Case 1221E Tier 3 Wheel Loader Operator's Manual 87729424 - PDF DOWNLOAD

OPERATOR’S MANUAL

WHEEL LOADER 1221E TIER 3

87729424 EUR

CNH AMERICA LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

European English Part Number 87729424 EUR Printed in U.S.A. • Bur

Issued 01Mar 08

OPERATOR’S MANUAL WHEEL LOADER

1221E TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01Mar 08 Printed in U.S.A. • Book/Form Number 87729424 EUR Copyright © 2007. CNH America, LLC. All Rights Reserved.

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.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01Mar 08

1221E Tier 3 Wheel Loader

87729424 EUR

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. 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. If 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: ❷ Is instructed in safe and proper use of the machine. ❷ Reads and understands the Manual(s) pertaining to the machine. ❷ Reads and understands ALL Safety Decals on the machine. ❷ Clears the area of other persons. ❷ 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 instructions on machine operation and maintenance.

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.

TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine.

Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service 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.

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A..

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 BEFORE SERVICING THIS MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CHAPTER 2 SAFETY AND SAFETY DECALS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 SAFETY AND SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 CHAPTER 3 SPECIFICATIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 SPECIFICATION FOR MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 CHAPTER 4 CONTROL DEVICES TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 AIR CONDITIONER AND HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 CHAPTER 5 OPERATION TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 CHECK BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 STARTING AND STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 WARMING-UP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 OPERATION OF THE ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 EFFICIENT WORKING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 ADJUSTMENT OF THE BUCKET/ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 OPERATION IN SPECIAL WORK SITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 CHAPTER 6 TRANSPORTATION TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADING AND UNLOADING BY CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-3 6-4 6-5 6-6 6-7 6-8

CHAPTER 7 MAINTENANCE TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 87729424EUR

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SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 SPECIFICATION OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 MAINTENANCE CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 AIR CONDITIONER AND HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 CHAPTER 8 TROUBLESHOOTING TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-3 8-4 8-5 8-6

CHAPTER 9 INDEX

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER 1221E Read this manual before you start the engine or operate the machine. If you need more information, see your Case Dealer.

Your Dealer can give you help with Case approved service parts. Your Dealer has experienced and trained technicians who know the best methods of repair and maintenance for your machine.

Use this manual as a guide. Your Wheel Loader will remain a reliable working tool as long as it is kept in 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.

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 handling. This machine is not intended to be used for lifting other objects or transporting loads at high speeds.

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. 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.

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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.

This manual contains a number of instructions and safety recommendations regarding driving, handling, lubrication, maintenance, inspection and adjustment of the wheel loader.

The manual is to promote safety maintenance and enhance machine performance.

Keep this manual handy and have all personnel read it periodically.

If you sell the machine, be sure to give this manual to the new owners.

This machine complies with EC directive "98/37/EEC".

1. Read and understand this manual before operating the machine.

This operator's manual may contain attachments and optional equipment that are not available in your area.

Please consult your local Case Dealer for those items you require.

Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death.

Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual.

The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses of actions as described in this manual.

2. Inspect the job site and follow the safety recommendations in the safety hints section before operating the machine.

3. Use genuine Case spare parts for the replacement of parts.

We expressly point out that Case New Holland will not accept any responsibility for defects resulting from non genuine parts or non Dealer repair.

In such cases, Case cannot assume liability for any damage.

Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Case or your Case Dealer for the latest available information for your machine or for questions regarding information in this manual.

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CHAPTER 1 - GENERAL INFORMATION

BEFORE SERVICING THIS MACHINE It is the responsibility of the owner and all service and maintenance personnel to avoid accidents and serious injury by keeping this machine properly maintained.

It also is the responsibility of the owner and all service and maintenance personnel to avoid accidents and serious injury while servicing the machine.

No one should service or attempt to repair this machine without proper training and supervision.

All service and maintenance personnel should be thoroughly familiar with the procedures and precautions contained in this manual.

All personnel also must be aware of any federal, state, provincial or local laws or regulations covering the use and service of construction equipment.

The procedures in this manual do not supersede any requirements imposed by federal, state, provincial or local laws.

Case can not anticipate every possible circumstance or environment in which this machine may be used and serviced.

All personnel must remain alert to potential hazards.

Work within your level of training and skill.

Ask your supervisor if you are uncertain about a particular task. Do not try to do too much too fast.

Use your common sense.

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CHAPTER 1 - GENERAL INFORMATION READ THIS 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.

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE

DO NOT remove this manual or the safety manual from the machine. See your Dealer for additional manuals.

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

When you see this symbol refer to your Repair Manual.

EC REGULATION APPROVED

• Noise

level (EN474-1 ANNEX4.10 2000/14/EC) are as followings.

and

LWA : 108dB (EU only) LPA : 73dB

• The value of vibrations transmitted by the operator's seat are lower than standard value of (2000/14/EC)

Figure 1

BS08B694

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.

NOISE LEVEL DECAL

This decal reflects the Guaranteed Sound Power Level for this machine.

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CHAPTER 1 - GENERAL INFORMATION IDENTIFICATION NUMBERS

PRODUCT IDENTIFICATION NUMBER (P.I.N.)

MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE When ordering par ts, obtaining infor mation or assistance, always supply your dealer with the type and serial number of your machine or accessories.

Machine serial no.

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.

Figure 2

HL7807A0FW02

ENGINE

Engine serial no.

PRODUCT IDENTIFICATION PLATE ➤ Model ➤ Serial Number ➤ Manufacturing Year

ENGINE

BD07A056

Figure 3

➤ Make and Model ➤ Serial Number

COMPONENT SERIAL NUMBERS ➤ Transmission ➤ Axle ➤ ROPS Cab ➤

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NOTES

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CHAPTER 2 - SAFETY AND SAFETY DECALS

Chapter 2 SAFETY AND SAFETY DECALS TABLE OF CONTENTS SAFETY AND SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 GENERAL AND SPECIFIC SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personnel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operator - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Proper Entry And Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting And Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Roll-over Protective Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 To Fasten The Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 To Unfasten The Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Specific Precautions To This Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

READ OPERATOR’S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

READ REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DECAL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY DECAL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................................................................................

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NOTES

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CHAPTER 2 - SAFETY AND SAFETY DECALS

SAFETY AND SAFETY DECALS This Chapter will cover general safety practices and precautions for the operator. This chapter will also show where safety decals are located and provide the information needed to replace any damaged or illegible decals through your local Dealer.

GENERAL AND SPECIFIC SAFETY INFORMATION 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.

Figure 1

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 decals on the machine before you operate or service the machine. See your Dealer if you have any questions.

Safety Decals on this machine 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 that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

• CAUTION: Indicates a potentially hazardous Figure 2

BD08B706-01

OPERATOR’S MANUAL STORAGE LOCATED IN POUCH RIGHT OF THE OPERATOR’S SEAT

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 this machine before you start to operate.

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 Title pages (first and second pages in front of the Table of Contents) of this manual.

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

and

STOP

if

used, are RED.

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

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

IMPORTANT: Safety messages in this section point out situations which can be encountered during the normal operation and maintenance of your machine.

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

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CHAPTER 2 - SAFETY AND SAFETY DECALS UTILITY SAFETY Safety precaution 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.

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

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

If a part of the machine touches high voltage power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

Figure 3

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION.

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.

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.

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CHAPTER 2 - SAFETY AND SAFETY DECALS OPERATOR PRECAUTIONS PERSONNEL PRECAUTIONS

PROPER ENTRY AND EXIT

• Be prepared for emergencies. Always have a firstaid 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 users intention. Faded and soiled vest are no longer as highly visible as original intent.

See the manufacture’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

Figure 4

BD07A003

• Always face the machine and use the hand holds when getting on and off. Do not rush.

• Exit the machine slowly and use the hand holds.

OPERATOR - GENERAL

Do not jump down.

• 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.

WARNING: Never exit the machine with the engine operating.

• Do not operate this machine or perform

WARNING: Never exit the machine without first confirming the parking brake is set.

maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

• Wear the seat belt to maximize the protection capability of the ROPS (Roll Over Protective Structure).

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

• Do not permit riders on the machine if there is no manufacturer’s designated place for a rider.

• Make sure that all protective guards, canopies, doors, etc. are in place and secure before starting and operating the machine.

• Remove all loose objects stored in the machine.

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

Figure 5

Figure 6

WARNING: Never exit the machine unless the blade and attachment or tools are down resting on the ground.

Figure 7

• Use the recommended hand holds and steps with at least three points of support when getting on and off the machine. Keep steps and platform clean.

• 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.

• After service has been performed, make certain all tools, parts and equipment have been cleared from the machine area.

• Do not lift personnel or allow personnel to work while standing in the bucket or on other attachments. This machine is not a man-lift.

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CHAPTER 2 - SAFETY AND SAFETY DECALS 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 machines tool, attachment, or furthermost contact point to view operation danger area from the work site personnel view and angle.

• Check that the parking device is applied, place the direction control lever in neutral or park as specified by the manufacturer, 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.

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

Ventilate the battery area before using jumper cables. Make sure that using jumper 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 or track securely blocked.

• Before leaving the operator station lower the equipment to the ground and shut off the engine.

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

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CHAPTER 2 - SAFETY AND SAFETY DECALS

• Use the recommended transport devices when

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. 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 moved.

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

• Never transport a loaded bucket at full height.

Operate the machine with the load as low as possible until it becomes necessary to raise the boom to discharge the load into a truck, container, etc..

roading the machine.

• 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 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.

• Confirm that the attachment is properly mounted to the mounting mechanism as specified by the manufacturer.

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

• Contact

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

• Operate and drive the machine with care and at

• Before you drive or operate in an area with high

speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

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. You must also know any federal, state/ provincial, or local safety codes or regulations that apply to the job site.

• 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.

• Know and understand the job site traffic flow patterns and obey signalmen, road signs and flagmen.

• 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.

If a part of the machine touches high voltage power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

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.

• If you have extreme conditions, such as a fire, or

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

contact with power lines, etc. and you are forced to leave the machine, do not step off the machine.

Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

• Select a gear that will prevent excessive speed

• Do not operate the machine if you do not feel well.

• Watch for bystanders and never allow anyone to

when going downhill. Do not coast downhill.

• When roading a machine, know and use the

This can be dangerous for you and for the people around you.

signaling devices required on the machine.

Provide an escort for roading where required.

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CHAPTER 2 - SAFETY AND SAFETY DECALS

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

Maintenance Precautions

• Do not attempt repairs unless trained. Refer to

• Stay away from hazardous areas such as ditches,

manuals and experienced repair personnel for help.

overhangs, etc. Walk around the work area before you start and look for hazards.

• Never make repairs on pressurized components,

• Be alert and always know the location of all 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.

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

fluid, gas or mechanical until the pressure has been relieved according to proper service procedures in the Repair Manual.

• 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 machine.

when

servicing

or

repairing

the

• 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 direction control lever in neutral, apply the parking device, place the equipment in a safe position, securely block the wheels and use extreme caution.

• 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.

• Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure caps.

Park the machine and let it cool down before opening a pressurized tank.

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

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

WARNING: In order to reduce the risk of fires due to the build-up of debris in the engine compartment and elsewhere on your Case Wheel Loader. It is recommended that you clean all radiators, coolers and engine compartments daily. Failure to comply could result in serious injury or death.

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• 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 cannot be braked, a tow bar 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. It is not recommended to tow this machine.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alternative: 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. Keep all safety signs clean.

FUEL HANDLING PRECAUTIONS

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

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.

WARNING: 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. Figure 8

• When the battery electrolyte is frozen, the battery

engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

can explode if, you try to charge the battery, or 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.

• To avoid spilling fuel maintain control of the fuel

• Hot coolant can spray out if the radiator cap is

• Never remove the fuel cap or refuel gasoline

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 nonapproved cap without proper venting may result in pressurization of the tank.

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

• Confirm that all components, hydraulic, engine, etc., are cool procedures.

before

attempting

service

HAZARDOUS CHEMICAL PRECAUTIONS

• If you are exposed to or come in contact with hazardous chemicals you can be seriously injured.

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

• 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 Dealer for correct disposal information.

TRANSPORTING PRECAUTIONS

• Know the rules, laws, and safety equipment necessary for transporting this machine on a road or highway.

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CHAPTER 2 - SAFETY AND SAFETY DECALS ROLL-OVER PROTECTIVE STRUCTURE

To Unfasten The Seat Belt

• Do NOT modify the ROPS in any manner.

Unauthorized modifications such as welding, drilling, cutting, or adding attachments can weaken the structure and reduce your protection. Replace ROPS if it is subjected to roll-over or damage. Do not attempt to repair.

To release the seat belt, push the red bar or button on the buckle, while holding the retractable end.

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. Failure to follow these instructions may result in death or serious injury.

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.

SEAT BELT PRECAUTIONS

Figure 11

SPECIFIC PRECAUTIONS TO THIS MACHINE

WARNING: Before starting the engine ensure the seat belt is 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 follow these instructions may result in death or serious injury.

• Welding in certain areas may require the controller be disconnected and grounded. Contact your Dealer before you weld.

• Whenever leaving the machine, always place the Safety Lock Lever in the LOCK position. This lever will lock out the hydraulic functions on this machine.

WARNING: Failure to lock out the hydraulic functions before exiting the machine can cause serious injury or death.

Figure 9

TO FASTEN THE SEAT BELT

1

Figure 12

2

BD99J183-01

Figure 10

1. RETRACTABLE HALF OF THE SEAT BELT 2. BUCKLE HALF OF THE SEAT BELT

77071SH01

Figure 13

77071SH01

SAFETY LOCK LEVER

Pull the seat belt retractable half (1) across the operator and buckle securely with the buckle half (2).

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CHAPTER 2 - SAFETY AND SAFETY DECALS

SAFETY DECALS READ REPAIR MANUAL WARNING: Replace any missing or damaged safety decals and keep all safety decals clean. See your Case dealer for new safety decals. If you can not read a decal or if a decal is missing, the result can be serious injury or death.

SC002

When a decal displays the “Read Repair Manual” symbol, refer to the Repair Manual for fur ther infor mation concer ning the ser vice operation, maintenance or adjustment about to be performed.

Specific information concerning this procedure will be detailed in the Repair Manual.

Make sure that you read all the safety decals and all instructional decals. Check these decals every day before you start. Clean these decals if they are not legible.

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

You must replace a decal if the decal is damaged, missing, or can not be read. If a decal is on a part that is replaced, make sure the decal is on the new part. See your Case dealer for new decals. Part numbers are on the decal.

READ OPERATOR’S MANUAL Decals which display the “Read Operator’s Manual” symbol are intended to direct the operator to the Operator’s Manual for further information regarding safety, maintenance, adjustments and/or procedures for specific areas of the machine. When a decal displays the following symbol refer to the Operator’s Manual.

BC00G075

Figure 15

One or both of these symbols may appear on a decal relating to safety, machine operation or service.

Below is a sample decal that directs the Machine Operator or Repair Technician to the Operator’s Manual for additional information concerning this procedure.

329044A1

Figure 14

384270A1A

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CHAPTER 2 - SAFETY AND SAFETY DECALS DECAL LOCATION Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label.

BS08B321

1 2 3 4 5 6 7 8 9 10 11 12

Start Motor Turbocharger Cover Hyd Oil Level Shut Off Valve Grease (A) Grease (B) Grease (C) Service Instruction Crush Hazard Do Not Use Ether Roll Over Rops Cab

13 14 15 16 17 18 19 20 21 22 23 24

Steering Warning-Lh Steering Warning-Rh Reference Manual Control Air Conditioner Filter ECU Connector Hammer Slinging Air Cleaner Radiator Cap Fueling Battery

25 26 27 28 29 30 31 32 33 34 35

Hyd Oil Lub Hyd Pressure Accumulator Run Over Hazard Fan Entanglement Shearing-engine Hood Alternate Exit Low Emission Engine Fire Extinguisher Ride Control Run Over Hazard Do Not Step

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CHAPTER 2 - SAFETY AND SAFETY DECALS SAFETY DECAL LOCATION

Figure 18 USE SEAT BELT CRUSH HAZARD DECAL: WARNING, LOCATED NEAR LOCATION 11 ON PAGE 12 OF THIS CHAPTER. (1) IN ROPS CAB. 386241A1

Figure 16 SERVICING VALVE CRUSH HAZARD DECAL: DANGER, LOCATED NEAR LOCATION 4 ON PAGE 12 OF THIS CHAPTER. (2) ONE EACH SIDE. 87453132

Figure 19 KEEP CLEAR CRUSH HAZARD DECAL: WARNING, LOCATED NEAR LOCATION 13 ON PAGE 12 OF THIS CHAPTER. (2) ONE EACH SIDE. 323695A1

Figure 17 RUNOVER HAZARD: CAUTION, LOCATED NEAR LOCATION 7 ON PAGE 12 OF THIS CHAPTER. (1) 329050A1

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CHAPTER 2 - SAFETY AND SAFETY DECALS

Figure 22 HOT LIQUID UNDER PRESSURE HAZARD DECAL: WARNING, (1) LOCATED NEAR LOCATION 22 ON PAGE 12 OF THIS CHAPTER. 329045A1

Figure 20 ENGAGE LOCK LINK BEFORE SERVICE CRUSH HAZARD DECAL: WARNING, LOCATED NEAR LOCATION 14 ON PAGE 12 OF THIS CHAPTER. (2) ONE EACH SIDE. 329048A1

Figure 23 BATTERY EXPLOSION HAZARD DECAL: DANGER, LOCATED NEAR LOCATION 24 ON PAGE 12 OF THIS CHAPTER. (2) ONE EACH SIDE. 412476A1

Figure 21 READ OPERATOR’S MANUAL DECAL: WARNING, LOCATED NEAR LOCATION 15 ON PAGE 12 OF THIS CHAPTER. (1) IN ROPS CAB. 256147A1

Figure 24 RUNOVER HAZARD DECAL: DANGER, LOCATED ON THE REAR COUNTERWEIGHT NEAR LOCATION 34 ON PAGE 12 OF THIS CHAPTER. (2) ONE EACH SIDE. 328753A1

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Figure 27 EXPLOSION HAZARD DO NOT USE ETHER: WARNING, LOCATED ON THE HOOD, REAR OF THE CAB, NEAR LOCATION 10 ON PAGE 12 OF THIS CHAPTER. 8603095

Figure 25 START ENGINE FROM OPERATOR’S SEAT ONLY: DANGER, (1) LOCATED NEAR LOCATION 1 ON PAGE 12 OF THIS CHAPTER. 334455A1

Figure 28 DO NOT STEP HERE: WARNING, LOCATED NEAR LOCATION 35 ON PAGE 12 OF THIS CHAPTER. E134402

Figure 26 ENTANGLEMENT HAZARD: WARNING LOCATED INSIDE THE REAR GRILL (2) ONE EACH SIDE NEAR LOCATION 28 ON PAGE 12 OF THIS CHAPTER. 332511A1

Figure 29 PRESSURIZED SYSTEM: WARNING, (5) LOCATED NEAR LOCATIONS 26 ON PAGE 12 OF THIS CHAPTER. 328903A1

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CHAPTER 2 - SAFETY AND SAFETY DECALS

Figure 30 PRESSURIZED SYSTEM: WARNING, LOCATED NEAR LOCATION 25 ON PAGE 12 OF THIS CHAPTER (3).

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CHAPTER 3 - SPECIFICATIONS

Chapter 3 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 MAJOR COMPONENTS (top view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 MAJOR COMPONENTS (side view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 BOLT-ON CUTTING EDGE TYPE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 WITH TOOTH TYPE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 SPECIFICATION FOR MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 MAIN PUMP(+BRAKE PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 STEERING PUMP(+FAN PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 DYNAMIC POWER TRAIN DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

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CHAPTER 3 - SPECIFICATIONS

NOTES

3-2

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CHAPTER 3 - SPECIFICATIONS

SPECIFICATIONS MAJOR COMPONENTS (TOP VIEW)

BS08C467

1. Bucket 5. Air Cleaner 9. Step

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3. Head Light 7. Counterweight 11. Bucket Cylinder

4. Hydraulic Tank 8. Radiator 12. Boom

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CHAPTER 3 - SPECIFICATIONS MAJOR COMPONENTS (SIDE VIEW)

7807ASE01

1.

5.

9.

13.

Bucket Link Precleaner Rear Axle Front Axle

2. Bell Crank 6. Muffler 10. Transmission 14.

3. Steering Cylinder 7. Engine 11. Main Pump 15.

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4. Cab 8. Fuel Tank 12. Boom Cylinder 16.

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CHAPTER 3 - SPECIFICATIONS

J

64

30

D

0

K

C

G

40

755

3620

H

4510

6160

F I

B

WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET

E

2680

A 7807ASE02

7807ASE02

Description Operating weight Struck

Bucket capacity

Heaped

Unit

Specification

kg(lb)

29300(64600)

m³(yd³)

4.1(5.4) 4.8(6.3)

Overall length

A

9325(30' 7")

Overall width

B

3450(11' 4")

Overall height

C

3805(12' 6")

Ground clearance

D

475(1' 7")

Wheelbase

E

Tread

F

2440(8' 0")

Dump clearance at 45°

G

3385(11' 1")

Dump reach at 45°

H

1330(4' 4")

Width over tires

I

3220(10' 7")

Dump angle

J

Roll back angle(Carry position)

K

mm(ft-in)

Degree (°)

Lift(With load) Dump(With load)

Cycle time

sec

Minimum turning radius(Center of outside tire)

Forward

Issued 03-08

33.9(21.1) 12(39' 4") 6.43(21' 1") 30 6.2(3.9)

Second gear

11.4(7.1)

Third gear

Reverse

1.4

First gear

Fourth gear

Travel speed

87729424 EUR

m(ft-in) Degree (°)

Gradeability

48

3 km/h(mph)

Braking distance

47 6.4

Lower(Empty) Maximum travel speed

3700(12' 2")

17.5(10.9) km/h(mph)

33.9(21.1)

First gear

6.2(3.9)

Second gear

11.4(7.1)

Third gear

23.6(14.7)

Bur

3-5

CHAPTER 3 - SPECIFICATIONS

J

64

30

D

5

K

C

G

40

758

3620

H

4510

6160

F I

B

BOLT-ON CUTTING EDGE TYPE BUCKET

E

2680

A 7807ASE03

7807ASE03

Description Operating weight Struck

Bucket capacity

Heaped

Unit

Specification

kg(lb)

29300(64600) 4.3(5.6)

m³(yd³)

5.1(6.7)

Overall length

A

9440(31' 0")

Overall width

B

3450(11' 4")

Overall height

C

3805(12' 6")

Ground clearance

D

475(1' 7")

Wheelbase

E

Tread

F

2440(8' 0")

Dump clearance at 45°

G

3300(10' 10")

Dump reach at 45°

H

1365(4' 6")

Width over tires

I

3220(10' 7")

Dump angle

J

Roll back angle(Carry position)

K

3700(12' 2")

mm(ft-in)

47

Degree (°)

48

Lift(With load) Dump(With load)

Cycle time

6.4 sec

1.4

Lower(Empty)

3 km/h(mph)

Maximum travel speed Braking distance Minimum turning radius(Center of outside tire)

12(39' 4")

m(ft-in)

6.43(21' 1")

Degree (°)

Gradeability

Forward

Reverse

30

First gear

6.2(3.9)

Second gear

11.4(7.1)

Third gear Fourth gear

Travel speed

17.5(10.9) 33.9(21.1)

km/h(mph)

First gear

6.2(3.9)

Second gear

11.4(7.1)

Third gear

23.6(14.7)

Issued 03-08

3-6

33.9(21.1)

Bur

87729424 EUR

CHAPTER 3 - SPECIFICATIONS

J

64

30

D

0

K

C

G

40

767

3620

H

4510

6160

I

F

B

WITH TOOTH TYPE BUCKET

E

2680

A 7807ASE04

7807ASE04

Description Operating weight Struck

Bucket capacity

Heaped

Unit

Specification

kg(lb)

29300(64600)

m³(yd³)

4.1(5.4) 4.8(6.3)

Overall length

A

9600(31' 6")

Overall width

B

3500(11' 6")

Overall height

C

3805(12' 6")

Ground clearance

D

Wheelbase

E

Tread

F

2440( 8' 0")

Dump clearance at 45°

G

3140(10' 4")

Dump reach at 45°

H

1485( 4' 10")

Width over tires

I

3220(10' 7")

Dump angle

J

Roll back angle(Carry position)

K

475( 1' 7") mm(ft-in)

Degree (°)

Lift(With load) Dump(With load)

Cycle time

Minimum turning radius(Center of outside tire)

m(ft-in) Degree (°)

Gradeability First gear Forward

87729424 EUR

Issued 03-08

33.9(21.1) 12(39' 4") 6.43(21' 1") 30 6.2(3.9) 11.4(7.1)

Third gear

17.5(10.9)

First gear Reverse

1.4

Second gear Fourth gear

Travel speed

48

3 km/h(mph)

Braking distance

47 6.4

sec

Lower(Empty) Maximum travel speed

3700(12' 2")

km/h(mph)

33.9(21.1) 6.2(3.9)

Second gear

11.4(7.1)

Third gear

23.6(14.7)

Bur

3-7

CHAPTER 3 - SPECIFICATIONS WEIGHTS Item

kg

lb

Front frame assembly

2714

5983

Rear frame assembly

3531

7785

Front fender(LH & RH)

74

163

Counterweight

1300

2866

Cab assembly

1030

2271

Engine assembly

984

2169

Transmission assembly

835

1841

Drive shaft(Engine to transmission)

14

31

Drive shaft(Front)

44

97

Drive shaft(Center)

46

101

Drive shaft(Rear)

27

60

Front axle(Include differential)

1550

3417

Rear axle(Include differential)

1550

3417

Tire(4EA)

430

948

Hydraulic tank assembly

253

558

Fuel tank assembly

509

1122

Main pump assembly

37

82

Steering pump assembly

24

53

Main control valve

95

209

Flow amplifier

29

64

Boom

2095

4619

Bell crank

263

580

Bucket link

55

121

5.1m³ bucket, with bolt on cutting edge

2590

5710

4.8m³ bucket, with tooth

2460

5423

4.7m³ bucket, without tooth and cutting edge

2250

4960

Boom cylinder assembly(2EA)

290

639

Bucket cylinder assembly(2EA)

130

287

Steering cylinder assembly(2EA)

60

132

Seat

40

88

Battery

55

121

Issued 03-08

3-8

Bur

87729424 EUR

CHAPTER 3 - SPECIFICATIONS

SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item

Specification

Model

Cummins QSM 11-C

Type

4-cycle turbocharged, charge air cooled diesel engine

Control type

Electronic control

Cooling method

Water cooling

Number of cylinders and arrangement

6 cylinders, in-line

Firing order

1-5-3-6-2-4

Combustion chamber type

Direct injection type

Cylinder bore X stroke

125 ×147mm(4.92"×5.79")

Piston displacement

10800cc(659cu in)

Compression ratio

16.3 : 1

Rated gross horse power

340ps at 2000rpm

Maximum gross torque at 1400rpm

171kgf·m(1235lbf·ft)

Engine oil quantity

38 l (10 U.S. gal)

Wet weight

984kg(2170lb)

High idling speed

2130 ± 50rpm

Low idling speed

800 ± 50rpm

Rated fuel consumption

162g/ps·hr

Starting motor

Delco Remy 42MT(24V)

Alternator

Delco Remy 22SI(24V-70Amp)

Battery

2×12V×200Ah

87729424 EUR

Issued 03-08

Bur

3-9

CHAPTER 3 - SPECIFICATIONS MAIN PUMP(+BRAKE PUMP) Specification

Item

Main pump

Brake pump

Type

Fixed displacement double vane pump

Capacity

113.5cc/rev

15.9cc/rev

Maximum operating pressure

210kgf/cm2(2987psi)

150kgf/cm2(2130psi)

Rated oil quantity

212 l /min(56U.S.gpm)

30 l /min(7.9U.S.gpm)

Rated speed

2000rpm

STEERING PUMP(+FAN PUMP) Item

Specification Steering pump

Fan pump

Type

Fixed displacement double vane pump

Capacity

137.5cc/rev

24.9cc/rev

Maximum operating pressure

210kgf/cm2(2987psi)

140kgf/cm2(1990psi)

Rated oil quantity

270 l /min(71.3U.S.gpm)

49 l /min(12.9U.S.gpm)

Rated speed

2000rpm

MAIN CONTROL VALVE Item

Specification

Type

2 spool

Operating method

Hydraulic pilot assist

Main relief valve pressure

210kgf/cm2(2987psi)

Overload relief valve pressure(Boom)

240kgf/cm2(3414psi)

Overload relief valve pressure(Bucket)

240kgf/cm2(3414psi)

REMOTE CONTROL VALVE Item Type Operating Single operation stroke

Specification Pressure reducing type

Minimum

5.8kgf/cm2(82.5psi)

Maximum

24kgf/cm2(341psi)

Lever

75mm(3.0in)

Issued 03-08

3-10

Bur

87729424 EUR

CHAPTER 3 - SPECIFICATIONS CYLINDER Item

Specification

Boom cylinder

Bore dia × Rod dia × Stroke

Ø 200 × Ø 110 × 863mm

Bucket cylinder

Bore dia × Rod dia × Stroke

Ø 160 × Ø 80 × 580mm

Steering cylinder

Bore dia × Rod dia × Stroke

Ø 110 × Ø 55 × 480mm

DYNAMIC POWER TRAIN DEVICES Item

Specification

Model

ZF 4WG310

Type Transmission

Axle Wheels Brakes

Steering

87729424 EUR

Converter

Single-stage, single-phase

Transmission

Full-automatic power shift

Gear shift

Forward fourth gear, reverse third gear

Adjustment

Electrical single lever type, kick-down system, Automatic kick down from 2nd to 1st gear FNR Switch on joystick lever(option)

Drive devices

4-wheel drive

Front

Front fixed location

Rear

Oscillation 13° of center pin-loaded

Tires

29.5-25, 22PR(L3)

Travel

Four-wheel, wet-disc type, full hydraulic

Parking

Spring applied, hydraulic released brake on front axle

Type Steering angle

Full hydraulic, articulated 40° to both right and left angle, respectively

Issued 03-08

Bur

3-11

CHAPTER 3 - SPECIFICATIONS

Issued 03-08

3-12

Bur

87729424 EUR

CHAPTER 4 - OPERATING INSTRUCTIONS

CHAPTER 4 CONTROL DEVICES TABLE OF CONTENTS OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 TRANSMISSION OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 BATTERY VOLT METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 HYD OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 DIRECTION SIGNAL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 MIRROR DEFROST LAMP (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 HIGH BEAM LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 PARKING BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 PREHEATER LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 CLUTCH CUT OFF LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 ENGINE OVERHEAT WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 ENGINE OIL PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 TRANSMISSION ERROR WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 AIR CLEANER WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 HYD OIL TEMPERATURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 BATTERY CHARGING WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 FUEL LOW LEVEL WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 FNR SELECT LAMP (OPTION)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 STEERING SYSTEM WARNING LAMP (OPTION)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HAZARD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH CUT OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WORK LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WIPER AND WASHER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MIRROR DEFROST SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUTO SELECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEACON SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RIDE CONTROL SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMERGENCY STEERING SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAB LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KICK DOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MULTI FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17 4-18 4-18 4-18 4-18 4-19 4-19 4-19 4-19 4-20 4-20 4-20 4-21 4-21 4-21 4-22 4-22

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FNR JOYSTICK CONTROL LEVER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEAR SELECTOR LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC CONTROL LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-24 4-25 4-25 4-26 4-26 4-26 4-26

Issued 03-08

Bur

87729424 EUR

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS STEERING WHEEL ADJUSTMENT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 AIR CONDITIONER AND HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 POWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 AIR CONDITIONER SWITCH (COMPRESSOR SWITCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 FAN SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 TEMPERATURE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 OUTLET CHANGE OVER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 INLET CHANGE OVER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 12V ACCESSORY SOCKET (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 MASTER ELECTRICAL DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 MACHINE CONTROL UNIT(MCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 TRANSMISSION CONTROL UNIT(TCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 ENGINE CONTROL MODULE (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 RADIO AND CASSETTE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37 RADIO AND CD PLAYER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37

4-2

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87729424 EUR

CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS INSTRUMENTS AND CONTROLS (1) The ergonomically designed console box and suspension type seat provide the operator with comfort.

(2) The centralized electronic monitor system allows the status and conditions of the machine to be monitored at a glance.

(3) It is equipped with a safety warning system for early detection of machine malfunction.

BS08B642

1.

5.

9.

13.

17.

Brake Pedal Steering Wheel Radio & CD (Opt) Arm Rest Operator Seat

87729424EUR

2.

6.

10.

14.

18.

Kick Down Switch Multi-Function Switch Radio Cassette (Std) Ignition Switch Accelerator Pedal

Issued 03-08

Bur

3.

7.

11.

15.

19.

Gear Select Lever FNR Remote Control Kick Down Switch Switch Panel

4.

8.

12.

16.

20.

Instrument Cluster Aircon & Heat Switch Hydraulic Safety Lever Cigarette Lighter

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS

INSTRUMENT CLUSTER The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection.

• Gauges : Indicate operating status of the machine.

• Warning lamp: Indicate abnormality of the machine.

• Pilot lamp : Indicate operating status of the machine.

IMPORTANT: The monitor installed on this machine does not entirely guarantee the condition of the machine.

Daily inspection should be performed according to Chapter 7, MAINTENANCE. When the monitor provides a warning immediately check the problem, and perform the required action.

BS08C095

1.

4.

7.

10.

13.

16.

19.

22.

25.

28.

4-4

Engine Oil Pressure Warning Emergency Steering Warning Left Turn High Beam Hydraulic Oil Temp. Warning Fuel Low Level Warning T/M Error Warning Next Switch (Buzzer Stop Select) speedometer Battery Voltage Gauge

2.

5.

8.

11.

14.

17.

20.

23.

26.

29.

Engine Overheat Warning Brake Failure Warning Mirror Defrost Right Turn Clutch Cut Off FNR Select Menu Switch Select Switch Fuel Gauge T/M Oil Temp Gauge

3.

6.

9.

12.

15.

18.

21.

24.

27.

30.

Primary Steering Warning Preheater System Warning Parking Brake Warning Battery Charging Warning Air Cleaner Warning Back Switch LCD Engine Coolant Temp Gauge Hydraulic Oil Temp Gauge

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87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS SPEEDOMETER

ENGINE COOLANT TEMPERATURE GAUGE

(1)The speedometer displays machine in mph and km/h.

the

speed

of

(1)This indicates the temperature of coolant.

• Red range : Above 104°C (219°F) (2)Keep idling engine at low speed until the indicator is in the operating range.

(3)If the indicator stays in the red range, turn OFF the engine, check the radiator and engine.

Red

mph

7807A3CD03

Operating range

7807A3CD03

7807A3CD05

FUEL GAUGE (1)This gauge indicates the amount of fuel in the fuel tank.

(2)Fill the fuel when the indicator moves E point, refuel as soon as possible to avoid running out of fuel.

7807A3CD05

TRANSMISSION OIL TEMPERATURE GAUGE (1)This range indicates the temperature transmission oil.

• Red range : Above 107°C (225°F)

of

(2)Keep idling engine at low speed until the indicator is in the operating range.

(3)If the indicator stays in the red range, it means the transmission is overheated. Be careful that the indicator does not move into the red range.

7807A3CD04

Red 7807A3CD04

Operating range

7807A3CD06

7807A3CD06

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4-5

CHAPTER 4 - OPERATING INSTRUCTIONS BATTERY VOLT METER

WARNING LAMP

(1)This gauge indicates the voltage in the charging system when the engine is running.

(1)When all warning lamp or fault codes are being displayed, this warning lamp will flash.

(2)If the indicator is below 24V(Yellow range), it means that the electricity is being discharged. If the indicator is above 30V(Red range), an u nu s u a l l y h i g h vo l t a g e m ay d a m a g e t h e alternator. Check the charging system in both cases.

(2)When this warning lamp flashes, machine must be checked or serviced as soon as possible.

77073CD09

77073CD09

7807A3CD08

DIRECTION SIGNAL LAMP (1)This lamp flashes when the direction signal indicator lever is moved.

7807A3CD08

HYD OIL TEMPERATURE GAUGE (1)This range indicates the temperature hydraulic oil.

• Red range : Above 105°C (221°F)

of

(2)Keep idling engine at low speed until the indicator is in the operating range.

(3)If the indicator is in the red range, reduce the load on the system. If the gauge stays in the red range, stop the machine and check the cause of the problem.

77073CD10

77073CD10

Red

MIRROR DEFROST LAMP (1)This lamp comes ON when mirror defrost switch is pressed.

Operating range

7807A3CD08

7807A3CD09

7807A3CD11

7807A3CD11

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87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS HIGH BEAM LAMP

PREHEATER LAMP

This lamp comes ON when the switch is operated from dim to high beam.

(1)This lamp lights ON when start switch is turned clockwise to the ON position. Light will turn off after approximately 5 - 45 seconds, depending on engine temperature, indicating that preheating is completed.

(2)When the lamp goes out the operator should start cranking the engine.

77073CD12

77073CD12

PARKING BRAKE WARNING LAMP When the parking brake is actuated, the lamp is ON. IMPORTANT: Make sure the lamp is OFF before driving.

77073CD14

CLUTCH CUT OFF LAMP (1)When the clutch cut off switch is pressed, the lamp lights ON.

77073CD13

77073CD13

77073CD65

77073CD65

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4-7

CHAPTER 4 - OPERATING INSTRUCTIONS BRAKE WARNING LAMP

ENGINE OIL PRESSURE WARNING LAMP

(1)The lamp lights ON when the oil pressure of service brake drops below the normal range.

(1)This lamp is comes ON after starting the engine because of the low engine oil pressure.

(2)When the lamp is ON, stop the engine and check for its cause. See your Dealer or refer to th e Repa ir Manual for the corre ct repair procedure.

(2)If the lamp comes ON during engine operation, shut OFF engine immediately. Check engine oil level.

WARNING: Do not operate the machine until all problems have been corrected.

77073CD18

77073CD18

77073CD16

TRANSMISSION ERROR WARNING LAMP (1)This lamp lights ON and the LCD display show the error codes when an error occurs in the transmission.

77073CD16

ENGINE OVERHEAT WARNING LAMP (1)This lamp is turned ON when the temperature of cooling water is over the nor mal temperature(104°C, 219°F).

(2)Check the cooling system when the lamp is ON.

(2)Immediately pull the machine to a convenient stop. Stop the engine. Investigate the cause.

WARNING: Consult your Dealer to investigate the cause. Do not operate until the cause has been corrected.

77073CD17 77073CD19

77073CD17 77073CD19

4-8

Issued 03-08

Bur

87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS AIR CLEANER WARNING LAMP

BATTERY CHARGING WARNING LAMP

(1)This lamp operates when the air filter is clogged.

(2)Check the filter and clean or replace it when the lamp is ON.

(1)This lamp is ON when the key switch is in the ON position, it goes OFF after star ting the engine.

(2)Check the battery charging circuit when this lamp comes ON, during engine operation.

77073CD20

77073CD22 77073CD20

HYD OIL TEMPERATURE WARNING LAMP (1)This warning lamp operates and the buzzer sounds when the temperature of hydraulic oil is over 105°C (221°F).

(2)Check the hydraulic oil level when the lamp is turned ON.

77073CD22

FUEL LOW LEVEL WARNING LAMP (1)Fill the fuel tank immediately when the lamp is ON.

(3)Check for debris between oil cooler and radiator.

77073CD23

77073CD21 77073CD23

77073CD21

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4-9

CHAPTER 4 - OPERATING INSTRUCTIONS FNR SELECT LAMP (OPTION)) (1)The lamp comes ON when FNR select button on the optional FNR joystick control lever is pressed.

2. Emergency This lamp indicates the emergency steering system is active.

WARNING: Immediately pull the machine to a convenient stop and stop the engine. The emergency steering system can be manually tested.

7807A3CD24

7807A3CD24

77073CD15

STEERING SYSTEM WARNING LAMP (OPTION)) 1. Primary This lamp indicates that the primary steering has failed. When the indicators come on and the a c t i o n a l a r m s o u n d s, s t e e r t h e m a c h i n e immediately to a convenient location and stop the machine. Stop the engine and investigate the cause.

77073CD15

WARNING: Do not operate the machine until the cause has been corrected.

77073CD66

77073CD66

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87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS LCD

Cluster

1 MENU

2

BACK

3

NEXT

4 5

SELECT

BS08B481

7807A3CD72

NORMAL DISPLAY

BS08B480

No.

1

2

3

Symbol

Remarks

LCD 1

Forward, Reverse, Neutral

LCD type 1

Display symbol during AEB mode

F, R, N

Forward, Reverse, Neutral

LCD type 2

Display symbol during AEB mode

1,2,3,4

Actual Gear

-

P

Parking Brake mode active

-

a

Wiper motor intermittently operating

-

b

When operating intermittently, it shows an operating time interval.

-

c,d e

4

Hour

5

Temp.

6

Meaning

Up and Down Shifting Pre-Selected Gear

c: Forward d: Reverse

Automatic Mode

-

Hour Meter

Display the total operation hours of the machine

Engine Coolant Temperature

Display in accordance with selected items

Aut

Ride Control mode active

Ride Control switch Auto position

On

Ride Control mode active

Ride Control switch On position

Off

Ride Control mode turned off

Ride Control switch Off position

f

Reversible Fan active

-

g

Buzzer stop

-

h

Mirror Defrost active

-

NOTE: Both type1 and type2 are LCD modes and they can be changed by operator’s selection.

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CHAPTER 4 - OPERATING INSTRUCTIONS

DISPLAY MAP Normal

Main menu Press

MENU

Sub menu Press

ACCESSORY

ACCESSORY CLOCK USER ADJUSTMENT DIAGNOSTICS

Press

Previous menu

Activate item Press

ACCESSORY

JOB TIMER

JOB TIMER

STOP WATCH ODOMETER LIGHT CONT

Previous menu

Press

ON OFF RESET

Press

Previous menu

7807A3CD60

7807A3CD60

Main group Accessory

Sub group

Meaning

Job timer

• Measure the various job time.

• Press : Display ON, OFF or RESET

Stop watch

• Measures time in seconds.

• Press : Start. Press again

Odometer

Latest

• Distance until recent times.

Total

• Total distance.

: Stop.

Light control

• Control of LCD display luminosity.

• Brightness control : , .

Time set

• When 12H or 24H is selected, the current hour appears.

• , : input, : setting.

Clock

Clock ON/OFF

•

: Clock display ON or OFF.

1 Alarm

2 3

User

• Raise the idle rpm to 1200rpm 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)

• Press button once : Shift down, press button again ; shift up.

Mode 2 (Down)

• Press button every time : Shift to lower gear respectively.

Auto Select Aux-sw Clutch Cut-off Cooling fan control

• Alarm setting. It is possible to set 3 alarms.

• Stop alarming :

• 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: * Reverse mode quickly cleans out dirt and dust on radiator and cooler by reverse rotation of cooling fan.

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87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS

Main group

Adjustment

Sub group Unit

Choose between metric and inch unit display.

Wiper Intermittence

When using the intermittent function of wiper motor, it regulates operation time.

Alternate RPM

Regulate idle rpm.

Press back/next arrow: Adjust idle rpm increments by 25rpm.

Pulse

Press Select: Modification.

AEB

It controls the disk interval of the transmission, automatically.

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.

Fault Code

Error code display.

Refer to page 4-14.

Monitor

Hydraulic temperature and battery voltage display.

Press Select: Display ON or OFF.

Fault Code

Error code display.

Consult a Case Dealer to error code.

Monitor

Engine coolant temperature display.

Press Select: Display ON or OFF.

Fault Code

Error code display.

Consult a Case Dealer to error code.

Monitor

Transmission oil temperature display.

Press Select: Display ON or OFF.

Machine

Diagnostics

Engine

Transmission

Version

87729424EUR

Meaning

Issued 03-08

Display the controller (MCU)) and cluster version.

Bur

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS

Machine Fault Codes When selecting the fault code menu, it shows all of the fault codes which mean abnormal conditions of present time.

• To go out from fault explanation window, press up arrow button.

Press (Press Enter, M to go out to first menu.)

• No error will be indicated in case that there’s no

Er : 030

030 050 025 046

fault.

Fuel level sensor open or short to power

77073CD60

77073CD60

Description

Electrical system

Hydraulic system

Engine system

T/M system

Steering system

Communication

Code

Meaning

Remark

010

Power input voltage low

Below 18V

011

Power input voltage high

Above 38V

012

Alternator voltage low

Below 5V

013

Alternator voltage high

Above 36V

014

Buzzer circuit open or short to ground

015

Buzzer circuit short to power

020

Hydraulic oil temperature sensor open or short to power

021

Hydraulic oil temperature sensor short to ground

030

Fuel level sensor open or short to power

031

Fuel level sensor short to ground

034

Cooling fan driving valve open or short to ground

035

Cooling fan driving valve short to power

050

Auto select switch supply power open or short to power

051

Auto select switch supply power short to ground

052

Clutch cutoff supply power open or short to power

053

Clutch cutoff supply power short to ground

060

Emergency steering relay open or short to ground

Option

061

Emergency steering relay short to power

Option

070

MCU communication error

071

TCU communication error

072

ECM communication error

MCU : Machine Control Unit TCU : Transmission Control Unit ECM: Engine Control Module

4-14

Issued 03-08

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87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS

Transmission Warning Symbol

Meaning

Remarks

LF, LR

Limp home gear

–

F/R/up arrow/ down arrow flashing

Direction F or R selected while turbine speed is too high, CAUTION gear will engage if turbine speed drops

–

Oil temperature too low, no gear available

Warm up engine / transmission

WS

Warning sump temperature

Changes between actual gear/direction while driving, in neutral only displayed if no fault is detected

WT

Warning torque converter temperature

Changes between actual gear/direction while driving, in neutral only displayed if no fault is detected

WE

Warning high engine speed

Changes between actual gear/direction while driving, in neutral only displayed if no fault is detected

87729424EUR

Issued 03-08

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4-15

CHAPTER 4 - OPERATING INSTRUCTIONS

Display During AEB Mode Symbol

Meaning

Remarks

K1~K4, KV, KR

Calibrating clutch K1~K4, KV or KR respectively

- And Kx

Wait for start, initialization of clutch Kx, x : 1, 2, 3, 4, V, R

And Kx

Fast fill time determination of clutch Kx

= And Kx

Compensating pressure determination of clutch Kx

OK

Calibration for all clutches finished

Transmission stays in neutral, you have to restart the TCU (Ignition off/on)

STOP

AEB canceled (Activation stopped)

Transmission stays in neutral, you have to restart the TCU (Ignition off/on)

STOP and Kx

AEB stopped, clutch Kx can't be Transmission stays in neutral, you have to restart the calibrated TCU (Ignition off/on)

Spanner and Kx

Kx couldn't be calibrated, AEB finished

up arrow E

Engine speed too low, - Raise engine speed

down arrow E

Engine speed too high, - Lower engine speed

up arrow T

Transmission oil temperature too low, - Heat up transmission

down arrow T

Transmission oil temperature too high, - Cool down transmission

FT

Transmission temperature not in defined range during calibration

Transmission stays in neutral, you have to restart the TCU (Ignition off/on) Transmission stays in neutral, you have to restart the TCU (Ignition off/on)

FB

Operating mode not NORMAL or transmission temperature sensor defective or storing of calibrated values to EEPROM has failed

FO

Output speed not zero

Transmission stays in neutral, you have to restart the TCU (Ignition off/on)

FN

Shift lever not in neutral position

Transmission stays in neutral, you have to restart the TCU (Ignition off/on)

FP

Park brake not applied

Transmission stays in neutral, you have to restart the TCU (Ignition off/on)

STOP

AEB-Starter was used incorrect Transmission stays in neutral, you have to restart the or is defective. Wrong device or TCU (Ignition off/on) wrong cable used

Transmission stays in neutral, you have to restart the TCU (Ignition off/on)

AEB mode : It controls the disk internal of the transmission, automatically.

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87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS

SWITCHES

Figure 1

BS08B637

1.

4.

7.

10.

13.

16.

Kick Down Switch Horn Button Ride Control (option) Mirror Defrost Switch (option) Main Light Switch Clutch Cutoff Switch

87729424EUR

Issued 03-08

2.

5.

8.

11.

14.

17.

Bur

Hazard Switch Kick Down Switch Ignition Switch Rear Wiper/Washer Switch Work Lamp Switch

3.

6.

9.

12.

15.

18.

Multi-function Switch Pump Motor Switch (option) Beacon Switch (option Parking Brake Switch Auto Select Switch

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS STARTING SWITCH

CLUTCH CUT OFF SWITCH

There are four positions, ACC, OFF, ON and START.

• (ACC): Activates accessory switches and instrument cluster.

• (OFF) : None of electrical circuits activate.

• (ON) : All the systems of machine operate.

• (START) : Use when starting the engine.

Release key immediately after starting.

1. This switch is pressed, it will cut off the clutch when brake operates.

WARNING: Be careful not to use this switch when driving on a slope.

2. When the switch failure occurs, it will be able to operate a clutch off function from LCD. NOTE: Refer to page 4-12.

WARNING: Key must be in the ON position with engine running to maintain electrical and hydraulic function and prevent serious machine damage.

77073CD43

77073CD43

PARKING BRAKE SWITCH This switch is pressed, the parking brake will start to operate and the gauge panel warning lamp will comes ON.

BS08B316

HAZARD SWITCH Use for parking, or roading machine.

IMPORTANT: If the switch is left ON for a long period of time, the battery may be discharged.

WARNING: Before operating the gear selector lever, be sure to release the parking brake. If the machine is operated with the parking brake engaged, the brake will overheat and may cause the brake system to be damaged and fail.

OFF ON

77073CD42

77073CD44 77073CD42

77073CD44

4-18

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Bur

87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS MAIN LIGHT SWITCH

REAR WIPER AND WASHER SWITCH

This switch operates the clearance lamp and head lights - two steps.

This switch operates the rear wiper and washer - two step.

• First step : Clearance lamp and cluster

• First step : The rear wiper operates.

• Second step : The washer liquid is sprayed

illumination lamp comes ON. Also, all indicator lamp of switches come ON.

• Second step : Head light comes ON.

and the rear wiper is operated only while pressing.

77073CD45

77073CD47

77073CD45

77073CD47

WORK LAMP SWITCH

MIRROR DEFROST SWITCH

This switch operates the front and rear work lamps two step.

• First step : Front work lamp located on the cab comes ON.

• Second step : Rear work lamp located on the cowl comes ON.

1. With the key switch in the ON position, pressing this switch will activate the mirror defroster for 15 minutes. After 15 minutes, the defrost function stops automatically.

2. One more press of the switch, while in operation, stops the defrost function.

7807A3CD48

77073CD46

7807A3CD48

77073CD46

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4-19

CHAPTER 4 - OPERATING INSTRUCTIONS AUTO SELECT SWITCH

RIDE CONTROL SWITCH (OPTION)

(1) Manual mode

(1) AUTO position

Press the top of the switch for the manual mode of the autoshift function. The operator selects the desired speed and the desired direction in the manual mode with the gear selector lever.

(2) Automatic mode Press the bottom of the switch for the autoshift function in the automatic mode. Press the bottom of the switch pr ior to shifting the transmission into forward or reverse in order to activate the autoshift function.

Push in the top of the ride control switch in order to tur n on the automatic ride control. The automatic ride control automatically turns on when the travel speed exceeds a preset speed of approximately 9.5km/h. The automatic ride control automatically shuts off during low speed 8km/h travel mode.

WARNING: The operator can select two kinds of automatic modes. (1st ↔ 4th, 2nd ↔ 4th) When the switch failure occurs, it will be able to operate an auto select function from LCD. 77073CD51

NOTE: Refer to page 4-12.

77073CD51

(2) ON position Push in the bottom of the ride control switch in order to turn on the system for ride control regardless speed. The ride control will smooth the ride of the machine during travel.

77073CD49

77073CD49

BEACON SWITCH (DEALER INSTALLED ACCESSORY) This switch turns ON the rotary light on the cab.

77073CD51-1

77073CD51-1

77073CD50

77073CD50

4-20

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87729424EUR

CHAPTER 4 - OPERATING INSTRUCTIONS (3) MIDDLE position

HORN BUTTON

Push the ride control switch to the middle position in order to turn off the system for the ride control.

If you press the button on the top of the multifunction switch, the horn will sound.

Ho b to nu tr button Horn

73033CD28A 77073CD51-2

73033CD28A 77073CD51-2

CAB LAMP SWITCH EMERGENCY STEERING SWITCH (OPTION)

This switch turns ON the operator’s cab lamp.

1. If equipped, the emergency steering system can be manually tested. Push this switch in order to determine if the emergency steering and the emergency steering lamp are functional.

2. When the switch is pushed, the emergency steering pump motor will run. The emergency steering lamp will light.

WARNING: If the emergency steering lamp does not light, do not operate the machine.

See your Dealer and have the machine repaired immediately.

73033CD24

73033CD24

77073CD52

77073CD52

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CHAPTER 4 - OPERATING INSTRUCTIONS KICK DOWN SWITCH

MULTI FUNCTION SWITCH

(1) Manual mode

Front wiper and washer switch:

It is effective 2nd speed to 1st speed only and recover to 2nd speed quickly when push the switch one more time.

(2) Automatic mode A. Mode 1(Down/Up) It shifts down quickly from current gear to one step lower speed by pushing the switch and recover to original speed quickly when push the switch one more time.

B. Mode 2(Down) It shifts down from current gear to one step lower speed when push the switch every time.

(1)When the switch is in J position, the wiper moves intermittently.

(2)When placed in I or II position, the wiper moves continuously.

(3)If you press a button at the end of the lever, washer liquid will be sprayed and the wiper will be activated 2-3 times.

IMPORTANT: Check the quantity of washer liquid in the tank. If the level of the washer liquid is LOW, add the washer liquid (In cold, winter days) or water. The capacity of the tank is 1 liter.

NOTE: Refer to page 4-12.

O J

I II

Kick down switch

73033CD29

73033CD29

(3) Dimmer switch A. This switch is used to control the head lights.

B. Switch positions 7807ACD34 7807ACD34

• Up : To flash for passing • Middle : Head lights low beam ON • Down : Head lights high beam ON C. If you release the switch when it's in up position, the switch will return to middle.

Up M Down 73033CD30

73033CD30

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CHAPTER 4 - OPERATING INSTRUCTIONS (4) Turning switch 1. This switch is used to warn or signal the turning direction of the machine to other vehicles or equipment.

2. Push the lever up for turning left, pull the lever down for turning right.

Left turning

Right turning 73033CD31

73033CD31

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CHAPTER 4 - OPERATING INSTRUCTIONS

CONTROLS

BS08C470

1. Gear Select Lever 4. FNR Remote Control Lever (opt) 7. Accelerator Pedal

4-24

2. Steering Wheel 5. Remote Control Lever (std) 8. Brake Pedal

3. Steering Wheel Adjust Lever 6. Hydraulic Safety Lock Lever 9.

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CHAPTER 4 - OPERATING INSTRUCTIONS FNR JOYSTICK CONTROL LEVER (OPTION)

GEAR SELECTOR LEVER

If equipped this switch is used for forward and backward drive.

1. This lever is used for gear selection, forward 4 stages and reverse 3 stages.

NOTE: Gear range can be selected by gear selector lever.

2. If you push the gear selector lever, the machine moves forward, but if pull the gear selector lever, the machine moves backward.

Select button (1)If the select button is pressed, the indication lamp on the cluster will be ON and this FNR switch will start to operate.

3. If you turn the gear selector lever forward, the machine increases the speed, but if you turn the gear selector lever backward, the machine reduces the speed.

WARNING: With the machine running, machine stopped, park brake released and the gear selector (FNR Controller) in neutral position, this function can be actuated by pressing the select button. Shown below.

FNR switch

• F : Forward drive • N : Neutral • R : Reverse drive (1)If the upper side of this switch is pushed, the machine moves forward.

BS08C098

(2)If the down side of this switch is pushed, the machine moves backward.

(3)This function is automatically released when the engine is stopped, parking brake is ON or gear selector lever is out of neutral.

Kick down button : Refer to page 4-22.

BS08C097

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CHAPTER 4 - OPERATING INSTRUCTIONS STEERING WHEEL

HYDRAULIC CONTROL LOCK LEVER

1. Two cylinders in the center of the machine will operate the steering function.

2. If the steering wheel is turned to left, the machine will move to the left and turn it to the right, the machine will move to the right.

Left Le f

When the lever is turned to LOCK position, the hy d r a u l i c p i l o t l i n e w i l l b e c u t o f f, s o t h e bucket/attachment(s) will not operate.

Right Ri gh

77073CD33

73033CD33 77073CD33

STEERING WHEEL ADJUSTMENT LEVER 73033CD33

1. By pulling down the lever, the steering wheel is allowed to tilt toward/away from the operator.

BRAKE PEDAL 1. If the pedal is pushed, this will generate braking force and bring the machine to a stop.

2. By pulling up the lever, the wheel is adjustable to telescope.

2. If the power train operation is to be cut off, set the clutch cut off switch to ON and press the pedal.

WARNING: If the brake is applied while this switch is OFF, power train will not cut off.

IMPORTANT: Do not operate the machine with the foot brake pedal unnecessarily, or bring premature wear of brake disc.

ACCELERATOR PEDAL

77033CD70

1. This pedal controls the engine speed. The engine speed will increase in proportion to the distance this pedal is pressed downward.

77033CD70

2. Unless this pedal is pressed, the machine will run at low idling.

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CHAPTER 4 - OPERATING INSTRUCTIONS

AIR CONDITIONER AND HEATER Air conditioner and heater are equipped for pleasant operation against outside temperature and defrost on window glass.

BS08B315

1. Air Conditioner Switch 4. Power Switch 7.

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2. Fan Speed Switch 5. Temerature Control Switch 8.

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3. Outlet Change Over Switch 6. Inlet Change Over Switch 9.

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS POWER SWITCH

FAN SPEED SWITCH

1. This switch turns the system and the LED simultaneously ON or OFF. 2. Default setting values Function

Value

Air conditioner

OFF

Fan speed

1

Temperature

Max cool

Outlet

Face

Inlet

Recirculation

1. It is possible to control the fan to four steps.

2. The first step or the fourth step gives 5 times beeps.

21073CD52

21073CD52

TEMPERATURE CONTROL SWITCH 1. There are 9 steps of temperature control, from max cool to max warm, controlled up and down by pushing the desired button one step per push.

2. When set to Max cool or max warm the control will beep 5 times.

BS08B314

AIR CONDITIONER SWITCH (COMPRESSOR SWITCH) 1. Operating this switch turns the compressor and the LED simultaneously on or off.

2. In accordance with the evaporator temperature, compressor turns on or off automatically without changing LED stare.

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

Temperature

Max cool

Max warm

Air conditioner

ON

OFF

Fan speed

4

3

Outlet

Face

Foot

Inlet

Recirculation

Fresh

IMPORTANT: Air conditioner operates to remove vapor and drains water through a drain hose. Water can be sprayed into the cab in case that the vacuum valve of drain hose has a problem. If this occurs, replace the vacuum valve.

Cool Warm 21073CD50

21073CD50

BS08B314

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CHAPTER 4 - OPERATING INSTRUCTIONS OUTLET CHANGE OVER SWITCH

INLET CHANGE OVER SWITCH

(1)There are four settings for air flow.

(1) It is possible to change the air-inlet method.

A. Fresh Intake air from the outside to pressurize cab inside.

Mode Switch position A Outlet

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)In case of heating range(5~Max warm), air conditioner will not turn ON.

IMPORTANT: Inspect the fresh air filter periodically to keep a good efficiency.

B. Recirculation It recycles the heated or cooled air to increase the system efficiency.

IMPORTANT: Change air occasionally when using recirculation for a long time. Inspect the recirculation filter periodically to maintain efficiency.

(2) Recirculation function operates when the system is OFF but it can be changed whenever needed.

Fresh Recirculation

77073CD35

21073CD49

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CHAPTER 4 - OPERATING INSTRUCTIONS

OTHERS

BS08C469 3

1.

4.

7.

10.

4-30

Operator Seat Radio Relay Board Master Disconnect Switch

2. Machine Control Unit (MCU) 5. Transmission Control Unit (TCU) 8. Cigarette Lighter 11.

3. Engine Control Unit 6. Fuse Box 9. 12 Volt Accessory Outlet 12.

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CHAPTER 4 - OPERATING INSTRUCTIONS CIGAR LIGHTER (1)This can be used when the engine starting switch is ON. (2)The lighter can be used when it springs out in a short while after being pressed down.

IMPORTANT: Service socket. Use cigar lighter socket when you need emergency power. Do not use the lighter exceeding 24V, 100W.

73033CD49

73033CD49

12V ACCESSORY SOCKET

12

V

(1)12 volt, 30 watt maximum accessory socket.

77073CD62

77073CD62

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATOR’S SEAT STANDARD SEAT

1 4

Figure 5

RD06F052

Figure 2

RD06F051

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 up and adjust the seat forward or backward as required. Release the lever to lock the seat in position.

2

5 2 Figure 6

BD06F048

Figure 3

BD06F047

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. 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. Tur n the knob counterclockwise to decrease the weight resistance. Adjust the seat to operator preference and comfort.

HEIGHT ADJUSTMENT, STANDARD SEAT: 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.

3

RD06F046

Figure 4

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

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CHAPTER 4 - OPERATING INSTRUCTIONS OPTIONAL AIR RIDE SEAT

1

2

4 Figure 9

BD06G182

Figure 7

BD06G181

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

3

5. HEIGHT ADJUSTMENT HANDLE:

Figure 8

BD06F046

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 weight 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 weight adjustment tab until the desired height is reached. Release the weight 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.

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CHAPTER 4 - OPERATING INSTRUCTIONS SEAT BELT

6 7

BD06G182

Figure 10

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

Figure 12

BD03J071

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.

8

Figure 13

RD97F255 BD06G1823

Figure 11

8. RIDE CUSHION ADJUSTMENT LEVER

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

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS MASTER ELECTRICAL DISCONNECT SWITCH

FUSE BOX

(1)This switch is used to shut off the entire electrical system.

(1)The fuses protect the electrical parts and wiring from burning out.

(2)I l : The battery remains connected to the electrical system.

O : The battery is disconnected to the electrical system.

(2)The fuse box cover indicates the capacity of each fuse and circuit it protects.

㡞゚㣿

㡞゚㣿

㡞゚㣿

IMPORTANT: Never turn the master switch to O (OFF) with the engine running. Engine and electrical system damage could result.

WARNING: Before replacing a fuse, be sure to turn OFF the key switch. Replace a fuse with another of the same capacity.

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㓺䐇⧾䝚/䤚㰚

㢋㎮㧻䂮

㠪㰚䄾䔎⪺⩂

䋊⩂㓺䔎

ἓ㩗/䄾⻚䎆

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㓺㥚䂮 䕦⎂

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OFF 7807A3CD100

7807A3CD100

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㞞㩚 Ⰺ⩞㧊

7807A3CD40 7807A3CD40

MACHINE CONTROL UNIT(MCU) (1)It consists of electronic parts and controls all lamps and buzzers on cluster in accordance with signals transmitted from the switches, the ECM, TCU, the engine and the hydraulic pressure sensors.

77033CD68

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CHAPTER 4 - OPERATING INSTRUCTIONS TRANSMISSION CONTROL UNIT(TCU) (1)The control unit is shifting the required speeds fully-automatically under consideration of the following criteria.

• Gear selector lever position • Driving speed • Load level

77073CDS91

77073CDS91

ENGINE CONTROL MODULE (ECM) (1)The engine control module (ECM) is the control center of the engine system.

M OE T R PO

AT TU AC T R PO

OR NS SE T OR P O R

7807A3CD92

7807A3CD92

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CHAPTER 4 - OPERATING INSTRUCTIONS RADIO AND CASSETTE (STANDARD)

BS08B319

RADIO AND CD PLAYER (OPTION)

BS08B320

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

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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 4-37

CHAPTER 4 - OPERATING INSTRUCTIONS

AUDIO

(3) Sound button

(1) Power and mute button (1)POWER ON/OFF Press to switch on the set. Press more than 2 seconds to switch off the set.

(2)MUTE(Silence) Shor t press mute(silence).

for

(1)SOUND Whether you listen to Jazz, Vocal, Pop, Classic or Rock music, the SOUND button is the perfect setting for your choice.

• Press SOUND then the sound button to select BASS-Treb for your own sound style, or adjust the settings with the volume up/down buttons to select one of the pre define sound styles:

key to mute or cancel the

IMPORTANT: The silence period may be interrupted

by ALARM announcement or traffic announcement messages (If TA is switched on).

- BASE -TRE : Your own settings of bass and treble.

- FLAT : Original - JAZZ : Jazz music - VOCAL : Speech - POP : Pop music - CLASSIC : Classical music - ROCK : Rock music (2)AUDIO SETTING

MUTE

7807A3CD09A

• Press SOUND to select desired audio mode.

• Adjust the settings with the volume up/down buttons : 7807A3CD09A

- Sound style : BASS-TRE, FLAT, JAZZ, VOCAL, POP, CLASSIC, ROCK

(2) Volume button (1)Press the volume button up/down to adjust the volume.

- BASS : Low notes - TREBLE : High notes - BALANCE : Left-right - FADER : Rear-front - LOUD : OFF, LOW, MID, HIGH

• Press the volume button to adjust the

+

selected audio mode.

After 5 seconds the display goes back to the last mode of operation.

Adjustment of Bass and Treble settings is only possible when BASS-TRE is selected as the sound style.

VOLUME

VOLUME

-

7807A3CD11

7807A3CD11

SOUND

7807A3CD10

7807A3CD10

(4) Source button 4-38

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CHAPTER 4 - OPERATING INSTRUCTIONS (1)Press SOURCE to select the desired source : - TUNER - CD IMPORTANT: Radio with cassette mechanism will change source to cassette only when a tape is inserted.

(3) MANUAL TUNING(If you know the frequency of the required station)

• To switch to manual tuning : • Long press the search button

or for more than 2 seconds will switch the tuning to manual tuning.

• Then press to tune to a station of a lower frequency or to a higher frequency.

• When keys are released, a time-out start to count. After 5 seconds time-out, display 'Auto' for one second and return to automatic search.

BAND AST

SOURCE RDS

7807A3CD13

BAND AST

7807A3CD13

SOURCE RDS

RADIO

7807A3CD13

(1) Wave band / Automatic (1) search button (1)WAVEBAND

• Press BAND to select the desired band: (2) AUTOMATIC SEARCH Use search tuning to automatically search for a station.

• Press

to tune a station of a lower frequency or to a higher frequency.

• To search for another station, press the key again.

7807A3CD13

(2) Preselected button Preselected stations (1)Manually storing stations in a preset Five stations per band can be stored and recalled using the preset keys(1 to 5).

• Tune in to the desired station.

• Press the desired preset key(1 to 5) for more than 2 seconds to store the current tuned station.

NOTE: When storing an FM station, the current program station name and the AF mode are stored on the preset (Some stations use alternating program service name).

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

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CHAPTER 4 - OPERATING INSTRUCTIONS (3)Automatically storing stations(AUTO-STORE) You can automatically store 5 strongest FM stations on the FM AST band or 5 strongest MW(AM) stations on the MW(AM) AST band.

When you use Auto store, the new stations replace any stations previously stored in the FM AST band or the MW(AM) AST band.

TA

• Press AST to activate autostore.

• The set gives a beep and then mutes.

• When it has finished, you hear a beep

AF

7807A3CD15

followed by the station stored on preset 1.

• Sometimes it may not be possible to find 5 stations.

7807A3CD15

NOTE: The following may or may not be available in your area.

1

4

2

5

3

TA

(3) Alarm messages(PTY ALARM) This set autom atically receives em ergency messages made by the broadcaster.

• During the messages the display shows 'ALARM' and the station name alternately.

AF

7807A3CD14

7807A3CD14

RADIO DATA SYSTEM (RDS) ON FM More and more stations broadcasts RDS i n fo r m a t i o n s i n o r d e r t o o f fe r y o u m a n y advantages including: (1) Program service name(PS) Allows the radio to display the name of the station instead of its frequency.

(2) Automatic returning(AF) The set remains tuned to the current station by continually searching the best alternative frequency for best reception. You can switch AF off.

– Activate/Deactivate AF This set continuously searches for other alternative frequencies for the tuned radio station and automatically selects the best frequency for reception. Long press TA AF for more than 2 seconds to activate/deactivate AF.

4-40

(4) Traffic announcements(TA) You can activate the TA modes to give priority so as to hear traffic announcements related to these subjects(even if you play a cassettes/CD or mute the set).

– Activate/Deactivate TA

• Short press BAND to select an FM band.

• Press TA to activate/deactivate TA. AF

– If you activate TA mode

• You will hear the traffic announcements when broadcast by station(even if you play a cassette/CD or mute the set).

• If the tuned station does not enable the reception of traffic announcements, the display shows 'NO TA'. The radio automatically searches for an appropriate station.

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CHAPTER 4 - OPERATING INSTRUCTIONS – Interrupting traffic announcement mode If you do not wish to continue listening to a particular traffic announcement

• Short press

Display during playback

Action

key to interrupt traffic announcement without switching off the mode.

Fast forward

• The set will return to the previous operating

Fast forward

TA

AF

Fast rewind

Fast rewind

mode.

NOTE: You can switch off RDS features if not required.

• Long press RDS key to switch off RDS. • All RDS related features e.g., TA, etc...will be deactivated when RDS is switched off.

Key to press

During fast forward or rewind the radio resumes. If you continue fast winding until the end of the tape, play back restarts automatically.

(5)To stop fast winding To stop fast winding before the end of the tape, press the key which is not pressed( or ).

Playback is then resumed.

(6)End of the tape At the end of the tape, playback continues in the revers direction.

BAND

(7)Maintenance After extended use of the cassette player, dust, contamination or grime can accumulate on the playback head. This results in diminishing high-note reproduction. This can be remedied using a cleaning cassette (one or twice a month) and playing it through like an ordinary cassette.

AST

SOURCE RDS

7807A3CD13

7807A3CD13

CASSETTE PLAYER (1) Winding/Rewinding button IMPORTANT: Only use good quality cassettes. To avoid possible tape damage always take out the cassette after use. Protect your cassettes. Put them back in their boxes immediately after use. Never expose cassettes to heat or direct sunlight.

(1)Play back Slide the cassette, with the open side to the right into the cassette opening. Playback starts.

The direction of playback is shown by indicator .

(2)Stopping playback(

7807A3CD12

7807A3CD12

)

• To stop playback, Press the

button fully

home.

• The unit will switch over to radio reception.

• The cassette is partially ejected.

(3)Reverse(before the end of the tape) Press the and buttons at the same time halfway in.

(4)Fast rewind / Fast forward( or ) The direction of fast winding depends on the direction of play indicated on the display.

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CHAPTER 4 - OPERATING INSTRUCTIONS

CD PLAYER

RADIO SETTING

(1) Winding/ Rewinding button (1)CD playback This CD player is suitable only for 12cm disc, do not use irregular shaped CD.

• Slide the disc into the slot with label facing upwards. Playback starts.

• If a disc is already inserted : Press SOURCE to select CD as the source. Playback starts.

(2)Previous / Next track (

• Short press the

or

)

or

button to select the

desired track.

(1) NORTH AMERICA Press , No. 1 and No. 4 buttons at the same time. Set up completes displaying " AMERICA".

(2) SOUTH AMERICA Press , No. 2 and No. 5 buttons at the same time. Set up completes displaying " SOUTH".

(3) ASIA Press , No. 1 and No. 5 buttons at the same time. Set up completes displaying " ASIA".

(4) EUROPE Press power, No. 2 and No. 4 buttons at the same time. Set up completes displaying " EUROP".

• Playback resume with the chosen track.

(3)Fast rewind / Fast forward (

or

)

• Long press the

or button for more than 2 seconds to quickly move rewind or forward through the disc.

JAZZ

ROCK

• Normal play back resumes when you

VOCAL POP

FLAT

LOUD

TA

CLASSIC

AF AST

PRESET

release the button.

(4)Random track playback

7807A3CD16

• Press RND to activate / deactivate random track playback.

(5)Repeat track

7807A3CD16

• Press RPT to activate / deactivate repeat current track.

(6)Scan track The scan function enables you to listen to the first few seconds of each track.

• Press SCN to activate / deactivate scan track.

(7)Disc eject

• Press

to eject the disc.

BAND AST

SOURCE RDS

7807A3CD13

7807A3CD13

4-42

Issued 03-08

Bur

87729424EUR

CHAPTER 5 - OPERATION

Chapter 5 OPERATION TABLE OF CONTENTS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 CHECK BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 STARTING AND STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 CHECK INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 STARTING ENGINE IN NORMAL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 STARTING ENGINE IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 INSPECTION AFTER ENGINE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 TRANSMISSION COLD STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 TO STOP THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 WARMING-UP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 OPERATION OF THE ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 TRAVELING ON A SLOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 EFFICIENT WORKING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXCAVATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15 5-15 5-15 5-17 5-17 5-17 5-17 5-18

ADJUSTMENT OF THE BUCKET/ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 ADJUSTMENT OF THE BOOM KICK OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 BUCKET LEVELER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 OPERATION IN SPECIAL WORK SITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 OPERATING THE MACHINE IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 OPERATION IN SANDY OR DUSTY WORK SITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 SEA SHORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POSITION OF EACH PART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MASTER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREVENTION OF DUST AND MOISTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Issued 03-08

Bur

87729424 EUR

5-23 5-23 5-23 5-23 5-23 5-23 5-23

5-1

CHAPTER 5 - OPERATION

5-2

Issued 03-08

Bur

87729424 EUR

CHAPTER 5 - OPERATION

OPERATION RUN IN PERIOD FOR A NEW MACHINE 1) It takes about 100 operation hours to enhance its designed performance.

2) Operate according to below three steps and avoid excessive operation for the initial 100 hours.

Service meter

Load

Until 10 hours

About 60%

Until 100 hours

About 80%

After 100 hours

100%

IMPORTANT: Excessive operation of a new machine may deteriorate the potential performance and shorten lifetime of the machine.

3) During the initial 100 hours operation do the following: (1)Check daily for the level and leakage of coolant, engine oil, hydraulic oil and fuel.

(2)Grease daily all lubrication points.

(3)Tighten bolts.

(4)Warm up the machine fully before operation.

(5)Check the gauges frequently during operation.

(6)Monitor if the machine is operating normally during operation.

4) Replace following after initial 50 hours of operation.

Checking items

Service

Engine oil

Replace

Engine oil filter

87729424 EUR

Issued 03-08

Bur

5-3

CHAPTER 5 - OPERATION

CHECK BEFORE STARTING THE ENGINE 1) Make sure that the steering frame lock bar is stored in the unlocked position.

WARNING: The steering frame lock bar must be removed in order to steer the machine.

2) Look around the machine and under the machine to check fo r loos e nu t or bolts, collection of dirt, or leakage of oil, fuel or coolant and check the condition of the work equipment and hydraulic system. Check also loose wiring, and collection of dirt and debris in areas that reach high temperature. Clean these areas of any material before starting the machine.

IMPORTANT: Refer to the daily check list in Chapter 7, Maintenance.

3) Adjust seat to fit the contours of the operator's body for the pleasant operation.

4) Make sure that the machine is equipped with a lighting system that is adequate for the job conditions. Ensure that all lights are in proper working condition.

5) Adjust the rear view mirror.

6) Make sure that there are no personnel in the area before you start the engine. Make sure that there are no personnel in area before you move the machine. Make sure that there are no personnel on the machine, underneath the machine, or around the machine.

WARNING: If a warning tag is attached to the starting switch or to the controls, do not start the engine. Also, do not move any controls.

Issued 03-08

5-4

Bur

87729424 EUR

CHAPTER 5 - OPERATION

STARTING AND STOPPING THE ENGINE CHECK INDICATOR LIGHTS

STARTING ENGINE IN NORMAL TEMPERATURE

1) Check if parking brake switch is ON. WARNING: Check for personnel or obstacles in the work area. Sound the horn to warn people you are starting the machine.

2) Check if gear selector lever is in neutral position.

3) Check if hydraulic safety lever is in the lock position.

4) Turn the key switch to the ON position, and check following.

(1)If all the lamps light ON after sounding buzzer for 3 seconds.

IMPORTANT: If the lamps do not light or the buzzer is not sounded, check for a disconnected wire.

(2)Only below lamps will light ON and all the other light will be turned OFF after 3 seconds.

– Charging warning lamp(1) – Engine oil pressure warning lamp(2) – Brake system warning lamp(3)

1) Turn the starting switch to START position to start the engine.

IMPORTANT: Do not crank the engine for more than 20 seconds. If the engine does not start, allow the starter to cool for about 2 minutes before attempting to start the engine again.

2) Release the starting switch instantly after the engine starts to avoid possible damage to the starting motor.

BS08B317

87729424 EUR

Issued 03-08

Bur

5-5

CHAPTER 5 - OPERATION STARTING ENGINE IN COLD WEATHER WARNING: Check for personnel or obstacles in the work area. Sound the horn to warn people you are starting the machine.

Replace the engine oil and fuel using those recommended on 7-9.

Fill the anti-freeze coolant solution to the level as required.

1) Check if the parking brake is locked (With the parking switch ON).

2) Check if the gear selector lever is in the neutral position.

3) Check if the hydraulic control lock lever is in the lock position.

4) Turn the starting switch to ON position, and wait for the preheater pilot lamp to turn OFF. IMPORTANT: When the preheater pilot lamp is turned ON, the time of pre-heating will be 5 - 45 seconds depending on the temperature of the air intake manifold.

5) Start the engine by turning the key switch to START position after the preheater warning lamp OFF. 6) Release key switch immediately after starting engine. The key switch will automatically return to the ON position.

NOTE: After engine started, the preheating function is actuated to reduce the white smoke.

BS08B318

Issued 03-08

5-6

Bur

87729424 EUR

CHAPTER 5 - OPERATION INSPECTION AFTER ENGINE START

TRANSMISSION COLD STARTING

Inspect and confirm the following after engine starts.

1) Is the level gauge of hydraulic oil tank in the normal level?

2) Are there leakages of oil or water?

3) Are all the warning lamps(1-11) OFF? 4) Check the following after warming up operation.

(1)Is the indicator of coolant temperature gauge (12) in the operating range?

(2)Is the indicator of transmission oil temperature gauge(13) in the operating range?

1) If the temperature at start up is less than -12°C (10°F) the transmission must be warmed up.

2) This must be carried out in neutral by using a high idle engine speed.

3) Until operating oil temperature is reached, the transmission remains in neutral, and the symbol of the cold start phase will be indicated on the display.

4) When the cold transmission oil display clears, the machine is ready to start operation.

(3)Is the engine sound and the color of exhaust gas normal?

(4)Are the sound and vibration normal?

IMPORTANT: Do not increase engine speed quickly after starting, it can damage engine or turbocharger.

If the control panel gauges indicate a problem, stop the engine immediately and repair as required.

5 4 3 2 1

6 7 8 9 10 11

77073CD67

77073CD67

MENU

BACK

mph

Km/h

NEXT

SE E L C

13

12 7807A4OP06

7807A4OP06

87729424 EUR

Issued 03-08

Bur

5-7

CHAPTER 5 - OPERATION TO STOP THE ENGINE WARNING: Sudden stopping of the engine, will greatly shorten the engine life, especially if the engine is overheated. Stop machine operation and run the engine at high idle to allow gradual cooling. Then stop the engine.

In case of emergency stop the engine/ machine immediately.

1) Place the gear selector lever in neutral.

2) Turn the parking brake switch ON. 3) Run the engine for five minutes at low idle with no load.

4) Turn the key switch to the OFF position.

5) Remove the key to prevent other people from using the machine and LOCK hydraulic control lever.

6) Lock the cab door.

Issued 03-08

5-8

Bur

87729424 EUR

CHAPTER 5 - OPERATION

WARMING-UP OPERATION IMPORTANT: The most suitable temperature for the hydraulic oil is about 50°C (112°F). The hydraulic system can be damaged by sudden operation if the hydraulic oil is below 25°C (77°F). The temperature must be raised to at least 25°C (77°F) before starting work.

1) Run the engine at low idling for 5 minutes.

2) Increase the engine speed to midrange.

3) Release the hydraulic control lock lever.

4) Lift the boom slightly and extend the bucket cylinder to the stroke end and hold the control to bucket extend, allowing the hydraulic system to be in system pressure relief.

5) Retract the bucket cylinder to the stroke end and hold the control in bucket retract, allowing the hydraulic system to be in system pressure relief.

WARNING: Do not leave hydraulic pressure relieved for more than 30 seconds.

6) Repeat the procedure 4) - 5) several times until warm-up operation is completed.

87729424 EUR

Issued 03-08

Bur

5-9

CHAPTER 5 - OPERATION

OPERATION OF THE ATTACHMENT IMPORTANT: Confirm the operation of control lever and attachment.

5

1) Control lever operates the boom and the bucket.

4

1

2) When you release the control lever, control lever returns to neutral position automatically.

2

3

3) When the control lever operates to the position of boom float, boom kick out and bucket leveler; the function is completed, then the control lever returns to the neutral position.

Control lever Boom lower (1) Push the control lever forward in order to lower the boom.

Boom raise (2) Pull the control lever backward in order to raise the boom.

Bucket roll back (3) Move the control lever toward the left in order to tilt the bucket backward.

5

Bucket dump (4) Move the control lever toward the right in order to dump a load from the bucket.

3

Boom float (5) Push the control lever forward into the detent.

The boom will lower to the ground.

The boom will float along the contour of the ground.

1 4

2

3 2 4

1

7807AOP04

Issued 03-08

5-10

Bur

87729424 EUR

CHAPTER 5 - OPERATION

MACHINE OPERATION BASIC OPERATION (1) Traveling position Lift the boom so that the bucket is placed 40 50cm (15 - 20in) above the ground.

(3) Changing direction and speed (1)The gear selector is designed for the mounting on the left side of the steering column.

(2)The positions (speeds) 1 to 4 are selected by a rotary motion, the driving direction Forward (F)- Neutral (N)-Reverse (R) by tilting the gear selector lever.

(3)A neutral lock is installed as protection against inadvertent drive off.

• Position N - Gear selector lever blocked in this position • Position D - Driving

40~50cm

(4)When doing digging or dumping work, run the machine in the 1st or 2nd speed.

7807AOP08 7807AOP08

(2) Traveling operation When warm-up operation is completed after the engine is started, move the machine according to the following procedure.

(1)Release the hydraulic control lock lever.

(2)Release the parking brake.

(3)Put the gear selector lever in the 1st stage of forward or reverse direction and press the accelerator pedal gently to move the machine.

BS08C140

WARNING: 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.

87729424 EUR

Issued 03-08

Bur

5-11

CHAPTER 5 - OPERATION (4) Turning the machine

(6) Stopping the machine

(1)Turn the machine by moving the steering wheel into the desired direction.

(2)You can turn the machine to the left or right by 40 degrees.

WARNING: Do not turn the machine abruptly when traveling at high speed and avoid turning on a slope. Steering does not function with engine OFF, unless equipped with the secondary steering option.

(1)Press the brake pedal to stop the machine.

(2)Put the gear selector (FNR) lever in the neutral position.

(3)Press the parking brake switch.

(4)Lower the bucket to the ground.

40 40 7807OP32 7807OP32

(5) Precautions when driving (1)If the monitor warning lamp lights up, position the machine safely, put the gear selector lever in the neutral position and stop the machine.

Stop the engine after running it at low idling.

T h e n r e s o l ve a n y p r o bl e m s r e g a r d i n g operation of the machine.

(2)When operating the machine, if the load is lightened rapidly, the speed of the machine will increase. So, be careful.

(3)When the machine travels on uneven ground, keep the machine traveling at low speed.

Issued 03-08

5-12

Bur

87729424 EUR

CHAPTER 5 - OPERATION (5)Put the hydraulic control lever in the lock position.

WARNING: When parking on a slope, block the tires.

BS08C141

(7) Stopping engine WARNING: Sudden stopping of the engine, will greatly shorten the engine life, especially if the engine is overheated. Stop machine operation and run the engine at high idle to allow gradual cooling. Then stop the engine.

In case of emergency stop the engine/ machine immediately.

(1)Check if the parking brake is in the lock position.

(2)Check if the gear selector lever (FNR) is in the neutral position.

(3)Check if the hydraulic control lever is in the LOCK position.

(4)Run the engine at low speed without operating the equipment for about 5 minutes. Turn the starting key to the OFF position and remove the key.

(8) Checks after the engine stopped (1)Check for leakage of oil and coolant around the bucket/attachment and the exterior of the machine.

(2)Refill the fuel tank.

(3)Remove any debris inside of the engine compartment and any debris attached to the machine.

87729424 EUR

Issued 03-08

Bur

5-13

CHAPTER 5 - OPERATION TRAVELING ON A SLOPE WARNING: Never travel down a slope with the transmission in neutral. You can loose control of the machine causing serious injury or death.

1) Never travel down a slope in neutral.

2) Lower the bucket to 20-30cm(12 in) from the ground so that it can be used as a brake in case of an emergency.

3) If the machine starts to slide or loses stability, lower the bucket immediately and brake the machine.

4) When parking on a slope, use the bucket as a brake and place blocks behind the tires to prevent sliding.

IMPORTANT: Machine cannot travel effectively on a slope when the oil temperature is low. Do the warming-up operation when it is going to travel on a slope.

WARNING: Be careful when working on slopes. The machine may lose its balance and turn over, causing serious injury or death.

20~3 0cm

0cm 20~3

7807AOP15

7807AOP15

Issued 03-08

5-14

Bur

87729424 EUR

CHAPTER 5 - OPERATION

EFFICIENT WORKING METHODS GENERAL

EXCAVATION WORK

1) Lift the bucket about 40-50cm (15 - 20in) above the ground to ensure safety and to gain a good range of view.

(1) Shovel work As the bucket fills while traveling forward, the tires may start to slip because of the heavy load. Lift the bucket slightly to reduce load and add traction to the tires.

1) Keep the bucket shovel parallel to the ground. If the bucket is pushed in a non-hor izontal position, power may be reduced, and the bucket cannot dig deeply into the heap of soil).

40~50cm

7807AOP08 7807AOP08

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

3) Be careful that excessive force is not applied to the bucket.

4) When handling hard materials, use bucket teeth or bolt on cutting edge.

5) When doing dumping work, put the control lever in the DUMP position, then return it to a former state. Repeat this procedure until the work is finished.

73034OP04 73034OP04

2) When the bucket is sufficiently deep into the pile, advance the machine with the control lever pulled down. And by placing the control lever in the bucket roll-back position, fill the bucket with soil.

6) Position the machine with the rear into the wind so that dust does not get into the engine.

7) Check that the proper bucket is used for the work. If the capacity of the bucket exceeds that of the machine, the machine's service life may be shortened.

73034OP05 73034OP05

87729424 EUR

Issued 03-08

Bur

5-15

CHAPTER 5 - OPERATION 3) When it is difficult to dig into the soil, move the bucket control lever forward and backward to move the bucket teeth up and down.

2) Advance the machine and lift the bucket using the bucket control lever to dig out the soil.

73034OP08 73034OP06 73034OP06

IMPORTANT: If the machine operates with its front tires lifted, its driving force will deteriorate and excessive force will be applied to the rear tires. Avoid operating in that position.

73034OP08

3) Advance the machine while controlling the depth of digging with the control lever.

IMPORTANT: Do not force the bucket into the ground. It may damage the drive train. Use the correct bucket for the working condition when digging. Avoid applying load to one side of the bucket.

7807AOP16 7807AOP16

(2) Excavation on level ground Advance the machine with the bucket lowered slightly and make sure that the bucket is evenly loaded on both sides.

73034OP09 73034OP09

1) Lower the bucket edge slightly.

73034OP07 73034OP07

Issued 03-08

5-16

Bur

87729424 EUR

CHAPTER 5 - OPERATION LEVELING

COMPACTION

1) Load the bucket with material and dump gradually while driving backward.

When operating, keep the bottom of the bucket horizontal to the ground.

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

IMPORTANT: Do not work with the bucket set in the DUMP position.

3) Load the bucket with material and place the bucket in the horizontal position. Then put the control lever in the BOOM FLOAT position and move backward.

IMPORTANT: Make sure that the machine always moves backward when doing leveling work.

7807AOP09 7807AOP09

LOADING Maximum efficiency can be attained by carrying out work in such a way that the swinging angle and the traveling distance are kept as small and short as possible in accordance with the terrain.

(1) "I" method

73034OP10

1) After digging out the soil, move backward and position the dump truck between the heap of soil and the machine to load the soil into the truck.

TRANSPORTATION WARNING: Make sure that the traveling path is always cleared. When transporting material, lift the bucket 40-50cm (15 - 20in) above the ground.

2) This is the fastest and most efficient way to load material.

IMPORTANT: The ground of the job site should be always level and do not swing or step on a brake pedal abruptly with the boom raised.

73034OP11 73034OP11

73034OP12

87729424 EUR

Issued 03-08

Bur

5-17

CHAPTER 5 - OPERATION (2) "V" method

PRECAUTIONS DURING OPERATION

1) Park the truck at an angle of 60 degrees toward the machine. After loading the bucket, drive backward and position the machine at a right angle with the truck and load the truck.

2) Position the machine so that the load can be dumped in the center of the truck. If the length of the truck is more than double the width of the bucket, perform the dumping work from forward to backward.

(1) Permissible water level 1) Do not work in water or damp ground deeper than the permissible depth (Up to lower part of the axle housing).

2) After the work is completed, grease parts which have been immersed in water.

Axle housing

3) Move the control lever to the right and dump the bucket.

4) Shake the bucket to release the material stuck inside.

73034OP14 73034OP14

(2) When the brake does not operate 1) If the machine does not stop even though the brake pedal is applied, use the parking brake.

IMPORTANT: After using the parking brake as an emergency brake, ask your Case Dealer to check complete brake system.

73034OP13

5) Shake the bucket before moving it to the DUMP position so that loaded materials are evenly distributed inside the bucket. This will prevent materials from slipping back when the bucket is placed in the DUMP position.

7807AOP10 7807AOP10

Issued 03-08

5-18

Bur

87729424 EUR

CHAPTER 5 - OPERATION 1. Precautions when driving on a slope: WARNING: Be careful when working on a slope. The machine may lose its balance and turn over causing serious injury or death.

1) When turning on a slope, lower the bucket/ attachment to lower its center of gravity. Avoid turning on a slope if possible.

2) When traveling down a slope: (a)If the main brake is used to often when traveling down a slope, it may be overheated and damaged. To assist braking, place the transmission lever in low speed position and use the engine as a brake. (b)If there is a mismatch of speed, torque converter oil temperature may be overheated.

Set the speed in 1st speed position to allow the temperature to drop. (c)If the gauge does not move into the green range in 1st speed, stop the machine and put it in neutral. Run the engine at a mid range speed until the gauge moves into the green range.

3) If the engine stops: If the engine stops on a slope, press the parking brake switch immediately and lower the bucket/ attachment to stop the machine.

(3) Precautions when traveling Do not travel a long distance at high speed. It may overheat tires and cause premature damage. If it is necessary to travel a long distance at high speed, observe the following.

1) Comply with the regulations concerning this machine to ensure safety.

2) Do the pre-inspection before starting.

3) As the optimum air pressure of tire and optimum driving speed is different according to the kinds of tires and road conditions, consult your Case Dealer or tire distributor.

4) Check the air pressure of tire before driving.

5) After 1 hour driving, stop for 30 minutes to check any abnormality of tires and other parts, and level of oil and coolant.

6) Travel with the bucket empty.

87729424 EUR

Issued 03-08

Bur

5-19

CHAPTER 5 - OPERATION

ADJUSTMENT OF THE BUCKET/ATTACHMENT The bucket can be adjusted to a height desired by using the boom kick-out device.

WARNING: Park the machine on level ground and block the tires to prevent unexpected movement of the machine. Press the parking brake switch. Secure the front and rear frames by using the safety lock bar.

Keep clear of the bucket/attachment.

3) Loosen the bolts (or nuts). Move the plate (or proximity switch) so that the boom is in line with the center of the sensing surface of proximity switch. Then tighten the bolts (or nuts).

Bolt

ADJUSTMENT OF THE BOOM KICK OUT

Nut

Boom

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

Plate WARNING: Avoid crush hazard from lowering of bucket/attachment. Support raised bucket/attachment and/or lift linkage.

Serious injury or death may result if support is not provided.

BS08C142

77074OP24 77074OP24

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

77074OP25

2) Put the hydraulic control lock lever in the LOCK position.

BS08C141

Issued 03-08

5-20

Bur

87729424 EUR

CHAPTER 5 - OPERATION 5) To check the adjustment, clear the area of people and start the engine. Position the bucket on the ground. Then lift the bucket to a desired height by using the control lever and release the hand. Confirm the lever automatically returns to the neutral position and the boom (the bucket/ attachment) stop at the adjusted position.

Neutral

Detent position

77074OP26 77074OP26

BUCKET LEVELER 1) The bucket angle of this machine is set to be in parallel to the level operating surface.

VIEW A

A 77070OP27 77070OP27

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5-21

CHAPTER 5 - OPERATION

OPERATION IN SPECIAL WORK SITES OPERATING THE MACHINE IN COLD WEATHER

SEA SHORE OPERATION

1) Use proper engine oil and fuel for the expected temperature.

1) Prevent ingress of salt by securely tightening plugs, cocks and bolts of each part.

2) Fill the required amount of antifreeze in the cooling system.

2) Wash machine after operation to remove salt residue. Pay special attention to electrical parts and hydraulic cylinders to prevent corrosion.

3) Be sure to open the heater valve when using the heater.

4) Always keep the battery completely charged.

5) Refer to the starting engine in cold weather section. Star t the engine and extend the warming-up operation period.

3) Inspection and lubrication must be carried out more frequently. Supply sufficient grease to replace all old grease in bearings which have been submerged in water for a long time.

IMPORTANT: Discharged batteries will freeze more easily than fully charged.

6) Clean the machine and park on wood planks.

50 C

7807AOP05

OPERATION IN SANDY OR DUSTY WORK SITES 1) Inspect air cleaner element frequently. If warning lamp comes ON and the buzzer sounds, clean or replace element more frequently, regardless of inspection period.

2) Inspect radiator frequently, and keep cooling fins clean.

3) Prevent sand or dust from getting into fuel tank and hydraulic tank during refilling.

4) Prevent sand or dust from penetrating into hydraulic circuit by keeping the hydraulic oil tank breather cap closed tightly. Replace hydraulic oil filter frequently.

5) Keep all lubricated part, such as pins and bushings, clean at all times.

6) If the air conditioner/heater filters clog, the heating or cooling capacity will drop. Clean or replace the filters more frequently.

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5-22

Bur

87729424 EUR

CHAPTER 5 - OPERATION

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.

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

4. Replace the filtering element of the fuel filters.

5. Install the batteries.

6. Grease the machine thoroughly.

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

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.

6. Grease the cylinder rods.

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).

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.

87729424 EUR

Issued 03-08

10. Check the travel reduction gears and swing reduction gear oil level, and add more oil if necessary.

11. Clean the cylinder rods.

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

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

Keep non-authorized personnel clear of the machine.

14. 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.

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5-23

CHAPTER 5 - OPERATION

THIS PAGE LEFT INTENTIONALLY BLANK.

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5-24

Bur

87729424 EUR

CHAPTER 6 - TRANSPORTATION

CHAPTER 6 TRANSPORTATION TABLE OF CONTENTS TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 ROAD TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 PREPARATION FOR TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 LOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 LOADING AND UNLOADING BY CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 WHEN THE ENGINE DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

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CHAPTER 6 - TRANSPORTATION

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CHAPTER 6 - TRANSPORTATION

TRANSPORTATION ROAD TRAVELING If it is necessary to travel on a road, observe the following, if allowed on road.

1) Comply with regulations regarding this machine for the sake of safety.

2) Perform daily inspection before starting the machine.

3) Check the air pressure of tires and traveling speed limitations.

• Air pressure : 3.3kgf/cm² (47psi) • Maximum speed : 33.9km/h (21.1mph) 4) When traveling for a long distance, stop every hour or every 40km (25 mile) to allow tires and other components to cool down and check any abnormality.

5) Drive with the bucket empty.

6) Travel at a mid-range speed and be careful to drive within the limited speed when driving on a public road, if allowed.

40~50cm

40~50cm

787AOP08

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Issued 03-08

Bur

6-3

CHAPTER 6 - TRANSPORTATION

PREPARATION FOR TRANSPORTATION 1) When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc.

2) Make sure the cooling system has proper antifreeze if moving machine to a cold climate.

Overall width

3) Select proper trailer after confirming the weight and dimensions from the Specification section, 3-4.

4) Check the whole route such as the road width, the height of bridge and limit of weight and etc., which will be passed.

Overall height

5) Obtain permission from the proper authority if necessary.

Overall length

6) Prepare ramp for safe loading referring to the below table and illustration.

A

B

1.0m (3.3ft)

3.65 - 3.85m (12.0 - 12.6ft)

1.1m (3.6ft)

4.00 - 4.25m (13.1 - 13.9ft)

1.2m (3.9ft)

4.35 - 4.60m (14.3 - 15.1ft)

1.3m (4.3ft)

4.75 - 5.00m (15.6 - 16.4ft)

1.4m (4.6ft)

5.10 - 5.40m (16.7 - 17.7ft)

1.5m (4.9ft)

5.50 - 5.75m (18.0 - 18.9ft)

7807ATA01 7807ATA01

73035TA01

Issued 03-08

6-4

Bur

87729424 EUR

CHAPTER 6 - TRANSPORTATION

LOADING THE MACHINE 1) Load and unload the machine on a flat ground.

2) Use the ramp with sufficient length, width, thickness and slope.

3) Move slowly and carefully when the machine is on the ramp. Do not change the direction of the machine while it is on the ramp.

2) Apply the parking brake and stop the engine.

Remove the key from the key switch and turn the Master Disconnect switch to the OFF position.

3) Put blocks at the front and the rear of each tire on the machine.

4) Use chains to fasten the machine to the trailer.

Use the specified tie down locations for this machine.

5) Make sure that all doors, hoods and access panels are closed and locked.

6) The transport lock bar must be secured.

7) Chains must be fastened around the right and left sides of the loader arm to secure it in place.

8) Measure from the ground to the highest point of t h e m a c h i n e. Yo u mu s t k n ow t h e ove ra l l clearance height of the machine on the trailer.

7807ATA02 7807ATA02

4) Do the following after loading the machine to the trailer.

9) Advise the driver of the weights, heights of the machine and attachments and if there are any special permits or guidelines required.

(1)Lower the bucket/attachment gently after the machine is positioned on the trailer.

IMPORTANT: Place rectangular timber under the bucket cylinder to prevent the damage of it during transportation.

WARNING: Do not operate any other attachment when loading. Balance the load on the trailer.

7807ATA03 7807ATA03

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 the transport/service link in the LOCKED position.

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CHAPTER 6 - TRANSPORTATION

SECURING THE MACHINE 1) Secure front and rear frame by linking safety lock bar.

2) Switch on the parking brake.

6) Block the tires and fix firmly with wire rope or chain to prevent the machine from moving during transportation.

BS08C147

3) Put the hydraulic control lock lever in the LOCK position to prevent the hydraulic system from operating.

4) Stop the engine, turn the key switch off and remove the key.

BS08B324

BS08C141

5) Secure all locks.

Cover Cab

Radiator cap Fuel tank

Cowl

7807ATA05

Issued 03-08

6-6

Bur

87729424 EUR

CHAPTER 6 - TRANSPORTATION

LOADING AND UNLOADING BY CRANE WARNING: Make sure wire rope is proper size. Place the transport lock bar and hydraulic control lock lever to LOCK position to prevent the machine moving when hoisting the machine. The wrong hoisting method or installation of wire rope can cause damage to the machine. Do not load abruptly. Keep area clear of personnel.

BS08B322

1) Check the weight, length, width and height of the machine referring to 3-4, (Specifications) when you are going to hoist the machine.

2) Use long wire rope and a brace to keep the wire rope from contact with the machine.

3) Where there is the possibility the wire rope may contact the machine, use protective material to prevent damage.

4) Position the crane in the proper place/surface.

5) Install the wire rope and brace like the illustration.

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6-7

CHAPTER 6 - TRANSPORTATION

TOWING THE MACHINE WARNING: Personal injury or death could result when towing a disabled machine incorrectly. Block the machine to prevent movement before releasing the brakes. The machine can roll free if it is not blocked.

Except for an emergency, do not tow this machine. If this machine must be towed, observe the following.

GENERAL 1) Parking brake cylinder of the machine is operated by the spring force and released by hydraulic pressure. If the engine does not operate, the park brake will be engaged holding the machine.

If the engine does not run, the parking brake will need to be de-activated using the method on the following page.

2) When the machine is towed move it for a repair to nearby place at the speed less than 2km/h (1.2mph). Transport it on a trailer, if it has to be moved for a long distance.

3) When the steering device and the brake of the machine to be towed can not be operated, transport by trailer.

WARNING: Be careful when towing.

Understand that the brake will not work if there is any problem in the braking system.

4) .When you tow the machine from the rear, attach the tow line to the towing pin(1).

5) Do not use a chain for pulling a disabled machine. A chain link can break. This may cause personal injury. Use a wire rope cable with ends that have loops or rings. Place an observer in a safe position in order to watch the pulling procedure. The observer can stop the procedure, if necessary. The procedure should be stopped if the cable starts to break. Also, stop the procedure if the cable starts to unravel.

Stop pulling whenever the towing machine moves without moving the towed machine.

7807ATA08

6) Keep the tow line angle to a minimum. Do not exceed a 30 degree angle from the straight ahead position.

7) Quick machine movement could overload the tow line or the tow bar. This could cause the tow line or the tow bar to break. Gradual, steady machine movement will be more effective.

8) Normally, the towing machine should be as large as the disabled machine. Make sure that the towing machine has enough brake capacity, enough weight, and enough power. The towing machine must be able to control both machines for the grade that is involved and for the distance that is involved.

9) You must provide sufficient control and sufficient braking when you are moving a disabled machine downhill.

10) All situation requirements cannot be listed.

Minimal towing machine capacity is required on smooth, level surfaces. On inclines or on surfaces in poor condition, maximum towing machine capacity is required.

11) When any towed machine is loaded, this machine must be equipped with a brake system that is operable from the operator compartment.

NOTE: Consult your Case Dealer for the equipment that is necessary for towing a disabled machine.

WHEN THE ENGINE WORKS 1) When the transmission system or steering wheel is workable and the engine is running, the machine can be towed only for a shor t distance. For example, pull the machine out of mud or pull the machine to side of the road.

2) The operator of the towed machine should turn the steering wheel into the direction in which the machine is towed.

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6-8

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87729424 EUR

CHAPTER 6 - TRANSPORTATION WHEN THE ENGINE DOES NOT WORK When towing the machine with an engine that is not running, do the following in order: 1) Block the wheels to prevent movement of the machine.

unexpected

2) Disconnect the front and rear drive shafts.

3) Loosen the steering cylinder as the steering operation is not working.

NOTE: You may need to consult a Repair manual or your local Case Dealer to loosen the steering cylinder.

IMPORTANT: Even if the brake is in good condition, the machine has only wheel braking capability. As the hydraulic booster is not working, more force is required when pressing the pedal.

4) The parking brake is activated by spring and released by hydraulic pressure. If the engine does not work, the brake will be activated, so r e l e a s e t h e p a r k i n g b r a ke ; R e m ove t h e protecting cap and loosen the nut.

Nut

Spring

Front axle Protecting cap 77045TA01 77045TA01

5) Connect the towing machine to the towed machine at the rear towing pin.

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CHAPTER 6 - TRANSPORTATION

NOTES

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6-10

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CHAPTER 7 - MAINTENANCE

Chapter 7 MAINTENANCE TABLE OF CONTENTS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 INTERVAL OF MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 PROPER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 PERIODIC REPLACEMENT OF SAFETY PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 BOLT AND NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 TIGHTENING TORQUE OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 SPECIFICATION OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 MAINTENANCE CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 10 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INITIAL 50 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 50 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INITIAL 100 HOUR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 500 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 1000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 2000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10 7-10 7-10 7-10 7-10 7-11 7-11 7-11 7-12 7-13

MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 CHECK ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 REPLACEMENT OF ENGINE OIL AND OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 CHECK COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 FLUSHING AND REFILLING OF RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 COOLING SYSTEM FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 CLEAN RADIATOR AND OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 CHECK CHARGE AIR COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 INSPECTION OF COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 BELT TENSIONER, AUTOMATIC ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 CLEANING OF AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 FUEL WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 REPLACEMENT OF FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 CORROSION RESISTOR (COOLANT FILTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 LEAKAGE OF FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 HYDRAULIC OIL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 FILLING HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 CHANGE THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 CLEANING AND REPLACING RETURN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 REPLACE OF PILOT LINE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 CLEANING BRAKE LINE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 LUBRICATE REMOTE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 ADDING AIR TO THE TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 TIRE OR RIM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Issued 03-08

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87729424 EUR

7-1

CHAPTER 7 - MAINTENANCE TIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30 STORING TIRES AFTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31 CHECK TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 REPLACEMENT OF TRANSMISSION OIL AND FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 CLEANING TRANSMISSION AIR BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33 CHECK AND ADDING AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33 CHANGING THE AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 CLEANING AXLE BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 REPLACEMENT OF BOLT ON CUTTING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36 REPLACEMENT OF BUCKET TOOTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36 MAINTENANCE OF LOADER LIFT ARM AND BUCKET/ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37 BUCKET/ATTACHMENT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 BATTERY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 BATTERY FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 BATTERY VENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 CLEANING THE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 WIRING, GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41 STARTING THE ENGINE WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42 AIR CONDITIONER AND HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 CLEAN AND REPLACE OUTER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 CLEAN AND REPLACE INNER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 PRECAUTIONS FOR USING AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45

7-2

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CHAPTER 7 - MAINTENANCE

MAINTENANCE INTERVAL OF MAINTENANCE

2. Use genuine Case replacement parts.

(1)You may inspect and service the machine by the period as described on page 7-9 based on the service meter at the control panel.

3. Use the recommended lubricants.

(2)Shorten the interval of the inspection and service depending on the site conditions. (Such as dusty area, quarry, sea shore, etc.)

5. Drain the oil when the temperature of the machine is warm.

(3)Perform the entire related details at the same time when the service interval is reduced. For example, in case of 250 hours, carry out all the maintenance items for 250 hours each 100 hours and the daily service at the same time.

4. Remove any dust or water around the inlet of the oil tank before refilling.

6. Do not repair anything while the engine is running. Stop the engine when you fill the oil.

7. Relieve the hydraulic system of pressure by opening th e brea th er when ser vicing th e hydraulic system.

8. Confirm that all the Instruments are in the normal condition after the completion of service.

9. For more detailed information on maintenance, please contact your local Case Dealer.

WARNING: To avoid serious injury or death read and understand Chapter 2, Safety and Safety Decals, BEFORE repair or service of the machine.

Figure 1

77076MI52

PRECAUTIONS 1) Before you begin maintenance on this machine you should be familiar with its operation and safety precautions.

2) The monitor installed on this machine does not entirely guarantee the condition of the machine.

Daily inspection should be performed according to the instructions in this chapter.

RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM WARNING: Be sure to relieve the pressure in the system before repairing the hydraulic system to avoid serious injury or death.

(1)Park the machine in service position, and stop the engine.

3) Engine and hydraulic component intervals have b e e n p r e s e t a t t h e fa c t o r y. D o n o t l e t unauthorized personnel reset them.

4) Ask your local Case Dealer for maintenance advise if you are unsure.

5) Drain the used oil and coolant in a container and handle according to the method of handling for industrial waste to meet with the regulations in your province or country.

PROPER MAINTENANCE

7807AOP02 7807AOP02

Replacement and Repair of Parts.

(2)Release the pressure in the tank by pressing the air breather.

(1)It is required to replace the wearable and consumable parts such as the bucket tooth, cutting edge, filter and etc. regularly. Replace damaged or worn parts promptly to maintain the performance of the machine.

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CHAPTER 7 - MAINTENANCE

7807AMI02

7807AMI02

PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES WARNING: Be sure to relieve the pressure in the system before repairing the hydraulic system to avoid serious injury or death.

(1)Take care that the hose and pipe connections a r e n o t c o n ta m i n a t e d o r d a m a g e d w h e n ser viced to prevent damage to hydraulic systems.

(2)Assemble after cleaning the hose, pipe and joint of functioning item.

(3)Use genuine parts.

(4)Do not assemble the hose in the condition of twisted or sharp radius.

(5)Keep the specified torque on all connections.

PERIODIC REPLACEMENT OF SAFETY PARTS (1)These are the parts which the operator can not judge the remained lifetime by visual inspection.

(2)Repair or replace if any abnormality of these parts is found even before the recommended replacement interval.

Periodical replacement of safety parts Fuel hose(Engine-tank) Steering system hose Packing, seal and O-ring of steering cylinder Brake system hose Piston and packing of brake master cylinder

Interval

Every 2 years

IMPORTANT: Replace the O-ring and gasket at the same time when replace the hose.

IMPORTANT: Replace clamp at the same time if the hose clamp is cracked when checking and replacing the hose.

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CHAPTER 7 - MAINTENANCE

SPECIFICATIONS Use following table for unspecified torque.

BOLT AND NUT Coarse Thread

Bolt size

8T

10T

kgf/m

lbf/ft

kgf/m

lbf/ft

M 6 × 1.0

0.85 ~ 1.25

6.15 ~ 9.04

1.14 ~ 1.74

8.2 ~ 12.6

M 8 × 1.25

2.0 ~ 3.0

14.5 ~ 21.7

2.73 ~ 4.12

19.7 ~ 29.8

M10 × 1.5

4.0 ~ 6.0

28.9 ~ 43.4

5.5 ~ 8.3

39.8 ~ 60

M12 × 1.75

7.4 ~ 11.2

53.5 ~ 79.5

9.8 ~ 15.8

71 ~ 114

M14 × 2.0

12.2 ~ 16.6

88.2 ~ 120

16.7 ~ 22.5

121 ~ 167

M16 × 2.0

18.6 ~ 25.2

135 ~ 182

25.2 ~ 34.2

182 ~ 247

M18 × 2.5

25.8 ~ 35.0

187 ~ 253

35.1 ~ 47.5

254 ~ 343

M20 × 2.5

36.2 ~ 49.0

262 ~ 354

49.2 ~ 66.6

356 ~ 482

M22 × 2.5

48.3 ~ 63.3

350 ~ 457

65.8 ~ 98.0

476 ~ 709

M24 × 3.0

62.5 ~ 84.5

452 ~ 611

85.0 ~ 115

615 ~ 832

M30 × 3.5

124 ~ 168

898 ~ 1214

169 ~ 229

1223 ~ 1655

M36 × 4.0

174 ~ 236

1261 ~ 1703

250 ~ 310

1808 ~ 2242

Fine Thread

Bolt size

8T

10T

kgf/m

lbf/ft

kgf/m

lbf/ft

M 8 × 1.0

2.17 ~ 3.37

15.7 ~ 24.3

3.04 ~ 4.44

22.0 ~ 32.0

M10 × 1.25

4.46 ~ 6.66

32.3 ~ 48.2

5.93 ~ 8.93

42.9 ~ 64.6

M12 × 1.25

7.78 ~ 11.58

76.3 ~ 83.7

10.6 ~ 16.0

76.6 ~ 115

M14 × 1.5

13.3 ~ 18.1

96.2 ~ 130

17.9 ~ 24.1

130 ~ 174

M16 × 1.5

19.9 ~ 26.9

144 ~ 194

26.6 ~ 36.0

193 ~ 260

M18 × 1.5

28.6 ~ 43.6

207 ~ 315

38.4 ~ 52.0

278 ~ 376

M20 × 1.5

40.0 ~ 54.0

289 ~ 390

53.4 ~ 72.2

386 ~ 522

M22 × 1.5

52.7 ~ 71.3

381 ~ 515

70.7 ~ 95.7

512 ~ 692

M24 × 2.0

67.9 ~ 91.9

491 ~ 664

90.9 ~ 123

658 ~ 890

M30 × 2.0

137 ~ 185

990 ~ 1338

182 ~ 248

1314 ~ 1795

M36 × 3.0

192 ~ 260

1389 ~ 1879

262 ~ 354

1893 ~ 2561

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CHAPTER 7 - MAINTENANCE PIPE AND HOSE (FLARE TYPE) Thread Size

Width across flat (mm)

kgf/m

lbf/ft

1/4"

19

4

28.9

3/8"

22

5

36.2

1/2"

27

6

43.4

3/4"

36

12

86.8

1"

41

14

101

Thread Size

Width across flat (mm)

kgf/m

lbf/ft

13/16-16"

24

4.4

32.5

1-3/16-12"

36

9.3

67.3

1-7/16-12"

41

13.2

95.5

1-11/16-12"

50

18.3

132

2-12"

55

22.6

164

Thread Size

Width across flat (mm)

kgf/m

lbf/ft

1/4"

19

4

28.9

3/8"

22

5

36.2

1/2"

27

6

43.4

3/4"

36

13

94.0

1"

41

15

109

PIPE AND HOSE (ORFS TYPE)

FITTING

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CHAPTER 7 - MAINTENANCE TIGHTENING TORQUE OF MAJOR COMPONENTS No.

Items

Size

kgf/m

lbf/ft

1

Engine mounting bolt (Rubber, 4EA)

M24 x 3.0

100+/-15.0

723+/-108

2

Engine mounting bolt (Fly wheel housing, 8EA)

M16 x 2.0

19.4+/-3.0

140+/-21.7

Engine mounting bolt (Gear housing, 6EA)

M10 x 1.5

4.6+/-0.7

33.3+/-5.1

4

Radiator mounting bolt

M20 x 2.5

57.9+/-8.7

419+/-62.9

5

Fuel tank mounting bolt, nut

M16 x 2.0

29.7+/-4.5

215+/-32.5

6

Main pump housing mounting bolt

M16 x 2.0

29.7+/-4.5

215+/-32.5

7

Steering pump housing mounting bolt

M10 x 1.5

6.9+/-1.4

49.9+/-10.1

8

Main control valve mounting bolt

M12 x 1.75

12.8+/-3.0

92.6+/-21.7

9

Steering unit mounting bolt

M10 x 1.5

6.9+/-1.4

49.9+/-10.1

Flow amplifier mounting bolt

M10 x 1.5

6.9+/-1.4

49.9+/-10.1

Brake valve mounting bolt

M8 X 1.25

2.5+/-1.25

18.1+/-3.6

12

Cut-off valve mounting bolt

M12 x 1.75

12.3+/-2

89.0+/-14

13

Remote control lever mounting bolt

M6 X 1.0

1.1+/-0.2

8.0+/-1.4

14

Pilot supply unit mounting bolt

M8 X 1.25

2.5+/-0.5

18.1+/-3.6

15

Safety valve

M8 X 1.25

2.5+/-0.5

8.1+/-3.6

16

Hydraulic oil tank mounting bolt

M20 x 2.5

57.9+/-8.7

419+/-62.9

17

Transmission bolt, nut (Rubber, 4EA)

M24 x 3.0

100+/-15.0

723+/-108

18

Transmission bolt (Converter cover, 4EA)

M16 x 2.0

18.4+/-2.0

133+/-14.5

Front axle mounting bolt, nut

M33 X 2.0

225+/-25.0

1627+/-181

Rear axle support mounting bolt, nut

M33 X 2.0

225+/-25.0

1627+/-181

21

Tire mounting nut

M22 X 1.5

48.5+/-2.5

351+/-18

22

Drive shaft joint mounting bolt, nut

M20 x 2.5

57.9+/-8.7

419+/-62.9

23

Counterweight mounting bolt

M30 X 2.0

199+/-29.9

1439+/-216

Operator’s seat mounting bolt

M8 X 1.25

3.4+/-0.8

24.6+/-5

ROPS cab mounting bolt (4EA)

M27 X 2.0

124

900

3

Engine

10 11

19 20

24

Hydraulic System

Powertrain System

Others

25

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CHAPTER 7 - MAINTENANCE

SPECIFICATION OF FUEL, COOLANT AND LUBRICANTS Engine Oil .............................................................................................................................SAE 15W-40 (API CH-4) Hydraulic Oil ............................................................................................................ ISO VG46 (Case Akcela AW 46) Transmission Oil ...................................................................................................................................... SAE 15W40 Axle Oil .......................................................SAE 80W-90LS (API GL-5) for wet type brake & limited slip differentials Grease......................................................................................................................Lithium base grease NLGI No. 2 Fuel.................................................................................................................................................ASTM D975-No. 2 Coolant .....................................................................Mixture of 50% ethylene glycol base antifreeze and 50% water

• • • • •

SAE: Society of Automotive Engineers API: American Petroleum Institute ISO: International Organization for Standardization NLGI: National Lubricating Grease Institute ASTM: American Society of Testing and Material

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87729424 EUR

CHAPTER 7 - MAINTENANCE RECOMMENDED LUBRICANTS Use only oils listed below or equivalent.

Service point

Capacity l (U.S. gal)

Kind of fluid

Do not mix different brand oil.

-20

Ambient temperature °C (°F) -10 0 10 20

(-4)

(14)

30

40 (32)

(50)

(68)

(86)

(104) SAE 30 SAE 10W Engine oil pan

Engine oil

38 (10.0) SAE 10W-30 SAE 15W-40

SAE 10W-30 Transmission

Oil

43 (11.4) SAE 15W-40

Axle

Gear oil

Front : 60 (15.9) Rear : 60 (15.9)

Tank: 210 (55.5) Hydraulic Tank

SAE 80W-90LS/API GL-5

ISO VG 32 ISO VG 46

Hydraulic oil System: 340 (90)

ISO VG 68

ASTM D975 NO. 1 Fuel tank

Diesel fuel

470 (124) ASTM D975 NO. 2

NLGI NO. 1

Fitting (Grease nipple)

Grease

Radiator

Mixture of antifreeze and water 50 : 50

87729424 EUR

As required NLGI NO. 2

Issued 03-08

65 (17.2)

Ethylene glycol base permanent type

Bur

7-9

CHAPTER 7 - MAINTENANCE

MAINTENANCE CHECK LIST Scheduled maintenance is the normal maintenance necessary to provide proper and efficient machine operation.

To protect your investment and prolong the service life of your machine, follow the scheduled maintenance list below.

EVERY 10 HOURS SERVICE Check items

Service

Page

Hydraulic oil level

Check, Add

7-26

Engine oil level

Check, Add

7-16

Radiator coolant

Check, Add

7-18 ~ 7-20

Check Check

7-22 7-21

Service

Page

Engine oil

Change

7-16 , 7-17

Engine oil filter

Replace

7-16 , 7-17

Hydraulic oil return filter

Replace

7-27

Pilot line filter element

Replace

7-27

Fuel filter element

Replace

7-24

Service

Page

Lubricate

7-37

Check, Add

7-28 , 7-30

Drive shaft(Front, center)

Lubricate

7-37

Steering cylinder pins

Lubricate

7-35

Rear axle pivot

Lubricate

7-35

Check, Tight

7-31

Service

Page

Transmission oil

Change

7-32

Transmission filter

Replace

7-32

Front axle oil

Change

7-34

Rear axle oil

Change

7-34

Belt tension & damage Visual inspection of fan

INITIAL 50 HOURS SERVICE Check items

EVERY 50 HOURS SERVICE Check items Attachment pins Tire (Air)

Wheel nuts

INITIAL 100 HOUR SERVICE Check items

Issued 03-08

7-10

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE EVERY 250 HOURS SERVICE Check items

Service

Page

Lubricate

7-37

Check, Add

7-28 , 7-30

Drive shaft(Front, center)

Lubricate

7-37

Steering cylinder pins

Lubricate

7-35

Rear axle pivot

Lubricate

7-35

Check, Tight

7-31

Service

Page

Engine oil

Change

7-16 , 7-17

Engine oil filter

Replace

7-16 , 7-17

Drain

7-23 , 7-24

Check, Clean

7-28

Check

7-41 , 7-42

Hydraulic oil return filter

Replace

7-27

Hydraulic tank air breather element

Replace

7-27

Pilot line filter element

Replace

7-27

Air conditioner and heater outer filter

Change

7-44 , 7-45

Service

Page

Fuel filter element

Replace

7-24

Corrosion resister

Replace

7-25

Check, Clean

7-20

Clean

7-23

Service

Page

Center pivot pin

Lubricate

7-35

Transmission oil

Change

7-32 , 7-32

Transmission oil filter

Replace

7-32 , 7-32

Front axle oil

Change

7-34 , 7-35

Rear axle oil

Change

7-34 , 7-35

Attachment pins Tire (Air)

Wheel nuts Check items

Fuel tank(Water, sediment) Brake line filter(Strainer) Battery(Voltage)

EVERY 500 HOURS SERVICE Check items

Radiator, oil cooler, change air cooler Air cleaner element (Primary)

EVERY 1000 HOURS SERVICE Check items

87729424 EUR

Issued 03-08

Bur

7-11

CHAPTER 7 - MAINTENANCE EVERY 2000 HOURS SERVICE Check items

Service

Page

Hydraulic oil

Change

7-26

Radiator coolant

Change

7-18 ~ 7-20

Issued 03-08

7-12

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE WHEN REQUIRED Check items

Service

Page

• Air cleaner element

Check, Clean, Replace

7-23

• Safety

Check, Clean, Replace

7-23

• Primary

Check, Clean, Replace

7-23

• Air conditioner and heater

Check, Clean, Replace

7-44

• Outer filter

Check, Clean, Replace

7-44 , 7-45

• Inner filter

Check, Clean, Replace

7-44 , 7-45

87729424 EUR

Issued 03-08

Bur

7-13

CHAPTER 7 - MAINTENANCE

MAINTENANCE CHART

7807AMI991

Caution 1. Service intervals are based on the hour meter reading.

2. The number of each item shows the lubrication point on the machine.

3. Stop engine while filling oil, and use no open flames.

4. For other details, refer to the service manual.

Issued 03-08

7-14

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE Service interval

10 Hours or daily

50 Hours or weekly

Item No.

Description

Service action

Hydraulic oil level

Check, Add

HO

340(90)

1

2

Engine oil level

Check, Add

EO

38(10)

1

4

Radiator coolant

Check, Add

C

65(17.2)

1

5

Belt tension & damage

6

Attachment pins

7

Tire(Air)

8

Drive shaft(Front, center)

Lubricate

PGL

2

9

Steering cylinder pins

Lubricate

PGL

2

Lubricate

PGL

2

Check, Clean Lubricate

2

Engine oil

Change

3

Engine oil filter

Replace

13 Brake line filter(Strainer)

18 4

Drain

76 EO

38(10)

1 1

DF

470(124)

1

Check, Clean

1

Check, Add

2

15 Hydraulic oil return filter

Replace

3

16 Hydraulic tank air breather element

Replace

1

17 Pilot line filter element

Replace

1

Check, Clean

1

18 Fuel filter element

Replace

2

19 Corrosion resistor

Replace

1

Check, Clean

3

27 Air cleaner element(Primary)

Replace

1

21 Center pivot pin

Lubricate

PGL

22 Transmission oil

Change

EO

23 Transmission oil filter

Replace

24 Front Axle oil

Change

GO

60(15.9)

1

25 Rear Axle oil

Change

GO

60(15.9)

1

1

Hydraulic oil

Change

HO

340(90)

1

4

Radiator coolant

Change

C

65(17.2)

1

Air conditioner and heater outer filter

Replace

1

Air conditioner and heater inner filter

Clean, Replace

1

Air cleaner element(Safety)

Replace

1

Air cleaner element(Primary)

Replace

1

14 Battery(Voltage)

26 Air conditioner and heater outer filter

2000 Hours

PGL

Check, Tight

12 Fuel tank(Water, sediment)

1000 Hours

1

Check, Add

11 Wheel nuts

500 Hours

Service points No.

1

10 Rear axle pivot

250 Hours

Oil Capacity symbol L / (U.S. gal)

20 Radiator, oil cooler, change air cooler

26 When required 27

2 43(11.4)

1 2

Oil symbol Refer the recommended lubricants for specification.

EO : Engine oil HO : Hydraulic oil DF : Diesel fuel

87729424 EUR

GO : Gear oil PGL : Grease C : Coolant

Issued 03-08

Bur

7-15

CHAPTER 7 - MAINTENANCE

SERVICE INSTRUCTIONS CHECK ENGINE OIL LEVEL

REPLACEMENT OF ENGINE OIL AND OIL FILTER

Check the oil level with the machine on a level surface before starting engine.

IMPORTANT: If the oil is contaminated or diluted, change the oil regardless of the regular change interval. Check oil level after engine has been stopped for 15 minutes.

(1)Pull out the dipstick and wipe with a clean cloth.

(2)Check the oil level by inserting the dipstick completely into the hole and pulling out again.

(1)Operate the engine until the coolant temperature reaches 60°C (140°F). Shut off the engine.

(2)Remove the plug and allow the oil to drain.

• Wrench size : 27mm NOTE: A drain pan with a capacity of 40 liters (10.6 U.S.gallons) will be adequate.

ENGINE OIL DRAIN

FU

EL

(3)If oil level is LOW, add oil and then check again.

TA

NK

WARNING: Do not operate unless the engine oil level is in the normal range.

7807AMI103 7807AMI103

(3)Clean the area around the oil filter head.

(4)Use oil filter wrench to remove the oil filter.

(5)Clean the gasket surface of oil filter head.

NOTE: The O-ring can stick on the filter head; make sure it is removed.

Dipstick Engine oil fill Normal

Dipstick 7807AMI01

7807AMI06 7807AMI01

7807AMI06

Issued 03-08

7-16

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE 6. Apply a light film of lubricating oil to the gasket sealing surface before installing the filter.

NOTE: Fill the filter with clean lubricating oil.

Oil Oil

7807AMI10 7807AMI10

7807AMI07 7807AMI07

(7)Install the filler to the filter head.

IMPORTANT: Mechanical over-tightening may distort the threads or damage the filter element seal.

(10)Operate the engine at low idle and inspect for leaks at the filter and the drain plug. Shut the engine off and check oil level with dipstick. Allow 15 minutes for oil to drain down before checking.

NOTE: Do not overfill the engine with oil.

FU

EL

TA

NK

7807AMI11 7807AMI11

7807AMI08 7807AMI08

(8)Clean and inspect the oil drain plug threads and the seal surface. If any damage is found, the oil drain plug must be replaced. Install and tighten the oil drain plug.

ENGINE OIL DRAIN

FU

EL

TA

NK

Drain plug 7807AMI05 7807AMI05

(9)Fill the engine with clean oil to the proper level.

• Quantity ; 38L (10 U.S.gallons)

87729424 EUR

Issued 03-08

Bur

7-17

CHAPTER 7 - MAINTENANCE CHECK COOLANT LEVEL

FLUSHING AND REFILLING OF RADIATOR

(1)Check the coolant level at the sight gauge.

Change Coolant

(2)Add the mixture of antifreeze and water if level is not sufficient.

WARNING: Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged repeated contact can cause skin disorders or other bodily injury. Avoid excessive contact-wash thoroughly after contact. Keep out of reach of children.

(3)The sight gauge should indicate the middle position.

Sight gauge

77076MI45 77076MI45

(4)Replace gasket of radiator cap when it is damaged.

77076MI37 77076MI37

WARNING: DO NOT remove the radiator cap from a hot engine. Wait until the coolant temperature is below 50°C (120°F) before removing the radiator cap. Heated coolant spray or steam can cause personal injury.

IMPORTANT: Do not add cold coolant to a hot engine; engine castings can be damaged. Allow the engine to cool to below 50°C (120°F) before adding coolant.

OK

IMPORTANT: Protect the environment : Handling and disposal of used antifreeze can be subject to federal, state, and local law regulation. Use authorized waste disposal facilities, including civic amenity sites and garages providing authorized facilities for the receipt of used antifreeze. If in doubt, contact your local authorities for guidance as to proper handing of used antifreeze.

WARNING: DO NOT remove the radiator cap from a hot engine. Wait until the temperature is below 50°C (120°F) before removing the coolant system radiator cap.

Failure to do so can cause personal injury from heated coolant spray.

NOT OK

77076MI08 77076MI08

Issued 03-08

7-18

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE Drain the cooling system by removing the coolant drain plug on the fuel tank and removing the plug in the bottom of the water inlet. A drain pan with a capacity of 70 liters (18.5 U.S.gallons) will be adequate in most applications.

2. Operate the engine for 5 minutes with the coolant temperature above 80°C (176°F). Shut the engine off, and drain the cooling system.

COOLANT DRAIN

FU

EL

TA

NK

FU

EL

COOLANT DRAIN

TA

NK

OFF

7807AMI12 7807AMI12

7807AMI13

(3)Fill the cooling system with clean water.

IMPORTANT: Be sure to vent the engine and aftercooler for complete filling. Do not install the radiator cap or the new coolant filter.

7807AMI13

Flushing of Cooling System (1)Fill the system with a mixture of sodium carbonate and water(or a commercially available equivalent).

IMPORTANT: Use 0.5kg (1.0 pound) of sodium carbonate for every 23 liters (6.0 U.S. gallons) of water. Do not install the radiator cap. The engine is to be operated without the cap for this process.

OK 7803AMI38 7803AMI38

(4)Operate the engine for 5 minutes with the coolant temperature above 80°C (176°F). Shut the engine off, and drain the cooling system.

NOTE: If the water being drained is still dirty, the system must be flushed again until the water is clean.

7803A6MI16

COOLANT DRAIN

FU

EL

7803A6MI16

TA

NK

OFF

7807AMI12 7807AMI12

87729424 EUR

Issued 03-08

Bur

7-19

CHAPTER 7 - MAINTENANCE COOLING SYSTEM FILLING (1)Use a mixture of 50 percent water and 50 percent ethylene glycol antifreeze to fill the cooling system.

2. Install the radiator cap. Operate the engine until it reaches a temperature 80°C (176°F), and check for coolant leaks. Check the coolant level again to make sure the system is full of coolant.

NOTE: Coolant capacity (Engine only); 13 (3.4 U.S.gallons) Use the correct amount of DCA4 corrosion inhibitor to protect the cooling system.

COOLANT DRAIN

FU

EL

TA

NK

NOT OK

7807AMI14

7807AMI14

18036MI22 18036MI22

CLEAN RADIATOR AND OIL COOLER Check, and if necessary, clean and dry outside of radiator and oil cooler. After working in a dusty place, clean radiator more frequently.

(1)Visually inspect the radiator for clogged radiator fins.

(2)Use 550kPa (80psi) air pressure to blow the dirt and debris from the fins. Blow the air in the opposite direction of the fan air flow.

NOT OK

550kPa (80psi) 7803AMI39 7803AMI39

(3)Visually inspect the radiator for bent or broken fins.

Issued 03-08

7-20

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE DRIVE BELTS IMPORTANT: If the radiator must be replaced due to bent or broken fins which can cause the engine to overheat, refer to the manufacturer's replacement procedures.

(4)Visually inspect the radiator for core and gasket leaks.

I n s p e c t t h e b e l t s d a i l y. C h e ck t h e b e l t s fo r intersecting cracks. Transverse (across the belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect the transverse cracks are not acceptable. Replace a belt if is frayed or has pieces of material missing.

OK

NOT OK 7803AMI40

73036MI23

7803AMI40

73036MI23

CHECK CHARGE AIR COOLER

INSPECTION OF COOLING FAN

Inspect the charge air cooler for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, please contact your Case Dealer.

WARNING: Personal injury can result from a fan blade failure. Never pull or pry on the fan.

This can damage the fan blade and cause fan failure.

IMPORTANT: Rotate the crankshaft by using the engine barring gear.

IMPORTANT: A visual inspection of the cooling fan is required daily. Check for cracks, loose rivets, and bent or loose blades. Check the fan to make sure it is securely mounted. Tighten the capscrews if necessary. Replace any fan that is damaged.

36076MI02 36076MI02

NOT OK

21076MI10B 21076MI10B

87729424 EUR

Issued 03-08

Bur

7-21

CHAPTER 7 - MAINTENANCE BELT TENSIONER, AUTOMATIC ADJUSTMENT (1)Every 1000 hours, or 1 year, whichever occurs first, inspect the automatic belt tensioner. With the engine turned off, check that neither the top nor bottom tensioner arm stop is touching the cast boss on the tensioner body. If either of the stops is touching a boss, the alternator belt must be replaced. Also check to make sure the correct belt part number is being used if either condition exists.

7807AMI52 7807AMI52

(4)Inspect the tensioner for evidence of the pivoting tensioner arm contacting the stationary circular base. If there is evidence of these two areas touching, the pivot tube bushing has failed and the tensioner must be replaced.

7807AMI50 7807AMI50

(2)Check the tensioner pulley and body for cracks.

If any cracks are noticed, the tensioner must be replaced. Refer to a Cumins Authorized Repair facility. Check the tensioner for dirt buildup. If this condition exists, the tensioner must be removed and cleaned.

7807AMI53 7807AMI53

(5)A worn tensioner that has play in it or a belt that “walks” off its pulley possibly indicates pulley misalignment.

IMPORTANT: Maximum pulley misalignment is three degrees. This measurement can be taken with a straightedge and an inclinometer.

(6)Install the belt.

7807AMI51 7807AMI51

(3)Check that the bottom tensioner arm stop is in contact with the bottom tensioner arm stop boss on the tensioner body. If these two are not touching, the tensioner must be replaced.

7807AMI54 7807AMI54

Issued 03-08

7-22

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE CLEANING OF AIR CLEANER

Safety Element

Primary Element

IMPORTANT: The safety element should be replaced at the time the primary element is replaced.

Always replace the safety element. Never attempt to reuse the safety element by cleaning the element.

(1)Loosen the wing nut and remove the element.

(2)Clean the inside of the body.

(3)Clean the element with pressurized air.

• Remove the dust inside of the element by the pressurized air (Below 3kgf/cm2, (40psi) forward and backward equally.

(4)Inspect for cracks or damage of element by putting a light bulb inside of the element.

(5)Insert element and tighten wing nut.

IMPORTANT: When the air cleaner warning lamp is ON, clean the primary element. The primary element should be replaced if the warning lamp is ON after installation of a clean primary element, or if the exhaust smoke is still black. Replace the primary element after cleaning 4 times.

Wing nut

21076MA11A 21076MA11A

FUEL TANK (1)To avoid water build up in the fuel tank from condensation, fill the fuel tank at the end of operation daily.

(2)Drain the water and sediment in the fuel tank by opening the plug.

Pressurized air 3kgf/cm below 2

(40psi)

IMPORTANT: Be sure to LOCK the cap of fuel tank.

Remove the strainer of the fuel tank and clean it if contaminated. Stop the engine when refueling.

WARNING: Keep all lights and flames away from machine while refueling.

FUEL TANK

7807AMI19

DRAIN PLUG 7807AMI20

7807AMI20

87729424 EUR

Issued 03-08

Bur

7-23

CHAPTER 7 - MAINTENANCE FUEL WATER SEPARATOR IMPORTANT: Drain the fuel water separator into a container, and dispose of contents in accordance with local environmental regulations.

(1)Drain the water and sediment from the separator daily. Shut off the engine.

(2)Use your hand to open the drain valve.

(3)Turn the valve counterclockwise approximately 3 1/2 turns until the valve drops down 25.4mm (1 inch) and draining occurs.

(4)Drain the filter sump until clear fuel is visible.

IMPORTANT: When closing the drain, do not overtighten the valve. Overtightening can damage the threads.

(5)To close the valve, lift the valve and turn clockwise until it is hand-tight.

BS08C163

Open

Close 7807AMI17

7807AMI17

REPLACEMENT OF FUEL FILTER (1)Clean the area around the fuel filter and fuel filter head.

(2)Remove the fuel filter with filter wrench.

(3)Replace the sealing ring.

(4)Lubricate the fuel filter gasket with clean engine oil.

(5)Fill the new filter with clean diesel fuel.

(6)Install the filter on the filter head. Turn the filter until the gasket contacts the filter head surface.

(7)Tighten the filter, by hand, an additional 1/2 to 3/ 4 of a turn after gasket contacts the filter head surface.

IMPORTANT: If the filter canister is damaged in any way, do not use it. Dents or scrapes can lead to a rupture or premature failure of the filter. Mechanical overtightening of filter can distort the threads and damage the fuel filter seal. Check for fuel leakage after the engine starts.

Issued 03-08

7-24

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE CORROSION RESISTOR (COOLANT FILTER) WARNING: Do not remove the radiator cap from a hot engine. Wait until the coolant temperature is below 50°C (120°F) before removing the radiator cap. Heated coolant spray or steam can cause personal injury.

(1)Remove the radiator cap.

NOT OK 7803A6MI25 7803A6MI25

(5)Install a new filter on the filter head. Tighten the filter until the gasket contacts the filter head surface.

(6)Tighten the filter an additional 1/2 to 3/4 of a turn.

7807AMI21

IMPORTANT: Over tightening can distort the filter threads or damage the filter head.

7807AMI21

(2)Turn the valve to the OFF position.

(3)Remove and discard the filter. Clean the coolant filter head gasket's surface.

WARNING: A small amount of coolant can leak when servicing the filter with the shutoff valve in the OFF position. To avoid personal injury, avoid contact with hot coolant.

7803A6MI26

OFF

7803A6MI26

(7)Turn the valve to the ON position, and install the radiator cap.

OFF

(8)Operate the engine and check for leaks.

IMPORTANT: The valve must be in the ON position to prevent engine damage.

ON 7807AMI22

ON

7807AMI22

(4)Apply a thin film of clean engine oil to the gasket sealing surface before installing the new filter.

IMPORTANT: If the filter canister is damaged in any way, do not use it. Dents or scrapes can lead to a rupture or premature failure of the filter.

7807AMI23 7807AMI23

87729424 EUR

Issued 03-08

Bur

7-25

CHAPTER 7 - MAINTENANCE LEAKAGE OF FUEL

FILLING HYDRAULIC OIL

WARNING: Leakage from the fuel hose, injection pump, fuel filters and other parts and connections can cause a fire. Clean and inspect daily. Have any fuel leaks repaired immediately by a qualified service technician.

(1)Place the machine on a level surface and stop the engine.

(2)Relieve the pressure in the tank by pressing the breather on the top of hydraulic oil tank.

(3)Remove the breather on the top of oil tank and fill the oil to the specified level.

(4)Start engine after filling and operate the bucket/ attachment several times.

FIRE !!!

(5)Check the oil level on a level surface after the engine stops.

Air breather

7807AMI24 7807AMI24

HYDRAULIC OIL CHECK (1)Lower the bucket on the ground at a flat location as in the illustration. Stop the engine and then leave for about 5 minutes.

(2)Check the oil level at the sight gauge. The sight gauge is located on the left side of the hydraulic oil tank.

(3)The sight gauge should indicate the middle position.

NOTE: Add hydraulic oil, If necessary.

Sight gauge

7807AMI26

7807AMI26

CHANGE THE HYDRAULIC OIL (1)Lower the bucket on the ground extend the bucket cylinder to the maximum.

(2)Relieve the pressure in the tank by pressing the breather on the top of the oil tank.

(3)Prepare a suitable container.

(4)To drain the oil loosen the drain plug at the fuel tank block.

(5)Tighten the drain plug.

(6)Fill proper amount of recommended oil.

(7)Put the breather in the correct position.

(8)Start engine and run at 1000 rpm. Operate the loader controls several times to remove any air in the lines.

7807AMI25

Issued 03-08

7-26

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE IMPORTANT: The hydraulic oil must be free of bubbles. If bubbles are present in the oil, air is entering the hydraulic system. Inspect the suction hoses and hose clamps.

REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER (1)Open the breather cap on the top of the oil tank and relieve the system pressure.

(2)Remove the cap and pull out the filter element.

Hyd tank

(3)Replace the filter element with new one.

(4)Apply oil on the O-ring and reassemble by reverse order of disassembly.

• Tightening torque : 0.7~0.9kgf·m(5~6lbf·ft)

Element

Air breather

Drain plug

FU

EL

TA

NK

7807AMI29 7807AMI29

7807A6MI100

CLEANING AND REPLACING RETURN FILTER Clean and replace the return filter in the following manner.

(1)Open the breather cap on the top of the hydraulic oil tank and relieve the system pressure.

REPLACE OF PILOT LINE FILTER (1)Loosen the nut positioned on the filter body.

(2)Pull out the filter element and clean filter housing.

(3)Install the new element and tighten using specified torque.

(2)Remove the cover.

(3)Remove spring, by-pass valve and return filter from the tank.

Rear frame

(4)Replace element with new one and assemble spring and by-pass valve after cleaning.

(5)Install the cover on the tank.

• Tightening torque : 6.9 ±1.4kgf·m (50 ±10lbf·ft) Pilot Filter

Cover O-ring Spring

78076AMI26 78076AMI26

By-pass valve Return filter

7807AMI28 7807AMI28

87729424 EUR

Issued 03-08

Bur

7-27

CHAPTER 7 - MAINTENANCE CLEANING BRAKE LINE FILTER (1)Remove the strainer from the filter body.

(2)Wash the strainer with cleaning oil.

(3)Install and tighten using specified torque.

• Tightening torque : 6 - 8kgf·m(43.4 - 57.9lbf·ft)

Cut off valve

(1)Continuous operation will produce heat and increase pressure on tire. But this condition was already taken into account when designing a tire. Do not try to adjust air pressure on tires of a machine that has been operating. Doing so can result in tires with the wrong air pressure.

(2)The three major causes for excessive heat and pressure of tire are insufficient pressure, ex c e s s i ve l o a d a n d t r ave l s p e e d . Avo i d excessive load and travel speed in order to keep tires in good shape.

Filter body

WARNING: Exploding tires and/or rim parts can cause serious 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 injury or death.

77076MI27 77076MI27

LUBRICATE RCV LEVER WARNING: Explosive separation of the tire and/or rim parts can cause serious injury or death. When tire service is necessary have a qualified tire technician service the tire.

Remove bellows and grease the joint(A) and the sliding parts(B).

A B

78036MI29 78036MI29

TIRE PRESSURE

BD06H041

(1)Incorrect tire pressure is a primary cause for tire damage. Low tire air pressure will damage internal carcass of tire. Repeated excessive bending will damage or break the carcass. High tire air pressure will also cause damage to the tire.

(2)Recommended tire pressure when tire is cool: Size 29.5 × 25, 22PR (L3)

Pressure 3.3 bar (47psi)

Keep all non-authorized personnel clear of the area.

To add air to a tire: (1)Use an air hose with a remote shutoff valve and a self-locking air chuck.

(2)Stand BEHIND the tread of the tire and make sure ALL personnel are away from the side of the tire before you start.

(3)Inflate the tire to the recommended air pressure.

DO NOT inflate the tire to more than the recommended pressure.

Issued 03-08

7-28

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE ADDING AIR TO THE TIRE

Tire Tread Direction

This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following:

• Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage).

B770164

When the tire is installed on the rim, make sure the tire tread is in the direction shown.

B790490

• Use an air hose with a remote shutoff valve and a self-locking air chuck.

TIRE OR RIM SERVICE Always have a qualified tire technician service the tires and rims for this machine. It is recommended that you have this technician inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment and correct procedures. Explosive separation of the tire (single piece rim) or the tire and/or rim parts (multi-piece rim) can cause serious injury or death.

87729424 EUR

Issued 03-08

Bur

7-29

CHAPTER 7 - MAINTENANCE NOTE: Avoid the following when traveling.

(1)Rubbing tires against road bank or rack at cargo-unloading spot.

(2)Tires slippage during working.

(3)Abrupt starting of machine.

(4)When oil, grease or gasoline smeared on tire, clean those. Otherwise it may cause permanent deformation.

TIRE REPLACEMENT Tires That Must be Replaced (1)Tires with broken or bent bead wires (2)Tires exposed more than 1/4 of carcass fly.

(3)Tires whose carcass is damaged more than 1/3 of the tire width.

(4)Tires which show fly separation.

(5)Tires which has a radial crack near the carcass.

(6)Tires which are judged to be unsuitable for use because of deformation or damage.

Tread

Break

Side wall Carcass

Normal

Bead

Valve

7807AMI15 7807AMI15

Removal Of Tire

Too low pressure

(1)After moving the machine to flat ground, lower the bucket to the ground and engage the parking brake.

Excess pressure

7807AMI30

7807AMI30

73036MI10

Issued 03-08

7-30

Bur

87729424 EUR

CHAPTER 7 - MAINTENANCE 2. Loosen slightly all wheel mounting.

• • Tools: Socket 32mm Torque wrench Extension bar (3)Lift the machine with a jack of sufficient capacity.

(4)Loosen all wheel mounting nuts and replace the tire.

BS08C224

STORING TIRES AFTER REMOVAL

Torque wrench

73036MI12

As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored outside, always erect a fence around the tires and put up "No Entry" and other warning signs that even young children can understand.

73036MI12

WARNING: A tire that falls or unexpectedly rolls can result in serious injury or death.

Stand the tire on level ground and block it securely. DO NOT attempt to hold a tire in position. Tire service should be done by only qualified tire technicians that have the proper service equipment.

Direction Of Tire To Be Installed (1)Be careful that the valve should be facing the outside.

Valve

Block

73036MI13 73036MI13

60 - 70°

Tire Installation (1)Lightly tighten nuts as shown in the illustration.

73036MI20

(2)Lower the jack after tire is installed.

(3)Tighten nuts according to the specified tighten torque.

• • Tightening torque: 79±2.5kgf·m (571±18lbf·ft)

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CHAPTER 7 - MAINTENANCE CHECK TRANSMISSION OIL LEVEL

REPLACEMENT OF TRANSMISSION OIL AND FILTER ELEMENT

WARNING: Before checking transmission oil, engage the park brake and install the transport lock link to lock the machine front and rear frames.

The oil level check must be carried out as follows; (1)Oil level check(weekly).

WARNING: As the machine is hot after operation wait until the temperature has dropped before servicing.

(1)Operate the machine for a few minutes in order to warm the transmission oil.

(2)Move the machine to a level surface. Lower the bu cke t t o t h e g r o u n d a n d s l i g h t l y a p p l y downward force.

(2)Machine parked on level surface.

(3)Transmission in neutral position.

(4)In cold start phase, the engine must be running about 2 - 3 minutes at idling speed, and the marking on the oil level gauge must then be lying above the cold start mark COLD. (5)At operating temperature of the transmission about 80 - 90°C (176 - 194°F).

(6)At engine idling speed.

(3)Press the parking brake switch and stop the engine.

(4)Open transmission air breather to relieve internal air pressure.

(5)Remove the transmission drain plug. Allow the t ra n s m i s s i o n o i l t o d r a i n i n t o a s u i t a bl e container.

Air breather

(7)Loosen oil level gauge by counterclockwise rotation, remove and clean it.

(8)Insert oil level gauge slowly into the oil level tube until contact is obtained, and pull it out again.

(9)On the oil level gauge, the oil level must be lying in the zone HOT (10)Insert the oil level gauge again, and tighten it by clockwise rotation.

Level gauge HOT

COLD

ZONE " HOT"

Drain plug

7803A6MI34

7803A6MI34

(6)Remove the transmission oil filter cartridge.

Dispose of the used transmission oil filter cartridge properly.

(7)Clean the filter cartridge mounting base.

Remove any part of the filter cartridge gasket that remains on the filter cartridge mounting base.

RH Platform

7803A6MI33 7803A6MI33

Transmission Filters

7807AMI36

7807AMI36

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CHAPTER 7 - MAINTENANCE (8)Apply a light coat of oil to the gasket of a new transmission oil filter cartridges.

(9)Install the new transmission oil filter cartridges.

Screw the filter in until contacts with the sealing surface is obtained and tighten it by hand about 1/3 to 1/2 turn.

CLEANING TRANSMISSION AIR BREATHER (1)Remove dust or debris around the air breather.

(2)Remove the air breather and wash it with cleaning oil.

Air breather

7803A6MI36

73036MI14

7803A6MI36

CHECK AND ADDING AXLE OIL

73036MI14

(10)Mount the drain plug of transmission after cleaning it.

(11)Fill the oil through level gauge inlet and check if the oil is at the appropriate level.

(1)Move the machine to flat ground.

(2)Open the axle air breather to relieve internal air pressure.

(12)The proper oil amount is 43 liters (11.4 U.S. gallons)

Air breather

IMPORTANT: It is imperative to pay attention to absolute cleanliness of oil and filter. The marking on the oil level gauge is binding in any case.

Level gauge HOT

COLD

ZONE " HOT" 7803A6MI37 7803A6MI37

(3)Remove the plug and check the oil amount. If the oil level is at the hole of the plug, it is normal.

Differential gear Plug

7803A6MI33

7803A6MI33

7803A6MI38 7803A6MI38

(4)If the oil level is below the plug hole, add oil through the plug hole.

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CHAPTER 7 - MAINTENANCE

Planetary gear

OIL LEVEL

WARNING: When checking the oil level, engage the parking brake and install front and rear frames using the transport lock bar.

The machine is hot after operation, wait until the temperature has dropped before servicing.

NOTE: Rotate the plug of the planetary gear until parallel with the ground.

OIL DRAIN

Planetary gear 78036MI41 78036MI41 OIL DRAIN

(5)After draining, rotate the drain plug of planetary gear until parallel to the ground.

OIL LEVEL

Planetary gear

78036MI39 OIL DRAIN

78036MI39

OIL LEVEL

CHANGING THE AXLE OIL (1)Place a suitable container under drain plug to catch oil.

(2)Remove the air breather to relieve internal pressure.

(3)Drain oil the differential gear.

A. Remove the refilling plug and remove the drain plug to drain oil off.

B. Wash drain plug and install it.

78036MI39 78036MI39

(6)Add oil into the differential gear and the planetary gear.

• • Oil amount(For each axle) : 60 liters (15.9 U.S. gallons) (7)Add oil until it overflows from the oil filler, then install the plug.

Air breather Fill plug Drain plug

WARNING: The machine is hot after operation, wait until the temperature has dropped before servicing.

IMPORTANT: If operation requires frequent use of brake, replace oil earlier than normal change interval.

78036MI40 78036MI40

(4)Drain oil planetary gear.

A. Drain oil by removing drain plug.

NOTE: The drain plug should be facing the ground.

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CHAPTER 7 - MAINTENANCE 8. Run the engine at low idling for 5 minutes. Allow the oil to flow completely through the axle oil cooler and hoses.

(9)Remove the refill plug for the differential and recheck the oil level. Fill the differential with oil, as required.

LUBRICATION (1)Add grease through the grease nipple, using grease gun.

(2)After lubricating, clean off spilled grease.

WARNING: Apply the parking brake switch and lock front and rear frames using the transport lock link. Set the bucket/attachment in a stable position and turn the hydraulic control lock valve into the lock position.

IMPORTANT: When steering machine, there may be frictional noise from disc. The noise is normal, it is not an issue of axle durability.

(3)Rear axle pivot : 2EA

Differential gear

Plug

Rear Frame

Planetary gear

7807AMI33K

7807AMI33K

(4)Center pivot pin : 2EA (5)Drive shafts OIL DRAIN

• Front(flange bearing) : 1EA • Center(slip yoke) : 1EA

OIL LEVEL

78036MI42 78036MI42

CLEANING AXLE BREATHER

Center pivot pin

(1)Remove dust or debris around the breather.

(2)Remove the breather and wash it with cleaning oil.

Air breather Steering cylinder pin

Center drive shaft Center pivot pin 78036MI37 7807AMI34

78036MI37

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7-35

CHAPTER 7 - MAINTENANCE REPLACEMENT OF BOLT ON CUTTING EDGE

REPLACEMENT OF BUCKET TOOTH

Replacement Time Replace the cutting edge before it has worn to the end of bucket.

Replacement Time Replace the bucket tooth before it has worn to the end of the bucket.

Replacement Method

Replacement Method

WARNING: Make sure the bucket/ attachment does not move when replacing the cutting edge. Set the bucket/attachment in a stable position, put the hydraulic control lock lever in the LOCK position, stop the engine and engage the parking brake.

(1)Lift the bucket to a proper height and insert blocks so that the bucket does not fall down.

WARNING: Make sure the bucket/ attachment does not move when replacing the bucket tooth. Set the bucket/attachment in a stable position, put the hydraulic safety lock lever in the LOCK position and stop the engine.

(1)Lift the bucket to a proper height and insert blocks so that the bucket does not fall down.

73036MI15

(2)Loosen bolts and nuts, and remove the cutting edge.

73036MI15 73036MI15

(3)Clean the contacted surface.

(2)Loosen bolts and nuts, and remove bucket tooth.

(4)Turn the cutting edge and install on the bucket.

(3)Clean the contacted surface.

IMPORTANT: If both sides have worn out, replace it with new parts. If the contacted face of cutting edge has worn out, repair the contacted face of it.

(5)Tighten evenly bolts and nuts to remove the clearance between bucket and cutting edge.

• • Tightening torque : 275 ± 40 kgf·m

IMPORTANT: If the contacted face of bucket tooth has worn out, repair the contacted face of it.

(4)Install new bucket tooth on the bucket, and tighten bolts and nuts.

• • Tightening torque : 275 ± 40 kgf·m (1990 ± 290 lbf·ft)

(1990 ± 290 lbf·ft)

(5)After a few hours of operation, retighten bolts.

(6)After a few hours of operation, retighten bolts.

7807A6MI102 7807A6MI101 7807A6MI102 7807A6MI101

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CHAPTER 7 - MAINTENANCE MAINTENANCE OF LOADER LIFT ARM AND BUCKET/ATTACHMENT

(3)Check for damage of boom and bell crank.

(1)Lubricate to each pin of working device.

Lubr icate the grease to grease nipple in accordance with lubrication intervals.

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

7807AMI31 7807AMI31

(4)Dust seal are mounted on the rotating part of working device to extend the lubricating interval.

NOTE: Shorten lubricating interval when working in the water or dusty place.

K L N

O

Front frame LH side

M

E G H F I

J

C A D B Front frame RH side 7807AMI32

7807AMI32

(2)Check for wear and tear of work equipment pins and bushings.

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CHAPTER 7 - MAINTENANCE IMPORTANT: Mount the lip to be faced out side when replace the dust seal. If it is assembled in wrong direction, it will cause fast wear of pin and bushing, and create noise and vibration during operation. Make sure the seals are not damaged or deformed.

Outside

73036MI26 73036MI26

BUCKET/ATTACHMENT SUPPORT When carrying out inspection and maintenance with the equipment raised, fit a support stand of sufficient capacity under the lift arm securely to prevent the bucket/attachment from coming down. Also, set the bucket/attachment control levers to the Hold position and Lock with the control lock lever.

7807AMI35 7807AMI35

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CHAPTER 7 - MAINTENANCE

ELECTRICAL SYSTEM BATTERY SAFETY 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.

SA046

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Insure 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.

SAFETY_ID_1C02

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

WARNING: 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.

SA033

WARNING: 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.

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.

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.

SAFETY_ID_1C02

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.

SAFETY_ID_1C02

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CHAPTER 7 - MAINTENANCE BATTERY SERVICE

WIRING, GAUGES

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Check regularly and repair loose or malfunctioning gauges when found.

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.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

73036MI27 73036MI27

BATTERY FLUID LEVEL 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.

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.

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CHAPTER 7 - MAINTENANCE BATTERY

Specific gravity meter

WARNING: When opening the battery cover for servicing and checking the battery, be careful not to be injured by a falling cover.

Remove the cover and store it in a safe place until re-installed.

Height of sight Battery

Check And Repair (1)Check the electrolyte level and fill with distilled water to the prescribed level as necessary.

(2)Wash the terminal with hot water if it is contaminated, and apply grease to the terminals after washing.

73036MI29

Removing The Battery Cable

Battery Electrolyte Level

Remove the cable from the ground connection first and reconnect it last when reassembling.

Plug

IMPORTANT: Make sure to reassemble the cables correctly noting the battery polarity.

Upper level Lower level 10 ~15mm

73036MI28

Ground

Specific Gravity Of Battery

73036MI30

Judge the charging rate of battery by the specific gravity. The specific gravity changes by the ambient temperature. Check the charging rate by referring to the chart below.

Charging Rate 100% 90% 80% 75%

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Battery relay

73036MI30

Temperature 20°C(68F) 10°C(50F) -10°C(12F) 1.26 1.27 1.28 1.24 1.25 1.26 1.22 1.23 1.24 1.21 1.22 1.23

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CHAPTER 7 - MAINTENANCE STARTING THE ENGINE WITH BOOSTER CABLES Connection Of Booster Cable IMPORTANT: Make sure that the voltage of the booster batteries are the same as that of the machine system.

Taking Off The Booster Cable (1)Take off the booster cable (Black).

(2)Take off the booster cable (Red) connected to the (+) terminal.

(3)Run engine with high idle until the discharged battery is fully charged.

(1)Connect the red terminal of booster cable to the battery (+) terminal between discharged battery and new battery.

WARNING: Explosive gas is generated while using the battery or charging it. Keep flame away and be careful not to cause a spark.

(2)Connect the black terminal of the booster cable to the battery (-) terminal between discharged battery and new battery.

WARNING: Charge the battery in a well ventilated place. Place the machine on the earth or concrete. Avoid charging the machine on a steel plate. Do not connect (+) terminal and (-) terminal when connecting booster cable because it will be shorted.

NOTE: Keep all connections firm, the spark will be caused by the final connection.

CONNECTING BOOSTER CABLES

DISCONNECTING BOOSTER CABLES

CONNECTION ORDER 1, 2, 3, 4

BS08C164

DISCONNECTION ORDER 4, 3, 2, 1

Starting The Engine (1)Start engine with key switch.

(2)If the engine does not start the first time, allow the batteries to charge for 2 minutes and try again.

BS08C164

BS08B317

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CHAPTER 7 - MAINTENANCE Welding Repair Before welding, follow the procedure below.

(1)Shut off the engine and remove the starting key.

(2)Disconnect ground cable from battery by turning the master disconnect switch to the OFF position.

(3)Before carrying out any electric welding on the machine, the batter y cables should be disconnected and the connectors pulled out of the electronic control units(MCU, TCU, ECM, cluster etc.).

(4)Connect the earth (ground) lead of the welding equipment as close to the welding points as possible.

WARNING: Do not weld or flame cut on pipes or tubes that contain flammable fluids.

IMPORTANT: Before welding or flame cutting, clean surfaces thoroughly with non-flammable solvent.

WARNING: Do not attempt welding work before carrying out the above instructions. If not, it will cause serious damage to electric system.

ECM

Cluster OR NS SE R ORT P

CN-169 M OE T R PO

CN-15

ATO TU AC T R PO

ECM Master switch MCU

CN-59

OFF

CN-58

Battery TCU CN-157

RH LH 7807AECU1

7807AECU1

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CHAPTER 7 - MAINTENANCE

AIR CONDITIONER AND HEATER CLEAN AND REPLACE OUTER FILTER IMPORTANT: servicing.

Always

stop

the

engine

CLEAN AND REPLACE INNER FILTER before

NOTE: Always stop the engine before servicing.

(1)Open the cover.

(1)Open the door, loosen the wing bolt and remove the outer filter.

(2)Remove the inner filter.

Cover

Outer filter

Inner filter

77076MI51

77076MI49 77076MI51 77076MI49

(2)Clean the filter using a pressurized air below 2kgf/cm² (28psi).

(3)Clean the inner filter using a pressurized air (Below 2kgf/cm², 28psi) or washing with water.

WARNING: When using pressurized air, be sure to wear safety glasses.

WARNING: When using pressurized air, be sure to wear safety glasses.

(3)Inspect the filter after cleaning. If it is damaged or badly contaminated, replace it with a new filter.

(4)Inspect the filter after cleaning. If it is damaged or badly contaminated, replace it with a new filter.

NOTE: Dry off after washing with water.

2

Pressurized air 2kgf/cm2 below

Pressurized air 2kgf/cm below (28psi)

(28psi)

77076MI50

77076MI50

73036MI19 73036MI19

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CHAPTER 7 - MAINTENANCE PRECAUTIONS FOR USING AIR CONDITIONER (1)When using the air conditioner for a long time, open the window once every one hour.

(2)Be careful not to over cool the cab.

(3)The cab is properly cooled if the operator feels cool when entering from outside (About 5°C (9°F) lower than the outside temperature).

(4)When cooling, change air occasionally.

Check During Season A s k t h e s e r v i c e c e n t e r fo r r e p l e n i s h m e n t o f refrigerant or other maintenance service so that the cooling performance is not maintained.

Check During Off-Season Operate the air conditioner 2 or 3 times a month (Each for a few minutes) to avoid loss of oil film lubrication in the compressor.

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CHAPTER 7 - MAINTENANCE

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CHAPTER 8 - TROUBLESHOOTING

CHAPTER 8 TROUBLESHOOTING TABLE OF CONTENTS TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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8-1

CHAPTER 8 - TROUBLESHOOTING

8-2

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CHAPTER 8 - TROUBLESHOOTING

TROUBLESHOOTING GUIDE ENGINE This guide is not intended to cover every condition, however many of the more common possibilities are listed.

Trouble

Service

Remark

Engine oil pressure lamp fails to go • Add the oil to the specified level. off immediately after the engine is • Replace the oil filter. started.

• Check oil leakage from the tube or the joint.

Steam is emitted from the top part of the radiator(The pressure valve).

Engine cooling water temperature gauge indicates red range.

• Add the cooling water and check leakage.

• Adjust fan belt tension.

• Wash out inside of cooling system.

• Clean or repair the radiator.

• Check the thermostat.

• Check the engine cooling water temperature gauge.

• Tighten the radiator cap firmly or replace the gasket.

Engine does not start when the starting motor is turned over.

• Check for air in the fuel system.

• Check the fuel pump or the injector nozzles.

Exhaust gas is white or blue.

• Check the valve clearance.

Exhaust gas occasionally turns black.

• Check for specified oil level.

• Replace with specified fuel.

• Clean or replace the air cleaner element.

• Check the injector nozzles.

Combustion noise occasionally changes to breathing sound.

• Check engine compression pressure.

• Check or replace the turbocharger.

Unusual combustion noise or mechanical noise.

• Check the injector nozzle.

• Check the fuel pump.

• Check for specified fuel.

• Check overheating.

• Check the muffler.

• Adjust valve clearance.

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CHAPTER 8 - TROUBLESHOOTING

ELECTRICAL SYSTEM Trouble

Service

Remark

• Check for loose terminals open-circuit wiring.

Voltmeter fluctuates greatly even with the engine running at a constant • Adjust belt tension. speed. Lamp does not glow brightly even when engine runs at high speed. Lamp flickers while engine runs.

Voltmeter does not fluctuate even with an increase in the engine speed.

• Check the alternator.

• Inspect and repair wiring.

Starting motor does not turn when starting switch is turned on.

• Place the gear selector lever in neutral.

• Inspect and repair the wiring.

• Charge the battery.

• Check starting switch.

• Check battery relay switch.

Starting motor turns the engine slowly.

• Charge the battery.

• Check the starting motor.

Starting motor disengages before the engine starts up.

• Charge the battery.

• Check and repair the wiring and battery cables.

Engine oil pressure lamp does not light up when engine is stationary (When the starting switch is in ON position).

• Check the lamp.

• Check the oil pressure switch.

Charge lamp does not light up when • Check the lamp. the engine is stationary. (When the • Check and repair the wiring. starting switch is in ON position.)

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CHAPTER 8 - TROUBLESHOOTING

POWER TRAIN SYSTEM Trouble

Service

Engine is running but machine will not move.

Remark

• Release parking brake.

• Put gear selector lever in correct position • Add oil to transmission case to the specified level.

Even at full throttle, machine moves • Add oil to transmission case to the specified level. slowly and lacks power.

• Disassemble transmission strainer and clean.

Transmission oil overheats.

• Add oil to transmission case to the specified level or drain oil.

• Use a suitable gear speed.

• Reduce time using torque converter at stall speed.

• Check engine.

Abnormal noise is produced.

• Add oil to transmission case to the specified level.

• Add oil to axle case to the specified level.

Brake does not work when pedal is • Add brake oil. depressed.

• Bleed hydraulic oil from brake system.

• Raise hydraulic oil pressure to specified level.

Brake drags or stay on when applied.

• Clean breather and bleed air from brake system.

Brake slips.

• Raise hydraulic oil pressure to the specified level.

Brake does not work properly.

• Clean brake pad.

• Replace spring in hydraulic oil cylinder.

• Adjust or replace brake pad.

Steering effort is heavy.

• Repair or replace the pump.

• Repair, clean and reset the relief valve.

• Apply a coat of grease to connections and bearings of steering gear.

• Check the assembly of the steering column.

Steering wheel turning by itself.

• Replace leaf springs.

Slow steering.

• Check or replace the pump.

Impossible to turn the steering wheel • Clean spool and sleeve. Replace leaf springs. into neutral position.

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CHAPTER 8 - TROUBLESHOOTING

HYDRAULIC SYSTEM Trouble

Service

Remark

Bucket lacks lifting power. Bucket lifting speed is slow.

• Check the hydraulic oil level and add if necessary.

• Replace filter in hydraulic tank.

Bubbles in oil.

• Add oil if needed.

• Replace with specified oil.

Oil pressure is too low.

• Add oil and bleed air.

• Bleed air from oil line.

Cylinder vibrates when operating.

• Add oil.

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CHAPTER 9 - INDEX

Chapter 9

INDEX A

G

Accessory Jack, (12 volt) ................................... 4-31 Air Cleaner ......................................................... 7-23 Air Conditioner and Heater Maintenance .......... 7-44 Air Conditioner and Heater Operation ............... 4-27 Air Conditioner Filter .......................................... 7-44 Attachment Adjustments .................................... 5-20 Attachment Operation ........................................ 5-10 Axle Oil .............................................................. 7-33

Gear Selector Lever ...........................................4-25 General Information ..............................................1-1

B Battery ............................................................... 7-41 Cleaning ........................................................ 7-40 Fluid Level ..................................................... 7-40 Safety ............................................................ 7-39 Service .......................................................... 7-39 Vents ............................................................. 7-40 Before Starting the Engine .................................. 5-4 Belt Tensioner ................................................... 7-22 Boom Kick Out ................................................... 5-20 Brake Line Filter ................................................ 7-28 Bucket Adjustments ........................................... 5-20 Bucket Leveler ................................................... 5-21

C Charge Air Cooler .............................................. 7-21 Cigar Lighter ...................................................... 4-31 Controller ........................................................... 4-35 Controls ............................................................. 4-24 Coolant Level ..................................................... 7-18 Corrosion Resistor ............................................. 7-25

E Electrical System ............................................... 7-39 Electrical, Disconnect Switch ............................. 4-35 Engine Control Module (ECM) ........................... 4-36 Engine Oil Filter ................................................. 7-16 Engine Oil Level ................................................ 7-16 Engine Specifications .......................................... 3-8

F Fan Belt ............................................................. 7-21 Fault Code ......................................................... 4-14 Fuel Filter ........................................................... 7-24 Fuel Handling Precautions .................................. 2-9 Fuel Water Separator ........................................ 7-24 Fuse Box ........................................................... 4-35 87729424EUR

Issued 03-08

Bur

H Hazardous Chemical Precautions ........................2-9 Heater and Air Conditioner Maintenance ...........7-44 Heater and Air Conditioner Operation ................4-27 Hydraulic Control Lock Lever .............................4-26 Hydraulic Oil Changing .......................................7-26 Hydraulic Oil Filling .............................................7-26 Hydraulic Oil Level .............................................7-26 Hydraulic Return Filter ........................................7-27

I Identification Numbers ..........................................1-5 Instrument Cluster ................................................4-4 Instruments and Controls .....................................4-3

L LCD ....................................................................4-11 Loading and Unloading ........................................6-7 Loading the Machine ............................................6-5 Lubrication ..........................................................7-35

M Machine Control Unit (MCU) ..............................4-35 Machine Fault Codes .........................................4-14 Machine Operation .............................................5-11 Maintenance .........................................................7-3 Maintenance Chart .............................................7-14 Maintenance Check List .....................................7-10 Maintenance Precautions .....................................2-8 Master Electrical Disconnect Switch ..................4-35

O Operating Instructions ..........................................4-3 Operating Precautions ..........................................2-7 Operation ..............................................................5-3 Operation of the Attachment ..............................5-10

P Pilot Line Filter ....................................................7-27 Power Train Specifications .................................3-10 Product Identification Number ..............................1-5

9-1

CHAPTER 9 - INDEX

R Radiator and Oil Cooler ..................................... 7-20 Radio and Cassette ........................................... 4-37 Recommended Lubricants ................................... 7-9 Return Filter, Hydraulic ...................................... 7-27 Run In Period ....................................................... 5-3

S Safety .................................................................. 2-3 Safety and Safety Decals .................................... 2-3 Safety Decals .................................................... 2-11 Safety, Battery ................................................... 7-39 Seat Standard ........................................................ 4-32 Seat Belt Precautions ........................................ 2-10 Securing the Machine .......................................... 6-6 Serial Numbers .................................................... 1-5 Service Instructions ........................................... 7-16 Sides of the Machine Right-hand, Left-hand, Front, and Rear .......... 1-4 Specific Machine Precautions ........................... 2-10 Specifications ...................................................... 3-3 Specifications, Engine ......................................... 3-8 Specifications, Power Train ............................... 3-10 Starting and Stopping Precautions ...................... 2-6 Starting and Stopping the Engine ........................ 5-5 Storage .............................................................. 5-23 Switches ............................................................ 4-17

T Tire .................................................................... 7-28 Towing the Machine ............................................ 6-8 Transmission Cold Starting ................................. 5-7 Transmission Control Unit (TCU) ...................... 4-36 Transmission Oil Filter ....................................... 7-32 Transmission Oil Level ...................................... 7-32 Transportation ..................................................... 6-3 Troubleshooting Guide ........................................ 8-3

U Utility Safety ......................................................... 2-4 Utility Safety Rules Message ............................... 2-4

W Warming Up Operation ........................................ 5-9 Weights ................................................................ 3-7 Working Methods ............................................... 5-15

9-2

Issued 03-08

Bur

87729424EUR

OPERATOR’S MANUAL

WHEEL LOADER 1221E TIER 3

87729424 EUR

CNH AMERICA LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

European English Part Number 87729424 EUR Printed in U.S.A. • Bur

Issued 01Mar 08