John Deere 3800 Telescopic Handler Manual

*DCY*
3800
Telescopic Handler
OPERATOR’S MANUAL
3800 Telescopic Handler
OMZ93152 F1 (ENGLISCH)
*OMZ93152*
John Deere Werke Zweibrücken

European Version
Printed in U.S.A.
Introduction
Foreword
READ THIS MANUAL carefully to learn how to operate BEFORE DELIVERING THIS MACHINE, your dealer
and service your machine correctly. Failure to do so performed a predelivery inspection. After operating for
could result in personal injury or equipment damage. the first 100 hours, schedule an after-sale inspection
This manual and safety signs on your machine may with your dealer to ensure best performance.
also be available in other languages (see your John
Deere dealer to order). THIS MACHINE IS DESIGNED SOLELY for use in
customary agricultural or similar operations
THIS MANUAL SHOULD BE CONSIDERED a (“INTENDED USE”). Use in any other way is
permanent part of your machine and should remain considered as contrary to the intended use. The
with the machine when you sell it. manufacturer accepts no liability for damage or injury
resulting from this misuse, and these risks must be
MEASUREMENTS in this manual are given in both borne solely by the user. Compliance with and strict
metric and customary U.S. unit equivalents. Use only adherence to the conditions of operation, service and
correct replacement parts and fasteners. Metric and repair as specified by the manufacturer also constitute
inch fasteners may require a specific metric or inch essential elements for the intended use.
wrench.
THIS MACHINE SHOULD BE OPERATED, serviced
RIGHT-HAND AND LEFT-HAND sides are determined and repaired only by persons familiar with all its
by facing the direction of forward travel. particular characteristics and acquainted with the
relevant safety rules (accident prevention). The
WRITE PRODUCT IDENTIFICATION NUMBERS accident prevention regulations, all other generally
(P.I.N.) in the Specification or Identification Numbers recognized regulations on safety and occupational
section. Accurately record all the numbers to help in medicine and the road traffic regulations must be
tracing the machine should it be stolen. Your dealer observed at all times. Any arbitrary modifications
also needs these numbers when you order parts. File carried out on this machine will relieve the
the identification numbers in a secure place off the manufacturer of all liability for any resulting damage or
machine. injury.
SETTING FUEL DELIVERY BEYOND PUBLISHED

factory specifications or otherwise overpowering will
result in loss of warranty protection for this machine.
GS,IFC 1 –19–01SEP95–1/1
072501
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Introduction
Predelivery Inspection
The following checks, adjustments and service jobs

were performed prior to delivery of the machine.
❒ 1. Lights are working correctly. ❒ 15. Brake system has been checked and is working
properly.
❒ 2. The lines and hoses have been checked and are free of ❒ 16. Paintwork and decals have been checked and are OK.
leaks.
❒ 3. All the machine controls and safety rules etc. have been ❒ 17. Engine oil level is correct.
explained to the operator.
❒ 4. Engine coolant level is correct. ❒ 18. Transmission oil level is correct.
❒ 5. Hydraulic system oil level is correct ❒ 19. All safety shields are in place and in good condition.
❒ 6. Drive axle oil levels are correct. ❒ 20. All instrument panel gauges and lights are working
correctly.
❒ 7. Cab controls (heater, blower, windshield wiper) are ❒ 21. Start switch works correctly.
working correctly.
❒ 8. Engine shut-off device is working correctly. ❒ 22. Transmission shift components are working correctly.
❒ 9. The steering is working correctly. ❒ 23. The handbrake is working correctly.
❒ 10. All pivot pins and wear pads are correctly installed. ❒ 24. The load indicator is working correctly.
❒ 11. All the hydraulic system controls are working correctly. ❒ 25. All seat adjustment have been checked and are OK.
❒ 12. The tire pressure has been checked and is OK. ❒ 26. Wheel nuts are tightened to specified torque.
❒ 13. Breathers on axles and transmission are clear. ❒ 27. The transmission oil pressure has been checked and is
OK.
❒ 14. The main and steering hydraulic pressure has been ❒ 28. All grease fittings are lubricated.
checked and is OK.
Signature Dealer/Service Technician: Date:
OUZXMAG,000102E –19–18JUN01–1/1
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Introduction
072501
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Contents
Page Page
Identification View Work Light Switch. . . . . . . . . . . . . . . . . . . . . . . . 20-5

Boom Work Light Switch (Option). . . . . . . . . . . . 20-6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1 Beacon Light Switch (Option) . . . . . . . . . . . . . . . 20-6
Reverse Travel Alarm. . . . . . . . . . . . . . . . . . . . . 20-7
Safety Decals Seven-Terminal Trailer Socket . . . . . . . . . . . . . . 20-7
Pictorial Safety Signs . . . . . . . . . . . . . . . . . . . . . 10-1
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . 10-1 Operator’s Platform and Cab
Maintenance and Repair. . . . . . . . . . . . . . . . . . . 10-1 Roll-Over Protective Structure . . . . . . . . . . . . . . 25-1
Stay Clear of Raised Boom . . . . . . . . . . . . . . . . 10-1 Falling-Object Protective Structure . . . . . . . . . . . 25-1
Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . 10-2 Windshield Guard . . . . . . . . . . . . . . . . . . . . . . . . 25-2
Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Opening Doors . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3
Boom in Raised Position . . . . . . . . . . . . . . . . . . 10-2 Opening Rear Side Windows . . . . . . . . . . . . . . . 25-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Deluxe Suspension Seat . . . . . . . . . . . . . . . . . . 25-5
Wheel Attaching Nuts . . . . . . . . . . . . . . . . . . . . . 10-3 Deluxe Air Suspension Seat . . . . . . . . . . . . . . . . 25-6
Hydraulic Accumulator . . . . . . . . . . . . . . . . . . . . 10-3 Super Deluxe Air Suspension Seat. . . . . . . . . . . 25-7
Pivoting Area . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Armrest Console Position Adjustment. . . . . . . . . 25-8
Pivoting Area Cylinders . . . . . . . . . . . . . . . . . . . 10-4 Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 25-9
Steering Wheel Height/Tilt Adjustment . . . . . . . 25-10
Controls and Instruments Cab Interior Light . . . . . . . . . . . . . . . . . . . . . . . 25-10
General View of Controls and Instruments . . . . . 15-2 Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-11
Armrest Control Panel . . . . . . . . . . . . . . . . . . . . 15-3 Front Sun Visor . . . . . . . . . . . . . . . . . . . . . . . . 25-11
Roof Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 Roof Sun Visor . . . . . . . . . . . . . . . . . . . . . . . . . 25-11
Multi-Function Lever . . . . . . . . . . . . . . . . . . . . . . 15-5 Windshield and Cab Roof Wiper and
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6 Washer System. . . . . . . . . . . . . . . . . . . . . . . 25-12
Coolant Temperature Gauge . . . . . . . . . . . . . . . 15-7 Rear Window Wiper . . . . . . . . . . . . . . . . . . . . . 25-13
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7 Blower and Air Louvers . . . . . . . . . . . . . . . . . . 25-14
Speedometer - Hour Meter . . . . . . . . . . . . . . . . . 15-8 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-14
Corner Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8 Air Conditioning System (Option) . . . . . . . . . . . 25-15
Forward Stability Indicator (Load Monitor) . . . . . 15-9 Tool Box (Option) . . . . . . . . . . . . . . . . . . . . . . . 25-15
Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10 Coat Hanger Hook . . . . . . . . . . . . . . . . . . . . . . 25-15
Gear Shift Lever (Synchro-Shuttle) . . . . . . . . . . 15-10 Cigarette Lighter. . . . . . . . . . . . . . . . . . . . . . . . 25-16
Gear Shift Switch (PowerShift) . . . . . . . . . . . . . 15-11 Manual Storage . . . . . . . . . . . . . . . . . . . . . . . . 25-16
Forward-Neutral-Reverse Lever (FNR) . . . . . . . 15-12 Armrest Storage Box . . . . . . . . . . . . . . . . . . . . 25-16
Outside Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . 15-13 Can/Cup Holders and Storage Trays . . . . . . . . 25-17
Rear Mounted Mirror (Option). . . . . . . . . . . . . . 15-13 Radio (Special Equipment) . . . . . . . . . . . . . . . . 25-18
Lighting System and Signals Break-In Period

Lights (Standard) . . . . . . . . . . . . . . . . . . . . . . . . 20-1 After First 4 and 8 Hours of Operation . . . . . . . . 30-1
Lights (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2 Within First 100 Hours of Operation . . . . . . . . . . 30-1
Light Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3 After First 100 Hours of Operation . . . . . . . . . . . 30-2
Operating the Hazard Warning Light Switch . . . . 20-4
Switch for Turn Signal Lights and Horn . . . . . . . 20-5 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  2001
DEERE & COMPANY
European Office Mannheim
All rights reserved
A John Deere ILLUSTRUCTION Manual
i 072501
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Contents
Page Page
Prestarting Checks Digging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-16

Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Avoiding Injury or Death from Falling
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Round Bales . . . . . . . . . . . . . . . . . . . . . . . . . 55-16
Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . 35-1 Picking up a Round Bale . . . . . . . . . . . . . . . . . 55-17
Transmission Oil Level . . . . . . . . . . . . . . . . . . . . 35-2 Picking up a Round Bale on a Slope . . . . . . . . 55-17
After Long Storage Period . . . . . . . . . . . . . . . . . 35-2 Transporting a Round Bale. . . . . . . . . . . . . . . . 55-18
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3 Operating Attachments
Lubricate Handler . . . . . . . . . . . . . . . . . . . . . . . . 35-3 Attachments (General Information) . . . . . . . . . . . 60-1
Checks in Operator’s Cab . . . . . . . . . . . . . . . . . 35-3 Pallet Forks (John Deere Carrier) . . . . . . . . . . . . 60-2
Attaching/Detaching Equipment (John
Operating the Engine Deere Carrier). . . . . . . . . . . . . . . . . . . . . . . . . 60-3
Safety Rules for Starting Engine. . . . . . . . . . . . . 40-1 Attachment Auxiliary Functions. . . . . . . . . . . . . . 60-4
Battery Main Switch . . . . . . . . . . . . . . . . . . . . . . 40-1 Front Auxiliary Hydraulic Functions. . . . . . . . . . . 60-4
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . 40-2 Rear Auxiliary Hydraulic Functions . . . . . . . . . . . 60-5
Starting the Engine With a Slave Battery . . . . . . 40-3 Hose Unions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5
Starting the Engine by Means of a Booster Connecting Attachment Hoses . . . . . . . . . . . . . . 60-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3 Mechanical Rear Hitch (Option) . . . . . . . . . . . . . 60-6
Cold Weather Starting Aids . . . . . . . . . . . . . . . . 40-3 Semi Automatic Wagon Hitch (Option) . . . . . . . . 60-7
Electrical Starting Aid . . . . . . . . . . . . . . . . . . . . . 40-4 Tip a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-7
Engine Warm-Up Period. . . . . . . . . . . . . . . . . . . 40-4
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . 40-5 Fuel, Lubricants, Coolant and Capacities
Stalling of Engine . . . . . . . . . . . . . . . . . . . . . . . . 40-5 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-1
Handling and Storing Diesel Fuel . . . . . . . . . . . . 65-1
Driving and Transporting the Handler Diesel Engine Break-In Oil . . . . . . . . . . . . . . . . . 65-2
Driving on Public Roads . . . . . . . . . . . . . . . . . . . 45-1 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 65-3
Reverse Travel Alarm. . . . . . . . . . . . . . . . . . . . . 45-2 Transmission and Hydraulic Oil . . . . . . . . . . . . . 65-4
Transport Information . . . . . . . . . . . . . . . . . . . . . 45-2 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-5
Parking the Machine. . . . . . . . . . . . . . . . . . . . . . 45-4 Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-5
Chock Block (Option) . . . . . . . . . . . . . . . . . . . . . 45-5 Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 65-6
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 65-6
Operating the Machine Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . . 65-7
Reduce Fuel Consumption . . . . . . . . . . . . . . . . . 50-1 Operating in Warm Temperature Climates . . . . . 65-8
Shifting Transmission (Synchro-Shuttle) . . . . . . . 50-3 Alternative and Synthetic Lubricants. . . . . . . . . . 65-8
Shifting Transmission (PowerShift) . . . . . . . . . . . 50-4 Use Genuine John Deere Parts . . . . . . . . . . . . . 65-9
Hydraulic Foot Brakes . . . . . . . . . . . . . . . . . . . . 50-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-9
Transmission Declutch . . . . . . . . . . . . . . . . . . . . 50-5
Lubrication and Periodic Service
Operating the Boom Articulation Joint Safety Rod. . . . . . . . . . . . . . . . 70-1
Raising and Lowering the Boom. . . . . . . . . . . . . 55-1 Service Intervals. . . . . . . . . . . . . . . . . . . . . . . . . 70-2
Observe Lift Capacity Limits . . . . . . . . . . . . . . . . 55-1 Opening the Hood . . . . . . . . . . . . . . . . . . . . . . . 70-3
Forward Stability Indicator (Load Monitor) . . . . . 55-2 Access to Fuses. . . . . . . . . . . . . . . . . . . . . . . . . 70-4
Forward Stability Indicator Test . . . . . . . . . . . . . 55-3 Access to Battery . . . . . . . . . . . . . . . . . . . . . . . . 70-4
Examples of Overload Situations . . . . . . . . . . . . 55-6 Important Instructions Regarding Alternator . . . . 70-5
Boom Safety Devices . . . . . . . . . . . . . . . . . . . . . 55-7 Daily or Every 10 Hours . . . . . . . . . . . . . . . . . . . 70-5
Boom Lift Cylinder Safety Channel . . . . . . . . . . . 55-8 Every 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . 70-6
Operating the Boom . . . . . . . . . . . . . . . . . . . . . . 55-9 After the First 100 Hours . . . . . . . . . . . . . . . . . . 70-6
Approaching a Load . . . . . . . . . . . . . . . . . . . . . 55-11 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . 70-6
Picking Up a Load . . . . . . . . . . . . . . . . . . . . . . 55-12 Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . 70-7
Placing a Load . . . . . . . . . . . . . . . . . . . . . . . . . 55-13 Every 750 Hours . . . . . . . . . . . . . . . . . . . . . . . . 70-7
Lifting Unpalletized Loads. . . . . . . . . . . . . . . . . 55-14 Every 1000 Hours or Every Year . . . . . . . . . . . . 70-7
Travelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-15
Removing Material from a Pile . . . . . . . . . . . . . 55-15 Continued on next page
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Contents
Page Page
Every 2000 Hours or Every Two Years . . . . . . . 70-8 Changing Transmission Oil. . . . . . . . . . . . . . . . 100-3
Every 3000 Hours or Every Three Years . . . . . . 70-8 Changing Axle Final Drive Oil. . . . . . . . . . . . . . 100-4
As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-8 Changing Axle Differential Oil . . . . . . . . . . . . . . 100-5
Service / Daily or Every 10 Hours Service / Every 2000 Hours or 2 Years

Every 10 Hours—Checking Engine Changing Air Cleaner Inner Element . . . . . . . . 105-1
Crankcase Oil Level . . . . . . . . . . . . . . . . . . . . 75-1 Replacing Coolant (Without JD
Every 10 Hours—Checking Coolant Level . . . . . 75-1 COOL-GARD Coolant) . . . . . . . . . . . . . . . . . 105-1
Every 10 Hours—Checking Lights . . . . . . . . . . . 75-1 Adjusting Engine Valve Tappet Clearance . . . . 105-2
Every 10 Hours—Carrier Pivots (John
Deere Carrier). . . . . . . . . . . . . . . . . . . . . . . . . 75-2 Service / Every 3000 Hours or 3 Years
Every 10 Hours—Checking Transmission Replacing Coolant (With JD COOL-GARD
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3 Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-1
Every 10 Hours—Checking Hydraulic Oil
Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3 Service / As Required
Every 10 Hours—Other Service Jobs Electrical Connector Handling. . . . . . . . . . . . . . 115-1
(Under Extreme Conditions) . . . . . . . . . . . . . . 75-4 Hydraulic System Cleanliness . . . . . . . . . . . . . 115-2
Observe Air Conditioning Precautions . . . . . . . 115-2
Service / Every 50 Hours Winterize Cooling System. . . . . . . . . . . . . . . . . 115-3
Every 50 Hours—Grease Fittings . . . . . . . . . . . . 80-1 Cleaning Cab Air Filters . . . . . . . . . . . . . . . . . . 115-3
Every 50 Hours—Grease Fittings (Continued) . . 80-2 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-4
Checking Oil Level in Axles . . . . . . . . . . . . . . . . 80-5 Keep Radiator Screens Clean . . . . . . . . . . . . . 115-6
Checking Parking Brake and Lubricating Brake System Pressure . . . . . . . . . . . . . . . . . . 115-6
Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-6 Replacing Fan/Alternator V-Belt . . . . . . . . . . . . 115-7
Do Not Modify Fuel System . . . . . . . . . . . . . . . 115-8
Service / Every 250 Hours Checking Fuel Filter . . . . . . . . . . . . . . . . . . . . . 115-9
Checking Air Cleaner Elements . . . . . . . . . . . . . 85-1 Bleeding the Fuel System. . . . . . . . . . . . . . . . 115-10
Wheel Retaining Bolts . . . . . . . . . . . . . . . . . . . . 85-1 Lubricate All Lubricating Points. . . . . . . . . . . . 115-11
Neutral Start Circuit . . . . . . . . . . . . . . . . . . . . . . 85-2 Checking Tire Pressure . . . . . . . . . . . . . . . . . 115-11
Checking Electrolyte Level of Battery . . . . . . . . . 85-2 Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . 115-11
Checking Air Conditioning Receiver-Drier . . . . . . 85-2 Starting Motor. . . . . . . . . . . . . . . . . . . . . . . . . 115-12
Replacing Thermostat. . . . . . . . . . . . . . . . . . . 115-13
Service / Every 500 Hours Battery—Checking Specific Gravity . . . . . . . . 115-14
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . 90-1 Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . 115-15
Changing Engine Crankcase Filter Element . . . . 90-2
Changing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . 90-3 Troubleshooting
Servicing Fuel Tank . . . . . . . . . . . . . . . . . . . . . . 90-4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . 120-1
Checking Belt Tensioner Spring Tension Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-2
and Belt Wear. . . . . . . . . . . . . . . . . . . . . . . . . 90-4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . 120-3
Checking Tensioner Spring Tension . . . . . . . . . . 90-5
Air Intake Hose. . . . . . . . . . . . . . . . . . . . . . . . . . 90-5 Storage
Replacing Air Cleaner Outer Element . . . . . . . . . 90-6 Storage for Long Period . . . . . . . . . . . . . . . . . . 125-1
Replacing Transmission Oil Filter . . . . . . . . . . . . 90-7 Removing Machine From Storage . . . . . . . . . . 125-2
Replacing Hydraulic Oil Filter . . . . . . . . . . . . . . . 90-7
Greasing Boom Extension Wear Pads . . . . . . . . 90-8 Specifications
Adjusting Parking brake . . . . . . . . . . . . . . . . . . . 90-8 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130-1
Transmission (Synchro-Shuttle) . . . . . . . . . . . . 130-1
Service / Every 750 Hours Transmission (PowerShift) . . . . . . . . . . . . . . . . 130-1
Checking Engine Speeds . . . . . . . . . . . . . . . . . . 95-1 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . 130-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . 130-2
Service / Every 1000 Hours or 1 Year Vibrations at Operator’s Position . . . . . . . . . . . 130-2
Replacing Cab Air Filters . . . . . . . . . . . . . . . . . 100-1
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . 100-2 Continued on next page
iii 072501
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Contents
Page
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 130-2

Dimensions - 3800 Telescopic Handler . . . . . . 130-3
Lift Capacity and Lifting Height . . . . . . . . . . . . . 130-3
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . 130-4
Safety Note Regarding the Subsequent
Installation of Electrical and Electronic
Appliances and/or Components . . . . . . . . . . 130-4
Declaration of Conformity . . . . . . . . . . . . . . . . . 130-5
Serial Numbers
Type Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 135-1
Handler Type Plate. . . . . . . . . . . . . . . . . . . . . . 135-1
Product Identification Number. . . . . . . . . . . . . . 135-1
Front Axle Serial Number . . . . . . . . . . . . . . . . . 135-2
Rear Axle Serial Number . . . . . . . . . . . . . . . . . 135-2
Engine Serial Number . . . . . . . . . . . . . . . . . . . 135-2
Transmission Serial Number. . . . . . . . . . . . . . . 135-2
Torque Converter Serial Number . . . . . . . . . . . 135-3
iv 072501
PN=4
Identification View
–UN–28JUN01
ZX026096
Telescopic Handler 3800
OUZXMAG,000102F –19–18JUN01–1/1
00-1 072501
PN=7
Safety
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the
potential for personal injury.
–UN–07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT –19–29SEP98–1/1
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
–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL –19–03MAR93–1/1
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
–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
TS201
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
05-1 072501
PN=8
Safety
Protect People and Animals
Never allow anyone to walk or work under a raised boom.
Be sure that people, livestock, or pets are not standing in

the working area of the machine while operating.
–UN–20JAN01
Do not use the handler as a work platform.
Do not lift or carry anyone on handler or in bucket or
ZX023703
attachment.
ZX023703
OUZXMAG,0000867 –19–20JAN01–1/1
Prevent Machine Runaway
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals.
–UN–25MAY00
Machine will start in gear if normal circuitry is bypassed.
NEVER start engine while standing on ground. Start

engine only from operator’s seat, with transmission in
ZX019247
neutral.
AG,OUZXMAG,172 –19–20NOV99–1/1
Avoid Power Lines
Serious injury or death can result if handler contacts

electric lines.
Check height clearance before raising boom. –UN–20JAN01
Do not leave the operator’s seat if any part of handler

contacts lines.
ZX023704
ZX023704
OUZXMAG,0000868 –19–20JAN01–1/1
05-2 072501
PN=9
Safety
Dig Safely
Before digging, check location of cables, gas lines and

water mains.
Do not leave the operator’s seat if any part of handler
–UN–21JAN01
contacts cables.
ZX023705
ZX023705
OUZXMAG,0000869 –19–20JAN01–1/1
Avoiding Injury or Death from Falling Round

Bales
CAUTION: Improper use of handler to handle

round bales can result in injury to the handler
operator from:
- The bale rolling back down the handler boom

on the operator’s station.
- A handler roll-over accident caused by

instability when the bale is not carried low.
To help prevent personal injury or death caused

by falling loads :
• DO NOT handle round bales unless handler is equipped

with an approved bale handling device. Otherwise, the
bale can fall on the operator when the boom is raised.
• To avoid handling and stability problems, do not exceed
–UN–20JAN01
the manufacturer’s rated capacity of the handler.
• Carry loads low, drive slowly, maintain adequate
visibility and ground clearance at all times.
• Handle raised loads with caution.
ZX023706
• Jerky operation causes handler instability. Operate the ZX023706
handler controls smoothly.
• When handling round bales on a slope, approach the
bale with handler facing uphill.
OUZXMAG,000086A –19–20JAN01–1/1
05-3 072501
PN=10
Safety
Transporting Round Bales Safely
To help prevent personal injury or accidents caused by a

bale falling off the handler, carry the bale low and fully
rolled back. Travel slowly over rough ground.
–UN–20JAN01
Follow the instructions in “Operating The Boom” Section
of this manual.
ZX023713
ZX023713
OUZXMAG,000086C –19–20JAN01–1/1
Service Handler Safely
Always engage parking brake or place transmission in

"PARK", lower boom to the ground, shut off engine and
remove key before servicing the handler.
–UN–20JAN01
Do not walk, work or perform service under a raised
boom, bucket or attachment unless it is securely blocked
or held in position. Do not support the boom on cinder
blocks, hollow tiles, or props that may crumble under
ZX023707
continuous load. Do not work under the boom supported
solely by a jack. ZX023707
Follow recommended procedures in this manual.
Before disconnecting hydraulic hoses, relieve all hydraulic

pressure.
Do not climb on handler to service or lubricate. Use a

platform or step ladder to service or lubricate handler.
Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.
Hydraulic hoses can fail due to physical damage, kinks,

age and exposure. Check hoses regularly. Replace
damaged hoses.
OUZXMAG,000086B –19–20JAN01–1/1
05-4 072501
PN=11
Safety
Use Seat Belt Properly
Use a seat belt when you operate the machine to

minimize chance of injury from an accident such as an
overturn.
–UN–25MAY00
ZX019248
AG,OUZXMAG,173 –19–20NOV99–1/1
Work in Ventilated Area
Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
–UN–23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR –19–17FEB99–1/1
05-5 072501
PN=12
Safety
Driving on Public Roads
Always check the road and general operating safety of the

machine before using.
Operate machine only when all guards are fitted and in

their correct position.
Before moving away, always check immediate vicinity of

machine (e.g. for children). Ensure adequate visibility.
Always adapt your ground speed to meet the ground

conditions. Avoid making sharp turns when driving up or
down slopes or when driving across the slope. Always
drive a loaded machine Forward Uphill and in Reverse
Downhill. Always drive an unloaded machine in Reverse
Uphill and Forward Downhill.
Reduce your ground speed when driving the machine on

slopes or over uneven ground and before making sharp
–UN–21JAN01
turns. Before descending a steep hill, shift to a lower gear.
Never coast downhill! Keep the boom fully retracted and
low to the ground.
ZX023708
Avoid holes, ditches and obstructions which may cause
the machine to tip, particularly on hillsides. ZX023708
Reversing at high speeds can cause accidents. Do not

reverse in third or fourth gear with full throttle. Always
drive at a safe speed, to suit the conditions.
Never drive near the edge of a gully or steep

embankment — it might cave in!
OUZXMAG,000086D –19–20JAN01–1/1
05-6 072501
PN=13
Safety
Operating the Machine Safely
Careless use of the machine can result in unnecessary • One-Fork Lifting: A load lifted on one fork can slip
accidents. In some countries an Operator’s Certificate off. Never lift a load with one fork.
is required to operate handlers. Be alert to hazards of
machine operation. Understand causes of accidents • Unloading: Never unload the forks by stopping the
and take every precaution to avoid them. Most machine suddenly.
common accidents are caused from:
• Uneven Ground: Loads stacked on uneven ground
• Machine roll-over can topple. Never stack loads on uneven ground.
• Improper starting procedures
• Crushing and pinching during hitching • Scaffolding: Overloaded scaffolding can collapse.
• Collisions with other motor vehicles Never load scaffolding beyond the regulation
capacity.
Avoid accidents by taking the following precautions:
• Overhead Clearance: A raised boom can strike
• Apply parking brake before dismounting. Leaving overhead objects. Always check for overhead
transmission in gear with engine stopped will NOT clearance before raising the boom.
prevent the machine from moving.
• Boom/Travelling: Operating the boom while travelling
• Be sure everyone is clear of machine before starting can cause accidents. You will not have total control.
engine. Never operate the boom while travelling. Always
travel with the boom fully retracted.
• Never try to get on or off a moving machine.
• Forks/Working Platform: Never use the forks as a
• Fork Spacing: Loads can fall off incorrectly spaced working platform. You can fall off the forks and be
forks. Always space the forks correctly for the load. severely injured or killed.
Make sure the forks are completely under the load
before lifting.
GS,DRIVEHANDLER –19–10DEC95–1/1
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 the
machine. Riders also obstruct the operator’s view resulting
in the machine being operated in an unsafe manner.
GS,OMITF1 –19–01JUL95–1/1
05-7 072501
PN=14
Safety
Parking and Leaving the Machine
Lower attachment or carriage to the ground before leaving

the machine.
Shut off engine, select neutral with both the gear lever
–UN–17JAN95
and the forward/reverse control.
Apply handbrake, remove main switch key and lock the

operator’s cab. Position chock blocks.
LX002510
Never leave machine unattended as long as engine is still
running.
Never leave the cab when driving.
GS,PARK –19–01SEP95–1/1
Handle Fuel 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
–UN–23AUG88
outdoors.
Prevent fires by keeping machine clean of accumulated

trash, grease, and debris. Always clean up spilled fuel.
TS202
DX,FIRE1 –19–03MAR93–1/1
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,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
DX,FIRE2 –19–03MAR93–1/1
05-8 072501
PN=15
Safety
Wear Protective Clothing
Wear close fitting clothing and safety equipment

appropriate to the job.
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR –19–10SEP90–1/1
Use Safety Lights and Devices
Prevent collisions between other road users, slow moving

tractors with attachments or towed equipment, and
self-propelled machines on public roads. Frequently check
for traffic from the rear, especially in turns, and use turn
signal lights.
Use headlights, flashing warning lights, and turn signals

day and night. Follow local regulations for equipment
lighting and marking. Keep lighting and marking visible,
clean, and in good working order. Replace or repair
–UN–12APR90
lighting and marking that has been damaged or lost. An
implement safety lighting kit is available from your John
Deere dealer.
TS951
DX,FLASH –19–07JUL99–1/1
05-9 072501
PN=16
Safety
Safely Transporting the Machine
The machine is best transported on a flatbed carrier.

Chock the wheels of the machine. Lash the wheels to the
transporter and anchor machine by securing it across the
–UN–25MAY00
forks and through the drawbar.
Towing the machine:
ZX019249
• Always remove drive shafts before towing the machine.
• Never tow the machine above 8 km/h (5 mph) as the
lack of power assistance makes manual steering very
slow and strenuous.
OUZXMAG,0001030 –19–18JUN01–1/1
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.
–UN–23AUG88
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
TS212
replaced, not reused.
DX,ROPS3 –19–03MAR93–1/1
05-10 072501
PN=17
Safety
Practice Safe Maintenance
Understand service procedure before doing work. Keep

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

moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be

raised for service work.
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.
On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems
–UN–23AUG88
or welding on machine.
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
05-11 072501
PN=18
Safety
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.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 76 mm (3 in.) from area to

be affected by heating.
TS220
• 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.
Do all work in an area that is ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–22OCT99–1/1
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
other flammable materials. Pressurized lines can be
–UN–15MAY90
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH –19–03MAR93–1/1
05-12 072501
PN=19
Safety
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
X9811
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
Service Cooling System Safely
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP –19–04JUN90–1/1
Retighten Wheel Nuts
Retighten wheel nuts at the intervals specified in sections

“Break-In Period” and “Service”.
Failure to do so could result in a wheel falling off during

–UN–28JUN01
operation, causing the machine to tip over with serious

injury to the operator and extensive damage to the
machine.
ZX026097
OUZXMAG,0001031 –19–18JUN01–1/1
05-13 072501
PN=20
Safety
Prevent Acid Burns
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:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.
–UN–23AUG88
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not
TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON –19–21APR93–1/1
Support Machine Properly
A raised boom can drop suddenly and cause serious

injury. Before working under a raised boom, install a boom
safety strut.
Do not support the machine on cinder blocks, hollow tiles,

–UN–23AUG88
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.
TS229
AG,OUZXMAG,392 –19–04MAY00–1/1
05-14 072501
PN=21
Safety
Service Tires Safely
Explosive separation of a tire and rim parts can cause

serious injury or death.
Do not attempt to mount a tire unless you have the proper

equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
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 extension

hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged

rims or missing lug bolts and nuts.
–UN–23AUG88
TS211
DX,RIM –19–24AUG90–1/1
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
05-15 072501
PN=22
Safety Decals
Pictorial Safety Signs
At several important places of this machine safety signs

are affixed intended to signify potential danger. The
hazard is identified by a pictorial in a warning triangle. An
adjacent pictorial provides information how to avoid
personal injury. These safety signs, their placement on the
–19–07OCT88
machine and a brief explanatory text are shown below.
TS231
FX,WBZ –19–19NOV91–1/1
Operator’s Manual
This operator’s manual contains important information

necessary for safe machine operation. Carefully observe
all safety rules to avoid accidents.
–UN–02JUL01
ZX026098
OUZXMAG,0001032 –19–18JUN01–1/1
Maintenance and Repair
Before carrying out maintenance and repair work, shut off

engine and remove key.
–UN–02JUL01
ZX026099
OUZXMAG,0001033 –19–18JUN01–1/1
Stay Clear of Raised Boom
Before working under a raised boom, install a boom safety

strut.
–UN–02JUL01
ZX026100
OUZXMAG,0001034 –19–18JUN01–1/1
10-1 072501
PN=23
Safety Decals
Boom Lift Cylinder
Secure lifting cylinder with locking device before entering

hazardous area.
–UN–02JUL01
ZX026101
OUZXMAG,0001035 –19–18JUN01–1/1
Fan
Keep your hands away from fan and drive belt when the
engine is running.
–UN–02JUL01
ZX026102
OUZXMAG,0001036 –19–18JUN01–1/1
Boom in Raised Position
To avoid injury or death, keep sufficient distance away

from electrical power lines.
When boom is raised, check for overhead power lines
–UN–02JUL01
(dependent on local conditions).
ZX026103
OUZXMAG,0001037 –19–18JUN01–1/1
Hydraulic System
Avoid fluid escaping under pressure. Consult Technical

Manual for service procedures.
–UN–02JUL01
ZX026104
OUZXMAG,0001038 –19–18JUN01–1/1
10-2 072501
PN=24
Safety Decals
Exhaust System
Stay clear of hot surfaces.
–UN–02JUL01
ZX026105
OUZXMAG,0001039 –19–18JUN01–1/1
Wheel Attaching Nuts
Retighten rear and front wheels nuts at specified intervals.
–UN–02JUL01
ZX026106
OUZXMAG,000103A –19–18JUN01–1/1
Hydraulic Accumulator
Hydraulic accumulators contain gas and oil under

pressure. For removal and repair follow the instructions
given in the Technical Manual.
–UN–02JUL01
ZX026107
OUZXMAG,000103B –19–18JUN01–1/1
Pivoting Area
Never reach into the crushing danger area as long as

parts may move.
–UN–02JUL01
ZX026108
OUZXMAG,000103C –19–18JUN01–1/1
10-3 072501
PN=25
Safety Decals
Pivoting Area Cylinders
Secure pivoting cylinders with locking device before

entering hazardous area.
–UN–02JUL01
ZX026109
OUZXMAG,000103D –19–18JUN01–1/1
10-4 072501
PN=26
Controls and Instruments
15-1 072501
PN=27
General View of Controls and Instruments
–UN–28JUN01
ZX026110
Continued on next page OUZXMAG,000103E –19–18JUN01–1/2
15-2 072501
PN=28
A—Accelerator pedal E—Turn signal switch K—Switch for work lights P—Armrest control panel
B—Brake and transmission F—Light switch L—Boom work light (option) Q—Gear shift lever and clutch
control pedals G—Hazard warning switch M—Roof console disengage button
C—Main switch H—Speedometer, km/h-mph N—Corner post (Forward (Synchro-Shuttle, option)
D—FNR lever1 J—Windshield and cab roof stability indicator) R—Parking brake
wiper switch O—Multi-function lever
(PowerShift, option)
1
FNR lever=Forward-Neutral-Reverse lever
OUZXMAG,000103E –19–18JUN01–2/2
Armrest Control Panel
–UN–28JUN01
ZX026111
A—Boom/attachment hydraulic D—Rear auxiliary hydraulic F—Second and third front H—Gear shift switch
function lock switch function control switch auxiliary function (option) (PowerShift option)
B—Armrest (option) G—Declutch switch
C—Rear auxiliary hydraulic E—Rear pickup hitch/auxiliary
function lock switch function select switch
(option) (option)
OUZXMAG,000103F –19–18JUN01–1/1
15-3 072501
PN=29
Roof Console
–UN–28JUN01
ZX026116
A—Air conditioning system B—Heater/air conditioning C—Heater control switch D—Blower switch
switch (option) control switch (cold) (warm)
OUZXMAG,0001041 –19–19JUN01–1/1
15-4 072501
PN=30
Multi-Function Lever
NOTE: Interlock switch actuator (D) prevents accidental

actuation of the multi-function lever. The lever can
be operated only when the actuator (D) is open
(the operator’s hand must hold it open).
A—Boom extend/retract function switch
B—Boom auxiliary function switch (extend/retract)
C—Boom auxiliary function switch (extend/retract)
D—Interlock switch actuator
E—Hand rest
F—Attachment crowd/dump and boom lift/lower
function lever
G—Gear shift switch (PowerShift option)
–UN–28JUN01
ZX026114
–UN–28JUN01
ZX026115
OUZXMAG,0001040 –19–19JUN01–1/1
15-5 072501
PN=31
Indicator Lights
–UN–28JUN01
ZX026117
These lights monitor the most important handler 3-This light indicates that the transmission oil
functions (road and operating safety, engine). temperature is too high. Stop machine and select
neutral. Run engine at fast idle until light cancels. If
Warning display panel shows red, yellow, blue or light remains on, stop engine and see your John Deere
green lights for the following conditions: dealer. DO NOT operate machine with this light on.
Priority 1: 4-The parking brake indicator light glows when parking

brake is applied and engine is running.
Red warning light—Stop engine at once and correct
problem. Priority 2:
1-This light indicates that the hydraulic oil pressure in Yellow warning light—Service or correct problem. Stop
the power braking system has fallen too low. The engine as required.
machine must NOT be operated with this light on,
because brake efficiency will be impaired. 5-Lights up when an engine malfunction or minor
priority occurs. See your John Deere dealer (at the
2-This light glows when a very serious engine latest at the end of the working day).
malfunction occurs. Shut off engine immediately! The
light may glow briefly when the engine is started, and 6-If air cleaner indicator light glows with engine
should go out when engine is running. The engine running, the air cleaner element must be cleaned or
must NOT be operated with this light on. replaced.
Continued on next page OUZXMAG,0001042 –19–19JUN01–1/2
15-6 072501
PN=32
7-This light indicates that the hydraulic oil temperature 11-The turn signal indicator light for trailer starts
is too high. If light remains on, stop engine and see flashing when the turn-signal or hazard warning lights
your John Deere dealer. DO NOT operate machine are switched on.
with this light on.
12-The full beam indicator light will glow whenever the
8-If hydraulic and transmission oil filter indicator light headlights are switched on at full beam.
glows with engine running, the filter is clogged.
NOTE: Indicator light 9 should glow as soon as the
9-If alternator indicator light glows with engine running, main switch is turned on.
this indicates a defect at alternator. Check alternator
cables. If necessary, have alternator checked by your Bulb Test:
John Deere dealer.
When the main switch is turned on and the FNR lever
9-This indicator light glows whenever the work lights or a gear is engaged, the following lights should glow:
are switched on. 1, 2, 3, 6 and 8. If this is not the case, a defective bulb
or blown fuse may be the cause. Check and replace
Priority 3: parts as necessary.
Green or blue warning light—Be aware of condition. The indicator lights should go out as soon as the
engine is running.
10-The turn signal indicator light for the machine starts
flashing when the turn-signal or hazard warning lights
are switched on.
OUZXMAG,0001042 –19–19JUN01–2/2
Coolant Temperature Gauge
Should the coolant gauge needle move into the red zone
(A), the engine is overheating. Immediately reduce load or
shift to a lower gear.
–UN–15DEC00
Should the needle remain in the red zone, shut off engine
and determine cause of overheating (coolant level low,
dirty radiator or dirty radiator screen).
ZX023284
AG,OUZXMAG,398 –19–12DEC00–1/1
Fuel Gauge
The fuel gauge indicates the amount of fuel in the tank

from “full” to “empty” (end of red sector). When the
indicator needle enters the red sector (A), there are still
approx. 35 L (9.2 U.S. gal.) remaining in the tank
–UN–15DEC00
NOTE: Never run the tank completely dry, otherwise you

will have to bleed the fuel system.
ZX023285
15-7 072501
PN=33
Speedometer - Hour Meter
The gauge (A) indicates the travel speed in km/h and

mph.
The hour meter (B) records the time the engine is in

operation.
–UN–15DEC00
ZX023287
Corner Post
A—Forward stability indicator (load monitor)

B—Gear indicator (PowerShift only)
C—Digital clock
–UN–28JUN01
ZX026118
OUZXMAG,0001044 –19–20JUN01–1/1
15-8 072501
PN=34
Forward Stability Indicator (Load Monitor)
The digital forward indicator (A) is an important safety

device located in the corner post for good visibility. The
device informs the operator, audio-visually, about the
forward stability of the machine via a sensor on the rear
axle.
Different colored LEDs on the monitor indicate the

following:
• Green (1)= Safe lifting capacity, 50 to 80% of the load

is on the front axle meaning the handler is still stable.
• Amber (2)= Borderline lifting capacity, 85 to 100% of
the load is on the front axle making the handler
unstable when driven quickly or under sudden braking.
The load monitor buzzer sounds at 1/2 second intervals.
• Red (3)= Unsafe lifting capacity, more than 100% of the
load is on the front axle, the load monitor buzzer
sounds continuously. The boom must be retracted or
–UN–28JUN01
the load reduced to increase the stability before further
action is taken.
CAUTION: When transporting with a load, the
ZX026119
boom MUST be fully retracted and lowered to
keep the handler as stable as possible. See
“Operating the Boom” Section for details.
Always test indicator BEFORE work

commences. See “Operating the Boom” Section
for details.
CAUTION: Always observe the lift capacity

limits listed under “Lift Capacity and Lifting
Height” in the “Specifications” Section.
OUZXMAG,0001043 –19–20JUN01–1/1
15-9 072501
PN=35
Start Switch
CAUTION: Sound horn before starting engine to

clear people away from the machine.
–UN–28JUN01
To avoid the possibility of personal injury or
death, start the engine ONLY from the
operator’s seat. Do not start engine by shorting
across starter terminals. Telescopic handler will
ZX026120
start in gear if normal circuit is bypassed.
Start switch (A) is located on right side of steering column.

Key positions are:
First Position (O) .............................................................................. Off

Second Position (1) ........................................... Accessories and Run
Third Position (2) .......................................................................... Start
Fourth Position (3) ............................................................ Accessories
–UN–28JUN01
Turn key to the third position to start.
When released, it will return to run or second position.
ZX026121
OUZXMAG,0001045 –19–20JUN01–1/1
Gear Shift Lever (Synchro-Shuttle)
The telescopic handler can be equipped with a

synchromesh unit with fully synchronized 4/4 speed
electro-hydraulic shuttle reverser coupled to a torque
converter.
To shift gears, there are two alternatives:
1. The clutch disengage button (B) is pressed on the gear

lever (A) to allow shifting. Once in the new gear the
button can be released to allow drive to continue.
2. The FNR lever can be returned to neutral before the
gear lever (A) is shifted.
NOTE: See “Forward-Neutral-Reverse Lever (FNR)” in

this Section.
–UN–28JUN01
ZX026122
OUZXMAG,0001046 –19–20JUN01–1/1
15-10 072501
PN=36
Gear Shift Switch (PowerShift)
–UN–28JUN01
ZX026124
–UN–28JUN01
–UN–28JUN01
ZX026125
ZX026123
The telescopic handler can be equipped with a PowerShift

transmission unit with fully synchronized 5/3 speed
electro-hydraulic shuttle reverser coupled to a torque
converter.
To shift gears, there are two alternatives:
1. Press upper part of the switch (A) on multi-function

lever to upshift and lower part of switch (A) to
downshift.
2. Press upper part (rabbit) of the switch (B) on armrest
control panel to upshift and lower part (tortoise) of
switch (B) to downshift.
NOTE: Using the switch (B) allows easier gear shifting

while driving.
While shifting, the gear indicator (C) will indicate the gear
engaged depending on FNR lever position:
15-11 072501
PN=37
• With FNR lever in “forward” position — 1F, 2F, 3F, 4F

or 5F.
• With FNR lever in “Neutral” position — 1N, 2N, 3N, 4N
or 5N.
• With FNR lever in “Reverse” position — 1R, 2R or 3R.
NOTE: See “Forward-Neutral-Reverse Lever (FNR)” in

this Section.
OUZXMAG,0001047 –19–20JUN01–2/2
Forward-Neutral-Reverse Lever (FNR)
Use FNR lever (A) to drive machine forward or reverse.
FNR lever (A) has three built in safety features:
–UN–28JUN01
1. Guard—to prevent accidental shifting of the lever when
mounting and dismounting the machine.
2. Neutral detent—the lever needs to be simultaneously
lifted and moved to select forward or reverse.
ZX026126
3. Return to neutral—the FNR lever automatically
returns to neutral when the ignition is switched off and
when the parking brake is applied.
See “Operating the Machine” Section for proper use of

FNR lever
OUZXMAG,0001048 –19–20JUN01–1/1
15-12 072501
PN=38
Outside Mirrors
–UN–28JUN01
–UN–28JUN01
ZX026127
ZX026128
Left-Hand Mirror Right-Hand Mirror
The machine is furnished with two wide outside

mirrors.
NOTE: As an option, a rear mounted mirror can be

installed to aid visibility to the rear hitch for
coupling purposes.
OUZXMAG,0001049 –19–20JUN01–1/1
Rear Mounted Mirror (Option)
A rear mounted mirror can be installed to aid visibility to

the rear hitch for coupling purposes.
–UN–28JUN01
ZX026129
OUZXMAG,000104A –19–20JUN01–1/1
15-13 072501
PN=39
Lighting System and Signals
Lights (Standard)
–UN–28JUN01
ZX026130
A—Headlights
B—Turn signal lights
C—Clearance lights
D—Front work lights
E—Tail, stop and turn signal lights
F—Socket for trailer lighting
–UN–28JUN01
G—Rear work lights1
ZX026131
–UN–28JUN01
ZX026132
1
Will also be on in reverse travel
OUZXMAG,000104B –19–20JUN01–1/1
20-1 072501
PN=40
Lights (Option)
A—Boom work light

B—License plate light
C—Beacon light
–UN–28JUN01
ZX026133
–UN–28JUN01
ZX026134
–UN–28JUN01
ZX026135
OUZXMAG,000104C –19–20JUN01–1/1
20-2 072501
PN=41
Light Switches
Light switch (A) can be set to the following positions:
1. Light switch in “off” position

2. Parking lights “on”
–UN–22MAY00
3. Headlights “on”
4. Work lights “on”
Switch headlights to “full beam” or “lower beam” position
ZX020717
by means of switch (B):
• Switch down = Full beam

• Switch in center = Low beam
• Switch up = Headlight flasher
Indicator light (C) will glow when headlight switch is in “full

beam” position.
–UN–28JUN01
NOTE: The light switch (A) also switches license plate
light “on”.
ZX026136
–UN–15AUG94
L102655
OUZXMAG,000104D –19–20JUN01–1/1
20-3 072501
PN=42
Operating the Hazard Warning Light Switch
If any trouble is encountered on the machine when driving

on public roads, switch on the hazard warning lights.
NOTE: Road traffic regulations in some countries require
–UN–22MAY00
that the hazard warning lights must be switched
on whenever the machine is stopped at the side
of the road.
ZX020719
–UN–28JUN01
ZX026137
–UN–28JUN01
ZX026138
OUZXMAG,000104E –19–20JUN01–1/1
20-4 072501
PN=43
Switch for Turn Signal Lights and Horn
Positions of stalk switch (A):
1. Turn signal, left-hand turn

2. Turn signal, right-hand turn
–UN–28JUN01
3. Horn (push towards steering column)
NOTE: The turn signals are not self cancelling so the

lever must be moved back to neutral.
ZX026139
NOTE: Horn (B) is located in the front frame, underneath
the boom lift cylinder.
–UN–28JUN01
ZX026140
OUZXMAG,0001050 –19–21JUN01–1/1
Work Light Switch
Work lights are switched on and off at the main light

switch (position 4). The various positions of switch (A)
allow the work lights to be selected as follows:
–UN–28JUN01
1. 0=Work light switch in “off” position
2. 1=Front work lights “on”
3. 2=Front and rear work lights “on”
4. 3=Rear work lights “on”
ZX026141
NOTE: Rear work light operates also if FNR lever is in
“reverse”.
OUZXMAG,0001051 –19–21JUN01–1/1
20-5 072501
PN=44
Boom Work Light Switch (Option)
A boom work light can be attached to boom extension to

illuminate high working area, particularly for stacking bales
in barns.
–UN–28JUN01
Switch (A) allows the operator to switch “on” boom light.
ZX026142
–UN–28JUN01
ZX026143
OUZXMAG,0001052 –19–21JUN01–1/1
Beacon Light Switch (Option)
The beacon light (not authorized in all countries) should

be used when driving extremely slowly. Switch it on at
switch (A).
–UN–28JUN01
Whenever necessary, beacon light can be disconnected
from cab support (B).
ZX026144
–UN–28JUN01
ZX026145
OUZXMAG,0001053 –19–21JUN01–1/1
20-6 072501
PN=45
Reverse Travel Alarm
A reverse travel alarm (A) will sound and rear work lights
glow when machine is driven in reverse travel.
–UN–28JUN01
ZX026146
–UN–28JUN01
ZX026147
OUZXMAG,0001054 –19–21JUN01–1/1
Seven-Terminal Trailer Socket
Socket (A) allows lights, turn signals and other electrical

equipment on a trailer to be connected.
–UN–28JUN01
ZX026148
Connection Function Wire color
1 L.h. turn signal Dark green

2 — —
3 Ground Black
4 R.h. turn signal Purple
5 R.h. tail light Grey
6 Stop lights Pale blue
7 L.h. tail light Grey
NOTE: Suitable plugs can be obtained from your John

Deere dealer
OUZXMAG,0001055 –19–21JUN01–1/1
20-7 072501
PN=46
Operator’s Platform and Cab
Roll-Over Protective Structure
CAUTION: A roll-over protective structure

(ROPS) is incorporated into each operator’s
cab. On this construction do not under any
circumstances modify structural members by
welding on additional parts, drilling holes,
cutting or grinding etc. Disregarding this
instruction will affect the rigidity of the ROPS.
A machine roll-over places a severe strain on

the ROPS. Therefore, replace the ROPS
immediately if structural members have been
bent, buckled or otherwise damaged.
–UN–28JUN01
ZX026149
OUZXMAG,0001056 –19–21JUN01–1/1
Falling-Object Protective Structure
The cab roof features a laser-cut falling object protective

structure for the operator’s safety when working with high
loads on uneven ground.
–UN–28JUN01
CAUTION: A falling-object protective structure
(FOPS) is incorporated into each operator’s
cab. On this construction do not under any
ZX026150
circumstances modify structural members by
welding on additional parts, drilling holes,
cutting or grinding etc. Disregarding this
instruction will affect the rigidity of the FOPS.
A heavy object fall places a severe strain on the

FOPS. Therefore, replace the FOPS immediately
if structural members have been bent, buckled
or otherwise damaged.
OUZXMAG,0001057 –19–21JUN01–1/1
25-1 072501
PN=47
Windshield Guard
A windshield guard is available as an attachment.
–UN–28JUN01
ZX026151
OUZXMAG,0001058 –19–21JUN01–1/1
25-2 072501
PN=48
Opening Doors
–UN–28JUN01
–UN–28JUN01
ZX026152
ZX026153
IMPORTANT: Always operate the machine with the
doors fastened shut or held back by its
retainer.
The machine is equipped with two wide opening glass

stable doors (A) and (B) for easy access and improved
–UN–28JUN01
visibility. The left hand door (A) can be held in half open
position to improve ventilation.
• To open the door from inside the cab push handle (C)
ZX026154
toward the inside of the cab.
• To open the left hand door completely, pull handle (D).
• Each door can be held in open position thanks to a lock
pin and retainer system (E)
• To release the door window from its retainer, simply pull
the door from its retainer.
A—L.H. side door
–UN–28JUN01
B—R.H. side door
C—Door handle
D—L.H. door handle
E—Lock pin and retainer
ZX026155
–UN–28JUN01
ZX026156
OUZXMAG,0001059 –19–22JUN01–1/1
25-3 072501
PN=49
Opening Rear Side Windows
To open the right and left hand rear side windows, pull
handle (A) until it locks in open position.
–UN–28JUN01
ZX026157
OUZXMAG,000105A –19–22JUN01–1/1
Seat Belt
CAUTION: Always use the seat belt.
–UN–28JUN01
ZX026158
OUZXMAG,000105B –19–22JUN01–1/1
25-4 072501
PN=50
Deluxe Suspension Seat
• The forward/rearward handle (A) allows the seat to slide

forward or rearward for best working position. Pull up on
the handle to allow adjustment then release handle
when seat is in desired position.
–UN–22MAY00
• The height adjustment crank (B) acts on the complete
seat height (no independent seat cushion adjustment).
• Attenuator lock-out lever (C) locks out or releases the
forward or rearward movement. Push lever to the right
ZX021234
to release; push lever to the left to lock.
• The weight adjustment crank (D) has four positions to
suit operator’s weight.
• Pull on lever (E) to adjust seat back (F) angle. Release
lever when seat back is in desired position
• Armrest (G) can be pulled up for better seat access.
The seat cushion has the presence system (H).
–UN–28JUN01
A—Forward/Rearward adjustment handle
B—Crank for height adjustment
C—Attenuator lock-out lever
D—Crank for adjusting seat to suit operator’s weight
E—Seat back support adjustment lever
ZX026159
F—Seat back
G—Armrest
H—Seat presence sensor
–UN–28JUN01
ZX026160
–UN–22MAY00
ZX021237
OUZXMAG,000105C –19–22JUN01–1/1
25-5 072501
PN=51
Deluxe Air Suspension Seat
This operator’s seat has an air suspension system for

added operator comfort. The seat has a self-contained
electric compressor to adjust the seat suspension to
match the operator’s height and weight.
–UN–28JUN01
Height adjustment is made with a push/pull knob (C). To
raise the seat, push in on the knob. To lower the seat, pull
out on the knob.
ZX026161
• Attenuator lock-out lever (B) locks out or releases the
forward or rearward movement. Push lever to the right
to release; push lever to the left to lock.
• Height adjustment is made with a push/pull knob (C).
–UN–28JUN01
To raise the seat, push in on the knob. To lower the
seat, pull out on the knob.
• Turn knob (D) to adjust lower back support (lumbar
support).
ZX026162
The seat cushion has the presence system (H).

B—Attenuator lock-out lever
C—Push/pull knob
–UN–28JUN01
D—Lower back support adjustment knob
F—Seat back
G—Armrest
H—Seat presence sensor
ZX026159
–UN–22MAY00
ZX021237
OUZXMAG,000105D –19–22JUN01–1/1
25-6 072501
PN=52
Super Deluxe Air Suspension Seat
–UN–28JUN01
–UN–28JUN01
ZX026164
ZX026165
This operator’s seat has an air suspension system and a
turning device for added operator comfort. The seat has a
self-contained electric compressor to adjust the seat
suspension to match the operator’s height and weight.
IMPORTANT: Before turning the seat, always switch
–UN–28JUN01
off the engine. This prevents the
handler or implements from moving if
any of the controls are accidentally
moved.
ZX026163
• Attenuator lock-out lever (B) locks out or releases the
lateral movement. Push lever to the front to release;
push lever to the rear to lock.
• Height and weight adjustments are made with a
push/pull lever (C). Pull or push on lever to suit operator
height/weight.

B—Attenuator lock-out lever
C—Seat height/operator weight adjustment
D—Lower back support adjustment knob
F—Seat back
G—Armrest
H—Armrest tilt adjustment knob
J—Armrest attaching knob
K—Lever for turning device
L—Attenuator lock-out lever
M—Seat base tilt adjustment
–UN–28JUN01
N—Seat base horizontal adjustment

ZX026166
Continued on next page OUZXMAG,000105E –19–22JUN01–1/2
25-7 072501
PN=53
• Turn knob (D) to adjust lower back support (lumbar

support).
Turn knob (H) to adjust armrest (G) tilt angle.
• Armrest (G) can be removed from the seat by unlocking
knob (J).
• Use lever (K) to turn seat 20° to the left.
• Attenuator lock-out lever (L) locks out or releases the
horizontal movement. Rotate lever to the front to
release; rotate lever to the rear to lock.
• Seat base position is adjustable by means of lever (M)
and (N). Pull lever to adjust.
NOTE: The seat cushion has the presence system.
OUZXMAG,000105E –19–22JUN01–2/2
Armrest Console Position Adjustment
Armrest console (A) can be set in several positions.
Push on knob (B) then turn knob clockwise or

counterclokwise to adjust armrest console (A) position.
Release knob (B) to keep the desired position.
–UN–02JUL01
ZX026310
OUZXMAG,0001083 –19–23JUN01–1/1
25-8 072501
PN=54
Parking Brake
IMPORTANT: The handler is equipped with manual

engage and disengage parking brake
lever. Be certain to engage the parking
brake when engine is running and
–UN–02JUL01
handler is parked and before leaving
the handler with the engine off.
To apply the brake: Fully raise lever (A) until it locks.
ZX026167
To release brake: Press on lever button (B) while slightly
raising lever (A) then release the lever.
OUZXMAG,000105F –19–23JUN01–1/1
25-9 072501
PN=55
Steering Wheel Height/Tilt Adjustment
Steering Wheel Height Adjustment:
Loosen hub (A). Push or pull wheel to position. Tighten

hub to lock.
–UN–28JUN01
NOTE: Only a slight tightening of the hub is needed to
hold steering wheel in position.
ZX026168
Steering Wheel Tilt Adjustment:
Pull lever (B) upward, move steering wheel to desired Steering Wheel Height Adjustment
angle and release the lever.
NOTE: If only the lever is pulled, the steering wheel will

rise to its highest position.
–UN–28JUN01
ZX026169
Steering Wheel Tilt Adjustment
OUZXMAG,0001060 –19–23JUN01–1/1
Cab Interior Light
The light (A) may be switched on and off with switch (B).
–UN–28JUN01
ZX026170
OUZXMAG,0001061 –19–23JUN01–1/1
25-10 072501
PN=56
Digital Clock
The digital clock display lights up whenever the ignition is

switched on.
It can be reset at buttons (A) and (B).
–UN–28JUN01
Reset:
Press the relevant button.
ZX026171
• A-Hours
• B-Minutes
NOTE: The digital clock must be reset every time the

battery is disconnected.
OUZXMAG,0001062 –19–23JUN01–1/1
Front Sun Visor
Adjust front sun visor (A) to suit conditions.
–UN–28JUN01
ZX026172
OUZXMAG,0001064 –19–23JUN01–1/1
Roof Sun Visor
Lock roof sun visor (A) in its retainers (B) to suit

conditions.
–UN–28JUN01
ZX026173
OUZXMAG,0001063 –19–23JUN01–1/1
25-11 072501
PN=57
Windshield and Cab Roof Wiper and Washer

System
Windshield wiper (A) and roof wiper (B) are operated by

means of switch (C) which has three positions:
–UN–28JUN01
1. Not used
2. Slow wipe
3. Fast wipe
ZX026174
Push switch (C) towards steering column to operate the
windshield washer system.
Add a suitable anti-freeze solution to water in reservoir (D)

if temperature is liable to drop below freezing point.
A—Windshield wiper
B—Cab roof wiper
C—Switch for windshield and roof wiper
D—Reservoir
–UN–28JUN01
1—Not used
2—Slow wipe
3—Fast wipe
ZX026175
–UN–02JUL01
ZX026176
–UN–28JUN01
ZX026177
OUZXMAG,0001065 –19–23JUN01–1/1
25-12 072501
PN=58
Rear Window Wiper
The rear window wiper (A) is operated by means of switch

(B). Push the switch once to operate rear wiper or fully
push and hold switch to operate rear window washer
system.
Add a suitable anti-freeze solution to water in reservoir (C)

if temperature is liable to drop below freezing point.
–UN–28JUN01
ZX026178
–UN–28JUN01
ZX026275
–UN–28JUN01
ZX026276
OUZXMAG,0001066 –19–23JUN01–1/1
25-13 072501
PN=59
Blower and Air Louvers
The four blower speeds are controlled by a switch (A).

The direction of the air flow can be altered by means of
air louvers (B).
–UN–28JUN01
Adjust air louvers (B) to prevent misting of windows.
ZX026277
–UN–28JUN01
ZX026278
OUZXMAG,0001067 –19–23JUN01–1/1
Heater
Heating is infinitely variable by means of the two heater

switches (A) and (B).
Use switch (A) to increase heating effect.
–UN–28JUN01
Use switch (B) to increase cooling effect.
Set blower and louvers to the desired position.

ZX026279
–UN–25MAY00
ZX021476
OUZXMAG,0001068 –19–23JUN01–1/1
25-14 072501
PN=60
Air Conditioning System (Option)
Switch on air conditioning system at switch (A). Regulate

the cooling effect at controls (B). The cooling effect is
increased by turning the knobs further counterclockwise.
–UN–28JUN01
Set the blower and louvers to the desired position.
IMPORTANT: Switch on the air conditioning system

(for two to three minutes) several times
ZX026280
a year, including the cooler seasons
(engine at slow idle). This lubricates the
moving parts (e.g the compressor) in
the system.
OUZXMAG,0001069 –19–23JUN01–1/1
Tool Box (Option)
The tool box is located on the left-hand side of the front

frame.
–UN–28JUN01
ZX026281
OUZXMAG,000106A –19–23JUN01–1/1
Coat Hanger Hook
The coat hanger hook is located on the rear wall of the

cab.
–UN–28JUN01
ZX026282
OUZXMAG,000106B –19–23JUN01–1/1
25-15 072501
PN=61
Cigarette Lighter
–UN–28JUN01
ZX026283
OUZXMAG,000106C –19–23JUN01–1/1
Manual Storage
Keep your manuals in the box (A) behind the backrest of

the seat.
–UN–28JUN01
ZX026284
OUZXMAG,000106D –19–23JUN01–1/1
Armrest Storage Box
The armrest lid (A) lifts for storage.

–UN–28JUN01
ZX026309
OUZXMAG,0001082 –19–23JUN01–1/1
25-16 072501
PN=62
Can/Cup Holders and Storage Trays
The cup holders (A) are big enough to accommodate

large beverage cans or cups.
Storage trays (B) are also available on each side of the
–UN–28JUN01
seat.
ZX026285
–UN–28JUN01
ZX026286
OUZXMAG,000106E –19–23JUN01–1/1
25-17 072501
PN=63
Radio (Special Equipment)
The handler cab may be equipped with a radio.
For operation, refer to the manufacturer’s instructions.
–UN–28JUN01
NOTE: Two loudspeakers and all internal cables are
pre-installed.
ZX026287
–UN–25MAY00
ZX021479
OUZXMAG,000106F –19–23JUN01–1/1
25-18 072501
PN=64
Break-In Period
After First 4 and 8 Hours of Operation
Tighten wheel retaining bolts to 550 N•m (400 lb-ft).
–UN–28JUN01
ZX026097
OUZXMAG,0001070 –19–23JUN01–1/1
Within First 100 Hours of Operation
Miscellaneous: Check torque of wheel retaining bolts • When necessary, top up with John Deere Engine
frequently. Break-In oil to the upper mark. If John Deere Engine
Break-In oil is not available, use a diesel engine oil
Engine: The engine is filled with a special oil for meeting one of the following specifications:
breaking it in. To break in the engine properly, comply – API specification CD or CE
with the following points: – CCMC specification D4
– ACEA specification E1
• Operate engine at normal loads (mid- to upper load IMPORTANT: During the first 100 hours, under NO
range). circumstances use John Deere
• Avoid light loads. PLUS-50 oil or any oil that meets the
• Avoid excessive engine idling. following: API specification CG-4,
• Check engine crankcase oil level frequently. API specification CF-4, ACEA
specification E2, ACEA specification
IMPORTANT: Top up with oil only when the level E3 or CCMC specification D5. These
has dropped to the lower mark. oils do not satisfy the requirements
for breaking in the engine.
NOTE: During the break-in period a higher-than-usual • After the first 100 hours, use a type of oil described
oil consumption should be considered as in the “Fuel, Lubricants, Coolant and Capacities”
normal. Section.
30-1 072501
PN=65
Break-In Period
After First 100 Hours of Operation
• Change engine oil. See “Service - Every 500 Hours”.

• Renew engine oil filter element. See “Service - Every
500 Hours”.
• Check air intake hoses for leaks. See “Service - Every
500 Hours”.
• Adjust parking brake. See “Service - Every 500 Hours”.
• Change hydraulic oil filter. See “Service - Every 500
Hours”.
• Change transmission oil filter. See “Service - Every 500
Hours”.
• Change oil in front and rear axle. See “Service - Every
1000 Hours”.
• Check all cab attaching screws for tightness. See your
John Deere dealer.
IMPORTANT: In some adverse conditions, material

accumulation between transmission
gearbox and upper protection guard
could occur. To avoid potential fire risk,
always make sure that no material
accumulation remains in this area.
Clean or check this area every 100
hours.
OUZXMAG,0001072 –19–23JUN01–1/1
30-2 072501
PN=66
Prestarting Checks
Daily Checks
• Engine • Fuel system

• Hydraulic system • Indicator light test
• Transmission system • Light functions
• Cooling system • Brakes
• Tires
Engine Oil Level
Do not operate the engine when oil level is below the low
level mark on dipstick.
The oil level should be kept between the upper and lower
–UN–02JUL01
marks. Always check oil level with handler parked on level
ground.
ZX026289
OUZXMAG,0001073 –19–23JUN01–1/1
Hydraulic Oil Level
Do not operate the hydraulic system when oil level is

below the low level mark on dipstick.
The oil level should be kept between the upper and lower
–UN–28JUN01
marks. Always check oil level with handler parked on level
ground.
ZX026290
OUZXMAG,0001074 –19–23JUN01–1/1
35-1 072501
PN=67
Prestarting Checks
Transmission Oil Level
Do not operate the transmission system when oil level is

below the low level mark on dipstick. Always check oil
level with handler parked on level ground.
–UN–28JUN01
1. Start engine and run for a few minutes to prime the
system.
2. With engine stopped, withdraw dipstick and wipe clean.
Replace dipstick fully into the tube and withdraw.
ZX026291
3. Oil level must be well above the full mark of the
dipstick. Top-up as required with specified oil (see
Section “Fuel, Lubricants, Coolant and Capacities”).
OUZXMAG,0001075 –19–23JUN01–1/1
After Long Storage Period
Bleed fuel system.
Refer to “Service - Engine” Section.
Tires
Inspect tires for cuts, breaks, or obviously low pressure.

Check tire pressure at least weekly with an accurate
gauge.
–UN–28JUN01
ZX026292
OUZXMAG,0001076 –19–23JUN01–1/1
35-2 072501
PN=68
Prestarting Checks
Fuel System
If necessary, drain water and sediment deposits from fuel

filter at drain screw (A).
–UN–28JUN01
ZX026293
OUZXMAG,0001077 –19–23JUN01–1/1
Lubricate Handler
If the machine is used in particularly wet and muddy

terrain, apply extra lubrication as follows:
• Lubricate drive shafts.

• Lubricate the pick-up hitch (if equipped).
These operations are described in “Service - Every 50

Hours” and “Service - Every 250 Hours”.
OUZXMAG,0001078 –19–23JUN01–1/1
Checks in Operator’s Cab
For indicator light and light function checks, refer to

Section “Lighting System and Signals”.
35-3 072501
PN=69
Operating the Engine
Safety Rules for Starting Engine
CAUTION: Make sure that everybody is clear of

the handler. Sound the horn to warn other
persons.
–UN–04APR95
Never run the engine in a closed building
without using an exhaust pipe extension.
Make sure there is plenty of ventilation.
Z19828
Battery Main Switch
This switch allows the battery to be cut off from the

handler’s electrical system.
–UN–28JUN01
CAUTION: Never switch off the power at the
battery main switch while the engine is running!
This may damage the handler’s electronics, and
the voltage peaks that will occur at the
ZX026294
alternator may be dangerous.
A—Switch ON
B—Switch OFF (grip may be removed)
OUZXMAG,0001079 –19–23JUN01–1/1
40-1 072501
PN=70
Starting the Engine
CAUTION: Never operate the engine in a closed

building. Make sure there is plenty of
ventilation.
–UN–28JUN01
Danger of asphyxiation!
1. Make sure that battery main switch (A) is in ON
ZX026295
position, as shown.
2. Apply parking brake (B).
NOTE: Applying parking brake will automatically set the

FNR lever (C) to neutral position.
3. On machines with Synchro-Shuttle transmission, set

gear shift lever (D) to neutral.
–UN–28JUN01
4. Depress the accelerator (E) approximately one third
through its travel.
ZX026296
5. Turn key in main switch (F) clockwise to end position.
Release key as soon as engine starts. Check that the
warning lights go out.
Do not operate starting motor for more than 20 seconds at

a time. Turn main switch key to “off” position and wait at
least one minute before trying again.
Do not adjust accelerator. The electronic fuel injection
–UN–28JUN01
pump is set at a higher slow idle (1050 rpm) until coolant
temperature reaches 20°C (68°F).
A—Battery main switch
B—Parking brake
ZX026297
C—FNR lever
D—Synchro-Shuttle gear shift lever
E—Accelerator pedal
F—Main switch
–UN–28JUN01
ZX026298
OUZXMAG,000107A –19–23JUN01–1/1
40-2 072501
PN=71
Starting the Engine With a Slave Battery
IMPORTANT: If the engine is to be run for a short (lights) while engine is running.
time without battery (using a slave Insulate battery end of disconnected
battery for starting), do not raise starter cable properly to avoid
engine speed above 1000 rpm. damage to both alternator and
Furthermore, use additional current regulator.
Starting the Engine by Means of a Booster

Battery
In very severe cold weather it may be necessary to

connect an additional 12-volt battery in parallel with the
handler’s battery.
–UN–23AUG88
CAUTION: Gas given off by batteries is
explosive. Avoid sparks or open flames near
the batteries. Make sure batteries are properly
TS204
connected (ground cable to negative pole and
starter cable to positive pole).
IMPORTANT: Reversed polarity between the battery

and alternator may result in severe
damage to the electrical system. Always
connect ground cable to negative pole
last.
Cold Weather Starting Aids
To assist in starting the engine at temperature near or

below freezing point, a block heater (220 or 110 V) is
available as an attachment. Contact your John Deere
dealer.
40-3 072501
PN=72
Electrical Starting Aid
CAUTION: Never use Ether starting fluid when

starting the engine with an electrical starting
aid.
–UN–28JUN01
Proceed as described under points 1 to 4, “Starting the
Engine”.
ZX026299
Turn the key clockwise to the ON position. Press the key
into the main switch to activate the heating element. Wait
for 30 seconds before starting the engine.
Never operate starting motor more than 20 seconds at a

time. Turn main switch key to “0” position and wait at least
one minute before trying again.
Do not adjust accelerator. The electronic fuel injection

pump is set at a higher slow idle (1050 rpm) until coolant
temperature reaches 20°C (68°F).
OUZXMAG,000107B –19–23JUN01–1/1
Engine Warm-Up Period
Do not place handler under full load until engine is

properly warmed up. To warm up the engine, run with
accelerator halfway down until operating temperature has
been obtained.
All lights except the parking brake must be out. If any

other lights stay on, stop the engine and correct.
40-4 072501
PN=73
Stopping the Engine
CAUTION: Before leaving the machine, lower

boom/fork to the ground and remove key from
main switch.
–UN–28JUN01
Stop machine. Apply parking brake.
IMPORTANT: Cooling of turbocharger and some
ZX026300
engine parts is provided by engine oil.
Stopping a hot engine may cause
damage to these parts.
Run engine for one to two minutes at slow idle to cool

turbocharger. Turn main switch (A) to “off” position.
OUZXMAG,000107C –19–23JUN01–1/1
Stalling of Engine
IMPORTANT: If engine stalls at operating

temperature, restart it immediately to
prevent overheating of certain engine
parts. Before finally shutting off the
engine, run at slow idle for 1-2 minutes.
40-5 072501
PN=74
Driving and Transporting the Handler
Driving on Public Roads
CAUTION: Handlers are difficult to see,

especially at night. Avoid personal injury or
death resulting from collision with a vehicle.
Whenever driving on public roads, use flashing

warning lights and turn signals according to
local regulation. To increase visibility, use the
lights and devices provided with your machine.
For some equipment, install extra flashing
warning lights.
Keep safety items in good condition. Replace

missing or damaged items. An implement safety
lighting kit is available from your John Deere
dealer.
NEVER exceed 8 km/h (5 mph) when carrying a

load.
–UN–21JAN01
• Check that the lights are working properly before driving
on public roads.
• It is advisable to lock out all hydraulic boom functions at
ZX023708
switch (A) and auxiliary functions at switch (B) while
driving on the road. Refer to “Locking Out Hydraulic ZX023708
Functions” in “Operating the Machine” Section.
• Fully retract boom and place it at the lowest position
that will give adequate ground clearance.
• Tilt front attachment as far back as possible.
• Do not carry loads that restrict visibility.
• Balance loads so weight is evenly distributed and load
is stable.
–UN–28JUN01
• Drive slowly if carrying materials. Rough conditions may
cause material to spill.
• Avoid carrying loads wider than the handler.
ZX026301
–UN–28JUN01
ZX026302
OUZXMAG,000107D –19–23JUN01–1/1
45-1 072501
PN=75
Reverse Travel Alarm
If the FNR lever is moved to reverse while the engine is

running, signal sending unit (A) will sound and rear work
lights glow.
–UN–28JUN01
ZX026146
–UN–28JUN01
ZX026147
OUZXMAG,000107E –19–23JUN01–1/1
Transport Information
CAUTION: To reduce risk of electrical shock, no

portion of machine should exceed a height of
4 m (13 ft).
–UN–25MAY00
Check local governmental regulations regarding
driving or towing equipment on public roads.
Use auxiliary lights and devices available from
ZX019249
your John Deere dealer to warn other road
users.
Transporting the machine:
A disabled machine is best transported on a flatbed

carrier.
Chock the wheels of the machine.
Lash the wheels to the transporter and anchor machine by

securing it across the front attachment carrier and through
the trailer hitch.
Continued on next page OUZXMAG,000107F –19–23JUN01–1/2
45-2 072501
PN=76
Towing the machine:
IMPORTANT: Always remove middle and rear drive

shafts before towing the machine. This
prevents undue wear on the tires.
–UN–28JUN01
Never tow the machine above 8 km/h (5 mph) as the lack
of power assistance makes manual steering very slow and
strenuous.
ZX026303
IMPORTANT: Never attempt to tow the handler to
start it!
–UN–28JUN01
ZX026304
OUZXMAG,000107F –19–23JUN01–2/2
45-3 072501
PN=77
Parking the Machine
• On machine with Synchro-Suttle transmission, select

neutral with both the gear lever and the forward/reverse
lever (FNR).
• On machine with PowerShift transmission, select neutral
–UN–28JUN01
with the forward/reverse lever (FNR).
• Apply parking brake when stationary.
• Lower attachment or carriage to the ground.
ZX026305
–UN–28JUN01
ZX026306
–UN–28JUN01
ZX026307
OUZXMAG,0001080 –19–23JUN01–1/1
45-4 072501
PN=78
Chock Block (Option)
When parking the handler on sloping ground, proceed as

follows:
1. Press chock block (A) together.
–UN–28JUN01
2. Pull chock block out of holder
3. Place chock block in front of or behind rear wheel.
ZX026308
–UN–03JAN95
L102664
OUZXMAG,0001081 –19–23JUN01–1/1
45-5 072501
PN=79
Operating the Machine
Reduce Fuel Consumption
Service Correctly
Replace air cleaner element and fuel, engine oil and

transmission/hydraulic filter elements at specified service
–UN–15AUG94
intervals (see “Service” Section).
Use only John Deere filters!
LX007829
Use recommended oils and lubricants only (see “Fuel,

Lubricants, Coolant and Capacities” Section).
–UN–15AUG94
L103642
Have the fuel system checked regularly by your John

Deere dealer.
–UN–18AUG95
GS049
Continued on next page AG,OUZXMAG,474 –19–24MAY00–3/4
50-1 072501
PN=80
Drive With Correct Tire Pressures
Adapt tire pressures to type of work and ground

conditions (consult your John Deere dealer or local tire
agent).
–UN–15AUG94
CAUTION: Never fill the tires with water or
water solution to increase the machine weight.
Select Correct Gear
L103645
Never operate in too high a gear as this will cause the
transmission oil to overheat, as indicated by the warning
light.
Always stop if the warning light comes on. To cool the

transmission run the engine at fast idle of 1000 to
1200 rpm with the FNR lever in neutral. Check indicator
light to ensure temperature has returned to normal.
Never restart after cooling the transmission unless the

load has been reduced or a lower gear selected.
50-2 072501
PN=81
Shifting Transmission (Synchro-Shuttle)
Transmission is controlled by means of FNR lever (A),

gear shift lever (B) and declutch switch (C). The
transmission has 4 gears.
–UN–28JUN01
IMPORTANT: When changing gears press declutch
switch. Never operate FNR lever while
machine is moving.
ZX026311
Shifting From Neutral
1. Run engine at idle speed.
2. Press declutch switch.
3. Engage gear, put FNR lever in desired position.
4. Accelerate engine.
Changing Gears
Two alternatives:
• Press declutch switch and select the next higher or

lower gear. Always change up or down through the
successive gears.
• Put FNR lever in neutral then select the next higher or
lower gear. Always change up or down through the
successive gears.
Changing Direction of Travel
1. Reduce engine speed.
2. Brake slowly to a stop.
3. Put FNR lever in desired position.
4. Release brake.
5. Accelerate the engine.
OUZXMAG,0001084 –19–23JUN01–1/1
50-3 072501
PN=82
Shifting Transmission (PowerShift)
–UN–28JUN01
ZX026124
Transmission is controlled by means of FNR lever (D) and
gear shift switches (A) or (B). The selected gear is
indicated at gear indicator (C).
IMPORTANT: Never operate FNR lever while machine

is moving.
–UN–28JUN01
Shifting From Neutral
1. Run engine at idle speed.
ZX026123
2. Select gear.
4. Accelerate engine.
Changing Gears
• Press switch (A) or (B) and select the next higher or
–UN–28JUN01
lower gear.
Changing Direction of Travel
ZX026125
1. Reduce engine speed.
2. Brake slowly to a stop.
4. Release brake.
5. Accelerate the engine.

–UN–28JUN01
ZX026312
OUZXMAG,0001085 –19–24JUN01–1/1
50-4 072501
PN=83
Hydraulic Foot Brakes
CAUTION: Be careful with sudden stops at high

speed. Especially in forward direction when
loaded.
–UN–25MAY00
The brake pedals (A) operate the four wheel brakes.
NOTE: Brakes are self-adjusting.
ZX021500
NOTE: Optional trailer brakes are available in both
hydraulic and pneumatic form depending on
country requirement.
OUZXMAG,0001086 –19–24JUN01–1/1
Transmission Declutch
CAUTION: When driving on gradients the

declutch facility MUST NOT be used to maintain
full engine braking.
–UN–28JUN01
When performing loading tasks the transmission can be
automatically disengaged/engaged by means of the
declutch switch (A).
ZX026314
• Press on top part of switch (A) and press the brake
pedals (B) to disconnect the drive from the
transmission.
This will enable the engine speed to be increased to
achieve maximum performance from the hydraulic
system without selecting neutral with the FNR lever.
• Release the brake pedals (B) to reconnect the drive to
the transmission temporarly. –UN–28JUN01
• Press on lower part of switch (A) to reconnect
permanently the transmission.
ZX026315
OUZXMAG,0001087 –19–24JUN01–1/1
50-5 072501
PN=84
Operating the Boom
Raising and Lowering the Boom
CAUTION: Help prevent bodily injury or death

from electrical contact. Beware of lift clearance
when raising boom to maximum height. Beware
of low electrical wires when boom is raised. Do
–UN–20JAN01
not leave the operator’s seat if any part of
handler contacts cables.
ZX023704
IMPORTANT: Stop boom gradually when lowering
heavy loads. Never drop a loaded ZX023704
attachment and "catch" hydraulically.
Stopping a load after it has gained
downward momentum may cause
damage to the handler.
OUZXMAG,000086E –19–20JAN01–1/1
Observe Lift Capacity Limits
Always observe the lift capacity limits listed under “Lift

Capacity and Lifting Height” in the “Specifications”
Section.
CAUTION: The specified lift capacities must not

be exceeded, otherwise machine stability is not
sufficient. Danger of accidents!
OUZXMAG,0001088 –19–24JUN01–1/1
55-1 072501
PN=85
Operating the Boom
Forward Stability Indicator (Load Monitor)
CAUTION: The forward stability Indicator does

not substitute to the operator’s vigilance!
Always use it as an assistant only and keep in
mind that specified lift capacities must not be
exceeded, otherwise machine stability is not
sufficient. Danger of accidents!
CAUTION: Always test the forward stability

Indicator before work commences!
The digital forward stability indicator (A) informs the

operator about the forward stability of the machine via a
sensor on the rear axle.
Different colored LEDs on the monitor indicate the

following:
–UN–28JUN01
• Green (1)= Safe lifting capacity, 50 to 80% of the load
is on the front axle meaning the handler is still stable.
• Amber (2)= Borderline lifting capacity, 85 to 100% of
the load is on the front axle making the handler
ZX026119
unstable when driven quickly or under sudden braking.
The load monitor buzzer sounds at 1/2 second intervals.
• Red (3)= Unsafe lifting capacity, more than 100% of the
load is on the front axle, the load monitor buzzer
sounds continuously. The boom must be retracted or
the load reduced to increase the stability before further
action is taken
It is important you understand the parameters of the

examples of overload situations that are shown in this
section.
The examples of overload situations show a series of

instances that would cause the colored lights on the
indicator to change from green through to unstable red as
the machine is endangered by incorrect operation.
55-2 072501
PN=86
Operating the Boom
CAUTION: Always observe and obey the load

monitor! Failure to do so will put your life and
the lives of others in danger.
IMPORTANT: The load monitor is a useful tool in

giving an indication of the machine’s
stability but it does not replace the
skills of a trained and experienced
operator.
OUZXMAG,0001089 –19–24JUN01–2/2
Forward Stability Indicator Test

not substitute to the operator’s vigilance!
Always use the indicator as an assistant only
and keep in mind that specified lift capacities
must not be exceeded, otherwise machine
stability is not sufficient. Danger of accidents!
CAUTION: Always test the forward stability

Indicator before work commences!
Normal Operation
Turn the key in main switch to ’ON’ position. All LEDs (A)
light and flash for 2-3 seconds and the alarm will sound
as the unit performs its internal self check and then the
LEDs go out leaving bottom LED (B) illuminated and the
alarm off.
–UN–28JUN01
If LED reactions are as follows, contact your John Deere
dealer:
Continued on next page ZX026316

OUZXMAG,000108A –19–24JUN01–1/3
55-3 072501
PN=87
Operating the Boom
1. No LEDs illuminated indicate that the unit is not

receiving power or that the internal protection device
has operated due to a system fault.
2. LEDs 4 and 5 illuminated and LED 1 flashing quickly
indicates that the output from the sensor is out of the
load range.
3. LEDs 2, 3, 4, 5, 6 and 7 flashing slowly (once per
second) indicates a fault with the internal circuit of the
display unit.
4. LED 2 and 11 flashing slowly with LED 1 flashing
quickly indicates that the sensor is in-operative or
disconnected.
CAUTION: If any other symptoms occur than

those mentioned above, contact your John
Deere dealer!
–UN–28JUN01
ZX026317
Continued on next page OUZXMAG,000108A –19–24JUN01–2/3
55-4 072501
PN=88
Operating the Boom
Display Unit Test Function

not substitute to the operator’s vigilance and
experience! Always use the indicator as an
assistant only and keep in mind that specified
lift capacities must not be exceeded, otherwise
machine stability is not sufficient. Danger of
accidents!
NOTE: The unit test function performs a full functional

test of the display by forcing a signal onto the
load sensor (C) input as if an excess weight had
been picked up. Load sensor (C) is located above
rear axle1 .
1. Turn the key in main switch to ’ON’ position.
2. Wait about 5 seconds that system is under normal

operation.
–UN–28JUN01
3. Press ’TEST’ button (A). All LEDs (B) will illuminate
and alarm will sound.
ZX026318
4. Release “TEST” button (A) to return to normal
operation.
The overload indicator must be tested at regular intervals

by your John Deere dealer. Any adjustments must be
carried out by a qualified technician.
CAUTION: Never use the machine with an
–UN–28JUN01
inoperative forward stability indicator!
ZX026319
1
Rear axle removed for picture purposes only.
OUZXMAG,000108A –19–24JUN01–3/3
55-5 072501
PN=89
Operating the Boom
Examples of Overload Situations
Overload with Boom in Constant Reach
Always reduce reach as the load increases.
–UN–18AUG95
A—Green
B—Amber
C—Red
GS058
Extending Boom with Constant Load
Never extend reach when you can move nearer, or

reduce load before extending.
A—Green
–UN–18AUG95
B—Amber
C—Red
GS059
Lifting/Lowering a Fully Extended Loaded Boom
Always fully retract boom before lifting or lowering.
A—Green
B—Amber
–UN–18AUG95
C—Red
GS060
Lifting Loads too Heavy for Reach
Always lift from close-in with as short a reach as possible.
A—Green
B—Amber
–UN–18AUG95
C—Red
GS061
55-6 072501
PN=90
Operating the Boom
Boom Safety Devices
Three safety devices allow to avoid accidental use of

Multi-function lever:
1. The operator presence switch in the seat. This switch
–UN–28JUN01
must be depressed to operate the Multi-function lever.
2. Interlock switch actuator (A) on the multi-function lever.
The lever can be operated only when the actuator (A)
is open (the operator’s hand must hold it open).
ZX026320
3. The boom lockout switch (B) stops the hydraulic flow in
the selected boom circuit:
• All functions locked (C) for road transport.
• All functions unlocked (D) for field work when
auxiliary circuit is used (grab, etc..).
• Auxiliary service locked only (E) for field work when
auxiliary circuit is not used. Locks the attachment
carrier lock pins from accidental retraction
• Auxiliary service and carrier crowd/dump (F) locked
for use with man-platform.
CAUTION: Always move switch (B) in position

(C) when driving on public roads.
A—Interlock switch actuator

B—Lockout switch
C—All functions locked
D—All function unlocked
E—Auxiliary functions locked
F—Auxiliary and carrier functions locked
–UN–28JUN01
ZX026321
OUZXMAG,000108B –19–24JUN01–1/1
55-7 072501
PN=91
Operating the Boom
Boom Lift Cylinder Safety Channel
The handler is furnished with a boom safety channel (A)

that must be used underneath the boom in raised position
each time service is required. Place channel (A) on
hydraulic cylinder rod (B) as shown.
Secure channel (A) with latch (C).
When not used, store channel (A) on its support as

shown.
–UN–28JUN01
ZX026322
–UN–28JUN01
ZX026323
OUZXMAG,000108C –19–24JUN01–1/1
55-8 072501
PN=92
Operating the Boom
Operating the Boom
–UN–02JUL01
ZX026326
CAUTION: Always consult the load monitor
before and during boom operation.
The boom and attachment carrier are controlled by the

Multi-function lever and switches.
–UN–28JUN01
Refer to illustration above for the Multi-function lever and
switch operation.
ZX026327
A—Carrier lock pin actuation
B—Attachment hydraulic function
C—Hydraulic connectors
D—Diverter valve lever
Continued on next page OUZXMAG,000108D –19–24JUN01–1/2
55-9 072501
PN=93
Operating the Boom
• To operate the attachment hydraulic functions (B),

connect hydraulic hoses to connectors (C) then place
diverter valve lever (D) in position (I).
• To operate the carrier locking pin (A), place diverter
valve lever (D) in position (II).
–UN–02JUL01
NOTE: Refer to “Operating Attachments” Section for front
equipment attaching/detaching procedures.
ZX026328
–UN–02JUL01
ZX026329
OUZXMAG,000108D –19–24JUN01–2/2
55-10 072501
PN=94
Operating the Boom
Approaching a Load
CAUTION: When approaching a load always

ensure that the ground surface is firm and level.
The ground surface must be capable of
supporting a fully laden machine. NEVER raise
a load using only one fork. NEVER bring the
boom or load within 6 m (20 ft.) of overhead
power cables.
The load is approached ’square-on’.
1. Fully retract the boom.
2. Stop the machine at the face of the stack.
3. Apply parking brake.
4. Forks should be parallel with the ground. Adjust the

spread of the forks equally on either side of the
–UN–06JUN00
carriage centre line to suit the width of the load and
ensure they are locked in position.
5. Extend the boom, making certain that the forks enter
ZX021521
the pallet cleanly. If necessary, raise or lower the boom
until the carriage touches the load.
55-11 072501
PN=95
Operating the Boom
Picking Up a Load
CAUTION: NEVER operate the boom or

attachments with the machine at speed. NEVER
leave the machine unattended with the load or
boom raised.
–UN–18AUG95
1. Ensure forks pass cleanly under load. Drive slowly,
engage forks centrally until the carriage touches the
load (A). Apply the parking brake. Select neutral.
GS064
2. Raise the boom slowly to lift the load whilst monitoring
the boom angle and load indicator to ensure that the
boom remains within the safety limits. Replace load if
in danger or doubt (B).
3. Tilt the carriage back to stabilize the load. First retract

then lower the boom to the travelling position (C),
which is the lowest position that will give adequate
ground clearance over the work site area.
4. When the area behind the machine is clear, select a

reverse gear, release the parking brake and slowly
reverse away from the stack (D).
55-12 072501
PN=96
Operating the Boom
Placing a Load
CAUTION: ALWAYS ensure any scaffolding,

loading platform or stack can support the load
before unloading on to it. NEVER attempt to
place a load on ground that is not firm, is
–UN–18AUG95
unstable or not capable of supporting a fully
laden machine.
1. Approach the stack squarely with the load low, tilted
GS065
backwards and the boom fully retracted. Then apply
the parking brake and select neutral gear.
2. Raise then extend the boom until the load is directly

over the stack (A). Monitor the boom angle, extension
and load indicator. Cancel the operation if the safety
limits are exceeded, by firstly retracting the boom then
lowering it.
3. Tilt the load forward and lower the load on to the stack
by adjusting the boom angle. Retract the boom slightly
if necessary to position the load (B).
4. Free and withdraw the forks by alternative use of the

boom retract, lift and tilt controls. On level ground the
forks may be withdrawn by reversing the machine from
the stack after freeing the forks and ensuring the way
is clear (C).
5. When clear of the stack, tilt the carriage backwards,

retract then lower the boom to just above the ground
level before moving off.
55-13 072501
PN=97
Operating the Boom
Lifting Unpalletized Loads
CAUTION: Perform a ’test’ lift before completely

lifting clear of the ground.
1. Tilt the carriage forward and then extend and slightly
–UN–18AUG95
raise the boom to slide the forks under the load. If
necessary, wedge the load to stop it moving away from
the forks. When loaded, chain securely on the carriage.
GS066
2. Tilt the carriage back and raise the boom to the
travelling position (A).
3. Always find the centre of gravity or point of balance of

loads of irregular shape and weight distribution. Ensure
that this centre of gravity is placed mid-way between
the forks.
CAUTION: NEVER raise a load using only one

fork (A).
NEVER sling a rope or chain from any part of

the boom, forks or carriage (B) around the load.
–UN–18AUG95
GS067
55-14 072501
PN=98
Operating the Boom
Travelling
CAUTION: ALWAYS keep the load facing up-hill.

NEVER exceed 8 km/h (5 mph) when carrying a
load.
–UN–06JUN00
1. When travelling, the boom must be fully retracted and
in the lowest position (A) that will give adequate
ground clearance (B).
ZX021523
2. The carrier (and forks) must be tilted as far back as
possible (C).
Removing Material from a Pile
1. Approach and enter pile with bucket level. If the pile is

high, remove the top first.
NOTE: Bucket top is parallel to bottom. Bucket is level

when top is level.
2. Move forward slowly, lifting the boom and rolling back

bucket.
NOTE: Overfilling the bucket in heavy or packed material

may cause the handler to stall. If handler stalls,
back up or take less material.
–UN–20JAN01
ZX023709
ZX023709
OUZXMAG,0000870 –19–20JAN01–1/1
55-15 072501
PN=99
Operating the Boom
Digging
CAUTION: Check underground utility locations

before digging. To help prevent injury or death,
do not leave the operator’s seat if any part of
handler contacts cables. Back away from the
–UN–21JAN01
cable before getting off handler.
1. Angle bucket slightly below ground level and move
ZX023705
forward slowly.
ZX023705
2. When bucket has penetrated material, level bucket and
move forward until bucket is full.
–UN–20JAN01
ZX023710
ZX023710
OUZXMAG,0000871 –19–20JAN01–1/1
Avoiding Injury or Death from Falling Round

Bales
CAUTION: To help prevent personal injury or

death caused by falling loads:
1. DO NOT handle round bales unless handler is

equipped with an approved bale handling attachment.
Otherwise, the bale can fall on the operator when the
boom is raised.
2. Handle raised loads with caution.
3. Carry loads low and drive slowly.

–UN–20JAN01
ZX023706
ZX023706
OUZXMAG,0000872 –19–20JAN01–1/1
55-16 072501
PN=100
Operating the Boom
Picking up a Round Bale
1. Approach bale with fork level, and centered on bale.
2. Push fork in bale until bale is against fork frame.
–UN–20JAN01
3. Raise and roll back bale just high enough to provide
ground clearance for transport.
ZX023711
ZX023711
AG,CC03745,96 –19–20JAN01–1/1
Picking up a Round Bale on a Slope
CAUTION: To help prevent injury caused by

handler rollover when handling round bales on
a slope, avoid side slope travel whenever
possible. Drive up slope to pick up a bale and
–UN–20JAN01
down in reverse. Move bale as close to the
ground as possible.
ZX023712
To help prevent injury caused by being struck
by a bale rolling down a slope, never use the ZX023712
handler to stop a rolling bale.
1. Approach bale with handler facing uphill, fork level and

centered on bale.
2. Push fork in bale until bale is against fork frame.
3. Raise and roll back bale just high enough to provide

ground clearance for transport.
4. Select low handler speed before moving or turning on

a slope.
OUZXMAG,0000873 –19–20JAN01–1/1
55-17 072501
PN=101
Operating the Boom
Transporting a Round Bale
CAUTION: To help prevent personal injury or

accidents caused by a bale falling off the fork,
carry the bale low and slightly rolled back.
Travel slowly over rough ground.
–UN–20JAN01
ZX023713
ZX023713
OUZXMAG,0000874 –19–20JAN01–1/1
55-18 072501
PN=102
Operating Attachments
Attachments (General Information)
A wide range of specialized attachments such as pick-up

hitch, grabs, buckets, forks, clamps or spikes are available
for the telescopic handler.
–UN–15DEC00
As an alternative to the John Deere carrier, the handler
can be equipped with different carrier types to match most
of front tools available on the market. For more
information, contact your John Deere dealer.
ZX023277
Claas Attachment Carrier
–UN–15DEC00
ZX023278
Matbro Attachment Carrier
–UN–15DEC00
ZX023279
JCB Attachment Carrier
–UN–15DEC00
ZX023280
Manitou Attachment Carrier
60-1 072501
PN=103
Pallet Forks (John Deere Carrier)
Different pallet fork types are available:
• 42 in. type for John Deere and Matbro carrier.

• 48 in. type for John Deere and Matbro carrier.
–UN–06JUN00
Distance between pallet forks (A) can be adjusted.
Proceed as follows:
ZX021524
1. Unscrew all four locking collars (B).
2. Slide forks (A) to an equal distance from center line, at

the desired position.
3. Place locking collars (B) on each side of fork then

secure.
Pallet forks can easily be removed from carrier frame.
–UN–02JUL01
Proceed as follows:
1. Unscrew all four locking collars (B).
ZX026330
2. Remove quick-lock pins (C) then pins (D).
3. Slide fork supporting tubes (E) just enough so that

forks (A) can be removed.
4. Slide back tubes (E) in place then secure with pins (D)
and quick-lock pins (C).
–UN–02JUL01
CAUTION: It is recommended that pallet forks
are laid flat on the ground for safe storage.
A—Forks
ZX026331
B—Locking collars
C—Quick-lock pin
D—Pins
E—Tube
OUZXMAG,000108E –19–25JUN01–1/1
60-2 072501
PN=104
Attaching/Detaching Equipment (John Deere

Carrier)
Proceed as follows to attach attachment on John Deere

carrier:
–UN–02JUL01
1. Ensure locking pins (A) are fully retracted. If
necessary, place diverter valve lever (B) as shown and
press lower part of switch (D) on Multi-function lever to
retract locking pins (A).
ZX026332
2. Extend the boom approximately 1 m (3 ft.), tilt the
carrier slightly forward and drive up to the attachment
(I).
3. Drive the machine forward, until the pick-up cones

pass under the rings on the attachment (II) then lift the
boom until the attachment is clear of the ground.
–UN–02JUL01
4. Tilt the carrier backwards (III) and engage the locking
pins by operating the upper part of switch (C).
ZX026333
CAUTION: Always check locking pins before
tilting or operating any attachment.
5. Raise and tilt back the attachment to the travelling

position. Move the boom lockout switch (E) to the
position (F). The machine is now ready for work.
To detach attachment from carrier, proceed in reverse

order.
–UN–06JUN00
A—Locking pins
B—Diverter valve lever
C—Locking pin retract switch
D—Locking pin extend switch
ZX021529
E—Lockout switch
–UN–02JUL01
ZX026334
OUZXMAG,000108F –19–25JUN01–1/1
60-3 072501
PN=105
Attachment Auxiliary Functions
Install attachment as described under

’Attaching/Detaching Equipment to Carrier’ in this Section.
–UN–02JUL01
CAUTION: Always check locking pins before
tilting or operating any attachment.
The position of lever (A) decides whether the hydraulic
ZX026335
pin-locking system is operated or the attachment hydraulic
functions. Place lever (A) as shown to operate hydraulic
functions of attachment.
If necessary and depending on lever (A) position , place

lockout switch (B) to position (C) to prevent accidental use
of pin-locking system or to position (D) to lock all
attachment hydraulic functions.
–UN–02JUL01
A—Lever
B—Lockout switch
C—Locking pins locked
D—Attachment functions locked
ZX026336
OUZXMAG,0001090 –19–25JUN01–1/1
Front Auxiliary Hydraulic Functions
The handler can be equipped with front auxiliary hydraulic

circuits.
Use switches as follows:
–UN–02JUL01
1. Press part (II) of switch (A) to to select second
hydraulic function or part (III) of switch (A) for third
function.
ZX026341
2. Press top of switch (B) to retract hydraulic cylinder and
bottom of switch (B) to extend.
–UN–02JUL01
ZX026342
OUZXMAG,0001093 –19–25JUN01–1/1
60-4 072501
PN=106
Rear Auxiliary Hydraulic Functions
The handler can be equipped with rear auxiliary hydraulic

circuits.
Use switches as follows:
–UN–02JUL01
1. Press top of switch (A) to lock all rear auxiliary
hydraulic functions and bottom of switch to unlock.
ZX026337
IMPORTANT: Use this switch to lock out the pick-up
hitch hook (if equipped with) when
driving on public roads.
2. Press top of switch (B) to select rear auxiliary function

at coupler (C) and bottom of switch (B) to select
pick-up hitch operation (if equipped).
3. Depending on switch (B) position press top of switch
–UN–02JUL01
(D) to extend hydraulic cylinder connected at coupler
(C) or raise pick-up hitch hook, and bottom of switch to
retract cylinder at coupler (C) or lower pick-up hitch
hook.
ZX026338
A—Rear auxiliary function lock switch
B—Rear auxiliary function selection switch
C—Rear coupler
D—Rear auxiliary function retract/extend switch
OUZXMAG,0001091 –19–25JUN01–1/1
Hose Unions
The hose unions used must comply with ISO standards.
• Dimension (A) must be between 23.66 and 23.74 mm

(0.931 and 0.934 in.). –UN–15AUG94
• Dimension (B) must be at least 24 mm (0.945 in.).

LX006613
60-5 072501
PN=107
Connecting Attachment Hoses
Proceed as follows:
CAUTION: The hydraulic system has a
–UN–02JUL01
maximum stand-by pressure of 22500 kPa
(225 bar; 3263 psi) . For your own protection
and to ensure proper functioning of the system,
use only genuine John Deere parts.
ZX026339
1. Lower attachment to the ground, stop engine and apply
parking brake.
2. To relieve hydraulic pressure from the lines, switch

ignition on (without starting) and press auxiliary buttons
(A) on the Multi-function lever.
3. Operate lever (B) to transfer the hydraulic circuit to
–UN–02JUL01
quick-couplers (C).
4. Connect hoses to couplers. Raise attachment from the

ground and check that the attachment operates
ZX026340
correctly.
–UN–28JUN01
ZX026327
OUZXMAG,0001092 –19–25JUN01–1/1
Mechanical Rear Hitch (Option)
A mechanical rear hitch is available as an attachment.

Contact your John Deere dealer.
IMPORTANT: This hitch can be used to tow the

handler but not to hitch any trailer or
wagon!
OUZXMAG,0001095 –19–25JUN01–1/1
60-6 072501
PN=108
Semi Automatic Wagon Hitch (Option)
A semi automatic wagon hitch is available as an

attachment and can be operated from the cab. Contact
your John Deere dealer.
–UN–02JUL01
ZX026343
OUZXMAG,0001096 –19–25JUN01–1/1
Tip a Trailer
Proceed as follows:
1. Connect trailer hose to the machine’s quick coupler

(A). Connect trailer electrics to electrical socket (B).
–UN–02JUL01
2. Press top of switch (C) to select rear auxiliary hydraulic
function at coupler (A).
ZX026344
3. Press switch (D) to tip trailer.
A—Quick coupler
B—Electrical socket
C—Select switch
D—Switch
–UN–02JUL01
ZX026345
OUZXMAG,0001097 –19–25JUN01–1/1
60-7 072501
PN=109
Fuel, Lubricants, Coolant and Capacities
Diesel Fuel
Consult your local fuel distributor for properties of the Fuel lubricity should pass a minimum of 3100 gram
diesel fuel available in your area. load level as measured by the BOCLE scuffing test.
In general, diesel fuels are blended to satisfy the low Sulfur content:
temperature requirements of the geographical area in
which they are marketed. • Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
Diesel fuels specified to EN 590 or ASTM D975 are • If diesel fuel with sulfur content greater than 0.5%
recommended. sulfur content is used, reduce the service interval for
engine oil and filter by 50%.
In all cases, the fuel shall meet the following • DO NOT use diesel fuel with sulfur content greater
properties: than 1.0%.
Cetane number of 40 minimum. Cetane number Bio-diesel fuels may be used ONLY if the fuel
greater than 50 is preferred, especially for properties meet DIN 51606 or equivalent specification.
temperatures below -20°C (-4°F) or elevations above
1500 m (5000 ft). DO NOT mix used engine oil or any other type of
lubricant with diesel fuel.
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5°C (9°F) below the expected low temperature.
DX,FUEL1 –19–24JAN00–1/1
Handling and Storing Diesel Fuel
IMPORTANT: The fuel tank is vented through the

CAUTION: Handle fuel carefully. Do not fill
filler cap. If a new filler cap is
the fuel tank when engine is running.
required, always replace it with an
original vented cap.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
When fuel is stored for an extended period or if there
is a slow turnover of fuel, add a fuel conditioner to
Fill the fuel tank at the end of each day’s operation to
stabilize the fuel and prevent water condensation.
prevent condensation and freezing during cold
Contact your fuel supplier for recommendations.
weather.
DX,FUEL4 –19–18MAR96–1/1
65-1 072501
PN=110
Diesel Engine Break-In Oil
New engines are filled at the factory with John Deere • ACEA Specification E1
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 PLUS-50 oil or engine
oils meeting API CH-4, API CG4, API
After engine overhaul, fill the engine with John Deere CF4, ACEA E3, or ACEA E2
ENGINE BREAK-IN OIL. performance levels during the first
100 hours of operation of a new or
If John Deere ENGINE BREAK-IN OIL is not available, rebuilt engine. These oils will not
use a diesel engine oil meeting one of the following allow the engine to break-in
during the first 100 hours of operation: properly.
• API Service Classification CE
PLUS-50 is a registered trademark of Deere & Company. DX,ENOIL4 –19–24JAN00–1/1
65-2 072501
PN=111
Diesel Engine Oil
Use oil viscosity based on the expected air temperature

range during the period between oil changes.
The following oil is preferred:
• John Deere PLUS-50
The following oil is also recommended:
• John Deere TORQ-GARD SUPREME
Other oils may be used if they meet one or more of the
–UN–10OCT97
following:
• API Service Classification CH-4

• API Service Classification CG-4
TS1661
• API Service Classification CF-4
• ACEA Specification E3
• ACEA Specification E2
Multi-viscosity diesel engine oils are preferred.
If diesel fuel with sulfur content greater than 0.5% is used,

reduce the service interval by 50%.
Extended service intervals may apply when John Deere

preferred engine oils are used. Consult your John Deere
dealer for more information.
PLUS-50 is a registered trademark of Deere & Company.

TORQ-GARD SUPREME is a registered trademark of Deere & Company DX,ENOIL –19–24JAN00–1/1
65-3 072501
PN=112
Transmission and Hydraulic Oil
Use oil viscosity based on the expected air temperature

range during the period between oil changes.
The following oils are preferred:
• John Deere HY-GARD

• John Deere Low Viscosity HY-GARD
Other oils may be used if they meet one of the following:
• John Deere Standard JDM J20C

• John Deere Standard JDM J20D
–UN–10OCT97
TS1660
HY-GARD is a trademark of Deere & Company ZX09161,000096A –19–31JAN01–1/1
65-4 072501
PN=113
Grease
Use grease based on NLGI consistency numbers and the

expected air temperature range during the service interval.
The following greases are preferred:
• John Deere SD POLYUREA GREASE
The following greases are also recommended:
• John Deere HD MOLY GREASE

• John Deere HD LITHIUM COMPLEX GREASE
• John Deere HD WATER RESISTANT GREASE
John Deere GREASE-GARD
–UN–30JUN99
•
Other greases may be used if they meet the following:
TS1667
• NLGI Performance Classification GC-LB
IMPORTANT: Some types of grease thickener are not

compatible with others. Consult your
grease supplier before mixing different
types of grease.
DX,GREA1 –19–24JAN00–1/1
Oil Filters
Filtration of oils is critical to proper operation and

lubrication.
Always change filters regularly as specified in this manual.
Use filters meeting John Deere performance

specifications.
DX,FILT –19–18MAR96–1/1
65-5 072501
PN=114
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.
DX,LUBST –19–18MAR96–1/1
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.
Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant
performance.
DX,LUBMIX –19–18MAR96–1/1
65-6 072501
PN=115
Diesel Engine Coolant
The engine cooling system is filled to provide water is recommended for mixing with ethylene glycol
year-round protection against corrosion and cylinder base engine coolant concentrate.
liner pitting, and winter freeze protection to -37°C
(-34°F). IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
John Deere COOL-GARD is preferred for service. sealing additives.
If John Deere COOL-GARD is not available, use a low Coolant Drain Intervals
silicate ethylene glycol base coolant concentrate in a
50% mixture of concentrate with quality water. Drain the factory fill engine coolant, flush the cooling
system, and refill with new coolant after the first 3
The coolant concentrate shall be of a quality that years or 3000 hours of operation. Subsequent drain
provides cavitation protection to cast iron and intervals are determined by the coolant used for
aluminum parts in the cooling system. John Deere service. At each interval, drain the coolant, flush the
COOL-GARD meets this requirement. cooling system, and refill with new coolant.
A 50% mixture of ethylene glycol engine coolant in When John Deere COOL-GARD is used, the coolant
water provides freeze protection to -37°C (-34°F). If drain interval is 3 years or 3000 hours of operation.
protection at lower temperatures is required, consult
your John Deere dealer for recommendations. If COOL-GARD is not used, the drain interval is
reduced to 2 years or 2000 hours of operation.
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
DX,COOL8 –19–12FEB99–1/1
65-7 072501
PN=116
Operating in Warm Temperature Climates
John Deere engines are designed to operate using glycol

base engine coolants.
Always use a recommended glycol base engine coolant,

even when operating in geographical areas where freeze
protection is not required.
IMPORTANT: Water may be used as coolant in

emergency situations only.
Foaming, hot surface aluminum and

iron corrosion, scaling, and cavitation
will occur when water is used as the
coolant, even when coolant
conditioners are added.
Drain cooling system and refill with

recommended glycol base engine
coolant as soon as possible.
DX,COOL6 –19–18MAR96–1/1
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require

lubricant recommendations different from those printed in
this manual.
Some John Deere brand coolants and lubricants may not

be available in your location.
Consult your John Deere dealer to obtain information and

recommendations.
Synthetic lubricants may be used if they meet the

performance requirements as shown in this manual.
The temperature limits and service intervals shown in this

manual apply to both conventional and synthetic oils.
Re-refined base stock products may be used if the

finished lubricant meets the performance requirements.
DX,ALTER –19–15JUN00–1/1
65-8 072501
PN=117
Use Genuine John Deere Parts
Genuine John Deere parts have been specifically

designed for John Deere machines.
Other parts are neither examined nor released by John
–UN–07JUN95
Deere. Installation and use of such products could have
negative effects upon the design characteristics of the
machine and thereby affect its safety.
ES118837
Avoid this risk by using only genuine John Deere parts.
FX,ORI –19–04DEC90–1/1
Capacities
Fuel tank ..................................................................................................................... 180 liters (48 U.S.gal)
Cooling system ............................................................................................................ 19 liters (5 US. gal.)
Crankcase with filter .................................................................................................... 12.5 liters (3.3 US. gal.)
Transmission (PowerShift) .......................................................................................... 12.5 liters (3.3 US.gal)

Transmission (Synchro-Shuttle) .................................................................................. 18.5 liters (4.9 US.gal)
Hydraulic system ......................................................................................................... 106 liters (28 US. gal.)
Front/rear axle differential: .......................................................................................... 15 liters (4 US. gal.)
Front/rear axle final drive: ........................................................................................... 0.8 liters (0.21 US. gal.)
OUZXMAG,0001098 –19–25JUN01–1/1
65-9 072501
PN=118
Articulation Joint Safety Rod
The handler is furnished with an articulation joint safety

rod (A) that must be used each time service is required in
area of articulation joint. Place rod (A) on pins (B) as
shown.
–UN–28JUN01
Secure rod (A) with quick-lock pins (C).
When not used, store rod (A) on its support as shown.
ZX026324
–UN–28JUN01
ZX026325
OUZXMAG,00010ED –19–28JUN01–1/1
70-1 072501
PN=119
Service Intervals
CAUTION: Do not lubricate or adjust the

machine while the engine is running unless
recommended to do so. Always use a safety
channel if working under the raised boom.
The intervals at which the various parts should be

checked, lubricated, serviced or adjusted are based on
the actual hours of operation as shown on the hour meter
(A). The meter operates whenever the engine is running
and shows the accumulated hours of engine operation.
Always check to make sure that the hour meter is

serviceable.
The lubrication and periodic service intervals are for

normal working conditions. These intervals should be
shortened when operating under adverse conditions.
–UN–15DEC00
If the machine is operated, for long periods, in extreme
climatic conditions e.g. below -15°C (5°F) or above 33°C
(91°F), the service schedules must be reduced to 50% of
operating hours quoted.
ZX023288
IMPORTANT: After servicing, cleaning or repairing
your machine, reinstall any safety
guards or shields before operating the
machine again.
70-2 072501
PN=120
Opening the Hood
CAUTION: Always shut off engine and remove

key before opening engine hood (A). To avoid
bodily injury, do not open hood until all rotating
parts have stopped completely.
–UN–09JUN00
To open the engine hood (A), use a suitable tool (13 mm
across flats) or else use tool (B), which is available
through spare parts channels (see arrow).
ZX021550
Open hood, it will be held in position by gas-filled struts
(C).
This will give access to:
• Radiator and coolers

• Alternator, fan belt and starting motor
• Engine oil and fuel filters
–UN–02JUL01
• Transmission and hydraulic filters
• Air cleaner
ZX026346
–UN–02JUL01
ZX026347
OUZXMAG,0001099 –19–25JUN01–1/1
70-3 072501
PN=121
Access to Fuses
The fuses are located at the rear left side of operator’s

seat.
To access the fuse and relay board, press on latches (A)
–UN–02JUL01
then take off cover (B) .
ZX026348
–UN–02JUL01
ZX026349
OUZXMAG,000109B –19–25JUN01–1/1
Access to Battery
The battery (A) is located behind the engine hood, on left

hand side.
NOTE: Battery is held in place by support (B).
–UN–02JUL01
ZX026350
OUZXMAG,000109C –19–25JUN01–1/1
70-4 072501
PN=122
Important Instructions Regarding Alternator
NOTE: The alternator is equipped with overvoltage

protection.
Cable connections:
–UN–02JUL01
• Red cable to B+ (A)
• Green cable to D+ (B)
ZX026351
• If engine is to be run for a short time without battery
(using a slave battery for starting), do not run engine at
a speed above 1000 rpm. Switch on an additional
consumer (lights) while engine is running.
• With the battery removed and when starting by means
of a slave battery, insulate the battery end of the
disconnected starter cable in order to avoid damage to
the alternator and regulator.
• Slave battery cables must be connected only to the
poles provided for this purpose.
• With the engine running, do not short-circuit or ground
the alternator and regulator even momentarily. Connect
battery and charger with the correct polarity. If they are
improperly connected (“+” and “-”), the rectifier diodes
will be destroyed immediately.
• Before carrying out any electrical welding jobs on the
machine, disconnect both cables at alternator. Connect
ground terminal of welding apparatus directly to the part
being welded.
• Before carrying out repairs on electrical system,
disconnect battery ground strap. This will avoid the
danger of a short circuit.
OUZXMAG,000109D –19–25JUN01–1/1
Daily or Every 10 Hours
Component Description Lubricant

Engine crankcase Check oil level
Radiator Check coolant level
Lights Check lights are functioning properly
Carrier pivots Lubricate Multipurpose grease
Transmission Check oil level
Hydraulics Check oil level
OUZXMAG,000109E –19–25JUN01–1/1
70-5 072501
PN=123
Every 50 Hours
(In addition carry out 10 hour service)

All grease fittings Lubricate Multipurpose grease
Axles Check oil level
Parking brake Check and lubricate linkage Multipurpose grease
AG,OUZXMAG,567 –19–05JUN00–1/1
After the First 100 Hours

Engine crankcase Drain and refill (see “Service - Every 500 Hours”) Engine oil
Engine crankcase filter Replace filter element. Replace with a John Deere element (see
“Service - Every 500 Hours”)
Air intake hoses Check connections for leaks (see “Service - Every 500 Hours”)
Hydraulic oil filter Replace return line filter (see “Service - Every 500 Hours”)
Transmission Replace filter element (see “Service - Every 1000 Hours”)
Parking brake Adjust (see “Service - Every 500 Hours”)
Axles Drain and refill with fresh oil (see “Service - Every 1000 Hours”) Axle oil
OUZXMAG,000109F –19–25JUN01–1/1
Every 250 Hours
(In addition carry out 10 and 50 hour services)

Air cleaner Check filter elements
Wheel retaining bolts Check for tightness
Neutral start circuit Check circuit functions correctly
Battery Check level of electrolyte
Air conditioning receiver-drier Check presence of bubbles at sight glass
OUZXMAG,00010A0 –19–25JUN01–1/1
70-6 072501
PN=124
Every 500 Hours
(In addition carry out 10, 50 and 250 hour services)

Engine crankcase filter Replace filter element. Replace with a John Deere element
Engine crankcase Drain and refill Engine oil
Fuel filter Replace filter element
Air intake hose Check connections for leaks
Air cleaner outer element Replace element
Transmission oil filter Replace filter element
Hydraulic oil filter Replace return line filter
Fuel tank Drain residue
Automatic belt tensioner Check
Belt Check for wear
Parking brake Adjust
Boom extension wear pads Lubricate Multipurpose grease
Engine Check ground connection
OUZXMAG,00010A1 –19–25JUN01–1/1
Every 750 Hours
(In addition carry out 10, 50 and 250 hour services)

Engine speeds Have engine speeds checked by your John Deere dealer
Every 1000 Hours or Every Year
(In addition carry out 10, 50, 250 and 500 hour
services)

Hydraulic system Drain and refill with fresh oil, and clean suction filter Hydraulic oil
Transmission Drain and refill with fresh oil, and clean suction filter Transmission oil
Replace oil filter
Axle differential and final drives Drain and refill with fresh oil Axle oil
Cab air filter Replace
70-7 072501
PN=125
Every 2000 Hours or Every Two Years
(In addition carry out 10, 50, 250, 500 and 1000 hour
services)

Cooling system (without JD Drain, flush and refill
COOL-GARD)
Air cleaner Replace inner element
Engine valves Have valve tappet clearances checked by your John Deere dealer
Every 3000 Hours or Every Three Years
(In addition carry out 10, 50, 250, 500, 1000 and 2000
hour services)

Cooling system (with JD Drain, flush and refill
COOL-GARD)
As Required

Air cleaner Clean filter element
Cab Filters Clean
Radiator Clean
Brakes Have hydraulic brakes serviced by your John Deere dealer
Fuel system Check fuel filter; bleed system
Tires Check tire pressure
Lubricating points Lubricate, if machine has been washed with high-pressure water Multipurpose grease
Fuses Replace
Battery Check concentration of electrolyte
Injection nozzles and pump Have these checked by your John Deere dealer
Fan/alternator V-belt Replace
Operator’s seat Lubricate slide rails
Thermostat Have thermostats replaced by your John Deere dealer
OUZXMAG,0000876 –19–20JAN01–1/1
70-8 072501
PN=126
Service / Daily or Every 10 Hours
Every 10 Hours—Checking Engine
Crankcase Oil Level
If oil level is at or below bottom mark on dipstick, add

sufficient oil to bring level to top mark on dipstick.
–UN–28JUN01
Do not operate engine with oil level at or below bottom
mark on dipstick.
ZX026352
A—Dipstick
B—Oil filler cap
OUZXMAG,00010A2 –19–25JUN01–1/1
Every 10 Hours—Checking Coolant Level
CAUTION: Never check coolant level with

engine running. The coolant system is
pressurized. Be careful when removing filler
–UN–02JUL01
cap.
Turn filler cap (A) anti-clockwise until resistance is felt,

wait until pressure has escaped, then press down the cap
ZX026353
and turn further until it can be lifted off.
Coolant level should be between MAX and MIN levesl. If

necessary, top up with the specified coolant (see Section
“Fuel, Lubricants, Coolant and Capacities”).
OUZXMAG,00010A3 –19–25JUN01–1/1
Every 10 Hours—Checking Lights
Check that the lights are operating correctly, especially

before driving on public roads.
Comply with all legal regulations.
LX,LICHT 002082 –19–01FEB92–1/1
75-1 072501
PN=127
Every 10 Hours—Carrier Pivots (John Deere Carrier)
–UN–02JUL01
ZX026354
A—Compensating lever top B—Compensating lever rear C—Carrier top fitting (1x) D—Carrier bottom fittings (2x)
fitting (1x) fittings (2x)
Lubricate grease points of carrier and compensating

lever (6 points). Use specified grease (see Section
“Fuel, Lubricants, Coolant and Capacities”).
OUZXMAG,00010A4 –19–25JUN01–1/1
75-2 072501
PN=128
Every 10 Hours—Checking Transmission Oil

Level
IMPORTANT: Machine must be parked on level

ground with parking brake applied.
–UN–02JUL01
Before starting the engine, make sure
there is sufficient oil in the
transmission housing (oil level between
the two marks on dipstick).
ZX026355
Always practice extreme cleanliness
when servicing hydraulic components.
1. Start engine and run for a few minutes to prime the

system.
2. With engine stopped, withdraw dipstick (A) and wipe
clean. Replace dipstick fully into the tube and
withdraw.
–UN–28JUN01
3. Oil level must be well above the full mark of the
dipstick. Top-up as required with specified oil (see
Section “Fuel, Lubricants, Coolant and Capacities”).
ZX026356
OUZXMAG,00010A5 –19–25JUN01–1/1
Every 10 Hours—Checking Hydraulic Oil

Level
IMPORTANT: Machine must be parked on level

ground with the boom fully retracted
and in its lowest position. All
–UN–28JUN01
attachment cylinders must also be
retracted.
Always practice extreme cleanliness
ZX026357
when servicing hydraulic components.
1. Apply parking brake and STOP engine.

2. Remove filler cap/dipstick. The oil level must be up to
the full mark.
IMPORTANT: Never overfill the hydraulic tank as this

will cause leakage from the filler cap.
Use specified oil (see Section “Fuel, Lubricants, Coolant

and Capacities”).
OUZXMAG,00010A6 –19–26JUN01–1/1
75-3 072501
PN=129
Every 10 Hours—Other Service Jobs (Under Extreme Conditions)
–UN–02JUL01
ZX026358
A—Gearbox drive shafts (4x)
If operating the machine in extremely wet and muddy Drive shafts (4 points). Use specified grease (see
conditions, lubricate the following: Section “Fuel, Lubricants, Coolant and Capacities”).
OUZXMAG,00010A7 –19–26JUN01–1/1
75-4 072501
PN=130
Service / Every 50 Hours
Every 50 Hours—Grease Fittings
–UN–02JUL01
ZX026358
A—Gearbox drive shafts (4x)
Lubricate grease points of drive shaft and pick-up hitch Clean the carrier cross tubes with a solvent. Allow the
(4 points). Use specified grease (see Section “Fuel, tubes to dry and then coat them with grease.
Lubricants, Coolant and Capacities”).
OUZXMAG,00010A8 –19–26JUN01–1/1
80-1 072501
PN=131
Every 50 Hours—Grease Fittings (Continued)
–UN–02JUL01
ZX026359
A—Boom lift/Compensating C—Boom extend cylinder E—Boom lift/Compensating F—Rear axle pivots (2x)
cylinder (bottom - 2x) (bottom - 1x) cylinder (top - 2x)
B—Boom pivot (2x) D—Boom extend cylinder (top
- 1x)
Lubricate grease points of boom pivot, lift and

CAUTION: Secure boom with lift cylinder
compensating cylinders, rear axle pivots (10 points).
safety channel prior to lubricating grease
points with boom raised.
Continued on next page OUZXMAG,00010A9 –19–26JUN01–1/2
80-2 072501
PN=132
Use specified grease (see Section “Fuel, Lubricants,

Coolant and Capacities”).
OUZXMAG,00010A9 –19–26JUN01–2/2
80-3 072501
PN=133
Every 50 Hours—Grease Fittings (Continued)
–UN–02JUL01
ZX026360
A—Pivoting frame pivot (top - B—Pivoting frame pivot C—Pivoting frame pivot D—Pivoting frame pivot
1x) cylinder (R.H. - 2x) (bottom - 1x) cylinder (L.H. - 2x)
Use specified grease (see Section “Fuel, Lubricants,

CAUTION: Secure pivoting frame with lift
Coolant and Capacities”).
cylinder safety rod prior to lubricating
grease points.
Lubricate grease points of pivoting frame (6 points).
OUZXMAG,00010AB –19–26JUN01–1/1
80-4 072501
PN=134
Checking Oil Level in Axles
IMPORTANT: Check oil level after machine has been

stationary for 2 minutes. Clean area
around the level plugs before removing.
–UN–02JUL01
Checking Axle Differential Oil Level:
• Remove level plug (A).

• Oil should be level with plug bore. If necessary top up
ZX026361
at fill plug (C) with specified oil (see Section “Fuel,
• Re-fit plugs (A) and (C) then tighten to 180 N•m
(132 lb-ft)
Checking Axle Final Drive Oil Level:
• Check each hub individually.

• Turn hub until plug (B) is in 3 or 9 o’clock position, as
–UN–02JUL01
shown.
• Remove plug. Oil should be level with plug bore. If
necessary top up with specified oil (see Section “Fuel,
ZX026362
• Re-fit plug (B) and tighten to 180 N•m (132 lb-ft)
–UN–10JUL01
ZX026364
–UN–02JUL01
ZX026363
OUZXMAG,00010AA –19–26JUN01–1/1
80-5 072501
PN=135
Checking Parking Brake and Lubricating

Linkage
Check function of the parking brake and adjust, if

necessary (see “Adjusting Parking Brake” in Section
“Service/As Required”).
–UN–02JUL01
IMPORTANT: Parking brake pivot (A) lubrication
requires the caliper (B) to be removed.
Therefore it is advised to contact your
ZX026365
John Deere dealer to carry out this
service.
Clean pivots (A) and apply grease to them.
–UN–08JUN00
ZX021644
OUZXMAG,00010AC –19–26JUN01–1/1
80-6 072501
PN=136
Checking Air Cleaner Elements
Check both air cleaner elements. Proceed as follows:
1. Release all latches (A) to remove air cleaner cover (B).
–UN–02JUL01
2. Remove both the outer (C) and inner (D) elements.
3. Discard the elements if they are distorted or the

bonded gaskets are loose.
ZX026369
4. Hold each element up to the light to check for damage
to the paper. The elements should be discarded if pin
pricks of light can be seen, or if there are areas of
paper that appear thin.
5. Refit new or existing elements as required.
–UN–02JUL01
A—Latch
B—Cover
C—Outer element
D—Inner element
ZX026370
–UN–02JUL01
ZX026371
OUZXMAG,00010AF –19–26JUN01–1/1
Wheel Retaining Bolts
Tighten wheel retaining bolts to 550 N•m (400 lb-ft).

–UN–28JUN01
ZX026097
OUZXMAG,00010B0 –19–26JUN01–1/1
85-1 072501
PN=137
Neutral Start Circuit
1. Move FNR lever (A) to the “forward” position.
2. Turn key in main switch as far as it will go to the right.

The starter must NOT turn over. If it does, see your
–UN–28JUN01
John Deere dealer immediately.
3. Repeat the test in the “reverse” position.
ZX026126
OUZXMAG,00010B1 –19–26JUN01–1/1
Checking Electrolyte Level of Battery
• Remove filler caps (A). Level of electrolyte should be

above the mark. Fill with distilled water only.
• Check that the vent holes in the battery caps are open
at all times. If terminal connectors are corroded, remove
–UN–10AUG94
corrosion with a stiff bristle brush and then coat the
terminals with an acid-free grease.
LX000539
Checking Air Conditioning Receiver-Drier
If there are bubbles in the sight glass (A) after the

compressor has run for 30 seconds or more, see your
John Deere dealer.
–UN–02JUL01
ZX026372
OUZXMAG,00010B2 –19–26JUN01–1/1
85-2 072501
PN=138
Changing Engine Oil
Drain oil with engine shut off, but with engine oil still
warm. Proceed as follows:
1. Remove drain screw (A).
2. While crankcase is draining, replace filter element.
3. Install drain screw, using new seal ring, and tighten to

70 N•m (52 lb-ft).
4. Fill crankcase with fresh oil of proper viscosity (see

Section “Fuel, Lubricants, Coolant and Capacities”) at
filler neck (B). With filter, capacity is approx. 12.5 liters
(3.3 U.S. gal.).
5. Run engine for a short time and check for leaks at filter
base and drain screw.
–UN–02JUL01
6. Shut off engine.
7. Wait 15 minutes then recheck oil level. Oil should be

up to the upper mark on dipstick. If necessary, top up
ZX026366
with oil.
IMPORTANT: Change oil whenever a seasonal change

in temperature makes oil of a different
viscosity necessary.
NOTE: Carry out first oil change after first 100 hours of
operation.
–UN–02JUL01
ZX026367
OUZXMAG,00010AD –19–26JUN01–1/1
90-1 072501
PN=139
Changing Engine Crankcase Filter Element
Proceed as follows:
1. Remove filter element (A) and clean mounting surface.
–UN–02JUL01
2. Apply a thin film of oil to sealing ring of new filter.
3. Tighten new filter element until sealing ring touches

mounting surface and then turn an additional 3/4 to
ZX026368
1-1/4 turns. Do not overtighten!
4. Start engine and check base of filter for leaks.
5. Shut off engine and check oil level.
NOTE: Carry out first oil filter change after first 100 hours
of operation.
OUZXMAG,00010AE –19–26JUN01–1/1
90-2 072501
PN=140
Changing Fuel Filter
1. Unfasten filter retaining ring (A) and remove filter,

sealing the old filter with the cover of the new filter.
2. Remove water trap (B) and attach it to the new filter.
–UN–02JUL01
3. Install new filter, ensuring that the marks on the filter
and housing are properly aligned.
ZX026373
4. Tighten retaining ring (A) until it can be heard to
engage.
Bleed Using Electronic Transfer Pump A—Filter retaining ring

B—Water trap
C—Bleed orifice in filter base
The bleed is automatically performed by a small orifice (C) D—Overflow valve
inside the filter base connected to the overflow valve (D) E—Fuel return line
on injection pump. This system allows air to escape
continually through the fuel return line (E) when ignition is
ON.
1. Turn key in main switch to the right as far as the first

switch position so that the fuel transfer pump is
operating.
2. Allow 40 seconds for electronic transfer pump to

complete priming.
3. If additional system bleeding is required, bleed the

circuit by loosening fuel line connections at injection
nozzles (see “Bleeding The Fuel System”.)
OUZXMAG,00010B3 –19–26JUN01–1/1
90-3 072501
PN=141
Servicing Fuel Tank
Open tank filler cap (A).
NOTE: The tank can be equipped with a lockable filler

cap (A).
–UN–02JUL01
Slacken off drain screw (B) by one turn. Drain water and
contaminants. Re-insert drain screw and tighten by hand.
ZX026380
–UN–02JUL01
ZX026381
OUZXMAG,00010B4 –19–27JUN01–1/1
Checking Belt Tensioner Spring Tension and

Belt Wear
Belt drive systems equipped with automatic (spring) belt

tensioners cannot be adjusted or repaired. The automatic
belt tensioner is designed to maintain proper belt tension
–UN–02JUL01
over the life of the belt. If tensioner spring tension is not
within specification, replace tensioner assembly.
Checking Belt Wear:

ZX026382
• The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops (A) and
(B) when correct belt length and geometry is used.
• Visually inspect cast stops (A) and (B) on belt tensioner
assembly.
• If the tensioner stop on swing arm (A) is hitting the fixed
stop (B), check mounting brackets (alternator, belt
tensioner, idler pulley, etc.) and the belt length. Replace
belt as needed.
OUZXMAG,00010B5 –19–27JUN01–1/1
90-4 072501
PN=142
Checking Tensioner Spring Tension
A belt tension gauge will not give an accurate measure of

the belt tension when automatic spring tensioner is used.
Measure tensioner spring tension using a torque wrench
and procedure outlined below:
–UN–24SEP97
1. Release tension on belt using a long-bar and adequate
wrench applied on cap screw (C) provided with
left-hand thread. Remove belt from pulleys.
ZX012181
2. Release tension on cap screw (C), then remove bar
and wrench.
3. Put a mark (A) on swing arm of tensioner as shown.
4. Measure 20 mm (0.79 in.) from (A) and put a mark (B)

on tensioner mounting base.
–UN–24SEP97
5. Rotate the swing arm using a torque wrench applied
on cap screw (C) until marks (A and B) are aligned.
NOTE: Before rotating, the torque wrench must be
ZX012182
aligned with the tensioner fastening cap screw.
6. Record torque wrench measurement and compare with

specification below. Replace tensioner assembly as
required.
Specification
Spring Tension—Torque .............................................. 20 N•m (14.8 lb-ft)
–UN–10JUN96
ZX009262
Air Intake Hose
Check hose and tighten clamps (A).
Leaking or damaged hose is the cause of dirt entering the

engine.
–UN–02JUL01
ZX026383
OUZXMAG,00010B6 –19–27JUN01–1/1
90-5 072501
PN=143
Replacing Air Cleaner Outer Element
Proceed as follows:
–UN–02JUL01
2. Replace outer element (C).
3. Discard the inner element (D) if it is distorted or the

bonded gasket is loose.
ZX026369
A—Latch
B—Cover
C—Outer element
D—Inner element
–UN–02JUL01
ZX026370
–UN–02JUL01
ZX026371
OUZXMAG,00010B7 –19–27JUN01–1/1
90-6 072501
PN=144
Replacing Transmission Oil Filter
CAUTION: Make the machine safe before

working on it. Park on level ground, fully lower
the boom, apply the parking brake, put the
–UN–02JUL01
transmission in neutral and stop engine.
Replace filter as follows:
ZX026384
1. Clean the outside of the filter housing.
2. Using a spanner unscrew the bowl (A) and discard old

element and head-to-bowl seal ring.
3. Clean the inside of the bowl and filter head, install new
element and seal ring.
4. Refit bowl and tighten to a torque of 10 N•m (7.5 lb-ft).
OUZXMAG,00010B8 –19–27JUN01–1/1
Replacing Hydraulic Oil Filter
CAUTION: Make the machine safe before

working on it. Park on level ground, fully lower
the boom, apply the parking brake, put the
–UN–02JUL01
transmission in neutral and stop engine.
Prior to removing oil filter, release any pressure

in the hydraulic tank by slowly unscrewing the
ZX026385
oil filler cap.
Replace filter as follows:
1. Clean the outside of the filter housing.
2. Using a spanner unscrew the bowl (A) and discard old

element and head-to-bowl seal ring.
3. Clean the inside of the bowl and filter head, install new
element and seal ring.
4. Refit bowl and tighten to a torque of 10 N•m (7.5 lb-ft).
OUZXMAG,00010B9 –19–27JUN01–1/1
90-7 072501
PN=145
Greasing Boom Extension Wear Pads
Fully extend boom, lower to ground, apply parking brake

and stop engine.
Clean areas1 and ensure that they are dry. Brush/apply
–UN–02JUL01
grease evenly over the slide running surfaces. Retract the
boom.
ZX026386
1
Upper wear pads area shown.
OUZXMAG,00010BA –19–27JUN01–1/1
Adjusting Parking brake
1. Before adjusting parking brake, set brake lever (A) to

lowest notch of segment.
2. Slacken off lock nut (B) and tighten adjusting nut (C)
–UN–02JUL01
until brake pads are in contact with the disk.
3. Secure with lock nut (B).
ZX026387
NOTE: When the parking brake is correctly adjusted, it
must be possible to pull the lever (A) into the 4th
notch using a force of 100 to 150 N (22 to 34 lb).
–UN–02JUL01
ZX026388
OUZXMAG,00010BB –19–27JUN01–1/1
90-8 072501
PN=146
Checking Engine Speeds
Have adjustments carried out by your John Deere dealer.
The following guidelines apply:
• Slow idle: 845 to 855 rpm

• Fast idle: 2345 to 2355 rpm
OUZXMAG,00010BC –19–27JUN01–1/1
95-1 072501
PN=147
Service / Every 1000 Hours or 1 Year
Replacing Cab Air Filters
1. Remove cover (A) then remove air filter (B).
2. Replace filter with a new one.
–UN–02JUL01
3. Repeat on opposite side.
ZX026389
–UN–02JUL01
ZX026390
OUZXMAG,00010BD –19–27JUN01–1/1
100-1 072501
PN=148
Changing Hydraulic Oil
Change hydraulic oil as follows:
1. Run the engine and operate the hydraulics to warm the

oil.
–UN–02JUL01
2. Ensure all cylinders are fully retracted. Apply the
parking brake and shut off engine.
ZX026391
CAUTION: Before removing drain plug (B),
release any pressure in the hydraulic tank by
slowly unscrewing tank filler cap.
IMPORTANT: Before removing drain plug (B) ensure a

suitable container is placed on the
ground to catch the full capacity of oil
in the tank. When removing drain plug,
–UN–09JUL01
be sure to stand to one side to avoid oil
which will spill from the hole.
3. Drain the tank (A) by removing plug (B).
ZX026392
4. Remove cover plate (C), discard gasket
5. Remove the suction filter (D) by unscrewing from the

suction pipe.
6. Clean and re-fit the suction filter (D) to the suction

pipe.
–UN–09JUN00
7. Flush out the tank with clean hydraulic oil taking
extreme care to remove all dirt and foreign matter.
8. Re-fit cover plate (C) to tank using new gasket and
ZX021661
re-fit drain plug (B).
9. Fill the system with correct oil (see Section “Fuel,

Specification
Hydraulic Oil—Capacity.......................................... 106 liters (28 US. gal.)
10. Run the engine to circulate the oil. Operate the

hydraulic controls to purge any air from the system.
11. Stop the engine and refill the tank as required (check
at oil level indicator).
OUZXMAG,00010BE –19–27JUN01–1/1
100-2 072501
PN=149
Changing Transmission Oil
CAUTION: Machine must be parked on level

ground, with the boom assembly fully lowered,
parking brake applied, engine stopped and all
–UN–02JUL01
wheels chocked on both sides.
Proceed as follows:
ZX026393
1. Remove drain plug (A) and allow oil to drain into a
suitable container.
2. Fill the system with new oil of the correct grade at

dipstick/filler neck (B)
IMPORTANT: Do not fill past the top mark on the

dipstick.
–UN–02JUL01
Specification
Transmission Oil (PowerShift)—
Capacity ................................................................ 12.5 liters (3.3 US. gal.)
Transmission Oil
(Synchro-Shuttle)—Capacity ................................ 18.5 liters (4.9 US. gal.)
ZX026394
For correct oil type and grade see Section “Fuel,
Lubricants, Coolant and Capacities”.
OUZXMAG,00010BF –19–27JUN01–1/1
100-3 072501
PN=150
Changing Axle Final Drive Oil
IMPORTANT: Clean the area surrounding plugs

before removing. Ensure a suitable
container is placed on the ground to
catch oil. When removing drain plugs,
–UN–02JUL01
Proceed as follows:
ZX026395
1. Hand rotate the final drive (A) so that plug (B) is at the
bottom.
2. Drain lubricating oil by removing the plug.
3. Turn final drive 180°.
4. Re-fill with clean oil of the correct type and grade (see
Section “Fuel, Lubricants, Coolant and Capacities).
Specification
Front/Rear Final Drive—Capacity ........................ 0.8 liters (0.21 US. gal.)
5. Turn the final drive so that the plug (B) hole is at the 3
or 9 o’clock position. Oil level should be flush with
bottom of hole.
6. Re-fit plug (B) and tighten to 180 N•m (132 lb-ft).
OUZXMAG,00010C0 –19–27JUN01–1/1
100-4 072501
PN=151
Changing Axle Differential Oil
IMPORTANT: Clean the area surrounding plugs

before removing. Ensure a suitable
container is placed on the ground to
catch oil. When removing drain plugs,
–UN–02JUL01
Proceed as follows:
ZX026396
1. Drain lubricating oil by removing the drain plug (A) in
differential casing (B).
2. Re-fill with clean oil of the correct type and grade at fill
plug (C) (see “Fuel, Lubricants, Coolant and
Capacities”).
Specification
–UN–10JUL01
Front/Rear Axle Differential
Housing—Capacity ..................................................... 15 liters (4 US. gal.)
3. The differential case oil levels are correct when they
ZX026364
reach the level plug hole (D).
4. Re-fit all plugs and tighten to 180 N•m (132 lb-ft)

A—Drain plug
B—Casing
C—Fill plug
D—Level plug
OUZXMAG,00010C1 –19–27JUN01–1/1
100-5 072501
PN=152
Service / Every 2000 Hours or 2 Years
Changing Air Cleaner Inner Element
Proceed as follows:
–UN–02JUL01
2. Remove both the outer (C) and inner (D) elements.
3. Discard the inner element (D).
ZX026369
4. Refit new element.
A—Latch
B—Cover
C—Outer element
D—Inner element
–UN–02JUL01
ZX026370
–UN–02JUL01
ZX026371
OUZXMAG,00010C2 –19–27JUN01–1/1
Replacing Coolant (Without JD COOL-GARD

Coolant)
IMPORTANT: Replace engine coolant after 2000 hours

of operation only if John Deere
COOL-GARD coolant is not used! Refer
to Section “Service/Every 3000 Hours or
Three Years” to proceed.
105-1 072501
PN=153
Adjusting Engine Valve Tappet Clearance
After the first 2000 hours of operation have valve tappet

clearance checked and, if necessary, adjusted by your
John Deere dealer.
–UN–02JUL01
ZX026397
OUZXMAG,00010C3 –19–27JUN01–1/1
105-2 072501
PN=154
Replacing Coolant (With JD COOL-GARD
Coolant)
CAUTION: Remove radiator cap (A) only when

coolant temperature is below boiling point.
–UN–02JUL01
Then loosen cap to relieve pressure before
removing the cap completely.
NOTE: The service interval for replacing engine coolant
ZX026398
must be reduced to 2000 hours/2 years when
John Deere Cool-Gard is not used.
1. Remove radiator cap (A).
2. Remove radiator drain plug (B) (radiator is removed for

illustration purpose).
3. Remove coolant drain plug (C) from engine block.
–UN–02JUL01
4. Drain the coolant into a suitable container.
5. As soon as system is empty, re-install drain plugs and
ZX026399
fill the system with a commercial cooling system
cleaning solution.
6. Run engine until it reaches operating temperature.

Shut off engine and drain cooling system.
7. Re-install drain plugs again and fill the system with

clean water.
–UN–02JUL01
IMPORTANT: Never pour cold water or coolant into
the hot engine. Always use warm water
or wait until engine has cooled down.
ZX026400
8. Again run engine until it has reached operating
temperature. Shut off engine and drain system again.
9. Re-install drain plugs again, and this time fill the

system with the specified coolant (see Section “Fuel,
Specification
Coolant—Capacity ...................................................... 19 liters (5 US. gal.)
–UN–02JUL01
10. When filling is completed, run the engine. This will

allow the thermostat to open, ensuring that coolant is
circulated throughout the entire cooling system.
ZX026401
Continued on next page OUZXMAG,00010C4 –19–27JUN01–1/2
110-1 072501
PN=155
11. Recheck coolant level. Coolant level should be

between MAX and MIN levels. If necessary top up
with the specified coolant.
12. For efficient cooling, the radiator screen must be kept

clean. Remove any dust or oil and carefully straighten
any bent fins.
OUZXMAG,00010C4 –19–27JUN01–2/2
110-2 072501
PN=156
Service / As Required
Electrical Connector Handling
Electrical connectors must not be forcibly mated or

unmated. All are designed to be mated easily. If you have
to use tools, you may be doing something wrong. Prying
or forcing connectors may cause permanent damage to
the locking mechanism, contacts, or both.
–UN–01FEB89
When working on connectors, make sure you are working
on the correct terminal. Remember that male and female
halves are mirror images of one and other. Look for the
terminal number on the connector body. The connection
H37083
of wrong electrical circuits can cause unusual electrical
symptoms.
When an electrical connector is repaired, it is important

that the proper terminals are used. In some of these
connectors, different terminals are used to carry different
currents. If contacts of different materials are mated,
corrosion may develop that could affect performance.
When removing terminals from a connector, it is very

important to use the correct extraction tool and gently
remove the terminal. The connector body can be
damaged if terminals are just “jerked” out of it. The
damage caused will prevent the new terminal from staying
in the connector and cause replacement of the connector
body.
When installing a new terminal on a wire, make sure the

insulation crimp and wire crimp are both made properly.
Each part of the terminal crimps is designed for a specific
purpose. Failure to properly crimp the wire contact area
can result in poor or no electrical contact. Failure to crimp
the insulation support properly can result in problems
getting the terminal into the connector body, thus causing
premature failure.
115-1 072501
PN=157
Hydraulic System Cleanliness
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
–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
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.
Cleanliness
If the hydraulic system should be disconnected for

service, protect the ends of hoses, tubing and ports of
components from contamination with clean, lint-free towels
or clean plastic bags.
Before installing any replacement hose, flush the inside

with unused diesel fuel or unused commercial petroleum
cleaning solvent for ten seconds minimum. Do not use
water, water soluble cleaners or compressed air.
Observe Air Conditioning Precautions
CAUTION: Refrigerant (R134A) is under

pressure. Improper servicing may cause
refrigerant to penetrate eyes and skin or cause
burns.
–UN–20JUL92
Special equipment and procedures are required to service

air conditioning system. (See your John Deere dealer.)
H44933
115-2 072501
PN=158
Winterize Cooling System
IMPORTANT: Do not drain cooling system to protect

against freezing. The heater does not
drain completely, so damage would
result.
Before cold weather, be sure the cooling system has

enough antifreeze. Use a reliable brand of permanent-type
ethylene glycol antifreeze which contains a rust inhibitor
and water pump lubricant, but does not contain a
leak-stopping additive.
See “Fuel, Lubricants, Coolant and Capacities” Section for

the correct recommendations.
After adding antifreeze, turn heater on and run engine

until it reaches operating temperature. This mixes the
solution and circulates it through the system.
Cleaning Cab Air Filters
If the handler is operated in very dusty conditions, remove

cover (A) then clean air filter (B).
Replace filter, if necessary. Repeat on opposite side.
–UN–02JUL01
ZX026389
–UN–02JUL01
ZX026390
OUZXMAG,00010C5 –19–27JUN01–1/1
115-3 072501
PN=159
Air Cleaner
If the air cleaner indicator lamp glows during operation,

remove and clean the outer filter element.
The service interval may be extended briefly, e.g. until the
–UN–02JUL01
next suitable opportunity. Provided the outer filter element
is serviced properly, this will not adversely affect it’s
performance.
ZX026369
The outer element may be cleaned up to 5 times. After
that, or after 500 hours at the latest, it must be replaced.
• Open the hood then un-hook latches (A).

• Remove the cover (B) then pull outer element (C) out of
the cleaner housing.
IMPORTANT: Never run the engine without the outer

filter element!
–UN–02JUL01
ZX026370
OUZXMAG,00010C6 –19–27JUN01–1/4
Cleaning Outer Filter Element
When the element (A) must be serviced in the field, tap it

on the palm of your hand as temporary measure.
IMPORTANT: The guide ring (B) must not be
–UN–09JUN00
damaged or deformed.
When you return to your service area, clean the filter

element thoroughly, or replace it with a new one.
ZX021676
Cleaning Dusty Element
If tapping element does not remove dust, blow out dust

with compressed air (not exceeding 500 kPa; 5 bar;
75 psi) by inserting nozzle inside the element and blowing
from the inside of the filter to the outside.
Replace element if air cleaner indicator light continues

glowing after the element has been cleaned.
115-4 072501
PN=160
Cleaning the Dust Unloading Valve
IMPORTANT: Never run the engine when the dust

unloading valve is removed!
Remove dust deposits by squeezing the valve (A).
–UN–02JUL01
During the harvest, grass and chaff may adversely affect
the performance of the dust unloading valve. Remove and
clean the dust unloading valve as necessary.
ZX026402
Replace any damaged valve immediately.
NOTE: In dusty conditions, clean the dust unloading valve

every day.
OUZXMAG,00010C6 –19–27JUN01–3/4
Inner Filter Element
The inner element (A) must be changed if it becomes

damaged and at every fourth service of the outer element.
Change it at the latest after 2000 hours of operation.
–UN–02JUL01
IMPORTANT: Always replace inner element, do not
attempt to clean it.
ZX026403
OUZXMAG,00010C6 –19–27JUN01–4/4
115-5 072501
PN=161
Keep Radiator Screens Clean
For efficient cooling, the radiator (A), condenser (B) and

hydraulic oil cooler (C) screens must be kept clean.
Remove any dust or oil and carefully straighten any bent
fins.
A—Radiator
B—Condenser
C—Hydraulic oil cooler1
1
Available as an option in certain countries –UN–02JUL01
ZX026404
–UN–02JUL01
ZX026405
OUZXMAG,00010C7 –19–27JUN01–1/1
Brake System Pressure
If brake system pressure is too low the warning light will

glow. Have brake system serviced by your John Deere
dealer immediately.
–UN–02JUL01
CAUTION: Never operate the machine with this

light glowing, as brake efficiency will be
impaired.
ZX026406
OUZXMAG,00010C8 –19–27JUN01–1/1
115-6 072501
PN=162
Replacing Fan/Alternator V-Belt
Refer to "Checking Belt Tensioner Spring Tension and

Belt Wear" to determine if V-belt needs replacing.
1. Release tension on belt.
2. Remove V-belt from pulleys and discard belt.
3. Install new belt (A), be sure that belt is correctly routed

and seated in all pulley grooves as shown.
4. Apply tension to belt with tensioner.
5. Start engine and check belt alignment.
A—V-Belt
B—Compressor pulley (air conditioning system)
C—Deflection roll
D—Fan pulley
E—Crankshaft pulley
–UN–02JUL01
F—Water pump pulley
G—Idler roll
H—Alternator pulley
ZX026407
115-7 072501
PN=163
–UN–08MAY00
ZX021147
A—Engine G—Alternator pulley 1—Drive belt arrangement 3—Drive belt arrangement with
B—Crankshaft pulley H—Compressor (air without air conditioning air brake and system
C—Water pump pulley conditioning system) and air brake systems without air conditioning
D—Fan pulley pulley 2—Drive belt arrangement with 4—Drive belt arrangement with
E—Deflection roll J—Air brake system pulley air conditioning and air conditioning and air
F—Idler roll (optional in Germany only) without air brake systems brake systems
Arrangement of Drive Belt
OUZXMAG,00010C9 –19–27JUN01–2/2
Do Not Modify Fuel System
IMPORTANT: Modification or alteration of the

injection pump, injection pump timing,
or fuel injectors in ways not
recommended by the manufacturer will
–UN–02JUL01
terminate the warranty obligation to the
purchaser. See warranty information
inside front cover.
ZX026408
Do not attempt to service injection
pump or fuel injectors yourself. Special
training and special tools are required.
See your John Deere dealer.
Never steam clean or spray water on a

warm injection pump. This could cause
damage to pump parts.
OUZXMAG,00010CA –19–27JUN01–1/1
115-8 072501
PN=164
Checking Fuel Filter
Should water or sediment deposits have settled in filter,

proceed as follows:
1. Loosen drain screw (A) and water trap bleed screw
–UN–02JUL01
(B).
2. Retighten both screws as soon as water and sediment

deposits have drained out.
ZX026409
operating. Keep the pump running for approx. 20
secondes.
If water was present in fuel filter, then also slacken off the
drain screw (C) on fuel tank by one turn. After draining off
any water deposits, retighten drain screw by hand.
–UN–02JUL01
A—Drain screw
B—Bleed screw
C—Drain screw (fuel tank)
ZX026410
OUZXMAG,00010CB –19–27JUN01–1/1
115-9 072501
PN=165
Bleeding the Fuel System
The fuel system must be bled whenever the fuel tank has
been run dry.
Proceed as follows:
–UN–02JUL01
Bleed Using Electronic Transfer Pump
The bleeding is automatically performed by a small orifice
ZX026411
(A) inside the filter base connected to the overflow valve
(B) on injection pump. This system allows air to escape
continually through the fuel return line (C) when ignition is
ON.

operating.
2. Allow 40 seconds for electronic transfer pump to

complete priming.
If engine will not start after this bleeding procedure,

continue as follows:
Bleed Fuel System at Fuel Injection Nozzles

operating.
IMPORTANT: Always use a backup wrench when

loosening or tightening fuel lines at
nozzles and/or injection pump to avoid
damage.
2. Using two open-end wrenches, loosen two fuel line

connections at injection nozzles.
3. Crank engine over with starting motor for 15 seconds

(but do not start engine) until fuel free from bubbles
flows out of loosened connection. Retighten connection
to specifications.
Specification
Fuel Injection Nozzle Delivery
Lines—Torque ................................................................. 27 N•m (20 lb-ft)
Continued on next page OUZXMAG,00010CC –19–27JUN01–1/2
115-10 072501
PN=166
4. Repeat procedure for remaining injection nozzles (if

necessary) until air has been removed from fuel
system.
OUZXMAG,00010CC –19–27JUN01–2/2
Lubricate All Lubricating Points
If the machine has been washed with high-pressure water,

lubricate all lubricating points.
Checking Tire Pressure
3800 Handler Front Rear

14.9-24 .................................................................. 260 kPa (2.6 bar; 38 psi) 210 kPa (2.1 bar; 30 psi)
460/70 R 24 .......................................................... 240 kPa (2.4 bar; 35 psi) 170 kPa (1.7 bar; 25 psi)
15.5/80-24 ............................................................. 260 kPa (2.6 bar; 38 psi) 210 kPa (2.1 bar; 30 psi)
445/70 R24 ........................................................... 240 kPa (2.4 bar; 35 psi) 170 kPa (1.7 bar; 25 psi)
19.5 LR 24 ............................................................ 240 kPa (2.4 bar; 35 psi) 170 kPa (1.7 bar; 25 psi)
17.5 LR24 ............................................................. 240 kPa (2.4 bar; 35 psi) 170 kPa (1.7 bar; 25 psi)
OUZXMAG,00010CD –19–27JUN01–1/1
Operator’s Seat
Lubricate slide rails (A) with John Deere multipurpose

grease.
–UN–02JUL01
ZX026413
OUZXMAG,00010CE –19–27JUN01–1/1
115-11 072501
PN=167
Starting Motor
If the starter fails to operate after the starter switch has

been operated, the complete starter system must be
thoroughly checked. Check specific gravity of battery with
an hydrometer and make sure that none of the cables are
–UN–02JUL01
broken or worn through and that none of the cable
connections are loose or corroded.
If the above checks fail to improve the operation of the
ZX026414
starter, see your John Deere dealer.
OUZXMAG,00010CF –19–27JUN01–1/1
115-12 072501
PN=168
Replacing Thermostat
Thermostat can be tested and replaced as follows:
1. Take out cap screws and remove thermostat cover (A).
2. Remove thermostat (B) and all gasket material .
3. Visually inspect thermostat for corrosion or damage.
CAUTION: DO NOT allow thermostat or

thermometer to rest against the side or bottom
of container when heating water. Either may
rupture if overheated.
–UN–23NOV97
4. Suspend thermostat and a thermometer in a container
of water.
5. Stir the water as it heats. Observe opening action of
RG5971
thermostat and compare with specification given in
chart below.
NOTE: Due to varying tolerances of different suppliers,

initial opening and full open temperatures may
vary slightly from specified temperatures.
Thermostat Test Specifications

Rating Initial Opening (Range) Full Open
–UN–02JUL01
(Nominal)
82 °C (180 °F) 80-84 °C (175-182 °F) 94 °C (202 °F)
ZX026412
6. Remove thermostat from container and observe its
closing action as it cools. In ambient air the thermostat
should close completely. Closing action should be
smooth and slow. A—Cover
B—Thermostat
Replace thermostat if it is defective. C—Pin
7. Coat new gasket with sealant, and install.
8. Install new thermostat with the pin (C) on top for a

proper filling.
9. Install cover, then tighten cap screws to 70 N•m

(52 lb-ft).
OUZXMAG,00010D0 –19–27JUN01–1/1
115-13 072501
PN=169
Battery—Checking Specific Gravity
Use an hydrometer to check the specific gravity of the

electrolyte in each battery cell.
A fully charged battery should have a specific gravity of
–UN–10AUG94
1.28 kg/l. Recharge battery if reading drops below
1.20 kg/l.
NOTE: In tropical regions, the battery is fully charged
LX000538
when the reading is 1.23 kg/l.
115-14 072501
PN=170
Fuses and Relays
Load Center
Fuses:
F1 — 30 A, Starting Motor
F2 — Not used
F3 — 30 A, Heater, Air Conditioning
F4 — 30 A, Front/Rear Working Lights
F5 — 30 A, Radio, Dome Lamp, Horn, Clock
F6 — 20 A, Reverse Lights
F7 — 30 A, Full Beam Headlights
F8 — 10 A, Brake Lights
F9 — 30 A, Hazard, Turn Signal
F10 — Not used
F11 — Not used
F12 — 30 A, Heater, Air Conditioning
F13 — 20 A, Air Comfort Seat Motor
F14 — 30 A, Electrical Socket
F15 — 30 A, Trailer Socket
F16 — 10 A, Trailer Lighting
F17 — 10 A, Console/Instrument Display
F18 — Not used
F19 — Not used
F20 — 20 A, FNR Lever (Synchro-Shuttle)
F20 — 20 A, Transmission Control Unit (TCU), FNR Lever (PowerShift)
F21 — 10 A, Rear Auxilliary Function Solenoid Valve
F22 — Not used
F23 — 20 A, Engine Control Unit (ECU)
F24 — 10 A, Operator’s Seat Presence Switch
F25 — 10 A, Hydraulic Control Unit (HYD)
F26 — 10 A, Boom Work Light
F27 — 10 A, Boom Work Light
F28 — 20 A, Rear R.H. Lamp, Front Position L.H. Lamp, License Plate Lamp
F29 — 20 A, Rear L.H. Lamp, Front Position R.H. Lamp
F30 — Not used
F31 — 20 A, Front Wiper
F32 — 30 A, Roof/Rear Wiper
F33 — 20 A, Second Auxiliary Diverter Valve
F34 — 20 A, Boom Extend/Retract Solenoid Valve
F35 — Not used
F36 — Not used
F37 — Not used
Relays:
K1 — Ignition
K2 — Accessories
K3 — Front Wiper
K4 — Air Conditioning/Heater
K5 — Rear Work Lights
K6 — Front Work Lights
K7 — Headlight Flasher
K8 — Start Safety
K9 — Starting Aid
K10 — Starting Motor
Continued on next page OUZXMAG,00010D1 –19–27JUN01–1/2
115-15 072501
PN=171
K11 — Roof Wiper

K12 — Right Blower Motor
K13 — By-Pass Start 1
K14 — By-Pass Start 2
K15 — Left Blower Motor
K16 — Turn Signal Enable 1
K17 — Turn Signal Enable 2
K18 — Park Light
K19 — R.H. Turn Signal
K20 — L.H. Turn Signal
K21 — Not USed
K22 — Head Lamps
K23 — Brake Light
K24 — Not used
K25 — Turn Signal/Warning Flasher
K26 — Not used
K27 — Not used
K28 — Trailer Power
K29 — Front Attachment Extend
K30 — Front Attachment Retract
K31 — Not Used
K32 — Rotary Injection Pump
K33 — Parking Brake
K34 — Second Auxiliary Diverter Valve
K35 — Third Auxiliary Diverter Valve
K36 — Boom Extend
K37 — Boom Retract
K38 — Clutch
K39 — Forward Travel
K40 — Reverse Travel
K41 — Hydraulic Block Power
OUZXMAG,00010D1 –19–27JUN01–2/2
115-16 072501
PN=172
Troubleshooting
Hydraulic System
Symptom Problem Solution
Hydraulic system fails to Not enough oil in the system Top up to mark on dipstick.
function
Clogged hydraulic oil filters Replace hydraulic oil filters.
Dirt in hydraulic pump Check filter for clogging.
Hydraulic oil overheats Dirt in hydraulic pump Check filter for clogging.
GS,TROUBL1 –19–15JUL95–1/1
120-1 072501
PN=173
Troubleshooting
Engine
Engine hard to start or will not No fuel Fill tank with proper fuel.
start
Air in the fuel system Bleed air from fuel system.
Low ambient air temperature Use cold weather starting aids.
Clogged fuel filter Replace filter element.
Crankcase oil too heavy Use oil of proper viscosity.
Engine knocks Insufficient oil in engine Add more oil.
Fuel injection pump incorrectly timed See your dealer.
Engine overheats Low coolant level Fill radiator to proper level. Check
cooling system for leaks.
Loose or defective fan belt Adjust or replace fan belt.
Cooling system needs flushing Drain, flush and refill cooling system.
Dirty oil cooler or grille screens Clean oil cooler and screens.
Defective thermostat Remove and check thermostat.
Engine oil pressure too low Low engine oil level Add more engine oil.
High oil consumption Oil of too low viscosity Drain and refill with oil of correct
viscosity.
Oil leaks Check for leaks in lines and around

gaskets.
High fuel consumption Wrong type of fuel Use a suitable fuel grade.
Incorrect valve clearance See your dealer.
Fuel injection nozzles dirty or See your dealer.

damaged
Engine incorrectly timed See your dealer.
Clogged or dirty air cleaner Service air cleaner.
Continued on next page LX,OTRO 000448 –19–01JUL94–1/2
120-2 072501
PN=174
Troubleshooting
Engine emits black or grey Unsuitable fuel grade Use a suitable fuel grade.
exhaust smoke
Clogged air cleaner Service air cleaner.
Defective muffler Replace muffler.
Fuel injection nozzles dirty or See your dealer.

damaged
Engine emits white smoke Unsuitable fuel grade Use a suitable fuel grade.
Cold engine Run engine until normal operating

temperature is reached.
Defective thermostat Replace thermostat.
Engine incorrectly timed See your dealer.
LX,OTRO 000448 –19–01JUL94–2/2
Electrical System
Battery will not charge Loose or corroded connections Clean and tighten battery
connections.
Loose or defective alternator belt Adjust belt tension or replace belt.
Starter inoperative Loose or corroded connections Clean and tighten loose connections.
Low battery output Check and recharge battery.
Starter cranks slowly Low battery output Check and recharge battery.
Crankcase oil too heavy Drain crankcase and add correct oil.
Loose or corroded connections Clean and tighten loose connections.
GS,OTRO 000449 –19–10DEC95–1/1
120-3 072501
PN=175
Storage
Storage for Long Period
Drain, flush and refill the cooling system with fresh Once the rust inhibitor has been added, the engine
coolant. For proper composition of coolant see section must not be started again.
“Fuel, Lubricants, Coolant and Capacities”.
IMPORTANT: Rust inhibitor agents evaporate very
Do not store machine with crankcase or transmission easily. For this reason, seal all
filled with dirty oil. Drain oil, replace filter element and openings after adding inhibitor. Keep
fill with fresh oil. Drain the oil while it is still hot. the inhibitor container closed at all
times.
Operate engine for a few minutes before adding rust
inhibitor. Remove and clean the battery. Charge the battery
and store it in a cool, dry place where it will not
To protect the engine, use AR41785 rust inhibitor, freeze. Keep battery fully charged while in storage.
which is available from your John Deere dealer. The Seal all openings such as the vent tube and
kit provided under this order no. includes one can of exhaust outlet.
rust inhibitor, masking tape and protective caps to
cover all engine openings. Wash the exterior and painted surfaces of the
machine using clear, cold water. Wipe dry with a
Proceed as follows: soft cloth.
1. Add 375 cm3 (23 cu.in.) of rust inhibitor to the Replace or repair worn or damaged parts. Touch up
engine oil. any damaged paintwork.
2. Fill the fuel tank. Start engine and operate all Store the machine in a dry, protected place. If the
hydraulic functions several times. Shut off engine. machine is stored outside, cover it with a
waterproof tarpaulin.
3. Prepare 15 cm3 (0.9 cu.in.) of rust inhibitor for each
cylinder. Remove plug from intake manifold or Block up the machine so that tires do not touch the
starting fluid connecting pipe, and inject rust ground. Protect tires from heat and sunlight.
inhibitor into the aperture. Disconnect the electric
cable at the injection pump and insulate the end of
it. Crank the engine several times with the starter to
spread the rust inhibitor around.
OUZXMAG,00010D2 –19–27JUN01–1/1
125-1 072501
PN=176
Storage
Removing Machine From Storage
Remove all protective coverings. Check tire inflation • Replace engine crankcase filter (see “Every 500
and remove blocks. Hours).
• Carry out 750-hour check (see “Every 750 Hours).
Install battery and connect cable and ground straps
(negative terminals grounded).
CAUTION: Never operate the engine in a
closed building. Danger of asphyxiation!
• Check transmission and hydraulic oil levels.
• See that fuel tank is filled.
Turn the engine over with the starter for several
• Check coolant level in radiator.
seconds so that engine oil pressure builds up. Then
• Check crankcase oil level.
connect the cable to the fuel injection pump and start
• Drain and refill engine crankcase (see “Every 500
the engine.
Hours).
OUZXMAG,00010D3 –19–27JUN01–1/1
125-2 072501
PN=177
Specifications
Engine
Engine type .................................................................................................................. 4045HZ050
Power, ECE-R24 at rated speed with fan ................................................................... 80.9 kW (110 hp)
Max. torque at 1400 rpm ............................................................................................. 454 N•m (334 lb-ft)
Number of cylinders ..................................................................................................... 4
Bore ............................................................................................................................. 106.5 mm (4.19 in.)
Stroke ........................................................................................................................... 127 mm (5 in.)
Displacement ............................................................................................................... 4.5 L (276 cu.in.)
Firing order .................................................................................................................. 1-3-4-2
Intake valve clearance ................................................................................................. 0.35 mm (0.014 in.)
Exhaust valve clearance .............................................................................................. 0.45 mm (0.018 in.)
Slow idle ...................................................................................................................... 845 to 855 rpm
Fast idle ....................................................................................................................... 2345 to 2355 rpm
Rated engine speed .................................................................................................... 2200 rpm
Working speed range .................................................................................................. 1200 to 2200 rpm
OUZXMAG,00010D4 –19–27JUN01–1/1
Transmission (Synchro-Shuttle)
Transmission ................................................................................................................ synchronized gears, mechanically actuated

Gear selection .............................................................................................................. 4 forward and reverse gears
Clutch ........................................................................................................................... electrical/hydraulic
Max. travel speed ........................................................................................................ 40 km/h (24.8 mph)
OUZXMAG,00010D5 –19–27JUN01–1/1
Transmission (PowerShift)
Transmission ................................................................................................................ synchronized gears, elector-hydraulically actuated
Gear selection .............................................................................................................. 5 forward and 3 reverse gears
Clutch ........................................................................................................................... electrical/hydraulic
Max. travel speed ........................................................................................................ 40 km/h (24.8 mph)
OUZXMAG,00010D6 –19–27JUN01–1/1
130-1 072501
PN=178
Specifications
Hydraulic System
Type ............................................................................................................................. open-center with Load-Sensing control
Pump ............................................................................................................................ gear type pump
Pump Capacity ............................................................................................................ 99 l/min (21.8 US. gal./min)
System pressure .......................................................................................................... 22500 kPa (225 bar; 3263 psi)
Steering system ........................................................................................................... hydrostatic power
OUZXMAG,00010D7 –19–27JUN01–1/1
Electrical System
Battery .......................................................................................................................... 12 V, 154 Ah

Alternator with overvoltage protection ......................................................................... 14 V, 95 A
Starting motor .............................................................................................................. 12 V, 3.0 kW (4.0 hp)
Battery terminal grounded ........................................................................................... Negative
OUZXMAG,00010D8 –19–27JUN01–1/1
Vibrations at Operator’s Position
Measured according to provision pr EN13059.
1. Max. acceleration value to which the body of operator is subjected ..................... 3.15 m/s2 at 20 Hertz
2. Max. acceleration value to which the seat surface is subjected ............................ 3.39 m/s2 at 20 Hertz
OUZXMAG,000081E –19–12DEC00–1/1
Sound Level
Sound level at operator’s ear (cab closed) is 73 dB(A).
Sound level at operator’s ear (cab open) is 76 dB(A).
Measurement method in accordance with Directive

ISO4871 and provision EN12053.
OUZXMAG,000081D –19–12DEC00–1/1
130-2 072501
PN=179
Specifications
Dimensions - 3800 Telescopic Handler
–UN–19MAR01
ZX024440
A—4965 mm (16 ft 4 in.) C—2500 mm (8 ft 4 in.) E—1890 mm (6 ft 2 in.) —Weight: 6480 kg (14285 lb)
B—2660 mm (8 ft 5 in.) D—445 mm (1 ft 6 in.) F—2210 mm (7 ft 3 in.)
NOTE: The dimensions given refer to a handler with

standard tires (15.5/80x24).
OUZXMAG,00010D9 –19–27JUN01–1/1
Lift Capacity and Lifting Height
3800 Telescopic Handler
With pallet fork 2500 kg (5511 lb) at 500 mm (20 in.) load center (with boom retracted), up to 5.50 m (18 ft 5 in.)
(fork lift duties) ......................................... high
1250 kg (2755 lb) at 500 mm (20 in.) load center, up to 3.06 m (10 ft 4.7 in.) forward reach
CAUTION: Increasing the load center of 500 mm

(20 in.) will reduce the lift capacity of the
handler.
The use of any attachment which has a net

weight greater than the weight of the standard
pallet fork will also reduce the lift capacity of
the handler correspondingly.
Always refer to the load chart related to the

attachment being used.
OUZXMAG,00010DA –19–27JUN01–1/1
130-3 072501
PN=180
Specifications
Tire Pressures
CAUTION: Never fill the tires with water or

water solution to increase the machine weight.
3800 Handler Front Rear

14.9-24 .................................................................. 260 kPa (2.6 bar; 38 psi) 210 kPa (2.1 bar; 30 psi)
460/70 R 24 .......................................................... 240 kPa (2.4 bar; 35 psi) 170 kPa (1.7 bar; 25 psi)
15.5/80-24 ............................................................. 260 kPa (2.6 bar; 38 psi) 210 kPa (2.1 bar; 30 psi)
19.5 LR 24 ............................................................ 240 kPa (2.4 bar; 35 psi) 170 kPa (1.7 bar; 25 psi)
17.5 LR24 ............................................................. 240 kPa (2.4 bar; 35 psi) 170 kPa (1.7 bar; 25 psi)
OUZXMAG,00010DB –19–27JUN01–1/1
Safety Note Regarding the Subsequent Installation of Electrical and Electronic

Appliances and/or Components
The machine is equipped with electronic components subsequently, the following extra requirements must be
whose function may be influenced by electromagnetic met:
radiation from other appliances. Such influences may
be hazardous, so take the following safety instructions • Only devices with an approval complying with the
into account: valid national regulation (i.e. BZT approval in
Germany) shall be installed;
No tampering with the handler’s on-board electrical • The device shall be installed securely;
system is permitted. Subsequent installation of • Portable or mobile devices may be operated in the
electrical/electronic appliances in the machine must vehicle only if connected to a fixed outside antenna;
make use of sockets and connectors provided for this • Transmitters shall be installed separately from the
purpose. In every case, the user must verify whether vehicle’s electronics;
the installation affects the electronics or other • The antenna must be installed in a professional
components. This applies particularly to: manner, with a good ground connection between the
antenna and the vehicle ground.
• Forward Stability Indicator
Wiring, installation and maximum permissible current
In particular, subsequently installed electrical/electronic supply must be as stated in the installation instructions
components must comply with the relevant edition of of the machine manufacturer.
EMC Directive 89/336/EEC, and be CE marked.
If mobile communication systems (e.g. radio

communication, telephone) are to be installed
130-4 072501
PN=181
Specifications
Declaration of Conformity
John Deere Werke Zweibrücken

Homburger Straße 117
D-66482 Zweibrücken
The Telescopic Handler:

Model .............................. 3800
complies with the EU provisions:

98/37/EEC .............. Machine Directive
89/336/EEC ............ EMC Directive
and EN1459 ............ Safety of Industrial Trucks
Zweibrücken 01 June 2001
–UN–09JUL01
ZXTHP
OUZXMAG,00010DC –19–27JUN01–1/1
130-5 072501
PN=182
Serial Numbers
Type Plates
Serial numbers identifying handler components or To ensure that you always have these numbers at
assemblies are stamped on components or factory hand, enter the appropriate serial numbers in the
serial number plates. spaces provided in each illustration.
These numbers and letters are required when ordering

parts or components for the handler.
Handler Type Plate
A—Product identification number

B—Homologation number (in certain countries only)
C—Model
D—Year of production
–UN–17JUN99
E—Version (in certain countries only)
F—Engine power
G—Absorption coefficient
H—French homologation purpose only
J—Permissible drawbar load
ZX017478
K—Permissible trailer load
L—Permissible rear axle load
M—Permissible front axle load
N—Permissible total weight
Product Identification Number
The plate bearing the product identification number is

located on the right side of the main frame.
–UN–02JUL01
ZX026416
OUZXMAG,00010DD –19–27JUN01–1/1
135-1 072501
PN=183
Serial Numbers
Front Axle Serial Number
The serial number plate is located on front of axle on the

right-hand side. The plate also gives the transmission ratio
of the front axle. This information will be required if the
type of tires used on the front wheel drive axle is to be
–UN–02JUL01
changed.
ZX026417
OUZXMAG,00010DE –19–27JUN01–1/1
Rear Axle Serial Number
The serial number plate is located on front of axle on the

right-hand side. The plate also gives the transmission ratio
of the rear axle. This information will be required if the
type of tires used on the rear wheel drive axle is to be
–UN–02JUL01
changed.
ZX026418
OUZXMAG,00010DF –19–27JUN01–1/1
Engine Serial Number
Engine serial number is located on left-hand side of the

engine.
–UN–09JUN00
ZX021692
Transmission Serial Number
Transmission serial number is located at the rear lower

part of the transmission case.
–UN–09JUN00
ZX021693
135-2 072501
PN=184
Serial Numbers
Torque Converter Serial Number
Torque converter serial number is located underneath the

hydraulic pump.1
–UN–09JUN00
ZX021694
1
Hydraulic pump removed for illustration purpose.
135-3 072501
PN=185
Index
Page Page
A B
Adjusting Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-4

Steering wheel height . . . . . . . . . . . . . . . . . . 25-10 Battery main switch . . . . . . . . . . . . . . . . . . . . . . 40-1
Steering wheel tilt . . . . . . . . . . . . . . . . . . . . . 25-10 Battery, access to. . . . . . . . . . . . . . . . . . . . . . . . 70-4
Air cleaner, changing . . . . . . . . . . . . . . . . . . . . 105-1 Battery, checking electrolyte level. . . . . . . . . . . . 85-2
Air cleaner, checking . . . . . . . . . . . . . . . . . . . . . 85-1 Battery, checking gravity. . . . . . . . . . . . . . . . . 115-14
Air cleaner, cleaning . . . . . . . . . . . . . . . . . . . . . 115-4 Beacon light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Air cleaner, replacing . . . . . . . . . . . . . . . . . . . . . 90-6 Beacon light switch. . . . . . . . . . . . . . . . . . . . . . . 20-6
Air Conditioning Precautions, Observing. . . . . . 115-2 Before starting the engine . . . . . . . . . . . . . . . . . 40-1
Air conditioning system. . . . . . . . . . . . . . . . . . . 25-15 Belt tension, checking. . . . . . . . . . . . . . . . .90-4, 90-5
Air intake hose, checking . . . . . . . . . . . . . . . . . . 90-5 Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-14
Air louvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-14 Boom
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-5 Approching a load . . . . . . . . . . . . . . . . . . . . . 55-11
Lifting unpalletized loads . . . . . . . . . . . . . . . . 55-14
Alternator V-belt . . . . . . . . . . . . . . . . . . . . . . . . 115-7
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-9
Approching a load . . . . . . . . . . . . . . . . . . . . . . 55-11
Picking up a load . . . . . . . . . . . . . . . . . . . . . 55-12
Armrest Position . . . . . . . . . . . . . . . . . . . . . . . . . 25-8
Placing a load . . . . . . . . . . . . . . . . . . . . . . . . 55-13
Armrest storage box . . . . . . . . . . . . . . . . . . . . . 25-16
Safety device . . . . . . . . . . . . . . . . . . . . .55-7, 55-8
As required
Boom extension, lubricating . . . . . . . . . . . . . . . . 90-8
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 115-4
Booster battery . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . 115-2
Brake system, pressure . . . . . . . . . . . . . . . . . . 115-6
Battery specific gravity . . . . . . . . . . . . . . . . 115-14
Break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Bleeding fuel system. . . . . . . . . . . . . . . . . . 115-10
Brake system pressure . . . . . . . . . . . . . . . . . 115-6
Cab air filters . . . . . . . . . . . . . . . . . . . . . . . . 115-3
Checking fuel filter . . . . . . . . . . . . . . . . . . . . 115-9 C
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . 115-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-15 Cab air filters . . . . . . . . . . . . . . . . . . . . .100-1, 115-3
Handling electrical connectors. . . . . . . . . . . . 115-1 Cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3
Lubricate grease point. . . . . . . . . . . . . . . . . 115-11 Cab interior light . . . . . . . . . . . . . . . . . . . . . . . . 25-10
Operator’s seat . . . . . . . . . . . . . . . . . . . . . . 115-11 Cab roof wiper . . . . . . . . . . . . . . . . . . . . . . . . . 25-12
Radiator Screens . . . . . . . . . . . . . . . . . . . . . 115-6 Can/cup holder . . . . . . . . . . . . . . . . . . . . . . . . . 25-17
Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-15 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-9
Replacing V-belt . . . . . . . . . . . . . . . . . . . . . . 115-7 Carrier pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-2
Starting motor . . . . . . . . . . . . . . . . . . . . . . . 115-12 Changing axle oil . . . . . . . . . . . . . . . . . .100-4, 100-5
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 115-13 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . 100-2
Tire pressure. . . . . . . . . . . . . . . . . . . . . . . . 115-11 Changing transmission oil. . . . . . . . . . . . . . . . . 100-3
Winterize cooling systen . . . . . . . . . . . . . . . . 115-3 Chock block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-5
Attaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3 Cigarette lighter . . . . . . . . . . . . . . . . . . . . . . . . 25-16
Attachments Coat hanger hook. . . . . . . . . . . . . . . . . . . . . . . 25-15
Attaching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3 Cold weather starting aids . . . . . . . . . . . . . . . . . 40-3
Auxiliary functions . . . . . . . . . . . . . . . . . . . . . . 60-4 Controls and instruments
Connecting hoses . . . . . . . . . . . . . . . . . . . . . . 60-6 Armrest control panel . . . . . . . . . . . . . . . . . . . 15-3
Detaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3 Cigarette lighter. . . . . . . . . . . . . . . . . . . . . . . 25-16
Front auxiliary hydraulic function . . . . . . . . . . . 60-4 Coolant temperature gauge. . . . . . . . . . . . . . . 15-7
General information. . . . . . . . . . . . . . . . . . . . . 60-1 Corner post . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
Mechanical rear hitch . . . . . . . . . . . . . . . . . . . 60-6 Forward stability indicator . . . . . . . . . . . . . . . . 15-9
Rear auxiliary hydraulic function . . . . . . . . . . . 60-5 Forward/reverse lever . . . . . . . . . . . . . . . . . . 15-12
Tip a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-7 Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Wagon hitch . . . . . . . . . . . . . . . . . . . . . . . . . . 60-7 Gear shift lever . . . . . . . . . . . . . . . . . . . . . . . 15-10
Axles, checking oil level in . . . . . . . . . . . . . . . . . 80-5 Gear shift switch . . . . . . . . . . . . . . . . . . . . . . 15-11
Index-1 072501
PN=1
Index
Page Page
General view. . . . . . . . . . . . . . . . . . . . . . . . . . 15-2 Engine, stalling of . . . . . . . . . . . . . . . . . . . . . . . . 40-5

Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8 Every three years
Indicator lights. . . . . . . . . . . . . . . . . . . . . . . . . 15-6 Replacing coolant . . . . . . . . . . . . . . . . . . . . . 110-1
Indicator, stability . . . . . . . . . . . . . . . . . . . . . . 15-9 Every two years
Load monitor. . . . . . . . . . . . . . . . . . . . . . . . . . 15-9 Changing air cleaner inner element. . . . . . . . 105-1
Multi-function lever . . . . . . . . . . . . . . . . . . . . . 15-5 Engine valve tappet clearance . . . . . . . . . . . 105-2
Outside mirrors . . . . . . . . . . . . . . . . . . . . . . . 15-13 Replacing coolant . . . . . . . . . . . . . . . . . . . . . 105-1
Rear mirror . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13 Every year
Roof console. . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 Cab air filters . . . . . . . . . . . . . . . . . . . . . . . . 100-1
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 15-8 Changing axle oil . . . . . . . . . . . . . . . .100-4, 100-5
Start switch . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10 Changing transmission oil . . . . . . . . . . . . . . . 100-3
Coolant Replacing hydraulic oil . . . . . . . . . . . . . . . . . 100-2
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . 65-7 Every 10 hours
Warm temperature climates . . . . . . . . . . . . . . 65-8 Carrier pivots . . . . . . . . . . . . . . . . . . . . . . . . . 75-2
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1 Checking hydraulic oil level . . . . . . . . . . . . . . . 75-3
Coolant, replacing. . . . . . . . . . . . . . . . . .105-1, 110-1 Checking transmission oil level . . . . . . . . . . . . 75-3
Cooling system, winterize . . . . . . . . . . . . . . . . . 115-3 Engine coolant level . . . . . . . . . . . . . . . . . . . . 75-1
Corner post . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8 Engine crankcase oil level. . . . . . . . . . . . . . . . 75-1
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1
Other service jobs. . . . . . . . . . . . . . . . . . . . . . 75-4
Every 250 hours
D Battery electrolyte level . . . . . . . . . . . . . . . . . . 85-2
Checking air cleaner element . . . . . . . . . . . . . 85-1
Daily checks . . . . . . . . . . . . . . . . . . . 35-1, 35-2, 35-3
Checking receiver-drier . . . . . . . . . . . . . . . . . . 85-2
Detaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3
Neutral start circuit . . . . . . . . . . . . . . . . . . . . . 85-2
Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . . 65-3
Wheel retaining bolts . . . . . . . . . . . . . . . . . . . 85-1
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-1
Every 50 hours
Digging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-16
Checking axle oil level . . . . . . . . . . . . . . . . . . 80-5
Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-11
Checking Parking Brake . . . . . . . . . . . . . . . . . 80-6
Dimensions
Lubricate all grease fittings . . . . . . 80-1, 80-2, 80-4
3800 Handler . . . . . . . . . . . . . . . . . . . . . . . . 130-3
Every 500 hours
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . .45-1, 45-2
Adjusting parking brake. . . . . . . . . . . . . . . . . . 90-8
Public roads . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Changing engine filter element . . . . . . . . . . . . 90-2
Reverse travel alarm. . . . . . . . . . . . . . . . . . . . 45-2
Changing engine oil . . . . . . . . . . . . . . . . . . . . 90-1
Changing fuel filter . . . . . . . . . . . . . . . . . . . . . 90-3
Checking air intake hose. . . . . . . . . . . . . . . . . 90-5
E Checking belt tensioner. . . . . . . . . . . . . .90-4, 90-5
Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . 90-4
Electrical connectors . . . . . . . . . . . . . . . . . . . . 115-1 Lubricating boom extension . . . . . . . . . . . . . . 90-8
Electrical starting aid . . . . . . . . . . . . . . . . . . . . . 40-4 Replacing air cleaner outer element . . . . . . . . 90-6
Engine Replacing hydraulic oil filter . . . . . . . . . . . . . . 90-7
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Replacing transmission oil filter . . . . . . . . . . . . 90-7
Engine crankcase oil level . . . . . . . . . . . . . . . . . 75-1 Every 750 hours
Engine filter element, changing. . . . . . . . . . . . . . 90-2 Checking engine speeds . . . . . . . . . . . . . . . . . 95-1
Engine oil
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-2
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-3
Engine oil, changing . . . . . . . . . . . . . . . . . . . . . . 90-1 F
Engine speeds . . . . . . . . . . . . . . . . . . . . . . . . . . 95-1
Engine valve tappet . . . . . . . . . . . . . . . . . . . . . 105-2 Falling-object protective structure . . . . . . . . . . . . 25-1
Engine warm-up period . . . . . . . . . . . . . . . . . . . 40-4 Foot brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Engine, shutting off. . . . . . . . . . . . . . . . . . . . . . . 40-5 Forks, pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Index-2 072501
PN=2
Index
Page Page
Forward stability indicator L

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2
Display unit test function . . . . . . . . . . . . . . . . . 55-5 Lift capacity limits . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Normal operation . . . . . . . . . . . . . . . . . . . . . . 55-3 Lights . . . . . . . . . . . . . . . . . . . . . . . . 20-1, 20-2, 20-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3 Lights, check . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1
Forward-Neutral-Reverse lever (FNR) . . . . . . . 15-12 Load indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2
Fuel Load monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-1 Lubricant
Handling and storing . . . . . . . . . . . . . . . . . . . . 65-1 Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-6
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-9 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-6
Fuel filter, changing . . . . . . . . . . . . . . . . . . . . . . 90-3 Lubricating grease fittings. . . . . . . . . 80-1, 80-2, 80-4
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-8 Lubrication
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3
Fuel system, bleeding. . . . . . . . . . . . . . . . . . . 115-10
Fuel tank, draining . . . . . . . . . . . . . . . . . . . . . . . 90-4
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . .70-4, 115-15
Fuses, access to . . . . . . . . . . . . . . . . . . . . . . . . 70-4 M
Machine safety . . . . . . . . . . . . . . . . . . . . . . . . . . 05-7

Manual Storage . . . . . . . . . . . . . . . . . . . . . . . . 25-16
G Mixing lubricants. . . . . . . . . . . . . . . . . . . . . . . . . 65-6
Multi-function lever . . . . . . . . . . . . . . . . . . . . . . . 15-4
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . .15-7, 15-8
Gear shift lever. . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Gear shift switch. . . . . . . . . . . . . . . . . . . . . . . . 15-11 N
Grease
Extreme pressure and multipurpose . . . . . . . . 65-5 Neutral start circuit, checking . . . . . . . . . . . . . . . 85-2
H O
Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-5

Handbrake adjustment . . . . . . . . . . . . . . . . . . . . 90-8 Operating machine . . . . . . . . . . . . . . . . . . . . . . . 05-7
Hazard warning lights . . . . . . . . . . . . . . . . . . . . . 20-4 Operating the boom
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-14 Lowering safely . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Hood, opening . . . . . . . . . . . . . . . . . . . . . . . . . . 70-3 Raising safely . . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5 Operating the engine
Hose unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5 Battery main switch. . . . . . . . . . . . . . . . . . . . . 40-1
Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8 Before starting the engine . . . . . . . . . . . . . . . . 40-1
Hydraulic Cold weather starting aids. . . . . . . . . . . . . . . . 40-3
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Electrical starting aid. . . . . . . . . . . . . . . . . . . . 40-4
Hydraulic oil filter, replacing . . . . . . . . . . . . . . . . 90-7 Stalling of engine . . . . . . . . . . . . . . . . . . . . . . 40-5
Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . 75-3 Starting the engine . . . . . . . . . . . . . . . . . . . . . 40-2
Hydraulic system, cleanliness. . . . . . . . . . . . . . 115-2 Stopping the engine . . . . . . . . . . . . . . . . . . . . 40-5
Warm-up period . . . . . . . . . . . . . . . . . . . . . . . 40-4
With booster battery . . . . . . . . . . . . . . . . . . . . 40-3
With slave battery . . . . . . . . . . . . . . . . . . . . . . 40-3
I Operating the machine
After first 100 hours . . . . . . . . . . . . . . . . . . . . 30-2
Identification view . . . . . . . . . . . . . . . . . . . . . . . . 00-1 Foot Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6 Transmission declutch. . . . . . . . . . . . . . . . . . . 50-5
Index-3 072501
PN=3
Index
Page Page
Operator’s cab Service intervals . . . . . . . . . . . 70-5, 70-6, 70-7, 70-8

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3 After first 100 hours . . . . . . . . . . . . . . . . . . . . 70-6
Operator’s seat. . . . . . . . . . . . . . . . . . . . . . . . 115-11 As required . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-8
Deluxe air suspension seat . . . . . . . . . . .25-6, 25-7 Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-5
Deluxe suspension seat . . . . . . . . . . . . . . . . . 25-5 Every three years . . . . . . . . . . . . . . . . . . . . . . 70-8
Other service jobs . . . . . . . . . . . . . . . . . . . . . . . 75-4 Every two years . . . . . . . . . . . . . . . . . . . . . . . 70-8
Outside mirrors. . . . . . . . . . . . . . . . . . . . . . . . . 15-13 Every 1000 hours . . . . . . . . . . . . . . . . . . . . . . 70-7
Overload situations. . . . . . . . . . . . . . . . . . . . . . . 55-6 Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . 70-6
Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . 70-6
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . 70-7
Every 750 hours . . . . . . . . . . . . . . . . . . . . . . . 70-7
P Seven terminal trailer socket . . . . . . . . . . . . . . . 20-7
Shifting transmission
Pallet forks PowerShift . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2 Synchro-Shuttle. . . . . . . . . . . . . . . . . . . . . . . . 50-3
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2 Slave battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-9 Socket, trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7
Parking brake, lubricating . . . . . . . . . . . . . . . . . . 80-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 130-1
Parking the machine. . . . . . . . . . . . . . . . . . . . . . 45-4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 130-3
Picking up a load . . . . . . . . . . . . . . . . . . . . . . . 55-12 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
Picking up a round bale . . . . . . . . . . . . . . . . . . 55-17 Start switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Placing a load . . . . . . . . . . . . . . . . . . . . . . . . . 55-13 Starting motor. . . . . . . . . . . . . . . . . . . . . . . . . 115-12
Starting the engine . . . . . . . . . . . . . . . . . . .40-2, 40-3
Steering wheel
R Height adjustment . . . . . . . . . . . . . . . . . . . . . 25-10
Steering Wheel
Tilt adjustment . . . . . . . . . . . . . . . . . . . . . . . 25-10
Radiator screen, cleaning . . . . . . . . . . . . . . . . . 115-6
Storage tray . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-17
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18
Storage, machine . . . . . . . . . . . . . . . . . . . . . . . 125-1
Rear mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
Storing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-1
Rear side windows . . . . . . . . . . . . . . . . . . . . . . . 25-4
Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . . 65-6
Rear window wiper . . . . . . . . . . . . . . . . . . . . . . 25-13
Sun visor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-11
Receiver-drier, checking . . . . . . . . . . . . . . . . . . . 85-2
Switches
Reduce fuel consumption . . . . . . . . . . . . . . . . . . 50-1
Battery cut-off . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Relays . . . . . . . . . . . . . . . . . . . . . . . . . .70-4, 115-15
Beacon light . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Removing machine from storage . . . . . . . . . . . 125-2
Boom work light . . . . . . . . . . . . . . . . . . . . . . . 20-6
Removing material from a pile . . . . . . . . . . . . . 55-15
Hazard warning lights . . . . . . . . . . . . . . . . . . . 20-4
Reverse travel alarm . . . . . . . . . . . . . . . . .20-7, 45-2
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
Roll-over protective structure . . . . . . . . . . . . . . . 25-1
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Roof console . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Turn signal lights. . . . . . . . . . . . . . . . . . . . . . . 20-5
Work lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
Safety decals . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 T

Safety rules for starting the engine . . . . . . . . . . . 40-1
Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4 Thermostat, replacing . . . . . . . . . . . . . . . . . . . 115-13
Serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . 135-1 Tires
Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Safety device . . . . . . . . . . . . . . . . . . . . . . . . . 70-1 Tires, checking pressure. . . . . . . . . . . . . . . . . 115-11
Service - Engine Tool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-15
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . 115-8 Towing machine . . . . . . . . . . . . . . . . . . . . . . . . 05-10
Index-4 072501
PN=4
Index
Page
Towing the machine . . . . . . . . . . . . . . . . . . . . . . 45-2

Trailer socket . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7
Transmission
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Transmission declutch . . . . . . . . . . . . . . . . . . . . 50-5
Transmission oil filter, replacing . . . . . . . . . . . . . 90-7
Transmission oil level . . . . . . . . . . . . . . . . . . . . . 75-3
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2
Round bale . . . . . . . . . . . . . . . . . . . . . . . . . . 55-18
Transporting machine . . . . . . . . . . . . . . . . . . . . 05-10
Travelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 120-1
Turn signal lights . . . . . . . . . . . . . . . . . . . . . . . . 20-5
Type plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . 135-1
Unpalletized loads . . . . . . . . . . . . . . . . . . . . . . 55-14

Unsafe operation . . . . . . . . . . . . . . . . . . . . . . . . 55-6
Wheel bolts, checking. . . . . . . . . . . . . . . . . . . . . 85-1

Windshield Guard . . . . . . . . . . . . . . . . . . . . . . . . 25-2
Windshield wiper . . . . . . . . . . . . . . . . . . . . . . . 25-12
Work light switches. . . . . . . . . . . . . . . . . . .20-5, 20-6
Index-5 072501
PN=5
Index
Index-6 072501
PN=6
John Deere Service Keeps You On The Job
John Deere Parts
We help minimize downtime by putting genuine John

Deere parts in your hands in a hurry.
That’s why we maintain a large and varied inventory—to

stay a jump ahead of your needs.
–UN–23AUG88
TS100
DX,IBC,A –19–04JUN90–1/1
The Right Tools
Precision tools and testing equipment enable our Service

Department to locate and correct troubles quickly . . . to
save you time and money.
–UN–23AUG88
TS101
DX,IBC,B –19–04JUN90–1/1
Well-Trained Technicians
School is never out for John Deere service technicians.
Training schools are held regularly to be sure our

personnel know your equipment and how to maintain it.
–UN–23AUG88
Result?
Experience you can count on!
TS102
DX,IBC,C –19–04JUN90–1/1
Prompt Service
Our goal is to provide prompt, efficient care when you

want it and where you want it.
We can make repairs at your place or at ours, depending

on the circumstances: see us, depend on us.
–UN–23AUG88
JOHN DEERE SERVICE SUPERIORITY: We’ll be around

when you need us.
TS103
DX,IBC,D –19–04JUN90–1/1
072501
PN=189

John Deere 3800 Telescopic Handler Manual

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John Deere Werke Zweibrücken

SETTING FUEL DELIVERY BEYOND PUBLISHED

The following checks, adjustments and service jobs

Signature Dealer/Service Technician: Date:

Identification View Work Light Switch. . . . . . . . . . . . . . . . . . . . . . . . 20-5

Lighting System and Signals Break-In Period

All information, illustrations and specifications in this manual are based on

Prestarting Checks Digging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-16

Service / Daily or Every 10 Hours Service / Every 2000 Hours or 2 Years

Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 130-2

This is a safety-alert symbol. When you see this symbol

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

Protect People and Animals

Never allow anyone to walk or work under a raised boom.

Be sure that people, livestock, or pets are not standing in

Do not lift or carry anyone on handler or in bucket or

Prevent Machine Runaway

Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals.

NEVER start engine while standing on ground. Start

Avoid Power Lines

Serious injury or death can result if handler contacts

Check height clearance before raising boom. –UN–20JAN01

Do not leave the operator’s seat if any part of handler

Before digging, check location of cables, gas lines and

Do not leave the operator’s seat if any part of handler

Avoiding Injury or Death from Falling Round

CAUTION: Improper use of handler to handle

- The bale rolling back down the handler boom

- A handler roll-over accident caused by

To help prevent personal injury or death caused

• DO NOT handle round bales unless handler is equipped

Transporting Round Bales Safely

To help prevent personal injury or accidents caused by a

Service Handler Safely

Always engage parking brake or place transmission in

Follow recommended procedures in this manual.

Before disconnecting hydraulic hoses, relieve all hydraulic

Do not climb on handler to service or lubricate. Use a

Keep all parts in good condition and properly installed. Fix

Hydraulic hoses can fail due to physical damage, kinks,

Use Seat Belt Properly

Use a seat belt when you operate the machine to

Work in Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is

Driving on Public Roads

Always check the road and general operating safety of the

Operate machine only when all guards are fitted and in

Before moving away, always check immediate vicinity of

Always adapt your ground speed to meet the ground

Reduce your ground speed when driving the machine on

Reversing at high speeds can cause accidents. Do not

Never drive near the edge of a gully or steep

Operating the Machine Safely

Keep Riders Off Machine

DCY