450g Crawler

O
450G, 550G, and 650G
C
Torque Converter
D
and Direct Drive
Crawler Dozers
OPERATORS MANUAL
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O M T 1 6 3 9 7 4
John Deere Dubuque Works

OMT163974 A8
(This manual replaces OMT159724)
LITHO IN U.S.A.
ENGLISH
Introduction
READ THIS MANUAL carefully to learn how to operate record all the numbers to help in tracing the machine
and service your machine correctly. Failure to do so should it be stolen. Your dealer also needs these
could result in personal injury or equipment damage. numbers when you order parts. File the identification
This manual and safety signs on your machine may numbers in a secure place off the machine.
also be available in other languages. (See your John
Deere dealer to order.) WARRANTY is provided as part of John Deere’s
support program for customers who operate and
THIS MANUAL SHOULD BE CONSIDERED a maintain their equipment as described in this manual.
permanent part of your machine and should remain The warranty is explained on the warranty certificate
with the machine when you sell it. which you should have received from your dealer.
MEASUREMENTS in this manual are given in both This warranty provides you the assurance that John
metric and customary U.S. unit equivalents. Use only Deere will back its products where defects appear
correct replacement parts and fasteners. Metric and within the warranty period. In some circumstances,
inch fasteners may require a specific metric or inch John Deere also provides field improvements, often
wrench. without charge to the customer, even if the product is
out of warranty. Should the equipment be abused, or
RIGHT-HAND AND LEFT-HAND sides are determined modified to change its performance beyond the original
by facing in the direction of forward travel. factory specifications, the warranty will become void
and field improvements may be denied. Setting fuel
WRITE PRODUCT IDENTIFICATION NUMBERS delivery above specifications or otherwise
(P.I.N.) in the Machine Numbers section. Accurately overpowering machines will result in such action.
CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive
harm.
MODT158728IFC7 –19–26SEP95–1/3
121997
PN=2
Introduction
–UN–12DEC92
T7896AM
T7883AQ –UN–09DEC92
MODT158728IFC7 –19–26SEP95–2/3
121997
PN=3
Introduction
T7883AR –UN–09DEC92
MODT158728IFC7 –19–26SEP95–3/3
121997
PN=4
Introduction
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publications. Please FAX or mail your comments, ideas
and improvements.
SEND TO: John Deere Dubuque Works

P.O. Box 538
Dubuque, Iowa 52004-0538
Dept. 304
Attn: Publications Supervisor
FAX NUMBER: 319-589-5800
OMT163974 450G/550G/650G Crawler Dozer Operator’s Manual

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MODTXFAXRR5501 –19–26SEP95–1/1
121997
PN=5
Introduction
121997
PN=6
Contents
Page Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1 Adjust Non-Suspension Seat . . . . . . . . . . . . . . 10-14

Adjust Suspension Seat—If Equipped . . . . . . . 10-15
Safety Signs Adjust Armrest . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Safety Sign. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-1 Check Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Operator’s Manual Holder. . . . . . . . . . . . . . . . . 10-16
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Operator’s Station
Operating Lights—If Equipped . . . . . . . . . . . . . 10-18
Instrument Panel (S.N. —823918) . . . . . . . . .. . 10-1
Instrument Panel (S.N. 823919— ). . . . . . . . .. . 10-2 Break-In
Stop Engine Indicator and Alarm Indicator . . .. . 10-3 Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . 15-1
Service Required Indicator . . . . . . . . . . . . . . .. . 10-3 After the First 10 Hours . . . . . . . . . . . . . . . . . . . 15-1
Engine Oil Pressure Indicator . . . . . . . . . . . . .. . 10-3 Between the First 50 to 100 Hours—
Engine Coolant Temperature Indicator . . . . . .. . 10-4 After Sales Inspection (ASI) . . . . . . . . . . . . . . 15-2
Engine Alternator Voltage Indicator . . . . . . . .. . 10-4
Transmission Oil Temperature Indicator . . . . .. . 10-4 Pre-Start Inspection
Transmission Oil Filter Indicator . . . . . . . . . . .. . 10-5 Inspect Machine Daily Before Starting . . . . . . . . 20-1
Hydraulic Oil Filter Indicator . . . . . . . . . . . . . .. . 10-5
Instrument Panel—Gauges—If Equipped Operating the Engine
(S.N. —823918) . . . . . . . . . . . . . . . . . . . . . . . 10-6 Check Instruments Before Starting—
Instrument Panel—Gauges—If Equipped Instrument Panels With Indicators Only. . . . . . 25-1
(S.N. 823919— ). . . . . . . . . . . . . . . . . . . . . . . 10-7 Check Instruments Before Starting—
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Instrument Panels With Gauges . . . . . . . . . . . 25-1
Engine Water Temperature Gauge—If Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . 25-2
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Starting Fluid—If Equipped (Cold Weather
Engine Oil Pressure Gauge—If Equipped. . . . . . 10-8 Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Transmission Oil Temperature Gauge—If Using Coolant Heater—If Equipped . . . . . . . . . . 25-5
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Using Booster Batteries With Jumper
Low Voltage Indicator Light—If Equipped . . . . . . 10-8 Battery Terminal—If Equipped . . . . . . . . . . . . 25-6
Transmission Oil Filter Indicator Light—If Using Booster Batteries—12 Volt System. . . . . . 25-7
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Check Instruments After Starting—
Hydraulic Oil Filter Restriction Indicator Instrument Panels With Indicators Only. . . . . . 25-8
Light—If Equipped . . . . . . . . . . . . . . . . . . . . . 10-9 Check Instruments After Starting—
Transmission Oil Pressure Indicator Light— Instrument Panels With Gauges Only . . . . . . . 25-8
If Equipped . . . . . . . . . . . . . . . . . . . . . . . . .. . 10-9 Engine Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . 25-8
Dozer Control Lever—One Lever Option . . . .. 10-10 Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . . 25-9
Dozer Control Levers—Two Lever Option . . .. 10-10 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . 25-10
Pedals With Lever Steering—If Equipped. . . .. 10-11 Adjusting Engine For High Elevation
Pedals With Pedal Steering—If Equipped. . . .. 10-11 (S.N. —
Pedals With Pedal Steering With Torque 840460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-11
Converter—If Equipped. . . . . . . . . . . . . . . .. 10-12
Steering Levers—If Equipped . . . . . . . . . . . . .. 10-12 Driving the Machine
Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-13 Driving the Machine . . . . . . . . . . . . . . . . . . . . . . 30-1
Battery Disconnect Switch—If Equipped. . . . .. 10-13
Vandal Shield . . . . . . . . . . . . . . . . . . . . . . . . .. 10-14 Continued on next page
All information, illustrations and specifications in this manual 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  1997
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  1993,1991,1988,1987,1994,1996
i 121997
PN=1
Contents
Page Page
Using Park and Brake Lock Lever . . . . . . . . .. . 30-2 Bucket Digging . . . . . . . . . . . . . . . . . . . . . . . . . 36-13
Shifting the Transmission . . . . . . . . . . . . . . . .. . 30-3 Crowd Digging . . . . . . . . . . . . . . . . . . . . . . . . . 36-13
Using Engine Speed Control Lever. . . . . . . . .. . 30-3 Planning Spoil Piles . . . . . . . . . . . . . . . . . . . . . 36-14
Decelerator Pedal With Torque Converter . . .. . 30-4 Preparing To Operate Dozer After
Steering the Machine With Lever Steering— Operating Backhoe . . . . . . . . . . . . . . . . . . . . 36-14
If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4 Operating Winch. . . . . . . . . . . . . . . . . . . . . . . . 36-15
Steering the Machine With Pedal Fasten Cable To Winch Drum—4000 Series . . 36-16
Steering—If Equipped . . . . . . . . . . . . . . . . .. . 30-5 Winch Free Spool Drag Adjustment . . . . . . . . . 36-19
Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . .. . 30-6 Greasing Winch Fairlead—If Equipped. . . . . . . 36-19
Stopping the Machine. . . . . . . . . . . . . . . . . . .. . 30-8 Greasing Ripper—If Equipped . . . . . . . . . . . . . 36-19
Emergency Stopping—Pedal Steering . . . . . .. . 30-9 Greasing Log Arch—If Equipped . . . . . . . . . . . 36-20
Emergency Stopping—Lever Steering . . . . . .. . 30-9
Parking the Machine. . . . . . . . . . . . . . . . . . . .. 30-11 Transporting
Lock All Compartments . . . . . . . . . . . . . . . . .. 30-11 Loading Machine on a Trailer . . . . . . . . . . . . . . . 40-1
Towing Procedures. . . . . . . . . . . . . . . . . . . . . . . 40-2
Operating the Crawler
Operating Blade—Two Lever Option .. .. .. .. . 35-1 Fuels and Lubricants
Tilting Blade—Two Lever Option . . . .. .. .. .. . 35-2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Angling Blade—Two Lever Option . . .. .. .. .. . 35-3 Low Sulfur Diesel Fuel Conditioner. . . . . . . . . . . 45-2
Changing Blade Pitch . . . . . . . . . . . . .. .. .. .. . 35-4 Diesel Fuel Storage . . . . . . . . . . . . . . . . . . . . . . 45-3
Operating Blade—One Lever Option .. .. .. .. . 35-6 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4
Tilting Blade—One Lever Option . . . .. .. .. .. . 35-6 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 45-5
Angling Blade—One Lever Option . . .. .. .. .. . 35-7 Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 45-6
Using Decelerator Pedal Declutch Track Roller, Front Idler, and Carrier
Option (Direct Drive Machines) . . . .. .. .. .. . 35-7 Roller Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-6
Operating Suggestions . . . . . . . . . . . .. .. .. .. . 35-7 Transmission, Steering Clutches, and
Operating Tips . . . . . . . . . . . . . . . . . .. .. .. .. . 35-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Operating Crawler Dozer On Slopes .. .. .. .. . 35-8 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-8
Operating and Maintenance Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 45-8
Undercarriage Tips . . . . . . . . . . . . .. .. .. .. . 35-9 Alternative and Synthetic Lubricants. . . . . . . . . . 45-9
Operating In Rough Terrain . . . . . . . .. .. .. .. 35-10
Side-by-Side Dozing . . . . . . . . . . . . . .. .. .. .. 35-10 Periodic Maintenance
Slot Dozing. . . . . . . . . . . . . . . . . . . . .. .. .. .. 35-11 Service Your Machine At Specified Intervals . . . 50-1
Tilt Dozer Ditching . . . . . . . . . . . . . . .. .. .. .. 35-11 Check the Hour Meter Regularly . . . . . . . . . . . . 50-2
Straight Dozer Ditching. . . . . . . . . . . .. .. .. .. 35-11 Use Correct Fuels and Lubricants . . . . . . . . . . . 50-3
Backfilling . . . . . . . . . . . . . . . . . . . . . .. .. .. .. 35-12 Prepare Machine For Maintenance. . . . . . . . . . . 50-4
Leveling A Stockpile . . . . . . . . . . . . . .. .. .. .. 35-13 Remove Bottom Guard. . . . . . . . . . . . . . . . . . . . 50-5
Moving Boulders. . . . . . . . . . . . . . . . .. .. .. .. 35-14 Maintenance and Repair Record
Bench Cut . . . . . . . . . . . . . . . . . . . . .. .. .. .. 35-15 Keeping System . . . . . . . . . . . . . . . . . . . . . . . 50-5
Brush Removal. . . . . . . . . . . . . . . . . .. .. .. .. 35-15 OILSCAN Plus, CoolScan 3–WAY
Tree Removal. . . . . . . . . . . . . . . . . . .. .. .. .. 35-16 Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Stump Removal . . . . . . . . . . . . . . . . .. .. .. .. 35-17 Maintenance and Repair Record
Keeping System . . . . . . . . . . . . . . . . . . . . . . . 50-7
Attachments
Attaching Backhoe to Crawler Tractor . . . . . . . . 36-1 Maintenance—As Required
Detaching Backhoe From Crawler Tractor . . . . . 36-3 Check and Adjust Belt Tension (S.N. —
Prepare to Operate Backhoe . . . . . . . . . . . . . . . 36-6 840460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . 36-7 Inspect Serpentine Belt (S.N. 840461— ) . . . . . 55-2
Operating Stabilizers . . . . . . . . . . . . . . . . . . . . . 36-7 Check the Air Restriction Indicator . . . . . . . . . . . 55-2
Backhoe Control Levers—John Deere Pattern . . 36-8 Check the Pre-Cleaner . . . . . . . . . . . . . . . . . . . . 55-2
Grease Backhoe—If Equipped . . . . . . . . . . . . . . 36-9 Check Track Sag . . . . . . . . . . . . . . . . . . . . . . . . 55-3
Changing Backhoe Bucket Position . . . . . . . . . 36-10
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-11 Continued on next page
ii 121997
PN=2
Contents
Page Page
Adjusting Track Sag . . . . . . . . . . . . . . . . . . . . . . 55-4 Maintenance

Drain Fuel Tank Sump . . . . . . . . . . . . . . . . . . . . 55-7 Checking Hoses and Radiator . . . . . . . . . . . . . . 90-1
Test the Coolant Freeze—Protection Level . . . . 90-2
Maintenance—Every 10 Hours or Daily Do Not Service Injection Nozzles . . . . . . . . . . . . 90-2
Check Engine Oil Level . . . . . . . . . . . . . . .. .. . 60-1 Do Not Change Injection Pump . . . . . . . . . . . . . 90-3
Check Transmission Oil Level . . . . . . . . . .. .. . 60-2 Draining Fuel Filter Sediment . . . . . . . . . . . . . . . 90-3
Check Hydraulic Oil Level . . . . . . . . . . . . .. .. . 60-3 Checking Fuel Filler Screen . . . . . . . . . . . . . . . . 90-4
Check Coolant Level . . . . . . . . . . . . . . . . .. .. . 60-4 Cleaning Fuel Tank Outlet Screen—Earlier
Lubricate Dozer Linkage. . . . . . . . . . . . . . .. .. . 60-5 Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Cleaning Fuel Tank Outlet Screen—Later
Maintenance—Every 250 Hours Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Change Engine Oil and Filter . . . . . . . . . . . . . . . 75-1 Fuel Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-6
Check Final Drives Oil Level . . . . . . . . . . . . . . . 75-2 Inspect Air Cleaner Elements Restriction
Clean Transverse Case . . . . . . . . . . . . . . . . . . . 75-2 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
Grease Track Adjuster Cylinder (S.N. — Cleaning Dusty Primary Element . . . . . . . . . . . . 90-8
745426) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-2 Inspecting Element . . . . . . . . . . . . . . . . . . . . . . . 90-8
Check Coolant Level . . . . . . . . . . . . . . . . . . . . . 75-3 Precautions For Alternator and Regulator. . . . . . 90-9
Service Batteries Carefully . . . . . . . . . . . . . . . . 90-10
Maintenance—Every 500 Hours
Checking Electrolyte Specific Gravity . . . . . . . . 90-12
Change Fuel Filter (S.N. —840460) . . . . . . . . . . 80-1
Using Battery Charger . . . . . . . . . . . . . . . . . . . 90-13
Change Fuel Filter/Water Separator (S.N.
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . 90-14
840461— ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-3
Removing Batteries . . . . . . . . . . . . . . . . . . . . . 90-15
Check Air Intake Hose . . . . . . . . . . . . . . . . . . . . 80-4
Resetting Circuit Breakers . . . . . . . . . . . . . . . . 90-16
Change Transmission Oil Filter. . . . . . . . . . . . . . 80-5
Changing Reverse Warning Alarm Volume. . . . 90-17
Change Hydraulic Reservoir Breather
Check Neutral Start System . . . . . . . . . . . . . . . 90-18
Filter and Hydraulic Oil Filter. . . . . . . . . . . . . . 80-6
Adding Attachments/Accessories To
Batteries
Roll-Over Protective Structure (ROPS) . . . . 90-18
Check Electrolyte Level and Terminals . . . . . . 80-8
Track Sag General Information. . . . . . . . . . . . . 90-19
Check Coolant Conditioner In Radiator. . . . . . . 80-10
Remove and Install Lubricated Track
Maintenance—Every 1000 Hours Chain—Split Link—Earlier Machines. . . . . . . 90-20
Check Transmission Accumulator—Direct Remove and Install Lubricated Track
Drive Machines . . . . . . . . . . . . . . . . . . . . . . . . 85-1 Chain—Single Tooth Split Link—Later
Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . 85-1 Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
Change Transmission Oil and Clean Check Front Idler Vertical Movement . . . . . . . . 90-25
Suction Screen . . . . . . . . . . . . . . . . . . . . . . . . 85-4 Idler Height Adjustment . . . . . . . . . . . . . . . . . . 90-26
Change Final Drives Oil . . . . . . . . . . . . . . . . . . . 85-8 Checking Track Carrier Roller Oil Level . . . . . . 90-29
Check Engine Speed . . . . . . . . . . . . . . . . . . . . . 85-8 Checking Idler Oil Level . . . . . . . . . . . . . . . . . . 90-31
Check and Adjust Engine Speed Control Checking Track Roller Oil Level . . . . . . . . . . . . 90-33
Linkage Without Declutch . . . . . . . . . . . . . . . . 85-9 Steering Brake Adjustment—(S.N. —
Check and Adjust Engine Speed Control 770807) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
Linkage With Declutch—Direct Drive Steering Brake Adjustment—(S.N.
Machines—If Equipped . . . . . . . . . . . . . . . . . 85-11 770808— ) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-36
Clean Engine Crankcase Ventilation Tube . . . . 85-12 Check Fire Extinguisher—If Equipped . . . . . . . 90-38
Measure and Adjust Engine Valve Reversible Fan—If Equipped . . . . . . . . . . . . . . 90-38
Clearances (S.N. —840460) . . . . . . . . . .. .. 85-13 Do Not Service Control Valves and
Drain the Cooling System. . . . . . . . . . . . . .. .. 85-14 Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-38
Diesel Engine Coolant . . . . . . . . . . . . . . . .. .. 85-15 Hardware Torque Specifications . . . . . . . . . . . . 90-39
Fill the Cooling System. . . . . . . . . . . . . . . .. .. 85-16 Keep ROPS Installed Properly . . . . . . . . . . . . . 90-39
Changing Air Cleaner Elements . . . . . . . . .. .. 85-17 Checking Track Shoe Cap Screw Torque. . . . . 90-40
Unified Inch Bolt and Cap Screw Torque
Maintenance—Every 2000 Hours Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-41
Measure and Adjust PowerTech Engine
Valve Clearances (S.N. 840461— ) . . . . . . . . 86-1 Continued on next page
iii 121997
PN=3
Contents
Page Page
Metric Bolt and Cap Screw Torque Values . . . . 90-43 Power Control Clutch Valve Check. . . . . . . . . . 95-10
Check Oil Lines and Fittings. . . . . . . . . . . . . . . 90-44 Driving Checks . . . . . . . . . . . . . . . . . . . . . . . . . 95-11
Service Recommendations For 37° Flare Transmission Slip Check . . . . . . . . . . . . . . . . . 95-11
and 30° Cone Seat Connectors . . . . . . . . . . 90-45 Transmission Noise Check . . . . . . . . . . . . . . . . 95-11
Service Recommendations for O-Ring Boss Transmission Sealing Check . . . . . . . . . . . . . . 95-11
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-46 Hydraulic System Checks. . . . . . . . . . . . . . . . . 95-12
Service Recommendations for Flat Face Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . 95-12
O-Ring Seal Fittings . . . . . . . . . . . . . . . . . . . 90-48 Hydraulic Warm-Up Procedure . . . . . . . . . . . . . 95-12
Service Recommendations for Inch Oil Cooler Circuit Check (If Equipped) . . . . . . . 95-12
Series Four Bolt Flange Fittings . . . . . . . . . . 90-49 Hydraulic Reservoir Breather Check . . . . . . . . . 95-13
Service Recommendations for Metric Undercarriage Checks . . . . . . . . . . . . . . . . . . . 95-13
Series Four Bolt Flange Fitting . . . . . . . . . . . 90-50 Track Sag Roller and Idler Leakage Checks . . 95-13
Sprocket Wear Check. . . . . . . . . . . . . . . . . . . . 95-13
Operational Checkout Grouser Wear, Bent Track Shoe, and
Operational Checkout . . . . . . . . . . . . . . . . . . . . . 95-1 Loose Hardware Checks. . . . . . . . . . . . . . . . 95-14
Indicators, Shift Lever Linkage and Track Link Roller and Front Idler Wear
Reverse Warning Alarm Checks (With Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-14
Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-2 Accessory Checks . . . . . . . . . . . . . . . . . . . . . . 95-14
Monitor Indicator Lights and Alarm Checks . . . . 95-2 Horn Circuit Check . . . . . . . . . . . . . . . . . . . . . . 95-14
Engine Low Pressure and Alternator Hour Meter Circuit Check . . . . . . . . . . . . . . . . . 95-15
Low Voltage Monitor Indicator Light Checks . . 95-2 Work Light Check—If Equipped . . . . . . . . . . . . 95-15
Air Restriction Indicator Check . . . . . . . . . . . . . . 95-3 Seat Adjustment Checks . . . . . . . . . . . . . . . . . 95-15
Shift Lever Linkage and Reverse Warning Seat Height and Backrest Adjustment
Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . 95-3 Checks (Non-Suspension). . . . . . . . . . . . . . . 95-16
Park and Brake Lock Check . . . . . . . . . . . . . . . . 95-3 Seat Height and Backrest Adjustment
Neutral Start Switch and Start Circuit Checks. . . 95-4 Checks (Suspension Seat) . . . . . . . . . . . . . . 95-16
Neutral Start Switch Check. . . . . . . . . . . . . . . . . 95-4 Seat Belt Check . . . . . . . . . . . . . . . . . . . . . . . . 95-16
Start Circuit Check . . . . . . . . . . . . . . . . . . . . . . . 95-4 Start Aid System Check (If Equipped) . . . . . . . 95-17
Park and Brake Lock/Neutral Switch Fuel Shut-Off Valve Check—Earlier
Adjustment Check. . . . . . . . . . . . . . . . . . . . . . 95-5 Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-17
Engine Speed Control and Decelerator Fuel Shut-Off Valve Check, Later Units . . . . . . 95-17
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5 Fuel Water Trap Valve Check, Earlier Units . . 95-18
Engine Speed Control Lever Linkage Check . . . 95-5 Vandal Protection Checks . . . . . . . . . . . . . . . . 95-18
Decelerator Linkage Check . . . . . . . . . . . . . . . . 95-6 Service Decal Check . . . . . . . . . . . . . . . . . . . . 95-19
Speed Control Lever Linkage Check . . . . . . . . . 95-6
Brake System Checks . . . . . . . . . . . . . . . . . . . . 95-7 Troubleshooting
Brake Pedal Upper Stop and Return Spring Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-2
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-7 Electrical System . . . . . . . . . . . . . . . . . . . . . . 100-10
Brake Drag, Park, and Brake Lock Linkage Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 100-14
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-7 Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . 100-17
Brake Capacity Check . . . . . . . . . . . . . . . . . . . . 95-7 Gauges and Indicators . . . . . . . . . . . . . . . . . . 100-21
Steering System Checks (Steering Clutches
and Brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . 95-8 Storage
Steering Clutch Engagement Check (Pedal Prepare Machine For Storage . . . . . . . . . . . . . 105-1
Steer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-8 Monthly Storage Procedure . . . . . . . . . . . . . . . 105-3
Hydraulic Warm-Up Procedure . . . . . . . . . . . . . . 95-8
Steering Clutch Adjustment Check . . . . . . . . . . . 95-9 Crime Prevention Tips
Steering Clutch Adjustment Check— Help Prevent Crime . . . . . . . . . . . . . . . . . . . . . 110-1
Continued . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-9 Record Identification Numbers . . . . . . . . . . . . . 110-1
Steering Brake Operation Check . . . . . . . . . . . 95-10 Keep Proof Of Ownership. . . . . . . . . . . . . . . . . 110-1
Power Control Pedal Checks—Direct Drive Park Indoors Out Of Sight . . . . . . . . . . . . . . . . 110-2
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-10
Power Control Clutch Drag Check . . . . . . . . . . 95-10 Continued on next page
iv 121997
PN=4
Contents
Page
When Parking Outdoors . . . . . . . . . . . . . . . . . . 110-2

Reduce Vandalism . . . . . . . . . . . . . . . . . . . . . . 110-2
Report Thefts Immediately . . . . . . . . . . . . . . . . 110-3
Specifications
450G Crawler Dozer Specifications . . . . . .. . . 115-1
450G Drain and Refill Capacities . . . . . . . .. . . 115-4
450G—LT Crawler Dozer Specifications. . .. . . 115-5
450G—LT Drain and Refill Capacities . . . .. . . 115-8
450G—LGP Crawler Dozer Specifications .. . . 115-9
450G—LGP Drain and Refill Capacities . . .. . 115-12
550G—LT Crawler Dozer Specifications. . .. . 115-13
550G—LT Drain and Refill Capacities . . . .. . 115-16
550G—LGP Crawler Dozer Specifications .. . 115-17
650G Crawler Dozer Specifications . . . . . .. . 115-21
650G Drain and Refill Capacities . . . . . . . .. . 115-24
650G—LGP Crawler Dozer Specifications .. . 115-25
9310 Backhoe Specifications . . . . . . . . . . .. . 115-29
9310 Backhoe Lift Capacity (G Series
Loaders) . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-30
9310 Backhoe Lift Capacity (G-Series
Dozers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-31
4000 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . 115-32
Machine Numbers
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-1
Record Engine Serial Number . . . . . . . . . . . . . 120-1
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . CLIS-1
John Deere Service Literature Available

Technical Information . . . . . . . . . . . . . . . . . . . SLIT-1
John Deere Service Keeps You On the Job

John Deere Is At Your Service When
You Need It . . . . . . . . . . . . . . . . . . . . . . . . . IBC-1
v 121997
PN=5
Contents
vi 121997
PN=6
Safety
T112466 –19–11DEC97
TX,05,RR7003 –19–16OCT95–1/1
05–1 121997
PN=9
Safety
RECOGNIZE SAFETY INFORMATION
This is the safety —alert symbol. When you see this

symbol on your machine or in this manual, be alert to the
potential for personal injury.
T81389 –UN–07DEC88
Follow recommended precautions and safe operating
practices.
TX,05,RB46 –19–03DEC97–1/1
UNDERSTAND SIGNAL WORDS
A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
TS187 –19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
DX,SIGNAL –19–03MAR93–1/1
05–2 121997
PN=10
Safety
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and on

your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
TS201 –UN–23AUG88
available from your John Deere dealer.
Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without
instruction.
Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need

assistance, contact your John Deere dealer.
DX,READ –19–03MAR93–1/1
05–3 121997
PN=11
Safety
AVOID INJURY FROM ROLLOVER

ACCIDENTS
------------------------------------
WEAR YOUR SEAT BELT
------------------------------------
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE--SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
------------------------------------
MACHINE WILL TIP OVER FASTER THAN
YOU CAN JUMP FREE
To avoid rollovers:
Be careful when operating on a slope.
Avoid sharp turns.
Balance loads so weight is evenly distributed and load is
T8358AG –19–21NOV94
stable.
Carry tools and loads close to the ground to aid visibility

and lower center of gravity.
Reduce speed before turning or swinging load.
Know capacity of machine. Do not overload.
Be careful when operating at the edge of an excavation,

trench, or drop-off, and loading or unloading from a trailer.
Read and understand the operating instructions in the

operator’s manual.
TX,05,RR4660 –19–20DEC94–1/1
05–4 121997
PN=12
Safety
AVOID INJURY FROM:

LOADING MACHINE ON A TRAILER,
FASTENING MACHINE TO TRAILER,
UNLOADING MACHINE FROM TRAILER
ALWAYS USE CAUTION WHEN LOADING
AND UNLOADING MACHINES ON A TRAILER
–UN–28JUN95
ALWAYS KNOW AND FOLLOW THE
RECOMMENDED PROCEDURES FOR THE
MACHINE BECAUSE ALL MACHINES ARE
T8513AB
NOT LOADED, FASTENED AND UNLOADED
THE SAME WAY.
ALWAYS KEEP BYSTANDERS CLEAR OF
THE AREA
To avoid injury:
Keep the trailer bed clean
–UN–29NOV90
Park the trailer on a firm, hard, level surface that will not
give way when the weight of the machine is on the trailer
T7405BJ
Put chock blocks against truck wheels.
Use a ramp or loading dock. Ramps must be strong

enough to adequately handle the load and have a low
angel and correct height.
If machine is equipped with a seat belt, fasten it before

starting the engine.
Fasten chains or cables to machine tracks or track or

track chain links. Do not place chains or cable over or
against hydraulic lines or hoses.
TX,05,RR7004 –19–16OCT95–1/1
05–5 121997
PN=13
Safety
AVOID INJURY FROM BACKOVER

ACCIDENTS
----------------------------------
BEFORE MOVING MACHINE, BE SURE ALL
PERSONS ARE CLEAR OF AREA
----------------------------------
–UN–21FEB90
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE
HORN OR OTHER SIGNAL TO WARN
T7241AY
BYSTANDERS BEFORE MOVING MACHINE
----------------------------------
WHEN USING A SIGNAL PERSON, KEEP
PERSON IN VIEW AT ALL TIMES, BE SURE
SIGNAL PERSON IS CLEAR BEFORE
BACKING UP
To avoid backover accidents:
Always look around before you back up. Be sure that

everyone is in the clear.
Keep bystanders away from pivot area of an articulated

machine.
Keep reverse warning alarm in working condition
Use a signal person when backing up if view is

obstructed. Always keep signal person in view.
Learn the meaning of all flags, signs, and markings used

on the job and who has the responsibility for signaling.
Keep windows, mirrors, and lights clean and in good

condition.
Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper lighting.
Read and understand the operating instructions in this

TX,05,RR,491 –19–06SEP94–1/1
05–6 121997
PN=14
Safety
AVOID INJURY FROM ROLLAWAY

ACCIDENTS
--------------------------------
TO PREVENT ROLLAWAY, ALWAYS MAKE
SURE MACHINE IS PROPERLY SECURED
BEFORE LEAVING OPERATOR’S SEAT
T7241AZ –UN–21FEB90
--------------------------------
DEATH OR SERIOUS INJURY MAY RESULT
IF YOU ATTEMPT TO MOUNT OR STOP A
MOVING MACHINE
To avoid rollaways:
Select level ground when possible to park machine.
Put in park or set park brake and place transmission

controls in neutral and lock.
Lower all equipment to ground.
Stop the engine.
Block all wheels if you must park on a grade, position

machine to prevent rolling.
Park a reasonable distance from other machines.
Read and understand the operating instructions in this

TX,05,RR,492 –19–03JUN92–1/1
INSPECT MACHINE
Inspect your machine carefully each day by walking

around it before you start it. (See Pre-Start Inspection
Chapter.)
T6607AQ –UN–18OCT88
T82,BHSA,CL –19–14MAR90–1/1
05–7 121997
PN=15
Safety
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you get on and off the machine, always maintain a

three point contact with the steps and handrails and face
T6981AN –UN–15JUN89
the machine. Do not use any controls as handholds.
Never jump either on or off the machine. Never mount or

dismount a moving machine.
Be careful of slippery conditions on platforms, steps, and

handrails when leaving the machine.
02T,05,K69 –19–14MAR90–1/1
PREVENT MACHINE RUNAWAY
Avoid possible injury or death from machine runaway.
Do not start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.
T6607AO –UN–18OCT88
NEVER start engine while standing on ground. Start
engine only from operator’s seat, with transmission in
neutral or park.
TX,05,FF1682 –19–15JAN91–1/1
USE SEAT BELT PROPERLY
Use a seat belt when you operate with a roll-over

protective structure (ROPS) or cab to minimize chance of
injury from an accident such as an overturn.
T7860AQ –UN–09NOV92
Do not use a seat belt if operating without a ROPS or

cab.
TX,05,RR2734 –19–08FEB93–1/1
05–8 121997
PN=16
Safety
OPERATING ON SLOPES
Avoid side slope travel whenever possible. The danger of

tipping is always present.
In steep slope operation, do not allow engine to

overspeed. Select proper gear speed before starting down
slope.
The grade of the slope you should attempt will be limited

by such factors as ground condition, and load being
handled.
02T,05,M15 –19–07JAN91–1/1
AVOID POWER LINES
Keep away from power lines. Serious injury or death may

result. Never move any part of the machine or load closer
to power line than 10 ft (3 m) plus twice the line insulator
length.
02T,05,M59 –19–12OCT88–1/1
KEEP RIDERS OFF MACHINE
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off of the
machine. Riders also obstruct the operator’s view resulting
in the machine being operated in an unsafe manner.
02T,05,J44 –19–19JAN88–1/1
05–9 121997
PN=17
Safety
HANDLE FLUIDS SAFELY—AVOID FIRES
Handle fuel with care; it is highly flammable. Do not refuel

the machine while smoking or when near open flame or
sparks. Always stop engine before refueling machine. Fill
fuel tank outdoors.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn

spontaneously.
TX,05,FF1622 –19–14JUN90–1/1
PREPARE FOR EMERGENCIES
Be 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.
DX,FIRE2 –19–03MAR93–1/1
05–10 121997
PN=18
Safety
HANDLE STARTING FLUID SAFELY
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
–UN–18MAR92
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
TS1356
Do not incinerate or puncture a starting fluid container.
02T,05,M38 –19–22FEB90–1/1
CLEAN TRASH FROM MACHINE
Keep engine compartment, radiator, batteries, hydraulic

lines, fuel tank, and operator’s station clean.
Temperature in engine compartment may go up
T6669AG –UN–18OCT88
immediately after engine is stopped. BE ON GUARD FOR
FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean

engine compartment.
02T,05,J33 –19–14MAR90–1/1
PROTECT AGAINST FLYING DEBRIS
When you drive connecting pins in or out, guard against

injury from flying pieces of metal or debris; wear goggles
or safety glasses.
T6642DK –UN–18OCT88
02T,05,J45 –19–30MAY90–1/1
05–11 121997
PN=19
Safety
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment

appropriate to the job.
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR2 –19–03MAR93–1/1
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
DX,NOISE –19–03MAR93–1/1
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious injury.
Before performing any work on the machine, attach a "DO

NOT OPERATE" tag to the vandal cover latch.
T7447AO –19–22APR91
TX,10,RR2401 –19–03AUG92–1/1
05–12 121997
PN=20
Safety
KEEP ROPS INSTALLED PROPERLY
Make certain all parts are reinstalled correctly if the

roll-over protective structure (ROPS) is loosened or
removed for any reason. Tighten mounting bolts to proper
torque.
The protection offered by ROPS will be impaired if ROPS
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting. A damaged ROPS should be
replaced, not reused.
DX,ROPS3 –19–03MAR93–1/1
05–13 121997
PN=21
Safety
PRACTICE SAFE MAINTENANCE
Understand service procedure before doing work. Keep

area clean and dry.
Never lubricate or service machine while it is moving.

Keep hands, feet and clothing from power-driven parts.
Before servicing machine:
• Park machine on a level surface.

• Lower equipment to the ground.
• Move transmission shift lever to neutral.
• Move park and brake lock lever to lock position.
• Run engine at 1/2 speed no load for 2 minutes.
• Move speed control lever to slow idle position.
• Turn key switch to OFF to stop engine. (If maintenance
must be performed with engine running, do not leave
machine unattended.)
• Remove key from switch.
• Release hydraulic pressure by moving control lever until
equipment does not move.
• Attach a "Do Not Operate" tag on the metal loop at the
top of the instrument panel.
• Turn battery disconnect switch off.
• Allow engine to cool.
If maintenance procedure must be performed with engine

running, do not leave machine unattended.
Support any machine element that must be raised for

service work. Never work under a machine supported by a
jack.
Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
TX,05,FF2231 –19–12JAN93–1/1
05–14 121997
PN=22
Safety
STAY CLEAR OF MOVING PARTS
Entanglements in moving parts can cause serious injury.
To prevent accidents, use care when working around

rotating parts.
–UN–08JUN90
T7273AS
TX,05,RR,572 –19–12JUN90–1/1
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to the ground

before you work on the machine. If you must work on a
lifted machine or attachment, securely support the
machine or attachment.
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
DX,LOWER –19–04JUN90–1/1
05–15 121997
PN=23
Safety
AVOID HIGH-PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
X9811 –UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands

and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from
Deere & Company Medical Department in Moline, Illinois,
U.S.A.
DX,FLUID –19–03MAR93–1/1
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into

any water source.
Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1
05–16 121997
PN=24
Safety
AVOID HARMFUL ASBESTOS DUST
Avoid breathing dust that may be generated when

handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for

cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
Keep bystanders away from the area.
DX,DUST –19–15MAR91–1/1
REMOVE PAINT BEFORE WELDING OR

HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose of

paint and solvent properly.
Remove paint before welding or heating:
• If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with

soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
DX,PAINT –19–03MAR93–1/1
05–17 121997
PN=25
Safety
AVOID HEATING NEAR PRESSURIZED FLUID

LINES
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
TS953 –UN–15MAY90
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
DX,TORCH –19–03MAR93–1/1
PREVENT BATTERY EXPLOSIONS
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
DX,SPARKS –19–03MAR93–1/1
CLEAN THE MACHINE REGULARLY
Remove any grease, oil or debris build-up to avoid

possible injury or machine damage.
–UN–18OCT88
T6642EJ
02T,05,M40 –19–22FEB90–1/1
05–18 121997
PN=26
Safety
STORE ATTACHMENTS SAFELY
Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.
Securely store attachments and implements to prevent

falling. Keep playing children and bystanders away from
storage area.
TX,05,RR,576 –19–26APR90–1/1
TRAVEL SAFELY
Know the location of bystanders before moving the

machine.
Always keep the reverse warning alarm in working
T6964AD –UN–20DEC88
condition. It warns people when the machine starts to
move in reverse.
Use a signal person when moving the machine in

congested areas. Coordinate hand signals before starting
the machine.
TX,05,DH496 –19–02AUG89–1/1
05–19 121997
PN=27
Safety Signs
SAFETY SIGN
T112472 –UN–09DEC97
A-Safety Decal
T6914AU –19–24FEB89
TX,06,RR2914 –19–08FEB93–1/3
T7972AO –19–22MAR93
TX,06,RR2914 –19–08FEB93–2/3
06–1 121997
PN=28
Safety Signs
T7860AN –UN–09NOV92
(S.N. —840460)
T112378 –UN–09DEC97
(S.N. 840461— )
TX,06,RR2914 –19–08FEB93–3/3
06–2 121997
PN=29
Safety Signs
SAFETY SIGN
–19–27FEB89
T8055AH –UN–27JUL93
T6988AM
TX,06,RR7113 –19–10JAN96–1/1
SAFETY SIGN
–UN–09NOV92
–19–06JAN89
T6283BG1
T7860AM
A-Safety Decal (S.N. —840460)
TX,06,RR7114 –19–10JAN96–1/1
06–3 121997
PN=30
Safety Signs
SAFETY SIGN
T8358AH –UN–30NOV94
T112469 –19–11DEC97
TX,06,RR7115 –19–10JAN96–1/1
06–4 121997
PN=31
Safety Signs
SAFETY SIGN
–UN–10FEB89
T6884AX
–19–23MAR89
T6884BK
TX,06,RR7116 –19–10JAN96–1/1
06–5 121997
PN=32
Safety Signs
SAFETY SIGN
–UN–18OCT88
T6884AJ
T6884BO –19–23MAR89
A-Safety Decal-If Equipped
TX,06,RR7109 –19–10JAN96–1/1
SAFETY SIGN
–UN–06AUG90
T7324AI –19–29AUG90
T7349AV
(S.N. —794017)
TX,06,RR7110 –19–10JAN96–1/1
06–6 121997
PN=33
Safety Signs
SAFETY SIGN
T7593AC –19–30AUG91
A-Safety Decal
T8358AL –UN–30NOV94
TX,06,RR7111 –19–10JAN96–1/1
06–7 121997
PN=34
Safety Signs
SAFETY SIGN
–UN–02FEB93
T7744AR –19–08APR92
T7931AK
TX,06,RR7112 –19–10JAN96–1/1
06–8 121997
PN=35
INSTRUMENT PANEL (S.N. —823918)
T8196BL –UN–14APR94
A—Light Switch—If F—Fuel Gauge (S.N. I—Transmission Oil Filter L—Engine Oil Pressure
Equipped 794618- ) Hour Meter Restriction Indicator Indicator
B—Stop Indicator (S.N. -794617) J—Transmission Oil M—Engine Coolant
C—Audible Alarm G—Key Switch Temperature Indicator Temperature Indicator
D—Start Aid H—Hydraulic Oil Filter K—Engine Alternator Low
E—Service Required Restriction Indicator Voltage Indicator
Indicator
IMPORTANT: When the stop indicator is activated, developing. It is not necessary to

stop engine immediately and stop the engine immediately, but the
investigate cause of problem. DO cause should be investigated as
NOT start engine until problem has soon as possible.
been corrected.
The service required indicator is activated every time
The stop indicator (B) and audible alarm (C) are the engine alternator volts, transmission oil
activated (intermittent) every time the engine oil temperature, transmission oil filter, or hydraulic oil filter
pressure is too low, engine coolant temperature is too restriction sender is activated.
high or transmission oil pressure is too low.
IMPORTANT: When the service required (E)

indicator is activated, a problem is
TX,10,RR4283 –19–14APR94–1/1
10–1 121997
PN=36
INSTRUMENT PANEL (S.N. 823919— )
T112463 –UN–09DEC97
A—Light Switch G—Hour Meter K—Transmission Oil N—Engine Coolant
B—Stop Indicator H—Key Switch Temperature Indicator Temperature Indicator
C—Audible Alarm I—Hydraulic Oil Filter L—Engine Alternator Low
D—Start Aid Restriction Indicator Voltage Indicator
E—Service Required J—Transmission Oil Filter M—Engine Oil Pressure
Indicator Restriction Indicator Indicator
F—Fuel Gauge
IMPORTANT: When the stop indicator is activated, developing. It is not necessary to

stop engine immediately and stop the engine immediately, but the
investigate cause of problem. DO cause should be investigated as
NOT start engine until problem has soon as possible.
been corrected.
The service required indicator is activated every time
The stop indicator (B) and audible alarm (C) are the engine alternator volts, transmission oil
activated (intermittent) every time the engine oil temperature, transmission oil filter, or hydraulic oil filter
pressure is too low, engine coolant temperature is too restriction sender is activated.
high or transmission oil pressure is too low.
IMPORTANT: When the service required (E)

indicator is activated, a problem is
TX,10,RB71 –19–08DEC97–1/1
10–2 121997
PN=37
STOP ENGINE INDICATOR AND ALARM

INDICATOR
IMPORTANT: If STOP-engine indicator flashes and

alarm sounds, stop engine immediately
and investigate cause of problem. Do
–UN–06JAN92
not start engine until problem has been
corrected.
The stop engine indicator flashes and alarm sounds when:
T7673AM
Engine oil pressure is low. Engine coolant temperature is
excessively high. Transmission oil pressure is low.
TX,10,RR2826 –19–14APR94–1/1
SERVICE REQUIRED INDICATOR
If service required indicator lights, a problem is

developing. It is not necessary to stop the engine
immediately, but the cause should be investigated as
soon as possible.
T6201BL –UN–18OCT88
The service required indicator lights when:
Engine alternator voltage is low. Transmission oil filter is

restricted. Hydraulic oil filter is restricted. Transmission oil
temperature is excessively high.
02T,25,M116 –19–03JAN91–1/1
ENGINE OIL PRESSURE INDICATOR
NOTE: It is normal for light to come on at start-up and

stay on for a few seconds.
Indicator will light when engine oil pressure is low. The

–UN–18OCT88
STOP light will flash and the audible alarm will sound.
Immediately park the machine in a safe environment, shut
the engine off and check for the problem.
T6201BB
02T,25,M31 –19–20DEC94–1/1
10–3 121997
PN=38
ENGINE COOLANT TEMPERATURE

INDICATOR
Indicator will light when engine coolant temperature is

high. The STOP light will flash and the audible alarm will
sound. Immediately take load off the machine and run
T6201BC –UN–18OCT88
engine at high idle. If indicator continues to stay on after
several minutes of operation, stop engine and check
engine for problem. (See the Troubleshooting chapter in
this manual to solve the problem.)
TX,10,RB72 –19–08DEC97–1/1
ENGINE ALTERNATOR VOLTAGE

INDICATOR
Service required light and Indicator will light with no

alternator output. Immediately park the machine in a safe
environment, shut the engine off and check for the
T6201BD –UN–18OCT88
problem. (See the Troubleshooting chapter in this manual
to solve the problem.)
T82,25,C27 –19–20DEC94–1/1
TRANSMISSION OIL TEMPERATURE

INDICATOR
This indicator plus the service required light will light when
transmission oil pressure is too low. Immediately park the
machine in a safe environment, shut the engine off and T6201AW –UN–18OCT88
check for the problem. (See the Troubleshooting chapter

in this manual to solve the problem.)
TX,10,FF1815 –19–20DEC94–1/1
10–4 121997
PN=39
TRANSMISSION OIL FILTER INDICATOR
Indicator will light and service required indicator will light

when transmission filter element is restricted. Immediately
park the machine in a safe environment, shut the engine
off and check for the problem. (See the Troubleshooting
–UN–18OCT88
chapter in this manual to solve the problem.)
T6201AX
02T,25,M118 –19–20DEC94–1/1
HYDRAULIC OIL FILTER INDICATOR
Indicator will light and service required indicator will light

when transmission filter element is restricted. Immediately
–UN–18OCT88
T6201AY
02T,25,M25 –19–20DEC94–1/1
10–5 121997
PN=40
INSTRUMENT PANEL—GAUGES—IF EQUIPPED (S.N. —823918)
T112464 –UN–09DEC97
A—Light Switch—If F—Engine Alternator Low I—Transmission Oil Filter
Equipped Voltage Indicator Restriction Indicator
B—Start Aid G—Hydraulic Oil Filter J—Transmission Oil
C—Fuel Gauge Restriction Indicator Pressure
D—Key Switch H—Engine Oil Pressure K—Engine Water
E—Transmission Oil Gauge Temperature Gauge
Temperature Gauge
TX,10,RR4692 –19–20DEC94–1/1
10–6 121997
PN=41
INSTRUMENT PANEL—GAUGES—IF EQUIPPED (S.N. 823919— )
T112470 –UN–09DEC97
A—Light Switch G—Engine Alternator Low J—Transmission Oil Filter
B—Start Aid Voltage Indicator Restriction Indicator
C—Fuel Gauge H—Hydaulic Oil Filter K—Transmission Oil
D—Hour Meter Restriction Indicator Pressure
E—Key Switch I—Engine Oil Pressure L—Engine Water
F—Transmission Oil Gauge Temperature Gauge
Temperature Gauge
TX,10,RR4692 –19–20DEC94–1/1
FUEL GAUGE
Always fill fuel tank at the end of the day to eliminate

condensation in fuel tank. T8368BC –UN–10DEC94
TX,10,RR4693 –19–20DEC94–1/1
10–7 121997
PN=42
ENGINE WATER TEMPERATURE GAUGE—IF

EQUIPPED
The gauge needle will move to the red zone when engine
coolant temperature is high. Immediately take load off the
machine and run engine at high idle. If indicator continues
–UN–15DEC94
to stay on after several minutes of operation, stop engine
and check engine for problem. (See the Troubleshooting
T8368AX
TX,10,RR4694 –19–20DEC94–1/1
ENGINE OIL PRESSURE GAUGE—IF

EQUIPPED
After engine is started, gauge needle must point to green

zone (B) immediately and not drop into red zone (A) after
warm-up.
–UN–10DEC94
T8368BA
TX,10,RR4695 –19–20DEC94–1/1
TRANSMISSION OIL TEMPERATURE

GAUGE—IF EQUIPPED
After engine is started and operating at working

temperature, gauge needle must point to center of green
zone (B) and not drop into red zone (A) after warm-up.
–UN–10DEC94
T8368BB
TX,10,RR4696 –19–20DEC94–1/1
LOW VOLTAGE INDICATOR LIGHT—IF

EQUIPPED
Indicator will light with no alternator output. Immediately

T8368BG –UN–10DEC94
TX,10,RR4697 –19–20DEC94–1/1
10–8 121997
PN=43
TRANSMISSION OIL FILTER INDICATOR

LIGHT—IF EQUIPPED
Indicator will light will light when transmission filter

element is restricted. Immediately park the machine in a
safe environment, shut the engine off and check for the
T8368BF –UN–10DEC94
TX,10,RR4698 –19–20DEC94–1/1
HYDRAULIC OIL FILTER RESTRICTION

INDICATOR LIGHT—IF EQUIPPED
Indicator will light when transmission filter element is

restricted. Immediately park the machine in a safe
environment, shut the engine off and check for the
–UN–10DEC94
T8368BE
TX,10,RR4699 –19–20DEC94–1/1
TRANSMISSION OIL PRESSURE INDICATOR

LIGHT—IF EQUIPPED
NOTE: It is normal for light to come on at start-up and

stay on for a few seconds.
T8368BD –UN–10DEC94
Indicator will light when engine oil pressure is low.
Immediately park the machine in a safe environment, shut
the engine off and check for the problem.
TX,10,RR4700 –19–20DEC94–1/1
10–9 121997
PN=44
DOZER CONTROL LEVER—ONE LEVER

OPTION
T7860AO –UN–09NOV92
A—Blade Control Lever
TX,10,RR2745 –19–12JAN93–1/1
DOZER CONTROL LEVERS—TWO LEVER

OPTION
T6499AG –UN–09FEB89
A—Blade Control (Raise, Lower and Tilt)

B—Blade Control (Angle)
02T,10,K27 –19–12JAN93–1/1
10–10 121997
PN=45
PEDALS WITH LEVER STEERING—IF

EQUIPPED
–UN–08AUG90
T7349AA
A—Power Control Pedal (Direct Drive Machines)
B—Brake Pedal
C—Decelerator/declutch Pedal
TX,10,FF1825 –19–20DEC94–1/1
PEDALS WITH PEDAL STEERING—IF

EQUIPPED
NOTE: Brake is engaged by pushing down on overlapped

portion (C) of steering pedals.
–UN–08AUG90
T7349AB
A—Power Control Pedal/Direct Drive Machines
B—Left Steering Pedal
C—Brake Pedal
D—Right Steering Pedal
E—Decelerator/Declutch Pedal
TX,10,FF1826 –19–20DEC94–1/1
10–11 121997
PN=46
PEDALS WITH PEDAL STEERING WITH

TORQUE CONVERTER—IF EQUIPPED
T7896AO –UN–09DEC92
A—Decelerator Pedal
B—Right Steering Pedal
C—Left Steering Pedal
TX,10,RR2808 –19–12JAN93–1/1
STEERING LEVERS—IF EQUIPPED
T6508AN1 –UN–01JUN89
A—Left Steering
B—Right Steering
02T,10,M156 –19–08FEB93–1/1
10–12 121997
PN=47
LEVERS
–UN–30NOV94
T8358AM
A—Transmission Shift Lever
B—Speed Control Lever
C—Park and Brake Lock Lever
TX,10,RR4662 –19–20DEC94–1/1
BATTERY DISCONNECT SWITCH—IF

EQUIPPED
Battery disconnect switch (A) is located on right side of

operator seat on the battery box cover.
–UN–10FEB89
T6642FU
02T,10,M158 –19–08FEB93–1/1
10–13 121997
PN=48
VANDAL SHIELD
T6508AN –UN–01JUN89
A—Vandal Shield
02T,10,M159 –19–16AUG93–1/1
ADJUST NON-SUSPENSION SEAT
Push lever (B) to the left to move seat forward or

rearward. Release lever and slide seat to lock in place.
Loosen cap screw (A) from each side and lift platform up
–UN–10FEB89
or down to one of three positions.
T6553AB
02T,10,M160 –19–16AUG93–1/1
10–14 121997
PN=49
ADJUST SUSPENSION SEAT—IF EQUIPPED
Seat height adjusts automatically according to weight of

operator.
Turn weight adjustment knob (A) clockwise for firm ride
T6540AI –UN–10FEB89
and counterclockwise for soft ride. Use flip-out handle to
crank the knob.
Lift up on lever (B) to tilt seat cushion higher. Keep weight

off seat when making this adjustment. Release lever to
lock in place.
Push lever (C) to the left to move seat forward or

rearward. Release lever and slide seat to lock in place.
Lift up on seat back and tilt to one of three positions (D).
T6540AN –UN–10FEB89
A—Weight Adjustment Knob
B—Tilt Seat Cushion Lever
C—Fore/Aft Lever
D—Seat Back Tilt Positions
02T,10,M161 –19–16AUG93–1/1
ADJUST ARMREST
Loosen cap screws (A) and slide armrest up or down to

adjust. T6499DP –UN–09FEB89
02T,10,M162 –19–30AUG88–1/1
10–15 121997
PN=50
CHECK SEAT BELT
Inspect condition of seat belt and mounting hardware

regularly.
02T,10,M163 –19–12JAN93–1/1
OPERATOR’S MANUAL HOLDER
Operator’s Manual holder is located on back of seat.
T6684AU –UN–10FEB89
02T,10,M164 –19–30AUG88–1/1
10–16 121997
PN=51
HORN SWITCH
Push horn switch (A) to sound horn.
T6508AL2 –UN–10FEB89
(S.N. —804207)
(S.N. 804208— )
02T,10,M165 –19–20DEC94–1/1
10–17 121997
PN=52
OPERATING LIGHTS—IF EQUIPPED
Pull out switch (A) to operate lights (B).
T8196BL1 –UN–14APR94
T6684AI –UN–23JUL90
T6499EL –UN–09FEB89
TX,10,RR2750 –19–14APR94–1/1
10–18 121997
PN=53
Break-In
ENGINE BREAK-IN OIL
New engines are filled at the factory with John Deere • CCMC Specification D4
ENGINE BREAK-IN OIL. During the break-in period,
add John Deere ENGINE BREAK-IN OIL as needed to After the break-in period, use John Deere PLUS-50 or
maintain the specified oil level. other diesel engine oil as recommended in this
manual.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine. IMPORTANT: Do not use John Deere PLUS-50 oil
or engine oils meeting API CG4, API
After engine overhaul, fill the engine with John Deere CF4, or CCMC D5 performance levels
ENGINE BREAK-IN OIL. during the first 100 hours of
operation of a new or rebuilt engine.
If John Deere ENGINE BREAK-IN OIL is not available, These oils will not allow the engine
use a diesel engine oil meeting one of the following to break-in properly.
during the first 100 hours of operation:
• API Service Classification CE
PLUS-50 is a trademark of Deere & Company DX,ENOIL4 –19–17OCT94–1/1
AFTER THE FIRST 10 HOURS
1. Perform 10 hour or daily service. (See

Maintenance-Every 10 Hours or Daily chapter.)
2. Watch for fluid leaks.
TX,15,FF1819 –19–03JAN91–1/1
15–1 121997
PN=54
Break-In
BETWEEN THE FIRST 50 TO 100 HOURS—

AFTER SALES INSPECTION (ASI)
1. Perform 10 hours and 250 hours service. (See

Maintenance—Every 10 Hours or Daily and
Maintenance—Every 250 Hours chapters.)
2. Change hydraulic reservoir oil filter. (See

Maintenance—Every 500 Hours chapter.)
3. Change transmission oil filter. (See Maintenance—

Every 500 Hours chapter.)
4. Check hardware torque.
5. Check steering brake adjustment . (See Maintenance

chapter in this manual.)
TX,15,RR7102 –19–03JAN96–1/1
15–2 121997
PN=55
Pre-Start Inspection
INSPECT MACHINE DAILY BEFORE
STARTING
• Check grille screen (A).

• Check air cleaner restriction indicator (B). Check oil
level. Check fuel filter.
• Clean pre-cleaner if necessary (C).
• Check pedal travel (D).
• Check transmission oil level (E).
• Check hydraulic system oil level (F).
• Check fuel tank fuel level (G).
• Clean operator’s station (H).
• Clean radiator area and check coolant level (I).
ELECTRICAL SYSTEM: Check for worn or frayed wires

and loose or corroded connections.
EQUIPMENT, SHEET METAL, TRACKS, HARDWARE:

Check for bent, broken, loose or missing parts.
HYDRAULIC SYSTEM: Check for leaks, missing or loose

clamps, kinked hoses, and lines or hoses that rub against
each other or other parts.
LUBRICATION: Check lubrication points shown on

Periodic Maintenance Chart.
PROTECTIVE DEVICES: Check guards, shields, ROPS,

covers, seat belt.
FIRE PREVENTION: Clean machine of debris.
SAFETY: Walk around machine to clear all persons from
T6891AO –UN–10FEB89
machine area.
02T,20,M21 –19–20DEC94–1/1
20–1 121997
PN=56
Operating the Engine
CHECK INSTRUMENTS BEFORE
STARTING—INSTRUMENT PANELS WITH
INDICATORS ONLY
CAUTION: Use a seat belt when you operate
with a roll-over protective structure (ROPS) to
minimize chance of injury from an accident
such as an overturn.
Do not use a seat belt if operating without a

(S.N. —823918 Shown)
ROPS.
Turn key switch to BULB CHECK position. All indicator

lights must come on.
If lights do not come on, check bulbs.
TX,10,RR2915 –19–14APR94–1/1
CHECK INSTRUMENTS BEFORE

STARTING—INSTRUMENT PANELS WITH
GAUGES

T8368BL –UN–10DEC94
such as a overturn.

ROPS.
(S.N. 794618—823918 Shown)
Turn key switch to RUN.
The low voltage and engine oil pressure indicators must

light and gauge needles must move a little.
If lights do not come on, check bulbs.
TX,25,RB73 –19–08DEC97–1/1
25–1 121997
PN=57
STARTING THE ENGINE
CAUTION: Avoid possible injury or death from a

runaway machine.
Do not start engine by shorting across starter
terminals. Machine will start in gear if normal
starting circuitry is bypassed.
NEVER start engine while standing on ground.

Start engine only from operator’s seat with
transmission shift lever in neutral. Engage park
brake.
Use of seat belt with this rollover protective

structure is recommended under almost all
circumstances.
1. Fasten seat belt.
2. Turn battery disconnect switch (if equipped) to ON.
3. Move park and brake lock lever (C) to locked position.

Transmission shift lever (A) will move to PARK
position.
4. Move speed control lever (B) to 1/3 speed position.
5. Push horn switch to sound horn.
–UN–30NOV94
T8358AM

TX,25,RR4663 –19–20DEC94–1/2
25–2 121997
PN=58
IMPORTANT: Never operate starter motor for more

than 20 seconds at a time. If engine
fails to start after two or three tries,
return key switch to OFF. Wait for about
2 minutes, then try again.
After a false start, do not turn key

switch until engine stops or starter may
be damaged.
Engine will not start by towing or

pushing. Permanent damage to
transmission will result.
6. Turn key switch to START position. Do not crank

engine more than 20 seconds. Wait 2 minutes before
trying again. If engine fails to start after two or three
tries, return key switch to OFF.
7. Operate crawler at half speed and at less than normal

load until engine is at operating temperature.
TX,25,RR4663 –19–20DEC94–2/2
25–3 121997
PN=59
STARTING FLUID—IF EQUIPPED (COLD

WEATHER STARTING AID)
• Using Starting Fluid
CAUTION: Prevent possible injury from

exploding container. Starting fluid is highly
flammable. Keep container away from heat,
sparks, and open flame. Contents are
pressurized. Do not puncture or incinerate
container. Remove container from machine if
engine does not need starting fluid.
IMPORTANT: Prevent damage to engine. Use starting

aid when temperatures are below -4.5°C
(40°F) and only when engine is COLD.
1. Turn key switch clockwise to START position.
IMPORTANT: Excess starting fluid could damage
engine; push starting aid button only
when engine is cold and cranking.
Starting aid fluid is being injected into
engine as long as you push button.
2. After one or two revolutions of engine crankshaft,

push starting aid button (A) at short intervals. Crank
engine for 20 seconds maximum, then allow 2
minutes between cranking periods.
TX,25,RR2409 –19–20DEC94–1/2
25–4 121997
PN=60
• Replacing Starting Aid Can
1. Turn container (B) counterclockwise to remove the

container and starting aid can.
2. Remove safety cap and spray button from new can.
3. Place new can in container.
4. Turn container clockwise in starting aid base (C) to

install starting aid can.
• Operating Machine Without Starting Aid Can Installed
IMPORTANT: Protect starting aid components from

possible damage. Install the starting aid
can container upside down.
Remove container from base, turn upside down, and

reinstall.
TX,25,RR2409 –19–20DEC94–2/2
USING COOLANT HEATER—IF EQUIPPED
CAUTION: Prevent possible personal injury

from an electrical shock. Use a heavy-duty,
grounded cord to connect heater to electrical
power.
Connect the coolant heater to 115-volt electrical power 10

hours before you start the engine.
TX,25,FF1223 –19–08FEB93–1/1
25–5 121997
PN=61
USING BOOSTER BATTERIES WITH JUMPER

BATTERY TERMINAL—IF EQUIPPED
Before boost starting, machine must be properly shut

down and secured to prevent unexpected machine
movement when engine starts.
CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep
flames or sparks away from the battery area.
Charge batteries in a well-ventilated area.
IMPORTANT: The machine electrical system is a

12-volt negative (-) ground. Use only
12-volt booster batteries (C).
Connect booster batteries as shown. Make last connection

to frame.
1. Remove terminal cover (B).
T6884BG –UN–10FEB89
2. Connect positive (+) cable to battery jumper terminal
(A).
3. Reinstall cover (B) on jumper terminal after use.
(S.N. —763177) Shown
–UN–09NOV92
T7860AP
(S.N. 763178—XXXXXX) Shown
A—Machine Jumper Battery Terminal

B—Battery Terminal Cover
C—Booster Batteries (2—12 v)
TX,25,RR2746 –19–20DEC94–1/1
25–6 121997
PN=62
USING BOOSTER BATTERIES—12 VOLT

SYSTEM
Before boost starting, machine must be properly shut

down and secured to prevent unexpected machine
movement when engine starts.
CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep
flames or sparks away from the battery area.
Make sure the batteries are charged in a well
ventilated area.
IMPORTANT: The machine electrical system is a 12

volt negative (-) ground. Use only 12
volt booster batteries.
Connect booster battery(s) as shown for your battery

application. Make last connection to frame.
T6508AE1 –UN–24OCT91
Single Battery Application
–UN–24OCT91
T6713AI1
A—Machine Battery(s)
B—Booster Battery(s)
Two Battery Application
TX,FF,133 –19–15OCT90–1/1
25–7 121997
PN=63
CHECK INSTRUMENTS AFTER STARTING—

INSTRUMENT PANELS WITH INDICATORS
ONLY
IMPORTANT: If indicator lights do not go out after
starting engine, IMMEDIATELY STOP
THE ENGINE. Find and correct the
cause.
Cold oil may cause hydraulic oil filter and transmission oil
(S.N. —823918) Shown
filter light to come on.
TX,25,RR2505 –19–20DEC94–1/1
CHECK INSTRUMENTS AFTER STARTING—

INSTRUMENT PANELS WITH GAUGES ONLY
IMPORTANT: If indicator lights do not go out and

gauges do not read in the safe zones,
IMMEDIATELY STOP THE ENGINE. Find
T112465 –UN–09DEC97
and correct the cause.
1. Cold oil may cause hydraulic oil filter and transmission

oil filter light to come on.
2. All indicator lights should go out.

(S.N. —823918) Shown
3. Gauges should read in safe zones.
TX,25,RR2505 –19–20DEC94–1/1
ENGINE WARM-UP
1. After engine starts, run at 1/2 speed for 2 minutes. Do

not run at fast or slow idle. Do not accelerate rapidly
during warm-up.
2. Operate machine at less-than-normal loads and

speeds until engine is at normal operating temperature.
02T,25,M24 –19–03AUG92–1/1
25–8 121997
PN=64
COLD WEATHER WARM-UP
NOTE: If hydraulic oil is cold, hydraulic functions move

slowly. Do not attempt machine operations until
hydraulic functions move at close-to-normal cycle
times.
In extremely cold conditions, an extended warming up

period will be necessary.
Avoid sudden operation of hydraulic functions until engine

is thoroughly warmed up. Remove ice, snow, and mud
from machine before operation.
1. Run engine at 1/2 speed for 5 minutes.
2. Cycle all hydraulic functions to distribute warmed oil

until all functions operate freely.
02T,25,J28 –19–15MAR93–1/1
25–9 121997
PN=65
STOPPING THE ENGINE
IMPORTANT: If engine stops when operating under

load, move speed control lever to slow
idle. Restart engine immediately.
1. Park machine on a level surface.
2. Move transmission shift lever (A) to neutral.
3. Move park and brake lock lever (C) to lock position.
IMPORTANT: To avoid damage to turbocharger, run

engine at 1/2 speed no load for 2
minutes.
4. Run engine at 1/2 speed no load for 2 minutes.
5. Move speed control lever (B) to slow idle position.
–UN–30NOV94
6. Turn key switch to OFF to stop engine.
7. Remove key from switch.
T8358AM
8. Release hydraulic pressure by moving control lever
until equipment does not move.
9. Turn battery disconnect switch off. A—Transmission Shift Lever

TX,25,RR4665 –19–20DEC94–1/1
25–10 121997
PN=66
ADJUSTING ENGINE FOR HIGH ELEVATION

(S.N. —840460)
NOTE: This applies only to 300 Series Engines.
IMPORTANT: The engine may be seriously damaged

at high elevations unless you have the
fuel injection pump adjusted.
If you operate the engine above 3000 m (10,000 ft)

without this adjustment, the warranty on this engine will be
invalid.
The fuel injection pump adjustment must be made by an

authorized injection pump service center.
NOTE: Fuel delivery must be reduced by 3% for every

300 m (1000 ft) machine is operated above the
specified altitude.
02T,25,R7 –19–09MAY95–1/1
25–11 121997
PN=67
Driving the Machine
DRIVING THE MACHINE

such as an overturn.
ROPS.
DO NOT coast the machine.
IMPORTANT: During freezing weather, park machine

on a hard surface to prevent tracks
from freezing to the ground. Clean
debris from tracks.
If tracks are frozen to the ground, move

machine carefully to prevent damage to
drive train and tracks.
If engine stops under load, remove

load. Start engine immediately.
TX,30,RR2809 –19–12JAN93–1/1
30–1 121997
PN=68
Driving the Machine
USING PARK AND BRAKE LOCK LEVER

unexpected machine movement. Always move
park and brake lock lever to lock position
before starting or dismounting.
WHEN LEVER IS IN RUN POSITION (A):
Park lock is disengaged—transmission shift lever can be

moved from first through four speeds forward or reverse.
Park brakes are disengaged, machine can move if on

slope. Cap screw can be installed to hold lever in neutral
for service work. (See Manual Steering Adjustment in
Maintenance chapter.)
WHEN LEVER IS IN LOCKED POSITION (B):
Park lock is engaged—transmission shift lever cannot be
T8358AR –UN–30NOV94
moved out of PARK.
Park brakes are engaged.
–UN–30NOV94
T8358AS
TX,30,RR4666 –19–20DEC94–1/1
30–2 121997
PN=69
Driving the Machine
SHIFTING THE TRANSMISSION
NOTE: Transmission shift lever cannot move out of PARK

until park and brake lock lever is in run position.
When park and brake lock lever is moved to

locked position, transmission shift lever will go
back into PARK.
Move park and brake lock lever (A) to run position.
Change speed and direction of crawler by moving

transmission shift lever (B). Machine has four speeds
forward and four speeds reverse. Select a speed suitable
for operating and conditions.
To prevent high speed operation and excessive

undercarriage wear during high speed operation, a 4th
gear lock-out hole (C) can be used to block out the
forward/reverse operation. This change was effective with
(S.N. 804208— ).
TX,30,RR4667 –19–20DEC94–1/1
USING ENGINE SPEED CONTROL LEVER
Beginning with (S.N. 804208— ), the direction of operation

of the engine speed control lever (A) was reversed. Move
the lever rearward (B) to increase engine speed. Move
lever forward (C) to decrease engine speed.
TX,30,RR4668 –19–20DEC94–1/1
30–3 121997
PN=70
Driving the Machine
DECELERATOR PEDAL WITH TORQUE

CONVERTER
Push decelerator pedal (A) down to decrease engine

speed. When decelerator is released, engine speed will
return to speed control lever setting.
T7349AD –UN–08AUG90
WITH DIRECT DRIVE TRANSMISSION:
CAUTION: Decelerator/declutch pedal should

not be used in place of the power control
inching pedal when on slopes.
Push decelerator pedal (A) down to decrease engine

speed. Near the bottom of the pedal stroke, you will feel
increased resistance from the pedal. Below this point, the
transmission disengages. The machine will slowly creep
similarly to torque converter equipped crawlers.
Depressing brake pedal will stop movement.
When pedal is released, transmission engages before

engine speed returns to speed control lever setting.
TX,30,RR4669 –19–20DEC94–1/1
STEERING THE MACHINE WITH LEVER

STEERING—IF EQUIPPED
CAUTION: If the machine does not steer

properly, do not operate it. See your authorized
dealer for service.
• With the machine traveling forward, pull left lever (A)
until rotation of left track is slowed. Machine will turn
left. Pull the right lever (B) to turn right.
IMPORTANT: Move levers only far enough to stop

track.
02T,30,K105 –19–16AUG93–1/1
30–4 121997
PN=71
Driving the Machine
STEERING THE MACHINE WITH PEDAL

STEERING—IF EQUIPPED

unexpected machine movement, if the machine
does not steer properly, do not operate it. See
T7896AQ –UN–12DEC92
your authorized dealer for service.
If both pedals are used at once, unit will not steer and
brakes will come on. Move pedals only far enough to stop
track.
With machine traveling forward, push left pedal (A) until

rotation of left rack is slowed. Machine will turn left.
Release left pedal and push the right pedal (B) to turn
right.
TX,30,RR4670 –19–20DEC94–1/1
30–5 121997
PN=72
Driving the Machine
TRAVEL SPEEDS
Travel Speeds at 2250 rpm:

Serial No. ( —770807) Serial No. (770808— )
450G Standard Dozer:
Forward
Speeds: km/h mph km/h mph
1 2.15 1.34 2.33 1.45
2 3.60 2.24 3.88 2.41
3 5.68 3.53 5.29 3.29
4 9.50 5.91 8.87 5.51
Reverse
1 2.38 1.48 2.57 1.60
2 3.98 2.47 4.30 2.67
3 6.28 3.91 5.84 3.63
4 10.50 6.53 9.80 6.09
Forward
1 2.00 1.24 2.48 1.54
2 3.34 2.08 4.15 2.58
3 5.28 3.27 5.28 3.28
4 8.82 5.48 8.82 5.49
Reverse
1 2.20 1.37 2.74 1.70
2 3.69 2.29 4.59 2.85
3 5.82 3.62 5.83 3.62
4 9.75 6.06 9.75 6.06
Forward
1 2.14 1.33 2.43 1.51
2 3.58 2.23 4.07 2.52
3 5.64 3.50 5.37 3.34
4 9.44 5.86 9.00 5.59
Reverse
1 2.36 1.47 2.69 1.67
2 3.95 2.45 4.49 2.79
3 6.24 3.87 5.95 3.69
4 10.44 6.48 9.96 6.18
TX,30,RR4619 –19–20DEC94–1/2
30–6 121997
PN=73
Driving the Machine
Travel Speeds (Continued)

450G TC Dozer:
Forward Speeds: km/h mph
1 3.70 2.30
2 5.33 3.31
3 6.61 4.11
4 9.51 5.91
Reverse Speeds: km/h mph
1 4.02 2.50
2 5.76 3.58
3 7.19 4.47
4 9.54 5.93
550G TC Dozer:
1 3.72 2.31
2 5.34 3.32
3 6.58 4.09
4 9.46 5.88
1 4.02 2.50
2 5.78 3.59
3 7.02 4.36
4 9. 3 5.86
650G TC Dozer:
1 3.67 2.28
2 5.28 3.28
3 6.58 4.09
4 9.44 5.87
1 3.96 2.46
2 5.70 3.54
3 6.92 4.30
4 9.33 5.80
TX,30,RR4619 –19–20DEC94–2/2
30–7 121997
PN=74
Driving the Machine
STOPPING THE MACHINE
Move transmission shift lever (A) to neutral or depress

power control pedal (torque converter machines will use
the decelerator pedal). Then depress both steering pedals
simultaneously on overlapped section.
CAUTION: Prevent injury from unexpected

machine movement. The lever steer machine
will declutch both steering clutches when both
levers are simultaneously pulled (approximately
2 in.) back causing the machine to freewheel.
Both brakes will apply when levers are pulled
back approximately 5 in.
The pedal steer machines WILL NOT declutch

either steering clutch when both steering
pedals are simultaneously depressed. For pedal
machines, always depress power control pedal
(torque converter machines will use the
–UN–30NOV94
decelerator pedal) or move transmission shift
lever to neutral before braking.
NOTE: Park brake automatically engages when engine is
T8364AP
dead or if the park lever is pushed down. Brake
pedals will lower on pedal steer machines only.
• For lever steer machines, move transmission shift lever

to neutral or depress power control pedal. Then depress
center brake pedal.
• For pedal steer machines, move transmission shift lever

to neutral or depress power control pedal. Then depress
both pedals simultaneously on overlapped section.
TX,30,RR4671 –19–20DEC94–1/1
30–8 121997
PN=75
Driving the Machine
EMERGENCY STOPPING—PEDAL STEERING
Stop crawler by doing one of the following:
1. Move transmission shift lever (A) to neutral or depress

power control pedal (torque converter machines will
use the decelerator pedal). Then depress both steering
pedals simultaneously on overlapped section.
CAUTION: Prevent injury from unexpected

machine movement. The lever steer machine
will declutch both steering clutches when both
levers are simultaneously pulled (approximately
2 in.) back causing the machine to freewheel.
Both brakes will apply when levers are pulled
back approximately 5 in.
The pedal steer machines WILL NOT declutch

either steering clutch when both steering
pedals are simultaneously depressed. For pedal
–UN–30NOV94
machines, always depress power control pedal
(torque converter machines will use the
decelerator pedal) or move transmission shift
lever to neutral before braking.
T8364AP
2. Move park and brake lock lever (B) to lock position.
CAUTION: Machine may overturn if blade is

dropped when moving rapidly down a steep hill.
3. As a last resort, drop blade to stop machine.
TX,30,RR4672 –19–20DEC94–1/1
EMERGENCY STOPPING—LEVER STEERING
Stop crawler by doing one of the following:
1. Move transmission shift lever to neutral or depress

power control pedal (torque converter machines will
use the decelerator pedal). Then depress center brake

pedal.
TX,30,RR4673 –19–20DEC94–1/2
30–9 121997
PN=76
Driving the Machine
2. Pull steering levers (A and B) back all the way.
CAUTION: No machine damage will occur if

park and brake lock lever is moved to lock
–UN–30NOV94
position when machine is moving. However,
operator must be prepared for machine to stop
abruptly, particularly when traveling at a higher
speed.
T8358AS
3. Move park and brake lock lever (B) to lock position.
CAUTION: Machine may overturn if blade is

dropped when moving rapidly down a steep hill.
4. As a last resort, drop blade to stop machine.
TX,30,RR4673 –19–20DEC94–2/2
30–10 121997
PN=77
Driving the Machine
PARKING THE MACHINE
2. Lower equipment to the ground.
NOTE: Park brake automatically engages when engine is

dead or park brake lever is down.

minutes.
–UN–30NOV94
T8358AM
10. Turn battery disconnect switch off. B—Speed Control Lever
TX,30,RR4675 –19–20DEC94–1/1
LOCK ALL COMPARTMENTS
Your crawler is equipped with a lock on the right service

door.
Hood access door, fuel tank cap, hydraulic tank cap

(earlier machines only) and instrument panel cover can be
locked with padlocks.
Use these locks to help safeguard your machine.
02T,30,K111 –19–14APR94–1/1
30–11 121997
PN=78
OPERATING BLADE—TWO LEVER OPTION
IMPORTANT: To avoid overheating of hydraulic oil,

allow control lever to return to neutral
when cylinders reach the end of their
travel.
–UN–09FEB89
Move control lever rearward (A) to raise blade. Move
control lever forward (B) to lower blade.
T6499AM
Move lever to full forward detent (C) for float position. This
position allows the blade to follow the contour of the
ground. Manually release lever from this position.
A—Raise
B—Lower
C—Float
TX,35,RR4676 –19–20DEC94–1/1
35–1 121997
PN=79
TILTING BLADE—TWO LEVER OPTION
T6508AW –UN–19MAY89
A—Tilt Blade Left
B—Tilt Blade Right
TX,35,RR2753 –19–12JAN93–1/1
35–2 121997
PN=80
ANGLING BLADE—TWO LEVER OPTION
Pull lever back (A) to angle blade right. Push lever

forward (B) to angle the blade left.
T6499AD –UN–09FEB89
–UN–09NOV92
T7860AS
TX,35,RR2771 –19–12JAN93–1/1
35–3 121997
PN=81
CHANGING BLADE PITCH
You may want to change the pitch of the blade depending

on the type of work you are doing, the soil conditions you
are dozing, or to change the feel of the dozer to
operator’s preference.
Pitching the Blade Forward Advantages:
With the blade pitched forward (A), the blade will not carry
as much soil. The weight of the soil carried by the blade
adds to the weight of the dozer and moves the balance of
weight on the tracks forward. This can cause the front
idlers of the crawler to sink in loose or soft soils. When
the idlers sink, the blade cuts unevenly into the soil. With
the blade forward, the dozer balance does not change as
much with a full blade, therefore, the tendency for idlers to
sink is reduced.
With the blade forward, there is less of a tendency for dirt

to come over the back of the blade when dozing uphill. It
is also easier to drop dirt at the end of a push when
dozing uphill or when dozing very sticky materials.
Pitching the Blade Back Advantages:
With the blade pitched back (B), the cutting edge lays
more horizontal resulting in a heavier cut into soils.
Having the cutting edge more horizontal also provides a
smoother cut in heavy soils. More soil is carried by the
blade when it is pitched back. Carrying more soil on the
blade adds to the weight of the dozer. This added weight
can increase push force in heavy soils. The soil carried by
the blade also moves the balance of weight forward on
the machine. In heavy soils, this can be an advantage
because the increased weight can help keep the front of
the machine down and keep the cutting edge penetrating
during heavy cutting.
TX,35,RR2831 –19–20DEC94–1/2
35–4 121997
PN=82
CAUTION: Prevent possible injury form

unexpected machine movement. NEVER work
under a raised blade unless the blade or
supporting blade frame is supported to keep
blade from falling if hydraulic pressure is lost.
1. Lower the blade to the ground and put blade in the

float position.
2. Shut engine off.
3. Pitch of blade is done by positioning the pining link (D)

to align either hole (E or C) with the tower pin (F).
Remove two cap screws (A) and two protective caps
(B).
4. Pry pining link (D) off of tower pin and select suitable
pitch mounting hole (E or C).
• For the blade pitch back position, move the blade
T6560AN –UN–10DEC94
control lever to position the blade.
• For the blade pitch forward position, start engine and
use slow blade raise increments to align the pining
link hole to the tower pin.
NOTE: At this time, twist the blade control lever in small

increments to relieve the angle cylinder hydraulic
pressure. This will allow the blade to fall back as
the pining link (D) becomes loose from the tower
pin.
5. When the new position is aligned, tap the pining link

down on the tower pin. Start the engine and raise
T7896AZ –UN–09JAN93
blade so pining link falls into place on the tower pin.
6. Stop engine and install covers and cap screws on the

pining link.
NOTE: Do not use the blade angle function while the

engine is running.
A—Cap Screws
B—Caps
C—Blade Pitch Forward Mounting Hole
D—Pining Link
E—Blade Pitch Back Mounting Hole
F—Tower Pin
TX,35,RR2831 –19–20DEC94–2/2
35–5 121997
PN=83
OPERATING BLADE—ONE LEVER OPTION
IMPORTANT: To avoid overheating of hydraulic oil,

allow control lever to return to neutral
when cylinders reach the end of their
travel.
T7860AU –UN–09NOV92
Move control lever (A) rearward to raise blade. Move
control lever forward to lower blade.
Move lever to full forward detent for float position. This

position allows the blade to follow the contour of the
ground. Manually release lever from this position.
TX,35,RR2754 –19–12JAN93–1/1
TILTING BLADE—ONE LEVER OPTION
T7860AT –UN–09NOV92
A—Tilt Blade Left

B—Tilt Blade Right
TX,35,RR2755 –19–12JAN93–1/1
35–6 121997
PN=84
ANGLING BLADE—ONE LEVER OPTION
Twist lever to right to angle blade to right.
Twist lever to left to angle blade to left.
–UN–09NOV92
T7860AV
TX,35,RR2756 –19–12JAN93–1/1
USING DECELERATOR PEDAL DECLUTCH

OPTION (DIRECT DRIVE MACHINES)
With a heavy blade load the decelerator (A) pedal can be

released abruptly to get a smooth resumption of travel.
Too slow a release with heavy blade load can cause an
T7349AD –UN–08AUG90
engine kill.
TX,35,FF1926 –19–20DEC94–1/1
OPERATING SUGGESTIONS
Select the engine rpm and ground speed to meet your

needs.
Consider the ground conditions, operating area, work load

and grade desired in making your speed selection.
Know your machine, its capabilities and its limits.
T82,CROM,O –19–07JUN91–1/1
35–7 121997
PN=85
OPERATING TIPS
• When blade digs in and rear of tractor rises, raise blade

to continue even cut.
• When a heavy load causes reduced travel speed, shift
to a lower gear and/or raise the blade slightly.
• Angle the blade to: Fill a trench. Cut a road through a
rough area. Side cast into a ditch. Level a grade.
• Tilt the blade to: Cut into a hillside. Crown a road. Make
a narrow cut or shallow ditch. Rough grade.
• Use float position to: Back drag (transmission in
reverse). Push material over a hard surface.
• In float position, the blade will follow the contour of the
ground.
• When finishing or leveling, a partially loaded blade
handles easier than an over-loaded or empty one.
• Do not turn with ripper teeth in the ground. Teeth may
bend or break.
02T,35,J42 –19–03AUG92–1/1
OPERATING CRAWLER DOZER ON SLOPES
On slopes up to approximately 30°, work parallel to the

slope. Earth will fall to lower side of the slope in windrow.
This will help hold crawler from sliding down.
On slopes over 30 °, work diagonally, starting from the

base of the slope, working upwards.
Always travel at slow speeds with blade as low as

possible.
02T,35,J43 –19–13FEB92–1/1
35–8 121997
PN=86
OPERATING AND MAINTENANCE

UNDERCARRIAGE TIPS
Proper maintenance and adjustment of your machine’s

undercarriage will provide the maximum wear life for your
operating and soil conditions. You, the operator, can and
will make a difference in getting maximum wear life from
the components. Here are some operating tips that will
make a difference:
Proper Track Sag Adjustment— Maintaining the proper

amount of track sag 51 mm (2 in.) is the single most
important adjustment the operator can make. Tight tracks
can reduced the amount of wear life by more than 50%
over tracks which are properly maintained at 51 mm (2
in.) of sag. Tight tracks increase the loading on the
undercarriage components and accelerate the wear rate.
Track sag should be adjusted as the soil conditions
change. Observe the amount of sag every day and adjust
as needed. Refer to the periodic service chart interval in
this manual or the decal on the machine for proper
adjustment procedure.
Reduce the Amount Of Reverse Operation— On all track

machines, bushing and sprocket wear rate increases
significantly when operating in reverse rather than
forward. This is normal. To get the most life out of your
undercarriage, minimize the amount of the time operating
in reverse.
Reduce Operating and Travel Speed When Possible— As

machine speed increases, wear rates increase. Operate at
the minimum ground speed required to match the type of
work. Excessive track slipping will also increase wear,
particularly on the grouser tips.
Added Weight Increases Undercarriage Wear—

Significant additional machine weight due to attachments
or counterweighting will cause faster wear rate.
Proper Chain Guides Or Guards Will Increase

Undercarriage Life— Properly installed and maintained
track guides or guards will keep the track chain properly
aligned. This extends wear life by keeping track chain
aligned with roller and idler.
TX,35,RR2515 –19–16AUG93–1/2
35–9 121997
PN=87
Proper Selection Of Track Pad Width— Wider track pads

increase the loading and wear on the undercarriage
components. Use the narrowest pad possible for your
operating conditions.
TX,35,RR2515 –19–16AUG93–2/2
OPERATING IN ROUGH TERRAIN
When possible, avoid obstacles, rough terrain, rocks,

curbs, ditches, railroad tracks. Cross small obstructions at
an angle at reduced speed in low gear. Ease up to the
"breakover" point, balance slowly on the obstruction, ease
down to minimize the impact of contact on the other side.
Cross shallow gullies or ditches at an angle at reduced

speed.
02T,35,J44 –19–26SEP95–1/1
SIDE-BY-SIDE DOZING
Use two machines side by side for high production of

loose material. –UN–10FEB89
T6705AB
02T,35,J45 –19–03AUG92–1/1
35–10 121997
PN=88
SLOT DOZING
Make several dozing passes over the same path. As

depth of cut or slot deepens, the sides of the cut hold the
material in, with less side spillage.
–UN–10FEB89
When moving dirt from one area to another, follow the
same path each time. As dirt spills from each side of the
blade, it will form ridges. These ridges help keep material
in front of the blade.
T6705AA
02T,35,J46 –19–07DEC87–1/1
TILT DOZER DITCHING
Tilt dozer blade left (A) or right (B) to cut shallow "vee"
ditches.
02T,35,J47 –19–12JAN93–1/1
STRAIGHT DOZER DITCHING
For large ditches, doze at right angle to ditch centerline.

After required depth is reached, doze length of ditch to
smooth sides and bottom.
T6705AC –UN–10FEB89
02T,35,J48 –19–16DEC87–1/1
35–11 121997
PN=89
BACKFILLING
CAUTION: Prevent possible injury from cave-in

or machine overturn. Work a safe distance from
trenches with deep vertical sidewalls.
T6705AD –UN–10FEB89
To backfill into shallow trenches with blade angled, travel
parallel to ditch.
02T,35,J49 –19–31MAR95–1/2
To backfill into deep trenches with blade straight, push at

near a 90° angle to the ditch.
–UN–10FEB89
T6705AE
02T,35,J49 –19–31MAR95–2/2
35–12 121997
PN=90
LEVELING A STOCKPILE
CAUTION: Prevent possible injury from cave-in

or machine overturn. Operate slowly on
hillsides, rough ground, and ramps. Work a safe
distance from trenches and banks with deep
–UN–10FEB89
vertical sidewalls.
Small stockpiles: Move into the edges until the stockpile

has been leveled.
T6705AF1
Large stockpiles: Move into the center of the stockpile and
divide it into two or more smaller stockpiles.
Tall stockpiles: Build a ramp and remove the top of the

stockpile.
T6705AG –UN–10FEB89
T6705AH –UN–10FEB89
02T,35,J51 –19–31MAR95–1/1
35–13 121997
PN=91
MOVING BOULDERS

boulders moving unexpectedly. Move large
boulders very carefully.
T6705AI –UN–10FEB89
Contact boulder at the strongest part of the blade.
Angle dozer: Contact boulder at center of blade at slow

speed.
02T,35,J52 –19–26SEP95–1/4
Straight dozer: Contact boulder at one side of blade.
–UN–10FEB89
T6705AJ
02T,35,J52 –19–26SEP95–2/4
If the boulder is too large to be directly pushed by dozer,

move it by pushing alternate sides of boulder.
Round boulders may be rolled by pushing forward while

lifting blade.
–UN–10FEB89
T6705AK
02T,35,J52 –19–26SEP95–3/4
35–14 121997
PN=92
Buried boulder: Dig around base to free boulder. Push the

boulder up and out. Fill under the boulder as it is moved
forward.
T6705AL –UN–10FEB89
02T,35,J52 –19–26SEP95–4/4
BENCH CUT
T6705AM1 –UN–10FEB89
If possible, start cut downgrade. Angle to outside of cut Make a final grading pass to straighten the uphill bank
to cast material downhill. and level the bench.
While turning with a full load of material, raise blade

slightly to side cast material. Tilt blade rapidly from
side to side to help remove material.
02T,35,J53 –19–14JAN88–1/1
BRUSH REMOVAL
To remove brush and small trees, doze a few inches

below ground and move forward. When brush is out, raise
blade to loosen earth from roots.
Windrow or stack brush, as best suits the area.
Remove as little topsoil as possible.
02T,35,J54 –19–14JAN88–1/1
35–15 121997
PN=93
TREE REMOVAL
CAUTION: Prevent possible injury from falling

trees. Use only ROPS equipped dozer for tree
removal.
T6705AN1 –UN–10FEB89
Place blade in float and back away immediately
when tree begins to fall.
1. Remove dead limbs.
2. Cut tree roots:
1. On side opposite direction of fall

2. On side parallel to direction of fall.
CAUTION: Prevent possible injury or death or

machine damage from falling tree. Do not jar or
ram blade against a large tree that could be
–UN–10FEB89
dead. It may snap off and fall on top of crawler.
3. Push on tree 12—16 in. (300—400 mm) above ground

in direction of fall. Move forward while lifting blade.
T6705AO1
Build earth ramp, if necessary, to contact tree at best
height.
4. Back off and get under roots for next pass.
5. Do not drive onto stump while tree is falling.
T6705AP1 –UN–10FEB89
02T,35,J55 –19–23OCT91–1/1
35–16 121997
PN=94
STUMP REMOVAL
Push on stump 300—400 mm (12—16 in.) above the

ground. Lift and tilt blade while pushing.
If the stump cannot be pushed out, dig out the base of the
T6705AQ –UN–10FEB89
stump and cut the large roots in the pattern shown. Push
the stump after each large root is cut; it may not be
necessary to cut all the roots.
T6705AR –UN–10FEB89
02T,35,J56 –19–06SEP94–1/1
35–17 121997
PN=95
Attachments
ATTACHING BACKHOE TO CRAWLER TRACTOR
T7394AC –UN–10OCT90
NOTE: The selector valve control lever may be either 6. Move speed control lever to slow idle position.
up or down during this procedure.
1. On a level surface, back crawler close enough to
backhoe to reach backhoe controls from operator’s 8. Remove key from switch.
station and to connect hydraulic hoses.
2. Lower equipment to the ground. until equipment does not move.
3. Move transmission shift lever to neutral. 10. Disconnect hydraulic lines at backhoe and crawler.
4. Move park and brake lock lever to locked position. 11. Loop pressure hose (A) upward and connect to
coupler.
IMPORTANT: To avoid damage to turbocharger,
run engine at 1/2 speed no load for 2 12. Loop return hose (B) downward and connect to
minutes. coupler.
TX,36,FF1946 –19–14APR94–1/2
36–1 121997
PN=96
Attachments
IMPORTANT: The diverter valve fittings MUST be

indexed as follows:
13. Index top pressure fitting (A) to right and slightly

downward (as viewed from operator’s seat).
Index bottom return fitting (B) to operator’s left and to

the outside.
CAUTION: To avoid bodily injury, operate

backhoe controls from operator’s station only.
T7394AD –UN–10OCT90
14. Go to operator’s station to operate backhoe controls.
Using stabilizers, raise backhoe to approximate height
for attaching to crawler.
15. Back crawler until crawler attaching hooks are aligned

with backhoe rods.
16. Raise stabilizers until backhoe base rests on crawler

attaching hooks.
17. Use boom control lever to align holes of backhoe and

crawler. Insert pins and retainers.
TX,36,FF1946 –19–14APR94–2/2
36–2 121997
PN=97
Attachments
DETACHING BACKHOE FROM CRAWLER

TRACTOR
NOTE: The selector valve control lever may be either up

or down during this procedure.
CAUTION: To avoid bodily injury, operate

backhoe from operator’s seat only.
1. On a level surface, lower stabilizers to the ground and

fully retract the bucket and crowd cylinders.
4. Move park and brake lock lever (C) to locked position.

–UN–30NOV94
minutes.
T8358AM
9. Drive out the tapered pins from the upper main frame
attaching holes. This will allow the backhoe to rest on
the crawler attaching hooks and bucket.
10. Alternately raise and lower the stabilizers and boom

to free the main frame from the crawler attaching
hooks.
IMPORTANT: Separate crawler from backhoe only

enough to get hoses clear. Do not
stretch hoses.
11. Carefully drive the crawler tractor from the backhoe

and completely retract both stabilizers until main
frame is resting on blocks or on the ground.
TX,36,FF1947 –19–20DEC94–1/3
36–3 121997
PN=98
Attachments
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Keep hands and body
away from pinholes and nozzles which eject
X9811 –UN–23AUG88
fluids under high pressure. Use a piece of
cardboard or paper to search for leaks. Do not
use your hand.
Shut off crawler engine before connecting or

disconnecting the hydraulic lines to backhoe. If
engine is left running, escaping hydraulic oil
may cause personal injury.
If an accident occurs, see a doctor immediately.

any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
13. Move transmission shift lever to neutral.
14. Move park and brake lock lever to locked position.

minutes.
–UN–10OCT90
16. Move speed control lever to slow idle position.
T7394AE

20. Disconnect hydraulic lines keeping one hose with

crawler and one hose with backhoe.
TX,36,FF1947 –19–20DEC94–2/3
36–4 121997
PN=99
Attachments
Both ends of the hose remaining with the crawler

must be connected to crawler as shown to complete
hydraulic circuit.
Both ends of hose remaining with the backhoe must

be connected to backhoe to close the system and
prevent dirt from entering it.
TX,36,FF1947 –19–20DEC94–3/3
36–5 121997
PN=100
Attachments
PREPARE TO OPERATE BACKHOE
CAUTION: Stabilizers must be set on a firm

surface. Do not dig under stabilizers. Be alert to
possible machine movement when raising
stabilizers and dozer blade.
Clear all persons from area of operation and

machine movement.
Avoid swinging bucket to the downhill side

when operating on the slope. Dump on uphill
side if possible.
Move boom slowly when raising loaded

backhoe bucket to full height.
1. Place transmission shift lever in neutral. Engage park

and brake lock lever.
2. Turn seat to face backhoe.
3. Lower stabilizers.
On level ground: Lower stabilizers until they are firmly

on the ground so machine is steadied during backhoe
operation.
On uneven ground: Lower stabilizers until they are

firmly on the ground and machine is level.
If ground level on dozer blade end of machine is lower

than tracks, lowered blade to the ground for additional
machine stability.
4. Remove swing lock and boom lock pins.
TX,36,RR2832 –19–20DEC94–1/1
36–6 121997
PN=101
Attachments
CONTROL LEVERS
T6673AV1 –UN–09NOV88
A—Left Backhoe Control Lever
B—Left Stabilizer Control Lever
C—Right Stabilizer Control Lever
D—Right Backhoe Control Lever
02T,10,FF16 –19–08JAN91–1/1
OPERATING STABILIZERS

unexpected machine movement when raising
stabilizers and loader bucket. Stabilizers must
be set on a firm surface. Do not dig under
stabilizers.
Before you dig, use stabilizers to steady and level the

machine. Stabilizers support the backhoe and give it a
firm base. Keep ground clearance at a minimum.
When operating on slopes, adjust each stabilizer

individually to keep the machine level.
Push stabilizer control lever to lower stabilizer.
Pull stabilizer control lever to raise stabilizer. T6673AD –UN–09NOV88
Stabilizers may be moved simultaneously or one at a

time.
A—Left Stabilizer Down

B—Left Stabilizer Up
C—Right Stabilizer Down
D—Right Stabilizer Up
02T,35,FF47 –19–14APR94–1/1
36–7 121997
PN=102
Attachments
BACKHOE CONTROL LEVERS—JOHN

DEERE PATTERN

unexpected machine movement. Do not operate
backhoe unless you are in the operator’s seat
facing the backhoe. Make sure you know the
function of each control lever before operating.
This machine is equipped with John Deere control pattern.
IMPORTANT: When you swing the boom, do not hit

stabilizer cylinder with boom.
T6673AI –UN–09NOV88
A—Lower Boom
B—Raise Boom
C—Boom Left
D—Boom Right
E—Extend Dipperstick
F—Retract Dipperstick
G—Load Bucket
H—Dump Bucket
02T,35,FF49 –19–12JAN93–1/1
36–8 121997
PN=103
Attachments
GREASE BACKHOE—IF EQUIPPED
Lubricate until grease escapes around joint. (See Fuels

and Lubricants chapter.)
T6673AG –UN–09NOV88
Four Points
T6656CP –UN–09NOV88
Eight Points
A—Right Side Shown
TX,60,FF2060 –19–14APR94–1/1
36–9 121997
PN=104
Attachments
CHANGING BACKHOE BUCKET POSITION
The backhoe bucket can be positioned for "truck loading"

(A) or "power digging" (B) by removing pin (C) and
repositioning links (D).
1. Remove cotter pin and drive out pin.
2. Operate bucket cylinder until holes in links align with

holes in bucket.
3. Install pin and cotter pin.
T6231AN –UN–17OCT88
–UN–17OCT88
T6231AM
A—Truck Loading Position

B—Power Digging Position
C—Pin
D—Link
T82,35,C15 –19–16AUG93–1/1
36–10 121997
PN=105
Attachments
LIFTING
CAUTION: Never move the load suddenly. Never

move load over person’s head. Do not allow
any persons near the load.
Keep all persons away from raised load until

blocks are supporting it or load is setting on
the ground.
Make sure chain/sling is in good condition and

is rated for the load you are lifting.
1. For maximum lifting capability, attach chain/sling to

machine as shown.
NOTE: Refer to the Specifications chapter for capacities

of the backhoe.
2. Coordinate hand signals with your signal man before
T8059CH –UN–09AUG93
starting.
3. Know locations of all persons in working area.
CAUTION: For soft ground, use wide pads such

as boards under each stabilizer foot to provide
stability.
4. When using the backhoe, use the stabilizers to keep

machine level.
TX,36,RR4677 –19–20DEC94–1/2
36–11 121997
PN=106
Attachments
5. Attach a hand line to the load and make sure the

person holding it is away from the load.
CAUTION: Do not install swing lock pin for

lifting loads.
6. Before starting the job, test your load.
a. Park your machine close to the load.
b. Attach the load to the machine.
c. Raise the load 50 mm (2 in.) above the ground.
d. When using the backhoe, swing the load all the way
to one side.
e. While keeping the load close to the ground, move it

away from the machine.
T8214AQ –UN–27APR94
f. If there is any indication of reduced stability of your
machine, lower the load to the ground.
If Equipped
TX,36,RR4677 –19–20DEC94–2/2
36–12 121997
PN=107
Attachments
BUCKET DIGGING
Lower the bucket to the ground making sure the bucket is

in the correct position (C) when starting to dig.
Use downward motion of the boom to force the bucket
T7394BO –UN–12OCT90
into the ground. After the bucket is in the ground,
simultaneously retract the dipperstick and roll back the
bucket until the bucket is full.
If the bucket stalls, raise the boom slightly and continue to

dig until the bucket is full.
Bucket digging is used to excavate rocks or tightly packed A—Bucket Too Far Forward
material and in situations where more precise control is B—Bucket Too Far Back
C—Correct Position
required, e.g., excavating near pipes and cables.
Raise bucket and swing boom until bucket can be

dumped in spoil area.
TX,35,FF2054 –19–08FEB93–1/1
CROWD DIGGING
Lower the bucket to the ground making sure the bucket is

in the correct position (C) when starting to dig.
Roll bucket until the cutting edge teeth are flat on the
T7394BO –UN–12OCT90
ground. Retract the dipperstick, dragging the bucket
through the trench until the bucket is approximately half
full. Begin to roll the bucket while continuing to retract the
dipperstick until the bucket is completely full.
Raise bucket and swing boom until bucket can be

dumped in spoil area.
TX,35,FF2055 –19–08FEB93–1/1
36–13 121997
PN=108
Attachments
PLANNING SPOIL PILES
Carefully plan location of spoil piles so minimum effort is

required to back fill. Make spoil pile at least 1 m (3 ft)
away from ditch. The deeper the excavation the further
the spoil pile should be placed from the excavation.
When operating on hillsides, place spoil pile on the uphill

side of trench. The machine will be more stable and
backfilling will be easier.
02T,35,FF54 –19–29SEP87–1/2
When operating on level ground, the backhoe-crawler can

be moved backward quickly by pushing it with the bucket
against the ground as shown. Raise front-mounted
equipment and stabilizers before attempting to move
backhoe-crawler.
–UN–09NOV88
T6673AK
02T,35,FF54 –19–29SEP87–2/2
PREPARING TO OPERATE DOZER AFTER

OPERATING BACKHOE
1. Retract backhoe bucket and dipperstick. Raise boom.
2. Center boom. Install swing lock and boom lock pins.
3. Raise stabilizers.
TX,36,RR4678 –19–20DEC94–1/1
36–14 121997
PN=109
Attachments
OPERATING WINCH
Operate the winch only from operator’s station.
Before operating winch, place winch control in freespool to

circulate oil through winch until transmission oil reaches
operating temperature.
A-Move lever to FREESPOOL position so cable can be

pulled out freely.
B-Move lever to the BRAKE OFF position so cable can be

pulled out with tension.
C-Move lever to the BRAKE ON position to hold cable.
D-Move lever to POWER IN position to wind cable on

drum.
E-Move lever to POWER OUT position (if equipped) to

unwind cable from drum.
T7440BG –UN–20DEC90
Standard Control Pattern
T7440BH –UN–20DEC90
Power In, Power Out Control Pattern

TX,36,FF2210 –19–08FEB93–1/1
36–15 121997
PN=110
Attachments
FASTEN CABLE TO WINCH DRUM—4000

SERIES
To conform with certain state laws, the cable must be

attached to the drum so that it can come loose if the cable
is unwound from winch drum.
Attach cable to winch drum using one of the following

methods:
IMPORTANT: If a ferruled cable is used, the drum

plug (B) MUST be install to prevent
cable from bending cable slot.
CAUTION: Prevent possible personal injury

from cutting wire .Wear gloves when you
handle cable to protect hands from cable wire
cuts. DO NOT guide cable on winch with your
–UN–27SEP90
hands.
• First Method—Breakaway Anchor:
T7347AS
1. Attach a ferrule or cable clamp (A) to end of cable.
2. Wrap cable around the drum and slide the ferrule or

cable clamp under the cable and into slot in drum and
secure with tab (C).
T7382AH –UN–03OCT90
TX,35,RR,798 –19–20DEC94–1/3
36–16 121997
PN=111
Attachments
• Second Method—Fixed Anchor:
1. Remove drum plug.
2. Thread cable up through small hole and wrap cable

around wedge (A). Insert cable back down through
–UN–03OCT90
lower hole and pull wedge into drum (B).
T7382AK
–UN–03OCT90
T7382AJ
TX,35,RR,798 –19–20DEC94–2/3
36–17 121997
PN=112
Attachments
• Method 2:
IMPORTANT: If you unwind cable below one turn on

drum, cable will come off drum.
1. Remove drum plug (B).
CAUTION: Prevent possible injury from cable

wire. Wear gloves when handling cable to
protect hands from cable wire cuts. DO NOT
guide cable on winch with your hands.
2. Thread cable up through small hole and insert cable

back down through lower hole. Pull loop into drum.
3. Adjust free spool drag to operator’s preference. (See

Winch Free Spool Drag Adjustment in this chapter.)
NOTE: Factory free spool drag setting was done without

cable; adjust free spool drag to operator’s
–UN–27SEP90
preference when cable is added.
T7347AS
T7382AI –UN–03OCT90
TX,35,RR,798 –19–20DEC94–3/3
36–18 121997
PN=113
Attachments
WINCH FREE SPOOL DRAG ADJUSTMENT
The winch drum drag can be adjusted to operator’s

preference.
1. Start engine.
2. Lower equipment to ground.
3. Engage park brake.
4. Place winch control handle in FREE SPOOL position.
5. Loosen nut (A).
–UN–10DEC94
6. Adjust slotted shaft (B) to desired winch drum drag.
7. Tighten nut.
T8368BK
TX,35,RR4679 –19–20DEC94–1/1
GREASING WINCH FAIRLEAD—IF EQUIPPED
If necessary, lubricate daily with grease specified in Fuels

and Lubricants chapter.
T90674 –UN–10FEB89
TX,36,RR2818 –19–20DEC94–1/1
GREASING RIPPER—IF EQUIPPED
Lubricate daily, if necessary, with grease specified in

Fuels and Lubricants chapter.
–UN–09FEB89
T6015BP
TX,36,RR2819 –19–20DEC94–1/1
36–19 121997
PN=114
Attachments
GREASING LOG ARCH—IF EQUIPPED
Lubricate daily, if necessary, with grease specified in

T6015BQ –UN–09FEB89
TX,36,RR2820 –19–20DEC94–1/1
36–20 121997
PN=115
Transporting
LOADING MACHINE ON A TRAILER
1. Keep the trailer bed clean.
2. Put chock blocks (A) against truck wheels.
T87155 –UN–09NOV88
3. Use a ramp or loading dock. Ramps must be strong
enough, have a low angle, and correct height.
4. If machine is equipped with roll-over protective

structure (ROPS), fasten seat belt before starting
engine.
5. Load and unload the machine on a level surface.

unexpected machine movement. Whenever
possible, back the machine onto the trailer to
prevent possible tipping.
6. Drive the machine onto the ramps squarely.
7. The centerline of the machine should be over the

centerline of the trailer.
8. Lower all equipment onto blocks.
9. Move transmission shift lever to neutral.
10. Move park and brake lock lever to lock position.

minutes.
13. Turn key switch to OFF. Stop engine.

16. Turn battery disconnect switch off.
02T,40,K36 –19–14APR94–1/2
40–1 121997
PN=116
Transporting
17. Cover exhaust opening to prevent entry of wind and

water.
IMPORTANT: Fasten chains or cables to machine

frame or track chain links. Do not place
chains or cables over or against
hydraulic lines or hoses.
18. Fasten each corner of the machine to the trailer with

a chain or cable.
19. Put blocks in front and behind tracks.
02T,40,K36 –19–14APR94–2/2
TOWING PROCEDURES

unexpected machine movement. Do not try to
start engine by towing. Extensive machine
damage and/or personal injury may result.
T7860AW –UN–09NOV92
IMPORTANT: DO NOT tow machine faster than 8.1
km/h (5 mph).
1. Fasten a tow bar or chain to crawler frame drawbar

(A).
2. Block machine tracks before working on machine to

prevent unexpected machine movement.
TX,40,RR2758 –19–14APR94–1/3
40–2 121997
PN=117
Transporting
• If Engine Is Running (LEVER AND PEDAL STEER

MACHINES):
IMPORTANT: When park brake pins are locked in

DOWN position, brake pedal(s)/steering
levers can be used to control track
–UN–10FEB89
movement for steering and stopping by
operator.
1. Remove operator’s station front floor plate to locate the
T6561AE
two park brake disconnect pins (A).
2. With transmission in neutral, hold down on one of the

lock-out pins.
3. Turn key off and then quickly push down and hold
other lockout pin.
4. Both lockout pins must stay locked down, then unit is

ready to be towed.
• If Engine Is NOT Running (LEVER STEER

MACHINES):

unexpected machine movement when
disengaging park brake. Block tracks before
working on machine.
1. Block tracks before working on machine to prevent

unexpected movement.
TX,40,RR2758 –19–14APR94–2/3
40–3 121997
PN=118
Transporting
IMPORTANT: Prevent damage to park brake assembly

when towing. Park automatically
engages when engine is dead and must
be disengaged by setting disconnect
pins before machine is towed.
–19–19MAY89
2. To gain access to park brake lockout pins, remove
covers from left side of machine below fuel tank and
from right side of machine below hydraulic tank.
T6561AB
3. On left side of machine, pull bellcrank (A) all the way
back using a screwdriver to apply force.
Simultaneously push down left side park brake lockout
pin to disengage brake. (Lockout pin must stay down.)
4. On right side of machine, using a ratchet and 15 mm

(9/16 in.) combination wrench, pull bellcrank all the
way back and then push down on right side park brake
lockout pin to disengage brake. (Pin must stay down.)
If engine is NOT running: (PEDAL STEER MACHINES)

unexpected machine movement when
disengaging park brake. Block tracks before
working on machine.
1. Block tracks before working on machine to prevent

unexpected movement.
IMPORTANT: Prevent damage to park brake assembly

when towing. Park automatically
engages when engine is dead and must
be disengaged by setting disconnect
pins before machine is towed.
2. To gain access to park brake lockout pins, remove

covers from left side of machine below fuel tank and
from right side of machine below hydraulic tank.
3. Pull each brake pedal to upper stop and then push

down park brake lockout pin. Release brake pedal;
lockout pin must stay down.
TX,40,RR2758 –19–14APR94–3/3
40–4 121997
PN=119
Fuels and Lubricants
DIESEL FUEL
Consult your local fuel distributor for properties of the • Sulfur content: — Sulfur content should not exceed
diesel fuel available in your area. 0.5% Sulfur content less than 0.05% is preferred. —
If diesel fuel with sulfur content greater than 0.5%
In general, diesel fuels are blended to satisfy the low sulfur content is used, reduce the service interval for
temperature requirements of the geographical area in engine oil and filter by 50% — DO NOT use diesel
which they are marketed. Recommended standard fuel with sulfur content greater than 1.0%
grades are:
• Lubricity — Fuel lubricity must pass the BOCLE
Use Grade No. 1-D fuel at temperatures from -30 to scuffing test at 3300 gram minimum load level. — If
+30°C (-22 to +86°F). fuel of low or unknown lubricity is used, add John
Deere All-Season Diesel Fuel Conditioner at
Use Grade No. 2-D fuel at temperatures from -10 to specified concentration.
+50°C (+14 to +122°F).
Bio-diesel fuels with these properties and meeting an
Diesel fuels meeting Military Specification VV-F-800E appropriate specification may be used as an
are preferred. If diesel fuel specified to ASTM D975 is alternative to petroleum-based diesel fuel.
used, the fuel must meet the following properties:
Arctic fuels (such as Military Specification VV-F-800E,
• Cetane Number 40 minimum. Cetane number Grade DF-A) may be used at temperatures below
greater than 50 is preferred, especially for -30°C (-22°F).
temperatures below -20°C (-4°F) or elevations above
1500 m (5000 ft). CAUTION: Handle fuel carefully. Do not fill
the fuel tank when engine is running. DO
• Cold Filter Plugging Point (CFPP) below the NOT smoke while you fill the fuel tank or
expected low temperature OR Cloud Point at least service the fuel system.
5°C (9°F) below the expected low temperature
TX,45,DH3547 –19–09NOV94–1/1
45–1 121997
PN=120
LOW SULFUR DIESEL FUEL CONDITIONER
When possible, use existing fuel formulations for engines

used off-highway. This fuel will not require any additives
to provide good performance and engine reliability.
However, many local fuel distributors will not carry both
low and regular sulfur diesel fuels.
If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere PREMIUM DIESEL FUEL
CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
anti-oxidant, fuel stabilizer, corrosion inhibitor and others.
John Deere PREMIUM DIESEL FUEL CONDITIONER is
specifically for use with low sulfur fuels. Nearly all other
diesel fuel conditioners only improve cold weather flow
and stabilize long-term fuel storage. They do not contain
the lubrication additives needed by rotary fuel injection
pumps.
TX,45,RB74 –19–08DEC97–1/1
45–2 121997
PN=121
DIESEL FUEL STORAGE
IMPORTANT: DO NOT store diesel fuel in galvanized

containers. Diesel fuel stored in
galvanized containers reacts with zinc
coating on container to form zinc
flakes. If fuel contains water, a zinc gel
will also form. The gel and flakes will
quickly plug fuel filters, damage
injection nozzles and injection pump.
DO NOT use brass-coated containers

for fuel storage. brass is an alloy of
copper and zinc.
Proper fuel storage is critically important. use clean

storage and transfer tanks. Periodically drain water and
sediment from bottom of tank. Store fuel in a convenient
place away from buildings.
Store diesel fuel in plastic, aluminum, and steel containers

specially coated for diesel fuel storage.
Avoid storing fuel over long periods of time. If fuel is

stored for more than a month prior to use, or there is a
slow turnover in fuel tank, add a fuel conditioner such as
John Deere PREMIUM DIESEL FUEL CONDITIONER or
equivalent to stabilize the fuel and prevent water
condensation. John Deere PREMIUM DIESEL FUEL
CONDITIONER is available in winter and summer
formulas. Fuel conditioner also reduces fuel gelling and
controls wax separation during cold weather.
Consult your John Deere engine distributor or servicing

dealer for recommendations and local availability. Always
follow manufacturer’s directions on label.
TX,45,RB75 –19–08DEC97–1/1
45–3 121997
PN=122
FUEL TANK
CAUTION: Handle fuel carefully. If the engine is

hot or running, do not fill the fuel tank. Do not
smoke while you fill fuel tank or work on fuel
system.
To avoid condensation, fill the fuel tank at the end of each
day’s operation. Tank capacity is 159 L (41 gal).
TX,45,RR2759 –19–12JAN93–1/1
45–4 121997
PN=123
DIESEL ENGINE OIL
–19–27MAR95
T8358AJ
Use oil viscosity based on the expected air Other oils may be used if they meet one or more of
temperature range during the period between oil the following:
changes.
• John Deere UNI-GARD
The following oil is preferred. • API Service Classification CG-4
• API Service Classification CF-4
John Deere PLUS-50
Viscosity grade SAE 15W-40 is preferred.If diesel
If John Deere PLUS-50 engine oil and a John Deere fuel with sulfur content greater than 0.5% is used,
oil filter are used, the service interval for oil and reduce the service interval by 50%.
filter changes may be extended by 50 hours.
The following oil is also recommended:
• John Deere TORQ-GARD SUPREME 
PLUS-50 is a trademark of Deere & Company

TORQ-GARD SUPREME is a trademark of Deere & Company
UNI-GARD is a trademark of Deere & Company TX,45,JC276 –19–12APR95–1/1
45–5 121997
PN=124
FINAL DRIVE OIL
–19–03NOV92
T7883AE
Depending upon the expected air temperature range CD/SD, CD/SC, CC/SF, CC/SE, CC/SD, CC/SC
between oil changes, use oil viscosity shown on the (MIL-L-2104C, MIL-L-2104D, MIL-L-46152B).
temperature chart above.
You may also use oils which meet minimum John
John Deere HY-GARD Transmission and Hydraulic Deere Standards, or other oils meeting John Deere
Oil is recommended because it is specifically Standard J20A and J20C or J20B and J20D.
formulated to provide maximum protection against
wear of gears and bearings. Oil meeting MIL-L-46167A may be used as an arctic
oil.
Engine oil may be used provided if it meets one or
more of the following: API Service CD/SF, CD/SE,
HY-GARD is a trademark of Deere & Company 02T,45,RR2760 –19–12JAN93–1/1
TRACK ROLLER, FRONT IDLER, AND

CARRIER ROLLER OIL
Use SAE 80W90 gear oil meeting API Service GL-5

(MIL-L-2105B or MIL-L-2105C).
T82,CRFL,D –19–09APR91–1/1
45–6 121997
PN=125
TRANSMISSION, STEERING CLUTCHES, AND HYDRAULIC OIL
T7784AC –19–17JUN92
Depending upon the expected air temperature range CD/SC, CC/SF, CC/SE, CC/SD, CC/SC (MIL-L-2104C,
between oil changes, use oil viscosity shown on the MIL-L-2104D, MIL-L-46152B).
temperature chart above.
You may also use oils which meet minimum John
JOHN DEERE HY-GARD TRANSMISSION AND Deere standards, or other oils meeting John Deere
HYDRAULIC OIL IS RECOMMENDED because it is Standard J20C and J20D.
specifically formulated to minimize brake chatter, and
to provide maximum protection against mechanical Oils meeting MIL-L-46167A may be used as arctic oil.
wear.
Engine oil may be used provided it meets one or more

of the following: API Service CD/SF, CD/SE, CD/SD,
HY-GARD is a trademark of Deere & Company TX,45,RR2761 –19–12JAN93–1/1
45–7 121997
PN=126
GREASE
T8358AI –19–27MAR95
Use grease based on the expected air temperature Other greases may be used if they meet one of the
range during the service interval. following:
The following greases are preferred: • SAE Multipurpose EP Grease with a maximum of
5% molybdenum disulfide
• John Deere MOLY HIGH TEMPERATURE EP • SAE Multipurpose EP Grease
GREASE
• John Deere HIGH TEMPERATURE EP GREASE Greases meeting Military Specification MIL-G-10924F
• John Deere GREASE-GARD may be used as arctic grease.
TX,45,JC275 –19–31MAR95–1/1
LUBRICANT STORAGE
Your equipment can operate at top efficiency only Make certain that all containers are properly marked to
when clean lubricants are used. identify their contents.
Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
TX,45,RB88 –19–16DEC97–1/1
45–8 121997
PN=127
ALTERNATIVE AND SYNTHETIC LUBRICANTS
Conditions in certain geographical areas may require Synthetic lubricants may be used if they meet the
lubricant recommendations different from those printed performance requirements listed in this manual.
in this manual. Some John Deere lubricants may not
be available in your location. Consult your John Deere
dealer to obtain information and recommendations.
DX,ALTER –19–01FEB94–1/1
45–9 121997
PN=128
Periodic Maintenance
SERVICE YOUR MACHINE AT SPECIFIED
INTERVALS
Lubricate, make service checks and adjustments at

intervals shown on the periodic maintenance chart and on
the following pages.
–UN–09FEB89
T6499CZ
03T,50,M75 –19–19OCT88–1/1
50–1 121997
PN=129
CHECK THE HOUR METER REGULARLY
Use the hour meter (A) to determine when your machine

needs periodic maintenance.
Intervals on the periodic maintenance chart are for
–UN–10NOV92
operating in normal conditions. If you operate your
machine in difficult conditions, you should service it at
SHORTER INTERVALS.
T7784AG9
(S.N. —794617)
(S.N. 794618—823918)
T112491 –UN–09DEC97
(S.N. 823919– )
TX,50,RR2762 –19–20DEC94–1/1
50–2 121997
PN=130
USE CORRECT FUELS AND LUBRICANTS
IMPORTANT: To prevent machine damage when

servicing your machine, use correct
fuels and lubricants. (See Fuels and
Lubricants chapter.)
T82,EXPM,EA –19–06AUG91–1/1
50–3 121997
PN=131
PREPARE MACHINE FOR MAINTENANCE
Before performing maintenance procedures given in the

following chapters, park the machine as described below
unless another position is specified in the procedure.
–UN–26NOV90
IMPORTANT: Improperly disposing of waste can
threaten the environment and ecology.
Potentially harmful waste used with
John Deere equipment include such
TS1133
items as oil, fuel, coolant, brake fluid,
filters, and batteries. Do not pour waste
onto the ground, down a drain, or into
any water source.
2. Lower all equipment to the ground.

minutes.
5. Move speed control lever (B) to run engine at 1/2

speed no load for 2 minutes.
7. Turn key switch to OFF to stop engine. (If maintenance
–UN–30NOV94
must be performed with engine running, do not leave
machine unattended.)
T8358AM
9. Release hydraulic pressure by moving control lever(s)
10. Attach a "Do Not Operate" tag on the metal loop at

the top of the instrument panel.
11. Turn battery disconnect switch off.
TX,50,RR4680 –19–20DEC94–1/1
50–4 121997
PN=132
REMOVE BOTTOM GUARD
Oil pan bottom guard is hinged at end (A).
CAUTION: Support bottom with a hydraulic jack

when removing bottom guard from machine.
Bottom guard is heavy when mud and debris
accumulate on top of bottom guard.
03T,50,K95 –19–08FEB93–1/1
MAINTENANCE AND REPAIR RECORD

KEEPING SYSTEM
The checklist on the following page summarizes

scheduled maintenance, and parts and oil required at
each maintenance interval.
Use the checklist to:
• remind you to perform machine maintenance at

specified intervals to minimize downtime.
• calculate cost of machine operation and ownership
allowing you to make better job estimates.
• place yourself in a stronger position at trade-in time.
• satisfy your SECURE contract requirements
As maintenance is performed, check off each item on the

list and record date and hour meter reading. Use the
second (perforated) copy of this form (immediately
preceding the Service Literature order form inside the
–19–03APR89
back cover).
Do not tear out or mark on Checklist in the Periodic

Maintenance chapter; keep it to make extra copies.
T6828AA
03T,50,K67 –19–03AUG92–1/1
50–5 121997
PN=133
OILSCAN PLUS, COOLSCAN 3–WAY

TEST KIT
OILSCAN PLUS, COOLSCAN and 3-WAY Test Kit are

John Deere fluid sampling products to help you monitor
machine performance and system condition. The objective
of a fluid sampling program is to insure machine
availability when you need it and to reduce repair costs by
identifying potential problems before they become critical.
T111411 –UN–16SEP97
Oil and coolant samples should be taken from each
system on a periodic basis, usually prior to a filter and/or
fluid change interval. Certain systems require more
frequent sampling. Consult your John Deere dealer on a
maintenance program for your specific application. Your
dealer has the sampling products and expertise to assist OILSCAN
you in lowering your overall operating costs through fluid
sampling.
T111410 –UN–16SEP97
OILSCAN Plus is a trademark of Deere & Company 3–WAY Test Kit
CoolScan is a trademark of Deere & Company
3–Way is a trademark of Deere & Company TX,50,BG297 –19–24SEP97–1/1
50–6 121997
PN=134

KEEPING SYSTEM
BREAK-IN SERVICE INTERVALS

Break-in service is required for your machine at intervals shown in chapter 15. Refer to chapter 15 during the first 100 hours of machine
operation. After 100 hours, refer to service intervals in chapter 50.
SERVICE INTERVALS AFTER BREAK-IN
Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at
500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily.
AS REQUIRED
•Inspect belts and check tension •Check and adjust track sag
•Check air cleaner restriction indicator •Drain fuel tank sump
•Check pre-cleaner
EVERY 10 HOURS OR DAILY
•Grease dozer linkage •Check hydraulic system oil level
•Check engine oil level •Check coolant level at recovery tank (later machines)
•Check transmission oil level •Check radiator coolant level (earlier machines)
EVERY 100 HOURS
•Grease boom linkage and cylinders
REQUIRED PARTS
Insure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated
parts are also on-hand, i.e., filter O-rings.
03T,50,M76 –19–20DEC94–1/3
50–7 121997
PN=135
Description Unit Part Number ASI 250 500 1000 2000

Hours Hours Hours Hours
Engine Oil Filter T19044 1 1 1 1 1
Fuel Filter AR50041 1 1 1
Hydraulic System Oil Filter AT120444 1 1 1 1
Transmission Oil Filter:
(S.N. —774221) AH128449 1 1 1 1
(S.N. 774222— ) AT105663 1 1 1 1
Hydraulic Reservoir Breather AT101565 1 1 1
Engine Oil (Engine S.N. —742285)
PLUS-50 450G TY6389 8.5 L (9 8.5 L (9 8.5 L (9 8.5 L (9 8.5 L (9
qt) qt) qt) qt) qt)
550G, TY6389 12.3 L 12.3 L 12.3 L 12.3 L 12.3 L
650G (13 qt) (13 qt) (13 qt) (13 qt) (13 qt)
Engine Oil (Engine S.N. 742286— )
PLUS-50 450G, TY6389 14L (15 14L (15 14L (15 14L (15 14L (15
550G, qt) qt) qt) qt) qt)
650G
Air Cleaner Filter - Primary AT39124 1 1
(4045D engines)
AT65296 (4045T
engines)
Air Cleaner Filter - Secondary AT44378 1 1
(4045D engines)
AT31227 (4045T
engines)
Description Part Number ASI 250 500 1000 2000

HY-GARD Transmission and Hydraulic Oil
Without 4000 Winch TY6354 98.4 L 98.4 L
(26 gal) (26 gal)
With 4000 Winch TY6354 132 L (35 132 L
gal) (35 gal)
OILSCAN Kits
Diesel Engine Oil AT178840 1 1 1 1
Transmission Oil and Gearbox AT178843 1 1 1
Hydraulic Oil AT178844 1 1 1
Coolant Conditioner TY16004 As needed
CoolScan Kit (Ten samples per kit) AT183016 1 1

HY-GARD is a trademark of Deere & Company
OILSCAN is a trademark of Deere & Company
CoolScan is a trademark of Deere & Company 03T,50,M76 –19–20DEC94–2/3
50–8 121997
PN=136
Model: ❒ 450G ❒ 550G ❒ 650G Customer:

PIN/Serial Number: Delivery Date: Hour Meter Reading:
OIL SAMPLING
Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form: 250, 500, 1000, 2000
hours. Maintenance recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you
supply. Regular oil sampling will extend the operational life of your machine’s systems.
Every 250 Hours
❒ Check radiator coolant level—Later Machines ❒Clean top of transverse case
❒ Check inner and outer final drive oil level ❒ Change engine oil and filter elements
Comments:
Date: Hour Meter Reading: Maintenance Performed By:

Every 500 Hours
❒ Replace fuel filter ❒ Check air intake hoses
❒ Check battery water level, clean and tighten terminals ❒ Add non-chromate rust inhibitor to radiator
❒ Change hydraulic system oil filter ❒ Change transmission oil filter
❒ Change hydraulic reservoir breather filter
Comments:
Every 1000 Hours
❒ Check transmission accumulator ❒ Change final drive oil
❒ Check hydraulic system oil, clean suction screen ❒ Check engine speed linkage
❒ Change transmission oil, clean suction screen ❒ Adjust engine valve lash (S.N. —840460)
❒ Drain and flush engine cooling system ❒Clean enginie crankcase vent tube
Comments:
Every 2000 Hours (S.N. 840461— )
❒ Adjust engine valve lash (S.N. 840461— )
Comments:
OILSCAN is a registered trademark of Deere & Company. 03T,50,M76 –19–20DEC94–3/3
50–9 121997
PN=137
Maintenance—As Required
CHECK AND ADJUST BELT TENSION
(S.N. —840460)
1. A force of 111 N (25 lb) on a new belt halfway

between pulleys should deflect belt 8 mm (5/16 in.). A
force of 111 N (25 lb) on a used belt halfway between
pulleys should deflect belt 11 mm (7/16 in.).
2. If belt deflection is not within specifications, loosen

alternator mounting cap screws.
3. Apply force to FRONT alternator housing only (near

the belt) until tension is correct.
4. Tighten cap screws.
–UN–18OCT88
T6030AT1
A—Alternator Pulley
B—Fan Pulley
C—Crankshaft Pulley
D—Straight Edge
E—Belt Deflection Gauge
03T,55,K84 –19–18AUG93–1/1
55–1 121997
PN=138
INSPECT SERPENTINE BELT

(S.N. 840461— )
1. Check belt regularly for wear, especially for cracks at

the bottom of grooves and for frayed edges.
2. If necessary, replace belt.
3. Place the drive of a 1/2 in. drive ratchet in square hole.

Turn ratchet counterclockwise to pull tension adjuster
assembly away from belt, releasing belt tension.
4. Hold tension adjuster assembly away from belt while

removing old belt and installing new belt.
5. Slowly turn ratchet clockwise to place tension adjuster

assembly against new belt. Tension is automatically
adjusted.
6. Remove ratchet from assembly.
T7405BG –UN–15NOV90
TX,55,RB76 –19–08DEC97–1/1
CHECK THE AIR RESTRICTION INDICATOR
The red signal must not be visible in restriction indicator

(A).
If red signal is visible, clean or replace air filter elements.
(See Air Filter Elements in Maintenance chapter.)
03T,55,K85 –19–16AUG93–1/1
CHECK THE PRE-CLEANER
Check the pre-cleaner bowl. If dust or other material is up

to the mark (A) on the bowl, clean the bowl.
IMPORTANT: The pre-cleaner removes only part of

T6201AL1 –UN–18OCT88
the dirt as air goes to the engine. You

must still clean the air cleaner regularly.
03T,55,K86 –19–16AUG93–1/1
55–2 121997
PN=139
CHECK TRACK SAG
PROPER TRACK SAG ADJUSTMENT Maintaining the

proper amount of track sag 51 mm (2 in.) is the single
most important adjustment the operator can make. Tight
tracks can reduced the amount of wear life by more than
50% over tracks which are properly maintained at 51 mm
(2 in.) of sag. Tight tracks increase the loading on the
undercarriage components and accelerate the wear rate.
Track sag should be adjusted as the soil conditions
change. (See TRACK SAG GENERAL INFORMATION on
page 90-17 in this manual.)
1. Position track so that a track pin is centered over the

carrier roller.
2. Measure sag of track between carrier roller and front

idler from the top of track grosser (A) to a straight-edge
(B). (For 550G and 650G machines, measure track sag
between carrier rollers.)
SPECIFICATION
Track sag 51 ± 6 mm (2 ± 0.250 in.)
If adjustment is needed, see Adjusting Track Sag in this

chapter.
TX,55,RR2718 –19–12JAN93–1/1
55–3 121997
PN=140
ADJUSTING TRACK SAG
CAUTION: Grease for track adjuster cylinder is

under high pressure. Never remove special
grease fitting to release the grease. If grease
does not escape immediately from vent hole
with relief valve open, slowly drive unit in
forward and reverse until grease escapes. DO
NOT disassemble parts unless you know the
correct procedure and have correct tools. (See
your authorized dealer.)

any fluid injected into the skin must be
IMPORTANT: The adjustment cylinder has a track sag
adjustment fitting on the yoke end. DO
NOT use the grease fitting on the yoke
end for lubrication. Use this fitting
ONLY for track sag adjustment.
–UN–30NOV94
T8364AS
TX,55,RR4681 –19–20DEC94–1/3
55–4 121997
PN=141
(S.N. —781708)
• To decrease track sag, apply grease to special high

pressure fitting (C) using a 55,200 kPa (550 bar) (8000
psi) capacity grease gun. After adding grease, operate
machine to allow track adjuster cylinder to fully adjust
T7756AC –UN–03NOV92
and then check sag again.
• To increase track sag, loosen relief valve (B), [never the

special fitting (C)] one to two turns counterclockwise to
release grease through vent hole (A). Tighten relief
valve. Operate machine to allow track adjuster cylinder
to fully adjust and then check sag again. (Earlier Machines-S.N. —781708)
(S.N. 781709— )
• To decrease track sag, apply grease to special fitting

(C) using a 55,200 kPa (550 bar) (8000 psi) capacity
grease gun. After adding grease, operate machine to
allow track adjuster cylinder to fully adjust and then
check sag again.
• To increase track sag, loosen check valve (B), [not the

special fitting (C)] one to two turns counterclockwise to
release grease through vent hole (A). Tighten check
valve. Drive machine to allow track adjuster cylinder to
adjust and then check sag again.
–UN–03NOV92
T7756AA
(Later Machines-S.N. 781709— )
TX,55,RR4681 –19–20DEC94–2/3
55–5 121997
PN=142
Later Machines With Protective Cover:
1. Remove cap screw (A) from cover and raise cover.
2. To decrease track sag, apply grease to special fitting
–UN–10NOV92
(B) using a 55,200 kPa (550 bar) (8000 psi) capacity
grease gun. After adding grease, operate machine to
allow track adjuster cylinder to fully adjust and then
check sag again.
T7860AY
To increase track sag, loosen check valve (C), [not the
special fitting (B)] one to two turns counterclockwise to Later machines with protective cover
release grease through vent hole (D). Tighten check
valve. Drive machine to allow track adjuster cylinder to
adjust and then check sag again.
3. Lower cover over track sag special fitting and install

cap screw.
For general information on track sag, see Maintenance

chapter.
–UN–10NOV92
T7860AX
T7883AD –UN–10NOV92
TX,55,RR4681 –19–20DEC94–3/3
55–6 121997
PN=143
DRAIN FUEL TANK SUMP
CAUTION: Handle fuel carefully. Shut the

engine OFF. Do not smoke while you work on
–UN–09FEB89
fuel system.
1. Loosen cap screw(s) (A), move latch (B) to one side

(earlier machines only), and open or remove access
T6499CN1
cover.
Earlier Machines
–UN–17AUG90
T7349BX
Later Machines
A—Cap Screw
B—Latch
C—Access Cover
03T,55,K88 –19–14APR94–1/2
55–7 121997
PN=144
NOTE: Side panel removed for clarity of photograph.
2. Open drain cock (A) for several seconds to drain water

and sediment.
3. Close drain cock and replace cover. Tighten cap
T6499CM –UN–09FEB89
screw(s).
Earlier Machines
–UN–17AUG90
T7349BV
Later Machines
03T,55,K88 –19–14APR94–2/2
55–8 121997
PN=145
Maintenance—Every 10 Hours or Daily
CHECK ENGINE OIL LEVEL
IMPORTANT: Do not run engine when oil level is

below the ADD mark.
The most accurate oil level reading is obtained when the
–UN–09FEB89
engine is cold before starting the engine for the day’s
operation.
T6499BE
2. Engage the park and brake lock lever in the down
position.
3. Make sure dipstick is fully seated.
4. Remove dipstick (A) to check oil level.
BEFORE THE ENGINE IS STARTED: The engine is
RG5421 –UN–15DEC88
full when oil level is in the cross hatch area (C). It is
acceptable to run the engine when the oil level is
above the ADD mark.
AFTER THE ENGINE HAS BEEN RUN: Allow the oil

to drain into the oil pan for 10 minutes before checking
the oil level. Ten minutes after shutdown the engine oil
level must be above the ADD mark.
5. If necessary, remove the filler cap to add oil. (See

Fuels and Lubricants chapter.)
03T,60,K96 –19–14APR94–1/1
60–1 121997
PN=146
CHECK TRANSMISSION OIL LEVEL
1. Park machine on level ground.
2. Shut engine off.
T7349AU –UN–17AUG90
CAUTION: For machines (S.N. —794017):
System is slightly pressurized. Slowly loosen
and remove dipstick to allow pressure to
escape.
3. Unscrew dipstick (A) slowly from oil fill tube and wipe
oil from dipstick. (S.N. —794017)
4. Oil must be within the ADD mark and FULL mark on

dipstick.
5. If necessary, add oil. (See Fuels and Lubricants

chapter.)
(S.N. 794018— )
03T,60,K97 –19–20DEC94–1/1
60–2 121997
PN=147
CHECK HYDRAULIC OIL LEVEL
IMPORTANT: DO NOT operate engine without oil in

reservoir.
1. Park machine on level surface and lower all equipment
–UN–17AUG90
to ground.
2. Turn key switch to OFF.
T7349BP
3. Oil must be halfway up in oil level window (B).
4. Remove cap (A) and add oil. (See Fuels and

Lubricants chapter.)
5. Check gasket on cap before installing.
6. Add oil if necessary. (See Fuels and Lubricants

chapter.)
03T,60,K98 –19–08JAN91–1/1
60–3 121997
PN=148
CHECK COOLANT LEVEL
Earlier Machines (S.N. —763177):
CAUTION: Prevent injury from hot spraying

coolant. Do not remove radiator filler cap
–UN–18OCT88
unless engine is cool. Loosen cap slowly to the
stop. Release all pressure before removing cap.
1. Remove radiator filler cap. Coolant level must be 25.4
T6464AV
mm (1.0 in.) below bottom of filler neck. Add water or
antifreeze as necessary.
2. Install filler cap.
Later Machines (S.N. 763178— ):
With the engine cold, coolant level must be between

HOT and COLD marks on recovery tank (A).
T6274AQ –UN–18OCT88
If coolant is below the COLD mark, add coolant to the
recovery tank.
If there is no coolant in the recovery tank, add coolant

to the recovery tank and the radiator.
(S.N. —763177)
T8368BN –UN–10DEC94
(S.N. 763178— )
TX,60,RR2813 –19–20DEC94–1/1
60–4 121997
PN=149
LUBRICATE DOZER LINKAGE
Lubricate each grease fitting with two shots. (See Fuels

and Lubricants chapter.)
–UN–17AUG90
T7349BM
Six Points-Earlier Machines
Four Points-Later Machines

TX,60,RR4682 –19–20DEC94–1/2
60–5 121997
PN=150
T7896AL –UN–09DEC92
Three Points-Left Side Shown
–UN–30NOV94
T8364AV
Four Points-Left Side Shown
TX,60,RR4682 –19–20DEC94–2/2
60–6 121997
PN=151
CHANGE ENGINE OIL AND FILTER
1. Run engine to warm oil. Stop engine.
2. Remove two cap screws (A) and remove cover (B) to

remove drain plug. Allow oil to drain into a container.
T6561AD –UN–01JUN89
Dispose of waste oil properly.
SPECIFICATIONS
450G Capacity (S.N. —840460 ) 8.5 L (9 qt)
550G, 650G Capacity (S.N. — 12.3 L (13 qt)
840460)
450G, 500G, 650G Capacity 14 L (14.8 qt)
(S.N. 840461— )
TX,75,RB77 –19–08DEC97–1/2
3. On machines (S.N. —840460), remove filter plug (B) to

drain oil from filter.
4. Remove oil filter (A).
5. Apply thin film of oil to gasket of new filter.
6. Install new filter. Turn filter clockwise by hand until
gasket touches mounting surface.
7. Tighten 1/2 to 3/4 turn more.
8. On machines (S.N. —840460), install filter plug (B). (S.N. —840460)
9. Fill engine with oil. (See Fuels and Lubricants chapter).
10. Run engine for two minutes and then stop engine.
Check for leaks around filter and drain plug. Tighten
enough only to stop leaks.
T112377 –UN–09DEC97
11. Check oil level.
(S.N. 840461— )
TX,75,RB77 –19–08DEC97–2/2
75–1 121997
PN=152
CHECK FINAL DRIVES OIL LEVEL
1. Park machine on a level surface and turn engine OFF.
2. Remove oil level and filler plug (A). Oil must be within
13 mm (0.5 in.) of bottom of filler hole.
T7883AF –UN–09NOV92
3. Add oil if needed. (See Fuels and Lubricants chapter.)
4. Install plug.
450G Shown
03T,75,M49 –19–12JAN93–1/1
CLEAN TRANSVERSE CASE
Remove cover (A) (both sides), rear cover (B), and floor
plate to clean top of transfer case (C). Remove debris
around linkages and valve spools.
–UN–17AUG90
T7349AY
TX,75,FF1928 –19–08JAN91–1/1
GREASE TRACK ADJUSTER CYLINDER

(S.N. —745426)
Lubricate fitting until grease escapes past seal.
–UN–17AUG90
T6656AG1
03T,70,K17 –19–14APR94–1/1
75–2 121997
PN=153
CHECK COOLANT LEVEL
CAUTION: Prevent personal injury from hot

spraying coolant. DO NOT remove radiator cap
(A) unless engine is cool to the hand. Loosen
cap slowly to the stop. Release all pressure in
–UN–18OCT88
cooling system before you remove cap.
1. With the engine cold, coolant level must be between

FULL and LOW marks on the recovery tank.
T6464AV
2. If coolant is below the LOW mark, add coolant to the
recovery tank.
3. If coolant is not present in the recovery tank, add

coolant to the recovery tank and the radiator. Coolant
level must be at bottom of the filler neck.
NOTE: If recovery tank is full and radiator is low, check
–UN–09DEC92
for leaks on radiator cap, and hose connections
between radiator and coolant recovery tank.
T7896AP
TX,75,RR2812 –19–20DEC94–1/1
75–3 121997
PN=154
CHANGE FUEL FILTER (S.N. —840460)
1. Remove retainer spring (A) to remove filter (C). Push

on outer tab (B) while pulling up on center tab to
disengage inner tab from notch in filter base (D).
–UN–18OCT88
2. Clean filter base.
T6201AQ2
TX,80,RB78 –19–08DEC97–1/2
80–1 121997
PN=155
3. Install new filter and retainer spring.
4. Check drain screw (C) to be sure it is tight.
5. Loosen bleed screw (A). Operate primer lever (B) until

fuel flow from bleed screw is free of bubbles.
–UN–01NOV88
NOTE: If there is no fuel flow, push primer lever toward
engine. Turn crankshaft using starter motor to
reposition camshaft. Repeat Step 5.
T6201AO2
6. Tighten bleed screw.
7. Push primer lever toward engine as far as possible.
TX,80,RB78 –19–08DEC97–2/2
80–2 121997
PN=156
CHANGE FUEL FILTER/WATER SEPARATOR

(S.N. 840461— )
1. Thoroughly clean fuel filter/water separator assembly

and surrounding area, if not previously done.
T112372 –UN–09DEC97
NOTE: Lifting up on retaining ring (A) as it is rotated
helps to get it past raised locators.
2. Connect a drain line to filter drain adapters and drain

all fuel from filters.
3. Firmly grasp the retaining ring and rotate it

A—Retaining Ring
counterclockwise 1/4 turn. Remove ring with filter
B—Filter Element
element (B). C—Separator Bowl
4. Inspect filter mounting base for cleanliness. Clean as

required.
5. Remove water separator bowl, if equipped. Drain and

clean separator bowl. Dry with compressed air.
6. Install water separator bowl, if equipped, onto new filter

element. Tighten securely.
NOTE: The fuel filter must be indexed properly and the

key on canister must be oriented in slot of
mounting base for correct installation.
7. Thoroughly inspect filter base seal ring. Replace as

needed.
8. Install new filter element onto mounting base and

position element using a slight rocking motion. Be sure
element is properly indexed on mounting base.
9. Install retaining ring onto mounting base and tighten

about 1/3 turn until ring “snaps” into the detent. DO
NOT overtighten the retaining ring.
TX,80,RB79 –19–08DEC97–1/2
80–3 121997
PN=157
10. Open air bleed vent screw (A) two full turns by hand.
11. Pump the hand primer (B) on fuel pump until a

noticeable amount of fuel and air comes out of vent
opening. Continue pumping and close vent screw
when fuel starts to flow.
T112375 –UN–16DEC97
12. Pump the hand primer several times until resistance
is felt. Continue pumping and open air bleed vent
screw again.
13. Close air bleed vent screw and pump the hand primer
several times until resistance is felt again.
A—Air Bleed Vent Screw
B—Hand Primer
TX,80,RB79 –19–08DEC97–2/2
CHECK AIR INTAKE HOSE
1. Check hose (A) for cracks.
2. Check for loose hose clamps.
T6499CJ –UN–09FEB89
(S.N. —840460)
T112371 –UN–09DEC97
(S.N. 840461— )
03T,80,K91 –19–02SEP88–1/1
80–4 121997
PN=158
CHANGE TRANSMISSION OIL FILTER
1. For earlier machines (S.N. —803601), remove floor

plate. For later machines (S.N. 803602— ), open right
side service access door.
2. Remove oil filter (A) by turning counterclockwise.
(S.N. —803601)
T8381AZ –UN–10DEC94
(S.N. 803602— )
TX,80,RR4706 –19–20DEC94–1/2
80–5 121997
PN=159
3. Apply a thin film of oil to gasket of new filter.

5. Tighten 1/2 to 3/4 turn more.
T8364AZ –UN–30NOV94
6. Remove dipstick (A) and add oil in filler tube.
7. Start engine and run for 2 minutes. Stop engine and

check for leaks around filter base. Tighten filter only
enough to stop leaks.
8. Check level of oil and add if needed.
TX,80,RR4706 –19–20DEC94–2/2
CHANGE HYDRAULIC RESERVOIR

BREATHER FILTER AND HYDRAULIC OIL
FILTER
1. Loosen clamp.
2. Remove hoses from breather filter (A).
3. Install new filter with arrow pointing upward.
–UN–30NOV94
T8358AP
TX,80,RR4684 –19–20DEC94–1/2
80–6 121997
PN=160
4. Remove filter (A) by turning counterclockwise.
5. Apply thin film of oil to gasket of new filter.

7. Tighten 3/4 turn more.
8. Start the engine.
9. Stop the engine. Check for leaks around the filter base.
Tighten filter only enough to stop leaks.
Check oil level.
–UN–30NOV94
T8364AY
TX,80,RR4684 –19–20DEC94–2/2
80–7 121997
PN=161
CHECK BATTERY ELECTROLYTE LEVEL

AND TERMINALS
CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first

and replace it last.
Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
• Filling batteries in a well-ventilated area.
• Wearing eye protection and rubber gloves.
• Avoiding breathing fumes when electrolyte is
added.
• Avoiding spilling or dripping electrolyte
• 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 10—15
minutes. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
1. Remove hold-down clamps.
2. Remove battery covers.
TX,9015,RB21 –19–30OCT97–1/2
80–8 121997
PN=162
IMPORTANT: During freezing weather, batteries must

be charged after water is added to
prevent battery freezing. Charge battery
using a battery charger or by running
the engine.
T6996DB –UN–10FEB89
3. Fill each cell to within specified range with distilled
water. DO NOT overfill.
CAUTION: Battery gas can explode from sparks

of battery causing personal injury. Always
remove grounded (-) battery clamp first and
replace it last. Single Level Fill Tube Application
4. Disconnect battery clamps, grounded clamp first.
5. Clean battery terminals (A) and clamps with a stiff

brush.
6. Apply lubricating grease (B) around battery terminal
T6996DA –UN–10FEB89
base only.
7. Install and tighten clamps, grounded clamp last.
8. Install hold-down clamps.

Dual Level Fill Tube Application
A—Battery Post
B—Fill Tube
C—Electrolyte Level Range
TX,9015,RB21 –19–30OCT97–2/2
80–9 121997
PN=163
CHECK COOLANT CONDITIONER IN

RADIATOR
Coolant conditioner prevents rust, scale, and liner

cavitation.
CAUTION: Do not remove radiator cap unless
the engine is cool. Then loosen cap slowly to
the stop. Release all pressure before removing
cap.
1. Turn cap slowly to the stop to release pressure. Then

remove radiator cap.
2. Add TY16004 John Deere Coolant Conditioner or

equivalent non-chromate conditioner/rust inhibitor,
following instructions on container.
SPECIFICATION
Cooling system capacity Approx 17 L (18 qt)
NOTE: Add conditioner every 500 hours or 6 months, or if

you replace 1/3 or more of coolant.
John Deere Liquid Coolant Conditioner does not

protect against freezing.
TX,80,RR2732 –19–20DEC94–1/1
80–10 121997
PN=164
CHECK TRANSMISSION ACCUMULATOR—
DIRECT DRIVE MACHINES
CAUTION: Contents of this accumulator are

under pressure.
T6891AT –UN–10FEB89
1. Refer to proper Machine Model Technical
Manual for disassembly or charging
instructions and equipment required.
2. Charge with DRY NITROGEN only.
1. Remove operator’s station floor plate.
SPECIFICATION
Accumulator charge pressure 1034 ± 56 kPa
(150 ± 8 psi)
2. Using an air pressure gauge (A) check accumulator

pressure at air fitting (B).
03T,85,K122 –19–14APR94–1/1
CHANGE HYDRAULIC OIL
IMPORTANT: DO NOT operate engine without oil in

reservoir.
1. Remove fill cap (A).
–UN–17AUG90
T7349BP
TX,85,FF1949 –19–08JAN91–1/5
85–1 121997
PN=165
2. EARLIER MACHINES: Remove plug (A) and drain oil.

Allow oil to drain into a container. Dispose of waste oil
properly.
LATER MACHINES: Remove right side panel (A).
T6499ED –UN–09FEB89
Remove plug (A) and drain oil. Allow oil to drain into a
container. Dispose of waste oil properly.
Earlier Machines
T112374 –UN–09DEC97
Later Machines
TX,85,FF1949 –19–08JAN91–2/5
85–2 121997
PN=166
3. While oil is draining, clean hydraulic oil suction screen.
4. Remove starting aid canister bracket and disconnect

suction hose.
5. Remove access cover (A) by removing mounting nuts.
–UN–30NOV94
T8364AX
TX,85,FF1949 –19–08JAN91–3/5
6. Remove filter (A) from cover (B) and clean.
7. Replace filter (A) if screen is damaged or sealing

O-ring is cut.
8. Install cover (B) with a new gasket (C).
9. Install drain plug.
10. Replace hydraulic reservoir oil and breather filter.

(See Change Hydraulic Reservoir Breather filter and
Hydraulic oil Filter in chapter 80 of this manual.)
SPECIFICATIONS
Oil capacity 41.5 L (11 gal)
TX,85,FF1949 –19–08JAN91–4/5
85–3 121997
PN=167
11. Fill reservoir with oil. (See Fuels and Lubricants

chapter.)
12. Oil level must be halfway up in window (A).
T7349BQ –UN–18SEP90
TX,85,FF1949 –19–08JAN91–5/5
CHANGE TRANSMISSION OIL AND CLEAN

SUCTION SCREEN
1. Remove plug (A) to drain oil. Allow oil to drain into a

container. Dispose of waste oil properly.
–UN–09FEB89
2. While transmission is draining, change transmission
filter. (See Change Transmission Oil Filter in
Maintenance-Every 500 Hours chapter.)
T6499DQ
Earlier Machines
T6891AR –UN–10FEB89
Later Machines
TX,85,FF1952 –19–14APR94–1/4
85–4 121997
PN=168
3. If equipped with winch, remove plug (A) to drain winch

oil. Allow oil to drain into a container. Dispose of waste
oil properly.
For Direct Drive Machines Only, follow procedural

steps 4 through 11. For Torque Converter Machines,
follow steps 12 through 19.
–UN–27SEP90
T7348AA
TX,85,FF1952 –19–14APR94–2/4
85–5 121997
PN=169
4. Remove operator’s station floor plate.
5. Remove drain plug from housing (C). The drain plug is

located on the bottom of the housing.
6. Loosen hose strap (A) and remove from housing.
–UN–10FEB89
7. Remove cap screws (B) to remove hose from housing
cover with suction screen.
T6520AK
8. Clean screen in a non-flammable solvent.
9. Apply thin film of oil to new O-ring and install O-ring,

suction screen, drain plug, and hose.
IMPORTANT: Damage to pump may occur if pump is

not primed with oil. The transmission
reservoir is lower than pump inlet and
pump cannot draw oil fast enough after
initial start up.
10. Pour oil down suction hose and squirt oil into inlet
side of pump.
11. Connect hose.
TX,85,FF1952 –19–14APR94–3/4
85–6 121997
PN=170
12. Install transmission drain plug and, if equipped, winch

drain plug.
13. Fill transmission and winch (if equipped) with oil. (See
SPECIFICATION
Capacity without 4000 Series 80.25 L (21.2 gal)
Winch
Capacity with 4000 Series Winch 115.45 L (30.5 gal)
Machines without a winch:
Remove dipstick/fill cap. Add oil. Run engine;

transmission oil level must be checked after engine
has run 2—3 minutes. Stop engine.
Machines with a winch:
Remove plug (A) and fill winch with oil. Fill
–UN–18SEP90
transmission with oil. Install winch fill plug and
transmission dipstick/fill cap. Run engine 10 minutes
to completely fill winch with oil. Put winch in freespool
position. Stop engine. Fill transmission with remainder
T7374CF
of oil.
14. Check oil level. Oil must be between ADD and FULL
marks on dipstick (A).
Check for leaks around filter base. Tighten filter only

enough to stop leaks.
TX,85,FF1952 –19–14APR94–4/4
85–7 121997
PN=171
CHANGE FINAL DRIVES OIL
1. Remove fill plug (A) on each side of machine.
2. Remove drain plug (B) on each side of machine and

drain all oil. Allow oil to drain into a container. Dispose
–UN–09NOV92
of waste oil properly.
SPECIFICATION
Oil capacity:
T7883AJ
450G (each) 6.6 L (1.75 gal)
450G-LT (each) 8.5 L (2.25 gal)
450G Shown
550G, 650G (each) 9.5 L (2.5 gal)
3. Install drain plugs.
4. Fill housing with oil until oil flows from fill plug opening.
(See Fuels and Lubricants chapter.)
5. Install fill plugs.
TX,85,RR2733 –19–12JAN93–1/1
CHECK ENGINE SPEED
1. Warm engine to normal operating temperature.
2. Use tachometer to check engine speeds:
SPECIFICATION
Slow idle (torque converter 825 ± 25 rpm
machines)
Slow idle (direct drive machines) 900 ± 25 rpm
Fast idle 2275 ± 25 rpm
If engine speeds need adjustment, see your authorized

dealer.
04T,90,K182 –19–20DEC94–1/1
85–8 121997
PN=172
CHECK AND ADJUST ENGINE SPEED CONTROL LINKAGE WITHOUT DECLUTCH
T112525 –UN–18DEC97
(S.N. —840460 Shown)
A—Decelerator Rod E—Rod I—55 mm (2.2 in.) L—Cable Yoke Pin

B—Return Spring F—Upper Pedal Stop J—85 mm (3.3 in.) M—(S.N. 804208— ) Speed
C—Arm G—Lower Pedal Stop K—Cable Bracket Cap Direction Lever Design
D—Bellcrank Arm H—Friction Spring Nut Screw Change
SPECIFICATIONS 1. Move speed control lever to fast idle position.

Injection pump arm over travel 1—5 mm Adjust pedal upper stop (F) so pedal is 85 mm (3.3
(0.04—0.20 in.) in.) (J) above floor plate.
Speed control lever tension 44.5 N
(10 lb force) 2. Depress pedal and adjust pedal lower stop (G) so
Decelerator pedal is 55 mm (2.2 in.) (I) above floor plate.
Pedal travel 50 mm (2.5 m)
Pedal force 26.7—37.8 N
3. Adjust length of rod (E) at yoke so bellcrank arm
(6—8.5 lb force) (D) is horizontal (straight forward) when pedal is in
Return spring working length 190 mm (7.5 in.)
mid stroke position. (Left bellcrank arm should be
vertical or straight down.)
IMPORTANT: Distances (I and J) are measured
from floor plate to bottom of pedal
shank directly below front edge of
pedal.
TX,90,RR4727 –19–20DEC94–1/2
85–9 121997
PN=173
4. Adjust decelerator rod yoke (A) so high idle 7. Adjust decelerator pedal return spring (B) to a
over-travel on pump arm is 1—5 mm (0.04—0.20 spring length of 190 mm (7.5 in.) when pump arm is
in.). Measure from top of injection pump short lever in slow idle position. Pedal force should be 26.7—
to edge of long lever. Pedal stop (F) may need 37.8 N (6—8.5 lb force).
adjustment to get overtravel.
8. With hand lever in slow idle position, adjust lower
5. Adjust speed control cable and angle bracket to get pedal stop (G) to just contact pedal and tighten jam
over-travel when hand lever is in slow and fast idle nut.
positions.
6. Adjust friction spring nut (H) to get 35.6 N (8 lb

force) on hand lever.
TX,90,RR4727 –19–20DEC94–2/2
85–10 121997
PN=174
CHECK AND ADJUST ENGINE SPEED CONTROL LINKAGE WITH DECLUTCH—DIRECT

DRIVE MACHINES—IF EQUIPPED
T8368BI –UN–15DEC94
(S.N. —840460 Shown)
A—Speed Control Lever E—Switch I—(S.N.804208— ) Speed

B—Linkage Rod Yoke F—Bellcrank Direction Lever Design
C—Low Idle Stop Screw G—Low Idle Change
D—Retainer H—High Idle
1. Put speed control lever (A) in high idle position. 5. Adjust low idle stop screw to provide 1—3 mm
(0.04—0.125 in.) clearance between switch (E) and
2. Adjust linkage rod (B) so lowest point of pedal pad bellcrank (F) with pedal fully depressed.
is 101 mm (4.0 in.) from platform floor.
6. Tighten jam nut on low idle stop screw.
3. Loosen low idle stop screw jam nut and back out
low idle stop screw (C).
4. Move speed control lever to low idle position. Adjust

retainer (D) so that hook just contacts operator side
of firewall.
TX,85,RR4728 –19–20DEC94–1/1
85–11 121997
PN=175
CLEAN ENGINE CRANKCASE VENTILATION

TUBE
Clean the tube when you measure and adjust engine

valve lash (clearance).
–UN–30NOV94
T8368AS
(S.N. —840460)
T112373 –UN–09DEC97
(S.N. 840461— )
TX,85,FF1956 –19–20DEC94–1/1
85–12 121997
PN=176
MEASURE AND ADJUST ENGINE VALVE

CLEARANCES (S.N. —840460)
1. Disconnect crankcase ventilation tube from rocker arm

cover. Clean tube with solvent or diesel fuel. Check
that O-ring in rocker arm cover is in good condition.
T6872AF –UN–18OCT88
2. Remove rocker arm cover.
3. Set engine to No. 1 or No. 4 "TDC-Compression" using

the JDE-81-1 Engine Rotation Tool and the JDE-81-4
Timing Pin. Rotate flywheel until timing pin fits into hole
in flywheel.
A—No. 1 TDC Compression Stroke
B—No. 1 TDC Exhaust Stroke
4. Determine what cylinder (1 or 4) is pinned by moving C—Fan End of Engine
push rods of each cylinder (1 or 4). Only the cylinder
that has both the intake and exhaust push rod loose is
pinned by the JDE-81-4 Timing Pin. Both push rods
loose indicates the piston is at top dead center (TDC)
on compression stroke.
VALVE SPECIFICATIONS
Intake Valve Clearance 0.36 mm (0.014 in.)
Exhaust Valve Clearance 0.46 mm (0.018 in.)
5. If No. 1 cylinder is pinned. Set exhaust valves No. 1,

and No. 3. Set intake valves (B) No. 1 and 2.
If No. 4 cylinder is pinned. Set exhaust valves (A) No.

2 and No. 4. Set intake valves (B) No. 3 and 4.
6. Remove timing pin, rotate flywheel one revolution

(360°), and insert timing pin. Set valve clearance.
7. Clean cylinder head and rocker arm cover mating

surfaces.
8. Install a new rocker arm cover gasket. DO NOT use

any sealant on the gasket.
9. Install rocker arm cover. Tighten cap screws to 108

N•m (96 lb-in). Do not overtighten cap screws.
10. Remove flywheel turning tool and install timing pin.
TX,85,RB80 –19–08DEC97–1/1
85–13 121997
PN=177
DRAIN THE COOLING SYSTEM
Drain and flush cooling system using commercial

products, replace thermostats, and refill with new coolant.
CAUTION: DO NOT remove the radiator fill cap

unless the engine is cool. Then loosen the cap
slowly to the stop. Release all pressure before
removing the cap.
1. Release pressure and then remove cap.
2. Allow coolant to drain into a container. Dispose of

waste coolant properly.
3. Open radiator drain cock (A).
4. Open drain cock (B) to drain engine block. Use a

container to capture coolant.
NOTE: Earlier machines used a drain plug.
5. Flush system using commercial product.
6. Tighten the drain cock.
7. Add new coolant. (See Fuels and Lubricant chapter.)
Later Machines
TX,85,RR4686 –19–20DEC94–1/1
85–14 121997
PN=178
DIESEL ENGINE COOLANT
The engine cooling system is filled to provide heavy-duty diesel engines, for protection against
year-round protection against corrosion and cylinder corrosion and cylinder liner erosion and pitting.
liner pitting, and winter freeze protection to -37°C
(-34°F). A 50 percent mixture of ethylene glycol engine coolant
in water provides freeze protection to -37°C (-34°F). If
The following engine coolant is preferred for service: protection at lower temperatures is required, consult
your John Deere dealer for recommendations.
• John Deere PREDILUTED ANTIFREEZE/SUMMER
COOLANT Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
The following engine coolant is also recommended: water is recommended for mixing with ethylene glycol
base engine coolant concentrate.
• John Deere ANTIFREEZE/SUMMER COOLANT
CONCENTRATE in a 40 to 60 percent mixture of IMPORTANT: Do not use cooling system sealing
concentrate and quality water. additives or antifreeze that contains
sealing additives.
Other low silicate ethylene glycol base engine coolants
for heavy-duty diesel engines may be used if they Coolant drain intervals
meet one of the following specifications:
Drain and flush the cooling system and refill with fresh
• ASTM D5345 (prediluted coolant) coolant every 2 years or 2000 hours of operation.
• ASTM D4985 (coolant concentrate) in a 40 to 60
percent mixture of concentrate with quality water When John Deere PREDILUTED
ANTIFREEZE/SUMMER COOLANT is used, the
Coolants meetings these specifications require use of service interval may be extended to 5 years or 5000
supplemental coolant additives, formulated for hours of operation.
DX,COOL3 –19–12SEP95–1/1
85–15 121997
PN=179
FILL THE COOLING SYSTEM
CAUTION: DO NOT remove radiator cap unless

engine is cool. Then turn the cap slowly to the
stop. Release all pressure before removing cap.
SPECIFICATION
Cooling system capacity 17 L (18 qt)
Coolant level must be at bottom of the filler neck.
FREEZING TEMPERATURES: Fill with permanent-type,

low silicate, ethylene glycol antifreeze (without stop-leak
additive) and clean, soft water. Add TY16004 John Deere
Coolant Conditioner or equivalent.
IMPORTANT: Use only permanent-type, low silicate,

ethylene glycol base antifreeze in
coolant solution. Other types of
antifreeze may damage cylinder seals.
NOTE: All machines are shipped form the factory with a

50-50 mixtures (antifreeze and soft water) for
protection to -34°C (-30°F). Adjust mixture
accordingly to provide freeze protection for your
machine.
TX,85,FF1966 –19–20DEC94–1/1
85–16 121997
PN=180
CHANGING AIR CLEANER ELEMENTS
1. Remove cover.
2. Remove wing nut to remove primary element (A).
T6119AF –UN–01NOV88
3. Remove wing nut to remove secondary element (B).
4. Clean air cleaner canister.
5. Install new elements.
6. Install cover.
TX,90,FF1964 –19–17AUG93–1/1
85–17 121997
PN=181
MEASURE AND ADJUST POWERTECH
ENGINE VALVE CLEARANCES (S.N.
840461— )
1. Disconnect crankcase ventilation tube from rocker arm

cover. Clean tube with solvent or diesel fuel. Check
that O-ring in rocker arm cover is in good condition.
2. Remove rocker arm cover.
3. Set engine to No. 1 or No. 4 “TDC-Compression” using

the JDE-81–1 Engine Rotation Tool and the JDE-81–4
Timing Pin. Rotate flywheel until timing pin fits into hole
A—No. 1 TDC Compression Stroke
in flywheel. B—No. 1 TDC Exhaust Stroke
C—Fan End of Engine
4. Determine what cylinder (1 or 4) is pinned by moving
push rods of each cylinder (1 or 4). Only the cylinder
that has both the intake and exhaust push rod loose is
pinned by the JDE-81–4 Timing Pin. Both push rods
loose indicates the piston is at top dead center (TDC)
on compression stroke.
5.
VALVE SPECIFICATIONS
Intake Valve Clearance 0.36 mm (0.014 in.)
Exhaust Valve Clearance 0.46 mm (0.018 in.)
If No. 1 cylinder is pinned, set exhaust valve No. 1, and

No. 3. Set intake valves (B) No. 1 and 2.
If No. 4 cylinder is pinned, set exhaust valves (A) No. 2

and No. 4. Set intake valves (B) No. 3 and 4.
6. Remove timing pin, rotate flywheel one revolution

(360°), and insert timing pin. Set valve clearance.
7. Clean cylinder head and rocker arm cover mating

surfaces.
8. Install a new rocker arm cover gasket. DO NOT use

any sealant on the gasket.
9. Install rocker arm cover. Tighten cap screws to 108

N•m (96 lb-in). Do not overtighten cap screws
10. Remove flywheel turning tool and install timing pin.
TX,86,RB81 –19–08DEC97–1/1
86–1 121997
PN=182
Maintenance
CHECKING HOSES AND RADIATOR
Check hoses (A) for cracks and leaks. Tighten clamps.
Check radiator for dirt, damage, leaks, and loose or

broken mountings. Clean radiator fins.
Proper belt tension is essential to the operation of the

cooling system. Replace hoses, belts, and thermostats
periodically, BEFORE they fail.
(S.N. —840460)
T112376 –UN–09DEC97
(S.N. 840461— )
TX,85,FF1959 –19–20DEC94–1/1
90–1 121997
PN=183
Maintenance
TEST THE COOLANT FREEZE—

PROTECTION LEVEL
See your John Deere dealer for JT05460

SERVICE-GARD coolant and battery tester. Follow
directions included with the tester.
T85402 –UN–10NOV88
If you operate your engine in extremely cold temperatures,
see your John Deere dealer for information on arctic
operation.
UNDEFINED T82,EXMA,CK –19–28JUL94–1/1
DO NOT SERVICE INJECTION NOZZLES
IMPORTANT: Do not service or remove injection

nozzles. The service life of the injection
nozzles may be shortened by:
Overheating Improper operation Poor

quality fuel Excessive idling
If injection nozzles are not working correctly or are dirty,

the engine will not run normally. (See your authorized
dealer for service.)
T82,SKMA,A –19–28JUL94–1/1
90–2 121997
PN=184
Maintenance
DO NOT CHANGE INJECTION PUMP
IMPORTANT: Never steam clean or pour cold Changing the injection pump in any way not approved
water on an injection pump while the by the manufacturer will end the warranty. (See your
pump is running, or while it is still copy of the John Deere warranty on this machine.)
warm. To do so may cause seizure
of pump parts. Do not service an injection pump that is not operating
correctly. (See your authorized injection pump service
Clean trash regularly from under center.)
injection pump.
04T,90,C83 –19–16AUG93–1/1
DRAINING FUEL FILTER SEDIMENT
Drain water and sediment as necessary.
1. Loosen drain screw (A). Drain liquid for several

seconds.
T6201AM2 –UN–18OCT88
2. Tighten drain screw.
3. Bleed fuel system. (See Change Fuel Filter in

Maintenance-Every 500 Hours chapter.)
(S.N. —840460)
T112444 –UN–09DEC97
(S.N. 840461— )
T82,90,C1 –19–03FEB92–1/1
90–3 121997
PN=185
Maintenance
CHECKING FUEL FILLER SCREEN
1. Remove fill cap and snap ring.
2. Clean screen, as necessary, to remove any debris.

Use solvent or diesel fuel.
T6884AZ –UN–10FEB89
3. Replace screen if damaged.
04T,90,K188 –19–08FEB93–1/1
CLEANING FUEL TANK OUTLET SCREEN—

EARLIER MACHINES
If screen is plugged, debris must be removed and strainer

cleaned.
1. Drain fuel tank. Capacity is 159 L (42 gal).
TX,90,FF1968 –19–14APR94–1/3
2. Disconnect fuel line (B) from fuel tank by removing nut

(A).
3. Loosen shut-off valve from fuel tank.
–UN–10FEB89
T6548AB
TX,90,FF1968 –19–14APR94–2/3
90–4 121997
PN=186
Maintenance
4. Outlet screen (A) from tank will drop when shut-off

valve is removed.
5. Clean screen with solvent or diesel fuel. Replace

screen, if damaged.
6. Flush debris from tank.
7. Inspect O-ring (B) for damage before installing screen

and fittings. Fill tank.
TX,90,FF1968 –19–14APR94–3/3
CLEANING FUEL TANK OUTLET SCREEN—

LATER MACHINES
If screen is plugged, debris must be removed and strainer

cleaned.
T7349BT –UN–18SEP90
1. Drain fuel tank. Capacity is 159 L (42 gal).
2. Disconnect fuel line from fuel tank by removing nut (A).
3. Remove plug (B) from fuel tank.
TX,90,FF1969 –19–14APR94–1/2
90–5 121997
PN=187
Maintenance
4. Outlet screen (A) from tank will drop when plug is

removed.
5. Clean screen with solvent or diesel fuel. Replace

screen, if damaged.
–UN–18SEP90
6. Flush debris from tank.
7. Inspect O-ring (B) for damage before installing screen

and fittings. Fill tank.
T7374AE
TX,90,FF1969 –19–14APR94–2/2
FUEL SHUT-OFF
CAUTION: Handle fuel carefully. Shut the

engine off. Do not smoke while you work on
fuel system.
–UN–09FEB89
1. Loosen cap screw(s) (A), move latch (B) to one side
(earlier machines only), and open or remove access
cover.
T6499CN1
Earlier Machines
–UN–17AUG90
T7349BX
Later Machines
A—Cap Screw
B—Latch
C—Access Cover
TX,90,FF1962 –19–14APR94–1/2
90–6 121997
PN=188
Maintenance
2. EARLIER MACHINES: Push knob (A) to shut off fuel to

engine and pull knob to release fuel to engine.
LATER MACHINES: Turn petcock clockwise to shut off

fuel to engine. Turn petcock counterclockwise to
release fuel to engine.
–UN–09NOV92
NOTE: Cover removed for clarity of photograph.
T7883AK
Earlier Machines
–UN–18SEP90
T7349BS
Later Machines
TX,90,FF1962 –19–14APR94–2/2
INSPECT AIR CLEANER ELEMENTS

RESTRICTION INDICATOR
1. Push button (A) on end of air restriction indicator to

reset the indicator.
T6499AC –UN–09FEB89
TX,90,RB89 –19–16DEC97–1/1
90–7 121997
PN=189
Maintenance
CLEANING DUSTY PRIMARY ELEMENT
1. Tap element with the palm of you hand, NOT ON A
T47764 –UN–09NOV88
HARD SURFACE.
CAUTION: Reduce compressed air to less than

210 kPa (2.1 bar) (30 psi) when using for
cleaning purposes. Clear area of bystanders,
guard against flying chips, and wear personal
protection equipment including eye protection.
2. If this does not remove dust, use compressed air under

30 psi (210 kPa) (2.1 bar).
3. Direct air up and down the pleats from inside to

outside. Be careful not to make a break in the element.
TX,55,FF1266 –19–08FEB93–1/1
INSPECTING ELEMENT
IMPORTANT: A damaged or dirty element may cause

engine damage. Install a new primary
element:
T90684 –UN–10NOV88
1. If the element shows damage.
2. If element will not clean.
Install a new secondary element:
1. If the primary element is damaged

and needs to be replaced.
2. If the element is visibly dirty.
Do not clean a secondary element.

Install a new element carefully centering
it in the canister.
1. Inspect element and gasket for damage.
2. Air restriction indicator will not signal correctly if an

element has a break or is not correctly sealed in air
cleaner housing. Throw away element that has the
slightest damage. If gasket is broken or missing, install
a new element.
TX,55,FF1268 –19–09JUL93–1/1
90–8 121997
PN=190
Maintenance
PRECAUTIONS FOR ALTERNATOR AND REGULATOR
When batteries are connected, follow these rules: 6. Connect batteries or a booster battery in the correct
polarity (positive [+] to positive [+] and negative [-]
1. Disconnect negative (-) battery cable when you to negative [-]).
work on or near alternator or regulator.
7. Do not disconnect the batteries when engine is
2. DO NOT TRY TO POLARIZE ALTERNATOR OR running and alternator is charging.
REGULATOR.
8. Disconnect battery cables before you connect
3. Be sure alternator wires are correctly connected battery charger to the batteries.
BEFORE you connect batteries.
4. Do not ground alternator output terminal.
5. Do not disconnect or connect any alternator or

regulator wires while batteries are connected or
while alternator is operating.
T82,EXMA,I –19–03AUG92–1/1
90–9 121997
PN=191
Maintenance
SERVICE BATTERIES CAREFULLY

hydrometer.
Always remove grounded (—) battery clamp

first and replace it last.

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.

the acid.
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do
not exceed 1.9 L (2 quarts).
If electrolyte spills on the floor, use one of the following

mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda
in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia
in 4 L (1 gal) water.
04T,90,K153 –19–12MAY93–1/2
90–10 121997
PN=192
Maintenance
IMPORTANT: Electrolyte can damage paint and metal

surfaces of your machine. Do not
overfill the battery cells.
04T,90,K153 –19–12MAY93–2/2
90–11 121997
PN=193
Maintenance
CHECKING ELECTROLYTE SPECIFIC

GRAVITY

hydrometer.


eyes.

added.

the acid.
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do
not exceed 1.9 L (2 quarts).
Check the specific gravity of electrolyte in each battery

cell.
T85402 –UN–10NOV88
04T,90,FF20 –19–12MAY93–1/2
90–12 121997
PN=194
Maintenance
See your John Deere dealer for JD05460

SERVICEGARD battery and coolant tester. Follow
directions included with the tester.
A fully charged battery will have a corrected specific

gravity reading of 1.260. If the reading is below 1.200,
charge the battery.
NOTE: In tropical areas, use 1.225 for the full charge

reading. In cold areas, use 1.280 for the
full-charge reading.
SERVICEGARD is a trademark of Deere & Company 04T,90,FF20 –19–12MAY93–2/2
USING BATTERY CHARGER
CAUTION: Disconnect battery ground before

you charge batteries in the machine to prevent
damage to electrical components.
A battery may explode if charged when it is
frozen. Warm battery to 16°C (60°F) before
charging.
A battery charger may be used as a booster to start

engine.
IMPORTANT: Do not use battery charger as a booster

if a battery has a 1.150 specific gravity
reading or lower. Turn off charger
before connecting or disconnecting it.
T82,EXMA,G –19–03AUG92–1/1
90–13 121997
PN=195
Maintenance
REPLACING BATTERIES
Batteries are located under the operator’s seat. Remove

two cap screws from floorplate. Move seat back to farthest
position and lift seat forward.
CAUTION: Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.

added.

the acid.
1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
Your machine will have one or two 12 volt batteries with

negative (-) ground. Use only batteries meeting the
following specifications:
Battery Group 31
625 cold cranking amp at -18°C 160 minutes reserve capacity at
(0°F) 25 amps
950 cold cranking amps at -18°C 190 minutes reserve capacity at
(0°F) 25 amps (Cold weather climate)
TX,90,RB82 –19–08DEC97–1/1
90–14 121997
PN=196
Maintenance
REMOVING BATTERIES
Batteries are located under the operator’s seat. Remove

two cap screws from floorplate. Move seat back to farthest
position and lift seat forward.

hydrometer.

1. Disconnect negative battery cable(s) first then positive

(+) cable(s).
2. Remove nuts to remove hold frame(s).
3. Lift out battery/batteries.
4. Check cables and clamps for damage and wear.
5. Make certain that the battery/batteries are fully

charged.
6. Set the battery/batteries in the compartment making

sure they are level.
7. Install hold down frames.
8. Connect cables; positive then negative.
TX,90,RB83 –19–08DEC97–1/1
90–15 121997
PN=197
Maintenance
RESETTING CIRCUIT BREAKERS
The three circuit breakers are located under the front dash
of the machine.
If the circuit breaker opens because of a short circuit or

overloading, lights will go out.
Turn off the light switch (if equipped) and key switch. Wait
one minute before starting machine or turning on lights.
The circuit breaker will reset itself.
If circuit continues to open, lights flicker, become dim, or

engine does not run smoothly, see your authorized dealer.
If cigar lighter does not work, remove rear panel of cowl.

Insert a wire in the small hole on the end of the lighter to
reset the circuit breaker.
04T,90,K203 –19–16AUG93–1/1
90–16 121997
PN=198
Maintenance
CHANGING REVERSE WARNING ALARM

VOLUME
IMPORTANT: The reverse warning alarm is set on

high volume at the factory. It may be
necessary to adjust the volume to meet
local regulations.
NOTE: Alarm is located on machine frame under the rear

cab floor plate.
1. To change alarm to low volume, remove nut (A) and

disconnect wire from "POS HI" terminal.
T7673AI –UN–16DEC91
2. Remove nut (C) and shorting bar (B).
3. Attach wire to "POS LOW" terminal (D). Install nut and

tighten securely. Save shorting bar for future use.
T7673AH –UN–16DEC91
A—Nut
B—Shorting Bar
C—Nut
D—Terminal
TX,90,RR2514 –19–14APR94–1/1
90–17 121997
PN=199
Maintenance
CHECK NEUTRAL START SYSTEM
CAUTION: Avoid possible injury or death. Be

sure all people are away from machine.
1. Apply brake and engage lock.
2. Move shift lever to each gear position and try to start

engine.
If engine starts, see your authorized dealer.
04T,90,K204 –19–16AUG93–1/1
ADDING ATTACHMENTS/ACCESSORIES TO
ROLL-OVER PROTECTIVE STRUCTURE
(ROPS)
Do not add attachments or accessories to the ROPS

without contacting your John Deere dealer for information.
Improper attachment may impair the protection offered by
the ROPS.
04T,90,K117 –19–16MAR88–1/1
90–18 121997
PN=200
Maintenance
TRACK SAG GENERAL INFORMATION
Properly adjusted tracks prolong chain life. To get the

maximum life out of track bushings, keep the track sag
properly adjusted. Improperly adjusted track wears at a
more rapid rate.
–UN–31JUL92
A tight track causes higher loading which will increase
wear on the pins, bushings, links, sprocket and front idler.
The graph (A) shows how the loading on the track chain
T7800AJ
increases significantly when tracks are too tight. Also, a
tight track requires more horsepower, increasing fuel
consumption and decreasing productivity. Track Tension (lb) Vs Track Sag (in.)
Periodically check track sag. In some applications, tracks

may require adjustment several times during a working
day. This is especially true when working in different
conditions on the same job site, as moisture content of
the soil changes.
Tracks should always be adjusted in the actual operating

conditions. If material packs in the undercarriage, the
tracks should be adjusted with the material packed in the
components.
When packing occurs, track sag is taken up and must be

loosened to extend wear life. The track spring will recoil
and the machine will continue to operate with tight track.
However, continued operation without loosening the tracks
will result in excessive pin and bushing wear, sprocket
popping, tooth tip wear, and excessive loads on the entire
undercarriage and final drive system.
With sealed chain, internal pin and bushing wear creates
sag which reduces the effects of packing. However, if a
sealed chain is too tight, accelerated bushing wear
occurs.
Lubricated chain is different due to the absence of internal

pin and bushing wear. It is absolutely essential to keep
sag adjusted to prevent accelerated bushing outside
diameter wear.
Maintaining track sag is very important regardless of the

type of track being used.
TX,90,RR2516 –19–20DEC94–1/1
90–19 121997
PN=201
Maintenance
REMOVE AND INSTALL LUBRICATED

TRACK CHAIN—SPLIT LINK—EARLIER
MACHINES
1. Block track at front idler.
–UN–30NOV94
2. Put blocks (A) on top of recoil spring cover to keep
chain at correct level.
3. Release track tension. (See Adjusting Track Sag in
T8368AV
Chapter 55 of this manual.)
TX,90,RR2720 –19–20DEC94–1/6

chain. Do not stand in line of track chain when
shoe is removed. Split link may fall apart once
cap screws are removed from shoe.
4. Rotate track until split link, pin end, is at 11 o’clock
T6549BQ –UN–10FEB89
position (A) on idler.
5. Remove shoe at split link.
TX,90,RR2720 –19–20DEC94–2/6
90–20 121997
PN=202
Maintenance
6. Place 1/4 in. nuts (A) on pin end of split link.
Special cap screws for the DF1067 tool are: Four 1/2 x
2-1/2 in., "F" Grade—Fine (450G, 455G, 550G) Four
5/8 x 2-1/2 in., "F" Grade—Fine (555G, 650G)
T6549BR –UN–10FEB89
See your John Deere dealer for fabricated tool.
TX,90,RR2720 –19–20DEC94–3/6
90–21 121997
PN=203
Maintenance
NOTE: The John Deere Dealer Fabricated, Lubricated

Track Split Master Link Separator (A), tool number
DF1067, can also be used to separate master
link.
7. Install shoe using two cap screws in bushing half of
–UN–10FEB89
split link. Tighten bolts evenly to disassemble links.
Strike shoe while tightening cap screws if necessary.
8. Remove shoe.
T6549BS
9. Install the four cap screws to full thread engagement to
protect link surface during removal and installation.
T6549BT –UN–10FEB89
TX,90,RR2720 –19–20DEC94–4/6

track. Do not stand in line of track chain as it
will fall to the ground.
10. Alternately hammer down on pin end and up on

underside of shoe on bushing end to separate split
T6549BU –UN–10FEB89
link.
11. Locate split link, pin end, at 11 o’clock (12 o’clock on

new track) position on front idler.
12. Bring other end of chain over carrier roller.
13. Apply NEVER-SEEZ to mating surfaces of split link.
14. Use a come-along device to engage split link halves.

Bushing end must go over pin end.
NEVER-SEEZ is a trademark of Emhart Chemical Group TX,90,RR2720 –19–20DEC94–5/6
90–22 121997
PN=204
Maintenance
15.
SPECIFICATION
Split master link bolt torque:
450G, 550G (1/2 in. dia. cap 61 N•m (45 lb-ft) plus additional
screw) 1/2 (180°) turn
650G
Lubricated chain 149 N•m (110 lb-ft) plus
additional 1/6 (60°) turn with
NEVER-SEEZ
Alternately strike bushing end cap screws with lead

hammer while holding a bar under pin end.
16. Remove cap screws. Apply NEVER-SEEZ to threads

and under screw heads.
17. Install shoe. Start bolts by hand to avoid

crossthreading.
18. Tighten cap screws to specifications using a

criss-cross sequence.
19. Re-torque all bolts in the exact order they were

torqued originally.
TX,90,RR2720 –19–20DEC94–6/6
REMOVE AND INSTALL LUBRICATED

TRACK CHAIN—SINGLE TOOTH SPLIT
LINK—LATER MACHINES
1. Place blocks (A) on top of recoil spring cover to keep

chain at correct level. Also block chain at front of idler. –UN–30NOV94
T8368AV
TX,90,RR4687 –19–20DEC94–1/4
90–23 121997
PN=205
Maintenance
2. Rotate track until split link, pin end, is at 11 o’clock

position (A) on idler.
3. Release track tension through grease outlet hole (B).

(See Adjusting Track Sag in chapter 55 of this
manual.)
TX,90,RR4687 –19–20DEC94–2/4

chain. Do not stand in line of track chain when
track shoe is removed. Once cap screws are
removed from shoe, the separated chain could
fall to the ground.
4. Remove shoe at master link by removing cap screws

(A) and (B). Single tooth split links (C) may separate
once cap screws are removed.
T8381AD –UN–10DEC94
TX,90,RR4687 –19–20DEC94–3/4
90–24 121997
PN=206
Maintenance
NOTE: Cap screws (B) are shorter in length than cap

screws (A) and must be installed in the track shoe
mounting holes that are nearer the front of the
machine.
5.
SPECIFICATION
Split master link bolt torque:
450G, 550G
(9/16 in. dia. cap screw) 88 N•m (65 lb-ft) plus additional
1/2 (180°) turn
650G
Lubricated chain (5/8 in. dia. cap 163 N•m (120 lb-ft) plus
screw) additional 1/2 (180°) turn with
NEVER-SEEZ
After removal of cap screws, apply NEVER-SEEZ to

threads and under cap screw heads.
6. Install shoe. Start cap screws by hand to avoid

crossthreading.
7. Tighten cap screws to specifications using a

criss-cross sequence.
8. Re-torque all cap screws in the exact order they were

torqued originally.
TX,90,RR4687 –19–20DEC94–4/4
CHECK FRONT IDLER VERTICAL

MOVEMENT
Drive machine onto wood block. Make sure block is under

front idler.
–UN–09FEB89
Use feeler gauge to measure gap between idler bracket

and track frame. If gap is more than 1.8 mm (0.070 in.).
(See Idler Adjustment Procedure in this chapter.)
T6499DZ
04T,90,K219 –19–08FEB93–1/1
90–25 121997
PN=207
Maintenance
IDLER HEIGHT ADJUSTMENT
Adjust idler height to get optimum gradability.
NOTE: Adjust inside and outside shim packs at the same

time.
–UN–10FEB89
Do steps 1—4 if the track is removed. Do steps 5—8 if
track is still on unit.
T6555DI
1. Rotate idler 360° to find maximum runout point.
Position maximum runout point at (C). Place straight
edge on bottom side of several track rollers (A) and
under each tread surface of idler.
2. Measure distance (B) from straight edge to idler.
SPECIFICATIONS
Idler height:
450G, 550G, 650G 8 mm (0.31 in.) maximum
3. Adjust shims as required. Follow steps 11—14 and

16—18, below.
4. Install tracks.
04T,90,M194 –19–12JAN93–1/8
5. Place machine on flat concrete or asphalt.
6. Move unit so grouser tip is directly under centerline of

idler.
If grouser tip touches floor before it gets to centerline

T6555DK –UN–25MAY89
or if too high (over 2 mm [0.08 in.] off the ground),

adjust idler height. Shoe tips wear in a crown shape,
measure at the middle of shoe width.
NOTE: Track tension may need to be released to align

cap screws retaining bottom wear strip with
access slots in track frame.
7. Raise and block blade.
04T,90,M194 –19–12JAN93–2/8
90–26 121997
PN=208
Maintenance
8. Adjust idler height by adding or subtracting shims (D).

Then adjust shim pack (F) to obtain vertical clearance
of 0.5—1 mm (0.020—0.040 in.) measured at shim
pack (D) with machine on ground.
T6555DJ –UN–25MAY89
A—Guide Plate
B—Guide Outer Shims
C—Idler Block
D—Top Shims
E—Wear Strip
F—Bottom Shims
G—Track Frame
04T,90,M194 –19–12JAN93–3/8
9. Remove track shoe (A) for access to shims and cap

screws on inside.
10. Remove cap screws (B).
11. Remove bottom wear strip and shims from both sides.
–UN–10FEB89
T6549BV
04T,90,M194 –19–12JAN93–4/8
90–27 121997
PN=209
Maintenance
12. Remove guide plates.
13. Remove or add top shims as needed. A different

number of shims may be required from side to side to
keep front idler in a vertical position.
T6549BW –UN–10FEB89
14. Install shims and guide plates.
15. Lower bucket to raise track frame. Install block under

first roller for safety to prevent idler from moving up if
hydraulics move.
04T,90,M194 –19–12JAN93–5/8
16. Install bottom wear strips (A) and enough shims (B) to
clearance gap (C) of 0.5—1 mm (0.020—0.040 in.).
Place shims under wear strip.
T6555DL –UN–25MAY89
04T,90,M194 –19–12JAN93–6/8
17. Check cap screw thread engagement before inserting

cap screws. End of cap screw should be 0—5 mm
(0—0.2 in.) below (A) wear strip surface. Washers
can be added under head of cap screw if needed. T6555DM –UN–25MAY89
04T,90,M194 –19–12JAN93–7/8
90–28 121997
PN=210
Maintenance
18. Check guide plate clearance (B). Plate must be close

to frame but not tight. Adjust shims (A) as needed.
Use equal number of shims on both sides to center
idler on track frame.
19. Repeat procedure on other track.
T6555DN –UN–25MAY89
04T,90,M194 –19–12JAN93–8/8
CHECKING TRACK CARRIER ROLLER OIL

LEVEL
Removing the oil check plug in the roller does not always
show oil due to a vacuum in the oil cavity. Components
that appear low or out of oil may have sufficient oil. A
–UN–09FEB89
small amount of low volume air forced into the roller will
overcome the vacuum inside the roller and force a small
amount of oil to flow out.
T6499EF1
1. Position the oil level check cap screw (B) at the three
o’clock or nine o’clock position.
Inside of crawler
2. Remove the oil level fill plug (A). If oil runs out, oil level
is correct.
If oil does not run out of the fill hole, remove the oil
level check cap screw (B). Insert the nozzle of the
plastic bottle (C) into the check hole and squeeze air
pressure inside the roller assembly. A slight amount of
air pressure inside the roller will relieve any vacuum
inside the assembly and allow oil to flow out fill hole
(A).
Oil must be level with fill hole (A) or not more than 3
mm (0.12 in.) below the bottom of the hole.
3. Install plug and cap screw.
TX,90,RR2741 –19–16AUG93–1/2
90–29 121997
PN=211
Maintenance
Adding Oil To Roller:
1. To add oil, install the oil level plug (B).
2. Earlier units—Remove the fill plug (A) and

IMMEDIATELY install a 1/8 in. NPT grease fitting.
–UN–09FEB89
Later units—Remove the fill plug (A) and
IMMEDIATELY install a John Deere adapter fitting
AN142253 or equivalent adapter (male 7/16 x 20
T6499EF1
O-ring thread to female 1/8 in. NPT grease fitting into
the adapter.
Inside of Crawler
3. Remove the oil level plug.
4. Fill a grease gun with oil. (See Fuels and Lubricants

chapter in this manual.)
5. Add oil to grease fitting until it comes out of oil level

plug.
6. Install oil level plug. Tighten to 41 ± 4 N•m (30 ± 3

lb-ft).
7. Remove grease fitting and install fill plug.
TX,90,RR2741 –19–16AUG93–2/2
90–30 121997
PN=212
Maintenance
CHECKING IDLER OIL LEVEL
Removing the oil check plug (A) in the idler does not
always show oil due to a vacuum in the oil cavity. Idlers
that appear low or out of oil may have sufficient oil. A
small amount of low volume air forced into the idler will
–UN–10NOV92
overcome the vacuum inside the idler and force a small
amount of oil to flow out fill hole.
1. Remove the oil level fill plug (B). If oil runs out, oil level
T7883AP
is correct.
If oil does not run out of the fill plug hole, remove the
oil level check plug (A). Insert the nozzle of the plastic
bottle (C) into the oil check hole and squeeze air
pressure inside the idler assembly. A slight amount of
air pressure inside the idler will relieve any vacuum
inside the assembly and allow oil to flow out of the fill
hole (B).
–UN–10NOV92
2. Install plugs.
T7883AS
TX,90,RR2739 –19–16AUG93–1/2
90–31 121997
PN=213
Maintenance
Adding Oil To Idler:
IMPORTANT: Add oil to both idlers of machine. The

fitting for the left side is on the inside of
track frame.
–UN–10NOV92
1. To add oil, remove the oil check plug (A).
2. Remove the fill plug (B) and IMMEDIATELY install a

John Deere adapter fitting AN142253 (D) or equivalent
T7883AP
adapter (male 7/16 x 20 O-ring thread to female 1/8 in.
NPT grease fitting).
Inside of Crawler
3. Install a grease zerk fitting (E) into the adapter fitting.
4. Fill a grease gun (F) with oil. (See Fuels and

Lubricants chapter in this manual.)
5. Add oil to grease fitting until it comes out of oil check
–UN–03AUG93
plug (C).
6. Install oil check plug. Tighten to 41 ± 4 N•m (30 ± 3

lb-ft).
T8055AM
7. Remove grease fitting, adapter, and install fill plugs.
A—Check Plug
B—Fill Plug
C—Check Plug Hole
D—AN142253 Adapter Fitting
E—Grease Zerk Fitting
F—Grease Gun
TX,90,RR2739 –19–16AUG93–2/2
90–32 121997
PN=214
Maintenance
CHECKING TRACK ROLLER OIL LEVEL
Removing the oil check plug in the track roller does not
always show oil due to a vacuum in the oil cavity. Track
rollers that appear low or out of oil may have sufficient oil.
A small amount of low volume air forced into the roller will
T6499EB1 –UN–09FEB89
overcome the vacuum inside the roller and force a small
amount of oil to flow out fill hole.
1. Remove the oil level fill plug (B). If oil runs out, oil level
is correct.
If oil does not run out, remove the oil level check plug
(A). Insert the nozzle of the plastic bottle (C) into the oil
check hole and squeeze air pressure inside the roller
assembly. A slight amount of air pressure inside the
roller will relieve any vacuum inside the roller and allow
oil to flow out of the fill hole (B).
–UN–07JAN93
2. Install the plugs.
T7896AX
TX,90,RR2833 –19–16AUG93–1/2
Adding Oil To the Roller:
1. To add oil, install the oil level plug (A).
2. Remove the fill plug (B) and IMMEDIATELY install a

John Deere adapter fitting AN142253 or equivalent
T6499EB1 –UN–09FEB89
adapter (male 7/16 x 20 O-ring thread to female 1/8 in.
NPT grease fitting) into the adapter.
3. Remove the oil level check plug.
4. Fill a grease gun with oil. (See Fuels and Lubricants

chapter in this manual.) Inside of crawler
5. Add oil to grease fitting until it comes out of oil level

plug.
6. Install oil level plug. Tighten to 41 ± 4 N•m (30 ± 3

lb-ft).
7. Remove grease fitting and install fill plug.
TX,90,RR2833 –19–16AUG93–2/2
90–33 121997
PN=215
Maintenance
STEERING BRAKE ADJUSTMENT—(S.N. —

770807)
IMPORTANT: Over adjustment (too tight) can cause

erratic steering clutch operation.
T8079AC –UN–13SEP93
CAUTION: Install cap screw (A) through shift
control console to lock shift lever in neutral to
prevent accidental shifting into gear during this
adjustment.
Adjustment is required when lever or pedal travel required

to steer the machine is not acceptable to the operator.
1. Remove large plug from side of transverse case.
2. Start engine and shift to neutral.
T6499CK –UN–09FEB89
TX,90,RR7103 –19–03JAN96–1/3
90–34 121997
PN=216
Maintenance
IMPORTANT: Adjuster (A) must move easily. Do not

hammer or pry. Damage to adjuster
notches could occur. When loosening
brakes, the self-adjuster tab (B) may
have to be held away from notches to
reduce resistance.
T6677AH –19–21DEC92
3. Turn adjuster with large straight screwdriver.
PEDAL STEER:
1. Turn adjuster (A) until, when applying brake by

hand, brake pedal is firm when pedal is 279 mm (11 Left Side
in.) from firewall.
2. Push pedal to lower stop several times to seat
linkage then recheck step a.
LEVER STEER:
1. Turn adjuster nut (A) until approximately 55 N (12
T6677AI –19–21DEC92
lb) of resistance is felt when lever travels 127 mm
(5 in.) as measured at top of handles from forward
stop.
2. Pull levers to rear stop several times to seat linkage
and repeat step a.
Right Side
NOTE: Brakes can be self-adjusted tighter to operator’s
preference by pulling steering levers to rear stop
during operation. 450G, 455G and 555G adjust in
reverse, 550G and 650G adjust in forward. Brakes
can only be loosened by manual adjustment.
IMPORTANT: If brakes self-adjust too tight or to

loose, see Adjust Steering Brake
Self-adjuster Linkage in this group.
4. Check adjustment by operating machine in 1st gear at

low idle.
PEDAL STEER: Slowly push on brake pedal until track

stops. Measure pedal travel from firewall to bottom
center of pedal. Track should stop when pedal is
approximately 279 mm (11 in.) from firewall.
TX,90,RR7103 –19–03JAN96–2/3
90–35 121997
PN=217
Maintenance
LEVER STEER: Slowly pull back on lever until track

stops. Measure lever travel at top of lever handles.
Track should stop at approximately 127 mm (5 in.) of
lever travel.
NOTE: It is normal for brake pedals to vary up to 1/2 in.

in travel when checked to forward and reverse
stop track position. Lever steer machines can vary
up to 1 in. difference at stop track positions.
TX,90,RR7103 –19–03JAN96–3/3
STEERING BRAKE ADJUSTMENT—(S.N.

770808— )
IMPORTANT: Over adjustment (too tight) can cause

erratic steering clutch operation.
CAUTION: Install cap screw (A) through shift

control console to lock shift lever in neutral to
prevent accidental shifting into gear during this
adjustment.
1. Remove large plug from side of transverse case.
2. Start engine and shift to neutral.
–UN–30NOV94
T8368AY
T6499CK –UN–09FEB89
TX,90,RB47 –19–03DEC97–1/2
90–36 121997
PN=218
Maintenance
IMPORTANT: Adjuster (A) must tighten easily. Do not

hammer or pry. Damage to adjuster
notches could occur. End of retainer (B)
must be spring-loaded against teeth on
adjuster (A).
–19–21DEC92
3. Turn adjuster with large straight screwdriver.
PEDAL STEER:
T7896AV
a. Turn adjuster (A) until, when applying brake by
hand, brake pedal is firm when pedal is 279 mm
(11.0 in.) from firewall. Right Side
b. Push pedal to lower stop several times to seal

linkage then recheck step
LEVER STEER:
a. Turn adjuster (A) until approximately 55 N (12 lb) of
T7896AW –19–21DEC92
resistance is felt when lever travels 127 mm (5.0
in.) as measured at top of handles from forward
stop.
b. Pull levers to rear stop several times to seat linkage

and repeat step
Left Side
4. Check adjustment by operating machine in first gear at

low idle.
PEDAL STEER: Slowly push on brake pedal until track

stops. Measure pedal travel from firewall to bottom
center of pedal. Track should stop when pedal is
approximately 279 mm (11.0 in.) from firewall.
LEVER STEER: Slowly pull back on lever until track

stops. Measure lever travel at top of lever handles.
Track should stop at approximately 127 mm (5.0 in.) of
lever travel.
NOTE: It is normal for brake pedals to vary up to 0.5 in.

in travel when checked to forward and reverse
stop track position. Lever steer machines can vary
up to 1.0 in. difference at stop track positions.
TX,90,RB47 –19–03DEC97–2/2
90–37 121997
PN=219
Maintenance
CHECK FIRE EXTINGUISHER—IF EQUIPPED
IMPORTANT: Charge fire extinguisher after each use.
Check gauge regularly for correct charge. The pointer

must be in the green zone. If extinguisher needs to be
charged, see your authorized dealer.
TX,90,RR7118 –19–18JAN96–1/1
REVERSIBLE FAN—IF EQUIPPED
Fan blade angle can be changed to suck air into engine

compartment for cold weather operation.
1. Earlier Machines: Remove right side engine shield and

fan guard.
Later Machines: Remove right side engine shield and

open fan access door.
IMPORTANT: All fan blades must be at same angle to

properly ventilate air in engine
compartment. operation.
2. Fan blades are spring-loaded; push down on each

blade and turn to change angle.
TX,90,FF1971 –19–20DEC94–1/1
DO NOT SERVICE CONTROL VALVES AND

CYLINDERS
Special tools and information are needed to service

control valves and cylinders.
If these parts need service, see your authorized dealer.
T82,BHMA,K –19–16AUG93–1/1
90–38 121997
PN=220
Maintenance
HARDWARE TORQUE SPECIFICATIONS
Check cap screws and nuts to be sure they are tight. If

hardware is loose, tighten to torque shown on the
following charts unless a special torque is specified.
T82,SKMA,AT –19–01AUG94–1/1
KEEP ROPS INSTALLED PROPERLY
Make certain all parts are reinstalled correctly if the

roll-over protective structure (ROPS) is loosened or
removed for any reason. Tighten mounting bolts to proper
torque.
The protection offered by ROPS will be impaired if ROPS
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting. A damaged ROPS should be
replaced, not reused.
TORQUE SPECIFICATION
ROPS Supports-to-Transverse Case Bolts
(Apply John Deere No.242 1070 ± 214 N•m

Hydraulic Sealant) (790 ± 158 ft-lb)
ROPS Isolator Bolts 405 + 81 N•m
(300 ± 60 ft-lb)
TX,90,RB48 –19–03DEC97–1/1
90–39 121997
PN=221
Maintenance
CHECKING TRACK SHOE CAP SCREW

TORQUE
Track shoe bolt torque should be periodically checked. If

the cap screws do not meet the minimum torque
specifications, remove the shoes and clean the mating
surfaces of the shoes and links before tightening the bolts.
If unit is operated with loose track shoes, the cap screw

holes in the shoes and links will wallow out and it may be
difficult to keep the track shoes tight. Loose shoes can
also cause hardware failure and loss of track shoes.
Install all track shoe nuts with rounded edges against the
link and chamfered edges away from the link. Be sure nut
is properly positioned in the link so there is full contact
area between the nut and the link.
Tighten cap screws using torque-turn torque method.
–UN–23FEB89
TORQUE-TURN SPECIFICATIONS
450G, 550G
T6794AM
1/2 in. dia. cap screw 61 N•m (45 lb-ft) plus 1/2 turn
(180°)
9/16 dia. cap screw 88 N•m (65 lb-ft) plus 1/3 turn
(120°)
A—Rounded edge
650G B—Chamfered edge
5/8 dia. cap screw 163 N•m (120 ± 20 lb-ft) plus 1/3
turn (120°)
NOTE: Replacement hardware should be lubricated and

tightened to above specification.
TX,90,FF1972 –19–12JAN93–1/1
90–40 121997
PN=222
Maintenance
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
–19–04MAR91
TS1162
Grade 1a Grade 2b Grade 5, 5.1, or 5.2 Grade 8 or 8.2
c d c d c d
Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedc Dryd
Size N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 240 175 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 400 300 510 375 400 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
a
Grade 1 applies for hex cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length.
b
Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long.
c
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
d
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or Fasteners should be replaced with the same or higher
tightening procedure is given for a specific application. grade. If higher grade fasteners are used, these should
Torque values listed are for general use only. Check only be tightened to the strength of the original.
tightness of fasteners periodically.
Make sure fasteners threads are clean and that you
Shear bolts are designed to fail under predetermined properly start thread engagement. This will prevent
loads. Always replace shear bolts with identical grade. them from failing when tightening.
TX,03,SS3512 –19–20JUL94–1/2
90–41 121997
PN=223
Maintenance
Tighten plastic insert or crimped steel-type lock nuts to Tighten toothed or serrated-type lock nuts to the full
approximately 50 percent of the dry torque shown in torque value.
the chart, applied to the nut, not to the bolt head.
TX,03,SS3512 –19–20JUL94–2/2
90–42 121997
PN=224
Maintenance
METRIC BOLT AND CAP SCREW TORQUE VALUES
–19–04MAR91
TS1163
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
a b a b a b
Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Dryb
Size N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190
M16 100 73 125 92 190 140 240 175 275 200 350 255 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or Fasteners should be replaced with the same or higher
tightening procedure is given for a specific application. property class. If higher property class fasteners are
Torque values listed are for general use only. Check used, these should only be tightened to the strength of
tightness of fasteners periodically. the original.
Shear bolts are designed to fail under predetermined Make sure fasteners threads are clean and that you
loads. Always replace shear bolts with identical properly start thread engagement. This will prevent
property class. them from failing when tightening.
TX,03,SS3510 –19–20JUL94–1/2
90–43 121997
PN=225
Maintenance
Tighten plastic insert or crimped steel-type lock nuts to Tighten toothed or serrated-type lock nuts to the full
approximately 50 percent of the dry torque shown in torque value.
the chart, applied to the nut, not to the bolt head.
TX,03,SS3510 –19–20JUL94–2/2
CHECK OIL LINES AND FITTINGS
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
X9811 –UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

Any fluid injected into the skin must be
T85401 –UN–24JAN89
Check all oil lines, hoses and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching machine
parts which are moving.
Tubing with dents may cause the oil to overheat. If you

find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in torque

chart.
When you tighten connections, use two wrenches to

prevent bending or breaking tubing and fittings.
T82,FLMA,AI –19–14MAR90–1/1
90–44 121997
PN=226
Maintenance
SERVICE RECOMMENDATIONS FOR 37°

FLARE AND 30° CONE SEAT CONNECTORS
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or petroleum

jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torque

chart. Do not allow hoses to twist when tightening
fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART*

Thread Size N•m lb-ft
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 UN 190 140
1-7/8 - 12 UN 217 160
T82,BHMA,EL –19–16MAR92–1/1
90–45 121997
PN=227
Maintenance
SERVICE RECOMMENDATIONS FOR O-RING

BOSS FITTINGS
STRAIGHT FITTING
1. Inspect O-ring boss seat for dirt or defects.
–UN–18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
T6243AE
3. Tighten fitting to torque value shown on chart.
TX,90,RB49 –19–03DEC97–1/2
90–46 121997
PN=228
Maintenance
ANGLE FITTING
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
2. Turn fitting into threaded boss until back-up washer
–UN–18OCT88
contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).
T6520AB
4. Hold fitting head-end with a wrench and tighten locknut
and back-up washer to proper torque value.
NOTE: Do not allow hoses to twist when tightening

fittings.
TORQUE VALUE
Thread Size N•m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
NOTE: Torque tolerance is ± 10%.
TX,90,RB49 –19–03DEC97–2/2
90–47 121997
PN=229
Maintenance
SERVICE RECOMMENDATIONS FOR FLAT

FACE O-RING SEAL FITTINGS
1. Inspect the fitting sealing surfaces. They must be free

of dirt or defects.
T6243AD –UN–18OCT88
2. Inspect the O-ring. It must be free of damage or
defects.
3. Lubricate O-rings and install into groove using

petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum

jelly so O-ring is not displaced during assembly.
5. Index angle fittings and tighten by hand pressing joint

together to insure O-ring remains in place.
6. Tighten fitting or nut to torque value shown on the

chart per dash size stamped on the fitting. Do not allow
hoses to twist when tightening fittings.
FLAT FACE O-RING SEAL FITTING TORQUE

Nominal Tube O.D. Dash Thread Size Swivel Nut Bulkhead Nut
mm in. Size in. N•m lb-ft N•m lb-ft
6.35 0.250 -4 9/16-18 16 12 5.0 3.5
9.52 0.375 -6 11/16-16 24 18 9.0 6.5
12.70 0.500 -8 13/16-16 50 37 17.0 12.5
15.88 0.625 -10 1-14 69 51 17.0 12.5
19.05 0.750 -12 1 3/16-12 102 75 17.0 12.5
22.22 0.875 -14 1 3/16-12 102 75 17.0 12.5
25.40 1.000 -16 1 7/16-12 142 105 17.0 12.5
31.75 1.250 -20 1 11/16-12 190 140 17.0 12.5
38.10 1.500 -24 2-12 217 160 17.0 12.5
NOTE: Torque tolerance is +15 -20%.
TX,03,SS3515 –19–01AUG94–1/1
90–48 121997
PN=230
Maintenance
SERVICE RECOMMENDATIONS FOR INCH SERIES FOUR BOLT FLANGE FITTINGS
–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
a
1. Clean sealing surfaces (A). Inspect. Scratches TORQUE CHART
cause leaks. Roughness causes seal wear. N•m lb-ft
Out-of-flat causes seal extrusion. If defects cannot Nominal Cap Screw Min
be polished out, replace component. Flange Size
Size Max Min Max
2. Install O-ring (and backup washer if required) into 1/2 5/16-18 20 31 15 23
groove using petroleum jelly to hold it in place. UNC
3/4 3/8-16 UNC 28 54 21 40
3. Split flange: Loosely assemble split flange (B) 1 3/8-16 UNC 37 54 27 40
halves. Make sure split is centrally located and 1-1/4 7/16-14 47 85 35 63
perpendicular to port. Hand tighten cap screws to UNC
hold parts in place. Do not pinch O-ring (C). 1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
4. Single piece flange (D): Place hydraulic line in
center of flange and install cap screws. Flange 2-1/2 1/2-13 UNC 107 131 79 97
must be centrally located on port. Hand tighten cap 3 5/8-11 UNC 158 264 117 195
screws to hold flange in place. Do not pinch O-ring. 3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap a
Tolerance ± 10%. The torques given are enough for the given
screws. Tighten all cap screws as specified in the size connection with the recommended working pressure. Torques
chart below. can be increased to the maximum shown for each cap screw size
if desired. Increasing cap screw torque beyond this maximum will
DO NOT use air wrenches. DO NOT tighten one result in flange and cap screw bending and connection failures.
cap screw fully before tightening the others. DO
NOT over tighten.
TX,03,SS3517 –19–01AUG94–1/1
90–49 121997
PN=231
Maintenance
SERVICE RECOMMENDATIONS FOR METRIC SERIES FOUR BOLT FLANGE FITTING
–UN–01MAR90
T6890BB
1. Clean sealing surfaces (A). Inspect. Scratches DO NOT use air wrenches. DO NOT tighten one
cause leaks. Roughness causes seal wear. cap screw fully before tightening the others. DO
Out-of-flat causes seal extrusion. If defects cannot NOT over tighten.
be polished out, replace component.
a
TORQUE CHART
2. Install the correct O-ring (and backup washer if Thread b
N•m lb-ft
required) into groove using petroleum jelly to hold it M6 12 9
in place. M8 30 22
M10 57 42
3. Split flange: Loosely assemble split flange (B)
halves. Make sure split is centrally located and M12 95 70
perpendicular to the port. Hand tighten cap screws M14 157 116
to hold parts in place. Do not pinch O-ring (C). M16 217 160
M18 334 246
4. Single piece flange (D): Place hydraulic line in M20 421 318
center of flange and install four cap screws. Flange a
must be centrally located on port. Hand tighten cap size connection with the recommended working pressure.
screws to hold flange in place. Do not pinch O-ring. Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
5. After components are properly positioned and cap b
Metric standard thread.
screws are hand tightened, tighten one cap screw,
then tighten the diagonally opposite cap screw.
Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
TX,03,SS3516 –19–01AUG94–1/1
90–50 121997
PN=232
Maintenance
SERVICE RECOMMENDATIONS FOR METRIC SERIES FOUR BOLT FLANGE FITTING
–UN–01MAR90
T6890BB
1. Clean sealing surfaces (A). Inspect. Scratches DO NOT use air wrenches. DO NOT tighten one
cause leaks. Roughness causes seal wear. cap screw fully before tightening the others. DO
Out-of-flat causes seal extrusion. If defects cannot NOT over tighten.
be polished out, replace component.
a
TORQUE CHART
2. Install the correct O-ring (and backup washer if Thread b
N•m lb-ft
required) into groove using petroleum jelly to hold it M6 12 9
in place. M8 30 22
M10 57 42
3. Split flange: Loosely assemble split flange (B)
halves. Make sure split is centrally located and M12 95 70
perpendicular to the port. Hand tighten cap screws M14 157 116
to hold parts in place. Do not pinch O-ring (C). M16 217 160
M18 334 246
4. Single piece flange (D): Place hydraulic line in M20 421 318
center of flange and install four cap screws. Flange a
must be centrally located on port. Hand tighten cap size connection with the recommended working pressure.
screws to hold flange in place. Do not pinch O-ring. Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
5. After components are properly positioned and cap b
Metric standard thread.
screws are hand tightened, tighten one cap screw,
then tighten the diagonally opposite cap screw.
Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
TX,03,SS3516 –19–01AUG94–1/1
90–51 121997
PN=233
Operational Checkout
OPERATIONAL CHECKOUT
Use this procedure to check all systems and functions on

the machine. It is designed so you can make a quick
check of the operation of the machine while doing a walk
around inspection and performing specific checks from the
operator’s seat.
Should you experience a problem with your machine, you

will find helpful diagnostic information in this checkout that
will pinpoint the cause. This information may allow you to
perform a simple adjustment which will reduce the
downtime of your machine. Use the table of contents to
help find adjustment procedures.
The information you provide after completing the

operational checkout will allow you or your authorized
dealer to pinpoint the specific test or repair work needed
to restore the machine to design specifications.
A location will be required which is level and has

adequate space to complete the checks. No tools or
equipment are needed to perform the checkout.
Complete the necessary visual checks (oil levels, oil

condition, external leaks, loose hardware, linkage, wiring,
etc.) prior to doing the checkout. The machine must be at
operating temperature for many of the checks.
Start at the top of the left column and read completely

down column before performing check, follow this
sequence from left to right. In the far right column, if no
problem is found (OK), you will be instructed to go to next
check. If a problem is indicated (NOT OK), you will be
referred to either a section in this manual or to your
authorized dealer.
TX,95,FF,476 –19–16AUG93–1/1
95–1 121997
PN=234
’ INDICATORS, SHIFT LEVER LINKAGE AND REVERSE WARNING ALARM CHECKS (WITH ENGINE OFF)
– – –1/1
MONITOR INDICATOR LOOK: All six monitor indicator lights and CAUTION light OK: Go to next check.
LIGHTS AND ALARM must be on. STOP light must flash and alarm must beep.
CHECKS NOT OK: Go to
LISTEN: Starting motor must NOT operate. Troubleshooting chapter,
Engine off. Gauge and Indicators,
Monitor Lights Do Not
Turn key switch to BULB Come On During BULB
CHECK position. CHECK.
T6552AE –UN–19OCT88
NOT OK: If motor starts,
go to your authorized
dealer.
– – –1/1
ENGINE LOW Turn key switch to BULB CHECK position then back to OK: Go to next check.
PRESSURE AND ON position. Wait 3 seconds.
ALTERNATOR LOW NOT OK: No engine low
VOLTAGE MONITOR LOOK: Engine low pressure, low transmission pressure, pressure indicator light.
INDICATOR LIGHT and alternator low voltage indicators must be on, STOP Check wiring to sender
CHECKS indicator must flash and alarm must beep. connection. Go to
Troubleshooting chapter,
Engine off. Gauge and Indicators,
Engine Oil Pressure
Indicator Light Will Not
Light.
NOT OK: No alternator

low voltage indicator light.
Check wiring connector at
alternator. Go to
Gauges and Indicators,
Alternator Indicator Will
Not Light.
NOT OK: No low

pressure indicator. Check
wiring at switch.
– – –1/1
95–2 121997
PN=235
AIR RESTRICTION Open hood access door. OK: Go to next check.

INDICATOR CHECK
LOOK: Restriction indicator must not show red. NOT OK: Clean air
cleaner primary element.
Go to Maintenance
chapter, Check Air
Restriction Indicator.
T6499BE3 –UN–25OCT88
– – –1/1
SHIFT LEVER LINKAGE Release park lock. OK: Go to next check.

AND REVERSE
WARNING ALARM Move shift lever to each forward gear. NOT OK: Adjust shift
CHECK linkage. Go to your
FEEL / LOOK: Detents must be felt in each gear and authorized dealer.
Key on. lever must align with numbers.
NOT OK: Inspect wiring
Move gearshift to neutral then to reverse side (left) of to alarm. Go to your
T6627AB –UN–18OCT88
quadrant. authorized dealer.
LISTEN: Reverse warning alarm (if equipped) must

sound when lever is half way into reverse.
– – –1/1
PARK AND BRAKE Put shift lever in 4th gear. OK: Go to next check.
LOCK CHECK
Move lock lever to down position. NOT OK: Inspect and
repair linkage. Go to your
LOOK: Lock lever must force shift lever into park position. authorized dealer.
Pull shift lever.
FEEL: Shift lever must remain in locked position.
Release shift lock.
Attempt to push shift lever into park position.
LOOK / FEEL: Lever must not go into park position.
– – –1/1
95–3 121997
PN=236
( NEUTRAL START SWITCH AND START CIRCUIT CHECKS
– – –1/1
NEUTRAL START Apply both brakes. OK: Go to next check.

SWITCH CHECK
Turn key to start position and hold. NOT OK: Repair neutral
Release park and brake start switch or wiring.
lock lever. LOOK: All monitor functions must be on. Adjust or repair linkage.
Go to your authorized
Move shift lever into each gear detent. dealer.
LISTEN: Starting motor must NOT operate.
– – –1/1
START CIRCUIT CHECK Shift lever into park position. OK: Go to next check.
Turn key to START position. NOT OK: Go to

LISTEN: Starting motor must operate. Electrical System,
Starting Motor Will Not
LOOK: During engine cranking all indicator lights must Turn.
come on and alarm must beep. When engine starts, all
lights must go out.
LISTEN: Engine must start.
– – –1/1
95–4 121997
PN=237
PARK AND BRAKE Apply park and brake lock lever in the lock position. OK: Go to next check.
LOCK/NEUTRAL SWITCH
ADJUSTMENT CHECK Pull transmission shift lever back with moderate pressure to eliminate any linkage NOT OK: Starting motor
clearance. will not turn. Adjust or
repair linkage. Go to your
Turn key to START position. John Deere dealer.
LISTEN: Starting motor must operate.
LOOK: During engine cranking all indicator lights must

come on and alarm must beep. When engine starts, all
lights must go out.
LISTEN: Engine must start.
– – –1/1
) ENGINE SPEED CONTROL AND DECELERATOR CHECKS
– – –1/1
ENGINE SPEED Look through or remove left engine shield using 5/8 in. OK: Go to next check.
CONTROL LEVER (16 mm) wrench.
LINKAGE CHECK NOT OK: Adjust linkage.
Move speed control lever to fast idle. Go to Maintenance
chapter, Engine Speed
LOOK: Lever at injection pump must override spring by Control Linkage
1—5 mm (0.040—0.200 in.) Adjustment.
– – –1/1
95–5 121997
PN=238
DECELERATOR Start engine. OK: Go to next check.

LINKAGE CHECK
Move speed control lever to fast idle speed. NOT OK: Adjust lower
stop at pedal. Go to
Depress and hold decelerator pedal against lower stop. Maintenance chapter,
Engine Speed Control
LISTEN: Engine speed must decrease to slow idle. Linkage Adjustment.
Pull speed control lever to slow idle stop.
LISTEN: Engine speed must NOT change.
Release decelerator.
LISTEN: Engine speed must not change.
– – –1/1
SPEED CONTROL Start engine. OK: Go to next check.

LEVER LINKAGE CHECK
Move lever to fast idle then to slow idle. NOT OK: Adjust friction
disk nut.
FEEL: Lever must move with some resistance.
NOT OK: Check linkage
LOOK: Lever must hold at any position. at injection pump and
repair.
Depress decelerator and move lever slowly back and
forth several times. NOT OK: Adjust
decelerator lower stop.
FEEL: Linkage must not catch or bind.
LISTEN: Engine speed must not increase.
– – –1/1
95–6 121997
PN=239
* BRAKE SYSTEM CHECKS
– – –1/1
BRAKE PEDAL UPPER Pedal steering. OK: Go to next check.

STOP AND RETURN
SPRING CHECK LOOK: Brake pedals must be even. NOT OK: Inspect linkage
for binding or broken
Start engine. Pull up on each pedal or single pedal with lever steering. spring.
Shift lever to neutral. FEEL: Pedals must not move upward.
Depress and slowly release each pedal.
LOOK: Return spring must return pedal to upper stop.
– – –1/1
BRAKE DRAG, PARK, Start engine. OK: Go to next check.

AND BRAKE LOCK
LINKAGE CHECK Position unit on incline. NOT OK: Brake over
adjusted. Go to
Start engine. Shift to neutral and release brakes. Maintenance chapter,
Adjust Steering Brakes.
CAUTION: Fasten seat LOOK / FEEL: Unit must roll freely.
belt to prevent being NOT OK: Adjust Brakes.
jerked out of seat when With unit moving, push park and brake lock lever down. Go to Maintenance
T6583AF –UN–23AUG93
unit stops suddenly. chapter, Adjust Steering
LOOK / FEEL: Unit must slow to stop and hold on Brakes.
incline.
– – –1/1
BRAKE CAPACITY NOTE: It is normal for brake pedal/lever travel to vary from forward to reverse. OK: Go to next check.
CHECK
Firmly apply brakes. NOT OK: Adjust brakes.
Start unit. Go to Maintenance
Depress clutch. chapter, Adjust Steering
Increase engine speed to Brakes.
fast idle. Move shift lever to 3rd gear.
Slowly release clutch to load engine to near stall.
LOOK: Unit must not move.
– – –1/1
95–7 121997
PN=240
+ STEERING SYSTEM CHECKS (STEERING CLUTCHES AND BRAKES)
– – –1/1
STEERING CLUTCH Start machine , increase engine speed to approximately 1500 rpm. OK: Go to next check.
ENGAGEMENT CHECK
(PEDAL STEER) shift into 1st gear forward. NOT OK: Depress both
brake pedals at once,
Do not touch brake pedals. Shift to 1st gear reverse then repeat steps b and c
of check.
LOOK: Unit must "jerk" straight ahead.
NOT OK: Repair linkage.
LOOK: Machine must jerk straight rearward.
– – –1/1
HYDRAULIC WARM-UP 1. Start engine and operate at fast idle. OK: Go to next check.
PROCEDURE
2. Hold hydraulic control lever over relief for one minute. NOT OK: Repair system
relief. Go to your
3. Cycle all hydraulic cylinders twice. authorized dealer.
Repeat steps 1 & 2 until cylinders are warm-to-touch

(Approximately 40°C (100°F).
T6581AW1 –UN–25MAY89
LISTEN: Engine rpm must lower when control lever is
held over relief.
– – –1/1
95–8 121997
PN=241
STEERING CLUTCH Position machine against immovable object on a hard OK: Go to Continued.
ADJUSTMENT CHECK flat surface.
NOT OK: Go to next
Operate engine at slow idle. check.
NOTE: Power control pedal is not used on a torque

converter machine. Ignore step to depress or release
power control pedal and go to the next step.
T6627AN –UN–23AUG93
Depress power control pedal.
Shift transmission to 1st gear forward.
For machines (S.N. —770807), depress left pedal

approximately 25 mm (1 in.) or pull left lever 38 mm (1.5
in.).
For machines (S.N. 770808— ), depress left pedal

approximately 35 mm (1.4 in.) or pull left lever 55 mm
(2.2 in.).
Slowly release power control pedal until right track

moves.
For torque converter machine, slowly increase engine

speed until right track moves.
LOOK: Left track must not move.
– – –1/1
STEERING CLUTCH Depress power control pedal. OK: Go to next check.

ADJUSTMENT CHECK—
CONTINUED Release left pedal and depress right pedal approximately 25 mm (1 in.). NOT OK: Adjust steering
linkage. Go to your
Slowly release power control pedal until left track moves. authorized dealer.
LOOK: Right track must not move.
– – –1/1
95–9 121997
PN=242
STEERING BRAKE NOTE: It is normal for brake pedal/lever travel to vary from forward to reverse. OK: Go to next check.
OPERATION CHECK
Push left pedal or pull left lever until increased effort is felt. NOT OK: Adjust brakes.
Engine at slow idle and Go to Maintenance
transmission in 1st gear. LOOK: Left track must stop and crawler must turn left. chapter, Adjust Steering
Brakes.
Push right pedal or pull right lever until increased effort is felt.
LOOK: Right track must stop and crawler must turn right.
– – –1/1
, POWER CONTROL PEDAL CHECKS—DIRECT DRIVE MACHINES
– – –1/1
POWER CONTROL Depress power control pedal to lower stop and hold. OK: Go to next check.
CLUTCH DRAG CHECK
LOOK: Unit must stop and remain stopped while power NOT OK: Check power
Operate unit in 1st gear at control pedal is down. control pedal linkage. Go
fast idle on smooth flat to your John Deere
surface with blade or dealer.
bucket off ground.
– – –1/1
POWER CONTROL Operate engine at slow idle. OK: Go to next check.

CLUTCH VALVE CHECK
Depress power control pedal. NOT OK: Increase
Position unit on smooth flat engine speed to fast idle,
surface with blade or Shift transmission to 4th gear. repeat check.
bucket off ground.
Slowly release power control pedal. IF OK: Replace
transmission filter.
LOOK: Unit must move without stalling engine.
NOT OK: Repair clutch
valve spool. Go to your
John Deere dealer.
– – –1/1
95–10 121997
PN=243
- DRIVING CHECKS
– – –1/1
TRANSMISSION SLIP Operate engine at fast idle. OK: Go to next check.

CHECK
Shift transmission to 1st gear. NOT OK: Check
IMPORTANT: Do not slip transmission oil level.
clutch under full load more Apply brakes to lug engine.
than 5 seconds during this IF OK: Replace filter. Go
check. Shift transmission to 1st gear reverse. to your authorized dealer.
Apply brakes to lug engine.
LOOK / FEEL: Transmission must not slip.
Repeat check in each forward gear.
LOOK / FEEL: Transmission must NOT slip in ANY gear.
NOTE: If you stall engine, move speed control lever to slow idle position and restart
engine to lubricate turbocharger (if equipped).
– – –1/1
TRANSMISSION NOISE Operate engine at fast idle. OK: Go to next check.

CHECK
Shift into 1st gear. NOT OK: Go to your
IMPORTANT: Do not slip authorized dealer.
clutch under full load more Apply brakes to load engine.
than 5 seconds during this
check. LISTEN: Must not hear unusual gear noise.
Repeat in each gear in forward and reverse.
LISTEN: Must not hear unusual noise in any gear.
– – –1/1
TRANSMISSION Slowly remove transmission dipstick. OK: Go to next check.

SEALING CHECK
FEEL / LISTEN: Back pressure should escape from NOT OK: Check
Move transmission control transmission. transverse case for oil
lever to park position. seepage to locate leak.
NOTE: Transmission is a sealed system to prevent Go to your authorized
Operate machine at slow moisture and dirt from entering. dealer.
idle.
T6627AH –UN–18OCT88
– – –1/1
95–11 121997
PN=244
. HYDRAULIC SYSTEM CHECKS
– – –1/1
VISUAL CHECK Park machine on level surface. OK: Go to next check.
Lower all equipment to ground. NOT OK: Add oil.
LOOK: Hydraulic oil must be visible in sight glass. NOT OK: Repair leaks.
LOOK: Hydraulic lines and fittings must not seep or leak oil. dealer.
LOOK: Cylinder seals must not seep or leak oil.
– – –1/1
HYDRAULIC WARM-UP 1. Start engine and operate at fast idle. OK: Go to next check.
PROCEDURE
2. Hold hydraulic control lever over relief for one minute. NOT OK: Repair system
relief. Go to your
3. Cycle all hydraulic cylinders twice. authorized dealer.
Repeat steps 1 & 2 until cylinders are warm-to-touch

(Approximately 40°C (100°F).
T6581AW1 –UN–25MAY89
LISTEN: Engine rpm must lower when control lever is
held over relief.
– – –1/1
OIL COOLER CIRCUIT Open reservoir access door. OK: Go to next check.
CHECK (IF EQUIPPED)
Feel inlet line (A) at filter and outlet line (B) at reservoir. NOT OK: Check oil
cooler external condition
FEEL: Inlet line must feel warmer than outlet line. and clean.
NOTE: (S.N. —840460) Shown IF OK: Check lines. Go to

your authorized dealer.
T6627AG –UN–18OCT88
– – –1/1
95–12 121997
PN=245
HYDRAULIC RESERVOIR Open reservoir door and remove breather hose from OK: Go to next check.
BREATHER CHECK reservoir.
NOT OK: Check if
LISTEN: No air should be heard escaping from reservoir. restriction is in hose or
filter. Repair or replace.
Blow through hose.
FEEL: Breather filter and line must pass air.

T6627AZ –UN–18OCT88
Reinstall hose.
NOTE: (S.N. —840460) Shown
– – –1/1
/ UNDERCARRIAGE CHECKS
– – –1/1
TRACK SAG ROLLER Measure track sag from a straight edge placed between: OK: Go to next check.
AND IDLER LEAKAGE 450G, 455G: sprocket and carrier roller 550G, 650G:
CHECKS carrier rollers 555G: idler and carrier roller NOT OK: Adjust track
sag. Go to
LOOK: Track sag must be 50 ± 6 mm (2.0 ± 0.25 in.). Maintenance-As Required
chapter.
Inspect rollers and front idler.
NOT OK: Repair or
LOOK: No oil seepage must be noted from roller or replace. Go to your
idlers. authorized dealer.
– – –1/1
SPROCKET WEAR Inspect drive sprocket. OK: Go to next check.

CHECK
LOOK: Tooth wear must NOT be excessive. NOT OK: Go to your
authorized dealer.
NOTE: Do not evaluate sprocket by condition of tooth
tip.
Tooth tip wear does not affect sprocket operation if it

does not extend into the bushing contact area.
T6484AY –UN–19OCT88
NOTE: Reverse drive side wear is generally more than

forward drive side wear.
– – –1/1
95–13 121997
PN=246
GROUSER WEAR, BENT Inspect for worn grousers, bent track shoes and loose shoe hardware. OK: Go to next check.
TRACK SHOE, AND
LOOSE HARDWARE LOOK: Grouser bars must NOT be worn excessively and track shoes must NOT be NOT OK: If shoe
CHECKS bent and hardware must be tight. hardware is loose,
remove shoe and clean
NOTE: Excessive grouser wear weakens track shoes and may result in track shoes joint before tightening. Go
bending. to Maintenance chapter,
Check Track Shoe Cap
Screw Torque.
– – –1/1
TRACK LINK ROLLER Inspect links for pin boss wear. OK: Go to next check.
AND FRONT IDLER
WEAR CHECKS LOOK: Link pin boss areas must NOT indicate contact NOT OK: Go to
with roller flanges or track guides. Undercarriage Appraisal
Manual (SP326) for more
NOTE: Some contact or wear is normal. Excessive track component
contact or wear indicates excessive wear. information.
Inspect front idler flanges.

T6484AZ –UN–19OCT88
LOOK: Idler flanges must NOT contact bushings.
NOTE: Idler contact with bushings indicates excessive

chain rail wear and idler tread surface wear.
– – –1/1
ACCESSORY CHECKS
– – –1/1
HORN CIRCUIT CHECK Key ON. OK: Go to next check.
Press horn button. NOT OK: Check wiring to

horn.
LISTEN: Horn must sound.
IF OK: Go to
Gauges and Indicators,
Horn Does Not Work.
T6408AB –UN–24MAY89
– – –1/1
95–14 121997
PN=247
HOUR METER CIRCUIT Start engine. OK: Go to next check.

CHECK
LOOK: Hour meter must be rotating after 1/10 hour. NOT OK: Check wiring to
hour meter.
Stop engine. Turn key on.
IF OK: Go to your
LOOK: Hour meter must not rotate. authorized dealer.
T6552AN –UN–19OCT88
NOT OK: Hour meter is
wired wrong. See your
authorized dealer.
– – –1/1
WORK LIGHT CHECK— Key on. OK: Go to next check.

IF EQUIPPED
Pull light switch knob. NOT OK: Replace bulbs.
LOOK: Both front work lights and rear light must come IF OK: Check wiring. Go
on. to your authorized Dealer.
T6408AB –UN–24MAY89
– – –1/1
SEAT ADJUSTMENT Move seat "fore-aft" lever. OK: Go to next check.

CHECKS
Move seat forward and rearward and release lever. NOT OK: Inspect and
repair. Go to your
LOOK / FEEL: Lever must move freely, seat must slide authorized dealer.
and lock in desired position.
T6627AP –UN–18OCT88
– – –1/1
95–15 121997
PN=248
SEAT HEIGHT AND Manually adjust seat height. OK: Go to next check.
BACKREST
ADJUSTMENT CHECKS LOOK / FEEL: Seat must adjust and lock in each of NOT OK: Repair seat. Go
(NON-SUSPENSION) three positions. to your authorized dealer.
– – –1/1
SEAT HEIGHT AND Remove weight from seat and turn adjusting knob OK: Go to next check.
BACKREST clockwise.
ADJUSTMENT CHECKS NOT OK: Repair seat. Go
(SUSPENSION SEAT) LOOK: Knob must turn freely and seat spring resistance to your authorized dealer.
must increase.
Move backrest to each position.
T6627AP1 –UN–18OCT88
LOOK: Backrest must adjust freely and remain locked in
position.
– – –1/1
SEAT BELT CHECK Inspect seat belt for damage. OK: Go to next check.
LOOK: Seat belt must not be cut. NOT OK: Replace belt or
tether straps. Go to your
Install and adjust seat belt. authorized dealer.
LOOK / FEEL: Seat belt must adjust easily and must lock.
Check seat tether strap.
LOOK: Tether straps must be attached from seat frame to battery box cover and
battery cover must be bolted down.
– – –1/1
95–16 121997
PN=249
START AID SYSTEM Start engine. Operate at slow idle. OK: Go to next check.
CHECK (IF EQUIPPED)
Push start aid button and release. NOT OK: Check contents
of can (A).
LISTEN: Engine speed must increase slightly, then return to normal.
IF OK: Check power to
solenoid. Go to your
authorized dealer.
T6477AP –UN–19OCT88
– – –1/1
FUEL SHUT-OFF VALVE Push valve knob. OK: Go to next check.

CHECK—EARLIER
MACHINES FEEL: Valve must stay in detent position. NOT OK: Repair or clean
valve. Go to Maintenance
Run engine at LOOK: Fuel must not leak from valve in either position. chapter, Clean Fuel Tank
approximately fast idle in Outlet Screen.
park. Wait for engine to start to misfire, then pull valve knob
out immediately.
T6552AS –UN–19OCT88
LISTEN: Engine must return to original speed.
– – –1/1
FUEL SHUT-OFF VALVE Turn petcock clockwise to close. OK: Go to next check.
CHECK, LATER UNITS
FEEL: Petcock must stay in closed position. NOT OK: Repair or clean
Run engine at petcock. Go to
approximately fast idle in LOOK: Fuel must not leak from petcock. Maintenance chapter,
park. Clean Fuel Tank Outlet
Wait for engine to start to misfire, then open petcock immediately. Screen.
LISTEN: Engine must return to original speed.
– – –1/1
95–17 121997
PN=250
FUEL WATER TRAP Move handle down to open position. OK: Go to next check.
VALVE CHECK, EARLIER
UNITS LOOK: Fuel must flow from leak-off hose. NOT OK: No flow,
remove filler cap.
Move handle to up position.
IF OK: Replace filter cap
LOOK: Fuel must stop flowing from hose. breather.
T6552AR –UN–19OCT88
NOT OK: Replace valve.
dealer.
– – –1/1
VANDAL PROTECTION Cover instrument panel and install padlock. OK: Go to next check.
CHECKS
LOOK: Cover must protect all instruments. NOT OK: Repair lock or
tabs.
T6627AJ –UN–18OCT88
T6815BJ –UN–18OCT88 T6627AI –UN–18OCT88
Install padlock on following tabs:
1. Fuel Tank Cap.
2. Engine Access Door.
3. Hydraulic Reservoir Door.
T6815BI –UN–18OCT88
LOOK / FEEL: THIS SENSING HAS BEEN MOVED
Padlock must fit freely and must secure opening when in
place.
– – –1/1
95–18 121997
PN=251
SERVICE DECAL CHECK Check service decal on inside of reservoir door. OK: Operational
Checkout completed.
LOOK: Service decal must be legible.
NOT OK: Replace decal.
T6627AM –UN–18OCT88
– – –1/1
95–19 121997
PN=252
Troubleshooting
NOTE: Troubleshooting charts are arranged from the
simplest to verify, to least likely, more difficult to
verify. When diagnosing a problem, use all
possible means to isolate the problem to a single
component or system. Use the following steps to
diagnose problems:
Step 1. Operational Checkout Procedure
Step 2. Troubleshooting charts
Step 3. Adjustments
Step 4. See your authorized dealer
TX,100,RB50 –19–03DEC97–1/1
100–1 121997
PN=253
Troubleshooting
ENGINE
Symptom Problem Solution
Engine Will Not Start Or Starts Battery disconnect switch off Turn switch on.
Hard
Fuel shut off Open fuel shut-off valve.
Fuel tank empty Check fuel quantity.
Fuel tank vent plugged Remove cap and listen to sound of

air entering tank.
No electrical power to injection pump Turn key switch to ON position. Must

solenoid hear click at injection pump. Repair
wiring.
Water in fuel or water frozen in fuel Drain water from fuel tank trap.
line Change filter. Inspect fuel filter for
water.
Debris in fuel or wrong grade of fuel Check outlet strainer for debris.
Check water trap for debris with a
flashlight through the filter neck
toward bottom right corner of fuel
tank. Check fuel grade.
Air leak on suction side of fuel Check for bubbles in fuel filter and
system tighten connections. Inspect fuel
lines for damage.
Fuel transfer pump diaphragm Check engine oil for fuel dilution.
leaking
Slow cranking speed Check battery and connections.
Restricted air filter Check air filter restriction indicators

and air filters.
Stuck injection pump metering valve Tap injection pump housing (lightly).
If engine now starts, see your
authorized dealer.
Faulty electric shut-off solenoid See your authorized dealer.
Improper injection pump timing See your authorized dealer.
Continued on next page

TX,100,FF1683 –19–20DEC94–1/8
100–2 121997
PN=254
Troubleshooting
Injection pump See your authorized dealer.
Injection nozzle(s) See your authorized dealer.
Worn compression rings or low See your authorized dealer.

compression
Blown head gasket See your authorized dealer.
Engine Surges or Stalls Air in fuel Inspect filter for evidence of air in
Frequently fuel. Tighten connections and bleed
fuel system.
Fuel partially shut off Open fuel shut-off valve.
Fuel tank vent plugged Remove cap and listen to sound of

air entering tank. Replace cap.
Debris in fuel or wrong grade of fuel Check fuel tank outlet strainer for
debris. Check water trap for debris
with a flashlight through filler neck
toward bottom right corner of fuel
tank. Check fuel grade.
Water in fuel Drain water trap and inspect filter

element for water.
Fuel filter plugged Replace filter.
Return line restricted from injection See your authorized dealer.

pump to tank
Restrictor fitting on top fitting in See your authorized dealer.

injection pump plugged
Injection pump metering valve See your authorized dealer.

sticking
Fuel injection pump out of time See your authorized dealer.
Engine overheating See your authorized dealer.
Fuel transfer pump See your authorized dealer.
Fuel injection pump See your authorized dealer.

TX,100,FF1683 –19–20DEC94–2/8
100–3 121997
PN=255
Troubleshooting
Improper valve clearance Check and adjust valve clearance.
Valves sticking or burned See your authorized dealer.
Worn or broken compression rings See your authorized dealer.

or cylinder head gasket leaking
Engine Misses Air in fuel Check for evidence of air in filter.

Tighten connections and bleed fuel
system.
Debris in fuel or wrong fuel grade Check fuel tank strainer (with
flashlight) and examine fuel. Check
fuel filter for debris. Clean. Check
grade of fuel.
Idle speeds out of adjustment (too See your authorized dealer.

low)
Fuel injection pump out of time See your authorized dealer.
Fuel transfer pump See your authorized dealer.
Injection pump governor faulty or See your authorized dealer.

metering valve sticking
Engine overheating See your authorized dealer.
Incorrect valve clearance Check and adjust valve clearance.
Bent push rods See your authorized dealer.
Cylinder head gasket leaking See your authorized dealer.
Valve sticking or burned See your authorized dealer.
Worn or broken compression rings See your authorized dealer.

TX,100,FF1683 –19–20DEC94–3/8
100–4 121997
PN=256
Troubleshooting
Engine Does Not Develop Full Fuel tank strainer plugged Check water trap for debris with a
Power flashlight through filler neck toward
bottom right corner of fuel tank.
Fuel filter clogged Replace fuel filter.
Fuel tank strainer plugged Check water trap for debris with a
flashlight through filler neck toward
bottom right corner of fuel tank.
Fuel filter clogged Replace fuel filter.
Wrong grade of fuel Drain and add correct fuel.
Air system restricted Check air filter restriction indicator

and air filters.
Incorrect high idle speed (too low) Linkage out of adjustment. Adjust.
See your authorized dealer.
Incorrect engine or injection pump See your authorized dealer.

timing
Incorrect valve clearance Adjust valve clearance.
Injection pump return fuel tube or See your authorized dealer.

fittings are restricted
Fuel transfer pump problem. See your authorized dealer.
Fuel line restricted See your authorized dealer.
Excess drag in brakes See your authorized dealer.
Excess drag in transmission See your authorized dealer.
Injection pump delivery or governor See your authorized dealer.

faulty
Injection nozzle See your authorized dealer.
Muffler restricted See your authorized dealer.

TX,100,FF1683 –19–20DEC94–4/8
100–5 121997
PN=257
Troubleshooting
Low compression See your authorized dealer.
Turbocharger problem (Turbocharger See your authorized dealer.

machines only)
Air leak between turbocharger and See your authorized dealer.

manifold (Turbocharger machines
only)
Worn camshaft See your authorized dealer.
Engine Emits Excessive Black or Restricted air filter Check air filter restriction indicator
Gray Exhaust Smoke and air filters. Replace.
Incorrect grade of fuel Use correct grade of fuel
Incorrect injection pump timing See your authorized dealer.
Excessive fuel delivery See your authorized dealer.
Turbocharger problem (Turbocharger See your authorized dealer.

machines only)
Air leak between turbocharger and See your authorized dealer.

manifold (Turbocharger machines
only)
Engine Emits Excessive Blue or Cranking speed too slow Check batteries and connections.
White Smoke
Incorrect grade of fuel Use correct grade of fuel.
Engine running too cold Check thermostat operation. See

Injection pump out of time See your authorized dealer.
Low compression See your authorized dealer.
Excessive wear in liners and/or See your authorized dealer.

piston rings stuck

TX,100,FF1683 –19–20DEC94–5/8
100–6 121997
PN=258
Troubleshooting
Slow Acceleration Improper fuel Use correct grade of fuel.
Detonation (Excess Engine Stuck ether applicator See your authorized dealer.
Knock)
Incorrect injection pump timing or See your authorized dealer.
injection pump advance faulty
Abnormal Engine Noise Low or incorrect engine oil Add correct oil to proper level.
Loose or worn hydraulic pump Inspect. Repair.
Engine oil fuel diluted Inspect engine oil. Determine cause.
Excessive valve clearance Adjust valve clearance.
Bent push rods See your authorized dealer.
Incorrect fuel injection pump timing See your authorized dealer.
Worn rocker arm shafts See your authorized dealer.
Loose connecting rod caps See your authorized dealer.
Loose main bearing caps See your authorized dealer.
Worn main bearings See your authorized dealer.
Worn connecting rod bearings See your authorized dealer.
Incorrect cam timing See your authorized dealer.
Scored piston See your authorized dealer.
Worn piston pin bushings and pins See your authorized dealer.
Low Oil Pressure (Oil Pressure Low oil level Add oil to proper level. Inspect
Light On Red STOP Indicator engine oil.
Flashing)
Wrong viscosity oil/oil diluted with Change oil. See your authorized
diesel fuel dealer.

TX,100,FF1683 –19–20DEC94–6/8
100–7 121997
PN=259
Troubleshooting
Oil pressure gauge or sensor See your authorized dealer.
Oil pressure control valve See your authorized dealer.
Plugged oil pump intake screen See your authorized dealer.
Loose oil pump drive gear See your authorized dealer.
Worn oil pump gear or housing See your authorized dealer.
Excessive main bearing clearance See your authorized dealer.
Excessive connecting rod bearing See your authorized dealer.

clearance
Cracked cylinder block See your authorized dealer.
Leakage at internal oil passage See your authorized dealer.
Engine Overheats (Engine Low coolant level Fill cooling system and check for
Coolant Indicator and Red STOP leaks.
Indicator Flashing)
Low engine oil level Add oil.
Loose or broken fan belt Tighten or replace belt.
Fan on backwards Check for correct fan installation.
Radiator dirty or plugged Check air flow. Clean radiator.
Radiator shroud missing or damaged Inspect. Repair or replace.
Engine overloaded, operating in Reduce load.

wrong gear
Wrong fuel Use correct grade of fuel.
Radiator cap Replace cap.
Faulty sender See your authorized dealer.
Excessive transmission drag See your authorized dealer.

TX,100,FF1683 –19–20DEC94–7/8
100–8 121997
PN=260
Troubleshooting
Excessive brake drag See your authorized dealer.
Faulty thermostat (stuck closed) See your authorized dealer.
Thermostat missing, cooling system Flush cooling system. See your

coated with lime deposits authorized dealer.
Water pump See your authorized dealer.
Excessive fuel delivery See your authorized dealer.
Scored piston See your authorized dealer.
Engine Runs Cold Thermostat (stuck open) See your authorized dealer.
Oil in Coolant or Coolant in Oil Leaking cylinder head gasket See your authorized dealer.
Leaking cylinder liner packings See your authorized dealer.
Check cylinder head See your authorized dealer.
Cracked cylinder liner See your authorized dealer.
Cracked cylinder block See your authorized dealer.
Excessive Fuel Consumption Air system restricted Check filter restriction indicator and
air filters. Replace.
Leakage in fuel system Inspect. Repair.
Incorrect grade of fuel Refill with correct fuel.
Operator holding hydraulics over Return control levers to neutral

relief position.
Faulty injection nozzles See your authorized dealer.
Turbocharger problem See your authorized dealer.

(Turbocharged machines only)
TX,100,FF1683 –19–20DEC94–8/8
100–9 121997
PN=261
Troubleshooting
ELECTRICAL SYSTEM
Starter Will Not Turn Battery disconnect switch turned off Turn switch on.
Starter Listen for click from starter solenoid.

If click is heard, the starter control
circuit is functioning. If click is not
heard, repair starter. See your
authorized dealer.
Starter relay With vehicle in neutral, and clutch

depressed, open right engine service
door and listen for click from starter
relay when the key switch is in
START position. If click is heard, the
key switch, circuit breaker, start fuse
connectors, and neutral start switch
are functioning and the starter relay,
relay ground, or starter is defective.
Key switch See your authorized dealer.
Neutral start switch See your authorized dealer.
Start relay ground See your authorized dealer.
Start relay contacts See your authorized dealer.
Battery See your authorized dealer.
Corroded, loose, or broken battery See your authorized dealer.

post
Wiring See your authorized dealer.
Excessive engine load See your authorized dealer.
Starter Solenoid Chatters Poor or corroded connections at Inspect, clean, and tighten if
battery, battery ground strap, or necessary.
starter
Low battery voltage See your authorized dealer.

05T,100,M62 –19–16AUG93–1/4
100–10 121997
PN=262
Troubleshooting
Starter Spins But Will Not Crank Pinion gear not moving into engine See your authorized dealer.
Engine flywheel ring gear
Broken teeth on flywheel See your authorized dealer.
Engine Cranks Slowly Loose or corroded battery cables Inspect and clean or tighten.
Loose battery ground cable Open battery cover and inspect and
tighten battery ground cable.
Excessive engine load Change engine oil to proper grade

for temperature.
Starter Continues to Run Starter solenoid stuck Lightly tap on case of starter
solenoid.
Starter not disengaging Lightly tap on starter case to

determine if starter "shift" lever is
stuck.
Starter relay stuck on Lightly tap on starter relay to

determine if relay is stuck.
Wiring harness See your authorized dealer.
Excessive Noise When Engine is Broken teeth in ring gear See your authorized dealer.
Cranking
Overrunning clutch slipping See your authorized dealer.
Starter See your authorized dealer.
Battery Uses Too Much Water Cracked battery case Replace battery.
High ambient temperature Refill with water.
Battery cell Check if one or more cells take more

water than the others.
Battery being overcharged See your authorized dealer.
Cracked Battery Case No battery hold down clamp Replace battery and install hold
down clamp.

05T,100,M62 –19–16AUG93–2/4
100–11 121997
PN=263
Troubleshooting
Loose battery hold down clamp Replace battery and install hold
down clamp.
Battery hold down clamp too tight Replace battery and install battery
hold down clamp correctly.
Frozen battery Keep battery fully charged in cold

weather.
Low Battery Output Low water level Add water.
Dirty or wet battery top causing Clean and wipe battery top dry.
discharge
Corroded or loose battery cables Clean and tighten battery cables.
Broken battery post Wiggle battery post by hand. If post

wiggles or turns, replace battery.
Battery cell See your authorized dealer.
Excessive electrical load See your authorized dealer.
Wrong size battery See your authorized dealer.
Too many accessories See your authorized dealer.
Charge Indicator and Low Oil Broken ground wire to alternator Inspect and repair.
Pressure Indicator Stays On With
Key Off
Failed alternator Repair or replace alternator.
Charging Indicator Light Loose or glazed alternator belt. Check belt. Replace if glazed.
(Remains on with Engine Engine rpm low Tighten if loose. Raise engine rpm
Running) above 1200 rpm. If light remains on,
see your authorized dealer.
Diode or phase winding Increase engine rpm to fast idle. If

light goes out or gets dim, it
indicates a defective diode or phase
winding. See your authorized dealer.

05T,100,M62 –19–16AUG93–3/4
100–12 121997
PN=264
Troubleshooting
Excessive electrical load from added See your authorized dealer.

accessories
Loose or corroded electrical Inspect, clean, or tighten electrical

connections on battery, ground connections.
strap, starter, or alternator
Battery See your authorized dealer.
Regulator or alternator See your authorized dealer.
Monitor circuit breaker Turn key off. Wait for circuit breaker
to reset. Turn key switch to BULB
CHECK position. If no lights, see
Alternator Light Out, But Low Indicator light bulb Inspect and replace if necessary.
Charging System Voltage
Loose wiring connector Inspect and repair.
High Charging System Voltage Poor connection or broken wire See your authorized dealer.
(Battery Boiling) between alternator and starter
solenoid
Regulator See your authorized dealer.
Noisy Alternator Worn or defective bearings in Remove belt and feel for rough
alternator bearing while turning alternator
pulley.
Drive belt Inspect and replace if necessary.
Pulley not aligned Inspect.
Loose alternator belt or mounting Inspect and tighten if necessary.
Diodes See your authorized dealer.
05T,100,M62 –19–16AUG93–4/4
100–13 121997
PN=265
Troubleshooting
HYDRAULIC SYSTEM
No Hydraulics Low oil level Add oil to correct level.
Failed pump shaft If transmission drive shaft is not

turning, see your authorized dealer.
Suction screen plugged Remove and clean screen in

hydraulic reservoir. (See
Maintenance chapter).
Obstruction in oil lines or valves See your authorized dealer.
Hydraulic Filter Restriction Cold hydraulic oil Indicator light for hydraulic filter may
Indicator Light Is On flash on momentarily when oil is
cold. Allow oil to warm up.
Hydraulic filter plugged Replace filter.
Slow Hydraulic Functions Low oil level Add oil to correct level.
Engine rpm too low Increase rpm.
Suction screen restricted Remove and clean screen in

hydraulic reservoir. (See
Hose or line leakage Inspect and tighten fittings.
System relief valve dirty or leaking See your authorized dealer.
Low pump flow See your authorized dealer.
Hydraulics Operate Slowly In Incorrect position of control levers Change position of levers to get
One Function equal valve spool travel in each
direction.
Hydraulic cylinder leakage See your authorized dealer.
Hydraulic control valve faulty See your authorized dealer.
Slow Hydraulics (Low Pump Wrong or defective circuit relief valve See your authorized dealer.
Output)

05T,100,M65 –19–14APR94–1/3
100–14 121997
PN=266
Troubleshooting
Hydraulic pump suction screen Remove and clean screen in

restricted hydraulic reservoir. (See
Worn main pump See your authorized dealer.
Low Hydraulic Power (Low Low oil level (aeration of oil). Air leak Add oil to correct level. Check
Hydraulic Pressure) on pump suction hose suction hose and tighten clamps.
Hydraulic pump suction screen Remove and clean screen in

restricted hydraulic reservoir. (See
Leakage within work circuit Feel components for heat. See your
authorized dealer.
Excessive leakage in hydraulic See your authorized dealer.

system
Incorrect system relief valve setting See your authorized dealer.
Hydraulic Function Makes Low oil level Add oil to correct level.
Chattering Noise
Hydraulic pump suction screen Remove and clean screen hydraulic
restricted reservoir.
Wrong circuit relief valve installed in See your authorized dealer.

backhoe valve
Functions Drift Oil leaking past cylinders or control See your authorized dealer.
valve
Control Valve Sticks Or Works Control valve linkage binding See your authorized dealer.
Hard
Broken return spring See your authorized dealer.
Contamination in control valve See your authorized dealer.
Scored valve bore or bent spool See your authorized dealer.
Hydraulic Oil Overheats Excessive load Reduce load.

05T,100,M65 –19–14APR94–2/3
100–15 121997
PN=267
Troubleshooting
Operator holding hydraulic system Return levers to neutral when not in

over relief use.
Using low viscosity oil in hot weather Use recommended oil
Incorrect system relief valve See your authorized dealer.

pressure
Foaming Oil Oil level too low or too high Check oil level. Adjust to full mark
on dipstick.
Incorrect type of oil Use recommended oil.
Air leak on suction side of pump See your authorized dealer.
Hydraulic Pump Leaking Cap screws that hold pump sections Tighten to torque specification. See
are loose your authorized dealer.
Worn shaft seal See your authorized dealer.
Broken diaphragm "vee" seal or See your authorized dealer.

backup gasket
Excessive Pump Noise Low oil level Add oil to correct level.
Slow idle set too low Reset engine RPM.
Hydraulic filter restricted Replace filter.
Oil lines in contact with frame Inspect and repair.
Loose pump drive coupling to See your authorized dealer.

flywheel
Pump attaching hardware loose Retighten to specification torque.
Leakage in hydraulic circuit See your authorized dealer.
Transmission Oil Filter Restrictor Plugged filter Change filter.

Indicator Light Remains on with
the Machine at Operating
Temperatures
Sender wire grounded Remove wires from senders. If light
remains on, circuit is grounded. See
05T,100,M65 –19–14APR94–3/3
100–16 121997
PN=268
Troubleshooting
POWER TRAIN
Transmission Slippage (Low Low oil level Check and add oil.
Pressure)
Restricted oil filter Inspect and replace filter.
Transmission pump suction screen Remove and clean screen.

restricted
Clutch pedal linkage out of See your authorized dealer.

adjustment
Weak or broken pressure regulating See your authorized dealer.

valve spring
Excessive clutch or brake element See your authorized dealer.

seal leakage
Filter bypass valve stuck open See your authorized dealer.
Low transmission pump flow due to See your authorized dealer.

worn pump or manifold gasket
leakage
Pressure regulating valve housing See your authorized dealer.

gasket, shift valve housing gasket, or
piston seal leakage
Transmission Shifts Too Slowly Low oil level (aeration of oil) Check and add oil.
Plugged filter Inspect and replace filter.
Rate of shift adjustment See your authorized dealer.
Low transmission pressure See your authorized dealer.
Transmission pump suction screen See your authorized dealer.

restricted
Low transmission pump flow See your authorized dealer.
Excessive clutch or brake circuit See your authorized dealer.

leakage
Transmission Shifts Too Fast System pressure too high See your authorized dealer.

TX,100,RR7104 –19–03JAN96–1/4
100–17 121997
PN=269
Troubleshooting
Rate of shift adjustment See your authorized dealer.
Clutch or brake piston not returning See your authorized dealer.

properly or warped disks and plates
Erratic Shifts (Wrong Gears Or Control valve or lever pivots binding Inspect cable and linkage. See your
No Gear Change When Gearshift authorized dealer.
Lever Is Moved)
Valve sticking See your authorized dealer.
Dump valve sticking or shift valve See your authorized dealer.

housing gasket failed
Unit Will Not Move In Any Gear Gearshift or clutch linkage worn Inspect and repair linkage.
(No Load Put On Engine When
Shifted Into Gear)
Transmission filter plugged Replace transmission filter.
Drive shaft between pump Inspect and repair drive shaft.

transmission failed
No system pressure See your authorized dealer.
Mechanical failure in transmission Inspect transmission suction screen

for metal particles. See your
authorized dealer.
Unit Will Not Move (Load Put On Mechanical failure in transmission Inspect transmission suction screen
Engine Or Engine Stalls When for metal particles. If particles are
Shifted Into Gear) present, see your authorized dealer.
Steering valve problem See your authorized dealer.
Transmission control valve gasket See your authorized dealer.

leakage or stuck shift valve
Unit Creeps In Neutral (Load Put Transmission overfilled with oil Check oil level.
On Engine When Brakes Are
Applied)
Warped disks and plates in See your authorized dealer.
transmission

TX,100,RR7104 –19–03JAN96–2/4
100–18 121997
PN=270
Troubleshooting
Transmission Hydraulic System Transmission overfilled with oil Check oil level.
Overheats (Transmission
Slippage May Also Occur)
Air flow through oil cooler or radiator See your authorized dealer.
restricted
Drag in transmission See your authorized dealer.
Oil cooler bypass valve (at oil cooler) Check bypass valve. See your
stuck open authorized dealer.
Cooler relief valve stuck open or See your authorized dealer.

spring broken
Filter relief valve stuck open See your authorized dealer.
Leakage in transmission hydraulic See your authorized dealer.

system
Low transmission pump output See your authorized dealer.
Unit Moves Suddenly When Clutch valve sticking or spring in See your authorized dealer.
Releasing Power Control Pedal clutch valve broken
Unit Jerks When Releasing Brakes too tight Loosen brake (See Maintenance
Steering Clutch Chapter).
Unit Jerks When Releasing Improper linkage adjustment Adjust linkage (See Maintenance
Decelerator/Declutch Pedal chapter).
Crawler Mistracks Brakes dragging Adjust manually and see your

authorized dealer.
Steering pedal sticks or does not Inspect linkage. See your authorized
return to full up position dealer.
Left and right track sag not adjusted Adjust track sag to specifications.
the same
Brakes Not Working Correctly Brakes will not release, too tight. Need adjustment. See Maintenance
chapter in this manual.

TX,100,RR7104 –19–03JAN96–3/4
100–19 121997
PN=271
Troubleshooting
Brakes will not engage, too loose Adjust brakes. See Maintenance
chapter in this manual.
Excessive Transmission Noise Engine slow idle too low See your authorized dealer.
(under load or no load)
Parts worn or damaged in Remove transmission suction
transmission screen. Inspect for metal particles.
Low or no lube flow See your authorized dealer.
TX,100,RR7104 –19–03JAN96–4/4
100–20 121997
PN=272
Troubleshooting
GAUGES AND INDICATORS
Engine Coolant Temperature Indicator light Turn key to BULB CHECK. If no

Indicator Light Does Not Indicate light, replace bulb.
Overheating Or Bulb Does Not
Light in BULB CHECK Position
Wire or connector Ground "yellow" wire at sender,
indicator light must light. If not,
replace wiring.
Sender Replace sender.
Transmission Temperature Indicator light Turn key to BULB CHECK. If no

Indicator Light Bulb Does Not light, replace bulb.
Indicate Overheating Or Bulb
Does Not Light in BULB CHECK
Position
Wire or connector Ground "yellow" wire at sender,
indicator light must light. If not, repair
wiring.
Sender Replace sender.
Engine Oil Pressure Indicator Indicator light Turn key to BULB CHECK. If no
Will Not Light light, replace bulb.
Wire, connector or sender Ground "yellow" wire at sender,

indicator must light. If not, repair
wiring or replace sender.
Alternator Indicator Will Not Indicator light Turn key to BULB CHECK. If no
Light light, replace bulb.
Wire or connector Ground "violet" wire at alternator,

indicator light must light. If not, repair
wiring. Replace alternator.
Monitor Lights Do Not Come On Indicator light Replace bulb.

During BULB CHECK
Wire or connection See your authorized dealer.
Monitor module See your authorized dealer.

05T,100,M70 –19–16AUG93–1/3
100–21 121997
PN=273
Troubleshooting
Charge Indicator and Low Oil Broken ground wire to alternator Inspect and repair.
Pressure Indicator Stay On With
Key Off
Failed alternator Repair or replace alternator.
Horn Does Not Sound Horn ground Ground horn to tractor frame.
Horn Replace horn.
Horn button Replace horn button.
Windshield Wiper Does Not Wiper fuse Check and replace.

Operate
Loose or broken wire Inspect wiring for breaks or loose
connections. Repair.
Wiper switch See your authorized dealer.
Wiper motor See your authorized dealer.
Heater Fan Does Not Operate Heater fuse Check and replace.
Loose or broken wire Inspect wiring for breaks or loose

connections. Repair.
Heater switch See your authorized dealer.
Heater motor See your authorized dealer.
No Work Or Driving Lights Driving light circuit breaker Turn key off to reset.
Poor ground light switch Inspect and tighten. See your

authorized dealer.
Burnt out burner Replace with new burner.
Rear Lights Do Not Operate Loose connector in wiring harness of Inspect and reconnect.
ROPS
Poor ground at light Inspect and tighten.
Dim Lights Low battery charge Check battery connections.

05T,100,M70 –19–16AUG93–2/3
100–22 121997
PN=274
Troubleshooting
Low alternator output Check belt tension and adjust.
Poor ground at lights Clean and tighten.
Return-To-Dig Does Not Operate Boom switch out of adjustment Check cam to see if it activates
switch. Adjust as required.
Wiring Inspect and repair wiring.
Solenoid on loader valve See your authorized dealer.
05T,100,M70 –19–16AUG93–3/3
100–23 121997
PN=275
Storage
PREPARE MACHINE FOR STORAGE
1. Repair worn or damaged parts. Install new parts, if
T47764 –UN–09NOV88
necessary, to avoid needless delays later.
2. Loosen alternator and fan belts.
TX,105,FF1190 –19–03AUG92–1/3
3. Clean primary air cleaner element.
4. Wash the machine. Paint areas to prevent rust.

Replace decals, where needed.
–UN–09FEB89
5. Retract all hydraulic cylinders, if possible. Stop engine.
IMPORTANT: LPS 3 Rust Inhibitor can destroy
T5813AM
painted finish. Do not spray LPS 3 Rust
Inhibitor on painted surfaces.
6. Coat exposed cylinder rods with LPS 3 Rust Inhibitor.
7. Lubricate all grease points.
8. Apply waste oil to track chains. Run machine back and

forth several times. Park on a hard surface to prevent
tracks from freezing to ground.
9. Remove seat cushion and other perishable items.
TX,105,FF1190 –19–03AUG92–2/3
105–1 121997
PN=276
Storage
10. Store machine in a dry, protected place. If stored

outside, cover with a waterproof material.
IMPORTANT: Prevent possible machine damage from

unauthorized persons operating
machine. Attach a "DO NOT OPERATE"
tag to the steering wheel.
11. Place a "DO NOT OPERATE" tag on the front

console latch.
12. Remove batteries.
13. Remove keys and lock all covers and doors.
T7447AO –19–22APR91
TX,105,FF1190 –19–03AUG92–3/3
105–2 121997
PN=277
Storage
MONTHLY STORAGE PROCEDURE
CAUTION: Start engine ONLY in a

well-ventilated area.
1. Drain water and sediment from fuel tank when air
T6181AU –UN–18OCT88
temperature is above freezing.
IMPORTANT: During cold temperatures, check fluidity

of engine oil on dipstick. If the oil
appears waxy and/or jelly-like rather
than liquid, DO NOT attempt to start
engine. Use external heat source to
warm the crankcase until oil appears
fluid.
2. Check all fluid levels. If low, check for leaks and add
oil as required.
3. Check and adjust belts.
4. Check electrolyte level.
5. Fill fuel tank.
6. Pre-lubricate turbocharger bearings:
a. Remove fuel shut-off solenoid wire (A) (on injection

pump. b. Turn engine crankshaft for no more than 20
seconds to prevent starting motor damage. Wait 2
minutes. Repeat starting a second time. c. Install
solenoid wire. d. Start engine. Run several minutes at
1/2 speed before operating under full load.
7. Bleed fuel system. If engine fails to start or runs poorly

after starting, change fuel filter(s). Bleed fuel system
again.
8. Run engine several minutes at 1/2 speed. Do not run

at fast or slow idle.
TX,105,RB84 –19–08DEC97–1/1
105–3 121997
PN=278
Crime Prevention Tips
HELP PREVENT CRIME
You can help take a bite out of crime by properly

documenting ownership and discouraging theft.
TS140 –19–07OCT88
DX,CRPRV,A –19–03MAR93–1/1
RECORD IDENTIFICATION NUMBERS
1. Mark your machines with your own unique numbering

system.
2. Record the Product Identification Number (PIN) of the

unit and also individual component identification
TS156 –UN–23MAR89
numbers for engines, axles, pumps, etc. Include the
PIN numbers on all documentation, such as insurance,
financial, and warranty papers.
DX,CRPRV,H –19–04JUN90–1/1
KEEP PROOF OF OWNERSHIP
1. Take color photographs from several angles of each

machine.
2. Maintain an up-to-date inventory of all your machines. TS157 –UN–23MAR89
3. Keep your documented identification numbers, color

photographs, and inventory in a safe, secure location.
DX,CRPRV,I –19–04JUN90–1/1
110–1 121997
PN=279
PARK INDOORS OUT OF SIGHT
Make machines hard to move:
• Park large equipment in front of exits.

• Lower equipment to the ground. Remove key.
• Remove battery when unit is in storage.
TS158 –UN–23MAR89
• Lock cab doors, windows, and vandal-proof devices.
• Lock building.
DX,CRPRV,J –19–04JUN90–1/1
WHEN PARKING OUTDOORS
Make machines hard to move:
• Park in a well-lighted, fenced area.

• Lower all equipment to the ground.
• Remove ignition key.
• Remove battery when unit is storage.
• Lock cab doors, windows, and vandal-proof devices.
DX,CRPRV,K –19–04JUN90–1/1
REDUCE VANDALISM
1. Install vandal-proof devices.
2. Participate in a neighborhood watch program. Take

written notes of suspicious vehicles or persons and
–UN–22FEB90
report your findings to law enforcement agency.
3. Regularly verify that identification plates have not been

removed. If they have, notify law enforcement agency.
Order duplicate plates from your dealer. T7223BB
TX,110,DH1093 –19–09DEC93–1/1
110–2 121997
PN=280
REPORT THEFTS IMMEDIATELY
1. Immediately notify your local law enforcement agency

and insurance agent.
2. Provide a complete description of the machine, all of

the documented identification numbers and color
photographs.
3. Request verification of the identification numbers after

they have been entered with any regional or national
crime information center. Double check the numbers to
be sure they are correct.
4. Notify your John Deere dealer of the theft and request

that its loss be posted with full description and
identification numbers.
TS146 –UN–09JAN89
DX,CRPRV,G –19–03MAR93–1/1
110–3 121997
PN=281
Specifications
450G CRAWLER DOZER SPECIFICATIONS
T7347AC –UN–23JUL90
TX,115,FF1816 –19–12JAN93–1/4
115–1 121997
PN=282
Specifications
NOTE: Specifications and design subject to change 80 kg (175 lb) operator, and standard
without notice. Whenever applicable, equipment.
specifications are in accordance with ICED
and SAE standards. Except where otherwise Blade capacity shown is for a 2230 mm (7 ft
noted, these specifications are based on a unit 3.8 in.) blade. All blades are interchangeable
with roll-over protective structure, full fuel tank, between the 450G, 550G, and the 650G.
A—Canopy extension 60 mm (2.4 in.)

B—Canopy height 2.70 m (8 ft 10 in.)
C—Blade height 827 mm (2 ft 8.6 in.)
D—Blade lift height 815 mm (2 ft 8.1 in.)
E—Digging depth 504 mm (1 ft 7.9 in.)
F—Blade tilt (right side):
Standard blade 330 mm (1 ft 1 in.)
Wide blade 391 mm (1 ft 3.4 in.)
G—Blade tilt (left side):
H—Drawbar extension 280 mm (11 in.)
I—Overall length 3917 mm (12 ft 10.2 in.)
J—Blade width:
Standard blade (angled width) 2230 mm (7 ft 3.8 in.)
Wide blade (angled width) 2686 mm (8 ft 9.7 in.)
Standard 2464 mm (8 ft 1 in.)
Wide 2921 mm (9 ft 7 in.)
Track gauge: 1450 mm (57 in.)

Blade capacity:
Standard blade 1.3 m3 (1.63 yd3 )
Wide blade 1.6 m3 (2.1 yd3 )
TX,115,FF1816 –19–12JAN93–2/4
115–2 121997
PN=283
Specifications
Engine: John Deere 4045D (Direct Drive only) or 4045T (S.N. —840460) or John Deere PowerTech 4.5L engine type 4045TT061 (S.N.
840461— )
Type Naturally aspirated (4045D) altitude compensating
turbocharge (4045T)
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. —840460) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Fuel consumption, typical (S.N. 840461— ) 6.3 to 9.5 L/h (1.7 to 2.5 gal/hr)
Compression ratio (S.N. —840460) 17.8 to 1
Compression ratio (S.N. 840461— ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator 65 amp
SAE net power at 2100 rpm 52 kW (70 hp)
SAE gross power at 2100 rpm 54.5 kW (73 hp)
Maximum net torque at 1300 rpm 309 N•m (228 lb-ft)
Drawbar 38 kW (51 hp)
Displacement (S.N. —840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461— ) 4.5 L
Transmission: Powershift (4F-4R) with torque converter or direct drive. Full power shift, Dura-Shift with torque converter or direct drive,
designed and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or
using a clutch. Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the
working conditions.
Hydraulic pump: Gear

Pressure 18 961 kPa (2750 psi)
Flow at 2100 rpm 64 L/min (17 gpm)
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closed-center 406 mm (16 in.)
Track shoes, each side 37
Ground contact area 15 690 cm2 (2432 in.2 )
Ground pressure (direct drive) 44.6 kPa (6.47 psi)
Ground pressure (torque converter) 45.2 kPa (6.55 psi)
TX,115,FF1816 –19–12JAN93–3/4
115–3 121997
PN=284
Specifications
Operating Weight (with ROPS):

Direct Drive 7152 kg (15 732 lb)
Torque Converter 7243 kg (15 932 lb)
With Wide Shoes (Direct Drive) 7586 kg (16 688 lb)
With Wide Shoes (Torque Converter) 7677 kg (16 888 lb)
TX,115,FF1816 –19–12JAN93–4/4
450G DRAIN AND REFILL CAPACITIES

Metric English
Fuel tank 155 L 41 gal
Engine coolant 17 L 18 qt
Engine oil, including filter change (S.N. —840460) 8.5 L 9 qt
Engine oil, including filter change (S.N. 840461— ) 14 L 14.8 qt
Transmission:
Transmission, direct drive (S.N. —790984) 80.25 L 21.2 gal add 34 L (9 gal) w/winch if
equipped
Transmission, direct drive (S.N.790985— ) 102 L 27 gal add 34 L (9 gal) w/winch if
equipped
Transmission, torque converter 102 L 27 gal add 34 L (9 gal) w/winch if
equipped
Hydraulic reservoir 38 L 10 gal
Hydraulic system 55.3 L 14.6 gal
Final drive (each side) 6.6 L 7 qt
TX,115,FF1917 –19–08OCT93–1/1
115–4 121997
PN=285
Specifications
450G—LT CRAWLER DOZER SPECIFICATIONS
TX,115,FF1816 –19–12JAN93–1/3
115–5 121997
PN=286
Specifications

J—Blade width:

Blade capacity:
TX,115,FF1816 –19–12JAN93–2/3
115–6 121997
PN=287
Specifications
840461— )
Type Naturally aspirated (4045D) or altitute compensating
turbocharge (4045T)
No. of cylinders 4
Battery 12 volt
Alternator (S.N. —840460) 65 amp
Alternator (S.N. 840461— ) 95 amp
working conditions.

Steering:
Brakes Wet band
Undercarriage:

TX,115,FF1816 –19–12JAN93–3/3
115–7 121997
PN=288
Specifications
450G—LT DRAIN AND REFILL CAPACITIES
Metric English
Transmission:
equipped
equipped
equipped
TX,115,FF1917 –19–08OCT93–1/1
115–8 121997
PN=289
Specifications
450G—LGP CRAWLER DOZER SPECIFICATIONS
TX,115,FF1816 –19–12JAN93–1/3
115–9 121997
PN=290
Specifications

J—Blade width:

Blade capacity:
TX,115,FF1816 –19–12JAN93–2/3
115–10 121997
PN=291
Specifications
840461— )
Type Naturally aspirated or altitude compensating
turbocharge
No. of cylinders 4
Battery 12 volt
Alternator 65 amp
working conditions.

Steering:
Brakes Wet band
Undercarriage:

450G—LGP Direct Drive 7833 kg (17 232 lb)
450G—LGP Torque Converter 7924 kg (17 432 lb)
TX,115,FF1816 –19–12JAN93–3/3
115–11 121997
PN=292
Specifications
450G—LGP DRAIN AND REFILL CAPACITIES
Metric English
Transmission:
equipped
equipped
equipped
TX,115,FF1917 –19–08OCT93–1/1
115–12 121997
PN=293
Specifications
550G—LT CRAWLER DOZER SPECIFICATIONS
TX,115,FF1816 –19–12JAN93–1/3
115–13 121997
PN=294
Specifications

Standard blade 357 mm (1 ft 2.1 in.)
J—Blade width:

Blade capacity:
TX,115,FF1816 –19–12JAN93–2/3
115–14 121997
PN=295
Specifications
Engine: John Deere 4045T (S.N. —840460) or John Deere PowerTech 4.5L engine type 4045TT062 (S.N. 840461— )
Type Turbocharged
No. of cylinders 4
Fuel consumption, typical (S.N. —840460) 7.0 to 10.5 L/h (1.8 to 2.8 gal/h)
Fuel consumption, typical (S.N. 840461— ) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Battery 12 volt
SAE net power at 2100 rpm 59.5 kW (80 hp)
SAE gross power at 2100 rpm 62 kW (83 hp)
working conditions.

Steering:
Brakes Wet band
Undercarriage:

TX,115,FF1816 –19–12JAN93–3/3
115–15 121997
PN=296
Specifications
550G—LT DRAIN AND REFILL CAPACITIES
Metric English
Transmission:
equipped
equipped
equipped
TX,115,FF1917 –19–08OCT93–1/1
115–16 121997
PN=297
Specifications
TX,115,FF1816 –19–12JAN93–1/3
115–17 121997
PN=298
Specifications

J—Blade width:

Blade capacity:
TX,115,FF1816 –19–12JAN93–2/3
115–18 121997
PN=299
Specifications
Type Turbocharged
No. of cylinders 4
Battery 12 volt
SAE gross power at 2100 rpm 62 kW (83 hp)
working conditions.

Steering:
Brakes Wet band
Undercarriage:

TX,115,FF1816 –19–12JAN93–3/3
115–19 121997
PN=300
Specifications
Metric English
Transmission:
equipped
equipped
equipped
TX,115,FF1917 –19–08OCT93–1/1
115–20 121997
PN=301
Specifications
650G CRAWLER DOZER SPECIFICATIONS
TX,115,FF1816 –19–12JAN93–1/3
115–21 121997
PN=302
Specifications

B—Canopy height 2794 mm (9 ft 2 in.)
I—Overall length 4070 mm (13 ft 4 in.)
J—Blade width:

Blade capacity:
TX,115,FF1816 –19–12JAN93–2/3
115–22 121997
PN=303
Specifications
Type Turbocharged
No. of cylinders 4
Battery 12 volt
SAE gross power at 2100 rpm (direct drive) 71 kW (95 hp)
SAE gross power at 2100 rpm (torque converter) 74 kW (99 hp)
working conditions.

Steering:
Brakes Wet band
Undercarriage:

TX,115,FF1816 –19–12JAN93–3/3
115–23 121997
PN=304
Specifications
650G DRAIN AND REFILL CAPACITIES
Metric English
Transmission:
equipped
equipped
equipped
Hydraulic system 56.8 L 15 gal
TX,115,FF1917 –19–08OCT93–1/1
115–24 121997
PN=305
Specifications
TX,115,FF1816 –19–12JAN93–1/4
115–25 121997
PN=306
Specifications

B—Canopy height 2794 mm (9 ft 2 in.)
I—Overall length 4070 mm (13 ft 4 in.)
J—Blade width:

Blade capacity:
TX,115,FF1816 –19–12JAN93–2/4
115–26 121997
PN=307
Specifications
Type Turbocharged
No. of cylinders 4
Battery 12 volt
SAE gross power at 2100 rpm (direct drive) 71 kW (95 hp)
SAE gross power at 2100 rpm (torque converter) 74 kW (99 hp)
working conditions.

Steering:
Brakes Wet band
Undercarriage:
Grouser, closed-center (standard shoe) 610 mm (24 in.)
Grouser, closed-center (wide shoe) 660 mm (26 in.)
Ground contact area (standard shoe) 26 510 cm2 (4109 in.2 )
Ground contact area (wide shoe) 28 717 cm2 (4451 in.2)
Ground pressure (direct drive, standard shoe) 32.1 kPa (4.65 psi)
Ground pressure (torque converter, standard shoe) 32.4 kPa (4.70 psi)
Ground pressure (direct drive, wide shoe) 30.4 kPa (4.41 psi)
Ground pressure (torque converter, wide shoe) 30.7 kPa (4.45 psi)
TX,115,FF1816 –19–12JAN93–3/4
115–27 121997
PN=308
Specifications

TX,115,FF1816 –19–12JAN93–4/4
Metric English
Transmission:
equipped
equipped
equipped
Hydraulic system 56.8 L 15 gal
TX,115,FF1917 –19–08OCT93–1/1
115–28 121997
PN=309
Specifications
9310 BACKHOE SPECIFICATIONS
A 3.25 m (10 ft 8 in.)

B 5.30 m (17 ft 4.5 in.)
C—Flat Bottom 4.00 m (13 ft 1.2 in.)
2440 mm (8 ft)
D—Flat Bottom 4.35 m (14 ft 3.4 in.)
610 mm (2 ft)
E 4.40 m (14 ft 5.3 in.)
–UN–20DEC90
T7394BK
TX,115,FF2056 –19–14APR94–1/1
115–29 121997
PN=310
Specifications
9310 BACKHOE LIFT CAPACITY (G SERIES LOADERS)
T7395DA –19–12OCT90
A—1700 kg (3750 lb) F—910 kg (2010 lb) K—795 kg (1755 lb) P—785 kg (1730 lb)
B—1525 kg (3365 lb) G—900 kg (1990 lb) L—770 kg (1700 lb) Q—Dipper Lift, Boom at
C—1530 kg (3370 lb) H—880 kg (1940 lb) M—750 kg (1660 lb) 65°
D—1640 kg (3620 lb) I—850 kg (1880 lb) N—740 kg (1630 lb) R—Swing Pivot
E—880 kg (1950 lb) J—820 kg (1814 lb) O—740 kg (1630 lb) S—Boom Lift
Lifting capacity ratings made from bucket hinge pin, percent of the tipping load. Angle between boom and
loader bucket and stabilizer on firm, level ground. ground at 65 degrees. Machine equipped with 610 mm
Lifting capacities are 87 percent of the maximum lift (24 in.) trenching bucket and standard dipperstick.
over any point on the swing arc and do not exceed 75
TX,115,FF2057 –19–08FEB93–1/1
115–30 121997
PN=311
Specifications
9310 BACKHOE LIFT CAPACITY (G-SERIES DOZERS)
T7395DA1 –UN–12DEC92
A—1700 kg (3750 lb) F—960 kg (2120 lb) K—845 kg (1865 lb) P—835 kg (1845 lb)
B—1525 kg (3365 lb) G—955 kg (2105 lb) L—820 kg (1810 lb) Q—Dipper Lift, Boom at
C—1530 kg (3370 lb) H—930 kg (2050 lb) M—800 kg (1765 lb) 65°
D—1670 kg (3685 lb) I—900 kg (1990 lb) N—790 kg (1740 lb) R—Swing Pivot
E—930 kg (2050 lb) J—870 kg (1925 lb) O—790 kg (1740 lb) S—Boom Lift
Lifting capacity ratings made from bucket hinge pin, tipping load. Angle between boom and ground at 65
loader bucket and stabilizer on firm, level ground. degrees. Machine equipped with 610 mm (24 in.)
Lifting capacities are 87° of the maximum lift over any trenching bucket and standard dipperstick.
point on the swing arc and do not exceed 75° of the
TX,115,FF2058 –19–12JAN93–1/1
115–31 121997
PN=312
Specifications
4000 WINCH
Maximum Cable Capacities

Cable Size Winch Capacity
15.88 mm (0.625 in.) 77.4 m (254 ft)
19.05 mm (0.75 in.) 54.6 m (179 ft)
22.23 mm (0.875 in.) 39.3 m (129 ft)
TX,115,RR2763 –19–12JAN93–1/1
115–32 121997
PN=313
Machine Numbers
GENERAL
Record Product Identification Number (Pin)
Purchase Date:
–UN–09NOV92
NOTE: Record all 13 characters of the Product
Identification Number.
T7883AM
TX,120,RB51 –19–03DEC97–1/1
RECORD ENGINE SERIAL NUMBER

Engine Serial Number (A):
05T,120,M8 –19–12JAN93–1/1
120–1 121997
PN=314
Checklists
KEEPING SYSTEM
BREAK-IN SERVICE INTERVALS

Break-in service is required for your machine at intervals shown in chapter 15. Refer to chapter 15 during the first 100 hours of machine
operation. After 100 hours, refer to service intervals in chapter 50.
SERVICE INTERVALS AFTER BREAK-IN
Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at
500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily.
AS REQUIRED
•Inspect belts and check tension •Check and adjust track sag
•Check air cleaner restriction indicator •Drain fuel tank sump
•Check pre-cleaner
EVERY 10 HOURS OR DAILY
•Grease dozer linkage •Check hydraulic system oil level
•Check engine oil level •Check coolant level at recovery tank (later machines)
•Check transmission oil level •Check radiator coolant level (earlier machines)
EVERY 100 HOURS
•Grease boom linkage and cylinders
REQUIRED PARTS
Insure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated
parts are also on-hand, i.e., filter O-rings.
03T,50,M76 –19–20DEC94–1/3
CLIS–1 121997
PN=315
Checklists
Description Unit Part Number ASI 250 500 1000 2000

Engine Oil Filter T19044 1 1 1 1 1
Fuel Filter AR50041 1 1 1
Hydraulic System Oil Filter AT120444 1 1 1 1
Transmission Oil Filter:
(S.N. —774221) AH128449 1 1 1 1
(S.N. 774222— ) AT105663 1 1 1 1
Hydraulic Reservoir Breather AT101565 1 1 1
Engine Oil (Engine S.N. —742285)
PLUS-50 450G TY6389 8.5 L (9 8.5 L (9 8.5 L (9 8.5 L (9 8.5 L (9
qt) qt) qt) qt) qt)
550G, TY6389 12.3 L 12.3 L 12.3 L 12.3 L 12.3 L
650G (13 qt) (13 qt) (13 qt) (13 qt) (13 qt)
Engine Oil (Engine S.N. 742286— )
PLUS-50 450G, TY6389 14L (15 14L (15 14L (15 14L (15 14L (15
550G, qt) qt) qt) qt) qt)
650G
Air Cleaner Filter - Primary AT39124 1 1
(4045D engines)
AT65296 (4045T
engines)
Air Cleaner Filter - Secondary AT44378 1 1
(4045D engines)
AT31227 (4045T
engines)
Description Part Number ASI 250 500 1000 2000

HY-GARD Transmission and Hydraulic Oil
Without 4000 Winch TY6354 98.4 L 98.4 L
(26 gal) (26 gal)
With 4000 Winch TY6354 132 L (35 132 L
gal) (35 gal)
OILSCAN Kits
Diesel Engine Oil AT178840 1 1 1 1
Transmission Oil and Gearbox AT178843 1 1 1
Hydraulic Oil AT178844 1 1 1
Coolant Conditioner TY16004 As needed
CoolScan Kit (Ten samples per kit) AT183016 1 1

HY-GARD is a trademark of Deere & Company
OILSCAN is a trademark of Deere & Company
CoolScan is a trademark of Deere & Company 03T,50,M76 –19–20DEC94–2/3
CLIS–2 121997
PN=316
Checklists
Model: ❒ 450G ❒ 550G ❒ 650G Customer:

PIN/Serial Number: Delivery Date: Hour Meter Reading:
OIL SAMPLING
Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form: 250, 500, 1000, 2000
hours. Maintenance recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you
supply. Regular oil sampling will extend the operational life of your machine’s systems.
Every 250 Hours
❒ Check radiator coolant level—Later Machines ❒Clean top of transverse case
❒ Check inner and outer final drive oil level ❒ Change engine oil and filter elements
Comments:

Every 500 Hours
❒ Replace fuel filter ❒ Check air intake hoses
❒ Check battery water level, clean and tighten terminals ❒ Add non-chromate rust inhibitor to radiator
❒ Change hydraulic system oil filter ❒ Change transmission oil filter
❒ Change hydraulic reservoir breather filter
Comments:
Every 1000 Hours
❒ Check transmission accumulator ❒ Change final drive oil
❒ Check hydraulic system oil, clean suction screen ❒ Check engine speed linkage
❒ Change transmission oil, clean suction screen ❒ Adjust engine valve lash (S.N. —840460)
❒ Drain and flush engine cooling system ❒Clean enginie crankcase vent tube
Comments:
Every 2000 Hours (S.N. 840461— )
❒ Adjust engine valve lash (S.N. 840461— )
Comments:
OILSCAN is a registered trademark of Deere & Company. 03T,50,M76 –19–20DEC94–3/3
CLIS–3 121997
PN=317
Checklists
CLIS–4 121997
PN=318
Index
Page Page
4 Cleaner elements inspection . . . . . . . . . . . . . . 90-8

Alarm indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
450G crawler Alarm, reverse warning. . . . . . . . . . . . . . . . . . . 90-17
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 115-1 Alternator
450G-LGP crawler Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 115-9 Voltage indicator . . . . . . . . . . . . . . . . . . . . . . . 10-4
450G-LT crawler Antifreeze test . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 115-5 Antifreeze
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-14
Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-4
Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
5 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-1
550G-LGP crawler
Specifications . . . . . . . . . . . . . . . . . . . . . . . 115-17
550G-LT crawler B
Specifications . . . . . . . . . . . . . . . . . . . . . . . 115-13
Backhoe
Attaching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-1
Bucket digging . . . . . . . . . . . . . . . . . . . . . . . 36-13
6 Bucket, changing positions . . . . . . . . . . . . . . 36-10
Control lever . . . . . . . . . . . . . . . . . . . . . . . . . . 36-7
650G crawler Control levers . . . . . . . . . . . . . . . . . . . . . . . . . 36-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . 115-21 Detaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-3
650G-LGP crawler Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . 115-25 Battery
Acid burns. . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-6
Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
9 Disconnect switch . . . . . . . . . . . . . . . . . . . . . 10-13
Electrolyte level. . . . . . . . . . . . . . . . . . . . . . . . 80-8
9310 backhoe specifications. . . . . . . . . . . . . . 115-29
Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . 25-7
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
A Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-10
Accumulator Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Transmission check . . . . . . . . . . . . . . . . . . . . 85-1 Blade lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1
Acid burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13 Blade pitch operation . . . . . . . . . . . . . . . . . . . . . 35-4
Adjustment Booster, battery . . . . . . . . . . . . . . . . . . . . . . . . . 25-6
Belt tension. . . . . . . . . . . . . . . . . . . . . . .. .. . 55-1 Bottom guard removal . . . . . . . . . . . . . . . . . . . . 50-5
Engine speed control linkage, declutch . .. .. 85-11 Brake lock lever . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Engine speed control linkage . . . . . . . . .. .. . 85-9 Brake
Engine valve clearances . . . . . . . . . . . . .. .. 85-13 Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Front idler height. . . . . . . . . . . . . . . . . . .. .. 90-26 Break-In Engine Oil . . . . . . . . . . . . . . . . . . . . . . 15-1
Injection pump . . . . . . . . . . . . . . . . . . . .. .. 25-11 Break-in
Reverse warning alarm volume. . . . . . . .. .. 90-17 10 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Track sag . . . . . . . . . . . . . . . . . . . . . . . .. .. . 55-4 100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Winch free spool drag . . . . . . . . . . . . . . .. .. 36-19
Air intake hose . . . . . . . . . . . . . . . . . . . . . .. .. . 80-4
Air restriction indicator . . . . . . . . . . . . . . . .. .. . 55-2 C
Air
Changing elements . . . . . . . . . . . . . . . . . . . . 85-17 Cable, winch. . . . . . . . . . . . . . . . . . . . . . . . . . . 36-16
Index-1 121997
PN=1
Index
Page Page
Capacity, fuel tank . . . . . . . . .. .. .. .. .. .. .. . 45-4 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-15

Carrier roller oil specification .. .. .. .. .. .. .. . 45-6 Crankcase vent tube . . . . . . . . . . . . . . . . . . . 85-12
Circuit breakers . . . . . . . . . . .. .. .. .. .. .. .. 90-16 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1
Cold weather starting . . . . . . .. .. .. .. .. .. .. . 25-4 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Cold weather Oil pressure indicator . . . . . . . . . . . . . . . . . . . 10-3
Machine warming . . . . . . . .. .. .. .. .. . . . . . 25-9 Speed control lever . . . . . . . . . . . . . . . . . . . . . 30-3
Compartments . . . . . . . . . . . .. .. .. .. .. . . . . 30-11 Speed control linkage adjustment . . . . . . . . . . 85-9
Console . . . . . . . . . . . . . . . . .. .. .. .. .. .10-1, 10-2 Speed linkage with declutch . . . . . . . . . . . . . 85-11
Control valve . . . . . . . . . . . . .. .. .. .. .. . . . . 90-38 Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-8
Coolant, engine . . . . . . . . . . .. .. .. .. .. . . . . 85-15 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
Coolant Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10
Changing . . . . . . . . . . . . . .. .. .. .. .. . . . . 85-14 Valve clearances, adjust . . . . . . . . . . . . . . . . 85-13
Conditioner . . . . . . . . . . . . .. .. .. .. .. . . . . 80-10 Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8
Heater. . . . . . . . . . . . . . . . .. .. .. .. .. . . . . . 25-5
Level. . . . . . . . . . . . . . . . . .. .. .. .. .. .60-4, 75-3
Test . . . . . . . . . . . . . . . . . .. .. .. .. .. . . . . . 90-2
Cooling system fill . . . . . . . . .. .. .. .. .. . . . . 85-16
Cylinder service . . . . . . . . . . .. .. .. .. .. . . . . 90-38 F
Cylinder
Track adjuster . . . . . . . . . . . . . . . . . . . . . . . . . 75-2 Fan, reversible . . . . . . . . . . . . . . . . . . . . . . . . . 90-38
Filter
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1
Fuel (SN -840460) . . . . . . . . . . . . . . . . . . . . . 80-1
D
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
Decelerator pedal declutch operation . . . . . . . . . 35-7 Hydraulic oil indicator . . . . . . . . . . . . . . . . . . . 10-5
Decelerator Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . 80-6
Pedal . . . . . . . . . . . . . . . . . . . . . . . . . .10-11, 30-4 Hydraulic reservoir breather . . . . . . . . . . . . . . 80-6
Diesel engine oil . . . . . . . . . . . . . . . . . . . . . . . . . 45-5 Transmission oil indicator . . . . . . . . . . . . . . . . 10-5
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1 Transmission suction screen . . . . . . . . . . . . . . 85-4
Digging Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . 80-5
Backhoe bucket . . . . . . . . . . . . . . .. .. .. .. 36-13 Final drive
Crowd . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. 36-13 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-8
Dozer linkage, lubricate . . . . . . . . . . .. .. .. .. . 60-5 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-2
Driving the machine . . . . . . . . . . . . . .. .. .. .. . 30-1 Oil specification. . . . . . . . . . . . . . . . . . . . . . . . 45-6
Fire extinguisher. . . . . . . . . . . . . . . . . . . . . . . . 90-38
Front idler
Oil specification. . . . . . . . . . . . . . . . . . . . . . . . 45-6
E Vertical movements. . . . . . . . . . . . . . . . . . . . 90-25
Fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-6
Electrolyte
Fuel tank
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 90-12
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4
Emergency stopping-pedal steering . . . . . . . . . . 30-9
Engine oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-7
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Outlet screen . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-5 Fuel
Engine Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2
Alternator voltage indicator . . . . . . .. .. .. .. . 10-4 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Altitude adjustment . . . . . . . . . . . . .. .. .. .. 25-11 Filler screen . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Boost starting . . . . . . . . . . . . . . . . .. .. .. .. . 25-7 Filter change (SN -840460) . . . . . . . . . . . . . . . 80-1
Coolant heater . . . . . . . . . . . . . . . .. .. .. .. . 25-5 Filter change (SN 840461- ) . . . . . . . . . . . . . . 80-3
Coolant level . . . . . . . . . . . . . . . . . .. .. .. .. . 60-4 Filter drain sediment . . . . . . . . . . . . . . . . . . . . 90-3
Coolant temperature indicator . . . . .. .. .. .. . 10-4 Injection pump adjustment . . . . . . . . . . . . . . 25-11
Index-2 121997
PN=2
Index
Page Page
G Instrument
Before starting check . . . . . . . . . . . . . . . . . . . 25-1
Grease Panel (SN -823918) . . . . . . . . . . . . . . . . . . . . 10-1
Extreme pressure and multipurpose . . . . . . . . 45-8 Panel (SN 823919- ) . . . . . . . . . . . . . . . . . . . . 10-2
Greasing Instruments
Backhoe . . . . . . . . . . . . . . . . . . . . . . .. .. .. . 36-9 Check after starting. . . . . . . . . . . . . . . . . . . . . 25-8
Log arch-if equipped . . . . . . . . . . . . . .. .. .. 36-20
Ripper-if equipped. . . . . . . . . . . . . . . .. .. .. 36-19
Track adjuster cylinder . . . . . . . . . . . .. .. .. . 75-2 L
Winch fairlead-if equipped. . . . . . . . . .. .. .. 36-19
Left steering pedal . . . . . . . . . . . . . . . . . . . . . . 10-11
Lever
Backhoe control . . . . . . . . . . . . . . . . . . .36-7, 36-8
H Blade, one lever option . . . . . . . . . . . . . . . . . . 35-6
Blade, two lever option . . . . . . . . . . . . . . . . . . 35-1
Horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Brake lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Hydraulic oil Engine speed control . . . . . . . . . . . . . . . . . . . 30-3
Filter restriction indicator . . . . . . . . . . . . . . . . . 10-5 One lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Hydraulic Park and brake lock . . . . . . . . . . . . . . . . . . . 10-13
Fittings, 30° cone seat . . . .. .. .. .. .. .. .. 90-45 Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Fittings, 37° flare. . . . . . . . .. .. .. .. .. .. .. 90-45 Speed control . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Oil change . . . . . . . . . . . . .. .. .. .. .. .. .. . 85-1 Stabilizer control . . . . . . . . . . . . . . . . . . . . . . . 36-7
Oil filter . . . . . . . . . . . . . . . .. .. .. .. .. .. .. . 80-6 Steering . . . . . . . . . . . . . . . . . . . . . . . .10-12, 30-4
Oil level. . . . . . . . . . . . . . . .. .. .. .. .. .. .. . 60-3 Transmission shift . . . . . . . . . . . . . . . . . . . . . 10-13
Reservoir breather filter. . . .. .. .. .. .. .. .. . 80-6 Two lever option . . . . . . . . . . . . . . . . . . . . . . 10-10
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-11
Lights operation . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Loading
I Machine on a trailer . . . . . . . . . . . . . . . . . . . . 40-1
Lubricant
Idler height adjustment . . . . . . . . . . . . . . . . . . . 90-26 Alternative. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9
Idler Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-8
Height adjustment . . . . . . . . . .. .. .. .. .. .. 90-26 Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-9
Oil fill . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. 90-31 Lubricate
Oil level. . . . . . . . . . . . . . . . . .. .. .. .. .. .. 90-31 Fittings, dozer linkage . . . . . . . . . . . . . . . . . . . 60-5
Vertical movement check . . . .. .. .. .. .. .. 90-25
Inch torque values . . . . . . . . . . .. .. .. .. .. .. 90-41
Indicator M
Air restriction. . . . . . . . . . . . . .. .. .. .. .. .. . 55-2
Alarm . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. . 10-3 MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Engine alternator voltage . . . .. .. .. .. .. .. . 10-4 Machine
Engine coolant temperature . .. .. .. .. .. .. . 10-4 Cold weather warming . . . . . . . . . . . . . . . . . . 25-9
Engine oil pressure . . . . . . . . .. .. .. .. .. .. . 10-3 Maintenance position . . . . . . . . . . . . . . . . . . . 50-4
Hydraulic oil filter . . . . . . . . . .. .. .. .. .. .. . 10-5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-1
Service required . . . . . . . . . . .. .. .. .. .. .. . 10-3 Maintenance repair record . . . . . . 50-5, 50-7, CLIS-1
Stop . . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. . 10-3 Metric torque values . . . . . . . . . . . . . . . . . . . . . 90-43
Transmission oil filter . . . . . . .. .. .. .. .. .. . 10-5
Transmission oil temperature .. .. .. .. .. .. . 10-4
Injection N
Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 Neutral start system . . . . . . . . . . . . . . . . . . . . . 90-18
Index-3 121997
PN=3
Index
Page Page
Non-suspension seat . . . . . . . . . . . . . . . . . . . . 10-14 P
Park brake
Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
O Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Parking machine. . . . . . . . . . . . . . . . . . . . . . . . 30-11
Pedal Pedal steering with torque converter . . . 10-12
O-ring boss fittings . . . . . . . . . . . . . . . . . . . . . . 90-46
Pedal
Oil change
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Engine . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . 75-1
Decelerator declutch option. . . . . . . . . . . . . . . 35-7
Final drive. . . . . . . . . . . . . . . . . . . . . .. .. .. . 85-8
Decelerator . . . . . . . . . . . . . . . . . . . . . .10-11, 30-4
Hydraulic. . . . . . . . . . . . . . . . . . . . . . .. .. .. . 85-1
Power control . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Transmission. . . . . . . . . . . . . . . . . . . .. .. .. . 85-4
Steering with torque converter . . . . . . . . . . . . 30-5
Winch . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . 85-4 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Oil level Power control pedal . . . . . . . . . . . . . . . . . . . . . 10-11
Engine . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . 60-1 Pre-cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2
Final drive. . . . . . . . . . . . . . . . . . . . . .. .. .. . 75-2
Hydraulic. . . . . . . . . . . . . . . . . . . . . . .. .. .. . 60-3
Idler . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. 90-31
Track carrier . . . . . . . . . . . . . . . . . . . .. .. .. 90-29 R
Track roller . . . . . . . . . . . . . . . . . . . . .. .. .. 90-33
Transmission. . . . . . . . . . . . . . . . . . . .. .. .. . 60-2 ROPS cap screw torque . . . . . . . . . . . . . . . . . . 90-39
Oil Radiator
Final drive. . . . . . . . . . . . . . . . . . . . . .. .. .. . 45-6 Coolant conditioner . . . . . . . . . . . . . . . . . . . . 80-10
Final drives . . . . . . . . . . . . . . . . . . . . .. .. .. . 45-7 Coolant level . . . . . . . . . . . . . . . . . . . . . .60-4, 75-3
Hydraulic. . . . . . . . . . . . . . . . . . . . . . .. .. .. . 45-7 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
Specification carrier roller . . . . . . . . . .. .. .. . 45-6 Recovery tank coolant level . . . . . . . . . . . . . . . . 60-4
Specification front idler . . . . . . . . . . . .. .. .. . 45-6 Regulator precaution . . . . . . . . . . . . . . . . . . . . . 90-9
Specification track roller . . . . . . . . . . .. .. .. . 45-6 Repair record . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Steering clutches . . . . . . . . . . . . . . . .. .. .. . 45-7 Reverse warning alarm. . . . . . . . . . . . . . . . . . . 90-17
Transmission. . . . . . . . . . . . . . . . . . . .. .. .. . 45-7 Right steering pedal . . . . . . . . . . . . . . . . . . . . . 10-11
Operating lights . . . . . . . . . . . . . . . . . . .. .. .. 10-18 Roller
Operating tips . . . . . . . . . . . . . . . . . . . . .. .. .. . 35-8 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
Operating
Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-6
Operational check S
Accessory . . . . . . . . . . . . . . . . . . . . . .. .. .. 95-14
Driving . . . . . . . . . . . . . . . . . . . . . . . .. .. .. 95-11 Screen
Hydraulic system. . . . . . . . . . . . . . . . .. .. .. 95-12 Fuel filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Power control clutch . . . . . . . . . . . . . .. .. .. 95-10 Fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Undercarriage . . . . . . . . . . . . . . . . . . .. .. .. 95-13 Transmission suction . . . . . . . . . . . . . . . . . . . 85-4
Operational checkout Seat
Brake system check . . . . . . . . . . . . . . . . . . . . 95-7 Non-suspension adjustment . . . . . . . . . . . . . 10-14
Engine speed and decelerator check . . . . . . . 95-5 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Grouser wear and bent shoe. . . . . . . . . . . . . 95-14 Seatbelt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Hydraulic warm-up . . . . . . . . . . . . . . . .95-8, 95-12 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
Indicators, shift linkage, alarm . . . . . . . . . . . . . 95-2 Service required indicator. . . . . . . . . . . . . . . . . . 10-3
Neutral start switch and circuit . . . . . . . . . . . . 95-4 Shield vandal . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-16 Shifting the transmission. . . . . . . . . . . . . . . . . . . 30-3
Sprocket wear. . . . . . . . . . . . . . . . . . . . . . . . 95-13 Specification
Steering system . . . . . . . . . . . . . . . . . . . . . . . 95-8 9310 backhoe lift capacities . . . . . . . . . . . . 115-30
Operator’s manual holder . . . . . . . . . . . . . . . . . 10-16 Battery electrolyte . . . . . . . . . . . . . . . . . . . . . 90-12
Index-4 121997
PN=4
Index
Page Page
Carrier roller oil . . . . . . . . . . . . . .. .. .. .. .. . 45-6 Chain-single tooth split link . . . . . . . . . . . . . . 90-23

Final drive oil . . . . . . . . . . . . . . .. .. .. .. .. . 45-6 Chain-split link . . . . . . . . . . . . . . . . . . . . . . . 90-20
Front idler oil. . . . . . . . . . . . . . . .. .. .. .. .. . 45-6 Roller oil specification . . . . . . . . . . . . . . . . . . . 45-6
Track roller oil . . . . . . . . . . . . . . .. .. .. .. .. . 45-6 Shoe torque . . . . . . . . . . . . . . . . . . . . . . . . . 90-40
Speed Trailer loading . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 Transmission
Stabilizer control levers . . . . . . . . . . . . . . . . . . . 36-7 Accumulator check . . . . . . . . . . . . . . . . . . . . . 85-1
Starting fluid, cold weather start . . . . . . . . . . . . . 25-4 Low pressure indicator . . . . . . . . . . . . . . . . . . 10-4
Steering Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-4
Levers,if equipped. . . . . . . . . . . .. .. .. .. .. 10-12 Oil filter indicator . . . . . . . . . . . . . . . . . . . . . . . 10-5
Pedals. . . . . . . . . . . . . . . . . . . . .. .. .. .. .. 10-11 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-5
The machine-lever steering . . . . .. .. .. .. .. . 30-4 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Torque converter, pedal . . . . . . .. .. .. .. .. . 30-5 Oil temperature indicator. . . . . . . . . . . . . . . . . 10-4
Stop indicator . . . . . . . . . . . . . . . . .. .. .. .. .. . 10-3 Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Stopping the machine-emergency Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Lever steering . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Suction screen . . . . . . . . . . . . . . . . . . . . . . . . 85-4
Pedal steering . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Transverse case, clean . . . . . . . . . . . . . . . . . . . 75-2
Stopping the machine. . . . . . . . . . . . . . . . . . . . . 30-8 Travel speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Storage Troubleshooting
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-1 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-10
Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . . 45-8 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-2
Suspension seat adjustment. . . . . . . . . . . . . . . 10-15 Gauges and indicators . . . . . . . . . . . . . . . . 100-21
Switch Hydraulic system. . . . . . . . . . . . . . . . . . . . . 100-14
Battery disconnect . . . . . . . . . . . . . . . . . . . . 10-13 Power train . . . . . . . . . . . . . . . . . . . . . . . . . 100-17
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . 45-9
U
Undercarriage operating tips. . . . . . . . . . . . . . . . 35-9

T
Torque converter
Pedal steering . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 V
Torque value
30° cone seat hydraulic fittings . .. .. . . . . . . 90-45 Valve clearance adjustment . . . . . . . . . . . . . . . 85-13
37° flare hydraulic fittings . . . . . .. .. . . . . . . 90-45 Valve, control . . . . . . . . . . . . . . . . . . . . . . . . . . 90-38
Flat face O-ring seal fitting . . . . .. .. . . . . . . 90-48 Vandal shield . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Inch SAE four bolt flange fitting. .. .. . . . . . . 90-49
Metric four bolt flange fitting . . . .. .. .90-50, 90-51
O-Ring boss fitting . . . . . . . . . . .. .. . . . . . . 90-46 W
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . .. .. .. .. .. 90-41 Warming engine . . . . . . . . . . . . . . . . . . . . . . . . . 25-8
Metric . . . . . . . . . . . . . . . . . . . . .. .. .. .. .. 90-43 Warming machine
Towing procedures . . . . . . . . . . . . .. .. .. .. .. . 40-2 Cold weather. . . . . . . . . . . . . . . . . . . . . . . . . . 25-9
Track roller oil fill . . . . . . . . . . . . . .. .. .. .. .. 90-33 Water Separator
Track sag Change (SN 840461- ) . . . . . . . . . . . . . . . . . . 80-3
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-4 Winch
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-16
General information. . . . . . . . . . . . . . . . . . . . 90-19 Drag adjustment . . . . . . . . . . . . . . . . . . . . . . 36-19
Track Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-15
Adjuster cylinder, lubricate . . . . . . . . . . . . . . . 75-2
Carrier roller oil level . . . . . . . . . . . . . . . . . . . 90-29
Index-5 121997
PN=5
Index
Index-6 121997
PN=6
John Deere Service Literature Available
TECHNICAL INFORMATION
Technical information is available from John Deere. Some

of this information is available in electronic as well as
printed form. Order from your John Deere dealer or call
1–800–522–7448. Please have available the model
numbers, serial numbers, and name of the product.
Available information includes:
• Parts catalogs listing service parts available for your

machine with exploded view illustrations to help you
identify the correct parts. It is also useful in assembling
and disassembling.
• Operator’s Manuals providing safety, operating,
maintenance, and service information. These manuals
and safety signs on your machine may also be available
in other languages.
• Technical manuals outlining service information for
your machine. Included are specifications, illustrated
TS191 –UN–02DEC88
assembly and disassembly procedures, hydraulic oil
flow diagrams, and wiring diagrams. Some products
have separate manuals for repair and diagnostic
information. Some components, such as engines, are
available in separate component technical manuals.
• Fundamental manuals detailing basic information
regardless of manufacturer:
— Agricultural Primer series covers technology in
farming and ranching, featuring subjects like computers,
the Internet, and precision farming.
— Farm Business Management series examines
“real-world” problems and offers practical solutions in
the areas of marketing, financing, equipment selection,
and compliance.
— Fundamentals of Services manuals show you how to
repair and maintain off-road equipment.
— Fundamentals of Machine Operation manuals explain
machine capacities and adjustments, how to improve
machine performance, and how to eliminate
unnecessary field operations.
–UN–10OCT97
TS1663
TX,SLIT,RB52 –19–04DEC97–1/1
SLIT–1 121997
PN=321
John Deere Service Keeps You On the Job
JOHN DEERE IS AT YOUR SERVICE WHEN YOU NEED IT
–UN–12SEP95
TS1643
Division 1—Calgary Division 4—Moline Division 8—Atlanta
John Deere Industrial Equipment Co. John Deere Industrial Equipment Co. John Deere Industrial Equipment Co.
6715 8th Street NE, Suite 218 400 19th Street 1201 Roberts Blvd., Suite 230
Calgary, AB T2E 7H7 Canada Moline, IL 61265 Kennesaw, GA 30144
403-531-5731; fax: 403-531-5739 309-765-3316; fax: 309-765-3357 404-423-2400; fax: 404-423-2411
Division 2—Denver Division 5—Grimsby a—John Deere Intercontinental Limited
John Deere Industrial Equipment Co. John Deere Industrial Equipment Co. Overseas Industrial Division
6101 Stapleton North Drive, Suite A P.O. Box 999 P.O. Box 2000
Denver, CO 80216 Grimsby, ON L3M 4S9 Canada Moline, IL 61265 U.S.A.
303-336-1204; fax: 303-336-1208 905-945-7389; fax: 905-945-7470 309-765-3316; fax: 309-765-3279
Division 3—Dallas Division 6—Baltimore
John Deere Industrial Equipment Co. John Deere Industrial Equipment Co.
P.O. Box 999 72 Loveton Circle, Suite 101
Lewisville, TX 75029-2610 Sparks, MD 21152
214-355-4513; fax: 214-355-4508 410-785-4118; fax: 410-785-4145
CUSTOMER SATISFACTION is important to John Precision tools and testing equipment enable
Deere. We take pride in providing superior service. technicians to locate and correct troubles.
We’ll be around when you need us:
We hold regular training schools for service
We maintain a large and varied parts inventory to help technicians so they know your equipment and how to
minimize downtime. maintain it.
DX,IBC,4 –19–12SEP95–1/2
IBC–1 121997
PN=322

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450G, 550G, and 650G

John Deere Dubuque Works

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OMT163974 450G/550G/650G Crawler Dozer Operator’s Manual

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Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1 Adjust Non-Suspension Seat . . . . . . . . . . . . . . 10-14

All information, illustrations and specifications in this manual are based on

Adjusting Track Sag . . . . . . . . . . . . . . . . . . . . . . 55-4 Maintenance

When Parking Outdoors . . . . . . . . . . . . . . . . . . 110-2

John Deere Service Literature Available

John Deere Service Keeps You On the Job

RECOGNIZE SAFETY INFORMATION

This is the safety —alert symbol. When you see this

UNDERSTAND SIGNAL WORDS

A signal word—DANGER, WARNING, or CAUTION—is

DANGER or WARNING safety signs are located near

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and on

Learn how to operate the machine and how to use

Keep your machine in proper working condition.

If you do not understand any part of this manual and need

AVOID INJURY FROM ROLLOVER

Be careful when operating on a slope.

Avoid sharp turns.

Balance loads so weight is evenly distributed and load is

Carry tools and loads close to the ground to aid visibility

Reduce speed before turning or swinging load.

Know capacity of machine. Do not overload.

Be careful when operating at the edge of an excavation,

Read and understand the operating instructions in the

AVOID INJURY FROM:

Keep the trailer bed clean

Use a ramp or loading dock. Ramps must be strong

If machine is equipped with a seat belt, fasten it before

Fasten chains or cables to machine tracks or track or

AVOID INJURY FROM BACKOVER

To avoid backover accidents:

Always look around before you back up. Be sure that

Keep bystanders away from pivot area of an articulated

Keep reverse warning alarm in working condition

Use a signal person when backing up if view is

Learn the meaning of all flags, signs, and markings used

Keep windows, mirrors, and lights clean and in good

Dust, heavy rain, fog, etc., can reduce visibility. As

Read and understand the operating instructions in this

AVOID INJURY FROM ROLLAWAY

Select level ground when possible to park machine.

Put in park or set park brake and place transmission

Lower all equipment to ground.

Stop the engine.

Block all wheels if you must park on a grade, position

Park a reasonable distance from other machines.

Read and understand the operating instructions in this