250d and 300darticulated dump trucks200537609165moffatpipe.com/equipment-manuals/adt 01 - jd250d/adt...

250D and 300DArticulated Dump Trucks

(Serial No. 200537 - 609165)*OMT201340*

OPERATOR'S MANUAL250D and 300D Articulated Dump Trucks

OMT201340 ISSUE G2 (ENGLISH)

CALIFORNIAProposition 65 Warning

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

birth defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING

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

The State of California requires the above two warnings.

Additional Proposition 65 Warnings can be found in this manual.

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.

Introduction

Continued on next page CED,TX14740,6463 -19-18DEC01-1/2

Introduction

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

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

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

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

WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.)in the Machine Numbers chapter. Accurately record allthe numbers to help in tracing the machine should it bestolen. Your dealer also needs these numbers when youorder parts. File the identification numbers in a secureplace off the machine.

WARRANTY is provided as part of John Deeres supportprogram for customers who operate and maintain theirequipment as described in this manual. The warranty isexplained on the warranty certificate which you shouldhave received from your dealer.

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

THE TIRE MANUFACTURER'S warranty supplied withyour machine may not apply outside the U.S.

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Introduction

CED,TX14740,6463 -19-18DEC01-2/2

EMISSIONS CONTROL WARRANTY STATEMENT FORNEW JOHN DEERE CONSTRUCTION EQUIPMENT (U.S. AND CANADA)

To determine if the engine in your machine qualifies for the additional warranties set forth below, look for the "Engine Information"label located on your engine. If you reside in the United States and the engine label states: "Engine conforms toUS EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control WarrantyStatement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy dutynon road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement."

U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

Emissions control-related parts and components are warrantedby John Deere for five years or 3000 hours of operation, whicheveroccurs first. John Deere further warrants that the engine coveredby this warranty was designed, built, and equipped so as toconform at the time of sale with all U.S. emissions standards atthe time of manufacture, and that it is free of defects in materialsand workmanship which would cause it not to meet thesestandards within the period of five years or 3000 hours ofoperations, whichever occurs first.

Operator's Manual. John Deere recommends that you retain allreceipts covering maintenance on your heavy-duty engine, butJohn Deere cannot deny warranty solely for the lack of receiptsor for your failure to ensure the performance of all scheduledmaintenance.

However, as the heavy-duty engine owner, you should be awarethat John Deere may deny you warranty coverage if your heavy-duty engine or a part has failed due to abuse, neglect, impropermaintenance or unapproved modifications.

Your engine is designed to operate on diesel fuel only. Use ofany other fuel may result in your engine no longer operating incompliance with California's emissions requirements.

You are responsible for initiating the warranty process. The CARBsuggests that you present your machine to the nearest authorizedJohn Deere dealer as soon as a problem is suspected. Thewarranty repairs should be completed by the service dealer asexpeditiously as possible.

If you have any questions regarding your warranty rights andresponsibilities, you should contact John Deere at 1-319-292-5400, or the State of California Air Resources Board, Mobile SourceOperation Division, PO Box 8001, El Monte, CA 91731-2900

The warranty period begins on the date the machine is deliveredto an ultimate purchaser, or when otherwise put into service.John Deere warrants to the ultimate purchaser and eachsubsequent purchaser that the engine is designed, built andequipped so as to conform with all applicable regulations adoptedby the Air Resources Board, and that it is free from defects inmaterials and workmanship which would cause the failure of awarranted part.

Any warranted part which is scheduled for replacement asrequired maintenance by the operator's manual is warranted byJohn Deere for the period of time prior to the first scheduledreplacement point for that part. If the part fails prior to the firstscheduled replacement point, the part shall be repaired orreplaced under warranty. Any such part repaired or replacedunder warranty is warranted for the remainder of the period priorto the first scheduled replacement point for that part.

Any warranted part which is not scheduled for replacement asrequired maintenance, or which is scheduled only for regularinspection to the effect of repairing or replacing as necessary, iswarranted for the warranty period.

Repair or replacement of a warranted part will be performed at nocharge to you by an authorized John Deere dealer. You will notbe charged for diagnostic labor which leads to the determinationthat a warranted part is defective, if the diagnostic work isperformed by a John Deere dealer.

John Deere is liable for damages to other engine componentscaused by failure under warranty of any warranted part.

John Deere is NOT liable for travel or mileage on extendedemissions warranty service calls.

Any replacement part may be used in the performance of anymaintenance or repairs, and such use will not reduce the warrantyobligations of John Deere. However, the use of add-on ormodified parts are grounds for disallowing a warranty claim.

Warranties stated on this certificate refer only to emissions-relatedparts and components of your engine. The complete machinewarranty, less emisions-related parts and components, isprovided separately as "John Deere "Secure Warranty" For NewConstruction Products."

YOUR WARRANTY RIGHTS AND OBLIGATIONS

JOHN DEERE'S WARRANTY COVERAGE:

OWNER'S WARRANTY RESPONSIBILITIES:

As the heavy-duty engine owner, you are responsible for theperformance of the required maintenance as outlined in the

The California Air Resources Board (CARB) and John Deere arepleased to explain the emission control system on your newengine. In California, new heavy-duty engines must be designed,built and equipped to meet the State's stringent anti-smogstandards. John Deere must warrant the emission control systemon your engine for the periods of time listed below provided therehas been no abuse, neglect, or improper maintenance of yourmachine.

Where a warrantable condition exists, i.e. failure due to defect inJohn Deere-supplied material and/or workmanship, John Deerewill repair your heavy-duty engine at no cost to you includingdiagnosis, parts and labor

The emission control system of your heavy-duty engine iswarranted for five years or 3000 hours of operation, whicheveroccurs first. If any emission-related part on your engine isdefective, the part will be repaired or replaced by John Deere.Warranties stated on this certificate refer only to emissions-relatedparts and components of your engine. The complete machinewarranty, less emissions-related parts and components, isprovided separately as the "John Deere "Secure Warranty" ForNew Construction Products."

Your emissions control system includes:

Fuel Metering System Fuel Injection System Air Induction System Intake Manifold Turbocharger System Charge Air Cooling System

Miscellaneous Items used in Above Systems

T1321261928JU

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Introduction

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

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

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

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

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

Email Address:

THANK YOU!

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Contents

Page

SafetySafety FeaturesSafety Features .................................................1-1-1

SafetyGeneral PrecautionsRecognize Safety Information ...........................1-2-1Follow Safety Instructions..................................1-2-1Operate Only If Qualified...................................1-2-1Wear Protective Equipment...............................1-2-1Avoid Unauthorized Machine Modifications.......1-2-2Inspect Machine ................................................1-2-2Stay Clear of Moving Parts................................1-2-2Avoid High-Pressure Oils ..................................1-2-3Beware of Exhaust Fumes ................................1-2-3Prevent Fires .....................................................1-2-4Prevent Battery Explosions ...............................1-2-4Handle Chemical Products Safely .....................1-2-4Dispose of Waste Properly ................................1-2-5Prepare for Emergencies...................................1-2-5

SafetyOperating PrecautionsUse Steps and Handholds Correctly .................1-3-1Start Only From Operator's Seat .......................1-3-1Use and Maintain Seat Belt ...............................1-3-1Prevent Unintended Machine Movement ..........1-3-1Avoid Work Site Hazards...................................1-3-2Keep Riders Off Machine ..................................1-3-2Avoid Backover Accidents .................................1-3-2Avoid Machine Tip Over ....................................1-3-3Operating on Slopes..........................................1-3-3Operating Or Traveling On Public Roads ..........1-3-3Inspect and Maintain ROPS ..............................1-3-4Add and Operate Attachments Safely ...............1-3-4

SafetyMaintenance PrecautionsPark And Prepare For Service Safely................1-4-1Service Tires Safely...........................................1-4-1Service Cooling System Safely .........................1-4-2Remove Paint Before Welding or Heating.........1-4-2Make Welding Repairs Safely ...........................1-4-2Drive Metal Pins Safely .....................................1-4-3

SafetySafety SignsSafety Signs ......................................................1-5-1

OperationOperators StationOperator Controls ..............................................2-1-1

Page

Operator Control Functions ...............................2-1-3Instrument Panel ...............................................2-1-4Instrument Panel Functions...............................2-1-5Heater and Air Conditioner Controls..................2-1-6Steering Column Lever......................................2-1-7Circuit Breaker Compartment ............................2-1-8Operator Seat and Instructional Seat ................2-1-9Air Suspension SeatIf Equipped ..................2-1-10Seat Belt ..........................................................2-1-10Battery Disconnect Switch and Battery

Circuit Breakers...........................................2-1-11Miscellaneous Equipment................................2-1-12Monitor Display UnitDefault Display Menu...2-1-14Monitor Display UnitMenu Function .............2-1-16

OperationOperating the MachineBefore Starting Work .........................................2-2-1Operator's Daily Machine Check

Before Starting ..............................................2-2-1Starting Engine..................................................2-2-2Replace Start Aid Can.......................................2-2-3Driving Machine.................................................2-2-3Steering Machine...............................................2-2-4Shifting Transmission ........................................2-2-5Using Range Hold .............................................2-2-6Using Inter-Axle Lock ........................................2-2-6Slowing and Stopping the Machine ...................2-2-7Operating on a Hill.............................................2-2-8Off-Road Operation ...........................................2-2-8Loading and Unloading Dump Body..................2-2-9Freeing Stuck Machine....................................2-2-10Parking the Machine........................................2-2-10Towing the Machine.........................................2-2-11Releasing Park Brake for Towing ....................2-2-12Mechanically Releasing Park Brake................2-2-12Machine Lifting Points .....................................2-2-13Loading and Unloading Machine from Trailer ..2-2-14Lock All Compartments ...................................2-2-15

MaintenanceMachineDiesel Fuel.........................................................3-1-1Low Sulfur Diesel Fuel Conditioner ...................3-1-1Testing Diesel Fuel ............................................3-1-1Handling and Storing Diesel Fuel ......................3-1-2Diesel Engine Oil ...............................................3-1-2Diesel Engine Oil and Filter Service Intervals ...3-1-3Hydraulic Oil ......................................................3-1-4

Continued on next page

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

The right is reserved to make changes at any time without notice.COPYRIGHT 2012DEERE & COMPANY

Moline, IllinoisAll rights reserved.

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 2004, 2005, 2006, 2007, 2008, 2009

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Contents

Page

Transmission and Transfer Case Oil .................3-1-4Axle Gear Oil .....................................................3-1-5Diesel Engine Coolant .......................................3-1-5Grease...............................................................3-1-6Oil Filters ...........................................................3-1-6Lubricant Storage ..............................................3-1-6Alternative And Synthetic Lubricants.................3-1-7

MaintenancePeriodic MaintenanceService Your Machine at Specified Intervals .....3-2-1Use Correct Fuels and Lubricants .....................3-2-1Prepare Machine for Maintenance ....................3-2-1Install Dump Body Prop.....................................3-2-2Install Articulation Safety Lock Bar ....................3-2-2Lower and Raise Bottom Guard ........................3-2-2Relieve Pneumatic Pressure .............................3-2-3Tilt Cab ..............................................................3-2-4Maintenance and Repair Record

Keeping System............................................3-2-5Fluid Analysis Program Test Kits and

3-Way Coolant Test Kit..................................3-2-5Maintenance and Repair Record

Keeping System............................................3-2-6

MaintenanceAs RequiredService Engine Air Intake System .....................3-3-1Inspect and Clean Cooling Systems..................3-3-2Clean, Inspect, and ReplaceTrans-

mission, Transfer Case, and AxleBreathers.......................................................3-3-3

Inspect Tires, Check Pressure ..........................3-3-4Drain Fuel Filters (S.N.201014) .....................3-3-6Drain Fuel Filters (S.N. 201015) ....................3-3-6Inspect Serpentine Belt .....................................3-3-6

MaintenanceEvery 10 Hours or DailyCheck Engine Coolant Level .............................3-4-1Check Engine Oil Level .....................................3-4-1Check Transfer Case Oil Level..........................3-4-2Check Hydraulic Oil Level .................................3-4-2Grease Dump Body Pivot Pins ..........................3-4-3Lubricate Tailgate PivotsIf Equipped..............3-4-3

MaintenanceInitial Service - 100 HoursChange Engine Oil and Replace Filter ..............3-5-1Replace Hydraulic System Oil Return Filter ......3-5-2Replace Primary Fuel Filter (S.N. 201015)....3-5-3Change Transfer Case Oil .................................3-5-3Change Axle Oil.................................................3-5-4Change Final Drive Oil ......................................3-5-4

MaintenanceEvery 500 HoursCheck Park Brake Pad Wear.............................3-6-1Check Dry Caliper Service Brake Pad Wear .....3-6-1Check Front Axle Suspension Struts.................3-6-2Inspect, Clean, and Replace Cab Air Filter .......3-6-3Check Batteries, Clean and Tighten Terminals ..3-6-4

Page

Lubricate Oscillation Tube, ArticulationJoints, Steering Cylinder Rod Ends,and Oscillation Tube Through DriveShaft Bearings...............................................3-6-5

Check Transmission Oil Level ...........................3-6-6Clean and Inspect Hydraulic Reservoir

Breather ........................................................3-6-7Replace In-line Fuel Filter (S.N. 201015).......3-6-7Replace Fuel Filters (S.N.201014).................3-6-8Replace Final Fuel Filter (S.N. 201015).........3-6-8Check Coolant Conditioner in Radiator .............3-6-9

MaintenanceEvery 1000 HoursCheck Axle Oil Levels........................................3-7-1Check Final Drive Oil Levels .............................3-7-1Replace Hydraulic Reservoir Breather ..............3-7-2Check and Adjust Bin Shock Pad......................3-7-3Grease Prop Shaft Slip Joint .............................3-7-3

MaintenanceEvery 2000 HoursAdjust Engine Valve Clearance .........................3-8-1Change Transmission Oil ..................................3-8-1Replace Transmission Oil Filter.........................3-8-2Change Transfer Case Oil .................................3-8-3Change Axle Oil.................................................3-8-3Change Final Drive Oil ......................................3-8-4Replace Pneumatic System Dryer-Filter ...........3-8-4

MaintenanceEvery 4000 HoursChange Hydraulic Oil.........................................3-9-1Replace Hydraulic Suction Screen....................3-9-2Replace Pneumatic Block Silencer Filter...........3-9-2

MaintenanceEvery 4500 HoursReplace Engine Crankshaft Dampener ...........3-10-1

MaintenanceEvery 5000 HoursDrain, Flush and Refill Engine Cooling

System ........................................................3-11-1

MiscellaneousMachineDo Not Service Control Valves,

Cylinders, Pumps or Motors..........................4-1-1Do Not Service Injection Nozzles ......................4-1-1Bleeding Fuel System........................................4-1-1Check Engine Air Intake System.......................4-1-2Check Brake Accumulators ...............................4-1-3Check Wheel Nuts.............................................4-1-3Lubricate Hinges................................................4-1-3Using Booster Batteries24-Volt System.........4-1-3Using Battery Charger .......................................4-1-4Handling, Checking And Servicing

Batteries Carefully.........................................4-1-5Replace Batteries ..............................................4-1-6Replace Front Turn Signal Bulb,

Headlight Bulb, and Front Park Light Bulb ....4-1-7Adjust Headlights...............................................4-1-9

Continued on next page

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Contents

Page

Replace Backup Light and WorkLightIf Equipped.......................................4-1-10

Replace Tail and Brake Light and RearTurn Signal ..................................................4-1-10

Replace Dome Light Bulb and CircuitBreaker Compartment Light Bulb................4-1-11

Clean The Machine Regularly .........................4-1-11Unified Inch Bolt and Screw Torque Values.....4-1-12Metric Bolt and Screw Torque Values..............4-1-13Imperial and SAE (Inch) Cap Screw

and Nut Torque Values................................4-1-14Metric Cap Screw and Nut Torque Values.......4-1-15Welding on Machine ........................................4-1-16

MiscellaneousOperational CheckoutOperational Checkout........................................4-2-1

MiscellaneousTroubleshootingUsing Troubleshooting Charts ...........................4-3-1Engine ...............................................................4-3-2Transmission .....................................................4-3-4Axle....................................................................4-3-5Tires...................................................................4-3-6Brakes ...............................................................4-3-6Hydraulic System...............................................4-3-7Instruments and Controls ..................................4-3-7Electrical System...............................................4-3-8Rear Frame and Cab.........................................4-3-9MDU Displayed Service Codes .......................4-3-10

MiscellaneousStoragePrepare Machine for Storage ............................4-4-1

MiscellaneousSerial NumbersRecord Product Identification Number (PIN) .....4-5-1Record Engine Serial Number...........................4-5-1Record Transmission Serial Number.................4-5-1Front Axle Serial Number ..................................4-5-2Middle Axle Serial Number ................................4-5-2Rear Axle Serial Number...................................4-5-2

MiscellaneousSpecifications250D Articulated Dump Truck Specifications ....4-6-1300D Articulated Dump Truck Specifications ....4-6-5250D and 300D Engine Specifications..............4-6-8250D and 300D Travel Speeds .........................4-6-9250D and 300D Drain and Refill Capacities ......4-6-9

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Contents

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SafetySafety Features

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Safety Features

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T147632

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Please remember, the operator is the key topreventing accidents.

1. ROPS/FOPS Cab Protection. Structures designed tohelp protect the operator are certified to ISO, SAE,and OSHA. Enclosures also deflect sun and rain.

2. Cab with Heater/Defroster. Cab ventilation systemcirculates both outside and inside air through filters fora clean working environment. Built in defroster ventsdirect air flow for effective window defogging/deicing.

3. Dump Body Service Lock. A mechanical lock isprovided for working on or around this machine withthe dump body raised.

4. Stop/Backup Lights. Highly visible lights arestandard equipment.

5. Backup Alarm. Alerts bystanders when reverse traveldirection is selected by operator.

6. Independent Parking Brake. Is air released/springapplied and engages whenever the key switch isturned off.

7. Articulation Locking Bar. A self-storing mechanicallock is provided for transport or service.

8. Secondary Steering. Ground driven, continuously inoperation. Secondary steering indicator light will light.

9. Horn. Standard horn is useful when driving orsignalling co-workers.

10.Halogen Lights and Turn Signals. High intensityhalogen drive/work lights and high-visibility turnsignals are standard equipment.

11. Engine Fan Guard. A secondary fan guard insidethe engine compartment helps prevent contact withrotating fan blades.

12.Bypass Start Protection. Shielding over the starterterminals helps prevent dangerous bypass starting.

13. Transmission Retarder. Engages whenever the truckis in motion and the operator lets up on the accelerator.

14. Seatbelt Retractors. Help keep belts clean andconvenient to use.

15.Mirrors. Large exterior mirrors on both sides offer theoperator a view of activity behind him.

16. Large Windshield Wiper With Washer. Extra longwiper cleans large windshield area.

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SafetyGeneral Precautions

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Recognize Safety InformationThis is the safety alert symbol. When this symbol isnoticed on the machine or in this manual, be alert forthe potential of personal injury.

Follow the precautions and safe operating practiceshighlighted by this symbol.

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

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

T133555UN28AUG00

T1335881928AUG00

Follow Safety Instructions

Read the safety messages in this manual and on themachine. Follow these warnings and instructions carefully.Review them frequently.

Keep safety signs in good condition.

Be sure new equipment components and repair partsinclude the current safety signs.

Be sure all operators of this machine understand everysafety message. Replace operator's manual and safetysigns immediately if missing or damaged. Replacementsafety signs are available from your authorized dealer.

Operate Only If Qualified

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

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

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

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

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

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionableor uncomfortable loud noises.

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Avoid Unauthorized Machine Modifications

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

Modifications of this machine, or addition of unapprovedproducts or attachments, may affect machine stabilityor reliability, and may create a hazard for the operator

or others near the machine. The installer of anymodification which may affect this machine is responsiblefor establishing that the modification does not adverselyaffect the machine or its performance. This applies to allaspects of the machine, including electronic controls.

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

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

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

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

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

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

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

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

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

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Beware of Exhaust FumesPrevent asphyxiation. Engine exhaust fumes can causesickness or death.

If you must operate in an enclosed space, provideadequate ventilation. Use an exhaust pipe extension toremove the exhaust fumes or open doors and windows tobring outside air into the area.

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

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

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

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

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Prevent Battery ExplosionsBattery gas can explode. Keep sparks, lighted matches,and open flame away from the top of battery.

Never check battery charge by placing a metal objectacross the posts. Use a voltmeter or hydrometer.

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

TS204UN23AUG88

Handle Chemical Products SafelyExposure to hazardous chemicals can cause seriousinjury. Under certain conditions, lubricants, coolants,paints and adhesives used with this machine may behazardous.

If uncertain about safe handling or use of these chemicalproducts, contact your authorized dealer for a MaterialSafety Data Sheet (MSDS) or go to internet websitehttp://www.jdmsds.com. The MSDS describes physicaland health hazards, safe use procedures, and emergencyresponse techniques for chemical substances. Follow

T133580UN25AUG00

MSDS recommendations to handle chemical productssafely.

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Dispose of Waste ProperlyImproper disposal of waste can threaten the environment.Fuel, oils, coolants, filters and batteries used with thismachine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants can damage the atmosphere.Government regulations may require using a certifiedservice center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact yourlocal environmental or recycling center or your dealer formore information.

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Prepare for EmergenciesBe prepared if an emergency occurs or 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.

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SafetyOperating Precautions

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

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

33468UN30AUG00

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

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

33715UN07SEP00

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

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

The complete seat belt assembly should be replacedevery 3 years, regardless of appearance.

T1337161914SEP00

Prevent Unintended Machine MovementBe careful not to accidentally actuate controls whenco-workers are present.

Ensure dump body is lowered during work interruptions.Place transmission control in neutral, engage park brakeand stop engine before allowing anyone to approach themachine.

Follow these same precautions before standing up,leaving the operator's seat, or exiting the machine.

PT1

43805UN20JU

L01

1-3-1 080112PN=15


VD76477,0001583 -19-06JUL07-1/1

TX14740,0001D33 -19-23SEP10-1/1

TX14740,0001D34 -19-22JUN01-1/1

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

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

Avoid boom or attachment contact with overheadobstacles or overhead electrical lines. Never movemachine closer than 3 m (10 ft) plus twice the line insulatorlength to overhead wires.

Keep bystanders clear at all times. Use barricades or asignal person to keep vehicles and pedestrians away. Usea signal person if moving machine in congested areas orwhere visibility is restricted. Always keep signal person inview. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficientto support machine. Be especially alert working nearembankments or excavations.

Avoid working under over-hanging embankments orstockpiles that could collapse under or on machine.

Reduce machine speed when operating with tool on ornear ground when obstacles may be hidden (e.g., duringsnow removal or clearing mud, dirt, etc.). At high speeds

T143350UN06JU

L01

T143748UN20JU

L01

hitting obstacles (rocks, uneven concrete or manholes)can cause a sudden stop. Always wear your seatbelt.

Keep Riders Off MachineUse seat belt at all times.

Only allow operator on machine except when necessaryfor instruction or short periods of observation.

Riders are subject to injury. They may fall from machine,be caught between machine parts, or be struck by foreignobjects. They also may obstruct operators view or impairhis ability to operate machine safely.

Use the instructional seat only to accommodate trainersor persons needing to observe machine operation forshort periods.

T143354UN06JU

L01

Avoid Backover AccidentsBefore moving machine, be sure all persons are clearof machine path. Where conditions permit, raise dumpbody for better visibility to the rear. Use mirrors to assist inchecking all around machine. Keep windows and mirrorsclean, adjusted, and in good repair.

Be certain backup alarm is working properly.

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

T143356UN06JU

L01

1-3-2 080112PN=16


TX14740,0001D3E -19-20JUL01-1/1

TX14740,0000003 -19-24JAN03-1/1

TX03679,00017C8 -19-30APR01-1/1

Avoid Machine Tip OverUse seat belt at all times. Do not jump if the machinetips. You will be unlikely to jump clear and the machinemay crush you.

Use extra care when dump body is raised. Machinestability is greatly reduced when dump body is raised.Drive slowly. Avoid sharp turns and uneven ground.

Be careful on slopes and soft, rocky, or frozen ground.Traction and stability are reduced by slopes and adverseterrain. Avoid piles of dirt and banks or excavations thatmay cave in and cause the machine to tip or fall.

Do not overload the machine. Oversize loads reducemachine stability, increase tire flex, and erode travelsurfaces. Braking capability and brake life are alsoreduced.

If machine tips, carefully inspect brake and hydraulic lines,electrical wiring, and machine structure before operating.

T1337161914SEP00

T144185UN23JU

L01

Operating on SlopesAvoid sideslope travel whenever possible.

Check service brake condition frequently when operatingon slopes.

Select low gear speed before starting down slope. Themaximum slope you can operate on will be limited byground conditions and the load being handled.

Use transmission retarder and service brakes, to controlspeed. Sudden brake application with a loaded dumpbody could cause loss of machine control.

T143361UN27JU

N01

Operating Or Traveling On Public RoadsMachines that work near vehicle traffic or travel slowerthan normal highway speeds must have proper lightingand markings to assure they are visible to other drivers.Mirrors are especially important for the operator when onroadways.

Install additional lights, beacons, slow moving vehicle(SMV) emblems, or other devices and use as required tomake the machine visible and identify it as a work machine.Check state and local regulations to assure compliance.Keep these devices clean and in working condition.

T141891UN22MAY

01

1-3-3 080112PN=17


TX03679,000179F -19-07SEP06-1/1

TX03679,00016F0 -19-24JAN07-1/1

Inspect and Maintain ROPS

A damaged roll-over protective structure (ROPS) shouldbe replaced, not reused.

The protection offered by ROPS will be impaired if ROPSis subjected to structural damage, is involved in anoverturn incident, or is in any way altered by welding,bending, drilling, or cutting.

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

To maintain the ROPS:

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

Add and Operate Attachments Safely

Always verify compatibility of attachments by contactingyour authorized dealer. Adding unapproved attachmentsmay affect machine stability or reliability, and may createa hazard for others near the machine.

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

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

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

1-3-4 080112PN=18

SafetyMaintenance Precautions

TX14740,0001D36 -19-22JUN01-1/1

DX,RIM -19-24AUG90-1/1

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

Park machine on a level surface. Lower dump body unless raised position is requiredfor service. Engage park brake. Stop engine and remove key. Attach a Do Not Operate tag in an obvious place inthe operator's station. Install the articulation safety locking bar. Install service locks if dump body or cab are raised forservice.

Securely support machine before working under it.

Install wheel chocks to ensure machine cannot movebackward or forward during service.

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

T1333321914DEC01

TS229UN23AUG88

Service Tires SafelyExplosive separation of a tire and rim parts can causeserious injury or death.

Do not attempt to mount a tire unless you have the properequipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflatethe tires above the recommended pressure. Never weldor heat a wheel and tire assembly. The heat can causean increase in air pressure resulting in a tire explosion.Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extensionhose long enough to allow you to stand to one side andNOT in front of or over the tire assembly. Use a safetycage if available.

Check wheels for low pressure, cuts, bubbles, damagedrims or missing lug bolts and nuts.

TS211UN23AUG88

1-4-1 080112PN=19


DX,RCAP -19-04JUN90-1/1

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

TX03679,00016D5 -19-25APR08-1/1

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

Shut off engine. Only remove filler cap when cool enoughto touch with bare hands. Slowly loosen cap to first stopto relieve pressure before removing completely.

TS281UN23AUG88

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

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

Remove paint before heating:

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

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

TS220UN23AUG88

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

Dispose of paint and solvent properly.

Make Welding Repairs SafelyIMPORTANT: Disable electrical power before

welding. Turn off main battery switchor disconnect positive battery cable.Separate harness connectors to engine andvehicle microprocessors.

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

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

T133547UN31AUG00

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

1-4-2 080112PN=20


TX03679,0001745 -19-03JAN07-1/1

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

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

33738UN14SEP00

1-4-3 080112PN=21

SafetySafety Signs

Continued on next page OUO1043,0000DF4 -19-30OCT01-1/2

Safety Signs

T148212

CAUTIONAVOID DEATH OR SERIOUS INJURY

*READ AND UNDERSTAND OPERATOR'S MANUAL BEFORE OPERATING THIS MACHINE.*OPERATE ONLY FROM THE OPERATOR'S SEAT.*BEFORE LEAVING SEAT: LOWER BODY TO FRAME REST. PLACE TRANSMISSION IN NEUTRAL. APPLY PARK BRAKE. STOP ENGINE (TURN KEY SWITCH TO OFF).*DO NOT PERMIT RIDERS.*AVOID CONTACT WITH OVERHEAD OBSTACLES WHEN OPERATING OR HAULING THE TRUCK.*USE EXTRA CARE TO AVOID TIP-OVER WHEN DUMPER BODY IS RAISED.

COMPRESSED AIR RESERVOIRAvoid injury, draincompletely before carrying out maintenance.Typical working pressure:800 kPa (116 PSI).

WARNING

WARNINGHIGH PRESSUREHYDRAULICSSee manual for correct maintenance procedure.Typical working pressure: 8000 kPa (1160 PSI).

WARNING

AVOID INJURY Ensure propshaftguards are in place at all times

Ensure that the cabsupport is properly engaged before carrying out any maintenance in this area.

WARNING

WARNING

Read the manualbefore carrying outmaintenance in thisarea

SPRING UNDERPRESSURE

WARNING

AVOID SERIOUSINJURY

Block wheels to prevent machine movement before deactivating parkbrake for towing.

This instructional seat has been provided only for training operators or to diagnose machine problems. Keep all other riders off thismachine. Always wear your seat belt.

CAUTION

Torque all wheel nuts to 650 N.m[480 LB.FT.] after the first5 hours and then again after50 hours. Repeat this procedureif wheels are changed.

T1482121921NOV01

1-5-1 080112PN=22

SafetySafety Signs

OUO1043,0000DF4 -19-30OCT01-2/2

T1649201903FE

B03

1-5-2 080112PN=23

OperationOperators Station

Continued on next page OUO1043,0000DF5 -19-30OCT01-1/2

Operator Controls

T147633B

UN08NOV01

1Dome Light Switch2Headlight Switch3Warning Lights Switch4Rear View Mirrors Defrost

SwitchIf Equipped5Air Vent (6 used)6 Instrument Panel

7 Inter-Axle Lock Switch8Range Hold Switch9Start Aid Switch10 Rear View Mirrors

Adjustment ControlsIfEquipped

11 Transmission TorqueRetarder Control Lever

12 Park Brake Lever13 Dump Body Control Lever14 Gearshift Control15 Ash Tray (2 used)16 Steering Wheel17 Cigarette Lighter18 Telescopic Steering Adjust

Lever

19 Key Switch20 Steering Column Lever21 Tilt Steering Adjust Lever22 Service Brake Pedal23 Accelerator Pedal

2-1-1 080112PN=24


OUO1043,0000DF5 -19-30OCT01-2/2

T142703C

UN15NOV01

24 Operator's ManualCompartment

25 Dome Light

26 RadioIf Equipped27 Circuit Breaker

Compartment Latch

28 Circuit BreakerCompartment

29 Visor30 Heater and Air Conditioner

Control Panel

2-1-2 080112PN=25


Continued on next page TX14740,0000008 -19-06FEB03-1/2

Operator Control Functions

1. Dome Light Switch: Push lower half of switch to turndome light ON. Push upper half of switch to turn domelight OFF.

2. Headlight Switch:

NOTE: The parking lights, tail lights, and instrumentpanel lighting will light when headlight switch isin center position with key switch ON or OFF.The headlights will light only when switch isin down position with key switch ON.

The headlight switch is a 3-position switch used tocontrol headlights, tail lights and park lights.- Upper half of switch pushedlights OFF- Lower half of switch pushed to first detentparklights, tail lights, and instrument panel lighting ON

- Lower half of switch pushed to furthestpositionheadlights ON

3. Warning Lights Switch: Push lower half of switch toturn warning lights ON. Push upper half of switch toturn warning lights OFF.

4. Rear View Mirrors Defrost Switch (If Equipped):Push lower half of switch to turn mirror defrosters ON.Push upper half of switch to turn mirror defrosters OFF.

5. Air Vent (6 Used): Adjust air vents to control air flowin the cab.

6. Instrument Panel: Contains instruments andindicators.

7. Inter-Axle Lock Switch:

IMPORTANT: The inter-axle lock must only beused when ground conditions are very poor.DO NOT use on graded or tarred surfaces.

Reduce engine speed (accelerator pedal less than10% depressed) and push lower half of switch toengage inter-axle lock. Push upper half of switch todisengage inter-axle lock.

8. Range Hold Switch: Push lower half of switch toturn range hold ON. Push upper half of switch to turnrange hold OFF.

9. Start Aid Switch:

IMPORTANT: Never operate starter motor for morethan 17 seconds at a time. If engine fails tostart after 2 or 3 tries, return key switch toOFF. Wait for about 1 minute, then try again.

IMPORTANT: Prevent damage to engine. Usestart aid when temperatures are below 0C(32F) and only when engine is COLD.

If temperature is below 0C (32F) and engine isCOLD, press start aid switch while starting engine.

10.Rear View Mirrors Adjustment Controls (IfEquipped): Select left or right side mirror. Adjustmirror, up, down, left or right, to operator's preference.

11. Transmission Torque Retarder Control Lever:Move lever forward or rearward, as driving conditions

require, to adjust the percentage of torque retarderapplied when accelerator pedal is released.

12. Park Brake Lever:

CAUTION: Prevent possible injury fromunexpected machine movement. DONOT leave machine unattended withengine running.

If the operator must leave machine withengine running, the operator MUST shift thetransmission to neutral (N), engage the parkbrake, chock wheels and take all other stepsnecessary to prevent machine from moving.

IMPORTANT: After releasing park brake, waituntil park brake indicator on instrumentpanel goes out before driving.

Lift and push lever forward to release park brake. Pulllever rearward until it locks into place to engage parkbrake.

13.Dump Body Control Lever:

NOTE: The dump body control lever is spring-loadedand will return to center position when released.

Pull lever rearward to raise dump body. Push leverforward to lower dump body. Push lever forward todetent for dump body float.

14. Transmission Control Panel: Selects travel directionand maximum gear.

15.Ash Tray: Ash trays are provided for operatorconvenience.

16. Steering Wheel: Turn steering wheel to controlmachine steering.

17.Cigarette Lighter: Cigarette lighter is provided foroperator convenience.

18. Telescopic Steering Adjust Lever: Loosenstelescopic steering clamp to allow steering column tobe pulled out or pushed in to operator preference.

19.Key Switch: Insert key and turn to start engine.20. Steering Column Lever: Steering column lever

controls horn, windshield wiper/washers, turnindicators and headlight beam intensity.

21. Tilt Steering Adjust Lever: Loosens tilt steeringclamp to allow steering column to be tilted up or downto operator preference.

22. Service Brake Pedal: Push pedal to engage servicebrakes.

23.Accelerator Pedal: Push pedal to increase speed.Release pedal to slow machine. Retarder will engage,as necessary, when pedal is released.

24.Operator's Manual Compartment: Store operator'smanual in the operator's manual compartment.

25.Dome Light: Provides operator with light in the cab.26.Radio (If Equipped): Provided for operator

convenience.27.Circuit Breaker Compartment Latch: Push latch

button to open circuit breaker compartment.

2-1-3 080112PN=26


TX14740,0000008 -19-06FEB03-2/2

OUO1043,0000DD0 -19-27JUL01-1/1

28.Circuit Breaker Compartment: Open circuit breakercompartment door to access machine circuit breakers.

29. Visor: Lower and adjust visor as necessary.

30.Heater and Air Conditioner Control Panel: Useheater and air conditioner control panel to control cabtemperature.

Instrument Panel

FUEL

80

4030

20

10

50

60

70

0

km/h

mph

50

40

3020

10

0

ENGINE OILPRESSURE

COOLANTTEMP

TRANS OILTEMP

AIRPRESSURE

SELECT

NEXT

BACK

MENU

HYDRAULICTEMP

TRANSMISSIONFAULT

INTER-AXLEDIFF LOCK

DIFFLOCK

BINUP

COOLANTLEVELCOLD

START

ENGINEFAULT

BATTERYCHARGE

RETARDER

EMERGENCYSTEERING

n/min

n/min

AUTO

voltsMILES / Km

PARKBRAKE BRAKE

PRESSURE BRAKETEMP

T142483

25

24

23

2221

17

161514

121110984321

19 2018

13

5 6 7

26

27

28

2931

30

T142483UN03OCT0

1

1Cold Start Indicator2Coolant Level Indicator3Engine Service Indicator

(Marked Engine Fault)4Secondary Steering Indicator

(Marked Emergency Steering)5Battery Charge Indicator6Transmission Retarder

Indicator7Transmission Service

Indicator (MarkedTransmission Fault)

8Left Turn Indicator9Service Required Indicator10 High Beam Indicator11 Engine Overspeed Indicator12 Right Turn Indicator13 Message Display14 Park Brake Indicator15 Brake Oil Pressure Indicator16 Brake Temperature Indicator

17 Hydraulic Oil TemperatureIndicator

18 Dump Body Raised Indicator(Marked Bin Up)

19 Inter-Axle Lock Indicator(Marked Inter-Axle Diff Lock)

20 Differential Lock Indicator(Marked Diff Lock)NotUsed

21 Data Display22 Menu Button23 Back Button

24 Next Button25 Select Button26 Fuel Gauge27 Speedometer28 Transmission Oil

Temperature Gauge29 Coolant Temperature Gauge30 Air Pressure Gauge31 Engine Oil Pressure Gauge

2-1-4 080112PN=27


Continued on next page OUO1043,0000DAE -19-06FEB03-1/2

Instrument Panel Functions

1. Cold Start Indicator: Indicator lights when key switchis turned clockwise to ON position. Indicator will go outafter 20 seconds, depending on engine temperature,indicating that preheating is completed.

2. Coolant Level Indicator:

IMPORTANT: If low coolant level indicator lights,stop machine and shut down engineimmediately to prevent engine damage.

NOTE: Low engine coolant level indicator will flashbriefly during start-up when ignition key isturned to the ON position.

Indicator lights when engine coolant level is low.3. Engine Service Indicator (Marked Engine Fault):

Engine service indicator lights and stays lit when anengine service code has been detected.

4. Secondary Steering Indicator (Marked EmergencySteering):

IMPORTANT: If there is an engine or main pumpmalfunction, the ground-driven secondarysteering system will enable operator tosteer machine to a controlled stop.

Indicator will light when secondary steering system isactivated. Stop machine and take corrective action.Secondary steering system is ground driven and notintended for continuous use.

5. Battery Charge Indicator: Indicator lights whenalternator output is low.

6. Transmission Retarder Indicator: Indicator lightswhen transmission retarder is engaged.

7. Transmission Service Indicator (MarkedTransmission Fault): Transmission service indicatorlights and stays lit when a transmission clutch slippageservice code has been detected.

8. Left Turn Indicator: Indicator lights when left turnindicator is switched ON.

9. Service Required Indicator: Indicator lights ifservice is required. It is not necessary to stop engineimmediately, but cause should be investigated andcorrected as soon as possible.

10.High Beam Indicator: Indicator lights when headlighthigh beams are ON.

11. Engine Overspeed Indicator:

IMPORTANT: If engine overspeed indicatorlights, reduce engine speed immediatelyusing the service brake.

DO NOT exceed 2800 rpm or serious engineor transmission damage may occur.

Indicator lights when engine speed exceeds 2800 rpm.12.Right Turn Indicator: Indicator lights when right turn

indicator is switched ON.13.Message Display: Displays machine information for

operator.

14. Park Brake Indicator: Indicator lights when parkbrake is engaged and transmission control lever is inneutral.

15.Brake Oil Pressure Indicator: Indicator lights whenbrake oil pressure is low or brake accumulator has lostits charge. Stop machine immediately and engagepark brake. Take corrective action.

16.Brake Temperature Indicator: Indicator lights whenbrake temperature is too high.

17.Hydraulic Oil Temperature Indicator: Indicatorlights when hydraulic oil temperature exceeds 104C(220F). If hydraulic oil temperature is too high, stopwork. Allow engine to operate at high idle for 3minutes and allow oil to cool. If indicator stays on, stopmachine and see your authorized dealer.

18.Dump Body Raised Indicator (Marked Bin Up):Indicator lights when body is raised off the frame.

19. Inter-Axle Lock Indicator (Marked Inter-Axle DiffLock): Indicator lights when inter-axle lock is engaged.

20.Differential Lock Indicator (Marked Diff Lock): Notused.

21.Data Display: Displays machine information.22.Menu Button: Used to navigate through Monitor

Display Unit.23.Back Button: Used to navigate through Monitor

Display Unit.24.Next Button: Used to navigate through Monitor

Display Unit.25. Select Button: Used to navigate through Monitor

Display Unit.26. Fuel Gauge: Gauge indicates fuel level in tank.

Always fill fuel tank at end of day to eliminatecondensation in fuel tank.

27. Speedometer: Speedometer indicates travel speed inkilometers per hour (km/hr) or miles per hour (mph).

28. Transmission Oil Temperature Gauge:

IMPORTANT: DO NOT exceed maximumtransmission operating temperature of 145C(293F) to avoid damage to the transmission.

Gauge indicates temperature of transmission oil.Normal operating temperature is indicated by greenzone. If indicator points to red zone, allow transmissionto cool.

29.Coolant Temperature Gauge:

IMPORTANT: To prevent machine damage,DO NOT operate machine when enginecoolant temperature is high.

Gauge indicates temperature of engine coolant.Normal operating temperature is indicated by thegreen zone. If indicator points to red zone, stopmachine and allow engine to cool.

30.Air Pressure Gauge:

CAUTION: To prevent personal injury ormachine damage, DO NOT operate machinewhen air pressure is low.

2-1-5 080112PN=28


OUO1043,0000DAE -19-06FEB03-2/2

OUO1043,0000DC9 -19-03JUL01-1/1

Gauge indicates system air pressure. Normaloperating pressure is indicated by the green zone. Ifindicator points to red zone, stop machine and takecorrective action.

31. Engine Oil Pressure Gauge:

IMPORTANT: To prevent machine damage,DO NOT operate machine when engineoil pressure is low.

Gauge indicates engine oil pressure. Normal operatingpressure is indicated by the green zone. If indicatorpoints to red zone, stop machine and take correctiveaction.

Heater and Air Conditioner Controls1. Air Conditioner Switch: Push lower half of switch to

turn air conditioner or defrost ON. Push upper half ofswitch to turn air conditioner or defrost OFF.

2. Temperature Control Knob: Turn counterclockwisefor cooler air. Turn clockwise for warmer air.

3. Blower Speed Control Knob: Turn blower speedcontrol knob to adjust blower speed.

4. Air Flow Control Knob: Turn knob to defrost, low,high or divided flow.

5. Recirculating Air Switch: Push lower half of switchto recirculate air. Push the upper half of the switchfor fresh air.

T143696B

UN05JU

L01

1Air Conditioner Switch2Temperature Control Knob3Blower Speed Control Knob

4Air Flow Control Knob5Recirculating Air Switch

2-1-6 080112PN=29


OUO1043,0000DB4 -19-20JUN01-1/1

Steering Column Lever1. High Beam Headlight: Push lever forward to high

beam headlight position (1).

2. Low Beam Headlight: Move lever to center dimheadlight position (2).

3. Flash-to-Pass Headlight: Pull lever rearward toflash-to-pass headlight position (3). Lever will returnto dim headlight position when released.

4. Horn Button: Push to sound horn.

5. Windshield Washer Button: With key switch in ONor ACCESSORY position, push to activate windshieldwasher.

6. Intermittent Windshield Wiper: With key switch inON or ACCESSORY position, turn steering columnlever forward to intermittent wiper position (6).Intermittent wiper time interval can be adjusted usingthe monitor display unit (MDU).

7. Windshield Wiper Off: Turn steering column leverforward or rearward, as necessary, to windshield wiperOFF position (7) to turn wiper OFF.

8. Low Speed Windshield Wiper: With key switch inON or ACCESSORY position, turn steering columnlever rearward to low speed windshield wiper position(8) to activate low speed windshield wiper.

9. High Speed Windshield Wiper: With key switch inON or ACCESSORY position, turn steering columnlever rearward to high speed windshield wiper position(9) to activate high speed windshield wiper.

10.Right Turn Indicator: Lift steering column lever up toright turn indicator position (10) to activate right turnindicator.

T143150B

UN20JU

N01

1High Beam HeadLightPosition

2Low Beam HeadLightPosition

3Flash-to-Pass HeadlightPosition

4Horn Button5Windshield Washer Button6 Intermittent Windshield

Wiper Position

7Windshield Wiper OffPosition

8Low Speed WindshieldWiper Position

9High Speed WindshieldWiper Position

10 Right Turn IndicatorPosition

11 Left Turn IndicatorPosition

11. Left Turn Indicator: Push steering column leverdown to left turn indicator position (11) to activate leftturn indicator.

2-1-7 080112PN=30


TX14740,0000009 -19-27JAN03-1/1

Circuit Breaker Compartment

T143685B

UN05JU

L01

T148487B

UN29NOV01

115 Amp Circuit Breaker(F1)Park Lights, InteriorLights, Brake Lights,Hazards/Indicators, VoltageRegulator

230 Amp Circuit Breaker(F2)Battery Supply to FusesF12, F13, F18, F19, F20, andF21

320 Amp Circuit Breaker(F3)Ignition Supply toFuses F11, F14, F15, and F16

430 Amp Circuit Breaker(F4)Back Up Lights,Headlights, Work Lights, andRotating Beacon

525 Amp Circuit Breaker(F5)Air Conditioner,Headlights Relay

615 Amp Circuit Breaker(F6)Gear Hold, Bin DownLatch Solenoid, Park BrakeSolenoid, CTD Solenoid,Automatic Greaser, and FanDrive Solenoid

725 Amp Circuit Breaker(F7)Seat Pump, WiperMotor, Mirror Defrost,Electrical Mirrors,Washer Motor, HornSolenoid/Electrical Horn

825 Amp Circuit Breaker(F8)Cold Start

9 15 Amp Circuit Breaker(F9)Bin Float Solenoid,Neutral Relay, Start Relay,MDU/CCU Power Relay

10 10 Amp Fuse(F11)Transmission,Engine Brake, and VoltageRegulator

11 10 Amp Fuse(F12)Transmission

12 5 Amp Fuse(F13)MDU/CCU (Battery toRelay), Hazard Input to CCU

13 5 Amp Fuse (F14)Alterna-tor D+

14 10 Amp Fuse (F15)CCUProgram, MDU Program,Diagnostic

15 20 Amp Fuse (F16)Engine16 10AmpFuse (F17)Reverse

Camera, FM RadioIfEquipped

17 5 Amp Fuse (F19)MDU18 10 Amp Fuse

(F20)Diagnostic19 10 Amp Fuse (F21)Battery

Balancer, Accessory,Battery Balancer Enable

20 15 Amp Fuse (F22)2-WayRadio

The circuit breaker panel consists of 9 circuit breakerswhich provide electrical overload protection for theidentified circuits. Push circuit breaker button to reset atripped circuit breaker.

The fuse block consists of 11 fuses which provideoverload protection for the identified circuits. Replacefuses as necessary.

2-1-8 080112PN=31


OUO1043,0000DD1 -19-06FEB03-1/1

Operator Seat and Instructional SeatThe operator's seat is fully adjustable to suit operator'sheight, weight and reach.

1. Backrest Adjustment Knob: Turn knob to movebackrest to desired position.

2. Weight Adjustment Lever: Use adjustment lever toobtain the most comfortable seat suspension.

3. Seat Height Adjustment Lever: Pull and holdadjustment lever up to obtain the most comfortabledriving position.

4. Arm Rest Angle Adjustment Knob: The arm restsmay be lifted to allow easier access to seat and thenlowered for driver comfort. To adjust angle of armrests, turn arm rest angle adjustment knob underarm rest clockwise or counterclockwise until the mostcomfortable position is reached.

5. Seat Belt:

CAUTION: Use seat belt to prevent personalinjury. Check condition of seat belt andmounting hardware before operating machine.Replace seat belt at least every 3 years,regardless of condition.

Seat belt must fit snugly over abdomen. Seat beltextends as necessary to fit comfortably.

6. Fore/Aft Adjustment Lever: Lift and hold seatcushion adjustment lever and adjust seat cushion angleas desired. Release lever to lock seat into position.

7. Instructional Seat: The instructional seat isnon-adjustable and is equipped with a seat belt.

1Backrest Angle AdjustmentKnob

2Weight Adjustment Lever3Seat Height Adjustment

Lever4ArmRest Angle Adjustment

Knob

5Seatbelt6Fore/Aft Adjustment Lever7 Instructional Seat

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Air Suspension SeatIf EquippedThe operator's seat is fully adjustable to suit operator'sheight, weight and reach.

1. Fore/Aft Adjustment Lever:Lift to move seat forwardor rearward. Release lever to lock seat into position.

2. Air/Height Lever:Lift and hold air/height lever toobtain the most comfortable driving position.

3. Lumbar:Push lumbar support button to adjust seatback lumbar support to the most comfortable position.

4. Armrest Height:The armrests may be lifted to alloweasier access to seat and then lowered for drivercomfort.

5. Backrest Tilt:Lift seat back tilt lever to adjust seatback tilt. Release lever to lock seat back into position.

6. Fore/Aft Cushion Lock:Adjust cushion to improveoperator comfort.

7. Ride Control/Stiffness:Adjust seat to improve overallride control and to reduce stiffness.

1Fore/Aft Adjustment Lever2Air/Height Lever3Lumbar4Armrest Height

5Backrest Tilt6Fore/Aft Cushion Lock7Ride Control/Stiffness

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UN02AUG05

Seat BeltSeat belt and mounting hardware must be inspected forwear or damage before operating the machine. Replacethe belt or mounting hardware if worn or damaged.

Replace the complete seat belt assembly every threeyears regardless of appearance.

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Battery Disconnect Switch and BatteryCircuit BreakersThe battery disconnect switch (4) is located inside thebattery compartment.

IMPORTANT: Always turn battery disconnect switchOFF when engine is stopped and machineis left unattended. If switch is left ON forlong periods while engine is stopped, thebatteries may become discharged.

IMPORTANT: Always turn battery disconnect switchOFF before any maintenance or repair isperformed on machine's electrical system orany welding work is performed.

The battery disconnect switch is used to isolate electricalpower from batteries to machine.

The battery disconnect switch has 2 positions, OFF andON.

Three circuit breakers are located in the batterycompartment to protect the machine's electrical circuitsfrom a possible overload condition or problem frombatteries.

The main circuit breaker (3) (marked Ignition) is ratedat 60 amps. The battery balancer circuit breaker (2) (marked 12 V)is rated at 20 amps. The purging units, fuel filter and coolant level switchcircuit breaker (1) is rated at 20 amps.

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120 Amp CircuitBreakerPurging Units,Fuel Filter, and CoolantLevel Switch

220 Amp CircuitBreakerBattery Balancer(Marked 12 V)

360 Amp CircuitBreakerMain (MarkedIgnition)

4Battery Disconnect Switch

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Miscellaneous EquipmentLights

High beam and low beam headlights (1) are controlledusing the steering column lever.

Tail, brake and park lights (4) light when brake pedal isdepressed or when accelerator pedal is released andtorque retarder is activated.

Turn indicator lights (2 and 3) light when warning lights orturn signals are turned ON.

Back-up lights (5) light when machine transmission isshifted to reverse.

1Headlight and Front ParkLight (2 used)

2Front Turn Indicator Light(2 used)

3Rear Turn Indicator Light (2used)

4Tail, Brake and Park Light(2 used)

5Back Up Light (3 used)

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UN29NOV01

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Secondary Exit

If necessary, use the secondary exit tool (1) to break theglass of the right-side window.

1Secondary Exit Tool

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UN06JU

L01

12-Volt Accessory Outlet

The 12-volt accessory outlet is used to power operatoraccessories, as necessary.

112-Volt Accessory Outlet

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UN19JU

L01

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Storage Compartment

Store items in compartment located behind the operator'sseat to keep them clean and dry.

1Storage Compartment

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UN27JU

L01

Wheel Wrench and Brace

NOTE: Brace is also used as cab tilt pump handle.

The wheel wrench (1) and brace (2) are located at rearof cab, behind the operator's seat and are secured inposition by 2 plates.

1Wheel Wrench 2Brace

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UN06JU

L01

Windshield Washer Reservoir

The windshield washer reservoir (1) is located at front ofcab under hood.

To fill reservoir:

1. Tilt hood.

2. Remove filler cap (2) and fill reservoir with washercleaning fluid.

3. Install cap. Ensure that electrical connection and fluiddelivery hose are also secure.

4. Close hood.

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UN06JU

L01

1Windshield WasherReservoir

2Filler Cap

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Continued on next page OUO1043,0000DCC -19-19JUL01-1/3

Monitor Display UnitDefault Display Menu1. Message Display: When key switch is turned ON or

machine is started, the default menu will be displayed.The default menu can be configured to suit theoperator. The information on the bottom row can bechanged by pressing the NEXT button.When other menus are selected or service codesare detected, message display will show relevant,descriptive information.

2. Gear Display: When machine is in neutral (N), thegear display will show 0. When machine is in drive(D), gear display will show the current of 6 forwardgears that the machine is in. When machine is inreverse (R), the gear display will display 1; there isonly a single reverse gear.

3. Drive/Neutral/Reverse Display: When machine is indrive (D), display will show F. When machine is inneutral (N), display will show N. When machine is inreverse (R), display will show R.

4. NEXT Button: To change the information shown in theinformation display, press and hold NEXT button for 3beeps to access default menu. Once default menu isaccessed, push NEXT button repeatedly until messagedisplay (1) shows that desired default informationis being shown in information display (5). Oncedefault screen has been changed, the selected defaultinformation will be displayed any time the key switch isturned to the ON position or the machine is started.

5. Information Display: Information displayed varies,depending on which default display is currently

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1

1Message Display2Gear Display3Drive/Neutral/Reverse

Display4NEXT Button

5 Information Display6Tachometer Display7Hour Meter Display

selected. When ignition is switched OFF and then ONagain, the last selected information will be displayed.

6. Tachometer Display: Displays current engine speedrpm.

7. Hour Meter Display: Displays the machine hours inwhole hour increments. The hour meter accumulateshours only when the engine is running.

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Continued on next page OUO1043,0000DCC -19-19JUL01-2/3

T143037UN11OCT0

1

Default Menu FunctionDefault Menu Description

Machine Model Message display shows machine model number. Data display shows machine system voltage in volts.Bin Tip Counter Data display shows number of times dump body was tipped since bin tip counter was last reset.Trip Distance Data display shows distance machine traveled, in kilometers or miles, since counter was last reset.Trip Time Data display shows machine operation time since counter was last reset.Trip Fuel Data display shows machine fuel consumption rate since trip fuel counter was last reset.Odometer Odometer displays total distance machine has travelled in kilometers or miles. Odometer cannot be reset.Lockup Clutch Data display shows ON/OFF status of lock up clutch.Transmission Temperature Data display shows transmission oil temperature in C or F.Return Temperature Data display shows transmission return oil temperature in C or F.Retarder Torque Data display shows transmission torque as a percentage of available torque.Engine Temperature Data display shows engine temperature in C or F.Engine Oil Pressure Data display shows engine oil pressure in bar or psi.Engine Oil Level Data display shows engine oil level as a percentage.Fuel Consumption Data display shows fuel consumption in L/h or gal/h.Actual Torque Data display shows machine torque as a percentage of available torque.Engine Retarder Torque Data display shows engine brake torque as a percentage of available torque.Fuel Level Data display shows fuel supply in L or gal.System Air Pressure Data display shows system air pressure in bar or psi.

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Continued on next page OUO1043,0000DB5 -19-21JUN01-1/12

Default Menu FunctionDefault Menu Description

Hydraulic Temperature Data display shows hydraulic oil temperature in C or F.Brake Temperature If machine is equipped with wet brakes, data display shows wet brake temperature in C or F.

Monitor Display UnitMenu Function1. Message Display: Shows description of current menu

screen selected.2. Menu Display: Shows which menu is currently

selected.3. Sub Menu Display: Shows which sub menu is

currently selected.4. Sub Sub Menu Display: Shows which sub sub menu

is currently selected.5. Information Display: Information displayed varies,

depending on which menu screen is currently selected.6. MENU Button: Push to advance through 5 menus (A,

B, C, D, and E) and the default menu.Push MENU at any time while navigating through amenu to return to default data display.

7. BACK Button: Push to return to the next highermenu. For example, if navigating in the A 01 submenu level, pressing BACK will return the MDU datadisplay to the A menu of the top menu level.

8. NEXT Button: Push to advance from one menu tothe next in the same sub menu level or sub sub menulevel. For example, if navigating in the A 01 sub level,push NEXT button once to go to the A 02 menu.

9. SELECT Button: Push to access the menu below thecurrently shown menu. For example, if sub level menu

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L01

1Message Display2Menu Display3Sub Menu Display4Sub Sub Menu Display5 Information Display

6MENU Button7BACK Button8NEXT Button9SELECT Button

A 01 is currently displayed, press SELECT to displaythe A 011 sub sub level.

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Menu FunctionsMenu Description

A00 Counters

Menu displays counter information and allows counters to be reset.

A01

Trip Information Menu displays trip counter information since counters were last reset.

A011

Trip Distance Data display shows distance machine traveled, in kilometers or miles, since trip distancecounter was last reset.

A0111

Reset Press SELECT for longer than 3 beeps to reset trip distance counter.

A012

Trip Time Data display shows machine operation time since trip time counter was last reset.

A0121

Reset? Press SELECT for longer than 3 beeps to reset trip time counter.

A013

Trip Fuel Data display shows machine fuel consumption rate since trip fuel counter was last reset.

A0131

Reset? Press SELECT for longer than 3 beeps to reset trip fuel counter.

A014

Reset All Trip Data? Press SELECT for longer than 3 beeps to reset all trip counters.

A02

Bin Tip Counter Data display shows number of times dump body was tipped since bin tip counter waslast reset.

A021

Reset? Press SELECT for longer than 3 beeps to reset bin tip counter.

A03

Odometer Odometer displays distance machine has traveled in kilometers or miles. Odometercannot be reset.

B00 Actual Values

Menu displays machine sensor information.

B01 Engine Values

Menu displays engine sensor information.

B011 Engine Oil Pressure

Data display shows engine oil pressure in bar or psi.

B012

Engine Coolant Temperature Data display shows engine coolant temperature in C or F.

B013

Throttle Position Data display shows throttle position as a percentage of full throttle.

B014

Actual Torque Data display shows actual engine torque as a percentage.

B015

Engine Retarder Torque Data display shows engine brake as a percentage.

B016

Engine Oil Level Data display shows engine oil level as a percentage of full.

B017

Fuel Consumption Data display shows fuel consumption in L/h or gal/h.

B02 Transmission Values

Menu displays transmission sensor information.

B021 Transmission Temperature

Data display shows transmission temperature in C or F.

B022

Lock-Up Clutch Data display shows ON/OFF status of lock-up clutch.

B023

Current Gear Data display shows the currently activated travel gear.

B024

Retarder Torque Data display shows actual transmission retarder torque as a percentage.

B025

Retarder Oil Temperature Data display shows retarder oil temperature in C or F.

B03 Vehicle Values

Menu displays miscellaneous machine sensor information.

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B031 Air Pressure

Data display shows system air pressure in bar or psi.

B032

Fuel Level Data display shows fuel supply in L or gal.

B033

Bin Position Data display shows body position as a percentage of body in full up position.

B034

Hydraulic Temperature Data display shows hydraulic oil temperature in C or F.

B035

Brake Temperature If machine is equipped with wet brakes, data display shows wet brake temperature inC or F.

B036

Inter-Axle Lock Data display shows ON/OFF status of differential lock.

C00 Diagnostics

This menu is used to display service codes and diagnose inputs and outputs of CCU.

C01 Actual Service Codes

Menu displays CCU service code. If service code appears, see Service Codes inMiscellaneousTroubleshooting section.

C011 Service Code 1

Data display shows first active service code. See Service Codes inMiscellaneousTroubleshooting section.

C012

Service Code 2 Data display shows second active service code. See Service Codes inMiscellaneousTroubleshooting section.

C01X

Service Code X Continue to press NEXT button to advance through all active service codes.

C01Y

End Continue to press NEXT button until END is displayed on message display. Press NEXTbutton again to return to first active service code.

C02 Stored Service Codes

Menu displays CCU service code. If service code appears, see Service Codes inMiscellaneousTroubleshooting section.

C021 Clear Service Codes?

Press SELECT for longer than 3 beeps to reset trip time counter.

C022

ECU/TCU/CCU Service Code Data display shows first stored service code. See Service Codes inMiscellaneousTroubleshooting section.

C02X

ECU/TCU/CCU Service Code X Continue to press NEXT button to advance through maximum of 5 stored service codes.

C02Y

End Continue to press NEXT button until END is displayed on data display. Press NEXTbutton again to return to CLEAR FAULT CODES? display.

C03 CCU Inputs

Menu displays ON/OFF status of CCU digital inputs.

C031 Low Coolant Level

Data display shows ON/OFF status of low coolant level sensor.

C032 Park Brake

Data display shows ON/OFF status of pressure switch controlling park brake light.

C033 Latch Control

Data display shows ON/OFF status of park brake lever.

C034 Coldstart

Data display shows ON/OFF status of machine coldstart function.

C035 Inter-Axle Lock Dash Switch

Data display shows ON/OFF status of inter-axle lock dash switch.

C036 Left Indicator

Data display shows ON/OFF status of left turn indicator input from steering column switch.

C037 Right Indicator

Data display shows ON/OFF status of right turn indicator input from steering column switch.

C038 Hazards

Data display shows ON/OFF status of hazard switch.

C039 Intermittent Wipers

Data display shows ON/OFF status of intermittent wiper input from steering column switch.

C0310

Start SignalData display indicates if key switch is in START position. ON indicates key switch is inSTART position; OFF indicates key is not in start position.

C0311

IgnitionData display indicates if key switch is in RUN position. ON indicates key switch is in RUNposition; OFF indicates key is not in RUN position.

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C0312

BrakeData display indicates if brake pedal is being depressed. ON indicates brake pedal isbeing depressed. OFF indicates brake pedal is not being depressed.

C0313

Gear HoldData display indicates ON/OFF status of range hold rocker switch.

C04 CCU Analog Inputs

Menu displays CCU analog inputs in milivolts for analog sensors as measured at CCUinput.

C041 Bin Position

Data display shows milivolts of at bin position sensor at CCU input and the associatedvalue of bin position as a percentage of full tip value.

C042 Air Pressure

Data display shows milivolts of air pressure sensor as measured at CCU input and theair pressure value in bar or psi.

C043 Hydraulic Temperature

Data display shows milivolts of hydraulic temperature sensor as measured at CCU inputand temperature value in C or F.

C044 Wet Brake Temperature

Data display shows milivolts of wet brake temperature sensor as measured at CCUinput and temperature value in C or F.

C045 Battery Voltage

Data display shows both single battery voltage and 2 battery voltage in volts.

C046 Fuel Level

Data display shows milivolts of fuel level sensor as measured at CCU input and fuellevel value in L or gal.

C05 CCU Outputs

Menu displays CCU analog output signal ON/OFF status.

C051 Intermittent Wipers

Data display shows CCU intermittent wiper output signal ON/OFF status.

C052 Left Indicator

Data display shows CCU left turn indicator output signal ON/OFF status.

C053 Right Indicator

Data display shows CCU right turn indicator output signal ON/OFF status.

C054 Inter-Axle Lock

Data display shows CCU inter-axle lock output signal ON/OFF status.

C055 Park Brake

Data display shows CCU park brake output signal ON/OFF status.

C056 Overspeed

Data display shows CCU overspeed output signal ON/OFF status.

C057 Hydraulic Cutout

Data display shows CCU hydraulic cutout output signal ON/OFF status.

C058 Brake

Data display shows CCU brake light output signal ON/OFF status, activated with enginebrake and transmission retarder.

C059 Bin Float

Data display shows CCU bin float output signal ON/OFF status.

C0510

Purging UnitData display shows CCU purging unit output signal ON/OFF status.

C0511

Engine RunningData display shows CCU engine run output signal ON/OFF status.

D00 Machine Configuration

Menu displays the current machine settings and allows them to be

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