Case 410 420 430 440 440CT Skid Steer Operator's Manual 87739574 - PDF DOWNLOAD

OM A4 Jaune Gabarit MM.qxd

31/10/2007

11:28

Page 1

Skid Steer 410, 420, 430, 440, 440CT

Operator's Manual 87739574 EN replaces 87643454 EN

OPERATOR’S MANUAL

410 420 430 440 440CT SKID STEER

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

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

• DANGER:

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

• WARNING:

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

• CAUTION:

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

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: • Is instructed in safe and proper use of the machine.

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

• Reads and understands ALL Safety Decals on the machine.

• Clears the area of other persons.

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

It is your responsibility to observe pertinent laws and regulations and follow the manufacture’s instructions on machine operation and maintenance.

TABLE OF CONTENTS TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAT BELT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFIC PRECAUTIONS TO THIS MACHINE . . . . . . . . . . . . . . . . . . .

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 22 23 24 28 29

INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 BATTERY MASTER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . 50 STEERING AND TRAVEL WITH H PATTERN CONTROLS . . . . . . . . . . 51 STEERING AND TRAVEL WITH H PATTERN CONTROLS . . . . . . . . . . 52 LIFT ARM AND BUCKET CONTROLS - H PATTERN . . . . . . . . . . . . . . 54 STEERING AND TRAVEL WITH ISO PATTERN PILOT CONTROLS . . 56 LIFT ARM AND BUCKET CONTROL WITH ISO PATTERN PILOT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 LEFT HAND CONTOL LEVER SWITCHES AND FUNCTIONS . . . . . . . 61 RIGHT HAND CONTOL LEVER SWITCHES AND FUNCTIONS . . . . . . 63 THROTTLE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 HYDRAULIC BYPASS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 AUXILIARY HYDRAULIC ATTACHMENT CONTROL PEDAL . . . . . . . . . . 68 AUXILIARY ELECTRO-HYDRAULIC CONTROLS (IF EQUIPPED) . . . . . . 71 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 CAB DOOR LATCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 SLIDING SIDE WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 PARKING THE MACHINE AND STOPPING THE ENGINE . . . . . . . . . . 81 RUN-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 BOOSTER BATTERY CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 MOVING A DISABLED MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 OPERATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 MANUAL ATTACHMENT COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 HYDRAULIC ATTACHMENT COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . 94 HIGH FLOW HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 ANTI-VANDAL LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 I

CRANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 WHEEL AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 LUBRICATION / MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TILTING THE OPERATORS COMPARTMENT FORWARD . . . . . . . . . . .

INSTALLING THE SUPPORT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE LUBRICATION SCHEDULE . . . . . . . . . . . . . . . . . . . .

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . .

ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION/MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . .

EVERY 10 HOURS OR DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

107 108 111 113 113 114 114 115 116 118 119 131 137 142 145

ADJUSTMENT/MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEEL TRACK ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE HAND THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE OF THE SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROLL-OVER PROTECTION STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . .

FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL OF SLIDING SIDE WINDOWS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

149 149 151 154 154 155 157 157

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

ALTERNATOR CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WORK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TAIL LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

159 159 160 162 163 165

158

MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 STORAGE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 STORAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

410 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

420 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

430 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

440/440CT ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II

169 169 169 170 170 171 172

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

POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIPPING WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADDITIONAL WEIGHTS FOR OPTIONAL EQUIPMENT . . . . . . . . . . .

BUCKET CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

410 - 420 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . .

430 - 440 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . .

440CT OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . .

MATERIAL WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172 172 172 173 173 174 174 175 176 177 181 184 187

AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

III

IV

TO THE OWNER

BD04N082

420 SKID STEER SHOWN WITH 10-16.5 TIRES AND 66 INCH LOW PROFILE BUCKET

This manual contains important information about the safe operation, adjustment and maintenance of your Skid Steer. Refer to the Detail Index at the end of this manual for locating specific items about your machine. This Skid Steer conforms to current safety regulations.

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

CNH America LLC P.O. Box 9228 Wichita, Kansas 67277

DEALER’S STAMP

1

TO THE OWNER 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 Skid Steer, with standard equipment and authorized attachments, is intended to be used for general earth moving purposes, material handling, ditch digging, etc. Make sure that the machines are properly equipped and follow the instructions and safety precautions in this manual.

2

TO THE OWNER

OFFICIAL JUSTIFYING DOCUMENTS EC Declaration of conformity and environmental noise conformity for an earth moving machine:

• Safety 98/37/EC Special Test Certificate

• Noise Level 2000/14/EC Electro-Magnetical compatibility 2004/108/EC

87360991

Guaranteed Sound Power Level to E.C. Regulation Requirements Guaranteed Sound Power Level: All Wheel Models .....................101dBA All Track Models ......................103 dBA Typical Operator Ear Levels (Open Cab) 410 / 420 ....................................85dBA 430 .............................................85dBA 440 .............................................82dBA Typical Operator Ear Levels (Cab With Side Windows) 410 / 420 ....................................87dBA 430 ...........................................87 dBA 440 ............................................85 dBA 440CT .......................................84 dBA

3

TO THE OWNER

BD05A053

440 SKID STEER

Do Not use this machine for any application or purpose other than those described in this manual. 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 will cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

The Operators 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 y o u r m a c h i n e . Yo u r D e a l e r h a s approved service parts. Your Dealer has technicians with special training that know the best methods of repair and maintenance for your Skid Steer.

Contact your Dealer for Operator Manuals translated into Spanish or French Canadian.

BD04D084

OPERATORS MANUAL STORAGE

4

TO THE OWNER

RIGHT, LEFT, FRONT AND REAR OF MACHINE Right-hand, left-hand, rear, and front, when used in this manual, indicate the right and left sides of the machine as seen from the operators seat.

MACHINE FRONT

MACHINE LEFT

MACHINE RIGHT

MACHINE REAR BS01F013

5

TO THE OWNER

PRODUCT IDENTIFICATION AND SERIAL NUMBERS Write your machine Model Number, Product Identification Number (P.I.N.) and Serial Numbers on the line provided below. If needed, give these numbers to your dealer when you need parts or information for your machine.

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

Locations may vary slightly between models and configurations.

Model Number

Engine

Product Identification Number (P.I.N.)

BD04N065

Serial Number BD04N039

Model Number ROPS P.I.N.

BD04N039

Serial Number

6

TO THE OWNER Hydrostatic Pump

Loader Bucket

BD04F031

BD04N051

Part Number

Serial Number

Starter

Control Valve Not shown Serial Number

BD04N057

Serial Number

7

TO THE OWNER

MACHINE COMPONENTS

1 6

5 2

3

4

BD05A053

1. OPERATORS COMPARTMENT 2. LOADER LIFT ARMS 3. BUCKET

4. ENGINE COMPARTMENT 5. HYDRAULIC RESERVOIR 6. LOADER CONTROLS

8

TO THE OWNER

2 6 3

4

1

5 BD04E071

1. DRIVE CHAIN COMPARTMENT 2. UPPER ENGINE ACCESS DOOR 3. FUEL RESERVOIR

4. LOWER ENGINE ACCESS DOOR 5. REAR TIE DOWN 6. HAND HOLD

4 1

2

3

2

2

BD06A060

1. FRONT IDLER WHEELS 2. TRACK ROLLER WHEELS 3 EACH SIDE

3. REAR IDLER WHEEL 4. FINAL DRIVE SPROCKET

9

TO THE OWNER

NOTES

10

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

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.

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: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine. These safety messages also give possible ways of dealing with these conditions.

BD04D084

OPERATOR’S MANUAL STORAGE BEHIND 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 o f t h e Ta bl e o f C o n t e n t s ) o f t h i s manual.

11

SAFETY

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 which, if not avoided will 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. 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

12

STOP

if used, are RED.

SAFETY

UTILITY SAFETY Safety precaution MUST be followed when wor king near bur ied and overhead Utility Lines.

During operation it is likely that you will be working around or near buried or ove r h e a d u t i l i t y l i n e s w h i c h m ay include, but are not limited to: ●

Electrical Power Line

●

Gas Line

●

Water Line

●

Communication Line - Telephone or Cable Television

●

Sewer Line

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

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

A LWAY S h a v e a l l l o c a l u t i l i t y companies mark the location of their lines..

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.

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

13

SAFETY

PERSONNEL

GENERAL

●

Be prepared for emergencies.

Always have a first aid kit and a working fire extinguisher with you and know how to use each.

●

●

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

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.

●

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 typed of equipment that may be required.

●

Do not operate this machine or perform 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 a 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.

●

Make sure that all protective guards, canopies, doors, etc. are in place and secure.

●

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

●

Do not use the machine as a manlift.

●

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 who has the responsibility for signaling.

14

SAFETY

PROPER ENTRY AND EXIT

Before exiting the skid steer: 1. Lower the boom and or attachments to the ground. If the operator must exit the skid steer with a raised boom always engage support strut.

2. Engage the parking brake.

3. Stop the engine.

4. Remove the seat belt.

WARNING: Never exit the skid steer with the engine operating. Never exit the skid steer without first confirming the parking brake is set. Never exit the skid steer unless the boom and attachment are down resting on the ground or the boom is resting on the support strut.

BD04D082

Always face the front of the machine when you get on or off the machine.

DO NOT RUSH! Enter the skid steer from the front by using the bucket step and cab hand hold.

BD04D083

Step into the cab from the bucket and cab step area. Hand holds are provided on the front cab posts for entry and exit.

WARNING: Never enter or exit the skid steer unless the boom and attachment are resting on the ground or on the loader support strut.

15

●

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.

SAFETY

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

●

Check that the parking device is applied, place the ground drive controls in neutral and check that the auxiliary controls or switches are in neutral or off positions.

●

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

●

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

●

Do not bypass the machine’s interlock system. The interlock system must be repaired if it malfunctions.

●

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.

16

●

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’s station, lower the equipment to the ground, shut off the engine and place the function cancellation lever into the locked or up position.

●

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

SAFETY

OPERATING PRECAUTIONS ●

●

Check brakes, steering and other machine control devices in accordance with the manufacturers instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key or disconnect switch key.

Place a do not operate tag on the machine until the malfunction is corrected.

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

●

Understand the machine limitations and keep the machine under control.

●

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

●

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

●

Carry loads in recommended positions for maximum stability.

●

Never lift loads in excess of capacity.

●

Use the recommended machine ballast and counterweighting.

17

●

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.

●

Watch for bystanders and never allow anyone to be under or to reach through the machine and its equipment while operating.

●

Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

●

When roading a machine, know and use the signaling devices required on the machine. Provide an escort for roading where required.

●

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

●

Use the recommended transport devices when roading the machine.

Proper lights, flashers, signals and beacons may be required. Follow local, state and federal regulations.

●

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

●

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

●

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

SAFETY ●

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.

If you have extreme conditions, such as a fire, 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.

●

Dust, fog, smoke, etc., can decrease your vision and cause an accident.

Stop the machine or decrease the speed until you can see.

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

●

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

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

●

Stay away from hazardous areas such as ditches, overhangs, etc.

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

●

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.

Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do. You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. You must also know any federal, state/ provincial, or local safety codes or regulations that apply to the job site.

If a part of the machine touches high voltage power: 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.

18

SAFETY

MAINTENANCE PRECAUTIONS ●

●

Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the 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, also.

●

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

●

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

●

Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps. 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 manufacturers. recommendations.

●

When inflating tires, use a selfattaching inflation chuck with remote shutoff and stand clear of the tire.

Position yourself beside the tire and not beside the rim.

Do not attempt repairs unless trained. Refer to manuals and experienced repair personnel for help.

321-4614

●

●

Before you service the machine, put a Do Not Operate tag on the key switch. Make sure that the machine is clearly “tagged out”. A DNO tag is included in this machines Operator Manual packet.

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

●

Wear gloves to protect hands when handling cable.

●

Disconnect the battery before working on the electrical system.

Know the consequences of disconnecting any electronic or computer devices.

19

SAFETY ●

It is not recommended to tow this machine.

●

Observe proper 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.

● ●

FUEL HANDLING PRECAUTIONS ●

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

●

Keep the brakes and steering systems in good operating condition.

Never remove the fuel cap or refuel gasoline 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.

●

Replace all missing, illegible or damaged safety signs. Keep all safety signs clean.

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

●

Do not fill the fuel tank completely to the top. Allow room for expansion.

●

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

●

Tighten the fuel tank cap securely.

Should the fuel cap be lost, replace it only with the original manufacturers 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.

maintenance

20

SAFETY

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. 84-108

●

●

When the battery electrolyte is frozen, the battery 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 Hot coolant can spray out if the radiator cap is 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.

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 ●

HAZARDOUS CHEMICAL PRECAUTIONS ●

●

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

ROLL-OVER PROTECTIVE STRUCTURE

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.

●

21

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.

SAFETY

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

22

SAFETY

SEAT BELT PRECAUTIONS 3

2

To unlatch the seat belt, press the red button (4) on the r ight latch mechanism.

1

The seat belt will automatically retract.

4

BP96N110

To latch the seat belt, pull the left belt strap (1) from the retractor.

Insert the metal end (2) into the right latch mechanism (3) on the right side of the seat.

BP96N109

WARNING: Before starting the engine ensure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

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. Do not rewire to bypass the seat switch or seat belt switch.

23

SAFETY

SPECIFIC PRECAUTIONS TO THIS MACHINE ●

Keep the load or tool as low as possible while moving the machine around the jobsite.

●

ALWAYS use the cylinder lock support strut to block up the loader arms before servicing the machine or leaving the cab with the loader arms in the up position.

INSTALLING THE SUPPORT STRUT:

BD04M021

4. Start the engine and slowly raise the loader lift arms until the support strut is on the lift cylinder rod.

Lower the loader lift arms until the support strut makes contact with the lift cylinder tube. Stop the engine.

IMPORTANT: Installing the Support Strut can be performed as a one or two person procedure so that the operator is not exiting the operators compartment under unsupported loader lift arms.

Remove the attachment from the loader lift arms before starting this procedure.

1. While sitting in the operator’s seat with the seat bar down lower the loader lift arms to the ground and stop the engine.

BD04M023

5. Install the pin in the support strut.

BD04M022

2. Remove the pin from the support strut.

3. After the pin is removed, lower the support strut onto the lift cylinder.

24

SAFETY

Storing the Support Strut: IMPORTANT: Storing the Support Strut should be performed as a two person procedure so that the operator is not entering the operator’s compartment under unsupported loader lift arms.

1. Have the operator enter the operator’s compartment and start the engine. Raise the loader lift arms approximately 25 to 55 mm (1 to 2 inches).

BD05A056

3. Have the second person raise the support strut to the storage position and install the pin. After installing the pin the second person should move away from the machine.

4. Have the operator start the engine and lower the loader lift arms to the ground. Stop the engine.

BD05A055

2. Stop the engine. Make sure the loader controls are locked. Do not exit the operator’s compartment.

Have a second person remove the support strut pin.

25

SAFETY

Operator Presence Switch The operator presence switch requires the operator to be seated in the operators seat when operating this skid steer.

2 1

1. LOCATION OF OPERATOR PRESENCE SWITCH 2. SWITCH VIEW FROM UNDER THE SEAT

BD04E078X / BD04F044

The operator presence switch is located in the seat cushion.

If the operator leaves the seat (even with the seat bar down) the loader controls and the ground drive system become disabled after 3 seconds. Refer to the right hand instrument panel warning light.

Make sure the operator presence (seat interlock system) is working properly at all times. See page 79 for testing procedures.

26

SAFETY

SEAT BAR Before this skid steer can be operated the restraint bar must be in the down position.

1

3

BD04M056

3. FASTEN SEAT BELT REMINDER (LOCATED ON TOP FACING PORTION OF THE RESTRAINT BAR) BK98E018

The seat bar provides the following features:

1. RESTRAINT BAR IN LOCKOUT POSITION

2

BK98E019

2. RESTRAINT BAR IN OPERATING POSITION

27

●

In combination with the seat belt, keeps the operator in the seat during operation.

●

Provides an arm rest while the operator is using the travel / loader control levers.

●

Locks the loader controls and the ground drive functions when in UP position.

SAFETY

EMERGENCY EXIT The rear window can be removed to provide an exit for the operator in the event the front exit is blocked.

2

1 BD01C270

2. TOP OF REAR WINDOW PUSHED OUT

Loosen the knobs.

BD04D084

Remove the rear window by pushing outward.

1. WINDOW RETAINING KNOBS

Turn the key switch OFF.

Exit the machine through the rear opening.

Raise the seat restraint bar.

Release the seat belt.

WARNING: Know and understand the emergency exit. Practice this procedure as you would a fire drill. Confirm that all operator’s know this emergency exit procedure.

Locate the two window retaining knobs attached to the rear window. One each side.

28

SAFETY

SAFETY DECALS The following safety decals have been placed on your machine in the areas indicated. The following graphics are for replacement location. Safety decals are intended for the personal safety of you and those working with you. Please take this manual, walk around your machine and note the content and location of these warning decals. Review these decals with all machine operators. It is the Owner’s responsibility to keep the decals legible. If they are not, obtain replacements from your dealer. Part numbers are on the decal.

NOTE: Locations may vary slightly between models and configurations.

WARNING: Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost painted over or no longer legible, with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part.

WARNING: Injury or death can result if you cannot read a safety decal or if a safety decal is missing. Replace any missing or damaged safety decal and keep all safety decals clean. See your dealer for new safety decals.

SC002

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

NORTH AMERICAN TEXT ISO 382622A1 / 256147A1

READ THE OPERATOR’S MANUAL DECAL

29

SAFETY

1 1

1

1. DANGER: ENGINE START WARNING (NORTH AMERICA)

1

175509A1

DANGER: ENGINE START WARNING (EUR)

30

BD04N057 / 321-7040 / BD04N061

SAFETY

2

2

BD04N041 / 251744A1

2. DANGER: CRUSH HAZARD

31

SAFETY

3 3

3. WARNING: ENTANGLEMENT HAZARD (NORTH AMERICA)

3

175504A1

WARNING: ENTANGLEMENT HAZARD (EUR)

32

BD05A005 / 384267A1

SAFETY

4

4

BD04N073 / 382622A1

4. WARNING: READ OPERATORS MANUAL

4

256147A1

33

SAFETY

5

5

5. INFORMATION DECAL: LIFT CAPACITY, 410 SHOWN

34

BD04H057 / 87459022

SAFETY

6

6

BD01C073

6. DANGER: CRUSH HAZARD (NORTH AMERICA)

7

7

7. WARNING: TIP HAZARD (NORTH AMERICA)

35

BD04F032 / 251748A1

SAFETY

8

8

8. CAUTION: INSPECT COUPLER-LATCH BEFORE OPERATING (NORTH AMERICA)

36

BD04H058

SAFETY

9

9

9

9

BD04D089 / BD05A083 / 139729A1

9. LIFT HOOK LOCATIONS

37

SAFETY

10

10

10

BD01C196 / BD04D093 / 139728A1

10. TIE DOWN LOCATIONS

11

11

BD04C039 / 384260A1

11. PRESSURIZED SYSTEM HAZARD (NORTH AMERICA) LOCATED UNDER THE FLOOR PLATE

38

SAFETY

12

12

12. LOCATED TO THE RIGHT OF THE OPERATOR

39

BD01C076 / 255927A1

SAFETY

13

13

13. 369848 WARNING: GREASE UNDER PRESSURE

40

06A078 / 369848

INSTRUMENTS AND CONTROLS INSTRUMENT PANEL The instrument panel is located on the upper right side of the cab. The operator may easily view the instrument lamps and indicators yet still have a clear and safe view of the worksite.

Once in the seat the alarm sounds and all lamps light briefly.

The fuel gauge and hourmeter will remain illuminated, for approximately 20 seconds, for operator monitoring.

The machine will be in Park when started. With the operator in the seat and th e Seat Bar down, the Par k Indicator Lamp will be illuminated and the Park Brake Switch blinking. The operator must Push the Park brake switch to release the brakes and activate the loader controls.

1

3

The Parking Brakes will be set when: ●

The park brake switch is activated and the park brake light is illuminated.

●

The engine is shut off.

●

The engine is running and the restraint bar is up.

●

The operator leaves the seat.

BS96H055

2

1. Seat Belt Reminder: This lamp flashes when the machine is first started to remind the operator to always fasten the seat belt and place the restraint bar

BD04C083

INSTRUMENT PANEL 1. SEAT BELT REMINDER LAMP 2. PARK BRAKE SWITCH 3. PARK BRAKE LIGHT

down.

41

INSTRUMENTS/CONTROLS

Key Switch 2. Key Switch: Located at the top of the Instrument Panel. This is a 4 position switch.

2

BD04N048

System Power (Accessory): This position energizes the instrument panel lamps and the accessory switches.

BS96H041

IMPORTANT: Battery will discharge if left in this position.

Stop: Turn the key to this position to stop the engine and deenergize the electrical system.

BS96H076

Run: This position energizes the electrical system and is the normal key position when the engine is running.

This is the position to be used if the machine is equipped with the BS96H078 Engine Pre-Heating Cold Start option. In cold temperatures the switch should remain in this position until the Engine Pre-Heating System Indicator Lamp goes out.

Start: Turn the key to this position to actuate the starter motor and start the engine.

BS96H077

42

INSTRUMENTS/CONTROLS

3 4

A_TEST

3. Fuel Gauge:

BS96H048

This symbol indicates the fuel level gauge, which is located to the right of the symbol. The gauge consists of a series of bars that indicate the level of fuel in the fuel tank. When all of the bars are visible the fuel tank is full. The first bar indicates the following amount

of fuel: Solid Bar ....................................................................... 4.0 U.S. gals (15.1 litres) Flashing Bar .................................................................. 3.0 U.S. gals (11.4 litres) 4. Hourmeter:

BS96H096

The hourmeter shows the total hours of engine operation. Both hours and tenths of an hour will display. The hourmeter should be used to measure the time between scheduled maintenance intervals.

43

INSTRUMENTS/CONTROLS

5

7

6 8

5. Work Lamps: Depress the work light symbol on this switch to turn the front and rear work lamps on. Depress the switch again to turn them off.

6. Auxiliary Hydraulic Interlock Override: When an operator leaves the seat, flow to an attachment will normally be halted via engine shutoff or direct hydraulic flow shutoff. Push this button and leave the seat within thirty seconds to defeat this interlock BS04F101

7. Road Lamps: Depress the light symbol on this switch to turn the front lamps and red tail lamps on. Depress the switch again to turn them off.

8. Parking Brake Switch: This lamp blinks when the Parking Brake is set. The Operator must have the restraint bar down, in the working position, and press the switch to release the brakes. Push the switch again to set the brakes.

BS96H049

44

INSTRUMENTS/CONTROLS

9 10 11

12

BD04E075

9. Engine Oil Pressure Lamp and Alarm: This warning lamp flashes and the alarm sounds if, with the engine running there is no or low oil pressure in the engine. DO NOT RUN the engine if this warning lamp illuminates.

BS96H052

10. Coolant Temperature Warning Lamp and Alarm: This lamp flashes and the alarm sounds when the engine is running and the engine temperature is too high. Stop the engine and service the problem.

BS96H050

11. Engine Air Filter Warning Lamp: This lamp will flash when the engine air filter becomes restricted and requires servicing. Service immediately.

BS96H056

BC02N191

12. Engine Pre-Heating System Lamp: In cold climate starting conditions, after turning the key switch to RUN, the Engine Pre-Heating System Lamp will illuminate, instructing the Operator that incoming air is being pre-conditioned for smoother starting. The Operator must wait until the lamp goes out before starting the engine.

45

INSTRUMENTS/CONTROLS

13

14

15 16

BD04E075

13. Charge Pressure Warning Lamp: This warning lamp flashes and the alarm sounds if there is no, or low oil pressure in the transmission. Do not run the machine if the warning lamp illuminates.

BS99J181

14. Hydraulic Fluid Temperature Warning Lamp: This warning lamp will flashes and the alarm will sound if the temperature of the hydraulic fluid becomes extreme. Do not work the machine if the condition exists.

BC0B123

BC00B113

15. Hydraulic Oil Filter Warning Lamp: This warning lamp will flash if the engine is running and the hydraulic filter is restricted. Lower the engine speed until the light goes out. If the oil is to operating temperature and the light is on continuously on, change the filter.

16. Brake Indicator Lamp: This warning lamp will illuminate when the brakes are engaged.

BS96H049

46

INSTRUMENTS/CONTROLS

Switch Panel 2

1

2

BD04N043X / 87035742B

1. SWITCH PANEL 2. SWITCH PANEL INSTRUCTIONAL DECAL

The switch panel located on the upper left side of the cab, will hold the following switches and controls, if equipped: ●

cab heat controls

●

air-conditioning controls

●

loader function disable switch (europe only)

●

hydraulic coupler switch

●

rotating beacon switch

●

hazard flasher

●

high / low auxiliary hydraulic flow switch

47

INSTRUMENTS/CONTROLS

4

1

5 2

3

BD04N044

1. TEMPERATURE CONTROL KNOB 2. BLOWER FAN SWITCH 3. AIR CONDITIONING SWITCH

BD04N045

4. BLANK FOR SWITCH 5. HYDRAULIC COUPLER SWITCH

1. Temperature Control Knob: Adjust the switch for the required comfort level.

Red area for wrm and blue for cold.

4. Blank Switch: May be used for optional switches.

5. Hydraulic Coupler Switch:

2. Blower Fan Switch: There are three blower switch speeds. By turning the switch clockwise from off, the blower speed will increase from low to medium high.

Use this two position switch in conjunction with the rollback, right control lever to couple and uncouple machine attachments.

3. Air Conditioning Switch: This two position switch turns the air conditioning system on or off. The switch is illuminated when in the ON position.

48

INSTRUMENTS/CONTROLS

8. High / Low Hydraulic Control Switch: Use this two position switch to regulate Auxiliary Hydrulic flow. The switch is illuminated when in the High Flow H position.

See Hydraulic Flow Rates on page 172 of this manual.

6 7

8

BD04N045

6. ROTATING BEACON SWITCH LOCATION 7. HAZARD FLASHER SWITCH LOCATION 8. HIGH / LOW HYDRAULIC CONTROL SWITCH

6. Rotating Beacon Switch: Push this switch to turn the rotating beach ON. The BC00B082 switch will illuminate when the beacon is ON. Push on the opposite end of the switch to turn it OFF. 7. Hazard Flasher: Push this switch to turn ON the hazard or emergency flashers. Push on the BC04K301 opposite end of the switch to turn it OFF. Hazard icon will illuminate when ON.

49

INSTRUMENTS/CONTROLS

BATTERY MASTER DISCONNECT SWITCH

IMPORTANT: DO NOT attempt to use the Battery Master Disconnect Switch to stop the engine. The Master Disconnect Switch will not stop the running engine and may cause damage to the electrical system or components if switched off with a running engine.

(If Equipped)

1

BD04N071

1. BATTERY MASTER DISCONNECT SWITCH

1. Battery Master Disconnect Switch The Battery Master Disconnect Switch has two positions: ON and OFF ON

BS98M034

This position supplies power from the battery to the electrical system.

OFF

BS98M034

This position disconnects all electrical power from the battery to the machine.

50

INSTRUMENTS/CONTROLS

STEERING AND TRAVEL WITH H PATTERN CONTROLS 1

F

F

N

N

R

R

2

BD05A015

1. LEFT HAND CONTROL LEVER 2. RIGHT HAND CONTROL LEVER

The H steering and travel controls are directed by the left-hand and right-hand control levers. The machines left and right drive motors will move in the direction the control lever is pushed or pulled from neutral, or center. The control on either side, completely and independently controls the drive motor on that side.

The travel speed is determined by the distance from neutral each lever is moved.

The farther the levers are pushed or pulled the faster that motor will move. To stop the machine move the control levers to neutral position.

Although the machine will turn and counter-turn sharply it is most efficient to travel through forward or reverse gradually. Track machines steer and travel with the same commands.

STRAIGHT AHEAD DRIVE:

STRAIGHT REARWARD DRIVE:

Push both of the controls forward, from neutral, equally, to move the machine forward.

Pull both of the controls rearward, from neutral, equally, to move the machine in reverse.

WARNING: Before moving the machine in any REVERSE direction, you must confirm that the area is clear of personnel and objects. Sound the horn, if equipped.

51

INSTRUMENTS/CONTROLS

STEERING AND TRAVEL WITH H PATTERN CONTROLS 1

F

F

N

N

R

R

2

BD05A015

LEFT TURN STEERING:

RIGHT TURN STEERING:

Push both levers slightly forward and once the machine begins moving, push the right-hand control lever slightly further than the left. Push the righthand control lever in a more forward direction and the machine will turn more sharply.

Push both levers slightly forward and once the machine begins moving push the left-hand control lever further than the right. Push the left-hand control lever in a more forward direction and the machine will turn more sharply.

For reverse right turning, slowly, pull both levers slightly rearward and once the machine begins moving, pull the left-hand control lever slightly further than the right. Pull the r ight-hand c o n t r o l l eve r i n a m o r e r e a r wa r d direction and the machine will turn more sharply.

For reverse left turning, slowly, pull both levers slightly rearward and once the machine begins moving, pull the righthand control lever slightly further than the left. Pull the right-hand control lever in a more rearward direction and the machine will turn more sharply.

52

INSTRUMENTS/CONTROLS

Turning A Machine With H Pattern Controls

BS06G023

BS06G022

COUNTER-ROTATION TURN - (POWER TO BOTH SIDES - OPPOSING DIRECTIONS)

PIVOT TURN - (POWER TO ONLY ONE SIDE)

To make a pivot turn left: Hold the left steering control lever in neutral and push the right steering control lever forward.

To counter rotate left: Pull the left steering control lever rearward and push the right steering control lever forward.

To make a pivot turn right: Hold the right steering control lever in neutral and push the left steering control lever forward.

To counter rotate right: Pull the right steering control lever rearward and push the left steering control lever forward.

To make a pivot turn in reverse left: After confirming that all personnel and objects are clear, Hold the left steering control lever in neutral and push the right steering control lever rearward.

To make a pivot turn in reverse right: After confirming that all personnel and objects are clear, hold the right steering control lever in neutral and pull the left steering control lever rearward.

BS06G024

GRADUAL TURN - (POWER TO BOTH SIDES SAME DIRECTION)

To make a gradual turn left: Push the right steering control lever fur ther forward while pushing the left steering control lever partially forward.

To make a gradual turn right: Push the left s teer ing control leve r fur ther forward while pushing the right steering control lever partially forward.

53

INSTRUMENTS/CONTROLS

LIFT ARM AND BUCKET CONTROLS - H PATTERN

BD05A015

1. Lift Arm Raise:

4. Bucket Rollback: (Curl)

The left-hand control lever controls the lift ar m. The lift ar m will raise by pivoting the handle UP toward the outside Left of the cab.

Pivot the control lever toward the inside of the machine to ROLLBACK or CURL the bucket.

2. Lift Arm Lower:

Pivot the control lever toward the outside right position to DUMP the bucket.

5. Bucket Dump:

Pivoting the handle DOWN to the inside of the cab will lower the lift arm.

3. Lift Arm FLOAT: Pivoting the handle DOWN until a slight jump is felt will place the control lever in the FLOAT position. This is a detented position and the lever will remain in this position until the operator pulls it back out and toward neutral.

In this detented, FLOAT position, the lift arm will float over changing ground contour.

54

INSTRUMENTS/CONTROLS

Instructional Decals For H Pattern Steering And Controls A

C

B

87438592 / 87573275 / 87573276

CONTROL LEVER APPLICATION DECALS

See the control lever application decals on the machine and understand the functions before starting the machine or beginning any operation. Decal (A) shown above, is located on the right inside of the cab. Decal (B) is located on the inside left cab upright. Decal (C) is located on the inside right cab upright. If you have any questions about the operation or function of the control levers contact your Dealer.

55

INSTRUMENTS/CONTROLS

STEERING AND TRAVEL WITH ISO PATTERN PILOT CONTROLS F 1 N

R

BS06N853

1. ISO PILOT CONTROL DRIVE LEVER

The ISO Pattern steering and travel controls are directed with this lever only. Use the face of a clock for orientation. The machine will move in the direction the lever is moved from neutral, center. To stop the machine release the lever and it will return to neutral. Although the machine will turn and counter-turn sharply it is best to travel through forward or reverse gradually when turning. Track type machines steer and travel with the same commands.

STRAIGHT AHEAD DRIVE:

LEFT TURN STEERING:

Push the control lever straight ahead, 12:00 position, and the machine will move forward.

From forward travel push the control lever to the 11:00 position and the machine will begin to travel left. Move the control lever, fur ther left, down toward 9:00 and the machine will move sharper left.

STRAIGHT REARWARD DRIVE: Pull the control lever straight rearward, 6:00 position and the machine will move rearward.

RIGHT TURN STEERING: From forward travel push the control lever to the 1:00 position and the machine will begin to travel right. Move the control lever, further right, down toward 3:00 and the machine will move sharper right.

WARNING: Before moving the machine in any REVERSE direction, you must confirm that the area is clear of personnel and objects. Sound the horn, if equipped.

56

INSTRUMENTS/CONTROLS

TURNING A MACHINE WITH ISO PATTERN PILOT CONTROLS

BS06G035

BS06G036

PIVOT TURN - (POWER TO ONLY ONE SIDE)

COUNTER-ROTATION TURN - (POWER TO BOTH SIDES - OPPOSING DIRECTIONS)

To make a pivot turn left: From neutral, push the pi lot control dr ive lever forward, slightly and then left toward 10:00.

To counter- rotate left: Push the pilot control drive lever straight left toward the 9:00 position. The left drive will engage reverse as the right drive will engage forward.

To m a ke a p i vo t t u r n r i g h t : Fr o m neutral, push the pilot control lever forward, slightly and then right toward 2:00.

To counter-rotate right: Push the pilot control drive lever straight right (inward) toward the 3:00 position. The right drive will engage reverse as the left drive will engage forward.

To make a pivot turn reverse left: From neutral, pull the pilot control drive lever rearward, slightly and then right toward 4:00.

To make a pivot turn reverse right: From neutral, pull the pilot control drive lever rearward, slightly and then left toward 8:00.

WARNING: Keep hands and feet on the appropriate controls at all times so control of the skid steer is maintained.

IMPORTANT: Although the machine will make sharp pivot and counterrotation turns it is more efficient to turn through forward or reverse, gradually when operating.

57

INSTRUMENTS/CONTROLS

TURNING A MACHINE WITH ISO PATTERN PILOT CONTROLS

BS06G037

GRADUAL TURN - (POWER TO BOTH SIDES SAME DIRECTION)

To make a gradual tur n left: From neutral, push the pilot control drive lever forward and then slightly toward the 11:00 position.

To make a gradual turn right: From neutral, push the pilot control drive lever forward and then slightly toward the 1:00 position.

58

INSTRUMENTS/CONTROLS

LIFT ARM AND BUCKET CONTROL WITH ISO PATTERN PILOT CONTROLS 3

1

2

4

N

5

1

1. PILOT LIFT ARM AND BUCKET CONTROL LEVER

BS06N853

Lift Arm Raise And Lower Control:

Bucket Dump And Curl Control:

The lift arm is controlled by pushing or pulling the right pilot control lever on this configuration.

The bucket is controlled by pivoting the r ight pilot control lever inward o r outward.

1. Lift Arm Up:

4. Rollback: (Curl)

The lift arm will raise UP by pulling back on the Right Pilot Control Lever.

The bucket will rollback (curl) when the Right Pilot Control Lever is pivoted inward.

2. Lift Arm Down:

5. Dump:

The lift arm will lower DOWN when the lever is pushed forward.

Pivoting the lever up toward the outside of the cab will dump the bucket.

3. Float:

NOTE: There is no detent or float position on the bucket dump and curl circuit.

To place the lift arm in Float, push the control lever all the way forward until a slight jump is felt. The lever will remain in this position until pulled back and out of detent. (toward neutral) In this detented, FLOAT position, the lift arm will float over changing ground contour.

59

INSTRUMENTS/CONTROLS

Instructional Decals For ISO Pattern Steering And Controls A

B

C

87573274 / 87573277 / 87573278\

See the control lever application decals on the machine and understand the functions before starting the machine or beginning any operation. Decal (A) shown above, is located on the right inside of the cab. Decal (B) is located on the inside left cab upright. Decal (C) is located on the inside right cab upright. If you have any questions about the operation or function of the control levers contact your Dealer.

60

INSTRUMENTS/CONTROLS

LEFT HAND CONTOL LEVER SWITCHES AND FUNCTIONS 2 1 3

BD04M027

BD04D094

2. Single Flow Auxiliary ElectroHydraulic Control Switch:

1. Turn Signal Indicator Switch:

Use this 2 position switch to control hydraulic flow to the Male coupler. Push the right side of the switch to activate constant flow.

Use this 3 position switch to turn the left or right hand turn signal on. Press the left arrow symbol of the switch to turn the left signal on. Press the right arrow symbol of the switch to turn the right signal on. The center position is neutral.

2 3

1

CTL_LVR_01

3. Dual Flow Auxiliary Electro Hydraulic Control Switch: Use this 3 position switch to control hydraulic flow to the Female and Male Coupler. Inter mittent flow may be controlled by pushing the left side of the switch for flow to the Female coupler. (momentary) Push the right side of the switch for flow to the Male coupler. ( m o m e n t a r y ) W h e n t h e sw i t c h i s released it will default to OFF.

CTL_LVR_01

The left tur n signal switch on this c o n t r o l l eve r c o m b i n a t i o n ( 3 ) i s activated by pushing the TOP portion of the turn signal switch. The right turn signal is activated by pushing on the BOTTOM portion of the switch.

61

INSTRUMENTS/CONTROLS

LEFT HAND CONTOL LEVER SWITCHES AND FUNCTIONS

4

6

BD04F041

4. 2 Speed Control Button: Located on front side of the left control lever. (If Equipped) Push the button to go from Low to High. Release the button again to go from High to Low. 410/420 Single speed or Low range 0 to 7.4 kph (0 to 4.6 mph) High range.........................................na 430/440 Single speed or Low range .....0 to 10.1 kph (0 to 6.3 mph) High range........0 to 16.4 kph (0 to 10.2 mph) 440CT Single speed or Low range 0 to 7.4 kph (0 to 4.6 mph) High range0 to 10.9 kph ( 0 to 6.8 mph)

62

INSTRUMENTS/CONTROLS

RIGHT HAND CONTOL LEVER SWITCHES AND FUNCTIONS 2

1

2 BD04D095

1. HORN BUTTON BD04C033

2. AUXILIARY ELECTRICAL SWITCHES

1. Horn Button: 2. Auxiliary Electrical Switches:

Use this momentary button to activate the horn.

These four electrical switches control functions BS04G121 of the auxiliary front electrical connector.

Consult your dealer to identify which pins in the connector are controlled by each switch.

BS98M064

1

BD04N107

HORN BUTTON LOCATION ON AUXILIARY ELECTRICAL SWITCH CONFIGURATION

BD04N075

AUXILIARY ELECTRICAL PIN CONNECTOR

63

INSTRUMENTS/CONTROLS

RIGHT HAND CONTOL LEVER SWITCHES AND FUNCTIONS

3

BD04F040

1. Ride Control Button: If equipped, this control button is located on the BS96H016 f r o n t s i d e o f t h e r i g h t control lever. See page 99 in this manual.

64

INSTRUMENTS/CONTROLS

THROTTLE CONTROLS Hand Throttles A

FAST

1

SLOW

A

398799A1

HAND THROTTLE INSTRUCTIONAL DECAL

BD04D097

1. Hand Throttle (non pilot machines):

3

2

3. Foot Throttle: W h e n t h e fo o t t h r o t t l e p e d a l i s depressed the engine speed is increased. By decreasing the pressure on the foot throttle pedal the engine speed is decreased.

1C_012

2. Hand Throttle (pilot control machines): Move the hand throttle forward to i n c r e a s e t h e e n g i n e s p e e d . To decrease the engine speed, move the hand throttle rearward.

The foot throttle is used when the operator requires maximum control, such as maneuvering in ver y tight conditions.

The hand throttle should be used during most operation. The full throttle position allows for maximum hydraulic flow from the hydrostatic drive and equipment pumps for increased drive and loader speed and response.

NOTE: Position the hand throttle for the desired minimum engine speed when using the foot throttle.

65

INSTRUMENTS/CONTROLS

HYDRAULIC BYPASS CONTROL In the event that the machine has lost engine or electrical power the operator can manually override the loader circuit lockout and lower the loader lift arms to the ground.

1. LIFT ARM BYPASS CONTROL HANDLE NON-PILOT CONTROL MACHINES 2. LIFT ARM BYPASS CONTROL DECAL LOCATION

1. Alert personnel in the area of your inte nt io ns. Sou nd t he h or n, if equipped.

Non-pilot control machines use a two lever sequence for Hydraulic Bypass Control and pilot control machines use only one lever for Hydraulic Bypass C o n t r o l . T h e s e c o n t r o l s a r e fo r emergency situations only and should not be used for day to day, normal operations.

2. Pull the lift arm bypass handle (1) UP.

3

WARNING: You MUST be in the operator’s seat and confirm that the surrounding area is clear prior to lowering the loader lift arms with the Hydraulic Bypass Control.

Lift Arm Bypass Control: Non-Pilot Control Machines

BD04N049

3. LIFT ARM BYPASS CONTROL DECAL

3. While pulling the lift arm bypass handle UP, move the left control lever (3) toward the inside of the machine, lift arm down position.

Before attempting to lower the lift arms on a machine that has lost engine or electrical power, alert personnel in the area of your intention. Do not leave the seat, raise the restraint bar or unfasten the seat belt.

2

1

BD05A014

66

INSTRUMENTS/CONTROLS L i f t A r m B y p a s s C o n t ro l : P i l o t Control Machines

WARNING: The Lift Arm Bypass Controls for Pilot Control and Non-Pilot control machines are ACTIVE at all times. Make sure the machine is clear of all personnel and objects or obstructions before engaging this control. Only engage this control while seated in the cab with the seat belt fastened and the restraint bar down. Failure to follow these instructions can result in death or serious injury.

1 1C_012

1. LIFT ARM BYPASS CONTROL KNOB PILOT CONTROL MACHINES

For pilot control machines the lift arm bypass knob is located behind the throttle lever.

1. Lift Arm Bypass Control: Use this lever only if the machine has lost engine 87568435 power and the loader arms are in the up position. Before attempting to lower the lift arms on a machine that has lost engine or electrical power, alert personnel in the area of your intention. Do not leave the seat, raise the restraint bar or unfasten the seat belt.

Slowly, pull the knob up to lower the lift arms.

67

INSTRUMENTS/CONTROLS

AUXILIARY HYDRAULIC ATTACHMENT CONTROL PEDAL

2 1

3

2

1. AUXILIARY HYDRAULIC CONTROL PEDAL 2. AUXILIARY HYDRAULIC FLOW CONTROL PEDAL DECAL 3. AUXILIARY HYDRAULIC CONTROL PEDAL IN ON POSITION

BD04D105 / BD04D101 / BD04D102

WARNING: Always relieve hydraulic pressure before attaching or removing auxiliary hydraulic attachments.

To relieve pressure: 1. Turn off engine.

2. Actuate the auxiliary hydraulic pedal both ways several times.

68

INSTRUMENTS/CONTROLS This pedal controls the hydraulic flow to the front att achment (hydraulic couplers on the left loader arm). Push down either the left or the right side of the pedal, depending on the direction of flow required. When foot pressure is removed from the pedal it will return to the OFF position.

4

NOTE: If the attachment operates opposite than described, reverse the two hose connections at the attachment and mark the hoses to avoid further confusion.

BD04D101

4. AUXILIARY HYDRAULIC FLOW CONTROL PEDAL IN THE OFF POSITION

If the attachment requires continuous hydraulic power, depress the foot pedal in the desired direction with one foot and move the locking lever in the same direction with the other foot. This will hold the pedal in place. The pedal can be locked in either direction.

To release the pedal, push the lock back to the center and the pedal will return to the OFF position.

IMPORTANT: Always read the auxiliary attachment manual before making the hydraulic connections and operating the attachment.

NOTE: With pedal depressed to the right, oil will flow out of the male coupler, of the units auxiliary connectors.

NOTE: Always clean hydraulic hose couplers prior to making connections.

69

INSTRUMENTS/CONTROLS Hydraulic hose couplers are provided on the left loader lift arm.

NOTE: If the attachment operates opposite than described, reverse the two hose connections at the attachment and mark the hoses to avoid further confusion.

1

2

NOTE: If it is necessary to get out of the cab with hydraulic flow to an attachment, it will be necessary to engage the Auxiliary Hydraulic Interlock Override switch on the instrument cluster to prevent the engine from stopping before leaving the seat or raising the restraint bar. After pushing the button, the lamp next to the button will flash, indicating that the override is activated and the operator may leave the cab. If the operator does not leave the cab within 30 seconds the override will reset.

BD04N074

1. AUXILIARY HYDRAULIC HOSE COUPLERS 2. AUXILIARY HYDRAULIC HOSE, CASE DRAIN COUPLER

70

INSTRUMENTS/CONTROLS

AUXILIARY ELECTRO-HYDRAULIC CONTROLS (IF EQUIPPED) Attachment electro hydraulic controls a r e fo r S t a n d a r d o r H i g h F l o w configurations.

6

Use the rocker switch on the left hand control lever to either activate the system or deactivate and control flow direction.

7

If constant flow is desired, use the top switch.

If intermittent flow is desired, use the lower switch.

BD04N075

6. HIGH FLOW HYDRAULIC COUPLERS 7. CASE DRAIN COUPLER

1

2

Push the rocker switch to the OFF position before installing or removing any attachment.

NOTE: Contact your Dealer if you have any questions concerning auxiliary hydraulic features on your machine.

3 4

WARNING: Always relieve hydraulic pressure before attaching or removing auxiliary hydraulic attachments.

To relieve pressure: 1.Turn off engine.

2.While sitting in the seat, with the seat bar down, turn key switch to ON position.

3.Push the Brake release button.

4.Actuate auxiliary controls, switches, and control levers in all directions several times.

5.Turn key switch to OFF.

5 BD04M027

1. OFF 2. ON (DETENT) - MALE COUPLER ENERGIZED 3. ON (MOMENTARY) - FEMALE COUPLER ENERGIZED 4. OFF 5. ON (MOMENTARY) - MALE COUPLER ENERGIZED

IMPORTANT: Always read the auxiliary attachment manual before making the hydraulic connections and operating the attachment.

NOTE: Always clean the hydraulic couplers prior to making connections.

Hydraulic couplers are provided on the right loader lift arm.

71

INSTRUMENTS/CONTROLS

OPERATOR’S SEAT Deluxe Seat (If Equipped)

4

3

2

1

BD04E078

1. Forward/ Rearward Adjustment Lever: Move the forward/rearward adjustment lever to the right and slide the seat to the most comfortable position. Release the lever.

2. Seat Suspension Control Knob: While sitting in the operators seat turn this knob to either increase or decrease the seat suspension. As the knob is moved, the indicator arrow will move along the graduated scale showing operator weight settings.

3. Lumbar Adjustment Control Knob: Turn this knob clockwise to increase the lumbar support. To decrease the lumbar support turn the knob counterclockwise.

4. Backrest Tilt Control Knob: Turn the knob clockwise to tilt the operators seat forward. Turn the knob counterclockwise to tilt the operators seat back.

NOTE: The Standard seat will feature the Forward/Rearward Adjustment Lever only and the location is identical for both Standard and Deluxe seats.

72

INSTRUMENTS/CONTROLS

AIR LOUVERS If equipped, louvers in this cab are adjustable and can be completely closed.

1

1

BD04E077

There are four rectangular louvers located above the operator’s seat on the head liner. The other two round louvers are located on each side of the operator and towards the front of the cab. These louvers are adjustable by tilting them in one direction or the other.

Located behind the operator and the headliner are two re-circulation vents (1).

AUXILIARY POWER SUPPLY (IF EQUIPPED)

A 12 volt power supply when the key switch is in System Power (Accessory) or RUN position.

1

BD04N073

1. AUXILIARY POWER SUPPLY

73

INSTRUMENTS/CONTROLS

CAB DOOR LATCHES 1

3 2

1C_020

1C_027

2. INNER CAB DOOR LATCH 3. GRAB BAR

1. OUTER CAB DOOR LATCH

Push the key button on the outer cab door latch (1) to release and pull on handle to open cab door. You may lock the door with the ignition key.

Lift handle on inner cab door latch (2) to release and push on grab bar (3) to open cab door.

IMPORTANT: Do not raise or lower loader lift arms with door not fully closed or damage will occur to the door assembly.

NOTE: To operate the loader functions without the front door installed you must install diode L71879 in the wiring harness. The diode should be installed in place of the molded plug in the front door harness connected to the plug on the cab harness. The harness is located under the ROPS toe guard. The diode is stored in the Operators Manual storage box when not in use.

SLIDING SIDE WINDOWS If equipped, the sliding side windows are opened by using the latch handle located on front of the window. Grasp the handle and push in on the release tab while sliding the window back to the desired position. Push forward on the handle to the latched position to close the window.

1

BD04N072

1. SLIDING WINDOW LATCH HANDLE

74

INSTRUMENTS/CONTROLS

WINDSHIELD WASHER CONTROLS The windshield washer control is located on the inside of the cab door to the right.

Use the three position knob (1) to control the windshield wiper and washer.

2

1

C

B

A

1C_016

A. Windshield Controls OFF: This position is OFF. B. Windshield Wiper Position: Turn the switch to this detent position to activate the wipers.

BS99N055

C. Windshield Washer Control Switch: Turn the switch all the way clockwise, to this momentary position, to activate the windshield washer.

BS99N054

IMPORTANT: Do not activate the washer position unless the washer bottle has sufficient fluid supply and is operational. Damage could occur to the washer motor.

The windshield washer bottle (2) is located to the right of the windshield wiper/ washer controls.

75

INSTRUMENTS/CONTROLS

DOME LAMP CONTROLS The deluxe cab dome lamp is located above the operators seat.

Move the switch either left or right to tur n the dome lamp on. When the switch is in the center position, the dome lamp is OFF. The Key Switch must be in the RUN or accessor y position for the dome lamp to work.

1

BD04E079

1. DOME LAMP

76

OPERATING INSTRUCTIONS DAILY INSPECTION When the seat bar is in the UP position, the brake should be engaged with ground dr ive pumps in neutral, preventing forward/rearward movement of the machine and locking out the hydraulic system, preventing movement of the loader lift arms and bucket.

Do the following each day before you s ta r t t h e e n g i n e a n d o p e ra t e t h e machine.

1. Check the machine for leaks.

Repair all leaks and clean the area with solvent, or pressure wash using soap and water.

Check the operation of the seat restraint bar:

2. Check the tires for damage.

3. Check for damaged, loose, or missing parts. Replace, tighten, or adjust as req uired b efore you operate the machine.

1. Sit in the operators seat, fasten the seat belt and lower the seat restraint bar.

2. With the engine stopped and the key switch in the OFF position, the control handles should be locked to prevent side to side movement.

Tur n the key switch to the ON position, press the par k brake switch and the control handles should move.

4. Clean all debris from the machine, especially around the engine and radiator.

5. Clean or replace any safety or instructional decals that cannot be read.

6. Clean the hand holds, steps, and operators compartment. Remove all loose items from the machine.

3. Start the engine and raise the seat bar to the full UP position.

4. Carefully move the steering control levers fore and aft. If the machine will move do the following:

7. See the Lubrication and Maintenance Chapters in this manual. Complete the procedures in the section marked Every 10 Hours of Operation beginning on page 119.

A. Stop the engine.

8. If this is a new machine, or a machine with a new or rebuilt engine, see Run-In Period on page 82.

77

OPERATING INSTRUCTIONS

1 3

2

BD04N095

BD04N094

3. CONTACT PAD

1. SEAT BAR PLUNGER SWITCH 2. CONTACT PAD

C. With the seat restraint bar in the fully lowered position, the contact pad on the seat restraint bar should contact the plunger of the switch and move it into the switch as shown.

B. Locate and inspect the seat restraint bar plunger switch located to the left, behind the operator seat. With the seat restraint bar in the fully raised position, the plunger on the switch should be extended and not make contact with the contact pad welded on the seat restraint bar as shown.

NOTE: The pad on the seat restraint bar should not contact the housing of the switch.

IMPORTANT: If either of the positions of the switch are not as shown in the photos, contact your Dealer for corrective action.

Repeat steps 1 through 4.

ATTENTION: If the skid steer moves with the seat bar in the raised position while sitting in the seat, contact your Dealer.

78

OPERATING INSTRUCTIONS Test the Operator’s Seat Presence Switch: 1. Sit in the operators seat with the seat bar in the down position.

2. Start the engine.

3. The Park lamp symbol should be illuminated.

4. Push the Park Brake switch symbol on the control panel below the warning lights. The Park light will extinguish and the brakes will release, the ground drive pumps will be activated, and the loader hydraulic control spools will be operational.

5. Carefully lift your weight off of the seat without moving any of the control levers. The Par k Light should come on after approximately 1 to 2 seconds. The ground drive pumps should be disengaged, the brakes will apply, and the loader controls should be locked in neutral.

6. With your weight off the operators seat carefully try the loader hydraulic and steer ing control levers. They should be inoperative.

IMPORTANT: If the operators presence switch does not function as described, contact your Dealer.

79

OPERATING INSTRUCTIONS

STARTING THE ENGINE WARNING: Before you start the engine, read and understand the operator’s manual and the safety decals for this machine. ALWAYS fasten the seat belt and pull seat bar down. Make sure all other persons in the area are away from the machine.

SC004

WARNING: Before starting the engine, study the operator’s manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow the manufacturer’s instructions on machine operation, service, and to observe pertinent laws and regulations.

Operator’s and service manuals can be obtained from your dealer.

SB055

1. If equipped, turn the master battery d i s c o n n e c t sw i t c h t o t h e O N position.

2. Adjust the seat and fasten the seat belt.

3. Pull the seat bar down.

4. Alert any person in the area that you are going to start the engine.

5. Push the throttle forward approximately 25 mm (one inch).

6. Turn the key switch to start.

7. Release the key switch when the engine has started.

80

OPERATING INSTRUCTIONS

PARKING THE MACHINE AND STOPPING THE ENGINE 1.Park on level ground whenever possible and lower the loader lift arms to the ground.

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

2.If the engine has been working at full load, run the engine at idle speed for two or three minutes to cool the engine parts evenly.

3.Turn the key to the OFF position to stop the engine.

4.Move the loader controls until locked. Remove the key, raise the seat bar, and release the seat belt.

Always use the hand holds and steps when exiting the machine.

NOTE: The parking brake is engaged automatically.

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

Always face the machine, use the hand holds and steps, and get on or off the machine slowly. Do not rush.

SA038

81

OPERATING INSTRUCTIONS

RUN-IN PERIOD ENGINE

DRIVE CHAINS

During the first 20 hours of operation for a new machine, or if the engine has been rebuilt, adhere to the following procedure:

Adjust, if necessary, the drive chains after 250 hours of operation if the drive c h a i n s h ave b e e n r e p l a c e d . S e e “Adjusting the Drive Chain Tension” page 152.

1.Operate the machine with normal loads for the first 8 hours. Do not wo r k t h e e n g i n e h a r d a t s t a l l speeds (wheels turning slow or stopped and engine speed at full throttle).

2.Keep the engine at normal operating temperatures.

3.Do not run the engine at low idle speeds for long periods of time.

WHEEL NUTS If the machine is new or if a wheel is removed for service, check and tighten the wheel nuts tightness every two hours of operation until they remain tight.

If the machine is equipped with stamped center wheels, the lug nuts will be tapered type lug nuts.Tighten each lug nut to a torque of 135 to 163 Nm (100 to 120 pound-feet).

If the machine is equipped with solid center wheels, the lug nuts will be flange type lug nuts.Tighten each lug nut to a torque of 224 to 265 Nm (165 to 195 pound-feet).

HYDRAULIC FILTER Replace the hydraulic filter after 20 hours of use if a major hy draulic component has been replaced. See Hydraulic Oil Filter Replacement on page 140.

82

OPERATING INSTRUCTIONS

OPERATING IN COLD WEATHER Cold weather conditions require specific procedures. During these conditions, your machine will require special attention to prevent serious damage. Cold weather maintenance will extend the ser vice life of your machine.

Cold temperature operation can cause moisture condensation in the fuel tank.

Keep the fuel tank full and check for water frequently. Failure to remove water from the fuel may result in an inoperative engine and damage to the fuel system.

NOTE: Before you work the machine, see Preventing Damage to the Hydrostatic System in Cold Weather, page 84.

4. COOLING SYSTEM: Check the coolant mixture before you operate in cold temperatures. A mixture of 50% ethylene glycol and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37° C (-34° F). If the ambient temperature is lower, adjust the mixture to 60% ethylene g l y c o l a n d 4 0 % w a t e r. I t i s recommended that ethylene glycol and water be used in your machine all year.

1 . BAT T E RY A N D E L E C T R I C A L SYSTEM: Clean the battery and make sure the battery is at full charge. Inspect the battery cables and terminals. Clean and spray the terminals with battery terminal protector to prevent corrosion.

NOTE: A fully charged battery at -17° C (0° F) has only 40 percent of the normal starting power. When the temperature falls to -29° C (-20° F), the battery has only 18 percent of its power remaining.

5. COLD TEMPERATURE STARTING AIDS: See your Dealer for extra starting aids such as a block heaters or Engine PreHeating Systems.

If distilled water is added to the battery when the temperature is below 0° C (32° F), charge the battery or run the engine for approximately two hours.

This procedure will prevent battery freezing.

If your machine is equipped with an Engine Pre-Heating System: Tu r n t h e k e y sw i t c h t o t h e RU N position. If the temperature is low enough for the Engine Pre-Heating System to activate, the Engine PreHeating System lamp will illuminate.

The operator should wait until this lamp goes out before cranking and starting the engine.

2. LUBRICANTS: Use the correct viscosity oil in each component. As an example: SAE 30 engine oil at 0° C (32° F) increases the starting load by about 250 percent.

M a k e s u r e y o u fo l l o w t h e recommended oil and filter service schedule as shown in this manual.

3. DIESEL FUEL SYSTEM: Check with your fuel supplier for the correct cold weather fuel. Diesel engine power will be reduced if wax particles are in the fuel filter.

83

OPERATING INSTRUCTIONS

OPERATING IN HOT WEATHER

PREVENTING DAMAGE TO THE HYDROSTATIC SYSTEM IN COLD TEMPERATURES

To prevent damage to the machine during hot weather operation do the following:

IMPORTANT: Below 0° C (32° F), operate the engine at 1/2 throttle for 10 minutes with the controls in the NEUTRAL position. Do not operate the hydraulic cylinders rapidly or against the stops rapidly until the hydraulic oil is warm. Increase the engine speed to 3/4 throttle and move the control levers to 1/2 forward. Move the machine at no load for one minute.

1. Keep the coolant at the correct level in the coolant reservoir and radiator.

2. With the engine cold, check the radiator cap for damage before hot weather starts. Replace the cap as required.

3. Keep all dirt and debris from restricting the radiator and engine area. Clean the radiator and hy d r a u l i c c o o l e r o f t e n w h e n wo r king in ver y dusty or dir ty conditions.

4. Check the condition and tension of the fan belt.

5. Use lubricants of the correct viscosity as recommended in this manual.

6. Use the correct solution of 50% (maximum) ethylene glycol and 50% water in the cooling system.

7. Check the air cleaner dust valve frequently during extremely dusty conditions.

84

OPERATING INSTRUCTIONS

BOOSTER BATTERY CONNECTION WARNING: Wrong jumper cable connections or shorting across the starter terminals can cause the machine to move suddenly out of control.

You can be injured or killed. Use the correct method shown on this page to connect jumper cables to this machine. Failure to follow these instructions can cause injury or death.

SA005

You can jump start this machine at the battery, or at the remote jump start terminals (if equipped).

Jump Starting at the Battery 1. Lower the loader lift arms and attachment to the ground.

2. Remove the floor plate to gain access to the battery.

3. If another machine is used for p o w e r, m a k e s u r e t h e t w o machines are not touching.

2 1

BD04N080

1. POSITIVE (+) JUMPER CABLE CONNECTION 2. MACHINE GROUND (-) JUMPER CABLE CONNECTION

4. Connect the positive (+) jumper cable to the positive (+) battery terminal.

5. Connect the negative (-) jumper cable to the machine frame away from the battery.

6. Start the engine and disconnect the negative (-) jumper cable first and the positive (+) jumper cable last.

85

OPERATING INSTRUCTIONS

Jump Starting at the Remote Jump Start Terminals 10. Replace the protective caps on the remote jump start terminals and close the rear access door.

1. Lower the loader lift arms and attachment to the ground.

2. Open the rear access door.

3. If another machine is used for p o w e r, m a k e s u r e t h e t w o machines are not touching.

4. Remove the protective caps from the positive (+) (1) and negative (-) (2) remote jump start terminals.

2 3

1 BD04N081

1. POSITIVE (+) REMOTE JUMP START TERMINAL 2. NEGATIVE (-) REMOTE JUMP START TERMINAL 3. BATTERY MASTER DISCONNECT SWITCH

5. Connect the positive (+) jumper cable to the positive (+) (1) remote jump start terminal.

6. Connect the negative (-) jumper cable to the negative (-) (2) remote jump start terminal.

7. Turn the battery master disconnect switch (3) to the ON position.

8. Sit in the operators seat and use the key switch to start the engine.

9. Disconnect the negative (-) (2) jumper cable first and the positive (+) (1) jumper cable last.

86

OPERATING INSTRUCTIONS

MACHINE OPERATION WARNING: Before you operate the machine, check the steering control levers, instruments, warning lamps, engine throttle, and equipment hydraulic controls. Also check the restraint bar. When the restraint bar is in the UP position, the park brake light is illuminated, the parking brake is ENGAGED, the loader hydraulic circuit is inoperative and the ground drive is disabled.

If you know there is a malfunction, a missing part, or a part that needs adjustment, stop the machine and correct the problem immediately.

Failure to follow these instructions can result in injury or death.

SA007

WARNING: DO NOT operate the machine while under the influence of alcohol or drugs.

SA112

ENGINE SPEED

1. Set the engine speed at desired throttle setting. Control the machine ground speed with the steering control levers.

Running the engine at idle speed for long periods can cause low operating temperatures. A low operating temperature can cause the formation of acids and deposits in the engine oil. It is recommended you run the engine at full throttle when operating conditions permit.

2. If you are a new operator, always operate the machine in an open area at a reduced machine ground speed until you get a feel for the controls. Move the steering control levers slowly and smoothly to avoid machine bouncing. If the machine does start bouncing, release the steering control levers and the machine will come to a stop.

3. Keep all machine and loader movements smooth and the work cycle as short as possible. You can get more done in a shorter time with a smooth short work cycle.

4. Keep the work area as smooth and level as possible.

5. Select the correct tires for the conditions, that is; wide or narrow, pneumatic or non-pneumatic.

87

OPERATING INSTRUCTIONS

MOVING A DISABLED MACHINE This machine must not be towed. If the machine is disabled and can not be repaired on the job site, lift the machine onto a trailer or truck. You can damage the hydrostatic system if you tow the machine. Contact your Dealer.

JOB SITE OPERATION

3. Electric power lines, gas pipes, water pipes or other underground installations can cause injury or death. Find out about the location of underground installations before you operate your machine in a new area.

1.Before starting work, familiarize yourself with the working area noting any holes, obstacles and debris that can be cleared from the site.

2.Locate any unavoidable “danger areas” (electric power lines, bridges, tight corners, etc.) and make sure you can work safely in these areas.

4.Inquire about the possibility of other persons being in the machine vicinity and be aware of others working in the same area. Clear t h e a r e a o f a ny u n a u t h o r i ze d personnel.

88

OPERATING INSTRUCTIONS

OPERATING THE LOADER Normal Use WARNING: When you operate, always keep all parts of your body inside the operators compartment. Then, before you leave the operators seat, always lower the loader bucket or attachment to the ground and stop the engine. You can be injured or killed if you do not follow these instructions.

SA010

WARNING: When you operate the machine, keep the loader bucket as low as possible. This low position gives better balance and permits you to see more clearly. If the bucket is full and you move the machine over ground that is rough or surfaces that can cause the machine to slide, always operate at slow speed. If you do not use this procedure, the machine can go out of control and roll-over.

SA041

WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operators compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine.

SA044

Filling and Dumping the Bucket 1.Lower the lift arms against the stops, increase the engine speed to full throttle and enter the stockpile at about 1/4 speed.

3.Keep the load low while carrying it to the dump area.

BI97C110

4.At the dump site, keep all movements smooth when you raise and dump the bucket.

BI97C108

2.Rollback and raise the bucket.

BI97C109 BI97C111

89

OPERATING INSTRUCTIONS

WARNING: Impact Hazard: Bucket edge or teeth can catch on frozen surface or buried object during surface scraping operations. Before operation inspect the area for objects the bucket can catch on and mark them. During operation make sure the bottom of the bucket is level with the surface to be scraped. Operate the machine around the objects and at slow speed. Injury to the operator and damage to the machine can result if these precautions are not followed. Always fasten the seat belt.

M465

Operating on a Hillside or Ramp WARNING: Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc., change the ground conditions. You must make a judgment if your machine can be safely operated on any hillside or ramp.

SB013

WARNING: When you are operating on a hill, be very careful. Do not turn the machine sideways to the bottom of the hill. The machine can roll over.

SA01

Load in the Bucket If you have a load in the bucket, drive the machine up the hill. With a load in the bucket, use reverse to back the machine down the hill.

BI97C112

BI97C113

Bucket Empty If the bucket is empty, drive the machine down the hill. Use reverse to back the machine up the hill when you have an empty bucket.

BI97C114

BI97C115

90

OPERATING INSTRUCTIONS

MANUAL ATTACHMENT COUPLER Installing a Bucket or Attachment IMPORTANT: Read the manufacturer’s instructions manual for attachments not included in this manual. DO NOT use attachments that are not approved. The use of additional equipment or accessories that are not authorized could invalidate CE compliance (applies to selected European countries for safety requirements).

3. Move the machine slowly forward and raise the loader lift arms. The 2 wedge shaped top edge of the attachment coupler must engage in the upper mounts of the bucket or attachment.

1

3 4 BD04M016

1. COUPLER LATCH PIN 2. ATTACHMENT LOCK LEVERS (SHOWN IN THE LOCK POSITION)

IMPORTANT: Before installing a bucket or attachment make sure the mounting area of the bucket, attachment and Case attachment coupler are clean.

Inspect the pin engagement areas for wear.

BK98E108

3. ATTACHMENT COUPLER LOCK LEVERS 4. COUPLER V ENDS

To Install a Bucket or Attachment: (bucket shown)

4. Roll the attachment coupler back while lifting the bucket or attachment off the ground. The attachment coupler will slide into position.

1. Make sure the attachment coupler lock levers are in the unlocked position.

5. Lower the bucket or attachment until it is 25 to 5 0 m m (1 to 2 inches) off the ground.

2. While sitting in the operators seat with the seat bar down, start the engine and tilt the attachment coupler forward.

6. Stop the engine and raise the seat bar.

91

OPERATING INSTRUCTIONS Before operating the machine, always inspect the coupler latch pin engagement into the attachment by raising the loader arms high enough to view the latch pin engagement from the operators seat.

BK98E109

7. Push both attachment coupler lock levers down securing the bucket or attachment in position.

BD04F046

It is the operators responsibility to confirm that the attachment or bucket are properly secured before operating the machine.

NOTE: If the attachment coupler lock levers do not lower into the LOCKED position, remove the attachment and investigate the cause.

BK98E088

ATTACHMENT LOCK LEVERS IN LOCKED POSITION

92

OPERATING INSTRUCTIONS

Removing a Bucket of Attachment IMPORTANT: Read the manufacturer’s instructions manual for attachments not included in this manual. DO NOT use attachments that are not approved. The use of additional equipment or accessories that are not authorized could invalidate CE compliance (applies to selected European countries for safety requirements).

1. Raise the bucket or attachment 25 to 50 mm (1 to 2 inches) off the ground.

2. Stop the engine, raise the seat bar and release the seat belt.

BK98E086

5. Rotate the attachment coupler out (bucket dump function) allowing the bucket or attachment to slide off the top edge of the coupler.

BK98E087

3. Pull both attachment lock levers upward to disengage the bucket or attachment.

4. Return to the operators seat, lower the seat bar, fasten the seat belt and start the engine.

93

OPERATING INSTRUCTIONS

HYDRAULIC ATTACHMENT COUPLER Installing a Bucket or Attachment If equipped, engaging or disengaging the hydraulic coupler lock pins requires holding the right-hand control lever over relief (holding the lever at its stop) and simultaneously pressing the hydraulic coupler switch. Practice this procedure before attempting to attach or remove a bucket or attachment.

NOTE: Any loader function held over relief will activate the coupler pins. Use the correct function for the attachment being used.

Before Installing or Removing an attachment the Operator must: 1. Make sure the mounting area of the bucket, attachment and attachment coupler are clean. See the safety decal located on the loader arm crosstube.

1 2

1. HYDRAULIC COUPLER SWITCH LOCATED ON THE SWITCH PANEL 2. RIGHT-HAND CONTROL LEVER

BD04C053 / BD04C048

2. Place the coupler lock pins into the disengaged position by holding the righthand control lever over relief in the full rollback position and engaging the unlock side of the hydraulic coupler switch. Release the control lever prior to releasing the switch.

94

OPERATING INSTRUCTIONS

3

3 4

4

3. COUPLER V ENDS 4. LOCK PIN INDICATORS SHOWN IN THE RED DISENGAGED POSITION

BD04F037

3. Slowly approach the bucket or attachment with the coupler V ends, as shown, until engaging the bucket or attachment.

BD04F038

4. After engaging the bucket or attachment slowly rollback the bucket or attachment to the full rollback position. Hold the right-hand control lever over relief, in the rollback position, and activate the lock side of the hydraulic coupler switch until the lock pins engage..

NOTE: When the bucket is rolledback the Lock Pin Indicators will lower and may become obscure to some operators, depending on their height.

95

OPERATING INSTRUCTIONS

5

5

BD04F035

5. GREEN LOCK PIN INDICATORS

5. Curl or roll the bucket or attachment out to view the Lock Pin Indicators. Only Green should be seen, as shown in above photo.

6

BD05A058

6. COUPLER LOCK PIN ENGAGED

6. Slowly raise the bucket or attachment to confirm that the Lock Pins are engaged.

96

OPERATING INSTRUCTIONS

Removing the Bucket 1.Raise the bucket or attachment 25 to 50 mm (1 to 2 inches) above the ground.

BD04C048

2. Hold the Right Control Lever over to the bucket rollback position and over relief while pushing the unlock side of the hydraulic coupler switch.

Release the control lever prior to releasing the switch.

3. Rotate the attachment coupler out (bucket dump function) allowing the bucket or attachment to slide off the top edge of the coupler.

97

OPERATING INSTRUCTIONS

HIGH FLOW HYDRAULIC SYSTEM Gear Pump 204 Bar (3000 PSI) High Flow System The gear pump 204 Bar (3000 psi) High Flow system supplies more flow than the auxiliary hydraulics, which allows the use of attachments designed for this pressure and flow.

1

2 3

This system is activated using the three position rocker switch in the left hand control lever. Pushing the rocker switch to the right (2) allows the oil to flow out to the male coupler. Pushing the rocker switch to the left (3) allows the oil to flow out to the female coupler.

BD04D094

1. ON (MOMENTARY) / FEMALE COUPLER ENERGIZED 2. OFF 3. ON (DETENT) / MALE COUPLER ENERGIZED

The High Flow System should be used as follows: 1. Install the attachment.

4

5

BD04N045

5. HIGH FLOW SWITCH BD04N076

4. HIGH FLOW HYDRAULIC COUPLERS

3. Turn the switch in the right-hand console to H for Hi Flow. Use L for Standard Flow.

2. Connect the attachment hydraulic hoses to the High Flow couplers located on the left side loader lift arms.

98

OPERATING INSTRUCTIONS

RIDE CONTROL Ride Control is a feature that improves the machine ride over all types of terrain with either an empty or loaded bucket. Ride Control will reduce fore and aft pitching motion during transport and material hauling operations, while allowing increased productivity and operator comfort. It also reduces shock loads to the machine.

2

1

BD04F040 / 255927A1

1. RIDE CONTROL BUTTON LOCATED ON THE FRONT SIDE OF THE RIGHT CONTROL LEVER

1. Ride Control (If Equipped): To activate the ride control feature, raise the loader lift arm off the chassis about 4 to 6 inches. Depress and hold the ride control button while ride control is desired. The ride control feature will allow the BS98M070 loader arms to float independent of the rest of the unit, therefore creating a smoother ride for the operator, and results in less material spillage from the bucket or forks. The ride control feature can also be used to eliminate tire hop while counter rotating on hard surfaces. To stop the ride control feature, release the ride control button. For additional information on ride control accumulator, see page 154.

NOTE: When the ride control button is depressed, the loader lift arms may slightly raise or lower itself during initial activation, then will float according to the terrain being driven on.

2

BD01C076

2. RIDE CONTROL WARNING DECAL LOCATION

99

OPERATING INSTRUCTIONS

ANTI-VANDAL LOCKOUT When the upper engine access door is locked the entire engine compartment is no longer accessible. \

1

2 BD04D103

BD04D104

2. ANTI-VANDAL LOCKOUT LOCATION WITH LOCK INSTALLED. SEE NOTE BELOW

1. ANTI-VANDAL LOCKOUT LOCATION

NOTE: Any brand of padlock will work as long as the shackle diameter is 6.35 mm (.25 in) and the shackle height is 44.45 mm (1.75 in) long.

100

OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE PRIOR TO LOADING WARNING: Know the rules, regulations, laws and safety equipment necessary for transporting or operating this machine on a road or highway.

Rotating Beacon, backup alarm, slow moving vehicle emblem and other safety equipment items are available from your dealer.

84-13A

WARNING: The machine can slip and fall from a trailer or ramp and cause injury or death. Make sure the trailer and ramp are not slippery. Remove all oil, grease, ice etc. Carefully move the machine off or onto the trailer with the machine centered on the trailer and ramp.

SB042

Observe all work site rules and local ordinances gover ning loading and transporting the machine. Ensure the h a u l i n g u n i t m e e t s a l l s a fe t y r e q u i r e m e n t s b e fo r e l o a d i n g t h e machine.

1. Put a block at the front and rear of the trailer or truck wheels.

5.Fasten the machine to the trailer at the points indicated by the tie down decals.

2

2. Carefully back the machine slowly onto the trailer.

3. Lower the loader lift arms to the trailer deck, stop the engine, and remove the key.

4. Put a block at the front and rear of each machine tire.

BP96N125

2. FRONT TIE DOWN LOCATIONS

6.Measure the clearance height of the machine and trailer or truck. Post the clearance height in the cab of the truck.

1

BD01C196

1. REAR TIE DOWN LOCATION (ONE EACH SIDE)

139728A1 TIE DOWN LOCATION DECAL

101

OPERATING INSTRUCTIONS

CRANING THE MACHINE WARNING: Only personnel with machine lifting experience should attempt craning the skid steer. Death or serious injury may result.

To crane the skid steer use only, chain, straps or cable with a rated capacity to handle the weight of the model skid steer being craned.

Refer to the Specifications Section of this manual for the operating weight of the model skid steer being craned.

Page 174 WARNING: The cumulative weight of the chains, straps, cables or other lifting devices must be added to the total weight being craned.

When lifting these machines with a crane, use a four leg sling with a 39 degree sling angle. Each leg of the sling must have a minimum length of 1.8 m (6 ft).

BD04D089 / BD05A083

LIFT HOOK LOCATIONS

WARNING: Remove all attachments before craning the skid steer.

2 Contact your Dealer for any questions that involve craning the machine.

1

IMPORTANT: Improper craning and improper craning devices could damage the machine.

BT97F064

1. 1.8 M (6 FEET) 2. FOUR LEG SLING

102

WHEEL AND TIRES WARNING: Exploding tires and/or rim parts can cause injury or death.

Keep yourself and others out of the DANGER AREA. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires.

SD020

BS97F041

The above illustrations show danger areas caused by exploding tires and/or rim parts. KEEP YOURSELF AND OTHERS OUT OF THESE DANGER AREAS. The next page shows the correct methods that you must use when adding air or servicing a tire.

103

WHEELS AND TIRES

WARNING: DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air/gas mixture that will be ignited with high temperatures. This can happen to tires inflated or deflated. Removing air or breaking bead is not adequate. Tire MUST be completely removed from the rim prior to welding.

SB134

WARNING: Explosive separation of the tire and/or rim parts can cause injury or death. When tire service is necessary, have a qualified tire mechanic service the tire.

84-113

Tire Pressure Check the air pressure and the condition of the tires every 50 hours of operation.

10 x 16.5 ....................................................................... 275 -344 kPa (40 - 50 psi) 12 x 16.5 ........................................................................ 241 - 310 kPa (35 -45 psi) 13 x 16.5 ....................................................................... 206 - 275 kPa (30 - 40 psi) 15.50 x 16.5 ................................................................. 172 - 341 kPa (25 - 35 psi)

Inflating the Tire Always have a qualified tire mechanic ser vice the tires and r ims on this machine. It is recommended that you have this mechanic inflate the tires. To p r eve n t a c c i d e n t s, a l way s u s e a restraining device (tire inflation cage), correct equipment, and correct procedure. Explosive separation of the tire can cause serious injury.

If the tire has lost all the pressure or service to the tire or rim is required, do the following: 1. Before you add air, have the tire correctly installed on the machine or put the tire in a restraining device (tire inflation cage).

104

BD05A059

2. Wear face protection and use an air hose with remote shut-off valve and a self-locking air chuck.

WHEELS AND TIRES 3. Stand behind the tread of the tire and make sure all persons are away from the side of the tire before you start to add air.

4. Inflate the tire to the recommended air pressure. DO NOT inflate the tire more than the recommended pressure.

Wheel Nuts If the machine is new or you have just installed the wheels, check the wheel nuts every 2 hours until the nuts remain tight.

If the machine is equipped with stamped center wheels, the lug nuts will be tapered type lug nuts.Tighten each lug nut to a torque of 135 to 163 Nm (100 to 120 pound-feet).

If the machine is equipped with solid center wheels, the lug nuts will be flange type lug nuts.Tighten each lug nut to a torque of 224 to 265 Nm (165 to 195 pound-feet).

When installing tires, make sure that the tread is in the same direction.

105

BD01C268

WHEELS AND TIRES

NOTES

106

LUBRICATION / MAINTENANCE WARNING: Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your dealer or the service manual for this machine.

SC021

Read the safety decals and information decals on the machine. Read the operators manual. Understand the operation of the machine before you start servicing.

WARNING: If you service the machine with the loader lift arms raised, always use the cylinder lock support strut to block up the loader lift arms.

Failure to follow this procedure can cause serious injury or death if the loader lift arms are lowered by accident.

SC018

Use the correct safety clothing and safety equipment. Understand how to use a fire extinguisher and first aid kit.

WARNING: Before servicing hydraulic components make sure all pressure is relieved. To relieve hydraulic pressure: BD05A063

Before you service the machine, put a Do Not Operate tag on the instrument panel. One Do Not Operate tag, is included with yo ur new machine.

Additional tags, part number 321-4614, are available from your Dealer.

●

Turn off engine

●

While sitting in the seat, with the seat bar down, turn key switch to ON position.

●

Push the Brake release button.

●

Actuate auxiliary controls, switches, control levers and pedals in all directions several times.

●

Turn key switch to OFF.

Spare parts must meet specifications. Use parts supplied by your authorized Dealer to ensure guarantee of quality.

WARNING: When handling lubricants (oil, grease etc.), and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters responsibly and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT service the engine or transmission when the engine or transmission oil temperatures exceed 49° C (120° F) 107

LUBRICATION

TILTING THE OPERATORS COMPARTMENT FORWARD You can only tilt the operator’s compartment with the loader lift arms in the raised position. When the loader lift arms are in the raised position, unobstructed access to the engine, hydrostatic pumps, motors, and control linkage is provided. To access all of the loader lift arm lubrication points the operator’s compartment must be in the operating position with the loader lift arms in the lowered position.

IMPORTANT: If an attachment is being used, the attachment should be removed before the loader lift arms are raised.

BD04N083

CAB TILTED WITH LOADER LIFT ARMS RAISED

108

BD05A060

CAB LOWERED WITH LOADER LIFT ARMS LOWERED

LUBRICATION

To Tilt The Cab: 1. Remove the attachment from the loader lift arms.

5. Gripping both front hand holds near the top, tilt the cab forward.

2

1 3

BD04D080

BP96N086

1. LOADER LIFT ARM SUPPORT STRUT 2. PIN 3. LIFT CYLINDER

2. Raise the loader lift arms and install the loader lift arm support strut (1) and pin (2). See Installing The Support Strut on page 111.

2

3. Lower the loader lift arms until the loader lift arm suppor t strut (2) makes contact with the lift cylinder (3).

BD01C175

6. Confirm that the cab is tilted completely forward and the cab hold open latch (2) is engaged, as shown.

BD01C171

4. Loosen and remove the two mounting bolts from the rear of the operator’s compartment.

109

LUBRICATION

LOWERING THE OPERATORS COMPARTMENT INTO THE OPERATING POSITION 1. Make sure all tools or other items have been removed from the interior of the chassis before the operators compartment is lowered.

1

BD01C171 BD04N097

2. Release the cab hold open latch by pushing the lever (1) forward.

4. Install and tighten the operator’s compar tment mounting bolts to torque of 180 to 320 Nm (130 to 235 pound-feet).

1

3 2 BD05A062

BD01C142

3. Gripping both front cab hand holds near the top, slowly lower the cab into operating position.

5. Raise the loader lift arms and remove the pin (2) from the loader lift arm support strut (1). Place the l o a d e r l i f t a r m i n t h e s t o ra g e position and install the pin (2). See Storing the Support Strut on page 112.

IMPORTANT: On pilot models use caution when closing ROPS to ensure the pilot control handles do not get caught on the ROPS seat plate.

110

6. Before operating the skid steer m a k e s u r e t h e o p e r a t o r ’s compartment is fully lowered and the mounting bolts are installed and tightened.

LUBRICATION

INSTALLING THE SUPPORT STRUT WARNING: If you service the machine with the loader lift arms raised, always use the cylinder lock support strut to block up the loader lift arms.

Failure to follow this procedure can cause serious injury or death if the loader lift arms are lowered by accident.

SC018

IMPORTANT: Installing the Support Strut can be performed as a one or two person procedure so that the operator is not exiting the operators compartment under unsupported loader lift arms. Remove the attachment from the loader lift arms before starting this procedure.

Before exiting a machine with the boom up engage the support strut: 1. While sitting in the operator’s seat with the seat bar down lower the loader lift arms to the ground and stop the engine.

BDO4M021

4. Start the engine and slowly raise the loader lift arms until the support strut is on the lift cylinder rod.

Lower the loader lift arms until the support strut makes contact with the lift cylinder tube. Stop the engine.

BD04M022

2. Remove the pin from the support strut.

3. After the pin is removed, lower the support strut onto the lift cylinder.

BD04M023

5. Install the pin in the support strut.

111

LUBRICATION

Storing the Support Strut: IMPORTANT: Storing the Support Strut should be performed as a two person procedure so that the operator is not entering the operator’s compartment under unsupported loader lift arms.

1. Have the operator enter the operator’s compartment and start the engine. Raise the loader lift arms approximately 25 to 55 mm (1 to 2 in).

BD05A056

BD05A055

2. Stop the engine. Make sure the loader controls are locked. Do not exit the operator’s compartment.

Have a second person remove the support strut pin.

112

3. Have a second person raise the support strut to the storage position and install the pin. After installing the pin the second person should move away from the machine.

4. Have the operator start the engine lower the loader lift arms to the ground. Stop the engine.

LUBRICATION

ENGINE HOURMETER The engine hourmeter, which displays in hours and tenths of an hour, shows the actual hours the engine has run. Use the engine hourmeter to service your machine at the correct time intervals. See the “Lubrication/Maintenance Chart” page 118.

1

BD04E075

1. ENGINE HOURMETER

MAINTENANCE LUBRICATION SCHEDULE Service your machine at the intervals and locations given in the Lubrication/ Maintenance Charts using the recommended lubricants.

Follow the maintenance lubrication schedule for this machine to reach maximum life of the machine and attachments.

1

BD04C056

1. MAINTENANCE LUBRICATION DECAL

113

LUBRICATION

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM Ask your Dealer about a Lubricant Analysis Program. Through this service, your lubricants are tested in an independent laboratory. You simply remove a sample of lubricant from your machine and send the sample to the laboratory. After the sample is processed, the laboratory will report back to you and guide you with maintenance requirements. A Lubricant Analysis Program can help support your equipment up time and provide you with a service that can pay back dividends when you trade for another piece of equipment.

ENVIRONMENT Before you service this machine and dispose of oil, 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, recycling center or your Dealer for correct disposal information.

114

LUBRICATION

FLUIDS AND LUBRICANTS FUEL TANK Capacity - All Models .............................................................83.3 litres (22.0 gal.)

Specifications ........................................................................................... #2 Diesel Grade #2 diesel fuel which meets ASTM and EMA requirements should be used in these machines.

See websites for American Society for Testing Materials Inter national @ w w w. a s t m . c o m a n d E n g i n e M a n u fa c t u r e r s A s s o c i a t i o n @ www.enginemanufacturers.org for more information.

COOLING SYSTEM Capacity - All Models (Radiator plus Engine) ............................ 17 litres (18.0 qt.)

Recovery Bottle ............................................................................... 2 litres (2.1 qt.)

Specifications ..................................................50% water and 50% ethylene glycol HYDRAULIC SYSTEM Capacity - All Models (Total System) ....................................50.2 litres (13.3 gal.)

Capacity - All Models (Reservoir) ............................................32.4 litres (7.1 gal.)

Specifications .................................................................... SAE 10W-30 Engine Oil CHAIN COMPARTMENTS Capacity - All Models (Each Side) ............................................. 5.7 litres (6.0 qt.)

Specifications ..................................................................... SAE 10W30 Engine Oil BATTERY Quantity ................................................................................................ As required Specifications ................................................................................... Distilled water GREASE FITTINGS Quantity ................................................................................................ As required Specifications ........................................................................ molydisulfide grease ENGINE CRANKCASE OIL Capacity - 410 / 420 (with filter change)...................................... 8.7 litres (9.2 qt.)

Specification.............................................................Case No. 1 Engine Oil 10W30 Capacity - 430 / 440 / 440CT (with filter change) ........................ 12 litres (12.7 qt.)

Specification.............................................................Case No. 1 Engine Oil 15W40 FINAL DRIVE GEAR OIL Track Machines Capacity - each side....................................................................... 0.55 L (0.58 qt.)

Specification................................................... Case 135H EP 80W-90 or 85W-140

115

LUBRICATION

ACCESS DOORS 2

1

BD04N084

1. UPPER REAR ACCESS DOOR HANDLE

BD04N085

2. REAR ACCESS DOORS OPEN (SHOWN WITH RADIATOR PULLED OUT IN SERVICE POSITION

Lift up on the handle to lift the upper rear access door.

The upper and lower rear doors will give the operator access to: ●

hydraulic fill

●

engine oil check and fill

●

master disconnect switch

●

fuel fill

●

air filter

●

remote battery boost (if equipped)

BD04N102

The rear door release lever is located on the left, top side of the door, as shown.

BD04N101

Pull up on the lever to open the lower access door.

116

LUBRICATION

3

3. ACCESS DOOR FOR TRACK TENSION ADJUSTMENT

117

3597

LUBRICATION

LUBRICATION/MAINTENANCE CHART

105 Wheel Nut Torque 104 Tire Pressure

REPLACE

CLEAN

CHECK

LUBRICATE

SERVICE POINTS INITIAL

PAGE NUMBER

SERVICE INTERVAL IN HOURS

AR AR

119 Loader Lift Arm, Bucket Pivots, Attachment Coupler Pins 121 Engine Oil Level

10 10

121 Hydraulic Res Oil Level

10

123 Hydraulic Oil Cooler 124 Engine Coolant Reservoir

10

125 Seat Restraint Bar Function 126 Operator’s Seat Presence Switch

10

10 10

128 Initial Track Tension Check

10

138 Initial Fan Belt Tension 155 Initial ROPS Hardware Check

20

20

129 Track Tension Check 130 Initial Final Drive - Check and Change

50 100

131 Grease the Attachment Coupler Handle

100

250

133 Battery Fluid Level/Clean 134 Radiator Coolant Level

250

134 Drain Water from the Fuel Filter 135 Final Drive Fluid Check

250

250 250

136 Drive Chain Tension

250

136 Spark Arresting Muffler (If Equipped) 138 Fan Belt Tension

250 500

139 Engine Oil and Filter 137 Fuel Filters Primary and In-Line

500 500

155 ROPS and Seat Belt

500

140 Hydraulic Oil Filter Replacement 141 Final Drive Oil Change

500 500

142 Fuel Tank Water and Sediment 142 Hydraulic Reservoir Oil

1000 1000

143 Check Engine Valve Clearance

1000

143 Chain Tank Oil 144 Cab Air Cleaner Filter Elements

250

1000

AR

145 Engine Coolant 146 Engine Air Filter Elements

2000 2000

118

LUBRICATION

EVERY 10 HOURS OR DAILY Loader Lift Arm, Bucket Pivots And Attachment Coupler Latch Pin Use Molydisulfide Grease.

1 2 3 6 BD04N077

1. BUCKET CYLINDER ROD END (1 EACH SIDE) 2. LIFT ARM TO ATTACHMENT COUPLER(1 EACH SIDE) 3. ATTACHMENT COUPLER LATCH PIN (1 EACH SIDE)

BP96N080

6. LIFT ARM (1 EACH SIDE)

7

BD04N089X

7. HEAD END OF LOADER LIFT CYLINDER (1 EACH SIDE)

4 BD04N090

4. LIFT CYLINDER ROD END (1 EACH SIDE)

5 BD04N090X

5. BUCKET CYLINDER HEAD END (EACH SIDE)

119

LUBRICATION

EVERY 10 HOURS OR DAILY ENGINE OIL Case No. 1 API Service CI 4 Engine Oil is recommended for use in these engines.

The recommended service intervals are specifically for Case No. 1 engine oil.

See the chart below for recommended viscosity at ambient temperature ranges.

NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case lubricants.

Oil Viscosity/Temperature Ranges

BS99N019

The 500 hour oil change interval is based on using Case No. 1 engine oil.

120

LUBRICATION

EVERY 10 HOURS OR DAILY ENGINE OIL LEVEL Check the engine oil level before you start the engine each day or before the start of each shift. Always check the oil with the engine stopped and when the machine is on level ground.

EVERY 10 HOURS OR DAILY HYDRAULIC RESERVOIR OIL LEVEL CHECK 1. Park the machine on a level surface and put the attachment on the ground when you check the oil level.

1

1

BD05A005

1. ENGINE OIL LEVEL DIPSTICK

BD04N087

Make sure the engine level dipstick is pushed completely down and pull out to check the oil level.

1. HYDRAULIC OIL LEVEL SIGHT GAUGE

The hydraulic oil sight gauge is located inside the lower rear access door on the left side. Shown above behind the optional remote start positive terminal.

2

BD05A006

2. ENGINE OIL FILL LOCATION

If the oil level is below the ADD mark add oil. DO NOT raise the oil level above the Full mark.

BD04N087

IMPORTANT: The normal fluid level is at the midpoint of the sight gauge when the loader arms and bucket are resting on the ground.

121

LUBRICATION

2

BD04N070

2. HYDRAULIC OIL FILL

2. Clean the filler cap and the area around the cap to reduce the risk of contamination.

3. Slowly turn the filler cap 1/2 turn to relieve pressure in the reservoir.

D o n o t r e m o ve t h e c a p u n t i l pressure is relieved.

4. Remove the filler cap and add oil as required.

WARNING: Fire Hazard: Do not smoke while filling the hydraulic reservoir. Do not fill near open flames.

M476

5. Apply clean oil to the filler cap seal and install the filler cap.

NOTE: The hydraulic and hydrostatic systems use the same reservoir.

122

LUBRICATION

EVERY 10 HOURS OR DAILY Hydraulic Oil Cooler

For High Flow Systems

1

2

BD04B096

BD04C065

1. RADIATOR RELEASE LATCH

2. RELEASE PIN

1. Push the radiator release latch to the right to release the radiator.

4. Pull the release pin, located on the bottom left of the radiator, to swing the secondary hydraulic cooler out.

3

BD04B097

2. Tip the radiator out to inspect or clean the hydraulic cooler.

3. Pull the bottom of the radiator out until it drops into the detent slots for additional clearance.

123

BD042M020

3. SECONDARY HYDRAULIC COOLER

5. Clean the radiator and coolers with soap and warm water. Flush with clean water.

LUBRICATION

EVERY 10 HOURS OR DAILY ENGINE COOLANT RESERVOIR CHECK Check the level of the coolant when the engine is stopped and the coolant is COLD. DO NOT remove the radiator cap during this check.

2 1

BD05A012

1. ENGINE COOLANT RESERVOIR 2. ENGINE COOLANT RESERVOIR FILL CAP

The coolant level must be between the add and the full mark on the coolant reservoir bottle.

If the coolant level falls below the add mark, add the proper coolant solution of 50% ethylene glycol and 50% water.

124

LUBRICATION

EVERY 10 HOURS OR DAILY SEAT RESTRAINT BAR AND INTERLOCKS FUNCTION Test the seat bar and loader/steering controls for correct operation.

When the seat bar is in the UP position, the brake should be engaged with ground dr ive pumps in neutral, preventing forward/rearward movement of the machine and locking out the hydraulic system, preventing movement of the loader lift arms and bucket.

1 2 BD04N094

LOCK FOR LOADER AND STEERING CONTROLS

1. SEAT BAR PLUNGER SWITCH 2. CONTACT PAD

1. Sit in the operators seat, fasten the seat belt and lower the seat restraint bar.

2. With the engine stopped and the key switch in the OFF position, the control handles should be locked to prevent side to side movement.

Tur n the key switch to the ON position, press the brake button and the control handles should move.

3. Start the engine and raise the seat bar to the full UP position.

4. Move the steering control levers fore and aft. If the machine will move do the following: A. Stop the engine.

125

B. Locate and inspect the seat restraint bar plunger switch located to the right, behind the operator seat. With the seat restraint bar in the fully raised position, the plunger on the switch should be extended and not make contact with the contact pad.

LUBRICATION

EVERY 10 HOURS OR DAILY TESTING THE OPERATOR’S SEAT PRESENCE SWITCH 1. Sit in the operators seat with the seat bar in the down position.

3

2. Start the engine.

3. The Park lamp symbol should be illuminated.

4. Push the Park Brake switch symbol on the control panel below the warning lights. The Park light will extinguish and the brakes will release, the ground drive pumps will be activated, and the loader hydraulic control spools will be operational.

BD04N089

3. CONTACT PAD

C. With the seat restraint bar in the fully lowered position, the contact pad on the seat restraint bar should contact the plunger of the switch and move it into the switch as shown.

5. Carefully lift your weight off of the seat without moving any of the control levers. The Par k Light should come on after approximately 1 to 2 seconds. The ground drive pumps should be disengaged, the brakes will apply, and the loader controls should be locked in neutral.

NOTE: The pad on the seat restraint bar should not contact the housing of the switch.

IMPORTANT: If either of the positions of the switch are not as shown in the photos, contact your Dealer for corrective action.

6. With your weight off the operators seat carefully try the loader hydraulic and steer ing control levers. They should be inoperative.

Repeat steps 1 through 4.

ATTENTION: If the skid steer moves with the seat restraint bar in the up position, contact your Dealer.

IMPORTANT: If the operators presence switch does not function as described, contact your Dealer.

126

LUBRICATION

EVERY 10 HOURS OR DAILY Clean Tracks and Components Periodically, and when the machine has been working in mud, the tracks, roller wheels, idler wheels, final drive sprocket areas, and guide teeth should be cleaned.

4 1 3

2

1.

2.

3.

4.

2

2

BD06A060

FRONT IDLER WHEEL (1 EACH SIDE) TRACK ROLLER WHEELS (3 EACH SIDE) REAR IDLER WHEEL (1 EACH SIDE) FINAL DRIVE SPROCKET (1 EACH SIDE)

127

LUBRICATION

INITIAL 10 HOURS Check the track tension after the first 10 hours on a new machine or if new tracks have been installed.

To I n c r e a s e o r D e c r e a s e Tr a ck Tension: Specification.........Molydisulfide grease

For this procedure, the tracks, rollers, idler wheels, and final drive sprockets must be clean of dirt and debris.

1. Park the machine on a firm, level surface.

2. The machine should be raised, blocked, and supported properly until the tracks are about 50.8 mm (2 inches) off the surface.

To measure the track tension: BD069062

1. Remove the access cover

1 WARNING: Use caution when adjusting track tension.

Grease is under extreme pressure. Wear approved, full coverage face protection.

2 BD05B033

1. CENTER ROLLER WHEEL 2. TOP INSIDE TRACK SURFACE

3. Measure from the lower track top surface to the bottom of the center roller wheel.

Allowable track sag 12.7 to 19.5 mm (1/ 2 to 3/4 inch) 3595

2. If the track tension needs to be Increased, add grease to the fitting shown.

3. If the track tension must be decreased, SLOWLY loosen the fitting.

128

LUBRICATION

Every 50 Hours Track Tension Check Check the track tension every 50 hours of operation as in the previous procedure.

Proper adjustment will increase the life of the track.

129

LUBRICATION

100 Hours INITIAL CHECK AND CHANGE FINAL DRIVE OIL CT MODELS After the first 100 hours of operation, check and change the final drive fluid.

Specification... Case 135H EP 80W90

3 2

NOTE: If operating in muddy conditions for 20 hours or more, the oil change interval should be shortened by 50 per cent.

1. Park the machine on firm, level ground with the final drive to be checked and drained in the position shown below. Thoroughly clean the area around the plugs.

BD05H004

2. CHECK/FILL AND DRAIN PLUG 3. SIDE PLUG

3. Position the machine so the check/ fill and drain plug is in the drain position.

4. Slowly remove one of the side plugs to vent and aid in draining oil into a suitable container.

1

3

4

BD05H005

1. CHECK/FILL AND DRAIN PLUG

2. Use a 5 mm Allen wrench and open the check/fill and drain plug.

Oil will flow out of the orifice.

BD05H010

4. CHECK/FILL AND DRAIN PLUG IN THE FILL AND CHECK POSITION

5. After the oil has drained, move the machine to place the check/fill and drain plug into the above position.

6. Fill with oil until the oil just begins running out of the hole.

7. Install the plugs, and repeat the procedure for the other side.

130

LUBRICATION

EVERY 250 HOURS LUBRICATE THE ATTACHMENT COUPLER LATCH HANDLE

CHECKING THE DRIVE CHAIN TENSION Check the tension of the four drive chains after the first 250 hours of operation on a new machine or if new chains have been installed.

1. Lower the loader lift arms to the ground. Turn the key switch to OFF and stop the engine.

1

2. Use a jack or hoist and lift the machine. Install blocks under the machine.

BP96N083

1. ATTACHMENT COUPLER LATCH WEDGES (1 EACH SIDE)

Grease the attachment coupler latch wedges. Use Molydisulfide Grease.

BS04H104X

3. Rotate each tire and check for allowable movement. 0 mm to 6 mm (0 to 1/4 in).

4. If the chains need adjustment see page 152.

131

LUBRICATION

Every 250 Hours CHECK THE BATTERY FLUID LEVEL AND CLEAN THE TERMINALS WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Seek medical attention immediately. EYES: flush with water for 15 minutes and get prompt medical attention. 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. M144B

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 (-) 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.

SB034

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.

SA033

WARNING: Before working on any part of the electrical system, disconnect the battery ground cable. Do not connect cable until all electrical work has been completed. This will prevent shorts or electrical shocks.

M198A

WARNING: DO NOT weld on this machine. (See your dealer for repairs).

Danger of explosion exists which can result in injury or death.

M478

132

LUBRICATION

Every 250 Hours If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

IMPORTANT: If the temperature is 0° C (32° F) or below and you have added water to the battery, do the following: Connect a battery charger to the battery or run the engine for approximately two hours.

This procedure is necessary to mix the water with the electrolyte.

Cleaning The Battery Check the battery every 250 hours for dirt, corrosion and damage. Dirt, mixed with electrolyte or moisture on the top of the battery, can cause a discharged condition in the battery. Use one of the following methods to clean the battery.

1. Use Case Battery Saver, part n u m b e r M 2 0 3 7 6 . Fo l l o w t h e instructions on the container. This cleaner does not need water.

2. Use baking soda or ammonia and flush the outside of the battery with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

Remove the left hand floor plate.

3. Spray the battery terminals with battery terminal protector. Do not use grease.

1

BD04N042

1. BATTERY

Clean the battery and surrounding area to reduce the risk of contamination before removing the battery caps.

2

BD04C043

2. BATTERY FILL (ONE OF SIX)

133

LUBRICATION

Every 250 Hours RADIATOR COOLANT LEVEL

DRAIN WATER FROM THE Every 250 hours check the radiator FUEL FILTER c o o l a n t l eve l w h e n t h e e n g i n e i s stopped and the coolant is cold.

Drain the water from the fuel filter after every 250 hours of operation.

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

Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance instructions.

1

BD04N055

1. FUEL FILTER DRAIN VALVE

SA023

Turn the drain valve on the fuel filter counterclockwise 2 or 3 turns and drain the water from the fuel filter.

1

BD04B097

1. RADIATOR CAP

Open the rear doors and remove the radiator cap. The coolant level must be up to the radiator cap opening.

NOTE: Only add the correct mixture of 50% ethylene glycol and 50% water to the radiator.

134

LUBRICATION

Every 250 Hours Final Drive Fluid Check Check the fluid in each final drive motor every 250 hours of operation.

Specification..... Case 135H EP 80W90 NOTE: Use 80W90 when temperatures are 35° C (95° F) or below.

Use 85W-140 when temperatures are 35° C (95° F) or above.

BD05H005

1. CHECK/FILL AND DRAIN PLUG IN THE CHECK POSITION

Park the machine on firm, level ground with the side to be checked in the position shown above. Clean around the plugs to help eliminate the risk of contamination.

Remove the check/fill and drain plug slowly. Oil should be just running out of the hole.

Add oil if necessary and replace the plug.

Repeat the procedure for the other side.

135

LUBRICATION

EVERY 250 HOURS CHECKING THE CHAIN TANK LEVEL

CLEAN THE SPARK ARRESTING MUFFLER (IF Check the tension of the four drive EQUIPPED) chains after the first 250 hours of operation on a new machine or if new chains have been installed.

This procedure should be performed ever y 250 hours of operation and requires two people.

1. Stop the engine.

1. Park on level, firm ground.

2. See the procedure on page 100 and tilt the ROPS forward to access the engine compartment.

1

3. Remove the plug from the bottom of the muffler.

4. Apply the parking brake and disconnect the wire to the injection pump solenoid on the engine.

BD04N079

1. CHAIN TANK OIL LEVEL PLUG

2. Remove the oil level plug.

The oil level should be within 1/8 inch of the bottom threads of the check plug hole.

5. Be sure to wear face protection for this step. Have another person hold a block of wood over the muffler outlet.

6. Turn the key switch to START for approximately 30 seconds.

7. Turn the key switch to OFF. 8. Connect the wire to the injection pump solenoid and install the plug in the muffler.

If required, add 10W30 oil.

3. Replace the oil level plug.

9. Return the ROPS to the operating position.

136

LUBRICATION

EVERY 500 HOURS Replace the Fuel Filters

3. Remove the rubber seal from the stud on the filter head.

Replace the in-line and primary fuel filter: ●

Every 500 hours or operation

●

If the engine is hard to start

●

If the engine lacks power.

4. Use a cloth and clean the gasket surfaces of the filter body.

NOTE: Remove the primary filter first for easier access to the in-line filter.

3 2

1 3 A_FIL_IN

3. QUICK CONNECTORS (3) 430 AND 440

BD04B082

NOTE: Primary fuel filters for the 430 and 440 are slightly larger but remain in the same location as the 410 and 420.

1. IN-LINE FUEL FILTER (410 SHOWN)

1. Clean the area around both filters before proceeding.

5. Depress the buttons on the sides of the connectors, on both sides of the in-line filter (2) and remove the filter for the 430 and 440.

6. Install the new in-line fuel filter.

Make sure the arrow on the filter is p oin tin g towa rd th e f ue l ha nd primer.

2

7. Apply clean engine oil to the new rubber seal.

8. Install the rubber seal on the primary filter head stud.

BD04N055

2. PRIMARY FUEL FILTER (410 SHOWN)

2. Use a strap wrench and turn the primary filter (2) counterclockwise to remove.

137

9. Apply clean oil to the gasket of the new filter. Do not fill the new filter with fuel before installation.

LUBRICATION 10. Turn the filter clockwise onto the filter body until the filter gasket makes contact with the filter body.

Continue to tighten the filter with your hand for 1/2 to 3/4 turn.

IMPORTANT: Do not use a strap wrench to tighten the filter.

11. Fill the fuel tank.

3

FAN BELT TENSION The Fan Belt should be checked for proper tension after the first 20 hours of operation on a new machine or new belt installation. Check for tension, wear or damage every 500 hours.

410 - 420: Depress the belt at center between the crankshaft pulley and the alternator pulley. With a force of approximately 5 kg (2.27 lbs.) the deflection should be 5 mm (0.2 inch).

430 - 440: Check the belt using the deflection method 1/4 inch at mid span between alternator and fan pulleys.

Used belt ......................... 23 = or - 1 lbf New belt .......................... 26 = or - 1 lbf

BD04C112

4. AIR REMOVAL SCREW

12. Loosen the air removal screw on the top of the fuel filter head.

13. Actuate the hand primer plunger up and down. When fuel comes out free of air, tighten the air removal screw.

14. Start the engine and check for fuel leaks around the fuel filter.

138

LUBRICATION

Every 500 Hours CHANGE THE ENGINE OIL AND FILTER

5. Turn the filter counterclockwise to r e m o ve . D i s p o s e o f t h e f i l t e r properly.

The 500 hour oil and filter change interval is based on Case No. 1 oil.

6. Use a clean cloth and wipe the sealing surface of the oil filter base to remove all dirt.

NOTE: For more complete removal of foreign material, change the engine oil while the engine is still warm, not hot from operation.

7. Apply a thin layer of clean grease or oil to the gasket of the new filter.

8. Put new oil into the engine oil filter.

IMPORTANT: The recommended oil change frequency is increased to 250 hours if diesel fuel with a sulphur content of more than 0.5% is used.

Change the engine oil more frequently when the engine operating conditions are severe (frequent stopping and star ting and high or low engine temperatures).

1. Before draining the oil, have a suitable container that will hold 12.0 litres (4.0 U.S. gallons).

9. Turn the new oil filter clockwise onto the base until the gasket m a ke s c o n t a c t w i t h t h e b a s e.

Continue to tighten the filter with your hand until tight.

IMPORTANT: DO NOT use a filter strap wrench to install the oil filter. An oil filter strap wrench can cause a leak if the filter is dented or overstressed.

10. Install the drain plug. Tighten to a torque of 68 to 82 Nm (50 to 60 pound-feet).

11. Install the correct type and quantity of oil. See page 120.

12. Start the engine and run at low idle speed. Check the engine oil filter and drain plug for leaks. After two minutes, stop the engine, wait for 2 or 3 minutes, and check the engine oil level again.

1

BD04N093

1. ENGINE OIL DRAIN PLUG ACCESS COVER

2. Remove the engine oil drain plug access cover.

3. Put a suitable container under the drain plug. Remove the engine oil drain plug.

13. Install the engine oil drain plug access cover.

IMPORTANT: Dispose of the oil in accordance with the local regulations.

DO NOT drain onto the ground or into a drain.

Be responsible for the environment.

4. To remove the engine oil filter, tilt the operators compar tment forward, see page 108.

139

LUBRICATION

Every 500 Hours HYDRAULIC OIL FILTER REPLACEMENT The Hydraulic Oil Filter should be replaced ever y 500 hours or if the warning lamp illuminates. The hydraulic filter is located on the left-hand side of the chassis.

1

WARNING: BURN HAZARD: Do not service the hydraulic system until the temperature of the oil is below 49° C (120° F).

M477

1. Remove the attachment and secure the loader lift ar ms for service as described on page 111.

2. Shut the engine off and remove the key.

3. Clean the area around the filler cap and hydraulic filter with cleaning solvent.

4. Turn the filler cap 1/2 turn to relieve the pressure in the reservoir. Do not remove the filler cap.

140

BD04N061

1. HYDRAULIC FILTER

5. To remove the filter, turn counterclockwise. Dispose of the filter properly.

6. Apply a thin layer of clean grease or oil on the O-ring of the new filter.

7. Install the filter. Hand tighten the filter 35 ft lb or 2/3 turn after the filter O-ring touches the filter head.

LUBRICATION

Every 500 Hours Final Drive Oil Change Drain and replace the oil in the final d r i ve m o t o r s eve r y 5 0 0 h o u r s o f operation or once a year.

Specification ... Case 135H EP 80W90 IMPORTANT: If operating in muddy conditions for 20 hours or more, the oil change interval should be shortened by 50 per cent.

4. Position the machine to place the check/fill and drain plug into the position shown below.

3

NOTE: Use 80W90 when temperatures are 35° C (95° F) or below.

Use 85W-140 when temperatures are 35° C (95° F) or above.

1. Place the machine on firm, level ground with the final drive to be drained in the position shown below. Clean around the plugs and make sure there is no contamination during the procedure.

2 1

BD05H004

1. CHECK/FILL AND DRAIN PLUG IN THE DRAIN POSITION 2. SIDE PLUG

2. Slowly remove the drain plug and drain the oil into a suitable container.

3. Slowly remove one of the side plugs to vent and aid in draining.

141

BD05H010

3. CHECK/FILL AND DRAIN PLUG IN THE CHECK/FILL POSITION

5. Fill with oil until it begins running out of the hole.

6. Install the plugs and repeat the procedure for the other side.

LUBRICATION

EVERY 1000 HOURS Change Hydraulic Reservoir Oil

Drain Water and Sediment from the Fuel Tank

2

1

2. FUEL TANK DRAIN PLUG (RIGHT REAR)

1. HYDRAULIC OIL RESERVOIR DRAIN PLUG (LEFT REAR)

1. Place the machine on a firm, level surface.

2. Clean the area around the drain plug.

3. Remove the plug and drain the oil into a suitable container.

4. Install the drain plug.

5. Refill the reservoir and apply clean oil to the filler cap seal before installing.

6. Start the engine and run at low idle for approximately 2 minutes.

7. Stop the engine and check for leaks.

WARNING: FIRE HAZARD: Do not smoke while filling the hydraulic reservoir. Do not fill near open flames.

1. Place the machine on a firm, level surface.

2. Clean the area around the drain plug.

3. Loosen the plug at the bottom of the fuel tank, located under the right rear side of the machine.

4. Turn the plug slowly counterclockwise until water starts to drain.

5. Once fuel begins to drain tighten the plug.

WARNING: Engine fuel is flammable and can cause a fire or explosion. Do not fill the fuel tank or service the fuel system near and open flame, welding, burning cigars, cigarettes, etc.

SA022

M476

142

LUBRICATION

EVERY 1000 HOURS Check Engine Valve Clearances

1

The valves should be checked for proper tolerance. See the Ser vice Manual for this machine or contact your Dealer.

Change the Chain Tank Oil The chain tank oil should be changed every 1000 hours of operation.

2

1. Park the machine on a firm level surface.

BD04N078

1. DRIVE CHAIN TANK INSPECTION COVER (ONE EACH SIDE) 2. OIL LEVEL PLUG (ONE EACH SIDE)

7. Level the machine.

8. Remove the oil level plugs.

1

9. Fill each chain tank with oil until it just begins to flow out of the oil level orifice.

10. Install the oil level plug.

1. RIGHT SIDE CHAIN TANK DRAIN PLUG (ONE EACH SIDE) 450 SHOWN

2. Clean the area around the drain plugs and inspection covers.

NOTE: Use an approved sealant between the inspection cover and the chassis if the inspection cover is removed.

3. Use a jack to raise the front of the machine to aid draining.

4. Remove the drain plug from each compartment.

5. Wearing proper safety gear, clean each chain tank compartment with an approved solvent.

NOTE: If chain adjustment is required at the same time as oil change, remove the inspection covers to flush/dry the chain tank components.

6. Install the drain plug.

143

LUBRICATION

EVERY 1000 HOURS Cab Filter

Cleaning with compressed air:

The cab filter should be checked every 1000 hours of operation. Inspect, clean or replace the filter as necessary. In extreme wor k conditions the filter should be checked and cleaned more frequently.

●

You must wear face protection for this procedure.

●

You must not use more than 2 bar (30 psi) of compressed air.

●

You must not hold the nozzle closer than 25 mm (1 inch) from the filter.

A

1

1

A_CAB _FIL

1. CAB FILTER THUMBSCREWS

BS99K083

To access the cab filter remove the two thumbscrews.

2

A_FIL

2. CAB FILTER

R e m o ve a n d c h e c k t h e f i l t e r fo r damage, debris or dirt.

144

LUBRICATION

EVERY 2000 HOURS Change Engine Coolant

5. Fashion a flat funnel to direct coolant above the bumper into a suitable container. Place the funnel in position under the radiator drain plug.

Drain, flush, and refill the engine coolant every 2000 hours of operation or each year, whichever occurs first.

6. Remove the radiator drain plug.

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

Scalding can result from fast removal of radiator cap.

Check and service the engine cooling system according to maintenance instructions.

7. After the coolant is removed, install the radiator drain plug.

8. Add cleaning solution to the cooling system and fill the cooling system w i t h c l e a n w a t e r. Fo l l o w t h e directions included with the cleaning solution.

9. After you drain the cleaning solution, flush with clean water.

10. Check the hoses, elbows and water pump for leaks.

SA023

1. Place the machine on firm, level ground and block the rear tires.

2. Raise the front of the machine and place 6 inch blocks under the front tires.

3. After the system is cool, remove the radiator cap.

11. Make sure that the outside of the engine and radiator is clean.

12. Remove the blocks from under the front tires and lower the machine to the ground.

13. Fill the cooling system until the coolant level is up to the top of the radiator cap opening and install the radiator cap.

14. Fill the coolant reservoir up to the FULL mark on the reservoir.

BD04B092

15. Start the engine and increase the temperature of the engine coolant.

When the coolant is at operating temperature, stop the engine and allow to cool. Check the coolant level at the coolant reservoir only.

Do not remove the radiator cap.

1. RADIATOR DRAIN VALVE

4. Release the top radiator latch and pull the bottom of the radiator rearward into the detents.

16. Dispose of drained coolant responsibly. Do not pour on ground or down drain.

145

LUBRICATION

EVERY 2000 HOURS Engine Air Filters

2

Replace the air filter elements every 2000 hours of operation or: ●

If the Air Filter Restriction Indicator Lamp illuminates.

●

The filters have been in the machine for one year.

3

BD05A007

2. FILTER COVER LATCH 3. FILTER INSTRUCTIONAL DECAL

2. Pull the filter cover latch out and turn the filter cover counterclockwise to remove. (See the decal on the cover).

1

3. Clean the inside of the filter cover and the dust valve.

4 BD04F074

1. ENGINE AIR FILTER WARNING LAMP

IMPORTANT: It is recommended to NOT remove the filter elements to check for restriction.

If the air filter lamp illuminates when the engine is running you must service the air filter elements.

1. Place the machine on firm, level ground with the lift arms down on the ground.

146

BD05A008

4. PRIMARY FILTER

4. Remove the primary filter.

LUBRICATION

5

BD05A009

BD04C060

5. SECONDARY FILTER

9. Install the filter cover with the filter cover latch at the TOP position, as indicated on the end of the cover and secure the latch.

5. Remove the secondary filter.

IMPORTANT: When installing the filters make sure the seals are making proper contact.

6

BD05A010

6. AIR FILTER HOUSING

6. Clean the filter housing before installing the new filters.

7. Install a new secondary filter.

8. Install a new primary filter.

147

LUBRICATION

NOTES

148

ADJUSTMENT/MAINTENANCE STEEL TRACK ADJUSTMENTS (IF EQUIPPED) Checking The Track Sag If the tracks become loose or are too tight, adjustment is required. Use the following procedure to maintain the proper track tension.

1. Check the existing track tension by measuring the track sag.

A. Place a straight edge between the tires resting on the highest point above each tire.

1

2

C. If the tracks are too tight or too loose adjustment will be necessary. See “Track Length Adjustment”.

Track Length Adjustment Use the following chart to determine the proper track length adjustment based on the length that needs to be removed or added.

IMPORTANT: Always wear face protection when adjusting the track length.

ADJUSTMENT CHART

BI97C129

1. STRAIGHT EDGE 2. 25 MM (1 IN) T0 75 MM (3 IN)

B. Measure the distance between the lower side straight edge and t h e t o p o f t h e t r a ck p a d t o determine the amount of track sag. Allowable track sag should be between 25 mm (1 in) to 75 mm (3 in).

Move 1 Hole

=

20.6 mm (.81 in)

Move 2 Hole

=

41.2 mm (1.62 in)

Move 3 Hole

=

61.7 mm (2.43 in)

Move 4 Hole

=

82.6 mm (3.25 in)

Move 5 Hole

=

103.1 mm (4.06 in)

Move 6 Hole

=

123.7 mm (4.87 in)

Move 7 Hole

=

144.3 mm (5.68 in)

Move 8 Hole

=

165.1 mm (6.50 in)

Move 9 Hole

=

185.7 mm (7.31 in)

Move 10 Hole

=

206.2 mm (8.12 in)

Move 11 Hole

=

2266.8 mm (8.93 in)

Move 12 Hole

=

247.7 mm (9.75 in)

1. Center the binder or come-along between the tires.

1

NOTE: Operating with the tracks too tight could result in damage to the tires, track or loader.

NOTE: Always maintain the correct tire pressure when tracks are being used.

BI97C128

1. BINDER

149

ADJUSTMENT/MAINTENANCE 2. Tighten the binder or come-along to relieve the tension in the area where the track link adjustment is to be made.

1

2

3. Remove the track link bolt.

4. If the track needs to be shortened move the link to the outer holes.

BI97C129

1. STRAIGHT EDGE 2. TAKE TRACK SAG MEASUREMENT HERE

1

8. If the track sag is still not correct repeat steps 1 through 7 in a different location.

2

9. Repeat the procedure on opposite side of the machine.

BI97C127

1. LENGTHENS TRACK 2. SHORTENS TRACK

10.

5. If the track requires lengthening use the inner holes.

6. Install the track link bolt and tighten to 95 to 114 Nm (70 to 84 ft. lbs.).

7. Remove the binder or come-along and remeasure the track sag.

150

the

ADJUSTMENT/MAINTENANCE

ADJUSTING THE HAND THROTTLE

1

2

If the hand throttle lever becomes loose o r i s t o o s t if f, a d ju s t m e n t w i ll b e required.

1. Remove the attachment and secure the loader lift ar ms for service as described on page 101.

2. Tilt the cab for service as described on page 109. ● ●

The throttle lever may be in any working position during adjustment.

BD05A084X

2. Tighten the inside jam nut (1) to provide lever effort of 50 ± 10N.

Measure the setting by pushing the lever from low to high.

1 2

●

The lever effort should be measured at the top of the lever.

●

The lever effort should be taken moving the lever from low to high.

3. When the lever effort is correct, tighten the outside jam nut (2) while holding inside jam nut (1).

4. Lower the cab back into operating position.

5. With the help of another person store the support strut.

BD05A084

VIEW OF THROTTLE PIVOT BOLT LOOKING FORWARD 1. INSIDE JAM NUT 2. OUTSIDE JAM NUT

1. Loosen the outside jam nut (2).

151

ADJUSTMENT/MAINTENANCE

Adjusting the Drive Chain Tension 1. Lower the bucket or attachment to the ground and stop the engine.

2. Use a jack or hoist and lift the machine. Install blocks under the machine as shown. Raise loader lift arms and engage support strut. Remove the wheels.

3. Clean the area around each axle housing.

1

1

BD01C274X

1. AXLE HOUSING

BD01C265X

BD01C267X

4. Loosen the axle housing mounting nuts so the axle is free to move forward or rearward.

5. Wear eye protection and tap the axle housing outward with a brass hammer until it stops moving.

6. Tighten two nuts to hold the axle housing in place. 7 Nm (5 lb ft)

152

ADJUSTMENT/MAINTENANCE 12. Tighten the axle housing mounting bolts to a torque of 223 to 265 Nm (165 to 190 pound-feet).

13. Install the four wheels.

If the machine is equipped with stamped center wheels, the lug nuts will be tapered type lug nuts.Tighten each lug nut to a torque of 135 to 163 Nm (100 to 120 pound-feet).

BS04H104X

7. Reinstall the wheel with two lugnuts, and recheck the chain deflection. Deflection should be 0 to 6 mm (0 to 1/4 in).

If the machine is equipped with solid center wheels, the lug nuts will be flange type lug nuts.Tighten each lug nut to a torque of 224 to 265 Nm (165 to 195 pound-feet).

8. Repeat the above steps for the remaining drive chains.

9. Following adjustment of all drive chains, start the engine and run at low idle.

10. Move the control levers all the way forward for five seconds. Stop the engine.

11. If required, tighten or loosen the drive chains to get the correct deflection.

BD01C268

14. Remove the blocks or stands and lower the machine to the floor.

NOTE: If axle housings are at extreme outward positions and chain adjustment is not correct, the drive chains and axle sprockets must be replaced.

153

ADJUSTMENT/MAINTENANCE

MAINTENANCE OF THE SEAT BELT 1. Check the seat belt for damage each time it is used. Replace all parts that are damaged.

2. Make sure that the mounting bolts of the seat belt are tight after every 500 hours of operation.

3. Keep the seat belt clean. Use only soap and water to wash the seat belt. Dye or other compounds can cause damage to the seat belt.

Torque Specifications For Seat Belt

1

1

1. TIGHTEN TO 52 TO 61 NM (38 TO 45 POUND-FEET)

BD04M004 / BD04M005

RIDE CONTROL ACCUMULATOR If the ride control accumulator must be replaced for any reason, it must be done by your Dealer.

154

ADJUSTMENT/MAINTENANCE

ROLL-OVER PROTECTION STRUCTURE Your machine has a roll-over protective structure (ROPS) which is also certified for falling object protection structure (FOPS). A ROPS/FOPS label is fastened to the structure. The label shows the serial number of the ROPS/FOPS, gross weight, approval, regulation, and model numbers of the machine.

ROPS Label

Seat Belt The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

Before you operate this machine, always make sure that the ROPS and Operators seat belts are correctly installed. See “Seat Belt Maintenance” on page 154.

Maintenance and Inspection of ROPS After the first 20 hours of operation and after every 500 hours of operation, do the following: 1. Check the operators seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See page 154. Replace parts that have wear or damage.

2. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, see your Case dealer.

155

ADJUSTMENT/MAINTENANCE

Damage to the ROPS If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transport), you must replace the damaged ROPS components to maintain as much protection as you had originally.

After an accident, check the following for damage: A. ROPS canopy and side screens.

B. Operators seat.

C. Seat belt mounting bolts and seat belt.

Before you operate the machine, replace all ROPS components that are damaged.

See the parts catalog or your Case dealer for components that are replaceable.

DO NOT TRY TO WELD OR STRAIGHTEN THE ROPS. WARNING: Do not modify 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 subjected to roll-over or damage. Do not attempt to repair.

SB026

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

SA028

WARNING: ALWAYS fasten the seat belt and pull the seat bar down before you start the engine. Make sure the buckle for the seat belt is fastened correctly.

SB030

156

ADJUSTMENT/MAINTENANCE

FIRE EXTINGUISHER Type of Fire Extinguisher

Inspection and Care

It is recommended that you have a fire extinguisher on your machine. This fire extinguisher shown below is available from your Case dealer and can be installed on the machine.

EVERY MONTH: It is recommended that you inspect the fire extinguisher once each month for damage and to i n s u r e t h a t t h e g a u g e i s wo r k i n g correctly.

ONCE EACH YEAR: Have the fire equipment representative inspect the fire extinguisher.

ONCE EVERY 6 YEARS: Have the dry chemical removed and refilled by a fire equipment representative.

ONCE EVERY 12 YEARS: Have the fire equipment representative hy d r o s t a t i c a l l y t e s t y o u r f i r e extinguisher.

B9409008

This dry chemical fire extinguisher has a 5 pound capacity and is approved for class A, B, and C type fires. The operating temperature is from -54° to 49° C (-65° to 120° F).

PLASTIC AND RESIN PARTS Avoid using gasoline, paint thinner, etc., when cleaning the windows, consoles, or any plastic or resin parts. Use only water, mild soap, and a soft cloth when you clean these parts.

Using gasoline, thinners, etc., can cause discoloration, cracking, or deformation of the part being cleaned.

157

ADJUSTMENT/MAINTENANCE

REMOVAL OF SLIDING SIDE WINDOWS (IF EQUIPPED) The sliding side windows may be removed for cleaning or replacement using the following procedure 1. Enter the operators compartment and slide the glass to the closed position.

2. Locate the slot on the top track near the rear end. Use a flat blade screwdriver to pry the inner track out and remove. Slide window back and lift bottom out of track.

Installing the Sliding Side Windows.

3. Lift up on the front of the glass while guiding it into the top channel. Slide the loose end of the flocked rubber still remaining on the glass into the channel and under the glass. If necessary, coat the end of the flocked rubber with soapy water. This will aid in sliding the flocked rubber into position.

Smooth out the flocked rubber and make sure the entire length is pressed into the channel.

4. Slide the glass to the closed position and install the rear piece of the flocked rubber in the same manner. Make sure both pieces of flocked rubber fit together end to end under the glass.

158

ELECTRICAL SYSTEM ALTERNATOR CHARGING SYSTEM Follow these general rules to prevent damage to the electrical system.

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 (-) battery cable first.

2.When you connect the battery cables, always connect the negative (-) battery cable last.

3.Do not short circuit the battery posts with metal items.

4.Do not weld, grind or smoke near a battery.

84-109

1. DO NOT make a reverse battery connection.

2. When you use an auxiliary battery for starting, connect negative to negative and positive to positive.

3. DO NOT use a battery charging machine to start the machine.

159

4. Never operate the machine when the battery cables are disconnected.

5. When you do maintenance on the engine, prevent foreign material from entering the alternator.

ELECTRICAL

BATTERY SERVICE WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Seek medical attention immediately. EYES: flush with water for 15 minutes and get prompt medical attention. 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. M144B

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 (-) 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.

SB034

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.

SA033

WARNING: Before working on any part of the electrical system, disconnect the battery ground cable. Do not connect cable until all electrical work has been completed. This will prevent shorts or electrical shocks.

M198A

WARNING: DO NOT weld on this machine. (See your dealer for repairs).

Danger of explosion exists which can result in injury or death.

M478

NOTE: The electrical system in this machine is 12 volts.

Do not run the engine with the battery cables disconnected or with the alternator wires disconnected.

160

ELECTRICAL

Battery Fluid Level Check the fluid level every 250 hours of operation.

If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

IMPORTANT: If the temperature is 0° C (32° F) or below and you have added water to the battery, do the following: Connect a battery charger to the battery or run the engine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

1

2

1. NEGATIVE BATTERY TERMINAL 2. POSITIVE BATTERY TERMINAL

BD04N042

Cleaning the Battery Check the battery every 250 hours for dirt, corrosion and damage. Dirt, mixed with electrolyte or moisture on the top of the battery, can cause a discharged condition in the battery. Use one of the following methods to clean the battery.

1. Use Case Battery Saver, part n u m b e r M 2 0 3 7 6 . Fo l l o w t h e instructions on the container. This cleaner does not need water.

161

2. Use baking soda or ammonia and flush the outside of the battery with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

3. Spray the battery terminals with battery terminal protector. Do not use grease.

ELECTRICAL

WORK LAMPS 1. To replace a bulb, shift the work lamp to one side depressing the spring retainer and lift the opposite side of the work lamp out of the ROPS frame.

BP96N049

4. Use tissue paper to hold the new bulb while installing it into the bulb socket. Grease and oil from your skin will shorten the bulb life.

5. Install the bulb socket in the back of the lamp assembly.

BP96N050

2. Rotate the electrical connector and bulb socket on the back of the lamp assembly 1/4 turn.

6. Install the lamp assembly into the RO P S f r a m e by i n s e r t i n g t h e SPRING CLAMP SIDE FIRST and depressing the spring. The other side will then slide into the ROPS frame.

Rear Work Lamp

BP96N048

3. Remove the bulb from the bulb socket and discard.

BD01C121

To replace the rear work lamp, open the rear access door and rotate the bulb socket assembly 1/4 turn. Remove the bulb from the socket. Install new bulb.

162

ELECTRICAL

TAIL LAMPS To replace the tail lamps use the following procedure.

3. Remove the lens cover. Remove the bulb and discard.

BD01C123

BD01C125

1. Remove the two screws which secure the lens cover to the tail lamp assembly.

4. Use tissue paper to hold the new bulb while installing it into the bulb socket. Grease and oil from your skin will shorten the bulb life.

2. Disconnect the wiring harness from the terminals on the back of the tail lamp assembly.

5. Install the lens cover.

6. Connect the wire harness to the terminals on the back of the tail lamp assembly.

7. Install the tail lamp assembly in the door with the two screws.

BD01C124

163

ELECTRICAL

Auxiliary Front Electric Controls (If Equipped) Auxiliary front electric control connector (if equipped) is located on the left loader lift arm at the front of the machine. Both of the auxiliary switches in the switch panel and the rocker switch on the right control handle power functions on the front electrical connector. Consult your dealer to identify which pins in the connector are controlled by each switch.

Accessory Power Outlet (If Equipped) The accessory power outlet (if equipped) is located on the lower left side of the operators compartment side panel. The accessory power outlet can provide power for operator convenience items.

1

BD04N073

1. ACCESSORY POWER OUTLET (IF EQUIPPED)

164

ELECTRICAL

FUSES AND RELAYS The fuses protect the electrical circuits. Switch off the power to a circuit before replacing a fuse. Make sure you install a fuse of the correct value when replacing a fuse.

The fuses and relays are located on the left side of the operator under the cover between the seat and the side of the ROPS. Use the thumbscrew to access these fuses and relays. See the fuse decal located under the cover.

BD04N050

165

ELECTRICAL Fuse Box Decal

1

5

2

6

3

7

4

8

9

13

10

14

11

15

12

16

17

373247A2

Location

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

AMP

Front Elec Pwr / Accessory H Vac Hazard And Optional High Flow Hydraulic Coupler / Beacon Lights Relay Wiper Inter lock / Inst Cluster Horn / Backup Inter Lock Relay Main Pwr Relay Starter Relay Work Road Light Relay Accessory Pwr Relay Aux Inter Lock / Fuel Shut Off Relay Aux Inter lock / Starter Relay Work Light / Road Light Relay Hazard Flasher

166

15 20 10 10 20 20 15 10

MACHINE STORAGE WARNING: Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in an enclosed space.

Always shield eyes when working near batteries.

SA031

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

STORAGE PREPARATION If the machine is to be in storage for more than 90 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

1. Prior to storing wash the machine.

2. Lubricate the machine at all grease fittings.

3. Paint any areas where the paint has been damaged.

4. Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

5. Drain the fuel tank.

12. Cover the exposed cylinder rods, and valve spools and any other bare metal parts with Case Rust and Corrosion Preventive (Par t Number B17510).

13. Charge the battery. Remove the battery from the machine and put the battery on a wooden pallet in a cool dry area. If possible, keep the batter y in a building where the temperature is above freezing 0° C (32° F). Make sure the battery is clean.

6. Put approximately 8 litres (2.1 gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue-white.

14. Cover the exhaust outlet.

7. Drain the flushing oil from the fuel tank.

15. Do periodical checks for protection.

Look for corrosion.

8. Put 15 ml (5 oz or one teaspoon) of Shell Oil Company VPI crystals in the fuel tank.

NOTE: Check the battery periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the battery.

9. Change the engine oil and replace the oil filter.

10. Drain the cooling system. Leave the drain valves open and do not tighten the radiator cap. Put a Do Not Operate tag in the cab.

Chain Compartments

11. Clean or replace the air cleaner elements.

167

1. Drain and flush compartments.

both

chain

2. Put new oil compartment.

each

chain

into

MACHINE STORAGE

STORAGE REMOVAL 1. Fill the fuel tank.

2. Tighten the cooling system drain valves.

10. Prime the turbocharger oil lines w i t h o i l u s i n g t h e fo l l o w i n g procedure: A. Disconnect the electrical connector to the injection pump solenoid. This will prevent the engine from starting.

3. Put coolant into the engine cooling system.

4. Check the engine oil level.

B. Make sure all persons are clear of the machine. Turn the key switch to START and actuate the star ter for about 10 to 15 seconds.

5. Check the condition of the engine fan belt and replace it if required.

6. Check the hydraulic fluid level.

7. Use a petroleum base solvent and remove the Case Rust and Corrosion Preventive from the hydraulic cylinder rods and spools, etc.

8. Install a fully charged battery.

9. Remove air from the engine fuel lines.

C. Reconnect the wire to injection pump solenoid.

the

IMPORTANT: Before starting the engine, make sure there are no leaks, missing or broken parts.

11. Start the engine and run at idle speed for 2 minutes. Check for leaks around the filters and drain plugs.

12. Stop the engine and check the fluid levels of the engine cooling system and drive chain compar tments.

See the Engine Cooling System and Drive Chain Compar tment sections for the correct procedure on checking the fluid levels.

168

SPECIFICATIONS 410 ENGINE Make and model............................................................................... Case 422/M2 Aspiration ...................................................................................................Natural Firing order .......................................................................................... 1- 3 - 4 - 2 Bore ........................................................................................... 84 mm (3.30 in) Stroke......................................................................................... 100 mm (3.93 in) Displacement ................................................................. 2.2 L (134 cubic inches) Compression ratio ....................................................................................... 22.4:1 Gross Bare Engine Power SAE net.............................................. 35 kW at 2585 r/min (47 hp at 2585 rpm) SAE gross .......................................... 37 kW at 2585 r/min (49 hp at 2585 rpm) Engine speeds High Idle, no load ........................................................................ 2735 ± 10 rpm Rated speed - full load ....................................................................... 2585 rpm Low Idle ...................................................................................... 1050 ± 50 rpm

420 ENGINE Make and model.............................................................................Case 422T/M2 Aspiration ..................................................................................................... Turbo Firing order .......................................................................................... 1- 3 - 4 - 2 Bore ........................................................................................... 84 mm (3.30 in) Stroke......................................................................................... 100 mm (3.93 in) Displacement ................................................................. 2.2 L (134 cubic inches) Compression ratio ....................................................................................... 22.4:1 Gross Bare Engine Power SAE net.............................................. 40 kW at 2600 r/min (54 hp at 2600 rpm) SAE gross .......................................... 43 kW at 2600 r/min (57 hp at 2600 rpm) Engine speeds High Idle, no load ..................................................................2850 -80 + 50 rpm Rated speed - full load ....................................................................... 2600 rpm Low Idle ...................................................................................... 1050 ± 50 rpm NOTE: All specifications are given according to SAE standards or Recommended Practices where the specification applies.

169

SPECIFICATIONS

430 ENGINE Make and model .............................................................................. Case 445/M2 Aspiration ................................................................................................... Natural Firing order ......................................................................................... 1- 3 - 4 - 2 Bore ......................................................................................... 104 mm (4.09 in) Stroke......................................................................................... 132 mm (5.20 in) Displacement ................................................................. 4.5 L (274 cubic inches) Compression ratio....................................................................................... 17.5:1 Gross Bare Engine Power SAE net............................................54.0 kW at 2100 r/min (72 hp at 2100 rpm) SAE gross...........................................58 kW at 2300 r/min (78 hp at 2100 rpm) Engine speeds High Idle, no load ........................................................................ 2200 ± 10 rpm Rated speed - full load ....................................................................... 2100 rpm Low Idle ...................................................................................... 1050 ± 50 rpm

440/440CT ENGINE Make and model ............................................................................. Case 445t/M2 Aspiration ......................................................................................................Turbo Firing order ......................................................................................... 1- 3 - 4 - 2 Bore ......................................................................................... 104 mm (4.09 in) Stroke......................................................................................... 132 mm (5.20 in) Displacement ................................................................. 4.5 L (274 cubic inches) Compression ratio....................................................................................... 17.5:1 Gross Bare Engine Power SAE net.........................................60.0 kW at 2100 r/min (80.0 hp at 2100 rpm) SAE gross...........................................65 kW at 2100 r/min (87 hp at 2100 rpm) Engine speeds High Idle, no load .........................................................................2200 ± 10 rpm Rated speed - full load ....................................................................... 2100 rpm Low Idle ......................................................................................... 1050 ± 50 rpm

170

SPECIFICATIONS

ELECTRICAL SYSTEM Alternator 430-440-440CT .............................................................................. 12 Volt, 95 Amp 410-420 .......................................................................................... 12 Volt, 55 Amp Battery (Standard)....................................................................... 12 Volt, 850 CCA Starter 430-440- 440CT .............................................................................. 12 Volt, 3.3 kW 410-420 ........................................................................................... 12 Volt, 2.0 kW Fuses Main Power Fuse Block Backup Alarm - Horn .............................................................................. 10 Amp RH Control - Turn Signals - Frt Aux. Elec Control High Flow - 2 Speed - Interlock System - Brake Light - Brake................ 10 Amp Wiper ...................................................................................................... 25 Amp Lights ...................................................................................................... 20 Amp Accessory Power Fuse Block Auxiliary Controls ................................................................................... 10 Amp Flasher/Rotating Beacon ........................................................................ 10 Amp Blower - AC ............................................................................................. 20 Amp Accessory Power Socket ....................................................................... 10 Amp Circuit Breakers Main Power Relay Feed ............................................................................ 40 Amp Accessory Power Relay Feed ................................................................... 40 Amp Key Switch Battery Feed ........................................................................... 15 Amp Relays Starter .......................................................................................... 12 Volt, 45 Amp System Power for Fuse Block 1 ................................................... 12 Volt, 45 Amp System Power Accessory for Fuse Block 2.................................. 12 Volt, 45 Amp Interlock System .......................................................................... 12 Volt, 45 Amp Front Work Lamps ..................................................................................... 50 Watt Rear Work Space Lamps ............................................................................ 50 Watt

171

SPECIFICATIONS

COOLING SYSTEM Radiator cap pressure............................................................... 89.6 kPa (13 psi) Thermostat ..................................................................................... 82° C (180° F) Opening range ...................................................... 83° to 95° C (181° to 203° F) Fully open ..................................................................................... 94° C (202° F)

HYDRAULIC SYSTEM Flow Rates 430-440-440CT Standard pump flow @ rated engine speed........................ 74.0 L/min - 19.6 gpm 440-440CT Optional high flow @ rated engine speed ............................. 123 L/min - 29.2 gpm 410-420 Standard pump flow @ rated engine speed........................ 65.5 L/min - 17.3 gpm 420 Optional high flow @ rated engine speed ............................. 110 L/min - 29.1 gpm

POWER TRAIN Drive Type ............................................................................................. Hydrostatic Drive Pump - Mechanical Control ....................................................Sauer-Danfoss Type ...................................................................................... Tandem Axial Piston Drive Pump - Pilot Control ........................................................................ Rexroth Drive Motor ................................................................................................. Rexroth Type ................................................................................................ Radial Piston Final Drive (wheel machine)..................................................... Sprocket and Chain Final Drive Chain Size 410-420 .................................................................................................. ASA 80HS 430-440 ................................................................................................ ASA 100HS Final Drive 440CT ........................................................ Single Reduction Planetary

BRAKES Brake Type ................................... SAHR (Spring Applied Hydraulically Released)

172

SPECIFICATIONS

TRAVEL SPEEDS Forward And Reverse 410/420 Single speed or Low range............................................ 0 to 7.4 kph (0 to 4.6 mph) High range........................................................................................................... na 430/440 Single speed or Low range ....................................... 0 to 10.1 kph (0 to 6.3 mph) High range................................................................. 0 to 16.4 kph (0 to 10.2 mph) 440CT Single speed or Low range............................................ 0 to 7.4 kph (0 to 4.6 mph) High range.................................................................. 0 to 10.9 kph ( 0 to 6.8 mph)

UNDERCARRIAGE 440CT Track adjustment ..........................................................................................Manual Frame .............................................................................................................. Rigid Length of track on ground .......................................................... 1436 mm (56.5 in) Track rollers per side ............................................................................................. 3 Front idler diameter ...................................................................... 350 mm (13.7 in) Rear idler diameter....................................................................... 290 mm (11.4 in) Track rollers and idlers sealed with duo cone face seals and permanently lubricated bushings.

173

SPECIFICATIONS

OPERATING WEIGHTS Basic Machine 410 ..................................................................................... 3494 kg (5498 pounds) 420 ..................................................................................... 2637 kg (5813 pounds) NOTE: Operating weight includes full fuel tank, 75 kg (165 pound) operator, 1524 mm (60 in) foundry/excavating bucket, mechanical attachment coupler, 10.00 x 16.5 tires and standard equipment.

430 ..................................................................................... 3047 kg (6718 pounds) 440 ..................................................................................... 3187 kg (7027 pounds) NOTE: Operating weight includes full fuel, 75 kg (165 pound) operator, 1676 mm (66 in) foundry/excavating bucket, mechanical attachment coupler, 12.00 x 16.5 tires and standard equipment.

440CT ................................................................................ 4043 kg (8915 pounds) NOTE: Operating weight includes full fuel, 75 kg (165 pound) operator, 1823 mm (72 in) foundry/excavating bucket, mechanical attachment coupler, 400 mm track.

SHIPPING WEIGHTS 410 .............................................................................................2279 kg (5025 lbs) 420 .............................................................................................2372 kg (5230 lbs) 430 .............................................................................................2783 kg (6135 lbs) 440 .............................................................................................2922 kg (6444 lbs) 440CT ........................................................................................3772 kg (8317 lbs) NOTE: Shipping weight includes 15.0 L (4 gal) fuel, no bucket and no operator.

174

SPECIFICATIONS

ADDITIONAL WEIGHTS FOR OPTIONAL EQUIPMENT 1524 mm (60 in) Buckets: Dirt / Foundry (Short Lip) ...............................................................122 kg (270 lbs) Low Profile Dirt (Standard Lip) .......................................................150 kg (330 lbs) Low Profile Heavy Duty ..................................................................200 kg (440 lbs) Low Profile Extended Dirt (Long Lip) .............................................163 kg (360 lbs) Utility / Light Material......................................................................159 kg (350 lbs) 1676 mm (66 in) Buckets: Dirt / Foundry (Short Lip) ...............................................................168 kg (370 lbs) Low Profile Dirt (Standard Lip) .......................................................181 kg (400 lbs) Low Profile Heavy Duty ..................................................................215 kg (474 lbs) Low Profile Extended Dirt (Long Lip) .............................................197 kg (434 lbs) 1829 mm (72 in) Buckets: Dirt / Foundry (Short Lip) ...............................................................177 kg (390 lbs) Low Profile Dirt (Standard Lip) ......................................................193 kg (425 llbs) Low Profile Heavy Duty ..................................................................227 kg (501 lbs) Low Profile Extended Dirt (Long Lip) .............................................216 kg (477 lbs) Utility / Light Material......................................................................197 kg (434 lbs) 1981 mm (78 in) Buckets: Dirt / Foundry (Short Lip) ...............................................................225 kg (495 lbs) Low Profile Heavy Duty ..................................................................239 kg (527 lbs) Low Profile Extended Dirt (Long Lip) .............................................228 kg (502 lbs) 2134 mm (84 in) Buckets: Utility / Light Material......................................................................225 kg (495 lbs)

175

SPECIFICATIONS

BUCKET CAPACITIES STRUCK CAPACITIES

SAE HEAPED CAPACITIES

m3 (ft3)

m3 (ft3)

Dirt / Foundry (Short Lip)

0.25 (8.7)

0.32 (11.5)

Low Profile (Standard Lip)

0.25 (8.7)

0.32 (11.5)

Low Profile Extended (Long Lip)

0.29 (10.3)

0.41 (14.3)

Utility / Light Material

0.45 (15.9)

0.56 (19.7)

Dirt / Foundry (Short Lip)

0.33 (11.6)

0.43 (15.2)

Low Profile (Standard Lip)

0.27 (9.7)

0.37 (13.2)

Low Profile Extended (Long Lip)

0.32 (11.2)

0.92 (32.5)

Dirt / Foundry (Short Lip)

0.36 (12.7)

0.47 (16.7)

Low Profile (Standard Lip)

0.30 (10.6)

0.41 (14.5)

Low Profile Extended (Long Lip)

0.35 (12.2)

0.50 (17.1)

Utility / Light Material

0.54 (19.0)

0.67 (23.7)

Dirt / Foundry (Short Lip)

0.39 (13.8)

0.52 (18.4)

Low Profile Extended (Long Lip)

0.37 (13.2)

0.53 (18.6)

0.63 (22.3)

0.79 (27.9)

TYPE 1524 mm (60 inch) Buckets

1676 mm (66 inch) Buckets

1829 mm (72 inch) Buckets

1981 mm (78 inch) Buckets

2134 mm (84 inch) Bucket Utility / Light Material

176

SPECIFICATIONS

410 - 420 OPERATING DATA AND DIMENSIONS A. Dump angle at maximum height D/F , LP , LPE ,Dirt Buckets ......................................................... 40 degrees B. Dump height, maximum D/F Bucket ......................................................................... 2270 mm (89.4 in) LP Dirt Bucket.................................................................... 2182 mm (85.9 in) LPE Dirt Bucket ................................................................. 2100 mm (82.7 in) C. Dump reach, maximum height D/F Bucket ........................................................................... 599 mm (23.6 in) LP Dirt Bucket...................................................................... 714 mm (28.1 in) LPE Dirt Bucket ................................................................... 809 mm (31.9 in) D. Overall operating height, max.

D/F Bucket ....................................................................... 3691 mm (145.3 in) LP Dirt Bucket.................................................................. 3833 mm (150.9 in) LPE Dirt Bucket ............................................................... 3961 mm (155.9 in) E. Overall height to top of ROPS w/ standard tires10 x 16.5.................................................... 1918 mm (75.5 in) F. Ground clearance To Bottom of Belly Pan .......................................................... 203 mm (8.0 in) G. Wheel base ......................................................................... 1046 mm (41.2 in) H. Overall length without Attachment ........................................ 2540 mm (100 in) J. Overall length with bucket on ground D/F Bucket ....................................................................... 3130 mm (123.2 in) LP Dirt Bucket.................................................................. 3278 mm (129.0 in) LPE Dirt Bucket ............................................................... 3401 mm (133.9 in) K. Clearance circle, front (without bucket)................................ 1222 mm (48.1 in) L. Clearance circle, front (with Attachment) 60 in (1524 mm) D/F Bucket.............................................. 1860 mm (73.2 in) 60 in (1524 mm) LP Bucket ............................................... 1991 mm (78.4 in) 60 in (1524 mm) LPE Bucket............................................. 2110 mm (83.1 in) M. Clearance circle, rear........................................................... 1463 mm (57.6 in)

177

SPECIFICATIONS

S

A

C

R P D B E

U

T F V

G H J

K

L

M

O N

Q

BC01E161 / BT97B194

178

SPECIFICATIONS

410 - 420 Operating Data And Dimensions N. Tread width with Standard Tires (10 x 16.5) ......................................... 1245 mm (49.0 in) O. Overall width with Standard Tires (10 x 16.5) ......................................... 1499 mm (59.0 in) P. Height to Bucket Hinge Pin - Fully Raised ......................... 2911 mm (114.6 in) Q. Bucket width Dirt / Foundry (short lip)........................................................ 1524 mm (60 in) Low Profile Dirt (standard lip) ............................................... 1676 mm (66 in) Utility / Light Material ............................................................ 1829 mm (72 in) R. Height to Bottom of Level Bucket W/Arm Fully Raised ...... 2725 mm (107.3 in) S. Maximum rollback with attachment full height ................................ 80 degrees T. Maximum rollback with attachment on ground................................ 32 degrees U. Rear departure angle...................................................................... 27 degrees V. Rear overhang ....................................................................... 900 mm (35.4 in)

179

SPECIFICATIONS

S

A

C

R P D B E

U

T F V

G H J J K

L

M

O N

Q

BS04M058 / BT97B194

180

SPECIFICATIONS

430 - 440 OPERATING DATA AND DIMENSIONS A. Dump angle at maximum height D/F , LP , LPE ,Dirt Buckets ......................................................... 39 degrees B. Dump height, maximum D/F Bucket ......................................................................... 2453 mm (96.6 in) LP Dirt Bucket.................................................................... 2365 mm (93.1 in) LPE Dirt Bucket ................................................................. 2286 mm (90.0 in) C. Dump reach, maximum height D/F Bucket ........................................................................... 541 mm (21.3 in) LP Dirt Bucket...................................................................... 658 mm (25.9 in) LPE Dirt Bucket ................................................................... 754 mm (29.7 in) D. Overall operating height, max.

D/F Bucket ....................................................................... 3870 mm (152.4 in) LP Dirt Bucket.................................................................. 4013 mm (158.0 in) LPE Dirt Bucket ............................................................... 4139 mm (163.0 in) E. Overall height to top of ROPS with 12x16.5 tires................. 1948 mm (76.7 in) F. Ground clearance To Bottom of Belly Pan .......................................................... 229 mm (9.0 in) G. Wheel base ......................................................................... 1095 mm (43.1 in) H. Overall length without Attachment ..................................... 2639 mm (103.9 in) J. Overall length with bucket on ground D/F Bucket ....................................................................... 3232 mm (127.2 in) LP Dirt Bucket.................................................................. 3376 mm (132.9 in) LPE Dirt Bucket ............................................................... 3503 mm (137.9 in) K. Clearance circle, front (without bucket)................................ 1278 mm (50.3 in) L. Clearance circle, front (with Attachment) 66in ( mm) D/F Bucket....................................................... 1949 mm (76.7 in) 66 in (mm) LP Dirt Bucket ................................................. 2080 mm (81.9 in) 66 in ( mm) LPE Bucket..................................................... 2196 mm (83.1 in) M. Clearance circle, rear........................................................... 1501 mm (59.1 in)

181

SPECIFICATIONS

S

A

C

R P D B E

U

T F V

G H J

L

K

K

L

M

O N

Q

BT97B194

182

SPECIFICATIONS

430 - 440 Operating Data And Dimensions N. Tread width with Standard Tires (12 x 16.5) ......................................... 1336 mm (52.6 in) O. Overall width with Standard Tires (12 x 16.5) ......................................... 1641 mm (64.6 in) P. Height to Bucket Hinge Pin - Fully Raised ......................... 3086 mm (121.5 in) Q. Bucket width Dirt / Foundry (short lip)........................................................ 1524 mm (60 in) Low Profile Dirt (standard lip) ............................................... 1676 mm (66 in) Utility / Light Material ............................................................ 1829 mm (72 in) R. Height to Bottom of Level Bucket W/Arm Fully Raised ...... 2901 mm (114.2 in) S. Maximum rollback with attachment full height ................................ 84 degrees T. Maximum rollback with attachment on ground................................ 32 degrees U. Rear departure angle...................................................................... 28 degrees V. Rear overhang ....................................................................... 930 mm (36.6 in)

183

SPECIFICATIONS

440CT OPERATING DATA AND DIMENSIONS

A. Overall operating height with foundry/excavating bucket - short lip........................ 3690 mm (143.3 in) with low profile bucket - standard lip................................ 3830 mm (150.9 in) with low profile extended bucket - long lip ....................... 3960 mm (155.9 in)

Height to: B. Bucket hinge pin ................................................................ 2910 mm (114.6 in) C. Top of rollover protective structure....................................... 1920 mm (75.5 in) D. Bottom of level bucket, loader arm fully raised .................. 2720 mm (107.3 in) E. Overall length without attachment - with coupler .................. 2540 mm (100 in) F. Overall length: with foundry/excavating bucket on ground ........................... 3130 mm (123.2 in) with low profile bucket on ground............................................ 3280 mm (129 in) with low profile extended bucket ............................................. 3400 mm (134 in) G. Dump angle at maximum height .................................................................. 40° H. Dump height - loader arm fully raised with foundry/excavating bucket.......................................... 2270 mm (89.4 in) with low profile bucket........................................................ 2180 mm (85.9 in) with low profile extended bucket........................................ 2100 mm (82.7 in) J. Dump reach - loader arm fully raised with foundry/excavating bucket ............................................... 630 mm (24.8 in)] with low profile bucket ............................................................. .740 mm (29.3 in) with low profile extended bucket ............................................. .840 mm (33.1 in) K. Maximum attachment roll back bucket on ground ....................................... 32° L. Maximum attachment roll back bucket at full height .................................... 80° M. Length of track on ground...................................................... 140 mm (56.5 in) P. Ground clearance To bottom of belly pan................................................................... 203 mm (8 in) Q. Angle of departure ....................................................................................... 27° R. Front clearance circle less bucket........................................ 1280 mm (50.3 in) S. Front clearance circle with 1.68 m (66 inch) bucket on ground foundry/excavating ................................................................ 1970 mm (77.5 in) low profile............................................................................... 2060 mm (81.2 in) low profile extended ............................................................... 2180 mm (85.8 in) T. Clearance circle rear ........................................................... 1420 mm (56.1 in) U. Track gauge - centerline to centerline.................................. 1300 mm (52.4 in)

184

SPECIFICATIONS

BS06A191 / BS06A192

185

SPECIFICATIONS

Operating Data And Dimensions Lift capacity to maximum height with Standard bucket per SAE J732 410 .......................................................................................... 1361 kg (3000 lbs) 420 .......................................................................................... 1588 kg (3500 lbs) 430 ...........................................................................................1815 kg (4000 lbs) 440 ............................................................................................ 1996 kg 4400 lbs) Rated Operating Capacity at 50% of Tipping Load 410 ............................................................................................ 681 kg (1500 lbs) 420 .............................................................................................794 kg (1750 lbs) 430 .............................................................................................907 kg (2000 lbs) 440 .............................................................................................998 kg (2200 lbs)

186

SPECIFICATIONS

MATERIAL WEIGHT MATERIAL

kg/m3

lbs/ft3

MATERIAL

kg/m3

lbs/ft3

Alum-Lump.

881

55

Oats

416

26

Pulverized

769

48

Peanuts - Shelled

280

17

Ashes

561-833

35-52

Peas

769

48

Bauxite

12021922

75-120

Peat - solid

753

47

Phosphate - Granular

1442

90

Beans

769

48

Potash

1089

68

Charcoal

368

23

Potatoes

769

48

Chips

288

18

Quartz - Granular

1762

110

Coal

1282

80

Rice

769

48

Coke -Lump Loose

8491009

53-63

Rye

705

44

Clay

368-513

23-32

Salt - Rock - Solid

2163

135

Sand & Gravel - Dry

1730

108

Concrete

13781778

86-111

Wet

2003

125

Copper Ore

1666

104

Sand - Foundry

1522

95

Corn - Shelled

673

42

Shale

1410

88

Cottonseed

401

25

Slag - Crushed

1121

70

Slate

2243

130

Earth -Dry Loam

9291089

58-68

Snow

15-50

Wet

16021666

100104

240801

Soybeans

743

46

Earth - Sand Gravel

1570

98

Sugar Beet Pulp Wet

561

35

Ensilage

577

36

Sugar - Raw

961

60

Granite

14901778

93-111

Sulphur - Lumpy

1330

83

Taconite

1714

107

Gravel - Dry

1522

95

Wheat

769

48

1906

119

Ice - Crushed

593

37

Iron Ore

2323

145

Limestone Loose Crushed

15381602

96-100

Wet

187

SPECIFICATIONS

TORQUE SPECIFICATIONS Use the following torques when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

108 to 132

12 to 15

5/16 inch

204 to 252

23 to 28

3/8 inch

420 to 504

48 to 57

7/16 inch

54 to 64

73 to 87

1/2 inch

80 to 96

109 to 130

9/16 inch

110 to 132

149 to 179

5/8 inch

150 to 180

203 to 244

3/4 inch

270 to 324

366 to 439

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

188

SPECIFICATIONS

Grade 8 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

7/16 inch

70 to 84

95 to 114

1/2 inch

110 to 132

149 to 179

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

3/4 inch

380 to 456

515 to 618

7/8 inch

600 to 720

814 to 976

1.0 inch

900 to 1080

1220 to 1465

1-1/8 inch

1280 to 1440

1736 to 1953

1-1/4 inch

1820 to 2000

2468 to 2712

1-3/8 inch

2380 to 2720

3227 to 3688

1-1/2 inch

3160 to 3560

4285 to 4827

Size

NOTE: Use thick nuts with Grade 8 bolts.

189

SPECIFICATIONS

Grade 10.9 Bolts, Nuts, and Studs

Grade 8.8 Bolts, Nuts, and Studs

10.9

8.8

Size

PoundInches

Newton metres

M4

24 to 36

3 to 4

M5

60 to 72

7 to 8

M6

96 to 108

11 to 12

M8

228 to 276

26 to 31

M10

456 to 540

52 to 61

M12

66 to 79

90 to 107

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Size

PoundInches

Newton metres

M4

36 to 48

4 to 5

M5

84 to 96

9 to 11

M6

132 to 156

15 to 18

M8

324 to 384

37 to 43

M10

54 to 64

73 to 87

M12

93 to 112

125 to 150

M14

149 to 179

200 to 245

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

M24

780 to 940

1050 to 1275

M30

1470 to 1770

2000 to 2400

M36

2580 to 3090

3500 to 4200

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

190

AFTER DELIVERY CHECK AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE Owners Name: Address: Dealers Name: Address: Machine Model Number:

Hourmeter Indication:

Machine Product Identification Number (P.I.N.): COOLING SYSTEM

GENERAL

Check the coolant levels.

Look for oil leaks and loose parts.

Check for leaks.

Check tire pressure.

FUEL SYSTEM

Tighten all hose clamps.

Check for leaks.

Check drive chain tension..

Drain water and sediment from fuel tanks.

Check wheel nut torque or Track Tension

ELECTRICAL SYSTEM

Check brake operation.

Check battery.

Check the control levers for correct operation.

Check operation of starter, alternator, and instruments.

Check operators seat bar for correct operation.

Check operation of all lamps.

SAFETY

LUBRICATION

Inspect the ROPS.

Lubricate all pivot points.

Check the safety decals and replace if necessary.

ENGINE Check condition of drive belt.

Check the operator restraint system.

Check engine oil level.

Check engine speed at idle and at full throttle.

Make sure the Operator’s Manual in in the manual storage box.

Service air cleaner.

Check the Operator Seat Presence Switch.

Check the restraint bar and interlock function.

HYDRAULIC SYSTEM Check the oil level.

Check pressure setting of main relief valve.

Replace the hydraulic oil filter.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature: Dealer Copy

191

192

AFTER DELIVERY CHECK AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE Owners Name: Address: Dealers Name: Address: Machine Model Number:

Hourmeter Indication:

Machine Product Identification Number (P.I.N.): COOLING SYSTEM

GENERAL

Check the coolant levels.

Look for oil leaks and loose parts.

Check for leaks.

Check tire pressure.

FUEL SYSTEM

Tighten all hose clamps.

Check for leaks.

Check drive chain tension..

Drain water and sediment from fuel tanks.

Check wheel nut torque or Track Tension

ELECTRICAL SYSTEM

Check brake operation.

Check battery.

Check the control levers for correct operation.

Check operation of starter, alternator, and instruments.

Check operators seat bar for correct operation.

Check operation of all lamps.

SAFETY

LUBRICATION

Inspect the ROPS.

Lubricate all pivot points.

Check the safety decals and replace if necessary.

ENGINE Check condition of drive belt.

Check the operator restraint system.

Check engine oil level.

Check engine speed at idle and at full throttle.

Make sure the Operator’s Manual in in the manual storage box.

Service air cleaner.

Check the Operator Seat Presence Switch.

Check the restraint bar and interlock function.

HYDRAULIC SYSTEM Check the oil level.

Check pressure setting of main relief valve.

Replace the hydraulic oil filter.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature: Owners Copy

193

194

INDEX A

F

Alternator Charging System .......... 159 Anti-Vandal Lockout ...................... 100 Attachment Coupler ........................ 91 Attachment Installation .................... 91 Auxiliary Front Electric Controls .... 164 Auxiliary Hydraulic Attachment Controls 68

Fire Extinguisher ........................... 157 Fluids and Lubricants .................... 115 Front Work Lamps Switch ............... 44 Fuel Gauge ..................................... 43 Fuel Handling Precautions .............. 20 Fuses ............................................ 165

B

Grease Fittings Attachment Coupler Latch Pin .. 119 Bucket Pivots ............................ 119 Loader Lift Arm ......................... 119

Battery Cleaning .................... 133, 161 Battery Fluid Level ........................ 161 Battery Service .............................. 160 Brake Specification ....................... 172 Bucket Installation ........................... 91

C Cab Door Latches ........................... 74 Case Hydraulic Attachment Coupler 94 Cold Weather Operation ................. 83 Components, Machine ...................... 8 Control Lever Left Hand .................................... 60 Controls Auxiliary Hydraulic Attachment ... 68 Operator Seat ............................. 72 Throttle ........................................ 65 Cooling System Specification ........ 172 Couplers Case Hydraulic Attachment ........ 94 High Flow Hydraulic .................... 71

G

H Hand Throttle Adjustment ............. 151 Hazardous Chemical Precautions ... 21 Hot Weather Operation ................... 84 Hydraulic Bypass ............................ 66 Hydraulic Bypass Control ................ 66 Hydraulic Pump Flow Rates .......... 172 Hydraulic System Specification ..... 172 Hydraulics High Flow Hydraulic System ....... 98 Hydrostatic Pump Serial Number ...... 7

I Inspection, Daily .............................. 77

J Job Site Operation .......................... 88

K

D Dimensions, Operating . 177, 179, 181, 183, 184, 186 Disabled Machine, Moving .............. 88 Drive Chain Tension, Adjusting ..... 152

Key Switch Run ............................................. 42 Start ............................................ 42 Stop ............................................. 42 System Power ............................. 42

E Engine Air Filter Warning Lamp ...... 45 Engine Hourmeter ......................... 113 Engine Oil Service Intervals .......... 120 Engine Serial Number ....................... 6 Environment .................................. 114

L Lamps Tail ............................................ 163 Work .......................................... 162 Loader Bucket Serial Number ........... 7 Loader Operation ............................ 89

195

Lubricants and Fluids .....................115 Lubrication Chart ............................118

M Machine Components ........................8 Machine Operation ...........................87 Maintenance Chart .........................118 Maintenance Lubrication Schedule 113 Maintenance Precautions ................19 Material Weight Specification .........176 Material Weight Specifications .......187

O Official Justifying Documents .............3 Oil Temperature ..............................120 Viscosity .....................................120 Operating Data ......177, 179, 181, 183, 184, 186 Operating Dimensions ..177, 179, 181, 183, 184, 186 Operating Precautions .....................17 Operating Weight Specifications ....174 Operation Cold Weather ...............................83 Hot Weather .................................84 Job Site ........................................88 Loader ..........................................89 Operators Compartment Tilting .........................................108 Operators Compatment Lowering ....................................110 Operators Seat Deluxe ..........................................72 Optional Equipment Specification ..175

P Parking Brake Lamp ........................44 Plastic and Resin Parts ..................157 Power Train Specification ..............172 Product Identification Number ............6

R Radiator Coolant Level ..................134 Rear Access Door ..........................116 Relays ............................................165 Ride Control .....................................99

Accumulator .............................. 154 Roll-Over Protection Structure ...... 155 Damage .................................... 156 Inspection ................................. 155 Label ......................................... 155 Maintenance ............................. 155 ROPS Serial Number ........................ 6 Run-In Period .................................. 82

S Safety Decals .................................. 29 Safety, Decals, and Hand Signals Safety Rules ............................... 11 Safety/Decals/Hand Signals Safety Decals .............................. 29 Seat Belt Maintenance ............................. 154 Torque Specifications ............... 154 Seat Belt Precautions ...................... 23 Serial Number Engine ........................................... 6 Hydrostatic Pump ......................... 7 Loader Bucket ............................... 7 ROPS ............................................ 6 Starter ........................................... 7 Specific machine precautions ......... 24 Specifications Brakes ....................................... 172 Cooling System ......................... 172 Hydraulic System ...................... 172 Material Weight ................. 176, 187 Operating Weight ...................... 174 Optional Equipment .................. 175 Power Train .............................. 172 Tire Options .............................. 176 Starter Serial Number ....................... 7 Starting and Stopping Precautions .. 16 Starting the Engine .......................... 80 Steel Track Adjustments ............... 149 Storage Preparation ............................... 167 Removal .................................... 168 Switch Panel ................................... 47 Switches Battery Master Disconnect Switch ..

50

196

Front Work Lamps ...................... 44 Systemgard Lubrication Analysis Program .................................. 114

T Tail Lamps ..................................... 163 Throttle Controls Foot ............................................. 65 Hand ........................................... 65 Tire Inflating ..................................... 104 Pressure .................................... 104 Tire Option Specification ............... 176 Torque Specification Charts .......... 188 Track Length, Adjustment ............. 149 Track Sag, Checking ..................... 149 Transporting the Machine ............. 101 Travel Speeds ............................... 173

U Utility Safety .................................... 13 Utility Safety Rules Message .......... 13

W Warning Lamp Engine Air Filter .......................... 45 Wheel Nuts .................................... 105 Windows Removal of Sliding Side Windows ..

158 Work Lamps .................................. 162

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OM A4 Jaune Gabarit MM.qxd

31/10/2007

11:28

Page 1

Skid Steer 410, 420, 430, 440, 440CT

Operator's Manual 87739574 EN replaces 87643454 EN