diesel(ULSD) fuel with a maximum sulfur contentof 15 mg/kg (15 ppm).

-40˚C

-30˚C

-20˚C

-10˚C

0˚C

10˚C

20˚C

30˚C

40˚C

50˚C

-40˚F

-22˚F

-4˚F

14˚F

32˚F

50˚F

68˚F

86˚F

104˚F

122˚F

SA

E 1

5W-4

0

SA

E 1

0W-4

0

SA

E 1

0W-3

0

SA

E 0

W-4

0

SA

E 5

W-3

0

TX1114353—UN—22MAY

12

Oil Viscosities for Air Temperature Ranges

Plus-50 is a trademark of Deere & Company

3-1-8 081214

PN=123


DX,ENOIL15,IT4,120toMAX -19-07FEB14-1/1

DX,FILT1 -19-11APR11-1/1

Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and StageIV Engines

Recommended oil and filter service intervals are basedon a combination of oil pan capacity, type of engine oiland filter used, and sulfur content of the diesel fuel.Actual service intervals also depend on operation andmaintenance practices.

Use oil analysis to evaluate the condition of the oil and toaid in selection of the proper oil and filter service interval.Contact your John Deere dealer for more information onengine oil analysis.

Change the oil and oil filter at least once every 12 monthseven if the hours of operation are fewer than the otherwiserecommended service interval.

Diesel fuel sulfur content affects engine oil and filterservice intervals. Higher fuel sulfur levels reduce oil andfilter service intervals.

Use of diesel fuel with sulfur content less than 15 mg/kg(15 ppm) is REQUIRED.

IMPORTANT: To avoid engine damage:

• Reduce oil and filter service intervals by 50%when using BioDiesel blends greater than B20.Oil analysis may allow longer service intervals.

• Use only approved oil types.

Approved Oil Types:

• John Deere Plus-50™ II• “Other Oils” include API CJ-4, ACEA E9, and ACEA E6

NOTE: The 500 hour extended oil and filter changeinterval is only allowed if all of the followingconditions are met:

• Use of diesel fuel with sulfur content lessthan 15 mg/kg (15 ppm)• Use of John Deere Plus-50™ II oil• Use of an approved John Deere oil filter

Engine Oil and Filter Service IntervalsJohn Deere Plus-50™ II 500 hoursOther Oils 250 hoursOil analysis may extend the service interval of “Other Oils” to amaximum not to exceed the interval of Plus-50™ II oils.

Plus-50 is a trademark of Deere & Company

Oil FiltersFiltration of oils is critically important for proper operationand lubrication. John Deere brand oil filters have beendesigned and produced specifically for John Deereapplications.

John Deere filters adhere to engineering specifications forquality of the filter media, filter efficiency rating, strength

of the bond between the filter media and the element endcap, fatigue life of the canister (if applicable), and pressurecapability of the filter seal. Non-John Deere branded oilfilters might not meet these key John Deere specifications.

Always change oil filters regularly as specified in thismanual.

3-1-9 081214

PN=124


ER79617,0000E41 -19-29APR14-1/1

Hydraulic OilIMPORTANT: This machine is factory filled with Super

EX 46HN extended life zinc-free hydraulic oil.

DO NOTMIX ZINC-BASED AND ZINC-FREE OILS.

Flushing system is required when changingfrom zinc-free to zinc-based oils. Contactauthorized dealer for the flushing procedure.

Avoid mixing different brands of oils. Oilmanufacturers engineer their oils to meetcertain specifications and requirements.Mixing different oils can degrade lubricantand machine performance.

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

Low Temperature Operation

• Do not mix zinc-based and zinc-free oils.• A preferred ISO 32 hydraulic oil may be added to themachine for low temperature operations. Hydraulicsystem oil viscosity must be 32Cst at 40°C minimumand must not be operated when ambient temperatureexceeds 30°C (86°F).• When switching back to warm weather operation apreferred ISO46 hydraulic oil may be added to themachine. The hydraulic system oil viscosity must be40Cst at 40°C minimum and must not be operatedwhen ambient temperature exceeds 40°C (104°F).

Seasonal Hydraulic Flushing

• Do not mix zinc-based and zinc-free oils.• Two hydraulic tank flushes are required when changinghydraulic oils for seasonal operation. Drain and refilltank with new oil (ISO32-cold, ISO46-warm.). Operatemachine to mix oil in system. Drain and refill tank again.Check oil viscosity.

The following oil is preferred:

5000 hour change interval:

• Zinc-Free Super EX 46HN oil from John Deere


• Zinc-Free Daphne Super Hydro A 32 (For lowtemperature operation.)

-40˚C

-30˚C

-20˚C

-10˚C

0˚C

10˚C

20˚C

30˚C

40˚C

50˚C

-40˚F

-22˚F

-4˚F

14˚F

32˚F

50˚F

68˚F

86˚F

104˚F

122˚F

Pre

miu

m A

W 4

6

Dap

hn

e S

up

er H

ydro

A 3

2

Pre

miu

m A

W32

Su

per

EX

46H

N

TX1079198—UN—24JU

N10

Hydraulic Oil


IMPORTANT: Avoid damage to the machine.Zinc-based oils must not be mixed with 2500hour and 5000 hour zinc-free oils.

The following products may be zinc-based and can beused provided a complete hydraulic system flush hasbeen performed. Contact your dealer for this procedure.

Premium AW oil: AW46 or AW32 (for low temperatureoperation)

Biodegradable Hydraulic Oil:

IMPORTANT: Other fire resistant and readilybiodegradable oil (also called FR oils) arenot approved in John Deere Constructionand Forestry equipment.

Use only Exxon Mobil EAL Envirosyn 46H SyntheticEsther Oil when a biodegradable oil is required. (Contactyour John Deere dealer for Registration and Routine OilAnalysis to meet warranty requirements.)

3-1-10 081214

PN=125


VD76477,00001F6 -19-29APR14-1/1

DB84312,000008E -19-29APR14-1/1

Swing Gear Case and Travel Gear Case OilsUse oil viscosity based on the expected air temperaturerange during the period between oil changes.

The following oils are preferred:

• John Deere GL-5 Gear Lubricant• John Deere EXTREME-GARD™Other oils may be used if they meet the following:

• API Service Category GL-5

TS1653

—UN—14MAR96

Swing Gear Case Oil

EXTREME-GARD is a trademark of Deere & Company

Pump Drive Gear Case OilIMPORTANT: This machine can use 15W/40 engine oil

or 80/90 gear oil in the pump drive gear case.

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

The following oil is preferred:

• John Deere Plus-50™ II

The following oil is also recommended:

• John Deere Torq-Gard™

Other oils may be used if they meet one or more of thefollowing:

• API Service Category CI-4• API Service Category CH-4• API Service Category CG-4

T197398—UN—21JAN04

Pump Gear Case Oil

Plus-50 is a trademark of Deere & CompanyTorq-Gard is a trademark of Deere & Company

3-1-11 081214

PN=126


OUT4001,00007D4 -19-21AUG12-1/1

Track Adjuster, Working Tool Pivot, SwingBearing, and Swing Bearing Gear GreaseUse grease based on NLGI consistency numbers and theexpected air temperature range during the service interval.

The following grease is preferred:

• John Deere SD Polyurea Grease

The following greases are also recommended:

• John Deere HD Lithium Complex Grease• John Deere HD Water Resistant Grease• John Deere GREASE-GARD™Other greases may be used if they meet the following:

• NLGI Performance Classification GC-LBIMPORTANT: Some types of grease thickener are not

compatible with others. Consult your greasesupplier before mixing different types of grease.

TS1673

—UN—31OCT03

Gear Grease

GREASE-GARD is a trademark of Deere & Company

3-1-12 081214

PN=127


DX,COOL3 -19-15MAY13-1/1

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Preferred Coolants

The following pre-mix engine coolants are preferred:

• John Deere COOL-GARD™II• John Deere COOL-GARD II PG

COOL-GARD II pre-mix coolant is available in severalconcentrations with different freeze protection limits asshown in the following table.

COOL-GARD II pre-mix Freeze Protection LimitCOOL-GARD II 20/80 -9 °C (16 °F)COOL-GARD II 30/70 -16 °C (3 °F)COOL-GARD II 50/50 -37 °C (-34 °F)COOL-GARD II 55/45 -45 °C (-49 °F)

COOL-GARD II PG 60/40 -49 °C (-56 °F)COOL-GARD II 60/40 -52 °C (-62 °F)

Not all COOL-GARD II pre-mix products are available inall countries.

Use COOL-GARD II PG when a non-toxic coolantformulation is required.

Additional Recommended Coolants

The following engine coolant is also recommended:

• John Deere COOL-GARD II Concentrate in a 40—60%mixture of concentrate with quality water.

IMPORTANT: When mixing coolant concentrate withwater, do not use less than 40% or greaterthan 60% concentration of coolant. Less than40% gives inadequate additives for corrosionprotection. Greater than 60% can result incoolant gelation and cooling system problems.

Other Coolants

Other ethylene glycol or propylene glycol base coolantsmay be used if they meet the following specification:

• Pre-mix coolant meeting ASTM D6210 requirements

• Coolant concentrate meeting ASTM D6210requirements in a 40—60% mixture of concentrate withquality water

If coolant meeting one of these specifications isunavailable, use a coolant concentrate or pre-mix coolantthat has a minimum of the following chemical and physicalproperties:

• Provides cylinder liner cavitation protection according toeither the John Deere Cavitation Test Method or a fleetstudy run at or above 60% load capacity• Is formulated with a nitrite-free additive package• Protects the cooling system metals (cast iron, aluminumalloys, and copper alloys such as brass) from corrosion

Water Quality

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycol andpropylene glycol base engine coolant concentrate.

Coolant Drain Intervals

Drain and flush the cooling system and refill with freshcoolant at the indicated interval, which varies with thecoolant used.

When COOL-GARD II or COOL-GARD II PG is used, thedrain interval is 6 years or 6000 hours of operation.

If a coolant other than COOL-GARD II or COOL-GARD IIPG is used, reduce the drain interval to 2 years or 2000hours of operation.

IMPORTANT: Do not use cooling system sealingadditives or antifreeze that containssealing additives.

Do not mix ethylene glycol and propyleneglycol base coolants.

Do not use coolants that contain nitrites.

COOL-GARD is a trademark of Deere & Company

3-1-13 081214

PN=128


DX,COOL11 -19-14APR11-1/1

DX,COOL16 -19-15MAY13-1/1

Drain Intervals for Diesel Engine Coolant

Drain and flush the cooling system and refill with freshcoolant at the indicated interval, which varies with thecoolant used.

John Deere COOL-GARD™ II Premix, COOL-GARDII PG Premix and COOL-GARD II Concentrate aremaintenance free coolants for up to six years or 6000hours of operation, provided that the cooling system istopped off using only John Deere COOL-GARD II Premixor COOL-GARD II PG Premix.

Test the coolant condition annually with Coolant TestStrips designed for use with John Deere COOL-GARDII coolants. If the test strip chart indicates that additiveis required, add John Deere COOL-GARD II CoolantExtender as directed.

If John Deere COOL-GARD™ II Premix, COOL-GARD IIPG Premix, or COOL-GARD II Concentrate is used, butthe coolant is not tested OR additives are not replenishedby adding John Deere COOL-GARD II Coolant Extender,the drain interval is four years or 4000 hours of operation.This drain interval only applies to COOL-GARD II coolantsthat have been maintained within a 40—60% mixture ofconcentrate with quality water.

If a coolant other than COOL-GARD II, or COOL-GARDII PG is used, reduce the drain interval to two years or2000 hours of operation.


John Deere COOL-GARD™ II Coolant Extender

Some coolant additives gradually deplete duringengine operation. For COOL-GARD™ II pre-mix andCOOL-GARD II Concentrate, replenish coolant additivesbetween drain intervals by adding COOL-GARD II CoolantExtender.

COOL-GARD II Coolant Extender should not be addedunless indicated by COOL-GARD II Test Strips. Thesetest strips provide a simple, effective method to check thefreeze point, additive levels, and pH of your engine coolant.

Test the coolant solution at intervals of 12 months andwhenever excessive coolant is lost through leaks oroverheating.

IMPORTANT: Do not use COOL-GARD II TestStrips with COOL-GARD II PG.

COOL-GARD II Coolant Extender is a chemically matchedadditive system for use with all COOL-GARD II coolants.

COOL-GARD II Coolant Extender is not intended for usewith nitrite-containing coolants.

IMPORTANT: Do not add a supplemental coolantadditive when the cooling system is drainedand refilled with any of the following:

• John Deere COOL-GARD II• John Deere COOL-GARD II PG

The use of non-recommended supplemental coolantadditives can result in additive drop-out, gelation of thecoolant, or corrosion of cooling system components.

Add the recommended concentration of COOL-GARDII Coolant Extender. DO NOT add more than therecommended amount.


3-1-14 081214

PN=129


DX,COOL4 -19-14APR11-1/1

DX,COOL6 -19-15MAY13-1/1

Supplemental Coolant Additives

Some coolant additives will gradually deplete duringengine operation. For nitrite-containing coolants,replenish coolant additives between drain intervals byadding a supplemental coolant additive as determinednecessary by coolant testing.

John Deere Liquid Coolant Conditioner is recommendedas a supplemental coolant additive for nitrite-containingcoolants.

John Deere Liquid Coolant Conditioner is not designedfor use with John Deere COOL-GARD™ II Premix,COOL-GARD II PG Premix, or COOL-GARD IIConcentrate.

IMPORTANT: Do not add a supplemental coolantadditive when the cooling system is drainedand refilled with any of the following:

• John Deere COOL-GARD II• John Deere COOL-GARD II PG

If other coolants are used, consult the coolant supplierand follow the manufacturer's recommendation for use ofsupplemental coolant additives.

The use of non-recommended supplemental coolantadditives may result in additive drop-out and gelation ofthe coolant.

Add the manufacturer's recommended concentration ofsupplemental coolant additive. DO NOT add more thanthe recommended amount.


Operating in Warm Temperature Climates

John Deere engines are designed to operate usingrecommended engine coolants.

Always use a recommended engine coolant, even whenoperating in geographical areas where freeze protectionis not required.

IMPORTANT: Water may be used as coolant inemergency situations only.

Foaming, hot surface aluminum and ironcorrosion, scaling, and cavitation occur whenwater is used as the coolant, even whencoolant conditioners are added.

Drain cooling system and refill withrecommended engine coolant as soonas possible.

3-1-15 081214

PN=130


DX,COOL17 -19-20APR11-1/1

Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™II Coolant Extender

Engine coolants are a combination of three chemicalcomponents: ethylene glycol (EG) or propylene glycol(PG) antifreeze, inhibiting coolant additives, and qualitywater.

Coolant Specifications

John Deere COOL-GARD™ II Premix either EG orPG, are fully formulated coolants that contain all threecomponents in their correct concentrations. DO NOTadd an initial charge of John Deere COOL-GARD IICoolant Extender to COOL-GARD II Premix. DO NOTadd any other supplemental coolant additive or water toCOOL-GARD II Premix.

John Deere COOL-GARD II Concentrate contains bothethylene glycol and inhibiting coolant additives. Mix thisproduct with quality water, but DO NOT add an initialcharge of John Deere COOL-GARD II Coolant Extenderor any other supplemental coolant additive.

Replenish Coolant Additives

Some coolant additives will gradually deplete duringengine operation. Periodic replenishment of inhibitorsis required, even when John Deere COOL-GARD IIPremix or COOL-GARD II Concentrate is used. Followthe recommendations in this manual for the use of JohnDeere COOL-GARD II Coolant Extender.

Why use John Deere COOL-GARD II CoolantExtender?

Operating without proper coolant additives will result inincreased corrosion, cylinder liner erosion and pitting, andother damage to the engine and cooling system. A simplemixture of ethylene glycol or propylene glycol and waterwill not give adequate protection.

John Deere COOL-GARD II Coolant Extender is achemically matched additive system designed to fortify theproprietary additives used in John Deere COOL-GARD IIPremix and COOL-GARD II Concentrate and to provideoptimum protection for up to six years or 6000 hours ofoperation.

Avoid Automotive-type Coolants

Never use automotive-type coolants (such as thosemeeting ASTM D3306). These coolants do not contain thecorrect additives to protect heavy-duty diesel engines. Donot treat an automotive engine coolant with supplementalcoolant additives because the high concentration ofadditives can result in additive fallout.

Water Quality

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycoland propylene glycol base engine coolant concentrate.Allwater used in the cooling system should meet thefollowing minimum specifications for quality:Chlorides <40 mg/LSulfates <100 mg/LTotal dissolved solids <340 mg/LTotal hardness <170 mg/LpH 5.5 to 9.0

Freeze Protection

The relative concentrations of glycol and water in theengine coolant determine its freeze protection limit.

Ethylene Glycol Freeze Protection Limit40% -24°C (-12°F)50% -37°C (-34°F)60% -52°C (-62°F)

Propylene Glycol Freeze Protection Limit40% -21°C (-6°F)50% -33°C (-27°F)60% -49°C (-56°F)

DO NOT use a coolant-water mixture greater than 60%ethylene glycol or 60% propylene glycol.


3-1-16 081214

PN=131


DX,COOL9 -19-11APR11-1/1

OUT4001,0000685 -19-09JUL10-1/1

Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol andinhibiting additives in the coolant is critical to protect theengine and cooling system against freezing, corrosion,and cylinder liner erosion and pitting.

Test the coolant solution at intervals of 12 months or lessand whenever excessive coolant is lost through leaks oroverheating.

Coolant Test Strips

Coolant test strips are available from your John Deeredealer. These test strips provide a simple, effectivemethod to check the freeze point and additive levels ofyour engine coolant.

When Using John Deere COOL-GARD II

John Deere COOL-GARD II Premix™ , COOL-GARDII PG Premix and COOL-GARD II Concentrate aremaintenance free coolants for up to six years or 6000hours of operation, provided that the cooling system istopped off using only John Deere COOL-GARD II Premixor COOL-GARD II PG premix. Test the coolant conditionannually with coolant test strips designed for use withJohn Deere COOL-GARD II coolants. If the test stripchart indicates that additive is required, add John DeereCOOL-GARD II Coolant Extender as directed.

Add only the recommended concentration of John DeereCOOL-GARD II Coolant Extender. DO NOT add morethan the recommended amount.

When Using Nitrite-Containing Coolants

Compare the test strip results to the supplemental coolantadditive (SCA) chart to determine the amount of inhibitingadditives in your coolant and whether more John DeereLiquid Coolant Conditioner should be added.

Add only the recommended concentration of John DeereLiquid Coolant Conditioner. DO NOT add more than therecommended amount.

Coolant Analysis

For a more thorough evaluation of your coolant, perform acoolant analysis. The coolant analysis can provide criticaldata such as freezing point, antifreeze level, pH, alkalinity,nitrite content (cavitation control additive), molybdatecontent (rust inhibitor additive), silicate content, corrosionmetals, and visual assessment.

Contact your John Deere dealer for more information oncoolant analysis.


Disposing of CoolantImproperly disposing of engine coolant can threaten theenvironment and ecology.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

Do not pour waste onto the ground, down a drain, or intoany water source.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour authorized John Deere dealer.

TS1133

—UN—15APR13

Recycle Waste

3-1-17 081214

PN=132

Maintenance—Periodic Maintenance

DB84312,0000043 -19-12JAN12-1/1

ER79617,0000D92 -19-05JAN11-1/1

Service Machine at Specified IntervalsLubricate and make service checks and adjustments atintervals shown on the periodic maintenance chart and onthe following pages.

The periodic maintenance chart is located on the inside ofthe right service door.

Perform service on items at multiples of the originalrequirement. For example, at 500 hours also servicethose items (if applicable) listed under 250 hours, 100hours, 50 hours, and 10 hours or daily.

TX1102188A

—UN—28NOV11

Periodic Maintenance Chart

Check the Hour Meter RegularlyNOTE: Hour meter display is located in the upper

right corner of the monitor.

Hour meter (1) displays total machine operation hours.Use the hour meter to determine when your machineneeds periodic maintenance.

Turn key to the ON position to view the default screenand the hour meter.

Intervals on the periodic maintenance chart are foroperating in normal conditions. If operating the machine insevere conditions, machine should be serviced at shorterintervals.

TX1086525A

—UN—05JAN11

Hour Meter

1—Hour Meter

3-2-1 081214

PN=133


ER79617,0000D96 -19-30APR12-1/1

Prepare Machine for MaintenanceBefore performing maintenance procedures in thefollowing chapters and before leaving operator's seat,park machine as described below unless another positionis specified in the procedure.

1. Park machine on a level surface as shown.


3. Turn auto-idle switch (1) to the A/I OFF position.

IMPORTANT: Turbocharger can be damagedif procedure to shutdown engine is notdone properly.

4. Run engine with engine speed dial (2) at 1/3 positionwithout load for 2 minutes.

5. Turn engine speed dial to slow idle position.

6. Turn key switch (3) to the OFF position. Remove keyfrom switch.

7. Place pilot shutoff lever (4) to locked (UP) position.

1—Auto-Idle Switch2—Engine Speed Dial

3—Key Switch4—Pilot Shutoff Lever

T6811A

I—UN—18OCT88

Machine Position

TX1087012A

—UN—18JAN11

Switch Panel

TX1087013A

—UN—18JAN11

Pilot Shutoff Lever

3-2-2 081214

PN=134


VD76477,00001C1 -19-28MAR11-1/1

DB84312,00000A0 -19-17MAY12-1/1

DB84312,0000037 -19-29DEC11-1/1

Open Access Doors for Service

CAUTION: Prevent possible injury from doorclosing. Secure door in the OPEN position.

To hold door open, remove rod (1) from stored position (2)and insert in tab (3).

1—Rod2—Stored Position

3—Tab

T214860A

—UN—04OCT05

Access Door Hold

Open Engine Cover for Service

CAUTION: Prevent possible injury from coverclosing. Unlock latch. Pull open latch to unlockcover. Raise the cover until the end of thebar is securely locked into catch.

1. Unlock latch (1).2. Pull open latch to unlock cover.3. Raise the cover until the end of the bar is securely

locked into catch (2).

1—Latch 2—Catch

TX1086587A

—UN—06JAN11

Engine Lock (closed position shown)

TX1105218A

—UN—10JAN12

Engine Cover Catch

Fuel Tank

CAUTION: Fuel is flammable and may ignite ifspilled on hot engine. To prevent injury, handlefuel carefully. If engine is hot or running, DO NOTfill the fuel tank. DO NOT smoke while fillingfuel tank or working on fuel system.

160GLC and 180GLC—SpecificationFuel Tank—Capacity.................................................................... 320.0 L

84.5 gal.

IMPORTANT: Avoid engine damage. If machine hasrun out of fuel, engine will not start. Contactyour authorized dealer for instructions.

To avoid condensation, fill the fuel tank at the end of eachwork day. Shut off engine before filling.

3-2-3 081214

PN=135


DW90712,000076A -19-11JUN07-1/1

TX,ANALYSIS -19-20JAN11-1/1

Hydraulic Breaker and Crusher AttachmentsIMPORTANT: Avoid mixing different brands or types

of oils. Oil manufacturers engineer their oils tomeet certain specifications and performancerequirements. Mixing different oil types candegrade lubricant and machine performance.

This excavator is factory filled with Super EX46HN extended life zinc-free hydraulic oil. Avoidservicing this excavator with products that donot meet this specification. If oils have beenmixed or if alternate service oils are desired,the complete hydraulic system needs to betotally flushed by an authorized dealer.

Hydraulic breaker or crusher operation subjects themachine’s hydraulic system to possible contaminationand accelerated deterioration. The hydraulic returnfilter and hydraulic oil must be replaced more often toprevent damage to hydraulic pumps and other hydrauliccomponents. Change the hydraulic return filter and oil atthe intervals recommended below based on the amountof machine operating time the attachment is used.

NOTE: John Deere recommends the addition ofthe hydraulic filter restriction indicator kitwith the attachment.

Percentage of Operating Time Hydraulic Return Filter Hydraulic OilBreaker or Crusher Used Change Interval (hours) Change Interval (hours)

100 100 60060 150 80040 200 100020 300 1300

Fluid Analysis Program Test Kits and 3-WayCoolant Test KitFluid Analysis Program Test Kits and the 3-Way CoolantTest Kit are John Deere fluid sampling products to help youmonitor machine maintenance and system condition. Theobjective of a fluid sampling program is to ensure machineavailability when you need it and to reduce repair costs byidentifying potential problems before they become critical.

Engine, hydraulic, power train, and coolant samples shouldbe taken from each system on a periodic basis, beforea filter or fluid change interval. Certain systems requiremore frequent sampling. Consult your authorized JohnDeere dealer on a maintenance program for your specificapplication. Your authorized John Deere dealer has thesampling products and expertise to assist you in loweringyour overall operating costs through fluid sampling.

TX1003513A

—UN—20FE

B06

3-2-4 081214

PN=136


Continued on next page DB84312,000009E -19-26JUL13-1/2

Service IntervalsModel: 160GLC and 180GLC PIN/Serial Number:Hour Meter Reading:

SERVICE INTERVALSService your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 500hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours, and 10 hours or daily.

FLUID SAMPLINGFluid samples should be taken from each system at its recommended change interval prior to actually draining the fluid. Regular oil sampling willextend the operational life of your machine.

As Required□ Remove and clean fuel tank inlet screen □ Check and adjust track sag□ Check windshield washer fluid level □ Clean rear camera lens—if equipped□ Check and clean air cleaner dust unloader valve □ Add coolant extender as indicated by COOL-GARD™ II test strips□ Service exhaust filter

Every 10 Hours or Daily□ Check hydraulic tank oil level □ Check engine oil level□ Check engine coolant level □ Lubricate hydraulic coupler—if equipped

Every 50 Hours or Weekly□ Drain water and sediment from fuel tank sump □ Drain primary fuel filter and water separator□ Drain auxiliary fuel filter and water separator—if equipped □ Drain final fuel filter

Every 100 Hours□ Lubricate working tool pivots □ Inspect and re-torque track hardware

Every 250 Hours□ Check swing gear case oil level □ Check travel gear case oil level□ Check pump drive gear case oil level □ Drain water and sediment from hydraulic tank□ Check battery electrolyte level and terminals □ Take engine oil sample

Every 500 Hours□ Lubricate front end pin joints □ Lubricate swing bearing□ Lubricate swing bearing gear □ Take diesel fuel sample□ Drain and refill engine oil and replace filter □ Take swing gear case oil sample□ Replace primary fuel filter and water separator □ Take hydraulic oil sample□ Replace auxiliary fuel filter and water separator—if equipped □ Take engine coolant sample□ Replace final fuel filter □ Take travel gear case oil sample□ Check air intake hoses □ Take pump drive gear case oil sample□ Clean cab fresh air and cab recirculating air filters (replace every 6 cleanings)

Every 1000 Hours□ Drain and refill swing gear case oil □ Inspect serpentine belt□ Replace hydraulic tank oil filter □ Replace air cleaner elements□ Replace pilot oil filter □ Replace air cleaner dust unloader valve□ Drain and refill pump drive gear case oil □ Check coolant□ Remove and clean open crankcase ventilation (OCV) hose

Every 2000 Hours□ Check and adjust engine valve lash □ Drain and refill travel gear case oil□ Replace open crankcase ventilation (OCV) filter

3-2-5 081214

PN=137


DB84312,000009E -19-26JUL13-2/2

Every 5000 Hours□ Drain and refill hydraulic tank oil □ Replace hydraulic tank vent cap filter

Every 6000 Hours□ Drain, flush and refill engine cooling system


3-2-6 081214

PN=138


DB84312,00000B9 -19-12AUG14-1/1

Required PartsREQUIRED PARTS

Insure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that anyassociated parts are also on hand, i.e., filter O-rings.

DescriptionPart Number Every 250

HoursEvery 500Hours

Every 1000Hours

Every 2000Hours

Every 5000Hours

Every 6000Hours

Engine Oil Filter RE539279 1 1 1 1 1Primary Fuel Filter Element RE541922 1 1 1 1 1Final Fuel Filter Element RE544394 1 1 1 1 1Auxiliary Fuel FilterElement—If Equipped AT365870 1 1 1 1 1

Hydraulic Tank Oil Filter FYA00033065 1 1 1 1Pilot Oil Filter 4630525 1 1 1 1Primary Air Filter AT332908 1 1 1 1Secondary Air Filter AT332909 1 1 1 1Dust Unloader Valve R48568 1 1 1 1Open Crankcase Ventilation(OCV) Filter RE540710 1 1

Engine Rocker Arm Gasket R52449 1 1Hydraulic Tank Vent Cap Filter 4437838 1Diesel Particulate Filter(component of exhaust filter) RE551147 As Required

Cab Fresh Air Filter 4S00686 As RequiredCab Recirculating Air Filter 4S00685 As RequiredPlus-50™ II Engine Oil TY266741 14.5 L

(3.8 gal.)15.4 L(4.0 gal.)

15.4 L(4.0 gal.)

15.4 L(4.0 gal.)

15.4 L(4.0 gal.)

API GL-5 Gear Oil TY62961 6.2 L(1.6 gal.)

19.8 L(5.2 gal.)

6.2 L(1.6 gal.)

19.8 L(5.2 gal.)

Hitachi SUPER EX 46HNHydraulic Oil 2908-0501 125.0 L

(33.0 gal.)COOL-GARD™ II Pre-Mix TY26575 23.5 L

(6.2 gal.)Coolant Extender TY26603 As RequiredFluid Analysis Kits2

Diesel Engine Oil AT346594 1 1 1 1 1 1Hydraulic Oil AT346594 1 1 1 1 1Travel Gear Case Oil AT346594 2 2 2 2 2Swing Gear Case Oil AT346594 1 1 1 1 1Pump Drive Gear Case Oil AT346594 1 1 1 1 1Diesel Fuel AT180344 1 1 1 1 1Engine Coolant TY26873 1 1 1 1 1COOL-GARD™ II Test Strips TY26605 1 1 1 11For recommended oil viscosities based on operating temperatures, see Maintenance-Machine. (Section 3-1.)2Based on fluid analysis results, intervals may need to be adjusted for your operating conditions. Consult your local John Deere dealer.

Plus-50 is a trademark of Deere & CompanyCOOL-GARD is a trademark of Deere & Company

3-2-7 081214

PN=139

Maintenance—As Required

ER79617,0000A84 -19-19MAR12-1/1

DB84312,000003A -19-22NOV11-1/1

DB84312,000003B -19-23NOV11-1/1

Remove and Clean Fuel Tank Inlet ScreenClean fuel tank inlet screen (1) using solvent or dieselfuel to remove any debris.

Replace screen if damaged.

1—Fuel Tank Inlet Screen

T135186—UN—06NOV00

Fuel Tank Inlet Screen

Check Windshield Washer Fluid Level1. On left side of machine, open service door to access

windshield washer fluid bottle (1).

NOTE: During winter season, use all-season windshieldwasher fluid which will not freeze.

2. Check fluid level in windshield washer fluid bottle andrefill as required.

1—Windshield Washer FluidBottle

TX1101877A

—UN—22NOV11

Windshield Washer Fluid Level

Check and Clean Air Cleaner Dust UnloaderValveIMPORTANT: Avoid machine damage. A missing,

damaged, or hardened air cleaner dust unloadervalve (1) will make the dust cup precleanerineffective, causing very short element life. Valveshould suck closed above 1/3 engine speed.

NOTE: If operating in high dust conditions, squeeze dustvalve every 2 hours of operation to release dust.

1. On left side of machine, open service door to accessair cleaner dust unloader valve (1).

2. Squeeze air cleaner dust unloader valve to removedust from the air cleaner.

3. Check condition of dust unloader valve. Replace ifhardened or damaged.

TX1101878A

—UN—22NOV11

Air Cleaner Dust Unloader Valve

1—Air Cleaner Dust UnloaderValve

3-3-1 081214

PN=140


DB84312,00000A1 -19-18MAY12-1/2

DB84312,00000A1 -19-18MAY12-2/2

Check and Adjust Track SagCheck Track Sag

1. Swing upperstructure 90°, and lower bucket to raisetrack off ground.

2. Keep the angle (1) between boom and arm 90—110°,and position the bucket’s round side on the ground.

CAUTION: Prevent possible injury fromunexpected machine movement. Place blocksunder machine frame to support machinewhile measuring track sag.

3. Place blocks under machine frame to support machine.

4. Rotate track forward two full rotations and then inreverse two full rotations.

5. Measure distance (2) at middle track roller from bottomof track frame to top surface of track shoe.

SpecificationTrack—Sag.........................................................................285—320 mm

11.2—12.6 in.

1—Boom-To-Arm Angle 2—Distance

T121723—UN—10JU

N99

Machine Position

TX1103806—UN—16DEC11

Track Sag Measurement

Adjust Track Sag

IMPORTANT: Prevent possible damage to trackcomponents. DO NOT use the grease fitting onthe track adjusting cylinder for lubrication. Usethis fitting ONLY for track adjustment.

1. To tighten track, connect a grease gun to grease fitting(1) (located through access hole (4) in track frame.)Add grease until sag is within recommended limits.

CAUTION: Prevent possible injury from highpressure grease. DO NOT remove greasefitting (1) from nut (2).

2. To loosen, slowly turn nut (2) counterclockwise; greasewill escape through the bleed hole (3).

3. When amount of track sag is satisfactory, turn nutclockwise to tighten.

SpecificationNut—Torque..................................................................................90 N·m

66.4 lb.-ft.

1—Grease Fitting2—Nut

3—Bleed Hole4—Access Hole

T135187—UN—06NOV00

Grease Fitting

T135188—UN—06NOV00

Access Hole

3-3-2 081214

PN=141


ER79617,0000D75 -19-01MAR11-1/1

Clean Rear Camera Lens—If EquippedInspect camera lens (1) for any accumulation of dirt, mud,snow, ice, or debris.

CAUTION: Avoid personal injury. DO NOTclimb on machine when inspecting orcleaning rear camera lens.

NOTE: The camera lens surface is a resin product.Lightly wipe the surface with a wet, clean cloth.Never use an organic solvent.

Clean lens as necessary.

1—Camera Lens

TX1086324A

—UN—28DEC10

Rear Camera

3-3-3 081214

PN=142


DB84312,000003D -19-04JUN14-1/1

Check Coolant

CAUTION: Prevent possible injury from hotspraying fluids. Shut off engine. Remove fillercap only when cool enough to touch with barehands. Slowly loosen cap to relieve pressurebefore removing completely.

IMPORTANT: John Deere COOL-GARD™ IICoolant Extender does not protect againstfreezing. Coolant extender prevents rust,scale, and liner cavitation.

NOTE: Check coolant every 1000 hours or 1 year,or when replacing 1/3 or more of coolant. Addcoolant extender as indicated by John DeereCOOL-GARD™ II test strips.

1. Open engine cover. Remove surge tank cap (1) andtest coolant solution. Use the following kit to checkcoolant:

• COOL-GARD II Test StripsCoolant test strips provide an effective method tocheck freeze point and additive levels of enginecoolant. See your authorized dealer for COOL-GARDII test strips and follow instructions on kit.

SpecificationCooling System—Capac-ity.................................................................................................... 23.5 L

6.2 gal.

2. Add John Deere COOL-GARD II Coolant Extenderas necessary. Follow instructions on container foramount.

3. Install surge tank cap.

4. Close engine cover.


Pressurized Fluids

TX1101879A

—UN—22NOV11

Surge Tank

1—Surge Tank Cap


3-3-4 081214

PN=143


DB84312,0000056 -19-06DEC11-1/1

Service Exhaust Filter

CAUTION: Under federal, state, and/or local lawsor regulations, exhaust filter ashmay be classifiedas a hazardous waste. Hazardous waste mustbe disposed of in accordance with all applicablefederal, state and local laws or regulationsgoverning hazardous waste disposal. Only aqualified service provider should remove ashfrom the exhaust filter. See your authorized dealerfor exhaust filter ash handling and disposal.

The exhaust filter (1) is designed to retain residual ash,which is a noncombustible result of additives used incrankcase lubrication oils and the fuel. As ash levelsrise, the capacity for soot storage is reduced. Engineperformance can be reduced due to increased exhaustsystem back pressure. The residual ash must be removedfrom the filter. Ash removal is performed by removingthe exhaust filter from machine and having it cleaned byspecialized equipment or replacing the exhaust filter.

Do NOT attempt to remove exhaust filter from machine.Contact your authorized dealer to remove exhaustfilter for ash removal or replacement.

TX1102580A

—UN—02DEC11

Exhaust Filter

1—Exhaust Filter

Failure to follow the approved ash removal methods mayviolate U.S. federal, state and local hazardous wastelaws, along with damage to the exhaust filter resulting inpotential denial of the emissions warranty.

3-3-5 081214

PN=144

Maintenance—10 Hours or Daily

DB84312,000004C -19-04JUN14-1/1

Check Engine Oil LevelIMPORTANT: Prevent engine damage. DO NOT run

engine when oil level is below the ADD mark.

The most accurate oil level reading is obtained when theengine is cold before starting the engine for the day’soperation.


2. Shut off engine and allow oil to drain into oil pan for10 minutes.

3. Open engine cover to access engine.

4. Make sure dipstick (1) is fully seated.

5. Remove dipstick to check oil level.

BEFORE THE ENGINE IS STARTED: The engineis full when oil level is in the cross-hatch area (3). Itis acceptable to run the engine when the oil level isabove the ADD mark.

AFTER THE ENGINE HAS BEEN RUN: Allow the oilto drain into the oil pan for 10 minutes before checkingthe oil level. Ten minutes after shutdown the engine oillevel must be above the ADD mark.

6. If necessary, remove filler cap (2) to add oil.

IMPORTANT: If oil level is low, the engine can bedamaged. DO NOT operate the engine whenoil level is below the ADD mark.

7. If oil level is below ADD mark, add oil as necessary.See Diesel Engine Oil—Interim Tier 4 and Stage IIIB Engines. (Section 3-1.)

8. Install dipstick and close engine cover.

1—Dipstick2—Filler Cap

3—Cross-Hatch Area

TX1102463A

—UN—30NOV11

Oil Dipstick and Filler Cap

FULL

3

ADD

T216546—UN—29NOV05

Dipstick Cross-Hatch Area

3-4-1 081214

PN=145


DB84312,000003E -19-04JUN14-1/1

Check Engine Coolant Level


IMPORTANT: Avoid machine damage. Mixing differentcoolant types can degrade coolant and machineperformance. Avoid mixing different brandsor types of coolant. Coolant manufacturersengineer their coolants to meet certainspecifications and performance requirements.

1. Open engine cover and check coolant level in surgetank (1).

2. With engine cold, coolant level must be between MINCOLD and MAX COLD marks on surge tank.

3. If coolant is below MIN COLD mark, add coolant tosurge tank. See Heavy Duty Diesel Engine Coolant.(Section 3-1.)

4. If surge tank is empty, check for leaks in tank, hoses,and radiator. Repair as required, then refill withcoolant.


1—Surge Tank


Pressurized Fluids

TX1101880A

—UN—22NOV11

Surge Tank

3-4-2 081214

PN=146


DB84312,000003C -19-21MAY12-1/1

Check Hydraulic Tank Oil Level

T6811A

I—UN—18OCT88

Machine Position


Pressurized Fluids

IMPORTANT: Prevent damage to hydraulic systemcomponents. DO NOT run engine withoutoil in hydraulic tank.

Avoid machine damage. Mixing different oiltypes can degrade lubricant and machineperformance. Oil manufacturers engineertheir oils to meet certain specifications andperformance requirements.

Avoid machine damage. This excavator isfactory filled with Super EX 46HN extendedlife zinc-free hydraulic oil. Avoid servicingthis excavator with products that do not meetthis specification. If oils have been mixedor if alternate service oils are desired, thecomplete hydraulic system needs to be totallyflushed by an authorized dealer.

1. Park machine on a level surface, and position machinewith arm cylinder fully retracted and bucket cylinderfully extended.

2. Stop engine.

3. On right side of machine, check hydraulic oil levelgauge (1) on hydraulic tank. Oil must be betweenmarks on window.

If necessary, add oil.

To add oil:

CAUTION: High pressure release of oil frompressurized system can cause serious burnsor penetrating injury. Relieve pressure bypushing pressure release button.

a. Push pressure release button (2).

b. Remove cap screws (3).

c. Remove hydraulic tank cover (4).

d. Add oil.

e. Install cover and cap screws.

TX1101882A

—UN—22NOV11

Hydraulic Oil Level Gauge

TX1101884A

—UN—03JAN12

Hydraulic Tank Cover

1—Hydraulic Oil Level Gauge2—Pressure Release Button

3—Cap Screw (6 used)4—Hydraulic Tank Cover

3-4-3 081214

PN=147


VD76477,0001376 -19-27MAY11-1/1

Lubricate Hydraulic Coupler—If EquippedNOTE: Cylinders that are supplied without grease zerks

DO NOT need to be lubricated.

To keep hydraulic coupler in proper working condition itmust be lubricated on a daily basis.

Most hydraulic couplers are supplied with a cylindergrease zerk (1) located on the head end of the cylinderor the cylinder barrel, a lock arm grease zerk (2), and agrease zerk on each side of the hydraulic coupler for thelocking wedge.

Apply grease to fittings until it escapes from joints. SeeTrack Adjuster, Working Tool Pivot, Swing Bearing, andSwing Bearing Gear Grease. (Section 3-1.)

TX1017854A

—UN—22JAN07

Lubrication Points

1—Cylinder Grease Zerk 2—Lock Arm Grease Zerk

3-4-4 081214

PN=148

Maintenance—Every 50 Hours or Weekly

DB84312,0000044 -19-21MAY12-1/1

DB84312,0000042 -19-28NOV11-1/1

Drain Water and Sediment from Fuel TankSump1. Park machine on a level surface. Rotate

upperstructure 90° for easier access.

2. Stop engine.

3. Remove fuel tank fill cap.

4. Open right service door to access the drain valve (1)for the fuel tank.

NOTE: Drain waste into a container. Disposeof waste properly.

5. Open drain valve for several seconds to drain waterand sediment into a container. Dispose of wasteproperly. Close drain valve.

6. Close service door and install fuel tank fill cap.

1—Drain Valve

T6811A

J—UN—18OCT88

Machine Position

TX1102194A

—UN—28NOV11

Drain Valve

Drain Primary Fuel Filter andWater Separator1. Open right service door to access primary fuel filter

and water separator (1).


2. Open drain valve (2) to extract water from fuel system.Drain fluid until water and sediment is removed. Collectwaste in a container and dispose of waste properly.

3. Close drain valve.

1—Primary Fuel Filter andWater Separator

2—Drain Valve

TX1102058A

—UN—23NOV11

Primary Fuel Filter and Water Separator

3-5-1 081214

PN=149

Maintenance—Every 50 Hours or Weekly

DB84312,0000040 -19-28NOV11-1/1

DB84312,0000041 -19-28NOV11-1/1

Drain Final Fuel Filter1. Open right service door to access final fuel filter (1).


2. Open drain valve (2) on bottom of filter to extract waterfrom fuel system. Drain fluid until water and sedimentis removed. Collect waste in a container and disposeof waste properly.


1—Final Fuel Filter 2—Drain Valve

TX1102059A

—UN—23NOV11

Final Fuel Filter

Drain Auxiliary Fuel Filter and WaterSeparator—If Equipped1. Open right service door to access auxiliary fuel filter

and water separator (1).


2. Open drain valve (3) on bottom of water separatorbowl (2) to extract water from fuel system. Drain untilwater and sediment is removed. Collect waste in acontainer and dispose of waste properly.


1—Auxiliary Fuel Filter andWater Separator

2—Water Separator Bowl

3—Drain Valve

TX1102060A

—UN—23NOV11

Auxiliary Fuel Filter

3-5-2 081214

PN=150

Maintenance—Every 100 Hours

VD76477,000036F -19-27MAY11-1/1

Lubricate Working Tool Pivots

Lubricate working tool pivots (4 points) until greaseescapes from joints. Lubricate every 4 hours for first 20hours. Lubricate every 10 hours during first 30—100hours and when working in mud and water.

TX1000687—UN—23NOV05

Four Points

3-6-1 081214

PN=151


KR46761,00009A5 -19-29JUL13-1/1

Inspect and Re-Torque Track HardwareEach inspection and re-torquing should be documentedby completing a service report for each unit, placing acopy of this report in the machine file, and forwarding acopy to the manufacturer’s attention.

For shoes with missing or loose cap screws and nuts,remove shoes and clean the mating surface of shoesand links before replacing cap screws and nuts. Thecap screws must be replaced because they have beenstretched to yield previously.

IMPORTANT: Prevent possible machine damage.Operating a machine with loose shoes cancause the cap screws and holes in the shoesand links to wear, making it difficult to keepthe shoes tight. Loose shoes can also causehardware malfunction and loss of shoes.

Improper track shoe cap screw torque willresult in serious damage to the undercarriagecomponents, shorter life expectancy, andwill void the manufacturer's warranty on theundercarriage components.

Checking Track Shoe Hardware Torque

1. Tighten cap screws in sequence to specification.Specification

Cap Screw—Torque....................................................................804 N·m593 lb.-ft.

2. Cap screws that have turned have reduced tightnessand need to be re-torqued.

3. Check track shoe holes for wear or damage. Replaceas necessary.

Re-Torquing Track Shoe Hardware

1. Loosen cap screw.


Cap Screw—InitialTorque.........................................................................................136 N·m

100 lb.-ft.

T6352A

H—UN—23FE

B89

Cap Screw Torque Sequence

3. Re-torque cap screws in sequence to specification.Specification

Cap Screw—FinalTorque.........................................................................................804 N·m

593 lb.-ft.

Torquing Replacement Track Shoe Hardware

IMPORTANT: Prevent possible machine damage.Clean shoe and link surfaces of dirt, paint,and debris before installation.

1. Clean shoe and link surfaces of dirt or paint.


Cap Screw—InitialTorque.........................................................................................136 N·m

100 lb.-ft.

3. Torque cap screws in sequence to specification.Specification

Cap Screw—FinalTorque.........................................................................................804 N·m

593 lb.-ft.

3-6-2 081214

PN=152


DB84312,0000045 -19-04JUN14-1/1

Check Swing Gear Case Oil Level1. Park machine on a level surface.

2. Remove dipstick (1). Wipe dipstick clean and replacecompletely into tube.

3. Remove dipstick. Oil must be in the dipstickcross-hatch area (3).

4. If oil is needed, remove filler cap (2), and add oil.

5. Check oil level.

6. Replace filler cap.


3—Dipstick Cross-Hatch Area

TX1102184A

—UN—28NOV11

Swing Gear Case

FULL

3

ADD

T216546—UN—29NOV05

Dipstick Cross-Hatch Area

3-7-1 081214

PN=153


DB84312,0000046 -19-21MAY12-1/1

Drain Water and Sediment from HydraulicTank1. Park machine on a level surface.

2. Stop engine.

CAUTION: High pressure release of oil frompressurized system can cause serious burnsor penetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).

3. Push the pressure release button (1) to relievepressure.

4. Remove cap screws (3).

5. Remove hydraulic tank oil cover (2).


6. After oil is cool, loosen drain valve cap screw (4) forseveral seconds to drain water and sediment intoa container. Do not remove cap screw completely.Dispose of waste properly.

7. Check hydraulic oil level. See Check Hydraulic TankOil Level. (Section 3-4.)

8. Tighten drain valve cap screw, and install hydraulictank oil cover and cap screws.

1—Pressure Release Button2—Hydraulic Tank Oil Cover

3—Cap Screw (4 used)4—Drain Valve Cap Screw


Pressurized Fluids

TX1102206A

—UN—01DEC11

Hydraulic Tank Oil Cover

TX1086692A

—UN—07JAN11

Drain Valve Cap Screw

3-7-2 081214

PN=154


DB84312,0000074 -19-21MAY12-1/1

Check Pump Drive Gear Case Oil Level1. Open right service door to access pump drive gear

case.

2. Remove dipstick (1).

3. Wipe dipstick clean and insert completely into tube.

4. Remove dipstick.

5. Oil level must be approximately halfway below the Hmark. Insert dipstick.

To add oil:

1. Remove filler plug (2).

2. Add oil.

3. Install filler plug.

1—Dipstick 2—Filler Plug

TX1103069A

—UN—08DEC11

Pump Drive Gear Case

T145092—UN—31AUG01

Pump Drive Gear Case Oil Level

3-7-3 081214

PN=155


Continued on next page TX14740,0001CBE -19-05MAR13-1/3

Check Battery Electrolyte Level andTerminals

CAUTION: Battery gas can explode. Keep sparksand flames away from batteries. Use a flashlightto check battery electrolyte level.

NEVER check battery charge by placinga metal object across the posts. Use avoltmeter or hydrometer.

ALWAYS remove grounded (-) battery clampfirst and replace it last.

Sulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin,eat holes in clothing, and cause blindnessif splashed into eyes.


1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when

electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.


1. Flush your skin with water.2. Apply baking soda or lime to help

neutralize the acid.3. Flush your eyes with water for 15—30 minutes.

Get medical attention immediately.


1. Do not induce vomiting.


Avoid Acid Burns

2. Drink large amounts of water or milk, butdo not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

1. Remove battery box cover.

3-7-4 081214

PN=156


TX14740,0001CBE -19-05MAR13-2/3

TX14740,0001CBE -19-05MAR13-3/3

IMPORTANT: If water is added to batteries duringfreezing weather, batteries must be chargedafter water is added to prevent batteries fromfreezing. Charge battery using a batterycharger or by running the engine.

2. Fill each cell to within specified range with distilledwater. DO NOT overfill.

CAUTION: Prevent possible injury. ALWAYSremove grounded (-) battery clamp firstand replace it last.

3. Disconnect battery clamps, grounded clamp first.

1—Battery Post2—Fill Tube

3—Electrolyte Level Range

T137535—UN—25JAN01

Battery Terminal and Fill Hole

T137536—UN—25JAN01

Fill Level

4. Clean battery terminals (1) and clamps with a stiffbrush.

5. Apply lubricating grease (2) around battery terminalbase only.

6. Install and tighten clamps, grounded clamp last.

1—Battery Terminal 2—Lubricating Grease

T137537—UN—25JAN01

Terminal and Grease

3-7-5 081214

PN=157


DB84312,000007D -19-20MAR12-1/1

OUT4001,000039B -19-14MAR12-1/1

Check Travel Gear Case Oil Level1. Park the machine on level ground rotating travel gear

case until positioned as shown.

2. Stop engine.

CAUTION: High pressure release of oils frompressurized system can cause serious burns.Wait for travel gear case oil to cool. Keep body andface away from check plug (2). Gradually loosencheck plug to release air to relieve pressure.

3. After travel gear case has cooled, slowly loosen checkplug (2) to release air to relieve pressure.

4. Remove check plug. Oil must be to bottom of hole.

5. If necessary, remove fill plug (1), and add oil until oilflows out of oil level check plug hole.

6. Wrap threads of plugs with sealing-type tape. Installplug. Tighten plugs to specification.

SpecificationPlug—Torque.................................................................................50 N·m

36.9 lb.-ft.

TX1000270—UN—15NOV05

Travel Gear Case

1—Fill Plug2—Check Plug

3—Drain Plug

7. Check second travel gear case oil level.

Take Engine Oil SampleSee your authorized dealer.

3-7-6 081214

PN=158


VD76477,0000368 -19-27MAY11-1/1

Lubricate Front End Pin Joints

Lubricate front end pin joints (20 points) until greaseescapes from joints. Lubricate every 4 hours for first 20

hours. Lubricate every 10 hours during first 30—100hours and when working in mud and water.

T134954—UN—01NOV00

Four Points

T136448—UN—18DEC00

Nine Points

T134956—UN—01NOV00

Five Points

T134957—UN—01NOV00

Two Points

3-8-1 081214

PN=159


VD76477,0000396 -19-26MAR12-1/1

ER79617,0000DE4 -19-11JUL13-1/1

Lubricate Swing Bearing

CAUTION: Prevent possible injury fromunexpected machine movement if controls aremoved by another person. Lubricating swingbearing and rotating the upperstructure must bedone by one person. Before you lubricate swingbearing, clear the area of all persons.


2. Stop engine.

3. Lubricate swing bearing with 8 shots of grease at bothgrease fittings.

4. Start engine. Raise bucket several inches off theground and turn upperstructure 45 degrees.

NOTE: It is not necessary to start the engine the last time.

T134968—UN—01NOV00

Swing Bearing

5. Repeat steps 2—4 three times.

Lubricate Swing Bearing Gear

CAUTION: Prevent possible injury fromunexpected machine movement if controls aremoved by another person. Lubricating swingbearing gear and rotating the upperstructuremust be done by one person.

1. Remove swing bearing gear access cover (1).

2. Grease must be 13—25 mm (1/2—1 in.) deepmeasured from the bottom of the ring gear. The greasemust also be free of contamination by dirt and water.

If the grease is contaminated, remove grease andreplace with clean grease.

IMPORTANT: If water or mud is found in swinggear area, see Operating in Water andMud. (Section 2-3.)

3. Add grease as required (approximately 0.5 kg [1.1 lb.]every 90°). See Maintenance—Machine. (Section3-1.)

IMPORTANT: Excessive grease can damage theswing gear case seal.

T136458—UN—18DEC00

Access Cover

1—Access Cover

4. Remove any excess grease from over the top of theswing drive pinion.

5. Install access cover.

3-8-2 081214

PN=160


DB84312,0000050 -19-06DEC11-1/1

Replace Primary Fuel Filter and WaterSeparator1. Ensure key switch is in the OFF position.

2. Open right service door to access primary fuel filterand water separator.

3. Thoroughly clean exterior of primary fuel filter andwater separator assembly and surrounding area.

CAUTION: Fuel in filter may be under highpressure. Escaping fuel under pressure canpenetrate the skin and cause serious injury.Relieve pressure before removing filter.

4. Disconnect the water-in-fuel (WIF) sensor wiring (2).

5. Loosen drain valve (1) to relieve pressure and drainwater and contaminates from water separator bowl (3)into a suitable container. Dispose of waste properly.Close drain valve.

6. Remove water separator bowl from filter element.Clean and dry separator bowl.

7. Inspect bowl. Replace if necessary.

8. Remove filter element and seal from mounting baseand discard.

IMPORTANT: DO NOT prefill fuel filters. Debrisin unfiltered fuel will damage fuel systemcomponents.

Only lubricate filter seal with diesel fuelbefore installing.

9. Install new filter element.

TX1102554A

—UN—02DEC11

Primary Fuel Filter and Water Separator

1—Drain Valve2—Water-in-Fuel (WIF) Sensor

Wiring


10. Install water separator bowl. Tighten 1/2 turn after sealcontacts mounting base.

11. Connect WIF sensor wiring.

12. Prime fuel system and bleed air. See Bleed FuelSystem. (Section 4-1.)

3-8-3 081214

PN=161


DB84312,000004D -19-01DEC11-1/1

Replace Final Fuel FilterNOTE: Do not clean fuel tank inlet screen and change

fuel filter at the same time. Clean fuel tank inletscreen and run engine before changing fuel filter.

1. Ensure key switch is in the OFF position.

2. Open right service door to access final fuel filter (1).

3. Thoroughly clean exterior of final fuel filter andsurrounding area.

NOTE: Some fuel will be present in final fuel filter housing.

4. Remove final fuel filter using a filter wrench. Disposeof used filter properly.

5. Clean filter mounting base (2).



6. Install new final fuel filter onto mounting base. Rotatefilter housing clockwise by hand. Tighten one turnafter seal contacts mounting base.

TX1102450A

—UN—30NOV11

Final Fuel Filter

1—Final Fuel Filter 2—Mounting Base


3-8-4 081214

PN=162


DB84312,0000048 -19-13JAN12-1/1

DB84312,0000075 -19-09DEC11-1/1

Replace Auxiliary Fuel Filter and WaterSeparator—If Equipped1. Ensure key switch is in the OFF position.

2. Open right engine service door to access auxiliary fuelfilter and water separator (1).

3. Thoroughly clean exterior of auxiliary fuel filter andwater separator assembly and surrounding area.

CAUTION: Fuel in filter may be under highpressure. Escaping fuel under pressure canpenetrate the skin and cause serious injury.Relieve pressure before removing filter.


4. Loosen drain valve (3) to relieve pressure and draincontaminates from water separator bowl (2). Disposeof waste properly. Close drain valve.

5. Rotate auxiliary fuel filter counterclockwise andremove from mounting base. Remove water separatorbowl from auxiliary fuel filter. Dispose of used fuelfilter properly.

6. Clean filter mounting base.

7. Clean and dry water separator bowl. Replace ifnecessary.

8. Install water separator bowl to new auxiliary fuel filter.



TX1102060A

—UN—23NOV11

Auxiliary Fuel Filter and Water Separator

1—Auxiliary Fuel Filter andWater Separator


3—Drain Valve

9. Install new auxiliary fuel filter onto mounting base.Rotate filter housing clockwise by hand. Tighten1/2—3/4 turn after seal contacts mounting base.


11. Operate engine and check for leaks.

12. Tighten filter element and bowl only enough to stopleaks.

Check Air Intake Hoses1. Check air intake hoses (1) for cracks. Replace as

necessary.

2. Check for loose connections and tighten clamps asnecessary.

1—Air Intake Hose

TX1103075A

—UN—08DEC11

Air Intake Hose

3-8-5 081214

PN=163


DB84312,0000051 -19-13JAN12-1/1

Drain and Refill Engine Oil and Replace Filter1. Run engine to warm oil.


3. Stop engine.

4. Remove middle access cover under the machine.Open drain valve on side of engine oil pan. Allow oil todrain into a container. Dispose of waste oil properly.

5. Close drain valve and install access cover.

6. Turn engine oil filter (3) counterclockwise to remove.Clean mounting surface on base.

7. Apply thin film of oil to rubber gasket of new filter.

8. Install new filter. Turn filter clockwise by hand untilgasket touches mounting surface.

9. Tighten filter 1/2—3/4 turn more.

10. Remove filler cap (2) and fill engine with oil. SeeDiesel Engine Oil—Interim Tier 4 and Stage III BEngines. (Section 3-1.)

160GLC and 180GLC—SpecificationEngine Oil WithFilter—Capacity.............................................................................. 14.5 L

3.8 gal.

11. Install filler cap.

12. Start engine.

13. Stop engine, remove dipstick (1) and check oil level.Engine is full when oil level is in the cross-hatch area.

14. Check for any leakage at filter. Tighten filter justenough to stop leakage.


3—Engine Oil Filter

TX1102558A

—UN—02DEC11

Engine Oil Filter

TX1102463A

—UN—30NOV11

Engine Oil Filler Cap and Dipstick

3-8-6 081214

PN=164


DB84312,0000049 -19-26MAR12-1/1

ER79617,0000A8F -19-22MAR10-1/1

Clean Cab Fresh Air and Cab RecirculatingAir FiltersNOTE: Replace filters after the sixth cleaning.

Removing Cab Fresh Air Filter:

1. Unlock cab side cover (1) on left side of machine withkey to access fresh air filter (2).

2. Squeeze tab on each side of the filter to remove.

Removing Cab Recirculating Air Filter:

1. Move operator's seat forward to access recirculatingair filter (3) located under the rear deck.

2. Squeeze tab (4) on right side of filter to remove.

Cleaning Filters:

1. Clean filters in one of two ways:

CAUTION: Avoid injury from flying debris. Cleararea of bystanders and wear personal protectionequipment including eye protection. Reducecompressed air to less than 196 kPa (1.96 bar)(28.4 psi) when using for cleaning purposes.

• Use compressed air opposite to the normal air flow.• Wash filters with water. Soak the filters in warm,soapy water for 5 minutes. Flush filter. Allow filter todry before installing.

2. Install filter.

1—Cab Side Cover2—Fresh Air Filter

3—Recirculating Air Filter4—Tab

TX1102304A

—UN—29NOV11

Cab Side Cover

TX1102306A

—UN—29NOV11

Cab Fresh Air Filter

TX1013147A

—UN—12OCT06

Cab Recirculating Air Filter

Take Fluid SamplesSee your authorized dealer for taking the following fluidsamples:

• Hydraulic Oil

• Coolant• Diesel Fuel• Swing Gear Case Oil• Travel Gear Case Oil• Pump Drive Gear Case Oil

3-8-7 081214

PN=165


DB84312,000004A -19-29DEC11-1/1

Drain and Refill Swing Gear Case OilSpecification

Swing Gear Case—OilCapacity........................................................................................... 6.2 L

1.6 gal.

1. To drain oil, remove drain plug through access holeunder machine. Dispose of waste properly.

2. Install plug.

3. Remove filler cap (2), and add oil. See Swing GearCase and Travel Gear Case Oils. (Section 3-1.)

4. Install filler cap.

5. Check oil level on dipstick (1).

TX1102184A

—UN—28NOV11

Swing Gear Case Oil

1—Dipstick 2—Filler Cap

3-9-1 081214

PN=166


DB84312,0000053 -19-04JUN14-1/1

Replace Hydraulic Tank Oil Filter1. Park machine on a level surface with arm cylinder fully

retracted and bucket cylinder fully extended.

2. Stop engine.

CAUTION: High pressure release of oil frompressurized system can cause serious burnsor penetrating injury. The hydraulic tankis pressurized. DO NOT remove hydrauliccap. Relieve pressure by pushing thepressure release button (7).

3. To release pressure, push the pressure release button(7).

4. Remove cap screws (8) and remove shield (9).

5. Hold down hydraulic oil filter cover (1) against lightspring load when removing the last two cap screws (2).

6. Remove spring (3), valve (5), and filter element (4).

7. Remove and discard filter element and O-ring (6).

NOTE: Remove element, and inspect for metal particlesand debris in bottom of filter canister. Excessiveamounts of brass and steel particles can indicate ahydraulic pump, motor, or valve malfunction, or amalfunction in process. A rubber type of materialcan indicate cylinder packing problem.

8. Install filter element, valve, and spring.

9. Install cover and tighten cap screws to specification.Specification

Cap Screw—Torque......................................................................50 N·m36.9 lb.-ft.

10. Install shield.

1—Cover2—Cap Screw (6 used)3—Spring4—Filter Element5—Valve

6—O-Ring7—Pressure Release Button8—Cap Screw (4 used)9—Shield

T6811A

I—UN—18OCT88

Machine Position

TX1102566A

—UN—12JAN12

Top of Hydraulic Tank

TX1087387—UN—27JAN11

Hydraulic Filter Element

3-9-2 081214

PN=167


DB84312,0000052 -19-06DEC11-1/1

Replace Pilot Oil Filter

CAUTION: High pressure release of oil frompressurized system can cause serious burnsor penetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingthe pressure release button (5).

1. To relieve hydraulic pressure, push the pressurerelease button (5).

2. Open right service door to access pilot oil filter (4).

3. Remove filter canister (1) from head cover by turningcounterclockwise.

4. Clean head cover contact area.

5. Remove filter element (2) and O-ring (3).

6. Install new O-ring and filter element.

7. Install filter canister clockwise by hand. Check for anyleakage.

1—Filter Canister2—Filter Element3—O-Ring

4—Pilot Oil Filter5—Pressure Release Button

TX1102353A

—UN—30NOV11

Hydraulic Tank Cover

TX1102568A

—UN—02DEC11

Pilot Oil Filter

T136461—UN—19DEC00

Filter Canister

3-9-3 081214

PN=168


DB84312,0000076 -19-04JUN14-1/1

DB84312,0000077 -19-20MAR12-1/1

Drain and Refill Pump Drive Gear Case Oil1. Open right service door to access pump drive gear

case.

2. Remove filler plug (2).


3. Remove drain plug (3). Allow oil to drain into acontainer. Dispose of waste oil properly.

4. Apply liquid pipe thread sealant to drain plug. Installplug.

SpecificationPump Drive GearCase—Oil Capacity.......................................................................... 0.9 L

1.0 qt

5. Add oil.

6. Remove dipstick (1), and check oil level. Oil level mustbe approximately halfway below H mark.

7. Install filler plug.

8. Install dipstick.

9. Close right service door.

1—Dipstick2—Filler Plug

3—Drain Plug

TX1103136A

—UN—08DEC11

Pump Drive Gear Case

T145092—UN—31AUG01

Pump Drive Gear Case Oil Level

Remove and Clean Open CrankcaseVentilation (OCV) Hose1. Open engine cover on top of machine.

2. Remove the open crankcase ventilation (OCV) hose(1).

IMPORTANT: Restrictions in the OCV hose cancause sludge to form in crankcase. Thiscan lead to clogging of oil passages, filters,and screens, resulting in serious enginedamage. Avoid engine damage by cleaningthe OCV hose at shorter intervals if operatingmachine in dusty conditions.

3. Inspect OCV hose for dirt and debris.

4. Clean OCV hose with solvent and compressed air ifrestricted.

5. Install OCV hose and close engine cover.

TX1103138A

—UN—08DEC11

OCV Hose

1—Open Crankcase Ventilation(OCV) Hose

3-9-4 081214

PN=169


OUT4001,0000AE1 -19-06JAN12-1/1

Inspect Serpentine Belt1. Check belt (1) regularly for wear, especially for cracks

at the bottom of grooves and for frayed edges.

2. If necessary, replace belt.

3. Install a 1/2 in. drive socket wrench to the belt tensionadjuster (2). Turn wrench to pull tension adjusterpulley away from belt, releasing belt tension.

4. Hold tension adjuster away from belt while removingold belt and installing new belt.

5. Slowly release wrench tension to allow tensionadjuster to move against new belt. Tension isautomatically adjusted.

6. Remove wrench.

1—Belt2—Belt Tension Adjuster3—Alternator

4—Crankshaft Pulley5— Idler Pulley

TX1105030—UN—07JAN12

Serpentine Belt

3-9-5 081214

PN=170


DB84312,000004B -19-01DEC11-1/1

DB84312,000004E -19-29DEC11-1/1

Replace Air Cleaner Elements1. Open left service door to access the air cleaner.

2. Release latch (1) to unlock and remove cover.

3. Remove primary element (2).

4. Remove secondary element (3).

5. Clean the inside of the filter canister.

6. Install elements, making sure the secondary elementis centered in canister.

7. Replace cover and secure latch.

8. Close service door.

1—Latch (3 used)2—Primary Element

3—Secondary Element

TX1102260A

—UN—29NOV11

Air Cleaner Cover Latch

TX1102257A

—UN—29NOV11

Primary Air Cleaner Element

TX1102452A

—UN—30NOV11

Secondary Air Cleaner Element

Replace Air Cleaner Dust Unloader ValveNOTE: A missing, damaged, or hardened dust

unloader valve (1) will cause the air filterelements to be ineffective.

1. Open left service door to access dust unloader valve(1).

2. Twist and pull on dust unloader valve to remove dustunloader valve from the air cleaner cover.

3. Install new dust unloader valve on air cleaner cover.

1—Dust Unloader Valve

TX1101878A

—UN—22NOV11

Dust Unloader Valve

3-9-6 081214

PN=171


OUT4001,0000365 -19-28JUL14-1/1

Check CoolantSee Check Coolant. (Section 3-3.)

3-9-7 081214

PN=172


CED,OUO1032,2768 -19-06APR10-1/1

DB84312,000004F -19-25MAY12-1/1

DB84312,000008D -19-12JAN12-1/1

Check and Adjust Engine Valve LashSee your authorized dealer for engine valve clearanceadjustment.

Drain and Refill Travel Gear Case Oil1. Park the machine on level ground rotating travel gear

case until pictured as shown.

2. Stop engine.

CAUTION: High pressure release of oils frompressurized system can cause serious burns.Wait for travel gear case oil to cool. Keep bodyand face away from check plug. Graduallyloosen check plug to release pressure.

3. After travel gear case has cooled, slowly loosen checkplug (2) to release pressure.


4. Remove drain plug (3). Allow oil to drain into acontainer. Dispose of waste oil properly.

5. Wrap threads of drain plug with a sealing-type tape.Install plug. Tighten plug to specification.

SpecificationPlug—Torque.................................................................................50 N·m

36.9 lb.-ft.

6. Remove oil fill plug (1).

7. Add oil until oil flows out of oil level check plug hole.

TX1000270—UN—15NOV05

Travel Gear Case

1—Fill Plug2—Check Plug

3—Drain Plug

SpecificationTravel Gear Case—OilCapacity (each)................................................................................ 6.8 L

1.7 gal.

8. Wrap threads of check plug, and fill plug withsealing-type tape. Install plugs. Tighten plugs tospecification.

9. Change oil of second travel gear case.

Replace Open Crankcase Ventilation (OCV)Filter1. Open engine cover on top of machine.

2. Remove open crankcase ventilation (OCV) filter cap(1) by turning counterclockwise.

3. Remove OCV filter element.

4. Inspect filter housing for dirt and debris.

5. Install new OCV filter element.

6. Install OCV filter cap. Hand tighten only.


TX1104748A

—UN—04JAN12

Open Crankcase Ventilation Filter

1—Open Crankcase Ventilation(OCV) Filter Cap

3-10-1 081214

PN=173


Continued on next page DB84312,0000054 -19-04JUN14-1/2

Drain and Refill Hydraulic Tank OilNOTE: Change original factory fill hydraulic oil after first

5000 hours. Change every 5000 hours thereafterif using Super EX 46HN, if using alternative oilssee Hydraulic Oil. (Section 3-1.)

NOTE: Perform this service at the 5000 hour interval whenoperating in normal conditions. When operating withan attachment, drain and refill as necessary.

CAUTION: Avoid personal injury from highpressure fluid. High pressure release of oilfrom pressurized system can cause seriousburns or penetrating injury. Relieve pressureby pushing pressure release button (5).

IMPORTANT: Prevent damage to hydraulicsystem components. DO NOT run enginewithout oil in the tank.

Avoid mixing different brands or types ofoils. Oil manufacturers engineer their oils tomeet certain specifications and performancerequirements. Mixing different oil types candegrade lubricant and machine performance.

This excavator is factory filled with Super EX46HN extended life zinc-free hydraulic oil. Avoidservicing this excavator with products that donot meet this specification. If oils have beenmixed or if alternate service oils are desired,the complete hydraulic system needs to betotally flushed by an authorized dealer.

1. Park machine on level surface with upperstructurerotated 90° for easier access.

2. Position machine with arm cylinder fully retracted andbucket cylinder fully extended.

3. Stop engine.

CAUTION: Avoid personal injury from highpressure fluid. High pressure release of oilfrom pressurized system can cause seriousburns or penetrating injury. Relieve pressureby pushing pressure release button.

4. To relieve pressure, press the pressure release button(5).

5. Remove cap screws (6).

6. Remove hydraulic tank oil cover with suction screen(7).


Pressurized Fluids

T6811A

J—UN—18OCT88

Machine Position

TX1102484A

—UN—02DEC11


5—Pressure Release Button6—Cap Screw (6 used)

7—Hydraulic Tank Oil CoverWith Suction Screen

SpecificationHydraulic Tank—OilCapacity....................................................................................... 125.0 L

33.0 gal.

3-11-1 081214

PN=174


DB84312,0000054 -19-04JUN14-2/2


7. Remove drain valve cap screw (4). Allow oil to draininto a container. Dispose of waste oil properly.

8. Clean inside of tank and suction screen.

NOTE: The hydraulic tank oil filter and pilot oil filter canbe changed at this point in the procedure. SeeMaintenance-Every 1000 Hours. (Section 3-9.)

9. Install suction screen with cover. Suction screen mustseal against outlet pipe in bottom of tank. If necessary,loosen nut (2) to adjust rod length.

10. Replace cap screw.

IMPORTANT: If the hydraulic pump is not filled withoil, it will be damaged when the engine is started.

11. Add oil until it is between marks on sight glass.Specification

Suction Screen Rod(1)—Length................................................................................. 869 mm

34.2 in.Suction Screen RodNut—Torque..................................................................................17 N·m

150 lb.-in.Hydraulic Cover CapScrew—Torque..............................................................................50 N·m

36.9 lb.-ft

12. Remove air bleed plugs (3) from hydraulic pump untiloil flows from bleed holes.

13. Install air bleed plugs in hydraulic pump.

14. Check oil level in sight glass. Add oil if necessary.Install and tighten tank cover.

15. Purge air from cylinders and swing motor by slowlycycling hydraulic functions.

1—Suction Screen Rod2—Suction Screen Rod Nut

3—Bleed Plug (2 used)4—Drain Valve Cap Screw

TX1086692A

—UN—07JAN11

Drain Valve Cap Screw

T135193—UN—06NOV00

Suction Screen

TX1103140A

—UN—08DEC11

Bleed Plugs

3-11-2 081214

PN=175


DB84312,0000055 -19-04JUN14-1/1

Replace Hydraulic Tank Vent Cap Filter


Pressurized Fluids

T6811A

I—UN—18OCT88

Machine Position

1. Park and position machine on solid level surface asshown. Stop engine.

CAUTION: High pressure release of oil frompressurized system can cause serious burnsor penetrating injury. Relieve by pushingpressure release button.

To prevent possible burn injury from hothydraulic oil, wait for hydraulic oil to coolbefore starting work.

2. Push the pressure release button (1) on top of thehydraulic tank oil cover (5).

3. Turn hydraulic tank vent cap filter cover (2) clockwiseabout a 1/4 turn. Turn rubber cap over pressurerelease button counterclockwise to remove.

4. Turn hydraulic tank vent cap filter covercounterclockwise to remove.

5. Remove vent cap filter (3). Install new filter.

IMPORTANT: Do not allow water or contaminantsbetween cover and body (4).

6. Install filter cover until it comes in contact with the filterelement. Then, further tighten the cover 1/4 turn.

7. Tighten rubber cap clockwise by hand. While holdingrubber cap, securely tighten filter cover by rotatingcounterclockwise 5—10° by hand.

1—Pressure Release Button2—Hydraulic Tank Vent Cap

Filter Cover3—Vent Cap Filter

4—Body5—Hydraulic Tank Oil Cover

TX1102488A

—UN—03JAN12


TX1001448—UN—16DEC05

Hydraulic Tank Oil Vent Cap

3-11-3 081214

PN=176


DB84312,0000078 -19-04JUN14-1/1

Drain Cooling System


1. Check coolant hoses for cracks and leaks. Replace ifnecessary.

2. Tighten clamps.

3. Check radiator, charge air, and oil cooler for dirt,grease, leaks, and loose or broken mountings. Cleanradiator, charge air, and oil cooler fins.


4. Remove surge tank cap (1) to relieve pressure.Specification

Cooling System—Capac-ity.................................................................................................... 23.5 L

6.2 gal.

5. Remove cover from underside of machine to accessradiator drain valve (2).


6. Turn radiator drain valve counterclockwise to open.Allow coolant to drain into a container. Dispose ofwaste coolant properly.

7. Close radiator drain valve and replace cover.

8. Install surge tank cap.

1—Surge Tank Cap 2—Radiator Drain Valve


Pressurized Fluids

TX1101879A

—UN—22NOV11

Surge Tank Cap

TX1103142A

—UN—08DEC11

Radiator Drain Valve

3-12-1 081214

PN=177


DB84312,0000079 -19-11MAR14-1/1

Cooling System Fill and Deaeration Procedure


IMPORTANT: Avoid mixing different brands or typesof coolant. Coolant manufacturers engineertheir coolants to meet certain specificationsand performance requirements. Mixingdifferent coolant types can degrade coolantand machine performance.

Use only permanent-type low silicate ethyleneglycol base antifreeze in coolant solution. Othertypes of antifreeze may damage cylinder seals.

John Deere COOL-GARD™ II Pre-Mixcoolant is recommended when adding newcoolant to cooling system.

Follow directions on container for correctmixture ratio.

FREEZING TEMPERATURES: Fill with permanent-type,low silicate, ethylene glycol antifreeze (without stop-leakadditive) and clean, soft water.

Fill

Remove surge tank cap (1) to relieve pressure. Fill surgetank to above the full hot mark. Replace surge tank cap.

Deaeration

The cooling system requires several warmup and cooldown cycles to deaerate. It will NOT deaerate duringnormal operation. Only during warmup and cool downcycles will the system deaerate.

1. Start engine. Run engine until coolant reaches a warmtemperature.

2. Stop engine. Allow coolant to cool.

3. Check coolant level at surge tank.

4. Repeat steps 1—3 until surge tank coolant level isrepeatedly at the same level (stabilized).

NOTE: The level of the coolant in the cooling systemMUST BE repeatedly checked after all drain andrefill procedures to insure that all air is out of thesystem which allows the coolant level to stabilize.Check coolant level only when the engine is cold.


Pressurized Fluids

TX1101879A

—UN—22NOV11

Surge Tank Cap

1—Surge Tank Cap

5. If necessary, fill surge tank to above the MIN COLDmark.

SpecificationCooling System—Capac-ity.................................................................................................... 23.5 L

6.2 gal.


3-12-2 081214

PN=178

Miscellaneous—Machine

ER79617,0000DF9 -19-28APR14-1/1

Continued on next page DB84312,000007E -19-12JAN12-1/2

Bleed Fuel System


NOTE: This procedure should be performed after each fuelfilter change or when the engine has run out of fuel.

Air can enter fuel system when changing fuel filters orwhen machine has run out of fuel. Air in the fuel systemcan prevent the engine from starting or cause rough idle.This machine is equipped with an electric priming pump.Prime fuel system and bleed air as follows:

1. Turn key to the ON position to energize ignition systemand fuel pump. Let pump run for 60 seconds to primefuel system.

2. After 60 seconds, turn key to the OFF position.

3. Turn key back to the ON position.

4. Run engine for 5 minutes at slow idle.

Clean Radiator, Oil Cooler, Charge AirCooler, and Fuel Cooler

CAUTION: Prevent possible injury from rotatingfan and flying debris. Shut off engine beforeopening cover. Avoid rotating fan and fan blast.

1. Turn machine off.

2. Open the engine cover until the end of the bar issecurely locked into catch (1).

3. Attach an air wand to an air compressor, and blow dirtand debris back through cooling system.


5. Open left service door to access coolers.

6. Use compressed air to clean out the heat exchanger(5).

7. Close left service door.

1—Catch2—Fuel Cooler3—Air Conditioner Condenser

4—Charge Air Cooler5—Radiator6—Hydraulic Oil Cooler

TX1105217A

—UN—10JAN12

Engine Cover Catch

TX1103290A

—UN—12DEC11

Coolers

4-1-1 081214

PN=179


DB84312,000007E -19-12JAN12-2/2

VD76477,0000366 -19-11AUG14-1/1

TX,90,DH2537 -19-20JUL12-1/1

CED,OUO1021,185 -19-05NOV08-1/1

If machine is equipped with a hydraulic reverse fanfunction, use the reversing fan switch to clean the coolingsystem. The reversing fan switch is located on the leftconsole.

NOTE: The reversing fan function shall not bereactivated within 1 minute of its last completion(this time includes AUTO cycle).

The reversing fan switch has three positions:

• AUTO: Every 60 minutes the radiator cooling fan willautomatically reverse direction for 30 seconds withoutintervention from the operator.• OFF: Fan resumes normal operation.• MANUAL: When pressed and held for 3 seconds, thefan will reverse direction for 30 seconds when rightportion of switch is pressed.

TX1000844A

—UN—29NOV05

Reversing Fan Switch—If Equipped

Do Not Service or Adjust Injection Nozzlesor High-Pressure Fuel PumpIf injection nozzles are not working correctly or are dirty,the engine will not run normally. (See your authorizeddealer for service.)

Changing the high-pressure fuel pump in any way notapproved by the manufacturer will end the warranty. (Seeyour copy of the John Deere warranty on this machine.)

Do not service a high pressure fuel pump that is notoperating correctly. See your authorized dealer.

Do Not Service Control Valves, Cylinders,Pumps, or MotorsSpecial tools and information are needed to servicecontrol valves, cylinders, pumps, or motors.

If these parts need service, see your authorized JohnDeere dealer.

Precautions for Alternator and Regulator

When batteries are connected, follow these rules:

1. Disconnect negative (-) battery cable when you workon or near alternator or regulator.

2. DO NOT TRY TO POLARIZE ALTERNATOR ORREGULATOR.

3. Be sure alternator wires are correctly connectedBEFORE you connect batteries.

4. Do not ground alternator output terminal.

5. Do not disconnect or connect any alternator orregulator wires while batteries are connected or whilealternator is operating.

6. Connect batteries or a booster battery in the correctpolarity (positive [+] to positive [+] and negative [-] tonegative [-]).

7. Do not disconnect the batteries when engine isrunning and alternator is charging.

8. Disconnect battery cables before you connect batterycharger to the batteries. If machine has more than onebattery, each battery must be charged separately.

4-1-2 081214

PN=180


Continued on next page DB84312,00000C3 -19-11MAR13-1/2

Handling, Checking, and Servicing BatteriesCarefully

CAUTION: Battery gas can explode. Keep sparksand flames away from batteries. Use a flashlightto check battery electrolyte level.

Never check battery charge by placinga metal object across the posts. Use avoltmeter or hydrometer.

Always remove grounded negative (-) batteryclamp first, and replace it last.

Sulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin,eat holes in clothing, and cause blindnessif splashed into eyes.


1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when

electrolyte is added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.


1. Flush contacted skin with water.2. Apply baking soda or lime to contacted

area to help neutralize the acid.3. Flush eyes with water for 15—30 minutes.

Get medical attention immediately.


1. Do not induce vomiting.2. Drink large amounts of water or milk, but

do not exceed 1.9 L (2 qt.).3. Get medical attention immediately.

WARNING: Battery posts, terminals, and relatedaccessories contain lead and lead compounds, chemicalsknown to the State of California to cause cancer andreproductive harm. Wash hands after handling.

If electrolyte spills on the floor, use one of the followingmixtures to neutralize the acid: 0.5 kg (1 lb.) baking sodain 4 L (1 gal.) water, or 0.47 L (1 pt.) household ammoniain 4 L (1 gal.) water.


Exploding Battery Gas


Battery Electrolyte

IMPORTANT: Do not overfill the battery cells.

Check the specific gravity of electrolyte in each battery cell.

4-1-3 081214

PN=181


DB84312,00000C3 -19-11MAR13-2/2

OUT4001,0000239 -19-03JAN12-1/1

See your authorized dealer for JT05460SERVICEGARD™ battery and coolant tester. Followdirections included with the tester.

A fully charged battery will have a corrected specificgravity reading of 1.260. If the reading is below 1.200,charge the battery.

T85402

—UN—10NOV88

Battery and Coolant Tester

SERVICEGARD is a trademark of Deere & Company

Using Battery Charger

CAUTION: Prevent possible injury from explodingbattery. Do not charge a battery if the batteryis frozen or it may explode. Warm battery to16°C (60°F) before charging.

Turn off charger before connecting ordisconnecting it.

IMPORTANT: Do not use battery charger as abooster if a battery has a 1.150 specificgravity reading or lower.

Disconnect battery ground (-) clamp beforeyou charge batteries in the machine to preventdamage to electrical components.

A battery charger may be used as a booster to start engine.

Ventilate the area where batteries are being charged.

Stop or cut back charging rate if battery case feels hot,or is venting electrolyte. Battery temperature must notexceed 52°C (125°F).


Prevent Battery Explosions

N36890—UN—07OCT88

Charger

4-1-4 081214

PN=182


OUT4001,0000238 -19-11AUG14-1/1

DB84312,000007A -19-12DEC11-1/1

Using Booster Batteries—24-Volt SystemBefore boost starting, machine must be properly shutdownto prevent unexpected machine movement when enginestarts.

CAUTION: An explosive gas is produced whilebatteries are in use or being charged. Keep flamesor sparks away from the battery area. Make surethe batteries are charged in a well-ventilated area.

IMPORTANT: The machine electrical system is a24-volt negative (-) ground. Connect two 12-voltbooster batteries together as shown for 24-volts.

1. Connect one end of the positive cable to the positiveterminal of the machine batteries (A) and the other endto the positive terminal of the booster batteries (B).

2. Connect one end of the negative cable to the negativeterminal of the booster batteries. Connect the otherend of the negative cable to the machine frame as faraway from the machine batteries as possible.

3. Start engine.

4. Immediately after starting engine disconnect the endof the negative cable from the machine frame. Then

T7233JN—UN—21MAY

90

Booster Batteries, 2-Battery Application

A—Machine Battery (2 used) B—Booster Battery (2 used)

disconnect the other end of the negative cable fromthe negative terminal of the booster batteries.

5. Disconnect positive cable from booster batteries andmachine batteries.

Replacing Batteries

CAUTION: Avoid personal injury from battery acid.Sulfuric acid in battery electrolyte is poisonous. Itis strong enough to burn skin, eat holes in clothingand cause blindness if splashed into eyes.

NOTE: Reserve capacity is the time in minutes ittakes a fully charged battery at 26.6°C (80°F)to drop below 10 volts.

Your machine has two 12-volt batteries (1) with negative(-) ground connected in series to provide 24-volts.

Use only batteries which meet the following specifications.Specification

Battery—Cold CrankingAmps At -18°C (0°F) perBattery.............................................................................................. 1400Battery—MinutesReserve Capacity At 25Amps per Battery................................................................................ 440

If one battery in a 24-volt system has failed but the other isstill good, replace the failed battery with one of the same

TX1103240A

—UN—09DEC11

Batteries

1—Battery (2 used)

type. For example, replace a failed maintenance-freebattery with a new maintenance-free battery. Differenttypes of batteries may have different rates of charge. Thisdifference could overload one of the batteries and cause itto fail.

4-1-5 081214

PN=183


DB84312,000007B -19-12DEC11-1/2

DB84312,000007B -19-12DEC11-2/2

TX,WOM -19-20JAN11-1/1

Fluid Sampling Test Ports—If EquippedEngine Oil Test Port

On right side of machine, open engine service door toaccess the engine oil test port (1).

1—Engine Oil Test Port

TX1103244A

—UN—09DEC11

Engine Oil Test Port

Hydraulic Oil Test Port

On right side of machine, open engine service door toaccess the hydraulic oil test port (1).

2—Hydraulic Oil Test Port

TX1103242A

—UN—09DEC11

Hydraulic Oil Test Port

Welding On MachineIMPORTANT: Disconnect both negative and

positive battery cables and microprocessorunit (if applicable).

Have only a qualified welder do this job.Connect welder ground clamp close to each

weld area so electrical current does notpass through any bearings.

Remove or protect all parts that can bedamaged by heat or weld splatter.

4-1-6 081214

PN=184


ER79617,0000D50 -19-24APR14-1/1

TX,90,DH3734 -19-29MAY14-1/1

VD76477,0001541 -19-20JUL12-1/1

Clean the Machine Regularly

CAUTION: Avoid personal injury from flyingdebris. Be careful when removing any grease,oil, fuel, or debris build-up.

IMPORTANT: Directing pressurized water atelectronic/electrical components or connectors,bearings and hydraulic seals, fuel injectionpumps or other sensitive parts and componentsmay cause product malfunctions. Reducepressure and spray at a 45—90° angle.

High pressure washing (greater than 1379 kPa (13.8bar) (200 psi) can damage freshly painted finishes. Paintshould be allowed to air dry for 30 days minimum afterreceipt of machine before cleaning with high pressure. Uselow pressure wash operations until 30 days have elapsed.

T6642E

J—UN—18OCT88

Clean Machine Regularly

Do not spray heat exchangers at an angle.

Adding 12—Volt Accessories

IMPORTANT: This machine has a 24-volt electricalsystem. Installing 12-volt accessories withoutaddition of 24-volt to 12-volt convertermay cause battery failure.

This machine is equipped with a 12-volt,5-amp outlet.

When possible, use 24-volt accessories. If 12-voltaccessories are added, use a 24-volt to 12-volt converter.Converters are available from your John Deere dealer.

Converter capacity requirements depend on the loadof the accessories installed. Follow electronic dealer

and manufacturer’s recommendations to determine thecapacity of the converter required and its installationrequirements. If standard equipment, verify if amperageis adequate for application.

IMPORTANT: DO NOT connect an accessory to onebattery. Connecting a 12-volt accessory to onebattery will cause one battery to overcharge,and the other battery to undercharge,causing battery failure.

JDLink™ Machine Monitoring System(MMS)—If EquippedJDLink™ is an equipment monitoring and informationdelivery system. JDLink™ automatically collects andmanages information about where and how construction

and forestry equipment is being used, as well as criticalmachine health data and service status.

For more information, see your authorized dealer or visitwww.deere.com (browse to Construction, Services andSupport, JDLink™).

JDLink is a trademark of Deere & Company

4-1-7 081214

PN=185


Continued on next page DB84312,00000D4 -19-22MAY14-1/4

Replacing FusesThe fuse box is located inside the cab underneath the leftrear panel labeled FUSE.

Remove cover.

IMPORTANT: Install fuse with correct amperagerating to prevent electrical system damagefrom overload.

Amperage Rating Color1 Black3 Violet4 Pink5 Tan7-1/2 Brown10 Red15 Light Blue20 Yellow25 Natural (white)30 Light Green

Fuse Color Codes

Early Production (S.N. —XXXXXX)

TX1157166

F10

F9

F8

F7

F6

F5

F4

F3

F2

F1

F20

F19

F18

F17

F16

F15

F14

F13

F12

F11

F30

F29

F28

F27

F26

F25

F24

F23

F22

F21

F40

F39

F38

F37

F36

F35

F34

F33

F32

F31

TX1157166—UN—03APR14

Fuse Blocks

F1 — LAMP 20 Amp fuseF2 — WIPER 10 Amp fuseF3 — HEATER 20 Amp fuseF4 — SOLENOID 20 Amp fuseF5 — OPT. 1 (ALT) 5 Amp fuseF6 — OPT. 2 (ALT) 20 Amp fuseF7 — START 5 Amp fuseF8 — ECU 30 Amp fuseF9 — BACK UP 10 Amp fuseF10 — CONTROLLER 5 Amp fuseF11 — NOT USED

F12 — RADIO 5 Amp fuseF13 — LIGHTER 10 Amp fuseF14 — MONITOR 5 Amp fuseF15 — AUX 10 Amp fuseF16 — START AID 20 Amp fuseF17 — POWER ON 5 Amp fuseF18 — IDLE STOP 5 Amp fuseF19 — HORN 10 Amp fuseF20 — OPT.3 (BAT) 5 Amp fuseF21 — SEAT HEATER 10 Amp fuseF22 — CAB LAMP FRONT 10 Amp fuse

4-1-8 081214

PN=186



F23 — CAB LAMP REAR 10 Amp fuseF24 — 12V UNIT 10 Amp fuseF25 — IMOBI 5 Amp fuseF26 — QUICK HITCH 5 Amp fuseF27 — AUX 3 5 Amp fuseF28 — NOT USEDF29 — NOT USEDF30 — NOT USEDF31 — SEAT COMPR 10 Amp fuse

F32 — CAB LAMP FRONT +2 10 Amp fuseF33 — WARNING LAMP 10 Amp fuseF34 — AUX 2 10 Amp fuseF35 — NOT USEDF36 — NOT USEDF37 — NOT USEDF38 — NOT USEDF39 — NOT USEDF40 — NOT USED

4-1-9 081214

PN=187



Late Production (S.N. XXXXXX— )

TX1157166

F10

F9

F8

F7

F6

F5

F4

F3

F2

F1

F20

F19

F18

F17

F16

F15

F14

F13

F12

F11

F30

F29

F28

F27

F26

F25

F24

F23

F22

F21

F40

F39

F38

F37

F36

F35

F34

F33

F32

F31

TX1157166—UN—03APR14

Fuse Blocks

F1 — LAMP 20 Amp FuseF2 — WIPER 10 Amp FuseF3 — HEATER 20 Amp FuseF4 — SOLENOID 20 Amp FuseF5 — OPT. 1 (ALT) 20 Amp FuseF6 — OPT. 2 (ALT) 20 Amp FuseF7 — START 5 Amp FuseF8 — ECU P1 20 Amp FuseF9 — BACK UP 10 Amp FuseF10 — CONTROLLER 5 Amp FuseF11 — TRAVEL ALARM 5 Amp FuseF12 — RADIO 5 Amp FuseF13 — LIGHTER 10 Amp FuseF14 — MONITOR 5 Amp FuseF15 — AUX 10 Amp FuseF16 — 12V UNIT 10 Amp FuseF17 — POWER ON 5 Amp FuseF18 — IDLE STOP 5 Amp FuseF19 — HORN 10 Amp FuseF20 — OPT.3 (BAT) 5 Amp Fuse

F21 — SEAT HEATER 10 Amp FuseF22 — CAB LAMP FRONT 10 Amp FuseF23 — CAB LAMP REAR 10 Amp FuseF24 — IMOBI 5 Amp FuseF25 — QUICK HITCH 5 Amp FuseF26 — AUX 3 5 Amp FuseF27 — NOT USEDF28 — NOT USEDF29 — NOT USEDF30 — NOT USEDF31 — SEAT COMPR 10 Amp FuseF32 — CAB LAMP FRONT +2 10 Amp FuseF33 — WARNING LAMP 10 Amp FuseF34 — AUX 2 10 Amp FuseF35 — DIAG 5 Amp FuseF36 — ECU P2 20 Amp FuseF37 — ECU P3 20 Amp FuseF38 — ECU P4 20 Amp FuseF39 — NOT USEDF40 — NOT USED

4-1-10 081214

PN=188


DB84312,00000D4 -19-22MAY14-4/4

Continued on next page 04T,90,M16 -19-28MAR11-1/3

JDLink™ In-Line Fuse—If Equipped

NOTE: JDLink in-line fuses may be equipped on earlyand late serial number machines.

1. Turn machine off.

2. Open battery compartment access door.

3. Remove cap screws (2) from cover to access the 7.5Amp JDLink™ unswitched power in-line fuse (1) onthe yellow wire.

4. To deactivate the JDLink™ Machine MonitoringSystem, remove the unswitched power in-line fuse.

5. Install cover and cap screws.

6. Close access door.

1—JDLink™ UnswitchedPower In-Line Fuse

2—Cap Screws (3 used)

3—JDLink™ Ground In-LineFuse (7.5 Amp Fuse)

4—JDLink™ Switched PowerIn-Line Fuse (3 Amp Fuse)

TX1104628A

—UN—03JAN12

Cover

TX1024511A

—UN—15DEC10

JDLink In-line Fuse

JDLink is a trademark of Deere & Company

Replacing Bucket Teeth

CAUTION: Guard against injury from flying piecesof metal; wear goggles or safety glasses.

IMPORTANT: Angle the drift toward the bucket toavoid damaging the rubber pin lock.

1. Use a hammer and drift to drive out locking pin.

NOTE: Alternate buckets may use different toothassemblies.

2. Remove tooth.

T95784

—UN—10NOV88

Bucket Teeth

4-1-11 081214

PN=189


04T,90,M16 -19-28MAR11-2/3

04T,90,M16 -19-28MAR11-3/3

3. Inspect rubber pin lock (A) for damage. Replace ifnecessary.

4. If rubber pin lock has moved, reposition in slot inadapter tooth shank.

A—Rubber Pin Lock

T95785

—UN—10NOV88

Rubber Pin Lock

5. Position the new tooth over the tooth shank.

6. Drive the locking pin into the hole fully.

NOTE: Check bucket teeth periodically so that wear doesnot extend to the bucket tooth shank.

T95786

—UN—10NOV88

Tooth Shank

4-1-12 081214

PN=190


04T,90,K273 -19-23AUG12-1/1

DB84312,00000BC -19-20JAN14-1/1

Replacing Bucket Tooth Tip—Heavy-DutyBucket1. Clean tooth (A) and tooth tip (B).

2. Insert lock removal tool under U-shaped pin (C).

CAUTION: Avoid possible injury. Pin may flyafter it is released from tooth tip. Keep a firmgrip on pin to prevent injury.

3. Remove pin.

4. Turn tooth tip counterclockwise and pull it towards youto remove.

5. Clean tooth shank.

6. Replace U-shaped pin at same time you replace toothtip.

7. Insert tooth tip on shank turning tip clockwise.

8. Install U-shaped pin. Side of pin marked "FRONT" (D)must face tooth tip. Make sure pin is firmly engagedover tooth tip.

A—ToothB—Tooth Tip

C—PinD—"Front" Mark

T6879E

E—UN—06DEC88

Bucket Tooth Tip—Heavy-Duty Bucket

T7527D

O—UN—27JU

N91

U-Shaped Pin—Heavy-Duty Bucket

Replacing Bucket Teeth—TK SeriesIMPORTANT: Prevent machine damage. Check

bucket teeth periodically so that wear doesnot extend to the bucket tooth shank.

1. Remove pin (1) by rotating counterclockwise 180°using a ratchet and socket.

2. Remove tooth.

3. Inspect pin and rubber locks (2) for damage. Replaceif necessary.

4. Position the new tooth over the tooth shank.

5. Install pin by rotating clockwise 180°.

1—Pin 2—Rubber Lock (2 used)

TX1150806—UN—10JAN14

Pin

TX1150895—UN—10JAN14

Rubber Lock

4-1-13 081214

PN=191


04T,90,M35 -19-28AUG09-1/1

VD76477,00001F7 -19-28AUG09-1/1

TX14740,0001CFC -19-03JAN12-1/1

TX,90,FF1225 -19-15MAR93-1/1

Removing the Bucket1. Lower bucket to the ground.

2. Remove snap rings and locking pins.

3. Slide O-ring seals out of way. Remove bucket pins.

Track Sag General Information

To maximize undercarriage life, keep track sag withinspecification. Tracks may require adjustment severaltimes during a working day due to changing soil type andmoisture content.

Adjust tracks in the actual operating conditions.

TIGHT TRACK: Packing causes a tight track. If materialpacks in the undercarriage, adjust tracks with the materialpacked in the components.

While the track spring will recoil and the machine cancontinue to operate with a tight track, continued operation

will result in excessive pin and bushing wear, sprocketpopping, tooth tip wear, and excessive loads on the entireundercarriage and travel drive system.

Machine productivity and fuel consumption are alsoadversely affected because increased horsepower isneeded to move the machine.

LOOSE TRACK: A loose track has more side to sidemotion, increasing side wear on the links, rollers, and frontidler. An excessively loose track will slap at high groundspeeds, resulting in high impact loads on the sprocketteeth, bushings, and carrier rollers.

Check Track Shoe HardwareTracks shoes should be checked periodically for looseor missing cap screws and nuts. For shoes with missingor loose cap screws and nuts, remove shoes and cleanthe mating surface of shoes and links before tighteningcap screws and nuts. The cap screws should be replacedbecause they have been stretched to yield previously.

Operating a machine with loose shoes can cause the capscrews and holes in the shoes and links to wear makingit difficult to keep the shoes tight. Loose shoes can alsocause hardware failure and loss of shoes.

1. Clean the mating surface of shoe and links. Installshoes.

2. Apply a light coating of oil to cap screw threads beforeinstalling.

3. Install nuts with the rounded corners against milledsurface of link and chamfered side is away from link.

T6352A

H—UN—23FE

B89

Cap Screw Tightening Sequence

Check that nuts are square with the milled surface oflink and there is full contact between nut and milledsurface. As necessary, hold the nut so it does not turn.

4. Starting at any cap screw, tighten all cap screws insequence shown to specification.

Hardware Torque SpecificationsCheck cap screws and nuts to be sure they are tight.If hardware is loose, tighten to torque shown on thefollowing charts unless a special torque is specified.

4-1-14 081214

PN=192


DX,TORQ1 -19-12JAN11-1/1

Unified Inch Bolt and Screw Torque ValuesTS1671 —UN—01MAY03

SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2Bolt or ScrewSize Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150

N·m lb.-ft. N·m lb.-ft.5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26

N·m lb.-ft. N·m lb.-ft.3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46

N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74

N·m lb.-ft.1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 1159/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 1655/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 2253/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 4007/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 6401 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960

1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 13501-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 19201-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 25001-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

Torque values listed are for general use only, based on the strength of the boltor screw. DO NOT use these values if a different torque value or tighteningprocedure is given for a specific application. For plastic insert or crimped steeltype lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see thetightening instructions for the specific application. Shear bolts are designed to failunder predetermined loads. Always replace shear bolts with identical grade.

Replace fasteners with the same or higher grade. If highergrade fasteners are used, tighten these to the strength of theoriginal. Make sure fastener threads are clean and that youproperly start thread engagement. When possible, lubricateplain or zinc plated fasteners other than lock nuts, wheel boltsor wheel nuts, unless different instructions are given for thespecific application.

aGrade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6in. (152 mm) long, and for all other types of bolts and screws of any length.b“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.c“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.

4-1-15 081214

PN=193


DX,TORQ2 -19-12JAN11-1/1

Metric Bolt and Screw Torque ValuesTS1670 —UN—01MAY03

4.84.8 8.8 9.8 10.9 12.9 12.9

12.912.910.99.88.84.8

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9Bolt or ScrewSize Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172

N·m lb.-ft. N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35

N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70

N·m lb.-ft.M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

Torque values listed are for general use only, based on the strength ofthe bolt or screw. DO NOT use these values if a different torque value ortightening procedure is given for a specific application. For stainless steelfasteners or for nuts on U-bolts, see the tightening instructions for thespecific application. Tighten plastic insert or crimped steel type lock nutsby turning the nut to the dry torque shown in the chart, unless differentinstructions are given for the specific application.

Shear bolts are designed to fail under predetermined loads. Alwaysreplace shear bolts with identical property class. Replace fasteners withthe same or higher property class. If higher property class fasteners areused, tighten these to the strength of the original. Make sure fastenerthreads are clean and that you properly start thread engagement. Whenpossible, lubricate plain or zinc plated fasteners other than lock nuts,wheel bolts or wheel nuts, unless different instructions are given for thespecific application.

a“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.b“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.

4-1-16 081214

PN=194

Miscellaneous—Operational Checkout

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DB84312,00000A3 -19-04JUN14-3/56

Continued on next page DB84312,00000A3 -19-04JUN14-4/56

Operational CheckoutThis procedure is used to check operation of machine.It is designed so you can do a walk around inspection,check machine operation, and perform specific checksfrom the operator's seat.

If there is a problem with machine, diagnostic informationin this checkout will help pinpoint the probable cause. Thisinformation may allow you to perform a simple adjustmentto correct the problem. Use the table of contents to helpfind adjustment procedures.

A location will be required which is level and has adequatespace to complete checks. No tools or equipment areneeded to perform checkout.

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

Read each check completely before performing. If noproblem is found, you will be instructed to go to the nextcheck. If a problem is indicated, you will be referred to aprocedure for adjustment, repair, or replacement.

The monitor can be used to perform diagnostic andoperational checks. The monitor can display enginespeed, pressures, and diagnostic trouble codes (DTCs).

Diagnostic Trouble Code Check

Display and Clear TroubleCodes

Always check for diagnostic trouble codes and correct them before performingoperational checkout.Diagnostic trouble codes can be displayed by using one of the following methods:

• Monitor• Service ADVISOR™

• MPDr YES: Correct all diagnostictrouble codes beforeproceeding.

LOOK: Are diagnostic trouble codes present? NO: Proceed withoperational checkout.


Operational Checks—Key Switch Off, Engine Off Checks

4-2-1 081214

PN=195



Horn Circuit Check

1

TX1093717 —UN—29JUN11Horn Circuit

1—Horn Button

Key switch in OFF position. YES: Go to next check.Press horn button (1) on top of left pilot control lever. NO: Check horn 10 A fuse

(F19).LISTEN: Does horn sound? IF OK: See your authorized

dealer.

4-2-2 081214

PN=196


DB84312,00000A3 -19-04JUN14-6/56


Hour Meter and FuelGauge Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

2

TX1086727 —UN—11JAN11Switch Panel

50.0 h

10:00

H

C

AM

F

E

1

6

TX1086583A —UN—11JAN11Hour Meter and Fuel Gauge Screen

1—Hour Meter2—Home Button6—Fuel Gauge

Press and hold home button (2) until default screen appears. YES: Go to next check.LOOK: Does hour meter (1) display machine hours? NO: Check power on 5 A

fuse (F17).LOOK: Does fuel gauge (6) display correct fuel level? IF OK: See your authorized

dealer.

Operational Checks—Key Switch On, Engine Off Checks

4-2-3 081214

PN=197



Monitor Start-Up Check

TX1086287A —UN—28DEC10System Starting Screen

TX1086304A —UN—28DEC10Default Screen

1—System Starting Screen2—Default Screen

NOTE: The exhaust filter auto cleaning disabled indicator will display on themonitor when the key switch is in ON position. Once the engine is started,the indicator will disappear unless exhaust filter auto cleaning has beendisabled by the operator through the monitor.

When the key switch is turned to the ON position, the system starting screen (1)displays for about 2 seconds and then the default screen (2) is displayed.Turn key switch to ON position. YES: Go to next check.LOOK: Does monitor display system starting screen? NO: Check controller 5 A

fuse (F10).LOOK: Does default screen with hour meter appear after system starting screendisappears?

IF OK: See you authorizeddealer.

4-2-4 081214

PN=198



Monitor, Gauges, andBattery Relay Checks

TX1087186A —UN—28JUN13Default Screen

50.0 h

10:00

H

C

AM

F

E

AUTO

24.0˚C FMVOL

CH1STMHz81.3

ECO 8

TX1089107 —UN—08MAR11Engine Preheat Indicator

1—Work Mode Indicator2—Exhaust Filter Auto Cleaning Disabled Indicator3—Power Mode Indicator4—Hour Meter5—Engine Coolant Temperature Gauge6—Fuel Gauge7—Travel Mode Indicator8—Engine Preheat Indicator

IMPORTANT: This machine is equipped with glow plugs. Glow plugsare automatically controlled by the engine controller when thekey is turned ON. Do not start the engine until the engine preheatindicator (8) disappears on the monitor. Indicator will not appearif ambient air temperature is above 0°C (32°F).


NOTE: If engine coolant temperature is below 30°C (86°F) enginetemperature gauge needle may not move.

4-2-5 081214

PN=199



Turn key switch to ON position.LISTEN: Does battery relay click?LOOK: Does engine coolant temperature gauge (5) display correct engine coolanttemperature?LOOK: Does fuel gauge (6) display correct fuel level?LOOK: Does hour meter (4) display machine hours?LOOK: Does work mode indicator (1) display correct work mode (dig or attachment)?LOOK: Does travel mode indicator (7) display correct travel mode? YES: Go to next check.LOOK: Does power mode indicator (3) display correct power mode? NO: Monitor does not turn

ON. Check monitor 5 A fuse(F14).

LOOK: Does engine preheat indicator (8) appear on monitor and then disappear afterglow plugs reach specific temperature?

IF OK: See your authorizeddealer.

4-2-6 081214

PN=200



Rear Camera Check

TX1086305A —UN—28DEC10Default Screen

5—Default Screen

TX1086306A —UN—28DEC10Main Menu Screen

1—Main Menu Screen

TX1086272A —UN—27DEC10Switch Panel

2—Monitor Dial3—Back Button4—Home Button

4-2-7 081214

PN=201



CAUTION: To avoid possible injury or death to operator or others. The rearview camera image is designed to supplement other safety practices andis not intended to be the sole method of collision avoidance. Always bealert and aware of the surroundings when operating this machine.

Turn key switch to ON position.When the default screen (5) is displayed, press monitor dial (2) on the switch panel.LOOK: Does main menu (1) display?Rotate monitor dial to highlight settings menu.Press monitor dial.LOOK: Does settings menu display?At settings menu, rotate monitor dial to highlight rear view camera monitor.Press monitor dial to display rear view camera monitor menu.LOOK: Does rear view camera monitor menu display?Press monitor dial to turn camera ON (enable).Press home button (4).

TX1087390A —UN—27JAN11Rear View Image

6—Rear View Image

LOOK: Does rear view image (6) display on default screen?Repeat above steps.At rear view camera monitor menu, press monitor dial to turn camera OFF (disable). YES: Go to next check.Press Home button. NO: Menus do not display.

Check monitor 5 A fuse(F14).

LOOK: Does default screen appear without rear view image? IF OK: See your authorizeddealer.

4-2-8 081214

PN=202



Travel Lever and PedalNeutral Checks 1

2

TX1093760 —UN—31AUG11Travel Lever and Pedal

1—Forward2—Rearward

Push both travel levers and pedals forward (1), then release.Pull both travel levers and pedals rearward (2), then release.FEEL: Do levers and pedals require equal effort to operate in forward and reverse? YES: Go to next check.LOOK: Do levers and pedals return to neutral at the same time when released? NO: See your authorized

dealer.

4-2-9 081214

PN=203



Light Circuit Checks

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

3


3—Work Light Switch

Turn work light switch (3) to 1st position.LOOK: Is monitor panel back light and base machine work light on?LOOK: Does switch panel illuminate?Turn light switch to 2nd position. YES: Go to next check.LOOK: Does base machine work light stay on and switch panel stay illuminated? NO: Check work and drive

lights 20 A fuse (F1) andcontroller 5 A fuse (F10).

LOOK: Does boom work light come on and monitor back panel light change to nightmode?


4-2-10 081214

PN=204



Windshield Wiper ControlCheck

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

4


4—Windshield Wiper and Washer Switch

NOTE: Front window must be fully closed and latched for windshield wiper to operate.Turn windshield wiper and washer switch (4) to 1st INT position.LOOK: Does wiper operate intermittently (8 second interval)?Turn windshield wiper and washer switch to 2nd INT position.LOOK: Does wiper operate intermittently, but faster than when in first position (5second interval)?Turn windshield wiper and washer switch to 3rd INT position.LOOK: Does wiper operate intermittently, but faster than when in second position (3second interval)?Turn windshield wiper and washer switch to ON position.LOOK: Does wiper operate continuously? YES: Go to next check.Turn windshield wiper and washer switch to OFF position. NO: Check windshield

wiper and washer 10 A fuse(F2).

LOOK: Does wiper arm stop and retract to left side of windshield? IF OK: See your authorizeddealer.

4-2-11 081214

PN=205



Windshield WasherControl Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

4



IMPORTANT: Washer motor may be damaged if washer switch isheld for more than 20 seconds, or continually operated withno fluid in the washer fluid tank.

NOTE: While wiper is being operated in INT mode, when windshield wiper and washerswitch is pressed, wiper mode is changed to continuous mode.

Press windshield wiper and washer switch (4).LOOK: Is washer fluid supplied to windshield?Press and hold windshield wiper and washer switch for 3 seconds. YES: Go to next check.LOOK: Does wiper start and continue operating until switch is released? NO: Check washer

fluid level. See CheckWindshield Washer FluidLevel. (Section 3-3.)

Release windshield wiper and washer switch. NO: Check windshieldwiper and washer 10 A fuse(F2).

LOOK: Does wiper stop and retract to left side of windshield? IF OK: See your authorizeddealer.

4-2-12 081214

PN=206



Windshield Wiper CircuitCheck

1

2

TX1001270 —UN—14DEC05Front Window Release Handle

1—Lock Pin2—Lock Release Bar

CAUTION: Prevent possible injury from window closing. Upper frontwindow comes down very forcefully. Close window only when sittingon operator's seat. Guide window down slowly.

CAUTION: Prevent possible injury from window closing. Alwayslock the pin in cab frame boss hole.

NOTE: The wiper cannot operate with the upper front window open. The washercan operate with the upper front window open. When closing window, checkthat window upper left corner makes good contact with the cab.

Slide lock pin (1) inward, then down into notch.Pull lock release bar (2) toward operator’s seat.While holding lower handle on window, pull window up and back as far as it can go.Slide lock pin into cab frame boss hole and rotate downward into the locked position.

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

4



Turn windshield wiper and washer switch (4) to ON position. YES: Go to next check.

4-2-13 081214

PN=207


DB84312,00000A3 -19-04JUN14-18/56

DB84312,00000A3 -19-04JUN14-19/56


LISTEN: Does wiper circuit click? NO: Check windshieldwiper and washer 10 A fuse(F2).

LOOK: Does wiper remain stationary in park position? IF OK: See your authorizeddealer.

Windshield WasherCircuit Check

IMPORTANT: Washer motor may be damaged if washer switch isheld for more than 20 seconds, or continually operated withno fluid in the washer fluid tank.

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

4


YES: Go to next check.

4—Windshield Wiper and Washer Switch NO: Check washerfluid level. See CheckWindshield Washer FluidLevel. (Section 3-3.)

Press windshield wiper and washer switch (4) and hold for 3 seconds. NO: Check windshieldwiper and washer 10 A fuse(F2).

LOOK: Is washer fluid supplied to windshield? IF OK: See your authorizeddealer.

Operational Checks—Key Switch On, Engine On Checks

4-2-14 081214

PN=208



Monitor and GaugeCircuit Checks

TX1087196A —UN—28JUN13Operating Screen

1—Power Mode Indicator2—Hour Meter3—Engine Coolant Temperature Gauge4—Fuel Gauge5—Alarm Indicator

IMPORTANT: Engine damage could occur if the alarm indicator (5)or engine oil pressure alarm indicator comes on after enginestarts. Turn off machine immediately.


Start engine. YES: Go to next check.LOOK: Do all alarm indicator displays remain off after engine starts? NO: Engine oil pressure

alarm displayed.Immediately stop engineand check engine oil level.See Check Engine OilLevel. (Section 3-4.)

LOOK: Does alarm indicator remain off after engine starts? IF OK: See your authorizeddealer.

LOOK: Does engine coolant temperature gauge (3) display correct engine coolanttemperature?

NO: Alternator alarmindicator displayed. Checkalternator drive belt.

LOOK: Does fuel gauge (4) display correct fuel level? IF OK: See your authorizeddealer.

4-2-15 081214

PN=209



Pilot Shutoff CircuitCheck

1

TX1093762 —UN—28JUN13Engine Speed Dial

TX1093763 —UN—19JUL11Locked

1—Engine Speed Dial

CAUTION: Avoid possible injury. Machine may move during this check.Make sure area is clear and large enough to operate all machine functions.

Turn engine speed dial (1) to L (slow idle) position.Place pilot shutoff lever in locked (UP) position.Slowly actuate dig and travel functions. YES: Continue check.LOOK: Do dig and travel functions operate? NO: See your authorized

dealer.

TX1093764 —UN—19JUL11Unlocked

Place pilot shutoff lever in unlocked (DOWN) position.Slowly actuate dig and travel functions. YES: Go to next check.LOOK: Do dig and travel functions operate? NO: See your authorized

dealer.

4-2-16 081214

PN=210



Fan Reversing System- If Equipped

TX1015264A —UN—09JAN07Fan Reversing Switch

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

TX1088406 —UN—21FEB11Switch Panel

1—Engine Speed Dial2—Auto-Idle Switch3—Blower Speed Switch9—Fan Reversing Switch

Place pilot shutoff lever in unlocked (DOWN) position.Turn engine speed dial (1) to H (fast idle) position.Turn auto-idle switch (2) to A/I OFF position.Press blower speed switch (3) OFF.Press reversing cooling fan switch to MANUAL position.LISTEN: Does fan speed slow down?LOOK/LISTEN: After approximately 20 seconds, does the fan speed increase androtate in reverse direction for approximately 30 seconds?LISTEN/LOOK: Does the fan speed slow for approximately 20 seconds? Does fandirection return to normal?


LISTEN: Does fan speed increase? NO: See your authorizeddealer.

4-2-17 081214

PN=211



Engine Speed Dial Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel

1—Engine Speed Dial2—Auto-Idle Switch3—Travel Mode Switch4—Power Mode Button

Turn auto-idle switch (2) to A/I OFF position.Place pilot shutoff lever in locked (UP) position.Turn engine speed dial (1) clockwise.LISTEN: Does engine speed increase? YES: Go to next check.Turn engine speed dial counterclockwise. NO: Check controller 5 A

fuse (F10).LISTEN: Does engine speed decrease? IF OK: See your authorized

dealer.

4-2-18 081214

PN=212



ECO (Economy) Mode andPWR (Power) Mode Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel

1—Engine Speed Dial2—Auto-Idle Switch3—Travel Speed Switch4—Power Mode Button

Press power mode button (4) until PWR (power) mode is displayed on monitor.Turn auto-idle switch (2) to A/I OFF position.Turn engine speed dial (1) to H (fast idle) position.Press power mode button until ECO (economy) mode is displayed on monitor.LOOK/LISTEN: Does engine speed decrease?Press power mode button until PWR (power) mode is displayed on monitor. YES: Go to next check.LOOK/LISTEN: Does engine speed increase? NO: See your authorized

dealer.

4-2-19 081214

PN=213



H/P (High Power) ModeCheck

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Press power mode button (4) until PWR (power) mode is displayed on monitor.Turn auto-idle switch (2) to A/I OFF position.Turn engine speed dial (1) to H (fast idle) position.Press power mode button until H/P (high power) mode is displayed on monitor. YES: Go to next check.Actuate arm in function over relief. NO: Check controller 5 A

fuse (F10).LOOK/LISTEN: Does engine speed increase as function goes over relief? IF OK: See your authorized

dealer.

4-2-20 081214

PN=214



Auto-Idle Circuit Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Turn engine speed dial (1) to H (fast idle) position.Press power mode button (4) until H/P (high power) mode is displayed on monitor.Turn auto-idle switch (2) to A/I off position.Place pilot shutoff lever in unlocked (DOWN) position.Turn auto-idle switch to A/I on position.LOOK/LISTEN: Does engine speed decrease after 4—6 seconds? YES: Go to next check.Slowly actuate dig function. NO: Check solenoid 20 A

fuse (F4).LOOK/LISTEN: Does engine speed return to fast idle? IF OK: See your authorized

dealer.

4-2-21 081214

PN=215



Travel Alarm Check

C

A B

TX1095497 —UN—09AUG11Travel Alarm

A—Pilot Shutoff LeverB—Travel Lever and Pedal ForwardC—Travel Lever and Pedal Rearward

CAUTION: Avoid possible injury. Machine will move during this check.Make sure area is clear and large enough to operate machine.

Place pilot shutoff lever (A) in unlocked (DOWN) position.Push travel pedals or levers forward (B).LISTEN: Does travel alarm sound? YES: Go to next check.Push travel pedals or pull levers rearward (C). NO: Check travel alarm 5

A fuse (F5).LISTEN: Does travel alarm sound? IF OK: See your authorized

dealer.

4-2-22 081214

PN=216



Travel Alarm CancelSwitch Circuit Check

TX1086700A —UN—08JAN11Left Console

1—Reversing Fan Switch2—Seat Heater Switch3—Travel Alarm Cancel Switch

CAUTION: Avoid possible injury. Machine will move during this check.Make sure area is clear and large enough to operate machine.

NOTE: Travel alarm must operate for this check.Place pilot shutoff lever in unlocked (DOWN) position.Push travel pedals or levers and allow travel alarm to operate for a minimum of 12seconds.LISTEN: Does travel alarm sound? YES: Go to next check.While continuing travel, push travel alarm cancel switch (3). NO: Check travel alarm 5

A fuse (F5).LISTEN: Does travel alarm stop sounding? IF OK: See your authorized

dealer.

4-2-23 081214

PN=217


DB84312,00000A3 -19-04JUN14-30/56


Hydraulic Oil TankPressurization Check 1

2

TX1093766 —UN—28JUN13Hydraulic Oil Tank Cover

1—Hydraulic Oil Tank Pressure Release Button2—Hydraulic Oil Tank Cover

IMPORTANT: The pressurized oil tank creates pressure at the inlet tothe hydraulic pumps. If tank cover does not seal, hydraulicpumps could cavitate and be damaged.

Raise boom to full height, then lower boom to ground.Slowly depress pressure release button (1) on hydraulic oil tank cover. YES: Go to next check.LISTEN: Is air heard escaping from the pressure release button on hydraulic oil tankcover?

NO: Replace hydraulic oiltank cover.

Control Lever PatternCheck-Excavator Pattern

5

3

1

6

87

2

4

TX1093767 —UN—28JUN13Control Lever Pattern Check - Excavator Pattern

1—Arm Out2—Arm In3—Swing Left4—Swing Right5—Boom Down6—Boom Up7—Bucket Load8—Bucket Dump

CAUTION: Prevent possible injury from unexpected machine movement.Clear all persons from the area before operating machine.

Turn engine speed dial to L (slow idle) position.Place pilot shutoff lever in unlocked (DOWN) position. YES: Go to next check.Slowly move hydraulic levers to all positions. NO: See Control Lever

Pattern Operation. (Section2-3.)

LOOK: Do bucket, boom, arm, and swing move according to pattern? IF OK: See your authorizeddealer.

4-2-24 081214

PN=218



Control Lever PatternCheck- Backhoe Pattern

1

2

873

5

6

4

TX1093769 —UN—28JUN13Control Lever Pattern Check - Backhoe Pattern

1—Arm Out2—Arm In3—Swing Left4—Swing Right5—Boom Down6—Boom Up7—Bucket Load8—Bucket Dump

CAUTION: Prevent possible injury from unexpected machine movement.Clear all persons from the area before operating machine.

Turn engine speed dial to L (slow idle) position.Place pilot shutoff lever in unlocked (DOWN) position. YES: Go to next check.Slowly move hydraulic levers to all positions. NO: See Control Lever

Pattern Operation. (Section2-3.)

LOOK: Do bucket, boom, arm, and swing move according to pattern? IF OK: See your authorizeddealer.

4-2-25 081214

PN=219



Swing Dynamic BrakingCheck

45˚

90˚

TX1095482 —UN—28JUN13Swing Dynamic Braking

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


CAUTION: Avoid possible injury. Make sure area is clear and large enoughto swing extended arm and bucket. Machine must be on level ground.

Position upperstructure with boom to the front.Move arm to the extended position, bucket to the retracted position, and bucket-to-armpivot pin at same level as boom-to-frame pivot pin.Turn engine speed dial (1) to H (fast idle) position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Fully actuate swing function. Swing clockwise 90 degrees and then release lever.LOOK: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasinglever?Position upperstructure with boom to the front.Fully actuate swing function. Swing counterclockwise 90 degrees and then release lever. YES: Go to next check.LOOK: Does upperstructure stop within 45 degrees (1/8 turn) or less after releasinglever?

NO: See your authorizeddealer.

4-2-26 081214

PN=220



Swing Park Brake andCircuit Drift Check

TX1093770 —UN—28JUN13Machine Position

Fill the bucket with dirt.Position machine on a hillside with a slope of approximately 25%. If a hill is notavailable, raise one side of machine approximately 300 mm (1 ft) with the boom andthen put a block under the track.Move arm to the fully extended position.Raise boom so arm-to-bucket pivot pin are the same height as boom-to-frame pivot pin.Position upperstructure with cab over travel motors, perpendicular to tracks.Turn engine speed dial to L (slow idle) position.Wait approximately 5 minutes with all functions in neutral.NOTE: Function does not need to be fully actuated to disengage the swing park brake.Slowly actuate bucket load function to disengage the swing park brake. Do not hold thefunction over relief for more than 10 seconds.LOOK: Does upperstructure hold position when swing park brake is engaged?LOOK: Does upperstructure move only slightly when swing park brake is disengaged?Swing upperstructure 180 degrees counterclockwise and repeat procedure.Turn engine speed dial to L (slow idle) position.Wait approximately 5 minutes with all functions in neutral.Slowly actuate bucket load function to disengage the swing park brake. Do not hold thefunction over relief for more than 10 seconds.LOOK: Does upperstructure hold position when swing park brake is engaged? YES: Go to next check.LOOK: Does upperstructure move only slightly when swing park brake is disengaged? NO: See your authorized

dealer.

4-2-27 081214

PN=221



Swing Power Check

TX1093770 —UN—28JUN13Machine Position

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Fill the bucket with dirt.Position machine on a hillside with a slope of approximately 25%. If a hill is notavailable, raise one side of machine approximately 300 mm (1 ft.) with the boom andthen put a block under the track.Move arm to the fully extended position. Raise boom so arm-to-bucket pivot pin is thesame height as boom-to-frame pivot pin.Swing upperstructure clockwise so it is 90 degrees to the slope.Turn engine speed dial (1) to H (fast idle) position.Press power mode button (4) until H/P (high power) mode is displayed on monitor.Actuate the swing function to swing uphill.LOOK: Does upperstructure swing uphill?Swing upperstructure 180 degrees counterclockwise and repeat procedure.Turn engine speed dial to H (fast idle) position.Power mode button in H/P (high power) mode.Actuate the swing function to swing uphill. YES: Go to next check.LOOK: Does upperstructure swing uphill? NO: See your authorized

dealer.

4-2-28 081214

PN=222



Dig Function Drift Check(loaded bucket)

TX1095487 —UN—28JUN13Machine Position—Loaded Bucket

Fill bucket with material to specification.

SpecificationLoaded Bucket—Weight (approximate)................................................................ 900 kg

1990 lb.Position bucket at maximum reach with bucket pivot pin the same height as boompivot pin.Retract arm cylinder, then extend about 50 mm (2 in.).Extend bucket cylinder, then retract about 50 mm (2 in.).Stop engine.Measure amount cylinders extend or retract in 5 minutes.Measure distance from bottom of bucket to ground.Compare measurements to specifications.

Dig Function Drift Specifications (loaded bucket)—SpecificationBoom Cylinder—Drift.............................................................................................. 5 mm

0.20 in.Arm Cylinder—Drift............................................................................................... 10 mm

0.39 in.Bucket Cylinder—Drift........................................................................................... 15 mm

0.59 in.Bottom Of Bucket-To-Ground—Drift................................................................... 100 mm

3.94 in.


LOOK: Is cylinder drift within specification? NO: See your authorizeddealer.

4-2-29 081214

PN=223



Dig Function Drift Check(empty bucket)

TX1109902 —UN—28JUN13Machine Position—Empty Bucket

1—Arm Tip Position Above Ground

Empty bucket of material.Extend arm cylinder, then retract about 50 mm (2 in.).Extend bucket cylinder, then retract about 50 mm (2 in.).Lower boom until the arm tip is 1 m (40 in.) above ground (1).Stop engine.Measure amount cylinders extend or retract in 5 minutes.Measure distance from arm tip to ground.Compare measurements to specifications.

Dig Function Drift Specifications (empty bucket)—SpecificationBoom Cylinder—Drift.............................................................................................. 5 mm

0.20 in.Arm Cylinder—Drift............................................................................................... 15 mm

0.59 in.Bucket Cylinder—Drift............................................................................................. 9 mm

0.35 in.Arm Tip-to-Ground—Drift...................................................................................... 80 mm

3.15 in.


LOOK: Is cylinder drift within specification? NO: See your authorizeddealer.

4-2-30 081214

PN=224



Swing Priority CircuitCheck CAUTION: Avoid possible injury. Make sure area is clear and large enough

to swing extended arm and bucket. Machine must be on level ground.

TX1095439 —UN—10AUG11Swing Priority Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


IMPORTANT: Avoid possible machine damage. Position machine as shown.Operate swing and arm in slowly a few times before attempting to performcheck to ensure bucket does not contact machine or ground.

Position machine as shown.Turn engine speed dial (1) to H (fast idle) position.Turn auto-idle switch (2) to A/I OFF position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Operate swing function and record time required for three complete revolutions.

160GLC—SpecificationSwing Function—Time—ThreeRevolutions.........................................................................................12.00—15.00 sec.

180GLC—SpecificationSwing Function—Time—ThreeRevolutions......................................................................................... 11.80—13.80 sec.Position machine as shown, arm extended, bucket curled, and upper structure 90degrees to tracks.Turn engine speed dial (1) to H (fast idle) position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Raise boom high enough so bucket does not contact the machine or ground duringarm in and swing combined operation.

4-2-31 081214

PN=225


DB84312,00000A3 -19-04JUN14-39/56


Operate swing function and slowly actuate arm in function when upperstructure is inline with tracks. Record time required for three complete revolutions.NOTE: Swing speed should not slow when actuating arm in. YES: Go to next check.LOOK: Does swing speed remain unchanged when actuating arm in? NO: See your authorized

dealer.

Control Valve LiftCheck Test

TX1095449 —UN—28JUN13Control Valve Lift

1

TX1093762 —UN—28JUN13Engine Speed Dial

1—Engine Speed Dial

Turn engine speed dial (1) to L (slow idle) position.Position machine as shown.Slowly lower boom, extend arm (retract cylinder), and dump bucket (retract cylinder). YES: See your authorized

dealer.LOOK: Do functions move in opposite direction as pilot control levers are first moved,then change direction as levers are moved farther?

NO: Go to next check.

4-2-32 081214

PN=226



Boom Up, Arm In,and Bucket CombinedFunction Operation Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Turn engine speed dial (1) to H (fast idle) position.Turn auto-idle switch (2) to A/I OFF position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Actuate boom up function, arm in function, and then bucket function in combination. YES: Go to next check.LOOK: Does boom continue to move at approximately the same speed after bucketfunction is actuated?


4-2-33 081214

PN=227



Boom Regenerative ValveOperation Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Turn engine speed dial (1) to H (fast idle) position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Raise boom and extend the arm to full extension.Actuate the boom down, then arm in and boom up functions in combined operation. YES: Go to next check.LOOK: Does the boom move smoothly through the complete cycle down and up andnot hesitate when it goes past the vertical position?


4-2-34 081214

PN=228



Arm Regenerative ValveOperation Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Turn engine speed dial (1) to H (fast idle) position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Extend the arm to full extension and then lower boom so bucket is on the ground.Actuate the boom up and arm in functions in combined operation. YES: Go to next check.LOOK: Does the arm move smoothly through the complete cycle and not hesitatewhen it goes through the vertical position?


4-2-35 081214

PN=229



Bucket RegenerativeValve Operation Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Turn engine speed dial (1) to H (fast idle) position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Actuate boom up, arm out and bucket dump functions.Actuate boom down function, arm in function, and then bucket curl function. YES: Go to next check.LOOK: Does the bucket move smoothly through the complete cycle and not hesitatewhen it goes to the curl position?


4-2-36 081214

PN=230



Travel Speed SelectionCheck

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Turn engine speed dial (1) to H (fast idle) position.Turn travel speed switch (3) to slow speed (turtle) mode.Actuate travel function to full speed.Turn travel speed switch to fast speed (rabbit) mode.LOOK: Does machine travel speed increase?Actuate a dig function and then return to neutral.LOOK: Does machine travel speed decrease and then increase as dig function isactuated and then released?Turn travel speed switch to slow speed (turtle) mode. YES: Go to next check.LOOK: Does machine travel speed decrease? NO: See your authorized

dealer.

4-2-37 081214

PN=231



Travel System TrackingCheck

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Turn engine speed dial (1) to H (fast idle) position.Turn auto-idle switch (2) to A/I OFF position.Turn travel speed switch (3) to fast speed (rabbit) mode.Press power mode button (4) until PWR (power) mode is displayed on monitor.

6

6

7

8

5

TX1120481 —UN—17AUG12Tracking Check

5—Distance of Mistrack6—Acceleration and Deceleration Zone (approximately): 3—5 m (10—16 ft.)7—Test Line (distance): 20 m (66 ft.)8—Track Print

4-2-38 081214

PN=232


DB84312,00000A3 -19-04JUN14-47/56


Operate machine at full travel forward speed on a flat and level surface approximately30 m (99 ft.).NOTE: When machine mistracks right, hydraulic pump 1 circuit oil flow may be

less than specification. When machine mistracks left, hydraulic pump2 circuit oil flow may be less than specification.

Observe direction of mistrack.Create a straight test line 20 m (66 ft.) (7) long between two points on track print (8).Measure and record greatest distance of mistrack (5) between inside edge of trackprint and test line.Repeat procedure in reverse travel. YES: Go to next check.LOOK: Does machine mistrack less than 200 mm (7.88 in.)? NO: See your authorized

dealer.

Travel System TrackingChecks While Operatinga Dig Function

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


NOTE: Machine will slow down during this test.Turn engine speed dial (1) to H (fast idle) position.Turn travel speed switch (3) to fast speed (rabbit) mode.Operate machine at full speed forward on a flat and level surface.After machine is moving, actuate arm out from neutral to full actuation and extendthe arm.

YES: See your authorizeddealer.

LOOK: Does machine mistrack excessively when the arm is extended? NO: Go to next check.

4-2-39 081214

PN=233



Travel SystemManeuverability Check

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

1

2

3

4TX1086753 —UN—11JAN11

Switch Panel


Turn engine speed dial (1) to H (fast idle) position.Turn travel speed switch (3) to fast speed (rabbit) mode.Drive machine at full speed forward down a slope.Turn in each direction.LOOK: Does each track slow down in response to pedal or lever movement in order toturn?Repeat the procedure in reverse travel.Turn travel speed switch to fast speed (rabbit) mode.Drive machine at full speed in reverse down a slope.Turn in each direction. YES: Go to next check.LOOK: Does each track slow down in response to pedal or lever movement in order toturn?


4-2-40 081214

PN=234



Cycle TimesCheck—160GLC only CAUTION: Prevent possible injury from unexpected machine movement.

Clear all persons from the area before operating machine.

NOTE: Warm hydraulic oil to operating temperature for this check.

ACC

ONS

TAR

T

5

9

3

8

5 4

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INT ON

PUSH

H L

PUSH

TUNE/AM-FM

PUSH

MODE

PUSH MENU/SET

min -1

L H

PUSH VOL/PWR

PUSH /VOL /PWR

1

5

2

3

4

TX1136301 —UN—10MAY13Switch Panel

1—Engine Speed Dial2—Auto-Idle Switch3—Travel Speed Switch4—Power Mode Button5—Monitor Dial

Turn engine speed dial (1) to H (fast idle) position.Turn auto-idle switch (2) to A/I OFF position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Rotate monitor dial (5) to highlight and select Dig mode from Work Mode menu.

TX1095475 —UN—11AUG11Boom

TX1095499 —UN—28JUN13Arm, Bucket, Swing

Move machine to position shown for each test.Record cycle time for each function.

4-2-41 081214

PN=235



SpecificationBoom Raise (cylinder extend)—CycleTime............................................................................................................2.7—3.3 sec.Boom Lower (cylinder retract)—CycleTime............................................................................................................1.9—2.5 sec.Arm In (cylinder extend)—Cycle Time........................................................3.3—3.9 sec.Arm Out (cylinder retract)—Cycle Time......................................................2.3—2.9 sec.Bucket Load (cylinder extend)—CycleTime............................................................................................................2.9—3.5 sec.Bucket Dump (cylinder retract)—CycleTime............................................................................................................1.7—2.3 sec.Swing Left or Right, 3 Revolutions—Cy-cle Time..................................................................................................12.0—15.0 sec.Drive 20 m (65 ft.) (check in forward andreverse with travel speed switch in FASTposition)—Cycle Time.............................................................................13.0—14.2 sec.Drive 20 m (65 ft.) (check in forwardand reverse with travel speed switch inSLOW position)—Cycle Time.................................................................20.0—22.0 sec.Track Raised for 3 Revolutions (checkin forward and reverse with travel modeswitch in FAST position)—Cycle Time....................................................14.9—18.9 sec.Track Raised for 3 Revolutions (checkin forward and reverse with travel modeswitch in SLOW position)—Cycle Time...................................................24.2—28.2 sec.


LOOK: Does machine perform within specifications? NO: See your authorizeddealer.

4-2-42 081214

PN=236



Cycle TimesCheck—180GLC only CAUTION: Prevent possible injury from unexpected machine movement.

Clear all persons from the area before operating machine.

NOTE: Warm hydraulic oil to operating temperature for this check.

ACC

ONS

TAR

T

5

9

3

8

5 4

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INT ON

PUSH

H L

PUSH

TUNE/AM-FM

PUSH

MODE

PUSH MENU/SET

min -1

L H

PUSH VOL/PWR

PUSH /VOL /PWR

1

5

2

3

4

TX1136301 —UN—10MAY13Switch Panel

1—Engine Speed Dial2—Auto-Idle Switch3—Travel Speed Switch4—Power Mode Button5—Monitor Dial

Turn engine speed dial (1) to H (fast idle) position.Turn auto-idle switch (2) to A/I OFF position.Press power mode button (4) until PWR (power) mode is displayed on monitor.Rotate monitor dial (5) to highlight and select Dig mode from Work Mode menu.

TX1095475 —UN—11AUG11Boom

TX1095499 —UN—28JUN13Arm, Bucket, Swing

Move machine to position shown for each test.Record cycle time for each function.

4-2-43 081214

PN=237



SpecificationBoom Raise (cylinder extend)—CycleTime............................................................................................................3.1—3.7 sec.Boom Lower (cylinder retract)—CycleTime............................................................................................................1.9—2.5 sec.Arm In (cylinder extend)—Cycle Time........................................................3.3—3.9 sec.Arm Out (cylinder retract)—Cycle Time......................................................2.4—3.0 sec.Bucket Load (cylinder extend)—CycleTime............................................................................................................2.9—3.5 sec.Bucket Dump (cylinder retract)—CycleTime............................................................................................................1.7—2.3 sec.Swing Left or Right, 3 Revolutions—Cy-cle Time.................................................................................................. 11.8—13.8 sec.Drive 20 m (65 ft.) (check in forward andreverse with travel speed switch in FASTposition)—Cycle Time.............................................................................13.0—14.2 sec.Drive 20 m (65 ft.) (check in forwardand reverse with travel speed switch inSLOW position)—Cycle Time.................................................................20.0—22.0 sec.Track Raised for 3 Revolutions (checkin forward and reverse with travel modeswitch in FAST position)—Cycle Time....................................................16.1—20.1 sec.Track Raised for 3 Revolutions (checkin forward and reverse with travel modeswitch in SLOW position)—Cycle Time...................................................26.0—30.0 sec.


LOOK: Does machine perform within specifications? NO: See your authorizeddealer.

4-2-44 081214

PN=238



Heater and AirConditioning CircuitCheck

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

5

6


5—Temperature Control/Mode Switch6—Blower Speed Switch

Start engine and warm to normal operating temperature.Turn temperature control/mode switch (5) clockwise to maximum heat position.FEEL: Does warm air come from the vents?Turn temperature control/mode switch counterclockwise to maximum cold position. YES: Go to next check.LISTEN: Does air conditioner compressor clutch solenoid “click”? NO: Heater does not

operate. Check airconditioner and heater 20 Afuse (F3).

FEEL: Does cool air come from the vents? IF OK: See your authorizeddealer.

4-2-45 081214

PN=239



Heater And AirConditioner ControlsCheck (AutomaticTemperature Control)

ACC

ONS

TAR

T

5

9

3

8

54

0

2

7

1

6

OFF

2

MODE 1

A/I ON

A/I OFF

OFF

OFF

INTON

PUSH

HL

PUSH

TUNE/AM-FM

PUSH

MODE

PUSHMENU/SET

min-1

L H

PUSHVOL/PWR

PUSH/VOL/PWR

5

6


50.0 h

10:00

H

C

AM

F

E

AUTO

24.0˚C FMVOL

CH1STMHz81.3

ECO

10

7

98

TX1087006 —UN—17JAN11Monitor-Air Conditioner and Heater Display

5—Temperature Control/Mode Switch6—Blower Speed Switch7—Fan Speed8—AUTO Display9—Vent Position10— Temperature Setting

Key ON, press blower speed switch (6).Start engine and warm to normal operating temperature.Press blower speed switch.LISTEN: Does air conditioner compressor clutch solenoid “click”?LOOK: Does AUTO display (8), display on monitor?LOOK: Does monitor display vent position (9), fan speed (7), and temperature setting(10)?

4-2-46 081214

PN=240


DB84312,00000A3 -19-04JUN14-56/56

Turn temperature control/mode switch (5) clockwise to maximum heat position.LOOK: Does vent position change?LOOK: Does temperature setting increase?FEEL: Does warm air come from the vents?Turn temperature control/mode switch counterclockwise to maximum cold position.LOOK: Does vent position change?LOOK: Does temperature setting decrease?FEEL: Does cool air come from the vents?Press blower speed switch.LISTEN: Does air conditioner compressor clutch solenoid “click”? (air conditioner andheater are ON in manual mode.)LOOK: Does AUTO display go OFF?Turn temperature control/mode switch clockwise to maximum heat position.LOOK: Does vent position change?LOOK: Does temperature setting increase?FEEL: Does warm air come from the vents?Turn temperature control/mode switch counterclockwise to maximum cold position.LOOK: Does vent position change?LOOK: Does temperature setting decrease?FEEL: Does cool air come from the vents?Press temperature control/mode switch.LOOK: Does vent position change?Repeat for all four vent positions.LOOK: Does vent position change each time switch is pressed? YES: Checks complete.Press blower speed switch. NO: Heater fan does

not blow air. Check airconditioner and heater 20 Afuse (F3).

LOOK: Are air conditioner and heater OFF? (press blower speed switch to start airconditioner and heater).


4-2-47 081214

PN=241

Miscellaneous—Troubleshooting

TX,TROUBLESHOOT -19-20JAN11-1/1

Troubleshooting ProcedureNOTE: Troubleshooting charts are arranged from the

simplest to verify, to least likely, more difficultto verify. When diagnosing a problem, useall possible means to isolate the problem to asingle component or system. Use the followingsteps to diagnose problems:

Step 1. Operational Checkout Procedure

Step 2. Troubleshooting Charts

Step 3. Adjustments

Step 4. See your authorized John Deere dealer.

4-3-1 081214

PN=242



EngineSymptom Problem Solution

Engine Cranks But Will Not Start OrHard To Start

No fuel Add correct fuel. Bleed air.

Incorrect fuel Use correct fuel.

Fuel filter clogged Replace filter. Bleed air. Clean fueltank inlet screen.

Primary fuel filter and water separatorclogged or not primed

Check primary fuel filter and waterseparator. Replace filter, prime filter,and bleed air from fuel system.

Water in fuel tank Check, drain, and refill.

Low battery power Charge or replace battery.

Slow cranking speed (poor electricalconnection)

Clean and tighten battery and starterconnections.

Incorrect engine oil Drain crankcase and refill with correctoil.

Engine Will Not Crank Low battery power Charge or replace battery.

Corroded or loose battery connections Clean battery terminals andconnections.

Fuse Check ECU fuse (F8) and POWERON 5 amp fuse (F17).

Engine Knocks, Runs Irregularly,Or Stops

Air filter clogged Clean or replace elements. Cleansystem.

Fuel filters clogged Replace filters. Bleed air. Clean fueltank inlet screen.

Air in fuel system Bleed air from fuel system.

Contaminated fuel Drain tank. Add clean fuel. Replaceprimary fuel filter and water separator.

Engine speed control system See authorized dealer.

Excessive Fuel Consumption Air cleaner restricted or dirty Replace air cleaner element asrequired.

Poor fuel quality Drain fuel and replace with quality fuelof the proper grade.

Leaks in fuel supply system Locate source of leak and repair asrequired.

4-3-2 081214

PN=243



Symptom Problem Solution

Exhaust filter restricted—if equipped See your authorized dealer.

Excessive Oil Consumption Poor fuel quality Drain fuel and replace with quality fuelof the proper grade.

Air cleaner restricted or dirty Replace air cleaner element asrequired.

Worn engine See authorized dealer.

Engine Idles Poorly Poor fuel quality Drain fuel and replace with quality fuelof the proper grade.

Air in fuel system Bleed air from fuel system.

Air filters Clean or replace engine air filters.

Fuel filters Clean or replace fuel filters.

Engine speed control system See your authorized dealer.


Auto-Idle Does Not Work Idle is not above 1000 rpm Advance engine speed dial to highidle.

Auto-idle is off Turn auto-idle to the A/I ON position.

Hydraulic functions operating Release hydraulic functions for 10seconds.

Engine Not Developing Full Power Air filters clogged Clean or replace filter elements.

Fuel filter clogged Change filter. Bleed air.

Contaminated fuel Drain fuel tank. Change primary fuelfilter and water separator, change fuelfilter, bleed air. Add clean fuel.


Fuel filter not installed correctly Install new filter and o-ring. Ensureproper o-ring seal.



Hydraulic issue See authorized dealer.

Engine Oil Pressure Low Low crankcase oil level Fill crankcase to proper oil level.

4-3-3 081214

PN=244


DB84312,00000A7 -19-03JUN14-3/3


Excessive oil temperature See authorized dealer.

Incorrect oil Drain crankcase and refill with correctoil.


Engine Oil Pressure High Incorrect oil Drain crankcase and refill with correctoil.

Engine Coolant Temperature AboveNormal

Plugged air filter Clean air filter, replace if necessary.

Lack of coolant in cooling system Fill cooling system to proper level.

Radiator core and/or side screens dirty Clean radiator as required.

Engine overloaded Reduce engine load.

Too low crankcase oil level Fill crankcase to proper oil level.

Loose recovery tank cap Secure cap properly.

Engine Emits Excessive Black orGray Exhaust Smoke


Clogged or dirty air intake or exhaustsystem

Clean air intake and exhaust system.

Exhaust filter is cracked ordamaged—if equipped

See your authorized dealer.

Engine Emits Excessive WhiteExhaust Smoke

Wrong fuel Use correct fuel.

Cold engine Run engine until warm.

Exhaust filter is cracked ordamaged—if equipped

See your authorized dealer.

4-3-4 081214

PN=245


Continued on next page DB84312,00000C6 -19-10JAN12-1/2

Hydraulic SystemSymptom Problem Solution

No Hydraulic Functions Pilot shutoff lever Place pilot shutoff in unlocked(DOWN) position.

Low hydraulic oil Add correct oil.

Fuse Check START 5 amp fuse (F7), andreplace if necessary.

Clogged suction filter Clean filter.

Hydraulic Functions Are Slow orHave Little or No Power

Low oil level Fill hydraulic tank oil to full mark.

Cold oil Perform cold weather warmup.

Incorrect oil Use correct oil.

Engine speed too slow Increase speed.

Suction screen clogged Inspect and clean.

Hydraulic tank cap/cover Replace cap/cover.

Hydraulic Oil Overheats Incorrect oil Use correct oil.

Clogged radiator or oil cooler Clean and straighten fins.

Radiator screen clogged Clean screen.

Clogged filters Install new filters.

Low oil level Fill tank to full mark.

Contaminated oil Drain hydraulic tank and refill withcorrect oil.

Oil Foams High or low oil level Correct level.

Incorrect oil Drain hydraulic tank and refill withcorrect oil.

Air leak on line from reservoir Repair leak.

Water in oil Change oil.

Kinks or dents in oil lines Check lines.

No Swing Function Pilot shutoff lever Place pilot shutoff in unlocked(DOWN) position.

Pilot control hoses pinched or kinked Inspect and correct.

4-3-5 081214

PN=246


DB84312,00000C6 -19-10JAN12-2/2


Swing Function Is Jerky Lack of grease in swing bearing Fill with grease.

Rocks or mud jammed in track frame Remove or repair.

Slow Travel Speed Only Pilot control valve hoses pinched orkinked

Inspect and correct.

Travel Is Jerky Engine speed too slow Increase speed.

Track sag adjustment Adjust track sag.

Rocks or mud jammed in track frame Remove and repair.

Engine Stops When Travel OrControl Lever Actuated

Water separator clogged Drain. Change element.

NOTE: If any other problems are encountered whichrequire special tools or machine knowledge tocorrect, see your authorized dealer.

4-3-6 081214

PN=247



Electrical SystemSymptom Problem Solution

No Electrical Functions Battery undercharged or dead Recharge or replace.

Fuse malfunction Check ALT 65 amp fuse (F60) andBAT 45 amp fuse (F61), and replace ifnecessary.

Batteries Undercharged Loose or corroded connections Clean and tighten or replace batteries.

Batteries Will Not Take A Charge Loose or corroded connections Clean and tighten.

Low battery power Replace both batteries.

Battery Uses Too Much Water Cracked battery case Replace battery.

High ambient temperature Refill with distilled water.

Cracked Battery Case No battery hold down clamp Replace both batteries and install holddown clamp.

Loose battery hold down clamp Replace both batteries and install holddown clamp.

Frozen battery Replace both batteries. Keep batteriesfully charged in cold weather.

Low Battery Output Low water level Add distilled water.

Dirty or wet battery top, causingdischarge

Clean and wipe battery top dry.

Corroded or loose battery cables Clean and tighten battery cables.

Broken battery post Wiggle battery post by hand. Ifpost wiggles or turns, replace bothbatteries.

Starter Will Not Turn Battery undercharged or dead Recharge or replace both batteries.

Battery cables making poorconnections

Clean connections.

Fuse Check Controller Key Switch Signal10 A Fuse (Marked POW ON), andreplace if necessary.

Starter Repair or replace starter.

Starter pinion jammed in flywheel gear Repair or replace starter, or ring gear.

Starter Turns But Will Not CrankEngine


Engine Cranks Slowly Battery cables damaged or brokeninternally

Inspect and replace cables.

4-3-7 081214

PN=248


DB84312,00000A8 -19-03JUN14-2/2


Battery or starter cable connectionsloose or corroded

Clean and tighten connections.

Battery discharged or will not hold acharge

Recharge or replace both batteries.


Low battery voltage Recharge or replace both batteries.

Starter Continues To Run AfterEngine Starts


Key switch malfunction Disconnect battery ground. Replacekey switch.

Starter relay Disconnect battery ground. Replacestarter relay.

Charging Indicator Light On,Engine Running

Loose or corroded electricalconnections on battery, ground strap,starter, or alternator

Inspect, clean, or tighten electricalconnections.

Fuse Check CONTROLLER 5 amp fuse(F10), ECU fuse (F8), and ALT 65amp fuse (F60). Replace if necessary.

Noisy Alternator Worn drive belt Replace belt.

Worn pulleys Replace pulleys and belt.

Pulley misaligned Adjust alternator mount.

Alternator bearing Loosen alternator belts. Turn pulleyby hand. If any roughness is felt,repair alternator.

No Monitor Panel Indicators OrGauges Work

Fuse Check CONTROLLER 5 amp fuse(F10), and replace if necessary.

No Switch Panel Switches OrEngine Speed Dial Work

Fuse Check POWER ON 5 amp fuse(F17), MONITOR 5 amp fuse (F14),SOLENOID 20 amp fuse (F4), andBACK UP 10 amp fuse (F9), andreplace if necessary.

4-3-8 081214

PN=249

Miscellaneous—Storage

ER93822,000007D -19-24FEB14-1/1

Prepare Machine for StorageIMPORTANT: Avoid machine damage, do not use

biodiesel during machine storage. Whenusing biodiesel blends, switch to petroleumdiesel for long term storage.

1. Before storage, operate engine on at least onecomplete tank of petroleum diesel fuel to purge thefuel system. Ensure that the fuel tank is full duringstorage to prevent water build up due to condensation.

NOTE: For blends up to and including B20, it isrecommended that biodiesel be used within threemonths of its manufacture. For blends greaterthan B20, it is recommended that the biodieselbe used within 45 days. The poor oxidationstability characteristic of biodiesel can result inlong-term storage problems. John Deere does notrecommend using biodiesel in engines poweringstandby applications or vehicles operating on aseasonal basis. Consult your John Deere dealer orfuel supplier for additives to improve fuel storageand performance of biodiesel fuels. These additivesmust be added to the biodiesel close to its timeof production for them to be effective.

2. Repair worn or damaged parts. Install new parts, ifnecessary, to avoid needless delays later.

3. Replace air cleaner elements.

IMPORTANT: High pressure washing greater than1379 kPa (13.8 bar) (200 psi) can damage freshlypainted finishes. Paint should be allowed toair dry for 30 days minimum after receipt ofmachine before cleaning parts or machineswith high pressure. Use low pressure washoperations until 30 days have elapsed.

4. Wash the machine. Use low pressure wash operations(less than 1379 kPa (13.8 bar) (200 psi) until 30 daysafter receipt of machine have elapsed. Paint areas toprevent rust. Replace decals, where needed.

5. Apply oil to track chains. Run machine back and forthseveral times. Park machine on a hard surface toprevent tracks from freezing to ground.

T5813A

M—UN—09FE

B89

Prepare Machine for Storage

6. Store machine in a dry, protected place. If storedoutside, cover with a waterproof material.

IMPORTANT: LPS 3 Rust Inhibitor can destroypainted finish. DO NOT spray LPS 3 RustInhibitor on painted areas.

7. Retract all hydraulic cylinders, if possible. If not, coatexposed cylinder rods with LPS® 3 Rust Inhibitor.

8. Place a DO NOT OPERATE tag on the right controllever.

9. Lubricate all grease points.

NOTE: If the batteries are kept disconnected for more thanone month or when the batteries are reconnected,contact your nearest John Deere dealer. Resettingof the information controller (ICX) may be required.

10. Remove the batteries and store in a dry, protectedplace after charging fully. If not removed, disconnectthe negative battery cable from the (—) terminal.

11. Add a fuel stabilizer additive and top off fuel tank withfuel to prevent condensation.

12. Drain water separator.

13. Remove keys and lock all covers and doors.

LPS is a trademark of the Holt Lloyd Corporation.

4-4-1 081214

PN=250

Miscellaneous—Storage

VD76477,0000003 -19-04JAN13-1/2

VD76477,0000003 -19-04JAN13-2/2

Monthly Storage Procedure

CAUTION: Prevent possible injury or deathfrom asphyxiation. Engine exhaust fumescan cause sickness or death. Start engineONLY in a well-ventilated area.

1. Drain water and sediment from fuel tank when airtemperature is above freezing.

2. Remove LPS 3® Rust Inhibitor from cylinder rods witha cleaning solvent.

T6191A

A—UN—18OCT88

Clean Cylinder Rods

LPS 3 Rust Inhibitor is a trademark of Illinois Tool Works.

IMPORTANT: Prevent possible engine damage.During cold temperatures, check fluidity ofengine oil on dipstick. If the oil appears waxyand/or jelly-like rather than liquid, DO NOTattempt to start engine. Use external heat sourceto warm the crankcase until oil appears fluid.

3. Check all fluid levels. If low, check for leaks and addoil as required.

4. Check belts.

5. Check condition of all hoses and connections.

6. Check battery electrolyte level. Charge and installbattery.

7. For machines with tires, check condition of tires andtire pressure.

For machines with tracks, check condition of tracksand track sag.

On crawler machines with non sealed-and-lubricatedtrack chains, apply oil to the pin-to-bushing joints. Runmachine back and forth several times.

8. Park machine on a hard surface to prevent tracks fromfreezing to ground.

9. Fill fuel tank.

10. Pre-lubricate turbocharger bearings, if equipped:

a. Disconnect fuel shutoff fuse.

b. Crank engine for 10 seconds.

c. Connect fuel shutoff fuse.

11. Inspect engine compartment, and remove any foreignmaterial that may have accumulated. Start engine and

T6181A

U—UN—18OCT88

Check Oil on Dipstick

run until it reaches operating temperature. Run at 1/2speed for 5 minutes. Do not run at fast or slow idle.

• If engine does not start or runs poorly after starting,change fuel filters. Bleed fuel system.

12. Operate all controls, levers, seat adjustments, etc.

CAUTION: Prevent possible injury fromunexpected machine movement. Clear thearea of all persons before running machinethrough the operation procedure.

13. Make sure the area is clear to allow for movement.Cycle all hydraulic functions several times. Checkcondition of all hoses and connections.

14. Park the machine with cylinder rods retracted, ifpossible. Shut engine off.

15. Apply LPS 3 Rust Inhibitor to exposed cylinder rodareas.

4-4-2 081214

PN=251

Miscellaneous—Machine Numbers

KR46761,0000C4F -19-19MAY14-1/1

DB84312,00000C2 -19-12JAN12-1/1

Record Product Identification Number (PIN)Purchase Date

Product Identification Number (PIN)

NOTE: Record all 17 characters of the productidentification number (PIN).

The PIN plate (1) is located on the front right corner ofthe operator's station frame.

1—PIN Plate TX1160624—UN—13MAY

14

PIN Plate Location—Early Production

TX1156411—UN—27MAR14

PIN Plate Location—Late Production

Record Engine Serial NumberEngine Serial Number

The engine serial number plate (3) is located on theengine behind the open crankcase ventilation (OCV) filter.

3—Engine Serial Number Plate

TX1105031—UN—07JAN12

Engine Serial Number Plate

4-5-1 081214

PN=252


ER79617,0000D8E -19-07JAN11-1/1

DB84312,0000084 -19-14DEC11-1/1

Record Travel Motor Serial NumbersTravel Motor Serial NumberTravel Motor Serial Number

NOTE: Remove cover to access travel motorserial number plate (1).

The travel motor serial number plate (1) is located behindthe travel motor cover.

1—Travel Motor Serial NumberPlate TX

1086495A

—UN—04JAN11

Travel Motor Serial Number (left side shown)

Record Swing Motor Serial NumberSwing Motor Serial Number

The swing motor serial number plate (1) is located on topof the swing motor.

1—Swing Motor Serial NumberPlate

TX1103245A

—UN—09DEC11

Swing Motor Serial Number

4-5-2 081214

PN=253


ER79617,0000D8F -19-29APR14-1/1

DB84312,0000085 -19-14DEC11-1/1

Record Hydraulic Coupler Serial Number—IfEquippedHydraulic Coupler Serial Number

The hydraulic coupler serial number plate (1) is located onthe front side of the coupler.

1—Hydraulic Coupler SerialNumber Plate

TX1086497A

—UN—04JAN11

Hydraulic Coupler Serial Number Plate Location

TX1086500A

—UN—04JAN11

Hydraulic Coupler Serial Number Plate

Hydraulic Pump Serial NumberHydraulic Pump Serial Number

Open the right service door to access the hydraulic pump.The hydraulic pump serial number plate (1) is located onthe front of the hydraulic pump.

1—Hydraulic Pump SerialNumber Plate

TX1103246A

—UN—09DEC11

Hydraulic Pump Serial Number

4-5-3 081214

PN=254


DX,SECURE1 -19-18NOV03-1/1

DX,SECURE2 -19-18NOV03-1/1

Keep Proof of Ownership1. Maintain in a secure location an up-to-date inventory

of all product and component serial numbers.2. Regularly verify that identification plates have not

been removed. Report any evidence of tampering tolaw enforcement agencies and order duplicate plates.

3. Other steps you can take:- Mark your machine with your own numbering system- Take color photographs from several angles of eachmachine

TS1680

—UN—09DEC03

Keep Machines Secure1. Install vandal-proof devices.2. When machine is in storage:

- Lower equipment to the ground- Set wheels to widest position to make loading moredifficult

- Remove any keys and batteries3. When parking indoors, put large equipment in front of

exits and lock your storage buildings.4. When parking outdoors, store in a well-lighted and

fenced area.5. Make note of suspicious activity and report any thefts

immediately to law enforcement agencies.6. Notify your John Deere dealer of any losses.

TS230—UN—24MAY

89

4-5-4 081214

PN=255

Miscellaneous—Specifications

DB84312,00000BA -19-10JAN12-1/1

DB84312,00000CC -19-10JAN12-1/1

160GLC Engine SpecificationsItem Measurement Specification

John Deere PowerTech PVX 4.5 L Type 4-Stroke Cycle, Turbocharged, withair-to-air charge air cooler

Bore And Stroke 106 x 127 mm4.17 x 5.0 in.

Cylinders 4Displacement 4.5 L

275 cu in.Net Torque @ 1400 RPM 508 N·m

375 lb.-ft.Compression Ratio 16.5:1Power At 2200 RPM 90 kW Net SAE

121 hp Net SAECooling Fan Variable Hydraulic SuctionElectrical system 24 VoltBatteries (2) 12 volt 440 Minutes Reserve Capacity

180GLC Engine SpecificationsItem Measurement Specification

John Deere PowerTech PVX 4.5 L Type 4-Stroke Cycle, Turbocharged, withair-to-air charge air cooler

Bore And Stroke 106 x 127 mm4.17 x 5.0 in.

Cylinders 4Displacement 4.5 L

275 cu in.Net Torque @ 1400 RPM 524 N·m

387 lb.-ft.Compression Ratio 16.5:1Power At 2200 RPM 90 kW Net SAE

121 hp Net SAECooling Fan Variable Hydraulic SuctionElectrical system 24 VoltBatteries (2) 12 volt 440 Minutes Reserve Capacity

4-6-1 081214

PN=256


DB84312,00000BB -19-24FEB12-1/1

160GLC and 180GLC Drain and RefillCapacitiesItem Measurement Specification

Fuel Tank Capacity 320.0 L84.5 gal.

Cooling System Capacity 23.5 L6.2 gal.

Engine Oil Capacity, Including Filter Change 14.5 L3.8 gal.

Hydraulic Tank Oil Capacity 125.0 L33.0 gal.

Hydraulic System Oil Capacity 210.0 L55.5 gal.

Swing Gear Case Oil Capacity 6.2 L1.6 gal.

Travel Gear Case (each) Oil Capacity 6.8 L1.7 gal.

Pump Drive Gear Case Oil Capacity 0.9 L1.0 qt

4-6-2 081214

PN=257


Continued on next page DB84312,00000BC -19-04JUN14-1/2

160GLC Machine Specifications

TX1001680

10

5

6 12

4

3

1

2

11

8

79

TX1001680—UN—03JAN06

160GLC Excavator

1—Sprocket Center To IdlerCenter

2—Undercarriage Length3—Counterweight Clearance

4—Rear End Swing Radius5—Overall Width6—Cab Height7—Minimum Ground Clearance

8—Center Of Sprocket To CenterOf Sprocket

9—Track Shoe Width10— Undercarriage Width

11— Overall Length12— Transport Height

NOTE: Specifications and design subject to changewithout notice. Wherever applicable, specificationsare in accordance with PCSA and SAE standards.Except where otherwise noted these specificationsare based on a machine equipped with 700 mm

(28 in.) shoes, 3210 kg (7077 lb.) counterweight,3.10 m (10 ft 2 in.) arm, 623 kg (1373 lb.) 0.62m 3 (0.81 yd. 3) bucket, full fuel tank, 79 kg (175lb.) operator and standard equipment.

Item Measurement Specification

1—Sprocket Center To Idler Center Distance 3098.8 mm10 ft 2 in

2—Undercarriage Length 3911.6 mm12 ft 10 in.

3—Counterweight Clearance Distance 1041.4 mm3 ft 5 in.

4—Rear End Swing Radius Distance 2540.0 mm8 ft 4 in.

5—Overall Width—With TripleSemi-Grouser Shoes 24-in.(600 mm)

Distance 2590.8 mm8 ft 6 in.

6—Cab Height 2946.4 mm9 ft 8 in.

7—Minimum Ground Clearance Distance 482.6 mm1 ft 7 in.

4-6-3 081214

PN=258


DB84312,00000BC -19-04JUN14-2/2




9—Track Shoe Width 600 mm (24 in.)700 mm (28 in.)

10—Undercarriage Width With 700 mm shoes: 2692.4 mmWith 28 in. shoes: 8 ft 10 in.

11—Machine Overall Length With 2590.8 mm Arm: 8610.6 mmWith 8 ft 6 in. Arm: 28 ft 3 in.With 3098.8 mm Arm: 8661.4 mmWith 10 ft 2 in. Arm: 28 ft 5 in.

12—Machine Transport Height With 2590.8 mm Arm: 2870.2 mmWith 8 ft 6 in. Arm: 9 ft 5 in.)With 3098.8 mm Arm: 3098.8 mmWith 10 ft 2 in. Arm: 10 ft 2 in.)

Machine Operating Weight 18 017 kg39 685 lb.

4-6-4 081214

PN=259


Continued on next page DB84312,00000CD -19-04JUN14-1/2

180GLC Machine Specifications

TX1001680

10

5

6 12

4

3

1

2

11

8

79

TX1001680—UN—03JAN06

180GLC Excavator

1—Sprocket Center To IdlerCenter

2—Undercarriage Length3—Counterweight Clearance

4—Rear End Swing Radius5—Overall Width6—Cab Height7—Minimum Ground Clearance


9—Track Shoe Width10— Undercarriage Width

11— Overall Length12— Transport Height

NOTE: Specifications and design subject to changewithout notice. Wherever applicable, specificationsare in accordance with PCSA and SAE standards.Except where otherwise noted these specificationsare based on a machine equipped with 700 mm

(28 in.) shoes, 3910 kg (8620 lb.) counterweight,3.21 m (10 ft 6 in.) arm, 785 kg (1731 lb.) 0.83m 3 (1.09 yd.3) bucket, full fuel tank, 79 kg (175lb.) operator and standard equipment.


1—Sprocket Center To Idler Center Distance 3378.2 mm11 ft 1 in.

2—Undercarriage Length 4165.6 mm13 ft 8 in.

3—Counterweight Clearance Distance 1041.4 mm3 ft 5 in.

4—Rear End Swing Radius Distance 2540.0 mm8 ft 4 in.

5—Overall Width—With TripleSemi-Grouser Shoes 24-in.(600 mm)


6—Cab Height 2946.4 mm9 ft 8 in.

7—Minimum Ground Clearance Distance 457.2 mm1 ft 6 in.

4-6-5 081214

PN=260


DB84312,00000CD -19-04JUN14-2/2




9—Track Shoe Width 600 mm (24 in.)700 mm (28 in.)800 mm (32 in.)

10—Undercarriage Width With 800 mm shoes: 2794.0 mmWith 32 in. shoes: 9 ft 2 in.

11—Machine Overall Length With 2692.4 mm Arm: 9042.4 mmWith 8 ft 10 in. Arm: 29 ft 8 in.With 3200.4 mm Arm: 9042.4 mmWith 10 ft 6 in. Arm: 29 ft 8 in.

12—Machine Transport Height With 2692.4 mm Arm: 3073.4 mmWith 8 ft 10 in. Arm: 10 ft 1 in.)With 3200.4 mm Arm: 3378.2 mmWith 10 ft 6 in. Arm: 11 ft 1 in.)

Machine Operating Weight 20 120 kg44 317 lb.

4-6-6 081214

PN=261


Continued on next page DB84312,00000BD -19-04JUN14-1/2

160GLC Working Ranges

TX1001681

1 9

2876

5

3

4

TX1001681—UN—03JAN06

Working Ranges

1—Maximum Digging Reach2—Maximum Digging Reach At

Ground Level

3—Minimum Swing Radius4—Maximum Cutting Height5—Maximum Dumping Height

6—Maximum Digging Depth7—Maximum Digging Depth (flat

bottom)

8—Maximum Vertical Wall9—Tail Swing Radius

NOTE: Specifications and design subject to changewithout notice. Wherever applicable, specificationsare in accordance with PCSA and SAEstandards. Except where otherwise noted thesespecifications are based on a machine equipped

with 700 mm (28 in.) shoes, counterweightand 3.10 m (10 ft 2 in.) arm.

Working Ranges—equipped with a 2590.8 mm (8 ft 6in.) Arm


4-6-7 081214

PN=262


DB84312,00000BD -19-04JUN14-2/2


1—Maximum Digging Reach Distance 8864.6 mm29 ft 1 in.

2—Maximum Digging ReachAt Ground Level


3—Minimum Swing Radius Radius 2921.0 mm9 ft 7 in.

4—Maximum Cutting Height Height 8890.0 mm29 ft 2 in.

5—Maximum Dumping Height Height 6172.2 mm20 ft 3 in.

6—Maximum Digging Depth Depth 5969.0 mm19 ft 7 in.

7—Maximum Digging Depth(flat bottom)

Depth 5740.4 mm18 ft 10 in.

8—Maximum Vertical Wall Depth 5156.2 mm16 ft 11 in.

9—Tail Swing Radius Radius 2540.0 mm8 ft 4 in.














4-6-8 081214

PN=263


Continued on next page DB84312,00000CE -19-04JUN14-1/2

180GLC Working Ranges

TX1001681

1 9

2876

5

3

4

TX1001681—UN—03JAN06

Working Ranges

1—Maximum Digging Reach2—Maximum Digging Reach At

Ground Level

3—Minimum Swing Radius4—Maximum Cutting Height5—Maximum Dumping Height

6—Maximum Digging Depth7—Maximum Digging Depth (flat

bottom)

8—Maximum Vertical Wall9—Tail Swing Radius

NOTE: Specifications and design subject to changewithout notice. Wherever applicable, specificationsare in accordance with PCSA and SAEstandards. Except where otherwise noted thesespecifications are based on a machine equipped

with 700 mm (28 in.) shoes, counterweightand 3.21 m (10 ft 6 in.) arm.

Working Ranges—equipped with a 2692.4 mm (8 ft10 in.) Arm


4-6-9 081214

PN=264


DB84312,00000CE -19-04JUN14-2/2


























4-6-10 081214

PN=265


DB84312,00000BE -19-31MAY12-1/1

160GLC Lift Capacity—Arm: 2.60 m (8 ft. 6 in.); Bucket: 528 kg (1164 lb.); Shoe: 600 mm(24 in.)

Ratings are at bucket lift hook, using standardcounterweight, situated on firm, level, uniform supportingsurface.

Figures do not exceed 87 percent of hydraulic capacityor 75 percent of weight needed to tip machine. Figures

marked with an asterisk (*) are hydraulically-limitedcapacities. Remaining figures are stability-limitedcapacities.

Arm: 2.60 m (8 ft. 6 in.) Bucket: 528 kg (1164 lb.) Shoe: 600 mm (24 in.)Power Dig: On

LIFTING OVER FRONTLoad Point Height Horizontal Distance from Centerline of Rotationm (ft.) 1.5 (5) 3.0 (10) 4.5 (15) 6.0 (20)6.0 (20) 2850*

4.5 (15) 4100*(8900*)

3850*(8400*)

3.0 (10) 8400*(17 850*)

5400*(11 700*)

4400*(9550*)

1.5 (5) 6800*(14 650*)

4300(9200)

Ground Line 5800*(13 450*)

6600(14 200)

4150(8950)

-1.5 (-5) 5300*(11 850*)

9950*(22 800*)

6550(14 050)

4100(8850)

-3.0 (-10) 9850*(22 250*)

10 550*(22 850*)

6600(14 200)

LIFTING OVER SIDELoad Point Height Horizontal Distance from Centerline of Rotationm (ft.) 1.5 (5) 3.0 (10) 4.5 (15) 6.0 (20)6.0 (20) 2850*

4.5 (15) 4100*(8900*)

2900(6250)

3.0 (10) 8400*(17 850*)

4450(9550)

2750(5950)

1.5 (5) 4100(8850)

2650(5650)

Ground Line 5800*(13 450*)

3900(8450)

2500(5400)

-1.5 (-5) 5300*(11 850*)

7450(15 950)

3850(8300)

2500(5350)

-3.0 (-10) 9850*(22 250*)

7600(16 300)

3900(8450)

* Hydraulically Limited Capacities

4-6-11 081214

PN=266


DB84312,00000BF -19-31MAY12-1/1

160GLC Lift Capacity—Arm: 2.60 m (8 ft. 6 in.); Bucket: 528 kg (1164 lb.); Shoe: 700 mm(28 in.)




Arm: 2.60 m (8 ft. 6 in.) Bucket: 528 kg (1164 lb.) Shoe: 700 mm (28 in.)Power Dig: On

LIFTING OVER FRONTLoad Point Height Horizontal Distance from Centerline of Rotationm (ft.) 1.5 (5) 3.0 (10) 4.5 (15) 6.0 (20)6.0 (20) 2850*

4.5 (15) 4100*(8900*)

3850*(8400*)

3.0 (10) 8400*(17 850*)

5400*(11 700*)

4400*(9550*)

1.5 (5) 6800*(14 650*)

4400(9450)

Ground Line 5800*(13 450*)

6800(14 600)

4300(9200)

-1.5 (-5) 5300*(11 850*)

9950*(22 800*)

6700(14 450)

4250(9150)

-3.0 (-10) 9850*(22 250*)

10 550*(22 850*)

6800(14 600)

LIFTING OVER SIDELoad Point Height Horizontal Distance from Centerline of Rotationm (ft.) 1.5 (5) 3.0 (10) 4.5 (15) 6.0 (20)6.0 (20) 2850*

4.5 (15) 4100*(8900*)

3000(6400)

3.0 (10) 8400*(17 850*)

4550(9800)

2850(6150)

1.5 (5) 4200(9100)

2700(5800)

Ground Line 5800*(13 450*)

4050(8650)

2600(5600)

-1.5 (-5) 5300*(11 850*)

7650(16 400)

3950(8550)

2550(5500)

-3.0 (-10) 9850*(22 250*)

7800(16 700)

4050(8700)


4-6-12 081214

PN=267


DB84312,00000C0 -19-31MAY12-1/1

160GLC Lift Capacity—Arm: 3.10 m (10 ft. 2 in.); Bucket: 528 kg (1164 lb.); Shoe: 600mm (24 in.)




Arm: 3.10 m (10 ft. 2 in.) Bucket: 528 kg (1164 lb.)Shoe: 600 mm (24in.)

Power Dig: On

LIFTING OVER FRONTLoad Point Height Horizontal Distance from Centerline of Rotationm (ft.) 1.5 (5) 3.0 (10) 4.5 (15) 6.0 (20) 7.5 (25)6.0 (20) 2950*

(6150*)4.5 (15) 3400*

(7450*)3.0 (10) 6950*

(14 800*)4800*(10 400*)

4000*(8700*)

2900*(5750*)

1.5 (5) 7100*(17 200*)

6300*(13 600*)

4300(9250)

2950(6350)

Ground Line 6400*(14 750*)

6600(14 200)

4150(8900)

2900(6200)

-1.5 (-5) 4700*(10 550*)

9200*(21 000*)

6500(13 950)

4100(8750)

-3.0 (-10) 8250*(18 600*)

11 200*(24 200*)

6500(14 000)

4100(8850)

-4.5 (-15) 8900*(19 050*)

5850*(12 300*)

LIFTING OVER SIDELoad Point Height Horizontal Distance from Centerline of Rotationm (ft.) 1.5 (5) 3.0 (10) 4.5 (15) 6.0 (20) 7.5 (25)6.0 (20) 2950*

(6150*)4.5 (15) 2950

(6300)3.0 (10) 6950*

(14 800*)4500(9750)

2800(6000)

1850(4000)

1.5 (5) 7100*(16 750)

4150(8950)

2650(5650)

1800(3850)

Ground Line 6400*(14 750*)

3900(8400)

2500(5400)

1750(3700)

-1.5 (-5) 4700*(10 550*)

7350(15 750)

3800(8200)

2450(5250)

-3.0 (-10) 8250*(18 600*)

7450(15 950)

3850(8250)

2450(5300)

-4.5 (-15) 7700(16 600)

4000(8650)


4-6-13 081214

PN=268


DB84312,00000C1 -19-31MAY12-1/1






Power Dig: On


(6150*)4.5 (15) 3400*

(7450*)3.0 (10) 6950*

(14 800*)4800*(10 400*)

4000*(8700*)

2900*(5750*)

1.5 (5) 7100*(17 200*)

6300*(13 600*)

4400(9500)

3050(6550)

Ground Line 6400*(14 750*)

6800(14 600)

4250(9150)

3000(6400)

-1.5 (-5) 4700*(10 550*)

9200*(21 000*)

6650(14 350)

4200(9000)

-3.0 (-10) 8250*(18 600*)

11 200*(24 200*)

6700(14 400)

4200(9100)

-4.5 (-15) 8900*(19 050*)

5850*(12 300*)


(6150*)4.5 (15) 3000

(6500)3.0 (10) 6950*

(14 800*)4650(10 000)

2900(6200)

1900(4100)

1.5 (5) 7100*(17 200)

4250(9200)

2700(5850)

1850(3950)

Ground Line 6400*(14 750*)

4000(8650)

2600(5550)

1800(3850)

-1.5 (-5) 4700*(10 550*)

7550(16 150)

3900(8450)

2500(5400)

-3.0 (-10) 8250*(18 600*)

7650(16 400)

3950(8500)

2550(5500)

-4.5 (-15) 7900(17 000)

4100(8900)


4-6-14 081214

PN=269


DB84312,00000C8 -19-31MAY12-1/1






Power Dig: On


(8850*)4.5 (15) 4850*

(10 450*)4400*(9550*)

3.0 (10) 6550*(14 050*)

5150*(11 150*)

3800(8150)

1.5 (5) 8200*(17 700*)

5350(11 500)

3700(7950)

Ground Line 4350*(10 150*)

8300(17 850)

5200(11 150)

3650(7800)

-1.5 (-5) 4700*(10 500*)

8300*(18 950*)

8250(17 650)

5100(11 000)

-3.0 (-10) 8800*(19 850*)

12 750*(27 650*)

8300(17 800)

5150(11 100)

-4.5 (-15) 10 150*(21 700*)

6900*(14 600*)

LIFTING OVER SIDELoad Point Height Horizontal Distance from Centerline of Rotationm (ft.) 1.5 (5) 3.0 (10) 4.5 (15) 6.0 (20) 7.5 (25)6.0 (20) 3750

(8000)4.5 (15) 4850*

(10 450*)3650(7800)

3.0 (10) 5500(11 850)

3450(7450)

2350(5000)

1.5 (5) 5100(10 950)

3250(7050)

2250(4850)

Ground Line 4350*(10 150*)

4850(10 450)

3150(6750)

2200(4700)

-1.5 (-5) 4700*(10 500*)

8300*(18 950*)

4800(10 300)

3100(6600)

-3.0 (-10) 8800*(19 850*)

9600(20 550)

4850(10 450)

3100(6700)

-4.5 (-15) 9900(21 300)

5050(10 900)


4-6-15 081214

PN=270


DB84312,00000CF -19-31MAY12-1/1






Power Dig: On


(8850*)4.5 (15) 4850*

(10 450*)4400*(9550*)

3.0 (10) 6550*(14 050*)

5150*(11 150*)

3900*(8350)

1.5 (5) 8200*(17 700*)

5450(11 700)

3800(8150)

Ground Line 4350*(10 150*)

8500(18 200)

5300(11 400)

3700(8000)

-1.5 (-5) 4700*(10 500*)

8300*(18 950*)

8400(18 000)

5250(11 250)

-3.0 (-10) 8800*(19 850*)

12 750*(27 650*)

8450(18 150)

5250(11 350)

-4.5 (-15) 10 150*(21 700*)

6900*(14 600*)


(8150)4.5 (15) 4850*

(10 450*)3700(7950)

3.0 (10) 5600(12 050)

3550(7600)

2400(5150)

1.5 (5) 5200(11 200)

3350(7200)

2300(4950)

Ground Line 4350*(10 150*)

4950(10 650)

3200(6900)

2250(4850)

-1.5 (-5) 4700*(10 500*)

8300*(18 950*)

4900(10 500)

3150(6750)

-3.0 (-10) 8800*(19 850*)

9750(20 950)

4950(10 650)

3200(6850)

-4.5 (-15) 10 100(21 700)

5150(11 100)


4-6-16 081214

PN=271


DB84312,00000D0 -19-31MAY12-1/1






Power Dig: On


(8850*)4.5 (15) 4850*

(10 450*)4400*(9550*)

3.0 (10) 6550*(14 050*)

5150*(11 150*)

3950(8450)

1.5 (5) 8200*(17 700*)

5550(11 900)

3850(8250)

Ground Line 4350*(10 150*)

8600(18 450)

5400(11 550)

3800(8100)

-1.5 (-5) 4700*(10 500*)

8300*(18 950*)

8500(18 300)

5300(11 400)

-3.0 (-10) 8800*(19 850*)

12 750*(27 650*)

8600(18 450)

5350(11 550)

-4.5 (-15) 10 150*(21 700*)

6900*(14 600*)


(8300)4.5 (15) 4850*

(10 450*)3750(8100)

3.0 (10) 5650(12 200)

3600(7700)

2450(5200)

1.5 (5) 5250(11 350)

3400(7300)

2350(5050)

Ground Line 4350*(10 150*)

5050(10 850)

3250(7000)

2300(4900)

-1.5 (-5) 4700*(10 500*)

8300*(18 950*)

4950(10 700)

3200(6900)

-3.0 (-10) 8800*(19 850*)

9900(21 250)

5000(10 800)

3250(7000)

-4.5 (-15) 10 150*(21 700*)

5200(11 250)


4-6-17 081214

PN=272


DB84312,00000D1 -19-31MAY12-1/1






Power Dig: On


(7650*)4.5 (15) 3900*

(8550*)3350*(6850*)

3.0 (10) 8950*(19 000*)

5850*(12 600*)

4700*(10 250*)

3800(8200)

1.5 (5) 7650*(16 500*)

5350(11 550)

3700(7950)

Ground Line 4700*(10 900*)

8350(17 900)

5200(11 150)

3600(7800)

-1.5 (-5) 4000*(8950*)

7450*(17 000*)

8200(17 600)

5100(10 950)

3600(7700)

-3.0 (-10) 7250*(16 350*)

11 750*(26 900*)

8200(17 600)

5100(10 950)

-4.5 (-15) 11 700*(26 500*)

11 300*(24 300*)

7700*(16 500*)


(7650*)4.5 (15) 3700

(7950)2450(5200)

3.0 (10) 8950*(19 000*)

5600(12 100)

3500(7550)

2350(5050)

1.5 (5) 5150(11 150)

3300(7100)

2250(4850)

Ground Line 4700*(10 900*)

4850(10 500)

3150(6750)

2150(4650)

-1.5 (-5) 4000*(8950*)

7450*(17 000*)

4750(10 200)

3050(6550)

2150(4600)

-3.0 (-10) 7250*(16 350*)

9450(20 200)

4750(10 250)

3050(6550)

-4.5 (-15) 11 700*(26 500*)

9700(20 850)

4900(10 600)


4-6-18 081214

PN=273


DB84312,00000D2 -19-31MAY12-1/1






Power Dig: On


(7650*)4.5 (15) 3900*

(8550*)3350*(6850*)

3.0 (10) 8950*(19 000*)

5850*(12 600*)

4700*(10 250*)

3900(8350)

1.5 (5) 7650*(16 500*)

5500(11 800)

3800(8150)

Ground Line 4700*(10 900*)

8500(18 250)

5300(11 400)

3700(7950)

-1.5 (-5) 4000*(8950*)

7450*(17 000*)

8350(17 950)

5200(11 150)

3650(7850)

-3.0 (-10) 7250*(16 350*)

11 750*(26 900*)

8400(18 000)

5200(11 200)

-4.5 (-15) 11 700*(26 500*)

11 300*(24 300*)

7700*(16 500*)


(7650*)4.5 (15) 3750

(8100)2500(5350)

3.0 (10) 8950*(19 000*)

5700(12 300)

3550(7700)

2400(5150)

1.5 (5) 5250(11 350)

3350(7250)

2300(4950)

Ground Line 4700*(10 900*)

4950(10 700)

3200(6850)

2250(4800)

-1.5 (-5) 4000*(8950*)

7450*(17 000*)

4850(10 450)

3100(6700)

2200(4700)

-3.0 (-10) 7250*(16 350*)

9600(20 600)

4850(10 450)

3100(6700)

-4.5 (-15) 11 700*(26 500*)

9900(21 250)

5000(10 800)


4-6-19 081214

PN=274


DB84312,00000D3 -19-31MAY12-1/1






Power Dig: On


(7650*)4.5 (15) 3900*

(8550*)3350*(6850*)

3.0 (10) 8950*(19 000*)

5850*(12 600*)

4700*(10 250*)

3950(8500)

1.5 (5) 7650*(16 500*)

5550(11 950)

3850(8250)

Ground Line 4700*(10 900*)

8650(18 500)

5400(11 550)

3750(8100)

-1.5 (-5) 4000*(8950*)

7450*(17 000*)

8500(18 200)

5300(11 350)

3700(8000)

-3.0 (-10) 7250*(16 350*)

11 750*(26 900*)

8500(18 250)

5300(11 350)

-4.5 (-15) 11 700*(26 500*)

11 300*(24 300*)

7700*(16 500*)


(7650*)4.5 (15) 3800

(8200)2550(5400)

3.0 (10) 8950*(19 000*)

5800(12 500)

3600(7800)

2450(5250)

1.5 (5) 5350(11 500)

3400(7350)

2350(5050)

Ground Line 4700*(10 900*)

5050(10 850)

3250(7000)

2250(4850)

-1.5 (-5) 4000*(8950*)

7450*(17 000*)

4950(10 600)

3150(6800)

2250(4800)

-3.0 (-10) 7250*(16 350*)

9750(20 900)

4950(10 650)

3150(6800)

-4.5 (-15) 11 700*(26 500*)

10 050(21 500)

5100(10 950)


4-6-20 081214

PN=275


4-6-21 081214

PN=276

Index

Page

A

AccessoryElectrical ................................................................ 4-1-7

Accessory power port ................................................ 2-1-4Acid burns.................................................................. 3-7-4AdjustmentArmrest ................................................................ 2-1-15Belt tension ............................................................ 3-9-5Seat...................................................................... 2-1-15Track sag ............................................................... 3-3-2

AirIntake hoses........................................................... 3-8-5

Air cleanerClean...................................................................... 3-9-6Replace.................................................................. 3-9-6Unloader valve.............................................3-3-1, 3-9-6

Air cleaner dust unloaderReplace.................................................................. 3-9-6

Air conditioner............................................................ 2-1-9Air conditioner display ............................................... 2-2-1Air filterCab fresh airClean.................................................................. 3-8-7

Cab recirculating airClean.................................................................. 3-8-7

Clean...................................................................... 3-9-6Replace.................................................................. 3-9-6

Air suspension seatAdjusting .............................................................. 2-1-16

Alternator ................................................................... 4-1-2ArmGrease ................................................................... 3-8-1Lubricate ................................................................ 3-8-1

Arm regenerative valveOperational check................................................ 4-2-35

ArmrestAdjustment ........................................................... 2-1-15

AttachmentsAdding safely ......................................................... 1-3-5Operating safely..................................................... 1-3-5

Auto shutdown indicator ............................................ 2-2-1Auto-idle circuitOperational check................................................ 4-2-21

Auto-idle indicator...................................................... 2-2-1Auto-idle switchFunction ................................................................. 2-1-3

Auxiliary fuel filter and water separatorDrain ...................................................................... 3-5-2

Auxiliary fuel filter and water separator (ifequipped)Replace.................................................................. 3-8-5

Auxiliary indicator ...................................................... 2-2-1Avoid static electricity risk when fueling .................... 1-2-5

Page

B

Back button................................................................ 2-1-3Backhoe patternControl lever pattern check.................................. 4-2-25

Backover Accidents ................................................... 1-3-3BatteriesUsing battery charger............................................. 4-1-4

BatteryAcid burns.............................................................. 3-7-4Booster batteries.................................................... 4-1-5Electrolyte level check ........................................... 3-7-4Explosion ............................................................... 3-7-4Handling, checking, and servicing ......................... 4-1-3Specification........................................................... 4-1-5Terminals................................................................ 3-7-4

Before starting work................................................... 2-3-1BeltTension adjust ........................................................ 3-9-5

BleedFuel system............................................................ 4-1-1

Blower speed switchFunction ................................................................. 2-1-3

Bolt and screw torque valuesMetric ................................................................... 4-1-16Unified inch .......................................................... 4-1-15

BoomGrease ................................................................... 3-8-1Lubricate ................................................................ 3-8-1

Boom lowerWith engine stopped ............................................ 2-3-20

Boom regenerative valveOperational check................................................ 4-2-34

Boom up, arm in, and bucket combinedfunctionOperational check................................................ 4-2-33

Boost starting............................................................. 4-1-5Break-In Plus engine oil............................................. 3-1-7Breaker ...................................................................... 3-2-4BucketRemoval............................................................... 4-1-14Tooth .................................................................... 4-1-13Tooth replacement ................................... 4-1-11, 4-1-13

Bucket regenerative valveOperational check................................................ 4-2-36

ButtonHorn ....................................................................... 2-1-4Power dig ............................................................... 2-1-4Power mode........................................................... 2-1-3

C

Cab dome light switch ............................................. 2-1-13Cab fresh air filterClean...................................................................... 3-8-7


Index-1 081214

PN=1

Index

Page

Cab recirculating air filterClean...................................................................... 3-8-7

Celsius and FahrenheitSelecting .............................................................. 2-1-10

Charge air coolerCleaning................................................................. 4-1-1

Clock.......................................................................... 2-2-1Change setting..................................................... 2-2-16

Cold weatherStarting................................................................... 2-3-4

Cold weather start aid................................................ 2-3-4ConsoleAdjust height ........................................................ 2-1-16

Console heightAdjusting .............................................................. 2-1-16

Control leverPattern conversion............................................... 2-3-17

Control lever patternConversion........................................................... 2-3-18Operation ............................................................. 2-3-16

Control lever pattern check - backhoe patternOperational check................................................ 4-2-25

Control lever pattern check - excavatorpatternOperational check................................................ 4-2-24

Control pattern........................................................... 1-2-2Control valve lift check valveOperational check................................................ 4-2-32

COOL-GARD II test strips ......................................... 3-3-4CoolantAdd coolant extender ...................................3-3-4, 3-9-7Additional information .......................................... 3-1-16Check...........................................................3-3-4, 3-9-7Diesel engineEngine with wet sleeve cylinder liners.............. 3-1-13

Disposing ............................................................. 3-1-17John deere COOL-GARD II coolant extender...... 3-1-14Sample................................................................... 3-8-7Supplemental additives........................................ 3-1-15Test ..............................................................3-3-4, 3-9-7Testing.................................................................. 3-1-17Warm temperature climates................................. 3-1-15

Coolant levelSurge tank.............................................................. 3-4-2

Coolant temperature gauge....................................... 2-2-1Coolant temperature mark......................................... 2-2-1Cooling systemCleaning................................................................. 4-1-1Deaeration ........................................................... 3-12-2Drain .................................................................... 3-12-1Fill ........................................................................ 3-12-2Service safely......................................................... 1-4-1

Coupler, hydraulicLocking................................................................. 2-3-13Lubricate ................................................................ 3-4-4Unlocking ............................................................. 2-3-15

CoverEngine.................................................................... 3-2-3

Page

Crusher...................................................................... 3-2-4Cycle times checkOperational check....................................4-2-41, 4-2-43

Cylinder ..................................................................... 4-1-2

D

Daily machine check.................................................. 2-3-1DateChange setting..................................................... 2-2-16

DecalsSafety................................................................... 1-5-14

Default screen ........................................................... 2-2-1Diagnose malfunctionsTroubleshooting procedure .................................... 4-3-1

Diagnostic trouble code checkOperational check.................................................. 4-2-1

Diesel fuel........................................................3-1-1, 3-1-3Sample................................................................... 3-8-7Specifications......................................................... 3-1-1

Diesel fuel specifications ........................................... 3-1-1Diesel fuel, testingTesting Diesel Fuel................................................. 3-1-4

Dig function driftOperational check....................................4-2-29, 4-2-30

Display and clear trouble codesOperational check.................................................. 4-2-1

Display unitSoftware update menu......................................... 2-3-11

Dome lightSwitch .................................................................. 2-1-13

DoorEngine access........................................................ 3-2-3

Drain and refillCapacities160GLC and 180GLC......................................... 4-6-2

Drain Intervals for Diesel Engine CoolantDiesel Engine Coolant, Drain Intervals ................ 3-1-14

DrivingSlopes.................................................................. 2-3-19

E

E (economy) modeOperational check................................................ 4-2-19

ElectricalSystem................................................................... 4-1-8System, troubleshooting ........................................ 4-3-7

Engine160GLC Specifications IT4 .................................... 4-6-1180GLC Specifications IT4 .................................... 4-6-1Break-in.................................................................. 2-3-2Cold weather warmup............................................ 2-3-5Crankcase vent filter ............................................ 3-10-1Oil drain and refill ................................................... 3-8-6Oil filter, replace ..................................................... 3-8-6Oil level check........................................................ 3-4-1


Index-2 081214

PN=2

Index

Page

Oil specificationBreak-In Plus...................................................... 3-1-7

Starting................................................................... 2-3-3Troubleshooting ..................................................... 4-3-2Valve lash............................................................. 3-10-1Warming................................................................. 2-3-3

Engine coolantDisposing of ......................................................... 3-1-17

Engine cover.............................................................. 3-2-3Engine oilSample................................................................... 3-7-6

Engine oil and filter service intervalsInterim tier 4, final tier 4, stage IIIB, andstage IV0.12 L/kW or greater oil pan............................... 3-1-9

Engine preheat indicator............................................ 2-2-1Engine serial number................................................. 4-5-1Engine speed dial ...................................................... 2-1-3Operational check................................................ 4-2-18

Engine valve lashCheck and adjust ................................................. 3-10-1

EnginelOil specificationIT4 and Stage III B ............................................. 3-1-8

Excavator patternControl lever pattern check.................................. 4-2-24

Exhaust filter.............................................................. 1-2-7Ash removal .................................................2-3-8, 3-3-5Auto cleaning ......................................................... 2-3-7Disable ............................................................. 2-2-18Enable .............................................................. 2-2-18

Cleaning types ....................................................... 2-3-7Information............................................................. 2-3-7Natural/passive cleaning........................................ 2-3-7Parked cleaning ..................................................... 2-3-7Parked cleaning procedure.................................... 2-3-9Parked cleaning switch .......................................... 2-1-7Restriction levels.................................................... 2-3-7Scheduled maintenance ........................................ 3-3-5

Exhaust filter indicator ............................................... 2-2-1Exhaust filter parked cleaning switch ........................ 2-1-7Exhaust Filter, SafetySafety, Exhaust Filter ............................................. 1-4-3

F

Fan reversing switchOperational check................................................ 4-2-17

FilterHydraulic tank oil.................................................... 3-9-2Pilot oilReplace .............................................................. 3-9-3

Filters, OilOil Filters................................................................ 3-1-9

Final fuel filterDrain ...................................................................... 3-5-2Replace.................................................................. 3-8-4

Fire extinguisher ...................................................... 2-1-12

Page

Fire prevention........................................................... 1-2-5Fluid analysis test kit ................................................. 3-2-4Fluid sampleTaking samples ...................................................... 4-1-6

FuelDiesel ...........................................................3-1-1, 3-1-3Handling and storing.............................................. 3-1-2Lubricity.................................................................. 3-1-2

Fuel coolerCleaning................................................................. 4-1-1

Fuel filterDrain ...................................................................... 3-5-2Replace, final ......................................................... 3-8-4Replace, primary.................................................... 3-8-3

Fuel FiltersFilters, Fuel ............................................................ 3-1-4

Fuel gauge................................................................. 2-2-1Operational check.................................................. 4-2-3

Fuel mark................................................................... 2-2-1Fuel systemBleed...................................................................... 4-1-1

Fuel tank.................................................................... 3-2-3Fuel tank inlet screenRemove and clean................................................. 3-3-1

Fuel tank sumpDrain ...................................................................... 3-5-1

FuseColor codes............................................................ 4-1-8Replacing............................................................... 4-1-8

G

GreaseBoom...................................................................... 3-8-1Bucket ..........................................................3-6-1, 3-8-1Extreme pressure and multipurpose.................... 3-1-12Front end pin joints ................................................ 3-8-1Specification......................................................... 3-1-12Swing bearing gear ................................................ 3-8-2Working tool pivots................................................. 3-6-1

H

Hardware torque valuesMetric ................................................................... 4-1-16Unified inch .......................................................... 4-1-15

HazardsAvoiding ................................................................. 1-3-2

Heated seat (if equipped) .......................................... 2-1-6Heater........................................................................ 2-1-9Heater and air conditioner controls checkOperational check................................................ 4-2-46

Heater and air conditioning circuit checkOperational check................................................ 4-2-45

High pressure fuelPump...................................................................... 4-1-2

Home button.............................................................. 2-1-3


Index-3 081214

PN=3

Index

Page

Horn........................................................................... 2-1-4Horn circuitOperational check.................................................. 4-2-2

Hour meter.......................................................2-2-1, 3-2-1Operational check.................................................. 4-2-3

HP (high power) modeOperational check................................................ 4-2-20

HydraulicBreaker .................................................................. 3-2-4Oil level check........................................................ 3-4-3Shutoff lever........................................................... 2-1-5System troubleshooting ......................................... 4-3-5

Hydraulic couplerLocking................................................................. 2-3-13Lubricate ................................................................ 3-4-4Unlocking ............................................................. 2-3-15

Hydraulic coupler serial number ................................ 4-5-3Hydraulic oilSpecification......................................................... 3-1-10

Hydraulic oil tank pressurizationOperational check................................................ 4-2-24

Hydraulic tankDrain ...................................................................... 3-7-2Vent cap filterReplace ............................................................ 3-11-3

Hydraulic tank oilDrain and refill...................................................... 3-11-1filterreplace................................................................ 3-9-2

I

IdentificationManual ........................................................................ -3

InjectionNozzle .................................................................... 4-1-2

J

JDLink........................................................................ 4-1-7JDLink in-line fuseUnswitched power.................................................. 4-1-8

Jump starting............................................................. 4-1-5

K

Key switchFunction ................................................................. 2-1-3

Key switch off, engine offOperational check.................................................. 4-2-1

Key switch on, engine offOperational check.................................................. 4-2-3

Key switch on, engine onOperational check................................................ 4-2-14

KeypadFunction ................................................................. 2-1-3

Page

L

Left consoleReversing fan switch.............................................. 2-1-6Seat heater switch (if equipped) ............................ 2-1-6Switches................................................................. 2-1-5Travel alarm cancel switch..................................... 2-1-5

LeverLeft control ........................................................... 2-3-16Pilot shutoff ............................................................ 2-1-5Right control......................................................... 2-3-16Steering.................................................................. 2-3-6

LeversLocation ................................................................. 2-1-1

Lift capacity160GLCArm: 2.60 m (8 ft. 6 in.);Bucket: 528 kg(1164 lb.);Shoe: 600 mm (24 in.).................... 4-6-11Arm: 2.60 m (8 ft. 6 in.);Bucket: 528 kg(1164 lb.);Shoe: 700 mm (28 in.).................... 4-6-12Arm: 3.10 m 10 ft. 2 in.);Bucket: 528 kg(1164 lb.);Shoe: 600 mm (24 in.).................... 4-6-13Arm: 3.10 m 10 ft. 2 in.);Bucket: 528 kg(1164 lb.);Shoe: 700 mm (28 in.).................... 4-6-14

180GLCArm: 2.71 m 8 ft. 10 in.);Bucket: 600 kg1323 lb.);Shoe: 600 mm (24 in.)..................... 4-6-15Arm: 2.71 m 8 ft. 10 in.);Bucket: 600 kg1323 lb.);Shoe: 700 mm (28 in.)..................... 4-6-16Arm: 2.71 m 8 ft. 10 in.);Bucket: 600 kg1323 lb.);Shoe: 800 mm (32 in.)..................... 4-6-17Arm: 3.21 m 10 ft. 6 in.);Bucket: 600 kg1323 lb.);Shoe: 600 mm (24 in.)..................... 4-6-18Arm: 3.21 m 10 ft. 6 in.);Bucket: 600 kg1323 lb.);Shoe: 700 mm 28 in.)...................... 4-6-19Arm: 3.21 m 10 ft. 6 in.);Bucket: 600 kg1323 lb.);Shoe: 800 mm 32 in.)...................... 4-6-20

Lifting....................................................................... 2-3-19Machine ............................................................... 2-3-23

Lifting objectsSpecial care ........................................................... 1-3-4

Light circuitOperational check................................................ 4-2-10

Lower boomWith engine stopped ............................................ 2-3-20

LubricantMixing..................................................................... 3-1-6

Lubricant StorageStorage, Lubricant.................................................. 3-1-6

Lubricants, SafetySafety, Lubricants .................................................. 3-1-6

LubricateBoom...................................................................... 3-8-1Bucket ..........................................................3-6-1, 3-8-1Front end pin joints ................................................ 3-8-1Swing bearing gear ................................................ 3-8-2Working tool pivots................................................. 3-6-1


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Lubricity of diesel fuel ................................................ 3-1-2

M

MachineClean regularly....................................................... 4-1-7Lifting ................................................................... 2-3-23

Machine modificationsAvoid ...................................................................... 1-2-2

Machine movementUnintended............................................................. 1-3-1

Machine numberHydraulic pump...................................................... 4-5-3

Machine specifications160GLC.................................................................. 4-6-3180GLC.................................................................. 4-6-5

Machine tip overAvoiding ................................................................. 1-3-4

Machine,inspect......................................................... 1-2-3Main menu................................................................. 2-2-4Air conditioner ...................................................... 2-2-11Information menu................................................. 2-2-23Maintenance..................................................... 2-2-25Monitoring......................................................... 2-2-26Operation.......................................................... 2-2-24Troubleshooting................................................ 2-2-25

Radio.................................................................... 2-2-13Setting menu........................................................ 2-2-15Attachment name input .................................... 2-2-16Auto shutdown.................................................. 2-2-17Brightness adjustment...................................... 2-2-21Date and time................................................... 2-2-16Language ......................................................... 2-2-21Main menu sequence change .......................... 2-2-22Unit selection.................................................... 2-2-22

Work mode........................................................... 2-2-14Main MenuAlarm list ................................................................ 2-2-5Setting menuDisplay item selection....................................... 2-2-21Exhaust filter..................................................... 2-2-18Rear view camera monitor ............................... 2-2-20Sub meter selection.......................................... 2-2-19

MaintenanceMachine position .................................................... 3-2-2Schedule and record.............................................. 3-2-5

ManualIdentification................................................................ -3

Mechanical suspension seatAdjusting .............................................................. 2-1-15

Metric bolt and screw torque values ........................ 4-1-16Mixing lubricants........................................................ 3-1-6Monitor....................................................................... 2-2-1Air conditioner ...................................................... 2-2-11Air condtioner display............................................. 2-2-1Alarm list ................................................................ 2-2-5Auto shutdown indicator......................................... 2-2-1Auto-idle indicator .................................................. 2-2-1

Page

Auxililary indicator .................................................. 2-2-1Back button............................................................ 2-1-3Clock...................................................................... 2-2-1Coolant temperature gauge ................................... 2-2-1Coolant temperature mark ..................................... 2-2-1Default screen........................................................ 2-2-1Dial......................................................................... 2-1-3Engine preheat indicator ........................................ 2-2-1Exhaust filter indicator............................................ 2-2-1Fuel gauge............................................................. 2-2-1Fuel mark ............................................................... 2-2-1Functions ............................................................... 2-2-2Home button .......................................................... 2-1-3Hour meter ............................................................. 2-2-1Information menu................................................. 2-2-23Maintenance..................................................... 2-2-25Monitoring......................................................... 2-2-26Operation.......................................................... 2-2-24Troubleshooting................................................ 2-2-25

Main menu ............................................................. 2-2-4Power mode indicator ............................................ 2-2-1Radio.................................................................... 2-2-13Radio display ......................................................... 2-2-1Seat belt indicator .................................................. 2-2-1Setting menu........................................................ 2-2-15Attachment name input .................................... 2-2-16Auto shutdown.................................................. 2-2-17Brightness adjustment...................................... 2-2-21Date and time................................................... 2-2-16Display item selection....................................... 2-2-21Exhaust filter..................................................... 2-2-18Language ......................................................... 2-2-21Main menu sequence change .......................... 2-2-22Rear view camera monitor ............................... 2-2-20Sub meter selection.......................................... 2-2-19Unit selection.................................................... 2-2-22

Start-up .................................................................. 2-2-3Sub meterBreaker hour consumption ................................. 2-2-1Fuel consumption............................................... 2-2-1

Travel speed indicator............................................ 2-2-1Work mode........................................................... 2-2-14Work mode indicator .............................................. 2-2-1

Monitor and gauge circuitOperational check................................................ 4-2-15

Monitor dial ................................................................ 2-1-3Monitor functions ....................................................... 2-2-2Monitor start-upOperational check.................................................. 4-2-4

Monitor, gauges and battery relayOperational check.................................................. 4-2-5

Motor ......................................................................... 4-1-2

O

OilChange attachment................................................ 3-2-4Engine filter ............................................................ 3-8-6


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Engine sample ....................................................... 3-7-6Engine, level .......................................................... 3-4-1Filter hydraulic........................................................ 3-9-2Hydraulic sample ................................................... 3-8-7Hydraulic specification ......................................... 3-1-10Pump drive gear case drain and refill .................... 3-9-4Pump drive gear case specification ..................... 3-1-11Swing gear case specification.............................. 3-1-11Travel gear case drain and refill........................... 3-10-1Travel gear case specification ............................. 3-1-11

Oil coolerCleaning................................................................. 4-1-1

Oil levelHydraulic ................................................................ 3-4-3

Oil, engineIT4 and Stage III B................................................. 3-1-8

Open crankcase ventilation (OCV) hoseClean...................................................................... 3-9-4

Operation qualification............................................... 1-2-1Operational checkArm regenerative valve ........................................ 4-2-35Auto-idle circuit .................................................... 4-2-21Boom regenerative valve ..................................... 4-2-34Boom up, arm in, and bucket combined function.. 4-2-33Bucket regenerative valve.................................... 4-2-36Control lever pattern check - backhoe pattern ..... 4-2-25Control lever pattern check - excavator pattern ... 4-2-24Control valve lift check valve................................ 4-2-32Cycle times check....................................4-2-41, 4-2-43Diagnostic trouble code check............................... 4-2-1Dig function drift .......................................4-2-29, 4-2-30Display and clear trouble codes............................. 4-2-1E (economy) mode............................................... 4-2-19Engine speed dial ................................................ 4-2-18Fan reversing switch ............................................ 4-2-17Fuel gauge............................................................. 4-2-3Heater and air conditioner controls check............ 4-2-46Heater and air conditioning circuit check ............. 4-2-45Horn circuit............................................................. 4-2-2Hour meter ............................................................. 4-2-3HP (high power) mode......................................... 4-2-20Hydraulic oil tank pressurization .......................... 4-2-24Key switch off, engine off ....................................... 4-2-1Key switch on, engine off ....................................... 4-2-3Key switch on, engine on..................................... 4-2-14Light circuit........................................................... 4-2-10Monitor and gauge circuit..................................... 4-2-15Monitor start-up...................................................... 4-2-4Monitor, gauges and battery relay.......................... 4-2-5Pilot shutoff circuit................................................ 4-2-16PWR (standard) mode ......................................... 4-2-19Rear camera .......................................................... 4-2-7Swing dynamic braking........................................ 4-2-26Swing park brake and circuit drift......................... 4-2-27Swing power check.............................................. 4-2-28Swing priority circuit ............................................. 4-2-31Travel alarm ......................................................... 4-2-22Travel alarm cancel switch circuit ........................ 4-2-23

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Travel lever and pedal ........................................... 4-2-9Travel speed selection ......................................... 4-2-37Travel system maneuverability ............................ 4-2-40Travel system tracking ......................................... 4-2-38Travel system tracking while operating adig function......................................................... 4-2-39Windshield washer circuit .................................... 4-2-14Windshield washer control ................................... 4-2-12Windshield wiper circuit ....................................... 4-2-13Windshield wiper controls .................................... 4-2-11

Operator conveniences ............................................. 1-1-1Operator's station ...................................................... 2-1-1

P

PanelsLocation ................................................................. 2-1-1

Parked cleaningOperation ............................................................... 2-3-9

Parking machine...................................................... 2-3-21Parts, movingStay clear ............................................................... 1-2-3

Pattern conversionControl ................................................................. 2-3-18Control levers....................................................... 2-3-17

PedalLocation ................................................................. 2-1-1Steering.................................................................. 2-3-6

Periodic maintenance chart ....................................... 3-2-1Pilot control leverAdjust height ........................................................ 2-1-16

Pilot oil filterReplace.................................................................. 3-9-3

Pilot shutoff circuitOperational check................................................ 4-2-16

Pilot shutoff lever .............................................1-3-1, 2-1-5Pins, metalDrive safely ............................................................ 1-4-2

Power digButton..................................................................... 2-1-4

Power mode buttonFunction ................................................................. 2-1-3

Power mode indicator................................................ 2-2-1Pre-start inspection.................................................... 2-3-1Primary fuel filterDrain ...................................................................... 3-5-1Replace.................................................................. 3-8-3

Product identification number .................................... 4-5-1PumpService................................................................... 4-1-2

Pump driveGear case oil drain and refill .................................. 3-9-4Gear case oil level ................................................. 3-7-3

Pump drive gear caseSample................................................................... 3-8-7

Pump drive gear case oilSpecification......................................................... 3-1-11


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PWR (standard) modeOperational check................................................ 4-2-19

R

RadiatorCleaning................................................................. 4-1-1

RadioOperation ............................................................. 2-1-11Power and volume switch ...................................... 2-1-3Settings................................................................ 2-2-13Tuning switch ......................................................... 2-1-3

Radio display ............................................................. 2-2-1Radio power and volume switchFunction ................................................................. 2-1-3

Radio tuning switchFunction ................................................................. 2-1-3

Rear cameraClean lens.............................................................. 3-3-3Operational check.................................................. 4-2-7

Rear left panel ........................................................... 2-1-4Rear view cameraOperation ............................................................. 2-2-20

RecognizeSafety, information ................................................. 1-2-1

Refueling, avoid static electricity risk......................... 1-2-5Regulator ................................................................... 4-1-2Required Parts........................................................... 3-2-7Reversing fan switch ................................................. 2-1-6Riding machine.......................................................... 1-3-2Right consoleExhaust filter parked cleaning switch..................... 2-1-7Right enable switch................................................ 2-1-7Service ADVISOR™ remote (SAR) switch ............ 2-1-8Switches................................................................. 2-1-6

Right enable switch ................................................... 2-1-7Right pilot control leverEnable switch......................................................... 2-1-7

Roof exit cover......................................................... 2-1-15ROPSInspect ................................................................... 1-3-3Maintain ................................................................. 1-3-3

S

SafetyAdd cab guarding for special uses...............1-2-1, 1-2-2Caution decals ....................................................... 1-5-1Clean debris from machine.................................... 1-2-7Operator's seat ...................................................... 1-3-1Protective equipment ............................................. 1-2-2Warning decals ...................................................... 1-5-1

Safety features .......................................................... 1-1-1Safety hazardsTravel ..................................................................... 1-3-5

Safety signsHydraulic coupler ................................................. 1-5-14

Page

Safety, Avoid High-Pressure FluidsAvoid High-Pressure Fluids ................................... 1-2-3

Safety, informationRecognize.............................................................. 1-2-1

Sample portsFluid sample........................................................... 4-1-6

SchedulePeriodic maintenance ............................................ 3-2-5

SeatAdjustment ........................................................... 2-1-15Air suspension ..................................................... 2-1-16

Seat belt indicator...................................................... 2-2-1Seat heater switch (if equipped) ................................ 2-1-6Secondary exitWindow ................................................................ 2-1-13

Secondary exit tool .................................................. 2-1-12Selecting displayCelsius and Fahrenheit ........................................ 2-1-10

Serial number ............................................................ 4-5-1Hydraulic coupler ................................................... 4-5-3Hydraulic pump...................................................... 4-5-3Swing motor ........................................................... 4-5-2Travel motor........................................................... 4-5-2

Service ADVISOR™Switch .................................................................... 2-1-8

Service ADVISOR RemoteOverview.............................................................. 2-3-10Reprogramming ................................................... 2-3-10Terms and conditions................................................ -13

Service ADVISOR™ remote (SAR) switch................ 2-1-8Service intervals ........................................................ 3-2-5ShoeCap screw inspection............................................. 3-6-2

SlopesDriving up............................................................. 2-3-19

Software updateDownload and installation .................................... 2-3-11

SpecificationFuel tank ................................................................ 3-2-3Grease ................................................................. 3-1-12Hardware torque .................................................. 4-1-14Hydraulic oil ......................................................... 3-1-10Pump drive gear case oil ..................................... 3-1-11Swing gear case oil.............................................. 3-1-11Travel gear case oil.............................................. 3-1-11

Specifications160GLC engine, IT4 engine................................... 4-6-1180GLC engine, IT4 engine................................... 4-6-1

Starting engine .......................................................... 2-3-3SteeringMachine ................................................................. 2-3-6

StepsUse correctlyHandholds .......................................................... 1-3-1

StorageMachine ................................................................. 4-4-1Monthly .................................................................. 4-4-2

Storing fuel ................................................................ 3-1-2


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Sub meterbreaker hour consumption ..................................... 2-2-1Fuel consumption................................................... 2-2-1

Surge tankCoolant level check................................................ 3-4-2

SwingArea cleaning....................................................... 2-3-19Gear case oil level check....................................... 3-7-1

Swing bearing gearGrease ................................................................... 3-8-2Lubricate ................................................................ 3-8-2

Swing dynamic brakingOperational check................................................ 4-2-26

Swing gear caseOil drain and refill ................................................... 3-9-1

Swing gear case oilDrain and refill........................................................ 3-9-1Sample................................................................... 3-8-7Specification......................................................... 3-1-11

Swing motor serial number........................................ 4-5-2Swing park brake and circuit driftOperational check................................................ 4-2-27

Swing power checkOperational check................................................ 4-2-28

Swing priority circuitOperational check................................................ 4-2-31

SwitchAuto-idle................................................................. 2-1-3Blower speed ......................................................... 2-1-3Exhaust filter parked cleaning switch..................... 2-1-7Key......................................................................... 2-1-3Left console............................................................ 2-1-5Reversing fan......................................................... 2-1-6Right console ......................................................... 2-1-6Right enable switch................................................ 2-1-7Seat heater (if equipped) ....................................... 2-1-6Service ADVISOR™ remote (SAR) ....................... 2-1-8Temperature control/mode..................................... 2-1-3Travel alarm cancel................................................ 2-1-5Travel speed .......................................................... 2-1-3Windshield wiper and washer ................................ 2-1-3Work light ............................................................... 2-1-3

Switch panel .............................................................. 2-1-2Auto-idle switch...................................................... 2-1-3Back button............................................................ 2-1-3Blower speed switch .............................................. 2-1-3Engine speed dial .................................................. 2-1-3Functions ............................................................... 2-1-3Home button .......................................................... 2-1-3Key switch.............................................................. 2-1-3Keypad................................................................... 2-1-3Monitor dial ............................................................ 2-1-3Power mode button................................................ 2-1-3Radio power and volume switch ............................ 2-1-3Radio tuning switch................................................ 2-1-3Temperature control/mode switch .......................... 2-1-3Travel speed switch ............................................... 2-1-3Windshield wiper and washer switch ..................... 2-1-3

Page

Work light switch .................................................... 2-1-3

T

TablePeriodic maintenance ............................................ 3-2-5

Temperature control/mode switchFunction ................................................................. 2-1-3

TimeChange setting..................................................... 2-2-16

Tip overAvoiding ................................................................. 1-3-4

ToolSecondary exit ..................................................... 2-1-12

Torque chartsMetric ................................................................... 4-1-16Unified inch .......................................................... 4-1-15

Towing machine....................................................... 2-3-23TrackSag....................................................................... 4-1-14Sag adjustment ...................................................... 3-3-2Sag check .............................................................. 3-3-2Shoe cap screw hardware ................................... 4-1-14Shoe, cap screw torque ......................................... 3-6-2

TransportLoading machine.................................................. 2-3-22Unloading machine .............................................. 2-3-22

Travel alarm............................................................... 2-1-5Cancel switch......................................................... 2-1-5Operational check................................................ 4-2-22

Travel alarm cancel switch ........................................ 2-1-5Travel alarm cancel switch circuitOperational check................................................ 4-2-23

Travel gear caseOil drain and refill ................................................. 3-10-1Oil level .................................................................. 3-7-6Sample................................................................... 3-8-7

Travel gear case oilSpecification......................................................... 3-1-11

Travel lever and pedalOperational check.................................................. 4-2-9

Travel motor serial number........................................ 4-5-2Travel speed indicator ............................................... 2-2-1Travel speed selectionOperational check................................................ 4-2-37

Travel speed switchFunction ................................................................. 2-1-3

Travel system maneuverabilityOperational check................................................ 4-2-40

Travel system trackingOperational check................................................ 4-2-38

Travel system tracking while operating a digfunctionOperational check................................................ 4-2-39

TroubleshootingElectrical system.................................................... 4-3-7Engine.................................................................... 4-3-2Hydraulic system.................................................... 4-3-5


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Troubleshooting procedure........................................ 4-3-1

U

Unified inch bolt and screw torque values ............... 4-1-15Unloader valveAir cleaner.............................................................. 3-3-1Air cleaner, replace ................................................ 3-9-6

V

ValveAir cleaner dust unloader ....................................... 3-3-1Control ................................................................... 4-1-2

W

WarrantyNon-road emissions control warrantystatement--compression ignitionCARB ...................................................................... -8EPA ......................................................................... -6

Water separatorDrain ...................................................................... 3-5-1Replace.................................................................. 3-8-3

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Welding...................................................................... 4-1-6Welding repairs.......................................................... 1-4-2WindowCab ...................................................................... 2-1-14Lower front ........................................................... 2-1-14Secondary exit ..................................................... 2-1-13

Windshield washer circuitOperational check................................................ 4-2-14

Windshield washer controlOperational check................................................ 4-2-12

Windshield washer fluid............................................. 3-3-1Windshield wiper and washer switchFunction ................................................................. 2-1-3

Windshield wiper circuitOperational check................................................ 4-2-13

Windshield wiper controlsOperational check................................................ 4-2-11

Work light switchFunction ................................................................. 2-1-3

Work mode indicator.................................................. 2-2-1Work site hazardsAvoid ...................................................................... 1-3-2

Working ranges160GLC.................................................................. 4-6-7180GLC.................................................................. 4-6-9

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160GLC and 180GLC Excavator(PIN: 1FF160GX …moffatpipe.com/Equipment-Manuals/EXC 12 - JD160GLC/EXC...

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Transcript of 160GLC and 180GLC Excavator(PIN: 1FF160GX …moffatpipe.com/Equipment-Manuals/EXC 12 - JD160GLC/EXC...