Case 420 420CT 430 440 440CT SERIES 3 TIER 3 Skid Steer Operator's Manual 87493825 - PDF DOWNLOAD

OPERATOR’S MANUAL

SKID STEER 420 420CT 430 440 440CT SERIES 3 TIER 3

87493825 EUR Replaces 87718205 EUR

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

European English Part Number 87493825 EUR Printed in U.S.A. • Bur

Issued 01Jan 08 Revised 01Aug 08

OPERATOR’S MANUAL SKID STEER

420 420CT 430 440 440CT SERIES 3 TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01Aug 08 Printed in U.S.A. • Book/Form Number 87493825 EUR Copyright © 2008. CNH America, LLC. All Rights Reserved.

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

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer This unit first became available 01-2008 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01Jan 08

420, 420CT, 430, 440, 440CT Series 3 Tier 3 Skid Steer

87718205 EUR

Revision 1

01Aug 08

420, 420CT, 430, 440, 440CT Series 3 Tier 3 Skid Steer

87493825 EUR

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED. ● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. ● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ● The first panel indicates the nature of the hazard. ● The second panel indicates the appropriate avoidance of the hazard. ● Background color is YELLOW ● Prohibition symbols such as and STOP if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ❷ Is instructed in safe and proper use of the machine. ❷ Reads and understands the Manual(s) pertaining to the machine. ❷ Reads and understands ALL Safety Decals on the machine. ❷ Clears the area of other persons. ❷ Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

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

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

Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

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

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

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

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

TABLE OF CONTENTS GENERAL INFORMATION RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 CHAPTER 2 SAFETY, AND SAFETY DECALS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 CHAPTER 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 CHAPTER 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 LUBRICATION, FILTERS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 TILTING THE OPERATOR’S COMPARTMENT FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 FLUIDS AND LUBRICANT CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-3 6-3 6-9

CHAPTER 7 ELECTRICAL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 MATERIAL WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 CHAPTER 9 INDEX CHAPTER 10 AFTER DELIVERY CHECK - DEALER COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 AFTER DELIVERY CHECK - OWNERS COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

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General Information

Figure 1

BD08G013

440 SKID STEER

CNH AMERICA LLC P.O. Box 9228 Wichita, Kansas U.S.A. 67277

Figure 2 DEALER’S STAMP

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. The 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.

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.

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CHAPTER 1 - GENERAL INFORMATION This Skid Steer, with standard equipment and authorized attachments, is intended to be used for above ground material handling. This operators manual does not cover the use of attachments. See the operator manual provided with the authorized attachment or contact your Dealer if you have any questions about the operation of authorized attachments.

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.

This 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 your machine. Your dealer has Corporation 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 other languages.

OFFICIAL JUSTIFYING DOCUMENTS

VIBRATION TO THE OPERATOR

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

The level of vibration to the operator depends upon the conditions of the ground on which operations take place, the mode of operation of the machine and its equipment.

• Safety 98/37/EC Special Test Certificate

• Noise Level 2000/14/EC Electro-Magnetical compatibility 2004/108/EC G u a r a n t e e d S o u n d Po w e r L e v e l t o E . C .

Regulation Requirements Guaranteed Sound Power Level: All wheel models. . . . . . . . . . . . . . . . . . . . . . 101 dBA All track models . . . . . . . . . . . . . . . . . . . . . . 103 dBA Typical Operator Ear Levels: (Open Cab) 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 dBA 420CT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 dBA 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 dBA 440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 dBA 440CT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 dBA Typical Operator Ear Levels: (Cab w/side windows) 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 dBA 420CT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 dBA 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 dBA 440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 dBA 440CT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 dBA

The exposure to vibration may be considerably reduced when the following recommendations are complied with:

• Use equipment compatible with the machine and the type of work to be done.

• Adjust and lock the seat into the correct position.

Regularly inspect the suspension of the seat, performing the adjustment and repairs as required.

• Regularly perform the current maintenance operation of the machine at the prescribed intervals.

• Operate the equipment in a steady manner, avoiding, if possible, excessive loads.

quick

movements

or

• When traveling, avoid, if possible, particularly rough terrain or the impact against possible obstacles.

These machines are equipped with an operator’s seat complying with the requirements of standard ISO 7096:2000. This ensures that the exposure of the operator’s body to vibration complies with the protection requirement against vibration when the machine operates as required by the operational scopes, in accordance with the prescriptions of this manual.

• The weighted average quadratic acceleration value to which the operator’s arms are subjected does not exceed 2.5m/s².

• The weighted average quadratic acceleration value to which the operator’s body is subjected does not exceed 0.5 m/s² These results were obtained using an acceleration gauge while loading trucks.

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RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE 1

FRONT

Figure 3

BD07M275

1. OPERATOR’S MANUAL COMPARTMENT BEHIND SEAT BACK

LEFT

RIGHT

REAR Figure 4

BS01F013

BASIC MACHINE

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

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IDENTIFICATION NUMBERS Write your machine model number, Product Identification Number (P.I.N.) and serial numbers on the lines provided below. Always give these numbers and component plate 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 numbers to your local law enforcement agency.

MACHINE MODEL AND TYPE ...................................................................................................................................

PRODUCT IDENTIFICATION NUMBER .....................................................................................................................

YEAR OF BUILD (Euro Machines)..............................................................................................................................

ENGINE SERIAL NUMBER ........................................................................................................................................

HYDROSTATIC PUMP SERIAL NUMBER ..................................................................................................................

FINAL DRIVE MOTOR SERIAL NUMBER ..................................................................................................................

CONTROL VALVE SERIAL NUMBER.........................................................................................................................

1

3

Figure 5

BD08D164

1. ROPS (ROLL OVER PROTECTIVE STRUCTURE CERTIFICATION), FOPS (FALLING OBJECT PROTECTIVE STRUCTURE) LOCATED JUST INSIDE THE ROPS ON THE INSIDE RIGHT

Figure 7 3. PILOT CONTROL PUMP SERIAL PLATE LOCATION IS ON THE TOP OF THE PUMP

BD08E070

NOTE: Manual Servo Pump Plate is in the same area on Non Pilot Machines.

4 2

Figure 6 2. ENGINE SERIAL NUMBER IS LOCATED ON THE REAR OF THE ENGINE 420-430 MACHINES

BD08E069

Figure 8 4. PRODUCT IDENTIFICATION PLATE LOCATED INSIDE LEFT LOADER LIFT ARM MOUNT (LEFT OF EXHAUST STACK)

BD07N512

NOTE: 440 engine serial number plate is located to the rear of the engine also.

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7

5

Figure 11 7. BUCKET IDENTIFICATION PLATES ARE LOCATED ON THE LEFT REAR CORNER OF THE BUCKET Figure 9

BD08F023

5. FINAL DRIVE PLATE

Figure 10 6. FINAL DRIVE PLATE IS LOCATED ON THE BACKSIDE OF THIS MOTOR

BD08F021

NOTE: There are two styles of final drives.

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MACHINE COMPONENTS 2

1 3 4

7 6

8 5 Figure 12

BD08G014

1.

2.

3.

4.

OPERATOR’S COMPARTMENT REAR WINDOW UPPER REAR SERVICE DOOR LOWER REAR SERVICE DOOR

5.

6.

7.

8.

REAR TIE DOWN LOCATIONS LEFT SIDE LOADER LIFT CYLINDER LEFT SIDE LIFT ARM LOW PROFILE BUCKET Figure 13

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2

2

3 1

4

6 5

Figure 14

BD08G015

1. ROPS CAB 2. FRONT WORK LIGHTS 3. SIDE WORK LIGHT

4. LEFT FINAL DRIVE 5. LEFT TRACK TENSION ACCESS PANEL 6. LEFT AND RIGHT ATTACHMENT CYLINDERS Figure 15

2

3

1 4

6 5 5

5

Figure 16

BD08H503

TRACK COMPONENTS 420CT

1. FINAL DRIVE 4. FRONT IDLER WHEEL ( 1 EACH SIDE) 2. TRACK ADJUSTMENT ACCESS COVER ( 1 EACH SIDE) 5. TRACK ROLLER WHEELS (3 EACH SIDE) 3. RUBBER TRACK 6. REAR IDLER WHEEL ( 1 EACH SIDE) Figure 17

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Chapter 2 SAFETY, AND SAFETY DECALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 PROPER ENTRY AND EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 STARTING AND STOPPING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 FUEL HANDLING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 HAZARDOUS CHEMICAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 TRANSPORTING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SEAT BELT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 SEAT RESTRAINT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 SPECIFIC PRECAUTIONS TO THIS MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 SECURING SKID STEER LIFT ARMS UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 LIFT ARM SUPPORT STRUT EQUIPPED MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 LIFT ARM LOCK PIN EQUIPPED MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 SECURING THE LIFT ARMS UP AND TILTING THE OPERATOR’S COMPARTMENT FORWARD . . . . . 2-16 LIFT ARM BYPASS CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 NO ENGINE POWER - LIFT ARM DOWN CONTROL - PILOT CONTROL MACHINES . . . . . . . . . . . . . 2-17 NO ENGINE POWER - LIFT ARM DOWN CONTROL - NON-PILOT CONTROL MACHINES . . . . . . . . 2-18 EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

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

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

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

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

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

• CAUTION: Indicates a potentially hazardous Figure 1

BD07M275

OPERATOR MANUAL STORAGE BEHIND THE SEAT

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

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals. Also see the manual information on the Title pages (first and second pages in front of the Table of Contents) of this manual.

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

• The first panel indicates the nature of the hazard.

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

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

and

STOP

if

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.

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UTILITY SAFETY Safety precaution MUST be followed when working near buried and overhead Utility Lines.

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

• • • •

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

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

Figure 2

RH99G001

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

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

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CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS OPERATOR PRECAUTIONS

• After service has been performed, make certain

PERSONNEL

• Never operate any type of equipment under the influence of certain medication. Explain to your physician exactly what type of work you do. Read the label carefully.

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

all tools, parts and equipment have been cleared from the machine area.

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

PROPER ENTRY AND EXIT

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

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

• Certain protective equipment should be replaced and renewed because of age and wear. Old hard hats may not afford the correct protection. Faded and soiled vest are no longer as highly visible as originally intended by the manufacturer. See the manufacturer’s recommendation.

• Do not rush. Walk, do not run.

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

who

has

the

GENERAL

• It is the responsibility of the operator to read and

BD04D082

Figure 3

Always face the front of the machine when you get on or off the skid steer. DO NOT RUSH! Enter the skid steer from the front by using the bucket step and cab hand holds.

Use at least three points of support when getting on the machine

understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Do not operate this machine or perform maintenance work if you have not had appropriate training 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 regular basis to ensure their integrity.

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

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

BD04D083

Figure 4

Step into the cab from the bucket and cab step area.

Hand holds are provided on the front cab posts for entry and exit.

• Remove all loose objects stored in the machine.

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

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2-5

CHAPTER 2 - SAFETY, AND SAFETY DECALS WARNING: Never enter or exit the skid steer unless the lift arm and attachment are resting on the ground, on the lift arm lock pins or the support strut. Failure to follow these instructions may cause Death or Serious Injury.

Figure 5

Before exiting the skid steer: 1. Lower the lift arms and or attachments to the ground. If the operator must exit the skid steer with raised lift arms, always engage the lift arm lock pin or support strut.

2. Stop the engine. automatically set.

The

parking

brake

is

3. Unlatch the seat belt and raise the restraint bar.

4. Move the controls until locked.

5. Use the recommended hand holds and at least three points of support when getting on or off the machine.

WARNING: Never exit the skid steer with the engine operating. Failure to follow these instructions may cause Death or Serious Injury.

Figure 6

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

Failure to follow these instructions may cause Death or Serious Injury.

Figure 7

WARNING: Never exit the skid steer unless the lift arms, attachment are down resting on the ground, or on the lock pin or support strut.

Failure to follow these instructions may cause Death or Serious Injury.

Figure 8

• 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 rails can cause an accident. Keep the steps and hand rails clean.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS STARTING AND STOPPING PRECAUTIONS

OPERATING PRECAUTIONS

• Walk around the machine and warn all personnel

• OSHA requirements make it the employer’s

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.

responsibility to fully instruct each operator in the proper and safe operation of all operative equipment. Both employer and employee should thoroughly familiarize themselves with this manual.

• Know exactly how far the machine or any tool or attachment may reach out, in order to make sure personnel or objects are clear of the machines work area.

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer, before starting the machine.

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

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

• To avoid potential serious injury by contact with the moving lift arm or bucket, DO NOT rewire to bypass the seat switch or restraint bar.

• Do not bypass the machine’s auxiliary hydraulic interlock system. The auxiliary hydraulic 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. Gases may be trapped at a level that might be dangerous. Make sure that using jumper cables will not interfere or harm electronic processing or computer devices.

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

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

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

Move controls until they are locked out.

• Remove the starter key or disconnect switch when leaving the machine parked or unattended. Lock the panel on keyless systems.

• Check brakes, steering and other machine control devices in accordance with the manufacturer’s instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the key from the key switch. 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 key from the key switch. Lock the panel on keyless systems. 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.

• 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.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

• When roading a machine, know and use the

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

signaling devices required on the machine.

Provide and escort for roading where required.

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

• Use the recommended transport devices when

• You must make a judgment if weather, road, or

roading the machine.

• Use the approved drawbar and / or attachment

earth conditions will permit safe operation on a hill, ramp, or rough ground.

point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Stay away from hazardous areas such as ditches,

• Before you operate at night, check that all lamps

• Be alert and always know the location of all

illuminate.

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

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

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

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

overhangs, etc. Walk around the work area before you start and look for hazards. workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

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

MAINTENANCE PRECAUTIONS

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

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

• Contact

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

• 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.

• 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.

2-8

Figure 9

BD07D175

• Before you service the machine, put a Do Not Operate Or Mark Out Tag on the instrument panel, key or at a location that must be seen by the Operator prior to beginning operation. Give a brief definition of the situation.

• Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

• Wear gloves to protect hands when handling cable.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

• Disconnect the battery before working on the

FUEL HANDLING PRECAUTIONS

electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Do not smoke or permit open flames while fueling

• Avoid lubrication or mechanical adjustments with

• Never remove the fuel cap or refuel gasoline

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.

or near fueling operations. 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.

• 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 non-approved 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.

• 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.

• Have

a certified professional pressurize accumulators with the proper gas according to manufacturer’s recommendations.

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

• It is not recommended to tow this machine.

• Observe proper maintenance procedures.

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

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

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

• Help reduce the risk of fires due to debris build-up in the engine compartment and coolers on your skid steer, check the radiator, coolers and engine compartment for build up of debris.

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2-9

CHAPTER 2 - SAFETY, AND SAFETY DECALS BURN PREVENTION

HAZARDOUS CHEMICAL PRECAUTIONS

• Never service components until they are cooled

• If you are exposed to or come in contact with

down.

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. M144B

Figure 10

• 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.

2-10

hazardous chemicals you can be seriously injured.

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

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

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

dealer

for

correct

disposal

TRANSPORTING PRECAUTIONS

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

ROLL-OVER PROTECTIVE STRUCTURE

• 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. You MUST replace the ROPS if it is subjected to roll-over, tip or fire damage. Do not attempt to repair.

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.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS SEAT BELT PRECAUTIONS 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.

3 1

Figure 13

WARNING: Securely fasten your seat belt.

Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection.

2

Figure 14

Figure 11

BD07C132

1. RETRACTABLE HALF OF THE SEAT BELT 2. BUCKLE HALF OF THE SEAT BELT 3. SHOULDER BELT (IF EQUIPPED)

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

1 2

A

Figure 12

BD07M324

A shoulder belt (3) is available from your Dealer or comes standard equipment on machines with a cab door.

To release the belt, push the red release lever, A. Hold onto the retractable half as it retracts into storage.

NOTE: California - required 3 inch webbing seat belt kit is available through the Dealer Service Parts. This belt may be necessary in some industrial applications. Check your local codes.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS SEAT RESTRAINT BAR The restraint bar must be down in the operating position before starting.

1

3 4 Figure 17

BD08F025

3. SEAT RESTRAINT BAR ADJUSTING LOCK NUT 4. SEAT RESTRAINT BAR STOPPER

The Seat Restraint Bar may be adjusted for operator comfort. Loosen the Seat Restraint Bar adjusting lock nut and adjust the stopper on each side of the machine. Secure the Seat Restraint Bar adjusting lock nut when both sides are in the same position.

Figure 15

BD07M270

After adjusting the Seat Restraint Bar, perform the Seat Restraint Bar and Interlocks Function on page 5-19.

1. SEAT RESTRAINT BAR IN LOCKOUT POSITION

2

Figure 16 2. SEAT RESTRAINT BAR IN THE OPERATING POSITION

BD07M271

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CHAPTER 2 - SAFETY, AND SAFETY DECALS SPECIFIC PRECAUTIONS TO THIS MACHINE

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

• Confirm that the bucket or attachment lock pins are in place before operating the machine.

• Be sure to place all auxiliary hydraulic controls in neutral before leaving the cab and be careful to not engage them accidently when entering or leaving the cab.

• Before exiting the cab, the operator must place all auxiliary hydraulic control functions into neutral or off. Do Not reach for handles, step on pedals or depress switches that will activate auxiliary hydraulic controls as you enter or leave the cab.

• Do not allow spill over the back of the bucket. Dirt, rocks, debris and construction site objects could enter the operator cab.

Figure 19

3. See the instructional decal on the inside of the right lift arm, just above the support strut. Read and understand these instructions before you perform this procedure.

WARNING: ALWAYS install the Lift Arm Support Strut or secure the Lift Arm Lock Pin into the proper position before exiting a machine with the lift arms up and/or when servicing or repairing the unit with the lift arms up. Failure to do so could result in death or serious injury.

WARNING: Never leave the cab with the Lift Arms up, unless the Lift Arm Support Strut or the Lift Arm Lock Pin is in the maintenance position. Failure to follow these instructions could result in death or serious injury.

Figure 20

Figure 18

• Before leaving the operator’s compartment check the interlock system so movement of controls do not result in machine movement.

SECURING SKID STEER LIFT ARMS UP All Case Skid Steer Family machines use Lift Arm Support Struts or Lift Arm Lock Pins to secure the lift arms up. Remove attachments before securing the lift arms up. If you have any questions about this procedure contact your Dealer.

LIFT ARM SUPPORT STRUT EQUIPPED MACHINES To Secure The Lift Arms Up And Install The Support Strut And Pin: 1. Remove any attachment.

2. Park the machine on firm and level surface.

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BD07N238

Figure 21

1. LIFT ARM SUPPORT STRUT PIN

4. Remove the pin that secures the lift arm support strut.

2-13

CHAPTER 2 - SAFETY, AND SAFETY DECALS

Figure 24

BD07K017

9. Insert the support pin in the support strut.

BD07N239

Figure 22

5. Lay the support strut down on the lift arm tubing and cylinder as shown.

IMPORTANT: If the seat is not in the forward most position it may interfere with the cab as it is tilted forward.

To Place The Lift Arm Support Strut Into The Working Or Storage Position: 1. Start the engine and raise the loader lift arms 1 to 2 inches (25 to 50 mm).

2. Stop the engine, raise the seat bar and make sure the loader hydraulics are inoperable. See page 5-19 in this manual.

3. Have a helper remove the support strut pin and secure the strut and pin into the working or storage position.

4. Lower the seat restraint bar and lower the loader lift arms to the ground.

Figure 23

6. Slowly raise the lift arms until the support bracket drops down onto the cylinder rod, as shown.

7. Gently, lower the lift arms down until the support strut is in contact with the cylinder.

If the cab is to be tipped forward for service: 8. Before leaving the cab, move the seat all the way forward to prevent contact between the bottom of the ROPS and the seat back.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS LIFT ARM LOCK PIN EQUIPPED MACHINES To Secure The Lift Arms Up And Engage The Lift Arm Lock Pin: 1. Remove any attachment.

2

2. Park the machine on firm and level surface.

3. While still in the seat, restraint bar down and the engine running, roll the coupler attachment all the way back.

4. Raise the lift arms to the maximum height.

Figure 27 2. LIFT ARM LOCK PIN SHOWN EXTENDED (LIFT ARM STILL AT MAXIMUM HEIGHT

1

3

Figure 25

BD07N682

1. LIFT ARM LOCK PIN CONTROL LEVER (SHOWN IN LOCK POSITION)

5. Engage the loader lift arm lock pin, using the lock pin control lever located in the right rear corner of the operator’s compartment, by moving the lever toward the center of the machine.

Figure 28 3. LIFT ARMS LOWERED TO MAKE CONTACT WITH LOCK PIN

6. Slowly lower the loader lift arms until the loader lift arm link rests against the lock pin.

Figure 26 LIFT ARM LOCK PIN INSTRUCTION DECAL

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CHAPTER 2 - SAFETY, AND SAFETY DECALS To Disengage The Lift Arm Lock Pin And Lower The Arms:

SECURING THE LIFT ARMS UP AND TILTING THE OPERATOR’S COMPARTMENT FORWARD The Operator’s compartment may be tilted forward, for service access, with the lift arms raised OR lowered. Access to the engine, hydrostatic pumps, motors, and control linkage is best when the loader lift arms are in the raised position.

NOTE: On machines with front door glass, a protective block must be installed to guard against accidental breakage when the lift arms are down.

The front door must be removed if the cab is tilted forward with the lift arms down.

WARNING: Always activate the mechanical loader arm lock pin before exiting a machine with the loader arms up. Failure to do so could result in death or serious injury.

BD07N684

Figure 31

Figure 29

1. While sitting in the operator’s seat, with the restraint bar down, start the engine and raise the lift arms until the loader lift arm link is no longer contacting the lock pin, as shown above.

WARNING: Never leave the cab with the lift arms up, unless the lock pin is in the maintenance position with the lock pin in place.

Figure 32

IMPORTANT: See page 5-7 for the procedure to tilt the cab.

BD07N683

Figure 30

To disengage the lock pin, move the lock pin control lever toward the right, or outside of the machine, as shown. Slowly lower the loader lift arms to the ground.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS LIFT ARM BYPASS CONTROLS The Case family of skid steers have two methods for lowering the lift arms to the ground in the event the machine has lost engine or electrical power.

• Pilot Control Machines use a single control to bring lift arms down.

• Non- Pilot Control Machines use a two lever sequence to bring lift arms down.

In the event of the loss of engine power, the override control will allow the operator to lower the lift arms to the ground. If you have any questions about these procedures, contact your Dealer.

NO ENGINE POWER - LIFT ARM DOWN CONTROL - PILOT CONTROL MACHINES WARNING: The No Power - lift arm Down Control is 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.

Figure 33

1. NO ENGINE POWER - LIFT ARM D OW N C O N T R O L - P I L OT CONTROL MACHINES: The control knob (1) is located down and to the right of the operator, while sitting in the seat, and just behind the right console. Before attempting to lower the lift arm/attachment on a machine that has lost engine power, alert personnel in the area of your intention. Do not leave the seat, unfasten the seat belt or raise the restraint bar. After confirming that personnel and obstacles are clear, slowly, pull the control knob UP to lower the lift arm/attachment down to the ground.

Figure 34

87568435

1

BD08G001

Figure 35

1. NO ENGINE POWER - LIFT ARM DOWN CONTROL KNOB AND INSTRUCTIONAL DECAL, PILOT CONTROL MACHINES

This red control knob is for emergency situations only and should not be used in day to day nor mal operations.

WARNING: Never exit the skid steer unless the lift arms and attachment are down resting on the ground, or lock pins or the support strut are in the maintenance position and safe. Failure to comply could result in death or serious injury.

Figure 36

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CHAPTER 2 - SAFETY, AND SAFETY DECALS NO ENGINE POWER - LIFT ARM DOWN CONTROL - NON-PILOT CONTROL MACHINES WARNING: Before attempting to bring the lift arm/attachment down on a machine that has lost engine power, alert personnel in the area of your intention. You must confirm that personnel and obstacles are clear before engaging the lift arm down control. Death or serious injury may result if these instructions are not followed.

Figure 37

Non-pilot machines use a two step sequence to lower the Lift Arms on a machine that has lost power.

C

2

Figure 38

BD08G002

2. LIFT ARM BYPASS CONTROL LOOP, NON-PILOT CONTROL MACHINES

If there is no electrical power, pull the Lift Arm Bypass Control Loop up, while moving the Lift Arm Control Lever to the lower position.

This procedure is for emergency situation only and should not be used in day to day normal operations.

See page 3-37 in this manual for more detailed instruction.

WARNING: Never exit the skid steer unless the lift arms and attachment are down resting on the ground. Failure to comply could result in death or serious injury.

Figure 39

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CHAPTER 2 - SAFETY, AND SAFETY DECALS EMERGENCY EXIT

1

Figure 40

BD07M272

1. EMERGENCY EXIT WINDOW TAG

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

To remove the rear window pull on the tag and remove the window molding lock strip.

1

BDO7M273

Figure 42

Push on the top half of the window to force it away from the cab window frame.

Pull the window down and out of the frame.

Push the window away from the machine and exit.

IMPORTANT: If the rear window was removed for exiting, reinstall the rear window moulding and secure in place with the window moulding lock strip before operating the skid steer.

Figure 41

87026871

EMERGENCY EXIT WINDOW TAG GRAPHIC

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

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. Some decal locations may vary slightly between various model configurations. If you have any questions about the decals or their replacement contact your Dealer.

1

2

Figure 43

384270A1A / BC00G075

1. READ THE APPROPRIATE INFORMATION IN THE OPERATOR’S MANUAL 2. READ THE APPROPRIATE INFORMATION IN THE REPAIR MANUAL

When you see the symbols shown above, refer to the appropriate information in the Operator’s Manual or the Service Manual. These symbols may occupy a portion of the safety or instructional decal. If you have any questions regarding operation or service contact your Dealer.

2

Figure 44

384260A1

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.

Figure 45

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.

Figure 46

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

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

4 3

5

Dd

Figure 47

BD07M305 / 382622A1 / 394581A1

3. DECAL LOCATION IS ON LEFT INSIDE CAB JUST ABOVE FUSE COMPARTMENT 4. 256147A1, NORTH AMERICA - WARNING: READ THE OPERATORS MANUAL. 5. 394581A1, ISO - WARNING: READ THE OPERATORS MANUAL.

7

6

Figure 48 6. DECAL LOCATION IS ON RIGHT INSIDE CAB JUST BEHIND THROTTLE CONTROL LEVER 7. 255927A1, NORTH AMERICA - WARNING: DO NOT TURN THE RIDE CONTROL ON IF LOADER ARMS AND BUCKET ARE HOLDING MACHINE UP.

BD07N236 / 255927A1

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

8

9

Figure 49 8. DECAL LOCATION IS ON INSIDE OF RIGHT LIFT ARM 9. 321-7029, NORTH AMERICA - WARNING: SERVICE PROCEDURES USING LIFT ARM SUPPORT STRUT AND INSTRUCTIONS

BD07K015 / 3217029

2-22

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

12

10

11

Figure 50

BD07N450 / 84135011 / 175509A1

10. DECAL LOCATION IS ON THE STARTER 11. 321-7040, NORTH AMERICA - DANGER: START ONLY FROM THE OPERATOR SEAT 12. 175509A1, ISO - DANGER: ONLY START FROM OPERATOR SEAT AND IN NEUTRAL

14

13 15

Figure 51

BD07N458 / 384267A1 / 175504A1

13. DECAL LOCATION IS ON THE RADIATOR TOP TO THE LEFT OF THE CAP 14. 384267A1, NORTH AMERICA / WARNING: ENTANGLEMENT HAZARD 15. 175504A1,ISO - WARNING: ENTANGLEMENT HAZARD 87493825NA

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

16

17

Figure 52

BD01C073 / 251745A1

16. DECAL LOCATION IS JUST BELOW THE FRONT SIDE CAB STEP 17. 251745A1, DANGER: CRUSH HAZARD

18

20

19

21

Figure 53

BD04F032 / D137186J / 251748A1

18.

19.

20.

21.

DECAL LOCATION IS ON THE LEFT SIDE OF THE LIFT ARM CROSSTUBE D137186J, CAUTION: ALWAYS INSPECT THE COUPLER LATCH PIN ENGAGEMENT BEFORE OPERATING DECAL LOCATION IS CENTERED ON THE LIFT ARM CROSSTUBE 251748A1, WARNING: TIP HAZARD

2-24

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

23

22

Figure 54

BD07M269 / 384260A1

22. DECAL LOCATION IS ON THE ACCUMULATOR UNDER THE FLOOR PLATE 23. 384260A1, NORTH AMERICA - WARNING: PRESSURIZED SYSTEM / RELIEVE PRESSURE BEFORE MAINTENANCE.

25 24

26

27

Figure 55

BD07M307 / 278216A / 87626172

24.

25.

26.

27.

DECAL LOCATION IS ON BOTH LEFT AND RIGHT REAR CAB TOP 87626172, ISO - WARNING: KEEP CLEAR - CRUSH HAZARD DECAL LOCATION IS ON THE LIFT ARM SUPPORT STRUT JUST IN FRONT OF THE SUPPORT STRUT PIN 278216A, ISO - WARNING: LIFT ARM SUPPORT STRUT MUST BE IN PLACE

87493825NA

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

29 28

Figure 56

BD08G006 / 87498030

28. DECAL LOCATION IS ON THE INSIDE OF THE RIGHT CAB UPRIGHT 29. 433957A1, NA AND ISO - DANGER: CRUSH HAZARD

30 31

Figure 57

BD08F010 / 87474789

30. DECAL LOCATION IS ON THE REAR OF THE FRONT DOOR WIPER MOTOR 31. 87474789, NA AND ISO - IMPORTANT: SEE OPERATOR MANUAL FOR DOOR REMOVAL

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 STANDARD INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 DELUXE INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 ANTI-THEFT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 STEERING AND TRAVEL WITH H PATTERN CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 TURNING A MACHINE WITH H PATTERN CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 LIFT ARM AND BUCKET CONTROLS WITH H PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 INSTRUCTIONAL DECALS FOR H PATTERN STEERING AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . 3-24 STEERING AND TRAVEL ISO PATTERN PILOT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 TURNING A MACHINE WITH ISO PATTERN PILOT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 LIFT ARM AND BUCKET CONTROL WITH ISO PATTERN PILOT CONTROLS . . . . . . . . . . . . . . . . . . . . . 3-27 INSTRUCTIONAL DECALS FOR ISO PATTERN STEERING AND CONTROLS . . . . . . . . . . . . . . . . . . . . 3-28 CONTROL HANDLE SWITCH CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 STANDARD AUXILIARY HYDRAULIC AND HIGH FLOW AUXILIARY HYDRAULICS . . . . . . . . . . . . . . . . 3-32 AUXILIARY HYDRAULIC CONTROL PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 NO ENGINE POWER - LIFT ARM BYPASS CONTROL - ISO PILOT CONTROL MACHINES . . . . . . . . . . 3-36 NO ENGINE POWER - LIFT ARM BYPASS CONTROL - H CONTROL MACHINES . . . . . . . . . . . . . . . . . . 3-37 OPERATORS SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 SEAT BELT AND SEAT RESTRAINT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 CAB DOOR LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENTS AND CONTROLS This Chapter identifies the location and gives a brief overview of functions and controls found on this family of machines. Use this Chapter to familiarize yourself with these locations and functions before operating the machine. See the Operating Instructions in the next chapter for more detailed instruction on the interaction of the Instruments and Controls, with the function desired. Example: This Chapter will explain the control lever for auxiliary hydraulic function and the auxiliar y hydraulic switches, such as High Flow, but, the Operating Instructions Chapter will explain the coordination of these functions for efficient use of your machine.

STANDARD INSTRUMENT PANEL The Instrument Panels are located on the upper right side of the cab. (Standard or Deluxe) This Panel houses the Key Switch, Warning Lamps, Machine Hydraulic Controls and Information necessary to monitor the machine functions and controls.

Machines with pilot controls will have drive systems identified at the bottom of this panel. Drive ISO or Drive H will alert the operator to the type of drive control that operates the machine.

Once in the seat, the audible alarm will beep once, Warning Lamps will illuminate briefly. The fuel gauge and hour meter will remain illuminated for operator monitoring.

The machine will be in Park when started. This machine is equipped with SAHR Park Brakes.

(Spring Applied Hydraulically Released) With the operator in the seat and the restraint bar down, the Park Brake / Hydraulic Enable Indicator Lamp will be blinking. The Operator must PUSH the Park Brake / Hydraulic Enable Switch to release the brakes and hydraulic controls.

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.

Figure 1

BD07M313

INSTRUMENT PANEL

The operator leaves the seat.

The Park Brake Switch on the right hand control handle is activated.

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3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS 3. Instrument Panel Park Brake / Hydraulic Enable Switch: This push button switch located to the right of the Auxiliary Override switch, shown above. On start up, the Yellow indicator lamp (4), below the switch, will blink off and on. When the Parking Brake has been set the indicator lamp will blink off and on. The Operator must have the restraint bar down, in the working position, and press this switch to release the brakes and activate lift arm hydraulics.

1

2

Push the switch again to set the brakes.

Figure 5

BS96H049

4. Park Brake / Hydraulic Enable Indicator Lamp: On start up, this Yellow indicator lamp below switch, will blink off and on. When ready, the Operator will press this switch to release the brakes and activate lift arm hydraulics.

3 5 4

Figure 6

BD07K068

5. Right Control Handle Park Brake Switch: This red push button switch is located on the right control handle. Push this switch to set the machine Park Brake. Do not activate this switch while the machine is moving. Stop the machine and then set the brake.

Figure 2

BD07K052

1. Seat Belt Reminder: This Red lamp flashes to remind the operator to place the restraint bar down into working position and fasten the seat belt.

Figure 3

BS96H055

2. Park Brake Lamp: This Red lamp stays illuminated when the Park Brake has been set. The Operator must do one of the following to release the brake.

Figure 7

BS96H041

• Push the Park Brake Switch on the Instrument Panel.

• Push the Park Brake Switch on the right control handle.

BS96H049

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87493825NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS KEY SWITCH

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

The Key Switch is located at the top of the Instrument Panel. This is a 4 position switch. Key positions are marked by the symbols.

BS96H055

3

Figure 12

4

2

5

1

Figure 8

BD04N048

1. KEY SWITCH

2. System Power (Accessory): This position powers accessory attachments.

Figure 9

BS96H041

IMPORTANT: The battery will discharge if left in this position.

3. Stop: Turn the key to this position to STOP the engine and de-energize the electrical system.

Figure 10

BS96H076

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

When the key is turned to RUN, the engine preheat light will illuminate at all temperatures. For temperatures below 50 ° F (10° C) turn the key to RUN position and wait until the lamp goes out before moving the switch to start position. For temperatures above 50 °F (10 ° C) turn the key directly to START. Figure 11

BS96H078

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3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS STANDARD INSTRUMENT PANEL WARNING LAMPS

4. Engine Malfunction Warning Lamp and Alarm: This Yellow lamp will flash and the alarm will sound when the engine air filter becomes restricted and requires servicing. Service immediately.

These lamps assist the Operator in monitoring the functions of the various machine components. On initial start up these lamps, with the exception of the engine pre-heat lamp, will glow momentarily.

Figure 17

BS07M318

NOTE: If this lamp remains on after replacing engine air filters contact your Dealer.

5. Engine Pre-Heating Lamp: When the key is turned to RUN, the engine pre-heat light will illuminate. The engine pre-heat lamp will illuminate in all ambient conditions. For temperatures below 50 ° F (10 ° C), turn the key to the RUN position and wait until the lamp goes out before moving the switch to the START position. For temperatures above 50 ° F (10 ° C), turn the key directly to the START position.

1 6

2 7

3 4

8

5

BD07K054

Figure 14

2. Engine Oil Pressure Lamp and Alarm: This Red 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.

BS99D060

6. Hydraulic Charge Pressure Warning Lamp and Alarm: This Red warning lamp will flash and the alarm sounds if there is no, or low oil pressure in the transmission. Do not run the machine if the war ning lamp illuminates. This condition may cause the SAHR Park Brake to engage. If this condition exists, the Park Brake Lamp will also flash.

Figure 13

1. Seat Belt Reminder: This Red lamp flashes to remind the operator to place the restraint bar down into working position and fasten the seat belt.

BS96H055

Figure 18

BC02N191

Figure 19

BS99J181

IMPORTANT: Low hydraulic charge pressure may cause engagement of the SAHR park brake. The Park Brake lamp and Charge Pressure Warning Lamp will flash and an audible alarm will sound, if this condition exists.

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

Figure 15

Figure 20

BC00B123

3. Coolant Temperature Warning Lamp and Alarm: This Red warning lamp flashes and the alarm sounds if, with the engine running, the coolant temperature is too high. DO NOT RUN the engine if this warning lamp illuminates.

BS96H053

8. Hydraulic Filter Warning Lamp and Alarm: This Yellow warning lamp will flash and the alarm will sound, if the engine is r u n n i n g a n d t h e hy d ra u l i c f i l t e r i s restr icted. Ser vice immediately by replacing the filter.

Figure 16

Figure 21

BC00B113

3-6

Issued 09-08

Bur

87493825NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 11. Auxiliary Hydraulic Interlock Override: When an operator leaves the seat, oil flow to an attachment will normally be halte d via e ngin e shu to ff or dire ct hydraulic flow shutoff. Depress this button and leave the seat within thirty seconds to defeat this interlock. Small Red indicator lamp below the switch illuminates when the inter lock is defeated.

9

10

BS04F101

11

Figure 25

12. Park Brake / System Enable Switch: Push this switch to enable the hydraulic loader, ground dr ive functions and release the SAHR brake. Subsequent pushing will toggle the SAHR brake on and off but will have no effect on the hydraulic loader functions.

12

BS96H049

Figure 26

Figure 22

BD07K067

The Digital Display provides information to the operator for monitoring the machine hours, 9. Hourmeter / Digital Display: The machines total engine hours will display here. Both hours and tenths of an hour will display. The hourmeter should be used to measure the time between scheduled maintenance intervals.

Figure 23

BS96H096

10. Fuel Gauge: The fuel level gauge, consists of a series of bars that indicate the level of fuel in the fuel tank. When all 8 bars are visible the fuel tank is full. The first bar indicates the following amount of fuel: Solid Bar 3.0 U.S. gals (15.1 liters) Figure 24

BS96H048

NOTE: One solid bar will blink when the tank reaches this level of fuel.

87493825NA

Issued 09-08

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3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS MACHINE LIGHTS

2. Work Light Position: Turn the switch to this position for the Work Lights to activate. This will activate the front and rear work lights.

Figure 29

BS96H045

1

3. Work Light / Side Light Position:

2

Turn the switch to this position for the front Work Lights and the Side Lights to be activated.

A 3

Figure 30

BS07K124

4

4. Road Lights: Turn the switch to this position for the Road Lights. This switch position will activate the front lights and rear red lights.

5 6

Figure 31

BC00B134

IMPORTANT: This is machine is not intended to be driven on public roads or highways. Contact your local and regional authorities before operating this machine on public roads or highways.

7

5. Turn Signal Indicator: If equipped, this indicator will activate when the turn signal switch has been activated.

Figure 27

BD07K069

A. CAB EXTERIOR LIGHT SWITCH

If equipped, the cab exterior lights are activated by a rotary switch located at the bottom portion of the Instrument Panel. This rotar y switch has four positions indicated by the symbol. The switch will remain in the position last selected. This switch is functional without a key.

Figure 32

BS96H047

6. Two Speed Drive Indicator: This indicator lamp will illuminate green when High Speed is selected. The button for speed selection is on the front of the left control handle.

1. OFF:

Figure 33

BS99J179

Turn the switch to this position for OFF.

BS00A017

Figure 28

IMPORTANT: Do not accidently leave this switch on without the engine running. Battery will discharge.

3-8

7. ISO or H Drive Identification: On pilot control machines this panel decal identifies which drive system the machine is equipped with. ISO drive (single lever controls drive) or H drive (traditional 2 lever drive control)

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Cab Switch Panel Located on the left-hand cab upright is the Cab Switch Panel. This switch panel houses temperature controls, and switch panels for various machine control options and configurations. For best performance use these heat and air controls in conjunction with the vents in the cab. See the Heat and Air Controls for Hot and Cold Weather in the Operations Chapter on page 4-8.

1

2

3

4 BD08F014

Figure 35

2. Temperature Control Knob: Adjust the knob for the required comfort level. Red area for warm and blue area for cold.

BC04K295

Figure 34

BD08F015

Figure 36

3. Blower Fan Switch: Turn the knob to one of three positions to activate the blower. Turn the switch clockwise from OFF to increase the fan speed.

1. Cab Temperature Controls: The first portion of the Cab Switch Panel is for Operator temperature controls, if equipped.

BS99N111

Figure 37

4. Air Conditioning Switch: This two-position switch turns the air conditioning system ON or OFF. The switch is illuminated when the system is activated.

BC00B112

87493825NA

Issued 09-08

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Figure 38

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Cab Switch Panel 1. Hydraulic Attachment Mounting Plate Switch: If equipped push the Lock side or the Unlock side of this switch to Lock or Unlock the mounting plate from the attachment. This switch must be used in conjunction with a lift arm up-down or curl in-out function.

1

Figure 40

BC04F113

2. Rotating Beacon / Strobe Light Switch: If equipped, push the top side of this switch to activate the rotating beacon or strobe light.

2

Figure 41

BC00B082

3. Hazard Flasher Switch: If equipped, use the symbol portion of the switch to activate the flashers.

3

Figure 42

BC04K301

4

4. Auxiliary Hydraulic Flow Switch: If equipped, push the top portion of the switch to engage high flow auxiliary hydraulic mode. The lamp will illuminate.

The bottom portion of the switch is standard flow.

5 Figure 43

BC04F114

5. Auxiliary Front Electric Switch: This switch is for the front electric connector. The switch is ON/OFF for continuous power.

6

Figure 44

BS04G121

6. Auxiliary Front Electric 3 Switch: This switch controls functions of the auxiliary front electrical connector.

Contact your Dealer to identify connector pins and functions.

BD07K053

3-10

Figure 39

Figure 45

BS04G121

Issued 09-08

Bur

87493825NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

7

8

9

Figure 46

7. Loader Lock Switch: This switch is used to lock lift arms into travel position for designated European requirements.

Figure 47

BC07D237

8. Blank Switch Panel: 9. Blank Switch Panel:

87493825NA

Issued 09-08

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3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS DELUXE INSTRUMENT PANEL The Deluxe Instrument Panel is located on the upper right side of the cab. This Panel houses the Warning Lamps, Machine Hydraulic Controls and Information necessary to monitor the machine functions and controls.

The Deluxe Instrument Panel includes all the functions on the Standard Panel plus the following:

• Keyless Start • Automatic Machine Shutdown Additional Display Functions

• Engine Speed • Engine Coolant Temperature • Engine Preheat Countdown

Additional Digital Gauges

• Engine Coolant Temperature • Engine Preheat Countdown Additional Digital Gauges

• Engine Coolant Temperature • Hydraulic Oil Temperature

Other Menu Functions Are

• • • •

Anti theft coded start Machine Fault Record Electrical System Diagnostics Job Timer

Once in the seat, the audible alarm will beep once, Warning Lamps will illuminate briefly. The fuel and temperature gauges and hour meter will remain illuminated for operator monitoring.

The machine will be in Park when started. This machine is equipped with SAHR Park Brakes.

(Spring Applied Hydraulically Released) With the operator in the seat and the restraint bar down, the Park Brake / Hydraulic Enable Button will be blinking. The Operator must PUSH the Park Brake / Hydraulic Enable Switch to release the brakes and hydraulic controls.

A semi-hidden SETUP menu allows the user to view, select, change and customize a number of machine settings. A security code may be entered into the Deluxe Instrument Panel. Once the security code has been entered, each user will have to enter the code before the machine will start. Diagnostic information and fault code history may be retrieved for servicing requirements.

Figure 48

BD07M310

3-12

Issued 09-08

Bur

87493825NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 2. Park Brake Lamp This Red lamp illuminates when the Park Brake has been set. The Operator must do one of the following to release the brake.

1

• Push the Park Brake Switch on the Instrument Panel.

• Push the Park Brake Switch on the right control handle.

Figure 51

BS96H049

2

3. Instrument Panel Park Brake / Hydraulic Enable Switch: This push button switch is located under the start button. On start up, the green indicator lamp will blink off and on. The Operator must have the restraint bar down, in the working position, and press this switch to release the brakes and activate lift arm hydraulics.

Push the switch again to set the brakes.

Figure 52

BS96H049

4

3

Figure 49

BD07M310

1. Seat Belt Reminder: This Red lamp flashes to remind the operator to place the restraint bar down into working position and fasten the seat belt.

Figure 50

BS96H055

BD07K068

Figure 53

4. Right Control Handle Park Brake Switch: This Red push button switch is located on the right control handle. Push this switch to set the machine Park Brake. Do not activate this switch while the machine is moving. Stop the machine and then set the brake.

Figure 54

87493825NA

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3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS KEYLESS START

3. Instrument Panel Park Brake / Hydraulic Enable Switch: Push this switch to enable the hydraulic loader functions and release the SAHR brake. Subsequent pushing will toggle the SAHR brake ON and OFF but will have no effect on the hydraulic loader functions.

W i t h o r w i t h o u t a s e c u r i t y c o d e t h e D e l u xe Instrument Panel allows for keyless operation of the machine.

1

Figure 58

BS96H049

2

3

4

BD07M311

Figure 55

1. Power Switch: Press this button to turn the machine power ON and OFF. This will begin the engine pre-heat system. The light will flash when the Operator sits in the seat.

Once the POWER button is pressed the light will remain on. When the POWER button is pressed, the engine preheat light will illuminate and a 30 second countdown will start on the digital display. (at all temperatures) For temperatures above 50 °F (10 ° C), immediately press START button.

BC04G175

4. Auxiliary Hydraulic Interlock Override: When an operator leaves the seat, oil flow to an attachment will normally be halted via engine shutoff or direct hydraulic flow shutoff. Depress this button and leave the seat within thirty seconds to defeat this interlock. Small Red indicator lamp below the switch illuminates when the interlock is defeated.

Figure 56

IMPORTANT: The battery will discharge if left in this position.

2. Start: Press this button to activate the starter motor and start the engine. Release the button when the engine starts.

Figure 59

BD07M311

Figure 60

BS04F101

Holding the button will continue cranking the starter, the same as holding the key to START. BS07M319

3-14

Figure 57

Issued 09-08

Bur

87493825NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS To start or stop the machine: When the Operator sits in the sit the Instrument Panel will wake up and begin monitoring machine functions. The Power button and Seat Lamp will flash. The Park Brake lamp will be illuminated.

NOTE: As there is a slight delay in the self-monitoring process, if the Operator pulls the restraint bar down too fast, it may be necessary to lift the bar up and back down again to properly cycle the start sequence procedure.

Push the power button. this is the equivalent of turning the key to ON. NOTE: See the POWER information on the previous page figure 53.

If the temperature is below 50° F (10° C) wait until the lamp goes out before resuming. This may be 30 seconds.

If the temperature is above 50° F (10° C) proceed directly to start.

Push the START button to start the machine.

To stop the engine, push and hold the POWER button.

After the POWER button has been pushed to stop the machine and the engine stops, the display will show LOCK? and the AUXILIARY OVERRIDE button will flash.

NOTE: See the Anti Theft details on the following page.

Push the AUXILIARY OVERRIDE button to lock the machine.

Exit the machine without pushing the AUXILIARY OVERRIDE button to leave the machine unlocked.

Your Dealer will assist with the LOCK? code. See the Anti Theft details on the next page.

NOTE: Machines are shipped without a LOCK? code. Without a LOCK? code the Operator may leave the machine without entering or responding to the LOCK? on display at POWER OFF.

87493825NA

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3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS ANTI-THEFT OPERATION LOCKING THE INSTRUMENT PANEL:

OWNER CODE:

Immediately after shutting off the engine the display will show LOCK? and the AUX OVERRIDE button will f l a s h . A n t i - T h e f t i s s e t by p r e ss i n g t h e AU X OVERRIDE button. The panel is now locked and LOCKd is displayed, restarting requires entering the code. If the AUX OVERRIDE button is not pressed the machine can be started with out a code. The panel does not automatically lock.

Once in the SETUP menu, press START to step to the LOCK menu. Press POWER to enter the LOCK menu.

UNLOCKING THE INSTRUMENT PANEL:

IMPORTANT: Once the code is created the panel can not be unlocked with out the code. If the panel can not be unlocked - contact your Dealer.

1. Sit in the seat to power the instrument panel. The warning lamps will illuminate and there will be an audible beep.

2. Press the flashing POWER button, the display will show UNLOC followed by 00000 prompting the code.

3. Enter code by using multiple presses of the START button for 1, 2, 3, the AUX OVERRIDE button for 4, 5, 6, or the PARK button for 7, 8, 9, 0. Press the POWER button to save each digit and move to the next.

4. Press POWER after the 5th digit to enter code the engine preheat lamp will illuminate and the display will begin the 30 second countdown.

For temperatures below 50 ° F (10 ° C) wait until the Engine Pre-Heating lamp goes out and the count down is completed before pressing the START button to crank the engine. For temperatures above 50 ° F (10 ° C) press the START button to crank the engine.

If the incorrect code is entered ERROR is displayed followed by 00000 prompting the operator to enter the correct code.

CREATING CODES: The panel can not be locked until a code is created.

The Deluxe Instrument Panel has one owner code and up to ten user codes. The owner code will always unlock the panel and is the master code required to create or change owner and user codes.

SETUP MENU:

TO CREATE OWNER CODE: If no owner code exists, OWNCR (Owner Create) will be displayed followed by 00000. Write down the planned 5 digit code or use a code you already know.

1. Enter code by using multiple presses of the START button for 1, 2, 3, the AUX OVERRIDE button for 4, 5, 6 or the PARK button for 7, 8, 9, 0.

Press the POWER button to save each digit and move to the next.

2. Press POWER after the 5th digit to save the code, the display will go blank and then show the code created. The panel will return to the SETUP menu.

3. Press START to step to the EXIT menu and press POWER to exit the SETUP menu The panel is not locked at this point.

TO MODIFY OWNER CODE: Once in the LOCK menu OWNER will be displayed.

Press the POWER button to enter the OWNER menu. OPEN will be displayed followed by 00000.

1. Enter the current Owner Code by using multiple presses of the START button for 1, 2, 3, the AUX OVERRIDE button for 4,5, 6, or the PARK button for 7, 8, 9, 0. Press the POWER button to save each digit and move to the next.

2. Press POWER after the 5th digit to save the code. OWNCR will be displayed followed by the saved Owner Code.

3. Enter a new Owner Code to overwrite the existing code. The panel will return to the SETUP menu.

4. Press START to step to the EXIT menu and press POWER to exit the SETUP menu. The panel is not locked at this point.

1. Sit in the machine with the restraint bar in the up position and wait 30 seconds for the panel to power off (all lights on the panel will turn off).

USER CODES:

2. Press and hold the AUX OVERRIDE button and PARK button at the same time for 5 seconds. The display will show SETUP.

Once in the SETUP menu, press START to step to the LOCK menu. Press POWER to enter the LOCK menu.

3. To exit the SETUP menu press POWER at the EXIT display. Or press and hold the PARK button for 5 seconds; this can be done at any point in the SETUP menu.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS TO CREATE OR MODIFY USER CODE:

JOB TIMER

An owner code must be save before a user code can be created.

The Job Timer is an hour meter that may be use to track hours for a particular job or rental period. It can be reset through the SETUP menu.

Once in the LOCK menu OWNER will be displayed.

Press the START button to step to the USER menu.

Press POWER to enter the USER menu.

1. Use START button to step to USERO through USER9. Press POWER to create or change that Us er Code. US RCR (user c reate) w ill be displayed followed by 00000.

2. Enter the Owner Code. 00000 or the existing User Code will be displayed.

3. Enter a new User Code to enter or overwrite the existing code. The panel will return to the SETUP menu.

Once in the SETUP menu, press the START button to select JTIME and press the POWER button to enter the menu. The current Job Timer hours will be shown.

1. To exit without clearing the Job Timer press and hold the PARK button for 5 seconds.

2. To reset the Job Timer press the START button to select ERASE. Press the POWER button to ERASE the Job Timer.

3. Select EXIT to exit the SETUP menu.

4. Press START to step to the EXIT menu and press POWER to exit the SETUP menu. The panel is not locked at this point.

SELECTING TEMPERATURE UNITS FOR DISPLAY The operator may choose temperature units to be displayed in Fahrenheit or Celsius.

Once in the SETUP menu, press the START button to select UNITS and press the POWER button to enter the menu. The current units will be shown.

1. Press the START button to select the units.

FAHR for Fahrenheit or CELC for Celsius.

2. Press the POWER button to save the selection.

3. Select EXIT to exit the SETUP menu.

DISPLAY OPTIONS The panel can be set to display any one of the following items.

• • • •

Machine Engine Hours (ENHRS) Engine Speed (ENRPM) Engine Coolant Temperature (COOLT) Hydraulic Oil Temperature (HOILT)

Once in the SETUP menu, press the START button to select dSPLY and press the POWER button to enter the menu. The current display option will be shown.

1. Press the START button to select the display option.

2. Press the POWER button to save the selection.

3. Select EXIT to exit the SETUP menu.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS DELUXE INSTRUMENT PANEL WARNING LAMPS

2. Engine Malfunction Warning Lamp: This Yellow lamp will flash and the alarm will sound when the engine air filter becomes restricted and requires servicing. Service immediately.

These lamps assist the Operator in monitoring the functions of the various machine components. On initial start up these lamps, with the exception of the engine pre-heat lamp, will glow momentarily.

Figure 63

BS07M318

NOTE: If this lamp remains on after replacing engine air filters contact your Dealer.

1

2

4

3. Engine Pre-Heating Lamp: When the POWER button is pushed, the engine pre-heat light will illuminate. The engine pre-heat lamp will illuminate in all ambient conditions. For temperatures below 50 ° F (10 ° C), push the POWER button and wait until the lamp goes out before pushing the START button. For temperatures above 50 ° F (10 ° C), push the START button as required.

5

3

Figure 64

BC02N191

4. Hydraulic Charge Pressure Warning Lamp This Red warning lamp will flash and the alarm sounds if there is no, or low oil pressure in the transmission. A 30 second engine shutdown warning will display in the digital display. Do not run the machine if the war ning lamp illuminates. This condition may cause the SAHR Park Brake to engage. If this condition exists, the Park Brake Lamp will also flash.

Figure 65

BS99J181

IMPORTANT: Low hydraulic charge pressure will cause engagement of the SAHR park brake. The Park Brake lamp and the charge Pressure warning Lamp will flash and an audible alarm will sound, if this condition exists.

5. Hydraulic Fluid Warning Lamp: BD07M310

1. Engine Oil Pressure Lamp and Alarm: This Red 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. A 30 second countdown is displayed in place of the hourmeter, if this warning exists. The engine will be shutdown at the end of the countdown.

BS99D060

3-18

This Red warning lamp will flash and the alarm will sound if the temperature of the hydraulic fluid becomes extreme. Do not work the machine if this condition exists.

Figure 61

Figure 66

BC00B123

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CHAPTER 3 - INSTRUMENTS AND CONTROLS DELUXE INSTRUMENT PANEL 6. Digital Display: This digital display will show the following, during normal operation, as selected by the operator.

• Engine Hours: Engine hours will always be displayed momentarily when the operator initially sits in the seat. The operator may choose to leave engine hours on display continuously or select one of the following.

• Engine RPM • Engine Coolant Temperature (degrees F or C) • Hydraulic Fluid Temperature (degrees F or C) The digital display will show the temperature or voltage, as required, when fault conditions are reached.

The digital display will also help the operator or technician with information as the SETUP menu is utilized.

7. Hydraulic Fluid Temperature Bar Graph: This Hydraulic Fluid Temperature Bar Graph indicates the relative temperature of the hydraulic fluid between 32° F (0° C) and 230° F (110° C). If the temperature exceeds 230° F (110° C), all 8 graph segments will display, backlighting will flash, the audible alarm will sound and the digital display will show the current temperature. This condition will be recorded in the machine fault history. See table below for bar and temperature correlation.

6

7

Figure 68

BC00B123

Figure 67

BD07M210

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°F (°C)

Bars Visible

230°F (110°C)

8

220°F (104°C)

7

210°F (99°C)

6

195°F (91°C)

5

180°F (82°C)

4

140°F (60°C)

3

100° F (38°C)

2

< 100° F (< 38°C)

1 Figure 69

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS °F (°C)

Bars Visible

228°F (109°C)

8

220°F (104°C)

7

215°F (102°C)

6

210°F (99°C)

5

180°F (82°C)

4

140°F (60°C)

3

100° F (38°C)

2

< 100° F (< 38°C)

1 Figure 72

8

9. Fuel Gauge: The fuel level gauge, consists of a series of bars that indicate the level of fuel in the fuel tank. When all 8 bars are visible the fuel tank is full. The first bar indicates the following amount of fuel:

9

Solid Bar 3.0 U.S. gals (15.1 liters) Figure 73

BS96H048

NOTE: One solid bar will blink when the tank reaches this level of fuel.

BD07M310

Figure 70

8. Engine Coolant Temperature Bar Graph: This bar graph indicates the relative temperature of the engine coolant between 32° F (0° C) and 228° F (109° C). If the coolant temperature goes above 228° F (109° C) all 8 bars will display, backlighting will flash, the audible alarm will sound and the digital display will show the current temperature. This condition will be recorded in the machine fault history.

BS96H053

3-20

Figure 71

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CHAPTER 3 - INSTRUMENTS AND CONTROLS STEERING AND TRAVEL WITH H PATTERN CONTROLS

1

F

F

N

N

R

R

2

Figure 74

BD07K072

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

LEFT SIDE STEERING:

STRAIGHT AHEAD DRIVE:

By moving the left hand control lever (1) forward (F), from neutral, the left side tires will move forward.

When the left hand control lever (1) is moved rearward (R), from neutral, the left side tires will move in reverse.

Push both of the controls forward, from neutral, equally, to move the machine forward. Move the controls forward a short distance for maximum power and slow speed. Move the controls completely forward for maximum speed.

RIGHT SIDE STEERING:

STRAIGHT REARWARD DRIVE:

By moving the right hand control lever (2) forward (F), the right side tires will move forward. When the right hand control lever is moved rearward (R), the right side tires will move in reverse.

Confirm that the area behind the machine is clear, then pull both of the controls rearward, from neutral, equally, to move the machine in reverse.

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

Figure 75

WARNING: You must confirm that a safe area behind the machine is clear BEFORE engaging reverse motion.

Figure 76

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CHAPTER 3 - INSTRUMENTS AND CONTROLS TURNING A MACHINE WITH H PATTERN CONTROLS

BS06G022

Figure 77 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 make a pivot turn right: Hold the right steering control lever in neutral and push the left steering control lever forward.

Figure 78

BS06G023

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

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

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

Figure 79

BS06G024

GRADUAL TURN - (POWER TO BOTH SIDES - SAME DIRECTION)

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

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS LIFT ARM AND BUCKET CONTROLS WITH H PATTERN

5 1

2 3

4

Figure 80

BD07K072

1. LIFT ARM RAISE:

4. BUCKET ROLLBACK: (CURL)

The left-hand control lever controls the lift arm. The lift arm 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.

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

5. BUCKET DUMP:

3. LIFT ARM FLOAT: Pivoting the handle DOWN until a slight jump is felt.

This 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 pushes it back out and toward neutral.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUCTIONAL DECALS FOR H PATTERN STEERING AND CONTROL

A

B

C

Figure 81

87715689/87715687/87715690

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.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS STEERING AND TRAVEL ISO PATTERN PILOT CONTROLS

F

1

N

R

Figure 82

BD07K072

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 forward in the direction the lever is moved from neutral, center, in forward. Reverse movement requires opposite directions. For forward 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 machines steer and travel with the same commands.

STRAIGHT AHEAD DRIVE:

RIGHT TURN STEERING:

Push the control lever(1) straight ahead, 12:00 position, and the machine will move forward (F).

From forward travel push the control lever (1) to the 1:00 position and the machine will begin to travel right.

STRAIGHT REARWARD DRIVE: Pull the control lever(1) straight rearward (R), 6:00 position and the machine will move rearward.

LEFT TURN STEERING: From forward travel push the control lever (1) to the 11:00 position and the machine will begin to travel left. Move the control lever (1), further left, down toward 9:00 and the machine will move sharper left.

COUNTER-ROTATION TURN LEFT: Push and hold the control lever (1) straight left to the 9:00 position and the machine will counter- rotate.

Avoid counter-rotation as much as possible for better efficiency and component wear. Plan the worksite accordingly.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS TURNING A MACHINE WITH ISO PATTERN PILOT CONTROLS

BS06G035

Figure 83 PIVOT TURN - (POWER TO ONLY ONE SIDE)

To make a pivot turn left: From neutral, push the pilot control drive lever forward, slightly and then left toward 10:00.

To make a pivot turn right: From neutral, push the pilot control lever forward, slightly and then right toward 2:00.

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

Figure 86

BS06G036

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

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 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 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.

Figure 84

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.

Figure 85

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

3-26

Figure 87

BS06G037

GRADUAL TURN - (POWER TO BOTH SIDES - SAME DIRECTION)

To make a gradual turn 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.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS LIFT ARM AND BUCKET CONTROL WITH ISO PATTERN PILOT CONTROLS

3 2

4

N

A

5

1

3

Figure 88

BD07K072

A. Lift arm and bucket control lever with ISO pilot controls.

LIFT ARM RAISE AND LOWER CONTROL: The lift arms are controlled by pushing forward or pulling rearward the right ISO Pilot Control Lever (A).

1. Lift Arm Up: The lift arm will raise UP by pulling back on the Right ISO Pilot Control Lever (A).

2. Lift Arm Down: The lift arm will lower DOWN when the Right ISO Pilot Control Lever (A) is pushed forward.

3. Float:

BUCKET DUMP AND CURL CONTROL: The bucket is also controlled by the Right ISO Pilot Control Lever (A).

4. Rollback: (Curl) The bucket will roll back (curl) when the Right ISO Pilot Control Lever (A) is pivoted inward.

5. Dump: Pivoting the Right ISO Pilot Control Lever (A) up toward the outside of the cab will dump the bucket.

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

The lift arm spool is equipped with a detented FLOAT circuit. In this detented position the lift arm will float over changing ground contour and the lever will remain in this position until pulled back toward neutral.

To place the lift arm in FLOAT, push the control lever all the way forward until a slight jump is felt. In this position the lever will remain until pulled back and out of the detent.

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3-27

CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUCTIONAL DECALS FOR ISO PATTERN STEERING AND CONTROLS

A

B

C

Figure 89-

87715691/87715688C/87715692

See the control lever instructional 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. This is a single lever drive control machine.

If you have any question about the operation or function of the control levers contact your Dealer.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CONTROL HANDLE SWITCH CONFIGURATIONS LEFT HANDLE

RIGHT HANDLE

1

2

3

Figure 90

BD07K075

1. HORN BUTTON: Press this momentary button to activate the horn. Located on the front side of the handle.

Figure 91

BS98M064

2. TURN SIGNAL SWITCH: If equipped, press the top portion of this switch down to activate the left turn signal. Press the right portion of the switch down to activate the right turn signal. The switch must be turned back to the center position to cancel.

BD07K068

Figure 93

3. RIGHT CONTROL HANDLE PARK BRAKE SWITCH: This red push button switch is located on the right control handle. Push this switch to set the machine Park Brake. Do not activate this switch while the machine is moving. Stop the machine and then set the brake.

Figure 94

NOTE: This Park Brake Switch is only active after the system enable switch button has been activated.

Figure 92

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Left Control Lever Configurations

Right Control Lever Configurations

6

5 7 4

Figure 99

BD07N234 BD07N231

Figure 95

4. Auxiliary Electric Control Switch: Use this switch to control the auxiliary front electrical connector.

BS04G122

Figure 96

5. Two Speed Button: Press this button to change from low to high speed or high to low speed.

BS99J179

6. Proportional Auxiliary Hydraulic Control: Push this switch to the top to control the flow at the male connector. Push to the bottom to control flow to the female connector. The switch will remain in full forward or full down. The flow is propor tional to the switch position. Center position is off.

7. Auxiliary Electric Control Switch: Use this switch to control the auxiliary front electrical connector.

Figure 97

When high speed is selected the indicator lamp below will illuminate green.

Figure 100

BS04G121

8

Figure 101

BD07K073

BD07K069

8. Ride Control Switch: To improve machine ride over uneven terrain, with or without a loaded bucket.

Raise loader lift arms off the chassis about 4 to 6 inches (101 to 152 mm) Depress and hold the button while Ride Control is desired. Release the button to return to normal ride.

Figure 98

The speed selection lamp is located on the lower portion of the instrument panel.

Figure 102

BS07N607

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

THROTTLE CONTROLS IMPORTANT: When the foot throttle is completely released, the minimum speed, will default to the setting that the hand throttle is set at.

Manual Throttle Control Lever

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

1

2

Figure 103

BD07K116

1. MANUAL THROTTLE CONTROL LEVER IN LOW IDLE POSITION 2. MANUAL THROTTLE CONTROL LEVER INSTRUCTION DECAL

The manual throttle control lever is located just to the right of the operator, while sitting in the seat. This lever will remain in the position selected by the Operator.

NOTE: Most operation conditions require full throttle position.

Foot Throttle

3

Figure 104

BD08G012

3. FOOT THROTTLE

The foot throttle is located at the right hand corner of the floor plate. Push down to increase the engine throttle speed. Release pressure and the engine throttle speed will decrease.

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3-31

CHAPTER 3 - INSTRUMENTS AND CONTROLS STANDARD AUXILIARY HYDRAULIC AND HIGH FLOW AUXILIARY HYDRAULICS

5

1

Figure 105

BD08H500

Figure 107

BD08H502

5. AUXILIARY HIGH FLOW COUPLERS

1. AUXILIARY HYDRAULIC COUPLERS

2 6 7 3

8

9

4

BD08H501

2. FRONT ELECTRIC CONNECTOR 3. AUXILIARY CIRCUIT COUPLERS 4. CASE DRAIN COUPLER

Figure 106

Figure 108

BD08H499

6.

7.

8.

9.

FRONT ELECTRICAL CONNECTOR HIGH FLOW HYDRAULIC COUPLERS AUXILIARY HYDRAULIC COUPLERS CASE DRAIN COUPLER

If the machine is equipped with a High Flow hydraulic kit it will have 1/2” and 5/8” couplers.

When using high flow, the 5/8” couplers should be used to prevent high back pressure and over heating of the hydraulic system.

When removing a hydraulic attachment reinstall the coupler covers, if equipped and lock the control in the neutral position.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS WARNING: Do not to accidently make contact with the auxiliary hydraulic foot control pedal while entering or exiting the cab. Accidental contact could alter hydraulic flow and cause Death or serious injury.

Figure 109

4

Figure 110 10. HIGH FLOW AUXILIARY HYDRAULIC CONTROL SWITCH

BD07K117

This switch is located on the left cab upright switch panel.

4. Auxiliary Hydraulic Flow Switch: Push the top portion of the switch to engage high flow auxiliary hydraulic mode. The green symbol portion of the lamp will illuminate. The bottom portion of the switch is standard flow.

Figure 111

BC04F114

IMPORTANT: The High Flow Switch must be turned to the OFF position when not in use or required.

Overheating of the hydraulic fluid or poor attachment operation may occur.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS AUXILIARY HYDRAULIC CONTROL PEDAL

1

2

3

2

Figure 112

BD05E493 / 139618A1 / BD04N106

1. AUXILIARY HYDRAULIC FOOT CONTROL PEDAL 2. AUXILIARY HYDRAULIC FOOT CONTROL PEDAL INSTRUCTIONAL DECAL 3. AUXILIARY HYDRAULIC FOOT CONTROL PEDAL IN ON POSITION (RIGHT SIDE OF PEDAL DOWN) Figure 113

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

To relieve pressure: 1. Turn off the engine.

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

Figure 114

WARNING: Make sure not to accidently make contact with the auxiliary hydraulic foot control pedal while entering or exiting the cab. Accidental contact could alter hydraulic flow and cause Death or serious injury.

Figure 115

IMPORTANT: The High Flow Switch must be turned to the OFF position when not in use or required. Overheating of the hydraulic fluid or poor attachment operation may occur.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 116

BD04D101

This Auxiliary Hydraulic Foot Control Pedal controls the hydraulic flow to the front attachment (hydraulic couplers on the lift arm).

Push down on the right side of the pedal to send auxiliary hydraulic flow to the male coupler.

Release the pedal and it will return to neutral or no hydraulic flow to the attachment.

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

Continuous Auxiliary Hydraulic Flow If the attachment requires continuous hydraulic power, depress the Auxiliary Hydraulic Foot Control Pedal and move the locking lever in the same direction. The pedal may be locked in either direction.

To release the pedal, push the lock back to the center and the pedal will return to neutral or no hydraulic flow.

WARNING: You must read the attachment manual before operating the attachment.

Contact your Dealer if you have any questions about Auxiliary Hydraulic Controls.

Figure 117

IMPORTANT: Always clean the hydraulic couplers and the areas around couplers prior to making connections. Avoid contamination of the system.

See page 3-14 for Auxiliary Hydraulic Interlock Override.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS NO ENGINE POWER - LIFT ARM BYPASS CONTROL - ISO PILOT CONTROL MACHINES This control is located behind the left console fuse compartment, just to the left of the Operator, while in the seat.

1. NO ENGINE POWER - LIFT ARM D OW N C O N T R O L - P I L OT CONTROL MACHINES: Befo re a ttem ptin g to lower the lift arm/attachment on a machine that has lost engine power, alert personnel in the area of your intention. Do not leave the seat, unfasten the seat belt or raise the restraint bar. After confir ming that personnel and obstacles are clear, pull the control knob UP to lower the lift arm/attachment down to the ground.

WARNING: The No Power - Lift Arm Hydraulic Bypass Control is 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 the restraint bar down. Failure to follow these instructions can result in death or serious injury.

This red control knob is for emergency situations only and should not be used in day to day normal operations.

Figure 118

In the event of the loss of engine power, this override control will allow the operator to lower the lift arms to the ground.

The control knob (1) is located to the left of the o p e r a t o r, j u s t b e h i n d t h e l e f t c o n s o l e f u s e compartment.

Figure 120

87568435

WARNING: Never exit the skid steer unless the lift arm and attachment are down resting on the ground or the lift arm is resting on the lift arm lock pins. Failure to comply could result in death or serious injury.

Figure 121

1

BD07M309

Figure 119

1. LIFT ARM HYDRAULIC BYPASS CONTROL KNOB / PILOT CONTROL MACHINES

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CHAPTER 3 - INSTRUMENTS AND CONTROLS NO ENGINE POWER - LIFT ARM BYPASS CONTROL - H CONTROL MACHINES In the event of loss of engine power, the Lift Arm/Attachment may be lowered to the ground. This procedure requires moving the release handle toward the outside of the machine and, at the same time, pushing the Lift Arm down control.

This control is located in the right storage tray just to the right of the Operator, while in the seat. It must be used in conjunction with the Lift Arm down control.

WARNING: Before attempting to bring the lift arm/attachment down on a machine that has lost engine power, alert personnel in the area of your intention. You must confirm that personnel and obstacles are clear before engaging the lift arm hydraulic bypass down control. Death or serious injury may result if these instructions are not followed.

Figure 122

Do not leave the seat, unfasten the seat belt or raise the restraint bar. Alert personnel in the area of your intentions, and confirm that personnel and obstacles are clear of the machine.

1

2

Figure 123

BD07K074 / BD07K120X

1. LIFT ARMS DOWN CONTROL ON H PATTERN MACHINE 2. LIFT ARMS HYDRAULIC BYPASS CONTROL LOOP

This procedure is for emergency situation only and should not be used in day to day normal operations.

WARNING: Never exit the skid steer unless the lift arm and attachment are down resting on the ground or the lift arm is resting on the lift arm lock pins. Failure to comply could result in death or serious injury.

Figure 124

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CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATORS SEATS

1

2

3

1 2

Figure 125

BD07M312

SUSPENSION SEAT

DELUXE HEATED SUSPENSION SEAT

1. SUSPENSION ADJUSTMENT: Tur n the adjustment control to the desired comfort level.

2. FORWARD / REARWARD ADJUSTMENT LEVER:

Figure 126

BD07K122

1

2

To a d j u s t , r o t a t e t h e l a t c h h a n d l e counterclockwise and slide the seat to the desired position. After adjusting the seat, rock the seat forward and rearward to make sure it is latched into position.

IMPORTANT: Seats should be adjusted so the Operator may easily move all levers and controls through their entire range of motion, as manufactured.

Figure 127

BD07K125

1. SEAT HEAT SWITCH: Push the red lamp por tion of this switch to activate the seat heat. The red la mp will illuminate when activated. The switch will remain in the position chosen by the operator.

2. SUSPENSION ADJUSTMENT: Tur n the adjustment control to the desired comfort level.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT AND SEAT RESTRAINT BAR

3

4 3

2 Figure 128

BD07K123

3. FORWARD LEVER:

1

/

REARWARD

ADJUSTMENT

To a d j u s t , r o t a t e t h e l a t c h h a n d l e counterclockwise and slide the seat to the desired position. After adjusting the seat, rock the seat forward and rearward to make sure it is latched into position.

NOTE: Before tilting the cab forward place the seat in the most forward position to allow clearance between the seat back and ROPS.

Figure 129

BD07K122

1.

2.

3.

4.

RETRACTABLE HALF OF BELT BUCKLE HALF SHOULDER BELT (IF EQUIPPED) SEAT RESTRAINT BAR

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

A shoulder belt (3) is available from your Dealer or comes standard equipment on machines with a cab door.

NOTE: A California - required 3” webbing seat belt kit is available as a field installed attachment or through Service Parts. This belt may be necessary in some industrial construction applications. Check your local codes.

WARNING: Do not operate the skid steer unless the seat belt is properly fastened around the operator.

Figure 130

WARNING: Never operate a skid steer if the seat belt is missing or damaged. Inspect the seat belt regularly to be sure it is not damaged in the buckle, webbing or securing hardware areas.

Figure 131 87493825NA

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB DOOR LATCH

1

2

3

Figure 134

BD07K118 BD07K107

Figure 132

3. INNER CAB DOOR RELEASE LEVER

1. OUTER CAB DOOR LATCH HANDLE 2. KEY LOCK AND PUSH BUTTON

Figure 135

BD07K124 BD07K108

Figure 133

Push on the button to release the door for entry. The starter switch key may be used to lock the door.

NOTE: The front door may be removed. See page 6-5 in the Maintenance Chapter of this manual.

3-40

Push down on the lever to release the door latch.

IMPORTANT: Do not raise or lower Loader Lift Arm until you have confirmed the door is fully closed.

Damage may occur to the door assembly.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS AUXILIARY POWER SUPPLY

SIDE WINDOW OPEN AND CLOSE The side windows, on machines so equipped, may b e o p e n e d a n d c l o s e d t o s u i t t h e o p e ra t i n g conditions.

2

1

Figure 136

BD07N242

1. SLIDING GLASS LOCK LEVERS 2. DETENT POSITIONS

BD07N531

Figure 137

If equipped the12 volt power supply is located inside the storage tray. The outlet will be activated when the key switch is in the Accessory or Run position.

To open or close the side windows, pinch the latch handles together and slide the window to the desired position. Release the levers and lock the glass into a detent position.

NOTE: The rear and front, side windows may be removed. See page 6-4 in the Maintenance Chapter of this manual.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDSHIELD WASHER / WIPER CONTROLS

2

1

Figure 141

BD07N244

2. Windshield Washer Reservoir: The windshield washer reservoir fill tube is located inside the cab and to the right of the Operator while sitting in the seat.

Figure 138

BD07N243

1. WINDSHIELD WIPER AND WASHER CONTROL SWITCH

1. Windshield Wiper Switch: This three position switch turns the wiper ON, OFF and operates the washer fluid spray.

Figure 139

BC07C711

Figure 142

BS99N054

IMPORTANT: Never operate the windshield washer motor without fluid in the washer reservoir. Damage to the motor could occur.

MASTER DISCONNECT SWITCH AND REMOTE JUMP START TERMINALS

1

Figure 143

BD07N462

2

3

4

Figure 140 2. LEFT POSITION - OFF 3. CENTER POSITION - WIPER ON - GREEN SYMBOL WILL LIGHT 4. PUSH THE SYMBOL END OF THE SWITCH FOR MOMENTARY SPRAY - WHEN RELEASED SWITCH RETURNS TO ON

BD07N240

3-42

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

The master disconnect switch is located at the left rear of the machine behind the door. All power to the machine may be shut off at this location. Do not use this switch to stop a running engine, damage may occur.

Remote jump start terminals are also located at the left rear of the machine.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS OVERHEAD GLASS The overhead glass may be easily removed for cleaning of the cab glass.

1

Figure 144

BD08E071

1. RELEASE TABS

Loosen the hardware and rotate the release tabs 90 degrees to fit through the roof slot.

Lift the front of the glass up and slide forward until the brackets at the back of the glass are free of the rops.

Clean the glass with a suitable cleaner. Be careful not to use abrasive cleaners or cloth that might scratch or scuff the surface.

Reverse the procedure to install the glass.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 RUN-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 PARKING THE MACHINE AND STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ATTACHMENT MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 FIELD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 MOVING A DISABLED MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 STORING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

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CHAPTER 4 - OPERATING INSTRUCTIONS

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CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS This Chapter explains the operation procedures for the machine and components. Run-In-Periods, Pre-Start Procedures, Hot and Cold Engine start procedures and some Work Site Operations. This Chapter explains multi-function operations such as auxiliary hydraulic functions, attaching and removing buckets. If you have any questions about the operation of this machine contact your Dealer before you begin operating.

WARNING: Before starting engine, study operators 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 manufacturers instructions on machine operation, service, and to observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer.

Figure 1

RUN-IN PERIOD

See page 5-16 for complete instructions.

Engine Operation

Pre Starting Checklist and Walk-Around Inspection

During the first 20 hours of operation, or if you rebuild the engine, make sure you do the following: 1. Check engine oil and coolant levels before operation.

2. Operate the machine with normal loads for the first 8 hours. Do not work the engine hard at stall speeds (wheels or track turning slow or stopped and engine speed at full throttle).

3. Keep the engine temperature.

at

normal

operating

4. On turbocharged machines the operator should let the machine idle for a cool down period before stopping the engine. Failure to follow these instructions could cause damage to the turbocharger.

5. Do not run the engine at idle speeds for long periods of time. Continue this practice after the run-in-period.

6. During the 20 hour run-in period, check the oil level at approximately one hour intervals. Oil consumption may be higher during the initial run-in period.

7. It is recommended that the operator run the engine at full throttle when operating conditions permit.

IMPORTANT: After the first 50 hours of operation change the engine oil and filter.

Wheel Nuts If the machine is new or if a wheel is removed for service, check and tighten the wheel bolts or wheel nuts every ten hours of operation until they remain tight.

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

If the machine is equipped with solid center wheels it will have flange type lug nuts. Torque for these will be 165 to 195 pound feet (224 to 265 Nm).

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Before each operating period, it is the responsibility of the operator to confirm that the machine is, in fact, safe and serviced.

Operating and environmental conditions must be considered and the following checked: 1. Fill the fuel tank with No. 2-Diesel fuel.

2. Confirm that the radiator and coolers are clear of debris and obstructions.

3. Check fluid levels of the engine, hydraulic reservoir and coolant tank.

4. Check for leaks under the machine.

5. Check the tire pressure and condition. On track machines, check track tension and condition.

Make sure debris are removed from around the sprocket and track.

6. Lubricate, as necessary, any fittings in accordance with the lubrication and maintenance schedule.

7. Inspect the machine for loose parts, damaged components or missing items. Watch for wear of hydraulic hoses and rubber components. Keep all shields in place.

8. Confirm that all Safety Decals are legible and properly placed on the correct component.

Replace any Safety Decals that are not legible.

Contact your Dealer for replacement Safety Decals.

9. If there is an attachment on the machine, confirm that it is mounted securely.

10. Clean all steps, hand holds and cab access areas.

11. Remove any loose items in the operators compartment.

12. Check the seat belt/seat switch for damage and proper operation. See page 5-20 in this manual.

13. Confirm that all controls operate freely and correctly.

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CHAPTER 4 - OPERATING INSTRUCTIONS 14. Confirm that the drive control is correct and the machine does not creep. Contact your Dealer, if the machine does not remain stationary with the drive controls in neutral.

15. Confirm that the parking brake does hold the machine from movement when powered or on an incline.

WARNING: You must repair or replace any items found to be malfunctioning or leaking BEFORE operating the machine.

Figure 2

16. See the Quick Reference Replication and Maintenance Chart on page 5-13 in this manual and do the items under 10 Hours or As Required.

17. Remove all dirt and debris from the foot control pedal area.

STARTING THE ENGINE

1. Adjust the seat and fasten the seat belt.

2. Pull the restraint bar down and make sure that all controls may be reached and you are able to move all controls to their full motion.

3. Sound the horn to alert others of your intention.

4. Push the throttle forward approximately 1 inch (25mm).

5. Turn the key switch to ON, or on keyless machines push the POWER button and monitor the instrument cluster lamps.

6. The engine pre-heat lamp will illuminate.

• If the temperature is below 50° F (10° C) wait until the lamp goes out before resuming. This may be 30 seconds. Monitor the countdown in the display.

• If the temperature is above 50° F (10° C) proceed directly to start.

The Instrument Panel controls the fuel solenoid, preheat circuits and the lift arm and bucket control valve spool locks. When the operator sits in the seat the Instrument Panel will become active. Indicator lights will illuminate in sequence according to function, and electrical circuits will go through a self check.

WARNING: Under no circumstance should ether, or any other starting fluid, be used on this machine. It is equipped with an Engine Pre-Heat Cold Start System. Fire, explosion, serious injury or death could result.

Figure 3

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 place the restraint bar into the operating position (down). Make sure all personnel in the area are away from the machine. Sound the horn before starting to warn those around of your intention.

Figure 4

7. If the skid steer is equipped with an auxiliary hydraulic foot control, make sure the pedal is in neutral.

8. Turn the ignition key to START or on keyless systems press the START button. After the engine starts allow the key to return to RUN. The engine must star t within 30 seconds. If the engine does not start, allow the starter to cool for one minute and then begin the procedure again by switching the ignition to OFF then ON again.

Do not operate the starter motor continuously for more than 30 seconds.

IMPORTANT: If the machine is to be operated in consistently low temperatures contact your dealer for the correct oil.

ALWAYS allow the engine and hydraulic system to warm up before applying a load.

9. After starting the engine monitor the indicator lights and confirm that machine functions are normal.

ENGINE SPEED Do not run the engine at idle speed for long periods.

This can cause a low operating temperature, which can cause acids and deposits in the engine oil. It is recommended that you run the engine at full throttle when operating conditions permit and when safe.

IMPORTANT: If the engine stalls during normal operation, start the engine immediately. This will prevent damage to the turbocharger.

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CHAPTER 4 - OPERATING INSTRUCTIONS PARKING THE MACHINE AND STOPPING THE ENGINE 1. When parking the machine, make sure the machine is parked on level ground 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. Run the engine at idle speed and allow time for the engine and component parts to cool evenly.

IMPORTANT: The turbocharger (if equipped) may be damaged if the engine is not properly shut down.

3. Place all control levers in their neutral position.

4. If equipped, place all auxiliary hydraulic controls in neutral.

5. Turn the key to the OFF position, or on keyless machines push POWER to stop the engine. The parking brake is engaged automatically.

6. Raise the seat restraint bar and move controls until they are locked.

7. Remove the key, release the seat belt and use the hand holds when exiting the machine.

MACHINE OPERATION WARNING: Before you operate the machine, check the steering control levers, instruments, warning lamps, engine throttle, and attachment hydraulic controls. Also check the seat belt/seat switch.

If you know there is a malfunction, missing part, or part that needs adjustment, stop the machine and correct the problem immediately. Failure to follow these instructions can result in death or serious injury.

Figure 5

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

Figure 6

1. Set the engine speed at the desired throttle setting. Control the machine ground speed with the ste er ing control levers. When jobsite conditions permit the throttle position should be set at maximum.

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, bring the levers back to the neutral position.

3. Keep all machine and loader movements smooth and the work cycle as short as possible. More work may be accomplished in a shorter time with a smooth short work cycle.

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

5. Use the correct tires for the jobsite conditions.

Contact your Dealer for tire options.

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

Figure 8

WARNING: To avoid potential serious injury by contact with the moving lift arm or bucket, do not rewire to bypass the seat switch.

Figure 9

WARNING: Maintain proper transmission oil level to prevent loss of hydrostatic braking.

Figure 10

WARNING: Never transport a loaded bucket at full height. Operate the machine with the load as low as possible until it becomes necessary to raise the lift arm to dump the load.

Figure 11

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand rails and steps, and get on or off the machine slowly. SA038 Figure 7

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4-5

CHAPTER 4 - 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 service life of the machine.

Allow extra time during cold weather to bring the machine and components up to operating temperature.

IMPORTANT: On pilot control machines - check controls for operation, in a clear area away from personnel and obstructions, before starting full use of the machine.

Battery and Electrical 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.

A fully charged battery at 0° F (-17°C) has only 40% of the normal starting power.

Lubricants Use the correct viscosity oil in each component.

Case No. 1, API CI-4 15W-40 for the engine.

Use 10W-30 engine oil for the hydraulic system and c h a i n c o m p a r t m e n t s. 0 W 4 0 S y n t h e t i c O i l i s recommended for the hydraulic system in cold temperatures.

Use 135H EP Gear Lube in the final drives, 80W-90 or 85W-140. Synthetic Gear Lube is also available for severe service as 75W-90.

Consideration for extreme temperatures and the correct viscosity are recommended.

See the oil viscosity char t on page 5-17 in the Lubrication, Filters and Fluids Chapter of this manual.

Contact your Dealer if you have any questions about fluids or lubricants for your machine.

Diesel Fuel System Verify with your fuel supplier for the correct cold weather fuel. Diesel engine power will be reduced if wax particles are in the fuel filter.

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.

WARNING: Under no circumstance should ether, or any other starting fluid, be used on this machine. It is equipped with an Engine Pre-Heat Cold Start System. Fire, explosion, serious injury or death could result.

Figure 12

Biodiesel Fuel Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

IMPORTANT: Biodiesel Fuel blends are approved for your engine only if they comply with Specification standards EN14214 or ASTM D6751.

IMPORTANT: It is imperative that you check which blend is approved for your engine with your local dealer. Beware that the use of Biodiesel Fuel that does not comply with the Standards mentioned above could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void Warranty coverage.

Biodiesel Fuel Usage Conditions IMPORTANT: The Biodiesel Fuel must meet the fuel Specification mentioned above.

Biodiesel Fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel Fuel must be pre-blended by the supplier. Mixing Biodiesel Fuels on-site can result incorrect mixture that can lead to problems with both engine and fuel system.

Engine perfor mance is affected by the use of Biodiesel Fuel. There may be up to 12 percent reduction in power or torque depending on the blend used.

IMPORTANT: DO NOT modify the engine and/or injection pump settings to recover the reduced performance.

The reduced power must be accepted if using any Biodiesel Fuel blend.

Some modification may be required to allow your engine to run Biodiesel Fuel. Consult you dealer for complete information on these modifications.

Biodiesel Fuel has a higher cloud point than Diesel Fuel.

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CHAPTER 4 - OPERATING INSTRUCTIONS IMPORTANT: The use of high Biodiesel Fuel blends are not recommended in cold weather conditions.

With Biodiesel Fuels, it may be necessary to change the engine oil, engine oil filter and fuel filter elements more frequently than with Diesel Fuels. Biodiesel Fuel can remove rust and particles from the inside of on-site fuel storage tanks that would normally adhere to the sides of the tank. Like particle deposits that commonly occur with Diesel Fuel, these particles can become trapped by the machine fuel filters, causing blockage and shortening filter life. In cold weather, this is more likely to happen. Consult your dealer for information on cold weather operation and proper maintenance intervals when using any Biodiesel Fuel blend.

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 34° F (1° C). If the ambient temperature is lower, adjust the mixture to 60% ethylene glycol and 40% water. It is recommended that ethylene glycol and water be used in your machine all year.

Cold Temperature Starting Aids See your Dealer for additional starting aids.

When handling Biodiesel Fuel, care must be taken not to allow water into the fuel supply. Biodiesel Fuel will actually attract moisture from the atmosphere.

Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel stored in the machine.

IMPORTANT: Machines must not be stored for more than 3 months with Biodiesel Fuel blends in the fuel system.

If long storage periods are necessary, the engine must run on Diesel Fuel for 20 hours to flush the Biodiesel Fuel out of the engine fuel system prior to storage.

IMPORTANT: Biodiesel Fuel must not be stored in on-site storage tanks for more than 3 months.

Any spillage of Biodiesel Fuel must be cleaned up immediately before it can cause damage to the environment and the paint finish of the machine.

Before using Biodiesel Fuel blends you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

IMPORTANT: Be aware that not fulfilling the requirements and conditions of Biodiesel Fuel usage will void your machine's warranty coverage.

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CHAPTER 4 - OPERATING INSTRUCTIONS Heat and Air Control Operation Heating the Cab - Cold Weather Operation

1 4

Figure 15

BD08F019

4. RECIRCULATING VENT TAB

• Open the recirculation vents to heat the cab more Figure 13

BD07N230

1. HEATER COOLANT VALVE IN ON POSITION

• Remove the floor plate and turn the heater/coolant valve to the ON position for water flow through the heater core.

• Allow the engine to warm up to operating temperature.

quickly. Push the tab to the rear.

• To minimize dust ingression into the cab, operate with the recirculation vents closed and the blower fan on high.

Defrosting / Defogging

• To defrost the front door, point the front two louvers toward the door.

• To defrost the side windows, point the two middle louvers toward the glass on each side.

• To defrost the rear window, point the rear two louvers towards the rear window.

• For maximum heat to the foot or floor area, close the two rear and two middle louvers. Point the front louvers to the foot area.

2

If the machine is equipped with air conditioning, turn the A/C switch on to help dehumidify and defog faster.

3

Figure 14 2. FAN OFF 3. LOW BLOWER FAN SPEED

• During winter operation it is suggested the blower speed be set to off or low speed until the engine is at operating temperature.

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CHAPTER 4 - OPERATING INSTRUCTIONS CAB HEAT AND AIR VENTS AND LOUVERS The louvers and recirculation vents are located in the cab headliner. Use these vents in conjunction with the heat and air controls to control the air, heat and circulation in the cab. Air flow, direction and volume may be adjusted.

1 2

2

3 3

4

4

5

5

Figure 16

BD07K102

1.

2.

3.

4.

5.

CAB DOME LIGHT - PUSH THE BUTTON TO ACTIVATE THE LIGHT FRONT ADJUSTABLE AIR LOUVERS MID ADJUSTABLE AIR LOUVERS REAR ADJUSTABLE AIR LOUVERS RE-CIRCULATION VENTS

Figure 17

BD07K103

Re-circulation vent open to reuse air from inside the cab and mix with fresh air from outside. Push the slide tab to the rear.

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BD07K104

Figure 18

Pull the slide tab forward to close the re-circulation vent. Only fresh air from outside the cab is used, minimizing dust ingression into the cab.

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING IN HOT WEATHER To prevent damage to the machine during hot weather: Cooling System and Air Conditioning

• Keep the coolant at the correct level in the reservoir and radiator. Use the correct solution of 50% (maximum) ethylene glycol and 50% water in the cooling system.

• With the engine cold, check the radiator cap for damage and wear before hot conditions begin.

Replace the cap if necessary.

• Keep dirt and debris from restricting the radiator and coolers. Take extra precaution to monitor build up while operating.

• Monitor the condition of the fan belt.

1

BD07N229

Figure 19

1. HEATER COOLANT VALVE IN OFF POSITION

• When operating the air conditioner, turn the heater coolant valve to the off position.

• Open the recirculation vent to cool the cab faster.

• Point the front, middle, and rear louvers toward the area to be cooled.

• Closing louvers will increase air flow to the open louvers.

• To minimize dust ingression to the cab, operate with the recirculation vents closed and the blower fan on high.

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CHAPTER 4 - OPERATING INSTRUCTIONS ATTACHMENT MOUNTING Mounting An Attachment With The Manual Attachment Coupler

WARNING: You must confirm that the coupler latch pins have extended into the bucket or attachment properly before beginning any work or operation.

IMPORTANT: Read the manufacturer’s instruction manual for authorized attachments.

Figure 24

WARNING: Attachments used with this skid steer must be compatible with the mounting system.

Figure 20

WARNING: Always make sure all dirt and debris are cleared from the machine, attachment, tool or bucket components before attempting attachment or removal procedures.

4

Figure 21

Manual Attachment Coupler Components

1 5 2

Figure 25

BD07K111

ATTACHMENT LOCK LEVERS AND COUPLER PINS IN LOCK POSITION

3

4. ATTACHMENT LOCK LEVERS IN THE LOCK POSITION 5. COUPLER LATCH PINS EXTENDED

Figure 22

BD07K110

1. COUPLER V END (1 EACH SIDE) 2. ATTACHMENT LOCK LEVER (1 EACH SIDE) 3. COUPLER LATCH PIN (1 EACH SIDE)

6 1

1

7

2

BD07K109

Figure 26

ATTACHMENT LOCK LEVERS AND COUPLER PINS IN THE UN LOCK POSITION 6. ATTACHMENT LOCK LEVERS IN THE UNLOCK POSITION 7. COUPLER LATCH PINS RETRACTED

3 Figure 23

BD07K111

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CHAPTER 4 - OPERATING INSTRUCTIONS To Install A Bucket: Before installing a bucket or attachment move the levers and latch pins through lock and unlock positions. Confirm that no debris or obstructions interfere with the full movement of levers or latch pins.

9

8

Figure 28

8

BK98E108

6. Push both attachment coupler lock levers down to engage the coupler latch pins into the bucket.

9

Figure 27

8. UPPER BUCKET MOUNT 9. COUPLER V ENDS

WARNING: It is possible to have the attachment lock levers in the lock position and not have proper contact with the attachment. You must check to confirm that the coupler pins are properly engaged with the attachment.

Figure 29

1. Place the attachment coupler lock levers in the unlocked position, handles up and coupler latch pins retracted.

2. While sitting in the operator’s seat with the restraint bar down, start the engine and tilt the attachment coupler forward so the coupler v ends are positioned to engage the upper mounts of the bucket.

3. Move the machine slowly forward and raise the lift ar ms. The top edge of the v ends must engage the upper mounts of the bucket.

10

10

4. Engage the roll back function while raising the lift arm so the bucket is just off the ground. The attachment coupler front surface should make complete contact with the bucket rear surface.

5. Stop the engine and raise the seat restraint bar.

Figure 30 10. COUPLER LATCH PINS ENGAGED INTO BUCKET

7. Confirm that the area around the machine is clear of personnel, machines, obstacles and hazards.

8. Re enter the cab and slowly raise the lift arms until the bucket reaches approximate operator eye level. Confirm that the coupler latch pins are correctly engaged with the attachment.

WARNING: You must confirm that the bucket or attachment is mounted correctly to the machine before operating. Death or serious injury may result if you do not follow these instructions.

Figure 31

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CHAPTER 4 - OPERATING INSTRUCTIONS Removing The Attachment To remove a bucket: 1. Raise the bucket or attachment 25 to 50 mm (1 to 2 inches) off the ground.

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

Figure 32

BK98E087

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

IMPORTANT: Be sure the latch handles are fully raised.

4. Return to the operator’s seat, lower the restraint bar, fasten the seat belt and start the engine.

5. Slowly rotate the attachment coupler out, bucket dump function, allowing the bucket or attachment to slide off the top edge of the coupler.

6. Slowly continue tilting the mounting plate forward a n d b a c k t h e s k i d s t e e r a w ay f r o m t h e attachment at the same time.

WARNING: Never exit the skid steer with the lift arms up UNLESS the lift arms rest on the lift arm support strut. Death or serious injury may result if you do not follow these instructions.

Figure 33

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CHAPTER 4 - OPERATING INSTRUCTIONS Mounting an Attachment With the Hydraulic Mounting Plate The operator may efficiently change a lift arm m ou nt ed at tac hm e nt , w h ile remaining in the operator’s seat, with this optional mounting plate.

Lock Pin Indicators The lock pin indicators show the operator which position the pins are in.

1

1 1

Figure 35

BD07N221

1. LOCK PIN INDICATORS IN THE GREEN OR LOCKED POSITION

2

2 BD07M315

Figure 34

1. HYDRAULIC ATTACHMENT MOUNTING PLATE SWITCH (LOCATED ON THE LEFT CAB UPRIGHT SWITCH PANEL)

The top or unlock portion of the switch will illuminate red when pushed.

Activating the coupler pins is a two step procedure to remove or release a bucket.

Read these instructions carefully and practice in a safe area until you are familiar with the process.

IMPORTANT: Use the function which best fits the attachment requirement. If you have any questions about mounting or dismounting attachments contact your Dealer.

Figure 36 2. LOCK PIN INDICATOR IN THE UNLOCK POSITION - RED SHOWN AT THE BOTTOM OF THE FLAG

BD07N223

IMPORTANT: The Lock Pin Indicators only show the position of the coupler pins. They DO NOT confirm that correct attachment has been made.

The operator must safely confirm that the coupler pins are engaged correctly.

WARNING: You must confirm that the bucket or attachment is mounted correctly to the machine before operating. Death or serious injury may result if you do not follow these instructions.

Figure 37

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CHAPTER 4 - OPERATING INSTRUCTIONS To Attach A Bucket Or Other Attachment:

1

1

2

2

4

Figure 38

BD07N223

1. UPPER BUCKET MOUNTS 2. COUPLER V ENDS

The following sequence uses the roll back function to activate the coupler pins. Any loader or auxiliary function will activate the pins. Use the activation function which best suits the attachment.

NOTE: It will not be necessary to engage the coupler switch for the attachment procedure.

1. Approach the bucket and stop the machine just before the coupler V ends make contact with the upper bucket mounts. The coupler pins should be retracted and the red por tion of the flag showing, as shown in the photo above.

2. Engage the bucket upper mounts and activate the roll back function.

3. Hold the roll back function completely to the end of it’s stroke and the pins will engage the bucket and the red portion of the flags will drop down.

Only the green portion of the flags will show.

Figure 40

BD07N222

4. LEFT SIDE COUPLER PIN SHOWN ENGAGED CORRECTLY

5. Before using the attachment, the operator must operate it through its full range of motion and confirm that the attachment is secure and safe.

WARNING: Make sure the attachment is securely latched and the green indicator is correctly confirming the pins are secure to the attachment.

Figure 41

WARNING: You must confirm that the bucket or attachment is mounted correctly to the machine before operating. Death or serious injury may result if you do not follow these instructions.

Figure 42

3

3

Figure 39 3. COUPLER PINS SHOWN IN THE LOCKED POSITION.

BD07N224

4. Slowly raise the bucket and roll it out to inspect the coupler pins. It is not necessary to raise the b u c k e t v e r y h i g h fo r t h i s i n s p e c t i o n .

Approximately 36 inches.

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CHAPTER 4 - OPERATING INSTRUCTIONS Removing the Attachment with the Hydraulic Mounting Plate Before beginning this procedure, you must confirm that the area behind the machine is clear of all obstacles and personnel. After releasing the bucket, it will be necessary to back away from it slightly to clear the upper bucket mounts.

5

5

To Remove The Bucket: 1. Place the bucket flat on the surface. Green flags should be showing.

Figure 44 5. COUPLER PIN INDICATORS SHOWN IN THE UNLOCKED POSITION. (RED FLAGS SHOWING)

BD07N223

7. When the mounting plate is unlocked the lock pin indicator will show red. The pins are retracted.

BD07M315

ATTENTION: together.

Figure 43

Steps 2 and 3 must be performed

2. Push and hold the UNLOCK (upper) portion of the hydraulic coupler switch. The red unlock symbol will illuminate.

3. Activate a loader function and hold to the end of it’s stroke until the coupler pins retract and the red portion of the flag moves up.

4. After releasing the loader function, release the switch.

5. Roll the bucket down until it is flat on the surface.

6. Slowly roll the bucket out until the V ends start to drop out of the upper bucket brackets and move the machine back.

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CHAPTER 4 - OPERATING INSTRUCTIONS

• Use low range for maximum skid steer efficiency.

FIELD OPERATION

WARNING: It is the responsibility of the operator to know the OPERATING LOAD capacity of the machine.

WARNING: Fasten your seat belt before starting the engine.

Figure 45

Figure 51

WARNING: Drive slowly over rough ground and on slopes. Keep alert for holes, ditches, and other irregularities that may cause the skid steer to overturn.

It is the Operator’s responsibility to know and understand the Rated Operating Capacity (ROC) of the machine.

Figure 46

WARNING: Avoid steep hillside operation which could cause the skid steer to overturn.

Figure 47

WARNING: Do not work under overhangs, electric wires, or where there is danger of a slide.

Figure 48

WARNING: Wear an approved safety hat when operating the skid steer and while in any work area.

BD07N236

Figure 52

Figure 49

JOB LAYOUT For an efficient operation, arrange the job to minimize the time required to perform the work cycle. In spotting the dump site, consider wind direction and ground slope. Whenever possible, position the dump site so that the wind will carry dust away from the operator. Before the work cycle begins, take a few minutes to level off the work area if it is not smooth.

Minimize transport distances for a fast work cycle.

See the Rated Operating Capacity decal on the machine. If you have any questions about the Operating Capacity of the machine contact your Dealer.

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

Figure 50

• Before starting work, familiarize yourself with the working area. Locate holes, obstacles and debris that can be cleared from the site. Be aware that the job site may change repeatedly during the course of the shift.

• Locate any unavoidable Danger areas such as, power lines, bridges, tight corners and make sure you can operate safely in these areas.

• Confirm the possibility of other personnel working in the machine vicinity and clear the area of unauthorized personnel.

• If possible, arrange the job site to minimize the time required to perform the work cycle. Consider wind direction and ground slope. Position the dump site so that the wind will carry dust and dirt away from the operator.

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CHAPTER 4 - OPERATING INSTRUCTIONS FILLING THE BUCKET There are two basic methods of filling a bucket from a pile. ARC Penetration and STEP Penetration. Judge the type of penetration needed for loading and vary the methods to suit the materials.

Figure 53

046

ARC PENETRATION With the arc penetration method, the bucket is forced into the pile and rolled back while raised in a continuous upward arc until the bucket is filled. When using this method, remember that too much roll back may overload the lift system. When activating both the lift and bucket hydraulic circuits at the same time, the lift system may occasionally stall. When this happens, disengage either the lift or roll back function to allow maximum hydraulic force to act upon one set of cylinders.

Figure 54

047

STEP PENETRATION With the step penetration method, the bucket is forced into the pile at ground level with the bucket bottom horizontal. Force the bucket into the pile as far as possible during the initial thrust. Raise the bucket about a foot and then force it further into the pile. Repeat this cycle as many times as necessary to fill the bucket.

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CHAPTER 4 - OPERATING INSTRUCTIONS DIGGING

TRANSPORTING

When digging with the skid steer, remove a thin layer with each pass. This method is efficient and minimizes wheel slippage. When encountering firmly packed materials, flutter the bucket control valve to assist penetration. Dirt teeth can be installed on the bucket to provide better penetration.

When backing out and transporting a load, carry the bucket just high enough to clear obstacles in the loader’s path. Raising the bucket higher than necessary reduces stability.

WARNING: Reduce speed when turning so there is no danger of the skid steer overturning.

Figure 55

WARNING: Never transport a loaded bucket at full height. Keep the bucket as low as possible for best stability.

Figure 56

WARNING: If the skid steer should start to tip forward with the lift arm raised, IMMEDIATELY lower the lift arm and load to regain skid steer stability.

Figure 57

NOTE: If the engine pulls down as the skid steer is engaging a load, the directional controls are being held too far in the direction of travel. Maximum torque is obtained at minimum ground speed in low range for all skid steers.

DUMPING THE BUCKET Coordinate the forward ground speed and lift arm lift speed to attain the desired bucket height when arriving at the dump site.

Before the forward and lifting motions are stopped, begin dumping the bucket to gradually empty the load at minimum lift arm height. By emptying before stopping, machine stability can be maximized.

When loading into a truck, the bucket can be used to push materials to the far side of the truck if the bucket is in a tilted down position. For greatest efficiency this should be done as the load is being dumped, before the machine’s forward motion is stopped. Try to spot the truck so that you dump over the low side and into the far side of the truck first.

When handling adhesive materials, the bucket can be fluttered to loosen the materials which tend to stick to the back of the bucket.

WARNING: You must confirm that the area behind the machine is clear of personnel, machines or obstacles before engaging reverse. Failure to follow these instructions may cause death or serious injury.

Figure 58

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CHAPTER 4 - OPERATING INSTRUCTIONS RETURNING THE BUCKET TO THE LOADING POSITION Immediately after the bucket has been fully dumped, begin the roll back cycle as the machine is backed away from the dump site. Repositioning the bucket for the filling cycle while lowering the lift arm is a good time saver. Fine adjustments in bucket height can be made as the skid steer begins forward on the filling cycle, thereby saving a period of dead time between the dumping and filling cycles.

Dozing with the Bucket The skid steer can be used for dozing by controlling the tilt of the bucket.

The skid steer can be used for leveling by placing the bucket in the dump position and back dragging loose soil. The tilt of the bucket will control the amount of soil that is transported.

Place the lift arm control valve spool in the detent position to allow the bucket to follow the ground contour and deposit soil in the low areas.

IMPORTANT: Do not push against objects with the lift arm fully raised or damage to the lift arm or lift arm cylinders may occur.

IMPORTANT: Do not push forward with the bucket fully dumped as the bucket cylinders may be damaged.

DISLODGING A MIRED MACHINE In most cases, when a machine becomes bogged down, the bucket can be used to push the loader to more solid ground. When this is done, the bucket is fully dumped as the lift arm is lowered. The bucket is then curled back as the steering control levers are pulled back. Then the bucket has stroked out of ground engagement, immediately return the steering control levers to neutral. Do not spin the wheels.

Repeat this cycle as many times as necessary to move the machine to solid ground.

WARNING: If the skid steer should start to tip forward with the lift arm raised, immediately lower the lift arm and load to regain skid steer stability.

Figure 59

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CHAPTER 4 - OPERATING INSTRUCTIONS 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 judgement if your machine can be safely operated on any hillside or ramp. Failure to follow these instructions may cause death or serious injury.

Figure 60

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 may roll over. Failure to follow these instructions may cause death or serious injury.

Figure 61

Bucket Empty

Load in the Bucket

Figure 62

BI97C112

If you have a load in the bucket, drive the machine up the hill.

Figure 63

BI97C113

WARNING: You must confirm that the area behind the machine is clear of personnel, machines or obstacles before engaging reverse. Failure to follow these instructions may cause death or serious injury.

BI97C114

Figure 65

If the bucket is empty, drive the machine down the hill.

BI97C115

Figure 66

WARNING: You must confirm that the area behind the machine is clear of personnel, machines or obstacles before engaging reverse. Failure to follow these instructions may cause death or serious injury.

Figure 64

Figure 67

With a load in the bucket, use reverse to back down the hill.

Use reverse to back the machine up the hill when you have an empty bucket.

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CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE WARNING: The machine can slip and fall from a trailer or ramp and cause injury or death. Make sure the trailer and ramp is not slippery. Remove all oil, grease, ice, etc.

Carefully move the machine off or onto the trailer with the machine centered on the trailer and ramp. Failure to follow these instructions may cause death or severe injury.

SB042

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

Figure 69 TIE DOWN LOCATION DECAL

1. Put a block on both sides of the trailer wheels, front and rear.

2. Confirm that the area behind the machine is clear and slowly back the machine onto the trailer.

2

3. Lower the bucket, attachment or loader lift arms down all the way.

4. Shut the engine off.

5. Remove the key or lock the panel.

Figure 70

BD01C196

2. REAR TIE DOWN LOCATIONS

1

7. Put blocks at both ends of the wheels or tracks, (if equipped).

1

8. Remove the blocks from the trailer wheels.

9. When moving the skid steer off of the trailer, use a low drive speed.

10. Drive slowly and keep the machine centered on the trailer and ramp.

BP96N125

Figure 68

1. FRONT TIE DOWN LOOP

6. Use chains to fasten the skid steer to the trailer.

Use the tie down locations, front and rear as indicate by the tie down decals.

4-22

WARNING: When moving the machine on or off of the trailer, drive slowly and keep the machine centered on the trailer and ramp.

Failure to follow these instructions may cause death or serious injury.

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CHAPTER 4 - OPERATING INSTRUCTIONS LIFTING THE MACHINE

The following precautions must be followed when craning (lifting or lowering) a machine.

WARNING: Only personnel with heavy machine lifting experience should attempt craning the machine. Contact your Dealer.

Figure 71

Use only lifting equipment with a rated capacity to handle the weight of the model skid steer being lifted.

The lifting equipment weight must be added.

Remove the attachment before lifting the machine.

Remove counterweights, if equipped.

• Never allow personnel on the machine while craning.

• • • •

Remove attachments before craning.

Remove counterweights, if equipped.

Use only properly rated lifting devices.

The weight of the lifting equipment must be added to the machine weight for proper lift capacity requirement.

• Always inspect the lifting equipment to confirm safe condition. Do not use if worn or damaged.

• Do not attach lifting devices to the loader lift arm or attachments on the skid steer.

• Make sure the loader lift arm is in the completely lowered position.

• Make sure the engine is shut off before craning.

• Keep bystanders a safe distance away from the machine while craning.

MOVING A DISABLED MACHINE Figure 72

BT97F064

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 feet).

WARNING: Death or serious injury may result when you attempt to tow a disabled machine incorrectly.

Figure 75

IMPORTANT: Towing the Skid Steer is not recommended. If your machine is disabled, you must make a judgment if the machine can be moved without more damage. If possible, repair the machine at the job site. This machine may be severely damaged if towing or moving is attempted incorrectly.

Contact your Dealer if the machine is disabled.

Figure 73

139729A1

LIFT POINT DECAL PROVIDED WITH LIFT KIT HARDWARE

To prevent sharp angles and damage to the skid steer cab and lift ar m, the correct length of equipment must be used and the proper lift hook point above the cab must be maintained.

WARNING: Always use properly rated lifting devices to prevent personal injury or damage to the skid steer.

Figure 74

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CHAPTER 4 - OPERATING INSTRUCTIONS BOOSTER BATTERY CONNECTION TO MACHINE BATTERY

3 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

4

Two persons are required for this procedure. Make sure the person making the connection is wearing face protection.

1. Sit in the operators seat and have the other person make the connections. Make sure the booster battery is 12 volts.

2. If using another machine for power, make sure the two machines do not touch.

3. Connect the positive (+) jumper cable to the positive (+) battery terminal. Use the positive remote post if the machine is equipped.

4. Connect the negative (-) jumper cable to a good frame ground away from the battery. Use the negative remote post if the machine is equipped.

5. See Starting the Engine in this manual and use the correct procedure to start the engine. Have the other person disconnect the negative (-) jumper cable first and the positive (+) jumper cable last.

2 1

Figure 77 3. NEGATIVE (-) REMOTE POST 4. POSITIVE (+) REMOTE POST

STORING THE MACHINE Long Term Storage Preparation Geographic, environmental and actual storage conditions make it difficult to follow a set storage procedure for all areas and conditions. The following procedure is for a storage period of six months or longer. This procedure is a good starting point but may not be all inclusive. If you have questions about storing your machine, contact your Dealer.

Machines using Biodiesel fuel that are to be stored for longer than three months must run diesel in the system for 20 hours before being stored and then follow the normal procedures by draining the fuel tank and flush as noted on step 7.

1. Prior to storing, inspect the machine for visible signs of wear, breakage or damage. Order any parts required and make the necessary repairs to avoid delays when starting the next operating period.

2. Prior to storing, wash the machine.

3. Lubricate the entire machine.

4. Paint any areas where the paint has been damaged.

5. Move all hydraulic controls through their complete ranges several times to relieve any pressure in the circuits.

BD07M249

1. NEGATIVE (-) JUMPER CABLE 2. POSITIVE (+) JUMPER CABLE (RED COVER)

Figure 76

6. Drain the fuel tank.

7. Put approximately 8 liters (2.1 gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue-white.

8. Drain the flushing oil from the fuel tank.

9. Fill the fuel tank and add a diesel fuel conditioner by following the directions on the container.

10. Change the engine oil and replace the oil filter.

11. Drain the cooling system. Leave the drain valves open and do not tighten the radiator cap.

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CHAPTER 4 - OPERATING INSTRUCTIONS 12. Put a Do Not Operate or Out Of Service tag or marker in the cab.

13. Replace the air cleaner elements if the hours of operation or time inter val will lapse during storage.

14. Cover the exposed cylinder rods, and valve spools and any other bare metal parts with a Rust and Corrosion Preventive.

15. Remove and clean the battery. Fully charge the battery. Store the battery in a cool, dry place where it will not freeze.

16. Cover the exhaust outlet.

17. 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 cover.

18. Block the machine up so that the tires are just off the surface, if possible.

A. Disconnect the electrical connector to the injection pump solenoid. This will prevent the engine from starting.

B. Make sure all persons are clear of the machine. Turn the key switch to START and actuate the starter for about 10 to 15 seconds.

C. Reconnect the wire to the injection pump solenoid.

IMPORTANT: Before starting the engine, make sure there are no leaks, missing or broken parts.

13. Start the engine and run at idle speed for 2 minutes. Check for leaks around the filters and drain plugs.

14. Stop the engine and check the fluid levels of the e n g i n e c o o l i n g s y s t e m a n d d r i ve c h a i n compartments. See the Engine Cooling System and Drive Chain Compartment sections for the correct procedure on checking the fluid levels.

IMPORTANT: Extreme precautions must be taken when blocking up a machine for long periods. Block the machine with the tires just off the surface. No more than 1 in. (25.4mm) above the surface.

19. Do periodical checks for protection. Look for corrosion.

NOTE: Check the battery periodically for the correct electrolyte level. Wear face protection and test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the battery (ies).

Storage Removal 1. If the machine is blocked, lower it to the ground and check the tires for pressure. Check the track condition and sag on equipped machines.

2. Change the fuel filters and fill the fuel tank if needed.

3. Tighten the cooling system drain valves.

4. Put coolant into the engine cooling system.

5. Check the engine oil level.

6. Check the condition of the engine fan belt and replace it if required.

7. Check the hydraulic fluid level.

8. Lubricate the machine grease fittings.

9. Use a petroleum base solvent and remove the Rust and Corrosion Preventive from the hydraulic cylinder rods and spools, etc.

10. Install a fully charged battery.

11. Remove air from the engine fuel lines.

12. Prime the turbocharger oil lines with oil using the following procedure:

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CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS LUBRICATION, FILTERS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

ENGINE HOURMETER / DIGITAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 5-3 5-4 5-5 5-6

TILTING THE OPERATOR’S COMPARTMENT FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 SECURING THE LIFT ARMS UP AND ENGAGINg THE LIFT ARM LOCK PIN . . . . . . . . . . . . . . . . . . . . . . 5-10 FLUIDS AND LUBRICANT CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 QUICK REFERENCE LUBRICATION AND MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 EVERY 10 HOURS OR DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 EVERY 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 EVERY 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION, FILTERS AND FLUIDS GENERAL SAFETY BEFORE YOU SERVICE WARNING: Before you begin any service or repair work you must know and understand how to relieve hydraulic pressure properly. Always have tools and attachments down in safe positions.

Figure 1

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.

Figure 2

SC021

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, lift arm, bucket, etc.) to the ground and stop the engine.

Use the correct safety clothing and safety equipment.

Understand how to use a fire extinguisher and first aid kit.

Maintenance and Lubrication schedules are defined for normal working environments and conditions.

Extreme working conditions and environments require more frequent service and care. Contact your Dealer if you have any questions about your service schedule or requirements.

WARNING: Do not attempt any service procedure or check, until components involved and surrounding components have cooled. Failure to follow these instructions may result in serious injury or death.

Figure 3

SA044

Figure 7

WARNING: Before you leave the operators compartment, confirm that all controls for hydraulics and auxiliary hydraulics are in neutral. Be extremely careful not to make accidental contact with a control as you leave the compartment.

3

Figure 4

Read the safety decals and information decals on the machine. Read the operators manual and safety manual.

1

Figure 5

BC00G075

1. READ REPAIR MANUAL SYMBOL

2

3. DO NOT OPERATE TAG

Before you ser vice the machine, put a Do Not Operate Or Mark Out Tag on the instrument panel, key or at a location that must be seen by the Operator prior to beginning operation. Give a brief definition of the situation.

WARNING: If you service the machine with the loader lift arms raised, always use the lift arm support strut or lock pin 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.

Figure 6 2. REPAIR MANUAL SYMBOL

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Figure 8

BD05A063

When you see the symbol above, you must see the Repair Manual. This symbol may occupy a portion of the Safety Decal. Understand the operation of the machine before you start servicing.

SC108

Bur

Figure 9

5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS PROPERLY SUPPORT A RAISED MACHINE

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM Ask your dealer about this lubr icant 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 independent 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.

BD01C274

Figure 10

If servicing, lubrication or maintenance requires the machine to be raised, remove attachments and securely support the machine with adequate blocks.

WARNING: When servicing any drivetrain component the skid steer should be on firm, level terrain, with the engine stopped and the entire skid steer blocked solidly, with the wheels off the ground.

PLASTIC AND RESIN PARTS Avoid using gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts.

Using gasoline, kerosene, thinners, etc., will cause discoloration, cracking or deformation of the part being cleaned.

Figure 11

WARNING: Never use the skid steer attachment or loader arms to raise the machine for service.

Figure 12

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ENVIRONMENT Before you service this machine and dispose of oil, f l u i d s a n d l u b r i c a n t s, a l way s r e m e m b e r t h e 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.

WARNING: Never use the skid steer attachment or loader arms to raise the machine for service.

Figure 13

Diesel Fuel System: Verify with your fuel supplier for the correct cold weather fuel. Diesel engine power will be reduced if wax particles are in the fuel filter.

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.

WARNING: Under no circumstance should ether, or any other starting fluid, be used on this machine. It is equipped with an Engine Pre-Heat Cold Start System. Fire, explosion, serious injury or death could result.

Biodiesel Fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel Fuel must be pre-blended by the supplier. Mixing Biodiesel Fuels on-site can result incorrect mixture that can lead to problems with both engine and fuel system.

Engine perfor mance is affected by the use of Biodiesel Fuel. There may be up to 12 percent reduction in power or torque depending on the blend used.

IMPORTANT: DO NOT modify the engine and/or injection pump settings to recover the reduced performance.

The reduced power must be accepted if using any Biodiesel Fuel blend.

Some modification may be required to allow your engine to run Biodiesel Fuel. Consult you dealer for complete information on these modifications.

Biodiesel Fuel has a higher cloud point than Diesel Fuel.

The use of high Biodiesel Fuel blends are not recommended in cold weather conditions.

Figure 14

Biodiesel Fuel: Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

IMPORTANT: Biodiesel Fuel blends are approved for your engine only if they comply with Specification standards EN14214 or ASTM D6751.

IMPORTANT: It is imperative that you check which blend is approved for your engine with your local dealer. Beware that the use of Biodiesel Fuel that does not comply with the Standards mentioned above could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void Warranty coverage.

Biodiesel Fuel Usage Conditions: IMPORTANT: The Biodiesel Fuel must meet the fuel Specification mentioned above.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ENGINE HOURMETER / DIGITAL DISPLAY Service your machine at the intervals and locations given in the Lubrication/Maintenance Chart. When you service your machine, use only high quality lubricants.

BD07K066

Figure 15

The engine hourmeter shows the amount of actual hours the engine has run. The first number to the right displays tenths of an hour and the remaining numbers to the left display hours. Use the engine hourmeter along with the Lubrication / Maintenance Chart to service your machine at the correct time periods.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

TILTING THE OPERATOR’S COMPARTMENT FORWARD The Operator’s compartment may be tilted forward, for service access, with the lift arms raised or lowered. The front door must be removed to tilt the cab with the lift arms down. See page 6-5 in the Maintenance Chapter of this manual for door removal. When the loader lift arms are in the raised position, access to the engine, hydrostatic pumps, motors, and control linkage is provided.

TO SECURE THE LIFT ARMS UP AND INSTALL THE SUPPORT STRUT OR LOCK PIN WARNING: Always place the loader lift arm support strut or lock pin into the maintenance position before exiting a machine with the lift arms up and/or when servicing the machine with the lift arms up. Failure to follow these instructions could result in serious death or serious injury.

Figure 16

1. Remove any attachment.

2. Park the machine on firm and level surface.

4. Remove the pin that secures the lift arm support strut.

1 2 3

BD01C080

Figure 17

1. LOADER LIFT ARM SUPPORT STRUT INSTRUCTIONAL AND SAFETY DECALS

3. See the instructional decal on the inside of the right lift arm, just above the support strut. Read and understand these instructions before you perform this procedure.

Figure 20 2. LIFT ARM SUPPORT STRUT 3. RIGHT SIDE LOADER LIFT ARM CYLINDER AND TUBING

BD07N329

5. Lay the support strut down on the lift arm tubing and cylinder, as shown.

WARNING: Never leave the cab with the loader arms up, unless the support strut or lock pin is in the maintenance position.

Figure 18

1

BD04M

Figure 21

6. Slowly raise the lift arms until the support bracket drops down onto the cylinder rod, as shown.

Figure 19

BD07N238

1. LIFT ARM SUPPORT STRUT PIN 87493825NA

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7. Gently, lower the lift arms down until the support strut is in contact with the cylinder.

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

4

Figure 24

BD01C171

BD07N237

Figure 22

10. Use a 24mm socket or wrench to remove the two rear ROPS bolts.

4. SEAT FORWARD/REARWARD CONTROL LEVER

8. Before leaving the seat, use the forward / rearward control and move the seat into the most forward position. This will prevent contact between the bottom of the ROPS and seat back.

5

IMPORTANT: If the seat is not in the forward position it may interfere with the cab as it is tilted forward.

6

Figure 25

BD07N220

5. CAB RELEASE LATCH 6. CAB RELEASE LATCH LEVER

BD07K017

Figure 23

9. Secure the support pin into the strut, as shown.

11. Locate the cab release latch, just above the floor plate on the inside right front corner of the cab.

Push the cab release lever up to move the latch off the pin and into cab release position.

Before continuing to tilt the cab, confirm that the following steps have been completed:

• The machine is on firm, level ground.

• The lift arms are up with the support strut or lock pin in position.

• The support strut pin is secure as shown in figure 21.

• The seat has been placed in the full forward position.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Figure 26

BD07N241

12. Use the cab entry hand holds and tip the cab fo r w a r d a s s h o w n . D e p e n d i n g o n t h e configuration and options on the machine, it may be necessary to use a helper.

13. Confirm that the cab support latch is engaged.

1

Figure 27

BD07K005

1. LOADER LIFT ARM SUPPORT STRUT LOADER LIFT ARMS RAISED WITH SUPPORT STRUT IN POSITION, CAB TILTED WITH CAB SUPPORT LATCH IN MAINTENANCE POSITION

To place the cab and loader lift arms back into the work position, reverse the procedure.

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5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS SECURING THE LIFT ARMS UP AND ENGAGING THE LIFT ARM LOCK PIN The Operator’s compartment may be tilted forward, for service access, with the lift arms raised OR lowered. The front door must be remove to tilt the cab with the loader arms down. Access to the engine, hydrostatic pumps, motors, and control linkage is best when the loader lift arms are in the raised position.

All Case Skid Steer Family machines use Lift Arm Support Struts or Lift Arm Lock Pins to secure the lift arms up.

Remove attachments before securing the lift arms up. If you have any questions about this procedure contact your Dealer.

WARNING: Always activate the mechanical loader arm lock pin or install the support strut before exiting a machine with the loader arms up. Failure to do so could result in death or serious injury.

Figure 28

WARNING: Never leave the cab with the lift arms up, unless the lock pin is in the maintenance position with the lock pin in place.

Figure 29

TO SECURE THE LIFT ARMS UP AND ENGAGE THE LOCK PIN: 1. Remove any attachment.

2. Park the machine on firm and level surface.

3. While still in the seat, restraint bar down and the engine running, roll the coupler attachment all the way back.

2

4. Raise the lift arms to the maximum height.

1 Figure 32 2. LIFT ARM LOCK PIN SHOWN EXTENDED (LIFT ARM STILL AT MAXIMUM HEIGHT

BD07N684

3 Figure 30

BD07N682

1. LIFT ARM LOCK PIN CONTROL LEVER (SHOWN IN LOCK POSITION)

5. Engage the loader lift arm lock pin, using the lock pin control lever located in the right rear corner of the operator’s compar tment. Move the lever toward the center of the machine. See the instructional decal located just above the lever.

Figure 33 3. LIFT ARMS LOWERED TO MAKE CONTACT WITH LOCK PIN

BD07N685

Figure 31

6. Slowly lower the loader lift arms until the loader lift arm link rests against the lock pin.

LIFT ARM LOCK PIN INSTRUCTION DECAL

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS To disengage the lift arm lock pin and lower the arms:

Figure 34

BD07N684

1. While sitting in the operator’s seat, with the restraint bar down, start the engine and raise the lift arms until the loader lift arm link is no longer contacting the lock pin, as shown above.

Figure 35

BD07N683

2. To disengage the lock pin, move the lock pin control lever toward the right, or outside of the machine, as shown. Slowly lower the loader lift arms to the ground.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANT CAPACITIES FUEL TANK All Models Capacity.........................................................................................................................88.2 L ( 23.3 gal) Specifications ............................................................................................................................................... #2 Diesel Check with your supplier for fuel requirements. Most regional suppliers will change the fuel supply for cold temperatures. See American Society for Testing Materials International at www.astm.com and Engine Manufactures Association at www.enginemanufactures.org for more fuel information.

Biodiesel may be used in this machine but recommendations for maintenance and start up are required. See page 5-5 in this chapter.

COOLING SYSTEM All Models Total System Capacity ........................................................................................................11.4 L (3 gal.)

Specifications ..................................................................................................... 50% water and 50% ethylene glycol HYDRAULIC SYSTEM All Models Reservoir ........................................................................................................................26.9 L ( 7.1 gal.)

All Models System...........................................................................................................................50.0 L (13.2 gal.)

Specifications ............................................................................................................................... 10W-30 Engine Oil Cold Temperature Specifications........................................................................................................0W40 Synthetic CHAIN COMPARTMENTS All Models Capacity - Each Side ........................................................................................................3.8 L (1.0 gal.)

Specifications ............................................................................................................................... 10W-30 Engine Oil TRACK DRIVE GEARBOX (Final Drives) 420CT Capacity - Each Side ................................................................................................................1.3 L (1.4 qts.)

Specification .........................................................................................................................Case 135H EP 85W-140 440CT Capacity - Each Side ................................................................................................................. 0.6 L (0.6 qt.)

Specification ...........................................................................................................................Case 135H EP 80W-90 GREASE FITTINGS Quantity ................................................................................................................................................... As required Specifications ............................................................................................................. Case Moly 251 EP-M Grease ENGINE CRANKCASE OIL 420 - 430 .............................................................................................................................................8.0 L (8.5 qts.)

420 - 430 total system w/filter...............................................................................................................8.5 L (9.0 qts.)

440 - 440CT......................................................................................................................................11.5 L (12.1 qts.)

440 - 440CT total system w/filter ......................................................................................................12.0 L (12.7 qts.)

Specifications ........................................................................................................... Case No. 1. 15W-40 Engine Oil

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS QUICK REFERENCE LUBRICATION AND MAINTENANCE CHART

5-16 5-16 5-17 5-19 5-18 10 Hours

5-21 5-22 5-22 5-23 5-23 5-24

50 Hours 100 Hours

5-25 5-26 5-28 5-30 5-32

250 Hours

5-16 5-31 5-31 5-33 5-34 5-41

500 Hours

5-36 5-37 5-38 5-38 5-40 5-41

1000 Hours

5-41 5-43 5-44

87493825NA

10 Wheel Nut Torque 10 Safety Signs and Safety Treads 10 Engine Oil Level 10 Seat Belt / Seat Switch Interlock 10 Check HVAC Filter, If Equipped 10 Hydraulic System Fluid Level 10 Radiator, Hydraulic Coolers, Engine, For Debris 10 Check The Engine Coolant Reservoir Level 10 Clean Track and Components 10 Initial Track Tension Lift Arm Pins, Mounting Plate Pins, Cylinder Pins 50 Track Tension 50 Initial Engine Oil and Filter 100 Final Drive Oil Check and Change (track models) 250 Tire Pressure 250 Drive Chain Tension 250 Wheel Nut Torque Drain Water from Fuel Filter 250 Radiator Coolant Level 500 ROPS and Hardware Change Engine Oil, Filter and Clean Engine Area Change Hydraulic Filter Replace Fuel Filters Hydraulic Oil Filter Change 500 Check Chain Tank Oil (Each Side) Final Drive Oil Change Change Air Filter Elements 1000 Inspect Machine Hardware Change Hydraulic Fluid Engine Coolant Change Chain Tank Oil Change

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REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

SERVICE POINTS

INITIAL

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

10 50 100

250

500 500 500 500 500 500 1000 1000 1000

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS LUBRICATION AND MAINTENANCE ACCESS

2

1

Figure 39

BD07N464 BD04N084

Figure 36

2. REAR ACCESS DOORS OPEN

1. UPPER REAR ACCESS DOOR HANDLE

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

With the rear access doors open the operator or technician may access and service:

• • • • • • • •

engine oil hydraulic oil add fuel check the radiator and coolers (fill, drain, clear debris) check the coolant reservoir bottle service the engine air filtration system access the master disconnect switch access the remote battery posts

NOTE: The door may be locked with a padlock.

BD04N102

Figure 37

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

BD04N101

Figure 38

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

The rear access door will allow the operator or technician to:

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Floor Plate

2

Figure 40

BD08G003

3. CAB FLOOR PLATE

Remove the bolts that secures the floor plate.

Carefully, lift the floor plate, that secures the battery, up and out of the cab to access the battery, and on machines so equipped, the windshield washer bottle and heater/coolant valve.

Figure 41

BD07M249

Battery, Windshield Washer Fluid Reservoir, and Heater/Coolant Valve under the floor plate.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS OR DAILY SAFETY SIGNS, DECALS AND SAFETY TREADS Walk around the machine and make sure all decals are clean, undamaged and readable. Replace any decals or signs that have become damaged or unreadable before operating the machine.

The decal part number is on the decal. Contact your Dealer Parts Department for replacements.

Some steps have been augmented with perforations for better traction. Make sure these steps are clean and clear of mud, dirt and debris.

WHEEL NUTS If the machine is new or you have just installed the wheels, check the wheel nuts every 10 hours until the nuts remain at torque.

Figure 42

BD01C269

Machines equipped with stamped center wheels have tapered type lug nuts. Torque for these nuts will be 100 to 120 pound feet. (135 to 163 Nm) Machines equipped with solid center wheels will have flange type lug nuts. Torque for these nuts will be 165 to 195 pound feet. (224 to 265 Nm) NOTE: When installing tires, make sure that the tread is in the same direction.

1

7

5

4

3 8

6 2 Figure 43

BD07K046

TORQUE PATTERN

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS OR DAILY

ENGINE OIL

Case Akcela No. 1, 15W-40 API Service CI-4 engine oil is recommended for use in your Engine. See the chart below for recommended viscosity at ambient temperature ranges.

The normal engine oil change interval is every 500 hours of operation, using Case Akcela No. 1, 15W-40 API Service CI-4, as a minimum oil grade. Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended that you use a lubricant analysis program to help protect your investment. Contact your Dealer for this information.

NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase.

Oil Viscosity / Temperature Ranges

Figure 44

BS99N019

ENGINE OIL LEVEL During the first 20 hours of operation check the oil level at approximately one hour intervals. After the initial 20 hours check the engine oil level daily or every 10 hours of operation. Always check the oil with the engine stopped and when the machine is on level ground.

NOTE: For the most accurate read of the oil level, allow enough time for all the oil to drain down to the pan before checking.

TIP: The best time to check the engine oil is after the machine has sat overnight or at the beginning of the work cycle.

1

BD07N449

Figure 45

1. ENGINE OIL LEVEL DIPSTICK

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

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5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS CAB INTAKE FILTERS

10 Hour Engine Oil Level Check - continued

If the machine is equipped with cab heater, the cab intake filters should be inspected, as necessary.

2

1

3 BD07K113

Figure 46

2. ENGINE OIL DIPSTICK FULL MARK 3. ENGINE OIL DIPSTICK ADD MARK

Figure 48

BD07K070

1. CAB FILTER ACCESS COVER

4

The access panel to the cab intake filter is located at t h e r e a r, t o p o f t h e c a b. B a ck o f f t h e t h r e e thumbscrews until the cover becomes loose, then slide the cover back until the three tabs at the front of the cover are free from the cab top and remove.

Replace the cab filters if:

• They are damaged or torn.

• They are clogged with debris and dirt.

The ser vice inter val for the cab filter is also determined by the amount of use and the operating conditions. It is recommended to check more often if working in extreme environmental conditions.

BD07N449

Figure 47

4. ENGINE OIL FILL LOCATION

If the oil level is below the FULL mark add oil. DO NOT raise the oil level above the Full mark, shown in figure 37.

2

Figure 49

BD07K071

2. CAB FILTER.

Remove and replace the filter.

Clean the cab filter compartment of dirt and debris.

The rubber gasket on the filter must seal properly with the compartment filter flange.

Replace the new components in reverse order.Make sure to get a good seal between the filter and the heating, ventilation, air conditioning system. (HVAC)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS OR DAILY SEAT RESTRAINT BAR AND INTERLOCKS FUNCTION Test the seat restraint bar and loader / steering controls for correct operation.

3

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

LOCK FOR LOADER AND STEERING CONTROLS 1. Sit in the operator’s 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.

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

4. Move the steering and loader control levers through their range of movement. If the machine moves, STOP the engine.

1

Figure 51

BD07K019

3. CONTACT PAD

6. 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.

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

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

WARNING: If the skid steer moves with the seat restraint bar in the up position, contact your Dealer and have the machine repaired immediately. Injury or death can occur.

2

Figure 52

Figure 50

BD07K020

1. CONTACT PAD 2. SEAT BAR PLUNGER SWITCH

5. 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.

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5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS OR DAILY TESTING THE OPERATOR’S SEAT PRESENCE SWITCH 1. Sit in the operator’s 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 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. After 5 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 operator’s seat carefully try the loader hydraulic and steering control levers. They should be inoperative.

WARNING: If the skid steer moves with the seat restraint bar in the up position, contact your Dealer and have the machine repaired immediately. Injury or death can occur.

Figure 53

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS OR DAILY HYDRAULIC RESERVOIR OIL LEVEL CHECK Specification . . . . . . . . . . . . . . . 10W-30 Engine Oil WARNING: Fire Hazard: Do not smoke while filling the hydraulic reservoir. Do not fill near open flames.

2

Figure 54

M476

IMPORTANT: When servicing the reservoir it is vital to prevent contamination. Clean the components and all areas around the components to help reduce the risk of contamination.

BD07N460

Check the hydraulic reservoir oil level daily, before beginning operation and or ever y 10 hours of operation. Check the level with the lift arms down on the ground.

The hydraulic oil filler and sight gauge are located behind the rear access door and to the left of the radiator.

1. Park the machine on a firm, level surface with safe access all around.

Figure 56

2. HYDRAULIC OIL FILLER CAP

If oil needs to be added: 1. Clean the filler cap and the area around the cap to reduce the risk of contamination.

2. Slowly turn the filler cap counterclockwise but Do Not remove the cap until pressure is relieved.

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

4. Replace the cap.

2. Lower the loader arms to the down position.

3. Open the rear access doors.

1

Figure 55

BD07N463

1. HYDRAULIC OIL LEVEL SIGHT GAUGE

The hydraulic oil should be to the midpoint of the sight gauge, as shown above.

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5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS OR DAILY

ENGINE COOLANT RESERVOIR CHECK

CLEAN RADIATOR - COOLERS - ENGINE AREA

Check the level of the coolant when the engine is stopped and the coolant is COLD.

Every 10 hours or more often, when working in extreme conditions, check the radiator and cooler for debris and build up that might impede the cooling of engine and components. Clean as necessary.

DO NOT remove the radiator cap during this check.

Check the engine area also, for debris and build up that might become combustible. Clean as necessary.

1

The radiator and cooler may be tipped out for this purpose. Follow the steps below to tip the radiator and cooler out.

1

1 Figure 59

BD07N464

1. ENGINE COOLANT RESERVOIR

The coolant level must be to the FULL mark stamped in the bottle.

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

BD07N458

Figure 57

1. RADIATOR TIPPING BRACKETS

Use a 16 mm socket or wrench and remove the two bolts that connect the brackets, shown above, to the top of the radiator.

BD07K014

Figure 58

Pull the top of the radiator and cooler out.

After cleaning the radiator and cooler from dirt and debris replace the two bolts.

Torque for the bolts is 37 pound feet. (50 Nm) NOTE: Be very careful when starting the bolts to ensure that they are threading correctly.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 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 area and guide teeth should be cleaned.

1

2

3

6 5

5 5

5

4

Figure 60

BD05C053

1. Rubber Track 2. Track Adjustment Access Cover (1 Each Side) 3. Final Drive Sprocket (1 Each Side)

4. Rear Idler Wheel (1 Each Side) 5. Track Roller Wheels (4 Each Side 440CT) 6. Front Idler Wheel (1 Each Side) Figure 61

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

TO INCREASE OR DECREASE TRACK TENSION: Specification . . . . . . . Case Moly 251 EP-M Grease WARNING: Exercise caution when adjusting track tension. Grease is under pressure.

Wear full face protection before adjusting track tension. Failure to follow these instructions could cause serious injury.

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 and level surface.

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

Figure 63

3 1

2

7559

Figure 62

BD05B033

1. CENTER ROLLER WHEEL 2. TOP INSIDE OF LOWER TRACK

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

Allowable track sag . . . . . . . . . . . . . . . 1/2 to 3/4 inch

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Figure 64

1. Use a 13 mm tool and remove the track adjustment access cover to expose the track adjustment fitting (3).

2. Add grease to increase track tension.

3. Use a 19 mm tool and turn the fitting counterclockwise, slowly, and allow grease to escape to decrease tension. Grease will escape from the bottom of the fitting.

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS OR DAILY LIFT ARM PIVOTS, MOUNTING PIVOTS, CYLINDER PINS AND ATTACHMENT COUPLER LATCH PIN 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.

Specification ............................................................................................................... Case Moly 251 EP-M Grease

1 5 3 2

Figure 67 5. RIGHT SIDE LIFT CYLINDER ROD END (1 EACH SIDE)

BD07K025

Figure 65

BD07K023

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

6

4 Figure 68 6. RIGHT SIDE LOADER LIFT CYLINDER, CLOSED END (1 EACH SIDE)

BD07K044

Figure 66 4. RIGHT SIDE BUCKET CYLINDER, CLOSED END (1 EACH SIDE)

BD07K024

7

Figure 69

BD04M018

7. RIGHT SIDE LIFT ARM (1 EACH SIDE)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 50 HOURS TRACK TENSION CHECK

TO INCREASE OR DECREASE TRACK TENSION:

Check the track tension every 50 hours of operation.

Specification . . . . . . . Case Moly 251 EP-M Grease

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

WARNING: Exercise caution when adjusting track tension. Grease is under pressure.

Wear full face protection before adjusting track tension. Failure to follow these instructions could cause serious injury.

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

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

Figure 71

3

1

2

Figure 70

BD05B033

1. CENTER ROLLER WHEEL 2. TOP INSIDE OF LOWER TRACK

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

Allowable track sag . . . . . . . . . . . . . . . 1/2 to 3/4 inch

7559

Figure 72

1. Use a 13 mm tool and remove the track adjustment access cover to expose the track adjustment fitting (3).

2. To increase track tension add grease to the fitting.

3. To decrease track tension, use a 19 mm tool and slowly turn the fitting counterclockwise. Be prepared to capture the grease with a suitable rag or container. Grease that is being release will come out of the bottom of the fitting.

IMPORTANT: Don’t allow the grease to fall down on the ground or into the track components.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS INITIAL 50 HOUR ENGINE OIL AND FILTER CHANGE

7. Clean the area around the engine oil drain line and the oil filter head and surrounding area.

Change the engine oil and filter after the first 50 hours on a new machine or engine rebuild.

420 - 430 total system w/filter. . . . . . . 8.5 L (9.0 qts.)

440 - 440CT total system w/filter . . 12.0 L (12.7 qts.)

Specification . . . . Case Akcela No. 1, SAE 15W-40

8. Remove the remote engine oil drain plug and drain the oil into a suitable container.

9. Inspect the drain hose for wear or abrasion.

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

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

3

1. Remove any attachments from the skid steer.

2. Place the machine on firm, level, ground, in park.

3. Raise the loader arms and place the support strut or lock pin into position for maintenance.

Figure 75

BD07N450

3. ENGINE OIL FILTER

10. Turn the old engine oil filter counterclockwise to remove. Dispose of the filter properly.

4. Tilt the cab.

5. Remove the dipstick.

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

12. Put new oil into the engine oil filter.

13. Turn the new oil filter clockwise onto the filter head until the gasket makes contact with the base. Continue to tighten the filter with your hand until tight.

1

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. continued on the following page Figure 73

BD04N093

1. ENGINE OIL DRAIN PLUG ACCESS COVER

6. Use a 19 mm wrench or socket and remove the engine oil drain access cover.

2

BD07M316

Figure 74

2. ENGINE OIL DRAIN LINE

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Initial 50 Hour Engine Oil, Filter Change cont. 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 overtightened.

14. Install the drain cap. Tighten to a torque of 50 to 60 pound feet. (68 to 82 Nm).

4

Figure 76

BD07N449

4. ENGINE OIL FILL CAP

15. Slowly add the correct type and quantity of oil into the engine oil fill cap. Do not overfill.

16. Replace the dipstick.

17. Start the engine and run at low idle speed.

Check for leaks around the drain plug or filter area.

18. After two minutes, stop the engine. Allow the engine oil to drain to the pan and then check the engine oil level.

19. Install the engine oil drain access cover, being careful to secure the drain hose so that it does not rub or chafe against the cover.

20. Close and secure all covers and panels.

21. 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.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 100 HOURS INITIAL CHECK AND CHANGE FINAL DRIVE OIL After the first 100 hours of operation, check and change the final drive fluid. Two final drive models are shown. Use the procedure that applies.

Specification 420CT .......................................................................................................Case 135H EP 85W-140 Capacity each side 420CT ..............................................................................................................1.3 L (1.4 qts.)

Specification 440CT .........................................................................................................Case 135H EP 80W-90 Capacity each side 440CT ................................................................................................................ 0.6 L (0.6 qt.)

NOTE: If your machine is equipped with the Rexroth final drive use 85W-140 gear oil if ambient temperatures exceed 35 C (95 F), do not use if ambient temperatures are below 4 C (40 F).

IMPORTANT: If operating in muddy conditions for 20 hours or more, the oil change interval should be shortened by half.

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.

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.

1 1

2

Figure 78

BD08F020

Figure 77

BD08F023

BONFIGLIOLI FINAL DRIVE 1. PLUG IN CHECK/FILL POSITION 2. DRAIN PLUG

2. Use a 5 mm allen wrench and open the check/fill plug. Oil should just be at the orifice.

REXROTH FINAL DRIVE 1. PLUG IN CHECK/FILL POSITION

2. Use a 5 mm allen wrench and open the check/fill/drain plug. Oil should just be at the orifice.

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

4. Replace the drain plug after all the oil has been drained.

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

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

NOTE: Both plugs on the above model final drive may be used for an oil check, as long as the position is horizontal at 9 or 3 0-clock.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

3

Figure 79

BD08F021

2. CHECK/FILL/DRAIN PLUG IN DRAIN POSITION

3. Move the machine to place the check/fill/drain plug into the position shown above.

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

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

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

7. Install the plug and repeat the procedure for the other side.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 250 HOURS TIRE PRESSURE 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.

Figure 80

Always have a qualified tire professional service the tires and rims on this machine. It is recommended that you have the tire professional inflate the tires. To prevent accidents, always use a restraining device (tire inflation cage), correct equipment, and correct procedure. Explosive separation of the tire can cause serious injury or death.

Stand behind the tread of the tire and make sure all persons are away from the side of the tire before you add air.

IMPORTANT: Tire pressure gauges should be checked at regular intervals for accuracy.

Inflate the tire to the recommended air pressure. DO NOT inflate the tire more than the recommended maximum pressure given on the tire. If you have any questions about the correct tire pressure for your machine and application, consult your Dealer.

Make sure, when installing tires, that the tread is in the same direction.

Figure 81

BD05A059

Tire

Size

Pressure

XD2002

10 x 16.5

45 psi

XD2002

12 x 16.5

40 psi

Beefy Baby II

10 x 16.5

45 psi

Beefy Baby II Hulk

12 x 16.5

45 psi

10 x 16.5

40 psi

Hulk

12 x 16.5

40 psi

Bulky Hulk

33/15.5 x 16.5

35 psi

King Kong

10 x 16.5

45 psi

King Kong

12 x 16.5

40 psi

Hippo

31/15.5 x 16.5

30 psi

Hippo

33/15.5x16.5

35 psi Figure 82

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 250 HOURS

RADIATOR COOLANT LEVEL

DRAIN WATER FROM THE FUEL FILTER

Check the radiator coolant level every 250 hours of operation. ONLY check the level with the engine stopped and all components are cold.

Check for water in the fuel filter after every 250 hours of operation.

Specification . . 50% ethylene glycol and 50% water WARNING: Hot coolant can spray out if radiator cap is removed. To remove the radiator cap: Let the system cool. Turn the cap counterclockwise to the first notch. Wait until all pressure is released.

Scalding can result from fast removal of the radiator cap.

Figure 84

1 Figure 83

BD07N459

1. FUEL FILTER DRAIN VALVE

Turn the drain valve on the fuel filter clockwise 2 or 3 turns and drain the fuel. If water is found in the filter, the fuel tank should be checked as well.

If the tank needs to be checked, place a suitable container under the tank drain, located at the, right rear of the machine.

Drain fuel and check for water.

BD07K050

Figure 85

1. Shut the engine off and allow all components to cool.

2. Open the rear access doors and slowly, remove the radiator cap.

The coolant level should be up to the level shown by the arrow.

3. Fill with coolant if necessary.

4. Secure the cap.

5. Close all doors.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FIRST 250 HOURS INITIAL 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

1

1

1

1

1

1

1

Figure 89

BD01C265X

1. RETAINING NUTS

Figure 86

BK98E107

With the machine blocked up rotate each tire and check for allowable movement. 0 to 1/4 inch is the acceptable range.

DRIVE CHAIN ADJUSTMENT

Each axle drive chain is adjusted by loosening the retaining nuts and sliding the axle-hub assembly to remove the excessive slack.

To tighten the chains slide the front axle-hubs forward and the rear axle-hubs rearward.

Torque the axle retaining hardware to 180 ft-lbf (244 Nm).

To adjust the final drive chains jack up and block the complete skid steer securely off the ground.

Figure 87

BD05E500

Block the machine securely.

WARNING: Use adequate blocking to insure that the skid steer is safely supported with all four wheels off the ground.

Figure 88

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS INSPECT THE ROPS, OPERATOR’S SEAT AND SEAT BELT AND RESTRAINT BAR HARDWARE The ROPS (roll over protective structure), seat belt and restraint bar are intricate components in the operator ‘s protection system. Inspect these components in accordance with the use of the machine. Machines working in extreme environments or with authorized attachments that may cause more than nor mal vibration should be ser viced and checked more frequently.

3

3

Check the hardware and components every 500 hours of operation.

1. Check the operator’s seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque.

Torque is 38 to 45 pound feet (52 to 61 Nm).

Figure 92

BD07K047

3. REAR ROPS BOLTS

2. Check the ROPS bolts at the back of the machine that are used to tilt the cab.

Torque for the rear ROPS bolts are: 130 to 235 pound feet (180 to 320 Nm).

1 4

Figure 90

BD07K021

1. RIGHT SIDE SEAT BELT BOLT

Figure 93

BD07N235

4. FRONT ROPS PIN

3. Inspect the pin that runs the width of the cab and attaches the front of the cab to the chassis.

Inspect the pin for wear and damage. Maker sure to keep the ends clear of dirt and debris.

2

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

Figure 91

BD07K022

SA080

Figure 94

2. LEFT SIDE SEAT BELT BOLT

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS CHANGE THE ENGINE OIL - FILTER - CLEAN ENGINE AREA Every 500 hours of operation change the engine oil and filter. Clean the engine area for debris or build up from work environment.

Engine crankcase w/ filter 420-430 . . 8.5 L (9.0 qts.)

Engine crankcase w/ filter 440-440CT . . . . . . .12.0 L (12.7qts)

2

Specification . . . . . Case Akcela No. 1, SAE 15W40 NOTE: For more complete removal of foreign material, change the engine oil while the engine is still warm, but not hot from operation.

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. Remove any attachments from the skid steer.

2. Place the machine on firm, level, ground, in park.

Figure 96

BD07K065

2. REMOTE ENGINE OIL DRAIN PLUG

7. Clean the area around the engine oil drain line and the oil filter head and surrounding area.

8. Remove the remote engine oil drain plug and drain the oil into a suitable container.

9. Inspect the drain hose for wear or abrasion.

3. Raise the loader arms and place the support strut or lock pin into position for maintenance.

4. Tilt the cab.

3

5. Remove the dipstick.

Figure 97

BD07N450

3. ENGINE OIL FILTER

10. Turn the old engine oil filter counterclockwise to remove. Dispose of the filter properly.

1

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

BD04N093

Figure 95

1. ENGINE OIL DRAIN PLUG ACCESS COVER

6. Use a 19 mm tool and remove the engine oil drain access cover.

12. Put new oil into the engine oil filter.

13. Turn the new oil filter clockwise onto the base until the gasket makes contact with the base.

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.

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

4

Figure 98

BD07N449

4. ENGINE OIL FILL CAP

15. Slowly add the correct type and quantity of oil into the engine oil fill cap. Do not overfill.

16. Replace the dipstick.

17. Tilt the cab back into the working position.

18. Start the engine and run at low idle speed.

Check for leaks around the drain plug or filter area.

19. After two minutes, stop the engine. Allow the engine oil to drain to the pan and then check the engine oil level.

20. Install the engine oil drain access cover, being careful to secure the drain hose so that it does not rub or chafe against the cover.

21. Close and secure all covers and panels.

22. 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.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS REPLACE THE FUEL FILTERS

3

Replace the fuel filter every 500 hours of operation or if large amounts of black smoke are emitted from the exhaust.

2

Check all the fuel lines and pipes for wear or damage. Replace as necessary.

3

Figure 100

BD07N451

1

2. IN LINE FUEL FILTER 3. FILTER QUICK RELEASE CLAMPS

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

Figure 99

BD07N459

1. PRIMARY FUEL FILTER

1. Clean the area proceeding.

around

the

filter

before

2. Use a strap wrench and remove the filter.

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

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

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

6. Install the rubber seal on the filter head stud.

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

8. Turn the filter 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.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS HYDRAULIC OIL FILTER REPLACEMENT The Hydraulic Oil Filter should be replaced every 500 hours or if the warning lamp illuminates.

IMPORTANT: Replace the hydraulic oil filter after 20 hours of use if a major hydraulic component has been replaced.

2

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

Figure 101

M477

1. Remove any attachments from the skid steer.

2. Place the machine on firm, level ground, in park.

3. Raise the loader arms and place the support strut or lock pin into position for maintenance.

4. Tilt the cab.

Figure 103 2. HYDRAULIC OIL FILTER (LEFT SIDE, INSIDE CHASSIS FRAME)

BD07K056

7. Clean the area around the hydraulic filter.

8. To remove the filter, turn counterclockwise.

Dispose of the filter properly.

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

10. Fill the new filter about 3/4 of the way up with new oil. Avoid spilling oil while installing.

11. Install the filter. Hand tighten the filter 1/2 turn after the filter O-ring touches the filter head.

1

IMPORTANT: Do not use a strap wrench to tighten filters. Hand tighten only.

12. Tilt the cab back into working position.

Figure 102

BD07N460

13. Start the engine, lower the lift arms to the ground and check for leaks.

1. HYDRAULIC OIL FILL CAP

5. Open the rear access doors and clean the area around the fill cap.

6. Slowly loosen the hydraulic fill cap to relieve pressure in the system. Leave the cap on, but loose.

3

BD08F024

Figure 104

3. HYDRAULIC OIL GAUGE

14. Shut the engine off and check the reservoir sight gauge. Add oil, if necessary. Oil should be half way up the sight gauge.

Specification . . . . . . . . . . . . . . . . 10W30 Engine Oil

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS CHECK THE CHAIN TANK OIL Specification . . . . . . . . . . . . . . . 10W-30 Engine Oil The chain tank oil should be checked every 500 hours of operation.

1. Park the machine on a firm level surface.

1

BD04N079

Figure 105

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

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

3. Remove the drain plug of each compartment.

The oil should just be to the bottom of the inspection orifice.

Add oil if necessary.

4. Replace the plug.

NOTE: Use Loctite 527 or an equivalent product on the thread of the plug.

FINAL DRIVE OIL CHANGE Change the oil in the final drives every 500 hours of operation. See page 5-28 in this chapter.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS DRIVE CHAIN TENSION Check the tension of the four drive chains every 500 hours of operation on a new machine or if new chains have been installed.

1

1

1

1

1

1

1

1

BD01C265X

Figure 109

1. RETAINING NUTS

Figure 106

BK98E107

With the machine blocked up rotate each tire and check for allowable movement. 0 to 1/4 inch is the acceptable range.

DRIVE CHAIN ADJUSTMENT To adjust the final drive chains jack up and block the complete skid steer securely off the ground.

Each axle drive chain is adjusted by loosening the retaining nuts and sliding the axle-hub assembly to remove the excessive slack.

To tighten the chains slide the front axle-hubs forward and the rear axle-hubs rearward.

Torque the axle retaining hardware to 165 - 190 pound feet (223 - 257 Nm).

FINAL DRIVE OIL CHANGE Change the oil in the final drives on track machines every 500 hours.

See page 5-28 on this chapter for procedure.

Figure 107

BD05E500

Block the machine securely.

WARNING: Use adequate blocking to insure that the skid steer is safely supported with all four wheels off the ground.

Figure 108

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS CHANGE AIR CLEANER ELEMENTS Both air cleaner elements should be changed at the 500 hour service interval. Change both elements.

Always change the air cleaner elements if the air restriction indicator is illuminated.

Figure 112

BD07K062

Remove the secondary filter.

BD07K060

Figure 110

Pull the yellow tab out, rotate the cover counterclockwise until the cap turns to open. See instructions symbols and decal on the cover. Pull the cap off and clean the inside.

Figure 113

BD07K063

Wipe the inside of the housing clean before installing the new filters. It is extremely important to have the contact surfaces clean.

NOTE: Make sure the filters are seated properly into the filter housing.

IMPORTANT: The inner end of the canister must be free of dirt and debris to insure that the element will seal properly. Failure of a good seal between the filter and canister may cause major engine damage.

BD07K061

Remove the primary filter.

5-40

Figure 111

Reinstall the cover so that the yellow release tab is near the top when the cap is secure shut.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS INSPECT THE ENTIRE MACHINE FOR LOOSE OR DAMAGE HARDWARE Check the entire machine for hardware that has become loose or damaged. Replace damaged hardware and use proper torque values.

Under extreme conditions this service interval should be decreased.

2

HYDRAULIC OIL AND FILTER CHANGE After every 1000 hours of operation or if a major hydraulic component has been replaced, rebuilt or damaged the hydraulic oil and filter should be changed.

Specification . . . . . . . . . . . . . . . 10W-30 Engine Oil System capacity . . . . . . . . . . . . . . . 50.0 L (13.2 gal) 1. Remove any attachments from the skid steer.

2. Place the machine on firm, level ground, in park.

3. Raise the loader arms and place the support strut or lock pin into position for maintenance.

Figure 115 2. HYDRAULIC OIL RESERVOIR DRAIN (LEFT REAR)

BD07K064

7. Clean the area around the hydraulic oil reservoir drain.

8. Remove the drain plug and drain into a suitable container.

4. Tilt the cab.

3

1

Figure 116 3. HYDRAULIC FLUID FILTER (LEFT SIDE, INSIDE CHASSIS FRAME)

BD07N452

Figure 114

BD07N460

1. HYDRAULIC OIL FILL CAP

5. Open the rear access doors and clean the area around the fill cap.

6. Slowly loosen the hydraulic fill cap to relieve pressure in the system. Leave the cap on, but loose.

9. Clean the area around the hydraulic filter.

10. Remove the filter by turning it counterclockwise.

Dispose of the filter properly.

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

12. Fill the new filter about 3/4 of the way up with new oil. Avoid spilling oil while installing.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Every 1000 Hours Hydraulic Oil And Filter Change - Continued WARNING: Fire Hazard: Do not smoke while filling the hydraulic reservoir. Do not fill near open flames.

M476

Figure 117

13. Install the filter. Hand tighten the filter 1/2 turn after the filter O-ring touches the filter head.

IMPORTANT: Do not use a strap wrench to tighten filters. Hand tighten only.

Figure 119

BD08F024

21. Slowly remove the hydraulic oil fill cap and add oil, if necessary, to bring the sight gauge up to half way.

BD07K064

Figure 118

14. Replace the Hydraulic Oil Reservoir plug.

NOTE: Use Loctite 527 or an equivalent product on the thread of the plug.

15. Add approximately 6 gallons of oil to the hydraulic oil fill and close the cap.

16. Tilt the cab back into working position.

17. Start the engine, lower the lift arms to the ground.

18. Stop the engine and check for leaks.

19. Start the engine and cycle the hydraulics through their full range of motion several times.

20. Lower the lift arms and shut the engine off.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS ENGINE COOLANT CHANGE Drain and flush the cooling system every 1000 hours or every year. Clean the system and replace the coolant if the coolant becomes dirty or has the color of rust.

DO NOT remove the radiator cap if the coolant is hot. This procedure is to be performed only when the engine components and coolant are cool.

System capacity ..................................................................................................................................11.4 L (3.0 gal) 3. Open the radiator valve and drain.

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.

After all coolant is removed: 1. Close the radiator drain valve.

2. Add a cleaning solution to the cooling system and fill the system with clean water. Follow the directions included with the cleaning solution.

3. After draining the solution flush with clean water.

Figure 120

1

2

BD07K059

Figure 123

3. RADIATOR FILL LINE Figure 121

BD07K057

1. RADIATOR CAP / NEVER TOUCH OR REMOVE UNTIL COOL TO THE TOUCH

1. Remove the radiator cap.

4. Fill the cooling system, with the proper mixture of water and ethylene glycol, until the coolant level is just to the overflow tube.

5. Install the radiator cap.

6. Fill the coolant reservoir up to the ADD mark.

7. Start the engine and increase the temperature of the engine coolant. Once the coolant is at operating temperature, stop the engine and allow to cool.

8. Check the coolant level at the reservoir only. DO NOT remove the radiator cap. Add coolant to the reservoir, if necessary.

9. Check the hoses, elbows and system for leaks.

Figure 122 2. RADIATOR DRAIN VALVE AND SUITABLE CONTAINER

BD07K058

Refill the cooling system with a 50-50 mixture of a permanent type anti-freeze, water and premixed with 5% inhibitor to provide increased protection from corrosion.

2. Attach a hose to the radiator drain valve, as shown, and run to a suitable container that will hold at least 18 litres or (19. 3 qts.).

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 6. After the oil has been completely drained, replace the chain tank drain plug.

EVERY 1000 HOURS CHAIN TANK OIL CHANGE Change the oil in the chain tanks every 1000 hours of operation.

Capacity each side . . . . . . . . . . . . . . . . 3.8L (1.0 gal) Specification . . . . . . . . . . . . . . . . 10W30 Engine Oil 1. Park the machine on a firm, level surface.

NOTE: Use Loctite 527 or an equivalent product on the thread of the plugs.

7. Fill the tank with new oil and replace the chain tank oil level plug.

8. Repeat this procedure for the other side.

NOTE: The chain tank may be cleaned with a solvent based cleaner by removing the inspection cover on each side, after the oil has been removed.

Allow the tank to dry thoroughly before filling with oil.

1

Figure 124

BD04N079

1. RIGHT SIDE CHAIN TANK OIL LEVEL PLUG (ONE EACH SIDE)

2. Clean the area around the chain tank plugs.

2

Figure 125 2. RIGHT SIDE CHAIN TANK DRAIN PLUG (ONE EACH SIDE)

3. Clean the area around the chain tank drain plugs.

4. Place a suitable container under the chain tank and slowly remove the tank drain plug.

NOTE: Use a jack and raise the front of the machine slightly for better draining.

5. Remove the chain tank oil level plug.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS MAINTENANCE AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 MAINTENANCE AND INSPECTION OF ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 SIDE WINDOW REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 FRONT DOOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 CHECK THE BATTERY AND CLEAN THE TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 CLEANING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 TYPE OF FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

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MAINTENANCE AND ADJUSTMENTS ROLL-OVER PROTECTIVE STRUCTURE Your machine has a roll-over protective structure.

The Rollover Protective Structure ROPS or Cab Structural Frame CSF is a special safety component of your machine.

DO NOT attach any device to the ROPS or CSF for pulling purposes.

The ROPS or CSF is a certified structural support and any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the ROPS or CSF MUST be replaced so that it will provide the same protection as a new ROPS or CSF. After an accident, fire or rollover, the following MUST be performed before returning the machine to field or job site.

• The ROPS or CSF structure MUST be replaced.

• The ROPS or CSF mounting or suspension, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST be replaced.

DO NOT WELD, ATTEMPT TO STRAIGHTEN OR R E PA I R T H E RO P S O R C A B ST RU C T U R A L FRAME. MAINTENANCE AND INSPECTION OF ROPS 1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

See ROPS Torque Specifications in this manual.

2. Check the operators seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. Replace the parts that have wear or damage.

3. 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 dealer.

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 operator’s seat belts are correctly installed.

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WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

SA080

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: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the parts catalog for this machine.

SA029

WARNING: Before you start the engine, always sit in the operators seat, fasten the seat belt, confirm the parking brake is engaged and make sure the direction control levers are in NEUTRAL. Give a warning to all persons around you that you are starting the engine.

Figure 1

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MACHINE CLEANING It is recommended that the complete machine be kept clean. Machine operation in water, mud, dust, landfill, land clearing or forestry will require complete machine clean up. Cleaning includes periodically removal of inspection covers and guards to gain access for cleaning and removal of dirt or debris.

Clean all dirt and foreign material from the front engine guard. Dirt will cause rust on the engine oil pan and the loss of engine oil.

1

2

After cleaning is complete, install ALL covers and guards.

DO NOT operate machine with covers or guards removed.

WARNING: Replace all covers or guards after servicing or cleaning the machine.

NEVER operate the machine with covers or guards removed.

CM115

SIDE WINDOW REMOVAL AND INSTALLATION The front and rear side windows, on machines so equipped, may be removed for cleaning or storage, if necessary.

The forward side glass must be removed first.

Figure 3

BD08F012

1. TAB 2. LATCH

2. Slide the track latch fully rearward while at the same time lifting the track using the tab.

3. With the track held up, release the track latch to hold the track up.

4. Tilt the top edge of the glass inward to clear the track and lift out to remove.

5. Remove the rubber stop from the lower track located just in front of the rear glass.

6. Slide the rear glass forward to where the glass clears the track.

7. Tilt the top edge of the glass inward and lift out.

To replace the windows reverse the procedure.

BD08F011

Figure 2

1. Slide the front window back to the rear in order to align the guide with the slot in the track.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FRONT DOOR REMOVAL AND INSTALLATION All Series 3 Family Skid Steers

NOTE: The jumper wire is tethered to the loom. Do not cut this tether.

Removing The Cab Door:

3

1

Figure 4

BD08F001

1. UPPER MULTI-WIRE CONNECTOR

1. Disconnect the upper multi-wire connector.

Figure 7

BD08F002

2. Disconnect the lower multi-wire connector (3) below the door. HL machine shown.

3

2

2

BD08F003

Figure 8

Figure 5

3. Install the jumper connection (2). HL machine shown.

The jumper and lower multi-connector are tied to the wire loom just under the inside door threshold.

IMPORTANT: If the jumper is not installed, the boom and bucket functions are not operational.

BD08F008

2. JUMPER WIRE HL MACHINES 3. LOWER MULTI-CONNECTOR - CP MACHINES

2 3

Figure 6 2. JUMPER WIRE CP MACHINES 3. LOWER MULTI-CONNECTOR - HL MACHINES

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4

Figure 9

BD08F005

4. RETAINER CLIP (HL MACHINE SHOWN)

4. Use a small screwdriver and remove the retainer clip that secures the strut, rod end, to the door and lift the end of the strut up off of the pin.

5

BD08F006

Figure 12

BD08F004

7. Lift the door up off of the hinges.

6

Figure 10

5. ROPS TILT STOPPER 6. ROPS TILT STOPPER RETAINING PIN

5. On HL models this ROPS tilt stopper, pull the retainer pin and pull the stopper straight forward off of the pin.

BD08F007

Figure 11

6. The stopper and pin will remain tethered to the door.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Installing The Door: WARNING: If the jumper is NOT removed AND the multi-wire connector is connected the boom and bucket functions are INABLED and damage may occur.

1. Place the door on the hinges.

Figure 16

Figure 13

BD08F005

2. Place the strut, rod end, back over the pin and secure it with the retainer clip.

BD08F002

Figure 17

5. Re-connect the lower multi-wire connector below the door.

6. Use plastic tie straps and secure the connectors back onto the loom.

Figure 14

3. On machines so equipped, place the ROPS tilt stopper back on the pin and install the retainer pin.

BD08F001

Figure 18

7. Re-connect the multi-wire connector.

8. Close the door and check that all functions and controls are operating correctly.

Figure 15

BD08F003

4. Remove the jumper.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK THE BATTERY 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. Place a protective pad or carpet over the battery.

SA046

Figure 1

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

Figure 2

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.

Figure 3

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.

Figure 4

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.

Figure 5

M198A

WARNING: DO NOT weld on this machine. (See your dealer for repairs). Danger of explosion exists which can result in injury or death.

Figure 6

M478

IMPORTANT: If the temperature is 0° C (32F) 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

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

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

Check the battery, as required 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 a battery saver product. Follow the instructions on the container. Usually these cleaners do not use water.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) TYPE OF FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. See your dealer.

2

Inspection and Care: EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

E V E RY 6 M O N T H S - H ave t h e d r y c h e m i c a l removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS or (Falling Object Protective Structure) FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

BD07M249

Figure 8

2. WINDSHIELD WASHER RESERVOIR

WINDSHIELD WASHER FLUID LEVEL As necessary, check the windshield washer fluid level.

1

Figure 7

BD07N244

1. WINDSHIELD WASHER FLUID FILL LOCATION (MOUNTED ON THE HEEL PLATE)

The windshield washer fluid reservoir is located under the floor plate. The fill location is mounted on the heel plate within easy reach.

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NOTES

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CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY SAFETY AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY VENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING THE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORY OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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ELECTRICAL SYSTEM BATTERY SAFETY AND SERVICE

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.

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

SAFETY_ID_1C02

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

SAFETY_ID_1C02

SB034

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

This machine is equipped with a maintenance free battery from the factory. Fluid is not serviceable.

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. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

SB032

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

SA033

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the off position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

SAFETY_ID_1C02

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BD04K021

1

Figure 1

1. POSITIVE BATTERY CABLE 2. NEGATIVE BATTERY CABLE

NOTE: The electrical system in this machine is 12 volts negative ground.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with a Battery Saver and Cleaner. Follow the instructions on the can.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

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CHAPTER 7 - ELECTRICAL BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Contact your Dealer for a battery cleaning product.

ACCESSORY OUTLET There is one 12 volt accessory outlet in the right console.

3

BD07N531

Figure 2

3. 12 VOLT ACCESSORY OUTLET

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CHAPTER 7 - ELECTRICAL FUSES AND RELAYS

1 3 2

BD07N227

Figure 5

3. FUSE DECAL UNDER CONSOLE LID.

3 Figure 3

BD08G004

1. FUSE AND RELAY ACCESS COVER 2. THUMBSCREW

Fuses and relays are located under the left console.

The cover is secured by a 1/4 turn fastener. Loosen the 1/4 turn fastener and slide the cover to the rear to access the fuses and relays.

87734526

Figure 6

Figure 4

BD07M325

After the console cover has been removed the individual fuse and relay covers will have to be removed.

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 HYDRAULIC SYSTEM FLOW RATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 WEIGHTS OF BUCKETS AND FORKS FOR CASE SKID STEER FAMILY . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 MATERIAL WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

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SPECIFICATIONS NOTE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

420 - 420CT - 430 TIER 3 ENGINES Manufacturer ....................................................................................................................................... Case / Iveco Model .........................................................................................................................................................432TM3 EPA Level ........................................................................................................................................ Tier 3 Certified Aspiration .......................................................................................................................................................Turbo Firing order...................................................................................................................................................1,3,4,2 Fuel ............................................................................................................................................................. Diesel Bore and Stroke ....................................................................................................... 99 x 104 mm (3.89 x 4.09 in) Displacement ....................................................................................................................3.2 L (195 cubic inches) Compression Ratio...........................................................................................................................................18:1 Horsepower 420 - 420CT Gross Bare Engine Power (SAE J1349)..................................................................... 55 kW (74 hp) 420 - 420CT Net Engine Power (SAE J1349) ................................................................................. 51 kW (69 hp) 420 - 420CT Peak Torque @ rpm ..................................................................... 275 Nm (203 ft. lbs.) @ 1400 rpm 430 Gross Bare Engine Power (SAE J1349).................................................................................... 61 kW (82 hp) 430 Net Engine Power (SAE J1349) ................................................................................................ 57 kW (77 hp) 430 Peak torque @ rpm .................................................................................... 310 Nm (229 ft. lbs.) @ 1400 rpm Engine Speeds 420 - 420CT - 430 High Idle - No Load ........................................................................................... 2675 ± 75 rpm 420 - 420CT - 430 Rated - full load ..........................................................................................................2500 rpm 420 - 420CT - 430 Low Idle............................................................................................................. 1075 ± 75 rpm 440 - 440CT TIER 3 ENGINES Manufacturer .................................................................................................................................................. Case Model .........................................................................................................................................................445TM3 EPA Level ........................................................................................................................................ Tier 3 Certified Aspiration .......................................................................................................................................................Turbo Firing order...................................................................................................................................................1,3,4,2 Fuel ............................................................................................................................................................. Diesel Bore and Stroke ..................................................................................................... 104 x 132 mm (4.09 x 5.20 in) Displacement ....................................................................................................................4.5 L (272 cubic inches) Horsepower Gross Bare Engine Power (SAE J1349)........................................................................................... 67 kW (90 hp) Net Engine Power (SAE J1349) ....................................................................................................... 62 kW (82 hp) Peak Torque @ 1300rpm ....................................................................................................... 390 Nm (288 ft. lbs.)

Engine Speeds High Idle - No Load ......................................................................................................................... 2415 ± 60 rpm Rated - full load ........................................................................................................................................2300 rpm Low Idle ........................................................................................................................................... 1075 ± 75 rpm

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CHAPTER 8 - SPECIFICATIONS TRAVEL SPEEDS 420 low range..............................................................................................................0 to 11.6 kph (0 to 7.2 mph) high range .............................................................................................................0 to 18.7 kph (0 to 11.6 mph) 420CT .......................................................................................................................... 0 to 9.3 kph (0 to 5.8 mph) high range ...............................................................................................................0 to 13.5 kph (0 to 8.4 mph) 430 low range..............................................................................................................0 to 12.4 kph (0 to 7.7 mph) high range .............................................................................................................0 to 20.0 kph (0 to 12.6 mph) 440 low range..............................................................................................................0 to 11.3 kph (0 to 6.7 mph) high range .............................................................................................................0 to 18.3 kph (0 to 11.4 mph) 440CT low range ..........................................................................................................0 to 8. 2 kph (0 to 5.1 mph) high range ...............................................................................................................0 to 12.9 kph (0 to 8.0 mph) HYDRAULIC SYSTEM FLOW RATES 420 - 420CT - 430 Auxiliary Hydraulic Circuit .........................................................................90.1 lpm (23.8 gpm) 420 - 420CT - 430 High Flow ...........................................................................................125.8 lpm (33.2 gpm) 440 - 440CT Auxiliary Hydraulic Circuit ..................................................................................82.9 lpm (21.9 gpm) 440 - 440CT High Flow ....................................................................................................143.0 lpm (37.8 gpm)

ELECTRICAL SYSTEM Battery....................................................................................................................... maintenance free / 1125 cca Alternator All 420 thru 440 .............................................................................................................................. 12 volt, 95 amp Starter All 420 thru 440 ............................................................................................................................... 2.7 kW, 12 volt WEIGHTS Operating Weights - with 165 lb (75 kg) operator, full fuel tank, spec. bucket 420 ........................................................................................................................................... 2996 kg (6605 lbs) 420CT ....................................................................................................................................... 3783 kg (8340 lbs) 430 ............................................................................................................................................ 3084 kg (6800 lbs) 440 ............................................................................................................................................ 3193 kg (7040 lbs) 440CT ....................................................................................................................................... 4048 kg (8925 lbs) Shipping Weight - with no operator and no attachment 420 ............................................................................................................................................ 2747 kg (6055 lbs) 420CT ....................................................................................................................................... 3588 kg (7690 lbs) 430 ............................................................................................................................................ 2780 kg (6150 lbs) 440 ............................................................................................................................................ 2896 kg (6390 lbs) 440CT ....................................................................................................................................... 3744 kg (8255 lbs)

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CHAPTER 8 - SPECIFICATIONS POWER TRAIN Drive Type .............................................................................................................................................Hydrostatic Drive Pump - Mechanical Control.................................................................................................... Sauer-Danfoss Type ................................................................................................................................... Tandem Axial Piston Drive Pump - Pilot Control.......................................................................................................................... Rexroth Drive Motor 420 / 430 / 440 / 440CT .......................................................................................................... Rexroth Type ...............................................................................................................................................Radial Piston Drive Motor 420CT .................................................................................................................................. Bonfiglioli Type ....................................................................................................................... Double Reduction Planetary Wheel Unit Final Drive............................................................................................................. Sprocket and Chain 420 / 430 / 440 Final Drive Chain Size ............................................................................................ASA 100HS 440CT Final Drive ................................................................................................... Single Reduction Planetary UNDERCARRIAGE 420CT / 440CT Track adjustment ......................................................................................................................................... Manual Frame ..............................................................................................................................................................Rigid Length of track on ground ..........................................................................................................1436 mm (56.6 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.

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Figure 1

BS08A025

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CHAPTER 8 - SPECIFICATIONS

Operating Data And Dimensions 420 with 1524 mm 60 inch Foundry & Excavating Bucket - Galaxy Beefy Baby 10 x 16.5 Tires A. Overall Operating Height - Fully Raised Bucket .....................................................................3850 mm (151.6 in) B. Height to Hinge Pin - Fully Raised .........................................................................................3065 mm (120.7 in) C. Overall Height to Top of ROPS ................................................................................................2003 mm (78.9 in) D. Overall Length w bucket on ground........................................................................................3249 mm (127.9 in) E. Overall Length without attachment.........................................................................................2604 mm (102.5 in) F. Wheelbase ...............................................................................................................................1074 mm (42.3 in) G. Dump Angle - Fully Raised Bucket .....................................................................................................39 degrees H. Dump Height - Fully Raised Bucket (45 degree dump angle) ..................................................2440 mm (96.1 in) I. Height to bottom of: Level Bucket ..........................................................................................2884 mm (113.5 in) J. Maximum rollback at ground with bucket ............................................................................................29 degrees K. Maximum rollback fully raised bucket..................................................................................................96 degrees L. Dump Height - Maximum Reach ...................................................................................................964 mm (38 in) M. Angle of departure ..............................................................................................................................26 degrees N. Rear overhang ...........................................................................................................................940 mm (37.0 in) O. Ground clearance.........................................................................................................................208 mm (8.2 in) P. Overall width (outside of tires)..................................................................................................1504 mm (59.2 in) Q. Tread width (centerline to centerline) .......................................................................................1379 mm (54.3 in) R. Clearance circle, rear ...............................................................................................................1504 mm (59.2 in) S. Clearance circle, coupler - without bucket................................................................................1440 mm (56.7 in) T. Clearance circle, front - with bucket .........................................................................................1930 mm (76.0 in) U. Bucket width .............................................................................................................................1524 mm (60.0 in) 430 and 440 with 1676 mm 66 inch Foundry & Excavating Bucket - Galaxy Beefy Baby 12 x 16.5 Tires A. Overall Operating Height - Fully Raised Bucket .....................................................................3912 mm (154.0 in) B. Height to Hinge Pin - Fully Raised .........................................................................................3089 mm (121.6 in) C. Overall Height to Top of ROPS ................................................................................................2032 mm (80.0 in) D. Overall Length w bucket on ground........................................................................................3287 mm (129.4 in) E. Overall Length without attachment.........................................................................................2604 mm (102.5 in) F. Wheelbase ...............................................................................................................................1074 mm (42.3 in) G. Dump Angle - Fully Raised Bucket .....................................................................................................39 degrees H. Dump Height - Fully Raised Bucket (45 degree dump angle) ..................................................2438 mm (96.0 in) I. Height to bottom of: Level Bucket ..........................................................................................2901 mm (114.2 in) J. Maximum rollback at ground with bucket ............................................................................................29 degrees K. Maximum rollback fully raised bucket..................................................................................................96 degrees L. Dump Height - Maximum Reach ................................................................................................960 mm (37.8 in) M. Angle of departure ..............................................................................................................................28 degrees N. Rear overhang ...........................................................................................................................940 mm (37.0 in) O. Ground clearance.........................................................................................................................234 mm (9.2 in) P. Overall width (outside of tires)..................................................................................................1636 mm (64.4 in) Q. Tread width (centerline to centerline) .......................................................................................1316 mm (51.8 in) R. Clearance circle, rear ...............................................................................................................1504 mm (59.2 in) S. Clearance circle, coupler - without bucket................................................................................1316 mm (51.8 in) T. Clearance circle, front - with bucket .........................................................................................1999 mm (78.7 in) U. Bucket width .............................................................................................................................1676 mm (66.0 in)

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CHAPTER 8 - SPECIFICATIONS

Figure 2

BS08A024

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87493825NA

CHAPTER 8 - SPECIFICATIONS 420CT with 1676 mm 66 inch Foundry & Excavating Bucket A. Overall Operating Height - Fully Raised Bucket .....................................................................3890 mm (153.2 in) B. Height to Hinge Pin - Fully Raised ..........................................................................................3068mm (120.8 in) C. Overall Height to Top of ROPS ................................................................................................2024 mm (79.7 in) D. Overall Length w bucket on ground........................................................................................3284 mm (129.3 in) E. Overall Length without attachment.........................................................................................2604 mm (102.5 in) F. Track on ground .......................................................................................................................1388 mm (54.6 in) G. Dump Angle - Fully Raised Bucket .....................................................................................................39 degrees H. Dump Height - Fully Raised Bucket (45 degree dump angle) ..................................................2440 mm (96.1 in) I. Height to bottom of: Level Bucket ..........................................................................................2881 mm (113.4 in) J. Maximum rollback at ground with bucket ............................................................................................29 degrees K. Maximum rollback fully raised bucket..................................................................................................96 degrees L. Dump Height - Maximum Reach ...................................................................................................964 mm (38 in) M. Angle of departure ..............................................................................................................................26 degrees N. Rear overhang ...........................................................................................................................940 mm (37.0 in) O. Ground clearance.........................................................................................................................213 mm (8.4 in) P. Overall width (outside of track).................................................................................................1656 mm (65.2 in) Q. Tread width (centerline to centerline) .......................................................................................1379 mm (54.3 in) R. Clearance circle, rear ...............................................................................................................1448 mm (57.0 in) S. Clearance circle, coupler - without bucket................................................................................1476 mm (58.1 in) T. Clearance circle, front - with bucket .........................................................................................2050 mm (80.7 in) U. Bucket width .............................................................................................................................1676 mm (66.0 in) 440CT with 1829 mm 72 inch Foundry & Excavating Bucket - 400 mm (15.7 inch) Track A. Overall Operating Height - Fully Raised Bucket .....................................................................3912 mm (154.0 in) B. Height to Hinge Pin - Fully Raised .........................................................................................3091 mm (121.7 in) C. Overall Height to Top of ROPS ................................................................................................2047 mm (80.6 in) D. Overall Length w bucket on ground........................................................................................3287 mm (129.4 in) E. Overall Length without attachment.........................................................................................2604 mm (102.5 in) F. Length of Track on Ground.......................................................................................................1438 mm (56.6 in) G. Dump Angle - Fully Raised Bucket .....................................................................................................39 degrees H. Dump Height - Fully Raised Bucket (45 degree dump angle) ..................................................2438 mm (96.0 in) I. Height to bottom of: Level Bucket ..........................................................................................2906 mm (114.4 in) J. Maximum rollback at ground with bucket ............................................................................................29 degrees K. Maximum rollback fully raised bucket..................................................................................................96 degrees L. Dump Height - Maximum Reach ................................................................................................980 mm (38.6 in) M. Angle of departure ..............................................................................................................................34 degrees N. Rear overhang ...........................................................................................................................721 mm (28.4 in) O. Ground clearance.........................................................................................................................236 mm (9.3 in) P. Overall width (outside of track)..................................................................................................1814 mm (71.4 in Q. Track Gauge (centerline to centerline) .....................................................................................1412 mm (55.6 in) R. Clearance circle, rear ...............................................................................................................1471 mm (57.9 in) S. Clearance circle, coupler - without bucket................................................................................1453 mm (57.2 in) T. Clearance circle, front - with bucket (carry position) .................................................................2060 mm (81.1 in U. Bucket width .............................................................................................................................1829 mm (72.0 in)

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CHAPTER 8 - SPECIFICATIONS

WEIGHTS Operating Weights - with 165 lb (75 kg) operator, full fuel tank 420 ........................................................................................................................................... 2996 kg (6605 lbs) 420CT ....................................................................................................................................... 3783 kg (8340 lbs) 430 ............................................................................................................................................ 3084 kg (6800 lbs) 440 ............................................................................................................................................ 3193 kg (7040 lbs) 440CT ....................................................................................................................................... 4048 kg (8925 lbs) Shipping Weight - with no operator and no attachment 420 ............................................................................................................................................ 2747 kg (6055 lbs) 420CT ....................................................................................................................................... 3588 kg (7690 lbs) 430 ............................................................................................................................................ 3084 kg (6800 lbs) 440 ............................................................................................................................................ 2896 kg (6390 lbs) 440CT ....................................................................................................................................... 3744 kg (8255 lbs) WEIGHTS OF BUCKETS AND FORKS FOR CASE SKID STEER FAMILY Size Inches / Millimeter

Case Compact Power Buckets

Weight Pounds / Kilograms

60

1524

FE Foundry / Excavating (short lip)

270

66

1676

FE Foundry / Excavating (short lip)

370

122 168

72

1829

FE Foundry / Excavating (short lip)

390

177

78

1981

FE Foundry / Excavating (short lip)

495

225

60

1524

LP Low Profile Bucket (standard lip)

330

150

66

1676

LP Low Profile Bucket (standard lip)

400

181

72

1829

LP Low Profile Bucket (standard lip)

425

193

60

1524

HD Heavy Duty Dirt (standard lip)

400

181

66

1676

HD Heavy Duty Dirt (standard lip)

474

215

72

1829

HD Heavy Duty Dirt (standard lip)

501

227

78

1981

HD Heavy Duty Dirt (standard lip)

527

239

60

1524

LPE Low Profile Extended Bucket (long lip)

360

163

66

1676

LPE Low Profile Extended Bucket (long lip)

434

197

72

1829

LPE Low Profile Extended Bucket (long lip)

477

216

78

1981

LPE Low Profile Extended Bucket (long lip)

502

205

60

1524

Light Material Bucket

350

159

72

1829

Light Material Bucket

434

197

84

2134

Light Material Bucket

497

225 Figure 3

Size Inches / Millimeter

Case Compact Pallet Forks

Weight Pounds / Kilograms

42

1097

Pallet Fork Set

210

66

1676

Pallet Fork Set

242

95 110

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CHAPTER 8 - SPECIFICATIONS

MATERIAL WEIGHTS MATERIAL

kg/m3

lbs/ft3

MATERIAL

kg/m3

lbs/ft3

Alum-Lump.

881

55

Oats

416

26

Pulverized

769

48

Peanuts - Shelled

280

17

Ashes

561-833

35-52

Peas

769

48

Bauxite

1202-19 22

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

849-100 9

53-63

Rye

705

44

Clay

368-513

23-32

Salt - Rock - Solid

2163

135

Sand & Gravel - Dry

1730

108

Concrete

1378-17 78

86-111

Copper Ore

1666

104

Corn - Shelled

673

42

Cottonseed

401

25

Earth - Dry Loam

929-108 9

58-68

1602-1 666

100-104

Earth - Sand Gravel

1570

98

Ensilage

577

36

Granite

1490-1 778

93-111

Gravel - Dry

1522

95

Wet

1906

119

Ice - Crushed

Wet

593

37

Iron Ore

2323

145

Limestone - Loose - Crushed

1538-1 602

96-100

Wet

2003

125

Sand - Foundry

1522

95

Shale

1410

88

Slag - Crushed

1121

70

Slate

2243

130

Snow

240-80 1

15-50

Soybeans

743

46

Sugar Beet Pulp - Wet

561

35

Sugar - Raw

961

60

Sulphur - Lumpy

1330

83

Taconite

1714

107

Wheat

769

48 Figure 6

Figure 5

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CHAPTER 8 - SPECIFICATIONS TORQUE CHARTS Use these charts when special torques are not given.

These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

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

Size

Grade 5 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

108 to 132

12 to 15

9/16 inch

160 to 192

217 to 260

5/16 inch

204 to 252

23 to 28

5/8 inch

220 to 264

298 to 358

3/8 inch

420 to 504

48 to 57

3/4 inch

380 to 456

515 to 618

7/16 inch

54 to 64

73 to 87

7/8 inch

600 to 720

814 to 976

1/2 inch

80 to 96

109 to 130

1.0 inch

900 to 1080

1220 to 1465

9/16 inch

110 to 132

149 to 179

1-1/8 inch

1280 to 1440

1736 to 1953

5/8 inch

150 to 180

203 to 244

1-1/4 inch

1820 to 2000

2468 to 2712

3/4 inch

270 to 324

366 to 439

1-3/8 inch

2380 to 2720

3227 to 3688

7/8 inch

400 to 480

542 to 651

1-1/2 inch

3160 to 3560

4285 to 4827

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

NOTE: Use thick nuts with Grade 8 bolts.

Figure 8

Figure 7

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CHAPTER 8 - 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 Figure 10

Figure 9

Grade 12.9 Bolts, Nuts, and Studs 12.9 Figure 11

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

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CHAPTER 9 - INDEX

Chapter 9 INDEX A

E

Accessory Outlet ................................................. 7-4 After Delivery Check ................................. 10-1, 10-3 Air Conditioning Controls ..................................... 3-9 Air Conditioning Operation ................................ 4-10 Anti-Theft Operation .......................................... 3-16 Attachment Mounting ......................................... 4-11 Attachment Removal ......................................... 4-13 Auxiliary and High Flow Hydraulic Controls ....... 3-32 Auxiliary Hydraulic Control Pedal ...................... 3-34 Auxiliary Hydraulic Flow Switch ......................... 3-33 Auxiliary Hydraulic Interlock Override ......... 3-7, 3-14 Auxiliary Power Supply ...................................... 3-41

Electrical Service Accessory Outlet ..............................................7-4 Electrical System ..................................................7-3 Engine Hourmeter ........................................................5-6 Specifications ...................................................8-3 Engine Coolant Change .....................................5-43 Engine Oil Filter Change ....................................5-34 Engine Oil Pressure Lamp ......................... 3-6, 3-18 Engine Oil Specifications and Service ................5-17 Engine Operation .................................................4-3 Engine Speed ..................................................4-4 Parking the Machine and Stopping the Engine 4-5 Starting the Engine ..........................................4-4 Engine Pre-Heating Lamp .......................... 3-6, 3-18 Engine Speed .......................................................4-4 Environment Lubricant,Oil and Fluid Disposal ......................5-5 Extinguisher Mounting, Fire ..................................6-9

B Battery Cleaning .......................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Battery Access ................................................... 5-15 Battery Cleaning .................................................. 6-8 Biodiesel Fuel Usage ........................................... 4-6 Booster Battery Connection to Machine Battery 4-24 Burn Prevention ................................................. 2-10

C Cab Air and Circulation Vents ............................. 4-9 Cab Door Latch ................................................. 3-40 Cab Switch Panel ................................................ 3-9 Cab Temperature Controls .................................. 3-9 Cab Window Install and Remove ........................ 6-4 Chain Tank Oil Change ..................................... 5-44 Chain Tank Oil Check ........................................ 5-38 Charge Pressure Warning Lamp ................ 3-6, 3-18 Cold Weather Operation ...................................... 4-6 Control Handle Switches ................................... 3-29 Craning the Machine ......................................... 4-23 Creating Codes .................................................. 3-16

D Deluxe Instrument Panel ................................... 3-12 Deluxe Instrument Panel Warning Lamps ......... 3-18 Diesel Fuel Specifications ............................ 4-6, 5-5 Display Options ................................................. 3-17 Door Removal and Installation ............................ 6-5 Drive Chain Tension Check ...................... 5-32, 5-39 87493825NA

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F Field Operation ...................................................4-17 Filling a Bucket ...................................................4-18 Fire Extinguisher Mounting ...................................6-9 Floor Plate ..........................................................5-15 Fluid and Lubricant Capacities ...........................5-12 Front Door Removal and Installation ....................6-5 Fuel Filter Replacement .....................................5-36 Fuel Gauge ................................................. 3-7, 3-20 Fuel Handling Precautions ...................................2-9

G General Information ..............................................1-1 General Safety before Service .............................5-3

H Hazardous Chemical Precautions ......................2-10 Heat and Air Vents ...............................................4-9 Heat Controls .......................................................3-9 Heating the Cab ...................................................4-8 Hourmeter Engine ................................................5-6 Hydraulic Fluid Temperature Warning Lamp .......3-6, 3-18 Hydraulic Mounting Plate ...................................4-14 Hydraulic Oil Change .........................................5-41 Hydraulic Oil Filter Replacement ........................5-37 Hydraulic Oil Filter Warning Lamp ........................3-6 9-1

CHAPTER 9 - INDEX

O

Hydraulic Oil Sight Gauge ................................. 5-37

I Identification Numbers Engine Serial Number ..................................... 1-4 Product Identification Number (P.I.N.) ............ 1-4 Instructions, General Safety before Service ........ 5-3 Instruments and Controls .................................... 3-3

J Job Layout ......................................................... 4-17 Job Timer ........................................................... 3-17 Jump Starting the Machine ................................ 4-24

Official Justifying Documents ...............................1-2 Oil Temperature ..................................................5-17 Viscosity .........................................................5-17 Operating in Cold Weather ...................................4-6 Operating Instructions Booster Battery Connection to Machine Battery ...

4-24 Transporting the Machine ..............................4-22 Operating Precautions ..........................................2-7 Operator Seat Presence Switch Test .................5-20 Overhead Glass .................................................3-43 Owner Code .......................................................3-16

K P

Key Switch ........................................................... 3-5

L Lift Arm and Bucket Control with ISO Pattern Controls 3-27 Lift Arm and Bucket Controls with H Pattern ..... 3-23 Lift Arm Bypass Control ..................................... 3-36 Lift Arms Disengage Lock Pin - Return to Work Procedure .

2-16 Securing Support Strut .................................. 2-13 Securing The Lock Pin .................................. 2-15 Support Strut Return to Work Procedure ...... 2-14 Lifting the Machine ............................................ 4-23 Light Switches ..................................................... 3-8 Locking the Instrument Panel ............................ 3-16 Loss of Engine Power / Boom/Attachment Up procedure - Manual Control Machines ........ 3-37 Loss of Engine Power / Boom/Attachment Up procedure - Pilot Control Machines ............. 3-36 Lubricant and Fluid Capacities .......................... 5-12 Lubrication and Maintenance Chart ................... 5-13

M Machine Cleaning ................................................ 6-4 Machine Components .......................................... 1-6 Machine Lights .................................................... 3-8 Machine Operation .............................................. 4-5 Maintenance Precautions .................................... 2-8 Maintenance/Adjustments Machine Cleaning ........................................... 6-4 Roll-Over Protective Structure ........................ 6-3 Seat Belt .......................................................... 6-3 Master Disconnect Switch ................................. 3-42 Modifying Codes ....................................... 3-16, 3-17 Mounting Attachments ....................................... 4-11 Moving a Disabled Machine .............................. 4-23 9-2

Park Brake Lamp ................................................3-13 Parking the Machine and Stopping the Engine ....4-5 Plastic and Resin Parts ........................................5-4 Pre Start Checklist and Walk-Around ...................4-3

Q Quick Reference Lubrication and Maintenance .5-13

R Remote Jump Start Terminals ............................3-42 Removing Attachments ......................................4-13 Reservoir, Winshield Washer ...............................6-9 Roll Over Protective Structure ..............................6-3 ROPS Maintenance and Inspection ............................6-3 Run-In Period .......................................................4-3

S Safety Decals .....................................................2-20 Safety Instructions before Service ........................5-3 Safety Sign, Decal and Tread Service ...............5-16 Safety, Battery ......................................................7-3 Seat Belt ...............................................................6-3 Seat Belt and Restraint Bar ................................3-39 Seat Belt Precautions .........................................2-11 Seat Controls ......................................................3-38 Seat Presence Test ............................................5-20 Seat Restraint Bar Adjuster ................................2-12 Seat Restraint Bar and Interlock Function ..........5-19 Securing Skid Steer Lift Arms Up .......................2-13 Selecting Temperature Display ..........................3-17 Service Intervals .................................................5-13 Side Window Operation ......................................3-41 Side Window Remove and Install .........................6-4 Sides of the Machine Issued 09-08

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87493825NA

CHAPTER 9 - INDEX Right, Left, Front, and Rear of the Machine .... 1-3 Sound Levels ....................................................... 1-2 Specific Machine Precautions ........................... 2-13 Specifications Engine Specifications ...................................... 8-3 Weights .................................................. 8-4, 8-10 Standard Instrument Panel .................................. 3-3 Standard Instrument Panel Warning Lamps ........ 3-6 Starting and Stopping Precautions ...................... 2-7 Starting the Engine .............................................. 4-4 Steering and Travel with H Pattern .................... 3-21 Steering and Travel with ISO Pattern Pilot Control ...

3-25 Storage Long Term Storage Preparation .................... 4-24 Supporting a Raised Machine ............................. 5-4 Systemgard Lubrication Analysis ........................ 5-4

T Temperature Display ......................................... 3-17 Throttle Control .................................................. 3-31 Tie Down Locations ........................................... 4-22 Tilting the Operator’s Compartment .................... 5-7 Torque Charts .................................................... 8-12 Track Components .............................................. 1-7 Transporting the Machine .................................. 4-22

U Utility Safety ......................................................... 2-4 Utility Safety Rules Message ............................... 2-4

W WEIGHTS ................................................... 8-4, 8-10 Weights ....................................................... 8-4, 8-10 Wheel Nut and Bolt Run-In .................................. 4-3 Wheel Nut Service ............................................. 5-16 Window Install and Remove ................................ 6-4 Windshield Washer and Wiper Controls ............ 3-42 Windshield Washer Fluid Reservoir .................... 6-9

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CHAPTER 10 - AFTER DELIVERY CHECK

Chapter 10 AFTER DELIVERY CHECK - DEALER COPY AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Hourmeter Indication:

Machine Model Number: Machine Product Identification Number (P.I.N.):

COOLING SYSTEM

HYDRAULIC SYSTEM

Check the coolant levels.

Check the oil level.

Check for leaks.

Replace the hydraulic oil filter.

FUEL SYSTEM

GENERAL

Check for leaks.

Look for oil leaks and loose parts.

Drain water and sediment from the fuel system.

Check tire pressure and wheel torque.

Tighten all hose clamps.

Check drive chain tension

ELECTRICAL SYSTEM Check battery.

Check track tension if equipped.

Check operation of starter, alternator, and instruments.

Check brake operation.

Check the control levers for correct operation.

Check operation of all lamps.

Check the operators seat for correct operation

SAFETY

LUBRICATION

Inspect the ROPS.

Lubricate all pivot points.

Check the safety decals and replace if necessary.

Check the operator restraint system.

ENGINE

Make sure the machine has the operators manual in the manual storage box.

Check condition of drive belt.

Check engine oil level.

Check engine speed at idle and at full throttle.

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:

87493825NA

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CHAPTER 10 - AFTER DELIVERY CHECK

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CHAPTER 10 - AFTER DELIVERY CHECK

AFTER DELIVERY CHECK - OWNERS COPY AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Hourmeter Indication:

Machine Model Number: Machine Product Identification Number (P.I.N.):

COOLING SYSTEM

HYDRAULIC SYSTEM

Check the coolant levels.

Check the oil level.

Check for leaks.

Replace the hydraulic oil filter.

FUEL SYSTEM

GENERAL

Check for leaks.

Look for oil leaks and loose parts.

Drain water and sediment from the fuel tanks.

Check tire pressure and wheel torque.

Tighten all hose clamps.

Check drive chain tension.

ELECTRICAL SYSTEM Check battery.

Check track tension if equipped.

Check operation of starter, alternator, and instruments.

Check brake operation.

Check operation of all lamps.

Check the control levers for correct operation.

Check the operators seat for correct operation.

SAFETY

LUBRICATION

Inspect the ROPS.

Lubricate all pivot points.

Check the safety decals and replace if necessary.

Check the operator restraint system.

ENGINE

Make sure the machine has the operators manual in the manual storage box.

Check condition of drive belt.

Check engine oil level.

Check engine speed at idle and at full throttle.

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:

87493825NA

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CHAPTER 10 - AFTER DELIVERY CHECK

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