Case 521D Loader Operator's Manual 6-26410 - PDF DOWNLOAD

OM 9X6 JAUNE Gabarit MM.qxd

31/10/2007

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Page 1

521D Loader Operator’s Manual

Bur 6-26410

TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE . . . . . . . . . . 4 IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 WHEEL AND TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . 19 READ OPERATORS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INTERNATIONAL SYMBOL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 INSTRUMENT/CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-49 INSTRUMENT PANEL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64 INFORMATION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-70 GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-77 TRANSMISSION DISPLAY CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-80 FOOT PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SIDE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-95 MASTER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 RUN - IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 STOPPING THE ENGINE AND PARKING THE MACHINE . . . . . . . . . . . . 111 BEFORE YOU OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 LOADER FUNCTION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 LOADER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 I

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BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 CLUTCH CUTOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED) . . . . . . . . . . . . 130 ROTATING BEACON (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 RIDE CONTROL(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 COUPLER PIN ENGAGEMENT (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . 133 LOADER OPERATING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 MACHINE DRAWBAR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 WHEELS/TIRES/BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 LUBRICATION/FILTERS/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . 151 SUPPORT STRUT FOR LOADER LIFT ARMS . . . . . . . . . . . . . . . . . . . . . 152 TRANSPORT/SERVICE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . 155 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 FLUIDS AND LUBRICANTS - 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 LUBRICATION/MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . 158-160 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 GREASE FITTINGS - 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 HYDRAULIC/BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

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AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 MAINTENANCE/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 TRANSMISSION CLUTCH CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 206 SECONDARY STEERING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 PARKING BRAKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 LOADER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . 217 TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS . . . . . . . . . . 220 ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT . 221 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . 222 SPARK ARRESTING MUFFLER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . 223 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 REPLACEMENT FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 SERVICE ELECTRICAL CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION . 230 REPLACEMENT BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 ENGINE DATA - 521D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . 236-239 SPECIAL BOLT TORQUES (521D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

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NOTES

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BD00M077

521D

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

Your dealer can give you help with Case Corporation approved service parts.

Your dealer has specially trained technicians who know the best methods of repair and maintenance for your machine.

Use this manual as a guide. Your Wheel Loader will remain a reliable working tool as long as it is kept in working condition and serviced properly CASE CORPORATION P.O. BOX 6006 FARGO, N.D. 58102

DEALERS STAMP

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TO THE OWNER

TO THE OWNER

BD00M082

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DO NOT operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

This Wheel loader, with standard equipment and attachments, is intended to be used for above ground level digging and general earthmoving purpose such as land leveling, truck loading, and material rehandling. This machine is not intended to be used for lifting other objects or transporting loads at high speeds.

DO NOT use this machine for any application or purpose other than those described in this manual. If the loader is to be used in a application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer or the Case Cor poration. Consult an authorized dealer or Case Corporation 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 you dealer to obtain additional manuals. Contact your dealer for any further information or assistance about your machine. Your dealer has Case Corporation approved service parts. Your dealer has technicians with special training that know best methods of repair and maintenance for your Wheel Loader.

Before permitting a new operator on this machine, make sure: 1. That the operator has received the necessary training on how to operate the machine correctly and safely in one of our training centers or from an approved organization.

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TO THE OWNER 2. That the operator has read and understood the instructions given in this manual.

Call your dealer if you need any assistance or information.

Operator Manual Storage Compartment 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 inside of the rear cover of this manual.

RD98K305

1. OPERATORS MANUAL STORAGE COMPARTMENT

OFFICIAL JUSTIFING DOCUMENTS Special Test Certificate (Copy) ●

Noise level (86/662/EEC with amendments 89/513/EEC and 95/27/EEC)

●

Special safety equipment (86/295/EEC and 86/296/EEC)

EEC Declaration of conformity for an earth-moving machine ●

Safety (98/37/EC, was (89/392/EEC with amendments 91/368/EEC and 93/44/ EEC)

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1

TO THE OWNER

AFTER DELIVERY CHECK Two copies of the After Delivery Check are in the back of this manual. One copy is for you and one copy is for the dealer. Make sure that your dealer does the After Delivery Check after the first 100 hours of machine operation.

NOTE: Your cost for this check will be for filters, oil or other accessories. If the dealer comes to your machine, there can also be a cost for the time and distance.

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

RIGHT SIDE

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FRONT

REAR

LEFT SIDE B891464J

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TO THE OWNER

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

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

MACHINE MODEL NUMBER PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER TRANSMISSION MODEL AND SERIAL NUMBER TRIM THIS EDGE

ROPS CAB OR CANOPY SERIAL NUMBER FRONT AXLE MODEL AND SERIAL NUMBER REAR AXLE MODEL AND SERIAL NUMBER BUCKET OR ATTACHMENT PART NUMBER

Product Identification Number (P.I.N.)

408373A1 BD00N059

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TO THE OWNER

Engine

Loader Bucket

BD00M015

RP95K195

Transmission

ROPS Cab and Canopy

TRIM THIS EDGE BD00M100

RD98K304

Axle

BD00M095

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TO THE OWNER

MACHINE COMPONENTS 2 8

6 3

4 1

7

5 BD00M077

1.

2.

3.

4.

5.

6.

7.

8.

9.

HAND RAILS ROPS CAB BUCKET CYLINDER LOADER ARM STANDARD BUCKET LOADER CONTROLS STEPS ENGINE ACCESS HOOD TRANSPORT SERVICE LINK

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TO THE OWNER

1 2

4 6

8 3 TRIM THIS EDGE

BD00M080

1.

2.

3.

4.

5.

6.

7.

8.

ENGINE ACCESS HOOD AIR CONDITIONER CONDENSER STEP HAND RAILS CAB AIR FILTERS LOADER ARM SUPPORT STRUT HYDRAULIC FILTERS DRAWBAR

4 5

4

7 3

BD00M075

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

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 inside of the rear cover of this manual.

RD98K305

1. OPERATORS MANUAL STORAGE BOX

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

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

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

!

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 PERSONAL INJURY OR DEATH. M171B

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1

SAFETY/DECALS/HAND SIGNALS

!

UTILITY SAFETY

!

Safety precaution MUST be followed when working near buried Utility Lines During operation it is likely that you will be working around or near buried utility lines which may include, but are not limited to: ●

Electrical Power LIne

●

Gas Line

●

Water Line

●

Communication LIne - Telephone or Cable Television

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Before beginning any loading or other construction work it is your responsibility to be aware of all such utility lines buried in the area of your project and to avoid them.

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

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU TRENCH/DRILL

After locating the 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.

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

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SAFETY/DECALS/HAND SIGNALS

!

PERSONAL SAFETY

!

Throughout this manual and on the machine’s safety decals, you will find precautionary statements: DANGER, WARNING or CAUTION followed by specific instructions or ISO two panel safety pictorial symbols. These precautions are intended for your personal safety.

Failure to follow the DANGER, WARNING or CAUTION instructions may result in death or serious bodily injury. ●

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

●

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

●

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.

●

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

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if used are RED.

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ISO two panel pictorial symbol decals are defined as follows:

SAFETY/DECALS/HAND SIGNALS

!

BEFORE OPERATION

●

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

●

Different jobs will require different protective equipment. Items such as hard hats, protective shoes, heavy gloves, reflector type vests, respirators, ear protection, and eye protection can be required. Before you start the job, determine what protective equipment is required.

Use this equipment at all times.

●

●

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Know the hand signals used on your job. Follow the instructions of the flagman, signs, etc. See Hand Signals starting on page 42.

●

Check that all doors, guards, and covers are installed correctly or closed.

●

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

To avoid falling, always face the machine and use the hand rails and steps when getting on or getting off.

Do not rush.

1 1

Be prepared for emergencies.

Always have a first aid kit and a working fire extinguisher with you and know how to use each. See page 222 for fire extinguisher inspection, service, etc.

●

!

2 BD00M065

1. HAND RAILS 2. STEPS ●

Remove all loose objects from the cab. Loose objects can jam controls and cause accidents.

●

Before you start each day, walk around the machine and check for oil or fluid leaks. Replace all broken or missing parts and do the required lubrication and maintenance as shown in this manual. Clean all trash and debris from the machine, especially from the engine area.

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SAFETY/DECALS/HAND SIGNALS Make sure all persons are away from the machine before you start the engine.

●

Before you start the engine, always fasten the seat belt.

●

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

!

●

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.

●

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

●

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

MACHINE OPERATION

●

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

●

Do not allow other persons to ride on the machine. Other persons can fall or can cause an accident. This is a one person machine with one operator’s seat.

●

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

Stop the machine or decrease the speed until you can see everything around you in the work area. Make sure the machine lamps are ON.

●

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 powerstation. Keep all parts of the machine at least 4.6 m (15 feet) 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:

●

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

●

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

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●

SAFETY/DECALS/HAND SIGNALS ●

●

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.

Then, hop away with your feet together until you are a safe distance from the machine and the electrical current. Do not take large steps.

Because of the voltage differential across the ground, one foot can be in a higher voltage area than the other foot. This difference can kill you.

TRIM THIS EDGE

●

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

●

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

●

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

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

●

Be alert and always know the location of all workers in your area.

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

●

Keep the loader bucket low when moving around the work area and be careful when you raise the load to dump.

●

Operate the machine within the specified capacities and limits. Lifting capacities, digging depths, etc, are shown in the Specifications section of this manual.

●

Operate the machine controls from the operators seat only.

●

Digging through underground cables, pipes, lines, etc., can cause injury or death. Learn the location of all underground hazards before you operate your machine in any area.

●

When working in areas where traffic is heavy always have a person direct the traffic and direct other persons for you. Have guard rails, warning signs, etc., as required for your job.

●

Stop operating the machine if a malfunction occurs. Watch the indicator and warning lamps in the machine. Listen and smell for things that are not normal on your machine.

●

Drive around large objects such as large rocks or trees.

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SAFETY/DECALS/HAND SIGNALS

PARKING THE MACHINE

!

●

When you park the machine and before you leave the operators area, always support or lower all attachments (loader, backhoe, etc.) to the ground, apply the parking brake, stop the engine, and remove the key.

●

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.

Put blocks in front of each wheel on the downhill side.

●

Follow the instructions in this manual for “Parking the Machine”.

●

Always face the machine and use the hand rails and steps when getting off. Do not rush and do not jump from the machine.

!

BURN PREVENTION

●

Batteries contain sulfuric acid which can cause severe burns. Avoid contact with skin, eyes, or clothing.

Antidote - EXTERNAL - Flush with water. INTERNAL - Drink large quantities of water or milk. DO NOT induce vomiting. Seek medical attention immediately. EYES - Flush with water for 15 minutes and seek medical attention immediately.

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

Ventilate when charging or using in enclosed area. Always wear eye protection when working with new batteries.

Wash hands after handling. KEEP OUT OF REACH OF CHILDREN.

●

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, 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 too quickly.

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

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!

SAFETY/DECALS/HAND SIGNALS

!

FIRE EXTINGUISHER

!

It is recommended that you have a fire extinguisher on your machine. See your Case dealer for availability.

A dry chemical fire extinguisher is approved for Class A, B, and C fires.

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SAFETY/DECALS/HAND SIGNALS

●

FIRE OR EXPLOSION PREVENTION ●

1. When disconnecting the battery cables, disconnect the negative (−) cable first; when connecting the batter y cables, connect the negative (−) cable last.

A fire can cause injury or death.

Always have a fire extinguisher near or on the machine. Make sure the fire extinguisher is serviced according to the manufacturer’s instructions.

●

2. When connecting jumper cables to start the engine, use the procedure shown in this manual on page 113.

If a fire extinguisher has been used, always recharge or replace the fire extinguisher before operating the machine. See page 222.

●

Remove all trash or debris from the machine as required. Especially check the engine area and exhaust system.

●

If the machine has an oil, fuel, or hydraulic leak, always repair the leak and clean the area before operating.

●

Keep the cooling system clean and maintain the correct coolant level.

●

Make sure that you do not store oily rags or other flammable materials on the machine.

●

If you weld, grind, or use a cutting torch on the machine, always remove the starting fluid container from the machine. Use compressed air to remove any ether fumes from the area.

●

Before welding or using a torch on the machine, clean the area to be repaired.

●

Check the electrical system for loose connections or frayed insulation.

Repair or replace the loose or damaged parts.

Sparks or flame can cause the hydrogen gas in a battery to explode.

To prevent an explosion, do the following:

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery. Keep open flame away from the battery. ●

Sparks from the electrical system or engine exhaust can cause an explosion or fire. Before you operate this machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors before you start.

●

Engine fuel can cause an explosion or fire. Do not fill the fuel tank while the engine is running.

●

DO NOT smoke while refueling the machine.

●

!

Use nonflammable cleaning solvent to clean parts.

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!

SAFETY/DECALS/HAND SIGNALS

! ●

MAINTENANCE ●

Before you service the machine, put a Do Not Operate tag on the steering wheel. One Do Not Operate tag is included with your new machine.

Additional tags, part number 3214614, are available from your Case dealer.

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●

●

●

If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

Material Safety Data Sheets (MSDS) provide (1) infor mation about the chemical substances within a product, (2) safe handling procedures, (3) first aid measures, and (4) procedures to be taken when the product is accidentally spilled or released. Material Safety Data Sheets (MSDS) are available from your Case dealer.

Before you ser vice your machine, c h e c k t h e M S D S fo r e a c h f l u i d , lubricant, etc., used in this machine.

This information indicates what the r i s k s ar e a n d how t o s e r v i c e t h e machine safely. Follow this information when servicing the machine.

B9502062

●

!

Improper service or repair procedures can cause injury or death. If you do not understand a service or adjustment procedure, see the service manual for this machine or see your Case dealer.

●

Unauthorized modifications to this machine can cause injury or death.

Do not make unauthorized modifications to this machine.

Always see your Case dealer before you weld, cut, or drill holes in your machine.

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

Check with your local environmental or recycling center or your Case dealer for correct disposal information.

If you must service this machine with the engine running, have another person help you. Follow the instructions in this manual or the service manual. Do not leave the operator’s seat while the engine is running.

Disconnect the batteries before working on the electrical system.

●

When you service this machine, always wear face or eye protection, safety shoes, and other protective items as required.

●

Metal chips or debris can cause eye injury. Always wear eye or face protection when you use a hammer on this machine. Use a hammer with a soft face, such as brass, to drive hardened pins.

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SAFETY/DECALS/HAND SIGNALS

●

Lower the bucket or tool to the ground or block up the machine securely before working on the machine. Follow the instructions in this manual when you service the machine.

●

Fluids such as Gasoline, Kerosene, Diesel Fuel, Hydraulic Oil, etc. contain chemicals that can be dangerous to your health and can cause cancer and/or birth defects.

Contact either internally or externally can cause infection or other injury. If any internal or external contact occurs, see your local Poison Control Center or doctor IMMEDIATELY.

WHEEL AND TIRE MAINTENANCE ●

Do NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air/gas mixture that will be ignited with high temperatures.

This can happen to tires inflated or deflated. Removing air or breaking bead is not adequate. Tire MUST be completely removed from the rim prior to welding.

! ●

Before welding on this machine, disconnect the battery ground (−).

Clean the machine regularly. A buildup of grease, dirt, and debris can cause possible injury or machine damage. Keep your work shop clean.

! ●

●

!

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.

ROLL-OVER PROTECTIVE STRUCTURE

!

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 it is subjected to roll-over or damage.

Do not attempt to repair.

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●

SAFETY/DECALS/HAND SIGNALS

READ OPERATORS MANUAL D e c a l s w h i c h d i p l ay t h e “ R e a d Operators Manual” symbol are intended to direct the operator to the O p e r a t o r s M a n u a l fo r f u r t h e r i n f o r m a t i o n r e g a r d i n g s a fe t y, maintenance, adjustments and/or procedures for specific areas of the machine. When a decal displays the following symbol refer to the Operators Manual.

When a decal displays the symbol shown below, refer to the appropriate page of the Service Manual.

BC00G075

“READ SERVICE MANUAL”

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237187A1

“READ OPERATORS MANUAL”

SAFETY DECALS !

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 Case dealer for new safety decals.

SB002

Make sure that you read all the safety decals and all instructional decals. Check these decals every day before you start. Clean these decals if you cannot read the words.

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

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

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SAFETY/DECALS/HAND SIGNALS

1

3

2

2

BD00B007

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1

READ THE OPERATOR’S MANUAL

3

364917A1

CRUSH HAZARD, CHECK BUCKET ENGAGEMENT.

EMERGENCY EXIT 21

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256147A1 329051A1

SAFETY/DECALS/HAND SIGNALS

43

5

4

ENVIRONMENTAL AND OPERATOR’S STATION NOISE LEVELS

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5

CRUSH HAZARD WEAR THE SEAT BELT

BD00B032 386241A1 408651A1 346639A1

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SAFETY/DECALS/HAND SIGNALS

6

7

CRUSH HAZARD, USE LIFT ARM SUPPORT BRACKET WHEN SERVICING

7

PRESSURIZED SYSTEM HAZARD, READ SERVICE MANUAL BD00N064 328903A1 412426A1

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6

SAFETY/DECALS/HAND SIGNALS

7

PRESSURISED SYSTEM HAZARD, READ SERVICE MANUAL

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7

328903A1 BD00N048

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SAFETY/DECALS/HAND SIGNALS

8

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8

RUNOVER HAZARD, KEEP CLEAR OF MACHINE BD00N041 328753A1

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SAFETY/DECALS/HAND SIGNALS

9

9

TRIM THIS EDGE BD00N039 329050A1

RUNOVER HAZARD BLOCK WHEELS TO PREVENT MACHINE MOVEMENT BEFORE DISENGAGING PARKING BRAKE FOR TOWING

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SAFETY/DECALS/HAND SIGNALS

10

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10

RUNOVER HAZARD START ENGINE FROM OPERATOR’S SEAT TRANSMISSION IN NEUTRAL

BD00N042 334455A1

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SAFETY/DECALS/HAND SIGNALS

11

11 TRIM THIS EDGE ENTANGLEMENT HAZARD KEEP CLEAR OR STOP ENGINE BERORE SERVICING BD00N042 332511A1

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SAFETY/DECALS/HAND SIGNALS

12

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12

BD00N043 332511A1 BD00N044

ENTANGLEMENT HAZARD KEEP CLEAR OR STOP ENGINE BEFORE SERVICING

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SAFETY/DECALS/HAND SIGNALS

14 13 14

13 TRIM THIS EDGE

PRESSURIZED SYSTEM HAZARD READ OPERATOR’S MANUAL

14

ENTANGLEMENT HAZARD, KEEP CLEAR OR STOP ENGINE BEFORE SERVICING

BD00N045 332511A1 333269A1 BD00N060

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SAFETY/DECALS/HAND SIGNALS

15

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15

BD00N043 388113A1

ENTANGLEMENT HAZARD, KEEP CLEAR OF STOP ENGINE BEFORE SERVICING

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SAFETY/DECALS/HAND SIGNALS

16

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16

BD00N046 329045A1

HOT LIQUID UNDER PRESSURE HAZARD, SERVICE WHEN COOL

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SAFETY/DECALS/HAND SIGNALS

17

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17

BD00N049 412476A1

EXPLOSION HAZARD READ OPERATOR’S MANUAL BEFORE JUMP START OR SERVICE

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SAFETY/DECALS/HAND SIGNALS

18

18

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CRUSH HAZARD ENGAGE LOCK LINK BEFORE SERVICE OR TRANSPORT

BD00N038 329048A1

19

19 MACHINE TIE DOWN BD00M042 94F25

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SAFETY/DECALS/HAND SIGNALS

20

20

BD00M032 94F25

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21

21

CRUSH HAZARD, SUPPORT DURING MAINTENANCE OR REPAIR

BD00N062 407741A1

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SAFETY/DECALS/HAND SIGNALS

22

22

LIFT POINT - REAR BD00M039 139729A1

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23

23

LIFT POINT - FRONT BD00M058 139729A1

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SAFETY/DECALS/HAND SIGNALS

24

BD00N061 408367A1

DRAWBAR: LOAD LIMITS

37

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24

SAFETY/DECALS/HAND SIGNALS

25

25

TRIM THIS EDGE BD00N063 412481A1

CRUSH HAZARD, OPENING VALVE WILL CAUSE LIFT ARMS TO FALL READ OPERATOR’S MANUAL

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SAFETY/DECALS/HAND SIGNALS

26

CRUSH HAZARD KEEP CLEAR

BD00N038 323695A1

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26

SAFETY/DECALS/HAND SIGNALS

INTERNATIONAL SYMBOL DECALS

139879A1

94F25

DIESEL FUEL

TIE DOWN POINT

TRIM THIS EDGE 139729A1 318764A1

LIFT POINT

187863A1

LIFT ARM AND BUCKET CONTROL

KEY SWITCH POSITIONS

BS00B355

HYDRAULIC OIL

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SAFETY/DECALS/HAND SIGNALS

187864A1

REMOTE GREASE FITTING LOCATION E134402

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NO STEP

346639A1/408651A1

NOISE LEVEL INTERIOR (LPA) NOISE LEVEL EXTERIOR (LWA)

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SAFETY/DECALS/HAND SIGNALS

HAND SIGNALS It is recommended that you and the flagman on the job use hand signals for communications. Before you start, make sure that you both understand the signals that will be used.

BI97D059

BI97D025

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START ENGINE

STOP ENGINE

BP97D022

BP97D023

COME TO ME

ALL STOP AND HOLD

Move hands forward and rearward (palms in)

Move hands forward and rearward (palms out).

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SAFETY/DECALS/HAND SIGNALS

BP97D030

BP97D060

ALL STOP AND HOLD

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GO THIS FAR

BI97D029

BI97D021

STOP

EMERGENCY STOP

Move one hand back and forth.

BI97D027

LOWER BUCKET

BI97D028

RAISE BUCKET

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SAFETY/DECALS/HAND SIGNALS

BI97D020

BI97D026

RAISE BUCKET SLOWLY

LOWER BUCKET SLOWLY

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BI97D033

TURN MACHINE LEFT SWING LOAD LEFT

TURN MACHINE RIGHT SWING LOAD RIGHT

To stop movement, stop moving hand and make a fist

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

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INSTRUMENT/CONTROLS FRONT CONSOLE 3

2

4

RD98K315

1. FOUR-WAY FLASHER SWITCH: Push the LH side of the of the flasher switch to actuate the flashers.

Push the RH side of the flasher switch for the OFF position.

BC00B087

BC00B048

2. PILOT CONTROL SWITCH: Push on the LH side of the switch to disable the pilot controls, the pilot control lamp will illuminate when the hydraulic control levers are disabled. The loader linkage will stay in position when the pilot controls are disabled. Push on the RH side of the switch to actuate the pilot controls. The hydraulic control levers will now function.

3. UP/DOWN COUNT SWITCH: Controls display, used with Program/Reset Switch (see Program Control in this manual for more information).

BC00B085

BS98M034

BC00B101

BS98M034

4. PROGRAM/RESET SWITCH: Control display, used with Up/Down Count Switch (see Program Control in this manual for more information).

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1

INSTRUMENTS/CONTROLS

FRONT CONSOLE

6 5

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RD98K322

RD98K321

5. TRANSMISSION CONTROL LEVER: The transmission control lever is used to shift the transmission gears from 1st through 4th gear. Turn the transmission control lever away from you to select a higher gear or toward you to select a lower gear. This control lever is also used to put the transmission in F O RWA R D, NEUTRAL and REVERSE.

6. COLD START BUTTON (IF EQUIPPED): The cold start system puts ether into the engine intake each time the button is pushed and released. This system operates only when the key switch is in t he O N o r RU N p o s i t i on w i th t h e transmission in NEUTRAL and the engine is cold. (See Cold weather starting and ether Cold starting in this m a n u a l fo r t h e c o r r e c t s t a r t i n g procedure).

A

A. Move the control lever a w ay f r o m y o u fo r FORWARD. B. The center position is NEUTRAL.

B

C. Move the control lever toward you fo r REVERSE.

C BS00B351

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INSTRUMENTS/CONTROLS

FRONT CONSOLE

8

7

9 RD97F213 RD98K311

7. STEERING WHEEL TILT CONTROL: This control has multiple positions. Pull the handle up and adjust the steering wheel to the correct angle. Release the control to hold in that position. Tilt the steering wheel completely up when leaving the machine. Always adjust the steering wheel to the correct position before starting the engine.

9. TURN SIGNAL LEVER: Push the control lever up to signal a left turn. Pull the control down to signal a BS00B352 right turn. You must move the control lever to the center position to stop the signal.

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8. HORN: Push the hor n button to actuate the horn.

INSTRUMENTS/CONTROLS NOTE: The service brake must be at operating pressure before the parking brake can be released. The Brake Pressure Indicator Lamp must not be illuminated when disengaging the parking brake. See Parking Brake in Operating Instructions in this manual.

10

P u s h d ow n o n t h e b o t t o m o f t h e parking brake switch, hold pressure on the brake pedals and put the transmission control lever either in F O RWA R D o r R E V E R S E t o DISENGAGE the parking brake

RD98K313

10. PARKING BRAKE SWITCH:

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NOTE: Make sure the machine has come to a BC00B095 complete stop before applying the parking brake.

Push down on the top of the park brake switch to ENGAGE the parking brake.

IMPORTANT: The Parking Brake is a spring applied, hydraulic released brake. When the key switch is turned to the OFF position or the brake system loses pressure the Park Brake will engage. Always wear your seat belt when operating.

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INSTRUMENTS/CONTROLS

FRONT CONSOLE

11 RB99J178

ON POSITION This position energizes all electrical systems. The key will return to this position after you release the key from the START position.

RD98K312

NOTE: The Ether Start System (if equipped) can only be actuated when the key switch is in the ON position and the engine temperature is below 50°F (10°C).The transmission control lever must be in the NEUTRAL position for the star ter to engage.

318764A

11. Key Switch The key switch has four positions:

RB98M031

ACCESSORY POSITION This position will energize the optional radio only. It will not energize the instruments or star t the engine.

OFF POSITION A l l sw i t c h c o n t r o l l e d current is OFF. Turn the key t o O FF t o s top th e RB99J175 engine. Remove the key and turn the Master Disconnect Switch to OFF.

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START POSITION Tu r n t h e k e y t o t h i s po s i ti on to e n ga ge th e starter motor to start the RB99J176 engine. T he sw itch is spring loaded and will return to the ON position when released.

INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS Instrument Cluster The instrument cluster will check each monitored system when you turn the key switch to the ON position. All LED’s (Light Emitting Diodes) will illuminate, six bar graphs will energize for three seconds, and the warning alarm will sound for three seconds. At the end of this check all monitored systems will return to normal operation. If there is an open circuit between a sensor and the instrument cluster, the LED will flash and the warning alarm will sound for 5 seconds.

IMPORTANT: If during operation, the stop master warning lamp (on front console) flashes and the warning alarm is continuous, stop the machine, stop the engine, and find the problem.

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2

1

1

RD98K315

1. INDICATOR LAMP FOR FOUR-WAY FLASHER AND TURN SIGNALS: This green indicator lamp will flash when you signal a turn or when you actuate the four-way flashers.

BS96H049

2. BEACON INDICATOR: This indicator illuminates when the Beacon is in the ON position.

BC00B082

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

4

5

6

RD98K315

3. LAMP INDICATOR: This indicator illuminates when the lamp are ON. BS98M062

4. PILOT LOCKOUT INDICATOR: This indicator illuminates when the pilot lockout is actuated.

BC00B048

5. LOW COOLANT INDICATOR: This indicator illuminates when the engine coolant is low. The alarm sounds continuously and the master indicator lamp will be red.

BC00B110

NOTE: Stop the engine and add coolant to the radiator.

6. BRAKE PRESSURE INDICATOR:

BC00B108

This indicator illuminates when the brake system pressure is too low.

The alarm sounds continuously and the stop master indicator will be red.

NOTE: Stop the machine and correct the problem.

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3

INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

7

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RD98K315

7. STOP MASTER INDICATOR (RED, CRITICAL): The Stop Master Indicator is a critical warning display. See Critical Warning Displays.

Critical Warning Displays When the Stop Master indicator illuminates you must bring the machine safely to a stop and immediately turn OFF the engine. Failure to do so may result in injury and/or damage to the machine. The following table is a listing of critical warning displays that may appear on the instrument cluster and the corrective action required. When a fault occurs, a continuous audible alarm will sound and the Stop Master Indicator will be RED and the display indicator will be illuminated.

BC00B290

Display

Description

Corrective Action

ENGINE OIL PRESSURE

Low Engine Oil Pressure. Below Bring the machine to a safe stop and shut 10 PSI the engine OFF immediately. Contact your Dealer.

BRAKE PRESSURE

Low Brake Pressure

Bring the machine to a safe stop and shut the engine OFF immediately. Contact your Dealer.

Low Steering Pressure.

Bring the machine to a safe stop and shut the engine OFF immediately. Contact your Dealer.

STEERING PRESSURE (W/ AUX STEERING)

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INSTRUMENTS/CONTROLS

Low Coolant Level.

Bring the machine to a safe stop and shut the engine OFF immediately. Check the coolant levels after allowing the engine and the coolant to cool down. Contact your Dealer.

COOLANT TEMPERATURE

High Engine Coolant Temperature.

Bring the machine to a safe stop and shut the engine OFF immediately. Check the coolant levels after allowing the engine and the coolant to cool down. Contact your Dealer.

HYDRAULIC OIL TEMPERATURE

High Hydraulic Oil Temperature.

Bring the machine to a safe stop and shut the engine OFF immediately. Contact your Dealer.

TRANSMISSION OIL TEMPERATURE

High Transmission Oil Temperature.

Bring the machine to a safe stop and shut the engine OFF immediately. Contact your Dealer.

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8. CAUTION MASTER INDICATOR (YELLOW, NON-CRITICAL): The Caution Master Indicator is a non-critical warning display. See Non - Critical Warning Displays.

Non - Critical Warning Displays When the caution is “on”, change your operating method, schedule a shutdown for maintenance or if the condition persists, contact your dealer. The following table is a listing of warning displays that may appear on the instrument cluster and the corrective action required. When a fault occurs, an audible alarm will sound for 3 seconds and the Caution Master Indicator will be YELLOW and the display indicator will be illuminated. When this occurs return the machine to a service position and shutdown the engine to help avoid expensive repairs.

BC00B291

Display PARKING BRAKE

Description

Corrective Action

Parking Brake engaged and Release the parking Brake. shifts to F or R.

COOLANT TEMPERATURE

High engine coolant temperature

1. Idle machine and monitor temperature.

2. Clean radiator.

3. If condition persists, contact your dealer.

HYDRAULIC TEMPERATURE

High hydraulic temperature

1.Idle machine and monitor temperature.

2. Clean cooler.

3. If condition persists, contact your dealer.

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TRANSMISSION TEMPERATURE

High transmission temperature

1. Idle machine and monitor temperature.

2. Clean the cooler.

3. Use a lower gear.

4. If condition persists, contact your dealer.

AIR CONDITIONING

High or Low air conditioning pressure.

1. Turn air conditioning OFF. 2. Low outside temperature.

3. Servicing required.

4. If condition persists, contact your dealer.

High air filter restriction

1. Clean air filter.

2. Replace primary and secondary filters.

3. If condition persists, contact your dealer.

Transmission filter restriction.

1. Replace transmission filter.

2. If condition persists, contact your dealer.

Hydraulic filter restriction.

1. Replace hydraulic filter.

2. If condition persists, contact your dealer.

Alternator malfunction.

1. Check electrical system.

2. Voltages are out of range.

3. Change operating procedure.

4. If condition persists, contact your dealer.

Low fuel.

1. Fill fuel tank within the next hour.

AIR FILTER

TRANSMISSION FILTER HYDRAULIC FILTER ALTERNATOR

FUEL

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INSTRUMENT PANEL INDICATORS

9

10

11

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9. SECONDARY STEERING INDICATOR (IF EQUIPPED):

BS00B111

This indicator illuminates when the primary steering system pressure is too low. The alarm sounds continuously and the stop master indicator turns red.

NOTE: If this situation occurs, stop the machine immediately and contact your dealer.

10. PARKING BRAKE INDICATOR:

BS96H049

This indicator illuminates when the parking brake is applied. When the parking brake is applied and you shift the transmission into FORWARD or REVERSE the alarm sounds for 3 seconds and the caution master indicator turns yellow.

11. AIR CONDITIONING INDICATOR:

This indicator illuminates when the air conditioner has stopped due to refrigerant pressures that are too high or too low. The alarm sounds for 3 seconds and the caution master indicator turns yellow. The BC00B112 system needs service or the outside air temperature is too cool for the system to work.

IMPORTANT: To start the air conditioner again, turn the air conditioning temperature control to the OFF position and back to the ON position again. If the indicator lamp stays ON, see your Service Manual or your dealer.

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12 13

RD98K315

12. HYDRAULIC OIL FILTER INDICATOR:

BC00B113

This indicator illuminates when the hydraulic filters are restricted and require service. The alarm sounds for 3 seconds and the caution master indicator turns yellow. Service the filters as required.

13. AIR FILTER INDICATOR:

BS98M026

This indicator illuminates when the air filter is restricted and requires service. The alarm sounds for 3 seconds and the caution master indicator turns yellow.

14. TRANSMISSION OIL FILTER INDICATOR (IF EQUIPPED):

BS99J182

This indicator illuminates when the transmission filters are restricted and require service. The alarm sounds for 3 seconds and the caution master indicator turns yellow. Service the filters as required.

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15

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15. TRANSMISSION OIL TEMPERATURE GAUGE: The transmission oil temperature gauge is shown with indicator bars.

Normal operating temperature is in the green zone. When the transmission oil temperature increases, the bars move into the yellow BS98M028 zone and begin to flash, the warning alarm sounds for three seconds, and the caution master indicator turns yellow. When the temperature continues to increase the bars move into the red zone and continue to flash, the warning alarm will sound continuously, and the stop master indicator turns red.

The machine must not be operated when the temperature is in the red zone. .

TRANSMISSION OIL TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

20°C and below (68°F and below)

Oil temperature is very low

Caution (Yellow)

Flashes

3 Seconds

20 to 120°C (68 to 248°F)

Oil temperature is normal

120 to 125°C Oil temperature (248 to 257°F) (See the is high note below.)

Caution (Yellow)

Flashes

3 Seconds

125°C and above (257°F and above)

Stop (Red)

Flashes

Continuous

Oil temperature is very high

NOTE: To prevent damage to the transmission, stop the machine, shift the transmission to NEUTRAL, and run the engine at full throttle until the transmission cools. If the transmission oil temperature does not return to normal operating temperature, run the engine at idle speed and check the transmission oil level.

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16. HYDRAULIC OIL TEMPERATURE GAUGE: The Hydraulic Oil Temperature Gauge indicates the oil temperature of the hydraulic system. The hydraulic oil temperature gauge is shown with indicator bars. Normal operating temperature is in the BC00B123 green zone. When the hydraulic oil temperature increases the bars move into the yellow zone and begin to flash, the warning alarm sounds for three seconds, and the caution master indicator turns yellow. When the temperature continues to increase the bars move into the red zone and continue to flash and the warning alarm sounds continuously. The stop master indicator turns red. The machine must not be operated when the temperature is in the red zone.

HYDRAULIC OIL TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

20°C and below (68°F and below)

Hydraulic oil temperature is very low

Caution (Yellow)

Flashes

3 Seconds

20 to 105°C (68 to 221°F)

Hydraulic oil temperature is normal

105 to 110°C (221 to 230°F)

Hydraulic oil temperature is high

Caution (Yellow)

Flashes

3 Seconds

110°C and above (230°F and above)

Hydraulic oil temperature very high

Stop (Red)

Flashes

Continuous

NOTE: Stop the machine and correct the problem.

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17. VOLT METER GAUGE: The volt meter gauge indicates the condition of the batteries and charging system. The amount of voltage is shown with indicator bars.

Normal operating range is in the green zone. When the voltage BS98M032 increases or decreases the bars move into the yellow zone and begin to flash, the warning alarm sounds for three seconds, and the caution master indicator turns yellow.

VOLTMETER GAUGE Gauge Indication 0 to 18 Volts

18 to 24 Volts

Engine Speed Condition o f Charging System

Master Indicator Stopped or low Very low battery charge Caution idle (Yellow)

Stopped or low idle Above low idle

26 to 32 Volts 32 Volts and above (See the note below.)

Alarm Status

Flashes

3 Seconds

3 Seconds

Stopped or low Low to normal battery idle charge Above low idle

24 to 26 Volts

Gauge Status Flashes

Above low idle

Problem system

in

charging

Normal battery charge Problem system

in

charging

Normal operating range Problem in charging Caution system (overcharging) (Yellow)

NOTE: Stop the machine and correct the problem.

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18 RD98K315

18. FUEL LEVEL GAUGE: The Fuel Level Gauge indicates the fuel level. The fuel level is shown on the gauge with indicator bars. Normal operating range is in the green zone. When the tank is almost empty the bars move into the BS98M034 yellow zone and begin to flash, the warning alarm sounds for three seconds, and the caution master indicator turns yellow.

NOTE: The fuel level can be checked without the key switch being turned to the ON position, by pushing in and holding the right side of the program reset switch.

FUEL LEVEL GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

5 percent and below

Fuel level low

Caution (Yellow)

Flashes

3 Seconds

5 percent and above

Fuel level normal

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19 TRIM THIS EDGE

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19. ENGINE OIL PRESSURE GAUGE The engine oil pressure gauge indicates the oil pressure in the engine lubrication system. The engine oil pressure is shown with indicator bars. Normal operation is in the green zone. When the oil pressure decreases below a safe operating BS99D060 pressure, the bars move into the red zone and flash and the warning alarm sounds continuously. The stop master indicator turns red. The machine must not be operated when the oil pressure is in the red zone.

ENGINE OIL PRESSURE GAUGE - LATE PRODUCTION Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

0 to 70 kPa (0 to 10 psi)

Very low (too low to run engine)

Stop (Red)

Flashes

Continuous

70 kPa and above 10 psi and above)

Normal (above low idle)

NOTE: Stop the engine immediately and correct the problem.

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20. ENGINE COOLANT TEMPERATURE GAUGE: The Engine Coolant Temperature gauge indicates the coolant temperature of the engine. The engine coolant temperature is shown with indicator bars. Normal operating temperature is in the green zone. When the engine coolant BS98H053 temperature increases the bars move into the yellow zone and begin to flash, the warning alarm sounds for three seconds. The caution master indicator turns yellow. When the temperature continues to increase the bars move into the red zone and continue to flash and the warning alarm sounds continuously. The stop master indicator turns red. The machine MUST NOT be operated when the temperature is in the red zone.

ENGINE COOLANT TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

20°C and below (68°F and below)

Coolant temperature is very low

Caution (Yellow)

Flashes

3 Seconds

20 to 105°C (68 to 221°F)

Coolant temperature is normal

105 to 110°C (221 to 230°F)

Coolant temperature is high

Caution (Yellow)

Flashes

3 Seconds

Stop (Red)

Flashes

Continuous

110°C and above Coolant temperature (230°F and above) (See the is very high note below.)

NOTE: Stop the engine immediately and correct the problem.

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INSTRUMENT PANEL INDICATORS

21 TRIM THIS EDGE

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21. Fog Lamps (If Equipped)

BC00B080

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

1. INFORMATION CENTER You can display many of the machine functions on your Programmable Information Center. It can be programmed to display all functions, or only the functions that are important to you.

Here are the functions you may choose to see on your Information Center: HOURMETER - Displays the accumulated running time of the engine in hours and tenths of an hour with an “hour glass” symbol.

NOTE: Machine hour can be checked with out the key switch being in the ON position, by pushing in and holding the right side of the program reset switch.

TACHOMETER - Displays the engine speed in revolutions per minute along with an “n/min” symbol.

SPEEDOMETER - Displays the ground speed in either kilometers per hour (km/h) or miles per hour (mph) along with either an “km/h or mph” symbol.

ENGINE COOLANT TEMPERATURE - Displays the engine coolant temperature in Celsius with the engine coolant temperature bar graph flashing.

ENGINE OIL PRESSURE - Displays the engine oil pressure in kilo pascals (kPa) with the engine oil pressure bar graph flashing.

FUEL LEVEL - Displays the fuel level in percent (%) remaining from a full tank with the fuel level bar graph flashing.

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INFORMATION CENTER

A B

C

D

1

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A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

TRANSMISSION OIL TEMPERATURE - Displays the transmission oil temperature in Celsius with the transmission oil temperature bar graph flashing.

HYDRAULIC OIL TEMPERATURE - Displays the hydraulic oil temperature in Celsius with the hydraulic oil temperature bar graph flashing.

VOLTMETER - Displays the electrical system voltage level in volts with the voltmeter bar graph flashing.

Programming Your Information Center NOTE: To program your instrument cluster the machine must be off.

To program your Information Center, you need to use two switches, the up/ down count (A, B) switch and the program/reset (C, D) switch. These switches are located on the Right Hand side of the front console.

For an up count (A) press the left side of the up/down count (A, B) switch. For a down count (B) press the right side of the up/down count (A, B) switch.

For programming (C) press the left side of the program/reset (C, D) switch. For resetting (D) press the right side of the program/reset (C, D) switch.

NOTE: The program/reset (C, D) switch is a three position rocker switch. The center position is OFF or NEUTRAL. 66

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INFORMATION CENTER

A B

C

D

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

To program your information center do the following: 1. Turn the key switch to the ON position.

2. Put the Information Center into the program mode by pressing the program switch down (C).

3. Up count (A) to program location 010.

4. Center the program/reset (C, D) switch. This will allow you to adjust to the desired value. You can personalize the cluster to your use (See Gauge Displays in this manual).

5. When adjusted you can push the program/reset (C, D) switch momentarily to the reset position. You have completed the change.

Service Interval Hours Locations 61 through 70 are service interval hour settings. The service interval hours will accumulate hours until they are reset. Once they are reset, they will begin accumulating hours independent from the machine hours until they are reset again.

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

1

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RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Example: If the operator wanted location 061 to indicate engine oil service intervals, when the engine oil is changed, location 061 would be reset to begin accumulating hours for the next oil change. The operator could then go into location 061 and monitor the accumulating hours. When location 061 reaches the engine oil change interval, the operator would change the oil and reset location 061 again.

To view the service hour interval locations: ●

Press the program (C) switch (left side of the program/reset (C, D) switch).

●

Press the up count (A) switch until the display reads the desired location (010 070).

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Read the accumulated hours shown on the Display Center.

To reset the service interval hours: ●

Press the program (C) switch (left side of the program/reset (C, D) switch).

●

Press the up count (A) switch until the display reads the desired location (010 070).

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Push the down count (B) switch and hold for 3 seconds. The service interval hours in the Display Center will reset to 0.

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Fault Code Status Locations 071 through 090 displayed fault codes and the hours the faults occurred. the Information Center continuously monitors the machines condition and records any fault codes; however, it will only record a duplicate code once every hour. When a fault code is written, the service indicator icon (a manual with a wrench) will be displayed on the Information Center.

To view the fault codes and the hours they occurred: ●

Press the program (C) switch (left side of the program/reset (C, D) switch).

●

Press the up count (A) switch until the display reads the desired location (071 090).

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Read any fault codes on the Display Center.

●

Press the program (C) switch again.

●

Press the up count (A) switch one time to advance to the next position.

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Read the hours at which the previous code occurred.

The hour location will always follow the fault code location.

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

1 TRIM THIS EDGE

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Example: Location 072 will display the hours on the machine when the fault code in location 071 was written. Location 074 will display the hours on the machine when the fault code in location 073 was written.

You can monitor a particular location without going into the programming mode by performing the following procedure: ●

Press the program (C) switch.

●

Press the up count (A) switch until the location to be monitored is displayed.

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Press the program/reset switch again and wait for 5 seconds. The numbers on the display will change.

●

Return the program switch program to the OFF (center) position.

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A C

D

1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

1. Gauge Displays What machine functions your Display Center will show you is determined by a Gauge Display you can control. You have 5 different Gauge Displays you may choose from. Three of them give you the capability to manually scroll through functions, and the other two automatically scroll for you.

01 - Manually scrolls through Hourmeter, Tachometer, and Speedometer (km/h).

02 - Manually scrolls through Hourmeter, Tachometer, and Speedometer (mph).

03 - Automatically scrolls through Hourmeter (at startup), Tachometer (in 1st - 3rd gears), and Speedometer (km/h) (in 4th gear).

04 - Automatically scrolls through Hourmeter (at startup), Tachometer (in 1st - 3rd gears), and Speedometer (mph) (in 4th gear).

05 - Manually scrolls through Hourmeter, Tachometer, and Speedometer (mph), Speedometer (km/h), Engine Oil Temperature (Celsius), Engine Oil Pressure, Fuel Level, Transmission Oil Temperature (Celsius), Hydraulic Oil Temperature (Celsius), and Voltmeter.

NOTE: 05 is the setting from the factory.

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A B

C

D

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1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Programming Your Gauge Display When you start your machine you will see the Hourmeter in the Display Center.

Your wheel loader is shipped from the factory with Gauge Display 05. To check what Gauge Display your machine currently is using do the following: ●

Press the program (C) switch (left side of the program/reset (C, D) switch).

●

Press the up count (A) switch until the display reads 010.

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Read the number (01, 02, 03, 04 or 05) shown on the Display Center. If this is the Gauge Display you want, press the reset (D) switch (right side of the program/reset (C, D) switch) momentarily and you are done.

●

If you want a different Gauge Display, press the up count (A) switch until the display reads the Gauge Display you want (between 01 to 05).

●

Press the reset (D) switch (right side of the program/reset (C, D) switch) momentarily.

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A C

D

1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Manual Scrolling Gauge Displays (01, 02 or 05) If you’ve chosen one of the manually scrolling Gauge Displays (01, 02 or 05), you may scroll through the functions by pressing the up count switch.

Example: Lets say you’ve chosen Gauge Display 01. You will first see the Hourmeter in the Display Center. ●

Pressing the up count (A) switch one time will show you the Tachometer.

●

Pressing the up count (A) switch again shows you the Speedometer (km/h).

●

Pressing the up count (A) switch again takes you back to the Hourmeter.

Automatically Scrolling Gauge Displays (03 or 04) If you’ve chosen one of the automatically scrolling Gauge Displays (03 or 04), the Display Center automatically scrolls through functions. Pressing the up count switch has no effect on the display.

Example: Lets say you’ve chosen Gauge Display 03. You will first see the Hourmeter in the Display Center after starting the machine. In 1st - 3rd gears you’ll see the Tachometer in the Display Center, and in 4th gear you’ll see the Speedometer (km/h).

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A B

C

D

1

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A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Displaying Individual Functions You also may choose to display any individual function at anytime, regardless of the Gauge Display you’ve chosen. You may show the following functions at any time on your Display Center.

000 - Hourmeter 001 - Tachometer 002 - Speedometer (mph) 003 - Speedometer (km/h) 004 - Engine Coolant Temperature 005 - Engine Oil Pressure 006 - Fuel Level 007 - Transmission Oil Temperature 008 - Hydraulic Oil Temperature 009 - Voltmeter

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A C

D

1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

To View a Selected Function On Your Display Center do the following: ●

Press the program (C) switch (left side of the program/reset (C, D) switch).

●

Press the up count (A) switch until the display reads the function of your choice (000 - 009).

●

Return the program/reset (C, D) switch to OFF (center) position.

You will now see the function you’ve chosen.

Example: Lets say you were interested in seeing the engine oil pressure. You would do the following: ●

Press the program (C) switch (left side of the program/reset switch).

●

Press the up count (A) switch until the display reads 005.

●

Return the program/reset (C, D) switch to the OFF (center) position.

You will now see the engine oil pressure on your Display Center.

The engine oil pressure bar graph will flash indicating this is the function being displayed.

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A B

C

D

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1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Setting Display Center Lamp You can set the brightness of your display lights for two separate conditions. The first is with your work lights OFF, and the second is with the work lights ON. ●

Press the program (C) switch.

●

Press the up count (A) switch until the display reads 012 (for lamps OFF) or 013 (for lamps ON).

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

To increase the brightness of the display lights press the up count (A) switch.

●

To decrease the brightness of the display lights press the down count (B) switch.

●

The brightness can be varied between 001 - 100, with 100 being the brightest.

Your machine is shipped from the factory with brightness setting of 070 for working lights OFF and 020 for lamps ON.

●

Press the reset (D) switch momentarily (0.25 second) and you are done.

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A C

D

1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Setting Master Reset This procedure will reset the Information Center to the values set at the factory for the Gauge Display, Information Center lighting for work lights off and work lights on, minimum gear selection in automatic mode, and maximum gear selection. ●

Press the program (C) switch.

●

Press the up count (A) switch until the display reads 042.

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Press the up count (A) switch to change the reading from 00 to 01.

●

Press the reset (D) switch momentarily (0.25 second) and you are done.

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INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER B A

C D

E

RD97F206

A. F - N - R B. DISPLAY CENTER

C. GEAR D. BAR

E. AUTOMATIC MODE

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The Transmission Display will show the status of the transmission control. The Display contains the following information: Direction Selected, shown at the top of the display center: F - Forward N - Neutral R - Reverse F - Flashing forward not engaged.

N - Flashing set control lever to neutral position.

R - Flashing reverse not engaged.

Requested Gear (gear position on shift lever), shown in the center of the gear symbol: 1 - 1st Gear 2 - 2nd Gear 3 - 3rd Gear 4 - 4th Gear Actual Gear, shown with bars to the right of the gear symbol.

The number of bars indicates the gear the transmission is actually in. This may vary from the requested gear when the transmission is in the Automatic Mode.

Transmission Mode (Automatic or Manual), shown in the lower left of the display center. A gear symbol with an “A” in the center will be displayed in the lower left of the display when the transmission is in the Automatic Mode. When the transmission is in the Manual Mode no symbol will be displayed.

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INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER

A C

D

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Minimum Gear Selection, Automatic Mode The transmission can be programmed for the lowest gear possible in the automatic mode. The operator can select 1st or 2nd gear. The gear that is chosen will be the gear that the transmission is in when the machine begins to move.

Machines shipped from the factory will have the minimum gear set a 1.

Programming Minimum Gear Selection ●

Press the program (C) switch.

●

Press the up count (A) switch until the display reads 050.

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Read the number (1 or 2) shown on the Display Center. If this is the gear selection you want, press the program (C) or reset (D) switch.

●

If you want the other minimum gear selection, press the up count (A) switch until the number you want is displayed.

●

Press the reset (D) switch momentarily (0.25 seconds).

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INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER

A B

C

D

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A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

Maximum Gear Selection, Automatic Mode The transmission can be programmed for the highest gear attainable in the automatic mode or the manual mode. The operator can select 2nd, 3rd or 4th gear. The gear that is chosen is the highest attainable gear that the transmission will be able to reach. Machines shipped from the factory will have the minimum gear set a 4.

Programming Maximum Gear Selection ●

Press the program (C) switch.

●

Press the up count (A) switch until the display reads 051.

●

Return the program/reset (C, D) switch to the OFF (center) position.

●

Read the number (2, 3, or 4) shown on the Display Center. If this is the gear selection you want, press the program (C) or reset (D) switch.

●

If you want a different maximum gear selection gear selection, press the up count (A) switch until the number you want is displayed.

●

Press the reset (D) switch momentarily (0.25 seconds).

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INSTRUMENTS/CONTROLS

FOOT PEDALS NOTE: Use the DECLUTCH SWITCH when you need maximum power (speed) for the loader lift arms and bucket (see Clutch Cut Out in this manual).

1

4

2 BD00M471

BD00M084

2. SINGLE BRAKE PEDAL: (STANDARD) Push down on the bottom of the Declutch switch (4). This turns OFF the Declutch feature. When either pedal is pushed down, the brakes are actuated, the brake light is illuminated, and the transmission clutch will remain engaged. Push down on the top of the Declutch switch and this will turn on the Declutch feature. When either brake pedal is pushed down the brakes are actuated, the brake light is illuminated and the transmission clutch is disengaged.

DECLUTCH SWITCH

NOTE: Use the DECLUTCH SWITCH when you need maximum power (speed) for the loader lift arms and bucket (see Clutch Cut Out in this manual)

3

BD001A001

3. DUAL BRAKE PEDALS: (OPTIONAL) The dual brake pedals function the same as the single in relation to the Declutch switch. Pushing either pedal will actuate the brakes.

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1. FOOT THROTTLE: Push the foot throttle to increase the engine speed. Release the foot throttle to decrease the engine speed.

INSTRUMENTS/CONTROLS

LOADER CONTROL LEVERS Two Spool - One Lever A

B

E

1.

G

1.

C

F

D TRIM THIS EDGE

410/BS00B353

1. LIFT ARM AND BUCKET CONTROL A. FLOAT (DETENT): This is a detent position. When in the FLOAT (Detent) position, the loader bucket can follow the level of the ground without movement of the control lever B. LOWER C. HOLD: the loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position. You must manually move the control lever from the FLOAT position to the HOLD position.

D. RAISE E. DUMP F. ROLLBACK G. KICKDOWN BUTTON (DOWNSHIFT TRANSMISSION)

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INSTRUMENTS/CONTROLS

Two Spool - Two Levers

3.

E

D

F

3

2.

G A

2 C B 409/BS00B354

2. BUCKET CONTROL B. ROLLBACK C. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position. You must manually move the control lever from the FLOAT position to the HOLD position.

3. LIFT ARM CONTROL D. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent) position, the loader bucket can follow the level of the ground without movement of the control lever.

E. LOWER F. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position. You must manually move the control lever from the FLOAT position to the HOLD position.

G. RAISE

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A. DUMP

INSTRUMENTS/CONTROLS

Two Spool - Two Levers (Continued) 4 A B C

5 409

4. Kickdown Button (Downshift Transmission) 5. FNR Switch

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A. Forward (Transmission) B. Neutral (Transmission) C. Reverse (Transmission)

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INSTRUMENTS/CONTROLS

Three Spool - Two Levers E

D

A

H

7.

G

7

6.

6

B

C

F

I 414/BS00B355

6. BUCKET AND LIFT ARM CONTROL A. DUMP C. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position. You must manually move the control lever from the FLOAT position to the HOLD position D. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent) position, the loader bucket can follow the level of the ground without movement of the control lever.

E. LOWER F. RAISE G. DOWNSHIFT 7. AUXILARY CONTROL H. AUXILIARY FUNCTION I. AUXILIARY FUNCTION

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B. ROLLBACK

INSTRUMENTS/CONTROLS

Three Spool - Three Levers A 8.

9.

H

D 8

10.

E C

10

I

F

B

G 412/376629A1

8. BUCKET CONTROL A. DUMP B. ROLLBACK

TRIM THIS EDGE

C. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position. You must manually move the control lever from the FLOAT position to the HOLD position.

9. LIFT ARM CONTROL D. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent) position, the loader bucket can follow the level of the ground without movement of the control lever.

E. LOWER F. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position. You must manually move the control lever from the FLOAT position to the HOLD position.

G. RAISE 10. AUXILIARY CONTROL H. AUXILIARY FUNCTION I. AUXILIARY FUNCTION

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INSTRUMENTS/CONTROLS

Three Spool - Three Levers (continued) 11

A B

12

C

412

11. Kickdown Button (Downshift Transmission.

12. FNR Switch A. Forward (Transmission) TRIM THIS EDGE

B. Neutral (Transmission) C. Reverse (Transmission)

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INSTRUMENTS/CONTROLS

Four Spool Valve - Three Levers D 14.

A

H

J

E

15.

G 14.

13.

15.

C

13.

B

I K

F 415/BS00N175

13. BUCKET AND LIFT ARM CONTROL A. DUMP

TRIM THIS EDGE

B. ROLLBACK C. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position. You must manually move the control lever from the FLOAT position to the HOLD position.

D. FLOAT (Detent): This is a detent position. When in the FLOAT (Detent) position, the loader bucket can follow the level of the ground without movement of the control lever.

E. LOWER F. RAISE G. DOWNSHIFT 14. AUXILIARY CONTROL H. AUXILIARY FUNCTION I. AUXILIARY FUNCTION 15. AUXILIARY CONTROL J. AUXILIARY FUNCTION K. AUXILIARY FUNCTION

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

3

1

BS00M472

1. WRIST REST: Adjust the wrist rest to a comfortable height to operate the loader control levers.

2. ADJUSTMENT KNOB: To adjust, loosen the adjustment knob and raise or lower the wrist rest to the correct height. Tighten the knob.

BC00B128

3. HEAT CONTROL (IF EQUIPPED); Turn the control clockwise for ON. Adjust the control to the needed temperature. Turn the control completely counterclockwise for OFF (see Recirculation Louvers in this manual). Select the desired fan speed.

NOTE: Make sure the water inlet on the engine for the heater is in the full ON position.

BC00B127

4. BLOWER FAN SWITCH (IF EQUIPPED): The blower fan switch has four positions: OFF, 1, 2 and 3. Turn the switch to 3 for maximum speed and to 1 for the slowest speed. Turn the switch completely counterclockwise for OFF (see Recirculation Louvers in this manual).

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4

2

INSTRUMENTS/CONTROLS

SIDE CONSOLE

5

TRIM THIS EDGE

BS00M473

5. WIPER/WASHER SWITCH (IF EQUIPPED): Th e w ip e r /wa s he r swi t ch ha s fi ve positions.

D C

A.OFF - Turn the switch completely counterclockwise for OFF. B.INTERMITTENT - Rotate the switch c l o ck w i s e t o t h e f i r s t p o s i t i o n fo r intermittent wiper speed.

B

C.LOW - Rotate the switch clockwise to the second position for low wiper speed.

A

E BC00B131

D.HIGH - Rotate the switch clockwise to the third position for high wiper speed.

E.WASH - Push down on the switch for washer fluid.

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

BS00M473

6. LAMP SWITCH: The lamp switch has five positions: A.OFF - Turn the switch completely counterclockwise for OFF.

E

B.PARK - Turn the switch to this position to illuminate the marker and tail lamps.

D

C.DRIVE - Turn the switch to this position to illuminate the console lamps, driving lamps, marker lamps and tail lamps.

C B

A BC00B133

D.ALL - Turn the switch to this position to illuminate the console lamps, driving lamps and flood lamps.

E. WORK - Turn the switch to this position to illuminate the console lamps and flood lamps.

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6

INSTRUMENTS/CONTROLS

SIDE CONSOLE 9 8

10

7

TRIM THIS EDGE

BS00M473

BS98M034

7. AIR CONDITIONING TEMPERATURE CONTROL (IF EQUIPPED): Turn the control clockwise for ON. Adjust the control to the needed temperature. Turn the control counterclockwise for OFF (see Recirculation Louvers in this manual). Select desired the fan speed.

NOTE: For maximum cooling make sure the water inlet on the engine for the heater is in the full OFF position.

BC00B098

8. DECLUTCH SWITCH: The clutch cutout disengages the transmission when maximum power is needed for the loader (the foot pressure required to disengage the transmission is adjustable. Push down on the top of the declutch switch and push on either brake pedal to operate the machine with the clutch cutout.

9. DETENT ON/OFF SWITCH: The Detent On/Off switch is used engage all detents. Push down on the top of the detent on/off switch to engage all detents. Push the bottom of the switch for the OFF position.

BC00B097

BC00B086

10. RETURN-TO-TRAVEL/FLOAT SWITCH: The Return-To-Dig switch is used to automatically return the loader bucket to the dig position after you have dumped the loader bucket.

Push down on the top of the Return-To-Travel switch to engage all detents. Push the bottom of the switch for the OFF position.

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

11 12

BS00M473

BC00B081

11. AUTOSHIFT SWITCH: The autoshift switch is used to select the automatic or manual mode of operation for the transmission. When the autoshift switch is in the ON position the transmission will automatically shift UP and DOWN between 1st or 2nd and the highest speed setting on the transmission lever (see Transmission Operation in this manual for complete

operation).

12. RIDE CONTROL SWITCH: Push on the top of the function switch for the ON position. Ride Control is OFF when key switch is OFF. Ride Control Must be reset once the engine is started again.

BC00B094 Ride Control can be left ON at all times, whether loading or roading.

To turn Ride Control OFF, push on the bottom of the function switch for the OFF position. Ride Control will automatically activate when ground speed is above 4 km per hour and automatically shut off when ground speed is below 5 km per hour.

13. REAR WIPER/WASHER SWITCH (IF EQUIPPED): The rear wiper/washer switch has three positions.

A.OFF - The switch completely off when the bottom of the switch is pushed down.

BC00B083 ON - Push down on the top of the switch for the ON position WASH - Push down on the top of the switch and hold, washer fluid will continue to flow as long as the switch is held down.

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13

INSTRUMENTS/CONTROLS

SIDE CONSOLE

14

TRIM THIS EDGE

BS00M473

14. ROTATING BEACON SWITCH (IF EQUIPPED): Push the tip of the rotating beacon switch for the ON position and push the bottom of the switch for the OFF position.

BC00B082

15. REAR FOG LAMP SWITCH (IF EQUIPPED):

BC00B080

15

BS00M475

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INSTRUMENTS/CONTROLS

SIDE CONSOLE 16

RD97K027

Slide the locking plate towards the center of the switch, push down on the top of the switch to RETRACT the pins. The switch lamp will illuminate when the pins are retracted. The switch will lock in the PIN BC00B099 EXTENDED position after the bottom of the switch has been pressed and the PINS EXTENDED.

17

BS00M473

17. FAN REVERSER SWITCH (IF EQUIPPED)

BC00N186

To use the fan reverser let the machine idle in neutral. Depress the fan reverser switch and depress the throttle to high idle for a minimum of 10 seconds or until debris stops blowing out of the coolers. Return the machine to an idle and then release the fan reverser switch.

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16. COUPLER PIN ENGAGE SWITCH:

INSTRUMENTS/CONTROLS

18

19

TRIM THIS EDGE

BD00N030

18. F-N-R Switch (IF EQUIPPED) Enable the auxiliary F-N-R switch by pushing down on the top of the enable switch. The indicator light on the bottom of the enable switch will illuminate when activated

BC00B099

!

19. BACKUP ALARM CANCELLATION SWITCH : Push down on the top of the backup alarm ON/OFF switch to turn the audible sound OFF for the backup alarm. The symbol on the switch will illuminate when the backup alarm is in the OFF position.

Push down on the bottom of the backup alarm ON/OFF switch to turn the audible sound ON for the backup alarm.

WARNING: The backup alarm OFF function is to be used ONLY when the wheel loader is driven on the road and MUST BE TURNED ON when back on the job site.

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INSTRUMENTS/CONTROLS

MASTER DISCONNECT SWITCH

1

BD00M013

BS00A018

ON - This position energizes the entire electrical system. When the master Disconnect switch is ON and the key switch is OFF, the following electrical components have power: dome lamp, horn, stop lamps, four-way flashers and the rotary light switch.

BS00A203

OFF - This position disconnects all power to the machine.

IMPORTANT: DO NOT use the master Disconnect Switch to stop the engine.

BS00A017

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1. MASTER DISCONNECT SWITCH The Master Disconnect Switch has two positions: ON and OFF.

INSTRUMENTS/CONTROLS

Recirculation Air Louvers The recirculation air louvers are behind the operators seat next to the floor. When open, air is recirculated in the cab. To open the louvers turn the knob clockwise.

To close the louvers turn the knob counterclockwise.

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

1

2

TRIM THIS EDGE

BD00B005

1. Rotate knob as required to open or close louvers.

2. Recirculation louvers (behind filter)

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INSTRUMENTS/CONTROLS

Main Air Louvers The louvers on the Right-Hand and Left-Hand side in front of the console direct air flow back to the operator.

The lower front louvers direct air flow back to the operator.

2

1

RD98K323

RD98K303

2. RIGHT-HAND-MAIN LOUVERS

TRIM THIS EDGE

1. LEFT-HAND MAIN LOUVERS

3

3

BD00M102

3. LOWER FRONT MAIN LOUVERS

The lower front louvers direct air flow back to the operator.

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INSTRUMENTS/CONTROLS

Defrost Air Louvers The upper louvers under the front windshield and the louver under the rear window direct the air flow to defrost the windows. To get maximum air flow on the windows, close all other louvers and turn the blower fan to the fastest speed.

If a fogging condition occurs make sure t h e r e c i r c u l a t i o n a i r l o u ve r s a r e C L O S E D. I f e q u i p p e d w i t h A i r Conditioning, turn the Air Conditioning ON and turn the Heat Control completely clockwise.

TRIM THIS EDGE

4

6

RD98K323

6. DEFROST LOUVERS

4

BD00M102

4. DEFROST LOUVERS

5

RD98K303

5. DEFROST LOUVERS

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INSTRUMENTS/CONTROLS

Radio (If Equipped)

Window Latch

1

RD97F215

RD98K301

TRIM THIS EDGE

1. LIFT TO OPEN

A radio (if equipped) is available for this machine from your dealer. Refer to the radio manufacturers instructions for correct operation.

Door Latch 1

2 1 RD98K302

1. LATCH PIN 2. HOLD LATCH

RD97F218

1. PUSH TO OPEN DOOR

The window can be kept partially open by lifting the Hold Latch and sliding it back on the Latch Pin until the Hold Latch locks in the Latch Pin. T h e w i n d ow m ay b e o p e n e d a n d locked against the side of the cab. To do this pull the hold latch toward the rear of the cab when the window is partially open. This will unlatch the window and allow the window to swing back against the cab and lock.

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

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INSTRUMENTS/CONTROLS

Window Retainer Latch

1. PULL TO RELEASE WINDOW

1

RD97F173

OPERATORS SEAT TRIM THIS EDGE

Standard Seat

1

3

2

2 RD98K266 RD98K267

1. LUMBAR ADJUSTMENT KNOB: Turn the knob clockwise to increase the lumbar suppor t, tur n the knob counterclockwise to decrease the lumbar support.

3. RECLINER ADJUSTMENT HANDLE: Lift up on the handle, move the b ack r es t t o t he d es i r e d p os i t i on , release the handle to lock the backrest in position.

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

NOTE: Each armrest will pivot to the up position.

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INSTRUMENTS/CONTROLS

Optional Air Ride Seat

4 1 2

5

6 2 RD98K266

5. WEIGHT ADJUSTMENT KNOB: To adjust the seat for your weight you must pull the release lever out of the knob, Use the release lever to turn the knob clockwise to increase the weight resistance.

Tu r n the knob counterclockwise to decrease the weight resistance.

RD98K267

1. LUMBAR ADJUSTMENT KNOB: Turn the knob clockwise to increase the lumbar suppor t, tur n the knob counterclockwise to decrease the lumbar support.

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

NOTE: Each armrest will pivot to the up position.

6. HEIGHT ADJUSTMENT, STANDARD SEAT: Lift the seat all the way up, drop the seat to the lowest position. Lift the seat to the desired position. The seat will lock into accepted positions.

3

RD98K268

3. RECLINER ADJUSTMENT HANDLE: Lift up on the handle, move the ba ck r e s t t o t he de s i r e d p os i t io n , release the handle to lock the backrest in position.

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4. SLIDE ADJUSTMENT LEVER: Pull this lever up and adjust the seat for wa r d o r r ea r war d as r e qu i r ed .

Release the lever to lock the seat in position.

INSTRUMENTS/CONTROLS B. (Manual Adjustment): The seat can be raised or lowered by increasing or decreasing the air pressure in the seat. Lift the handle UP to increase the air pressure. Push the handle D OW N t o d e c r e a s e t h e a i r pressure and lower the seat.

5 4 RD98K268

TRIM THIS EDGE

4. SLIDE ADJUSTMENT LEVER: Pull this lever up and adjust the seat for wa r d o r r ea r wa r d as r e qu i r ed .

Release the lever to lock the seat in position.

NOTE: When adjusting the seat height for the first time or for a different operator. Sit in the operators seat, lift up momentarily on the height adjustment handle. The seat will automatically adjust to the operators weight. See height adjustment handle for final adjustments.

5. HEIGHT ADJUSTMENT HANDLE: A. (Automatic Adjustment): With the operator sitting in the seat.

Lift the handle UP and release.

T h e s e a t w i l l a ut o m a ti c a l l y adjust UP and then bleed off air pressure to the optimum air pressure for the weight of the operator.

6 7 RD98K268

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

7. SEAT CUSHION ANGLE ADJUSTMENT HANDLE: Lift up on the handle. Move the seat to the desired angle. Release the handle to lock the cushion angle.

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INSTRUMENTS/CONTROLS

5

8

RD00B010

8. DAMPENING ADJUSTMENT LEVER: The dampening adjustment lever has four positions from soft to hard. The first adjustment is with the small end of the adjustment lever pointing toward the front of the seat, as shown. The other three adjustments can be obtained by rotating the small end of the adjustment lever out away from the seat. Each of the adjustments has a slight detent. The suspension can be adjusted to var ious operating conditions.

TRIM THIS EDGE

SEAT BELT

RD97F225

RD97F225

1. Pull belt from holder. Fasten the belt end into the right-hand buckle.

2. To release the seat belt, push the red button on the buckle.

NOTE: Make sure the belt end and buckle are securely fastened. Do not pull out the right-hand buckle.

!

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

M437

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INSTRUMENTS/CONTROLS

Inspection and Care 1. Keep sharp edges and items that can cause damage, away from the belts.

2. From time to time, check belts, buckles, retractors, tethers, slack take-up system and mounting bolts for damage.

3. Replace all parts that have damage or wear.

4. Replace belts that have cuts that can make the belt weak.

5. Check that bolts are tight on the seat bracket or mounting.

6. If belt is attached to seat make sure seat or seat brackets are mounted securely.

7. Keep seat belts clean and dry.

8. Clean belts only with a soap solution and warm water.

9. Do not use bleach or dye on the belts because this can make the belts weak.

Emergency Exit TRIM THIS EDGE

1 1

2

RD98K301

1. PIN 2. LATCH

BD00N075

1. EMERGENCY EXIT

Lift and pull the latch out of the pin.

Push the Right hand window open.

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OPERATING INSTRUCTIONS BEFORE STARTING THE ENGINE

!

2. See the Maintenance Chart in this manual and do the items in the 10 Hour section.

3. Check that the machine fuel tank is filled with clean fuel that has the specification given in this manual.

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

CM112

RUN - IN PROCEDURE It is impor tant that the run-in i n s t r u c t i o n s fo r a n ew e n g i n e b e followed. Proper run-in will increase engine power and service life. If the engine is not run-in properly, the piston rings and cylinder bore can be damaged.

2. Operate the machine with normal loads as much as possible.

3. Monitor the engine instruments frequently during operation.

Reduce throttle and/or load if the coolant temperature exceeds safe operating limits.

During the first 100 hours of operation, operate the machine as follows: 1. Do not run the engine at idle speed for long periods of time.

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1. Do a daily walk around, visual inspection of the machine. Check for such items as hoses rubbing against other components, oil leaks, debris or trash buildup, loose bolts, damaged, or missing parts that would effect the normal and safe operation of the machine.

Make any necessary corrections before operating the machine.

OPERATING INSTRUCTIONS

First Service Intervals The following items are to be done during the Run-In Period and are in addition to the items in the Lubrications/Maintenance Charts in this manual.

AFTER FIRST 100 HOURS OF OPERATION Have your dealer do the After Delivery Check .......................... See After Delivery Check in this manual AFTER FIRST 100 HOURS OF OPERATION Change the front and rear axle differential and planetary oil when the axles are new or repaired ................... See Axle Planetary in this manual Change the transmission oil and filter when the transmission is new or repaired ........................... See Transmission Specifications in this manual Check all hose clamps, tighten as required.

TRIM THIS EDGE

SEAT BELT Always securely fasten your seat belt before operating the machine. From time to time, carefully inspect the seat belts for worn areas and replace belts when needed.

!

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

SA121

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OPERATING INSTRUCTIONS

STARTING THE ENGINE !

WARNING: Before you start the engine, always sit in the operators seat, fasten the seat belt, apply the parking brake, and make sure the transmission direction control and digging control (if equipped) is in NEUTRAL. Give a warning to all persons around you that you are starting the engine.

SC037

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

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

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

4. Turn the key switch to the ON position and check the instrument cluster.

NOTE: If the weather is cold, See Cold Weather Starting in this manual. If the engine has not been started for several weeks or if the engine oil filter has been replaced, See Priming the Turbocharger in this manual.

6. After the engine starts, check the in st r ume nts to make s ur e th e indications are correct. Run the engine at approximately 1200 RPM with the transmission in neutral until the engine coolant temperature is warm.

NOTE: Operate the machine at reduced loads until all systems reach operating temperature. This is very important during extremely cold weather operation to protect both the engine and hydraulic systems. See Operating in Cold Weather in this manual.

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2. Adjust the seat and fasten your seat belt. Make sure you can push the foot pedals completely down with your back against the seat cushion.

5. Turn the key switch to the START position until the engine starts, then release the key.

OPERATING INSTRUCTIONS

Priming the Turbocharger Lines with Oil

Engine Speed Do not operate the engine at idle speed for long periods. This can cause a low operating temperature. A low operating temperature can cause acids and deposits in the engine oil.

1

BD00N068

1. WIRE CONNECTOR

TRIM THIS EDGE

If the weather is cold, if the machine has not been run for several weeks or if the engine oil filter has been replaced, fill the turbocharger oil lines with oil.

1. Make sure the parking brake is ENGAGED. 2. Disconnect the wire connector from the injection pump solenoid (see photograph).

3. Actuate the starter motor for about 15 to 20 seconds until there is oil in the lines.

4. Connect the wire to the injection pump solenoid and star t the engine.

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OPERATING INSTRUCTIONS

STOPPING THE ENGINE AND PARKING THE MACHINE !

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

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. Lower the loader to the ground.

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

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

6. If your machine has a cab, lock the cab door.

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

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

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

OPERATING INSTRUCTIONS

Engine Coolant Heater (If Equipped) The left side of the engine cylinder block has a passage for installing a coolant heater. See your dealer for this optional heater. Follow the heater m a n u fa c t u r e r s i n s t r u c t i o n s fo r installation.

BS00M477

Engine Oil Heater (If Equipped) TRIM THIS EDGE

The engine oil heater is installed on the side of the engine oil pan. See your dealer for this optional heater. Follow the heater manufacturers instructions for installation.

B830662P

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OPERATING INSTRUCTIONS

Booster Battery Connections to Machine Batteries (Jump Start) !

WARNING: Batteries contain acid and explosive gas. Explosion can result from sparks, flames or wrong cable connections. To connect the jumper cables correctly to the battery of this machine, see the correct method shown on this page. Failure to follow these instructions can cause serious injury or death.

SA006

!

WARNING: Battery explosion and/or damage to electrical components can result from improper connection of booster batteries or charger.

Connect positive to positive and negative to negative. Externally, battery acid can cause burns and blindness, and taken internally it is poison.

M146B

IMPORTANT: The machine may only be Jump Started from the LEFT side of the machine.

NOTE: Make sure the batteries are not frozen. Do not use batteries that have been frozen. Replace the batteries if the batteries have been frozen.

1. Open the rear hood. Sit in the operators seat and have the other person make the connections.

2. If using jumper batteries, make sure the jumper batteries are 24 volts.

3. If using another machine for power, make sure the two machines, DO NOT touch.

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

5. Connect the negative (-) jumper cable to the negative (-) terminal on the jumper batteries or the other machine. Connect the other end of the negative (-) jumper cable to a good frame ground away from the batteries.

6. Start the engine according to the instructions in this manual. See Starting the Engine in this manual.

7. Have the other person disconnect the jumper cables in the reverse order that the jumper cables were connected in. Close the rear hood.

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

OPERATING INSTRUCTIONS

Standard Batteries 1. CONNECT THE POSITIVE JUMPER CABLE HERE. CONNECT THE NEGATIVE CABLE TO A CHASSIS GROUND AWAY FROM THE BATTERY.

1

BD00N050

TRIM THIS EDGE

1

BS00N080

NOTE: One battery on each rear side of machine.

IMPORTANT: Machine may only be Jump Started from LEFT rear side.

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OPERATING INSTRUCTIONS

BEFORE YOU OPERATE !

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

SA040

Before You Operate the Machine Before you operate the machine each day or before shift test the machine for correct operation.

1. Have the machine in a clear level area and make sure all persons are clear of your machine.

3. Fasten and adjust the seat belt.

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

5. Check the loader controls for correct operation.

6. Periodically test the parking brake neutral interlock function: A. Apply the parking brake by pushing down on the left side of the switch.

B. Enable the pilot control levers by pushing down on the right side of the switch.

C. Push down and hold your foot against the brake pedal.

D. Raise the loader bucket above the ground.

E. Shift the transmission into first gear forward.

F. The warning buzzer will sound.

G. Take your foot off the brake pedal.

H. Increase the engine speed to 1/2 throttle. The machine must not move. If the machine moves, see the service manual or see your authorized dealer and correct the problem. When the par king brake is applied, the transmission is automatically shifted into Neutral.

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

OPERATING INSTRUCTIONS 7. Test the parking brakes at a maximum of 250 hour intervals: A. Apply the parking brake by pushing down on the top of the switch.

B. Shift the transmission into 3rd gear NEUTRAL. C. Press the program switch.

D. Press the up count switch until the Display Center reads 011.

E. Return the program/reset switch to the off (center) position.

F. Press the up count switch until the 01 is shown in the Display Center.

G. Push down and hold your foot against the brake pedal.

H. Enable the pilot control levers by pushing down on the right hand side of the pilot control switch.

I. Raise the loader bucket above the ground.

J. Shift the transmission to FORWARD and increase the engine speed to full throttle. The machine must not move. If the machine does move, see the service manual or see your dealer and correct the problem.

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K. Shift the transmission to REVERSE and increase the engine speed to full throttle. The machine must not move. If the machine does move, see the service manual or see your dealer and correct the problem.

L. Shift the transmission to the NEUTRAL position.

M.Press the reset switch momentarily to return to normal operation.

!

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

CM112

!

WARNING: Never operate the engine in a closed building. Proper ventilation is required under all circumstances.

M142A

!

WARNING: Operate the machine with the door closed to provide proper ROPS protection and to properly utilize the heating, ventilating or cooling systems.

M122B

!

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

SB013

8. Release the parking brake.

9. Test the foot brakes for correct operation at a maximum of 250 hour intervals.

A. Push down and hold your foot against the brake pedal.

B. Raise the loader bucket just above the ground.

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OPERATING INSTRUCTIONS C. Place the transmission in the manual mode.

D. Shift the transmission into 2nd gear forward.

E. Release the parking brake.

F. Increase the engine speed to full throttle. the machine must not move. If the machine does move, decrease engine speed to low idle. See your Service manual or your dealer for repairs.

G. Reset the parking brake.

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10. Test the secondary steering at a maximum of 250 hour intervals. (See Secondary Steering Check in Maintenance and Adjustments in this manual.)

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OPERATING INSTRUCTIONS

MACHINE OPERATION Transmission Operation The transmission in this machine has four (4) forward speeds and three reverse speeds. Always select the correct speed for the job. If you have frequent stalls (engine running at full throttle and the wheels not turning) select a lower gear.

The transmission can be operated in Automatic or manual mode.

The foot brake must be actuated while engaging the transmission to release the parking brake.

Manual Mode Operation To put the transmission in the Manual mode press the bottom of the Autoshift switch.

Up-Shifts Manual Mode TRIM THIS EDGE

You can shift the transmission from a lower gear to a higher gear without reducing the machine speed or engine speed. If the gear to be selected is two (2) or more higher than the present gear, the transmission will automatically shift gears at 2.5 second intervals until the gear selected has been reached.

Down-Shifts Manual Mode The transmission can be shifted from 4th to 1st gear without reducing machine or engine speed. If 1st gear is to be selected from 3rd or 4th gear, the transmission will down shift to 2nd gear for approximately 1.2 seconds and then shift to 1st gear. For smooth operation and operator comfort, reduce engine speed before down shifts.

Down-Shift Button, Manual Mode The down-shift button is used to shift the transmission from 2nd gear to 1st. The transmission will shift back to 2nd gear if (1) the down-shift button is pressed again or (2) if the transmission control lever is moved to NEUTRAL and then to FORWARD or REVERSE.

Automatic Mode Operation To put the transmission in the automatic mode press the top of the Autoshift switch.

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OPERATING INSTRUCTIONS

Shifting, Automatic Mode When the transmission is in the automatic mode, the transmission will start to move in 1st gear (when the machine is stopped) and automatically up-shift until the gear selected has been reached. The transmission will also down-shift automatically as the speed decreases.

Down-shift Button, Automatic Mode The down-shift button (1) is used to shift down through the gears in single steps.

Each time the switch is pressed down the transmission will shift down one gear range until 1st gear is reached. Once the down-shift button has been pressed down the transmission is taken out of the automatic mode. The transmission will remain in the gear that was selected by the down-shift button. It will return to the automatic mode when (1) the transmission control lever gear changes, or (2) the transmission control lever is moved to NEUTRAL and then to FORWARD or to REVERSE.

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1

410

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

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OPERATING INSTRUCTIONS

F-N-R SWITCH (If Equipped) The F-N-R switch can be enabled after the following conditions have been met: 1. Transmission controller is in neutral.

2. F-N-R switch is in neutral.

3. Parking brake is released.

4. Vehicle is stationary.

Depressing the F-N-R enable switch allows the transmission to be controlled by the auxiliary F-N-R switch. The indicator light on the bottom of the enable switch will illuminate when activated. If the column mounted transmission controller is moved from neutral, the auxiliary F-N-R mode is deactivated.

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1

BD00N030

1. F-N-R SWITCH

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OPERATING INSTRUCTIONS

CONTROL LEVERS TWO SPOOL VALVE - ONE CONTROL LEVER 4 2

5

1 3

1

4

2

3

B1119A88

1. DUMP BUCKET 3. RAISE LIFT ARMS 2. ROLLBACK BUCKET 4. LOWER LIFT ARMS 5. HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN HOLD. WHEN RELEASED, THE CONTROL LEVER WILL RETURN TO HOLD AUTOMATICALLY.

NOTE: This page shows the basic loader control lever positions. The Detent Switch for the loader functions is in the OFF position.

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410

See Loader Function Switches in this manual for RETURN-TO-DIG, BUCKET HEIGHT CONTROL and RETURN-TO-TRAVEL/FLOAT switches.

OPERATING INSTRUCTIONS

TWO SPOOL VALVE - TWO CONTROL LEVERS

5

3 1 4 5

2

409

See Loader Function Switches in this manual for RETURN-TO-DIG, BUCKET HEIGHT CONTROL and RETURN-TO-TRAVEL/FLOAT switches.

3

2

4

TRIM THIS EDGE

1

B1119A88J

1. DUMP BUCKET 3. LOWER LIFT ARMS 2. ROLLBACK BUCKET 4. RAISE LIFT ARMS 5. HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVERS ARE IN HOLD. WHEN RELEASED, THE CONTROL LEVERS WILL RETURN TO HOLD AUTOMATICALLY.

NOTE: This page shows the basic loader control lever positions. The Detent Switch is in the OFF position.

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OPERATING INSTRUCTIONS

THREE SPOOL VALVE - TWO CONTROL LEVERS 3

1

7

NOTE: This page shows the basic control lever positions. The Detent Switch for the loader functions is in the OFF position.

6

2 4

See Loader Function Switches in this m a n u a l fo r R E T U R N - TO - D I G , BUCKET HEIGHT CONTRO L and R E T U R N - TO - T R AV E L / F L O AT switches.

5

1

3

2

4

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414

B1119A88

1.

2.

5.

6.

DUMP BUCKET 3. LOWER LIFT ARMS ROLLBACK BUCKET 4. RAISE LIFT ARMS 5-6.) AUXILLARY FUNCTION 7.) HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVERS ARE IN HOLD. WHEN RELEASED, THE CONTROL LEVERS WILL RETURN TO HOLD AUTOMATICALLY.

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OPERATING INSTRUCTIONS

THREE SPOOL VALVE - THREE CONTROL LEVERS 5

1

NOTE: This page shows the basic loader control lever positions. The Detent Switch for the loader functions is in the OFF position.

3 7

7

See Loader Function Switches in this m a n u a l fo r R E T U R N - TO - D I G , BUCKET HEIGHT CONTRO L and R E T U R N - TO - T R AV E L / F L O AT switches.

7 6

2

4

412

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1

3

2

4

B1119A88

1.

2.

5.

6.

DUMP BUCKET 3. LOWER LIFT ARMS ROLLBACK BUCKET 4. RAISE LIFT ARMS 5-6.) AUXILLARY FUNCTION 7.) HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVERS ARE IN HOLD. WHEN RELEASED, THE CONTROL LEVERS WILL RETURN TO HOLD AUTOMATICALLY.

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OPERATING INSTRUCTIONS

FOUR SPOOL VALVE - THREE CONTROL LEVERS 3

9 1

2

5

NOTE: This page shows the basic loader control lever positions. The Detent Switch is in the OFF position.

7

4 6

See Loader Function Switches in this m a n u a l fo r R E T U R N - TO - D I G , BUCKET HEIGHT CONTRO L and R E T U R N - TO - T R AV E L / F L O AT switches.

8

1

3

2

3

TRIM THIS EDGE

415

B1119A88

1.

2.

5.

6.

7.

DUMP BUCKET 3. LOWER LIFT ARMS ROLLBACK BUCKET 4. RAISE LIFT ARMS 5-6.)FIRST AUXILARY FUNCTION 7-8.)SECOND AUXILARY FUNCTION 9.) HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN HOLD. WHEN RELEASED, THE CONTROL LEVER WILL RETURN TO HOLD AUTOMATICALLY.

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OPERATING INSTRUCTIONS

LOADER FUNCTION SWITCHES Push down on the top of the detent switch to engage all detents.(1) Push on the bottom of switch for the OFF position.

1

2 RD97F178

1. DETENT ON/OFF SWITCH 2. RETURN-TO-TRAVEL/ FLOAT SWITCH

Return-To-Dig TRIM THIS EDGE

The Return-To-Dig function is used to automatically return the loader bucket to the dig position after you have dumped the loader bucket. To enable the ReturnTo-Dig function press the bottom of the Return-To-Travel/Float switch.(2)

1

2 1

410

409

1. FLOAT AND ROLLBACK DETENT

1. FLOAT 2. ROLLBACK DETENT

To actuate, move the control lever(s) into the FLOAT and ROLLBACK detents.

The control lever(s) will automatically return to the HOLD position when the loader reaches the Return-To-Dig position. See Loader Adjustments in this manual for Return-To-Dig Adjustment.

B1125A88J

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OPERATING INSTRUCTIONS

Bucket Height Control The bucket height control is used to automatically stop the loader arms at the height that you select.

1

1

410

409

To actuate, move the control lever into the RAISE detent. The control lever(s) will automatically return to the HOLD position when the loader bucket reaches the height selected. See for Bucket Height Control Adjustments in this manual.

Return-To-Travel The Return-To-Travel function is used to automatically stop the loader bucket at the carry height that you select. To enable the Return-To-Travel function press the top of the return to Travel/Float switch.

1 1 2

409

1. ROLLBACK DETENT 2. FLOAT

410

1. FLOAT AND ROLLBACK DETENT

To actuate, move the control lever(s) into the FLOAT and ROLLBACK detents.

The control lever(s) will automatically return to the HOLD position when the loader reaches the Return-To-Travel position. See for Return-To-Travel Adjustment in this manual.

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1. RAISE

1. RAISE

OPERATING INSTRUCTIONS

Float The Float function is used to let the loader bucket float across rough ground.

B1128A88J

To actuate, move the control lever into the FLOAT detent. The control lever will remain in this position until manually removed.

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1

1

409

1. Float

410

1. Float

LOADER CONTROL T h e l o a d e r c o n t r o l l ev e r s a r e connected to a hydraulic accumulator through a pressure reducing valve. The pur pose of the reducing valve and accumulator combination is to: (1) allow the operator to lower the loader arms if the engine stops with the loader arms raised, or (2) give the control system hydraulic pressure assistance when operating the machine at low idle speed.

3. Stop the engine.

4. Turn the key to RUN. 5. Move the lift arm control to LOWER. The loader bucket must lower to the ground. If the bucket does not lower to the ground, see t h e S e r v i c e M a n u a l fo r t h i s machine or see your dealer.

1. Start the engine.

2. Raise the loader bucket.

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OPERATING INSTRUCTIONS

BRAKE ACCUMULATORS Two hydraulic accumulators are connected in the brake system. the purpose of the accumulators is to provide the brake modulating valve with a positive supply of pressurized hydraulic fluid.

Periodicall test the accumulators for correct operation.

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

3. Stop the engine.

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

5. Repeatedly pump the brake pedal until the brake pressure lamp is illuminated.

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

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

CLUTCH CUTOUT The Clutch Cutout function is used to allow the engine to increase speed and supply the loader with more hydraulic oil for greater loader power and faster control function. When the clutch cutout switch is in the ON position, and you push down on the brake pedal, the transmission is disengaged from the drive wheels. Release the brake pedal to engage the transmission power. The machine can roll free when the clutch cutout switch is pushed. If required, use the brake to stop the machine.

1 RD97F178

1. CLUTCH CUTOUT SWITCH

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1. Start the engine.

OPERATING INSTRUCTIONS

BUCKET LEVEL INDICATOR The bottom of the bucket is parallel with the ground when the flat portion of the bucket, (shown) is horizontal.

BD00N076

AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED) TRIM THIS EDGE

Your Wheel Loader is equipped with an Auxiliary Hydraulic System. A control lever on the console controls flow to the auxiliary hydraulic connection points on the lift arms. The auxiliary control lever (1) used with a joystick (2) is equipped with mechanical detents to lock it into full forward, full rearward and neutral positions. Auxiliary control levers on non-joystick machines DO NOT have mechanical detents.

2 1

BD00N032

414

Auxiliary Hydraulic System Specifications 521D Wheel Loader (XT and Z-Bar Linkage) Maximum System Pressure ....................................................248 Bar (3 600 PSI) Maximum Capacity at 2 150 Engine RPM ............................. 151 L/min (40 GPM) NOTE: Maximum system pressure measured on the machine at the pump pressure port.

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OPERATING INSTRUCTIONS

ROTATING BEACON (IF EQUIPPED) The rotating beacon control switch is on the RH console. Push the top of the switch for ON position and push the bottom of the switch for OFF position.

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RD97K027

RD98M059

RD98M060

TRANSPORT POSITION

OPERATING POSITION

To adjust the rotating beacon lamp to the TRANSPORT position, rotate the lamp assembly and mounting bar downward until the spr ing loaded detents hold the lamp assembly and mounting bar in the transport position as shown in the photograph.

To adjust the rotating beacon lamp to the OPERATING position, rotate the lamp assembly and mounting bar upward until the spring loaded detents hold the lamp assembly and mounting bar in the operating position as shown in the photograph.

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OPERATING INSTRUCTIONS

RIDE CONTROL(If Equipped) Ride Control is a feature that increases the ride comfort of the Wheel Loader over all types of terrain with either an empty or loaded bucket.

Ride Control will reduce Fore and Aft pitching motion during travel to allow faster speeds in load and carry applications for increased BC00B094 productivity and operator comfort. It will also reduce shock loads to the Wheel Loader for reduced tire flex, structural fatigue and vibration, resulting in longer component life and reduced costs.

The machine is equipped with speed dependent ride control. Push on the function switch symbol to activate. With ride control active, the green indicator light will illuminate anytime the machine is traveling faster than 3 mph, indicating that the ride control is functioning. Ride control will disengage automatically at slower speeds for loading and unloading.

Ride Control can be left ON at all times, whether loading or roading.

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

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

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OPERATING INSTRUCTIONS

COUPLER PIN ENGAGEMENT (IF EQUIPPED) Use the factory/field installed coupler system to change attachments quickly.

A control switch for the system is located on the RH console.

To connect an attachment, position the front coupler into the attachment, push and hold on the top of the COUPLER switch to RETRACT the PINS. Return the switch to the center position to RETRACT the PINS. Make sure the Coupler Pins are engaged before you use the machine.

!

WARNING: Before using the machine make sure the attachment is securely connected to the machine by putting the front of the attachment against the ground and putting down pressure on the attachment.

M781

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BD00B028

To change attachments, lower the attachment to the ground, push the top of the COUPLER switch (PINS RET RACT) . Back out of the attachment.

OPERATING INSTRUCTIONS

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

Leveling Operation Always operate the machine in reverse when leveling the surface.

Pushing Operation When pushing material do not set the bucket dumping angle more than 20 degrees.

163L96

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IMPORTANT: The bucket MUST NOT be in the FULL DUMP position during the pushing operation.

Scraping Operation When scraping hard or frozen surfaces the bucket must be level and flat to the surface. Operate the machine at a slow speed.

164L96

163L96

!

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

M465

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OPERATING INSTRUCTIONS

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

165L96

!

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

Operating on a Hill !

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

SB013

Before you operate this machine on a hill, always put the transmission in a lower range and test the brakes. DO NOT let the machine move down a hill with the transmission in NEUTRAL. DO NOT use the Clutch Cutout Switch when operating on a hill.

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SA041

OPERATING INSTRUCTIONS

TOWING THE MACHINE If your machine is disabled, you must make a judgment if the machine can be moved without further damage. If possible, repair the machine at the job location.

If you cannot repair the machine at the job location and if you have a transport trailer, park the trailer as close as possible to the machine (see Transporting the Machine in this manual).

NEVER TOW MACHINE FROM THE FRONT. 1. Attach a rigid drawbar to the machine.

2. If the machine cannot be started to release the parking brake, do the following: A. Put blocks in front of and behind each tire.

B. Remove the cover (1).

Parking

brake

1

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C. Loosen the lock nut (2).

D. Turn the adjusting screw counterclockwise until the parking brake is released (3).

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

4. Tow the disabled machine at a maximum speed of 8 km/h (5 mph).

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2

3 300372A1

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.

SB042

!

WARNING: Before you put the machine on a trailer, remove all snow, ice, oil or grease from the trailer and ramp.

46-76C

!

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

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

84-13A

You must know the rules or laws for transportation and safety that are used in each area that you will be in. Make sure that the truck and machine are e q u i p p ed wi t h t h e c o r r e c t s a fe t y equipment.

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

9. Use chains to fasten the machine to the trailer. See the Next Page for tie down locations of the machine.

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

2. Be Careful, move the machine SLOWLY onto the trailer.

3. Lower the loader bucket onto the trailer.

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

5. Apply the parking brake and stop the engine. Remove the key.

10. Put a cover over the exhaust pipe.

11. Rotate the beacon to the T R A N S P O RT p o s i t i o n . S e e beacon in this manual.

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

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

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

OPERATING INSTRUCTIONS

LIFTING THE MACHINE Four lifting attachment points, identified by the symbol below, are provided at the front and rear of the machine.

139729A1/BD00N080

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Always put the transport and service link in the LOCKED position before lifting the machine.

Always use lifting equipment of an appropriate type and capacity to lift the machine. Refer to the Product Identification Number (PIN) plate for the weight of a basic machine. The weight of your machine can vary from the basic machine weight depending on the options and attachments that you have selected for your machine. You must weigh your machine to determine it’s exact weight.

BD00M039

REAR LIFT POINT

BD00M058

FRONT LIFT POINT

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OPERATING INSTRUCTIONS

MACHINE DRAWBAR INFORMATION Your machine is equipped with a drawbar located on the rear counterweight.

The drawbar is to be used for retrieving or towing your machine if it becomes disabled.

The maximum horizontal force applied to the retrieval hitch must never exceed 20 000 kg (44 092 lb). The maximum vertical force applied to the hitch must never exceed 5 000 kg (11 023 lb).

BD00N061

408367A1

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The hitch may be used to temporarily pull loads. The maximum horizontal force applied must not exceed 6 500 kg (14 330 lb). The maximum vertical force must not exceed 2 200 kg (4 850 lb).

OPERATING INSTRUCTIONS

Transporting the Machine on a Trailer Machine Tie Down Locations

BD00M041

CHAINS MUST BE SECURELY FASTENED TO THE FRONT TIE DOWN HOLE.

BK00D002

TRANSPORT LINK MUST BE SECURED

TRIM THIS EDGE BD00B012 BD00M032

CHAINS MUST BE SECURELY FASTENED TO THE REAR TIE DOWN HOLE.

CHAINS MUST BE SECURELY FASTENED AROUND LOADER ARM.

FAR1069

CHAINS MUST BE SECURELY FASTENED AROUND LOADER ARM.

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OPERATING INSTRUCTIONS

OPERATING IN COLD WEATHER Cold weather conditions cause special problems. During these conditions your machine will require special start up, and warm up, and maintenance procedures for the best performance. Proper cold weather maintenance will extend the service life of your machine.

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

Inspect the batter y cables and terminals. Clean the terminals and apply electrical terminal sealers ( s e e y o u r d e a l e r ) t o p r ev e n t corrosion.

If you add water to the batteries and the temperature is below 0°C (32°F),make sure you charge the batteries or r un the engine for approximately two (2) hours. This procedure will prevent batter y freezing (see Batteries and Booster Batter y Connections in this manual.

Inspect the batter y cables and terminals. Clean the terminals and apply electrical terminal sealer (see your dealer) to prevent corrosion.

2. LUBRICANTS - Make sure you follow the recommended oil and filter service for the engine and the hydraulic system as shown in this manual. Use the correct viscosity oil i n ea ch co mpon ent for th e ambient temperatures the machine is operated in (see Lubrication in this manual).

3. FUEL SYSTEM - Check with your fuel supplier for the correct cold weather fuel. Engine power will be reduced if wax particles are in the fuel filters.

Check for water in the fuel system.

Col d tem peratu re s can c aus e condensation to form in the fuel tank. Check the first stage fuel filter for water. If no water is found, extend the interval (see Diesel Fuel System in this manual).

4. COOLING SYSTEM - Check the coolant mixture before you operate in cold temperatures. A mixture of 50% ethy lene gly col and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37°C (-34°F). If the ambient temperature is lower, adjust the mixture. It is recommended that ethylene glycol and water be used in your machine all year (S ee Engine Cooling System in this manual).

5. COLD TEMPERATURE STARTING AIDS See your dealer for extra starting aids (see Cold Weather Starting in this manual).

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1. BATTERIES/ELECTRICAL SYSTEM - Clean the batteries and make sure the batteries are at full charge.

OPERATING INSTRUCTIONS 6. MACHINE WARM-UP - Once the engine has started, run the engine at half throttle (1 100 to 1 300 RPM) for a minimum of 10 minutes under no load. This will help warm t h e hy d r a u l i c o i l a n d t h e transmission oil.

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After engine warm-up, enable the pilot controls by pushing down on the right hand side of the switch on the instrument control panel. Apply and hold the foot brake, and cycle all hydraulic functions several times. In severe cold weather conditions, the hydraulic functions may be slow to respond. Cycling all the hydraulic system functions s ev e r a l t i m e s w i l l w a r m t h e hydraulic oil and the hydraulic system components.

When the machine has been correctly warmed up, apply the foot brake and hold, shift the transmission to forward push the park brake to the Off position and release the foot brake. Operate the mac hi ne i n a c lear s afe a re a.

Check the full operation of the machine. DO NOT operate the machine in third or fourth gear until the transmission oil and axle oil have been war med up and the machine moves freely.

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

The hydraulic steering can become s l o w i n s ev e r e c o l d w e a t h e r conditions. Cycle the steering from full right to left a minimum of 3 to 5 t i m e s b e fo r e y o u d r i v e t h e machine.

NOTE: Make sure there is clearance around the machine before steering the machine from right to left.

In severe cold weather conditions the brakes response can be slow.

The use of correct oil in the hydraulic/brake system is required.

Even with the correct oil in the hydraulic/brake system the first few times the brakes are actuated there may be some delay before the brakes are applied. The operator must actuate the brake pedal a minimum of 8 to 10 times before the machine is moved.

7. If the machine has been left idling in cold temperature, the engine will stay warm. But the hydraulic/brake oil and the axle oil will not stay warm. The oil and components can b e c o m e c o l d a n d s l ow b r a k e function response time. If this s h o u l d h a p p e n yo u M U S T g o through the complete machine warm-up procedure.

8. The transmission is equipped with internal protection that does not allow the transmission to engage below -12°C (10°F). If the transmission does not engage below these temperatures, allow 2 to 4 minutes of running in neutral (this time will var y with temperature), then try again.

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OPERATING INSTRUCTIONS

OPERATING IN HOT WEATHER To prevent damage to the machine, do the following:

4. Clean all dirt and debris from the cooling system and engine area.

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

5. Check the condition of the drive belts.

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

6. Use lubricants viscosity.

of

the

correct

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3. Test the radiator cap before hot weather starts. Replace the cap as required. See your dealer.

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OPERATING INSTRUCTIONS

NOTES

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WHEELS/TIRES/BALLAST WHEELS AND TIRES !

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

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

SD020

!

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

!

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

SB134

BALLAST It is the recommendation of the Case Corporation NOT to add Ballast to the tires of your machine.

Make sure tires are properly inflated, see Tire Pressure Chart in this manual.

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84-113

WHEELS/TIRES/BALLAST

TRIM THIS EDGE B910410J

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

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WHEELS/TIRES/BALLAST

Adding Air to the Tires

4. Inflate the tire to the recommended air pressure. DO NOT inflate the tire more than the recommended pressure given on the following page.

This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following.

Tire or Rim Service Always have a qualified tire mechanic ser vice the tires and r ims for this machine. It is recommended that you have this mechanic inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment, and correct procedure.

Explosive separation of the tire (single piece rim) or the tire and/or rim parts (multi-piece rim) can cause serious injury or death.

Tire Tread Direction

B790490R

When the tire is installed on the wheel make sur e the tire tread is in the direction shown.

2. Use an air hose with remote shutoff valve and a self-locking air chuck.

3. Stand BEHIND the tread of the tire and make sure ALL persons are away fr om the side of the tir e before you start to add air.

FORWARD

B770164R

B4039288T

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1. Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage).

WHEELS/TIRES/BALLAST

Wheel Nut Torque Check the torque of the wheel bolts after every 20 hours of operation until the wheel bolts stay tight, if the machine is new or if a wheel has been removed and installed.

If a wheel is removed from the machine and installed, tighten the bolts using the sequence shown. First tighten the bolts to 278 Nm (220 pound-feet), then to a final torque of 640 to 720 Nm (475 to 530 pound-feet) in the same sequence.

Bolts are M22 - 1.5, GR. 10.9 1 8

10

6 3

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4 5 9

7 2

BS00J104

521D

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BD00M073

WHEELS/TIRES/BALLAST

Tire Pressure Chart - 521D TREAD

SIZE

TYPE

17.5X25

Front

L2

Rear 17.5X25

Front

L3

Rear 17.5R25

Front

XTLA TL*

Rear 17.5R25

Front

XHA TL

Rear 15.5X25

Front

L2

Rear 15.5X25

Front

L3

Rear 15.5R25

Front

XTLA TL*

Rear 15.5R25

Front

XHA TL*

Rear

TIRE PRESSURE kPa

(PSI)

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

DO NOT inflate the tires more than the recommended pressure.

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(bar)

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TIRE

WHEELS/TIRES/BALLAST

NOTES

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LUBRICATION/FILTERS/FLUIDS

LUBRICATION/FILTERS/FLUIDS GENERAL SAFETY BEFORE YOU SERVICE !

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

SC021

!

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

SA044

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

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Read the safety decals and information decals on the machine. Read the operators manual and safety manual.

Understand the operation of the machine before you start servicing

B770996R

B801147T

Before you service the machine, put a Do Not Operate tag on the instrument panel. One Do Not Operate tag is included with your machine. Additional tags are available from your dealer.

321-4614

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LUBRICATION/FILTERS/FLUIDS

SUPPORT STRUT FOR LOADER LIFT ARMS !

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

1. Empty the loader bucket, raise the loader lift arms to maximum height and stop the engine.

2. Remove the support strut from the transport position by removing the retaining bolt.(1) 3. Place the support strut onto the cylinder rod with guide lock tab on top of cylinder and pointing toward the bucket. (2) 3. Install the retaining bolt entirely into the support strut using all threads. (3) 4. Slowly lower the lift arms onto the support strut.

If you do not follow this procedure, you can cause death or serious injury if the loader lift arms are lowered by accident.

M824

TRIM THIS EDGE BD00M048

BD00N062

SUPPORT STRUT IN TRANSPORT POSITION

SUPPORT STRUT IN SERVICE POSITION

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LUBRICATION/FILTERS/FLUIDS

TRANSPORT/SERVICE LINK Before you transport or service this machine, always put the Transport/Service link in the LOCKED position.

RD98K363

RD98M044

OPERATING POSITION

After servicing and before you move the machine, return the Transport/Service link in the OPERATING position.

!

WARNING: Keep clear of this area when engine is running. Machine could pivot unless the transport and service link is in its LOCKED position.

After servicing is completed, unlock the transport and service link and secure in place on the rear frame pivot.

SA069

ENVIRONMENT 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 you dealer for correct disposal information.

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STRAIGHT AHEAD LOCKED POSITION

LUBRICATION/FILTERS/FLUIDS

ENGINE HOOD

2 1

3

BD00M035

1. HANDLE

1. Push the lock button and raise hood to open. Open hood until support strut locks full open.

BD01A003

2. ASSIST CABLE 3. STRUT RELEASE TAB

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2. To close the hood pull down on assist cable (2) while pushing red strut release tab (3).

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LUBRICATION/FILTERS/FLUIDS

SYSTEMGARD LUBRICATION ANALYSIS PROGRAM

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Ask your dealer about our lubricant analysis program, Systemgard. 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 Systemgard laboratory. After the sample is processed, the laboratory will report back to you and guide you with maintenance requirements. Systemgard 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 Case equipment.

B830752T

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 decoloration, cracking or deformation of the part being cleaned.

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LUBRICATION/FILTERS/FLUIDS

ENGINE HOURMETER Service your machine at the intervals and locations given in the Lubrication/ Maintenance Chart. When you service your machine, use only high quality lubricants.

TRIM THIS EDGE

RD98K315

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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LUBRICATION/FILTERS/FLUIDS

FLUIDS AND LUBRICANTS - 521D Engine Crankcase Oil Capacity - with filter change................................... 11.3 litres (12 U.S. Quarts) Specifications ............................................ See Engine Lubrication in this manual Cooling System Capacity ......................................................................... 34.1 litres (9.0 U.S. Gal.) Specifications .............................................. 50% water and 50% Ethylene Glycol Fuel Tank Capacity ....................................................................189.3 litres (50 U.S. Gallons Specifications ...........................................See Diesel Fuel System in this manual

Transmission Refill Capacity - with filter change ...................................7.8 litres (8 U.S. Quarts) Total System Capacity.................................................25.6 litres (27 U.S. Quarts) Specifications ............................................. Case No. 1 Engine Oil (SAE 15W-40) Axles: Front and Rear Capacity (each axle) .................................................20.4 liters (21.5 U.S.Quarts) The above amount includes Limited Slip additive ............... 2.4 liters (2.5 Quarts) Specifications ................................Case 135H EP gear lubricant (SAE 85W-140) Grease Fittings Quantity..............................................................................................As Required Specifications ............................................................. Case Molydisulfide Grease

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Hydraulic/Brake System Reservoir Refill Capacity with filter change............... 68.5 litres (18 U.S. Gallons) Total System Capacity............................................. 113.6 litres (30 U.S. Gallons) Specification..................................................................MS-1209, Hy-Tran Ultra

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

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176 Air Cleaner (See Note 1)

❉

190 Hydraulic Filter (See Note 2)

❉

221 Alternator Drive Belt

❉

221 Air Conditioning Compressor Belt (If Equipped)

❉

173 Engine Oil Level (See Note 3)

10

181 Radiator Coolant Level (See Note 4)

50

194 Transmission Oil Level (engine running oil warm)

50

189 Hydraulic Reservoir Fluid Level

50

162 Bucket Pivots

6

50

162 Front Drive Shaft Support Bearing

1

50

163 Steering Cylinder Pivots - Closed End

2

100

163 Steering Cylinder Pivots - Rod End

2

100

163 Loader Lift Arm and Cylinder Pivots

10

100

NOTE 1:Service the air filter elements if the air filter warning lamp illuminates.

NOTE 2:Service the hydraulic filters if the hydraulic filter lamp illuminates.

NOTE 3:Every 10 hours of operation or once each day, whichever comes first.

NOTE 4:Check the radiator coolant level if the cooling level warning lamp illuminates. ❉ - As Needed

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DRAIN WATERS

LUBRICATE

CLEAN

SERVICE POINTS

CHECK

NUMBER OF POINTS

PAGE NUMBER

FREQUENCY IN HOURS

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

174 Engine Oil (See Note 3 on Page 98)

DRAIN WATER

CLEAN

LUBRICATE

REPLACE

CHANGE

SERVICE POINTS

CHECK

NUMBER OF POINTS

250

174 Engine Oil Filter

250

221 Air Conditioning Compressor Belt (If Equipped)

250

226 Battery Fluid Level

500

145 Tire Condition and Air Pressure

250

199 Cab Air Filter (If Equipped)

250

186 Fuel Filter

500

185 Fuel Tank

500

218 ROPS and Seat Belt Mounting Bolts

500

190 Hydraulic Filters

1000

194 Transmission Filter (See Note 2)

1000

194 Transmission Oil (See Note 3 on Page 98)

1000

194 Transmission Breather

1000

163 Upper and Lower Chassis Pivots

2

1000

198 Front Axle Differential and Planetary Oil

1000

Axle Oil Level Front and Rear

250

NOTE 1:Use Case Filter A77659 NOTE 2:Replace the transmission filters if the transmission filter restriction warning lamp illuminates.

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PAGE NUMBER

FREQUENCY IN HOURS

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

197 Rear Axle Differential Oil and Planetary Oil

CLEAN

ADJUST

REPLACE

CHANGE

SERVICE POINTS

CHECK

NUMBER OF POINTS

PAGE NUMBER

FREQUENCY IN HOURS

1000

SM Turbocharger Mounting Bolt Torque

2000

189 Hydraulic Oil (See Note 3)

2000

182 Engine Coolant (See Note 1)

2000

176 Air Filter Elements

2000

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SM Engine Injectors (See Note 2)

6000

SM Fuel Pump (See Note 2)

6000 6000

NOTE 1:When you drain, flush, and refill the engine cooling system, install a new A77659 coolant filter.

NOTE 2:Contact your dealer.

NOTE 3:Or when ambient operating temperatures require.

SM - See Service Manual.

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LUBRICATION/FILTERS/FLUIDS

ACCESS DOORS

BD00M066

BD00M063

RAISE COOLING UNITS TO EXPOSE HYDRAULIC FILL CAP

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ENGINE ACCESS HOOD

BD00M059

RADIATOR AND HYDRAULIC FLUID ACCESS DOOR

BD00N055

HYDRAULIC FLUID

BD00M063

RADIATOR CAP

BD00M068

FUSE BOX AND CAB FILTER ACCESS DOOR

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 50 HOURS Z-Bar Linkage Use Case Molydisulfide Grease

1

1

1

B890716J

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1. Bucket and Bellcrank Pivot Points ................................................................ 6

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 100 HOURS Z-Bar Linkage

BC01A101

1.

2.

3.

4.

5.

6.

7.

8.

Loader Lift Arm Pivots ..........................................................2 (One each side) Lift Cylinders (Closed End) ...................................................2 (One each side) Steering Cylinders (Closed End, Remote)........................... 2 (One each side) Bucket Cylinder (Closed End)......................................................................... 1 Lift Cylinders (Rod End)........................................................2 (One each side) Front Driveshaft Support Bearing ................................................................... 1 Steering Cylinder (Rod End).................................................2 (One each side) Bucket and Bell Crank Pivot Points................................................................. 6

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Use Case Molydisulfide Grease

LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 1000 HOURS Z-Bar and XT Linkage Use Case Molydisulfide Grease

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2

1

BC00N081

1. Lower Chassis Pivot ....................................................................................... 1 2. Upper Chassis Pivot ....................................................................................... 1

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 50 HOURS XT Linkage Use Case Molydisulfide Grease

1

1

165

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907L92

1. Bucket and Bellcrank Pivot Points .............................................................. 10

LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 100 HOURS XT Linkage Use Case Molydisulfide Grease

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BC01A100

1. Loader Lift Arm Pivots ......................................................... 8 (Four each side) 2. Lift Cylinders (Closed End).................................................. 2 (One each side)

1

1 1

1

4 5

2

L917L92

3.

4.

5.

6.

7.

8.

Steering Cylinders (Closed End, Remote............................. 2 (One each side) Bucket Cylinder (Closed End, Remote) ................................ 2 (One each side) Lift Cylinders (Rod End) ....................................................... 2 (One sach side) Front Driveshaft Support Bearing (Remote) ................................................... 1 Steering Cylinder (Rod End)................................................. 2 (One each side) Bucket and Bell Crank Pivot Points .................................... 10 (Five each side) 166

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LUBRICATION/FILTERS/FLUIDS

FLUID LEVELS 10 Hours

1

RD98A190

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1. ENGINE OIL CASE NO. 1 ENGINE OIL (SAE 15W-40)

2

3

1

B910922J

2 3

BD00M062

RD98K315

2. RADIATOR COOLANT LEVEL ETHYLENE GLYCOL AND WATER

3. RADIATOR ETHYLENE GLYCOL AND WATER

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LUBRICATION/FILTERS/FLUIDS

50 Hours 4

5

4

RD98K299

4. HYDRAULIC RESERVOIR MS1209 HY-TRAN ULTRA

RD98A170

5. TRANSMISSION

5 TRIM THIS EDGE

4

B910922J

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LUBRICATION/FILTERS/FLUIDS

250 Hours

1

B1060A88

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1. BATTERIES DRINKING OR DISTILLED WATER (BOTH SIDES)

1

1 BX00N080

NOTE: One battery on each rear side of machine.

IMPORTANT: Machine may only be Jump Started from LEFT rear side.

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LUBRICATION/FILTERS/FLUIDS

1

BC00N081

1. One battery each side.

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LUBRICATION/FILTERS/FLUIDS

ENGINE LUBRICATION Engine Oil Selection Case No. 1 Engine Oil is recommended for use in your Case Engine. Case Engine Oil will lubricate your engine correctly under all operating conditions.

If Case Multi-Viscosity Engine Oil is not available, use only oil meeting API engine oil s er vice categor y CH- 4 (preferred) or CG-4

BP97H064

See the chart on following page for recommended viscosity at ambient air temperature ranges.

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

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RH99K130

LUBRICATION/FILTERS/FLUIDS

Oil Viscosity/Temperature Ranges

TRIM THIS EDGE BS99M162

NOTE: Use of an engine coolant heater may be required when operating temperatures are in Winter or Arctic conditions.

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below - 5°C (23°F). The continuous use of low viscosity oils can decrease engine life due to wear. See the chart above for the correct oil for ambient temperatures.

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LUBRICATION/FILTERS/FLUIDS

Engine Service Specifications Oil Level check interval ................................ Every 10 hours of operation or each day, whichever occurs first.

Oil Change interval .................................................. Every 250 hours of operation Oil filter change interval ........................................... Every 250 hours of operation or once a year whichever occurs first.

Oil type ....................................................... Case No. 1 Engine Oil (SAE 15W-40) Oil Capacity - with filter change ................................... 11.3 litres (12 U.S. Quarts)

To check the engine oil level put the machine on a level surface and stop the engine. Remove engine oil dipstick and wipe clean with a cloth. Replace dipstick in tube and push the engine oil dipstick completely DOWN and then remove. If the oil level is below the ADD mark, add oil to raise the oil level to the FULL mark.

BD00N068

ENGINE OIL LEVEL DIPSTICK

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Engine Oil Level

LUBRICATION/FILTERS/FLUIDS

Engine Oil Change and Filter Replacement Change the engine oil and replace the filter after every 250 hours of operation or once a year whichever occurs first.

NOTE: For more complete removal of foreign material, change the engine oil while the engine is still warm from operation.

IMPORTANT: You must shorten the oil change interval if you use diesel fuel with a sulphur content of more than 0.5%.

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

1. Before draining the oil, have a container that will hold at least 22.7 litres (6 US gallons).

2. Remove the engine oil drain plug.

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.

3. Open the rear engine access hood.

8. Install the drain plug.

TRIM THIS EDGE

9. See Engine Lubrication in this manual for the correct type and quantity of oil. Put new oil into the engine.

1 2 BD00M010

1. ENGINE OIL FILTER

4. Turn the oil filter counterclockwise to remove. Discard the oil filter.

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

BD00M031

2. ENGINE OIL DRAIN

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

7. Turn the new oil filter onto the base until the gasket makes contact with the base. Continue to tighten the filter for 3/4 turn with your hand.

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LUBRICATION/FILTERS/FLUIDS

BD00N069

BD00N069

1. ENGINE OIL FILLER PIPE

10. Fill the turbocharger oil lines with oil.

A. Disconnect the wire (Shown) from the injection pump solenoid. This will prevent the engine from starting.

B. Turn the key switch to the START and actuate the starter for 10 to 30 seconds.

C. Connect the wire to the injection pump solenoid.

!

11. Start the engine and run at idle speed. Check the engine oil filter for leaks. After two minutes, stop the engine, wait for 2 or 3 minutes, and check the engine oil level with the dipstick.

12. Close the engine access hood.

Systemgard Lubrication Analysis Program The normal engine oil change interval is every 250 hours of operation or once a y e a r w h i c h ev e r o c c u r s f i r s t .

Operating conditions, quality of the engine oil and sulphur content of the fuel can change this inter val. It is recommended to use the Systemgard Lubrication Analysis Program. See your dealer.

WARNING: Never drain oil or remove oil filter while engine is running.

CM107

!

WARNING: Replace all covers or guards after servicing or cleaning the machine. NEVER operate the machine with covers or guards removed.

CM115

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1. ELECTRICAL CONNECTOR

LUBRICATION/FILTERS/FLUIDS

AIR FILTER SYSTEM Service Specifications Air cleaner cap interval .............................................................................. As required Air filter element service interval Primary (Outer) Element ......Service the element if the air filter indicator lamp illuminates. Replace the element after three washings. Also, replace the element after 2000 hours of operation or each year, whichever occurs first.

Secondary (Inner) Element ............ Replace the element after the primary (outer) element has been cleaned three times, or after the primary element has been cleaned or replaced and the air filter indicator lamp is still illuminated with the engine running. Also, replace the element every 2000 hours or each year, whichever occurs first.

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The shelf life of a new air cleaner element is five years. DO NOT install a new element that is more than four years old. The date of manufacture is on the end cap of the element.

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LUBRICATION/FILTERS/FLUIDS

Dust Valve

Primary (Outer) Element 1. Open the hood and pull the yellow lock tab out.

Check the dust valve. Make sure there is no obstruction inside the valve.

BD00M009

2. Rotate the end counterclockwise to unlock.

cap

NOTE: If there is a large amount of dust inside the end cover, check aspirator check valve for proper operation

BD00M011

3. Carefully remove (outer) element.

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the

primary

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BD00M008

LUBRICATION/FILTERS/FLUIDS

BD00M012

BD00M012

4. Use a clean damp cloth and clean the inside of the filter body.

3. Use a clean damp cloth and clean the inside of the filter body.

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5. Install a clean or new primary (outer) element. Make sure the element has full gasket contact.

6. Install the end cover and rotate clockwise. Push the yellow lock tab in.

7. Close the engine hood.

8. Start the engine and check the air filter indicator lamp. If the air filter indicator lamp is still illuminated, replace the secondar y (inner) element.

Secondary (Inner) Element 1. Remove the primary (outer) element. See previous page.

RD007081

WARNING: Replace all covers or guards after servicing or cleaning the maching. NEVER operate the machine with covers or guards removed.

2. Remove the secondary (inner) element. Discard the secondary (inner) element.

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LUBRICATION/FILTERS/FLUIDS

Cleaning the Element

4. Use a water hose without a nozzle with pressure less than 40 psi (275 kPa, 2.8 bar) to remove all soap from the element.

Check the dirty element for damage and check the rubber seal on the end.

Push the rubber seal with your finger. If the rubber seal feels hard and does not move back to original shape, discard the element.

1. Wear face protection and remove the loose dirt with compressed air a t 3 0 p s i ( 2 0 7 k Pa , 2 . 1 b a r ) maximum. Hold the nozzle at least 1 inch (25 mm) from the element.

6. Use a light and inspect the element for holes or splits in the pleats.

Check for damage to the metal parts and rubber gasket. Replace the element if damaged.

777L94

2. Mix two tablespoons of D1400 detergent ( Case Par t Number A40910) with two gallons (7.6 litres) of water, one cup for 16 gallons (60 litres) water.

3. Soak the element in the soap solution for 15 to 20 minutes and then move the element up and down rapidly to loosen as much dirt as possible.

779L94

NOTE: If the element is not to be used for some time, cover the element with paper for storage.

780L94

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778L94

5. Allow the element to air dry. If you use a drier, do not exceed 160°F (71°C) and make sure the air is circulating in the drier.

LUBRICATION/FILTERS/FLUIDS

ENGINE COOLING SYSTEM Service Specifications Cooling System Capacity ................................................ 34.1 litres (9.0 U.S. Gal.) Cooling system drain, flush, and refill interval ....... Every 2000 hours of operation or each year, whichever occurs first.

Radiator Coolant Level Check Interval........................ Every 10 hours of operation

Thermostat Starts to open ................................................................................... 82°C (180°F) Completely open ............................................................................... 94°C (202°F) Radiator cap ............................................................ 103.4 kPa, 1 bar (15 psi)

Coolant Mixture TRIM THIS EDGE

A mixture of 50% Ethylene Glycol and 50% water must be used in this machine.

This mixture is used if the lowest ambient temperature is above -37°C- (34°F). If the ambient temperature is lower, adjust the mixture to 60% Ethylene Glycol and 40% water. It is recommended that Ethylene Glycol and water be used in your machine all year.

NOTE: After you fill the cooling system, mix the Ethylene Glycol and water completely by running the engine at operating temperature for approximately five minutes. This procedure must be done when the machine is in temperatures below 0°C (32°F).

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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.

SA023

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LUBRICATION/FILTERS/FLUIDS

Coolant Fluid Level The coolant fluid level is monitored at the instrument cluster. When the coolant level indicator illuminates, add coolant to the radiator as required to raise the coolant level.

BD00N044

RD98K316

Check the coolant reservoir fluid level when the coolant is cold and the engine is stopped. DO NOT remove the radiator cap during this check. The coolant level must be between the FULL and ADD marks on the reservoir. Add coolant as required to raise the coolant level to the FULL mark.

Radiator Fluid Level Check the radiator coolant level when the coolant is cold and the engine is stopped. Remove the radiator cap. The coolant level must be up to the radiator cap opening.

NOTE: If the radiator coolant level is low and the coolant reservoir level is at the FULL mark, check for air leaks in the hose between the radiator and coolant reservoir.

IMPORTANT: Only add the correct mixture of ethylene glycol and water to the radiator.

!

BD00N046

1. RADIATOR CAP

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.

SA023

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IMPORTANT: Cooling System is under pressure. Before adding coolant, allow radiator to cool and remove radiator cap SLOWLY.

LUBRICATION/FILTERS/FLUIDS

Cleaning the Cooling System Drain, flush, and replace the engine coolant every 2000 hours of operation or each year, whichever occurs first.

Clean the system and replace the coolant if the coolant becomes dirty or has the color of rust.

DO NOT remove the radiator cap if the coolant is hot.

1. Open the radiator drain valve and remove the radiator cap.

2. After all coolant is removed. Close the drain valves.

3. Add cleaning solution to the cooling system and fill the cooling system w i t h c l e a n w a t e r. Fo l l o w t h e directions included with the cleaning solution.

4. After you drain the cleaning solution flush with clean water and drain the water.

5. Replace the coolant filter with an A77659 coolant filter.

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6. Put a 50% mixture of Ethylene Glycol and water in the radiator.

See Coolant Mixture in this manual.

BD00M031

1. RADIATOR DRAIN VALVE

7. Start the engine and run at idle speed until the engine is at operating temperature. Check the instrument cluster monitor, if the monitor illuminates. Add coolant as required.

8. Install the radiator cap.

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LUBRICATION/FILTERS/FLUIDS

DIESEL FUEL SYSTEM Service Specifications Fuel Tank Capacity .................................................. 189.3 litres (50 U.S. Gallons) Interval for draining water from the fuel filter ....................... 50 hours of operation Fuel filter replacement interval .......................................... 250 hours of operation or once each year, whichever occurs first Adjust fuel injector .............................................................. see your CASE dealer Clean and calibrate fuel injectors and fuel pump ........ 6000 hours of operation or every 3 years, whichever occurs first.

Diesel fuel conditioner is available from your dealer. Follow the instructions on the can.

2. Disperse insoluble gummy deposits that can form in the fuel system.

The conditioner will:

3. Separate moisture from the fuel.

1. Clean the fuel injectors, valves and manifold for increased service life.

!

4. Stabilize the fuel in storage.

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

SA022

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WARNING: Never refuel the machine when the engine is hot or running.

Never smoke while refueling.

M139C

Fuel Filler Cap

BD00M036

139879A1

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Fuel Conditioner

LUBRICATION/FILTERS/FLUIDS

Diesel Fuel

Fuel Storage

Use No. 2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine power and high fuel consumption.

If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine problems are caused by water in the fuel.

In very cold temperatures, a mixture of N o. 1 a n d N o. 2 d i e s e l f u e l s i s temporarily permitted. See the following Note.

NOTE: See your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel lowers below the cloud point (wax appearance point), wax crystals in the fuel will cause the engine to lose power or not start.

Keep the fuel storage tank outside and keep the fuel as cool as possible.

R e m o ve w a t e r f r o m t h e s t o r a g e container at regular periods of time.

Fill the fuel tank at the end of the day to prevent condensation in the fuel tank.

When adding fuel to the machine, r e m o ve t h e f u e l c a p S L OW LY t o reduce the air pressure build up.

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The diesel fuel used in this machine must meet the specifications in the chart below or Specification D975-81 of the American Society for Testing and Materials.

Specifications for Acceptable No. 2 Diesel Fuel API Gravity, Minimum API Gravity, Minimum ..................................................... 34 Flash Point, Minimum ....................................................................... 60°C (140°F) Cloud Point (wax appearance point), Maximum ...... -20°C (-5°F) See Note Above Pour Point, Maximum ............................................ -26°C (-15°F) See Note Above Distillation Temperature, 90% Point ........................... 282 to 338°C (540 to 640F) Viscosity, at 38°C (100°F) Centistokes .......................................................................................... 2.0 to 4.3 Cetane Number, Minimum ...................... 43 (45 to 55 for winter or high altitudes) Water and Sediment, by Volume, Maximum ............................................... 0.05%

!

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

SA022

!

WARNING: Never refuel the machine when the engine is hot or running.

Never smoke while refueling.

M139C

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LUBRICATION/FILTERS/FLUIDS

Removing Water and Sediment from the Fuel System Drain the water for the fuel filter after every 50 hours of operation. Drain the water and sediment from the fuel tank after every 500 hours of operation.

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

2. Close the drain valve.

3. Use a large enough container and drain water and sediment from the fuel tank. Dispose of water and sediment properly.

BD00M022

1. WATER DRAIN

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1

LUBRICATION/FILTERS/FLUIDS

Fuel Filter Replace the fuel filter after every 250 hours of operation.

1. Clean the filter head and the outside of the fuel filter.

2. Turn the filter counterclockwise and remove the filter. Discard the filter.

3. Apply a thin layer of clean oil to the gasket on the new filter.

4. Install the filter. Use your hands to tighten the filter 1/2 to 3/4 turn after the filter makes contact with the filter head.

1

IMPORTANT: Do not use a filter wrench when installing a new filter.

RD98A218

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1. FUEL FILTER

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LUBRICATION/FILTERS/FLUIDS

In-Line Fuel Filter Replace the in-line fuel filter every 500 hours. To replace the filter do the following: 1. Loosen the nut or hose clamp (as equipped) at each end of the filter.

Remove the filter from the fuel line.

2. Install a new filter. Make sure the arrow on the filter points toward the primer pump.

3. Use the primer pump to prime the system. Check for leakage.

4. Start the engine and check again for leakage. and/or

BD00M091

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5. See Removing Water Sediment on Page 185.

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LUBRICATION/FILTERS/FLUIDS

HYDRAULIC/BRAKE SYSTEM Service Specifications Hydraulic/Brake System Fluid Chart Hydraulic Reservoir Refill Capacity w/filter change............ 68.5 Litres (18 gallons) Total System Capacity ...................................................... 113.6 Litres (30 gallons) Type of Fluid.....................................................................MS-1209, Hy-Tran Ultra® Hydraulic Reservoir Fluid Level Check Interval...............................Every 50 Hours Filter Replacement Interval ................................Every 1000 Hours of Operation or if the Hydraulic Filter Warning Lamp Illuminates Hydraulic Fluid Change Interval ..................................................Every 2000 Hours or once each year, whichever occurs first.

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!

WARNING: Pressurized hydraulic system. Before you replace the hydraulic filter or service the hydraulic system, wear face protection and slowly loosen the hydraulic reservoir fill cap to relieve the air pressure. If you do not follow these instructions, you can be injured.

SA047

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LUBRICATION/FILTERS/FLUIDS

Hydraulic Oil Level

3. Pivot the air conditioning condensor to the rear (if equipped).

Ensure that the cooler is locked open.

4. Clean the area around the filler cap.

To check the oil level in the hydraulic reservoir do the following: 1. Park the machine on a level s u r fa c e a n d l owe r t h e l o a d e r bucket to the ground. Apply the parking brake.

6. After oil has been added to the hydraulic reservoir, inspect the seal on the filler cap. Replace the seal as required.

7. Install the filler cap and hand tighten.

8. Repeat steps 2-3 in reverse order.

2. Stop the engine.

3. Check the oil level in the sight guage. If the oil is cold, the level is correct when the top of the float is aligned with the lower indicator mar k. If the oil is at operating temperature the level is correctwhen the top of the float is aligned with the upper indicator mark.

To add oil to the hydraulic reservoir do the following: 1. Ensure that the hood is closed and secured.

2. Open the access cover in the hood.

The release is in the center of the hood, directly behind the cab and can be accessed from the entry side platform.

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BD00N040

Check the oil level of the hydraulic reservoir every 50 hours of operation.

5. Slowly loosen the filler cap on the hy d r a u l i c r e s e r vo i r. T h i s w i l l release the air pressure in the hydraulic reservoir.Remove the f i l l e r c a p f r o m t h e hy d r a u l i c reservoir.

LUBRICATION/FILTERS/FLUIDS

Hydraulic Filters Replace the hydraulic filter every 1000 hours of operation or if the hydraulic oil filter LAMP illuminates.

RD98K317

BD00N081

Hydraulic Filter Replacement

To check the condition of the hydraulic filters do the following.

1. Park the machine on a level surface. Lower the loader bucket to the ground and stop the engine.

Apply the parking brake.

1. Start the engine. If the hydraulic oil is not at operating temperature or approximately 50°C (120°F) do the following.

2. Slowly loosen the filler cap on the hy d r a u l i c r e s e r vo i r. T h i s w i l l release the air pressure in the hydraulic reservoir.

Hydraulic Filter Test TRIM THIS EDGE

A. Dump the bucket and hold over relief while cycling the Lift arms up and down. It can take several minutes to bring the oil to operating temperature. Refer to instruction on the instrument c l u s t e r fo r u s i n g i t t o r e a d hydraulic oil temperature.

3. Remove the access cover.

4. Use a strap wrench to remove the o l d f i l t e r. Tu r n t h e f i l t e r counterclockwise to remove.

5. Lubricate the gasket on the new filter with MS-1209, Hy-Tran Ultra® fluid. Turn the new filter clockwise until the filter contacts the head of the filter assembly. Continue to tighten the filter 1/2 to 3/4 turn by hand.

B. After 15 seconds, move the c o n t r o l l ev e r t o t h e H O L D position.

C. Repeat steps a and b until the side of the hydraulic reservoir feels very warm.

IMPORTANT: DO NOT use a filter wrench to tighten the hydraulic filter.

2. Increase the engine speed to full t h r o t t l e . I f t h e L A M P fo r t h e hydraulic oil filters illuminates, replace both filters.

6. Tighten the filler cap.

7. Start and run the engine at approximately 1000 rpm. Check for oil leaks around each filter.

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LUBRICATION/FILTERS/FLUIDS 8. Stop the engine and check the hy d rau l i c oi l l evel . A d d o i l as required. See Hydraulic System in this manual fo r correct specifications.

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9. Install the access cover.

WARNING: Never drain oil or remove oil filter while engine is running.

SA047

WARNING: Replace all covers or guards after servicing or cleaning the machine. NEVER operate the machine with covers or guards removed.

SA047

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LUBRICATION/FILTERS/FLUIDS

HYDRAULIC/BRAKE OIL CHANGE Change the hydraulic/brake oil every 2000 hours of operation or one time each year, or when ambient operating t em p e r a tu r e s r e q u i r e, w hi c h eve r occurs first. When changing the hydraulic oil also replace the hydraulic oil filter.

1. Make sure the hydraulic oil is at operating temperature.

2. Park the machine on a level surface. Lower the loader bucket to the ground and apply the parking brake.

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3. Stop the engine. Put a DO NOT OPERATE tag on the steer ing wheel.

4. Make sure the accumulators are completely discharged. Push down and release the brake pedal a minimum of 30 times.

5. Cycle the pilot controller repeatedly for at least 30 seconds. Open the namual valve for the ride control and allow it to bleed for one minute or until the hiss of discharging oil cannot be heard.

6. Open the hydraulic reservoir remote drain over a container capable of holding 32 gallons. The remote drain is the rearmost of the three drains behind the left rear wheel.

9. Remove the access cover from the hydraulic reservoir and remove the suction screen. Turn the suction screen counterclock wise to remove.

10. Clean the inside of the hydraulic reservoir with clean cloths.

11. Install the access cover with a new seal and tighten the mounting bolt.

12. See Hydraulic System in this manual for the correct type and quantity of hydraulic oil. Put new oil into the reservoir.

13. Install the reservoir filler cap.

14. Start the engine and run at 1000 rpm. Check for oil leaks around the filters, access cover and the drain plug. When the balance pressure wa r n in g bu z zer s t op s m ak i n g noise, run the engine at 1500 rpm.

15. Bleed the brake system to remove old oil from the system. Remove a minimum of 1 Liter of oil from each bleed screw to make sure all old oil is removed from the system (See Bleeding the brake system in this manual).

16. Operate the loader controls several times to remove any air in the lines.

17. Lower the loader bucket to the ground and stop the engine. Check the hydraulic oil level.

18. Add oil as required.

7. Clean the area around the filler cap and access cover. Slowly remove the filler cap of the reservoir. This will remove the air pressure from the reservoir.

8. Replace the hydraulic oil filter.

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LUBRICATION/FILTERS/FLUIDS

TRANSMISSION Service Specifications Transmission refill capacity with filter ................................7.8 litres (8 U.S. Quarts) Total system capacity ....................................................25.6 litres (27 U.S. Quarts) Type of oil ................................................... Case No. 1 Engine Oil (SAE 15W-40) Oil lever check interval ............................................................................ 50 hours Filter replacement interval ............................ After the first 100 hours of operation and then every 1000 hours there after.

Breather cleaning interval ................................................................... 1000 hours Oil change interval ....................................... After the first 100 hours of operation and then every 1000 hours there after.

!

WARNING: Never drain oil or remove oil filter while engine is running.

CM107

IMPORTANT: Change the transmission oil and replace the filter after the first 100 hours of operation.

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IMPORTANT: If the machine is new or the transmission has been replaced or rebuilt, change the transmission oil and replace the filter after the first 100 hours of operation.

LUBRICATION/FILTERS/FLUIDS

Transmission Oil Level

Warm Oil Level Check

See this page for the two methods to check the transmission oil level.

Check the transmission oil level every 50 hours of operation when the oil is at operating temperature. Do the following.

Oil Change, Filter Replacement, and Breather Cleaning

BS00M474

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1. Park the machine on a level surface.

2. Apply the parking brake.

3. Shift the NEUTRAL.

transmission

to

Ch a n ge th e tra n s m i s s i on o il a n d replace the filter after the first 100 hours of operation with a new machine or if the transmission has been replaced or rebuilt. Then, do the above service and clean the breather every 1000 hours or operation.

If possible, drain the oil when the oil is at operating temperature. More contamination is removed when the oil is at operating temperature.

1. Put the transport/service link in the LOCKED position, apply the parking brake, and stop the engine.

4. Run the engine at idle speed.

5. If the oil level is at or below the bottom of the crosshatch region, put the transport/service link in the LOCKED position and add oil to raise the oil level up to the top of the crosshatch region. See Tr a n s m i s s i o n Service Specifications in this manual for the correct oil.

2. Clean the area around the filters, drain plug, breather, and filler tube.

3. Have a container that will hold approximately 30.3 litres (8 U.S. Gallons).

Cold Oil Level Check Before you start the engine, check the transmission oil level in the sight gauge. If the oil level is below the arrow, add oil to raise the oil level up to the arrow. See Transmission Service Specifications in this manual for the correct type of oil.

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LUBRICATION/FILTERS/FLUIDS 7. Install the filter as shown. Make sure the filter is SEATED against the filter base.

4. Remove the filler tube plug.

8. Spin the breather cap a few times w i t h y o u r f i n g e r ev e r y 1 0 0 0 hours.(It is located directly on top of the transmission.

9. If the breather cap does not spin easily perform lines 10 and 11.

11. Install the breather.

12. Install the drain plug. Put new oil into the transmission. See Tr a n s m i s s i o n Service Specifications in this manual.

13. Check the oil level in the sight gauge.

14. Start the engine and check for oil leaks around the filters and drain plug.

RB97G074J

1. DRAIN PLUG

2. O-RING

6. Remove the transmission filter.

Discard the old transmission filter.

15. Increase the transmission oil temperature to operating temperature and check the oil level again.

16. Stop the engine and return the transpor t/ser vice link to the OPERATING position.

BD00N081

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BD00M028

5. Remove the drain plug and drain the oil from the transmission.

10. Remove the breather. Clean the breather with solvent and dry with compressed air. Be sure to wear fa c e p r o t e c t i o n w h e n u s i n g compressed air.

LUBRICATION/FILTERS/FLUIDS

AXLES Service Specifications Front and Rear Axle Refill Capacity ........................................20.4 litres (21.5 qts.)

The above amount includes ...................2.4 litres (2.25 Qts) Limited Slip Additive.

Type of oil ............................................. Case 135H EP gear lube (SAE 85W-140) Alternate oil ............................................................................................. See note Oil change interval ................................... After the first 100 hours of operation and then every 1000 hours there after.

NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil.

Axle Oil Level TRIM THIS EDGE

To check the oil level at the center bowl and each planetary end, do the following procedure.

NOTE: The oil level and filler plugs in the center bowl and planetary ends are magnetic. Remove and clean these plugs after the first 50 and 100 hours of operation with a new or rebuilt axle.

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LUBRICATION/FILTERS/FLUIDS

Axle Planetary and Center Bowl 1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Remove the axle dipstick and check thelevel.

BD00N074

BD00M042

1. OIL LEVEL CHECK.

BD00N073

3. Add oil as required.

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IMPORTANT: Axle level must be checked by placing dipstick level in hole but not threading down.

LUBRICATION/FILTERS/FLUIDS

Axle Oil Change Change the axle oil every 1000 hours of operation.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

5. After removal of the oil install the center bowl drain plug.

6. Fill axle with new oil.

2. Clean the oil level and drain plugs.

3. With the oil warm from operation, remove the oil level dipstick.

BD00N073

3. AXLE DIPSTICK

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7. Check oil level by placing the d i p s t i ck i n t o t h e h o l e bu t n o t running the threads down.

BD00M043

1. CENTER BOWL DRAIN PLUG

4. Remove the drain plug from the axle center bow.Have a container with enough capacity to hold 20.3 L (21.5 qts).

BD00N074

4. AXLE DIPSTICK IN THE CHECK POSITION (THREADS NOT RUN DOWN)

8. Install and secure the dipstick.

BD00M096

2. WHEEL END DRAIN (ONE EACH SIDE)

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LUBRICATION/FILTERS/FLUIDS

CAB AIR FILTER Clean or replace the cab air filters (if equipped) every 250 hours of operation or if the air flow in the cab is reduced.

3. Install a filter that has been cleaned or a new filter.

NOTE: If your machine is new, make sure the plastic cover is removed from the filters.

Removal and Installation 1. Turn the handle and open the access door.

BD00M070

2. Pull the air filter out.

BD00M070

BD00M067

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RD98K285

4. Close the access door and turn the handle to the locked position.

LUBRICATION/FILTERS/FLUIDS

Circulation Cover

BD00N028

5. Remove the air circulation filter.

6. Install a filter that has been cleaned or a new filter.

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LUBRICATION/FILTERS/FLUIDS

Cleaning the Filter Check the dirty element for damage and check the rubber seal on the end.

Push the rubber seal with your finger. If the rubber feels hard and does not move back to original shape, discard the element.

3. Soak the element in the soap solution for 15 to 20 minutes and then shake the element up and down rapidly to loosen as much dirt as possible.

1. Remove the loose dirt with compressed air, 30 psi (207 kPa, 2 bar) maximum. Hold the nozzle at least one inch (25 mm) from the element. Make sure you wear face protection when using compressed air.

786L94

2. Mix two tablespoons of D1400 d et e r g e n t ( C a s e p a r t nu mb e r A40910) with two gallons (7.6 litres) of water, one cup for 16 gallons (60 litres) of water.

788L94

5. Allow the element to air dry. If you use a drier, do not exceed 160°F (71°C) and make sure the air is circulating in the drier.

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787L94

4. Use a water hose without a nozzle with pressure less than 40 psi (275 kPa, 2.7 bar) to flush all soap from the element.

LUBRICATION/FILTERS/FLUIDS 6. Use a light and inspect the element for holes or splits in the pleats.

Check for damage to the metal parts and rubber gasket.

789L94

NOTE: If the element is not to be used for some time, wrap the element with paper for storage.

WINDSHIELD WASHER RESERVOIR (IF EQUIPPED) TRIM THIS EDGE BD00N067

The windshield washer reservoir is located on the frame below the cab on the Right Hand side. To add washer fluid, pull the cap up.

IMPORTANT: When the ambient temperature decreases to 0°C (32°F) and below, always use an antifreeze type washer solution.

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MAINTENANCE/ADJUSTMENT

MAINTENANCE/ADJUSTMENT CAB SERVICE Air Conditioning The components of the operators cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

!

WARNING: Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions.

SA048

Condenser

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Lubrication of the Air Conditioning Compressor Seals Operate the air conditioning once every 250 hours to lubricate the compressor seals. Turn the air conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 32°F (0°C) put a c o v e r o ve r t h e a i r c o n d i t i o n i n g condenser. This will make sure the refrigerant and lubricants in the system will be at operating temperature.

BD00M063

1. CONDENSER AND FANS

Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the condenser. Also check and clean the grille screen.

IMPORTANT: Because the condenser fins bend easily, be careful when you clean the condenser.

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MAINTENANCE/ADJUSTMENT

Cab Headliner

Door Hinges

T h e fo a m h e a d l i n e r i n y o u r c a b decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

Use graphite to lubricate all hinges. DO NOT use oil.

IMPORTANT: DO NOT wash the headliner with water because water can cause damage to the headliner and lower the noise control capacity of the headliner.

Check all hoses and wiring for damage.

If damage occurred, see your dealer for repair or replacement.

Hoses and Wiring

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RD97F215

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MAINTENANCE/ADJUSTMENT

Operators Seat Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct use of a material cleaner.

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

!

WARNING: Never use gasoline, naptha or any other volatile material for any cleaning purposes. These materials may be toxic and/or flammable.

SA049

CLEANER FLUID - This type of cleaner can be used for grease or oil stains.

Carefully remove the item that caused the stain with a scraper or a knife that is not sharp. Use very little cleaner, no pressure, and clean cloths. Move the cloth from the outside of the stain toward the center of the stain and constantly change to a clean section of cloth.

NOTE: A difficult stain can need a second application of cleaner fluid followed immediately by the use of a soft brush to completely remove the stain.

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When the stain is removed from the material, immediately use a cloth to make dry the area and to prevent a cleaner circle pattern. If a circle pattern occurs, clean the complete area.

MAINTENANCE/ADJUSTMENT

TRANSMISSION CLUTCH CALIBRATION Tr a n s m i s s i o n c l u t c h c a l i b r a t i o n ensures optimum shifting of the transmission. Make sure of the fo ll owi n g b e for e p r o c ee d in g wi t h transmission clutch calibration.

●

The Modulation Cycle Number will be displayed in the 1st and 2nd spaces (2 00 XX - the XX represents the 1st and 2nd spaces).

●

During Clutch Calibration, the Clutch Calibration Main Code will change from 01 to 07 as the process is completed. The code 07 will indicate that the process is complete and the Information Center will return to normal working status.

●

If any of the Clutch Calibration parameters are incorrect, the display center will stop flashing and display the Clutch Calibration Main Code in the 1st, 2nd, 3rd, and 4th spaces.

A. The parking brake has been tested.

B. The transmission oil is warm.

C. The engine idle speed is correct.

D. The transmission is in neutral.

E. The parking brake is applied.

Do the following procedure to calibrate the transmission clutches:

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1. Put the transmission in the machine shift mode and the gear selector in 3rd gear neutral.

2. Press the program switch.

3. Press the up-count switch until the display reads 011.

4. Return the program switch to the center position.

5. Press the up-count switch twice so the display reads 02.

In the event, the code in the 3rd and 4th spaces will be 09 to 14 and will indicate the process that the calibration was in when it was aborted.

The 1st and 2nd spaces will produce the Clutch Calibration Sub-Code, which is the code that will inform the operator of the reason process was aborted.

At this time, 2 00 00 will begin flashing in the display center. ●

6. After completing the clutch calibration procedure, tur n the engine off for 15 seconds to set the calibration in the controller.

After one second, the Clutch Calibration Main Code status will be displayed in the 3rd and 4th spaces (2 XX 00 - the XX represents the 3rd and 4th spaces).

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MAINTENANCE/ADJUSTMENT

SECONDARY STEERING CHECK NOTE: Test the secondary steering a minimum of every 250 hours.

RD98K316

1. Prior to checking the secondary steering system, park the machine on hard packed level ground with en oug h c le aran ce a r oun d th e machine to allow you to completely steer from side to side. Raise the bucket approximately 500 mm (20 incees) above the ground.

2. With the key on and the engine off, confirm the secondary steering light within the cluster is on. This indicates the steering pressure is low.

3. Start the machine and let the engine r un for a few seconds.

Confirm the secondary steering light is out after the first second.

This confirms the electrical function of the circuit is operating correctly and also confirms pressure has been built and the module has been armed.

4. With the machine at low idle and steering straight ahead, turn the key switch to the OFF position to stop the engine and then immediately back to the ON position (not start position). The secondary steering pump/motor should start running immediately.

Confir m the light is on and the motor is running.

5. Steer the machine full left and then full right to confirm that the secondary steering pump is working. Confirm there is no lack ofsteering function.

WARNING: Do not run the secondary pump/motor continuously for more than 20 seconds at a time without a 2 minute cool down.

6. Look at the instrument cluster to verify that the secondary steering light comes on.

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The secondary steering system is electrically powered which allows you to steer the machine if the primary steering system stops working. Always maintain the batteries.

MAINTENANCE/ADJUSTMENT 7. Restart the engine. Confirm the secondary steering light stays on.

The secondar y steer ing motor should stop after about 3 seconds and the secondary steering light should go out.

8. If steps 2 through 7 function properly, the secondary steering is operating correctly. If not, repair and retest.

9. Let the engine run and allow the b a t t e r i e s t o r e c h a r g e fo r a minimum of 10 minutes.

C AU T I O N : D o n o t t u r n t h e d e y switch off if the machine is steered against either the right hand or left hand steering stop. The steering wheel may kick back.

PARKING BRAKE CHECK NOTE: Test the parking brake at a maximum of 250 hours.

Before you operate the machine periodically test the parking brake functions.

TRIM THIS EDGE RD98K316

1. To release the park brake, all the following are required:

2. To engage the park brake, any of the following is required:

A. Push the Park Brake switch to the release position.

A. Loss of service brake pressure in both axles.

B. Service brake depressed indicating brake lights.

B. Loss of system electrical power (key OFF).

C. Transmission shifter positioned from N to F or R for a second, and back to N.

C. Park Brake switch in engaged position.

D. Adequate service brake pressure to stop the machine.

3. To test these functions: A. Start on a clear level surface.

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MAINTENANCE/ADJUSTMENT B. With Step 1, A through C c o m p l e t e, s t a r t t h e e n g i n e release the par k brake, r ed warning light out.

4. Put the park brake switch in the release position, attempt B and C in Step 1. The park brake light must turn OFF,

C. Shutdown the engine turn the key switch to the ON position, engine off the Park Brake light should come ON.

A. Allow the machine to roll slowly forward with the transmission in F put the park switch to engage.

The machine must come to a stop immediately. Park light ON. Transmission disengages.

E. Pump the service brakes, the red warning light should come ON first. Continue to pump the service brakes. Pump until the brake light comes ON, pump the brakes three more times, it could require as many as forty pumps total.

If all steps are working positive the system works correct. If there was a problem with the test contact you dealer.

F. Start the engine and allow the brake pressure to build until the warning light goes out.

G. Depress the service brake and release. The light must stay ON. H. Put the transmission in F or R and back to N the brake light must stay ON. I. Put the park brake switch in the engaged position, attempt B and C in Step 1. The park brake light must stay ON.

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D. Release the park Brake using B and C in Step 1. Make sure the park brake light is out.

MAINTENANCE/ADJUSTMENT

LOADER ADJUSTMENTS Height Control and Return To Travel Adjustment Procedure 6 2

5

1

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4

3

BS00N076

1. Proximity Switch

4. Height Control Target

2. Return to Travel Target

5. Lift Arm

3. Target Mounting Plate

6. Front Chassis (Top Left Hand Side)

1. To avoid damage to the proximity switch, it must be adjusted back, away from the lift arm, to clear everything on the lift arm as it sweeps past.

2. Start the engine. Position the bucket flat on the ground. Shut the machine off.

Locate the return to travel target opposite the proximity switch and then tighten it to the target mounting plate. Next adjust the proximity switch out toward the target until and air gap of 3.5 to 5.0 mm (1/8 to 3/16 inch) is obtained. Lock the proximity switch in position with its jam nut. Torque the jam nut to 5 ft.lbs.

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MAINTENANCE/ADJUSTMENT

A

2

B

BS00N077

2.) Return to Travel Target 4.) Height Control Target

3. The Location of the height control target within its slot in the target mounting plate will determine the automatic stopping height of the lift arms as they are raised. The higher the target is positioned in its slot in the target mounting plate, the lower the lift arms will automatically stop as they are raised. Position the target per the table below. Tighten the target in this position.

APPROXIMATE RESULTING APPROXIMATE B mm (in) HEIGHT CONTROL HINGE PIN RESULTING REHEIGHT mm (in) TURN TO TRAVEL HINGE PIN HEIGHT

MACHINE

A mm (in)

521D Z-BAR

57 (2.24)

358 (14.09)

54 (2.12)

3302 (130)

521D XT

47 (1.85)

438 (17.24)

48 (1.88)

3302 (130)

4. The location of the return to travel target within its slot in the target mounting plate will determine where the lift arms will automatically stop while they are lowered. The higher this target is located in its slot in the target mounting plate the lower the lift arms will automatically stop as they are lowered. Position the target per the above table. Tighten the target in this position.

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4

MAINTENANCE/ADJUSTMENT 5. Make sure the proximity switch and all the mounting bolts are tight. Start the engine. Set the detent switch to the on position, and set the return to travel/ float detent switch to the return to travel position. Raise the lift arms to approximately the horizontal position. Put the loader control lever in the raise position, and verify that the electromagnet holds it in that position until the height control target passes in front of the proximity switch. Next, with the lift arms still raised, put the loader control lever in the lower position, and verify that the electromagnet holds it in that position until the return to travel target passes in front of the proximity switch. Position the bucket flat on the ground.

Shut the machine off.

XT Return To Dig Adjustment Procedure 1 2 TRIM THIS EDGE

6

5 3 4

BS00N078

1. Tilt Cylinder (Left Hand Side)

4. Target Bar

2. Proximity Switch Mounting Bracket

5. Proximity Switch

3. Proximity Switch Guard

6. Target Mounting Bracket

1. Start the engine. Raise the lift arms until they are approximately horizontal.

Roll the bucket all the way back. Lower the arms until they are on the ground.

Shut the machine off.

2. Loosen the bolts holding the target mounting bracket to the tilt cylinder clevis.

Align the target mounting bracket parallel to the tilt cylinder, and tighten the bolts.

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MAINTENANCE/ADJUSTMENT 3. Loosen the bolts holding the target bar to the target mounting bracket. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

4. Loosen the bolts holding the proximity switch mounting bracket to the cylinder. Position the proximity switch face parallel to the target bar surface, and tighten the bolts. Next adjust the proximity switch out toward the target bar until and air gap of 3.5 - 5.0 mm (1/8 - 3/16 inch) is obtained. The proximity switch must not protrude past the proximity switch guard. Lock the proximity switch in position with its jam nut. Torque the jam nut to 5.0 ft. lbs.

5. Start the engine. Position the bucket flat on the ground. Shut the machine off.

Loosen the bolts holding the target bar to the target mounting bracket. Slide the target bar away from the proximity switch until the face of the proximity switch is completely uncovered. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

7. Loosen the bolts holding the target bar to the target mounting bracket. Slowly slide the target bar towards the proximity switch. When the proximity switch face is nearly covered by the target bar, the switch will be activated, and the control lever will return to the center position. Tighten the bolts maintaining this location of the target bar. Verify that the 3.5 to 5.0 mm (1/8-3/16 inch) gap is maintained between the target bar and the proximity switch.

8. Make sure the proximity switch and all the mounting bolts are tight. Start the engine. Set the detent switch to the on position, and set the return to travel/ float detent switch to the return to travel position. Raise the lift arms to approximately the horizontal position. Position the bucket to the fully dumped position. Put the loader control lever in the roll back position, and verify that the electromagnet holds it in that position until th end of the target bar passes in front of the proximity switch. Lower the lift arms to the ground, and verify the bucket is flat on the ground.

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6. Turn the ignition switch to the on position (not accessory position). Do not start the engine. Position the bucket control lever to the full roll back position.

The electromagnetic detent should hold the control lever in this position.

MAINTENANCE/ADJUSTMENT

Z-Bar Return To Dig Adjustment Procedure

1 3

2

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7 5

4

6 BS00N079

1. Bell Crank

4. Proximity Switch Guard

2. Target Mounting Bracket

5. Proximity Switch

3. Tilt Cylinder

6. Proximity Switch Mounting Bracket 7. Target Bar

1. Start the engine. Raixe the lift arms until they are approximately horizontal.

Fully dump the bucket. Lower the arms until bucket edge is on the ground.

Shut the machine off.

2. Loosen the bolts holding the target mounting bracket to the tilt cylinder eye.

Align the target mounting bracket parallel to the tilt cylinder, and tighten the bolts.

3. Loosen the bolts holding the target bar to the target mounting bracket. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

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MAINTENANCE/ADJUSTMENT 4. Loosen the bolts holding the proximity switch mounting bracket to the tilt cylinder. Position the proximity switch face parallel to thje target bar surface, and tighten the bolts. Next adjust the proximity switch face parallel to the target bar surface, and tighten the bolts. Next adjust the proximity switch out toward the target bar until an air gap of 3.5 to 5.0 mm (1/8 to 3/ 16 inch) is obtained. The proximity switch must not protrude past the proximity switch guard. Lock the proximity switch in position with its jam nuts. Torque the jam nut to 5.0 ft lbs.

5. Start the engine. Position the bucket flat on the ground. Shut the machine off. Loosen the bolts holding the target bar to the target mounting bracket.

Slide the target bar towards the proximity switch until the face of the proximity switch is com0letely covered. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

7. Loosen the bolts holding the target bar to the target mounting bracket.

Slowly slide the target bar away from the proximity switch. When the proximity switch face is nearly uncovered, the switch will be activated, and the control lever will return to the center position. Tighten the bolts maintaining this location of the target bar. Verivy that the 3.5 to 5.0 mm (1/ 8 to 3/16 inch) gap is maintained between the target bar and the proximity switch.

8. Make sure the proximity switch and all the mounting bolts are tight. Start the engine. Set the detent switch to the on position, and set the return to travel/float detent switch to the return to travel position. Raise the lift arms to approximately the horizontal position. Position the bucket to the fully dumped position. Put the loader control lever in the roll back position, and verify that the electromagnet holds it in that position until the end of the target bar passes in front of the proximity switch. Lower the lift arms to the ground, and verify the bucket is flat on the ground.

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6. Turn the ingition switch to the on position (not accessory position). Do not start the engine. Position the bucket control lever to the full roll back position. The electromagnetic detent should hold the control lever in this position.

MAINTENANCE/ADJUSTMENT

Bucket Height Control Minor Adjustment 1. Park the machine on a level surface. Lower the loader bucket to the floor.

2. Apply the parking brake and stop the engine.

3. Loosen the rear actuator.

4. To increase the dump height, move the actuator down in the slot. To decrease the dump height, move the actuator up.

5. Tighten the actuator.

6. Start the engine and pull the lift control lever to the RAISE detent position.

When the loader arms stop moving, check the dump height.

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MAINTENANCE/ADJUSTMENT

ROLL-OVER PROTECTIVE STRUCTURE Yo u r m a c h i n e h a s a R o l l - O v e r Protective Structure (ROPS). A ROPS label shows the serial number of the ROPS, gross weight, appr oval, regulation, and model numbers of the machine. See Identification Numbers in this manual.

5. Do not put the seat belts in bleach or dye. You will make the seat belts weak.

Maintenance and Inspection of ROPS After the first 20 hours of operation and after every 500 hours of operation, do the following: 1. Check the torque of the ROPS m o u nt i n g b o l t s. I f n e c e s s a r y, tighten the bolts to the correct torque. See torque specifications on this page.

RD98K304

ROPS CANOPY LABEL

Seat Belt The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

2. Check the operators seat and the mounting parts for the seat belt.

Tighten the bolts to the correct torque. See Torque Specifications in this manual. Replace 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.

1. Keep the seat belts away from objects that can damage the seat belts.

2. Check the seat belts for damage.

Replace all par ts that are damaged.

3. Make sure that the mounting bolts of the seat belts are tight. See Torque Specifications for Seat in this manual.

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Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

4. Keep the seat belts clean. Wash the seat belts only in soap and water.

MAINTENANCE/ADJUSTMENT

Torque Specifications for ROPS Cab and ROPS Canopy

BD00M101

ROPS CAB AND ROPS CANOPY MOUNTING BOLTS (BOTH SIDES), TIGHTEN TO 772 TO 854 Nm (580 TO 630 POUND-FEET)

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NOTE: Torque specifications are for clean, dry threads.

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MAINTENANCE/ADJUSTMENT

Damage to the ROPS If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transpor t), you must replace the damaged ROPS components to get as much protection as you had originally.

After an accident, check the following for damage.

C. Seat belt mounting bolts and seat belt.

Be for e you ope ra te t he mac hin e, replace all ROPS components that are damaged.

See the Parts Catalog or your dealer for components that are replaceable.

D O N OT T RY TO W E L D O R STRAIGHTEN THE ROPS.

A. ROPS canopy or cab.

!

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 Case parts catalog for this machine SA029

!

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

SB026

!

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

!

WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label SA028

!

WARNING: Always fasten the seat belt securely before starting the engine SA036

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B. Operators seat.

MAINTENANCE/ADJUSTMENT

TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS 1

2

1 TRIM THIS EDGE 6397

1. 54-61 NM (40-45 FT LB) 2. 73-87 MN (54-64 FT LB)

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MAINTENANCE/ADJUSTMENT

ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT Service Interval Belt service interval .................................................................... Check as required Air conditioning compressor belt service interval ................Check every 250 hours 1. Park the machine on a level surface and apply the par king brake.

2. Turn the master disconnect to OFF.

4. Push the breaker bar forward just enough to release the tension on the drive belt. Remove the drive belt from the water pump pulley first and then from the other pulleys.

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3. Install a 1/2 inch breaker bar in the tension pulley bracket.

MAINTENANCE/ADJUSTMENT

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) Type of Fire Extinguisher It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Cl as s A , B and C ty pe fi r es. Th e operating temperature is from -65° to 120°F (-54° to 49°C).

Inspection and Care EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to i n s ur e t h at t he g a ug e i s wor k i n g correctly.

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EVERY 6 MONTHS - Have the dr y chemical removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

153L95

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS or FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

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MAINTENANCE/ADJUSTMENT

SPARK ARRESTING MUFFLER (IF EQUIPPED) Cleaning

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

The spark arresting muffler must be cleaned by removing the loose carbon in the muffler after every 250 hours of operation.

1. Place the transmission shift lever in the NEUTRAL position and engage the park brake.

2. Clean all debris from the machine.

5. Install the plug in the muffler.

6. Clean debris from the machine.

NOTE: Replacement plug (if required) must be of brass material.

WARNING: Exhaust surfaces may be HOT if the engine has been operatedrecently. Be careful not to touch the exhaust serfaces while cleanig the muffler.

M789

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!

4. Start the engine and run for 2 to 3 minutes while debris is ejected from the muffler.

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MAINTENANCE/ADJUSTMENT

NOTES

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ELECTRICAL SYSTEM Battery Safety !

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

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.

!

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: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (1) battery cable first.

2. When you connect the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

SB034

BATTERY SERVICE NOTE: The electrical system in this machine is 24 volts. Each battery is 12 volts.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Before you use an electric welder, disconnect the alter nator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

Do not run the engine with the battery c a bl e s d i s c o n n e c t e d o r w i t h t h e alternator wires disconnected.

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SB032

ELECTRICAL SYSTEM

Battery Fluid Level Check the fluid level of the batteries every 250 hours of operation. If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

IMPORTANT: If the temperature is 32°F (0°C) or below and you have added water to the batteries, do the following; Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

Battery Vents Keep the battery vents clean, make sure the vents are not restricted.

Cleaning the Batteries Check the batteries regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries. Use one of the following methods to clean the batteries.

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1. Use Case Battery Saver, Part Number M20376. Follow the instructions on the container. This cleaner does not need water.

2. Use baking soda or ammonia and flush the outside of the batteries with water.

If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

BS00N080

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ELECTRICAL SYSTEM

FUSES The fuses in this machine are blade type. To replace, pull the old fuse straight out and push the new fuse straight in. The amperage for each fuse is stamped on the fuse. Refer to the fuse panel decal for correct location of each fuse.

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RD97F154

BS00J105

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ELECTRICAL SYSTEM

REPLACEMENT FUSES FUSE

AMP

FUNCTION

A

7.5

TRANSMISSION CONTROL

B

5

FLASHER MODULE

C

5

RIDE/PILOT CONTROL

D

5

PARKING BRAKE

E

10

ETHER START

F

5

ENGINE SHUTDOWN

G

15

BLOWER SWITCH

H

5

BACK UP ALARM

J

10

FRONT WIPER/WASHER

K

10

REAR WIPER/WASHER

L

7.5

RADIO/CONVERTER

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M

7.5

SECONDARY STEERING

N

10

COMPRESSOR (SEAT)

P

7.5

COUP;ER

R

7.5

SECONDARY STEERING

S

5

T

7.5

TRANSMISSION CONTROL

INSTRUMENT CLUSTER

U

7.5

DOME LAMP-ENG COMP-HORN

V

7.5

VOLTMETER

W

15

CIGARETTE LIGHTER

X

7.5

BEACON

10

FRONT FLOOD LIGHTS

Y Z A’

10

REAR FLOOD LIGHTS

B’

5

HIGH BEAM LEFT

C’

5

HIGH BEAM RIGHT

D’

5

LOW BEAM LEFT

E’

5

LOW BEAM RIGHT

F’

5

LEFT TAIL LIGHTS

G’

5

RIGHT TAIL LIGHTS

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ELECTRICAL SYSTEM

SERVICE ELECTRICAL CONNECTOR The cigar lighter socket (24 volt) can be used for the connection of a lighting d ev i c e t o h e l p w i t h s e r v i c e a n d maintenance procedures.

NOTE: This is a 24 volt outlet.

BD00B030

AUXILIARY POWER OUTLET (IF EQUIPPED) TRIM THIS EDGE

The Auxiliary Power Outlet socket (12 volt) can be used for the connection of a lighting device to help with service and maintenance procedures.

NOTE: This is a 12 volt outlet.

BD00B003

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ELECTRICAL SYSTEM

AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION The auxiliar y power equipment mounting brackets are located behind the right and left ROPS post covers.

Th es e b ra cke ts a r e fo r m o un ti n g radios, phones, etc.

To locate the bottom of the mounting bracket measure 300 mm (11.8 inches) from the bottom edge of the plastic p a n e l . To l o c a t e t h e t o p o f t h e mounting bracket measure 420 mm (16.5 inches) from the bottom edge of the plastic panel. The mounting bracket is approximately 70 mm (2.75 inches) wide.

1

BD00B009

1. RIGHT ROPS POST COVER

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ELECTRICAL SYSTEM

REPLACEMENT BULBS CASE PART NUMBER

INDUSTRY NUMBER

HEADLAMP HIGH BEAM

410942A1

H3

HEADLAMP LOW BEAM

410941A1

H7

STOP/TURN/REVERSE

410939A1

S8

TAIL LAMP

411085A1

R10W

POSITION

410940A1

T4W Osvam 6429

DOME LAMP

395185A1

CONSOLE LAMP

---

464

*Rotating Beacon

A187543 (Halogen)

----

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* DO NOT touch the new halogen bulb with your fingers. Use gloves or use a tissue to hold the bulb.

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ELECTRICAL SYSTEM

NOTES

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MACHINE STORAGE Storage Preparation

1. Wash the machine.

2. Lubricate the machine at all grease fittings.

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

4. Move all hydraulic controls to relieve any pressur e in the hydraulic circuits.

5. Drain the fuel tank.

6. Put approximately 8 litres (2 U.S. Gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue-white.

7. Drain the flushing oil from the fuel tank.

8. Put 15 ml (one tablespoon) of Shell Oil Company VPI crystals in the fuel tank.

10. Drain the cooling system. Leave the drain open and do not tighten the radiator cap. Put a Do Not Operate tag in the cab.

11. Clean or replace the element for the air filter.

primary

12. Cover the exposed steering cylinder rods, equipment valve spools with Case Rust and C o r r o s i o n P r eve n t a t i ve ( Pa r t Number B17510).

13. Charge the batteries. Remove the batteries from the machine and put the batteries on a wooden pallet in a cool dry area. If possible, keep the batteries in a building where the temperature is above freezing (0°C [32°F]). Make sure the batteries are clean.

NOTE: Always wear face protection when checking batteries. Check the batteries periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the batteries.

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If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

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

MACHINE STORAGE

Removal from Storage Do not start the engine until steps 1 through 10 have been done.

9. Use petroleum base solvent and remove the Case Rust and Corrosion Preventive from the hydraulic cylinder rods.

1. Change the fuel filter.

2. Put coolant in the engine cooling system.

3. Check the condition of the drive belts. Replace if required.

10. See Battery Service in this manual and install the batteries.

11. Fill the fuel tank.

12. Prime the turbocharger with clean e n g i n e o i l . S e e yo u r S e r v i c e Manual or your dealer.

4. Check the engine oil level.

5. Check the hydraulic oil level.

6. Check the transmission oil level.

7. Check the oil level of both axles.

8. Lubricate the machine at all grease fittings.

13. Start the engine. It is important that you use the Star ting the Engine p r o c e d u r e i n t h i s m a n u a l fo r priming the turbocharger lines with oil.

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SPECIFICATIONS

SPECIFICATIONS Make and model .......................................................................... Case 4T AA-390 Air Induction ......................................Turbocharged and Intercooled Turbocharged Bore and stroke ........................................................ 102 x 120 mm (4.02” x 4.72”) Displacement ................................................................. (3.9 Liters) (238 cu inch) Compression ratio ..................................................................................... 17.8 to 1 Horsepower SAE gross ........................................ 88.0 kW at 2000 r/min (118 at 2000 rpm) SAE net ............................................ 82.0 kW at 2000 rpm (110 at 2000 rpm) Engine speeds Idle speed ................................................................................ 875 to 925 rpm Hydraulic Stall ...................................................................... 2120 to 2260 rpm Converter Stall ..................................................................... 2040 to 2240 rpm Combined Hydraulic and Converter Stall ............................ 1555 to 1790 rpm Valve Clearance (Engine Cold) Intake Valves ............................................................... 0.254 mm (0.010 inch) Exhaust Valves ............................................................. 0.508 mm (0.020 inch)

TRAVEL SPEEDS (521D with 15.5 x 25 Tires) FIRST km/h

(mph)

SECOND km/h

THIRD

(mph)

km/h

FOURTH

(mph)

km/h

(mph)

Forward

6.6

(4.1)

12.9

(8.0)

22.9

(14.2)

37.2

(23.1)

Reverse

7.0

(4.3)

13.5

(8.4)

24.0

(14.9)

-----

-----

Buckets DESCRIPTION

WIDTH

CAPACITIES SAE Heaped

WEIGHT

Struck

m3

yd3

m3

yd3

kg

lbs (1 704)

General Purpose

2540 mm (100 inch)

1.72

(2.25)

1.51

(1.98)

773

General Purpose

2616 mm (103 in)

1.91

(2.50)

1.64

(2.15)

920

(2 029)

Material Handling

2600 mm (102.4 in)

2.10

(2.75)

1.79

(2.34)

799

(1 762)

4-in-1

2540 mm (100 in)

1.53

(2.00)

1.35

(1.77)

1 236

(2 724)

XT Attachment

2616 mm (103 in)

1.72

(2.25)

1.48

(1.94)

1 257* (2 771*)

XT Attachment

2616 mm (103 in)

1.91

(2.50)

1.71

(2.24)

1 325* (2 921*)

*Weight includes coupler

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ENGINE DATA - 521D

SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

A D B

E H

C

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G

F

Machines with 1.53 m3 (2.0 yd3) General Purpose Bucket W/Bolt-On Edge A. B. C. D. E. F. G. H.

521DPROFILE

Tipping load, machine straight ......................................... 7 863kg (17 335lbs) Tipping load, 40 degree turn ............................................ 6 596kg (14 541lbs) Overall operating height, fully raised ............................... 4 606 mm (181.4 in) Height to bucket hinge pin, fully raised ............................ 3 610mm (142.1 in) Dump height, 45 degree dump, full height ....................... 2 713mm (106.8 in) Dump angle at full height ................................................................ 45 degree Bucket reach, 45 degree dump, full height .......................... 887 mm (34.9 in) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height .............................................. 1 318 (51.9 in) Wheel Base ...................................................................... 2 750 mm (108.3 in) Overall Length .................................................................. 6 561 mm (258.3 in) Overall height to top of ROPS cab.................................... 3 173 mm (124.9 in)

Specifications taken with 17.5 R25 XTLA tires, ROPS cab with heater and air conditioning, 1 088 kg (2400 lb) rear counterweight, fenders, standard batteries, lamps, full fuel tank, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234,J695,J742 and J818.

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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

A D B

E H

G

F

Machines with 1.72 m3 (2.25 yd3) General Purpose Bucket W/Bolt-On Edge A. B. C. D. E. F. G. H.

521DPROFILE

Tipping load, machine straight ....................................... 7 738 kg (17 060 bs) Tipping load, 40 degree turn .......................................... 6 483 kg (14 293 bs) Overall operating height, fully raised ................................ 4 686 mm (184.5 in) Height to bucket hinge pin, fully raised ........................... 3 610 mm (142.1 in) Dump height, 45 degree dump, full height ...................... 2 660 mm (104.7 in) Dump angle at full height ................................................................ 45 degree Bucket reach, 45 degree dump, full height .......................... 932 mm (36.7 in) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ....................................... 1 334 mm (52.5 in) Wheel Base ...................................................................... 2 750 mm (108.3 in) Overall Length .................................................................. 6 636 mm (261.3 in) Overall height to top of ROPS cab.................................... 3 173 mm (124.9 in)

Specifications taken with 17.5 R25 XTLA tires, ROPS cab with heater and air conditioning, 1 088 kg (2400 lb) rear counterweight, fenders, standard batteries, lamps, full fuel tank, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234, J695,J742 and J818.

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C

SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

A D B

E H

C

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G

F

XT Machines with 1.53 m3 (2.0 yd3) Bucket ACS Pro-Series 2000 Size 30 Coupler A. B. C. D. E. F. G. H.

521DPROFILE

Tipping load, machine straight ....................................... 6 112 kg (13 475 lbs) Tipping load, 40 degree turn .......................................... 5 081 kg (11 201 lbs) Overall operating height,(spillguard)................................. 4 940 mm (194.5 in) Height to bucket hinge pin, fully raised ........................... 3 769 mm (148.4 in) Dump height, 45 degree dump, full height ...................... 2 815 mm (110.8 in) Dump angle at full height ................................................................ 45 degree Bucket reach, 45 degree dump, full height ........................ 1 253 mm (49.3 in) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ....................................... 1 687 mm (66.4 in) Wheel Base ..................................................................... 2 750 mm (108.3 in) Overall Length ................................................................. 6 857 mm (270.0 in) Overall height to top of ROPS cab.................................... 3 173 mm (124.9 in)

Specifications taken with 17.5 R25 XTLA tires, ROPS cab with heater and air conditioning, 1 088 kg (2400 lb) rear counterweight, fenders, standard batteries, lamps, full fuel tank, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234, J695, J742 and J818.

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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

A D B

E H

G

F

XT Machines with 1.90 m3 (2.5 yd3) Bucket ACS Pro-Series 2000 Size 30 Coupler A. B. C. D. E. F. G. H.

521DPROFILE

Tipping load, machine straight ....................................... 6 226 kg (13 725 lbs) Tipping load, 40 degree turn .......................................... 5 198 kg (11 459 lbs) Overall operating height, (spillguard) ................................ 4 940 mm (194.5 in) Height to bucket hinge pin, fully raised ........................... 3 769 mm (148.4 in) Dump height, 45 degree dump, full height ...................... 2 733 mm (107.6 in) Dump angle at full height ................................................................ 45 degree Bucket reach, 45 degree dump, full height ........................ 1 253 mm (49.3 in) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ....................................... 1 732 mm (68.2 in) Wheel Base ..................................................................... 2 750 mm (108.3 in) Overall Length ................................................................. 6 974 mm (274.6 in) )Overall height to top of ROPS cab................................... 3 173 mm (124.9 in)

Specifications taken with 17.5 R25 XTLA tires, ROPS cab with heater and air conditioning, 1 088 kg (2400 lb) rear counterweight, fenders, standard batteries, lamps, full fuel tank, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234, J695, J742 and J818.

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C

SPECIFICATIONS

Z-Bar Machines with 48” ACS Forks w/ Series 30 Coupler Fork Tine Size......................................... 64 x 152 x 1219 mm (2.5” x 6” x 48”) Maximum Fork Width.......................................................1 372 mm (54.0 inch) Maximum Fork Clearance..................................................... 3.6 m (11 ft 10 in) Fork Reach at Full Height - Vertical....................................... 628 mm (24.7 in) Fork Clearance at Maximum Reach ......................................... 1.8 m (6 ft 0 in) Maximum Fork Reach......................................................... 1 721 mm (67.8 in) Fork Reach at Ground - Vertical ........................................... 704 mm (27.7 in) Fork Load Center...................................................................... 610 mm (24 in) Weight (Fork Attachment, Forks and Coupler) .....................776 kg (1 711 lbs) Operating Load................................................................. 2 442 kg (5 383 lbs) Tipping Load (Straight) .................................................... 5 806 kg (12 801lbs) Tipping Load (40 degree Turn) ........................................4 884 kg (10 766 lbs) Unit Operating Mass ........................................................ 9 870 kg (21759 lbs)

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SPECIFICATIONS

WEIGHTS - 521D Z-BAR Operating Weights with Machine Straight Bucket on Level Ground with 2.0 yd Bucket with edge

FRONT AXLE

REAR AXLE

TOTAL

3 763 kg (9 297 lbs)

6 035 kg (13 306 lbs)

9 799 kg (21 603 lbs)

WEIGHTS - 521D XT

with 2.0 yd Bucket with edge

FRONT AXLE

REAR AXLE

TOTAL

4 490 kg (9 898 lbs)

5 789 kg (12 762 lbs)

10 278 kg (22 660 lbs)

NOTE: Machine weights taken with 15.5 x 25 XTLA Radial tires; ROPS cab with heater and air conditioning; fenders; standard batteries; lamps; full fuel tank; 1 088 kg (2 400 lb) standard counterweight; 79 kg (175 lb) operator and standard equipment.

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Operating Weights with Machine Straight

SPECIFICATIONS

Weight Adjustments for Optional Equipment 521D Z-Bar ITEM

POUNDS

(kg)

-224

-111

-104

-47

-118

-54

58

26

-140

-64

68

31

224

101

-295

-134

15.5 x 25, L2 15.5 x 25, L3 15.5 R 25, XTLA 15.5 R 25, XHA 17.5 x 25, L2 17.5 x 25, L3 17.5 R 25 XHA ROPS Canopy

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Weight Adjustments for Optional Equipment 521D XT ITEM

POUNDS

(kg)

15.5 x 25, L2

-244

-111

15.5 x 25, L3

-104

-47

15.5 R 25, XTLA

-118

-54

15.5 R 25, XHA

58

26

17.5 x 25, L2

-140

-64

17.5 x 25, L3

68

31

17.5 R 25, XHA

224

101

The use of rear tire ballast is not permitted.

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SPECIFICATIONS

SPECIAL BOLT TORQUES (521D)

NOTE: All bolt torques are listed with dry threads. * See Wheel Nut Torque in this manual.

** No Impact Tools

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POUND-FOOT (44 to 51) (7.5 to 8.3)

(625 to 700) (185 to 205) (42 to 48) (52 to 58) (570 to 630) (73 to 94) (704 to 793) (510 to 575) (39 to 46) (42 to 48) (180 to 220) (28 to 31) (18 to 20) (52 to 58) (250 to 275) (175 to 225) (480 to 540) (17 to 20) (245 to 275) (25 to 32) (175 to 190) (480 to 540) (15 to 18)

(215 to 275) (30 to 35) (655 to 735) (185 to 235) (355 to 435) (4) (25 to 30) (45 to 60) (475 to 530)

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Nm Alternator Pulley ** ............................................................. 60 to 70 Air Cleaner Hose-Turbo Clamps .................................. 10.1 to 11.3 Articulation Mounting Pin Retainer Bolt .....................See ES-FA30 Articulation Pivot Pin Bolts ........................................See ES-FA30 Axle Mounting Bolts (Front) ............................................ 845 to 950 Axle Mounting Bolts (Rear) .......................................... 251 to 280 Brake Pump to Engine Mounting ....................................... 57 to 65 Brake Pump Gear Nut ** .................................................... 71 to 79 Cab and Canopy Mounting Bolts (2) .............................. 773 to 854 CAC Hose Clamps ..................................................... See INF7888 Carrier Bearing Mounting Bolts ........................................ 99 to 128 Counterweight Bolts .................................................... 955 to 1075 Counterweight Studs ...................................................... 693 to 780 Coupling to Flywheel ........................................................ 53 to 62 Drive Shaft to Coupling .................................................... 58 to 65 Engine (rubber ISO) Mounts (3) ..................................... 244 to 298 Exhaust Stack to Hood Bolts ............................................. 38 to 42 Fan to Fan Coupler .................................................................... 24 Fan Coupler to Shaft ** .............................................................. 74 Front Drive Shaft Yoke Nut ............................................. 339 to 373 Guide Link Nuts (XT Only) ............................................. 240 to 305 Guide Loader Linkage Bolts ......................................... 650 to 732 Hydraulic Oil Filter Mounting Bolts .................................... 23 to 27 Hydraulic Pump to Transmission Mounting ................... 335 to 375 Hydraulic Tank Cover Bolt .................................................. 34 to 44 Loader Linkage Pin Keeper ........................................... 325 to 373 Loader Linkage Bolts, Grade 8 (XT Only) ...................... 650 to 732 Muffler to Turbo Elbow Clamp ............................................ 20 to 25 Radiator Hose Clamp - Radiator Side ........................ See INF7888 Radiator Hose Clamp - Tube Side ............................ See INF7888 Steering Wheel Retaining Bolts ................................... 290 to 375 Steering Wheel Retaining Nut............................................ 40 to 47 Transmission (rubber ISO) Mounts (3) ......................... 890 to 1000 Transmission Upper Mounting Bracket Bolts ................. 251 to 319 Transmission Left and Right Lower Mounting Bracket Bolts481 to 590 Turbo to Turbo Elbow Clamp ........................................................ 5 410R Universal Joints (Entrance to Trans. ......................... 34 to 41 480R Universal Joints (Trans. to Axles).............................. 61 to 81 Wheel Mounting Bolts ................................................... 640 to 720

SPECIFICATIONS

NOTES

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A Access Doors ................................ 161 Accumulators, Brake ..................... 129 After Delivery Check ............. 253, 255 Air Conditioning Compressor .............................. 203 Compressor Belt ....................... 221 Compressor Seal Lubrication .... 203 Condenser ................................ 203 Condenser Blower Fans Circuit Breakers ............................... 204 Indicator ...................................... 56 Temperature Control ................... 92 Air Filter Cab ........................................... 199 Cleaning .................................... 179 Indicator ...................................... 57 Primary Element ....................... 178 Replacement ............................. 177 Secondary Element ................... 178 Service Specifications ............... 176 System ...................................... 176 Air Louvers, Cab ............................. 98 Alternator Belt ............................... 221 Autoshift Switch ............................... 93 Auxiliary Hydraulic Connection ................................ 130 System Specifications ............... 130 Auxiliary Power Equipment Mounting Bracket .... 230 Outlet ........................................ 230 Axle Oil Change ............................ 198 Oil Level ................................ 196 Service Specifications .......... 196

B Battery Cleaning .................................... 226 Cold Weather Operations ......... 141 Connection, Booster ................. 113 Fluid Level ................................. 226 Safety ........................................ 225 Service ...................................... 225

Vents ......................................... 226 Beacon Indicator ............................. 50 Before Operation Safety Message .. 12 Before Starting The Engine ........... 107 Belt Air Conditioning Compressor .... 221 Alternator .................................. 221 Fan ............................................ 221 Seat ........................... 105, 108, 217 Blower Fan Switch .......................... 89 Bolt Torques Special 521D ..................................... 243 Booster Battery Connection .......... 113 Brake Parking, Check .......................... 208 Parking, Switch ........................... 48 Pedals ......................................... 81 Pressure Indicator ....................... 51 Brake Accumulators ...................... 129 Bucket Height Control Function ................................ 127 Minor Adjustment .................. 216 Bucket Level Indicator ................... 130 Bulbs, Replacement .............. 228, 231 Burn Prevention Safety Message .... 15 Button Cold Start .................................... 46

C Cab Air Filter ..................................... 199 Cleaning ............................... 201 Removal and Installation ...... 199 Cab Headliner ........................... 204 Door Hinges .............................. 204 Hoses and Wiring ...................... 204 Operators Seat .......................... 205 Service ...................................... 203 Caution Master Indicator ................. 54 Charts Hydraulic System Fluid ............. 188 Lubrication ................ 158, 159, 160

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INDEX

INDEX

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Maintenance ..............158, 159, 160 Tire Pressure ..............................149 Clutch Calibration Transmission .............................206 Clutch Cutout .................................129 Cold Start Button ..............................46 Components, Machine .......................7 Conditioner, Fuel ............................183 Console Front ..........................45, 46, 47, 49 Side ..........89, 90, 91, 92, 93, 94, 95 Controls Air Conditioning Temperature ......92 Blower Fan ...................................89 Hand ..........................45, 46, 47, 49 Heat, Cab .....................................89 Lamp Switch ................................91 Steering Wheel Tilt ......................47 Wiper/Washer Switch ..................90 Coolant Fluid Level .................................181 Cooling System Cleaning .....................................182 Cold Weather Operations ..........141 Coupler Pin Engagement ...............133 Switch ....................................95, 96

D Declutch Switch ...............................92 Defrost Air Louvers ........................100 Detent On/Off Switch .......................92 Diesel Fuel System ........................183 Disabled Machine Towing ..............136 Display Center Lamp, Setting ...............................76 Transmission ...................78, 79, 80 Displays, Warning Non - Critical Warning Displays ...54 Do Not Operate Tag .........................18 Door Access .......................................161 Hinges ........................................204 Latch ..........................................101 Dust Valve ......................................177

E Electrical

Service Connector .................... 229 Electrical System ........................... 225 Emergency Exit ............................. 106 Engine Data ........................................... 235 Hourmeter ................................. 156 Lubrication ................................ 171 Service Specification ................ 173 Specifications ............................ 235 Speed ....................................... 110 Engine Coolant Cleaning the Cooling System ... 182 Fluid Level ................................ 181 Gauge ......................................... 63 Heater ....................................... 112 Mixture ...................................... 180 Engine Cooling System Coolant Mixture ......................... 180 Service Specifications ............... 180 Specifications ............................ 180 Thermostat ................................ 180 Engine Oil Change ..................................... 174 Filter .......................................... 174 Heater ....................................... 112 Level ......................................... 173 Pressure Gauge........................... 62 Selection ................................... 171 Exit Emergency ................................ 106 Extinguisher Mounting, Fire .......... 222

F Fact Attachment ............................ 133 Fan Belt ......................................... 221 Filter Air ............................................. 178 Cab Air ...................................... 199 Engine Oil ................................. 174 Fuel ........................................... 186 Hydraulic Oil ............................. 190 Transmission Oil ....................... 194 Filter Replacement Air ............................................. 177 Engine Oil ................................. 174 Hydraulic Oil ............................. 190

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INDEX Fuel Level Gauge ............................ 61 Fuel Storage .................................. 184 Fuel System Cold Weather Operations ......... 141 Diesel Fuel Specifications ......... 184 Filter, In-Line ............................. 187 Fuel Conditioner ........................ 183 Fuel Filter .................................. 186 Fuel Storage ............................. 184 Removing Water ....................... 185 Service Specifications ............... 183 Fuse Panel .................................... 227 Fuses ............................................ 227

G Gauge Displays 71, 72, 73, 74, 75, 76, 77 Programming .............................. 72 Gauges Engine Coolant ........................... 63 Engine Oil Pressure ..................... 62 Fuel Level ................................... 61 HydraulicOil Temperature ........... 59 Transmission Oil Temperature .... 58 Volt Meter .................................... 60 General Safety .............................. 151 Grease Fittings 100 Hours XT Linkage ........................... 166 Z-Bar Linkage ....................... 163 1000 Hours Z-Bar Linkage ....................... 164 50 Hours XT Linkage ........................... 165 Z-Bar Linkage ....................... 162

H Hand Signals ................................... 42 Heat Control, Cab ........................... 89 Horn ................................................ 47 Hoses and Wiring .......................... 204 Hot Weather Operation ................. 143 Hourmeter, Engine ........................ 156 Hydraulic Connection - Auxiliary ... 130 Hydraulic Filter Test ...................... 190 Hydraulic Oil Filter .......................................... 190

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Transmission Oil ....................... 194 Filters Fuel, In-Line .............................. 187 Fire Extinguisher Mounting ........... 222 Fire Extinguisher Safety Message .. 16 Fire or Explosion Safety Message .. 17 First Service Intervals .................... 108 Fittings, Grease 100 Hours XT Linkage ........................... 166 Z-Bar Linkage ....................... 163 1000 Hours Z-Bar Linkage ....................... 164 50 Hours XT Linkage ........................... 165 Z-Bar Linkage ....................... 162 Float .............................................. 128 Fluid and Lubricants 521D ......................................... 157 Fluid Levels ................................... 167 10 Hours ................................... 167 250 Hours ................................. 169 50 Hours ................................... 168 Coolant ...................................... 181 Engine Coolant ......................... 181 Radiator .................................... 181 Foot Pedals Brake Pedals ............................... 81 Foot Throttle ................................ 81 Four-Way Flasher Lamp ........................................... 50 Switch ......................................... 45 Front Console ................ 45, 46, 47, 49 Cold Start Button ......................... 46 Four-Way Flasher ....................... 45 Horn ............................................ 47 Key/Ignition Switch ...................... 49 Park Brake Switch ....................... 48 Pilot Control Switch ..................... 45 Program/Reset Switch ................ 45 Steering Wheel Tilt Control ......... 47 Transmission Control Lever ........ 46 Turn Signal .................................. 47 Up/Down Count Switch ............... 45 Fuel Conditioner ............................ 183 Fuel Filter ...................................... 186

INDEX Filter Indicator ..............................57 Temperture Gauge ......................59 Hydraulic System Filter Replacement .....................190 Fluid Chart .................................188 Hydraluic Filter Test ...................190 Service Specifications ................188

Lamp Indicator ........................ 51 Low Coolant ............................ 51 Parking Brake ......................... 56 Pilot Lockout ........................... 51 Rotating Beacon ..................... 50 Secondary Steering ................ 56 Stop Master ............................ 52 Transmission Oil Filter ............ 57 Turn Signal ............................. 50

I

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Identification Numbers .......................5 Indicator Air Conditioning ...........................56 Air Filter .......................................57 Beacon .........................................50 Brake Pressure ............................51 Caution Master ............................54 Hydraulic Oil Filter .......................57 Lamp ............................................51 Low Coolant .................................51 Parking Brake ..............................56 Pilot Lockout ................................51 Secondary Steering Master .........56 Stop Master .................................52 Transmission Oil Filter .................57 Indicator Lamps 50, 51, 52, 54, 56, 57, 58, 59, 60, 61, 62, 63, 64 Information Center ..65, 66, 67, 68, 69, 70 Programming ...............................66 Instructions, General Safety ...........151 Instrument Panel 50, 51, 52, 54, 56, 57, 58, 59, 60, 61, 62, 63, 64 Indicator Gauges Engine Coolant ........................63 Engine Oil Pressure .................62 Fuel Level ................................61 Hydraulic Oil Temperature ......59 Transmission Oil Temperature 58 Volt Meter ................................60 Indicator Lamps Air Conditioning .......................56 Air Filter ...................................57 Brake Pressure ........................51 Caution Master ........................54 Four-Way Flasher ....................50 Hydraulic Oil Filter ...................57

J Jump Start ..................................... 113

K Key Switch, Ignition ......................... 49

L Lamp Four-Way Flasher ....................... 50 Turn Signal ................................. 50 Lamp Indicator ................................ 51 Lamp Switch, Cab ........................... 91 Latch Door .......................................... 101 Window ..................................... 101 Window Retainer ...................... 102 Levers Transmission Control .................. 46 Turn Signal ................................. 47 Link Safety ........................................ 153 Transport .................................. 153 Loader Adjustments Return-To-Dig ........................... 210 Loader Control Levers Two Spool - Two Levers ............. 83 Loader Function Switches ............. 126 Loader Operating Tips .................. 134 Leveling Operation .................... 134 Pushing Operation .................... 134 Scraping Operation ................... 134 Transport and Carry Operation . 135 Loader Operations Cold Weather ............................ 141 Louvers, Air Defrost ...................................... 100 Main ............................................ 99

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INDEX

M Machine Components ....................... 7 Machine Operation Before Operating ....................... 115 Transmission Operation ............ 118 Machine Operation Safety Message ...

13, 15, 16, 17, 18, 19 Machine Storage ........................... 233 Removal .................................... 234 Storage Preparaton ................... 233 Machine Tie Down Locations ........ 140 Main Air Louvers ............................. 99 Maintenance and Inspection of ROPS 217 Maintenance Chart ........ 158, 159, 160 Maintenance Safety Message ......... 18 Master Disconnect Switch ............... 97 Material Safety Data Sheets ........... 18 MSDS Sheets .................................. 18 Muffler Cleaning .................................... 223 Spark Arresting ......................... 223

O Oil Change Axle ............................................ 198 Engine ....................................... 174 Oil Level Axle ........................................... 196 Engine ....................................... 173 Transmission ............................. 194 Oil Selection, Engine ..................... 171 Oil Viscosity/Temperature Ranges 172 Operating Data.....................................

Operating Dimensions... 236, 237, 238, 239 Operating In Hot Weather ............. 143 Operating Instructions ................... 107 Before Starting The Engine ....... 107

Operating The Machine ................. 115 Operating Tips - Loader ................ 134 Operator Manual Storage Compartment 3 Operators Manual, Read ................. 20 Operators Seat ...................... 102, 205 Owner, To The .................................. 1

P Parking Brake Check ........................................ 208 Indicator ...................................... 56 Switch ......................................... 48 Parking The Machine .................... 111 Parking the Machine Safety Message .

15 Pedals, Foot .................................... 81 Personal Safety Rules Message ..... 11 Pilot Control Switch ......................... 45 Pilot Lockout Indicator ..................... 51 Plastic and Resin Parts ................. 155 Power Outlet, Auxiliary .................. 230 Pressure, Tire ................................ 145 Primary Element, Air Filter ............ 178 Product Identification Number ........... 5 Program/Reset Switch ..................... 45 Programming Display Center Lamp, Setting ..... 76 Gauge Display ............................ 72 Information Center ...................... 66

R Radiator Fluid Level ................................. 181 Radio ............................................. 101 Read Operators Manual .................. 20 Rear Fog Lamp Switch .................... 94 Rear Wiper/Washer Switch ............. 93 Reservoir, Windshield Washer ...... 202 Return-To-Dig Adjustment ................................ 210 Function .................................... 126 Return-To-Travel ........................... 127 Switch ......................................... 92 Ride Control .................................. 132 Switch ......................................... 93

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Recirculation ............................... 98 Low Coolant Indicator ..................... 51 Lubrication Analysis, Systemgard 155, 175 Lubrication Chart ........... 158, 159, 160 Lubrication, Engine ....................... 171

INDEX Roll-Over Protective Structure .......217 Roll-Over Protective Structure Safety Message ....................................19 ROPS .............................................217 Damage Information ..................219 Maintenance and Inspection ......217 Seat Torque Specifications ............220 Seat Belt ....................................217 Torque Specifications ............220 Specifications Canopy Torque ......................218 Cap Torque ...........................218 Rotating Beacon ............................131 Switch ..........................................94 Run-In Procedure ...........................107

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Torque Specifications ............... 220 Secondary Element, Air Filter ....... 178 Secondary Steering Master Indicator ..

56 Sediment Removal, Fuel System .. 185 Serial Numbers ................................. 5 Service Electrical Connector ......... 229 Service Intervals - First ................. 108 Service Safety Link ....................... 153 Side Console 89, 90, 91, 92, 93, 94, 95 Air Conditioning Temperature ..... 92 Autoshift Switch .......................... 93 Blower Fan Switch ...................... 89 Coupler Pin Engage Switch .. 95, 96 Declutch Switch .......................... 92 Detent On/Off Switch .................. 92 Heat Control ................................ 89 S Lamp Switch ............................... 91 Safety Decals ...................................20 Rear Fog Lamp Switch ............... 94 Safety Instructions, General ...........151 Rear Wiper/Washer Switch ......... 93 Safety Link, Service .......................153 Return-To-Travel Switch ............. 92 Safety Rules .......................................9 Ride Control Switch .................... 93 Hand Signals ...............................42 Rotating Beacon Switch .............. 94 Utility ............................................10 Wiper/Washer Switch ................. 90 Safety, Battery ...............................225 Wrist Rest ................................... 89 Safety/Decals/Hand Signals ..............9 Wrist Rest, Adjustment ............... 89 Before Operation .........................12 Spark Arresting Muffler ................. 223 Burn Prevention ...........................15 Specifications ................................. 235 Fire Extinguisher ..........................16 Air Filter .................................... 176 Fire or Explosion ..........................17 Auxiliary Hydraulic System ....... 130 Machine Operation ...13, 15, 16, 17, Axle ........................................... 196 18, 19 Bolt Torques, Special Maintenance ................................18 521D ..................................... 243 Parking the Machine ....................15 Cooling System, Engine ........... 180 Personal Safety ...........................11 Diesel Fuel System ................... 183 Read Operators Manual ..............20 Dimensions Roll-Over Protective Structure .....19 521D .............. 236, 237, 238, 239 Safety Decals ...............................20 Engine Cooling System ............ 180 Wheel and Tire Maintenance .......19 Engine Data ............................... 235 Seat Engine Service .......................... 173 Belts ...........................105, 108, 217 Fuel System .............................. 183 Inspection and Care ..............106 Hydraulic System ...................... 188 Operators ...........................102, 205 Operating Data Optional Air Ride ........................103 521D ............. 236, 237, 238, 239 Standard ....................................102 ROPS Torque ........................... 218 Torque Specifications ................220 Seat Belt Torque ....................... 220 Seat Belt Seat Torque .............................. 220 250

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Thermostat ................................ 180 Transmission ............................. 193 Travel Speeds ........................... 235 Starting The Engine .................. 109 Steering Wheel Tilt Control ............. 47 Steering, Secondary ...................... 207 Stop Master Indicator ...................... 52 Stopping The Engine ..................... 111 Storage Compartment Operator Manual ........................... 3 Storage, Fuel ................................. 184 Storage, Machine Preparation ............................... 233 Removal .................................... 234 Switch Autoshift ...................................... 93 Blower Fan .................................. 89 Coupler Pin Engage .............. 95, 96 Declutch ...................................... 92 Detent On/Off .............................. 92 Four-Way Flasher ....................... 45 Key/Ignition ................................. 49 Lamp ........................................... 91 Loader Function ........................ 126 Bucket Height Control ........... 127 Float ...................................... 128 Return-To-Travel .................. 127 Master Disconnect ...................... 97 Park Brake .................................. 48 Pilot Control ................................ 45 Program/Reset ............................ 45 Rear Fog Lamp ........................... 94 Rear Wiper/Washer .................... 93 Return-To-Travel ......................... 92 Ride Control ................................ 93 Rotating Beacon ......................... 94 Up/Down Count ........................... 45 Wiper/Washer ............................. 90 Systemgard Analysis ............. 155, 175

Tire Tread Direction ....................... 147 Tires, Adding Air ............................ 147 Torque - Wheel Nut ....................... 148 Towing, Machine ........................... 136 Transmission Breather Cleaning ..................... 194 Clutch Calibration ...................... 206 Cold Oil Level Check ................ 194 Control Lever .............................. 46 Display Center ................ 78, 79, 80 Filter Replacement .................... 194 Oil Change ................................ 194 Oil Level .................................... 194 Operation of .............................. 118 Service Specifications ............... 193 Warm Oil Level Check .............. 194 Transmission Oil Filter .......................................... 194 Filter Indicator ............................. 57 Level ......................................... 194 Check ................................... 194 Temperture Gauge ...................... 58 Transmission Operation Automatic Mode Operation ....... 118 Down-Shift Button, Manual Mode ...

118 Down-Shifts Manual Mode ........ 118 Manual Mode Operation ........... 118 Shifting, Automatic Mode .......... 119 Up-Shifts Manual Mode ............ 118 Transport Link ............................... 153 Transporting The Machine ............ 137 On A Trailer ............................... 140 Turbocharger Priming the Lines with Oil ......... 110 Turn Signal Lamp ........................................... 50 Lever ........................................... 47

T

Up/Down Count Switch ................... 45 Utility Safety .................................... 10

Thermostat Specifications ............. 180 Throttle, Foot ................................... 81 Tire Or Rim Service ....................... 147 Tire Pressure ................................. 145 Chart .......................................... 149

U

V Volt Meter Gauge ............................ 60

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INDEX

INDEX

W Warning Displays Non - Critical Warning Displays ...54 Water Removal, Fuel System ........185 Weights Adjustments, Optional Equipment ....

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Operating ....................................241 Operating, Machine ....................241 Wheel and Tire Maintenance Safety Message ....................................19 Wheel And Tires ............................145 Wheel Nut Torque ..........................148 Window Latch ..........................................101 Retainer Latch ...........................102 Windshield Washer Reservoir ........202 Wiper/Washer Switch .......................90 Wrist Rest ........................................89 Adjustment Knob .........................89

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AFTER DELIVERY CHECK 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.

Check the pressure setting of the main relief valve.

Replace the hydraulic oil filter.

FUEL SYSTEM

GENERAL

Drain water and sediment from the fuel tanks.

Look for oil leaks and loose parts.

Check tire pressure.

ELECTRICAL SYSTEM Check battery.

Tighten all hose clamps.

Check operation of starter, alternator, and instruments.

Check drive chain tension..

Check operation of all lamps.

Check brake operation.

Check wheel nut torque.

LUBRICATION

Check the control levers for correct operation.

Check the operators seat bar for correct operation.

Lubricate all pivot points.

Engine SAFETY

Check condition of drive belt.

Check engine oil level.

Inspect the ROPS.

Check engine speed at idle and at full throttle.

Check the safety decals and replace if necessary.

Service air cleaner.

Check the operator restraint system.

Make sure the machine has the operators manual in the manual storage box.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature: Dealer Copy

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Check for leaks.

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AFTER DELIVERY CHECK 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.): ENGINE

HYDRAULIC SYSTEM

Check the engine oil level.

Check for leaks.

Check air cleaner.

Tighten all hose clamps.

Check the reservoir oil level.

COOLING SYSTEM

GENERAL

Check the coolant level of radiator and coolant reservoir.

FUEL SYSTEM

Check the operation of the brakes.

Check the control levers for correct operation.

SAFETY

Check for leaks.

Check the safety and information decals.

Drain water and sediment from the fuel tanks.

Check the torque of ROPS and seat belt mounting bolts.

ELECTRICAL SYSTEM

Make sure the Operator’s Manual and Safety Manual are in the Manual Storage Box.

Check operation of starter, alternator, and instruments.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

Check oil level of final drives.

Check transmission oil level.

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: Owner Copy

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Tighten all hose clamps.

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OM 9X6 JAUNE Gabarit MM.qxd

31/10/2007

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521D Loader Operator’s Manual

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