Case 521E Tier III Wheel Loader Operator's Manual 87479806A - PDF DOWNLOAD

521E - TIER III

521E TIER III Wheel Loader Wheel Loader

Operator’s Manual Print No. 87479806 A - EU

1st edition English 03/08

from serial no: FNH521E1N8HE82001 (Z-Bar) FNH521E1N8HE87001 (XT)

OPERATOR’S MANUAL WHEEL LOADER 521E TIER3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Issued 01 Mar 2008 Printed in E.C. • Book/Form Number 87479806 A - EU Copyright © 2008. CNH Italia S.p.A.. All Rights Reserved.

CNH Italia S.p.A. reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install thern on units previously sold.

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

This unit first became available 01- 2008 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01 Mar 2008

521E Tier 3 Wheel Loader

87647789 A - EU

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

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

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW Prohibition symbols such as and STOP if used, are RED.

WARNING IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: Is instructed in safe and proper use of the machine.

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

Reads and understands ALL Safety Decals on the machine.

Clears the area of other persons.

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

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

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

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

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

Issued 01 2008 Printed in E.C. • Book/Form Number 87479806 A - EU Any use of editorial or pictorial © content strictly prohibited without written permission from Copyright 2008. is CNH Italia S.p.A.. All Rightsexpress Reserved.

CNH Italia S.p.A. Modena, Italia 44100

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Official Justifying Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 CHAPTER 2 SAFETY, AND DECALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Instruments and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Front Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Instrument Panel Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Side Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Support Strut for Loader Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Engine Oil Viscosity / Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Access Doors and Fill Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Cab Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

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CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Machine Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Lift Capacity 521E Z-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Lift Capacity 521E XT Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 521E Z-Bar Operating Data and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 521E XT Lift Arm Operating Data and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Material Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 CHAPTER 9 INDEX

II

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

521E-3M002

521E

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

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

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.

CNH Italia S.p.A. Viale delle Nazioni, 55 Modena, Italia 44100

Dealer’s Stamp

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CHAPTER 1 - GENERAL INFORMATION

Figure 2

521E-3M003

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

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

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Figure 3

521E-3M004

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

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

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

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

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

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

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

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CHAPTER 1 - GENERAL INFORMATION

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

• Noise Level (2000/14/EC) - Amended in 2005 by 2005/88/EC • Safety (98/37/EC, was (89/392/EC with amendments 91/368/EC and 93/44/EC) SPECIAL TEST CERTIFICATE Noise level 2000/14/CE with amendments 89/513/EEC and 95/27/EEC Electro-Magnetical Compatibility 2004/108/EC Noise level 2000/14/EC Vibration Level The magnitude of vibration in the z-axis transmitted to the operator's body does not exceed 1.25 m/s2 when tested per ISO 7096, Class 3.

The magnitude of vibration for hand guided machinery transmitted to the arm and hand does not exceed 2.5m/s2 when tested per machinery direction 98/37/EC Guaranteed Sound Power Level to EC Regulation Requirements Guaranteed Sound Power Levels.................................................................................................................. 104 dBA Typical Operator Ear Levels (Closed Cab)...................................................................................................... 72 dBA

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

FRONT

Figure 4

BD06F071

OPERATOR MANUAL STORAGE COMPARTMENT To access the operator manual storage area located on the back of the operator’s seat, release the latch on top of the seat and open the compartment.

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

LEFT

RIGHT

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

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

When you see this symbol refer to your Repair Manual.

REAR B891464

Figure 5

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

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CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

6

1 7 5 1 4

8 2 3 Figure 6

521E-3M005

MACHINE COMPONENTS 1.

2.

3.

4.

1-6

CAB DOOR AND HAND HOLDS STEPS BUCKET BELLCRANK

5.

6.

7.

8.

BUCKET CYLINDER ROPS CAB ENGINE HOOD LEFT BATTERY ACCESS

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4 2 6

5

3 1

8

9 7 Figure 7

521E-3M006

MACHINE COMPONENTS 1. RIGHT SIDE BATTERY COMPARTMENT 2. ENGINE HOOD 3. FUSE AND RELAY ACCESS

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4. FRONT CONSOLE 5. BUCKET CYLINDER 6. LOADER LIFT ARM

7. BUCKET 8. WINDSHIELD WASHER RESERVOIR 9. CAB AIR FILTER ACCESS

1-7

CHAPTER 1 - GENERAL INFORMATION IDENTIFICATION NUMBERS MODEL, SERIAL NUMBER, AND YEAR OF MANUFACTURE When ordering parts, obtaining information or assistance, always supply your dealer with the type and serial number of your machine or accessories.

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

PRODUCT IDENTIFICATION PLATE The identification plate includes the main data of the machine.

Record the data of your machine below.

Model..........................................................................

Serial Number.............................................................

Manufacturing Year ....................................................

721E-3M002

Figure 8

521E-3M001

Figure 9

MARKING AND SERIAL NUMBER 1. Manufacturer code (FNH).

2. Machine code (521E1).

3. Check letter (N).

4. Year of production (8 for 2008).

5. Manufacturing Plant (H for Lecce Plant).

6. Product line (E for Wheel loader).

7. Machine serial number (last 5 digits).

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CHAPTER 1 - GENERAL INFORMATION ENGINE IDENTIFICATION Make and Model .........................................................

Serial Number.............................................................

BD06F092

Figure 10

BD02N124

Figure 11

BD02N126

Figure 12

TRANSMISSION IDENTIFICATION Model..........................................................................

Serial Number.............................................................

FRONT AND REAR AXLE IDENTIFICATION Front axle Type...........................................................

Front axle S/N.............................................................

Rear axle Type ...........................................................

Rear axle S/N .............................................................

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CHAPTER 1 - GENERAL INFORMATION ROPS CAB Serial Number.............................................................

Figure 13

BD06H167

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CHAPTER 2 - SAFETY, AND DECALS

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

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CHAPTER 2 - SAFETY, AND DECALS

NOTES

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CHAPTER 2 - SAFETY, AND DECALS

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

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

• DANGER: Indicates an immediate hazardous

situation which, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

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

Figure 1

BD06F071

OPERATOR’S MANUAL STORAGE SPACE

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

• CAUTION: Indicates a potentially hazardous

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

ISO two panel pictorial symbol decals, if used are defined as follows:

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

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate

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.

Prohibition symbols such as used, are RED.

avoidance of the hazard.

• Background color is YELLOW. and

STOP

if

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

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

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CHAPTER 2 - SAFETY, AND DECALS

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

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

• • • •

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

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

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

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

Figure 2

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

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

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

Keep machine and attachments a safe distance from electrical power lines. Failure to comply could result in injury or death.

2-4

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CHAPTER 2 - SAFETY, AND DECALS MOUNTING AND DISMOUNTING PRECAUTIONS

PERSONAL

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

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

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

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

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

• Do not rush. Walk, do not run.

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

GENERAL

• It is the responsibility of the operator to read and

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

• Do not operate this machine or perform

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

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

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

BD06F163-1

Figure 3

• Use the recommended hand holds and steps with

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

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

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

• Foreign material or grease on the steps and hand

holds can cause an accident. Keep the steps and hand holds clean.

STARTING AND STOPPING PRECAUTIONS

• Walk around the machine and warn all personnel

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

Sound the horn, if equipped, before starting.

• Walk around the machine’s tool, attachment, or

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

furthermost contact point to view operation danger area from the work site personnel’s view and angle.

• Make sure that all protective guards, canopies,

• Check that the parking device is applied, place the

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

• Remove all loose objects stored in the machine.

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

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

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

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

• Do not bypass the machine’s neutral-start system.

The neutral-start system must be repaired if it malfunctions.

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CHAPTER 2 - SAFETY, AND DECALS

• Use

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

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

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

• Park the machine on level ground whenever

possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

• Before leaving the operator’s station, lower the bucket/attachment to the ground, shut off the engine.

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

OPERATING PRECAUTIONS

• Check brakes, steering and other machine control

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

• If a failure that causes loss of control such as

steering, service brakes, or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key.

Place a DO NOT OPERATE tag on the machine, and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

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

• Operate and drive the machine with care and at

• Know and understand the job site traffic flow

patterns and obey signalmen, road signs, and flagmen.

• Know and understand that job site conditions may

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

• Watch for bystanders and never allow anyone to

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

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

• When roading a machine, know and use the

signaling devices required on the machine.

Provide an escort for roading where required.

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

• Use the recommended transport devices when

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

• Use the approved drawbar and/or attachment

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

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

• If your machine has a cab, make sure that all

windows are clean and that the windshield wipers and washers work correctly.

• Engine exhaust fumes can cause death. If you

operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

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

• Check all controls in a clear area and make sure

• Note and avoid all hazards and obstructions such

and cause an accident. Stop the machine or decrease the speed until you can see.

as ditches, underground lines, trees, cliffs, overhead electrical wires, or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

2-6

the machine is operating correctly.

• Dust, fog, smoke, etc., can decrease your vision • Contact

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

• Before you drive or operate in an area with high

voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

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

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CHAPTER 2 - SAFETY, AND DECALS

• Keep all parts of the machine a safe distance

away from the power source. See the decal on the machine. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

If a part of the machine touches high voltage power:

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

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

• If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

• 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.

• Avoid lubrication or mechanical adjustments with

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

• Securely block the machine or any component that

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

• To prevent unexpected movement, securely block

working elements when repairing or changing working tool parts such as cutting edges.

• Never make repairs on pressurized components,

fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

• Use extreme caution when removing radiator,

reservoir, or tank caps, drain plugs, grease fittings or pressure taps. Park the machine and let it cool before opening a pressurized tank.

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

• Use a piece of cardboard, newspaper, or wood to

• Stay away from hazardous areas such as ditches,

check for any pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturer’s recommendations.

• Be alert and always know the location of all

• When inflating tires, use a self-attaching inflation

• Develop fluid and smooth operating techniques,

• Towing this machine is not recommended.

• When absolutely necessary to tow the machine,

overhangs, etc. Walk around the work area before you start and look for hazards. workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions. and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

MAINTENANCE PRECAUTIONS

• Do not attempt repairs unless trained. Refer to

manuals and experienced repair personnel for help.

• Before you service the machine, put a DO NOT

OPERATE tag on the key switch. Make sure that the machine is clearly “tagged out”.

• Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

chuck with remote shutoff and stand clear of the tire. Position yourself beside the tire and not beside the rim.

do not exceed the recommended towing speed.

Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a towbar must be used or two towing machines must be used - one in front pulling and one in the rear to act as a brake.

Avoid towing over long distances.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins,

etc., use a brass drift or other suitable material between the hammer and pin. Alt: Use a brass hammer, drift or suitable material on the pin, etc.

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

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the

• Replace all missing, illegible or damaged safety

signs or decals as necessary. Keep all safety signs and decals clean and legible.

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

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CHAPTER 2 - SAFETY, AND DECALS

• Hot coolant can spray out if the cooling system

FUEL HANDLING PRECAUTIONS

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

• Never remove the fuel cap or refuel gasoline or

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

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

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

• Clean up spilled fuel immediately and dispose of

contaminated material in an environmentally correct manner.

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

• Never use fuel for cleaning purposes.

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

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. Failure to comply could result in serious injury or death.

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

HAZARDOUS CHEMICAL PRECAUTIONS

• If you are exposed to or come in contact with

hazardous chemicals you can be seriously injured.

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

• Material Safety Data Sheets (MSDS) provide

information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. This information is available from your dealer.

• Before you service your machine, check the

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

• Before you service this machine and before you

dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

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

dealer

for

correct

disposal

TRANSPORTING PRECAUTIONS Know the ru les, laws, and safety equipment necessary for transporting this machine on a road or highway.

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

M144B

• When the battery electrolyte is frozen, the battery

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

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CHAPTER 2 - SAFETY, AND DECALS SEAT BELT PRECAUTIONS

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

1

M422A

2 Figure 4

BD06G176

1. RIGHT-HAND BELT STRAP 2. LATCH MECHANISM

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

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

WARNING: Securely fasten your seat belt.

Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. Failure to comply could result in serious injury or death.

M437

Figure 5

BD06G176

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

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

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

• Never smoke while refueling.

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

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

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

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

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

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

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

M824

Figure 6

BD07N691

Figure 7

BD0N629-01

SUPPORT STRUT IN SERVICE POSITION

SUPPORT STRUT IN OPERATING POSITION

TRANSPORT SERVICE LINK

Figure 8

BD07N691

SERVICE LINK IN OPERATING POSITION

Figure 9

BD07N630-01

SERVICE LINK IN LOCKED POSITION

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

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CHAPTER 2 - SAFETY, AND DECALS

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

CE-NA000

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

CE-NA000

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

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

Figure 10

384270A1A

This symbol instructs you to refer the Operator’s Manual.

87479806 A - EU

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BC00G075

Figure 11

This symbol instructs you to refer to the Repair Manual.

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CHAPTER 2 - SAFETY, AND DECALS

1

2

3

Figure 12

BD07G079/3217030/386241A1

1. DECAL LOCATION - CAB DOOR SUPPORT 2. WARNING - NORTH AMERICAN DECAL NUMBER - 3217030 - USE SEAT BELT - DO NOT JUMP FROM MACHINE 3. WARNING - ISO NUMBER - 386241A1 - USE SEAT BELT - DO NOT JUMP FROM MACHINE

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4

5

Figure 13

BS07G080-01/329051A1/329051A1

4. DECAL LOCATION - RIGHT HAND CAB WINDOW 5. NOTIFICATION - ISO NUMBER - 329051A1 - EMERGENCY ESCAPE LOCATION (NORTH AMERICAN AND EUROPE)

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6

7

8

Figure 14

BD07G080-02364742A1/364917A1

6. DECAL LOCATION - RIGHT HAND CAB WINDOW 7. WARNING- NORTH AMERICAN DECAL NUMBER - 364742A1 - CHECK ATTACHMENT ENGAGEMENT 8. WARNING - ISO NUMBER - 364917A1 - CHECK ATTACHMENT ENGAGEMENT

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9

10

11

Figure 15

BD07G080-03/382622A1/256147A1

9. DECAL LOCATION - RIGHT HAND CAB SUPPORT 10. WARNING - NORTH AMERICAN DECAL NUMBER - 382622A1 - READ THE OPERATOR’S MANUAL 11. WARNING - DECAL NUMBER - 256147A1 - READ THE OPERATOR’S MANUAL

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CHAPTER 2 - SAFETY, AND DECALS

12

13

14

Figure 16

BD07N641/407737A2/407741A1

12. DECAL LOCATION - LEFT FRONT FRAME 13. DANGER - NORTH AMERICAN DECAL NUMBER - 407737A2 - CRUSH HAZARD - INSTALL LIFT ARM SUPPORT 14. DANGER - ISO NUMBER - 407741A1 - CRUSH HAZARD - INSTALL LIFT ARM SUPPORT

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15

16

17

Figure 17

BD07N641/87453132/87453136

15. DECAL LOCATION - FRONT FRAME - (ONE EACH SIDE) 16. DANGER - NORTH AMERICAN DECAL NUMBER - 87453132 - CRUSH HAZARD - SERVICING VALVE WILL CAUSE LIFT ARM TO FALL 17. DANGER - ISO NUMBER - 87453136 - CRUSH HAZARD - SERVICING VALVE WILL CAUSE LIFT ARM TO FALL

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CHAPTER 2 - SAFETY, AND DECALS

18

19

20

Figure 18

BD07N641/335889A1/333269A1

18. DECAL LOCATION - LEFT REAR FRAME 19. WARNING - NORTH AMERICAN DECAL NUMBER - 335889A1 - PRESSURIZED SYSTEM HAZARD 20. WARNING - ISO NUMBER - 333269A1 - PRESSURIZED SYSTEM HAZARD

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21

22

23

Figure 19

BD07N641/329049A1/329050A1

21. DECAL LOCATION - LEFT REAR FRAME 22. CAUTION - NORTH AMERICAN DECAL NUMBER - 329049A1 - RUN OVER HAZARD - BLOCK WHEELS 23. CAUTION - ISO NUMBER - 329050A1 - RUN OVER HAZARD - BLOCK WHEELS

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CHAPTER 2 - SAFETY, AND DECALS

24

25

26

Figure 20

BD07N641/329047A1/329048A1

24. DECAL LOCATION - LEFT FRONT FRAME 25. WARNING - NORTH AMERICAN DECAL NUMBER - 329047A1 - CRUSH HAZARD - INSTALL LOCK LINK 26. WARNING - ISO NUMBER - 329048A1 - CRUSH HAZARD - INSTALL LOCK LINK

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CHAPTER 2 - SAFETY, AND DECALS

27

28

29

Figure 21

BD07N641/328904A1/328903A1

27. DECAL LOCATION - LEFT REAR FRAME - BENEATH LADDER 28. WARNING - NORTH AMERICAN DECAL NUMBER - 328904A1 - PRESSURIZED SYSTEM HAZARD 29. WARNING - ISO NUMBER - 328903A1 - PRESSURIZED SYSTEM HAZARD

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CHAPTER 2 - SAFETY, AND DECALS

30

32

31

33

34

35

Figure 22

BD07N619-01/ 335889A1/333269A1/323694A1/323695A1

30.

31.

32.

33.

34.

35.

DECAL LOCATION - RIGHT REAR FRAME DECAL LOCATION - FRONT FRAME (ONE EACH SIDE) WARNING - NORTH AMERICAN DECAL NUMBER - 335889A1 - PRESSURIZED SYSTEM HAZARD WARNING - ISO NUMBER - 333269A1 - PRESSURIZED SYSTEM HAZARD WARNING - NORTH AMERICAN DECAL NUMBER - 323694A1 - CRUSH HAZARD WARNING - ISO NUMBER - 323695A1 - CRUSH HAZARD

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37 36

Figure 23

BD07N558-01/139729A1

36. DECAL LOCATION - REAR FRAME EACH SIDE 37. NOTIFICATION - ISO NUMBER - 139729A1 - LIFT EYE

38

40

39

Figure 24

BD07N652-01/328752A1/328753A1

38. DECAL LOCATION - REAR FRAME LEFT SIDE 39. DANGER - NORTH AMERICAN DECAL NUMBER - 328752A1 -RUN OVER HAZARD 40. DANGER - ISO NUMBER - 328753A1 - RUN OVER HAZARD

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CHAPTER 2 - SAFETY, AND DECALS

41

42

43

45

44

46

Figure 25

BD07N626-01/328754A1/412426A1/328904A1/328903A1

41.

42.

43.

44.

45.

46.

DECAL LOCATION - FRONT FRAME FACE DECAL LOCATION - FRONT FRAME FACE DANGER - NORTH AMERICAN DECAL NUMBER - 328754A1 -CRUSH HAZARD DANGER - ISO NUMBER - 412426A1 - CRUSH HAZARD WARNING - NORTH AMERICAN DECAL NUMBER - 328904A1 -PRESSURIZED SYSTEM HAZARD WARNING - ISO NUMBER - 328903A1 - PRESSURIZED SYSTEM HAZARD

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47

48

49

50

Figure 26

BD07N639-01/8603092/8603095

47.

48.

49.

50.

DECAL LOCATION - ENGINE COMPARTMENT - LEFT HAND SIDE DECAL LOCATION - AIR CLEANER HOUSING WARNING - NORTH AMERICAN DECAL NUMBER - 8603092 - EXPLOSION HAZARD - DO NOT USE ETHER WARNING - ISO NUMBER - 8603095 - EXPLOSION HAZARD - DO NOT USE ETHER

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CHAPTER 2 - SAFETY, AND DECALS

51 52

53

54

55

56

Figure 27

BD07N639-01/334456A1/334455A1/332512A1/332511A1

51.

52.

53.

54.

55.

56.

DECAL LOCATION - ENGINE COMPARTMENT - LEFT HAND SIDE DECAL LOCATION - AIR CLEANER HOUSING DANGER - NORTH AMERICAN DECAL NUMBER - 334456A1 - UNEXPECTED MOVEMENT HAZARD DANGER - ISO NUMBER - 334455A1 - UNEXPECTED MOVEMENT HAZARD WARNING - NORTH AMERICAN DECAL NUMBER - 332512A1 - ENTANGLEMENT HAZARD - KEEP CLEAR WARNING - ISO NUMBER -332511A1- ENTANGLEMENT HAZARD - KEEP CLEAR

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57

58

59

60

61

BD07N541-01/388112A1/388113A1/875987501A

57.

58.

59.

60.

61.

Figure 28

DECAL LOCATION - ENGINE COMPARTMENT - REAR ON BELT SHROUD DECAL LOCATION - ENGINE COMPARTMENT - REAR ON BELT SHROUD WARNING - NORTH AMERICAN DECAL NUMBER -388112A1 - ENTANGLEMENT HAZARD - KEEP CLEAR WARNING - ISO NUMBER - 388113A1- ENTANGLEMENT HAZARD - KEEP CLEAR INFORMATIONAL DECAL - 87598750 - PICTORIAL MAINTENANCE SCHEDULE

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CHAPTER 2 - SAFETY, AND DECALS

62

63

64

Figure 29

BD07N551-01/332512A1/332511A1

62. DECAL LOCATION - RIGHT HAND ENGINE COMPARTMENT - FAN SHIELD 63. WARNING - NORTH AMERICAN DECAL NUMBER - 332512A1 - ENTANGLEMENT HAZARD - KEEP CLEAR 64. WARNING - ISO NUMBER - 332511A1 - ENTANGLEMENT HAZARD - KEEP CLEAR

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65

66

67

Figure 30

BD07N692/412471A1/412476A1

65. DECAL LOCATION - INSIDE BATTERY COMPARTMENT - ONE EACH SIDE 66. DANGER - NORTH AMERICAN DECAL NUMBER - 412471A1 - EXPLOSION HAZARD 67. DANGER - ISO NUMBER - 412476A1 - EXPLOSION HAZARD

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CHAPTER 2 - SAFETY, AND DECALS

68

70

69

71

72

73

Figure 31

BD07N655-01/332512A1/332511A1/335889A1/333269A1

68.

69.

70.

71.

72.

73.

DECAL LOCATION - INSIDE TOP MACHINE COMPARTMENT DECAL LOCATION - INSIDE TOP MACHINE COMPARTMENT WARNING - NORTH AMERICAN DECAL NUMBER - 332512A1 - ENTANGLEMENT HAZARD -KEEP CLEAR WARNING - ISO NUMBER -332511A1 - ENTANGLEMENT HAZARD -KEEP CLEAR WARNING - NORTH AMERICAN DECAL NUMBER - 335889A1 - PRESSURIZED SYSTEM HAZARD WARNING - ISO NUMBER - 333269A1 - PRESSURIZED SYSTEM HAZARD

2-30

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CHAPTER 2 - SAFETY, AND DECALS

74

76

75

Figure 32

BD0N651-01/329044A1/329045A1

74. DECAL LOCATION - INSIDE TOP MACHINE COMPARTMENT - ON RADIATOR 75. WARNING - NORTH AMERICAN DECAL NUMBER - 329044A1 - HOT LIQUID UNDER PRESSURE 76. WARNING - ISO NUMBER - 329045A1 - HOT LIQUID UNDER PRESSURE

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Issued 03-08

2-31

CHAPTER 2 - SAFETY, AND DECALS

79 77 78

80

81

Figure 33

BD07N650-01/E134402/8603092/8603095

77.

78.

79.

80.

81.

DECAL LOCATION - ON TOP OF MACHINE - NEAR EXHAUST STACK DECAL LOCATION - ON TOP OF MACHINE - NEAR EXHAUST STACK NOTIFICATION - ISO NUMBER - E134402 - DO NOT STEP WARNING - NORTH AMERICAN DECAL NUMBER - 8603092 - DO NOT USE ETHER WARNING - ISO NUMBER - 8603095 - DO NOT USE ETHER

2-32

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CHAPTER 2 - SAFETY, AND DECALS

83

82

Figure 34

BD07G061//139728A1

82. DECAL LOCATION - FRONT AND REAR OF MACHINE 83. NOTIFICATION - ISO NUMBER - 139728A1 - TIE DOWN LOCATIONS

85

84

Figure 35

BD07H060-01/71477097

84. ISO LOCATION - LEFT HAND WINDOW) 85. NOTIFICATION - ISO NUMBER - 71477096 - DECIBEL INFORMATION

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Issued 03-08

2-33

CHAPTER 2 - SAFETY, AND DECALS

86

87

R Ride control (If equipped) 88 Hitch weight 89

Reflector

Speed sign

Figure 36

304083A1/1532083C1/123894A1

86.

87.

88.

89.

ISO LOCATION - FRONT FRAME BOTH SIDES - ISO NUMBER - 304083A1 - RIDE CONTROL (IF EQUIPPED) ISO LOCATION - MACHINE REAR - ISO NUMBER - 408367A1 - EUROPEAN MODELS ONLY ISO NUMBER - 123694A1 - REFLECTOR - EUROPEAN MODELS ONLY ISO NUMBER - 1532083C - SPEED SIGN - EUROPEAN MODELS ONLY

2-34

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

Figure 37

BI97D059

START THE ENGINE

COME TO ME

Wave hands back and forth (palms inward).

87479806 A - EU

STOP THE ENGINE

Figure 38

BP97D022

Issued 03-08

Figure 39

BI97D025

BP97D023

FIGURE 40

MOVE AWAY FROM ME

Wave hands back and forth (palms outward).

2-35

CHAPTER 2 - SAFETY, AND DECALS

Figure 41

BP97D030

GO THIS FAR

ALL STOP AND HOLD

Figure 42

BI97D029

EMERGENCY STOP

Move one hand back and forth.

2-36

Move both hands back and forth.

Figure 43 RAISE LOAD OR TOOL

Figure 45

BI97D021

STOP

BI97D028

Figure 44

BP97D060

Figure 46

BI97D027

LOWER LOAD OR TOOL

Issued 03-08

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CHAPTER 2 - SAFETY, AND DECALS

Figure 47

BI97D020

RAISE LOAD OR TOOL SLOWLY

LOWER LOAD OR TOOL SLOWLY

Figure 48

BI97D034

Figure 50

BI97D026

Figure 51

BI97D033

TURN MACHINE LEFT SWING LOAD LEFT

TURN MACHINE RIGHT SWING LOAD RIGHT

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

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

Figure 49

BP97D057

RAISE BOOM 87479806 A - EU

Issued 03-08

Figure 52

BI97D055

LOWER BOOM

2-37

CHAPTER 2 - SAFETY, AND DECALS

Figure 53

BI97D041

RETRACT ARM

FILL TOOL

2-38

EXTEND ARM

Figure 54

BI97D054

Figure 55

BI97D032

Figure 56

BI97D031

EMPTY TOOL

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Steps and Hand Holds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Inside Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Window Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Standard Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Optional Air Ride Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Steering Wheel Tilt Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Transmission Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Parking Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Air Louvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 INSTRUMENT PANEL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Critical Warning Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Non - Critical Warning Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Navigating Through the LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Viewing Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Setting Trip Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Entering the Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Options and Preference Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Spool Valve - One Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Spool Valve - Two Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Spool valve - Three Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four Spool Valve - Three Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wrist Rest Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-31 3-31 3-32 3-33 3-34 3-35

SIDE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-2

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENTS AND CONTROLS This chapter identifies the location and gives a brief overview of the functions and controls found on this machine.

New machines can have extremely sophisticated electronic instruments and controls that may be unfamiliar to even the most experienced operator. Use this chapter to familiarize yourself with the locations and functions of the machine controls before operating the equipment. See the operating instructions in the following chapter for more detailed information on how to safely operate this machine in the most time and fuel efficient manner.

ENGINE COVER

MASTER ELECTRICAL DISCONNECT SWITCH

Figure 1

BD08A012

The engine cover allows access to both engine sides. A locking mechanism is provided for the engine cover. Use the machine ignition key to open and close this cover.

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

BD07N653-01

Figure 3

The master electrical disconnect switch is located at the rear of the engine compartment. The switch has two positions: ON and OFF. MASTER ELECTRICAL SWITCH ON The master disconnect switch in the ON position energizes the entire electrical system. When the master disconnect BS00A2037 switch is ON and the key switch is OFF, the dome lamp, horn, stop lamps, four-way flashers, and rotary light switch are powered and functional.

MASTER ELECTRICAL SWITCH OFF In the OFF position, all machine power is interrupted.

BS00A017

IMPORTANT: Do not use the master electrical disconnect switch to stop the engine.

Figure 2

BD07N553-01

2. After releasing the lock, remove the key, push the button in and open the cover. The engine hood is supported with a gas operated strut, 3. To close the cover, push the strut latch in and use the hood strap to pull the cover down. Close the hood and latch in place securely.

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

CE-NA000

Issued 03-08

87479806 A - EU

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB CAB DOOR

STEPS AND HAND HOLDS WARNING: Always maintain three point support while getting on and off the machine and entering or exiting the operator’s cab. A three point support system has been provided that enables a person to use simultaneously two hands and one foot or two feet and one hand while ascending, descending or moving about the machine.

Failure to comply could result in injury or death.

CE-NA000

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

CE-NA000

Figure 5

BD06H085-01

DOOR HANDLE AND DOOR LOCK

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

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

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

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

INSIDE DOOR LATCH

BD06F163-1

Figure 4

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

Figure 6

BD06H086

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

Push the latch to open the door from the inside.

WARNING: Always lock the cab doors in the full open or full closed position before using the hand holds on them.

3-4

Issued 03-08

87479806 A - EU

CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDOW LATCH

1 Figure 9

BD06F158

Figure 7

BD06G177

1. LIFT TO OPEN

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

EMERGENCY EXIT

3 2

Figure 8

BD06G093

2. LATCH PIN 3. HOLD LATCH

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.

The window may be opened and locked against the side of the cab. To open and lock the window, 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 in place.

Issued 03-08

Figure 10

BD06F177

87479806 A - EU

EMERGENCY EXIT

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

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS STANDARD OPERATOR’S SEAT

1 4

Figure 11

BD06F051

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

Figure 14

BD06F052

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

2 5

2

Figure 12

BD06F047

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

NOTE: Each armrest will pivot to the up position.

Figure 15

BD06F048

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

HEIGHT ADJUSTMENT, STANDARD SEAT:

3

BD06F046

Lift the seat all the way up, drop the seat to the lowest position. Lift the seat to the desired position.

The seat will lock into accepted position.

Figure 13

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

3-6

Issued 03-08

87479806 A - EU

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPTIONAL AIR RIDE SEAT

1

2

4 Figure 18

BD06G182.

Figure 16

BD06G181

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

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

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

NOTE: Each armrest will pivot to the up position.

5 BD06G182

3

Figure 19

5. HEIGHT ADJUSTMENT HANDLE:

Figure 17

BD06F046

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

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

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

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

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

Issued 03-08

87479806 A - EU

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

6 7

BD06G182.

Figure 20

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

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

Figure 22

RD97F225

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

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

8

Figure 23

RD97F226 BD06G183

Figure 21

8. RIDE CUSHION ADJUSTMENT LEVER

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

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

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

The first adjustment is with the small end of the adjustment lever pointing toward the front of the seat, as shown. The other three adjustments can be obtained by rotating the small end of the adjustment lever out away from the seat. Each of the adjustments has a slight detent.

3-8

Issued 03-08

87479806 A - EU

CHAPTER 3 - INSTRUMENTS AND CONTROLS FOOT PEDALS

Figure 24

BD06F161

BD06H104

STEERING WHEEL TILT CONTROL The steering wheel tilt control allows the steering wheel to be adjusted to multiple positions. Pull the handle up, and adjust the steering wheel to the correct and most comfortable 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.

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

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

The brake pedal will actuate the machine brakes when pushed.

NOTE: The pedal will work in conjunction with the transmission declutch switch for more efficient braking.

See Declutch Switch in Operating Instructions- Chapter 4 for further information.

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

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

BD06H104

Figure 25

BD06F160

A. Move the control lever away from you for FORWARD. B. The center position of the control lever is NEUTRAL.

Figure 26

BRAKE PEDAL

Figure 27

FOOT THROTTLE Push the foot throttle to increase engine speed.

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

C. Mov e the co ntro l leve r to ward you for REVERSE. The F-N-R function of the transmission control lever may be moved to the loader control lever for operating efficiency.

Issued 03-08

87479806 A - EU

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS PARKING BRAKE RELEASE

PARKING BRAKE

NOTE: The service brake must be at operating pressure before the parking brake can be released to move the machine. The brake pressure indicator lamp must not be illuminated when disengaging the parking brake.

Attempting to move the machine prior to the service brake pressures being sufficient causing low operating pressure can result in premature parking brake pad wear.

Using transmission Forward-Neutral-Reverse (FNR) control on the left side of steering column All the following steps are required: BD06F099

Figure 28

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

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

IMPORTANT: The parking brake is a spring applied, hydraulic released brake which is applied to the drive shaft.

It will effectively hold the machine in place when used correctly.

1. Service brake pressure must be at operating pressure.

2. Transmission control lever must be in neutral.

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

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

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

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

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

Figure 29

BD06H025

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

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

3. Right side FNR switch must be in Neutral.

4. Machine speed must be zero.

5. Engine must be running.

3-10

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Figure 30

BD06089-04

6. Push down on the top of the transmission enable switch. (The switch is located on the side console.) The indicator light on the bottom of the enable switch will illuminate when activated.

7. Push down on the bottom of the parking brake switch to release the parking brake. This must occur within 8 seconds of Enable. (If the parking brake was NOT set when the machine was turned off, the parking brake switch must be cycled at this step).

8. Place the right side FNR switch in either FORWARD or REVERSE to move the machine.

(This must occur within 8 seconds of Enable).

BD06F155

Figure 32

KEY SWITCH The key switch has four positions: ACCESSORY POSITION This position will energize the optional radio only. It will not energize the instruments or start the engine.

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

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

HORN AND TURN SIGNAL

1 RADIO (IF EQUIPPED)

2

Figure 31

BD06F157

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

BC00B064

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

(2) TURN SIGNAL LEVER

BC00B087

Issued 03-08

Push the control lever up to signal a left turn. Pull the lever down to signal a right turn. The lever must be moved manually to the center position to stop the signals.

87479806 A - EU

BD06F053

Figure 33

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

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS AIR LOUVERS MAIN AIR LOUVERS

RECIRCULATION AIR LOUVER T h e r e c i r c u la ti o n a i r l o u v e r s a r e b e h i n d t h e operator’s seat next to the floor. When open, air is recirculated in the cab.

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

Figure 34

BD06F159

MAIN LOUVERS

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

1

2

Figure 36

BD06F095

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

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

Figure 35

BD06G096

LOUVERS

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

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

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

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

Figure 37

BD06F159

DEFROST LOUVERS

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

FRONT CONSOLE

1

2

Figure 38

BD07G075

1. PILOT CONTROL SWITCH:

BC00B048

Push on the left hand 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 right hand side of the switch to actuate the pilot controls. The hydraulic control levers will now function.

2. FOUR-WAY FLASHER SWITCH: Push the left hand side of the flasher switch to actuate the flashers. Push the right hand side of the flasher switch for the OFF position.

BC00B087

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3-13

CHAPTER 3 - INSTRUMENTS AND 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, 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, on some circuits 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.

3

4

2

5 6

1 1

Figure 39

BD06F096-6

1. FOUR-WAY FLASHER AND TURN SIGNALS INDICATOR: The green indicator lamps will flash when a turn is signaled or when the four-way flashers are activated.

BS96H047

2.BRAKE PRESSURE INDICATOR: This indicator illuminates when the brake system pressure is too low. The alarm sounds continuously and the stop master indicator will be red.

BC00B108

Stop the machine and correct the problem.

3.LAMP INDICATOR: This indicator illuminates when the driving high beam lamps are ON.

BS07A263

4.ENGINE GRID HEATER INDICATOR (IF EQUIPPED):

BCN02191

To start the engine, turn the key switch to the ON position. The indicator illuminates when the engine grid heater is operating. Wait until the indicator light is OFF before attempting to start the engine. The indicator light may come on again during cranking and shortly after the engine starts for post heating of the air to allow for smooth running conditions and cold weather warm-up.

5. SECONDARY STEERING INDICATOR (IF EQUIPPED): This indicator illuminates when the primary steering system pressure is too low. The alarm sounds continuously and the stop master indicator turns red.

BC00B111

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

6.PARKING BRAKE INDICATOR:

BS96H049

3-14

This indicator illuminates when the parking brake is applied. When the parking brake is applied and the transmission is shifted into FORWARD or REVERSE, the alarm sounds and the caution master indicator turns yellow.

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87479806 A - EU

CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

6. STOP MASTER INDICATOR (RED, CRITICAL):

BC00B290

6

The Stop Master Indicator is a critical warning display. See Critical Warning Displays.

CRITICAL WARNING DISPLAY When the Stop Master Indicator illum in ates, IMMEDIATELY bring the machine safely to a stop, and turn the engine OFF. Failure to do so may result in personal injury and/or damage to the machine.

Figure 40

BD06F096-2

The following table is a listing of critical warning displays that may appear on the instrument cluster and the corrective action that is required. When a fault occurs, a continuous audible alarm will sound and the Stop Master Indicator will be RED. A warning message will be displayed in the message area.

CRITICAL WARNINGS Display

Description

Corrective Action

ENGINE OIL PRESSURE

Low Engine Oil Pressure

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

BRAKE PRESSURE

Low Brake Pressure

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

STEERING PRESSURE (W/AUX STEERING)

Low Steering Pressure

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

COOLANT TEMPERATURE

High Engine Coolant Temperature

Bring the machine to a safe stop, and turn the engine OFF immediately.

Check the coolant levels after allowing the engine and the coolant to cool.

Contact your Dealer.

HYDRAULIC OIL TEMPERATURE

High Hydraulic Oil Temperature

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

TRANSMISSION OIL TEMPERATURE

High Transmission Oil Temperature

Bring the machine to a safe stop, and turn the engine OFF immediately.

Contact your Dealer.

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3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

7. CAUTION MASTER INDICATOR (YELLOW, NON-CRITICAL):

BC00B291

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.

7

Figure 41

BD06F096

When a fault occurs, an audible alarm will sound for 3 seconds and the Caution Master Indicator will be YELLOW. The caution message will be displayed in the message area. If this occurs, return the machine to a service position, and turn the engine off, and take corrective action to help avoid expensive repairs.

NON - CRITICAL WARNINGS Display

Description

Corrective Action

PARKING BRAKE

Parking Brake engaged and machine shifted Forward or Reverse

Release the parking brake.

COOLANT TEMPERATURE

High engine coolant temperature

1. Idle machine and monitor temperature.

2. Clean radiator or operate fan reverser (If equipped).

3. Check coolant level and add coolant if necessary.

4. If condition persists, contact your dealer.

HYDRAULIC TEMPERATURE

High hydraulic temperature

1. Idle machine and monitor temperature.

2. Clean cooler or operate fan reverser (If equipped).

3. Check hydraulic fluid level.

4. If condition persists, contact your dealer.

TRANSMISSION TEMPERATURE

High transmission temperature

1. Idle machine and monitor temperature.

2. Clean cooler or operate fan reverser (If equipped).

3. Use a lower gear.

4. If condition persists, contact your dealer.

AIR FILTER

High air filter restriction

1. Clean air filter.

2. Replace primary and secondary filters.

3. If condition persists, contact your dealer.

TRANSMISSION FILTER

Transmission filter restriction

1. Replace transmission filter.

2. If condition persists, contact your dealer.

HYDRAULIC FILTER

Hydraulic filter restriction

1. Replace hydraulic filter.

2. If condition persists, contact your dealer.

ALTERNATOR

Alternator malfunction

1. Check electrical system.

2. Voltages are out of range.

3. Change operating procedure.

4. If condition persists, contact your dealer.

FUEL

Low fuel

Fill fuel tank - do not allow tank to totally empty.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS 8. TRANSMISSION OIL TEMPERATURE GAUGE

8 BC00B291

T h e C a u t i o n M a s t e r I nd i c a t o r i s a non-critical warning display. See Non Critical Warning Displays.

The transmission oil temperature gauge indicates the oil temperature of the transmission. Normal operating t e m p e r at u re i s i n t h e gr e e n z o n e . W he n t h e transmission oil temperature increases, the gauge will move into the yellow zone, the warning alarm sounds for three seconds, and the caution master indicator turns yellow. When the temperature continues to increase the gauge moves into the red zone, the warning alarm will sound continuously, and the stop master indicator turns red. DO NOT operate the machine when the temperature is in the red zone.

Figure 42

BD06F096A .

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 (248 to 257 °F) (See the note below.)

Oil temperature is high

Caution (Yellow)

Flashes

3 Seconds

125 °C and above (257 °F and above)

Oil temperature is very high

Stop (Red)

Flashes

Continuous

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. Correct the problem before continuing to operate the machine.

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3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

9

Figure 43

BD06F096

9. HYDRAULIC OIL TEMPERATURE GAUGE: The hydraulic oil temperature gauge indicates the oil temperature of the hydraulic system. Normal operating temperature is in the green zone. When the hydraulic oil temperature increases the gauge will move into the yellow zone, the warning alarm sounds for three seconds, and the caution master indicator turns yellow. When the temperature continues to increase the gauge moves into the red zone and the warning alarm sounds continuously.

The stop master indicator turns red. DO NOT operate the machine when the temperature is in the red zone.

9

Figure 44

BD06F096B

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) (See note below.)

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: Do not operate the machine if the indicator turns red and the alarm sounds continuously. Stop the machine and correct the problem.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

10

Figure 45

BD06F096

10. FUEL LEVEL GAUGE: The fuel level gauge indicates the fuel level.

Normal operating range is in the green zone. When the tank is almost empty the BS98M034 gauge will move into the yellow zone and the fuel indicator will begin to flash, the warning alarm sounds for three seconds, and the caution master indicator turns yellow.

10

IMPORTANT: Do not allow the machine to run completely out of fuel.

Figure 46

BD06F96B

FUEL LEVEL GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

10 percent and below

Fuel level low

Caution (Yellow)

Flashes

3 Seconds

10 percent and above

Fuel level normal

WARNING: If the machine runs out of fuel, do not attempt to work on pressurized hydraulic lines.

Lines are under high pressure. Failure to comply could result in injury or death.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL INDICATORS

11

Figure 47

BD06F096

11. ENGINE COOLANT TEMPERATURE GAUGE: The engine coolant temperature gauge indicates the coolant temperature of the engine.

BS98H053 Normal operating temperature is in the green zone. When the engine coolant temperature increases the gauge will move into the yellow zone, and the warning alarm sounds for three seconds. The caution master indicator turns yellow.

When the temperature continues to increase the gauge moves into the red zone and the warning alarm sounds continuously. The stop master indicator turns red. DO NOT operate the machine when the temperature is in the red zone.

11

Figure 48

BD06F096A

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

Coolant temperature is very high

Stop (Red)

Flashes

Continuous

110 °C and above (230 °F and above) (See the note below.)

NOTE: Do not operate the machine if the indicator turns red and the alarm sounds continuously. Stop the machine and correct the problem.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS LCD MULTI-FUNCTION DISPLAY

1

2 3

A

B Figure 50

BD06F185A

Figure 49

BD06F097A

LCD MULTI-FUNCTION DISPLAY

The LCD Multi-Function Display (liquid crystal display) is located at the center of the modular dashboard. On start up, the console indicator lamps will momentarily flash. The LCD Multi-Display will flash Case along with the machine model. The initial standard driving screen will then appear. Once operator preferences are set, the screen will reflect those selections.

NOTE: Upon initial startup, the operator can push the return/escape key, and the language selection screen will appear immediately. This allows the operator to make a language selection without having to use an unknown language to scroll through to preferences.

TYPICAL LCD MULTI-FUNCTION DISPLAY

Information will be displayed in three zones on the LCD, as directed by the operator or machine. In most situations the operator or technician will be given specific information prompts to follow if conditions are not correct.

1. Zone One: The top section of the LCD display will show the machine hours, speed, or RPM’s.

The display is controlled by machine technology and geared toward operator preferences. The screen shown above is the default screen.

In the example shown, the machine hours are displayed. Machine hours will always be displayed briefly on start up. After the machine is started, the display will change to show engine RPM’s. When the machine is moving, this area will change to show speed or RPM’s. The operator can make a preference selection, programming the screen to show MPH, km/h, or RPM’s.

2. Zone Two: This center of the display is dedicated to transmission signals. The example above shows the transmission control lever in neutral (N), the gear numerically (4th), and the automatic transmission mode (A).

Fault codes will be displayed in Zone 2. As an example this section may list transmission fault codes. If the transmission is not operating correctly the display may show: • C - Substitute clutch • L - Limp home • S - Transmission shutdown • U - Transmission control unit shutdown 3. Zone Three: The lower section of the LCD display is divided in two sections. The left hand section indicates if the gearbox is clutched or unclutched. It also indicates the power mode Max/Std/Auto/Eco. The example above displays Auto.

The right hand section (B) displays the clock.

Time can be set in either 12 or 24 hour increments.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS USING THE ARROW KEYS

NAVIGATING THROUGH THE LCD MULTI-FUNCTION DISPLAY SCREENS

A

C

At any time during operation or with the key switch on, the operator may scroll through three information screens and two trip screens by using the arrow keys. These five screens are in a circular loop and may be accessed by pressing the up or down key.

The following sequence shown uses the down key only.

NOTE: Pressing the escape key will return the LCD back to the normal driving screen. In order to lock the changes into memory, the operator must press the confirm key, then use the escape key to return to the main screen. Turning the machine off will also lock the settings into memory.

B

D Figure 51

BD06F186A

KEY PAD

The key pad is located on the console just below the steering wheel. Use this key pad to move from one screen to another, choose various selections, monitor the machine func tions, and re trieve information.

All selections made with the computerized technology of the LCD screen are essentially programmed in the same manner.

When using the screen, use the arrow keys (C and D) to scroll to the desired selection, highlight that selection and press the confirm/enter key (B).

Figure 52

BD06F188

From the driving screen, push the down arrow, as shown.

Follow any screen prompts when given and use the confirm key to enter the selection. Use the escape key (A) to return to the main menu. This will lock the chosen selection into memory.

All functions can be accessed in the same basic manner.

A. Escape key: Use this key to exit and return to the driving screen. This key can be used anytime to start over and begin again or to exit a field. It can also be used to electronically check fault codes.

B. Enter/Confirm key: Use this key to confirm selections: Af ter selections have been highlighted, use the enter/confirm key to choose selections.

C. Up arrow key: Use this key to scroll up to selections.

D. Down arrow key: Use this key to scroll down to selections.

NOTE: Arrows on the screen will indicate if selections are up or down from the current selection.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS VIEWING SCREENS

BD06F170

Figure 53

BD06F183

Info 1 is the first information screen displayed when using the down arrow from the driving screen. It displays engine RPM’s, speed, fuel level, and the voltage level.

Figure 54

BD06F027C

Press the down key again to display Info 2 screen.

This screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Farenheit or Celsius, as well as oil pressure PSI.

BD06F169

Figure 55

Push the down key again to display the Info 3 screen.

This screen displays the temperature in Farenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and radiator coolant temperature.

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Figure 57

By continuing to scroll down, the fifth screen will display the Trip 1 screen. Trip 1 and Trip 2 screens can be reset independently.

BD06F170

BD06F184

Figure 56

Press the down key again and the Trip 2 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.

Figure 58

The previous screen can be accessed by using the up arrow key.

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS SETTING TRIP SCREENS

Figure 61

BD06F172 BD06F170

Figure 59

Highlight the trip screen you wish to set. (Capacity can be set in U.S. gallons, Imperial gallons, or metric liters when setting measurement preferences).

BD06F187A

The trip screen will indicate a reset message. At this screen, press the confirm key to clear the numbers and reset the trip information. The current date and time will display automatically. The hours, fuel consumption, and fuel used per hour will reset and revert to zero.

Figure 60

Press the confirm key to reset to the desired trip screen.

Figure 62

BD06H108

Press the escape key to return to the main driving screen and lock settings into memory. The screen will begin to record time and fuel usage immediately.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS ENTERING THE SERVICE SCREENS After the machine has been started or the key switch has been turned to ON, the operator or service technician may use this service menu to adjust machine configurations to working conditions, to test components, view faults that may have occurred, or to select preferences.

5. Clock Menu

• • • • •

Hour Minute Day Month Year

6. Cluster Hardware Menu

• • • •

Hardware Part Number Hardware Serial Number Hardware ID Hardware Version

7. Cluster Software Menu Figure 63

BD06F177A

Press and hold the confirm key for two seconds to arrive at the select service screen. The arrow keys can be used to scroll through menu selections.

Items and selections in this menu are: 1. Power Mode Menu

• Max - Maximum power possible • Standard - Normal operation • Auto - Will cycle between maximum and standard automatically

• Eco - Limited power for economy 2. Preferences Menu

• Language - English, French, German, Italian, Portuguese, Spanish

• Units - Metric, English, Imperial • Clock - 24 or 12 hour increments 3. Options Menu

• • • •

Fan Auto - manual or automatic Idle Auto - manual or automatic

Software Part Number Software Serial Number Software ID Software Version

8. Configuration Menu

• Change Model Number (indicates cluster serial number, not machine serial number)*

• • • • • • •

Slct Tires (Select tire size, etc.)

Calibrate clutch * Gear Limits (choose gear selection)* Park Brake (Park brake test)* Cold Start (choose cold start system)* Fan Test (sound level) Special (Reset error/factory set)*

*The tests in the configuration menu should be performed only by a qualified operator or technician, as some tests require the engine to be running at high RPM’s.

Show RPM Show MPH or KPH

NOTE: Pressing the escape key will return the LCD back to the normal driving screen.

4. Display Menu

• • • •

• • • •

Day Display Day LED Night Display Night LED

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SELECT SCREEN

SELECTING POWER MODES

The select screen will allow you to make time settings as well as give access to machine information. Navigate this screen also by highlighting your selection and pressing confirm. This will allow you to change clock settings or view the hardware and software screens. No operator changes can be made to the hardware or software screens.

The power mode allows the operator to choose the most effective machine power for the current job conditions. Idling can be changed from automatic to a fixed rate.

Most commonly Auto is chosen, as the power will automatically increase or decrease between maximum power and standard power while the machine is working. This allows for maximum power if necessary, but will switch to standard mode for economy. Maximum power can be chosen for more severe work conditions. Economy can be chosen for limited power and fuel efficiency.

Press and hold the confirm key for two seconds to arrive at the service screen.

BD06F192

Figure 64

NOTE: Pressing the escape key will return the LCD back to the normal driving screen. In order to lock the changes into memory, the operator must press the confirm key, then use the escape key to page back to the main screen.

Turning the machine off will also lock the settings into memory.

Figure 65

BD06F177A

At the screen shown above, highlight the power mode, and press the confirm key to move to the Power Mode Selection Menu.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS ESCAPING FROM ERRORS NOTE: Selecting options and navigating through the screen menus are the same for all functions. The display will tell the operator if errors have occurred.

Figure 66

BD06F178

At the Power Mode Menu press the confirm key again to activate the selections. The highlighted section will flash to indicate a new selection can be made.

Press the up or down key to select the Power Mode, and then press the confirm key. Use the escape key to return to the main driving screen and to lock the mode selection into memory.

BD06F176

Figure 67

Should an error message display, press the escape key and begin again.

Confirming the Selected Mode The selected mode will display in zone 3 (bottom) of the Multi-Function Display when power mode is correctly selected.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS OPTIONS AND PREFERENCE SCREENS CLOCK Setting The Hour and Date From the select screen, choose the clock designation and press the confirm key. Use the arrow keys to show field for time and date by pressing the arrow key. When the correct time and date have been entered by using the up and down arrow keys (up increases the numbers - down decreases the numbers), press the confirm key to lock in correct time. Press the escape key to return to the main driving screen and lock selections into memory.

DISPLAY MENU BD06F179

Figure 68

LANGUAGE SCREEN, MEASUREMENT UNITS, AND CLOCK The LCD screen can be set with language, measurements, and/or clock preferences. Use the arrow keys to scroll to the preferences menu. Press the confirm key on the correct selection. Press the escape key to return to the main driving screen and lock the selection into memory.

The display menu can be used to change the background and brightness of the screen. Use the arrow keys to make your selection from the display menu and press the confirm key until the screen reverts to the main driving screen to lock the selection into memory. The screen display can be changed to suit working conditions. The screen will change to night function illumination when the head lamps are turned on.

Choose the preferences desired: language in English, Spanish, Portuguese, Italian, German, French; measurement units in metric, English, or Imperial; and clock units in 12 or 24 hour cycles.

Highlight the preference you wish to change and press the confirm key. The preference will flash and allow you to scroll through the choices. When the correct preference is chosen, press the confirm key, then use the escape key to return to the main driving screen in order to lock the preference into memory.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS AUTO IDLE (If Equipped) Idling can be changed from automatic to a fixed rate.

The fixed idle rate is defined as standard idle at 1050 RPM. Highlight the auto idle selection by using the arrow keys, then press confirm. This will allow you to scroll through the idle choices. When you have made the selection, lock the selection into memory by pressing the confirm key and returning to the main screen with the escape key. Most commonly auto idle is used as the standard idle selection.

RPMS/SPEEDOMETER Figure 69

BD06F180

OPTIONS MENU Use the arrow keys to choose the options menu.

Press the confirm key, and the options sub-menu will appear. The options menu will allow the operator to choose options for the fan, grid heater, etc.

These settings allow the operator to show either speed or RPM’s on the main menu when operating the machine. If travel speed is the desired setting, the operator can choose between MPH or km/h for the display. Highlight the desired choice, press the confirm key, then escape back to the main screen to lock the selections into memory.

FAN AUTO (If Equipped) The fan will run at maximum speed with no reversal in the default mode. Automatic is the more common or preferred setting. It will switch between high, low, or reverse as conditions require depending on actual temperature of the coolant, turbocharger air, transmission oil, and hydraulic oil.

The operator can choose fan speed or reversing capabilities. Highlight the fan auto selection by using the arrow keys, then press the confirm key. This will allow you to scroll through the fan choices. When you have chosen the selection, lock the selection into memory by pressing the confirm key, then use the escape key until the screen displays the main driving screen. These steps apply only if the machine is equipped with an optional variable speed fan valve.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS HARDWARE/SOFTWARE SCREENS The hardware and software screens cannot be changed by the operator.

BD106F193

Figure 70

The hardware selection will display the part number, serial number, ID number and version of the hardware cluster. The software selection will display the part number, serial number, ID number and version of the software cluster. Press the escape key to exit from this field or use the up arrow key to scroll backwards for another selection from the select sub-menu.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CONTROL LEVERS TWO SPOOL VALVE - ONE CONTROL LEVER

E 2

1 B

A

C

D

Figure 71

BSD06H024

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

F Figure 72

835636095

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.

3

D. RAISE E. DUMP F. ROLLBACK 2. AUXILIARY F-N-R SWITCH: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch, the proper sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch. Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

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BD06G091

Figure 73

3. TRANSMISSION DOWNSHIFT BUTTON: Drops the transmission down one gear at a time.

BC00B118

NOTE: See Transmission Operation/Initial Machine Movement for moving machine after engine start up.

3-31

CHAPTER 3 - INSTRUMENTS AND CONTROLS THREE SPOOL VALVE - TWO CONTROL LEVERS

4

G

H

2

A E

D

1

C

F BD01F271

Figure 74

1. LIFT ARM AND BUCKET CONTROL

B

A. DUMP B. ROLLBACK C. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position.

You must manually move the control lever from the FLOAT position to the HOLD position.

Figure 75

87536094

4 3

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 2. AUXILARY CONTROL G. AUXILIARY FUNCTION

3. TRANSMISSION DOWNSHIFT BUTTON: Drops the transmission down one gear at a time.

H. AUXILIARY FUNCTION See Transmission Operation/Initial Machine Movement for moving the machine after start up.

Figure 76

BD06G091

BC00B118

4. FNR Switch: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper BC00B124 sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch. Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS THREE SPOOL VALVE - THREE CONTROL LEVERS

E 2

F

D

G

A

B

1 3 C H

I

Figure 77

BD06F004

1. BUCKET CONTROL A. DUMP B. ROLLBACK C. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position.

You must manually move the control lever from the FLOAT position to the HOLD position.

Figure 78

87536093

A

4

2. LIFT ARM CONTROL

B

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.

5 C

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 3. AUXILIARY CONTROL H. AUXILIARY FUNCTION I. AUXILIARY FUNCTION

NOTE: See Transmission Operation/Initial Machine Movement for moving the machine after start up.

Figure 79

BD06F004

4. TRANSMISSION DOWNSHIFT BUTTON: Drops the transmission down one gear at a time.

BC00B118

5. FNR Switch: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper BC00B124 sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch. Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS FOUR SPOOL VALVE - THREE LEVERS

2

I

J

G

H

2

A 33

1

D

E C F

BS01E142A

Figure 80

1. BUCKET AND LIFT ARM CONTROL

B

A. DUMP B. ROLLBACK C. HOLD: The loader arms and bucket will not move when the control lever is in the HOLD position. When released, the control lever will automatically return to the HOLD position.

You must manually move the control lever from the FLOAT position to the HOLD position.

Figure 81

87536096

5 4

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

4. TRANSMISSION DOWNSHIFT BUTTON: Drops the transmission down one gear at a time.

2. AUXILIARY CONTROL G. AUXILIARY FUNCTION H. AUXILIARY FUNCTION 3. AUXILIARY CONTROL I. AUXILIARY FUNCTION J. AUXILIARY FUNCTION

NOTE: See Transmission Operation/Initial Machine Movement for moving the machine after start up.

Figure 82

BD06G091

BC00B118

5. FNR Switch: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper BC00B124 sequence must be followed. The primary shift lever must be in the Neutral position before using the auxiliary FNR switch.Push the switch forward to place the transmission in Forward, place the switch in the middle position to place the transmission in Neutral, and pull the switch rearward to put the transmission in Reverse.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS WRIST REST ADJUSTMENTS

BF06F105

Figure 83

BD06F094

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

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Figure 84

ADJUSTMENT KNOBS: To adjust the wrist rest, loosen the adjustment knob.

The adjustment knob will allow the wrist rest to be raised or lowered. Adjust to the most comfortable working position, and tighten the knob.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

SIDE CONSOLE

Figure 85

BD08A001

The side console allows the operator to make adjustments to machine operation and functions. It also houses the climate control system.

NOTE: Your machine console configurations may vary slightly in appearance from the above photo, however all switch symbols and switch functions will remain the same.

BD08A004

Figure 86

The decals on the right side window indicates all the functions of the right hand console as well as the control levers for the machine. Make certain the decal matches the actual console buttons and the control levers before using the machine.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

CLIMATE CONTROL

2

3

1

Figure 87

BD06F093

1. AIR CONDITIONING/BLOWER FAN SWITCH (If Equipped): Push on the snowflake at the center of the dial to turn the air conditioning function on. When the air conditioner is on, the snowflake will illuminate. The blower fan switch has five positions: OFF, 1, 2, 3, and 4. Turn the switch to 4 for maximum speed and to 1 for the lowest speed.

BC00B087

2. FRESH AIR / RECIRCULATION (If Equipped): Turn knob to the left for recirculation and to the right for fresh air.

3. CLIMATE CONTROL (If Equipped): Turn the control clockwise for warmer temperatures, and adjust the control to the desired temperature. Turn the control counter clockwise for cooler temperatures. (Red markings indicate warmer temperatures; blue markings indicate cooler temperatures). Turn completely counter clockwise for OFF. NOTE: Make sure the water inlet for the heater is in the full ON position. This inlet is located in the left rear of the engine compartment.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE CONSOLE

4

5

6 7

Figure 88

BD08A003

BC0G111

6. DRIVING LIGHT SWITCH:

A.Push switch to the center position for on.

Push on the top of the switch for roading machine. Pushing on the bottom of the switch will turn the lights off. The middle position is for marker/position lights.

B.Push on the front of switch for washer fluid.

5. FRONT WIPER/WASHER TOGGLE SWITCH

BC00B132

Figure 89

BD08A002

4. REAR WIPER SWITCH:

A.OFF - Toggle switch is in the OFF position.

B.INTERMITTENT - Push toggle to the first position. There are six settings for intermittent wiper speeds.

BS07A263

7. WORK LIGHT SWITCH: Push on the top of the switch for front and rear working lights. The middle position is for front work lights only.

BS96045 Pushing on the bottom of the switch will turn the lights off.

C. LOW - Push toggle ahead until the wiper runs continuously for low wiper speed.

D. HIGH - Push toggle ahead for high wiper speed.

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE CONSOLE

11

10

9

8

Figure 90

BD08A001

BC00B118

BC00B118

8. TRANSMISSION ENABLE SWITCH: Use the transmission enable 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. By following the correct sequence and enabling the auxiliary F-N-R the operator may select FORWARD-NEUTRAL-REVERSE from the loader control lever or the auxiliary F-N-R switch. See Chapter 4 - Operating Instructions for further information.

9. 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).

10. DECLUTCH SWITCH: The declutch will disengage the transmission when maximum power is needed for the loader. Push down on the top of the declutch switch. The transmission declutch function is activated by brake pressure. See Chapter 4 - Operating Instructions for further information.

BS07A264

BC00B087

Issued 03-08

11. FAN REVERSER SWITCH (If Equipped) 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 idle and release the fan reverser switch. This is a three-position switch. Push the upper part of the switch for momentary reversal as described above. The center position of the switch is the automatic position, and the lower position disables the automatic fan.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE CONSOLE

16

15 14 13 12

Figure 91

BD08A001

12. RETURN TO DIG: Push on the top of the function switch for the ON position. This will allow the bucket to return to level with the ground for digging.

BS07A2657

13. RETURN-TO-TRAVEL, DETENT SWITCH:

BC00B087

The Return-To-Travel switch is used to automatically return the loader bucket to the travel position after you have dumped the loader bucket. Push down on the top of the Return-To-Travel switch to engage the return to travel detent. Push the bottom of the switch for the Float Detent position.

14. HEIGHT CONTROL: Push on the top of the function switch for the ON position. This will allow the bucket to be raised to set height position when activated.

BS07A266

15. RIDE CONTROL SWITCH (If Equipped): This is a 3-position switch. Push on the top of the switch for the manual ON position. Ride control can be left on at all times, whether loading or roading. The center position is the automatic and most commonly used position. In the automatic position, ride control will automatically activate when ground BC00B094 speed is above 5 km per hour (3.1 mph) and automatically shut off when ground speed is below 5 km per hour (3.1 mph). The indicator light on the switch will illuminate when ride control is activated. To turn ride control off, push on the bottom of the function switch for the OFF position.

16. COUPLER PIN ENGAGE SWITCH (If Equipped):

BC00B087

3-40

Slide the locking plate toward the center of the switch, push down on the top of the switch to retract the pins for the attachment. The switch lamp will illuminate when the pins are retracted. The switch will lock in the pin extended position after the bottom of the switch has been pressed and the pins are extended.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SIDE CONSOLE ENGINE COOLANT HEATER (If Equipped)

Figure 92

BD06H117

BACK-UP ALARM (If Equipped) To cancel the backup alarm, depress the switch.

The left side of the engine block has a connection for installing an optional coolant heater. See your Case Dealer for this cold weather option.

ENGINE GRID HEATER (If Equipped)

BC00B079

BD06F096

Figure 93

BD06H118

ROTATING BEACON (If Equipped)

BC00B082

Figure 94

BD06G097

Push the top of the rotating beacon switch for the ON position. Push the switch bottom for the OFF position.

Figure 95

The machine can be equipped with an engine grid heater for cold weather operation.

Turn the ignition switch to the ON position and wait for the indicator lamp to go off. The engine should be started only after the lamp is no longer illuminated.

The indicator light may come on again during cranking and shortly after the engine starts for post heating of the air. This will allow smooth running conditions during cold weather warm up.

WARNING: Do not use ether starting fluid with this machine as it can cause an explosion. Failure to comply could result in serious injury or death.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Spool Valve - One Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Spool Valve - Two Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Spool Valve - Three Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four Spool Valve - Three Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Function Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return-To-Dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Return-To-Travel Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Auxiliary Hydraulic Connection (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ride Control (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coupler Pin Engagement (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Transport and Carry Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating on a Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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4-13 4-13 4-14 4-15 4-16 4-17 4-17 4-18 4-18 4-19 4-19 4-20 4-20 4-21 4-21 4-21 4-22 4-23 4-24 4-24 4-24 4-25 4-26 4-27 4-28 4-29 4-30

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CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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

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

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

WARNING: Do not operate the machine while under the influence of alcohol or drugs.

Failure to comply could result in serious injury or death.

RUN-IN PERIOD Your machine will last longer, give better and more economical performance, if you pay particular attention to the engine during the initial run-in period.

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

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

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

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

Frequently check the instruments on the instrument panel.

Check the oil levels and coolant solution level frequently.

During the run-in period, the following checks and servicing operations should be carried out in addition to those specified in the service schedule: IMPORTANT: For turbocharged engines, only shut the engine down from the low idle position to prevent damage to the turbocharger.

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

CE-NA000

Before operating this machine, complete the following procedures: 1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids and lubricants are suitable for prevailin g conditions.

2. Carry out the daily maintenance operations.

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

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

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

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

7. Clean or replace any decals which are illegible.

See Decals in Chapter 2.

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

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

10. Remove any obstructions which hinder visibility.

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

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

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

The operator must be alone on the machine.

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

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

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

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4-3

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

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

SA040

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

18. Fasten and adjust the seat belt.

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

20. Check the loader controls for correct operation.

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

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

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

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

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

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

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

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

the the the try

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

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

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

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

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

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

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

4-4

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CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE AND PARKING THE MACHINE AFTER OPERATIONS WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand holds and steps, and get on or off the machine slowly. Failure to comply could result in serious injury or death.

SA038

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

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

2. Lower the attachment to the ground.

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

to

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

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

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

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

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

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand holds and steps, and get on or off the machine carefully. Failure to comply could result in serious injury or death.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

CE-NA000

Starting and Stopping the Loader

N

R Figure 3

BS03K026

4. The gearshift lever must be in NEUTRAL.

BD07N691

Figure 1

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

Figure 4

BD06F155

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

BD06H122

Figure 2

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

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

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

4-6

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CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 5

BD07N473

7. Push the pilot control lock out to the right in order to power the equipment.

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

9. To move the machine:

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

Figure 6

BD06F160

10. To shift gears manually: Use the transmission control lever to shift the transmission gears from first through fourth gear.

Turn the transmission control lever away from you to select a higher gear. Turn the lever toward you to select a lower gear. This control lever is also used to put the transmission in FORWARD, NEUTRAL, and REVERSE. A. Move the control lever away from you for FORWARD. B. The center position of the control lever is NEUTRAL. C. Mov e the co ntro l leve r to ward you for REVERSE.

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4-7

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

N

Figure 9

BD06F271

BS03K026

Figure 7

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

2. Lower the attachment to the ground.

BD06H127

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

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

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

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand holds and steps, and get on or off the machine carefully. Failure to comply could result in serious injury or death.

Figure 8

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

to

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

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

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

4-8

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CHAPTER 4 - OPERATING INSTRUCTIONS AUTOMATIC MODE OPERATION:

BD06F004

Figure 12

DOWN-SHIFT BUTTON, THREE LEVER CONTROL Figure 10

BD06H129

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

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

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.

Figure 11

BD06G091

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSMISSION ENABLE SWITCH

1

Figure 13

BD08A005

The Transmission Enable switch can be enabled after the following conditions have been completed: 1. Transmission controller is in neutral (left side).

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

3. The engine must be running.

4. Machine is stationary.

5. Parking brake is released.

Depressing the transmission enable switch allows the transmission to be controlled by the auxiliary F-N-R switch.

The indicator light on the bottom of the enable switch will illuminate when activated (See Note).

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

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

1. The parking brake switch must be released.

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

4-10

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CHAPTER 4 - OPERATING INSTRUCTIONS

AUXILIARY FORWARD, NEUTRAL, REVERSE (F-N-R) SWITCH FOR JOYSTICK CONTROL LEVER APPLICATIONS A 1

3

B

C

Figure 14

BD06F165

1. AUXILIARY JOYSTICK F-N-R SWITCH

Figure 16

BD06F099

5. The Parking Brake must be released (3).

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

4

2. The engine must be running.

3. The Auxiliary F-N-R Switch (1) must be in Neutral (B).

BD08A006

2

Figure 17

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

The transmission enable switch will be DEACTIVATED and F-N-R control will default back to the Standard Transmission Control Lever if: 1. The engine is stopped.

Figure 15

BD06F160

4. The Standard Transmission Control Lever (2) must be in neutral.

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2. The parking brake is applied.

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

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS

AUXILIARY FORWARD, NEUTRAL, REVERSE (F-N-R) SWITCH WITH THREE SPOOL VALVE THREE LEVERS A B 1

Figure 18

BD06F004

3

C

1. THREE LEVER AUXILIARY F-N-R SWITCH

Figure 20

RD06F099

5. The Parking Brake must be released (3).

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

2. The engine must be running.

4

3. The Auxiliary F-N-R Switch (1) must be in Neutral (B).

Figure 21

BD08A006

2

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

The transmission enable control will default back to the Standard Transmission Control Lever if: 1. The engine is stopped.

BD06F160

Figure 19

4. The Standard Transmission Control Lever (2) must be in neutral.

4-12

2. The parking brake is applied.

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

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CHAPTER 4 - OPERATING INSTRUCTIONS

CONTROL LEVERS TWO SPOOL VALVE - ONE CONTROL LEVER NOTE: This page shows the basic loader control lever positions.

6 4 2

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

1

5 3

Figure 22

BD06H024

1

4

2

3

Figure 23 5. HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH FLOAT DETENT SWITCH ENGAGED.) 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH FLOAT DETENT SWITCH ENGAGED.)

B1119A88

1.

2.

3.

4.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARMS LOWER LIFT ARMS

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CHAPTER 4 - OPERATING INSTRUCTIONS THREE SPOOL VALVE - TWO CONTROL LEVERS NOTE: This page shows the basic control lever positions.

6 4

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

1

5

7 2

3 8

Figure 24

BD06F271

1

4

2

3

B1119A88

1.

2.

3.

4.

5.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARMS LOWER LIFT ARMS HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH FLOAT DETENT SWITCH ENGAGED.)

4-14

Figure 25 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH FLOAT DETENT SWITCH ENGAGED.) 7. AUXILIARY FUNCTION 8. AUXILIARY FUNCTION

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CHAPTER 4 - OPERATING INSTRUCTIONS THREE SPOOL VALVE - THREE CONTROL LEVERS NOTE: This page shows the basic loader control lever positions.

6 4

5

1 7

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

5 3

5 2 8

Figure 26

BD06F004

1

4

2

3

B1119A88

1.

2.

3.

4.

5.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARMS LOWER LIFT ARMS HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH FLOAT DETENT SWITCH ENGAGED.)

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Figure 27 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH FLOAT DETENT SWITCH ENGAGED.) 7. AUXILIARY FUNCTION 8. AUXILIARY FUNCTION

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS FOUR SPOOL VALVE - THREE CONTROL LEVERS

6

7

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

9

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

4 5 2

1 8

10

3

Figure 28

BD06H025

1

4

2

3

B1119A88

1.

2.

3.

4.

5.

DUMP BUCKET ROLLBACK BUCKET RAISE LIFT ARMS LOWER LIFT ARMS HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVER IS IN THE HOLD POSITION. WHEN RELEASED, THE CONTROL LEVER MUST BE MANUALLY MOVED FROM THE FLOAT POSITION TO THE HOLD POSITION. (ONLY WITH FLOAT DETENT SWITCH ENGAGED.)

4-16

Figure 29 6. FLOAT (DETENT): THIS IS A DETENT POSITION. WHEN IN THE FLOAT (DETENT) POSITION, THE LOADER BUCKET CAN FOLLOW LEVEL OF THE GROUND WITHOUT MOVEMENT OF THE CONTROL LEVER. (ONLY WITH FLOAT DETENT SWITCH ENGAGED.) 7. FIRST AUXILIARY FUNCTION 8. FIRST AUXILIARY FUNCTION 9. SECOND AUXILIARY FUNCTION 10. SECOND AUXILIARY FUNCTION

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CHAPTER 4 - OPERATING INSTRUCTIONS LOADER FUNCTION SWITCHES

BUCKET HEIGHT CONTROL

Push down on the top of the switch to engage all detents.

The bucket height control is used to automatically stop the loader arms at the height selected. Press the top of the switch to engage the bucket height detent.

1 2

1

3

Figure 30

BD06F274

1. HEIGHT CONTROL 2. RETURN-TO-TRAVEL/ FLOAT SWITCH 3. RETURN TO DIG

Figure 31

BD06F004

1. RAISE

1

BD06F271

Figure 32

1. RAISE

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS RETURN-TO-DIG

RETURN-TO-TRAVEL FUNCTION

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 Return-To-Dig function press the top of the switch.

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

2

1 1

2

Figure 33

BD06F004

1. FLOAT 2. ROLLBACK DETENT

Figure 35

BD06F004

1. ROLLBACK DETENT 2. FLOAT

1

1

Figure 36

BD06F271 BD06F271

Figure 34

1. FLOAT AND ROLLBACK DETENT

To actuate, move the control lever(s) into the FLOAT and ROLLBACK detents. The bucket control lever will automatically return to the HOLD position and the loader arm will remain in float when the loader reaches the Return-To-Dig position. See Loader Adjustments in this manual for Return-To-Dig Adjustments.

4-18

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.

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CHAPTER 4 - OPERATING INSTRUCTIONS FLOAT

LOADER CONTROL

The Float function is used to let the loader bucket float across rough ground. To enable this function press the bottom of the Return-To-Travel/Float switch.

The loader control levers are connected to a hydraulic accumulator through a pressure reducing valve. The purpose 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.

To test accumulator performance: 1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

2. Start the engine.

3. Raise the loader bucket.

4. Stop the engine.

Figure 37

B1128A88

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

5. Turn the key to RUN. 6. Verify that the right hand side of the pilot control switch is depressed, allowing the pilot controls to function.

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 the Repair Manual for this machine or see your dealer.

1

Figure 38

BD06F004

1. Float

1

Figure 39

BD06F271

1. Float

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4-19

CHAPTER 4 - OPERATING INSTRUCTIONS BRAKE ACCUMULATORS

DECLUTCH FUNCTION

Two hydraulic accumulators are connected in the brake system.The accumulators provide the brake modulating valve with a positive supply of pressurized hydraulic fluid.

Test the accumulators for correct operation every 100 hours.

1. Start the engine.

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

3. Stop the engine.

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

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

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

Figure 40

BD08A006

DECLUTCH SWITCH

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

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

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

4-20

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CHAPTER 4 - OPERATING INSTRUCTIONS BUCKET LEVEL INDICATOR

AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED)

BD00N076

Figure 41

BD03A009

Figure 43

The bottom of the bucket is parallel with the ground when the flat portion of the bucket is horizontal.

2 RIDE CONTROL (IF EQUIPPED)

1 Figure 42

BD06F165

Your Wheel Loader may be 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.

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 applicatio ns for increase d 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 a 3-position ride cont ro l switch (manual, auto, an d off). Most commonly, the operator will choose to leave this switch in the automatic (center) position. With ride control active, the green indicator light will illuminate anytime the machine is traveling faster than 3.1 mph (5 km/h) 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.

The top position of the switch turns ride control on in the manual position.

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

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CHAPTER 4 - 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 right hand console. When changing attachments, making certain all unauthorized personnel are clear of the area.

NEW PHOTO DUPLICATE Figure 46

BD07N694

To connect attachment, position the front coupler into the attachment. Press the bottom of the switch until it fully locks into place to extend the pins. Make sure the coupler pins are fully engaged to the attachment and the amber light is off before using the machine.

NEW PHOTO DUPLICATE Figure 44

BD06G089

To disconnect and connect an attachment, lower the attachment to the ground. Slide the locking tab upward and press the top of the coupler switch to retract the pins.

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 downward pressure on the attachment.

Failure to comply could result in machine damage, injury, or death.

NEW PHOTO DUPLICATE BD07N693

Place the front of the attachment against the ground and apply downward pressure on the attachment to make certain the attachment is fully and securely connected. Make certain the locking tab on the console is in the correct (downward) position. The locking tab is designed to prevent accidental pin retraction.

M781

Figure 45

The amber light will illuminate and the pins will remain in the retracted position. Back carefully away from the attachment.

4-22

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

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.

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

163L96

Figure 47

164L96

Figure 48

163L96

Figure 49

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.

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

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

M465

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4-23

CHAPTER 4 - 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.

Figure 50

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 lose control and roll-over. Failure to comply could result in injury or death.

SA041

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

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 Declutch Switch when operating on a hill.

• Use extra caution on hillside operations.

• Make sure that the low speed travel is selected.

• Always travel in the same direction as the slope, to

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

prevent the machine from turning over.

OPERATING THE MACHINE IN WATER

• Make sure that the bottom of the stream, or water

• Before using the machine in water, inject large

• Do not allow the water level to reach above the

• After completing the operation make sure to inject

in which you will work, can support the weight of the machine. bottom of the center drain plug of the axles.

quantities of fresh grease into the appropriate grease fittings.

fresh quantities of grease into any fitting that was in water.

WARNING: Do not operate the machine in a fast flowing stream. Failure to comply could result in injury or death.

4-24

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

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

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

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

NEVER TOW THE MACHINE FROM THE FRONT

1

Figure 52

BD03A036

Figure 51

BD08A011

1. Attach a rigid drawbar to the machine.

b. Clean the area around the parking brake cover to eliminate contamination. c. Remove the parking brake cover (1).

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

2. If the machine cannot be started to release the parking brake, the brake must be mechanically released:

2

a. Put blocks in front of and behind each wheel.

BD03A037

Figure 53

d. Loosen the lock nut (2). e. Turn the adjusting screw counterclockwise until the parking brake is released. f. Tighten the lock nut and replace the cover.

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

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

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CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE 2

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

SB042

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

46-76C

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

84-13A

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

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

2. Carefully move the machine SLOWLY onto the trailer.

3. Lower the loader bucket onto the trailer.

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

5. Apply the parking brake and stop the engine.

Remove the key.

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

4-26

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

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

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

See the next page for tie down locations of the machine.

10. Put a cover over the exhaust pipe.

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

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

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

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

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

4. Secure the machine to the trailer using the tie downs provided.

5. The transport lock must be secured.

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

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

Consult an approved organization.

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

MACHINE TIE DOWN LOCATIONS

Figure 54

BD07N627-01

CHAINS MUST BE SECURELY FASTENED TO THE FRONT LEFT AND RIGHT TIE DOWN HOLES.

Figure 56

CHAINS MUST BE SECURELY FASTENED AROUND THE LEFT AND RIGHT SIDE OF THE LOADER ARM.

Figure 55

BD07N659-011

CHAINS MUST BE SECURELY FASTENED TO THE LEFT AND RIGHT REAR TIE DOWN HOLES.

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BD00M052

87479806 A - EU

BD07N630-01

Figure 57

TRANSPORT LOCK MUST BE SECURED.

4-27

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

BATTERIES

COLD TEMPERATURE STARTING AIDS

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

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

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

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

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

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

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

Check for water in the fuel system. Cold temperatures can cause condensation to form in the fuel tank. Check and drain the fuel filter and fuel tank for water as required.

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

4-28

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

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

After engine warm up, turn the pilot control switch (located on the console) to the on position. Place the lift arm into float and the bucket into roll back to load the engine in order to heat the hydraulic oil. Hold for approximately two minutes. This will yield approximately 20° C (68° F). Apply and hold the foot brake, cycle the lift arm and bucket. Repeat the float/roll back heating procedure again for approximately two minutes. Raise the lift arms enough to steer the unit full left and right to warm the oil in the steering cylinders. In extreme cold conditions, hold the float/roll back condition for five minutes maximum.

WARNING: Make sure there around the machine before machine left and right. non-authorized personnel clear Failure to comply could result in or death.

is clearance steering the Keep all of the area. serious injury

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

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

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

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

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

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

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

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

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

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

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

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

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

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4-29

CHAPTER 4 - OPERATING INSTRUCTIONS STORAGE PREPARATION FOR STORAGE

PERIODIC CHECKS

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

Before storing the machine, carry out the following operations:

Every month, check:

1. Clean the machine.

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

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

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

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

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

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

4. Clean or replace the air filter element.

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

6. Grease the cylinder rods.

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

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

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

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

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

1. The battery charge and battery electrolyte level.

Recharge the batteries if required.

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

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

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

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

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

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

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

4. Replace the filtering element of the fuel filters.

5. Install the batteries.

6. Grease the machine thoroughly.

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

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

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

10. Clean the cylinder rods.

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

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

Keep non-authorized personnel clear of the machine.

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

WARNING: Avoid running the engine in a confined place. Make certain there is adequate ventilation at all times. Failure to comply could result in injury or death.

11. Lock the hoods and the cab door.

4-30

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS SERVICING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SUPPORT STRUT FOR LOADER LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Capacities and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ENGINE OIL VISCOSITY / TEMPERATURE RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Transmission Oil Viscosity / Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 DAILY INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 ACCESS DOORS AND FILL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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5-15 5-16 5-17 5-19 5-26 5-28 5-32 5-38

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

Keep all non-authorized personnel clear of the area.

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

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

• • • • • •

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

• any accumulator pressure released for the appropriate circuit

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

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

Consult your dealer.

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

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

IMPORTANT: Oils and fluids must be disposed of properly.

HOURMETER

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

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

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

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

M959

WARNING: Be sure all the service operations in this section are carried out punctually at the intervals given, in order to insure optimum performance levels and maximum safety when using the machine.

Failure to comply could result in machine damage, serious personal injury or death.

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BD06F097B

Figure 1

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

Servicing intervals are carefully calculated to guarantee safe and efficient machine operation.

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

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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

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

2. Remove the support strut from the storage position by removing the retaining bolt (1).

3. Place the support strut onto the cylinder rod with guide lock tab on top of cylinder and pointing toward the bucket (2).

4. Install the retaining bolt entirely into the support strut using all threads (3).

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

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

M824

2 2 1 3 Figure 2

BD07N691

Figure 3

BD007N629-01

SUPPORT STRUT IN TRANSPORT POSITION

SUPPORT STRUT IN SERVICE POSITION

TRANSPORT SERVICE LINK

Figure 4

BD07N691

SERVICE LINK IN OPERATING POSITION

Figure 5

BD07N630-01

SERVICE LINK IN LOCKED POSITION

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

5-4

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground, lower the bucket/attachment to the ground and stop the engine.

BD06F271

Figure 7

3. Operate the control levers from right to left and front to rear approximately a dozen times. Turn the ignition key to the OFF position.

Figure 6

BD06F155

2. Turn the ignition switch key to the “ON” position.

Pilot control switch must be on.

WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed. Failure to comply with this warning could result in injury or death.

WARNING: Before carrying out any service work on the hydraulic system, it is necessary to allow the system to cool (the temperature should not be more than 40°C (104° F).

Failure to comply with this warning could result in injury or death.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS CAPACITIES AND SPECIFICATIONS Engine Type of oil.................................................................................................................. Case Akcela (SAE 15W-40) Capacity ..........................................................................................................................................10.9 l (11.5 qt.)

Capacity (with filter change) ............................................................................................................11.8 l (12.5 qt.)

Cooling System System capacity ..............................................................................................................................22.0 l (23.2 qt.)

Fuel System Reservoir capacity............................................................................................................................ 189 l (50 gal.)

Hydraulic / Brake System Type of fluid.................................................................................................................. Case Akcela Hy-Tran Ultra Total system capacity................................................................................................................. 113.6 l (30.0 gal.)

Reservoir capacity........................................................................................................................ 56.8 l (15.0 gal.)

Transmission Type of oil.................................................................................................................. Case Akcela (SAE 15W-40) Total system capacity..................................................................................................................... 26.0 l (27.5 qt.)

Refill capacity - with filter change ................................................................................................ 18.90 l (20.0 qt. ) Axles Type of oil........................................................................................ Case Akcela Transaxle Fluid (SAE 80W-140) Front Capacity ................................................................................................................................22.0 l (23.2 qt.)

Rear Capacity .................................................................................................................................22.0 l (23.2 qt.)

NOTE: Machines are shipped from the factory with break-in oil.

Fittings Grease fittings, as required .......................................................................................... Case Akcela Molydisulfide

5-6

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE OIL VISCOSITY / TEMPERATURE RANGES

Figure 8

BC07N452

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

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid starting the engine and in providing sufficient oil flow at ambient temperatures below -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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5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS TRANSMISSION OIL VISCOSITY / TEMPERATURE RANGES

Figure 9

BC04F193

HYDRAULIC/BRAKE SYSTEM - TEMPERATURE RANGE

Figure 10

BC04F192

5-8

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS COOLANT SOLUTION

BIODIESEL FUEL USAGE CONDITION

Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e . D o n o t u se n o n - a p p r o v e d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can mix and work against each other, reducing anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

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

Anti-freeze/Anti-corrosion

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

Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing.

For areas where the ambient temperature is over -36°C (-34°F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C (-34°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

FUEL IMPORTANT: The use of fuel/diesel not complying with specification standards could lead to severe damage to the machine’s engine and fuel system. The use of unapproved fuel, including biodiesel may void the machine’s warranty coverage.

Use fuel which complies with ASTM (American Society for Testing and Materials) D975 standard (North America). In Europe, fuel must comply with Specification Standard EN590 or its equivalent.

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption. Consult your dealer for specific fuel recommendations.

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

IMPORTANT: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751.

IMPORTANT: It is imperative that you check which blend is approved for your engine with your local dealer. Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

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Engine performance is effected by the use of biodiesel fuel. An up to 12% reduction in power/torque can be experienced.

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

Some modification may be required to allow the engine to use biodiesel. Consult your local dealer for complete information regarding approved modifications.

It may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently when using biodiesel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank.

These particles are then trapped by the vehicle filters and may cause shortened filter life and/or filter blockages.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Biodiesel will actually attract moisture from the atmosphere. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

BIODIESEL STORAGE IMPORTANT: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the engine fuel system.

Clean up any spills of biodiesel on the machine, as biodiesel fuel can cause paint damage.

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FUEL STORAGE Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Special considerations are required for machine storage with biodiesel fuel. See prior restrictions concerning biodiesel storage.

HYDRAULIC FLUID

Figure 11

RD97F136

Case Akcela Hy-Tran Ultra hydraulic fluid is specifically designed for high pressure applications and for Case hydraulic systems. Your Case Dealer can provide hydrau lic fluid to fulfill differen t climate/temperature conditions. Refer to the charts at the beginning of this section.

TRANSMISSION COMPONENT OIL Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is manufactured for your climate/temperature conditions such as Case Akcela No. 1 SAE 15W-40, Hy-Tran Ultra, Hy-Tran Ultra SS. See charts at the beginning of this section.

GREASE The type of grease to use depends on ambient temperature such as: Case Akcela Molydisulfide Grease ENVIRONMENT Before you service this machine and dispose of oil, fluids, and lubricants, obey environmental regulations. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

ENGINE OIL Case Akcela engine oil is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions. See charts at the beginning of this section to choose the correct oil for climate/temperatures.

If Case Akcela engine oil cannot be obtained, use only oil of the API SERVICE CI-4 category.

NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out utilizing Case lubricants.

5-10

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

DAILY INSPECTIONS Every day, before starting work, it is necessary to inspect the machine and service certain components.

WARNING: If the slightest defect is found, repair it immediately before using the machine or see your Dealer. Failure to comply with this warning could result in injury or death.

General Check for water or oil leaks.

Check that all screws and nuts are correctly tightened.

After Starting the Engine Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Check for abnormal noise on the hydraulic components.

Check for water or oil leaks on the components.

Check the audible alarm devices, working lights and windshield wipers.

Check that all hydraulic circuits are functioning correctly.

Wipe off any dust and clean off any accumulated debris (engine, operator's compartment, etc.).

Check tires for proper inflation.

Check for damage.

Engine Check the oil level and change the oil, if necessary.

Check the coolant reservoir fluid level.

Check for clogging or damage to the radiator.

Check the engine accessory drive belt tension.

Check for water or oil leaks on the components.

Check the condition of all lines.

Check the fuel tank level.

Check for any warning gauges or lights on console.

Other Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check the condition of all lines.

Check for electrical short-circuits.

Check that all battery connections are properly tightened.

Adjust the rear view mirrors.

Check for oil leaks on the cylinders.

Check the condition of the bucket/attachment.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

As Required

Every 50 hours

Every 100 hours

Every 250 hours

Every 500 hours

Every 1000 hours

Air filter

6-5

Tires

AR

5-15

Fuel water separator

AR

Engine oil level

10

Every 4000 hours

5-12

AR

Wheel torque check (until stable)

Run-in

5-20

Engine oil and filters (initial only)

Run-in

100

5-22

Fuel prefilter (initial only)

Run-in

100

5-22

Fuel filter (initial only)

Run-in

100

5-23

Hydraulic oil return filter (initial only)

Run-in

100

5-24

Front and rear axle oil (initial only)

Run-in

100

5-25

Transmission oil and filter (initial only)

Run-in

6-16

Transmission clutch calibration

10

100 250

5-17

Grease machine attachments

5-17

Hydraulic reservoir level

50

5-18

Coolant reservoir level

50

5-18

Transmission fluid

50

5-19

Grease loader linkage

100

5-19

Grease steering pins

100

5-19

Drive shaft carrier bearing

5-26

Cab air filter

5-26

Accessory drive belts

50

100 250 250

5-27

Coolant reservoir/radiator level

250

6-6

Tire pressure and condition

250

5-28

Engine oil and filter

500

5-30

Crankcase filter

500

5-30

Axle oil level

5-31

Fuel Filter

5-31

Fuel tank condensation

500

6-4

ROPS and seat belt

500

7-6

Battery fluid level

500

5-32

Pivot points/articulation fittings

1000

5-32

Drive shaft slip joint

1000

5-33

Axle oil (front and rear)

1000

5-34

Transmission fluid and filter(s)

1000

5-35

Fuel prefilter

1000

5-36

Hydraulic oil filter

1000

500 500

6-15

Transmission clutch calibration

5-37

Cab air filters

1000

6-8

Accessory drive belt

1000

5-38

Hydraulic fluid

2000

5-40

Engine coolant

2000

5-41

Primary air filter

2000

5-41

Secondary air filter

2000

5-42

Lubricate door and window hinges Engine valve clearance

DRAIN

LUBRICATE

REPLACE AR

6-7

Injector calibration

Every 2000 hours

CHECK

5-41

Every 10 hours 5-16 or shift change

Initial Run-in

CLEAN

PAGE

SERVICE POINTS

INITIAL NEW MACHINE

INTERVALS IN HOURS SERVICE INTERVALS

1000

See your Case Dealer

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ACCESS DOORS AND FILL LOCATIONS

Figure 12

BD07N552-01

ENGINE HOOD AND ACCESS DOOR RIGHT SIDE

CAB FILTER/FUSE ACCESS RIGHT SIDE

Figure 13

BD07N640-01

ENGINE HOOD ACCESS LEFT SIDE

Figure 14

BD07N692

BATTERY ACCESS ONE EACH SIDE

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87479806 A - EU

Figure 15

BD06F166-2

BD07N657-01

Figure 16

RADIATOR AND HYDRAULIC FLUID ACCESS DOOR

BD07N623-01

Figure 17

TRANSMISSION / HYDRAULIC FILTER ACCESS RIGHT SIDE

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

BD07N655-01

Figure 18

HYDRAULIC FILL CAP ACCESS - RAISE COOLING UNITS

BD07N637-01

Figure 20

BD07N542-01

ENGINE OIL FILL LOCATION AND DIPSTICK

Figure 19

TRANSMISSION CHECK AND FILL LEFT SIDE

5-14

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87479806 A - EU

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SCHEDULED MAINTENANCE VARIABLE PERIODIC MAINTENANCE Some working environments require that maintenance be performed more frequently. Dust, dirt, moisture, extreme hot or cold and many other factors should be taken into consideration when servicing the machine. Certain equipment or auxiliary tools may cause more stress on hydraulics, drivetrain, engines or filters. The following maintenance should be performed on regular schedules, but often need special attention when conditions require.

Fuel Filter

Engine Air Filter Check the primary air filter for restrictions if the air filter indicator lamp illuminates. Replace if necessary The primary element may be cleaned by using air, however a new element is recommended, if questionable.

The inner element must not be cleaned. It must be replaced.

Tires and Wheels Adjust the inflation pressure of the tires every time that circumstances require. A daily visual inspection during the pre-start walk around and mechanical checks when environmental or work conditions require more.

Wheels should be checked for proper torque every ten hours when new and until they remain tight. See the Wheel Bolt Torque in Chapter 6 for pressures and torques.

Air Conditioning Condenser Raise the hydraulic access door. The air conditioner condenser is located under the access door. Unlatch the condenser and raise. Use compressed air to remove debris and buildup on the condenser. See Chapter 6 Maintenance - Cab Air Conditioning for further information.

WARNING: Wear full coverage safety glasses with side panels when using compressed air. Limit the pressure to 29 psi (2 bar). Failure to comply may result in death or injury.

BD07N542-01

Figure 21

Drain water and sediment from the fuel prefilter as required. In certain geographic regions and climates, it may be necessary to drain condensation more frequently. The fuel prefilter is located on the right hand side of the machine.

To drain, slowly loosen the drain valve located under the filter by turning counterclockwise 2 or 3 turns.

Drain the water and/or contaminants from the fuel filter into a suitable container until clean fuel flows.

Do not allow fuel to spill on engine or the ground.

Close the drain valve. Check for leaks.

For further information, see fuel prefilter procedure in this chapter.

Bleeding Air from the Fuel System Prolonged period of inactivity or running out of fuel may allow air to get into the fuel system. If this should happen make sure the tank is full and then bleed the system.

Fuses Fuses may be reached by opening the access door located on the right side of the cab. If a fuse has blown, the indicator light will illuminate.

NOTE: If a fuse blows, replace it at once. Locate the problem and if it re-occurs, have it checked by a service technican.

Issued 03-08

87479806 A - EU

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE ENGINE OIL Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . 11.8 l (12.5 qt.)

The engine oil level should be checked every 10 hour shift or each day, whichever occurs first.

2

1

Figure 23

BD07N542-01

The fill location (2) is located in the main engine compartment. Do not overfill engine oil.

BD07N542-01

Figure 22

Keep all non-authorized personnel clear of the area.

Park the machine on a firm, level surface and turn off the engine. Remove the dipstick (1), and check the engine oil level. This procedure is best performed at the beginning of the work day with the engine cool and all oil drained to the pan.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE BUCKET/ATTACHMENT GREASE FITTINGS

HYDRAULIC OIL LEVEL

Service Specifications Grease. . . . . . . . . . . . . . . Case Akcela Molydisulfide

Service Specifications System capacity . . . . . . . . . . . . . . .113.6 l (30.0 gal.)

Grease the attachment fittings when the hourmeter registers 50 hours of operation or sooner if conditions so require.

BD07N632-01

Figure 25

Check the level of the hydraulic oil tank every 50 hours. Park the machine on hard, level ground.

Rest the bucket/attachment on the ground, turn-off the engine, and check the level on the indicator.

Figure 24

BS03J108A

Clean around the area to be greased before service.

In severe conditions, such as immersion in water, it may be necessary to grease more frequently.

WARNING: Prior to maintenance always have the machine on firm, level ground with the bucket/attachment on the ground. Make sure all residual pressure is relieved from circuits before beginning maintenance.

Failure to comply could result in serious injury or death.

WARNING: Do not work under or near the bucket/attachment of a machine or components which are not adequately supported or blocked. Failure to comply could result in serious injury or death.

If the oil is cold, the level is correct when the top of the float is aligned with the lower indicator mark. If the oil is at operating temperature, the level is correct when the top of the float is aligned with the upper indicator mark.

In the event oil is needed, relieve all pressure in the system, then slowly loosen the tank cap and top-off until the proper level is reached.

WARNING: The hydraulic oil tank is pressurized. If removal of the cap is required, loosen it slowly to relieve residual pressure in the tank. Do not overfill. Failure to comply may result in death or injury.

BD07N655-01

Figure 26

The hydraulic oil fill cap is located under the condenser core, behind the operator’s cab.

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5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE

ENGINE COOLANT RESERVOIR

TRANSMISSION OIL LEVEL

Service Specifications System capacity . . . . . . . . . . . . . . . . 22.0 l (23.2 qt.)

Service Specifications Total system capacity . . . . . . . . . . . . 26.0 l (27.5 qt.)

Refill capacity with filter change . . . . . 18.90 l (20 qt.)

Check the transmission oil level every 50 hours of operation. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied and the attachment lowered to the ground. The transmission oil level sight gauge is on the left side of the machine.

Check the coolant reservoir level every 50 hours of operation. Perform this check 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.

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.

Engine Running Check WARNING: This check must be performed with the engine running! Comply with the following: 1. Make sure the gear selector is in neutral and the parking brake is set.

2. Make sure the bucket or equipment is on the ground and the pilot lock out is engaged to neutralize hydraulic flow.

3. The transport/service link must be in place to prevent accidental articulation.

4. If this check must be performed in an enclosed area be sure to ventilate properly to reduce the deadly exhaust fumes.

5. Failure to comply may result in death or injury.

BS00M474

Figure 28

BD07N640-01

Raise the engine compartment access hood and check the indicator on the side of the coolant bottle.

NOTE: In the event that the system needs topping off make sure to use the proper ratio of water and antifreeze/coolant. Do not overfill.

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

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

Figure 27

Check the transmission oil level at idle speed with the oil temperature of 149 to 158 °F (65 to 70 °C).

When oil temperature reaches the above temperatures, oil level will rise to the top of the gauge. Oil level should be between the bottom and top of the cross hatch region. Add oil, if necessary.

Do not overfill.

5-18

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87479806 A - EU

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE MACHINE GREASE FITTINGS

Figure 29

875987501A/875987501C

XT GREASE POINTS

Figure 30

BS07G096

BS07G097

Figure 31

SERVICE SPECIFICATIONS Grease Specification .........................................................................................................Case Akcela Molydisulfide Grease the machine fittings when the hourmeter registers 100 hours of operation or sooner if conditions so require.

Clean around the area to be greased before service. Grease the bucket/attachment pivot pins, front driveshaft support bearing (remote), and steering cylinder pins (rod end).

Grease the steering cylinder pins (remote), boom pivot pins, bucket cylinder pins (remote) and the boom pivot pins.

IMPORTANT: In severe conditions, such as immersion in water, it may be necessary to reduce the greasing service intervals.

WARNING: Prior to maintenance always have the machine on firm, level ground with the bucket/attachment on the ground. Make sure all residual pressure is relieved from circuits before beginning maintenance. Failure to comply could result in serious injury or death.

WARNING: Do not work under or near the bucket/attachment of a machine or components which are not adequately supported or blocked. Failure to comply could result in serious injury or death.

Issued 03-08

87479806 A - EU

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE CHANGE ENGINE OIL AND FILTER (Initial) Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . 11.8 l (12.5 qt.)

Change the engine oil and filter when the hourmeter registers 100 hours for a new machine during the initial run-in period. The engine oil and filter should be changed every 500 hours thereafter or more frequently when the engine operating conditions are severe.

NOTE: When changing engine oil, the oil flow rate can be improved if the oil fill cap or dipstick is removed from the engine while draining.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

Figure 33

BD06F008

REMOTE ENGINE OIL DRAIN

4. Use a suitable container to capture the used oil, and remove the remote oil drain plug. Drain the engine oil completely.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

BD07N638-01

Figure 32

3. Remove the protective guard from the drain plug area by removing the two bolts securing it to the machine.

5-20

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE REPLACE OIL FILTER

BD07N542-01

Figure 35

11. Fill the engine with the proper amount of oil.

Figure 34

BD07N648-01

5. Raise the engine hood.

12. Start the engine and run at idle speed. Check the engine oil filter and remote drain for leaks.

6. Clean the area around the filter of dirt and debris.

13. After two minutes stop the engine.

7. Turn the filter counterclockwise to remove.

Remove and discard the filter following local environmental and waste regulations.

14. Wait for the engine oil to drain down for an accurate reading on the dipstick.

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

IMPORTANT: Never use a filter wrench to install a new filter.

15. Check the dipstick and add additional oil, if necessary.

16. Lower the engine hood completely.

9. Turn the new oil filter onto the base until the gasket makes contact with the base and then turn by hand an additional 3/4 turn.

10. Install the remote drain plug. Replace the protective cover for the drain plug area.

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5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE

REPLACE FUEL FILTER (Initial)

REPLACE FUEL PREFILTER (Initial)

Change the fuel filter when the hourmeter registers 100 hours for a new machine during the initial run-in period. Filters should be changed every 500 hours thereafter or more frequently when operating conditions are severe.

Change the fuel prefilter when the hourmeter registers 100 hours for a new machine during the initial run-in period. The filter should be changed every 1000 hours thereafter or more frequently when operating conditions are severe.

Figure 37

BD07N550-01

Figure 36

BD07N542-01

FUEL PREFILTER

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the filter head area, the outside of the filter and remove any dirt and debris around the area that might contaminate the system.

4. Turn the filter cartridge counterclockwise to remove. Capture any fuel remaining in the lines or the filter and discard properly.

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

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

7. Start the engine and check again for leakage.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the filter head area, the outside of the filter and remove any dirt and debris around the area that might contaminate the system.

4. Turn the filter counterclockwise and remove. Be sure to capture any fuel remaining in the lines or the filter and discard properly.

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

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

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

WARNING: Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, pipes, etc. Failure to comply could result in serious injury or death.

5-22

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE REPLACE HYDRAULIC OIL FILTER (Initial) Replace the hydraulic oil filter when the hourmeter registers 100 hours for a new machine during the initial run-in period. Filters should be changed every 1000 hours thereafter or more frequently when operating conditions are severe.

WARNING: Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system.

Failure to comply could result in serious injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

WARNING: Never drain oil or remove the oil filter while the engine is running. Failure to comply could result in serious injury or death.

BD07N561-01

Figure 38

5. Lubricate the gasket of the new filter(s) with clean oil and install. After the filter makes contact with the filter head tighten 1/2 to 3/4 turns.

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

6. Tighten the cap on the hydraulic reservoir.

7. Start the engine and run at 1000 rpm. Have an assistant check for leaks around the filter area.

8. Stop the engine, and check the hydraulic oil level. Top off, if necessary.

3. Slowly loosen the filler cap on the hydraulic reservoir to release pressure in the reservoir.

Leave it loose during the procedure.

4. Turn the filter(s) counterclockwise to remove.

Issued 03-08

87479806 A - EU

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE CHANGE FRONT AND REAR AXLE OIL (Initial) Service Specifications Front axle . . . . . . . . . . . . . . . . . . . . . . . 22 l (23.2 qt.)

Rear axle . . . . . . . . . . . . . . . . . . . . . . . 22 l (23.2 qt.)

Ch an ge the fro nt a n d re ar axle oil wh en the hourmeter registers 100 hours for a new machine during the initial run-in period. Axle oil should be changed every 1000 hours thereafter or more frequently when operating conditions are severe.

WARNING: Make sure that the bucket/attachment is resting on the ground and the transport/service link is installed.

Failure to comply could result in serious injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

Figure 40

BD07N661-01

5. Place a suitable container with sufficient capacity to capture the old oil under each axle end.

6. Remove the drain plug at the bottom of wheel end, and allow the oil to drain.

7. Reinstall the drain plugs of both axles and the four axle ends.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the area around the drain and fill caps of both axles and all four axle ends.

Figure 41

BD07N212-02

8. Fill with the proper amount of axle oil. Insert dipstick back into fill hole, but do not thread down. Remove the dipstick and measure the oil level. The oil level should be between the upper and lower marks on the dipstick.

BD02N123

Figure 39

4. Place a suitable container with sufficient capacity to capture the old oil under the front and rear axles and drain.

5-24

9. Add oil, if required. Replace the dipstick, being careful not to damage the O-ring.

NOTE: The oil will take some time to fill each axle. Allow time for the oil to circulate throughout the axle.

Issued 03-08

87479806 A - EU

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 100 HOUR MAINTENANCE CHANGE TRANSMISSION FLUID AND FILTER (Initial) Service Specifications Total system capacity . . . . . . . . . . . 26.0 l (27.5 qt.)

Refill capacity with filter change . . . . 18.90 l (20 qt.)

Change the transmission fluid and filter when the hourmeter registers 100 hours for a new machine during the initial run-in period. Transmission fluid and filters should be changed every 1000 hours thereafter or more frequently when operating conditions are severe.

BD00N666-01

Figure 43

7. Remove the drain plug and drain the oil.

1. Keep all non-authorized personnel clear of the area. Park the machine on a level surface and apply the parking brake.

2. Lower bucket/attachment to the ground and lock the pilot control lock lever.

3. Put the transport/service link into the locked service position to avoid unexpected articulation and stop the engine.

BD07561-01

Figure 44

8. Remove the filter.

9. Apply a film of clean transmission oil to the gasket of the new filter and install. Make certain proper contact is made with the base.

10. Spin the breather, located on the top of the transmission a few times.

Figure 42

11. If the breather is difficult to spin follow steps 12 and 13.

4. Clean the area around the filter head and around the transmission drain and fill caps.

12. Remove the breather. Clean it with solvent and dry with compressed air.

BD07N561-01

5. Remove the fill plug.

6. Have a suitable container that will hold the appropriate amount of fluid before draining.

WARNING: Wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

13. Install the breather.

14. Fill with the specified amount of oil. Fill port is located behind the ladder near the sight gauge.

15. Check the oil level at the sight gauge.

16. Start the engine and check for oil leaks around the filter and drain plug.

17. Bring the transmission oil up to working temperature, and check the level again.

Issued 03-08

87479806 A - EU

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE CAB AIR FILTER

CAB AIR FILTER The cab recirculation air filter is located behind the operator’s seat. Clean the cab air filters when the hourmeter registers 250 hours.

Figure 46

BD07191

Figure 45

BD06F095

1. Remove the retaining screw that holds the re-circulation air filter cover in place and remove the filter.

2. Check the filter for debris or tears.

3. Clean the re-circulation filter with detergent and water or replace with a new one. Dry with compressed air.

The cab filter is located on the right hand side of the machine, below the operator’s compartment.

Remove the two screws from the cab air filter cover and remove the cover. Pull filter forward at a slight angle. Check filter for debris or tears. Wipe the inside of the filter housing. Clean dust from filter, using compressed air, if necessary. Reinstall the filter and air filter cover.

ACCESSORY DRIVE BELT

WARNING: Wear full coverage safety glasses with side panels when using compressed air to clean components. Limit the pressure to 29 psi (2 bar). Failure to comply could cause injury or death.

4. Reinstall the filter, and secure the access filter cover.

Figure 47

BD08A011

The air conditioning and drive belts are located behind the rear grill on the machine.

Figure 48

BD07N573-01

Perform a visual inspection for cracks and damage.

To adjust and/or to replace belts, see procedure in Chapter 6.

5-26

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87479806 A - EU

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE ENGINE COOLANT RESERVOIR/RADIATOR Service Specifications System capacity . . . . . . . . . . . . . . . . 22.0 l (23.2 qt.)

Check the coolant reservoir level every 250 hours of operation. Perform this check when the coolant is cold and the engine is stopped.

BD07N651-01

Figure 50

NOTE: In the event that the system needs topping off make sure to use the proper ratio of water and antifreeze/coolant. Do not overfill.

Figure 49

BD07N640-01

Raise the engine compartment access hood and check the indicator on the side of the coolant bottle.

The coolant level must be between the full and add marks on the reservoir. If coolant is required, check the coolant level in the radiator also. Add coolant to the reservoir and radiator as required.

Issued 03-08

87479806 A - EU

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

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

5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE CHANGE ENGINE OIL AND FILTER Service Specifications Type of oil . . . . . . . . . . . Case Akcela (SAE 15W-40) Capacity (with filter change) . . . . . . . 11.8 l (12.5 qt.)

The engine oil and filter should be changed every 500 hours or more frequently when the engine operating conditions are severe.

NOTE: When changing engine oil, the oil flow rate can be improved if the oil fill cap or dipstick is removed from the engine while draining.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

BD07N638-01

Figure 52

BD06F008

REMOTE ENGINE OIL DRAIN

4. Use a suitable container to capture the used oil, and remove the remote oil drain plug. Drain the engine oil completely.

Figure 51

3. Remove the protective guard from the drain plug area by removing the two bolts securing it to the machine.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE REPLACE OIL FILTER

BD07N542-01

Figure 54

11. Fill the engine with the proper amount of oil.

Figure 53

BD07N648-01

5. Raise the engine hood.

12. Start the engine and run at idle speed. Check the engine oil filter and remote drain for leaks.

6. Clean the area around the filter of dirt and debris.

13. After two minutes stop the engine.

7. Turn the filter counterclockwise to remove.

Remove and discard the filter following local environmental and waste regulations.

14. Wait for the engine oil to drain down for an accurate reading on the dipstick.

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

IMPORTANT: Never use a filter wrench to install a new filter.

15. Check the dipstick and add additional oil, if necessary.

16. Lower the engine hood completely.

9. Turn the new oil filter onto the base until the gasket makes contact with the base and then turn by hand an additional 3/4 turn.

10. Install the remote drain plug. Replace the protective cover for the drain plug area.

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87479806 A - EU

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE

CRANKCASE FILTERS

AXLE OIL LEVEL

Change the crankcase breather filters when the hourmeter registers 500 hours and every 500 hours thereafter. Filters should be changed more frequently when operating conditions are severe.

Service Specifications Front axle . . . . . . . . . . . . . . . . . . . . . 22.0 l (23.2 qt.)

Rear axle . . . . . . . . . . . . . . . . . . . . . 22.0 l (23.2 qt.)

Check the oil level in the front and rear axles when the hourmeter registers 500 hours.

Figure 57

BD07N554-01

1. Remove the screws on the filter housing to access filter.

BD07N212-02

Figure 55

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Replace the two crankcase filters, and reinstall the cover housing.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Clean the area thoroughly then remove the axle dipstick. There is one in each wheel.

BD02N131

Figure 56

4. Insert the dipstick back into the fill hole, but do not thread down. Remove the dipstick and measure the oil level. The oil level should be between the upper and lower marks on the dipstick.

5. Add oil if required. Replace the dipstick, being careful not to damage the O-ring.

5-30

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87479806 A - EU

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DRAIN FUEL TANK CONDENSATION

500 HOUR MAINTENANCE REPLACE FUEL FILTER Fuel filters should be changed every 500 hours or more frequently when operating conditions are severe.

BD07665-01

Figure 59

Every 500 hours of operation the condensation must be removed from the fuel tank.

Figure 58

BD07N550-01

Clean the filter head area, the outside of the filter and remove any dirt and debris around the area that might contaminate the system.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Turn the filter counterclockwise and remove. Be sure to capture any fuel remaining in the lines or the filter and discard properly.

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

5. 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. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Have a suitable container ready to capture the condensation and fuel. Dispose of the waste following local regulations.

4. Open the fuel tank drain slowly, remove the tank drain plug, and allow the condensation to flow until only fuel is discharged.

NOTE: The drain plug and handle are located on the bottom left front corner of the fuel tank, behind the rear axle.

5. Turn the drain handle and close the drain.

Replace the tank drain plug.

NOTE: In certain geographic regions and climates it may be necessary to drain off condensation more frequently.

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

WARNING: Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, pipes, etc. Failure to comply could result in serious injury or death.

Issued 03-08

87479806 A - EU

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE GREASE DRIVE SHAFT SLIP JOINT AND PIVOT POINTS

Figure 61

BD06F010

BS06B144A

Figure 60

Grease the upper and lower chassis pivot points and front drive shaft slip joint when the hourmeter registers 1000 hours or sooner if conditions so require.

1. Keep all non-authorized personnel clear of the area. Park the machine on a level surface. Lower the loader bucket/attachment to the ground and stop the engine. Apply the parking brake.

2. Place the transport/service link into the lock position to stop unexpected articulation of the machine.

3. Clean the area around each fitting and grease.

5-32

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87479806 A - EU

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE CHANGE FRONT AND REAR AXLE OIL Service Specifications Front axle. . . . . . . . . . . . . . . . . . . . . . 22.0 l (23.2 qt.)

Rear axle . . . . . . . . . . . . . . . . . . . . . . 22.0 l (23.2 qt.)

Chan ge the front and re ar axle oil when the hourmeter registers 1000 hours. Axle oil should be changed every 1000 hours or more frequently when operating conditions are severe.

WARNING: Make sure that the bucket attachment is resting on the ground and the transport/service link is installed. Failure to comply could result in serious injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

BD07N661-01

Figure 63

5. Place a suitable container with sufficient capacity to capture the old oil under each axle end.

6. Remove the drain plug at the bottom of the wheel end, and allow the oil to drain.

7. Reinstall the drain plugs of both axles and the four axle ends.

3. Clean the area around the drain and fill caps of both axles and all four axle ends.

BD07212-02

Figure 62

BD07N662-01

4. Place a suitable container with sufficient capacity to capture the old oil under the front and rear axles and drain.

Figure 64

8. Fill with the proper amount of axle oil. Insert dipstick back into fill hole, but do not thread down. Remove the dipstick and measure the oil level. The oil level should be between the upper and lower marks on the dipstick.

9. Add oil, if required. Replace the dipstick, being careful not to damage the O-ring.

NOTE: The oil will take some time to fill each axle. Allow time for the oil to circulate throughout the axle.

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5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE TRANSMISSION FLUID AND FILTER Service Specifications Total system capacity . . . . . . . . . . . . 26.0 l (27.5 qt.)

Refill capacity with filter change . . . . . 18.90 l (20 qt.)

Change the transmission fluid and filter every 1000 hours or more frequently when operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on a level surface and apply the parking brake.

2. Lower bucket/attachment to the ground and lock the pilot control lock lever.

Figure 66

BD00N666-01

7. Remove the drain plug and drain the oil.

3. Put the transport/service link into the locked service position to avoid unexpected articulation and stop the engine.

Figure 67

BD07N623-01

8. Remove the filter.

Figure 65

9. Apply a film of clean transmission oil to the gasket of the new filter and install. Make certain proper contact is made with the base.

4. Clean the area around the filter head and around the transmission drain and fill caps.

10. Spin the breather, located on the top of the transmission a few times.

5. Remove the fill plug.

11. If the breather is difficult to spin follow steps 12 and 13.

BD07N623-01

6. Have a suitable container that will hold the appropriate amount of fluid before draining.

12. Remove the breather. Clean it with solvent and dry with compressed air.

WARNING: Wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

13. Install the breather.

14. Fill with the specified amount of oil. Fill port is located behind the ladder near the sight gauge.

15. Check the oil level at the sight gauge.

16. Start the engine and check for oil leaks around the filter and drain plug.

17. Bring the transmission oil up to working temperature, and check the level again.

5-34

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE REPLACE FUEL PREFILTER Change the fuel prefilter every 1000 hours or more frequently when operating conditions are severe.

Figure 68

BD07N624-01

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. The fuel prefilter is located on the right hand side of the engine. Have a s u i t a b l e c o n t a i n er available for discharging fuel.

4. Turn the drain connection counterclockwise to remove the drain tube from the bottom of the filter. Capture any fuel remaining in the lines or filter and discard properly.

5. Turn the filter cartridge counterclockwise to remove from the filter head.

6. Replace with a new filter cartridge, turning clockwise until cartridge meets filter head. Hand tighten firmly in place. Do not use a filter wrench.

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

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5-35

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE REPLACE HYDRAULIC OIL FILTER Replace the hydraulic oil filters every 1000 hours or more frequently when operating conditions are severe.

WARNING: Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground. Shut the engine off, turn the key to on, and move the hydraulic control levers through all movements several times to relieve residual pressure in the system.

Failure to comply could result in serious injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

WARNING: Never drain oil or remove the oil filter while the engine is running. Failure to comply could result in serious injury or death.

Figure 69

BD07N623-01

5. Lubricate the gasket of the new filter(s) with clean oil and install. After the filter makes contact with the filter head tighten 1/2 to 3/4 turns.

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

6. Tighten the cap on the hydraulic reservoir.

7. Start the engine and run at 1000 rpm. Have an assistant check for leaks around the filter area.

8. Stop the engine, and check the hydraulic oil level. Top off, if necessary.

3. Slowly loosen the filler cap on the hydraulic reservoir to release pressure in the reservoir.

Leave it loose during the procedure.

4. Turn the filter(s) counterclockwise to remove.

5-36

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE

CAB AIR RECIRCULATION FILTER

CAB AIR FILTER

The cab recirculation air filter is located behind the op e ra tor’s sea t. Rep lace the filte r w hen th e hourmeter registers 1000 hours.

Replace the cab air filter when the hourmeter registers 1000 hours or more frequently when operating conditions are severe.

BD06F095

Figure 70

BD07G077

The cab filter is located on the right hand side of the machine, below the operator’s compartment.

Remove the two screws from the cab air filter cover, and remove the cover.

Figure 72

1. Remove the retaining screw that holds the re-circulation air filter cover in place and remove the filter.

2. Replace with a new filter, and secure the access filter cover.

Figure 71

BD07G078-01

Pull filter forward to remove. Wipe the inside of the filter housing. Replace with a new filter. Reinstall the filter cover, replacing the two screws.

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5-37

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE CHANGE HYDRAULIC OIL AND FILTER Service Specifications Total system capacity . . . . . . . . . . .113.6 l (30.0 gal.)

Type . . . . . . . . . . . . . . . . Case Akcela Hy-Tran Ultra Change the hydraulic oil and filter every 2000 hours of operation. Change oil more frequently when operating conditions are severe.

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied. Stop the engine.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

3. Make sure the accumulators are completely discharged by pushing down on the brake pedal a minimum of 30 times.

Figure 73

BD07N638-01

7. Remove the protective guard from the drain plug area by removing the two bolts securing it to the machine.

4. Release pressure in ride control accumulators, if equipped.

5. With the ignition key in the ON position, cycle the bucket/attachment control levers repeatedly through their complete range of motion for at least 30 seconds.

6. Move the hydraulic controller to the float position and turn the key off.

Figure 74

BD07A034

8. Open the hydraulic reservoir remote drain, and drain the oil into a suitable container.

9. Clean the area around the filler cap, and slowly remove the cap.

5-38

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Figure 75

BD07N623-01

10. Remove and replace the hydraulic oil filter. To remove the filters, turn counter clockwise.

11. When installing new filter, apply a thin coat of oil to the gasket. Tighten the filter firmly to the filter head by hand. Do not use a filter wrench to tighten the filter.

BD07N655-01

Figure 76

12. Fill the reservoir with new hydraulic oil.

13. Install the reservoir filler cap.

14. Start the engine and run at 1000 rpm. Check for leakage around the filter and drain.

15. Operate the loader controls several times to remove any air in the lines.

16. Place the loader bucket/attachment on the ground and stop the engine. Check the hydraulic oil level.

17. If it is necessary to top off with more oil, remove the fill cap slowly to release pressure in the reservoir.

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5-39

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE ENGINE COOLANT Service Specifications System capacity . . . . . . . . . . . . . . . . 22.0 l (23.2 qt.)

Drain, flush and replace the engine coolant every 2000 hours of operation or each year, whichever occurs first. Clean the system and replace the coolant if it becomes dirty or is rust colored.

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

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

SA023

Figure 79

BD06F008

3. With a suitable container of the proper capacity un der the drain, open the cap by turning counterclockwise and drain the coolant from the system.

4. After all the coolant is drained, secure the drain cap.

5. Use a system cleaning product to clean and flush the system. Contact your Dealer.

6. After the system has been cleaned and flushed following the cleaning product instructions, close and secure the drain valve.

BD07N651-01

Figure 77

1. After the engine has cooled so the temperature of the coolant is safe, remove the cap.

Figure 80

BD07651-01

7. Fill with the proper mix of antifreeze/coolant and water for the system and for the prevailing weather conditions.

8. Start the engine, and let it run at low idle until the engine reaches operating temperature. Recheck the level of the system.

BD07N638-01

Figure 78

2. Remove the protective guard from the drain plug area by removing the two bolts securing it to the machine.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE REPLACE ENGINE AIR FILTER The air filter should be checked periodically for dirt and debris build up.

Replace the engine primary and secondary air filter every 2000 hours or each year, whichever occurs first.

NOTE: Replace the primary element if the filter warning lamp on the instrument cluster illuminates or the audible alarm sounds. Should the caution warnings continue after replacing the primary filter, replace the secondary filter as well.

BD07N537-01

Figure 83

5. Remove the primary and secondary filters.

Figure 81

BD07N534-01

1. Keep all non-authorized personnel clear of the area. Park the machine on level ground, in neutral with the parking brake applied.

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

BD07N540-01

Figure 84

6. Wipe the inside of the filter body, and clean any dirt and debris away before installing the new filters.

3. Access the engine air filter by raising the hood.

The engine air filter is located on the left hand side of the machine.

1

BD07N539-01

Figure 85

7. Install the new secondary filter. Do not clean the secondary filter. It must be replaced.

Figure 82

BD07N533-01

4. Pull the locking tab (1) at the top of the cover out to release. Turn the front cover counter clockwise and remove.

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5-41

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS LUBRICATE DOOR AND WINDOW HINGES Lubricate the door and window hinges when the hourmeter registers 2000 hours or more often if conditions so require.

Figure 86

BD07N537-01

8. Install the new primary filter, making certain it seats properly. .

Figure 89

BD07G071

Lubricate all door hinges to prevent rust and to allow ease of opening.

1

BD07N535-01

Figure 87

9. Install the air filter cover and turn clockwise to secure. Push the locking tab (1) at the top of the cover back until it secures the cover in place.

Figure 90

BD07G070

Lubricate all swinging window hinges paying particular attention to the emergency exit.

BD07N648-01

Figure 88

10. Push on the end of dust valve to drain dust and debris from filter housing.

11. Close the engine hood.

5-42

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS Roll-over Protection Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Torque Specifications for ROPS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Wheel Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Check Accessory Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Engine Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Air Conditioner Belt (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Spark Arresting Muffler (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Check Injector Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Check Engine Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Checking for Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Loader Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Height Control and Return to Travel Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 XT Return to Dig Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Z-Bar Return to Dig Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Calibrating the Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Transmission Declutch Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Parking Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Secondary Steering Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Cab Headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS ROLL-OVER PROTECTION STRUCTURE WARNING: Your machine is equipped with an operator Protective Structure, such as: a Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS). A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS.

The loader has a ROPS tag showing the certification of the ROPS, gross weight, approval, regulation, and model number of the machine.

Check and inspect the ROPS structure and the seat restraint system every 500 hours of operation.

The Protective Structure is a special safety component of your machine.

DO NOT attach any device to the Protective Structure for pulling purposes. DO NOT drill holes into the Protective Structure.

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Structure inspection and replacement.

BD06H167

Figure 1

The ROPS tag is located behind the operator’s seat.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: The protective structure MUST be replaced.

The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT.

BD06G176

Figure 2

Before you operate this machine, always make sure the ROPS and operator’s seat belt is correctly installed.

The seat belt is an important part of the ROPS. You must wear the seat belt at all times when you operate the machine.

Make sure all hardware that secures the seat to the cab is properly torqued. Make sure all seat belt hardware is secure and torqued.

Torque seat belt hardware to: 73 - 87 Nm (54-64 lb. ft.).

Keep seat belts away from objects that can damage the seat belts.

Keep the seat belts clean. Wash the seat belts only in soap and water. Do not put the seat belts in bleach or dye. This will weaken the seat belt composition.

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6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TORQUE SPECIFICATIONS FOR ROPS CAB AND ROPS CANOPY

BD07N513

OPERATOR PROTECTIVE STRUCTURE

Figure 3

Check the torque of the mounting bolts for the ROPS canopy and the ROPS cab during the run-in period of a new machine, as well as at the 500 hour maintenance interval.

1. Check for cracks, rust, or holes in the ROPS and ROPS components. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the integrity of the ROPS system, see your Case Dealer.

WARNING: Adding additional weight (bucket/attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

Failure to comply could result in serious injury or death.

SA028

Figure 4

6397

2. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

Torque Specifications ROPS cab mounting bolts (both sides) Torque to: 773 - 854 Nm (570 - 630 lb. ft.)

Seat mounting bolts Torque to: 73 - 87 Nm (54 - 64 lb. ft.)

NOTE: Torque specifications are for clean, dry threads.

6-4

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WHEELS AND TIRES WARNING: Exploding tires and / or rim parts can cause injury or death. Keep yourself and others out of the danger area. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires.

SD020

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

84-113

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

SB134

BALLAST Adding ballast to the tires of your wheel loader is NOT recommended. Make sure tires are properly inflated.

Figure 5

B910410J

The above illustration show danger areas caused by exploding tires and / or rim parts. KEEP YOURSELF AND OTHERS OUT OF THESE DANGER AREAS. Keep all non-authorized personnel clear of the area.

The next page shows the correct methods that you MUST use when adding air or servicing a tire.

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6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 250 HOUR MAINTENANCE TIRE PRESSURE Check tire pressure when the hourmeter registers 250 hours or more frequently when operating conditions warrant.

WARNING: Exploding tires and / or rim parts can cause injury or death. Keep yourself and others out of the DANGER AREA. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires. Failure to comply could result in serious injury or death.

WARNING: Explosive separation of the tire and / or rim parts can cause injury or death.

When tire service is necessary, have a qualified tire technican service the tire.

Figure 6

B790490R

To add air to a tire: This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following: 1. Keep all non-authorized personnel clear of the area.

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

Service Specifications Normal Work Tire Inflations: Tire Type

Front Pressure

Rear Pressure

17.5 X 25 L2 Bias

3.4 bar (50 psi)

2.8 bar (40 psi)

17.5 X 25 L3 Bias

3.4 bar (50 psi)

2.8 bar (40 psi)

17.5 R 25 L2 Radial

3.4 bar (50 psi)

2.8 bar (40 psi)

17.5 R 25 L3 Radial

3.4 bar (50 psi)

2.8 bar (40 psi)

20.5 X 25 L2 Bias

3.4 bar (50 psi)

2.8 bar (40 psi)

20.5 R 25 L2 Radial

3.4 bar (50 psi)

2.8 bar (40 psi)

20.5 X 25 L3 Bias

3.4 bar (50 psi)

2.8 bar (40 psi)

20.5 R 25 L3 Radial

3.4 bar (50 psi)

2.8 bar (40 psi)

Figure 7

BD03A024

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

4. Stand BEHIND the tread of the tire and make sure ALL personnel are away from the side of the tire before you start.

5. Inflate the tire to the recommended air pressure.

DO NOT inflate the tire more than the recommended pressure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TIRE OR RIM SERVICE

WHEEL BOLT TORQUE

Always have a qualified tire technician service the tires and rims for this machine. It is recommended that you have the technician inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment, and correct procedure. Explosive separation of the tire (single piece rim) or the tire and / or rim parts (multi-piece rim) can cause serious injury or death.

If the machine is new or if a wheel has been removed and installed, check the torque of the wheel bolts after the first 10 hours of operation. Check wheel bolt torque every 20 hours thereafter until torque is stable.

Use a hand wrench (not an impact) to tighten wheel bolts to pull the wheel against the planetary housing.

Tire Tread Direction

1 10

8

6

12

4

Figure 8

B770164R

3

11

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

5 7

BS07N843

2

9 Figure 9

Tighten the wheel bolts using the sequence shown.

First tighten the bolts to 278 Nm (220 pound-feet), then tighten to a final torque of 640 - 720 Nm (475-530 lb. ft.), using the same sequence.

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6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECK ACCESSORY DRIVE BELTS Maintenance Specifications Visual check . . . . . . Every 250 hours or as required Replace belts. . . . . . . . . . . . . . . . . Every 1000 hours Check the belt for correct tension, wear, and damage. Wrong belt tension may cause battery charge failure, engine overheating, or belt wear.

IMPORTANT: If the engine runs with the drive belt loose, the drive belt can slip and cause the engine to overheat or the battery to receive insufficient charge.

WARNING: Rotating parts can cause serious personal injury. Keep away from fan and belt when engine is running. Make sure to stop engine before servicing. Failure to comply could cause injury or death.

Figure 11

BD07N576-01

2. To replace belt, actuate the belt tensioner with a 3/8 inch breaker bar just enough to release the tension on the drive belt.

3. Remove the old belt. To install the new belt, lay it over the alternator, crankshaft pulleys, and complete the turn while lifting the tensioner with the breaker bar.

ENGINE DRIVE BELT

4. Replace cover guard with 4 screws.

BD07N573-01

Figure 10

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface, and apply the parking brake.

2. Open the hood and turn the master disconnect switch off.

3. You can visually check the belt at this point. If the belt is damaged, cracked, or frayed, replace as necessary.

REPLACING BELT 1. If the belt requires replacement, remove the 4 screws that hold the protective cover in place.

Figure 12

BD07N601-01

AIR CONDITIONER BELT (IF EQUIPPED) To adjust tension, loosen bolt (1) and (2), and manually adjust tension. Retighten bolts securely when correct belt tension is reached.

To replace belt, loosen bolts (1) and (2). Replace with new belt. Adjust tension accordingly. Tighten bolts securely.

New Belt Tension . . . . . . . . . . . . . . . 45 kg (100 lbs) Belt used more than 20 hours . . . . . . . 41 kg (90 lbs)

6-8

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SPARK ARRESTING MUFFLER (IF EQUIPPED) CLEANING 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.

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

Figure 13

BD07N601-01

4. Start the engine and run for 2 to 3 minutes while debris is ejected from the muffler.

WINDSHIELD WASHER RESERVOIR

5. Install the plug in the muffler.

The windshield washer reservoir is located on the right hand side of the machine beneath the steps.

Periodically check the level of washer solution and fill as necessary. Do not operate the windshield washer without solution in the reservoir, as washer motor damage can occur.

6. Clean debris from the machine.

IMPORTANT: When the ambient temperature decreases to 0°C (32°F) and below, always use an antifreeze type washer solution.

NOTE: Replacement plug (if required) must be of brass material.

WARNING: Exhaust surfaces may be HOT if the engine has been recently operated. Be careful not to touch the exhaust surfaces while cleaning the muffler, as personal injury may result.

CHECK INJECTOR CALIBRATION This procedure should be performed by a qualified service technician when the hourmeter registers 1000 hours. Contact your dealer.

CHECK ENGINE VALVE CLEARANCES This procedure should be performed by a qualified service technician when the hourmeter registers 4000 hours. Contact your dealer.

HOSES AND WIRING Check all hoses and wiring for damage. If damage occurred, see your dealer for repair or replacement.

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87479806 A - EU

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSPECTING AND CLEANING THE MACHINE

WELDING ON THE MACHINE Whenever carrying out a welding operation on the machine as authorized by the manufacturer and in accordance with manufacturer’s instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Always connect the welding apparatus to the same structure that is being welded.

Never connect the welding apparatus ground to a component of the hydraulic system.

WARNING: Any unauthorized modifications made to this machine can cause serious injury or death. Do not undertake any modifications without first consulting your dealer.

Maintenance Specifications Inspect and clean . . . . . . . . . . . . . . . . . . Periodically WARNING: Wear face protection when using high pressure water jets. Failure to comply could cause injury or death.

Clean immediately if oil or grease has been spilled on the machine. Clean with steam or a high pressure water jet.

Look for any leaks, and check the condition of all pipes and hoses.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the bucket/attachment linkages and check the teeth and tooth tips for correct retention and for wear.

FIRE EXTINGUISHER (NOT SUPPLIED)

CHECKING FOR CYLINDER LEAKAGE A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

1. Wipe the rod and bearing clean on the cylinder to be checked.

2. Operate normally for five or ten minutes.

3. Extend the cylinder rod.

TEST

Every month Examine the fire extinguisher and make sure it is not damaged.

Have an approved specialist empty and refill the fire extinguisher.

Every year

Normal

Slightly Paper remains stuck to rod greasy when run over rod.

Normal

Oily Paper remains stuck when placed on rod.

Normal

Each time the rod retracts, Leakage the excess oil drips from the gland.

6-10

CONCLUSION

Slight traces of oil when a Dry piece of paper is wiped over 20 cm (7.8 in) of the rod.

Very oily or Each time the cylinder rod weeping is extended, a ring of oil can be seen on the rod.

Maintenance Specification

Every six months

4. Carry out the leak test.

ROD APPEARANCE

It is strongly recommended a fire extinguisher be kept on the machine. An extinguisher is not supplied but can be purchased separately and placed in the operator’s compartment.

See your dealer

Have an approved specialist examine the fire extinguisher.

PLASTIC AND RESIN PARTS When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

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87479806 A - EU

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LOADER ADJUSTMENTS HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT PROCEDURE

6

2

5

1 4

3

Figure 14

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. Keep all non-authorized personnel clear of the area. Park the machine on firm, level ground.

4. 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.

2. Start the engine, and apply the parking brake.

3. Lower the lift arms, and place the bucket flat on the ground. Stop the engine.

NOTE: To avoid damage to the proximity switch (1), it must be adjusted back away from the lift arm to clear everything on the lift arm as it sweeps past.

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6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

A mm APPROXIMATE (in) RESULTING RETURN TO TRAVEL HINGE PIN HEIGHT mm (in)

B mm APPROXIMATE (in) RESULTING HEIGHT CONTROL HINGE PIN HEIGHT mm (in)

521E Z-BAR

57 (2.24)

358 (14.09)

54 (2.12)

3302 (130)

521E XT

47 (1.85)

438 (17.24)

48 (1.89)

3302 (130)

MACHINE

A

B

BX00N077

2

4

Figure 15

2.) Return to Travel Target 4.) Height Control Target 5. 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.

Tighten the target in this position.

6-12

6. 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.

7. 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.

Issued 03-08

87479806 A - EU

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS XT RETURN TO DIG PROCEDURE

1 2 6

5

3 4

Figure 16

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.

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.

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.

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.

Issued 03-08

87479806 A - EU

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 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.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Z-BAR RETURN TO DIG ADJUSTMENT PROCEDURE

1 2

3

7 5

6 4 Figure 17

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. Raise 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.

4. Loosen the bolts holding the proximity switch mounting bracket to the tilt cylinder. Position the proximity switch face parallel to the 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 th e target bar towards the proximity switch until the face of the proximity switch is completely covered. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

6-14

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 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.

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. Verify 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.

Issued 03-08

87479806 A - EU

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.

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CALIBRATING THE GEAR BOX Calibrate the gear box when the hourmeter registers 250 hours for a new machine during the initial run-in period. The gear box calibration should be performed at every 1000 hours thereafter.

After running the machine to warm the oil temperature: 1. Keep all non-authorized personnel clear of the area. Park the machine on a firm, level surface.

2. Place the NEUTRAL.

transmission

control

lever

in

3. Set the parking brake.

BD06F196

4. With the engine running at idle, enter the service screen menu and scroll to Config screen. Press the confirm key.

If machine conditions are incorrect, an error message will appear. The calibration procedure will not complete. Follow the prompts to aid in correcting any machine conditions.

Figure 20

The screen may display the following prompts to guide the user to correct machine conditions:

• • • • • • •

BD06F202

Figure 18

Use down arrow button to scroll to Calib G/B. Highlight Calib. G/B, and press the confirm key.

Always follow the prompts on the screen. Should an error occur, use the escape key to start over again.

Not in neutral Parking Brake OFF Machine moving Oil temp too low Oil temp too high Engine RPM low Engine RPM high

If conditions are correct, the user will see six calibration screens displayed. They will appear in the following order: • Adjust K1 • Adjust K2 • Adjust K3 • Adjust K4 • Adjust KV • Adjust KR Once the calibration process is complete, the user will be prompted to turn the engine Off and restart the machine.

If the process is not completed, the screen will prompt the user to escape.

BD06F195

Figure 19

The screen will show a confirm prompt. If you doubt your ability to perform this operation, press the escape key and call your dealer.

6-16

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87479806 A - EU

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRANSMISSION DECLUTCH PRESSURE ADJUSTMENT

1

2

Figure 21

BD07N514

1. Keep all non-authorized personnel clear of the area. Park the machine on firm, level ground.

Lower the arms until bucket edge is on the ground. Apply the parking brake, and stop the engine.

2. Remove the side panel beneath the operator’s compartment in order to access the transmission declutch pressure switch. Take care not to damage the panel during removal.

BD07A200

Figure 22

3. Loosen the set screw (1) located near the end of the adjustable transmission declutch pressure switch.

4. Rotate the outer body (2) of the adjustable transmission declutch pressure switch in either the clockwise or counter clockwise direction.

Turning the outer body clockwise will increase the amount of brake pressure required to activate the declutch function. Turning the outer body counter clockwise will decrease the amount of brake pressure required to activate the declutch function. Adjust the adjustable transmission declutch pressure switch according to operator preference.

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87479806 A - EU

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 5. The adjustable declutch pressure switch is set to 10.34 bar (150 psi) plus or minus 0.55 bar (8 psi) from the factory. For every 1/4 turn of the outer body there is a 1.03 bar (15 psi) pressure change in the switch. The pressure change is the same in either the clockwise or counter clockwise direction.

6. Tighten the set screw (1) located near the end of the adjustable transmission declutch pressure switch. Test the adjusted declutch function for desired effect in a clear open area away from obstacles. Readjust as desired.

7. The transmission declutch is activated by brake pressure. A higher brake pressure to activate the declutch function is desirable when operating on inclines. Higher brake pressure is the result of increasing brake pedal travel. A lower brake pressure to activate the declutch function is desirable when operating on firm, flat terrain.

Lower brake pressure is the result of limited brake pedal travel.

6-18

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87479806 A - EU

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PARKING BRAKE TEST

BD06F198

Figure 23

BD06F099

Parking brakes should be tested periodically. If you doubt your ability to perform this procedure correctly, call your dealer.

Figure 24

The screen will change to the test park brake screen and request confirmation. To confirm, press the confirm key again.

Keep all non-authorized personnel clear of the area when performing the parking brake test.

WARNING: Parking brake tests should only be performed by a skilled, qualified operator or technician. This test requires running the engine at high RPM’s. Failure to comply could result in machine damage, injury, or death.

Park the machine on a firm, level surface clear of any obstructions and any non-authorized personnel or vehicles. Run the machine at low idle in third gear neutral. Place the transmission auto switch to the manual position.

Place the parking brake switch to the ON position.

BD06F199

Figure 25

Follow the prompts on the screen to complete the park brake test. If all conditions are not met to test the brake, the monitor will display the condition that must be corrected prior to completion of the test. The parking brake must be engaged.

With the engine running at idle, enter the Service Screen Menu and scroll to the Config. menu.

1. When all conditions are met, the monitor will display: Test Park Brake Ready.

Use the arrow key to scroll to the sub menu Park Brake. Highlight Park Brake on the menu and press the confirm key.

2. Shift the gear selector into third gear forward, and slowly increase the engine speed to full open throttle.

3. Verify that the machine does not move.

4. Reduce ending speed to low idle, and return the transmission to neutral.

5. Shift the gear selector to third gear reverse and slowly increase the engine speed to wide open throttle.

6. Verify that the machine does not move.

7. Reduce the engine speed to low idle and return the transmission to neutral.

8. Press the escape key on the key pad to exit the test mode.

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87479806 A - EU

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS PARKING BRAKE CHECK NOTE: Test the parking brake at a minimum of every 250 hours.

Before you operate the machine, periodically test the parking brake functions.

E. Pump the service brakes, the low brake pressure warning light should come ON. Continue to pump the service brakes. Pump until the parking brake light comes ON, pump the brakes three more times. This could require as many as forty brake pumps.

F. Start the engine and allow the brake pressure to build until the warning light goes off.

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 parking brake switch in the engaged position, attempt B and C in Step 1. The parking brake light must stay ON. 4. Put the parking brake switch in the release position, attempt B and C in Step 1. The parking brake light must turn OFF.

BD06F099

Figure 26

A. Push the Parking Brake switch to the release position.

A. Allow the machine to roll slowly forward with the transmission in F. Engage the parking brake. The machine must come to a stop immediately. Parking light ON. Transmission disengages.

B. Service brake depressed indicating brake lights.

If there is any problem with the parking brake test, contact your dealer.

1. To release the parking brake, all the following are required:

C. Transmission shifter positioned from N to F or R for a second, and back to N. D. Adequate service brake pressure to stop the machine.

2. The parking brake will engage under the following conditions. Always wear your seat belt in the event that the parking brake would unexpectedly engage.

A. Loss of service brake pressure in both axles.

B. Loss of system electrical power (key OFF).

C. Parking Brake switch in engaged position.

3. To test these functions: A. Start on a clear level surface.

B. With Step 1, A through C complete, start the engine, and release the parking brake. The red warning light should be out.

C. Turn the engine off. Turn the key switch to the ON position. With the engine off, the parking brake light should come ON. D. Release the parking brake using B and C in Step 1. Make sure the parking brake light is out.

6-20

Issued 03-08

87479806 A - EU

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SECONDARY STEERING CHECK Check the secondary steering (if equipped) when the hourmeter reads 250 hours or any time electronic warnings may so indicate.

6. Look at the instrument cluster to verify that the secondary steering light comes on.

IMPORTANT: Do not run the secondary steering pump/motor continuously for more than 20 seconds at a time without a 2 minute cool down.

7. Restart the engine. Confirm the secondary steering light stays on. The secondary steering motor should stop after approximately 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. If you have any problems with this procedure, call your dealer.

Figure 27

BD06F096-3

WARNING: The secondary steering system is electrically powered. This system allows you to steer the machine if the primary steering system stops working. Maintain the batteries to assure the system will function.

Failure to comply could cause machine damage, injury or death.

WARNING: Do not turn the key switch off if the machine is steered against either the right hand or left hand steering stop. The steering wheel may kick back. Failure to comply could cause machine damage, injury or death.

1. Keep all non-authorized personnel clear of the area. Park the machine on hard packed level ground with enough clearance around the machine to allow complete steering from side to side. Raise the bucket approximately 20 inches (500 mm) above the ground.

2. With the key switch 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 run for a few seconds. Confirm the secondary steering light is out after the first few seconds. This confirms the electrical function of the circuit is operating correctly and adequate pressure has built. The secondary steering module is now functional.

4. With the machine at low idle and steering straight ahead, turn the key switch to the OFF position to stop the engine. Immediately turn the key back to the ON position (not start position). The secondary steering pump/motor should start running. Confirm 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 of steering function.

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87479806 A - EU

6-21

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CAB SERVICE AIR CONDITIONING (IF EQUIPPED) The components of the operator’s cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

WARNING: Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiar with air conditioning systems and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions. Failure to comply could cause injury or death.

SA048

LUBRICATION OF THE AIR CONDITIONING COMPRESSOR SEALS

RADIATOR/COOLER ACCESS FOR CLEANING

WARNING: Use a safety type air tool and wear full coverage safety glasses with side panels when using compressed air. Failure to comply could cause injury or death.

Operate the air conditioning once every 250 hours to lub ricate the co mpressor seals. Turn the air conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 0°C (32°F) put a cover over the air conditioning condenser. This will make sure the refrigerant and lubricants in the system will be at operating temperature.

Figure 29

BD04G022

Additional radiator access can be gained on both the left and right hand sides of the machine.

1. Remove bolts from each end of the plastic fender insert.

2. Slide fender insert to the rear of the machine 25mm (1 inch) to disengage fender insert from rear frame side plate.

3. The lower areas and radiator/cooler in general can be cleaned using a shop-vacuum and or pressure washer.

Figure 28

BD007N657-01

CONDENSER

Keep the air conditioning condenser core clean. Use safety type compressed air tool or a rigid brush to clean the condenser. Also check and clean the grille screen.

IMPORTANT: Because the condenser fins bend easily, use care when cleaning the condenser.

6-22

IMPORTANT: Be careful not to bend or damage radiator/cooler fins during cleaning. DO NOT exceed 6890 kPa (1000 psi) nozzle pressure when cleaning.

Check the radiator, coolers and engine compartment for build up of debris, dirt and material that might impede cooling components functions. This is particularly important under extreme conditions.

Inspection intervals should be adjusted accordingly.

Issued 03-08

87479806 A - EU

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS OPERATOR’S SEAT

CAB HEADLINER

Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct use of a material cleaner.

The foam headliner in your cab decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

IMPORTANT: DO NOT wash the headliner with water.

Water can cause damage to the headliner and lower the noise control capacity of the headliner.

WARNING: Never use gasoline, naptha or any other volatile material for any cleaning purposes. These materials may be toxic and/or flammable. Failure to comply could cause injury or death.

SA049

Cleaning Fluid - This type of cleaner can be used for grease or oil stains. Carefully remove the item that caused the stain with a scraper or a dull knife.

Use a minimum amount of cleaner and a clean cloth.

Move the cloth from the outside of the stain towards the center. When the stain is removed, use a clean cloth to dry the area to prevent a cleaning fluid pattern.

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6-23

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-24

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CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-4 7-4 7-4 7-4

BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Access to the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Connecting Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Check Battery Fluid Level and Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Replacing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Replacement Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 MACHINE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotating Beacon Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Power Outlet (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

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CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM BATTERY SAFETY WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

Failure to comply can cause injury or death.

SA046

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Insure adequate ventilation when charging batteries or when using in a confined place. Always protect your face when working near batteries. Failure to comply can cause injury or death.

SAFETY_ID_1C02

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Failure to comply can cause injury or death.

Antidote - EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil.

Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

SB032

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. Failure to comply can cause injury or death.

SA033

WARNING: Connecting jump start (booster battery) cables incorrectly or short- circuiting battery terminals can cause an accident.

Connect auxiliary starting cables as per the following instructions. Failure to comply can cause injury or death.

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

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

4. Do not weld, grind, or smoke near a battery.

Failure to comply can cause injury or death.

SB034

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-). Failure to comply can cause machine damage, injury or death.

SAFETY_ID_1C02

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the off position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last. Failure to comply can cause machine damage, injury or death.

SAFETY_ID_1C02

WARNING: Whenever carrying out a welding operation on the machine (authorized by the manufacturer and in accordance with manufacturer’s instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator. When reconnecting, check the markings on the wires. Failure to comply with the following warnings could result in machine damage, serious injury, or death.

SAFETY_ID_1C02

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7-3

CHAPTER 7 - ELECTRICAL BATTERY SERVICE

BATTERY FLUID LEVEL

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the container.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Whenever carrying out a welding operation on the machine as authorized by the manufacturer and in accordance with manufacturer’s instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Always connect the welding apparatus to the same structure that is being welded.

Never connect the welding apparatus ground to a component of the hydraulic system.

Do not use a steam cleaner or cleaning solvent to clean the alternator.

In extreme heat conditions check battery fluid every 250 hours.

IMPORTANT: If the temperature is 0°C (32°F) or below and you have added water to the batteries, perform the following: Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and battery compartment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver. Follow the instructions

on the container. This cleaner does not need water.

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

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CHAPTER 7 - ELECTRICAL

BATTERIES CONNECTING BOOSTER BATTERIES

ACCESS TO THE BATTERIES

1

Figure 1

BD07N556-01

Figure 2

BD07N692

Service Specifications Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . Two 12 volt

Make sure that the voltage of the booster batteries is the same as that of the machine system (24 volts).

The machine is electronically powered by a 24 volt system.

1. Turn off the ignition and all accessories on the machine(s). Remove the battery cover from the left hand side of the machine. Remove the left battery terminal cover.

NOTE: If the machine needs to be started using a booster battery, see Connecting Booster Battery.

Batteries are enclosed in compartments on both the left and right hand rear of the machine. To access the batteries, loosen and remove the bolts (1) that hold the cover in place. (One battery on each side of machine). Handles are provided for easy removal and installation.

WARNING: Before carrying out any service work on electrical system components, turn the starter switch key to the “OFF” position. When disconnecting batteries, always disconnect the negative (-) cable first.

When reconnecting batteries, always connect the negative (-) cable last. Failure to comply can cause machine damage, injury or death.

WARNING: Hydrogen gas may be present above the discharged battery. Do not make the negative connection directly to the discharged battery, as this may ignite the hydrogen gas. Failure to comply can cause machine damage, injury or death.

WARNING: An error when connecting booster battery cables or short-circuiting battery terminals can cause an accident. Be certain connections are correct. Failure to comply with the following warnings could result in serious injury or machine damage.

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2. Connect one end of the positive (+) cable to the positive (+) terminal on the booster battery.

Connect the other end of the positive (+) cable to the positive (+) terminal of the discharged battery.

3. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

4. Connect the other end of the negative cable to the engine block or frame of the machine with the discharged battery. Do not connect it to sheet metal or any rotating part, as damage can result.

Do not connect to the negative terminal on the discharged battery.

5. Start the engine.

6. Remove the booster battery negative (-) cable from the machine, then from the booster battery.

Remove the positive (+) cable from the machine and then from the booster battery.

7. Install the terminal covers.

IMPORTANT: Booster batteries should be of the same voltage as that of the machine system (24 volts) and should be connected on the left side only.

WARNING: Do not invert battery terminals.

Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (−). Failure to comply with the following warnings could result in serious injury or machine damage.

7-5

CHAPTER 7 - ELECTRICAL CHECK BATTERY FLUID LEVEL AND SPECIFIC GRAVITY

REPLACING A BATTERY

The battery fluid can decrease with high temperatures.

Check the battery fluid level in the morning before starting operation.

Remove the cell caps and check the level in each batteries cell. The level should be approximately 5 mm (3/16 in) of vent well bottom. Add distilled water if necessary, then install the cell caps.

Continuous use of the battery with low fluid will lower battery performance.

Check the battery fluid level periodically, and if insufficient, refill the battery with distilled water before the engine start-up (before charging battery).

1 Figure 4

BD06G101

Remove the terminal protection caps, disconnect negative terminal cables and then positive terminal cables. Remove the anti-sulfate pellets.

Remove the two screws, the washers, and retainer (1). Remove the old battery.

Install new battery of the correct voltage and replace retainer, washers and screws.

Clean the cables and battery terminals, and coat with grease. Install new anti-sulfate pellets. Reconnect positive cable ends to positive terminals first.

Reconnect negative cable ends to negative terminals, and install the terminal protection caps.

BD06H177A

Figure 3

If the terminals are dirty, wash with warm water, Reinstall the terminals, applying grease or spraying rust preventive solution to create good connections.

If the terminal is oxidized, polish it with a wire brush or emery paper.

NOTE: Measure the specific gravity of battery fluid with a gravimeter. The measured value will vary depending on the ambient temperature.

WARNING: Do not invert battery terminals.

Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (−). Failure to comply could result in serious injury or machine damage.

ALTERNATOR Service Specification Check . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours Ask your Dealer to check the alternator.

Make sure that the terminal protectors are correctly installed.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

STARTER MOTOR Service Specification Check . . . . . . . . . . . . . . . . . . . . . . Every 1000 hours Ask your Dealer to check the starter motor.

Make sure that the terminal protectors are correctly installed.

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CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS

ECC

ECD

ECA

ECB

Figure 7

BD06G174

POWER MODULE CENTERS

B

Figure 5

BD06G175

Fuses and relays can be found inside the access door on the right hand side of the machine.

E

D

A

If power does not come when the key switch is turned to the ON position, check the appropriate fuse.

If a fuse has failed, an indicator light will be illuminated at the location on the panel.

IMPORTANT: Before changing fuses or relays, turn the ignition key switch to the OFF (Shut Down) position.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

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.

Figure 8

87397077

FUSE AMP

FUNCTION

Power Relay Module B F1

40

Time Delay Power

F2

Spare Relay Time Delay

Power Relay Module E F1

20

Power Converter

F2

Spare Relay Power Converter

Power Relay Module D F1

40

Accessory Power

F2

Spare Relay Accessory Power

Power Relay Module A 40

Ignition Power

F2

20

Secondary Steering

Figure 6

BD07N660-01

LEFT HAND ENGINE COMPARTMENT

Additional fuses and relays are located in both the left and right hand engine compartment area.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

Issued 03-08

F1

87479806 A - EU

Relay Ignition Power Power Relay Module C F1

40

Fuel Filter Heater

F2

20

Voltmeter Relay Engine Compartment

7-7

CHAPTER 7 - ELECTRICAL

Figure 9

BD07G069

The fuse decal is located inside the access door.

7-8

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CHAPTER 7 - ELECTRICAL ECD FUSE PANEL

REPLACEMENT FUSES ECC FUSE PANEL

FUSE AMP

FUSE AMP

FUNCTION

FUNCTION

F1

7.5

TRANSMISSION CONTROL

F1

7.5

DOME LAMP - BEACON

F2

30

ENGINE STARTER

F2

15

WORK LIGHTS

F3

10

INSTRUMENT CLUSTER

F3

15

ROAD LIGHTS

F4

10

12 VOLT AUX. PLUG

10

12 VOLT AUX. PLUG

F4

10

BRAKE LIGHTS - FLASHER

F5

F5

10

ENGINE START

F6

10

RADIO

F6

7.5

HORN

F7

15

12 VOLT AUX. PLUG

F7

10

HOOD RAISE - LOWER

F8

F8

15

CIGARETTE LIGHTER

F9

BACKUP ALARM RELAY

F9

10

DIAGNOSTIC POWER

F10

BACKUP ALARM RELAY

F10 ECA FUSE PANEL

FUSE AMP F1

7.5

F2

5

F3 F4

FUNCTION TRANSMISSION CONTROL

ECB FUSE PANEL

FUSE AMP

FUNCTION

STEERING

F1

10

FRONT FLOOD LIGHTS

7.5

INSTRUMENT CLUSTER

F2

10

REAR FLOOD LIGHTS

7.5

SECONDARY STEERING

F3

5

HIGH BEAM LEFT HIGH BEAM RIGHT

F5

5

RIDE CONTROL

F4

5

F6

5

PARKING BRAKE

F5

5

LOW BEAM LEFT

F7

7.5

COUPLER/FAN REVERSER

F6

5

LOW BEAM RIGHT

F8

5

TURN SIGNAL/FLASHER

F7

5

LEFT TAIL LIGHTS

F9

10

ENGINE STOP

F8

5

RIGHT TAIL LIGHTS

F11

25

BLOWER SWITCH

F12

10

FRONT WIPER

F13

10

REAR WIPER

F14

5

BACK-UP ALARM

F15

7.5

AIR CONDITIONING

F16

10

COMPRESSOR (SEAT)

F17

7.5

SECONDARY STEERING

F10

F18 F19 F20

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7-9

CHAPTER 7 - ELECTRICAL

MACHINE LIGHTS WORK LIGHTS

1

2 3 521E-3M007

Figure 11

BD07A202

Figure 10

To replace work lights, remove the two Phillips screws from the rear of the light.

1. WORK LIGHTS 2. DRIVING LIGHTS 3. TAIL LIGHTS

Figure 12

BD07A201

Disconnect push on connectors, and replace the lamp assembly. Push the connectors on, making certain connections are firmly in place. Replace the two rear screws.

7-10

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CHAPTER 7 - ELECTRICAL ROTATING BEACON CONNECTION

DRIVING LIGHTS

1

Figure 13

BD06H181

Remove the screws fastening the light to the bracket.

Pull the light assembly away from the bracket. Do not lose rubber sealing gasket (1).

BD06H186

Figure 16

The rotating beacon is an optional feature. The plug-in connection for the beacon is located at the top right front of the cab.

2

Figure 14

BD06H182

Lift up on the wire clip (2) holding the bulb in place by pinching sides of clip together.

3

Figure 15

BD06H183

Disconnect the bulb at the wire connector (3) within the protective sleeve. Replace the bulb with a bulb of the same type and wattage. Reconnect and cover connection with the protective sleeve. Replace light assembly back in light bracket holder, and replace screws. Make certain rubber gasket is fitted correctly.

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87479806 A - EU

7-11

CHAPTER 7 - ELECTRICAL AUXILIARY POWER OUTLET (IF EQUIPPED) The Auxiliary Power Outlet socket (12 volt) can be used for the connection of a lighting device to help with service and maintenance procedures. There are two auxiliary power outlets, one in the right corner of the operator’s compartment, and one in the left corner of the operator’s compartment.

Figure 17

BD07A203

7-12

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 LIFT CAPACITY 521E Z-BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 LIFT CAPACITY 521E XT LIFT ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 521E Z-BAR OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 521E XT LIFT ARM OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 MATERIAL WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

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CHAPTER 8 - SPECIFICATIONS

8-2

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CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS Engine Model ................................................................................................................Case 445TA/EGE, Tier 3 Certified Type ........................................................................................................ 4-stroke, turbocharged, air-to-air cooled Cylinders .............................................................................................................................................................. 4 Bore/stroke .................................................................................................. 104 mm x 132 mm (4.09 in x 5.20 in) Displacement ................................................................................................................................ 4.5 l (275 cu in) Horsepower - Peak Max Power Gross ................................................................................................................ 109 kW (146 HP) at 1900 RPM Net .................................................................................................................... 101 kW (136 HP) at 1900 RPM Standard Power Gross ................................................................................................................ 101 kW (136 HP) at 1900 RPM Net ...................................................................................................................... 94 kW (125 HP) at 1900 RPM Economy Power Gross .................................................................................................................. 82 kW (110 HP) at 1700 RPM Net ...................................................................................................................... 77 kW (103 HP) at 1600 RPM Torque - Peak Max Power Gross ............................................................................................................... 573 Nm (422 ft lb) at 1600 RPM Net ................................................................................................................... 545 Nm (402 ft lb) at 1500 RPM Standard Power Gross ............................................................................................................... 554 Nm (408 ft lb) at 1400 RPM Net ................................................................................................................... 533 Nm (393 ft lb) at 1300 RPM Economy Power Gross ............................................................................................................... 547 Nm (403 ft lb) at 1200 RPM Net ................................................................................................................... 531 Nm (392 ft lb) at 1200 RPM Engine Speeds Rated speed, full load ............................................................................................................................. 2000 rpm Low idle, no load .........................................................................................................................1020 - 1080 RPM High idle, no load ........................................................................................................................2074 - 2244 RPM Electrical Batteries .................................................................................................................................................. 2 - 12 volt Alternator.................................................................................................................................................... 70 amp Voltage ........................................................................................................................... 24 volts, negative ground Drivetrain Transmission .............................................................................. 4F/3R Proportional with Electronic Control Module Torque Sensing Autoshift/Manual Shift and Modulation Gears ........................................................................................................................................................ Helical Cut Issued 03-08

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CHAPTER 8 - SPECIFICATIONS Gear Ratios

Forward

Reverse

1st

4.012

3.804

2nd

2.174

2.061

3rd

1.088

1.031

4th

0.619

-----

Torque converter stall ratio ........................................................................................................................... 2.30:1 Differential ..............................................................limited slip with 45% transfer in front and 45% transfer in rear Rear axle oscillation ...................................................................................................................................24° total Axles Axles Differential ratio Planetary ratio Final axle ratio

Front and Rear 3.36 6.40 21.53

Brakes Service brakes ............................................................. Hydraulically actuated, self-adjusting (maintenance free), multiple wet disc at all four wheels with accumulator for each axle.

Brake surface area ....................................................................................................... 0.310 m2 (480 in2) per hub Parking brakes ................................... spring-applied, hydraulic release disc caliper on transmission output shaft Travel Speeds 17.5 x 25L2/L3 Tires Travel Speeds

Forward, km/h (mph)

Reverse, km/h (mph)

1st

6.1 (3.8)

6.4 (4.0)

2nd

11.1 (6.9)

11.7 (7.3)

3rd

21.6 (13.4)

22.8 (14.1)

4th

35.9 (22.3)

-----

20.5 x 25L2/L3 Tires Travel Speeds

Forward, km/h (mph)

Reverse, km/h (mph)

1st

6.7 (4.2)

7.1 (4.4)

2nd

12.2 (7.6)

12.9 (8.0)

3rd

23.6 (14.7)

24.9 (15.5)

4th

39.0 (24.2)

-----

NOTE: Travel speeds @ full engine throttle

8-4

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87479806 A - EU

CHAPTER 8 - SPECIFICATIONS Hydraulics Pump .............................................................................................. Closed centered pressure/flow compensated Variable displacement ... 134 L/min @2000 rpm @ 18961 kPa4 (4.33 in³/rev/ 35.4 gpm @2000 rpm @2750 psi) Loader control valve ..................................................... closed-center, sectional 2, 3, or 4-spool with pilot control for lift, tilt, and auxiliary hydraulics, electromagnetic detents in float, raise and rollback Loader auxiliary steering .................................. hydraulic orbital center-pivot articulating with on demand oil flow Filtration ...................... 10-micron, full flow replaceable cartridges on return line, condition indicator light for filter Cylinders Lift cylinder Bore diameter ...................................................................................................................... 101.6 mm (4.00 in) Rod diameter ..........................................................................................................................57.2 mm (2.25 in) Stroke................................................................................................................................... 783.0 mm (30.8 in) Dump cylinder (Z-Bar, XR) Bore diameter ...................................................................................................................... 114.3 mm (4.50 in) Rod diameter ............................................................................................................................63.5 mm (2.5 in) Stroke..................................................................................................................................529.2 mm (20.84 in) Dump cylinder (XT) Bore diameter ...................................................................................................................... 101.6 mm (4.00 in) Rod diameter ......................................................................................................................... 57.2 mm (2.25 in) Stroke..................................................................................................................................758.2 mm (29.85 in) Instrumentation Speedometer, Tachometer, Travel selected (F/N/R), Transmission modes, Gear position, Engine coolant temperature, Fuel level, Transmission oil temperature, Hydraulic oil temperature, Hourmeter, Work mode Audible and Visual Indicator/Alarms Cautionary and critical levels, directional/brights indication, low fuel, grid heater (if equipped); direction signals, low oil pressure

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8-5

CHAPTER 8 - SPECIFICATIONS Standard Equipment Alternator and voltage regulator Electrical disconnect Batteries, electric starter Front and rear halogen flood lights, tail lights and stop light combination Key start switch Antifreeze Full suspension, fully adjustable bucket type seat Retractable seat belt Tilting engine hood ROPS/FOPS cab Tilt steering column Horn Bucket and lift levers with hydraulic power assist Single lever power shift transmission Planetary axles Transmission oil cooler Tubeless tires Four wheel drive Automatic return to dig Bucket position indication Fuse box with all electrical circuits protected Operator Environment ROPS cab w/heat Key Start Articulated power steering w/tilt column Adjustable, suspension seat Single lever 2-spool loader control Cup holder Coat hook Rear view mirror (interior) 2 inch (52 mm) retractable seat belt Storage tray Single brake pedal External rear view mirrors Lock box Dome light Sun screen Wipers - front and rear (intermittent front)

8-6

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CHAPTER 8 - SPECIFICATIONS

OPTIONAL EQUIPMENT Cab group:

Hydraulics:

Cloth-covered air suspension seat

Auxiliary hydraulics

Air conditioning w/heater

Ride Control

Radio

Secondary Steering

Radio-ready (12 volt)

3 or 4-spool loader valves with 2 or 3 lever loader control

12 volt auxiliary power Cab convenience package

Hydraulic reversing fan (Variable/Auto speed) Hydraulic cooler

Rotating beacon

Auxiliary steering

Second brake pedal Tool box

Loader

Fire extinguisher

Hydraulic attachment coupler Attachment auxiliary hydraulics

Engine Aspirator and spark arresting muffler

Buckets

Cold weather package Engine block heater Hydraulic cooler bypass Low temperature hydraulic oil Grid heater Fuel warmer

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Other Lift and tie down brackets Transmission and front drive belly guard Sound shield noise suppression package Rear frame side covers

8-7

CHAPTER 8 - SPECIFICATIONS

LIFT CAPACITY 521E Z-BAR Lift Capacity 521E Z-Bar 1.8 m3 (2.30 yd3) Bucket w/Bolt on Edge

1.8 m3 (2.30 yd3) Bucket w/Teeth and segments

Full Height

5567 kg (12272 lb)

5520 kg (12169 lb)

Ground

9620 kg (21208 lb)

9529 kg (21008 lb)

Lift Capacity 521E Z-Bar 2.0 m3 (2.60 yd3) Bucket w/Bolt on Edge Full Height

5596 kg (12338 lb)

Ground

9580 kg (22121 lb)

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CHAPTER 8 - SPECIFICATIONS

LIFT CAPACITY 521E XT LIFT ARM Lift Capacity 521E XT - Buckets with coupler 1.7 m3 (2.2 yd3 ) Bucket w/Bolt on Edge

1.7 m3 (2.2 yd3 ) Bucket w/Teeth and segments

Full Height

4945 kg (10903 lb)

5032 kg (11093 lb)

Ground

10502 kg (25153 lb)

10639 kg (23455 lb)

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8-9

CHAPTER 8 - SPECIFICATIONS

521E Z-BAR OPERATING DATA AND DIMENSIONS

Figure 1

BS07J055

521E Z-BAR MACHINES 1.8 M3 (2.30 YD3) MEDIUM DENSITY BUCKET W/CUTTING EDGE SAE bucket capacity Struck ........................................................................................................................................ 1.51 m³ (1.98 yd³) Heaped...................................................................................................................................... 1.76 m³ (2.30 yd³) A. Height to top of cab ........................................................................................................... 3 277 mm (129.0 in) B. Wheelbase......................................................................................................................... 2 750 mm (108.3 in) C. Ground clearance ................................................................................................................. 377 mm (14.85 in) D. Angle of departure ........................................................................................................................... 34 degrees Width Overall w/o bucket and with 17.5 X 25 XTLA tires............................................................... 2 389 mm (94.1 in) Centerline tread with 17.5 X 25 XTLA tires.......................................................................... 1 900 mm (74.8 in) Turning radius - outside with 17.5 X 25 XTLA tires .................................................................4 972 mm (195.8 in) Turning angle From center...................................................................................................................................... 40 degrees Total angle ....................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ........................................................................ 4 684 mm (184.4 in) F. Hinge pin height - fully raised............................................................................................. 3 608 mm (142.1 in) G. Overall length - bucket level on ground ............................................................................. 6 685 mm (263.2 in) H. Dump height - fully raised, 45 degree dump...................................................................... 2 713 mm (106.8 in) J. Bucket reach - fully raised, 45 degree dump........................................................................ 1 013 mm (39.9 in) K. Bucket reach - 2.13 m (7 ft 0 in) height, 45 degree dump ................................................... 1 444 mm (56.9 in) L. Dig depth..................................................................................................................................... 70 mm (2.8 in) Tipping load - ISO Machine straight................................................................................................................. 8 337 kg (18 381 lb) 40 degree turn..................................................................................................................... 7 262 kg (16 011 lb) Operating load - ISO..................................................................................................................... 3 631 kg (8 006 lb) Unit operating mass................................................................................................................... 10 503 kg (23 156 lb) NOTE: Machine operating weights stated are calculated with ROPS cab, heater, air conditioner, 1873 lb. counterweight, 17.5R25 XTLA tires, standard width front and rear fenders, full fuel, 175 lb (79 kg) operator.

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CHAPTER 8 - SPECIFICATIONS

Figure 2

BS07J055

521E Z-BAR MACHINES 1.8 M3 (2.30 YD3) MEDIUM DENSITY BUCKET W/TEETH AND SEGMENTED CUTTING EDGE SAE bucket capacity Struck ........................................................................................................................................ 1.51 m³ (1.98 yd³) Heaped...................................................................................................................................... 1.76 m³ (2.30 yd³) A. Height to top of cab ........................................................................................................... 3 277 mm (129.0 in) B. Wheelbase......................................................................................................................... 2 750 mm (108.3 in) C. Ground clearance ................................................................................................................. 377 mm (14.85 in) D. Angle of departure ........................................................................................................................... 34 degrees Width Overall w/o bucket and with 17.5 X 25 XTLA tires............................................................... 2 389 mm (94.1 in) Centerline tread with 17.5 X 25 XTLA tires.......................................................................... 1 900 mm (74.8 in) Turning radius - outside with 17.5 X 25 XTLA tires .................................................................4 972 mm (195.8 in) Turning angle From center...................................................................................................................................... 40 degrees Total angle ....................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ........................................................................ 4 684 mm (184.4 in) F. Hinge pin height - fully raised............................................................................................. 3 608 mm (142.0 in) G. Overall length - bucket level on ground ............................................................................. 6 834 mm (269.0 in) H. Dump height - fully raised, 45 degree dump...................................................................... 2 615 mm (103.0 in) J. Bucket reach - fully raised, 45 degree dump........................................................................ 1 114 mm (43.8 in) K. Bucket reach - 2.13 m (7 ft 0 in) height, 45 degree dump ................................................... 1 490 mm (58.6 in) L. Dig depth..................................................................................................................................... 80 mm (3.2 in) Tipping load - ISO Machine straight................................................................................................................. 8 268 kg (18 229 lb) 40 degree turn.....................................................................................................................7 194 kg (15 861 lb) Operating load - ISO..................................................................................................................... 3 597 kg (7 931 lb) Unit operating mass...................................................................................................................10 550 kg (23 259 lb) NOTE: Machine operating weights stated are calculated with ROPS cab, heater, air conditioner, 1873 lb. counterweight, 17.5R25 XTLA tires, standard width front and rear fenders, full fuel, 175 lb (79 kg) operator.

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CHAPTER 8 - SPECIFICATIONS

Figure 3

BS07J055

521E Z-BAR MACHINES 2.0 M3 (2.60 YD3) LOW DENSITY BUCKET W/CUTTING EDGE SAE bucket capacity Struck ........................................................................................................................................ 1.69 m³ (2.21 yd³) Heaped...................................................................................................................................... 1.99 m³ (2.60 yd³) A. Height to top of cab ........................................................................................................... 3 277 mm (129.0 in) B. Wheelbase......................................................................................................................... 2 750 mm (108.3 in) C. Ground clearance ................................................................................................................. 377 mm (14.85 in) D. Angle of departure ........................................................................................................................... 34 degrees Width Overall w/o bucket and with 17.5 X 25 XTLA tires............................................................... 2 389 mm (94.1 in) Centerline tread with 17.5 X 25 XTLA tires.......................................................................... 1 900 mm (74.8 in) Turning radius - outside with 17.5 X 25 XTLA tires .................................................................4 972 mm (195.8 in) Turning angle From center...................................................................................................................................... 40 degrees Total angle ....................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ........................................................................ 4 746 mm (186.8 in) F. Hinge pin height - fully raised............................................................................................. 3 608 mm (142.1 in) G. Overall length - bucket level on ground ............................................................................. 6 755 mm (265.9 in) H. Dump height - fully raised, 45 degree dump...................................................................... 2 667 mm (105.0 in) J. Bucket reach - fully raised, 45 degree dump........................................................................ 1 056 mm (41.6 in) K. Bucket reach - 2.13 m (7 ft 0 in) height, 45 degree dump ................................................... 1 462 mm (57.6 in) L. Dig depth..................................................................................................................................... 78 mm (3.1 in) Tipping load - ISO Machine straight................................................................................................................. 8 297 kg (18 291 lb) 40 degree turn..................................................................................................................... 7 230 kg (15 939 lb) Operating load - ISO..................................................................................................................... 3 615 kg (7 969 lb) Unit operating mass................................................................................................................... 10 473 kg (23 089 lb) NOTE: Machine operating weights stated are calculated with ROPS cab, heater, air conditioner, 1873 lb. counterweight, 17.5R25 XTLA tires, standard width front and rear fenders, full fuel, 175 lb (79 kg) operator.

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CHAPTER 8 - SPECIFICATIONS

521E XT LIFT ARM OPERATING DATA AND DIMENSIONS

Figure 4

BS07J056

521E MACHINES - XT LIFT ARM - BUCKET WITH COUPLER 1.7 M3 (2.2 YD3) MEDIUM DENSITY BUCKET W/TEETH AND SEGMENTED CUTTING EDGE SAE bucket capacity Struck ........................................................................................................................................ 1.36 m³ (1.78 yd³) Heaped...................................................................................................................................... 1.71 m³ (2.20 yd³) A. Height to top of cab ........................................................................................................... 3 277 mm (129.0 in) B. Wheelbase......................................................................................................................... 2 750 mm (108.3 in) C. Ground clearance ................................................................................................................. 377 mm (14.85 in) D. Angle of departure ........................................................................................................................... 34 degrees Width Overall w/o bucket and with 17.5 X 25 XTLA tires............................................................... 2 389 mm (94.1 in) Centerline tread with 17.5 X 25 XTLA tires.......................................................................... 1 900 mm (74.8 in) Turning radius - outside with 17.5 X 25 XTLA tires .................................................................4 972 mm (195.8 in) Turning angle From center...................................................................................................................................... 40 degrees Total angle ....................................................................................................................................... 80 degrees E. Operating height - fully raised w/spillguard ........................................................................ 5 019 mm (197.6 in) F. Hinge pin height - fully raised............................................................................................. 3 742 mm (147.3 in) G. Overall length - bucket level on ground ............................................................................. 6 652 mm (261.9 in) H. Dump height - fully raised, 45 degree dump...................................................................... 2 780 mm (109.4 in) J. Bucket reach - fully raised, 45 degree dump........................................................................ 1 115 mm (43.9 in) K. Bucket reach - 2.13 m (7 ft 0 in) height, 45 degree dump ................................................... 1 586 mm (62.5 in) L. Dig depth..................................................................................................................................... 56 mm (2.2 in) Tipping load - ISO Machine straight..................................................................................................................6 905 kg (15 223 lb) 40 degree turn.....................................................................................................................5 843 kg (12 882 lb) Operating load - ISO......................................................................................................................2 922 kg (6 441 lb) Unit operating mass...................................................................................................................12 076 kg (26 624 lb) NOTE: Machine operating weights stated are calculated with ROPS cab, heater, air conditioner, 1873 lb. counterweight, 17.5R25 XTLA tires, standard width front and rear fenders, full fuel, 175 lb (79 kg) operator.Material Weights.

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CHAPTER 8 - SPECIFICATIONS MATERIAL

kg/m3

lbs/ft3

MATERIAL

kg/m3

lbs/ft3

Alum-Lump.

881

55

Oats

416

26

Pulverized

769

48

Peanuts - Shelled

280

17

Ashes

561-833

35-52

Peas

769

48

Bauxite

1202-1922

75-120

Peat - solid

753

47

Beans

769

48

Phosphate - Granular

1442

90

Charcoal

368

23

Potash

1089

68

Chips

288

18

Potatoes

769

48

Coal

1282

80

Quartz - Granular

1762

110

Coke - Lump - Loose

849-1009

53-63

Rice

769

48

Clay

368-513

23-32

Rye

705

44

Concrete

1378-1778

86-111

Salt - Rock - Solid

2163

135

Copper Ore

1666

104

Sand & Gravel - Dry

1730

108

Corn - Shelled

673

42

Wet

2003

125

Cottonseed

401

25

Sand - Foundry

1522

95

Earth - Dry Loam

929-1089

58-68

Shale

1410

88

1602-1666

100-104

Slag - Crushed

1121

70

Earth - Sand Gravel

Wet

1570

98

Slate

2243

130

Ensilage

577

36

Snow

240-801

15-50

Granite

1490-1778

93-111

Soybeans

743

46

Gravel - Dry

1522

95

Sugar Beet Pulp - Wet

561

35

Wet

1906

119

Sugar - Raw

961

60

Ice - Crushed

593

37

Sulphur - Lumpy

1330

83

Iron Ore

2323

145

Taconite

1714

107

Limestone - Loose Crushed

1538-1602

96-100

Wheat

769

48

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CHAPTER 8 - SPECIFICATIONS

TORQUE CHARTS Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

PoundInches 108 to 132 204 to 252 420 to 504 54 to 64 80 to 96 110 to 132 150 to 180 270 to 324 400 to 480 580 to 696 800 to 880 1120 to 1240 1460 to 1680 1940 to 2200

Size 1/4 inch 5/16 inch 3/8 inch 7/16 inch 1/2 inch 9/16 inch 5/8 inch 3/4 inch 7/8 inch 1.0 inch 1-1/8 inch 1-1/4 inch 1-3/8 inch 1-1/2 inch

Newton metres 12 to 15 23 to 28 48 to 57 73 to 87 109 to 130 149 to 179 203 to 244 366 to 439 542 to 651 787 to 944 1085 to 1193 1519 to 1681 1980 to 2278 2631 to 2983

Grade 8.8 Bolts, Nuts, and Studs

PoundNewton Size Inches metres 1/4 inch 144 to 180 16 to 20 5/16 inch 288 to 348 33 to 39 3/8 inch 540 to 648 61 to 73 7/16 inch 70 to 84 95 to 114 1/2 inch 110 to 132 149 to 179 9/16 inch 160 to 192 217 to 260 5/8 inch 220 to 264 298 to 358 3/4 inch 380 to 456 515 to 618 7/8 inch 600 to 720 814 to 976 1.0 inch 900 to 1080 1220 to 1465 1-1/8 inch 1280 to 1440 1736 to 1953 1-1/4 inch 1820 to 2000 2468 to 2712 1-3/8 inch 2380 to 2720 3227 to 3688 1-1/2 inch 3160 to 3560 4285 to 4827 NOTE: Use thick nuts with Grade 8 bolts.

Grade 10.9 Bolts, Nuts, and Studs

8.8

10.9

PoundInches 24 to 36 60 to 72 96 to 108 228 to 276 456 to 540 66 to 79 106 to 127 160 to 200 320 to 380 500 to 600 920 to 1100 1600 to 1950

Size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M30 M36

Newton metres 3 to 4 7 to 8 11 to 12 26 to 31 52 to 61 90 to 107 144 to 172 217 to 271 434 to 515 675 to 815 1250 to 1500 2175 to 2600 Figure 5

Size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 M30 M36

PoundInches 36 to 48 84 to 96 132 to 156 324 to 384 54 to 64 93 to 112 149 to 179 230 to 280 450 to 540 780 to 940 1470 to 1770 2580 to 3090

Newton metres 4 to 5 9 to 11 15 to 18 37 to 43 73 to 87 125 to 150 200 to 245 310 to 380 610 to 730 1050 to 1275 2000 to 2400 3500 to 4200

Grade 12.9 Bolts, Nuts, and Studs Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

12.9

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CHAPTER 9 - INDEX

Chapter 9

INDEX A Access Door Locations ...................................... 5-13 Accumulators, Brake ......................................... 4-20 Air Conditioning Compressor ................................................... 6-22 Condenser ..................................................... 6-22 Autoshift Switch ................................................. 3-39 Auxiliary Hydraulic Connection .................................................... 4-21 System Specifications ................................... 4-21 Auxiliary Power Outlet ............................................................. 7-12

B Battery ................................................................. 7-5 Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before Operating Machine ................................... 4-3 Blower Fan Switch ............................................. 3-37 Brake Pressure Indicator ......................................... 3-14 Brake Accumulators .......................................... 4-20 Bucket Height Control Function .................................................... 4-17 Bucket Level Indicator ....................................... 4-21 Burn Prevention ................................................... 2-8

C Cab ...................................................................... 3-4 Cab Door ............................................................. 3-4 Cab Service ....................................................... 6-22 Caution Master Indicator ................................... 3-16 Checking for cylinder leakage ........................... 6-10 Components, Machine ......................................... 1-6 Control Levers ................................................... 4-13 Controls Blower Fan .................................................... 3-37 Heat, Cab ...................................................... 3-37 Lamp Switch .................................................. 3-38 Wiper/Washer Switch .................................... 3-38 Cylinder Leakage Check ................................... 6-10

D Daily inspections ................................................ 5-11 Decals ................................................................ 2-11 Issued 03-08

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DeClutch .............................................................4-20 Declutch Switch ..................................................3-39 Displays, Warning Non - Critical Warning Displays .....................3-16 Door Latch ................................................................3-5

E Electrical Maintenance .........................................7-6 Electrical System ..................................................7-3 Engine Coolant Gauge ............................................................3-20 Engine Grid Heater ....................................... 4-6, 4-8 Engine Oil Type ..................................................5-10 Environment .......................................................5-10

F Fan Reverser (option) ........................................3-39 Fire Extinguisher ................................................6-10 Fluid Capacities ....................................................5-6 Fluids and Capacities ...........................................5-6 Foot Pedals ..........................................................3-9 Four-Way Flasher Switch ............................................................3-13 Front Console ........................................... 3-13, 3-20 Four-Way Flasher ..........................................3-13 Key/Ignition Switch .........................................3-11 Pilot Control Switch ........................................3-13 Fuel Handling Precautions ...................................2-8 Fuel Level Gauge ...............................................3-19 Fuse Panel ...........................................................7-7 Fuses ....................................................................7-7 Fuses, Replacement ............................................7-9

G Gauges Engine Coolant ..............................................3-20 Fuel Level ......................................................3-19 Hydraulic Oil Temperature .............................3-18 General Information ..............................................1-1

H Hazardous Chemical Precautions ........................2-8 Heat Control, Cab ...............................................3-37 Hourmeter ............................................................5-3 Hydraulic Connection - Auxiliary ........................4-21 Hydraulic Oil Temperature Gauge .......................................3-18 9-1

CHAPTER 9 - INDEX

I

O

Identification Numbers ......................................... 1-8 Indicator Brake Pressure ............................................. 3-14 Caution Master .............................................. 3-16 Lamp ............................................................. 3-14 Parking Brake ................................................ 3-14 Secondary Steering Master ........................... 3-14 Stop Master ................................................... 3-15 Indicator Lamps ................................................. 3-14 Inspecting and Cleaning the Machine ............... 6-10 Instrument Panel ............................................... 3-14 Indicator Gauges Engine Coolant ......................................... 3-20 Fuel Level ................................................. 3-19 Hydraulic Oil Temperature ........................ 3-18 Indicator Lamps Brake Pressure ......................................... 3-14 Caution Master .......................................... 3-16 Lamp Indicator .......................................... 3-14 Parking Brake ........................................... 3-14 Secondary Steering .................................. 3-14 Stop Master ............................................... 3-15

Operating ............................................................4-29 Operating In Cold Climates ................................4-28 Operating Precautions ..........................................2-6 Operating the Machine in Hot climates ..............4-29 Operating the machine in water .........................4-24 Operating Tips - Loader .....................................4-23 Operator Manual Storage Compartment ..............1-5

K Key Switch, Ignition ........................................... 3-11

L Lamp Indicator ................................................... 3-14 Lamp Switch, Cab ............................................. 3-38 Latch Door ................................................................ 3-4 Levers Control ................................................... 4-13 Lift Capacity .................................................. 8-8, 8-9 Loader Function Switches ................................. 4-17 Loader Operating Tips ....................................... 4-23 Pushing Operation ........................................ 4-23 Louvers, Air Recirculation ................................................. 3-12

M Machine Components .......................................... 1-6 Maintenance Precautions .................................... 2-7 Maintenance, 10 Hour ....................................... 5-16 Maintenance, 100 Hour ..................................... 5-19 Maintenance, 1000 Hour ................................... 5-32 Maintenance, 2000 Hour ................................... 5-38 Maintenance, 250 Hour ................... 5-24, 5-25, 5-26 Maintenance, 500 Hour ..................................... 5-28 Moving a Disabled Machine .............................. 4-25 Muffler Cleaning .......................................................... 6-9 Spark Arresting ............................................... 6-9 9-2

P Parking Brake Indicator .........................................................3-14 Personal Safety ....................................................2-3 Pilot Control Switch ............................................3-13 Plastic and resin parts ........................................6-10 POWER MODES ................................................3-26 Power Outlet, Auxiliary .......................................7-12 Product Identification Number ..............................1-8

R Releasing Hydraulic System Pressure .................5-5 Return-To-Dig Function .........................................................4-17 Return-To-Travel ................................................4-18 Switch ............................................................3-40 Ride Control .......................................................4-21 Switch ............................................................3-40 Run-In Period .......................................................4-3

S Safety, Battery ......................................................7-3 Seat Belt Precautions ...........................................2-9 Secondary Steering Master Indicator .................3-14 Serial Numbers .....................................................1-8 Side Console Autoshift Switch .............................................3-39 Blower Fan Switch .........................................3-37 Declutch Switch .............................................3-39 Heat Control ...................................................3-37 Lamp Switch ..................................................3-38 Return-To-Travel Switch ................................3-40 Ride Control Switch .......................................3-40 Wiper/Washer Switch .....................................3-38 Wrist Rest ......................................................3-35 Wrist Rest, Adjustment ..................................3-35 Sides of the machine Right-hand, left-hand, front, and rear ...............1-5 Spark Arresting Muffler .........................................6-9 Specific machine precautions .............................2-10 Specifications .......................................................8-3 Auxiliary Hydraulic System ............................4-21 Specifications and Capacities ..............................5-6 Starter motor ........................................................7-6 Issued 03-08

87479806 A - EU

CHAPTER 9 - INDEX Starting and Stopping Precautions ...................... 2-5 Starting Engine .................................................... 4-4 Steps and access handles ................................... 3-4 Stop Master Indicator ........................................ 3-15 Stopping and Parking ................................... 4-5, 4-8 Stopping the engine ............................................. 4-8 Storage Compartment Operator Manual ............................................. 1-5 Support Strut ....................................................... 5-4 Switch Autoshift ........................................................ 3-39 Blower Fan .................................................... 3-37 Declutch ........................................................ 3-39 Four-Way Flasher ......................................... 3-13 Key/Ignition ................................................... 3-11 Lamp ............................................................. 3-38 Loader Function ............................................ 4-17 Bucket Height Control ............................... 4-17 Return-To-Travel ....................................... 4-18 Pilot Control ................................................... 3-13 Return-To-Travel ........................................... 3-40 Ride Control .................................................. 3-40 Wiper/Washer ............................................... 3-38

T Temperature Range, Hydraulic System .............. 5-8 Temperature Range, Oil Viscosity Engine ........... 5-7 Temperature Range, Transmission Oil Viscosity 5-8 Tire Pressure ....................................................... 6-6 Towing the machine .......................................... 4-25 Transporting The Machine ................................. 4-26 Transporting the machine .................................. 4-27

U Utility Safety ......................................................... 2-4 Utility Safety Rules Message ............................... 2-4

V Variable Periodic Maintenance .......................... 5-15

W Warning Displays Non - Critical Warning Displays ..................... 3-16 Welding on the Machine .................................... 6-10 Wheel Bolt Torque ............................................... 6-7 Wheels and Tires ................................................. 6-5 Wiper/Washer Switch ........................................ 3-38 Wrist Rest .......................................................... 3-35 Adjustment Knob ........................................... 3-35

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CHAPTER 9 - INDEX

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521E - TIER III

521E TIER III Wheel Loader Wheel Loader

Operator’s Manual Print No. 87479806 A - EU

1st edition English 03/08

from serial no: FNH521E1N8HE82001 (Z-Bar) FNH521E1N8HE87001 (XT)