Case 1221E TIER 3 Wheel Loader Operator's Manual 84293354 - PDF DOWNLOAD

1221E TIER 3 Wheel Loader

1221E TIER 3 Wheel Loader

Operator’s Manual Print No. 84293354 NA English 12/09 Replaces p/n 87729387 ©2009 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC.

1221E TIER III WHEEL LOADERS OPERATOR’S MANUAL Part Number: 84293354

CASE TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Repair Manuals, and Maintenance records.

Always give the Machine Name, Model, and P.I.N. (Product Identification Number) or S.N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

NOTE: CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY M171D

Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ●

DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

●

WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

●

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ●

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW

●

Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ●

Is instructed in safe and proper use of the machine.

●

Reads and understands the Manual(s) pertaining to the machine.

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow CNH America LLC instructions on machine operation and maintenance.

WARNING_01_NA

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

Copyright © 2009 CNH America LLC All Rights Reserved

Rac 84293354NA Issued December 2009 Case is a registered trademark of CNH America LLC

TABLE OF CONTENTS CHAPTER 1 To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 CHAPTER 2 SAFETY, AND DECALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Front Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Attachment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Basic machine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Support Strut for Loader Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Engine Oil Viscosity / Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Maintenance Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Cab Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-3 7-5 7-7

CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CHAPTER 9 INDEX I

II

CHAPTER 1 - GENERAL INFORMATION

Chapter 1 TO THE OWNER

Figure 1

BD07G056

1221E Wheel Loader Read this manual before you start the engine or operate the machine. If you need more information, see your Case dealer.

This manual contains important information about the safe operation, adjustment, and maintenance of your machine. Refer to the index at the back of this manual for locating specific items about your machine. The wheel loader conforms to current safety regulations.

Use this manual as a guide. Your wheel loader will remain a reliable working tool as long as it is kept in good working condition and serviced properly.

Do not operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation, and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely. All persons who will be operating this machine shall possess a valid local vehicle operating permit and/or other applicable local age work permit.

With experienced and trained technicians, your Case dealer can provide the best methods of repair and maintenance for your machine. Your dealer can give you assistance with Case approved service parts.

The information in this manual is provided on the basis of information that was available at the time the manual was written. Settings, procedures, part numbers, software and other items can change. These changes can affect the service that is given to the machine. Ensure that you have complete and current information from your dealer before you start any machine operation.

This Wheel Loader, with standard equipment and attachments is intended to be used for digging and general earth moving purposes such as land leveling, truck loading, and material rehandling. This machine is not intended to be used for lifting other objects or transporting loads at high speeds.

1-1

CHAPTER 1 - GENERAL INFORMATION DO NOT use this machine for any application or purpose other than those described in this manual. If the loader is to be used in an application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer. Do not use any attachments not authorized by your dealer. Consult an authorized dealer on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications may cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

This Operator’s Manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact your dealer to obtain additional manuals. Contact your dealer for any further information or assistance about your machine.

Before permitting a new operator on this machine, make certain:

• That the operator has received the necessary training to operate the machine correctly and safely.

• That the operator has read and understands the instructions given in this manual.

Always keep this manual in the operator's compartment. Make sure it is always complete and in good condition. If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your dealer.

Your dealer is at your disposal for any further information. He will also provide any after-sales service you may require and genuine Case replacement parts, your guarantee of quality and match.

ATTENTION: The engine and fuel system on your machine is designed and built to government emissions standards. Tampering by dealers, customers, operators and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only!

1-2

CHAPTER 1 - GENERAL INFORMATION RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE

FRONT

BD06F071

Figure 2

OPERATOR’S MANUAL STORAGE COMPARTMENT The operator’s manual storage compar tment is located to the right of the operator’s seat. Always keep the manual in good condition and stored in this location.

READ THE MANUAL COMPLETELY and make certain you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability and load characteristics of this machine before you start to operate.

LEFT

RIGHT

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals. Also see the manual information on the inside of the rear cover of this manual.

When you see this symbol read your Operator’s Manual.

When you see this symbol refer to your Repair Manual.

REAR B891464

Figure 3

The terms Right-hand, Left-hand, Front, and Rear are used in this manual to indicate the sides as they are seen from the operator's seat.

1-3

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

Figure 4

BC08378A

MACHINE COMPONENTS

1-4

CHAPTER 1 - GENERAL INFORMATION IDENTIFICATION NUMBERS

PRODUCT IDENTIFICATION NUMBER (P.I.N.)

MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE Machine serial no.

When ordering par ts, obtaining infor mation or assistance, always supply your dealer with the type and serial number of your machine or accessories.

Write the following information in the spaces below: The type, serial number and year of manufacture of your machine, accessories and the serial numbers of the various hydraulic and mechanical components.

Make a record of the numbers and keep the record and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

HL7807A0FW02

Figure 5

ENGINE

PRODUCT IDENTIFICATION PLATE ➤ Model ➤ Serial Number ➤ Manufacturing Year

ENGINE

BC08H250

Figure 6

➤ Make and Model ➤ Serial Number

COMPONENT SERIAL NUMBERS ➤ Transmission ➤ Axle ➤ ROPS Cab ➤

1-5

CHAPTER 1 - GENERAL INFORMATION

NOTES

1-6

CHAPTER 2 - SAFETY, AND DECALS

Chapter 2 SAFETY, AND DECALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Use caution when working near power lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Safety Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-1

CHAPTER 2 - SAFETY, AND DECALS

NOTES

2-2

CHAPTER 2 - SAFETY, AND DECALS

SAFETY RULES WARNING This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

Most accidents involving machine operation and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual and the safety signs on the machine before you operate or service the machine. See your dealer if you have any questions.

PERSONAL SAFETY Safety Decals on this machine may use the words, Danger, Warning or Caution, which are defined as follows:

• DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

• WARNING: Indicates a potentially hazardous situation which, if not avoided will result in serious injury. The color associated with Warning is ORANGE. Figure 1

BD06F071

OPERATOR’S MANUAL STORAGE SPACE

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability, and load characteristics of the machine before you start to operate this machine.

DO NOT remove this manual or the safety manual from the machine. The manual should be stored in the pouch to the right of the operator’s seat. See your dealer for additional manuals. Also see the manual information on the Title pages (first and second pages in front of the Table of Contents) of this manual.

The safety information given in this manual does not replace safety codes, insurance needs, federal, state, or local laws. Make sure that your machine has the correct equipment according to these rules or laws.

• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. ISO two panel pictorial symbol decals are defined as follows:

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW. Prohibition symbols such as used, are RED.

and

STOP

if

Additional safety messages are used in the text of the manual to show specific safety hazards.

IMPORTANT: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine.

These safety messages also give possible ways of dealing with these conditions.

2-3

CHAPTER 2 - SAFETY, AND DECALS

UTILITY SAFETY Safety precautions MUST be followed when working near buried and overhead utility lines.

During operation it is likely that you will be working around or near buried or overhead utility lines which may include, but are not limited to:

• • • •

Electrical Power Line Gas Line Water Line Communication Line - Telephone or Cable Television

• Sewer Line IMPORTANT: Before beginning any machine operation, it is your responsibility to be aware of all such utility lines buried and overhead in the area of your project and to avoid them.

RH99G001

ALWAYS have all local utility companies mark the location of their lines.

In U.S.A. and Canada, call one of many “One Call System Directory” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

IMPORTANT: Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

VOLTAGE (VOLTS)

SAFETY DISTANCE

50K OR LESS

10ft. (3.0M)

50K TO 200K

15ft. (4.5M)

200K TO 350K

20ft. (5.0M)

350K TO 500K

25ft. (7.5M)

500K TO 750K

35ft. (10.5M)

750K OR OVER

45ft. (13.5M)

WARNING Contact with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution. Keep machine and attachments a safe distance from electrical power lines. Failure to comply could result in injury or death.

2-4

Figure 2

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

CHAPTER 2 - SAFETY, AND DECALS USE CAUTION WHEN WORKING NEAR POWER LINES

• Contact

with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station.

• Keep all parts of the machine a safe distance away from the power source. See the decal on the machine. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

If a part of the machine touches high voltage power:

GENERAL

• It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Do not operate this machine or perform maintenance work if you have not had appropriate training. Read and fully understand all the instructions and warnings in this manual.

• Wear the seat belt to maximize the protection capability of a ROPS (Roll Over Protective Structure) when the machine is so equipped.

• Inspect the ROPS and seat belt mounting bolts on a daily basis to insure their integrity.

1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

• Do not permit riders on the machine if there is no

2. If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area. If you cannot break contact stay in the machine until the utility company de-energizes the line and tells you that the power is off.

• Make sure that all protective guards, canopies,

manufacturer’s designated place for a rider. doors, etc. are in place and secure.

• Remove all loose objects stored in the machine.

Remove all objects which do not belong in or on the machine and its equipment.

PERSONAL

• Be prepared for emergencies. Always have a first aid kit and a working fire extinguisher with you and know how to use each.

• Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles.

• Know and use the protective equipment that is to be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of equipment that may be required.

• Certain protective equipment should be replaced and renewed upon age and wear. Old hard hats may not afford the original intended protection.

Faded and soiled vests are no longer as highly visible as the original intent. See the manufacturer’s recommendation.

• Do not rush. Walk, do not run.

• Know and use the hand signals required for particular jobs and know responsibility for signaling.

who

has

the

2-5

CHAPTER 2 - SAFETY, AND DECALS MOUNTING AND DISMOUNTING PRECAUTIONS

• Use battery booster cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using booster cables. Make sure that using booster cables will not interfere or harm electronic processing or computer devices.

• Do not operate the engine in an enclosed area without adequate ventilation.

• Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the wheels securely blocked.

• Before leaving the operator’s station, lower the BD07A003-1

Figure 3

• Use the recommended hand holds and steps with at least three points of support when getting on and off the machine. The door must be latched and secured in the open position before using the door hand hold. Keep steps and platform clean.

Face the machine and use the hand holds and steps adhering to a three-point access system when climbing up and down.

• Do not use any control levers as hand holds when mounting or dismounting.

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

• Foreign material or grease on the steps and hand holds can cause an accident. Keep the steps and hand holds clean.

STARTING AND STOPPING PRECAUTIONS

• Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn, if equipped, before starting.

• Walk around the machine’s tool, attachment, or furthermost contact point to view operation danger area from the work site personnel’s view and angle.

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer, and disengage the PTO, if so equipped, before starting the machine.

• Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

• Start and operate the machine only from the operator’s station.

• Do not bypass the machine’s neutral-start system. The neutral-start system must be repaired if it malfunctions.

2-6

bucket/attachment to the ground, shut off the engine.

• Remove the starter key and/or use the disconnect switch when leaving the machine parked or unattended.

OPERATING PRECAUTIONS

• Check brakes, steering and other machine control devices in accordance with the manufacturer’s instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key or disconnect switch key. Place a DO NOT OPERATE tag on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as steering, service brakes, or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key. Place a DO NOT OPERATE tag on the machine, and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

• Understand the machine limitations, and keep the machine under control.

• Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires, or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

CHAPTER 2 - SAFETY, AND DECALS

• Know and understand the job site traffic flow

• Be alert and always know the location of all

patterns and obey signalmen, road signs, and flagmen.

workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

• Know and understand that job site conditions may change on an hourly basis. Hills of dirt, debris or obstructions may grow and change from the time you began the day. It is your responsibility to monitor the changes and keep the machine, tools and attachments, etc. a safe distance.

• Watch for bystanders and never allow anyone to

• Develop fluid and smooth operating techniques, and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

MAINTENANCE PRECAUTIONS

be under or to reach through the machine and its equipment while operating.

• Do not attempt repairs unless trained. Refer to

• Select a gear that will prevent excessive speed

manuals and experienced repair personnel for help.

when going downhill. Do not coast downhill.

• When roading a machine, know and use the signaling devices required on the machine.

Provide an escort for roading where required.

• On machines with independently operated wheel brakes, lock the brake pedals together when roading to provide equalized brake application.

• Use the recommended transport devices when roading the machine. Proper lights, flashers, signals, and beacons may be required. Use reflective slow moving vehicle signs where necessary. Follow local, state, and federal regulations.

• Use the approved drawbar and/or attachment point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Before you operate at night, check that all lamps illuminate.

• If your machine has a cab, make sure that all windows are clean and that the windshield wipers and washers work correctly.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Check all controls in a clear area and make sure the machine is operating correctly.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

• Do not operate the machine if you do not feel well. This can be dangerous for you and for the people around you.

• You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Before you service the machine, put a DO NOT OPERATE tag on the key switch. Make sure that the machine is clearly “tagged out”.

• Wear protective glasses and other required safety equipment when servicing or repairing the machine.

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the bucket/attachment in a safe position, securely block the wheels and use extreme caution.

• Do not touch exhaust pipe after operating machine, hot components can cause severe burns.

• Securely block the machine or any component that may fall before working on the machine or component. If possible, use a back up or secondary blocking device as well.

• To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges.

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

• Use extreme caution when removing radiator, reservoir, or tank caps, drain plugs, grease fittings or pressure taps. Park the machine and let it cool before opening a pressurized tank.

• Release all pressure before working on systems which have an accumulator.

2-7

CHAPTER 2 - SAFETY, AND DECALS

• Use a piece of cardboard, newspaper, or wood to check for any pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturer’s recommendations.

• When inflating tires, use a self-attaching inflation chuck with remote shutoff and stand clear of the tire. Position yourself beside the tire and not beside the rim.

• Towing this machine is not recommended.

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine has insufficient braking capabilities, a towbar must be used or two towing machines must be used - one in front pulling and one in the rear to act as a brake. Avoid towing over long distances.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alt: Use a brass hammer, drift or suitable material on the pin, etc.

• Keep the brakes and steering systems in good operating condition.

• Replace all missing, illegible or damaged safety signs or decals as necessary. Keep all safety signs and decals clean and legible.

FUEL HANDLING PRECAUTIONS

• Do not smoke or permit open flames while fueling or near fueling operations.

• Never remove the fuel cap or refuel gasoline or diesel engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow spilled fuel to contaminate the environment.

• To avoid spilling fuel, maintain control of the fuel filler nozzle when filling the tank.

• Do not fill the fuel tank completely to the top.

Allow room for expansion.

• Clean up spilled fuel immediately and dispose of contaminated material in an environmentally correct manner.

• Tighten the fuel tank cap securely. Should the fuel cap be lost, replace it only with the original manufacturer’s approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• Never use fuel for cleaning purposes.

• Use the correct diesel fuel grade for the operating season.

2-8

BURN PREVENTION

WARNING BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote: EXTERNAL - Flush with water.

Antidote: INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately.

BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away.

Ventilate when charging or using in enclosed area.

Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. Failure to comply could result in serious injury or death.

M144B

• When the battery electrolyte is frozen, the battery can explode if, you try to charge the battery, or if you try to boost start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

• Hot coolant can spray out if the cooling system cap is removed. To remove the cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the cooling system tank cap.

CHAPTER 2 - SAFETY, AND DECALS HAZARDOUS CHEMICAL PRECAUTIONS

TRANSPORTING PRECAUTIONS

• If you are exposed to or come in contact with

K n ow t h e r u l e s, l aw s, a n d s a fe t y e q u i p m e n t necessary for transporting this machine on a road or highway.

hazardous chemicals you can be seriously injured.

The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

• Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. This information is available from your dealer.

FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. Contact your dealer for the type and location of a fire extinguisher on this machine.

• Before you service your machine, check the MSDS for each fluid, lubricant, etc., used in this machine. This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine.

• Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

• Check with your local environmental or recycling center or your information.

dealer

for

correct

disposal

2-9

CHAPTER 2 - SAFETY, AND DECALS SEAT BELT PRECAUTIONS

WARNING Securely fasten your seat belt. Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

Failure to comply could result in serious injury or death.

1 2

M437

Figure 4

BD06G176

SAFETY LOCK LEVER

1. RIGHT-HAND BELT STRAP 2. LATCH MECHANISM

Unlock

Lock

1. Insert the metal end of the right-hand belt strap into the latch mechanism on the left-hand side of the seat.

2. Tighten the seat belt by pulling on the loose end of the right-hand seat belt.

Figure 6

77071SH01

When leaving the machine, always place the safety lock lever in the LOCK position. This lever locks out the hydraulic functions on the machine.

WARNING Figure 5

BD06G176

1. To unlatch the seat belt, press the red button on the left-hand side latch mechanism.

WARNING Before starting the engine insure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained.

Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. Failure to comply could result in serious injury or death.

M422A

2-10

Always use the lock out lever to lock out the hydraulic functions before exiting the machine.

Failure to comply could result in serious injury or death.

CHAPTER 2 - SAFETY, AND DECALS

• Never smoke while refueling.

SPECIFIC PRECAUTIONS TO THIS MACHINE

• Keep the load or bucket/attachment as low as possible while moving the machine around the jobsite.

LOADER LIFT ARM SUPPORT

WARNING If you service the machine with the loader lift arms raised, always use the support strut.

1. Empty the loader bucket, raise the loader lift arms to approximately 7 ft. (2.1m) and stop the engine.

2. Remove the support strut from the storage position by removing the retaining bolt.

3. Place the support strut onto the cylinder rod with guide lock tab on top of cylinder and pointing toward the bucket.

4. Install the retaining bolt entirely into the support strut using all threads.

5. Slowly lower the lift arms onto the support strut.

If you do not follow this procedure, you can cause death or serious injury if the loader lift arms are lowered unexpectedly. Failure to comply could result in serious injury or death.

M824

TRANSPORT SERVICE LINK

Figure 7

BD06G098-01

SERVICE LINK IN OPERATING POSITION

Figure 8

BD06G099-01

SERVICE LINK IN LOCKED POSITION

Prior to any maintenance, service work or transportation, lock the articulation transport service link. Remove the safety security pin to change positions of the service link.

2-11

CHAPTER 2 - SAFETY, AND DECALS

DECALS Safety decals are placed on your machine as a guide for your safety. Walk around the machine, and note the content and location of these decals before operating your machine.

WARNING An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary. Failure to comply can result in machine damage, injury, or death.

CE-NA000

WARNING Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part. Failure to comply can result in machine damage, injury, or death.

CE-NA000

NOTE: When you clean the decals, use only a cloth, water and soap. Do not use solvents, gasoline, etc.

NOTE: This chapter only covers decals relating to safety and machine operation and servicing. For information on all decals for the machine, consult your authorized dealer.

384270A1A

Figure 9

This symbol instructs you to refer the Operator’s M a n u a l fo r f u r t h e r i n fo r m a t i o n r e g a r d i n g maintenance, operational guidelines, etc.

BC00G075

Figure 10

This symbol instructs you to refer to the Service Manual. If you doubt your ability to perform service operations, contact your authorized dealer.

Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label.

2-12

CHAPTER 2 - SAFETY, AND DECALS SAFETY DECAL LOCATION

2

1

Figure 11

BS08G306

1. Warning: Use seat belt crush hazard decal - located inside operator’s compartment 2. North American decal number 321-7030

4

3

BS08G306/ 382622A1/256147A1

Figure 12

3. Warning: Read Operator’s Manual 4. North American decal number - 382622A1

2-13

CHAPTER 2 - SAFETY, AND DECALS

6

5

Figure 13

BS08G306/329051A1

5. Emergency/Alternate Exit 6. Decal number - 329051A1

8

7

BS08G306/ 91:B-01340

7. Emergency Hammer 8. Decal number - 91LB-01340

2-14

Figure 14

CHAPTER 2 - SAFETY, AND DECALS

10

9

Figure 15

BS08G311/ 87453132/407741A1

9. Crush hazard danger 10. North American decal number - 87453132

12

11

BS08G311/ 323694A1/329048A1

Figure 16

11. Crush hazard warning - Keep Clear 12. North american decal number - 323694A1

2-15

CHAPTER 2 - SAFETY, AND DECALS

14

13

Figure 17

BS08G306/ 329047A1/329048A1

13. Crush hazard warning - Engage lock link 14. North American decal number - 329047A1

16

15

BS08G306/ 328904A1./87597330

15. Pressurized system warning - Relieve pressure 16. North American decal number - 328904A1

2-16

Figure 18

CHAPTER 2 - SAFETY, AND DECALS

18

17

Figure 19

BS08G306/ 329049A1./329050A1

17. Runover hazard warning - Block wheels 18. North American decal number - 329049A1

20

19

BS08G306/ 328904A1./87597330

Figure 20

19. Pressurized system warning - Relieve pressure 20. North American decal number - 328904A1

2-17

CHAPTER 2 - SAFETY, AND DECALS

22

21

Figure 21

BS08G312/ 387585330/388113A1

21. Belt entanglement hazard warning 22. North American decal number - 387585330

24

23

BS08G312/412471A1/412476A1

23. Battery explosion hazard - danger 24. North American decal number - 412471A1

2-18

Figure 22

CHAPTER 2 - SAFETY, AND DECALS

26

25

Figure 23

BS08G312/328752A1/328753A1

25. Run over hazard danger 26. North American decal number - 328752A1

28

27 BS08G312/412471A1/412476A1

Figure 24

27. Crush hazard - danger 28. North American decal number - 325784A1

2-19

CHAPTER 2 - SAFETY, AND DECALS

30

29

BS08H864/328752A1/328753A1

29. Run-over hazard - danger 30. North American decal number - 328752A1

2-20

Figure 25

CHAPTER 2 - SAFETY, AND DECALS

32

31

Figure 26

BS08H865/334456A1/334455A1

31. Run-over hazard - danger 32. North American decal number - 334456A1

34

33

BS08H865/334456A1/334455A1

Figure 27

33. Hot liquid under pressure - warning 34. North American decal number - 329044A1

2-21

CHAPTER 2 - SAFETY, AND DECALS

36

35

Figure 28

BS08H867/8603092/8609095

35. Do not use ether- warning 36. North American decal number - 8603092

38

37

BS08H867328904A1/328903A1

37. Pressurized system hazard - warning 38. North American decal number 328904A1

2-22

Figure 29

CHAPTER 2 - SAFETY, AND DECALS

40

39

Figure 30

BS08H867/E134402

39. Do not step- warning 40. Decal number E134402

R Ride control (If equipped) 304083A1/123894A1

Reflector Figure 31

2-23

CHAPTER 2 - SAFETY, AND DECALS HAND SIGNALS When operating the machine, never attempt to carry out tasks calling for fine control or to work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

Figure 32

BI97D059-01

START THE ENGINE

STOP THE ENGINE

Figure 33

BP97D022-01

BP97D023

Wave hands back and forth (palms outward).

Wave hands back and forth (palms inward).

Figure 36 GO THIS FAR

FIGURE 35

MOVE AWAY FROM ME

COME TO ME

BP97D030-01

Figure 34

BI97D025

Figure 37

BI97D029-01

STOP

Move one hand back and forth.

2-24

CHAPTER 2 - SAFETY, AND DECALS

Figure 38

BI97D028-01

Figure 40

BI97D021-01

RAISE LOAD OR TOOL

EMERGENCY STOP

Move both hands back and forth.

Figure 39

BP97D060-01

ALL STOP AND HOLD

Figure 41

BI97D027-01

LOWER LOAD OR TOOL

2-25

CHAPTER 2 - SAFETY, AND DECALS

Figure 42

BI97D020-01

RAISE LOAD OR TOOL SLOWLY

LOWER LOAD OR TOOL SLOWLY

Figure 43

BI97D034-01

Figure 45

BI97D026-01

Figure 46

BI97D033

TURN MACHINE LEFT SWING LOAD LEFT

TURN MACHINE RIGHT SWING LOAD RIGHT

To stop movement, stop moving hand and make a fist.

To stop movement, stop moving hand and make a fist.

Figure 44

BP97D057-01

RAISE BOOM

2-26

Figure 47

BI97D055-01

LOWER BOOM

CHAPTER 2 - SAFETY, AND DECALS

Figure 48

BP97D057-01

RETRACT ARM

EXTEND ARM

Figure 49

BI97D026-01

FILL TOOL

Figure 50

BI97D033

Figure 51

BI97D055-01

EMPTY TOOL

2-27

CHAPTER 2 - SAFETY, AND DECALS

NOTES

2-28

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS Access Doors and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Inside Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Standard Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Optional Air Ride Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Cancellation Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Steering Wheel Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Parking Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Transmission Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Forward-Neutral-Reverse Control Lever (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Kick Down Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Horn And Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Windshield Washer and Wiper Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Work Light Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Mirror Defrost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Cab Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Beacon Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Auto Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Emergency Steering Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Voltage gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Directional Signal Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mirror Defrost Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Beam Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declutch Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preheat Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Overheat Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Pressure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Error Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Temperature Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charge Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Fuel Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17 3-17 3-17 3-18 3-18 3-19 3-19 3-20 3-20 3-20 3-20 3-20 3-20 3-21 3-21 3-21 3-21 3-22 3-22 3-22 3-22 3-23 3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS Forward-Neutral-Reverse Select Lamp (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 SteerIng System Warning Lamp (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 Emergency Steering Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 Liquid Crystal Display (LCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 Normal Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 Navigating through multi-function screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Air Conditioner Switch (Compressor Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Temperature Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Outlet Change Over Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Inlet Change Over Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Air Louvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 12 Volt Accessory Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 Radio and Cassette (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 Radio and CD Player (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 Radio Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS ACCESS DOORS AND COVERS

MASTER ELECTRICAL DISCONNECT SWITCH

Figure 1

BC08H386

KEY CYLINDER LOCKS

The hood, left, and right side engine covers allow access to both engine sides, air cleaner and coolers.

Use the ignition key to open and lock these covers.

1. Insert the key. Make sure to completely insert the key for proper operation. Damage can occur to the key or locking mechanism if key is improperly inserted and turned.

2. After releasing the lock, remove the key and open the cover.

BC08H278

Figure 2

The master disconnect switch is located in the compartment at the right rear of the machine. The m a s t e r e l e c t r i c a l d i s c o n n e c t sw i t c h h a s t w o positions: ON and OFF. MASTER ELECTRICAL SWITCH ON The master disconnect switch in the ON position energizes the entire electrical system. When the master disconnect switch is ON and the key switch is OFF, the dome lamp, horn, stop lamps, four-way flashers, and rotary light switch are powered and functional.

MASTER ELECTRICAL SWITCH OFF

WARNING

In the OFF position, all machine power is interrupted.

Before undertaking any travel, make sure the side doors are properly closed. Failure to comply could result in injury or death.

IMPORTANT: DO NOT use the master electrical disconnect switch to stop the engine.

CE-NA000

WARNING Keep hands clear of the hood as it closes. Keep all personnel clear of the hood as it closes. Failure to comply could result in injury or death.

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS STEPS AND HAND HOLDS

CAB DOOR Use the ignition key to lock or unlock door from outside the machine. Use the door handle to open the door from the outside.

WARNING Always maintain three point support while getting on and off the machine and entering or exiting the operator’s cab. A three point support system has been provided that enables a person to use simultaneously two hands and one foot or two feet and one hand while ascending, descending or moving about the machine. Failure to comply could result in injury or death.

CE-NA000

To lock in place, open the door completely until it latches in place against the cab. To close the door, use the door release knob.

IMPORTANT: The cab door must be locked into the full open or full closed position before using the door hand hold.

NOTE: The key provided with the machine can be used to lock and unlock the various panels and to activate the engine starter switch functions.

WARNING INSIDE DOOR LATCH Clean the steps and hand holds and remove all traces of grease, oil, mud, and ice in winter. Failure to comply could result in injury or death.

To secure the door in the open position, push the door back until the door locks on the door catch at the rear of the cab.

CE-NA000

Push the latch to open the door from the inside.

WINDOWS To release the window from the full open position, pull on the window release in the right hand rear corner of the cab.

EMERGENCY EXIT The right hand window of the cab can be used as an emergency exit. Be proactive and open and close the emergency window exit as a safety measure to become familiar with its operation.

BD06F163-1

Figure 3

When getting down from or getting onto the machine, use the steps and hand holds. Use at least three points of suppor t when getting on and off the machine. The cab door must be locked into the full open or full closed position before using the door hand hold.

3-4

CHAPTER 3 - INSTRUMENTS AND CONTROLS STANDARD OPERATOR’S SEAT

1 4

Figure 4

BD06F051-01

1. LUMBAR ADJUSTMENT KNOB: Turn the knob clockwise to increase the lumbar support. Turn the knob counterclockwise to decrease the lumbar support.

Figure 7

BD06F052-01

4. SLIDE ADJUSTMENT LEVER: Pull the slide adjustment lever up and adjust the seat forward or backward as required. Release the lever to lock the seat in position.

2 5

Figure 5

BD06F047-01

2. ARMREST HEIGHT CONTROL ADJUSTMENT: Turn the knob to raise or lower the armrest to the desired position.

NOTE: Each armrest will pivot to the up position.

BD06F048

Figure 8

5. WEIGHT ADJUSTMENT KNOB: To adjust the seat for your weight, pull the release lever away from the knob. Use the release lever to turn the knob clockwise to increase the weight resistance. Turn the knob counterclockwise to decrease the weight resistance. Adjust the seat to operator preference and comfort.

HEIGHT ADJUSTMENT, STANDARD SEAT:

3

BD06F046-01

Lift the seat all the way up, drop the seat to the lowest position. Lift the seat to the desired position. The seat will lock into accepted position.

Figure 6

3. RECLINER ADJUSTMENT HANDLE: Lift up on handle, move the backrest to the desired position, release the handle to lock in position.

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPTIONAL AIR RIDE SEAT

1

2

4 Figure 11

BD06G182-01

Figure 9

BD06G181-01

1. LUMBAR ADJUSTMENT KNOB: Turn the knob clockwise to increase the lumbar support. Turn the knob counterclockwise to decrease the lumbar support.

4. SLIDE ADJUSTMENT LEVER: Pull the slide adjustment lever, and adjust the seat forward or backward as required. Release the lever to lock the seat in position.

2. ARMREST HEIGHT CONTROL ADJUSTMENT: Turn the knob to raise or lower the armrest to the desired position.

NOTE: Each armrest will pivot to the up position.

5 BD06G182-01

3

BD06F046-01

Figure 12

5. HEIGHT ADJUSTMENT HANDLE:

Figure 10

3. RECLINER ADJUSTMENT HANDLE: Lift up on the handle, move the backrest to the desired position, release the handle to lock the backrest in position.

A. (Automatic Adjustment): With the operator sitting in the seat, lift the handle UP until the desired height is reached. Release the height adjustment tab. Perform a “hop” movement, briefly removing weight from the seat, then regain sitting position and reapply weight. This will reset the height latch.

B. To lower the seat, push down and hold the height adjustment tab until the desired height is reached. Release the height adjustment tab and perform the “hop” movement, briefly removing weight from the seat, then regain sitting position and reapply weight. This will reset the height latch.

NOTE: If the “hop” movement is not performed, the seat will return to its former latch point.

C. (Manual Adjustment): The seat can be raised or lowered by increasing or decreasing the air pressure in the seat. Lift the handle UP to increase the air pressure. Push the handle DOWN to decrease the air pressure and lower the seat.

3-6

CHAPTER 3 - INSTRUMENTS AND CONTROLS

9

6 7

BD06G182-01

Figure 13

6. SEAT DEPTH HANDLE: Lift handle up and move the cushion to the desired position. Release the handle to lock the cushion in place.

7. SEAT CUSHION ANGLE ADJUSTMENT HANDLE:

BD08K003-01

Figure 15

9. HEATED SEAT SWITCH An additional feature for operator comfort is the heated seat switch. This switch is located on the upper left hand side of the seat back and allows heat to circulate through the operator’s seat. Move the switch to the ON or OFF position as desired.

Lift up on the handle. Move the seat to the desired angle. Release the handle to lock the cushion angle.

8

BD06G183-01

Figure 14

8. RIDE CUSHION ADJUSTMENT LEVER The seat suspension can be adjusted to various operating conditions in order to gain the most comfortable ride for the operator.

The cushion adjustment lever has four positions from soft to hard in order to allow for maximum comfort over varying or rough terrain.

The first adjustment is with the small end of the adjustment lever pointing toward the front of the seat, as shown. The other three adjustments can be obtained by rotating the small end of the adjustment l ev e r o u t a w ay f r o m t h e s e a t . E a c h o f t h e adjustments has a slight detent.

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

BD07J105-01

Figure 16

The seat belt must be worn and properly adjusted before starting the machine.

Insert the metal end of the right-hand belt strap into the latch mechanism on the left-hand side of the seat. Tighten the seat belt by pulling on the loose end of the right hand seat belt.

BD07J106-01

Figure 17

To unlatch, press the red button on the left-hand side latch mechanism.

3-8

CHAPTER 3 - INSTRUMENTS AND CONTROLS CANCELLATION LEVER

BC08H2226

FOOT PEDALS

Figure 18

When the cancellation lock lever is turned to the LOCK position, the hydraulic controls will not operate. Put the lever in the lock position when leaving the machine.

STEERING WHEEL TILT CONTROL

BC08H313A

Figure 20

BRAKE PEDAL The brake pedal will actuate the machine brakes when pushed.

NOTE: The pedal will work in conjunction with the transmission declutch switch for more efficient braking. See Declutch Switch in Operating Instructions- Chapter 4 for further information.

IMPORTANT: On steep slopes using the down shift mode of the transmission is recommended to aid braking and to help prevent brake overheating and premature disc wear.

NOTE: When the machine is shut off, the parking brake is automatically set.

BC08H166

Figure 19

The steering wheel tilt control allows the steering wheel to be adjusted to multiple positions. Pull the handle down, and adjust the steering wheel to the correct and most comfortable angle. Pull the handle up and the wheel will telescope in height. Release the control to hold in that position. Tilt the steering wheel completely up when leaving the machine.

Always adjust the steering wheel to the correct position before starting the engine.

BC08H313A

Figure 21

FOOT THROTTLE Push the foot throttle to increase engine speed.

When the pedal is released the engine runs at low idle.

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS PARKING BRAKE

TRANSMISSION CONTROL LEVER The transmission control lever is used to shift the transmission gears from first through fourth gear.

Turn the transmission control lever away from you to select a higher gear. Turn the lever toward you to select a lower gear. This control lever is also used to put the transmission in FORWARD, NEUTRAL, and REVERSE (F-N-R).

BC08H201

Figure 22

PARKING BRAKE SWITCH Make sure the machine has come to a complete stop before applying the parking brake.

The parking brake button engages the parking brake on the transmission output shaft.

IMPORTANT: The parking brake is a spring applied, hydraulic released brake which is applied to the drive shaft. It will effectively hold the machine in place when used correctly.

ENGAGING THE PARKING BRAKE To engage the parking brake, move the gearshift lever to neutral N, stop the machine and engage the brake by pushing down on the top of the switch. The parking brake will automatically engage when the machine is shut off.

IMPORTANT: A failure in the operating procedure or a failure in the electrical or hydraulic function can result in abrupt engagement of the parking brake.

Always wear your seat belt.

PARKING BRAKE RELEASE NOTE: The service brake must be at operating pressure before the parking brake can be released to move the machine. The brake pressure indicator lamp must not be illuminated when disengaging the parking brake. Attempting to move the machine prior to the service brake pressures being sufficient causing low operating pressure can result in premature parking brake pad wear.

3-10

BD06F160-01

Figure 23

A. Move the control lever away from you for FORWARD. The machine has 4 forward gears (low to high). Turn the knob to change the gear from low to high.

B. The center position of the control lever is NEUTRAL. C. M ove t h e c o n tr o l l eve r towa r d yo u fo r REVERSE. The machine has 3 reverse gears (low to high). Turn the knob to change the gear from low to high.

The F-N-R function of the transmission control lever may be moved to the loader control lever for operating efficiency.

CHAPTER 3 - INSTRUMENTS AND CONTROLS FORWARD-NEUTRAL-REVERSE CONTROL LEVER (OPTIONAL) Using transmission Forward-Neutral-Reverse (FNR) control on the left side of steering column All the following steps are required: 1. Service brake pressure must be at operating pressure.

2. Transmission control lever must be in neutral.

3. Push down on the bottom of the parking brake switch to release the parking brake switch.

NOTE: If the parking brake was NOT set when the machine was turned off, the parking brake switch must be cycled at step 3.

4. Place the transmission control lever in either FORWARD or REVERSE to move the machine.

BC08H316

Figure 24

Using transmission Forward-Neutral-Reverse (FNR) control on the hydraulic controller lever All the following steps are required: 1. Service brake pressure must be at operating pressure.

2. Left side FNR of transmission control lever must be in Neutral.

3. Right side FNR switch must be in Neutral.

4. Machine speed must be zero.

5. Engine must be running.

6. When the upper side of the switch is pushed, the machine moves forward.

7. When the lower side of the switch is pushed, the machine moves backward.

NOTE: The function is automatically released when the engine is stopped, parking brake is on, or gear selector lever is out of neutral.

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS KICK DOWN SWITCH

AUTO SELECT SWITCH

Down shift button

Kick down ON/OFF

BC08J315A/BC08H315B

Figure 25

The kick down switch can be operated manually or in the automatic mode. Turn the switch on and off with the buttons on top of the control. Press the button on the front of the control to shift.

The switch can be used in either a manual mode or automatic mode.

Manual Mode The kick down switch allows manually shifting down from second speed to first speed and then back up to second speed by pushing the switch.

Automatic Mode In automatic mode, the gear will shift up and down automatically, as the load requires.

3-12

BD08H205

Figure 26

The autoshift switch is used to select the automatic or manual mode of operation for the transmission.

Automatic Mode When the autoshift switch is in the ON position, the transmission will automatically shift up and down between 1st or 2nd and the highest speed setting on the transmission lever (see Transmission Operation in this manual for complete operation).

Manual Mode Press the top of the switch for manual mode. The operator can then select the desired speed and direction with the gear selector lever.

CHAPTER 3 - INSTRUMENTS AND CONTROLS HORN AND TURN SIGNAL

IGNITION SWITCH

Figure 27

BC08H129

(1) HORN: Push the horn lever in to actuate the horn.

BC00B064

IMPORTANT: Always sound the horn prior to starting the machine.

(2) TURN SIGNAL LEVER Push the lever up for left turn signal, pull the lever down for right turn signal.

BC00B087

WINDSHIELD WASHER AND WIPER LEVER

Figure 29

KEY SWITCH The ignition key switch has four positions: ACCESSORY POSITION This position activates accessory functions and the instrument cluster.

OFF POSITION In this position, all switch controlled current is OFF. Turn the key to OFF to stop the engine. Remove the key and turn the Master Disconnect Switch to OFF. ON POSITION This position will energize all electrical systems. The key will return to this position after you release the key from the START position.

START POSITION Turn the key to this position to engage the starter motor to start the engine. The switch is spring loaded and will return to the ON position when released.

Intermittent

BC08H130

BC08H218

Figure 28

In the first position, the wiper will move intermittently.

Turn the wiper lever counter clockwise and the wipers will move continuously in either a slow or fast pattern.

IMPORTANT: Do not use the wipers on a dry windshield or a windshield that has iced over.

Damage can occur to the wiper blades.

Press the button on the end of the wiper for washer solution. Washer solution will spray and the wiper will automatically engage.

IMPORTANT: Do not push the washer button if the washer solution reservoir is empty. This may cause damage to the pump motor.

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS WORK LIGHT CONTROL

BC08H131

LIGHT SWITCH

Figure 30

Work lights can be used in three different phases:

BC08H202

UP: Flash for passing

Main Light Switch

CENTER: Head lights on low beam

The main light switch has two positions:

DOWN: Head lights on high beam

First position: Clearance lamp and cluster illumination lamp illuminates. All indicator switch lamps come ON.

NOTE: If the lever is released in the UP position, it will return to the center position (head lights on low beam).

Figure 31

Second position: Head lights come ON.

BD08H202

Figure 32

Work Lamp Switch The work lamp switch operates the front and rear work lamps.

First position: Front work lamps located on the cab illuminate.

Second position: Rear work lamps located on the cowl illuminate.

3-14

CHAPTER 3 - INSTRUMENTS AND CONTROLS

BD08H301

Figure 33

HAZARD LIGHT SWITCH Use this switch as a warning when parking or roading the machine. Lights on both sides of the machine will illuminate and flash alternately.

NOTE: If the switch is activated for an extended period of time the battery may discharge.

BD08H204

BD08H301

Figure 35

MIRROR DEFROST SWITCH The ignition key must be in the ON position to operate this switch. When pressed, the mirror defrost will activate for 15 minutes and then automatically turn off.

If the switch is pressed during the 15 minute interval, it can be manually turned off.

Figure 34

REAR WIPER AND WASHER SWITCH

BD08H128

Figure 36

This switch operates the rear wiper and washer.

CAB LIGHT SWITCH

First Position: Rear wiper will operate.

The switch turns the operator compartment light on and off. The center position will turn the light on when the door is opened.

Second Position: The washer fluid is sprayed and the wiper operates only when the switch is pressed.

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS DECLUTCH SWITCH

RIDE CONTROL Ride Control is a feature that increases the ride comfort of the Wheel Loader over all types of terrain with either an empty or loaded bucket. Ride Control will reduce fore and aft pitching motion during travel to allow faster speeds in load and carry applications for increased productivity and operator comfort. It will also reduce shock loads to the Wheel Loader for reduced tire flex, structural fatigue and vibration, resulting in longer component life and reduced costs.

Most commonly the operator will choose to leave this switch in the automatic (center) position.

Figure 37

BC09A310

The declutch function allows the engine to increase speed and supply the loader with more hydraulic oil for greater loader power and faster control function.

The declutch switch allows the transmission to be disengaged when the brakes are applied. When the declutch is not activated and the brake is applied, the transmission will remain engaged and drives against the brakes.

WARNING

BD08H207

Do not use the declutch switch when operating on a slope. Failure to comply could result in injury or death.

BEACON SWITCH (OPTIONAL)

Figure 39

This is a 3-position switch (manual, automatic, and off). When automatic ride control is activated, the operator will choose the center position on the switch. The indicator light will illuminate when the machine is traveling faster than 9.5 km (5.9 mph) indicating that ride control is functioning. When ground speed drops below 9.5 km (5.9 mph), ride control will automatically disengage.

Ride control will automatically disengage at slower speeds for loading and unloading. Ride control can be left on at all times in the automatic position whether loading or roading.

To turn Ride Control Off, push on the bottom of the switch for the OFF position.

The top position of the switch turns ride control on in the manual mode. Push on the top of the switch for the manual ON position.

BD08H206

Figure 38

The switch will turn on the optional rotary beacon.

The beacon can be installed by your authorized dealer.

3-16

NOTE: Ride Control should be OFF when the bucket is used in fine grading operations or when precision placement of a load suspended from the bucket or other attachment is required.

CHAPTER 3 - INSTRUMENTS AND CONTROLS EMERGENCY STEERING SWITCH (OPTIONAL)

Figure 40

BD08H210

The switch will allow the testing of the emergency steering system. When activated it will determine if the emergency steering and the emergency steering lamp both function. When the switch is pressed, the steering pump motor will run and the emergency steering lamp will light.

WARNING If the emergency steering switch does not cause the emergency steering lamp to illuminate, stop the machine. See your dealer and have the machine repaired immediately. Failure to comply could result in machine damage, injury, or death.

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS

FRONT CONSOLE

Figure 41

BD08J169

IMPORTANT: The machine monitor does not entirely guarantee the operating condition of the machine. Always perform specified (daily and periodic) maintenance on the machine as recommended in the Maintenance and Lubrication section of the book. Always note any irregularities in sound and/or operation, as well as any warning lamps or buzzers. Service the machine as required.

BC08H269

Figure 42

BC08H269

Figure 43

SPEEDOMETER

FUEL GAUGE

The speedometer displays the speed of the machine in mph and km/h.

The gauge indicates the amount of fuel in the tank.

Fill with fuel when the indicator moves to the E (empty) point. Avoid running the machine out of fuel.

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 44

BC08H271

Figure 45

BC08H271

COOLANT TEMPERATURE GAUGE

TRANSMISSION TEMPERATURE GAUGE

The gauge indicates the temperature of the coolant.

In the red range (high), temperature of the coolant is above 104° C (219° F). Idle the engine at low speed until the gauge indicates the machine is back in the operating normal range. If the indicator remains in the red range, turn the engine off and check radiator and engine.

T h e g a u g e i n d ic a t e s t h e t e m p e ra t u r e o f t h e transmission oil. In the red range (high), temperature of the transmission oil is above 107° C (225° F). Idle the engine at low speed until the gauge indicates the machine is back in the operating normal range. If the indicator remains in the red range, turn the engine off and check fluids and/or contact your authorized dealer.

WARNING Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap: Let the system cool, turn to first notch, then wait until all pressure is released.

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions. Failure to comply may result in injury or death.

WARNING Before carrying out any service work on any pressurized system, it is necessary to allow the system to cool (the temperature should not be more than 40°C (104° F). Failure to comply with this warning could result in injury or death.

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS

BC08H271

Figure 46

Figure 47

BC08H271

BATTERY VOLTAGE GAUGE

HYDRAULIC OIL TEMPERATURE GAUGE

The gauge indicates if the charging system is operating correctly. An indication below 24V (yellow range) indicates the system is discharging. If the indicator is above 30V (red range) the system can be overcharging and the high voltage may damage components. Check the charging system if the voltage gauge indicates a problem.

The gauge indicates the temperature of the hydraulic oil. In the red range (high), temperature of the coolant is above 105° C (221° F). Idle the engine at low speed and reduce the load on the system until the gauge indicates the machine is back in the normal operating range. If the indicator remains in the red range, turn the engine off and find the cause of the problem.

WARNING Before carrying out any service work on any pressurized hydraulic system, it is necessary to allow the system to cool (the temperature should not be more than 40°C (104° F). All pressure should be released from the system. Failure to comply with this warning could result in injury or death.

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS

BC08H275

Figure 48

BC08H284

Figure 51

WARNING LAMP

HIGH BEAM INDICATOR LAMP

When the warning lamp flashes, the machine should be checked or serviced as soon as possible.

The lamp is illuminated when the machine’s high beam lights are on.

BC08H277

Figure 49

BC08H288

Figure 52

DIRECTIONAL SIGNAL LAMP

PARKING BRAKE WARNING LAMP

The directional signal lamp indicates the directional signal is in use.

When the parking brake is actuated, the lamp is on.

Always r ele ase the brake be for e m oving th e machine.

BC08H281

Figure 50 BC08H302

Figure 53

MIRROR DEFROST LAMP The lamp indicates the mirror defrost is operating.

DECLUTCH LAMP When the declutch switch is pressed, the declutch lamp will illuminate.

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 54

BC08H292

BC08H238

Figure 56

PREHEAT LAMP

ENGINE OVERHEAT LAMP

When starting the engine, the lamp will turn on. The lamp will turn off in approximately 5 - 45 seconds, depending on engine temperature. When the lamp goes off, the preheat process is complete. Start the engine after the preheat process is complete.

The lamp will illuminate when the temperature of the coolant is over 104° C (219° F). Check the cooling system.

BC08H187

Figure 55

BC08H237

BRAKE WARNING LAMP The lamp will illuminate when the oil pressure of the service brake drops below the normal range. When the lamp is ON, stop the engine and check for problems. See your authorized dealer or refer to the Repair Manual for the correct repair procedure.

WARNING: Do not operate the machine if the brake warning lamp is illuminated. Failure to comply could result in machine damage, injury, or death.

3-22

Figure 57

ENGINE OIL PRESSURE LAMP This lamp will illuminate momentarily when the engine is started. If the lamp should illuminate during operation, turn the engine OFF immediately. Check engine oil level.

CHAPTER 3 - INSTRUMENTS AND CONTROLS

BC08H188

Figure 58

TRANSMISSION ERROR WARNING LAMP The lamp will illuminate and error codes will display.

Immediately stop the machine and find the problem.

Do not operate the machine until problem has been corrected. Consult your dealer for further information.

BC08H189

BC08H190

Figure 60

HYDRAULIC OIL TEMPERATURE WARNING LAMP The lamp will illuminate and the warning buzzer will sound when the temperature of the hydraulic oil is over 105° C (221° F). Check for debris between oil cooler and the radiator. Check the hydraulic oil level.

Figure 59

AIR CLEANER WARNING LAMP This lamp indicates a blockage in the air cleaner system. Stop the machine and check the air filter for blockage. Clean or replace the air filter.

BC08H191

Figure 61

BATTERY CHARGE WARNING LAMP The battery charge warning lamp will illuminate briefly when the engine is star ted. If the lamp illuminates during normal operation, check the battery charging system.

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 62

BC08H192

LOW FUEL WARNING LAMP Fill the tank immediately if the low fuel warning lamp illuminates. Do not allow the machine to run out of fuel.

WARNING

BC08H237

Figure 64

STEERING SYSTEM WARNING LAMP (OPTIONAL) The lamp indicates that the primary steering has failed. The indicator will come on and the alarm will sound. Steer the machine to a safe location and stop the engine immediately. Do not drive the machine w h e n t h i s l a m p i s i l l u m i n a t e d . C o n t a c t yo u r authorized dealer for further information.

If the machine runs out of fuel, do not attempt to work on pressurized hydraulic lines. Lines are under high pressure. Failure to comply could result in injury or death.

BC08H237

Figure 65

EMERGENCY STEERING ACTIVE BC08H297

Figure 63

FORWARD-NEUTRAL-REVERSE SELECT LAMP (OPTIONAL) The lamp comes ON when FNR select button on the optional FNR joystick control lever is pressed.

3-24

This lamp indicates that the emergency steering system is active. Steer the machine to a safe location and stop the engine immediately. Do not drive the machine when this lamp is illuminated. Contact your authorized dealer for fur ther infor mation. The emergency steering system can be manually tested.

CHAPTER 3 - INSTRUMENTS AND CONTROLS LIQUID CRYSTAL DISPLAY (LCD)

BS08J170

Figure 66

3-25

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Normal Multi-function Display

Figure 67

BS08J171

NO

SYMBOL

MEANING

REMARK

1

Monitoring Information

Job Timer, Odometer, Hydraulic Temperature, Battery Voltage, Coolant Temperature, TM Oil Temperature

2

State information

Buzzer, Fan State, Ride State (Option), Steering Joy Stick (Option, Warm Up

Wiper Display

When operating intermittently, displays operating time interval

a 3 b

4

FNR

Actual Gear Display

1234

LCD Type 1 changed by operator

Forward, reverse, neutral

LCD Type 2 changed by operator

Actual Gear

P

Parking brake mode active

cd

Up and Down shift

c: Forward d: Reverse

Preselected gear

Automatic Mode

Select Gear Display

5 e

6

Fault Code Display

Fault code occurrence - displays fault

7

Engine RPM Display

Current RPM

8

Hour meter display

Current hour meter record

Timer and Alarm Display

Current time and Alarm Display

9

3-26

Forward, Reverse, Neutral

PM 12:06

CHAPTER 3 - INSTRUMENTS AND CONTROLS NAVIGATING THROUGH MULTI-FUNCTION SCREENS

Figure 68

BS08J173

Main group Accessory

Sub group

Meaning

Job timer

• Measure the various job time.

• Press: ENTER Display ON, OFF or RESET

Stop watch

• Measures time in seconds.

• Press: ENTER to Start. Press ENTER again to Stop

Odometer

Can be set by operator

• Trip meter

Total

• Total distance

Light control

• Control of LCD display luminosity.

• Brightness control: Press the ARROW keys

Time set

• When 12H or 24H is selected, the current hour appears: Press right ARROW for input PRESS ENTER to set.

Clock ON/OFF

• Press ENTER: Clock display ON or OFF.

Clock

1 Alarm

2 3

User

• Raise the idle rpm to 1200 rpm automatically to warm up the engine

Alternate idle Mode 1 (1st-4th)

• Automatic travelling speed is applied from 1st to 4th gear

Mode 2 (2nd-4th)

• Automatic travelling speed is applied from 2nd to 4th gear

Auto 1/2

Quick shift

Mode 1 (Down/Up) Mode 2 (Down) Auto Select

Aux-sw Clutch Cut-off Cooling fan control

• Alarm setting. Three alarms can be set • Stop alarm - Press right ARROW:

• Press button once: Shift down, press button again; shift up • Press button: Each time machine will shift to lower gear • ON: Transmission auto condition • OFF: Transmission semi-auto condition • ON: Clutch cut-off is activated • OFF: Clutch cut-off is cancelled

Forward

• Forward active

Reverse

• Reverse active*

NOTE: * Fan reverse mode will clean dirt and dust from radiator and cooler by reverse rotation of cooling fan.

3-27

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Main group

Adjustment

Sub group Unit

Choose between metric and inch unit display

Wiper Intermittence

When using the intermittent function of wiper motor, regulate wiper time

Alternate RPM

Regulate idle rpm.

Press RIGHT arrow: Adjust idle rpm increments by 25 rpm Press LEFT arrow: Decrease rpm increments by 25 rpm

Pulse

Press ENTER: Modification

AEB

Automatically controls the disk interval of the transmission

ENG/KOR

English: Display in English Korean: Display in Korean

Display 1/2

Type 1: Indicate with the symbol Type 2: Indicate with a letter

Machine

Error code display Fault Code Error codes should be interpreted by an experienced technician/authorized dealer Monitor

Diagnostics

Meaning

Engine

Error code display Fault Code Error codes should be interpreted by an experienced technician/authorized dealer Monitor

Transmission

Engine coolant temperature display Press ENTER: Display ON or OFF

Error code display Fault Code Error codes should be interpreted by an experienced technician/authorized dealer Monitor

Version

Hydraulic temperature and battery voltage display Press ENTER: Display ON or OFF

Transmission oil temperature display Press ENTER Display ON or OFF Display the controller (MCU)) and cluster version

MCU: Machine control unit TCU: Transmission control unit ECM: Engine control module IMPORTANT: If fault codes display, contact your authorized dealer.

3-28

CHAPTER 3 - INSTRUMENTS AND CONTROLS CLIMATE CONTROL

BC08H196

Figure 69

3-29

CHAPTER 3 - INSTRUMENTS AND CONTROLS POWER SWITCH

TEMPERATURE CONTROL SWITCH

1. This switch turns the system ON or OFF and the LED will illuminate.

2. Default setting values Function

Value

Air conditioner

OFF

Fan speed

1

Temperature

Max cool

Outlet

Face

Inlet

Recirculation Figure 72

BC08H062

1. The climate control system offers nine temperature control settings from max cool to max warm. Change the setting by pushing the warm or cool button to turn the control switch up or down.

2. When set to max cool or max warm the control will beep 5 times to indicate it is set to maximum.

3. For optimum performance of max warm or max cool, see the following table.

BC08H064

Figure 70

AIR CONDITIONER SWITCH (COMPRESSOR SWITCH) Press the snowflake to turn the air conditioner on.

Press the OFF symbol to turn the air conditioner off.

IMPORTANT: The air conditioner will remove moisture in the operator’s compartment and will drain the moisture through an internal drain hose. If the valve of the drain should become blocked, water may be sprayed back into the cab. If this occurs replace the valve.

BS08B063

Figure 71

Fan Switch The fan has four speeds. Set speed to desired speed. Both the low speed and highest speed will be indicated by 5 successive beeps.

3-30

Temperature

Max cool

Max warm

Air conditioner

ON

OFF

Fan speed

4

3

Outlet

Face

Foot

Inlet

Recirculation

Fresh

CHAPTER 3 - INSTRUMENTS AND CONTROLS B. Recirculation Recirculates the heated or cooled air to increase the system efficiency.

OUTLET CHANGE OVER SWITCH

IMPORTANT: Change air occasionally when using recirculation for an extended period. Inspect the recirculation filter periodically to maintain efficiency.

Recirculation function operates when the system is OFF, but it can be changed as desired.

AIR LOUVERS MAIN AIR LOUVERS Figure 73

BC08H197

(1)There are four settings for air flow.

Louvers on the right and left hand cab supports direct air toward the operator.

Mode Switch position

Adjustments can be made to direct the air flow of the louvers.

A

Outlet

The louvers on the console direct air flow toward the operator or toward the front window.

B

• •

C D

•

•

• •

•

• •

•

(2)When defroster switch is operating, the INLET switch tur ns to FRESH mode and the air conditioner switch turns ON. (3)When using heater (5~Max warm), the air conditioner will not turn ON.

RECIRCULATION AIR LOUVER The recirculation air louvers are behind the operator’s seat next to the floor. When open, air is recirculated in the cab.

NOTE: Always have these louvers open for maximum cooling with the air conditioning or maximum heat with the heater.

Loosen knob (1) and remove cover to access recirculation filter (2).

DEFROST AIR LOUVERS The upper louvers under the front windshield on the console and the louvers on the cab supports direct the air flow to defrost the windows. Additional louvers are located on the cab support posts.

INLET CHANGE OVER SWITCH

To get maximum air flow on the windows, close all other louvers and turn the blower fan to the highest speed.

If a fogging condition occurs, make sure the recirculation air louvers are CLOSED. If equipped with air conditioning, turn the air conditioning ON and turn the heat control completely clockwise.

BC08H061

Figure 74

The air in-let has two settings: A. Fresh Intake fresh air from the outside to circulate in the cab interior.

IMPORTANT: Inspect the fresh air filter periodically for optimum performance.

3-31

CHAPTER 3 - INSTRUMENTS AND CONTROLS LIGHTER

BC08H135

Figure 75

The lighter can only be used when the key is on.

Press lighter in and it will “pop” out automatically. Do not hold in.

This is a 24 volt socket and can be used for 24 volt 100 watt accessories.

12 VOLT ACCESSORY SOCKET

BC08H135

Figure 76

The 12 volt accessory socket is located to the right rear of the operator’s seat. It can be used as a 30 watt maximum accessory outlet.

3-32

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO AND CASSETTE (STANDARD)

Figure 77

BS08B319

RADIO AND CD PLAYER (OPTIONAL)

GRAPHIC_1D

FRONT PANEL PRESENTATION 1 2 3 4 5 6 7 8

9 10

1 - - - - - - - - Preset button 1 RND - - - - - - - - - - - - CD random playback on/off - - - - - - - - Preset button 2 2 RPT - - - - - - - - - - - - CD repeat track on/off - - - -3- - - - - - - - - - - - - Preset button 3 SCN - - - - - - - - - - - - CD's track scan 4 - - - - - - - - Preset button 4 - - - -5- - - - - - - - - - - - - Preset button 5 TA AF - - - - - - - - Short press : TA on/off Long press : AF on/off SOUND - - - - - - Select sound/audio styles - - - - - - - - - - - - Short press : power on Long press : power off MUTE - - - - - - - - Short press : To mute or cancel mute.

- - - - - - - - - - - - - - - - - - - - - Display - - - - - - - - - - - - - - - - - - - - - Volume knob : Press up/down to adjust the volume ; adjust selected audio mode

11 SOURCE - RDS - - - - - - - - - BAND - - - - - - AST - - - - - - - - - - 12

----------

13 14 15

-------------------------------

16 - - - - - - - - - - - - - - - - - - -

Short press : Change source(CD) Long press : RDS on/off Short press : To select band Long press : Autostore(CD) Short press : Autostore(Cassette) Tuner mode Short press : Auto search up/down Long press : Manual search up/down Cassette mode : No function CD mode Short press : Next/previous track Long press : Fast forward or fast rewind Fast forward(cassette deck) Fast rewind(cassette deck) Disc eject(CD) Eject cassette CD opening / Cassette opening 3-33

CHAPTER 3 - INSTRUMENTS AND CONTROLS (1) Sound Type - Press Sound then choose: Bass - Tre: Your own settings of bass and treble Flat - Original Jazz - Jazz music Vocal - Talk radio Pop - Pop music Rock - Rock and roll music Adjust with the volume increase and decrease buttons.

(2) Sound Style - Press Sound then choose: BC08H276

Figure 78

Bass-Tre, Flat, Jazz, Vocal, Pop, Classic, Rock

AUDIO AND MUTE

Bass - Low notes

To turn the radio off and on press the power switch on the set. Hold the power key for two seconds or more to turn the radio off. The radio can be put in a mute mode by momentarily pressing the power key.

Balance - Left/right

NOTE: Mute may be interrupted by emergency messages.

Fader - Rear/front Loud - Off/Low/Mid/High Press the volume button to adjust the selected audio mode. After 5 seconds the display will go back to the last mode of operation.

NOTE: Adjustment of bass and treble setting is only possible when the bass-tre is selected as the sound style.

Source Press Source to select the desired sound source either tuner, cassette, or cd.

RADIO

BC08H282

Figure 79

VOLUME Press the volume button up or down to increase or decrease volume.

BC08H291

Figure 81

Band Press band to select AM or FM Automatic Search Press the arrow keys to search for a desired station.

The radio will automatically search.

BC08H279

Figure 80

ADJUSTING SOUND The sound on the radio can be adjusted by pressing the sound button to choose from: 3-34

Manual Search Press the arrow keys for more than 2 seconds and the radio can be manually tuned.

CHAPTER 3 - INSTRUMENTS AND CONTROLS

BC08H291

Figure 82

Storing Stations in Memory Five stations per band can be stored and recalled in memory.

To store stations:

• Tune to desired station • Press the desired preset key (1 to 5) for more than 2 seconds to commit station to memory.

BC08H295

Figure 84

When using digital radio, the radio will display the name of the station rather than its frequency.

Automatic returning (AF) - The set will remain tuned to the current station by continually searching for the best alternative frequency for the best reception. This feature can be turned off.

To Activate/Deactivate AF Press the TA button for more than 2 seconds to activate/deactivate AF.

Recalling a preset station:

The following may not be available in your area.

Press the desired preset key (1 to 5) to recall the stored station.

Alarm Messages

Auto Store You can automatically store the 5 strongest FM stations on the FM AST band or the 5 strongest AM stations on the MW(AM) AST band with auto store.

• Press AST to activate auto store.

• The radio will beep and then mute • When the storing is completed, the radio will beep again followed by the station stored on preset 1.

NOTE: It may not always be possible to find 5 strong radio signals.

SUBSCRIPTION RADIO - DIGITAL RADIO (RDS)

The set will automatically receive emergency messages made by the broadcaster. During the messages, the display will show ALARM and the station name alternately.

Traffic Announcements (TA) The traffic announcement modes can be given priority so these announcements can be heard even if playing a cassette or CD or the set has been muted.

To activate/deactivate TA: Press the Band once to select and FM band Press the TA button to activate or deactivate TA. If you activate TA mode you will hear the traffic announcements when broadcast by the station. If the tuned station does not have traffic announcements, the radio will automatically search for an appropriate station.

To cancel traffic announcement mode press the TA key once and the set will return to the previous broadcasting mode.

To switch off the Digital Radio Mode by pressing the RDS button and holding for 2 seconds or more. All D i g i ta l ra d i o fe a tu r e s w i l l b e c a n ce l l e d u n t i l reactivated.

BC08H293

Figure 83

3-35

CHAPTER 3 - INSTRUMENTS AND CONTROLS CASSETTE PLAYER Use only good quality cassettes. To avoid possible tape damage, always remove the cassette after use.

Return cassettes to their original protective cases.

Do not expose cassettes to heat or direct sunlight. A damaged cassette can cause damage to your tape player.

To play: Slide the cassette in with the open side to the right.

Playback will start. The direction of playback is shown by the indicator right directional arrow.

To stop playback, press the up arrow button. The unit will switch over to radio reception and the cassette will partially eject.

Normal play back will resume when you release the button.

Random Track Playback Press RND to activate or deactivate random track play back.

Repeat Track Press RPT to activate or deactivate repeat the current track.

Scan Track The scan function plays the first few seconds of each track. Press SCN to activate or deactivate scan track.

Press the UP arrow to eject the disc.

To reverse before the end of the tape press both direction arrows at the same time half way in.

For fast rewind or fast forward press the double directional keys. During fast forward or rewind, the radio will resume. If rewinding until the beginning of the tape play back will start automatically.

To stop fast rewinding, press the opposite double directional key.

At the end of the tape, play back will continue in the reverse direction.

After extended use of the cassette player, dust and contamination can accumulate on the playback head.

Use a cleaning cassette once or twice a month, playing it through as directions on the cleaning cassette require.

Display during playback

Action

Key to press

Fast forward Fast rewind Fast forward Fast rewind

CD PLAYER Use a quality CD and slide the disc into the slot with the label facing up. Play back will start.

If a disc is already in the CD player, press SOURCE to select CD as the source and play back will start.

Previous/Next tract Press the arrow button to select the desired track.

Play back will resume with the chosen track.

Fast Rewind/Fast Forward Press and hold the arrow button for 2 seconds to quickly move the play selections on the disc.

3-36

BC08H291

Figure 85

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO SETTING

BC08H296

Figure 86

Set the radio for use in country as follows: Nor th America: Press the On button and the Number 1 and Number 4 buttons at the same time.

Set up completes when displaying America.

South America: Press the On button and the Number 2 and Number 5 buttons at the same time.

Set up completes when displaying South.

Asia: Press the On button and the Number 1 and N u m b e r 5 bu t t o n s a t t h e s a m e t i m e. S e t u p completes when displaying Asia.

Europe: Press the On button and the Number 2 and N u m b e r 4 bu t t o n s a t t h e s a m e t i m e. S e t u p completes when displaying Europe.

3-37

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-38

CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 ATTACHMENT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 BASIC MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declutch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating On A Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting the Machine on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loading the Machine on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Cold Climate Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Machine In Hot Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment of Bucket/Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13 4-14 4-14 4-15 4-18 4-18 4-19 4-20 4-21 4-21 4-22 4-23 4-24 4-25 4-26

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS BEFORE STARTING THE ENGINE Perform a daily walk around and visual inspection of the machine. Check for loose connections, faulty hoses, oil leaks, debris or trash buildup, loose bolts, damaged, or missing parts that could effect the normal and safe operation of the machine. Make any necessary corrections before operating the machine.

See the Quick Reference Maintenance Chart in this manual and complete the items in the daily - 10 hour section of the chart.

Check that the machine fuel tank is filled with clean fuel that matches the specifications given in this manual.

WARNING

BEFORE OPERATING THE MACHINE

WARNING Do not attempt to operate this machine unless you have first read and fully understand the safety messages and instructions appearing in this manual. Failure to comply could result in serious injury or death.

CE-NA000

Before operating this machine, complete the following procedures: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids an d lubr icants ar e suitable for prevailing conditions.

2. Carry out the daily maintenance operations.

Do not operate the machine while under the influence of alcohol or drugs. Failure to comply could result in serious injury or death.

3. Inspect the machine, look for any signs of possible leakage and check the hoses. Tighten or replace as necessary.

RUN-IN PERIOD

4. See Run-in period if the machine is new or if the engine has been reconditioned.

Your machine will last longer, give better and more economical perfor mance, if you pay par ticular attention to the engine during the initial run-in period.

(See the Quick Reference Char t in Chapter 5 Lubrication and Maintenance for further information.)

During this period: Warm up the engine before using it under load.

Do not operate the engine at maximum power for prolonged periods of time.

5. Check the tires for any visible damage. Replace or repair as necessary. Check for correct tire air pressure and adjust pressure if necessary.

6. Clean the steps and hand holds. Grease, oil, mud, or ice in winter on the steps and hand holds can cause accidents. Make sure they are kept clean at all times.

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2.

Do not run the engine for a long period at idle speed.

8. Make sure that the engine access panels and all doors are properly closed and latched.

Frequently check the instruments on the instrument panel.

9. Secure the cab door in either fully closed or fully opened position.

Check the oil levels and coolant solution level frequently.

10. Remove any obstructions which hinder visibility.

Clean the windshield, the windows and the rear view mirrors.

During the run-in period, be sure to carry out the specified checks and servicing operations.

NOTE: For turbocharged engines, only shut the engine down from the low idle position to prevent damage to the turbocharger.

11. Check that no tools or other items have been left on the machine or in the operator's compartment.

12. Make sure no one is on or under the machine.

The operator must be alone on the machine.

13. Make sure no one is standing in the machine working area.

14. Find out about current safety measures in use on the work site.

15. Work out a convenient means of escape from the machine (emergency exit via the windshield, the rear or side window glass) in the event of the cab door being jammed or the machine turning over.

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 16. Before undertaking any travel or working operations during hours of darkness, make sure the lighting and signaling equipment is fully operative.

WARNING Before each period of operation, check the machine for correct operation of the steering, brakes, hydraulic controls, instruments, and safety equipment. Check the NEUTRAL position of the transmission control lever. A machine that runs correctly can prevent accidents. Make all necessary repairs or adjustments before you operate the machine. Failure to comply could result in serious injury or death.

SA040

17. Adjust the seat so that you can apply the foot brakes when your back is against the seat backrest.

18. Fasten and adjust the seat belt.

19. With the engine running and at operating temperature, check the instrument panel for correct indications.

20. Check the loader controls for correct operation.

STARTING THE ENGINE NOTE: If the machine has been out of use for some time, see Starting Up After Storage in this chapter.

NOTE: If you need to start the engine using a booster battery, see Connecting A Booster Battery in Chapter 7.

1. Turn the master disconnect switch to the ON position.

2. Take up the correct position in the operator's seat with the seat belt correctly fastened. Make sure you can push the foot pedals completely down with your back against the seat cushion.

3. Make certain the transmission direction control is in NEUTRAL and the parking brake is applied.

4-4

4. Turn the key switch to the ON position and check the instrument indicators. Monitor the engine grid heater indicator (if equipped). Do not attempt to start the engine until the grid heater indicator lamp is off.

NOTE: If the weather is cold, see Operating the machine in cold weather in this chapter.

5. Keep all non-authorized personnel clear of the area. Sound the horn to alert others of your intent to start the engine. Turn the key switch to the START position until the engine starts, then release the key.

IMPORTANT: Do not hold the starter key in the START position for more than 30 seconds. If the engine does not start, return the key switch to the OFF position, wait 120 seconds, and then try again.

6. After the engine starts, check the instruments to make sure the indications are correct. Run the engine at low idle with the transmission in neutral until the engine coolant temperature is warm.

IMPORTANT: Operate the machine at reduced loads until all systems reach operating temperature. This is very important during extremely cold weather operation to protect both the engine and hydraulic systems.

ENGINE SPEED DO NOT OPERATE the engine at idle speed for long periods. This can cause a low operating temperature.

A low operating temperature can cause acids and deposits in the engine oil.

Always bring the engine to low idle for a few minutes to let all parts cool evenly before shut down.

IMPORTANT: Always shut the engine down from the lowest idle to prevent damage to the turbocharger, if equipped.

CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE AND PARKING THE MACHINE AFTER OPERATIONS

WARNING Jumping on or off the machine can cause an injury.

Always face the machine, use the hand holds and steps, and get on or off the machine slowly. Failure to comply could result in serious injury or death.

SA038

1. Before you leave the machine, make sure the machine is parked on level ground. The machine must be on level ground before you perform any maintenance.

IMPORTANT: If you must temporarily park the machine on a hillside, put the front of the machine toward the bottom of the hill. Park the machine behind an object that will not move.

2. Lower the attachment to the ground.

3. Shift the transmission direction control NEUTRAL, and apply the parking brake.

to

4. Run the engine at idle speed for three to five minutes to decrease the temperature of the engine and turbocharger.

NOTE: Always turn the engine off at low idle to prevent damage to the turbocharger, if equipped.

5. Turn the key switch to the OFF position, and remove the key.

6. Slowly move the equipment control levers forward to rest the equipment on the ground.

7. Slowly move the equipment control levers forward and move the equipment levers through all rotations to insure that residual pressures in the hydraulic system are released.

8. Turn the master disconnect switch to the OFF position.

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in serious injury or death.

CE-NA000

Starting and Stopping the Loader

BD06G098

Figure 1

1. Remove the transport/service link from the lock position, and secure it in the work position 2. Place the master disconnect into the ON position.

BC08H346

Figure 2

3. Sit in the operator’s seat with the seat belt correctly fastened. Make sure you can push the foot pedals completely down with your back against the seat cushion. Confirm that the parking brake switch is ON (brake engaged).

4-6

BC08H370

Figure 3

4. The gearshift lever must be in NEUTRAL and the hydraulic safety lock lever in the locked position.

CHAPTER 4 - OPERATING INSTRUCTIONS

BC08H217

Figure 4

5. Keep all non-authorized personnel clear of the area. Sound the horn to warn those around the work area of your intentions.

6. Insert the key into the ignition switch and turn it to the ON position. Monitor the console indicators. Do not attempt to start the engine until the grid heater light is out. When the grid heater light is no longer illuminated, turn the key to the START position. Do not hold the starter key in the START position for more than 30 seconds. If the engine does not start, return the key switch to the off position, wait 2 minutes and then try again.

Once the engine starts, allow it to run at low idle until the engine coolant temperature is warm.

BC08H226

Figure 5

7. Unlock the hydraulic safety lock to power the equipment.

8. Raise the loader arms so that the equipment is raised approximately 380 mm (15 inches).

9. To move the machine:

• Cycle the parking brake switch • Place the gearshift into forward position • Release the foot brake and accelerate smoothly

NOTE: If the engine starts and then stops, do not engage the starter motor again until the starter motor stops turning. Do Not operate the starter motor more than 30 seconds at one time. Let the motor cool for two minutes before cranking again.

BC08H224

Figure 6

TO SHIFT GEARS MANUALLY: Use the transmission control lever to shift the transmission gears from first through fourth gear.

Turn the transmission control lever away from you to select a higher gear. Turn the lever toward you to select a lower gear. This control lever is also used to put the transmission in FORWARD, NEUTRAL, and REVERSE. A. Move the control lever away from you for FORWARD. B. The center position of the control lever is NEUTRAL. C. M ove t h e c o n tr o l l eve r towa r d yo u fo r REVERSE.

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE AND PARKING THE MACHINE AFTER OPERATIONS

Figure 9

BC08H278

BC08H224A

Figure 7

1. Stop the machine on hard, level ground and place the gearshift selector in NEUTRAL. IMPORTANT: If you must temporarily park the machine on a hillside, put the front of the machine toward the bottom of the hill. Park the machine behind an object that will not move.

2. Lower the attachment to the ground.

6. Slowly move the equipment control levers forward to rest the equipment on the ground.

7. Slowly move the equipment levers through all rotations to insure that residual pressures in the hydraulic system are released.

8. Turn the master disconnect switch to the OFF position. Close and lock the compartment.

WARNING Check all controls and safety devices in a safe, open area before starting work. Failure to comply could result in serious injury or death.

BC08H364

Figure 8

3. Shift the transmission direction control NEUTRAL and apply the parking brake.

to

4. Run the engine at idle speed for three to five minutes to decrease the temperature of the engine and turbocharger.

5. Turn the key switch to the OFF position and remove the key.

NOTE: Always turn the engine off at low idle to prevent damage to the turbocharger, if equipped.

4-8

CHAPTER 4 - OPERATING INSTRUCTIONS AUTOMATIC MODE OPERATION:

BC08H205

Figure 10

To put the transmission in the automatic mode, press the top of the auto shift switch (1).

AUTOMATIC SHIFTING MODE When the transmission is in the automatic mode, the transmission will start out in first gear or second gear (dependent upon gear minimum setting), and automatically up-shift until the gear selected has been reached. The transmission will also down-shift automatically as the speed decreases.

BC08315A

Figure 11

DOWN-SHIFT BUTTON, AUTOMATIC MODE The down-shift button is used to shift down through the gears in single steps. Each time the switch is pressed, the transmission will shift down one gear range until first gear is reached. Once the down-shift button has been pressed down, the transmission maximum gear allowed is lowered. It will return to the automatic mode when (1) the transmission control lever gear changes, or (2) the transmission control lever is moved to NEUTRAL and then to FORWARD or to REVERSE. NOTE: When the Automatic Mode has been chosen by the operator, the Automatic Mode indicator will be shown in the multi-function display.

SHUTTLE SHIFTING (DIRECTION CHANGE) MANUAL OR AUTOMATIC It is not necessary to bring the machine to a complete stop when changing directions from forward to reverse or reverse to forward. For smooth operation and operator comfort, reduce engine speed before direction changes.

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS TRANSMISSION ENABLE SWITCH The Transmission Enable switch can be enabled after the following conditions have been completed: 1. Transmission controller is in neutral (left side).

2. F-N-R switch is in neutral (right side).

3. The engine must be running.

4. Machine is stationary.

5. Parking brake is released.

Depressing the transmission enable switch allows the transmission to be controlled by the auxiliary F-N-R switch. The indicator light on the bottom of the enable switch will illuminate when activated (See Note).

If the column mounted transmission controller is moved from neutral, the engine is stopped or the parking brake is applied, the auxiliary F-N-R mode is deactivated and transmission control defaults back to the Transmission Control Lever.

NOTE: Within 8 seconds from depressing the transmission enable switch the following actions must take place or the F-N-R enable switch must be reactivated.

1. The parking brake switch must be released.

2. Shift to forward or reverse from the neutral position on the F-N-R switch.

4-10

CHAPTER 4 - OPERATING INSTRUCTIONS

OPTIONAL FORWARD, NEUTRAL, REVERSE (F-N-R) SWITCH FOR JOYSTICK CONTROL LEVER APPLICATIONS

BC08H201

Figure 13

5. The Parking Brake must be released.

When steps 1 through 5 have been completed the transmission enable switch may be enabled by pushing down on the top of the switch (4). The indicator light on the bottom of the switch will illuminate.

T h e t r a n s m i s s i o n e n a b l e sw i t c h w i l l b e DEACTIVATED and F-N-R control will default back to the Standard Transmission Control Lever if: 1. The engine is stopped.

BC08H316

Figure 12

1. AUXILIARY JOYSTICK F-N-R SWITCH A. FORWARD

2. The parking brake is applied.

3. The transmission control lever is taken out of the neutral position.

B. NEUTRAL C. REVERSE To actuate the Auxiliary F-N-R switch the following conditions MUST be met: 1. The machine must be stopped.

2. The engine must be running.

3. The Auxiliary F-N-R Switch must be in Neutral (B).

4. The Standard Transmission Control Lever must be in neutral.

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS THREE LEVER CONTROLS

4

E

3 2

F

D

G

A

B

1

C BC08H201

1.

2.

3.

4.

H

Figure 14

I

BUCKET LEVER CONTROL LIFT ARM CONTROL AUXILIARY FUNCTION CONTROL HYDRAULIC CONTROL PILOT LOCK OUT LEVER

Bucket Control A. Dump B. Rollback C. Hold: the loader arms and bucket will not move when the control lever is in the Hold position. When released, the control lever will automatically return to the Hold position. You must manually move the control lever from the Float position to the hold position.

Lift Arm Control D. Float: This is a detent position. When in the Float position, the loader bucket can follow the level of the ground without movement of the control lever.

E. Lower F. Hold: The loader arms and bucket will not move when the control lever is in the Hold position. When released, the control lever will automatically return to the hold position. The control lever must be manually moved from the Float position to the Hold position.

G. Raise AUXILLARY CONTROL H. Auxiliary Function I. Auxiliary Function

4-12

87536093

Figure 15

CHAPTER 4 - OPERATING INSTRUCTIONS

ATTACHMENT OPERATION

The control lever operates the boom and the bucket.

When the control lever is released, the control lever will return to a neutral position automatically.

When the control is moved to the boom float, boom kick out, and bucket level, the function is completed.

The control lever will then return to neutral position.

1. Boom Lower Push the control lever forward in order to lower the boom.

2. Boom Raise Pull the control lever back in order to raise the boom.

3. Bucket Roll Back Push the control lever toward the left in order to tilt the bucket backward.

4. Bucket Dump Push the control lever toward the right in order to dump a load from the bucket.

5. Boom Lower Push the control lever forward in to the detent.

The boom will lower to the ground and float along the contour of the ground.

BS08J061

Figure 16

IMPORTANT: Always confirm the operation of the control lever and the attachment.

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS

BASIC MACHINE OPERATION

BC08H390

Figure 17

Travel Position Lift the boom so the bucket is approximately 50 cm (15 - 20 in) above the ground.

Figure 19

BS08C140

4. The gear selector is mounted on the left side of the steering column.

5. Select a speed (1-4) by turning the shift counterclockwise. The direction (forward, neutral, and reverse) can be changed by moving the lever up and down through the three detents (forward, neutral, and reverse).

NOTE: A neutral lock has been designed as protection against an inadvertent move into gear.

6. When performing digging or dumping operations, place the machine in first or second speed.

WARNING

BC08H370

Figure 18

Travel Operation A f t e r c o m p l e t i n g t h e wa r m - u p p r o c e d u r e a s necessary, the machine is ready to move.

1. Release the hydraulic control lock lever.

2. Release the parking brake.

3. Move the gear selector lever in first (forward or reverse) and press the accelerator pedal to move the machine.

4-14

When traveling at high speed, do not abruptly decelerate by using the transmission lever. To slow down, press the brake pedal. When changing direction, check beforehand that there is no obstacle in the direction you will be headed.

Avoid changing direction at high speed. Failure to comply could result in machine damage, injury, or death.

CHAPTER 4 - OPERATING INSTRUCTIONS Turning the Machine BRAKE ACCUMULATORS The hydraulic accumulators are connected in the brake system.The accumulators provide the brake m o d u l a t i n g v a l ve w i t h a p o s i t i ve s u p p l y o f pressurized hydraulic fluid.

Test the accumulators for correct operation every 100 hours.

1. Start the engine.

2. Run the engine at 1/2 throttle for 15 seconds.

3. Stop the engine.

Figure 20

BC08H389

The machine can be turned left or right 40 degrees.

IMPORTANT: Steering does not function with engine OFF unless equipped with the secondary steering option.

WARNING Do not turn the machine abruptly when traveling at high speed and avoid turning on a slope. Failure to comply could result in machine damage, injury, or death.

4. Without starting the engine, turn the ignition key to the ON position. After the instrument cluster completes the diagnostic check, confirm that the brake pressure light is not on.

5. Repeatedly pump the brake pedal until the brake pressure lamp is illuminated. When pumping the brake pedal, there should be some resistance pressure felt. A slight increase should be felt in the pressure as the brakes are pumped.

6. After the lamp illuminates, continue to pump the brake pedal and count the number of full applications.

NOTE: If you can complete six (6) full brake applications after the indicator lamp illuminates, the accumulators are working correctly. If you can not complete six (6) applications, see the Repair Manual for this machine or see your dealer.

DECLUTCH FUNCTION

BC08H389

Figure 21

When the load is lightened, the speed of the machine will increase. When dumping loads, always maintain control of the machine’s speed.

When traveling on uneven ground, travel at a safe (low) speed.

Figure 22

BC08H302

DECLUTCH SWITCH

The Declutch function allows the engine to increase speed and supply the loader with more hydraulic oil for greater loader power and faster control function.

When the Declutch switch is in the ON position, and you push down on the brake pedal, the transmission is disengaged from the drive wheels. Release the brake pedal to engage the transmission power. If required, use the brake to stop the machine.

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS LOADER OPERATING TIPS This Wheel Loader, with standard equipment and authorized attachments, is intended to be used for above ground level digging and general earth moving purpose such as land leveling, truck loading, material rehandling and ditch cleaning. If the machine is to be used for lifting objects, make sure that the machine is properly equipped and follow the instructions and safety precautions in this manual.

Excavation Work

BC08H390

Figure 23

1. Lift the bucket about 50 - 50 cm (15 - 20 in) above the ground to ensure safety and allow good visibility while operating.

2. Clear the job site of obstacles and level the ground.

3. Be careful that excessive force is not applied to the bucket. When handling hard materials, use bucket teeth or bolt on cutting edge.

4. When performing dumping work, place the control lever in the DUMP position. Return it to carry position after dumping.

BC08H137

Figure 24

Shovel Work As the bucket fills while moving forward, the tires may start to slip because of the increase in load. Lift the bucket slightly to reduce load and add traction to the tires.

Keep the bucket parallel to the ground. If bucket is not kept parallel, power may be reduced and the bucket will not dig efficiently.

5. Use the proper capacity bucket for the type of work being performed.

BC08H138

Figure 25

When the bucket is deep enough into the soil being loaded, move forward with the control lever pulled down. Place the control lever in the bucket roll back position in order to fill the bucket.

4-16

CHAPTER 4 - OPERATING INSTRUCTIONS

BC08H139

Figure 26

If it is difficult to dig into the soil, move the bucket control lever back and forth to move the bucket teeth up and down.

Figure 29

BC08H141

Drive the machine forward, and lift the bucket using the bucket control lever. When moving forward, control the depth of dig with the control lever.

LEVELING OPERATION

BC08H374

Figure 27

IMPORTANT: It is possible to lift the front tires off the ground if load is excessive. This type of driving force will cause deterioration to the rear tires and/or possible damage to the loader arms.

Figure 30

BC08H143

Always operate the machine in reverse when leveling the surface.

Load the bucket with material and place the bucket in a horizontal position. The control lever should be in the Boom Float position when moving backward.

After dumping the material, move backward with the bucket lowered to the ground to level the area.

PUSHING OPERATION When pushing material, do not set the bucket dumping angle more than 20 degrees. Do not place the bucket in the full dump position.

WARNING

BC08H140

Figure 28

Excavating on Level Ground Advance with the bucket lowered slightly and make certain that the bucket loads evenly on both sides.

Lower the bucket edge slightly.

Impact Hazard - Bucket edge or teeth can catch on frozen surface or buried objects during surface scraping operations. Before operation inspect the area for objects the bucket can catch on and mark them. During operation make sure the bottom of the bucket is level with the surface to be scraped.

Operate the machine around the objects and at slow speed. Failure to comply could result in serious injury or death and/or damage to the machine.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS LOADING

COMPACTION

Figure 31

BC08H367

When compacting, keep the bucket horizontal to the ground. Do not work with the bucket in the dump position.

TRANSPORT AND CARRY OPERATION

BC08H145

Figure 33

Keep the swing angle small and the travel distance as short as possible.

I Method After digging the soil, move backward and position the dump tr uck between the heap of soil and machine in order to load material in the fastest most efficient way.

V Method

Figure 32

BC08H144

The bucket must be in the roll back position and the bottom of the bucket must not be more than 12 to 18 inches (305 to 457 mm) off the surface.

BC08H144

WARNING When you operate the machine, keep the loader bucket as low as possible. This low position gives better balance and permits you to see more clearly.

If the bucket is full and you move the machine over ground that is rough or surfaces that can cause the machine to slide, always operate at slow speed. If you do not use this procedure, the machine can lose control and roll-over. Failure to comply could result in injury or death.

4-18

Figure 34

1. Park the truck at an angle of 60 degrees to the m a c h i n e. A ft e r l o a d i n g th e bu cke t , m ove backward and position the machine at a right angle to the truck and load the truck.

2. Position the machine so the load can be dumped in the center of the truck. If the length of the truck permits, start at the front of the truck and work backwards with each dump.

3. Shake the bucket to release material inside and/or when loading to even the dump load.

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER

OPERATING ON A SLOPE

WARNING Hillside operations can be dangerous. Rain, snow, ice loose gravel, soft ground, etc., change the ground conditions. You must make a judgment if your machine can be safely operated on any hillside or ramp. Failure to comply could result in injury or death.

Figure 35

BC08H147

• Make sure that the bottom of the stream, or water in which you will work, can support the weight of the machine.

• Do not allow the water level to reach the top of the axles.

• Before using the machine in water, inject large quantities of fresh grease into the appropriate grease fittings.

• After completing the operation make sure to inject fresh quantities of grease into any fitting that was in water.

• WARNING

Before you operate this machine on a hill, always put the transmission in a lower range and test the brakes.

DO NOT let the machine move down a hill with the transmission in NEUTRAL. DO NOT use the Declutch Switch when operating on a hill.

• Use extra caution on hillside operations.

• The engine angularity limit is 30 degrees. Do not operate machine at a greater angle when operating on a slope either ascending or descending.

• Make sure that the low speed travel is selected.

• Always travel in the same direction as the slope, to prevent the machine from turning over.

IMPORTANT: On steep slopes using the down shift mode of the transmission is recommended to aid braking and to help prevent brake over heating and premature disc wear.

Do not operate the machine in a fast flowing stream.

Failure to comply could result in injury or death.

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS MOVING A DISABLED MACHINE ENGINE STALLS WHILE TRAVELING Brake System: The brakes can be applied by pressing the pedal for four or five applications until the accumulator is discharged. The operator must limit use of the brakes in this situation. In the event the brakes cannot be applied by the pedal, apply the parking brake switch.

Steering System: The steering effort increases when the hydraulic system loses power. In the event the engine stalls while traveling, park the loader in a safe position and find the problem.

ENGINE OR HYDRAULIC FAILURE If your machine is disabled, you must make a judgement if the machine can be moved without further damage. If possible, repair the machine at the job location.

If you cannot repair the machine at the job location and if you have a transport trailer, park the trailer as close as possible to the machine.

NEVER TOW THE MACHINE FROM THE FRONT

BS08J062

Figure 36

1. When towing the machine, attach suitable towing equipment to the towing pin (1).

IMPORTANT: Make certain the towing machine has adequate brake capacity to safely stop both machines.

2. If the machine cannot be started to release the parking brake, the brake must be mechanically released: a. Put blocks in front of and behind each wheel. b. Clean the area around the parking brake cover to eliminate contamination. c. Remove the parking brake cover. d. Loosen the lock nut. e. Turn the adjusting screw counterclockwise until the parking brake is released. f. Tighten the lock nut and replace the cover.

3. If the machine is to be towed more than 0.8 km (1/2 mile) you must disconnect the front and rear drive shafts.

4. Tow the disabled machine at a maximum speed of 2 km/h (1.2 mph). Tow the machine only for a short distance.

4-20

DISCONNECTING DRIVE SHAFTS

BC08H167

Figure 37

If the engine is inoperable and the machine must be towed, it will be necessary to disconnect the front and rear drive shafts.

1. Block the wheels to prevent any unexpected movement of the machine.

2. Disconnect the front and rear drive hafts.

3. Loosen the steering cylinder as the steering operation will not work.

4. The parking brake is activated by spring and hydraulic pressure. If the engine is not operating, the brake will not release. See steps for releasing parking brake or contact your authorized dealer.

CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE

WARNING The machine can slip and fall from a trailer or ramp. This can cause injury or death. Make sure the trailer and ramp is not slippery. Remove all oil, grease, ice, etc. Carefully move the machine off or onto the trailer with the machine centered on the trailer and ramp. Failure to comply could result in injury or death.

SB042

WARNING Before you put the machine on a trailer, remove all snow, ice, oil or grease from the trailer and ramp. Failure to comply could result in injury or death.

46-76C

WARNING Know the rules, regulations, laws and safety equipment necessary for transporting or operating this machine on a road or highway. Rotating beacon, backup alarm, slow moving vehicle emblem and other safety equipment items are available from your dealer. Failure to comply could result in injury or death.

84-13A

You must know the rules or laws for transportation and safety that are used in each area that you will be in. Make sure that the truck and machine are equipped with the correct safety equipment.

1. Put a block at the front and rear of each trailer wheel.

2. Carefully move the machine SLOWLY onto the trailer.

3. Lower the loader bucket onto the trailer.

4. Put the Transport/Service link in the LOCKED position.

5. Apply the parking brake and stop the engine.

Remove the key.

6. Make sure the transmission control is in the NEUTRAL position and loader controls are in the HOLD position.

7. Turn the battery master disconnect switch to the OFF position.

8. Put blocks at the FRONT and REAR of each tire of the machine.

9. Use chains to fasten the machine to the trailer.

10. Put a cover over the exhaust pipe.

11. Measure from the ground to the highest point of the machine. You must know the clearance height of the machine.

12. Advise driver of weights of machine and attachments if special permits or guidelines are necessary.

NOTE: Size of machine may require disassembly of machine components. Contact your authorized dealer for further information.

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE ON A TRAILER Make sure you know the safety rules and regulations before transporting the machine. Make sure both trailer and machine are fitted with the correct safety equipment.

BC08H384

Figure 40

3. Once the machine is loaded on the trailer, put the transportation/service link in the locked position.

4. Apply the parking brake and stop the engine.

Place blocks in front and back of each wheel.

BC08H382

Figure 38

Measure the distance between the ground and the highest point of the machine. You must know the overall height. See Machine overall dimensions in the Chapter 8 (Specifications).

LOADING THE MACHINE ON A TRAILER

5. Use chains to fasten the machine to the trailer.

6. Make sure that all doors, hoods, and access panels are correctly locked.

7. There are two tie down locations forward and two at the rear.

8. Supply any necessary permits as well as weights, heights, etc. to the driver.

TRANSPORTING THE MACHINE BY RAIL Transport by rail is subject to specific regulation.

Consult an approved organization.

BC08H383

Figure 39

1. Keep all unauthorized personnel clear of the area. Load the machine on flat ground. Use a ramp with sufficient weight and width capacity.

Do not change direction of the machine while it is on the ramp.

2. Move the machine slowly and carefully up the ramp.

4-22

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING IN COLD CLIMATE CONDITIONS Cold weather conditions require special operating procedures. During these conditions your machine will require special start up, warm up and maintenance procedures for the best performance. Proper cold weather maintenance will extend the service life of your machine.

BATTERIES

COLD TEMPERATURE STARTING AIDS

Clean the batteries and make sure they are at full charge. In cold conditions it is important to run the machine long enough to return the charge lost by starting. In most cold conditions this is about ten minutes, but in extreme cold it can be 30 minutes.

This machine may be equipped with an engine grid heater. Turn the key switch to ON and wait for the engine grid heater indicator lamp to go out. The indicator light may come on again during cranking and shortly after the engine starts for post heating of the air. This allows for smooth running conditions during cold weather warm up.

NOTE: A fully charged battery at -17° C (0° F) has only 40% of the normal starting power. At -29° C (-20° F) the battery has only 18%.

WARNING Inspect the battery cables and terminals. Clean the terminals and apply electrical terminal sealers to prevent corrosion. See your dealer.

If water is added to the batteries and the temperature is below 0° C (32° F), charge the batteries or run the engine for approximately 2 hours. This will prevent battery freezing.

LUBRICANTS Follow the recommended oil and filter service for the engine and hydraulic system as shown in this manual. Use the correct viscosity oil in each component for the ambient temperatures the machine is operating in. For extreme cold conditions, contact your dealer for alternative lubricants for the hydraulic and transmission systems.

FUEL Check with your fuel supplier for the correct cold weather fuel. Engine power will be reduced if wax particles are in the fuel filters. Some cold weather fuel blends result in lower engine power.

C h e c k fo r w a t e r i n t h e f u e l s y s t e m . C o l d temperatures can cause condensation to form in the fuel tank. Check and drain the fuel filter and fuel tank for water as required.

COOLING SYSTEM Check the coolant mixture before operating in cold temperatures. A mixture of 50% ethylene glycol and 50% water must be used. This mixture is used if the lowest ambient temperature is -37° C (-34° F). If the ambient temperature is lower, adjust the mixture. It is recommended that ethylene glycol and water be used in the machine all year long. See Engine Cooling System in this manual.

Do not use ether or other starting products with this machine. Failure to comply could result in serious injury or death.

MACHINE WARM UP Once the engine has started, run the engine at about half throttle (1100 to1300 rpm) for a minimum of four minutes under no load. This will help stabilize the engine.

After engine warm up, turn the pilot control switch (located on the console) to the on position. Place the lift arm into float and the bucket into roll back to load the engine in order to heat the hydraulic oil. Hold for approximately two minu tes. This will yield approximately 20° C (68° F). Apply and hold the foot brake, cycle the lift arm and bucket. Repeat the f l o a t / r o l l b a c k h e a t i n g p r o c e d u r e a g a i n fo r approximately two minutes. Raise the lift arms enough to steer the unit full left and right to warm the oil in the steer ing cylinders. In extreme cold conditions, hold the float/roll back condition for five minutes maximum.

WARNING Make sure there is clearance around the machine before steering the machine left and right. Keep all non-authorized personnel clear of the area. Failure to comply could result in serious injury or death.

Even with the correct oil in the hydraulic/brake system the first few times the brakes are actuated there may be some delay before the brakes are applied. The operator must actuate the brake pedal a minimum of 8 to 10 times before the machine is moved to obtain proper heating. Actuating and releasing the brakes should occur in a cycle of 3 seconds full on and 3 seconds off to obtain exchange of the brake oil.

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS In extreme cold weather conditions, the brake response can be slow. The use of correct oil in the hydraulic/brake system is required in persistently severe applications. Contact your dealer for the correct oil.

When the machine has been correctly warmed up, apply the foot brake and push the parking brake to the OFF position. Shift the transmission to forward, and carefully release the foot brake. Operate the machine in a clear and safe area. Check the full operation of the machine.

IMPORTANT: DO NOT operate the machine on the road until the transmission oil and axle oil have been correctly warmed up. Operate the machine in a clear safe area before road operation in first and second gear only.

If the machine has been left idling in cold temperature, the engine will stay warm, but the hydraulic/brake oil and the axle oil will not stay warm. The oil and components can become cold and slow brake function response time. If this should happen you MUST go through the complete warm up procedure.

NOTE: The transmission is equipped with internal protection that does not allow the transmission to engage below -12° C (10° F). If the transmission does not engage below these temperatures, allow 2 to 4 minutes of running in neutral and try again.

Warm up time necessary may vary depending on temperature and conditions.

4-24

OPERATING THE MACHINE IN HOT CLIMATES 1. Keep the coolant at the correct level in the coolant reservoir and in the radiator.

2. Use the correct solution of ethylene glycol and water in the cooling system.

3. Check the cooling system cap before hot weather starts. Replace the cap as required.

Replace with a genuine replacement part to insure the correct PSI rated cap.

4. Clean all dirt and debris from the radiator, cooler, and engine area.

5. Check the condition of the engine accessory drive belt.

6. Use lubricants of the correct viscosity. See fluids and lubricants in the Chapter 5, Lubrication, Filters, and Fluids.

CHAPTER 4 - OPERATING INSTRUCTIONS STORAGE PREPARATION FOR STORAGE

PERIODIC CHECKS

The following procedure applies when the machine is to be stored for a month or more. Store the machine on firm, level ground, inside a building or, if not possible, outside and covered with a tarpaulin.

Before storing the machine, carry out the following operations:

Every month, check:

1. Clean the machine.

2. Retract the arm cylinder rod as far as possible, and lower the boom until the attachment is resting on the ground.

3. Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your Case Dealer.

1. The battery charge and battery electrolyte level.

Recharge the batteries if required.

2. The grease on the cylinder rods and/or perform attachment functions monthly.

3. The fuel level in the fuel tank and the corrosive oil level in the engine. Add more if necessary.

4. The condition of all lines, connectors and clamps (rust). Grease if necessary.

5. The condition of the paint work. Apply a coat of anti-rust treatment where necessary.

STARTING UP AFTER STORAGE 1. Close the drain valves and fill the cooling system.

NOTE: When the machine resumes service, the film will disappear automatically.

2. Drain the fuel reservoir and top up with suitable fuel, see “Fluids and Lubricants” in section 5.

1. Drain the fuel tank, and fill with a mixture of 90% diesel fuel and 10% anti-corrosive oil. Run the engine at idle speed for five minutes to allow the anti-corrosive oil to reach the lines, filters, pump and injectors.

3. Drain the engine sump, fill with clean engine oil and check the oil level.

4. Replace the filtering element of the fuel filters.

2. While the engine is still warm, drain the oil sump, fill with anti-corrosive oil, and replace the engine oil filter.

7. Check the condition of the engine accessory drive belt, and replace it if necessary.

5. Install the batteries.

6. Grease the machine thoroughly.

3. When the engine is cold, clean the outer parts of the engine with diesel fuel.

8. Check the condition of the air conditioning drive belt and replace it if necessary.

4. Clean or replace the air filter element.

9. Check the hydraulic fluid level, and add more fluid if necessary.

5. Drain the cooling system, leave the drain valves open, and do not tighten the radiator cap.

10. Clean the cylinder rods.

6. Grease the cylinder rods.

11. Unplug the air filter inlet and the exhaust pipe.

7. Remove the batteries, clean the battery housings and make sure not to leave any traces of acid.

Store the batteries safely in a cool and dry location, where the temperature will be higher than 0° C (32° F).

12. Remove the “DO NOT OPERATE” tag and start the engine, following the starting up procedure.

Keep non-authorized personnel clear of the machine.

8. Paint any areas where the paint shows signs of deterioration.

9. Plug the air filter inlet and the exhaust pipe.

10. Remove the starter switch key and place a “DO NOT OPERATE” label on the right-hand control arm.

11. Lock the hoods and the cab door.

13. Keep a careful watch on all systems display panel lamps and indicators.

WARNING Avoid running the engine in a confined place. Make certain there is adequate ventilation at all times.

Failure to comply could result in injury or death.

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS ADJUSTMENT OF BUCKET/ATTACHMENT The bucket can be adjusted in height by using the boom kick-out device.

WARNING Park the machine on level ground and block the tires to prevent unexpected movement. Press the parking brake switch and use the safety lock bar.

Keep clear of the bucket/attachment. Failure to comply could result in injury or death.

BC08H221

Figure 43

3. Loosen the bolts and nuts. Move the plate or proximity switch so the boom is in line with the center of the sensing surface of the proximity switch. Tighten the bolts and nuts.

Figure 41

BS08C142

WARNING Always support the bucket and/or lift linkage. Failure to comply could result in injury or death.

1. Start the engine. Lift the boom up to the desired height, move the boom control lever to hold, then stop the engine.

BS08C141

Figure 42

2. Move the hydraulic control lock lever into the LOCK position.

4-26

BS08C142

Figure 44

4. Loosen the nuts so a clearance between the boom and the probe of the proximity switch is a maximum of 6 mm (.236 in).

5. To check adjustment, start the engine. Position the bucket on the ground, then lift bucket to the desired height by using the control lever. Release the lever and confirm the lever automatically returns to the neutral position and the bucket attachments stops at the adjusted position.

CHAPTER 4 - OPERATING INSTRUCTIONS BUCKET LEVEL

BS08C177

Figure 45

The bucket angle of the machine is set to be parallel to a level operating surface.

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-28

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS SERVICING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SUPPORT STRUT FOR LOADER LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Capacities and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ENGINE OIL VISCOSITY / TEMPERATURE RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Transmission Oil Viscosity / Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 DAILY INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 MAINTENANCE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15 5-17 5-19 5-25 5-29 5-37 5-41 5-46

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SERVICING INSTRUCTIONS GENERAL INFORMATION Follow the maintenance intervals by checking the hour meter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the bucket/attachment on the ground.

Keep all non-authorized personnel clear of the area.

Un less otherwise specified , all m aintenance operations should be carried out with:

• the engine stopped • the transport/service link locked into position to stop the machine from unexpected articulation

• • • • • •

the parking brake engaged the key removed from the key switch a DO NOT OPERATE tag on the key switch wheel chocks blocking the wheels all circuits cooled down prior to starting work all hydraulic pressure released in lift arm and bucket/attachment circuits

• any accumulator pressure released for the

When performing service work on the machine, place a Do Not Operate tag on the instrument panel or key switch. Turn off engine and remove key before leaving operator's compartment.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization.

Consult your dealer.

The service intervals in this chapter refer to normal operating conditions. During the first operation period of a new machine or rebuilt component and under particularly severe conditions, the service intervals should be carried out more frequently.

IMPORTANT: Take particular care to replace all filters regularly. Clean filters mean longer engine running life.

IMPORTANT: Oils and fluids must be disposed of properly.

HOUR METER

appropriate circuit Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits.

Wear suitable clothing and remember to use the necessary safety equipment.

WARNING There is a risk of serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your dealer. Failure to comply could result in machine damage, serious injury or death.

BS08J177

WARNING Before attempting any service procedures on the machine it is your responsibility to know how many accumulators are on the machine and how to properly release pressure of each. Failure to comply could result in serious injury or death.

M959

WARNING

Figure 1

The hour meter enables service operations to be scheduled. Its hourly indications are the same as those of a clock when the engine is running.

Ser vicing inter vals are carefully calculated to guarantee safe and efficient machine operation.

Be sure to carry out all the servicing operations properly as defined in this manual.

Be sure all the service operations in this section are carried out punctually at the intervals given, in order to insure optimum performance levels and maximum safety when using the machine. Failure to comply could result in machine damage, serious personal injury or death.

5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SUPPORT STRUT FOR LOADER LIFT ARMS WARNING If you service the machine with the loader lift arms raised, always use the support strut.

1. Empty the loader bucket, raise the loader lift arms to approximately 7 ft. (2.1m) and stop the engine.

2. Remove the support strut from the storage position by removing the retaining bolt.

3. Place the support strut onto the cylinder rod with guide lock tab on top of cylinder and pointing toward the bucket.

4. Install the retaining bolt entirely into the support strut using all threads.

5. Slowly lower the lift arms onto the support strut.

If you do not follow this procedure, you can cause death or serious injury if the loader lift arms are lowered unexpectedly. Failure to comply could result in serious injury or death.

M824

TRANSPORT SERVICE LINK

SUPPORT STRUT

Figure 2

BD03A092-01

SUPPORT STRUT IN SERVICE POSITION

Always place the support strut in the service position if raising in arms in order to service the machine.

5-4

BC08H241

Figure 3

Prior to any maintenance, ser vice work or transportation, lock the articulation transport service link. Remove the safety security pin to change positions of the service link.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground, lower the bucket/attachment to the ground and stop the engine.

Figure 5

BC08H223

3. Operate the control levers from right to left and front to rear approximately a dozen times. Turn the ignition key to the OFF position.

WARNING BC08H198

Figure 4

2. Turn the ignition switch key to the “ON” position.

Pilot control switch must be on.

Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed. Failure to comply with this warning could result in injury or death.

WARNING Before carrying out any service work on the hydraulic system, it is necessary to allow the system to cool (the temperature should not be more than 40°C (104° F). Failure to comply with this warning could result in injury or death.

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS CAPACITIES AND SPECIFICATIONS Engine Type of oil ................................................................................................................... Case Akcela (SAE 15W-40) Capacity (with filter change) ...............................................................................................................10 gal. (38 L) Cooling System System capacity ............................................................................................................................. 17.2 gal. (65 L) Fuel System Reservoir capacity......................................................................................................................... 124 gal. (470 L) Hydraulic / Brake System Type of fluid ...................................................................................................................Case Akcela Hy-Tran Ultra Total system capacity ...................................................................................................................... 90 gal. (340 L) Reservoir capacity........................................................................................................................ 55.5 gal. (210 L) Transmission Type of oil ................................................................................................................... Case Akcela (SAE 15W-40) Refill capacity - with filter change................................................................................................... 11.4 gal. (43 L) Axles Type of oil ........................................................................................ Case Akcela Transaxle Fluid (SAE 80W-140) Front Capacity .................................................................................................................................15.9 gal. (60 L) Rear Capacity .................................................................................................................................15.9 gal. (60 L) NOTE: Machines are shipped from the factory with break-in oil.

Fittings Grease fittings, as required .......................................................................................... Case Akcela Molydisulfide

5-6

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE OIL VISCOSITY / TEMPERATURE RANGES

BC02N250A

Figure 6

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures are in Winter or Arctic conditions.

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid starting the engine and in providing sufficient oil flow at ambient temperatures below 23°F (-5°C). The continuous use of low viscosity oils can decrease engine life due to wear. See the chart above for the correct oil for ambient temperatures.

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS TRANSMISSION OIL VISCOSITY / TEMPERATURE RANGES

Figure 7

BC04F193

HYDRAULIC/BRAKE SYSTEM - TEMPERATURE RANGE

BC04F192

5-8

Figure 8

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing.

For areas where the ambient temperature is over -36°C (-34°F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C (-34°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

FUEL Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In very low ambient temperatures, use a mixture of fuels No. 1 and No. 2 as necessary. Consult your fuel supplier for appropriate fuel supply.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.

BIODIESEL Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

IMPORTANT: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751.

IMPORTANT: It is imperative that you check which blend is approved for your engine with your local dealer. Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

BIODIESEL FUEL USAGE CONDITION Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing Biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

Engine perfor mance is effected by the use of biodiesel fuel. An up to 12% reduction in power/torque can be experienced.

IMPORTANT: DO NOT modify the engine and/or fuel injection pump to recover reduced performance.

The reduced power must be accepted if using any Biodiesel fuel blend.

Some modification may be required to allow the engine to use biodiesel. Consult your local dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

It may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently when using biodiesel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank.

These particles are then trapped by the vehicle filters and may cause shor tened filter life and/or filter blockages.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Biodiesel will actually attract moisture from the atmosphere. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BIODIESEL STORAGE

ENGINE OIL

IMPORTANT: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

Case Akcela engine oil is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions. See charts at the beginning of this section to choose the correct oil for climate/temperatures.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the engine fuel system.

Clean up any spills of biodiesel on the machine, as biodiesel fuel can cause paint damage.

If Case Akcela engine oil cannot be obtained, use only oil of the API SERVICE CI-4 category.

NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out utilizing Case lubricants.

FUEL STORAGE Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

HYDRAULIC FLUID Case Akc ela Hy -Tra n U ltra hy draulic fluid is specifically designed for high pressure applications and for Case hydraulic systems. Your Case Dealer can provide hy draulic fluid to fulfill different climate/temperature conditions. Refer to the charts at the beginning of this section.

TRANSMISSION COMPONENT OIL Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is m a n u fa c t u r e d fo r yo u r c l i m a t e / t e m p e r a t u r e conditions such as Case Akcela No. 1 SAE 15W-40, Hy-Tran Ultra, Hy-Tran Ultra SS. See charts at the beginning of this section.

GREASE The type of grease to use depends on ambient temperature such as: Case Akcela Molydisulfide Grease ENVIRONMENT Before you service this machine and dispose of oil, fluids, and lubricants, obey environmental regulations. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

5-10

RD97F136-01

Figure 9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

DAILY INSPECTIONS Every day, before starting work, it is necessary to inspect the machine and service cer tain components.

WARNING If the slightest defect is found, repair it immediately before using the machine or see your Dealer.

Failure to comply with this warning could result in injury or death.

After Starting the Engine Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Check for abnormal noise on the hydraulic components.

Check for water or oil leaks on the components.

Check the audible alarm devices, working lights and windshield wipers.

Check that all hydraulic circuits are functioning correctly.

General Check for water or oil leaks.

Check that all screws and nuts are correctly tightened.

Wipe off any dust and clean off any accumulated debris (engine, operator's compartment, etc.).

Check tires for proper inflation.

Check for damage.

Engine Check the oil level an d ch ange the oil, if necessary.

Check the coolant reservoir fluid level.

Check for clogging or damage to the radiator.

Check the engine accessory drive belt tension.

Check for water or oil leaks on the components.

Check the condition of all lines.

Check the fuel tank level.

Check for any warning gauges or lights on console.

Other Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check the condition of all lines.

Check for electrical short-circuits.

Check that all battery connections are properly tightened.

Adjust the rear view mirrors.

Check for oil leaks on the cylinders.

Check the condition of the bucket/attachment.

5-11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

5-36

Air filter

AR

6-5

Tires

AR

5-16

Fuel water separator

AR

5-36

Air conditioner and heater

AR

5-17

Engine oil level

10

Hydraulic oil level

10

Radiator coolant

10

Belt tension

10

5-18

Fan inspection

10

5-19

Lubricate machine attachments

5-21

Engine oil and filters (initial only)

Run-in

50

5-23

Fuel prefilter (initial only)

Run-in

50

5-23

Fuel filter (initial only)

Run-in

50

5-24

Pilot line filter

Run-in

50

6-7

Wheel torque check

50

6-5

Tire air pressure

50

5-25

Transmission oil and filter (initial only)

Run-in

100

5-27

Front and rear axle oil (initial only)

Run-in

100

5-29

Attachment

250

5-30

Drive shaft

250

5-30

Steering cylinder pins

250

5-30

Rear axle pivot

250

6-5

Tire pressure and wheel torque

5-31

Engine oil and filter

5-33

Fuel tank

5-33

Brake line filter

5-34

Pilot filter

250

5-34

Hydraulic oil return filter

250

5-35

Hydraulic air breather element

250

5-36

Climate control filters

250

7-5

Battery

5-37

Fuel filter

500

5-38

Coolant filter

500

5-39

Radiator, oil cooler

500

5-40

Air cleaner (primary)

500

DRAIN

LUBRICATE

REPLACE

CHECK

PAGE

SERVICE POINTS

CLEAN

SERVICE INTERVALS

INITIAL NEW MACHINE

INTERVALS IN HOURS

AR

As Required

5-17 Every 10 hours 5-18 or shift change 5-18

Every 50 hours

Every 100 hour

Every 250 hours

Every 500 hours

5-12

50

250 250 250 250

250

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Every 1000 hours

Every 2000 hours

5-41

Center pivot pin

5-42

Transmission oil

1000

5-42

Transmission oil filter

1000

5-44

Front and rear axle oil

1000

5-46

Hydraulic oil

2000

5-49

Coolant

2000

DRAIN

LUBRICATE

REPLACE

CHECK

PAGE

SERVICE POINTS

CLEAN

SERVICE INTERVALS

INITIAL NEW MACHINE

INTERVALS IN HOURS

1000

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

MAINTENANCE LOCATIONS

10 23 15 27 18

11

8

26

17

6

7

1

9

24 11

21

13

1

22

HYDRAULIC OIL LEVEL ENGINE ENGINE OIL LEVEL ENGINE OIL FILTER RADIATOR COOLANT BELT TENSION ATTACHMENT PINS TIRE FRONT-CENTER DRIVE SHAFT STEERING CYLINDER PINS

5-14

20

5

25 11

7

12

Figure 10

BC08H358

1.

2.

3.

4.

5.

6.

7.

8.

9.

14

2

3

6

4

1

10.

11.

12.

13.

14.

15.

16.

17.

18.

REAR AXLE PIVOT WHEEL NUTS FUEL TANK BRAKE LINE FILTER BATTERY HYDRAULIC RETURN FILTER HYDRAULIC TANK BREATHER PILOT LINE FILTER FUEL FILTER

19.

20.

21.

22.

23.

24.

25.

26.

27.

COOLANT FILTER RADIATOR, OIL COOLER CENTER PIVOT PIN TRANSMISSION OIL TRANSMISSION OIL FILTER FRONT AXLE OIL REAR AXLE OIL AIR CONDITIONER AND HEATER FILTERS AIR CLEANER ELEMENTS

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SCHEDULED MAINTENANCE VARIABLE PERIODIC MAINTENANCE Some working environments require that maintenance be performed more frequently. Dust, dirt, moisture, extreme hot or cold and many other factors should be taken into consideration when servicing the machine. Certain equipment or auxiliary tools may cause more stress on hydraulics, drivetrain, engines or filters. The following maintenance should be performed on regular schedules, but often need special attention when conditions require.

Engine Air Filter

Fuel Filter

Check the primary air filter for restrictions if the air filter indicator lamp illuminates. Replace if necessary

Raise the engine hood, the fuel prefilter is located on the right side of the chassis. Drain any water and sediment from the fuel prefilter. To drain, slowly loosen the drain valve located under the filter and allow to drain until clean fuel runs out.

The primary element may be cleaned by using air, h oweve r a n ew e l e m e n t i s r e c o m m e n d e d , i f questionable.

The inner element must not be cleaned. It must be replaced.

Retighten the valve, but do not overtighten.

For further information, see fuel prefilter procedure in this chapter.

Tires and Wheels Adjust the inflation pressure of the tires every time that circumstances require. A daily visual inspection during the pre-start walk around and mechanical checks when environmental or work conditions require more.

Wheels should be checked for proper torque every twenty hours when new and until they remain tight.

S e e t h e W h e e l B o l t To r q u e i n C h a p t e r 6 fo r pressures and torques.

Air Conditioning Condenser Use compressed air to remove debris and buildup on the air conditioning condenser. See Chapter 6 Maintenance - Cab Air Conditioning for fur ther information.

Bleeding Air from the Fuel System Prolonged period of inactivity or running out of fuel may allow air to get into the fuel system. If this should happen make sure the tank is full and then bleed the system.

Fuses Fuses may be reached by opening the access door located on the right side of the cab. If a fuse has blown, the indicator light will illuminate.

NOTE: If a fuse blows, replace it at once. Locate the problem and if it re-occurs, have it checked by a service technican.

WARNING Wear full coverage safety glasses with side panels when using compressed air. Limit the pressure to 29 psi (2 bar). Failure to comply may result in death or injury.

Oil Cooler Use compressed air to remove debris and build up that may impede proper function of the fuel and/or oil cooler.

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS VARIABLE PERIODIC MAINTENANCE

DRAIN FUEL FILTER CONDENSATION

PRECLEANER (If Equipped)

Drain the water and sediment from the fuel prefilter as required. In cer tain geographic regions and climates, it may be necessary to drain condensation more frequently. The prefilter is located on the right hand side of the engine.

Check the precleaner bowl and remove dust as required.

BD06F018-01

Figure 11

1. Loosen nut and remove the cap.

2. Remove bowl and clean with damp cloth.

3. Replace bowl and cap. Secure in place with wing nut.

Figure 12

BD03A015

1. Open the drain valve on the fuel prefilter by turning counterclockwise 2 or 3 turns. The valve will drop down. Drain the water and/or contaminants from the fuel filter into a suitable container until clean fuel flows. Do not allow fuel to spill on engine or ground.

2. Lift the valve and turn clockwise until hand tight.

Check for leaks.

WARNING Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, pipes, etc. Failure to comply could result in serious injury or death.

5-16

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE ENGINE OIL

HYDRAULIC OIL LEVEL

Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . . 10 gal. (38 L)

Service Specifications System capacity . . . . . . . . . . . . . . . .90.0 gal. (340 L)

The engine oil level should be checked every 10 hour shift or each day, whichever occurs first.

Figure 14

BC08H342

Check the level of the hydraulic oil tank every 10 hours or at the beginning of each shift. Park the machine on hard, level ground.

Rest the bucket/attachment on the ground, turn-off the engine, and check the level on the indicator.

The oil level should be aligned with the center indicator mark.

In the event oil is needed, relieve all pressure in the system, then slowly loosen the tank cap and top-off until the proper level is reached. See releasing hydraulic pressure and filling the hydraulic tank in this section.

BC08H320

Figure 13

Keep all non-authorized personnel clear of the area.

Park the machine on a firm, level surface and turn off the engine. Remove the dipstick, and check the engine oil level. This procedure is best performed at the beginning of the work day with the engine cool and all oil drained to the pan.

The fill location is located in the main engine compartment. Do not overfill engine oil.

WARNING The hydraulic oil tank is pressurized. All pressure should be removed before working on the hydraulic system. If removal of the cap is required, loosen it slowly to relieve residual pressure in the tank. Do not overfill. Failure to comply may result in death or injury.

IMPORTANT: Do not operate the machine unless the engine oil level is in the normal range.

5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS CHECK DRIVE BELTS

10 HOUR MAINTENANCE ENGINE COOLANT Service Specifications System capacity . . . . . . . . . . . . . . . . 17.2 gal. (65 L) Check the coolant reservoir level every 10 hours of operation or at the beginning of each shift. Perform this check when the coolant is cold and the engine is stopped. Do not remove the radiator cap during this check.

Figure 16

BC08H157

Inspect the drive belts every 10 hours or before the beginning of every shift. Check the belts for splits, cracks, separation, or fraying. Replace any belt that is visually defective.

ENGINE FAN Figure 15

BC08H230

The coolant level must be in the center of the sight gauge. Add coolant through the radiator cap as required to raise the coolant level to the full mark.

Do not add cold water or coolant to a hot engine.

Allow the engine to cool below 120 F° (50° C). See filling coolant in this section.

NOTE: In the event that the system needs topping off make sure to use the proper ratio of water and antifreeze/coolant. Do not overfill.

Figure 17

BC08H068

WARNING Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap: Let the system cool, turn to first notch, then wait until all pressure is released.

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions. Failure to comply may result in death or injury.

5-18

Perform a visual check of the fan every 10 hours or at the beginning of each shift. Check fan blades for any defects, loose rivets, bent, or broken blades. Check the fan to make certain it is securely mounted.

WARNING Rotating parts can cause severe personal injury. Do not work around the fan with the engine running.

Failure to comply may result in death or injury

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE BUCKET/ATTACHMENT GREASE FITTINGS Service Specifications Grease. . . . . . . . . . . . . . . Case Akcela Molydisulfide Grease the attachment fittings when the hour meter registers 50 hours of operation or sooner if conditions so require.

MAINTENANCE OF LOADER LIFT ARM AND BUCKET/ATTACHMENT (1)Lubricate each pin of attachment and arm. Inject grease into zerts as necessary.

No Description Qty .

A Bucket cylinder (Front frame side) right pin 1 B Boom cylinder (Front frame side) right pin 1 C Boom-front frame right connection pin 1 Steering cylinder (Front frame side) right D 1 pin E Boom-front frame left connection pin 1 F Boom cylinder (Front frame side) left pin 1 G Bucket cylinder (Front frame side) left pin 1 H Steering cylinder (Front frame side) left pin 1 I Drive shaft (middle) pin 1 J Boom cylinder-boom connection pin 2 K Bucket cylinder-bell crank connection pin 2 L Boom-bell crank connection pin 2 M Bell crank-bucket link connection pin 2 N Bucket-Bucket link connection pin 2 O Bucket-boom connection pin 2

BC08H348

Figure 18

(2)Check for wear and tear of attachment pins and bushings.

(3)Check for damage of boom and bell crank.

NOTE: Shorten lubricating interval when working in the water or dusty conditions.

BC08H347

Figure 19

(4)Dust seals are mounted on pins of attachment and arm to extend the lubricating interval.

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE IMPORTANT: If replacing dust seals, mount the lip facing out. If assembled in wrong direction, it will cause faster wear of pin and bushing, and create noise and vibration during operation. Make sure the seals are not damaged or deformed.

Figure 20

BC08H158

Clean around the area to be greased before service.

In severe conditions, such as immersion in water, it may be necessary to grease more frequently.

WARNING Prior to maintenance always have the machine on firm, level ground with the bucket/attachment on the ground. Make sure all residual pressure is relieved from circuits before beginning maintenance. Failure to comply could result in serious injury or death.

WARNING Do not work under or near the bucket/attachment of a machine or components which are not adequately supported or blocked. Failure to comply could result in serious injury or death.

5-20

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE CHANGE ENGINE OIL AND FILTER (Initial) Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . . 10 gal. (38 L) Change the engine oil and filter when the hour meter registers 50 hours for a new machine during the initial run-in period. The engine oil and filter should be changed every 250 hours thereafter or more frequently when the engine operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

BC08H327

Figure 22

4. The drain valve is located behind the rear axle on the skid plate of the fuel tank. Use a suitable container to capture the used oil, and remove the remote oil drain plug. Drain the engine oil completely.

NOTE: When changing engine oil, the oil flow rate can be improved if the oil fill cap or dipstick is removed from the engine while draining.

BC08H323

Figure 23

5. Clean area around filter head.

6. Use oil filter wrench to remove the oil filter.

BC08H320

Figure 21

7. Clean the gasket surface of the oil filter head.

The O-ring may adhere to the filter head. Make certain to remove the O-ring. Replace the O-ring if damaged.

3. Operate the machine until the engine temperature reaches 140° F (60° C). This will allow the oil to warm and drain faster. Shut the engine off.

5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE

BC08H326 BC08H324

Figure 24

Figure 26

13. Fill the engine with the proper amount of oil.

8. Apply a light film of lubricating oil to the gasket sealing surface before installing filter.

14. Start the engine and run at idle speed. Check the engine oil filter and remote drain for leaks.

9. Fill the filter with clean lubricating oil

15. After two minutes stop the engine.

16. Wait for the engine oil to drain down for an accurate reading on the dipstick.

10. Install the filter to the filter head.

17. Check the dipstick and add additional oil, if necessary. Do not overfill.

BC08H325

Figure 25

IMPORTANT: Never use a filter wrench to install a new filter.

11. Turn the new oil filter onto the base until the gasket makes contact with the base and then turn by hand an additional 3/4 turn.

12. Install the remote drain plug. Inspect the drain plug for proper tightening. Replace if plug is damaged or not providing a tight seal.

5-22

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE DRAIN FUEL FILTER CONDENSATION Drain the water and sediment from the fuel prefilter as required. In cer tain geographic regions and climates, it may be necessary to drain condensation more frequently. The prefilter is located on the right hand side of the engine.

Figure 27

BD03A015

WARNING Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, pipes, etc. Failure to comply could result in serious injury or death.

1. Open the drain valve on the fuel prefilter by turning counterclockwise 2 or 3 turns. The valve will drop down. Drain the water and/or contaminants from the fuel filter into a suitable container until clean fuel flows. Do not allow fuel to spill on engine or ground.

2. Lift the valve and turn clockwise until hand tight.

Check for leaks.

REPLACE FUEL FILTER(S) (Initial) Change the fuel filter when the hour meter registers 50 hours for a new machine during the initial run-in period. Filters should be changed every 500 hours thereafter or more frequently when operating conditions are severe.

BC08H335

Figure 28

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the filter head area, the outside of the filter and remove any dirt and debris around the area that might contaminate the system.

4. Turn the filter counterclockwise and remove. Be sure to capture any fuel remaining in the lines or the filter and discard properly.

5. Apply a thin layer of clean oil to the gasket on the new filter.

6. Install the filter. Use your hands to tighten the filter 1/2 to 3/4 turn after the filter makes contact with the filter head.

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE PILOT LINE FILTER (Initial)

Figure 29

BD06F031

WARNING Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

Replace the pilot line filter at 50 hours for a new machine. Replace every 250 hours of operation thereafter or more often if conditions so require.

1. Keep all unauthorized personnel clear of the area. Park the machine on a hard, level surface.

2. Rest the bucket/attachment on the ground, turn-off the engine, Place the safety lock in the locked position.

3. Loosen the nut on the filter body.

4. Pull the filter element out and clean the filter body with a clean, lint free cloth.

5. Install the new element and tighten using following torque chart.

5-24

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE R E P L AC E T R A N S M I S S I O N O I L TRANSMISSION OIL FILTER (Initial)

AND

Service Specifications System capacity . . . . . . . . . . . . . . . . 11.4 gal. (43 L) Change the transmission fluid and filter when the hour meter registers 100 hours for a new machine during the initial run-in period. Transmission fluid and f i l t e r s s h o u l d b e c h a n g e d eve r y 1 0 0 0 h o u r s thereafter or more frequently when operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on a level surface and apply the parking brake.

2. Lower bucket/attachment to the ground and lock the pilot control lock lever.

3. Put the transport/service link into the locked service position to avoid unexpected articulation and stop the engine.

BC08H352

Figure 31

9. Clean the filter cartridge mounting base. Make certain no part of gasket remains on mounting base.

10. Apply a film of clean transmission oil to the gasket of the new filter and install. Make certain proper contact is made with the base.

11. Install the new filter cartridges. Screw on until filter contacts base, then tighten by hand 1/3 to 1/2 turn more.

12. Install the drain plug.

BC08H256

Figure 30

4. Open transmission air breather to relieve internal air pressure. Clean the area around the filter head and around the transmission drain and fill caps.

5. Remove the fill plug.

6. Have a suitable container that will hold the appropriate amount of fluid before draining.

7. Remove the drain plug and drain the oil.

8. Remove the filter.

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE

Figure 32

BC08H255

13. Fill the oil through gauge inlet and check to make certain oil is at the appropriate level.

14. Remove the breather. Clean it with solvent and dry with compressed air.

WARNING Wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

15. Install the breather.

16. Fill with the specified amount of oil.

17. Check the oil level.

18. Start the engine and check for oil leaks around the filter and drain plug.

19. Bring the transmission oil up to working temperature, and check the level again.

5-26

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE CHANGE FRONT AND REAR AXLE OIL (Initial) Service Specifications Front axle. . . . . . . . . . . . . . . . . . . . . . 15.9 gal. (60 L) Rear axle . . . . . . . . . . . . . . . . . . . . . . 15.9 gal. (60 L) Change the front and rear axle oil when the hour meter registers 100 hours for a new machine during the initial run-in period. Axle oil should be changed every 1000 hours thereafter or more frequently when operating conditions are severe.

BC08H247

WARNING Make sure that the bucket/attachment is resting on the ground and the transport/service link is installed.

Failure to comply could result in serious injury or death.

Figure 34

4. Place a suitable container with sufficient capacity to capture the old oil under the front and rear axles and drain.

BC08H245

Figure 35

5. Place a suitable container with sufficient capacity to capture the old oil under each axle end.

BC08H245

Figure 33

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied. Make certain the plug is parallel with the ground.

6. Remove the drain plug and allow the oil to drain.

7. Reinstall the drain plugs of both axles and the four axle ends.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the area around the drain and fill caps of both axles and all four axle ends.

5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE

BC08H249

Figure 36

8. Fill with the proper amount of axle oil. Oil should overflow from the filler port. Install the plug.

9. Run the engine at low idle for five minutes. Allow the oil to flow completely through the axle oil cooler and hoses.

10. Remove refill plug for the differential and recheck the oil level. Add oil, if required.

NOTE: The oil will take some time to fill each axle.

Allow time for the oil to circulate throughout the axle.

5-28

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE BUCKET/ATTACHMENT GREASE FITTINGS Service Specifications Grease. . . . . . . . . . . . . . . Case Akcela Molydisulfide Grease the attachment fittings when the hour meter registers 250 hours of operation or sooner if conditions so require.

(1)Lubricate each pin of attachment and arm. Inject grease into zerts as necessary.

No .

A B C D E F G H I J K L M N O

Description

Qty

Bucket cylinder (Front frame side) right pin Boom cylinder (Front frame side) right pin Boom-front frame right connection pin Steering cylinder (Front frame side) right pin Boom-front frame left connection pin Boom cylinder (Front frame side) left pin Bucket cylinder (Front frame side) left pin Steering cylinder (Front frame side) left pin Drive shaft (middle) pin Boom cylinder-boom connection pin Bucket cylinder-bell crank connection pin Boom-bell crank connection pin Bell crank-bucket link connection pin Bucket-Bucket link connection pin Bucket-boom connection pin

1 1 1 1 1 1 1 1 1 2 2 2 2 2 2

NOTE: Shorten lubricating interval when working in the water or dusty conditions.

BC08H348

Figure 37

(2)Check for wear and tear of attachment pins and bushings.

(3)Check for damage of boom and bell crank.

BC08H347

Figure 38

(4)Dust seals are mounted on pins of attachment and arm to extend the lubricating interval.

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE IMPORTANT: If replacing dust seals, mount the lip facing out. If assembled in wrong direction, it will cause faster wear of pin and bushing, and create noise and vibration during operation. Make sure the seals are not damaged or deformed.

BC08H158

Figure 40

LUBRICATE MACHINE Add recommended grease through the zerts. Clean off any excess grease.

Figure 39

BC08H158

Clean around the area to be greased before service.

In severe conditions, such as immersion in water, it may be necessary to grease more frequently.

WARNING Prior to maintenance always have the machine on firm, level ground with the bucket/attachment on the ground. Make sure all residual pressure is relieved from circuits before beginning maintenance. Failure to comply could result in serious injury or death.

WARNING Do not work under or near the bucket/attachment of a machine or components which are not adequately supported or blocked. Failure to comply could result in serious injury or death.

BC08H350

Lubricate: Center pivot pin Front (flange bearing) Center (slip yoke)

5-30

Figure 41

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE CHANGE ENGINE OIL AND FILTER Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . . 10 gal. (38 L) The engine oil and filter should be changed every 250 hours thereafter or more frequently when the engine operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

BC08H327

Figure 43

4. The drain valve is located behind the rear axle on the skid plate of the fuel tank. Use a suitable container to capture the used oil, and remove the remote oil drain plug. Drain the engine oil completely.

NOTE: When changing engine oil, the oil flow rate can be improved if the oil fill cap or dipstick is removed from the engine while draining.

BC08H323

Figure 44

5. Clean area around filter head.

6. Use oil filter wrench to remove the oil filter.

BC08H320

Figure 42

3. Operate the machine until the engine temperature reaches 140° F (60° C). This will allow the oil to warm and drain faster. Shut the engine off.

7. Clean the gasket surface of the oil filter head.

The O-ring may adhere to the filter head. Make certain to remove the O-ring. Replace the O-ring if damaged.

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE

BC08H326 BC08H324

Figure 45

Figure 47

13. Fill the engine with the proper amount of oil.

8. Apply a light film of lubricating oil to the gasket sealing surface before installing filter.

14. Start the engine and run at idle speed. Check the engine oil filter and remote drain for leaks.

9. Fill the filter with clean lubricating oil

15. After two minutes stop the engine.

16. Wait for the engine oil to drain down for an accurate reading on the dipstick.

10. Install the filter to the filter head.

17. Check the dipstick and add additional oil, if necessary. Do not overfill.

BC08H325

Figure 46

IMPORTANT: Never use a filter wrench to install a new filter.

11. Turn the new oil filter onto the base until the gasket makes contact with the base and then turn by hand an additional 3/4 turn.

12. Install the remote drain plug. Inspect the drain plug for proper tightening. Replace if plug is damaged or not providing a tight seal.

5-32

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE

REPLACE BRAKE LINE FILTER

DRAIN FUEL TANK

Drain Plug BC08H337

Drain the fuel tank of water and sediment when the hour meter registers 250 hours and every 250 hours thereafter. Drain more frequently if conditions so require.

BC08H228

Figure 48

Clean the brake line filter when the hour meter registers 250 hours and every 250 hours thereafter.

Replace more frequently if conditions so require.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Remove the strainer from filter body.

3. Remove the drain plug in order to drain the fuel tank. When clean fuel runs from the tank, replace the plug. Make certain no fuel leaks from the plug.

5. Reinstall and torque to: 6 - 8 kgfm (43.4 -57.9 lbf. ft).

4. Clean the strainer with suitable cleaning solution.

WARNING Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, pipes, etc. Failure to comply could result in serious injury or death.

5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE

REPLACE HYDRAULIC OIL RETURN FILTER

PILOT LINE FILTER

Replace the retur n filter when the hour meter registers 250 hours and every 250 hours thereafter or more frequently if operating conditions are severe.

WARNING Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

Figure 49

BD06F031

WARNING Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Relieve all pressure in the hydraulic system.

3. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

4. Slowly loosen the filler cap on the hydraulic reservoir to release pressure in the reservoir.

Leave it loose during the procedure.

Replace the pilot line filter ever y 250 hours of operation or more often if conditions so require.

1. Keep all unauthorized personnel clear of the area. Park the machine on a hard, level surface.

2. Rest the bucket/attachment on the ground, turn-off the engine, Place the safety lock in the locked position.

3. Loosen the nut on the filter body.

4. Pull the filter element out and clean the filter body with a clean, lint free cloth.

5. Install the new element and tighten using following torque chart.

BC08H344

Figure 50

5. Remove cover, spring, by-pass valve, and return filter from the tank.

6. Clean spring and by-pass valve. Replace the filter element and reassemble spr ing and by-pass valve and reinstall.

7. Install the cover on tank. Torque to: 6.9 ± 1.4 kgfm (50 ± 10 lb. ft).

5-34

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE REPLACE BREATHER FILTER

Figure 51

BC08H345

Replace the breather filter in the hydraulic tank when the hour meter registers 250 hours and every 250 hours thereafter or more often if conditions so require.

WARNING Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

1. Open the breather cap on the top of the hydraulic tank and relieve the system pressure. Make certain all hydraulic pressure has been released.

2. Remove the cap and the filter element.

3. Replace the filter element with a new one. Apply oil on the O-ring and reassemble.

Torque to 0.7 - 0.9 kgfm (5 - 6 lbf ft).

5-35

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE

CLEAN CAB AIR RECIRCULATION FILTER

AIR CONDITIONER AND HEATER FILTERS

The cab recirculation air filter is located in the operator’s compar tment. Clean at 250 hours.

Replace the filter when the hour meter registers 1000 hours.

Clean and/or replace the air conditioner and heater filters when the hour meter registers 250 hours.

Figure 52

BC08H231

OUTER FILTER The cab filter is located on the left hand side of the machine. Open the compartment door and loosen the wing bolt and remove the outer filter.

Figure 54

1. Open the re-circulation air filter cover, and remove the filter.

2. Replace with a new filter and or clean with low pressurized air. Replace filter and secure the access filter cover.

Figure 53

BC08H232

Pull filter forward to remove. Wipe the inside of the filter housing. Replace with a new filter or clean with low pressure air. Reinstall the filter, replace cover.

WARNING Wear full coverage safety glasses with side panels when using compressed air. Limit the pressure to 29 psi (2 bar). Failure to comply may result in death or injury.

5-36

BC08H233

BC08H155

Figure 55

If using water on filter, make certain it is completely dry before replacing.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE REPLACE FUEL FILTERS Fuel filters should be changed when the hour meter registers 500 hours and every 500 hours thereafter or more frequently if operating conditions are severe.

5. Apply a thin layer of clean oil to the gasket on the new filter.

6. Install the filter. Use your hands to tighten the filter 1/2 to 3/4 turn after the filter makes contact with the filter head.

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

WARNING Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, pipes, etc. Failure to comply could result in serious injury or death.

BC08H335

Figure 56

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the filter head area, the outside of the filter and remove any dirt and debris around the area that might contaminate the system.

4. Turn the filter counterclockwise and remove. Be sure to capture any fuel remaining in the lines or the filter and discard properly.

5-37

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE COOLANT FILTER Coolant filters should be changed when the hour meter registers 500 hours and every 500 hours thereafter or more frequently if operating conditions are severe.

BC08H252

Figure 59

6. Apply a thin film of clean engine oil to the gasket sealing surface before installing the new filter.

Figure 57

BC08H338

WARNING Do not remove the radiator cap from a hot engine.

Allow the engine to cool until the temperature is below 50° C (120° F). Hot steam or coolant can cause severe burns. Failure to comply could result in serious injury or death.

BC08H325

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

7. Install the new filter on the filter head. Use your hands to tighten the filter 1/2 to 3/4 turn after the filter makes contact with the filter head.

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

BC08H340 BC08H339

Figure 58

3. Remove the radiator cap.

4. Turn the valve to the OFF position.

5. Remove and discard the filter. Clean the coolant filter head gasket surface.

5-38

Figure 60

Figure 61

8. Turn the valve to the ON position, and install the radiator cap.

9. Operate the engine and check for leaks.

IMPORTANT: Make certain the valve is in the ON position before operating the engine.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE CLEAN RADIATOR AND OIL COOLER Check and clean the radiator and oil cooler when the hour meter registers 500 hours and every 500 hours thereafter. Clean and check more frequently if conditions so require. Build up of debris can restrict cooling function.

Figure 64

BC08H069

CHECK TURBOCHARGER COOLER Inspect the turbocharger cooler for dirt and debris blocking fins. Check for cracks, holes, or the damage.

If visible damage exists, contact your authorized dealer.

Figure 62

BC08H264

1. Visually inspect radiator fins for clogging and/or debris. Inspect for bent or broken fins.

2. Use 550 kPa (80 psi) air pressure to blow dirt and debris from the fins.

WARNING Accumulation of debris in the engine compartment can be a fire hazard. Periodically check for accumulations of leaves, etc. Failure to comply could result in serious machine damage, injury or death.

WARNING Use a safety type air tool and wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

BC08H265

Figure 63

3. Visually inspect the radiator for core and gasket leaks.

IMPORTANT: If the radiator must be replaced because of broken fins or damage, consult your authorized dealer.

5-39

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE CLEAN AIR FILTER ELEMENT Check the air filter element when the hour meter registers 500 hours and every 500 hours thereafter.

The air filter should be checked periodically for dirt and debris build up. Check immediately if the warning light on the instrument cluster illuminates. Replace the both air filter after cleaning four times or if any damage to the filter is apparent (tears or holes).

BC08H336

Figure 65

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

NOTE: Replace the primary element if the filter warning lamp on the instrument cluster illuminates or the audible alarm sounds. Should the caution warnings continue after replacing the primary filter, replace the secondary filter as well.

3. Remove the wing nut and remove the primary element.

4. Wipe the inside of the filter housing, and clean any dirt and debris away before reinstalling the filter.

5. Clean the filter with low pressure air below 3 kgf/cm2 (40 psi).

6. Inspect for tears or damage.

7. Reinstall element and replace the wing nut. If the primar y element must be replaced, always replace the secondary element as well. Never clean and reuse the secondary element.

5-40

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE LUBRICATE CENTER PIVOT PIN Lubricate the center pivot pin when the hour meter r e g i s t e r s 1 0 0 0 h o u r s a n d eve r y 1 0 0 0 h o u r s thereafter. Lubricate more frequently if conditions so require.

BC08H350

Figure 66

Add recommended lubricant through zerts using grease gun. Clean any excess grease off machine.

5-41

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE R E P L AC E TRANSMISSION TRANSMISSION OIL FILTER

OIL

AND

Service Specifications System capacity . . . . . . . . . . . . . . . . 11.4 gal. (43 L) Change the transmission fluid and filter when the hour meter registers 1000 hours and every 1000 hours thereafter or more frequently when operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on a level surface and apply the parking brake.

2. Lower bucket/attachment to the ground and lock the pilot control lock lever.

3. Put the transport/service link into the locked service position to avoid unexpected articulation and stop the engine.

BC08H352

Figure 68

9. Clean the filter cartridge mounting base. Make certain no part of gasket remains on mounting base.

10. Apply a film of clean transmission oil to the gasket of the new filter and install. Make certain proper contact is made with the base.

11. Install the new filter cartridges. Screw on until filter contacts base, then tighten by hand 1/3 to 1/2 turn more.

12. Install the drain plug.

BC08H256

Figure 67

4. Open transmission air breather to relieve internal air pressure. Clean the area around the filter head and around the transmission drain and fill caps.

5. Remove the fill plug.

6. Have a suitable container that will hold the appropriate amount of fluid before draining.

7. Remove the drain plug and drain the oil.

8. Remove the filter.

5-42

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE

Figure 69

BC08H255

13. Fill the oil through gauge inlet and check to make certain oil is at the appropriate level.

14. Remove the breather. Clean it with solvent and dry with compressed air.

WARNING Wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

15. Install the breather.

16. Fill with the specified amount of oil.

17. Check the oil level.

18. Start the engine and check for oil leaks around the filter and drain plug.

Bring the transmission oil up to working temperature, and check the level again.

5-43

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE CHANGE FRONT AND REAR AXLE OIL Service Specifications Front axle . . . . . . . . . . . . . . . . . . . . . 15.9 gal. (60 L) Rear axle . . . . . . . . . . . . . . . . . . . . . 15.9 gal. (60 L) Change the front and rear axle oil when the hour meter registers 1000 hours and every 1000 hours thereafter or more frequently when operating conditions are severe.

BC08H247

WARNING Make sure that the bucket/attachment is resting on the ground and the transport/service link is installed.

Failure to comply could result in serious injury or death.

4. Place a suitable container with sufficient capacity to capture the old oil under the front and rear axles and drain.

BC08H245

BC08H245

Figure 70

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied. Make certain the plug is parallel with the ground.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the area around the drain and fill caps of both axles and all four axle ends.

5-44

Figure 71

Figure 72

5. Place a suitable container with sufficient capacity to capture the old oil under each axle end.

6. Remove the drain plug and allow the oil to drain.

7. Reinstall the drain plugs of both axles and the four axle ends.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE

BC08H249

Figure 73

8. Fill with the proper amount of axle oil. Oil should overflow from the filler port. Install the plug.

9. Run the engine at low idle for five minutes. Allow the oil to flow completely through the axle oil cooler and hoses.

10. Remove refill plug for the differential and recheck the oil level. Add oil, if required.

NOTE: The oil will take some time to fill each axle.

Allow time for the oil to circulate throughout the axle.

5-45

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE CHANGE HYDRAULIC OIL AND FILTER Service Specifications Total system capacity . . . . . . . . . . . 39 gal. (147.6 L) Type . . . . . . . . . . . . . . . . Case Akcela Hy-Tran Ultra Change the hydraulic oil and all hydraulic oil filters every 2000 hours of operation. Change oil more frequently when operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied. Stop the engine.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Make sure the accumulators are completely discharged by pushing down on the brake pedal a minimum of 30 times.

8. Clean the area around the filler cap, and slowly remove the cap.

9. Remove and replace the hydraulic oil filters. See replacement of return, breather, and pilot line filte rs.To re move the filters, tu r n co unte r clockwise.

10. Make certain the drain valve is closed. Fill the reservoir with new hydraulic oil.

11. Install the reservoir filler cap.

12. Start the engine and run at 1000 rpm. Check for leakage around the filter and drain.

13. Operate the loader controls several times to remove any air in the lines.

14. Place the loader bucket/attachment on the ground and stop the engine. Check the hydraulic oil level.

4. Release pressure in ride control accumulators, if equipped.

15. If it is necessary to top off with more oil, remove the fill cap slowly to release pressure in the reservoir.

5. With the ignition key in the ON position, cycle the bucket/attachment control levers repeatedly through their complete range of motion for at least 30 seconds.

WARNING

6. Move the hydraulic controller to the float position and turn the key off.

BD08M001-01

Figure 74

7. Open the hydraulic reservoir drain, and drain the oil into a suitable container. The drain valve is attached to the underside of the fuel tank.

5-46

Hydraulic fluid is under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE PILOT LINE FILTER

Figure 75

BD06F031

WARNING Fluid is under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

Replace the pilot line filter when replacing hydraulic oil.

1. Keep all unauthorized personnel clear of the area. Park the machine on a hard, level surface.

2. Rest the bucket/attachment on the ground, turn-off the engine, Place the safety lock in the locked position.

3. Loosen the nut on the filter body.

4. Pull the filter element out and clean the filter body with a clean, lint free cloth.

Install the new element and tighten using following torque chart.

5-47

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS REPLACE BREATHER FILTER

2000 HOUR MAINTENANCE REPLACE HYDRAULIC OIL RETURN FILTER Replace the return filter when replacing the hydraulic oil.

WARNING Hydraulic fluid is under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

Figure 77

BC08H345

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Relieve all pressure in the hydraulic system.

3. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

4. Slowly loosen the filler cap on the hydraulic reservoir to release pressure in the reservoir.

Leave it loose during the procedure.

Replace the breather filter in the hydraulic tank when replacing the hydraulic oil.

WARNING Hydraulic fluid is under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system. Failure to comply could result in serious injury or death.

1. Open the breather cap on the top of the hydraulic tank and relieve the system pressure. Make certain all hydraulic pressure has been released.

2. Remove the cap and the filter element.

3. Replace the filter element with a new one. Apply oil on the O-ring and reassemble.

Torque to 0.7 - 0.9 kgfm (5 - 6 lbf ft).

BC08H344

Figure 76

5. Remove cover, spring, by-pass valve, and return filter from the tank.

6. Clean spring and by-pass valve. Replace the filter element and reassemble spr ing and by-pass valve and reinstall.

7. Install the cover on tank. Torque to: 6.9 ± 1.4 kgfm (50 ± 10 lb. ft).

5-48

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE ENGINE COOLANT Service Specifications System capacity . . . . . . . . . . . . . . . . 17.2 gal. (65 L) Drain, flush and replace the engine coolant every 2000 hours of operation or each year, whichever occurs first. Clean the system and replace the coolant if it becomes dirty or is rust colored.

WARNING Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap: Let the system cool, turn to first notch, then wait until all pressure is released.

Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance instructions. Failure to comply may result in death or injury.

BC08H251

Figure 807

4. After all the coolant is drained, secure the drain cap.

5. Use a system cleaning product to clean and flush the system. Follow instructions on the cleaning product container

SA023

BC08H263 BC08H227

Figure 78

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

Figure 81

6. After the system has been cleaned and flushed following the cleaning product instructions, replace the drain plug securely.

2. After the engine has cooled so the temperature of the coolant is safe, remove the cap.

BC08H251

Figure 82

7. Fill with the proper mix of antifreeze/coolant and water for the system and for the prevailing weather conditions. Replace the radiator cap.

BC08H331

Figure 79

3. With a suitable container of the proper capacity under the drain, remove the drain plug at the bottom of the water inlet, and drain the coolant.

8. Start the engine, and let it run at low idle until the engine reaches operating temperature. Check for any leakage. Recheck the level of the system.

5-49

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-50

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS Roll-over Protection Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Torque Specifications for ROPS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Wheel Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Check Engine Accessory Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Check Injector Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Check Engine Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Checking for Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Cab Headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ROLL-OVER PROTECTION STRUCTURE

WARNING Yo u r m a c h i n e i s e q u i p p e d w i t h a n o p e ra t o r Protective Structure, such as: Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS). A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS.

The loader has a ROPS tag showing the certification of the ROPS, gross weight, approval, regulation, and model number of the machine.

Check and inspect the ROPS structure and the seat restraint system every 500 hours of operation.

The Protective Str ucture is a special safety component of your machine.

DO NOT attach any device to the Protective Structure for pulling purposes. DO NOT drill holes into the Protective Structure.

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Structure inspection and replacement.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: The protective structure MUST be replaced.

The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

All damaged parts MUST be replaced.

BC08H176

Figure 1

Before you operate this machine, always make sure the ROPS and operator’s seat belt is correctly installed.

The seat belt is an important part of the ROPS. You must wear the seat belt at all times when you operate the machine.

Replace all seat belts every three years, regardless of appearance.

Make sure all hardware that secures the seat to the cab is properly torqued. Make sure all seat belt hardware is secure and torqued correctly.

Keep seat belts away from objects that can damage the seat belts.

Keep the seat belts clean. Wash the seat belts only in soap and water. Do not put the seat belts in bleach or dye. This will weaken the seat belt composition.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF T H E S T RU C T U R E W H I C H C O U L D C AU S E DEATH OR SERIOUS INJURY IN THE EVENT OF F I R E , T I P, R O L L OV E R , C O L L I S I O N O R ACCIDENT

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TORQUE SPECIFICATIONS FOR ROPS CAB Check the torque of the mounting bolts for the ROPS canopy and the ROPS cab during the run-in period of a n ew m a c h i n e , a s w e l l a s a t t h e 5 0 0 h o u r maintenance interval.

1. Check for cracks, rust, or holes in the ROPS and ROPS components. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the integrity of the ROPS system, see your Case Dealer.

WARNING Adding additional weight (bucket/attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

Failure to comply could result in serious injury or death.

SA028

2. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

Torque Specifications ROPS cab mounting bolts (both sides) Torque to: 900 lb. ft. (124 kgf/m) Seat mounting bolts Torque to: 24.6 ± 5 lb. ft. (3.4 ± 0.8 kgf/m) NOTE: Torque specifications are for clean, dry threads.

6-4

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WHEELS AND TIRES

WARNING Exploding tires and / or rim parts can cause injury or death. Keep yourself and others out of the danger area.

Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires.

SD020

WARNING Explosive separation of the tire and / or rim parts can cause injury or death. When tire service is necessary, have a qualified tire technican service the tire.

84-113

WARNING DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air / gas mixture that will be ignited with high temperatures. This can happen to tires inflated or deflated. Removing air or breaking the bead is not adequate. Tires MUST be completely removed from the rim prior to welding. Failure to comply could result in serious injury or death.

SB134

BALLAST Adding ballast to the tires of your wheel loader is NOT recommended. Make sure tires are properly inflated.

B910410J

Figure 2

The above illustration show danger areas caused by exploding tires and / or rim parts. KEEP YOURSELF AND OTHERS OUT OF THESE DANGER AREAS. Keep all non-authorized personnel clear of the area.

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS The next page shows the correct methods that you MUST use when adding air or servicing a tire.250 HOUR MAINTENANCE TIRE PRESSURE Check tire pressure when the hourmeter registers 250 hours or more frequently when operating conditions warrant.

WARNING Exploding tires and / or rim parts can cause injury or death. Keep yourself and others out of the DANGER AREA. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires. Failure to comply could result in serious injury or death.

Figure 3

To add air to a tire: This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following: 1. Keep all non-authorized personnel clear of the area.

WARNING Explosive separation of the tire and / or rim parts can cause injury or death. When tire service is necessary, have a qualified tire technican service the tire.

2. Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage).

3. Use an air hose with a remote shutoff valve and a self-locking air chuck.

4. Stand BEHIND the tread of the tire and make sure ALL personnel are away from the side of the tire before you start.

Service Specifications Normal Work Tire Inflations: Tire Type

Front Pressure

Rear Pressure

29.5 X 25 L3 Bias

50 psi (3.4 bar)

40 psi (2.8 bar)

6-6

B790490R

5. Inflate the tire to the recommended air pressure.

D O N OT i n f l a t e t h e t i r e m o r e t h a n t h e recommended pressure.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TIRE OR RIM SERVICE

WHEEL BOLT TORQUE

Always have a qualified tire technician service the tires and rims for this machine. It is recommended that you have the technician inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment, and correct procedure. Explosive separation of the tire (single piece rim) or the tire and / or rim parts (multi-piece rim) can cause serious injury or death.

If the machine is new or if a wheel has been removed and installed, check the torque of the wheel bolts after every 10 hours of operation until the wheel bolts stay tight. Check wheel bolt torque every 250 hours thereafter.

Use a hand wrench (not an impact) to tighten wheel bolts to pull the wheel against the planetary housing.

Tire Tread Direction

B770164R

Figure 4

When the tire is installed on the wheel make sure the tire tread is in the direction shown.

8500170

Figure 5

Tighten the wheel bolts using the sequence shown.

First tighten the bolts to 278 Nm (220 pound-feet), then tighten to a final torque of 79 ± 2.5 kgf/m (571 ± 18 lbf. ft.), using the same sequence.

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK ENGINE ACCESSORY BELT Maintenance Specifications Visual check . . . . . . Every 250 hours or as required Replace belts. . . . . . . . . . . . . . . . . Every 1000 hours Inspect belt tensioner . . . . . . . . . . Every 1000 hours Check the belt for correct tension, wear, and damage. Wrong belt tension may cause battery charge failure, engine overheating, or belt wear.

IMPORTANT: If the engine runs with the drive belt loose, the drive belt can slip and cause the engine to overheat or the battery to receive insufficient charge.

BC08H353

WARNING Rotating parts can cause serious personal injury.

Keep away from fan and belt when engine is running. Make sure to stop engine before servicing.

Failure to comply could cause injury or death.

Figure 7

4. Check the tensioner pulley and body for cracks.

If any damage is visible, replace the tensioner.

Check for built up of dirt and debris. Remove and clean if necessary.

Check Drive Belt

BC08H354

BC08H157

Figure 6

Figure 8

5. Check that the bottom tensioner arm stop is in contact with the bottom tensioner arm stop boss on the tensioner body. If the tensioners are not in contact, the tensioner must be replaced.

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface, and apply the parking brake.

2. Open the hood and turn the master disconnect switch off.

3. You can visually check the belt at this point. If the belt is damaged, cracked, or frayed, replace as necessary.

BC08H355

Figure 9

6. Inspect the tensioner for evidence of the pivoting tensioner arm making contact with the stationary circular base. If contact is apparent, the pivot tube bushing has failed and the tensioner must be replaced.

6-8

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

BC08H356

Figure 10

7. A worn tensioner that has play or a belt that slides off its pu lley could indicate pulley misalignment.

BD06F033-01

Figure 12

10. To replace belt, actuate the belt tensioner with a 3/8 inch breaker bar just enough to release the tension on the drive belt.

11. Remove the belt. To install the new belt, lay it over the alternator, crankshaft pulleys, and complete the turn while lifting the tensioner with the breaker bar.

CHECK INJECTOR CALIBRATION This procedure should be performed by a qualified service technician when the hourmeter registers 1000 hours. Contact your dealer.

CHECK ENGINE VALVE CLEARANCES BC08H357

Figure 11

8. Maximum pulley misalignment is three degrees.

Measure with a straightedge and a inclinometer.

9. If the belt requires replacement or adjustment, remove the 4 screws that hold the protective cover in place.

This procedure should be performed by a qualified service technician when the hourmeter registers 4000 hours. Contact your dealer.

HOSES AND WIRING Check all hoses and wiring for damage. If damage occurred, see your dealer for repair or replacement.

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSPECTING AND CLEANING THE MACHINE

WELDING ON THE MACHINE Whenever carrying out a welding operation on the machine as authorized by the manufacturer and in accordance with manufacturer’s instr uctions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Always connect the welding apparatus to the same structure that is being welded.

Never connect the welding apparatus ground to a component of the hydraulic system.

WARNING Any unauthorized modifications made to this machine can cause serious injury or death. Do not undertake any modifications without first consulting your dealer.

Maintenance Specifications Inspect and clean . . . . . . . . . . . . . . . . . . Periodically

WARNING Wear face protection when using high pressure water jets. Failure to comply could cause injury or death.

Clean immediately if oil or grease has been spilled on the machine. Clean with steam or a high pressure water jet.

Look for any leaks, and check the condition of all pipes and hoses.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the bucket/attachment linkages and check the teeth and tooth tips for correct retention and for wear.

CHECKING FOR CYLINDER LEAKAGE

FIRE EXTINGUISHER (NOT SUPPLIED)

A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

It is strongly recommended a fire extinguisher be kept on the machine. An extinguisher is not supplied but can be purchased separately and placed in the operator’s compartment.

1. Wipe the rod and bearing clean on the cylinder to be checked.

2. Operate normally for five or ten minutes.

Maintenance Specification

3. Extend the cylinder rod.

Every month Examine the fire extinguisher and make sure it is not damaged.

4. Carry out the leak test.

ROD APPEARANCE

TEST

Normal

Slightly Paper remains stuck to rod greasy when run over rod.

Normal

Oily Paper remains stuck when placed on rod.

Normal

Each time the rod retracts, Leakage the excess oil drips from the gland.

Every six months Have an approved specialist empty and refill the fire extinguisher.

Slight traces of oil when a Dry piece of paper is wiped over 20 cm (7.8 in) of the rod.

Very oily or Each time the cylinder rod weeping is extended, a ring of oil can be seen on the rod.

6-10

CONCLUSION

See your dealer

Every year Have an approved specialist examine the fire extinguisher.

PLASTIC AND RESIN PARTS When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CAB SERVICE AIR CONDITIONING (IF EQUIPPED) The components of the operator’s cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

WARNING Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiar with air conditioning systems and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions. Failure to comply could cause injury or death.

SA048

AIR CONDITIONING

WARNING Use a safety type air tool and wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

Operate the air conditioning once every 250 hours to lub r icat e th e co m pr ess or s ea ls. Tu r n th e a ir conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 0°C (32°F) put a cover over the air conditioning condenser. This will make sure the refrigerant and lubricants in the system will be at operating temperature.

Keep the air conditioning condenser core clean. Use safety type compressed air tool or a rigid brush to clean the condenser. Also check and clean the grille screen.

IMPORTANT: Because the condenser fins bend easily, use care when cleaning the condenser.

RADIATOR/COOLER ACCESS FOR CLEANING

Figure 14

BC08H264

Visually check the radiator for core and gasket leaks.

The lower areas and radiator/cooler in general can be cleaned using a shop-vacuum and or pressure washer.

IMPORTANT: Be careful not to bend or damage radiator/cooler fins during cleaning. DO NOT exceed 550 kPa (80 psi) air pressure when cleaning.

Check the radiator, coolers and engine compartment for build up of debris, dirt and material that might impede cooling components functions. Debris build-up may create a risk of fire in the engine compartment or elsewhere on the machine. Keep the engine free of debris for optimum operation and safety. This is particularly important under extreme operating conditions, and inspection intervals should be adjusted accordingly.

WARNING Use a safety type air tool and wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

BC08H265

Figure 13

Check and clean the radiator and oil cooler. Pay particular attention to the radiator and oil cooler if conditions are particularly dusty.

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS OPERATOR’S SEAT

CAB HEADLINER

Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct use of a material cleaner.

The foam headliner in your cab decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

IMPORTANT: DO NOT wash the headliner with water. Water can cause damage to the headliner and lower the noise control capacity of the headliner.

WARNING Never use gasoline, naptha or any other volatile material for any cleaning purposes. These materials may be toxic and/or flammable. Failure to comply could cause injury or death.

SA049

Cleaning Fluid - This type of cleaner can be used for grease or oil stains. Carefully remove the item that caused the stain with a scraper or a dull knife.

Use a minimum amount of cleaner and a clean cloth.

Move the cloth from the outside of the stain towards the center. When the stain is removed, use a clean cloth to dry the area to prevent a cleaning fluid pattern.

6-12

CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-4 7-4 7-4 7-4

BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access to the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Battery Fluid Level and Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5 7-5 7-5 7-6 7-6

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Auxiliary Power Outlet (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM BATTERY SAFETY

WARNING

WARNING

Before you service a battery, always wear face protection, protective gloves and protective clothing.

Battery acid or battery explosion can cause serious injuries. Failure to comply can cause injury or death.

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

WARNING Batteries give off explosive gases. Keep all open flam es, spa rk s a n d c i g ar ett es a way. In sure adequate ventilation when charging batteries or when using in a confined place. Always protect your face when working near batteries. Failure to comply can cause injury or death.

SA046

WARNING WARNING: Battery acid causes severe burns.

Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Failure to comply can cause injury or death.

Antidote - EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

SB032

Failure to comply can cause injury or death.

SB034

WARNING Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-). Failure to comply can cause machine damage, injury or death.

SAFETY_ID_1C02

WARNING Before any operation on the components of the electrical circuit, put the key switch in the off position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last. Failure to comply can cause machine damage, injury or death.

WARNING

SAFETY_ID_1C02

When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. Failure to comply can cause injury or death.

SB033

WARNING

WARNING Whenever carrying out a welding operation on the machine (authorized by the manufacturer and in accordance with manufacturer’s instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator. When reconnecting, check the markings on the wires.

Failure to comply with the following warnings could result in machine damage, serious injury, or death.

Connecting jump start (booster battery) cables incorrectly or short- circuiting battery terminals can cause an accident. Connect auxiliary starting cables as per the following instructions. Failure to comply can cause injury or death.

SAFETY_ID_1C02

7-3

CHAPTER 7 - ELECTRICAL BATTERY SERVICE

BATTERY FLUID LEVEL

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the container.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Whenever carrying out a welding operation on the machine as authorized by the manufacturer and in accordance with manufacturer’s instr uctions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Always connect the welding apparatus to the same structure that is being welded.

Never connect the welding apparatus ground to a component of the hydraulic system.

Do not use a steam cleaner or cleaning solvent to clean the alternator.

In extreme heat conditions check battery fluid every 250 hours.

IMPORTANT: If the temperature is 0°C (32°F) or below and you have added water to the batteries, perform the following: Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver. Follow the instructions on the container. This cleaner does not need water.

Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

7-4

CHAPTER 7 - ELECTRICAL

BATTERIES ACCESS TO THE BATTERIES

CONNECTING BOOSTER BATTERIES

Figure 1

BD06G102

Service Specifications Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . Two 12 volt The machine is electronically powered by a 24 volt system.

NOTE: If the machine needs to be started using a booster battery, see Connecting Booster Battery.

Batteries are enclosed in compartments on both the left and right hand rear of the machine. To access the batteries, loosen and remove the bolts that hold the cover in place. (One batter y on each side of machine).

WARNING Before carrying out any service work on electrical system components, turn the starter switch key to the “OFF” position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last. Failure to comply can cause machine damage, injury or death.

WARNING Hydrogen gas may be present above the discharged battery. Do not make the negative connection directly to the discharged battery, as this may ignite the hydrogen gas. Failure to comply can cause machine damage, injury or death.

WARNING An error when connecting booster battery cables or short-circuiting battery terminals can cause an accident. Be certain connections are correct. Failure to comply with the following warnings could result in serious injury or machine damage.

BC08H164

Figure 2

Make sure that the voltage of the booster batteries is the same as that of the machine system (24 volts).

1. Turn off the ignition and all accessories on the machine(s). Remove the battery cover from the left hand side of the machine. Remove the left battery terminal cover.

2. Connect one end of the positive (+) cable to the positive (+) terminal on the booster battery.

Connect the other end of the positive (+) cable to the positive (+) ter minal of the discharged battery.

3. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

4. Connect the other end of the negative cable to the engine block or frame of the machine with the discharged battery. Do not connect it to sheet metal or any rotating part, as damage can result.

Do not connect to the negative terminal on the discharged battery.

5. Start the engine.

6. Remove the booster battery negative (-) cable from the machine, then from the booster battery.

Remove the positive (+) cable from the machine and then from the booster battery.

7. Install the terminal covers.

IMPORTANT: Booster batteries should be of the same voltage as that of the machine system (24 volts) and should be connected on the left side only.

7-5

CHAPTER 7 - ELECTRICAL CHECK BATTERY FLUID LEVEL AND SPECIFIC GRAVITY

REPLACING A BATTERY

The battery fluid can decrease with high temperatures.

Remove the terminal protection caps, disconnect negative terminal cables and then positive terminal cables. Remove the anti-sulfate pellets.

Check the battery fluid level in the morning before starting operation.

Remove the retainer. Remove the old battery.

Remove the cell caps and check the level in each battery cell. The level should be between 10 and 15 mm (.3 to .5 in) above the plates. Add distilled water if necessary, then install the cell caps.

Continuous use of the battery with low fluid will lower battery performance.

Check the battery fluid level periodically, and if insufficient, refill the battery with distilled water before the engine start-up (before charging battery).

Install new battery of the correct voltage and replace retainer.

Clean the cables and battery terminals, and coat with grease. Install new anti-sulfate pellets. Reconnect positive cable ends to positive ter minals first.

R e c o n n e c t n e g a t i ve c a bl e e n d s t o n e g a t i ve terminals, and install the terminal protection caps.

ALTERNATOR Service Specification Check . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours Ask your Dealer to check the alternator.

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Service Specification

Figure 3

BD06H177A

BATTERY CAP

If the terminals are dirty, wash with warm water, Reinstall the terminals, applying grease or spraying rust preventive solution to create good connections. If the terminal is oxidized, polish it with a wire brush or emery paper.

NOTE: Measure the specific gravity of battery fluid with a gravimeter. The measured value will vary depending on the ambient temperature.

WARNING Do not invert battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (−). Failure to comply with the following warnings could result in serious injury or machine damage.

7-6

Check . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours Ask your Dealer to check the starter motor.

Make sure that the terminal protectors are correctly installed.

CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS

BS08J179

Figure 4

Fuses and relays can be found inside the access door on the right hand side of the machine.

If power does not come when the key switch is turned to the ON position, check the appropriate fuse.

If a fuse has failed, an indicator light will be illuminated at the location on the panel.

IMPORTANT: Before changing fuses or relays, turn the ignition key switch to the OFF (Shut Down) position.

BC08H299

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

The fuse box cover indicates the capacity of each fuse and the circuit it protects.

To replace, pull the old fuse straight out and push the new fuse straight in. The amperage for each fuse is stamped on the fuse. Refer to the fuse panel decal for correct location of each fuse.

Additionally in this compartment there are module control units for the machine, the transmission, and engine. Only your authorized dealer should replace or repair items associated with these modules.

Figure 5

AUXILIARY POWER OUTLET (IF EQUIPPED) The Auxiliary Power Outlet socket (12 volt) can be used for the connection of a lighting device to help with service and maintenance procedures. The auxiliary power socket is in the right rear corner of the operator’s compartment.

7-7

CHAPTER 7 - ELECTRICAL

NOTES

7-8

CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 1221E Z-Bar DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 1221E XR DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19 MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS Engine Model ...............................................................................................................Cummins QSM 11, Tier 3 Certified Type..........................................................................................................4-stroke, turbocharged, air-to-air cooled Cylinders ...............................................................................................................................................................6 Bore/stroke ................................................................................................... 4.92 in x 5.79 in (125 mm x 147 mm) Displacement .............................................................................................................................660 cu in (10. 8 L) Fuel Injection ........................................................................................................................................... Electronic Engine Speeds Rated speed, full load ..............................................................................................................................2100 rpm Horsepower - Rated .................................................................................................................340 ps at 2000 rpm Max Power Range Gross....................................................................................................................... 365 hp (272 kW) @ 1800 rpm Net........................................................................................................................... 335 hp (250 kW) @ 2200 rpm Torque - Peak Max Power Range Gross................................................................................................................. 1090 lb ft (1478 Nm) @ 1000 rpm Net..................................................................................................................... 1066 lb ft (1446 Nm) @ 1000 rpm Torque rise (max power only) ........................................................................................................................50.3% Electrical Batteries ..................................................................................................................................................2 - 12 Volt Alternator.....................................................................................................................................................70 amp Voltage ............................................................................................................................ 24 volts, negative ground

8-3

CHAPTER 8 - SPECIFICATIONS Drivetrain Transmission...........................................................................................................Hydrodynamic power shift 4F/3R, electronically controlled clutch modulation with automatic and manual shift modes Gears......................................................................................................................................................... Helical Cut Gear Ratios

Forward

Reverse

1st

4.187

4.187

2nd

2.207

2.207

3rd

1.384

1.384

4th

0.608

-----

Torque converter stall ratio .................................................................................................................................2.987 Differential .......................................... limited slip front (up to 65% of available axle torque to wheel with traction) Differential ........................................limited slip rear (up to 72.5% of available axle torque to wheel with traction)

Axles Differential ratio Planetary ratio Final axle ratio

Front and Rear 4.25 6.353 27.00

Brakes Service brakes .............................................................. Hydraulically actuated, self adjusting (maintenance-free) multiple wet disc at all four wheels with accumulator for each axle Brake surface area ............................................................................................. 604 in2 (0.3896 m2) per front hub 604 in2 (0.3896 m2) per rear hub Parking brakes ................................... spring-applied, hydraulic release disc caliper on transmission output shaft

Travel Speeds Travel Speeds

Forward, mph (km/h)

Reverse, mph (km/h)

1st

3.9 (6.2)

3.9 (6.2)

2nd

7.1 (11.5)

7.1 (11.5)

3rd

10.9 (17.6)

14.8 (23.8)

4th

21.4 (34.4)

-----

NOTE: Travel speeds @ full engine throttle

8-4

CHAPTER 8 - SPECIFICATIONS Hydraulics Type...................................................................... Open centered, tandem circuit system, pilot operated controls.

Closed with pressure and vacuum relief Pump .............................................................................Vane type, 482 liters/min (127 gal/min) @ governed rpm Loader control valve ................................... 3 function valve with single or three lever controls with auxiliary lever Loader auxiliary steering .......................................hydraulic orbital center-pivot articulating w/on-demand oil flow High pressure standby .............................................................................................................. 2990 psi (210 Bar) Filtration....................... 10-micron, full flow replaceable cartridges on return line, condition indicator light for filter Cylinders Lift cylinder Bore diameter .......................................................................................................................7.87 in (200.0 mm) Rod diameter ........................................................................................................................... 4.33 (110.0 mm) Stroke..................................................................................................................................33.98 in (863.0 mm) Dump cylinder Bore diameter .........................................................................................................................6.3 in (160.0 mm) Rod diameter .............................................................................................................................3.1in (80.0 mm) Stroke....................................................................................................................................22.8 in (580.0 mm) Instrumentation Analog Gauges Transmission temperature, Engine coolant temperature, hydraulic oil temperature, fuel level Audible and visual Alarms Cautionary and critical levels, direction, bright indication, low fuel, grid heater (if equipped) direction signals, Low oil pressure LCD Screen Hour meter, time, FNR indication, trip computer, warning prompts, engine speed, automatic transmission indication, declutch indication, fuel consumption, engine diagnostics, error reporting, travel speed, current gear selection, engine mode indication, transmission diagnostics (metric/english multiple languages) Operator Environment ROPS cab w/heat Key Start Articulated power steering w/tilt column Adjustable heated, suspension seat Single lever 2-spool loader control Cup holder Coat hook Rear view mirror (interior) 2 inch (52 mm) retractable seat belt Storage tray Cooled storage box Single brake pedal External rear view mirrors Lock box Dome light Sun screen Wipers - front and rear (intermittent front) Windshield washers - front and rear Right and left steps and platforms

8-5

CHAPTER 8 - SPECIFICATIONS Lift Capacity 1221E Z-Bar 6.3 yd3 (4.8 m3) Bucket w/Teeth and Segments 137.8 in. (3500 mm) width

6.7 yd3 (5.1 m3) Bucket w/Bolt-on Edge 135.8 in. (3450 mm) width

Full Height

29010 lb (13160 kg)

28810 lb (13070 kg)

Ground

70770 lb (32100 kg)

69860 lb (31690 kg)

Lift Capacity 1221E Z-Bar 7.3 yd3 (5.60 m3) Bucket w/Teeth and Segments 137.8 in. (3500 mm) width

7.6 yd3 (5.8 m3) Bucket w/Bolt-on Edge 135.8 in. (3450 mm) width

Full Height

28590 lb (12970 kg)

28310 lb (12840 kg)

Ground

69420 lb (31490 kg)

68520 lb (31080 kg)

9.2 yd3 (7.0 m3) Bucket w/Bolt-on Edge 152.4 in. (3870 mm) width

6.3 yd3 (4.8 m3) Bucket Spade Nose Rock with Teeth and Segments 137.4 in. (3490 mm) width

Full Height

27620 lb (12530 kg)

26680 lb (12100 kg)

Ground

67660 lb (30690 kg)

66690 lb (30250 kg)

Lift Capacity 1221E Z-Bar

Lift Capacity 1221E XR 6.3 yd3 (4.8 m3) Bucket w/Teeth and Segments 137.8 in. (3500 mm) width

6.7 yd3 (5.1 m3) Bucket w/Bolt on Edge 135.8 in. (3450 mm) width

Full Height

27510 lb (12480 kg)

27580 lb (12510 kg)

Ground

59260 lb (26880 kg)

58880 lb (26670 kg)

7.3 yd3 (5.6 m3) Bucket w/Teeth and Segments 137.8 in. (3500 mm) width

7.6 yd3 (5.8m3) Bucket w/Bolt-on Edge 135.8 in. (3450 mm) width

Full Height

27310 lb (12390 kg)

27120 lb (12300 kg)

Ground

58420 lb (26500 kg)

57670 lb (26160 kg)

Lift Capacity1221E XR

Lift Capacity1221E XR 9.2 yd3 (7.0m3) Bucket w/Bolt on Edge 152.4 in. (3870 mm) width Full Height

26410 lb (11980 kg)

Ground

56840 lb (25780 kg)

8-6

CHAPTER 8 - SPECIFICATIONS 1221E Z-BAR DIMENSIONS 1221E Z-BAR DIMENSIONS WITH 6.3 YD³ (4.8 M³) PIN-ON BUCKET WITH TEETH AND SEGMENTS

BS08K885

Figure 1

ISO bucket capacity Struck ............................................................................................................................................. 5.4 yd³ (4.1 m³) Heaped........................................................................................................................................... 6.3 yd³ (4.8 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) ..................................................................................................................23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center.......................................................................................................................................40 degrees Total angle.........................................................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..........................................................................244.1 in (6200 mm) F. Hinge pin height - fully raised ...............................................................................................178.9 in (4545 mm) G. Overall length - bucket level on ground ...............................................................................384.0 in (9754 mm) H. Dump height - fully raised, 45 degree dump........................................................................124.9 in (3173 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................57.5 in (1460 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ..................................................83.6 in (2123.8 mm) L. Dig depth......................................................................................................................................0.9 in (22 mm) Tipping load - ISO Machine straight..................................................................................................................57360 lb (26020 kg) 40 degree turn ....................................................................................................................49500 lb (22450 kg) Operating load - ISO....................................................................................................................24747 lb (11225 kg) Unit operating mass.....................................................................................................................66180 lb (30020 kg) NOTE: Machine equipped with Z-Bar loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-7

CHAPTER 8 - SPECIFICATIONS 1221E Z-BAR DIMENSIONS WITH 6.7 YD³ (5.1 M³) PIN-ON BUCKET WITH BOLT-ON EDGE

BS08K885

Figure 2

ISO bucket capacity Struck ............................................................................................................................................. 5.6 yd³ (4.3 m³) Heaped........................................................................................................................................... 6.7 yd³ (5.1 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) .................................................................................................................. 23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center....................................................................................................................................... 40 degrees Total angle......................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ..........................................................................244.1 in (6200 mm) F. Hinge pin height - fully raised ...............................................................................................178.9 in (4545 mm) G. Overall length - bucket level on ground ...............................................................................376.4 in (9560 mm) H. Dump height - fully raised, 45 degree dump........................................................................130.9 in (3325 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................52.8 in (1340 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ..................................................80.7 in (2048.8 mm) L. Dig depth......................................................................................................................................2.4 in (60 mm) Tipping load - ISO Machine straight.................................................................................................................. 56460 lb (25610 kg) 40 degree turn .................................................................................................................... 48680 lb (22080 kg) Operating load - ISO.................................................................................................................... 24339 lb (11040 kg) Unit operating mass..................................................................................................................... 66470 lb (30150 kg) NOTE: Machine equipped with Z-Bar loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-8

CHAPTER 8 - SPECIFICATIONS 1221E Z-BAR DIMENSIONS WITH 7.3 YD³ (5.6 M³) PIN-ON BUCKET WITH TEETH AND SEGMENTS

BS08K885

Figure 3

ISO bucket capacity Struck ............................................................................................................................................. 6.3 yd³ (4.8 m³) Heaped........................................................................................................................................... 7.3 yd³ (5.6 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) ..................................................................................................................23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center.......................................................................................................................................40 degrees Total angle.........................................................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..........................................................................249.4 in (6335 mm) F. Hinge pin height - fully raised ...............................................................................................178.9 in (4545 mm) G. Overall length - bucket level on ground ...............................................................................389.1 in (9884 mm) H. Dump height - fully raised, 45 degree dump........................................................................121.4 in (3084 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................61.2 in (1554 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ..................................................85.7 in (2177.8 mm) L. Dig depth......................................................................................................................................0.9 in (22 mm) Tipping load - ISO Machine straight..................................................................................................................56660 lb (25700 kg) 40 degree turn ....................................................................................................................48840 lb (22150 kg) Operating load - ISO....................................................................................................................24416 lb (11075 kg) Unit operating mass.....................................................................................................................66650 lb (30230 kg) NOTE: Machine equipped with Z-Bar loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-9

CHAPTER 8 - SPECIFICATIONS 1221E Z-BAR DIMENSIONS WITH 7.6 YD³ (5.8 M³) PIN-ON BUCKET WITH BOLT-ON EDGE

BS08K885

Figure 4

ISO bucket capacity Struck ............................................................................................................................................. 6.5 yd³ (5.0 m³) Heaped........................................................................................................................................... 7.6 yd³ (5.8 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) .................................................................................................................. 23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center....................................................................................................................................... 40 degrees Total angle......................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ..........................................................................249.4 in (6335 mm) F. Hinge pin height - fully raised ...............................................................................................178.9 in (4545 mm) G. Overall length - bucket level on ground ...............................................................................381.5 in (9691 mm) H. Dump height - fully raised, 45 degree dump........................................................................127.2 in (3232 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................56.4 in (1432 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ..................................................82.5 in (2096.5 mm) L. Dig depth......................................................................................................................................2.4 in (60 mm) Tipping load - ISO Machine straight.................................................................................................................. 55830 lb (25320 kg) 40 degree turn .................................................................................................................... 48070 lb (21810 kg) Operating load - ISO.................................................................................................................... 24041 lb (10905 kg) Unit operating mass..................................................................................................................... 66930 lb (30360 kg) NOTE: Machine equipped with Z-Bar loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-10

CHAPTER 8 - SPECIFICATIONS 1221E Z-BAR DIMENSIONS WITH 9.2 YD³ (7.0 M³) PIN-ON BUCKET WITH BOLT-ON EDGE

BS08K885

Figure 5

ISO bucket capacity Struck ............................................................................................................................................. 7.6 yd³ (5.8 m³) Heaped........................................................................................................................................... 9.2 yd³ (7.0 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) ..................................................................................................................23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center.......................................................................................................................................40 degrees Total angle.........................................................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..........................................................................250.7 in (6368 mm) F. Hinge pin height - fully raised ...............................................................................................178.9 in (4545 mm) G. Overall length - bucket level on ground ...............................................................................382.7 in (9721 mm) H. Dump height - fully raised, 45 degree dump........................................................................126.4 in (3211 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................57.2 in (1453 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ..................................................83.1 in (2109.6 mm) L. Dig depth......................................................................................................................................2.4 in (60 mm) Tipping load - ISO Machine straight..................................................................................................................55060 lb (24970 kg) 40 degree turn ....................................................................................................................47300 lb (21450 kg) Operating load - ISO....................................................................................................................23645 lb (10725 kg) Unit operating mass.....................................................................................................................67660 lb (30390 kg) NOTE: Machine equipped with Z-Bar loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-11

CHAPTER 8 - SPECIFICATIONS 1221E Z-BAR DIMENSIONS WITH 6.3 YD³ (4.8 M³) BUCKET SPADE NOSE ROCK W/TEETH AND SEGMENTS

BS08K885

Figure 6

ISO bucket capacity Struck ............................................................................................................................................. 5.4 yd³ (4.1 m³) Heaped........................................................................................................................................... 6.3 yd³ (4.8 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) .................................................................................................................. 23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center....................................................................................................................................... 40 degrees Total angle......................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ..........................................................................247.0 in (6275 mm) F. Hinge pin height - fully raised ...............................................................................................178.9 in (4545 mm) G. Overall length - bucket level on ground ...............................................................................393.1 in (9985 mm) H. Dump height - fully raised, 45 degree dump........................................................................117.9 in (2995 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................63.5 in (1613 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ..................................................80.7 in (2048.8 mm) L. Dig depth......................................................................................................................................2.6 in (67 mm) Tipping load - ISO Machine straight.................................................................................................................. 55070 lb (24980 kg) 40 degree turn .................................................................................................................... 47160 lb (21390 kg) Operating load - ISO.................................................................................................................... 23578 lb (10695 kg) Unit operating mass..................................................................................................................... 68290 lb (30975 kg) NOTE: Machine equipped with Z-Bar loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-12

CHAPTER 8 - SPECIFICATIONS 1221E XR DIMENSIONS 1221E XR DIMENSIONS WITH 6.3 YD³ (4.8 M³) PIN-ON BUCKET WITH TEETH AND SEGMENTS

BS08K885

Figure 7

ISO bucket capacity Struck ............................................................................................................................................. 5.4 yd³ (4.1 m³) Heaped........................................................................................................................................... 6.3 yd³ (4.8 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) ..................................................................................................................23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center.......................................................................................................................................40 degrees Total angle.........................................................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..........................................................................261.0 in (6625 mm) F. Hinge pin height - fully raised ...............................................................................................195.0 in (4960 mm) G. Overall length - bucket level on ground ................................................................................402 in (10210 mm) H. Dump height - fully raised, 45 degree dump........................................................................141.7 in (3600 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................60.2 in (1528 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ..................................................98.3 in (2497.3 mm) L. Dig depth......................................................................................................................................1.4 in (35 mm) Tipping load - ISO Machine straight..................................................................................................................48770 lb (22120 kg) 40 degree turn ....................................................................................................................42220 lb (19150 kg) Operating load - ISO......................................................................................................................21109 lb (9575 kg) Unit operating mass.....................................................................................................................66730 lb (30720 kg) NOTE: Machine equipped with XR loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-13

CHAPTER 8 - SPECIFICATIONS 1221E XR DIMENSIONS WITH 6.7 YD³ (5.1 M³) PIN-ON BUCKET WITH BOLT-ON EDGE

BS08K885

Figure 8

ISO bucket capacity Struck ............................................................................................................................................. 5.6 yd³ (4.3 m³) Heaped........................................................................................................................................... 6.7 yd³ (5.1 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) .................................................................................................................. 23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center....................................................................................................................................... 40 degrees Total angle......................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ..........................................................................261.0 in (6625 mm) F. Hinge pin height - fully raised ...............................................................................................195.0 in (4960 mm) G. Overall length - bucket level on ground .............................................................................394.3 in (10015 mm) H. Dump height - fully raised, 45 degree dump........................................................................147.6 in (3750 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................55.1 in (1400 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ..................................................95.2 in (2417.3 mm) L. Dig depth......................................................................................................................................2.9 in (73 mm) Tipping load - ISO Machine straight.................................................................................................................. 48060 lb (21800 kg) 40 degree turn .................................................................................................................... 41560 lb (18850 kg) Operating load - ISO...................................................................................................................... 20779 lb (9425 kg) Unit operating mass..................................................................................................................... 67020 lb (30400 kg) NOTE: Machine equipped with XR loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-14

CHAPTER 8 - SPECIFICATIONS 1221E XR DIMENSIONS WITH 7.3 YD³ (5.6 M³) PIN-ON BUCKET WITH TEETH AND SEGMENTS

BS08K885

Figure 9

ISO bucket capacity Struck ............................................................................................................................................. 6.3 yd³ (4.8 m³) Heaped........................................................................................................................................... 7.3 yd³ (5.6 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) ..................................................................................................................23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center.......................................................................................................................................40 degrees Total angle.........................................................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..........................................................................266.3 in (6763 mm) F. Hinge pin height - fully raised ...............................................................................................195.0 in (4960 mm) G. Overall length - bucket level on ground ................................................................................407 in (10339 mm) H. Dump height - fully raised, 45 degree dump........................................................................138.2 in (3511 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................63.9 in (1622 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump ................................................100.6 in (2555.5 mm) L. Dig depth......................................................................................................................................1.4 in (35 mm) Tipping load - ISO Machine straight..................................................................................................................48180 lb (21860 kg) 40 degree turn ....................................................................................................................41650 lb (18890 kg) Operating load - ISO......................................................................................................................20823 lb (9445 kg) Unit operating mass.....................................................................................................................67200 lb (30480 kg) NOTE: Machine equipped with XR loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-15

CHAPTER 8 - SPECIFICATIONS 1221E XR DIMENSIONS WITH 7.6 YD³ (5.8 M³) PIN-ON BUCKET WITH BOLT-ON EDGE

BS08K885

Figure 10

ISO bucket capacity Struck ............................................................................................................................................. 6.5 yd³ (5.0 m³) Heaped........................................................................................................................................... 7.6 yd³ (5.8 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) .................................................................................................................. 23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center....................................................................................................................................... 40 degrees Total angle......................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ..........................................................................266.3 in (6763 mm) F. Hinge pin height - fully raised ...............................................................................................195.0 in (4960 mm) G. Overall length - bucket level on ground .............................................................................399.5 in (10146 mm) H. Dump height - fully raised, 45 degree dump........................................................................144.0 in (3658 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................58.7 in (1492 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .....................................................97.2 in (2468 mm) L. Dig depth......................................................................................................................................2.9 in (73 mm) Tipping load - ISO Machine straight.................................................................................................................. 47470 lb (21530 kg) 40 degree turn .................................................................................................................... 40990 lb (18590 kg) Operating load - ISO...................................................................................................................... 20492 lb (9295 kg) Unit operating mass..................................................................................................................... 67480 lb (30610 kg) NOTE: Machine equipped with XR loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-16

CHAPTER 8 - SPECIFICATIONS 1221E XR DIMENSIONS WITH 9.2 YD³ (7.0 M³) PIN-ON BUCKET WITH BOLT-ON EDGE

BS08K885

Figure 11

ISO bucket capacity Struck ............................................................................................................................................. 7.6 yd³ (5.8 m³) Heaped........................................................................................................................................... 9.2 yd³ (7.0 m³) A. Height to top of cab .............................................................................................................151.0 in (3840 mm) B. Wheelbase...........................................................................................................................146.0 in (3700 mm) C. Ground clearance ....................................................................................................................20.0 in (510 mm) D. Angle of departure (rear) ..................................................................................................................23 degrees Width Overall w/o bucket ...............................................................................................................128.9 in (3273 mm) Centerline tread .....................................................................................................................96.1 in (2440 mm) Turning radius - outside of tires ................................................................................................298.6 in (7585 mm) Turning angle From center.......................................................................................................................................40 degrees Total angle.........................................................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..........................................................................267.5 in (6795 mm) F. Hinge pin height - fully raised ...............................................................................................195.0 in (4960 mm) G. Overall length - bucket level on ground .............................................................................400.6 in (10176 mm) H. Dump height - fully raised, 45 degree dump........................................................................143.2 in (3637 mm) J. Bucket reach - fully raised, 45 degree dump ..........................................................................59.6 in (1513 mm) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .....................................................97.7 in (2482 mm) L. Dig depth......................................................................................................................................2.9 in (73 mm) Tipping load - ISO Machine straight..................................................................................................................46720 lb (21190 kg) 40 degree turn ....................................................................................................................40230 lb (18250 kg) Operating load - ISO......................................................................................................................20117 lb (9125 kg) Unit operating mass.....................................................................................................................68210 lb (30940 kg) NOTE: Machine equipped with XR loader arms, 29.5 R25 XHA tires, ROPS cab with heater, standard counterweight, standard batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

8-17

CHAPTER 8 - SPECIFICATIONS

MATERIAL WEIGHTS MATERIAL

kg/m3

lbs/ft3

MATERIAL

kg/m3

lbs/ft3

Alum-Lump.

881

55

Oats

416

26

Pulverized

769

48

Peanuts - Shelled

280

17

Ashes

561-833

35-52

Peas

769

48

Bauxite

1202-1922

75-120

Peat - solid

753

47

Beans

769

48

Phosphate - Granular

1442

90

Charcoal

368

23

Potash

1089

68

Chips

288

18

Potatoes

769

48

Coal

1282

80

Quartz - Granular

1762

110

Coke - Lump - Loose

849-1009

53-63

Rice

769

48

Clay

368-513

23-32

Rye

705

44

Concrete

1378-1778

86-111

Salt - Rock - Solid

2163

135

Copper Ore

1666

104

Sand & Gravel - Dry

1730

108

Corn - Shelled

673

42

Wet

2003

125

Cottonseed

401

25

Sand - Foundry

1522

95

Earth - Dry Loam

929-1089

58-68

Shale

1410

88

1602-1666

100-104

Slag - Crushed

1121

70

Earth - Sand Gravel

Wet

1570

98

Slate

2243

130

Ensilage

577

36

Snow

240-801

15-50

Granite

1490-1778

93-111

Soybeans

743

46

Gravel - Dry

1522

95

Sugar Beet Pulp - Wet

561

35

Wet

1906

119

Sugar - Raw

961

60

Ice - Crushed

593

37

Sulphur - Lumpy

1330

83

Iron Ore

2323

145

Taconite

1714

107

Limestone - Loose Crushed

1538-1602

96-100

Wheat

769

48

8-18

CHAPTER 8 - SPECIFICATIONS TORQUE CHARTS Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

PoundInches 108 to 132 204 to 252 420 to 504 54 to 64 80 to 96 110 to 132 150 to 180 270 to 324 400 to 480 580 to 696 800 to 880 1120 to 1240 1460 to 1680 1940 to 2200

Size 1/4 inch 5/16 inch 3/8 inch 7/16 inch 1/2 inch 9/16 inch 5/8 inch 3/4 inch 7/8 inch 1.0 inch 1-1/8 inch 1-1/4 inch 1-3/8 inch 1-1/2 inch

Newton metres 12 to 15 23 to 28 48 to 57 73 to 87 109 to 130 149 to 179 203 to 244 366 to 439 542 to 651 787 to 944 1085 to 1193 1519 to 1681 1980 to 2278 2631 to 2983

Grade 8.8 Bolts, Nuts, and Studs

PoundNewton Size Inches metres 1/4 inch 144 to 180 16 to 20 5/16 inch 288 to 348 33 to 39 3/8 inch 540 to 648 61 to 73 7/16 inch 70 to 84 95 to 114 1/2 inch 110 to 132 149 to 179 9/16 inch 160 to 192 217 to 260 5/8 inch 220 to 264 298 to 358 3/4 inch 380 to 456 515 to 618 7/8 inch 600 to 720 814 to 976 1.0 inch 900 to 1080 1220 to 1465 1-1/8 inch 1280 to 1440 1736 to 1953 1-1/4 inch 1820 to 2000 2468 to 2712 1-3/8 inch 2380 to 2720 3227 to 3688 1-1/2 inch 3160 to 3560 4285 to 4827 NOTE: Use thick nuts with Grade 8 bolts.

Grade 10.9 Bolts, Nuts, and Studs

8.8

PoundInches 24 to 36 60 to 72 96 to 108 228 to 276 456 to 540 66 to 79 106 to 127 160 to 200 320 to 380 500 to 600 920 to 1100 1600 to 1950

Size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M30 M36

10.9

Newton metres 3 to 4 7 to 8 11 to 12 26 to 31 52 to 61 90 to 107 144 to 172 217 to 271 434 to 515 675 to 815 1250 to 1500 2175 to Figure 2600 12

Size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M30 M36

PoundInches 36 to 48 84 to 96 132 to 156 324 to 384 54 to 64 93 to 112 149 to 179 230 to 280 450 to 540 780 to 940 1470 to 1770 2580 to 3090

Newton metres 4 to 5 9 to 11 15 to 18 37 to 43 73 to 87 125 to 150 200 to 245 310 to 380 610 to 730 1050 to 1275 2000 to 2400 3500 to 4200

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

8-19

CHAPTER 8 - SPECIFICATIONS MAJOR COMPONENTS

BC08H378

8-20

CHAPTER 9 - INDEX

Chapter 9

INDEX A Access Door Locations ...................................... 5-14 Access Doors and Covers ................................... 3-3 Accumulators, Brake ......................................... 4-15 Air Conditioning Compressor ................................................... 6-11 Condenser ..................................................... 6-11 Auxiliary Power Outlet ............................................................... 7-7

Fuse Panel ...........................................................7-7 Fuses ....................................................................7-7

H Hazardous Chemical Precautions ........................2-9 Hourmeter ............................................................5-3

I Identification Numbers ..........................................1-5 Inspecting and Cleaning the Machine ................6-10

B Battery ................................................................. 7-5 Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before Operating Machine ................................... 4-3 Brake Accumulators .......................................... 4-15 Burn Prevention ................................................... 2-8

C Cab Door ............................................................. 3-4 Cab Service ....................................................... 6-11 Checking for cylinder leakage ........................... 6-10 Components, Machine ......................................... 1-4 Cylinder Leakage Check ................................... 6-10

D Daily inspections ................................................ 5-11 Decals ................................................................ 2-12 DeClutch ............................................................ 4-15

E Electrical Maintenance ........................................ 7-6 Electrical System ................................................. 7-3 Engine Grid Heater ....................................... 4-6, 4-8 Engine Oil Type ................................................. 5-10 Environment ...................................................... 5-10

K Key Switch, Ignition ............................................3-13

L Latch Door .................................................................3-4 Lift .........................................................................8-6 Loader Operating Tips ........................................4-16 Pushing Operation .........................................4-17 Louvers, Air Recirculation ..................................................3-31

M Machine Components ..........................................1-4 Maintenance Precautions .....................................2-7 Maintenance, 10 Hour ........................................5-17 Maintenance, 2000 Hour ....................................5-46 Maintenance, 250 Hour ................... 5-27, 5-28, 5-45 Moving a Disabled Machine ...............................4-20

O Operating ............................................................4-24 Operating In Cold Climates ................................4-23 Operating Precautions ..........................................2-6 Operating the machine .........................................4-6 Operating the Machine in Hot climates ..............4-24 Operating Tips - Loader .....................................4-16 Operator Manual Storage Compartment ..............1-3

F

P

Fire Extinguisher ................................................ 6-10 Fluid Capacities ................................................... 5-6 Fluids and Capacities .......................................... 5-6 Foot Pedals ......................................................... 3-9 Front Console .................................................... 3-18 Key/Ignition Switch ........................................ 3-13 Fuel Handling Precautions .................................. 2-8

Personal Safety ....................................................2-3 Plastic and resin parts ........................................6-10 Power Outlet, Auxiliary .........................................7-7 Product Identification Number ..............................1-5

R Releasing Hydraulic System Pressure .................5-5 9-1

CHAPTER 9 - INDEX Run-In Period ...................................................... 4-3

S Safety and Decals Safety Rules .................................................... 2-3 Safety, Battery ..................................................... 7-3 Seat Belt Precautions ........................................ 2-10 Serial Numbers .................................................... 1-5 Sides of the machine Right-hand, left-hand, front, and rear .............. 1-3 Specific machine precautions ............................ 2-11 Specifications ...................................................... 8-3 Specifications and Capacities .............................. 5-6 Starter motor ........................................................ 7-6 Starting and Stopping Precautions ...................... 2-6 Starting Engine .................................................... 4-4 Steps and access handles ................................... 3-4 Stopping and Parking ................................... 4-5, 4-8 Stopping the engine ............................................. 4-8 Storage Compartment Operator Manual ............................................. 1-3 Support Strut ....................................................... 5-4 Switch Key/Ignition ................................................... 3-13

T Temperature Range, Hydraulic System .............. 5-8 Temperature Range, Oil Viscosity Engine ........... 5-7 Temperature Range, Transmission Oil Viscosity 5-8 Tire Pressure ....................................................... 6-6 Towing the machine .......................................... 4-20 Transporting The Machine ................................. 4-21 Transporting the machine .................................. 4-22

U Utility Safety ......................................................... 2-4 Utility Safety Rules Message ............................... 2-4

V Variable Periodic Maintenance ................. 5-15, 5-16

W Welding on the Machine .................................... 6-10 Wheel Bolt Torque ............................................... 6-7 Wheels and Tires ................................................. 6-5

9-2