Case 570MXT Loader Landscaper Operator's Manual 87612257 - PDF DOWNLOAD

OPERATOR’S MANUAL LOADER LANDSCAPER

570MXT

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 04-2006 (Revised 03-2007) Printed in U.S.A. • Book/Form Number 87612257 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

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

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

Issue

Issue Date

Applicable Machines

Remarks

First Edition

05-2001

570MXT

6-20590 NA

Revision 1

04-2006

570MXT

6-20591 NA

Revision 2

03-2007

570MXT

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

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

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

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: · 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.

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

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

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

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

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

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

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SAFETY, AND SAFETY DECALS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 GENERAL AND SPECIFIC SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 CHAPTER 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 LOADER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 CHAPTER 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE STARTING AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-3 4-6 4-9

CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 LUBRICATION, FILTERS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 FLUIDS AND LUBRICANT CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 MAINTENANCE AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 CHAPTER 7 ELECTRICAL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 CHAPTER 9 INDEX

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 General Information

Figure 1

BD07C123

570MXT LOADER LANDSCAPER

This manual contains important information about the safe operation, adjustment and maintenance of your loader landscaper. Refer to the index at the end of this manual for locating specific items about your machine. The loader landscaper conforms to current safety regulations.

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

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

This loader landscaper, with standard equipment and authorized attachments, is intended to be used for above ground material handling.

Do not use this machine for any application or purpose other than those described in this manual. Consult an authorized dealer on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications can cause serious injury or death.

Anyone making such unauthorized modifications is responsible for the consequences.

This Operators Manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact your dealer to obtain additional manuals. Contact your dealer for any further information or assistance about your machine. Your dealer has approved service parts. Your dealer has technicians with special training that know the best methods of repair and maintenance for your loader landscaper.

This machine was designed to power and move itself. It is intended to load and move materials with a variety of buckets and forks. Attachments supplied by other manufacturers can be used on the loader landscaper where recommended and approved by Case.

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CHAPTER 1 - GENERAL INFORMATION

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

BD05H088

OPERATOR’S MANUAL STORAGE

Figure 2

RIGHT

LEFT

REAR Figure 3

BC01G145

BASIC MACHINE

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

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CHAPTER 1 - GENERAL INFORMATION

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

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

Make a record of the numbers and keep the record and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, repor t the numbers to your local law enforcement agency.

BD07A165

Figure 4

PRODUCT IDENTIFICATION NUMBER (P.I.N.)

PRODUCT IDENTIFICATION PLATE ➤ Model ➤ Serial Number ➤ Manufacturing Year

ENGINE

BD01D050

➤

Figure 5

ENGINE Make and Model

➤ Serial Number

COMPONENT SERIAL NUMBERS ➤ Transmission ➤ Axle ➤

BP941086

ROPS Cab

Figure 6

TRANSMISSION

➤

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CHAPTER 1 - GENERAL INFORMATION

Figure 7

BP97N040

CAB CERTIFICATION PLATE

REAR AXLE

Figure 8

BK97K220

ROPS CERTIFICATION PLATE

4WD FRONT AXLE PLATE

1-4

Figure 11

BP9410113

STANDARD LOADER BUCKET (PART NUMBER)

Figure 9

BP9410089

Figure 10

BP9410090

Figure 12

BP9410117

FOUR IN ONE LOADER BUCKET (PART NUMBER)

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CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

2

9

5 8 1 4

3 6

7 Figure 13

BD07C141

1. LIFT ARM SUPPORT STRUT 4. BUCKET 2. ROPS CAB 5. EXHAUST PIPE 3. THREE POINT HITCH CONTROL VALVE 6. THREE POINT HITCH

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7. FUEL TANK STEP 8. HAND HOLD 9. OPERATOR’S COMPARTMENT

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CHAPTER 1 - GENERAL INFORMATION

1 7 6

8 2 5

3 4

Figure 14

BD07C125

1. AIR INTAKE 2. LOADER LIFT ARMS 3. BATTERY BOX

1-6

4. HYDRAULIC TANK 5. 4 IN 1 BUCKET 6. ENGINE HOOD

7. LOADER CONTROLS 8. TOOL BOX

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7

5

4 5

6 4

8

2 3

9

1

Figure 15

BD01D005

1. STEPS (EACH SIDE) 2. HAND HOLDS (EACH SIDE) 3. LOADER ARM

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7. SLOW MOVING FLASHER LAMPS 8. BRAKE LAMPS 9. ANTI-SWAY CALIPER

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CHAPTER 1 - GENERAL INFORMATION

NOTES

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

Chapter 2 SAFETY, AND SAFETY DECALS TABLE OF CONTENTS GENERAL AND SPECIFIC SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personnel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operator - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Proper Entry And Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Roll-Over Protective Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Installing The Support Strut For Loader Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

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

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

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

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

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

• CAUTION: Indicates a potentially hazardous Figure 1

BP97N041

OPERATOR’S MANUAL STORAGE

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

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

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

• The first panel indicates the nature of the hazard.

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

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

and

STOP

if

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

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

IMPORTANT: The safety messages in this chapter point out conditions which can happen during the normal operation and maintenance of your machine.

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

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UTILITY SAFETY Safety 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.

Figure 2

RH99G001

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

In U.S.A. and Canada, call one of many “One Call System Directory” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

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

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

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS OPERATOR PRECAUTIONS PROPER ENTRY AND EXIT

PERSONNEL PRECAUTIONS

• 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 provide the proper protection required.

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.

BD01D119

Figure 3

Enter the loader landscaper from the side by using the steps and hand holds. Always use a three point entrance and exit stance.

To exit the loader landscaper use the hand holds for support and step down carefully.

OPERATOR - 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 and have read and fully understand the instructions and warnings in this manual.

• Wear the seat belt to maximize the protection

Before exiting the loader landscaper: 1. Lower the boom and or attachments to the ground. If the operator must exit the loader landscaper with a raised boom always engage the support strut for the loader lift arms.

2. Place the direction control lever in neutral.

3. Stop the engine. Pull the parking brake control lever back to set the brake.

4. Remove the seat belt.

capability of the ROPS (Roll Over Protective Structure).

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

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

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

• Remove all loose objects stored in the machine.

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

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

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

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CHAPTER 2 - SAFETY, AND SAFETY DECALS WARNING: Never exit the loader landscaper with the engine operating. Failure to comply could result in injury or death.

WARNING: Never exit the loader landscaper without first confirming the parking brake is set. Failure to comply could result in injury or death.

WARNING: Never exit the loader landscaper unless the boom and attachment are down resting on the ground or the boom is resting on the support strut. Failure to comply could result in injury or death.

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

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

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

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

• Remove the starter key or 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. Place a DO NOT OPERATE TAG on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key. Place a DO NOT OPERATE TAG on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely moved.

STARTING AND STOPPING PRECAUTIONS

• Understand the machine limitations and keep the

• Walk around the machine and warn all personnel

• Never transport a loaded bucket at full height.

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

Sound the horn, if equipped, before starting.

• Walk around the machines tool, attachment, or furthermost contact point to view operation danger area from the work site personnel view and angle.

machine under control.

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

• Operate and drive the machine with care and at

• Check that the parking device is applied, place the

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

transmission in neutral or park as specified by the manufacturer, before starting the machine.

• Note and avoid all hazards and obstructions such

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

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

• Use 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 battery booster cables will not interfere or harm electronic processing or computer devices.

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

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

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

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

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

• 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.

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.

• Watch for bystanders and never allow anyone to

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

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

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

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

• Select a gear that will prevent excessive speed 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.

• Use the recommended transport devices when roading the machine.

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

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

• Engine exhaust fumes can cause death. If you

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

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

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

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all

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

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.

• Check all controls in a clear area and make sure

• Develop fluid and smooth operating techniques

the machine is operating correctly.

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

and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

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

• Contact

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

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

YOU MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

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

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

• Release all pressure before working on systems

Maintenance Precautions

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

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to proper service procedures in the Repair Manual.

which have an accumulator.

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

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

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed.

Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a 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. Towing this machine is not recommended.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins, Figure 4

87358697

• Before you service the machine, put a DO NOT OPERATE TAG on the key switch. Make sure that the machine is clearly “tagged out”.

• Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the equipment in a safe position, securely block the wheels and use extreme caution.

• Securely block the machine or any component that may fall before working on the machine or component. If possible, use a back up or secondary blocking device, also.

• To prevent unexpected movement, securely block

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

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

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

FUEL HANDLING PRECAUTIONS

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

• Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

• 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

• Use extreme caution when removing radiator

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.

caps, drain plugs, grease fittings or pressure taps.

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating

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

season.

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

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 injury or death.

Figure 5

M144B

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

• Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

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

before

attempting

service

HAZARDOUS CHEMICAL PRECAUTIONS

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

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

• Do NOT modify the ROPS in any manner.

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

FIRE EXTINGUISHER

• It is recommended that you have a fire extinguisher on your machine. Contact your dealer for the type and location of a fire extinguisher on this machine SEAT BELT PRECAUTIONS

1 2 Figure 6

BI01H141

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

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

WARNING: Before starting the engine ensure the seat belt is securely fastened. The seat belt can help ensure 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 injury or death.

• 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

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 ensure your safety if it is used and maintained.

Failure to comply could result in injury or death.

TRANSPORTING PRECAUTIONS

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

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CHAPTER 2 - SAFETY, AND SAFETY DECALS Specific Precautions to this Machine

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

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

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

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

2. Remove the rear pin from the support strut and lower the support strut onto the cylinder rod.

3. Install the rear pin in the support strut.

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

1

2

Figure 9

BD06A084

2. Remove the support strut pin (1), and lower the support strut (2) onto the cylinder rod.

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

Figure 7

SA068

INSTALLING THE SUPPORT STRUT FOR LOADER LIFT ARMS

Figure 10

BD06A086

3. Install the support strut pin to lock the strut onto the cylinder. Slowly lower the lift arms until the support strut makes contact with the cylinder.

Removing the loader support strut: 1. Raise the loader lift arms, and remove the pin from the support strut.

Figure 8

BD06A085

LOADER LIFT ARM

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

Raise the loader lift arms to maximum height and stop the engine.

2-10

2. Raise the support strut up to the storage position, and install the pin.

3. Lower the attachment to the ground.

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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 11

384270A1A

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

BC00G075

Figure 12

This symbol instructs you to refer to the Repair Manual.

The following safety decals have been placed on your machine in the areas indicated. The following graphics are for replacement location. Safety decals are intended for the personal safety of you and those working with you.

Please take this manual, walk around your machine and note the content and location of these warning decals.

Review these decals with all machine operators. It is the owner’s responsibility to keep the decals legible. If they are not, obtain replacements from your dealer. Part numbers are on the decal.

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

1 1

Figure 13

BD05H056 / 382622A1

1. WARNING: READ OPERATOR’S MANUAL

2 2

Figure 14

BD05H068 / BD05H077 / 384269A1

2. DANGER: EXPLOSION AND RUN OVER HAZARD

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

3 3

4

4

Figure 15

BD05H068 / BD05H077 / 384269A1

3. DANGER: EXPLOSION AND RUN OVER HAZARD 4. DANGER: START ENGINE FROM OPERATOR’S SEAT ONLY

5 5 3

Figure 16

BD05H072 / 321-7040

5. WARNING: ENTANGLEMENT HAZARD 87612257 NA

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

6

3 6

Figure 17

BD05H072 / 321-7040

6. WARNING: CRUSH HAZARD - KEEP CLEAR

7

7

Figure 18

BD05H072 / 321-6774

7. WARNING: SPRING UNDER COMPRESSION - SEE REPAIR MANUAL (NON-SUSPENSION SEATS)

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

8 8

8

Figure 19

BD05H074 / BD05H055 / 384258A1

8. WARNING: HOT LIQUID UNDER PRESSURE (ONE EACH SIDE)

9 9

Figure 20

BP9410011 / 321-7030

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

10

10

Figure 21

BD05H074 / BD05H055 / 384258A1

10. WARNING: DO NOT MODIFY OR REPAIR ROPS (ROLL OVER PROTECTION STRUCTURE)

11 11

Figure 22

BP9410011 / 321-7030

11. WARNING: CRUSH HAZARD - USE SUPPORT

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

12

12

Figure 23

BD001D135 / 335889A1

12. WARNING: SYSTEM UNDER PRESSURE HAZARD

13

13

Figure 24

BP9410011 / 321-7030

13. WARNING: PRESSURIZED SYSTEM (RIDE CONTROL ACCUMULATOR)

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

14 14

15

15

Figure 25

BD05J001 / 86985815 / 321-7033

14. WARNING: DO NOT TURN ON RIDE CONTROL WITH LOADER ARMS SUPPORTING THE MACHINE 15. WARNING: CONTROL EXCESSIVE SPEED

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CHAPTER 2 - SAFETY, AND SAFETY 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 26

BI97D059

START THE ENGINE

STOP THE ENGINE

Figure 27

BP97D022

COME TO ME

Issued 04-07

BP97D023

FIGURE 29

MOVE AWAY FROM ME

Wave hands back and forth (palms inward).

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Figure 28

BI97D025

Bur

Wave hands back and forth (palms outward).

2-19

CHAPTER 2 - SAFETY, AND SAFETY DECALS

Figure 30

BP97D030

GO THIS FAR

ALL STOP AND HOLD

Figure 31

BI97D029

BI97D021

STOP

Move both hands back and forth.

FIGURE 32

RAISE LOAD OR TOOL

2-20

FIGURE 34

EMERGENCY STOP

Move one hand back and forth.

BI97D028

Figure 33

BP97D060

BI97D027

FIGURE 35

LOWER LOAD OR TOOL

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CHAPTER 2 - SAFETY, AND SAFETY DECALS

Figure 36

BI97D020

RAISE LOAD OR TOOL SLOWLY

LOWER LOAD OR TOOL SLOWLY

Figure 37

BI97D034

Figure 39

BI97D026

BI97D033

FIGURE 40

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.

BP97D057

BI97D055

FIGURE 38

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FIGURE 41

LOWER BOOM

RAISE BOOM Bur

2-21

CHAPTER 2 - SAFETY, AND SAFETY DECALS

BI97D041

FIGURE 42

BI97D032

RETRACT ARM

BI97D054

2-22

EXTEND ARM

FIGURE 43

FILL TOOL

FIGURE 44

BI97D031

FIGURE 45

EMPTY TOOL

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator’s Compartment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Loader Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Three-point Hitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Windshield Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Cab Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Standard Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Cab Door handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Rear View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Operator Manual and Storage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Utility Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Tool Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Vandal Lockup Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Right Side Instrument Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

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3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-2

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENTS AND CONTROLS OPERATOR’S COMPARTMENT CONTROLS

8

7

6

9 10 5 11 1 12

4

2 3 1 Figure 1

BD07C026

1.

2.

3.

4.

5.

6.

BRAKE PEDALS FOOT THROTTLE OPERATOR MANUAL STORAGE DIRECTION CONTROL LEVER (F-N-R) TRANSMISSION CONTROL LEVER LOADER CONTROL LEVER

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7.

8.

9.

10.

11.

12.

EMERGENCY BRAKE LEVER VANDAL LOCK-UP KIT CONSOLE CONTROLS AND SWITCHES HAND THROTTLE THREE-POINT HITCH MODE CONTROL SWITCH THREE-POINT HITCH CONTROLS

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1

4

2 Figure 1

BD05H061

BC00B064

Figure 3

BD05H054

1. FLASHER LAMP SWITCH:

4. HORN

Push th e ro cke r switc h em ble m to illuminate the flashers. Push the opposite end of the rocker switch to turn the flashers OFF.

Push the rocker switch emblem to sound the horn.

BS98M064

2. TURN SIGNAL LEVER Push the rocker switch emblem on the left to signal a left turn. Push the rocker switch emblem on the right to signal a BC00B087 right turn. You must manually move the rocker switch to the center position to stop the signal.

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

3

Figure 2

BS06B005

3. DOME LIGHT SWITCH

BC00B005

3-4

Push th e ro cke r switc h em ble m to illuminate the dome light on cab models.

Push the opposite end of the rocker switch to turn the light OFF.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS TRANSMISSION CONTROLS

5 6

7 Figure 5

BD05H059

Figure 4

BD05H061

5. DIRECTION CONTROL LEVER: This lever controls the travel direction of the machine. The center position N is NEUTRAL. The top position F is FORWARD. To travel forward, lift the lever and push completely forward toward the F position. The bottom position R is REVERSE. To travel in reverse, lift the lever and pull completely rearward. Make sure the direction control lever is in N or NEUTRAL before you start the engine.

The direction control lever electrical circuit has an added feature which allows the operator to move the machine a short distance in the event the direction control lever receives intermittent signals that shift the transmission into neutral. By shifting the direction control lever to the opposite direction of travel that is desired, then back to the desired direction, the transmission will engage for approximately 5 seconds.

6. TRANSMISSION DISCONNECT BUTTON: P u s h t h i s b u t t o n b e fo r e y o u s h i f t t h e transmission gears. The transmission is in NEUTRAL when this button is pushed.

When shifting to a lower gear, reduce the travel speed before shifting.

7. TRANSMISSION SHIFT LEVER: The transmission has synchromesh in all four gears. You can shift to any gear without stopping the machine. Push the transmission disconnect button on the transmission shift lever before you s h i f t . R e l e a s e t h e bu t t o n t o e n g a g e t h e transmission after the shift.

IMPORTANT: This procedure is to be used only in the event of an emergency when the unit must be moved to a safe location. Have the machine repaired immediately.

8

BD05H091

Figure 6

8. FOOT THROTTLE: Push down on the foot throttle to increase the engine speed. Release the foot throttle to decrease the engine speed.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

9

10

Figure 7

BP00G002

Figure 9

BD06A088

9. LEFT BRAKE PEDAL:

BRAKE PEDAL LOCK ENGAGED

(With Brake Pedal Lock Disengaged) Push this pedal to help turn the machine to the left.

10. RIGHT BRAKE PEDAL: (With Brake Pedal Lock Disengaged) Push this pedal to help turn the machine to the right.

WARNING: Always lock the brake pedals together before you travel on roads or when you operate the machine in 3rd or 4th gear.

See the instructions in this manual for brake pedals. Failure to comply could result in machine damage, injury or death.

Figure 10

BP00G004

BRAKE PEDAL LOCK ENGAGED (OPERATOR’S VIEW)

BRAKE PEDAL LOCK:

1

BD06A089

Figure 8

1. BRAKE PEDAL LOCK LEVER

Move the lever up and slide the locking pin all the way to the right into the lock ENGAGED position. In this position, both brake pedals will be locked together.

3-6

Figure 11

BD06A090

BRAKE PEDAL LOCK DISENGAGED

Move the lever up and slide the locking pin all the way to the left into the lock DISENGAGED position.

In this position, the pedals will function separately.

Issued 04-07

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CHAPTER 3 - INSTRUMENTS AND CONTROLS PARKING BRAKE

PARKING BRAKE ADJUSTMENT

12

The parking brake should be checked for proper adjustment after the first 100 hours of operation on a new machine and as necessary thereafter. See Chapter 6 - Maintenance and Service for adjustment procedures.

NOTE: You can damage the parking brake, which is also the service brake, if you move the machine and the parking brake is applied.

12

Figure 12

BD05H062

PARKING BRAKE ENGAGED

12. PARKING BRAKE LEVER

BS06H049

Pull the parking brake control lever back to apply the parking brake. Push the lever forward to release the parking brake.

Figure 13

BD01H085

PARKING BRAKE RELEASED

1. Pull the parking brake control lever back to apply the parking brake.

2. Push the parking brake control lever forward to release the parking brake.

NOTE: A warning alarm will sound if you shift the direction control lever into FORWARD or REVERSE while the parking brake is engaged.

Figure 14 PARKING BRAKE INSTRUCTION DECAL

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

LOADER CONTROLS LIFT ARM AND BUCKET CONTROL:

A F

A

F

1

B

B D

D

G

E

E C

G

C Figure 15

BP01D068

A

D

B

E

C

F

Figure 16

B9410261

A. FLOAT: When in FLOAT, the bucket can follow the level of the ground without movement of the control lever.

B. LOWER: Moves the bucket down.

C. RAISE: Moves the bucket up.

D. ROLLBACK: Rolls the bucket back.

3-8

E. DUMP: Dumps the bucket.

F. RETURN-To-Dig: After the bucket is dumped, move the control to ROLLBACK and FLOAT. When the bucket is at the height selected, pull the control back to HOLD. G. HOLD

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CLAM CONTROL AND LOCKOUT (IF EQUIPPED):

4 3

2 A

C

B

Figure 19

BI01H083

Figure 17

BD01D072

A. CLAM OPEN B. CLAM CLOSED C. HOLD - NEUTRAL: The clam stops moving when the control handle is in HOLD. The clam control handle is equipped with a lock latch. The latch should be in the LOCKED position when the clam is not in use.

B

A

3. TRANSMISSION DISCONNECT BUTTON: Push the transmission disconnect button to allow the engine to increase speed BC00B064 and supply the loader with more hydraulic oil for greater loader power and faster control function. When you push the transmission disconnect button, the transmission is disengaged from the drive wheels. Release the transmission disconnect button to engage the transmission power.

The machine can move freely when the transmission disconnect button is pushed. If required, use the brake to stop the machine.

4. DIFFERENTIAL LOCK BUTTON U s e t h i s m o m e n t a r y bu t t o n fo r o n demand differential lock situations.

C BC00B087

B

To engage the differential lock use the following procedure:

A. Before engaging the differential lock make sure that neither rear wheel is spinning freely.

B. Press and hold the differential lock button, located on the loader control lever.

C. To disengage the differential lock, release the differential lock button.

NOTE: The differential lock will automatically when the load is removed.

release

A

Figure 18

384931A/B9410262

NOTE: The latch is not automatic - it must be manually engaged

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CHAPTER 3 - INSTRUMENTS AND CONTROLS LIFT ARM AND BUCKET CONTROL

A

BD01D072

Figure 20

(A) FLOAT: Push the Loader Control Lever forward completely to place the loader arms in the FLOAT position. When in FLOAT, the bucket can follow the level of the ground without movement of the control lever.

Figure 21

137290A1

A

The Loader Control Lever must be pulled out of the FL OAT po sition an d into neutral or HOLD to discontinue.

Figure 22

BC01G187

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CONSOLE CONTROLS

4 2

6

3

7

1 5

Figure 23

BD05H088

(1) DRIVING LAMP SWITCH:

BS96M062

Push the rocker switch emblem to turn the driving lamps ON. Push the opposite end of the rocker switch to tur n the driving lamps OFF. (2) FRONT WORK LAMP SWITCH

BS98M096

Push the rocker switch emblem to turn the front wor k lamps ON. Push the opposite end of the rocker switch to turn the front work lamps OFF. (3) REAR WORK LAMP SWITCH

BS98M096

Push the rocker switch emblem to turn the rear wor k lamps ON. Push the opposite end of the rocker switch to turn the rear work lamps OFF. (4) ROTATING BEACON SWITCH (IF EQUIPPED)

Push the rocker switch emblem to turn th e r o t a tin g b e a c o n O N . P u s h th e BS98M096 opposite end of the rocker switch to turn the rotating beacon OFF. 87612257 NA

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(5) COLD START SWITCH: The cold start system puts ether into the engine intake each time the rocker switch emblem is pushed and released.

BC00B064 This system operates only when the key switch is in the ON position and the engine is cold.

See Cold Weather Starting and/or Ether Cold Starting in this manual for the correct starting procedure.

(6) FOUR - WHEEL DRIVE FRONT AXLE SWITCH (IF EQUIPPED): Use this rocker switch to engage or the front drive axle. To BC00B064 disengage engage the front drive axle, push the rocker switch emblem. To disengage the front drive axle, push the opposite end of the rocker switch.

IMPORTANT: When the front drive axle is engaged, operate the machine only in first or second gear.

Disengage the front drive axle before you operate on a hard surface or in third or fourth gear.

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS CONSOLE CONTROLS

7

10 8

9

Figure 24

BD014D128

(10) KEY SWITCH:

(7) DIFFERENTIAL LOCK ENGAGE SWITCH:

BS98M066

Use this rocker switch to engage full time differential lock. Push the opposite end of the rocker switch to disengage.

NOTE: The differential lock will automatically when the load is removed.

release

(8) HAND THROTTLE: Pull the hand throttle toward the rear of the machine to increase the engine speed. Push the hand throttle toward the front of the machine to decrease the engine speed. ( 9 ) L OA D E R Q U I C K C O U P L E R SWITCH (IF EQUIPPED): Push the rocker switch emblem on the left side to disconnect the coupler.

Push the rocker switch emblem on the right side to connect the coupler.

The key switch has four positions: BS96M062

A. ACC Turn the key counterclockwise to ACC to give power to the accessories.

B. OFF To stop the engine, turn the key to the OFF position. After the engine has stopped, remove the key.

C. ON Turn the key clockwise to the ON position.

Before you start the engine, check the condition of the warning lamps. Use the voltmeter to check the condition of the batteries.

D. START Turn the key completely clockwise to the START position to actuate the starter motor. After the engine starts release the key. The key will return to the ON position.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CONSOLE CONTROLS

11

Figure 25

BD014D128

To disengage the Ride Control:

(11) RIDE CONTROL: Ride Control is a feature that improves the machine ride over terrain with either an empty or loaded bucket. Ride Control BC00B094 will reduce the fore and aft pitching motion dur ing transpor t and mater ial hauling operations, while allowing increased productivity and operator comfort. It also reduces shock loads to the machine.

1. Push the opposite end of the rocker switch. The green emblem lamp should go out.

NOTE: Ride Control should not be used for fine grading with the loader bucket or when precise placement of the loader is required.

To test the Ride Control contact your Dealer or refer to the Repair Manual. r.

To engage Ride Control: 1. Lower the loader bucket to or near the ground line.

2. Push the rocker switch emblem. The green emblem lamp should illuminate.

WARNING: Keep the attachment on or near the ground. If the Ride Control is turned on, with the key switch in the ON or ACC. position, the loader arms can drop slightly.

Failure to comply could cause injury or death.

IMPORTANT: There can be a slight loader arm drop when the Ride Control is activated due to accumulator pressure change.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CONSOLE CONTROLS

12

BD014D128

Figure 26

NORM

A

FLOAT UP

B

IMPORTANT: It is recommended when operating the three point hitch lift circuit in the laser mode that the Flow Control Regulator be at the 3 GPM setting. See Flow Control Regulator in this manual.

LASER

(12) THREE POINT HITCH MODE CONTROL SWITCH (IF EQUIPPED): The three point hitch mode control switch is a three position switch.

C

A. Normal Mode: Push the front of the rocker switch to put the three point hitch lift circuit in the NORMAL mode. In this mode the three point hitch cannot be lowered when the lift control is in the NEUTRAL position, or if the key switch is in the OFF position.

B. Float Up Mode: Put the rocker switch in the center position to put the three point hitch lift circuit in the FLOAT UP mode. Position the box scraper at the desired position. Move the rocker switch to FLOAT UP. Move the lift control to the FLOAT position. In this mode the three point hitch will not go any lower but will float up as required and then return to the original position.

C. Laser Mode (For use with optional laser valve): Push the rear of the rocker switch to put the three point hitch lift circuit in the LASER mode. In this mode the laser controls the lift circuit. Use of the lift control lever will over-ride the laser mode.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS INSTRUMENT PANEL

2

1

Figure 1

BD05H095

The Instrument Panel helps the operator to monitor functions and components of the machine. When the key switch is first turned ON the following lamps will illuminate for 3 seconds for a bulb self test.

• • • • •

Air Filter Restriction Warning Lamp Hydraulic Oil Filter Warning Lamp Rear Axle Oil Temperature Warning Lamp Parking Brake Indicator Lamp Air Conditioning System Pressure Indicator Lamp

With the key switch in the ON position and the engine NOT running the following lamps will illuminate.

• • • •

Air Filter Restriction Warning Lamp Hydraulic Oil Filter Warning Lamp Alternator Warning Lamp Low Engine Oil Pressure Lamp (2) PARKING BRAKE INDICATOR LAMP:

(1) DRIVING LAMP INDICATOR: This indicator illuminates when the driving lamp switch is in the ON position.

BS96M062

BS96H049

NOTE: The backlighting for the instrument panel works only when the driving lamp switch is in the ON position.

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This indicator illuminates when the parking brake is applied.

NOTE: A warning alarm will sound if you shift the direction control lever into FORWARD or REVERSE while the parking brake is engaged.

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENT PANEL 3

4

5

6 7

8

9

Figure 2

BD05H095

(3) LOW ENGINE OIL PRESSURE WARNING:

( 7 ) A I R F I LT E R R E S T R I C T I O N WARNING LAMP:

This warning lamp illuminates if, with the engine running there is low oil pressure BS99D060 in the engine. Do not run the engine if this warning lamp illuminates. The audible alarm will sound if this condition exists.

This warning lamp illuminates when, with the engine running, the air filter elements are restricted and require replacement.

(4) REAR AXLE OIL TEMPERATURE WARNING LAMP: This warning lamp illuminates when the oil temperature in the rear axle reaches BC00H041 305°F (152° C). Allow axle oil to cool, check axle oil level and/or see your Case Dealer.

(5) ALTERNATOR WARNING LAMP: This warning lamp illuminates if, with the engine running the alternator is not charging the batteries. See your Repair BS98M032 Manual and check the alternator or see your Case Dealer. ( 6 ) H Y D R AU L I C WARNING LAMP:

OIL

F I LT E R

This warning lamp illuminates if, with the engine running, the hydraulic filter is BC00B113 restricted and requires replacement.

Always replace the filter if the lamp illuminates.

3-16

BS96M026

( 8 ) L OW F U E L L E V E L WA R N I N G LAMP: This warning lamp illuminates when the fuel level is low. The machine will have BS98M034 approximately 6 U.S. Gallons (23 Liters) of usable fuel remaining in the tank and approximately 2 to 3 hours remaining operating time.

NOTE: The approximate remaining operating time is based on how the machine is being used and under what conditions.

(9) ENGINE COOLANT TEMPERATURE GAUGE: The engine coolant temperature gauge indicates the coolant temperature of the BS96H053 engine. The temperature of the coolant is normal when the gauge needle is in the green area of the gauge. If the gauge needle goes into the red area the audible alarm will sound, stop the engine and check the level of the coolant in the coolant reservoir, or check for debris on the radiator/oil cooler, or for a thermostat that does not operate correctly.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS Instrument Panel

12 11 13

10

Figure 3

BD05H095

BS96H096

(10) ENGINE HOURMETER:

(13) FUEL LEVEL GAUGE:

The hourmeter shows the hours the engine has run.The digit all the way to the right shows tenths of an hour (six minutes).

This gauge shows the amount of fuel in the fuel tank.

(11) TACHOMETER: The tachometer shows the engine speed in revolutions per minute (RPM). Each mark on the gauge is equal to 100 RPM. BS96H078 Recommended RPM for the engine is within the green area of the gauge.

(12) VOLTMETER GAUGE: This gauge shows the condition of the electrical system. The electrical system voltage is n or m al wh en the ga uge BS96M032 needle is in the green area of the gauge (11 to 15.3 volts) when the key switch is in the ON position. If the gauge needle is in the lower red area, the charge of the battery is too low or the alternator is not charging enough. Damage to the battery can result if this condition continues.

BS96M034

AUDIBLE ALARM: The alarm will sound if, (1) the engine oil pressure is too low, (2) the engine coolant temperature is too high, or (3) if the parking brake is applied and you shift the direction control lever to the FORWARD or REVERSE position. In addition to the warning lamps, the audible alarm is an indication of irregularities in the machine’s operation systems.

NOTE: When the battery is in good condition and you turn the key switch to the ON position, the gauge needle will move up to the bottom part of the green area. When the engine starts, the needle will move up to the upper part of the green area and stay there.

If the gauge needle does not move up after the engine starts, check the condition of the battery/alternator.

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3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS THREE-POINT HITCH CONTROL

1

2

3

4

5

1

2

3

4

5

Figure 4

BD01D128A

The control levers for the three-point hitch control are located on the right side of the operator compartment between the seat and the console.

1 1

Figure 5

BD01D128A

1. LIFT: The lever is pulled back toward the operator to raise the attachment. Push the lever forward, away from the operator, to lower the attachment. The middle position is HOLD. Push the lever completely forward for the FLOAT position. This will allow the attachment to follow the level of the ground. The lever will stay in this position until pulled back to HOLD.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Three-Point Hitch Control

2

2

Figure 6

BD01D128A

2. PITCH: Push this lever forward, away from the operator, to pitch the attachment REARWARD. Pull the lever back toward the operator to pitch the attachment FORWARD. The central or mid position is neutral or HOLD.

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3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Three-Point Hitch

3

3

Figure 7

BD01D128A

3. RIGHT TILT (Standard): Push the lever forward, away from the operator to lower the right side of the attachment.

Pull the lever back to raise the right side of the attachment.

The central or mid position is neutral or HOLD.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS THREE - POINT HITCH

4

4

Figure 8

BD01D128A

4. LEFT TILT (Optional) OR AUXILIARY: Push the lever forward away from the operator to lower the left tilt or auxiliary.

NOTE: If the machine is equipped with Optional Left Tilt, the first auxiliary control lever is the Left Hand Tilt and the second auxiliary control lever is the Scarifier.

If the machine is not equipped with Optional Left Tilt the first auxiliary control lever is the Scarifier.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Three - Point Hitch

5 1

5 1

Figure 9

BD01D128A

1. SCARIFIER

5. AUXILIARY: Push the control lever forward, away from the operator to lower the scarifier.

Pull the lever back toward the operator to raise the scarifier.

NOTE: If the machine is equipped with Optional Left Tilt the first auxiliary control lever is the Left Hand Tilt and the second auxiliary control lever is the Scarifier.

If the machine is not equipped with Optional Left Tilt the first auxiliary control lever is the Scarifier.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

FLOW CONTROL REGULATOR

Figure 10

BD05H013

The flow control regulator is located on the right rear of the machine under the rear deck.

BD05H011

Figure 12

Move the lever completely clockwise and flow will adjust to (MAX) 8 gal/min (36.3 L/min). Tighten the set screw to hold the lever in position.

1

Figure 11

BD05H012

SET SCREW

The flow control can be adjusted by loosening the set screw (1) and moving the lever either clockwise or counterclockwise.

By moving the lever counterclockwise completely, the flow is adjusted to (MIN) 3 gal/min (13.6 L/min).

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB CLIMATE CONTROLS

1

2

(5) HEATER SWITCH:

8

6 BC00B083

3

Tu r n the heat control clockwise to increase the temperature in the cab.

Turn the control counterclockwise to decrease the temperature.

4

(6) BLOWER FAN SWITCH:

7

Turn the switch clockwise to increase the air flow in the cab. Tur n the switch counterclockwise to the OFF position to stop the fan.

5

BC00G127

(7) AIR CONDITIONING SWITCH: Turn the temperature control clockwise to decrease the temperature in the cab.

Turn the control completely clockwise for BC00G112 the coldest temperature. Turn the control completely counterclockwise for the OFF position.

Figure 13

BD05J003

WINDSHIELD CONTROLS (1) FRONT WINDSHIELD WINDOW WASHER SWITCH: Push the LH side of this rocker switch emblem to activate the front windshield BS96H096 washer. Release the rocker switch to stop the washer.

(8) AIR CONDITIONING WARNING LAMP: T h i s wa r n i n g l a m p i l l u m i n a t e s w h e n t h e a i r c o n d i t i o n i n g h a s s t o p p e d d u e t o r e f r i g e ra n t pressures that are too low or high. The lamp will also illuminate when the system needs service or the outside air temperature is too cool for the system to function properly.

(2) REAR WINDSHIELD WINDOW WASHER SWITCH: Push the RH side of this rocker switch emblem to activate the rear windshield BC00B083 washer. Release the rocker switch to stop the washer.

(3) FRONT WIPER SWITCH:

BC00G012

This is a three position switch with settings for (1) OFF, (2) LOW, and (3) HIGH. Tur n the switch clockwise to increase the wiper speed.

(4) REAR WIPER SWITCH:

BS96H096

3-24

This is a three position switch with settings for (1) OFF, (2) LOW, and (3) HIGH. Tur n the switch clockwise to increase the wiper speed.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS STANDARD SUSPENSION SEAT

1

Figure 14

BK97M036

The operator’s seat can be raised, lowered, moved forward and backward. The seat cushion and backrest are also adjustable. For added operator comfort there is a lumbar support adjustment and a weight adjustment for ride comfort.

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1. SEAT CUSHION TILT ADJUSTMENT: Raise your weight off the cushion.

Pulling up on the lever will raise the front of the cushion. To lower the cushion you must raise it to the highest position at which point it will then release and drop to the lowest position. There are three positions available.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

5 7

4

6

2

3 Figure 15

BK97M035

2. FORWARD/REARWARD: Push the control lever rearward and move the seat forward or rearward. Release the control lever and make sure the seat is locked in position. Adjust the seat as required. Release the control and make sure the seat is locked in position.

5. WEIGHT ADJUSTMENT CONTROL: Turn the weight adjustment control knob either clockwise or counterclockwise. Clockwise will increase weight adjustment and counterclockwise will decrease weight adjustment. Set the arrow on the graduated scale at your weight.

3. SWIVEL CONTROL: This control lever allows the operator to rotate the seat 30° to the right.

6. BACK REST TILT ADJUSTMENT CONTROL: Raise the lever and tilt seat backrest until it is comfortable for you.

Releasing the lever will lock it in place.

4. HEIGHT ADJUSTMENT CONTROL: Pull the height control lever up and adjust the height of the seat. Release the control lever and make sure the seat is locked in position.

7. LUMBAR ADJUSTMENT CONTROL: Tur n the control knob clockwise to i n c r e a s e t h e l u m b a r s u p p o r t . To decrease the lumbar support turn the knob counterclockwise.

8. ARMREST ADJUSTMENT CONTROL (NOT SHOWN): Turn the control knob clockwise to raise the arm rest. To lower the arm rest, turn the knob counterclockwise.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB AND CANOPY OPTIONS The cab and canopy options include the following:

REAR WINDOWS

A. Radio Ready Package B. Windshield Washer C. Deluxe Interior D. Noise Reduction Package E. Sun Visor RADIO READY PACKAGE OPTION The radio ready package includes the radio mounting box, wiring harness, speakers and antenna. Radio not included.

Figure 18

BD07C142

CAB REAR WINDOW

The rear windows in the cab have four positions: 1. All closed - top window up and bottom window 1/2 up.

2. Top window up and bottom window full down.

Figure 16

BD01D083

RADIO LOCATION

3. Top window 1/2 down and bottom window full down.

4. Both windows full down.

Figure 17

BK97K175

RADIO SPEAKERS

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CAB DOOR HANDLES

2 1

BD06A091

Figure 19

2. INSIDE LEFT CAB DOOR HANDLE

1. LEFT OUTSIDE CAB DOOR HANDLE

BD06A092

Figure 20

Pull down on the handle to open the cab door from the outside.

3-28

Figure 21

BD06A093

Figure 22

BD06A094

Pull the knob back to open the cab door from the inside.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT BELT

REAR VIEW MIRROR

Figure 23

BI01H141

To fasten and release the seat belt:

BIO1H102

Figure 25

OPERATOR MANUAL AND STORAGE BOX

1. Fasten the belt end into the left-hand buckle.

WARNING: An accident or sudden machine movement can cause injury or death. Always fasten the seat belt and adjust the seat before you start the engine. Failure to comply could result in injury or death.

SA029

WARNING: You are protected by the ROPS system on this machine (Roll-Over Protective Structure). The seat belt is an important part of the ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine. Failure to comply could result in injury or death.

BD05H088

Figure 26

UTILITY TRAY

SA080

BI01H098

Figure 27

Figure 24

BD05H044

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

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CHAPTER 3 - INSTRUMENTS AND CONTROLS CUP HOLDER

VANDAL LOCKUP KITS RIGHT SIDE INSTRUMENT CONSOLE

BI01H097

Figure 28

Figure 30

BD05J005

TOOL BOX

Figure 31

BD005J004 BD01D001A

3-30

Figure 29

When the vandal cover is in place and locked, the console is no longer accessible.

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CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Run In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Procedure with Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 4-3 4-3 4-4 4-4 4-5 4-5 4-5

ENGINE STARTING AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Held Starting Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ether Cold Start Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6 4-6 4-6 4-8 4-8

MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Adjusting the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Selecting Transmission Gears and Machine Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Four Wheel Drive Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Loader Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Return-To-Dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Loader Hydraulic Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Three-Point Hitch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Anti-Sway Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Rear Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Transporting the Machine on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

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4-1

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS RUN IN PERIOD

ENGINE OPERATION

Wheel Nuts And Bolts

Prestarting Checklist And Walk-Around Inspection

If the machine is new or if a wheel is removed for service, check and tighten the wheel nuts every 10 hours of operation until they remain tight.

In-Line Fuel Filter Replace the in-line fuel filter after the first 100 hours of operation.

Before each operating period, it is the responsibility of the operator to confirm that the machine is safe a n d s e r v i c e d . O p e ra t i n g a n d e nv i r o n m e n t a l conditions must be considered and the following checked: 1. Check for leaks under the machine.

Engine

2. Check the tires for damage.

During the first 20 hours of operation, or if you rebuild the engine:

3. Check the machine for broken, missing, or loose parts.

1. Operate the machine with normal loads for the first 8 hours. Do not work the engine hard at stall speeds, (wheels slowly turning or stopped and the engine running at full throttle).

4. Clean any debris from the machine and make certain the radiator areas are clean.

2. Keep the engine temperature.

at

normal

operating

Engine Speed Do not run the engine at idle speed for long periods.

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

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

6. Clean the steps, hand holds and operator’s compartment.

7. Check the engine oil level.

WARNING: Before starting engine, study the Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow manufacturer’s instructions on machine operation, service, and to observe pertinent laws and regulation. Operators and repair manuals can be obtained from your dealer.

Failure to comply could result in injury or death.

Foot Brake Check Check the operation of the foot brakes on a hard level surface after the first 100 hours of operation.

See Chapter 6 - Maintenance and Adjustments. If the machine does not stop in a straight line or if the brake pedal effort feels soft see the Repair Manual or contact your Dealer.

SB055

Parking Brake Check Check the operation of the parking brake after the first 100 hours of operation. See Chapter 6 Maintenance and Adjustments for instruction.

WARNING: Brake tests should only be performed by a skilled, qualified operator or technician. Failure to comply could result in machine damage, injury, or death.

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CHAPTER 4 - OPERATING INSTRUCTIONS STARTING THE ENGINE 1. Make certain all unauthorized personnel are clear of the area.

2. Make sure the seat is in the LOADER position.

STARTING PROCEDURE WITH TURBOCHARGER If the machine has not been run for several weeks, or if the engine oil filter has been replaced, prime the turbocharger lines with oil.

3. Adjust the seat and fasten the seat belt.

4. Make sure the parking brake is applied, the direction control lever is in NEUTRAL and the engine hand throttle is pushed back to the IDLE position.

5. Sound the horn to alert others of your intent to start the engine and/or move the machine.

6. Turn the key switch to ON and check the engine oil pressure and alternator warning lamps. Both lamps must illuminate.

7. Push the foot throttle 1/4 to 1/2 way down and turn the key switch to the START position to actuate the starter motor. Before the engine starts, check the air cleaner and hydraulic fluid filter warning lamps. Both lamps must illuminate.

8. If the engine starts and stops, do not actuate the starter motor again until the starter motor stops turning.

NOTE: Do not operate the starter motor more than 30 seconds at one time. Let the starter motor cool for two minutes before you actuate the starter motor again. While the starter motor is engaged, white or black smoke must be seen at the exhaust pipe. If no smoke is seen, check the fuel supply.

Figure 1

BD01D050

INJECTION PUMP SOLENOID WIRE

1. Disconnect the wire to the injection pump solenoid to prevent the engine from starting.

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

3. Connect the wire to the injection pump solenoid and start the engine. Follow the Starting the Engine procedure on this page.

4. Run the engine at idle speed for one or two minutes before moving the machine.

9. After the engine starts, check the instruments to make sure the gauge indicators are correct. Run th e e ng i n e a t 1 0 00 r p m u n ti l t h e c oo l a n t temperature is warm.

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING IN COLD WEATHER

General

Cold weather conditions cause special problems.

During these conditions, your machine will require special attention to prevent serious damage. Cold weather maintenance will extend the service life of your machine.

Before you operate, move the machine slowly in FIRST gear. Stop the machine and actuate the loader or three point hitch control to bring the hydraulic component up to operating temperature.

Battery and Electrical System

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

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 could result in injury or death.

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

2. See your Dealer and test the radiator cap before hot weather operation. Replace the cap, if necessary.

3. Clean all dirt and debris from the radiator and engine area.

SA046

Clean batteries and confirm they are at full charge.

4. Check the condition of the fan belt.

NOTE: A fully charged battery at 0° F (-17° C) has only 40 percent of it’s normal starting power.

5. Use lubricants of the correct viscosity.

If water is added to batteries at temperatures below 3 2 ° F ( 0 ° C ) , t h e e n g i n e s h o u l d b e r u n fo r approximately two hours or they should be placed on charge to prevent freezing.

Inspect the batteries, cables and terminals. Clean the terminals and put a coat of grease on each terminal to prevent corrosion.

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

7. Check the precleaner more frequently during extreme dust conditions.

8. Remove the ether starting aid can.

PARKING THE MACHINE

Lubricants Use the correct viscosity oil in each component.

Example: SAE 30W engine oil at 32° F (0°C) increases the starting load by approximately 250 percent. Make sure to follow the recommended oil and filter service in this manual.

SA038

Fuel System Check with your fuel supplier for the correct cold weather fuel. Engine power will be reduced if wax particles are in the fuel filters.

Cooling System Check the coolant mixture before you operate in cold temperatures. A mixture of 50% ethylene glycol and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above - 34° F (- 37° C). If the ambient temperature is lower, adjust the mixture. Follow the directions on the coolant label.

Cold Temperature Starting Aids Contact your Dealer for cold weather starting aids such as battery heaters, ether cold start, coolant and engine oil heaters.

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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 injury or death.

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1. Before you leave the machine, make certain the machine is parked on level ground.

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

2. Lower the loader bucket to the ground.

3. Apply the parking brake and shift the direction control lever to NEUTRAL. 4. Run the engine at idle speed long enough to allow the engine and component parts to cool evenly.

5. Lower the attachment to the ground and stop the engine.

6. Turn the key switch to OFF and remove the key.

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CHAPTER 4 - OPERATING INSTRUCTIONS

ENGINE STARTING AIDS WARNING: Starting fluid (ether) can cause injury or death. An explosion can result if sparks, flame, or extreme heat contact the ether in the starting fluid container. Do not breathe starting fluid vapors. Wear face protection when you remove or install a starting fluid container or when you use an aerosol spray starting fluid. Use starting fluid according to instructions in this manual.

Failure to comply could result in injury or death.

SA039

Figure 2

6. Before discarding an empty container, use rubber gloves and push in the valve at the end of the container to remove any residual pressure.

DO NOT make a hole in the container or damage the container. DO NOT incinerate the container.

WARNING: Do not inject ether into a running engine. Failure to comply could result in machine damage, injury or death.

7. Do not store extra containers in the operator’s cab.

8. Always read the instructions on the ether container.

HAND HELD STARTING FLUID 1. This is a two person procedure.

2. Make sure the parking brake is engaged and the direction control lever is in NEUTRAL. 3. Push the foot throttle 1/4 to 1/2 way down.

4. Turn the engine key switch to START. 5. Have the second person inject the ether spray into the air intake.

NOTE: Do not operate the starter motor for more than 30 seconds at one time. Wait two minutes so the starter motor can cool.

6. When the engine starts, run at 1000 rpm until the coolant temperature is warm.

ETHER COLD START AID Important Rules When Using Ether 1. Know the correct method for starting the engine with ether.

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

3. Do not breathe the ether vapor or let the ether touch your skin.

4. Keep the starting fluid container out of the reach of children.

5. When the temperature is above 35° to 40° F (1 .6 ° to 4 .4 ° C) re move the star ting fluid container from the machine. See Chapter 6.

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CHAPTER 4 - OPERATING INSTRUCTIONS Starting the Engine with Ether The Ether Start Aid injects a measured amount of ether into the engine during cold weather starting.

The ether starting aid system will operate until the engine temperature goes above 55 °F (12.7 °C). The ether start aid system will operate after the engine temperature has dropped below 35°F (1.6°C).

7. To replace ether bottle in the machine, see Section 6 - Maintena nce a nd Adjustme nt Section.

8. If the engine does not start after two attempts, check the supply of ether in the container.

IMPORTANT: Do not attempt to replace or install an ether container until you have read and understand the instructions and warnings on the container. See Chapter 6 - Maintenance and Adjustments.

1

Figure 3

BI01H144

1. Read instructions for starting the engine at the b e g i n n i n g o f t h i s s e c t i o n fo r t h e c o r r e c t procedure to start the engine.

2. Turn the key switch to the ON position, and check the instrument indicators.

3. 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.

4. Push the foot throttle 1/4 to 1/2 way down and hold until the engine starts.

5. When cranking the engine, press and release the ether switch to inject a metered amount of ether into the engine. Release the key after the engine is running.

IMPORTANT: Do not hold the ignition 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 120 seconds, and retry starting the engine.

6. After the engine starts, check the instruments to make certain the machine is operating within normal range. 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 normal operating temperature.

This is extremely important during cold weather operation to protect both the engine and hydraulic system.

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4-7

CHAPTER 4 - OPERATING INSTRUCTIONS ENGINE COOLANT HEATER

ENGINE OIL HEATER

BD00F081

Figure 4

B830661M

Figure 5

BD00F130

Figure 6

B830662J

Figure 7

The right side of the engine cylinder block is provided with a passage for installing a coolant heater. See your Dealer for this option.

The engine oil heater is installed on the right side of the engine oil pan. See your Dealer for this option.

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE OPERATION 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 injury or death.

SELECTING TRANSMISSION GEARS AND MACHINE DIRECTION TRANSMISSION The transmission is synchronized in all gears. The operator may shift to any gear without stopping the m a c h i n e . B e fo r e s h i f t i n g g e a r s , p u s h t h e transmission disconnect button. When shifting gears, always make sure the engine speed remains in the green area of the tachometer.

SA040

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

2 1

ADJUSTING THE SEAT Before starting each day, adjust the position of the seat and fasten the seat belt so that all controls may be reached and the brake pedal can be operated correctly.

BD06A096

Figure 8

1. TRANSMISSION SHIFT LEVER 2. TRANSMISSION DISCONNECT BUTTON

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4-9

CHAPTER 4 - OPERATING INSTRUCTIONS MACHINE DIRECTION

DIFFERENTIAL LOCK If the Machine is Stuck 1. Make sure the rear wheels are not turning.

Figure 9

BD01D107

DIRECTION CONTROL LEVER

For forward travel, lift up the direction control lever and push completely forward. To travel in reverse, lift up the direction control and pull completely rearward.

The center position is NEUTRAL. The transmission direction control lever must be in the NEUTRAL position for the machine to start.

NOTE: For smooth operation before you change directions, reduce the engine speed.

Working on a Hill Before you work the machine on a hill, always put the transmission in a lower gear and test your brakes.

DO NOT let the machine move down the hill with the transmission in NEUTRAL. DO NOT let the engine speed increase greater than 2500 rpm. Use caution if you must use the transmission disconnect when you are digging with the loader on a hill.

WARNING: Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc., change the ground conditions.

You must make a judgment if your machine can be safely operated on any hillside or ramp. Failure to comply could result in injury or death.

SB013

WARNING: Excessive speed can cause loss of machine control. Do not coast down a hill with a transmission in NEUTRAL. DO NOT let the engine speed increase more than the normal operating speed. Before operating or driving on a hill, always shift to a lower gear.

You or others around you can be injured.

Failure to comply could result in injury or death.

Figure 10

BI01H083

2. Press and hold the differential lock momentary switch located on the loader control lever or push the differential lock rocker switch located on the instrument console.

3. Release the momentary switch or press the opposite end of the differential lock rocker switch once traction has been regained.

NOTE: The differential lock will release automatically when the load on the axle is removed.

Before Operating through a Soft or Muddy Area Engage the differential lock when the machine is moving in straight direction of travel.

1. Before moving the machine through a soft or muddy area, make sure that the machine is moving in a straight direction and that one of the rear wheels is not rotating faster than the other.

2. Push down and hold the differential lock button on the loader control lever or activate the full time differential lock switch located on the console.

3. After moving through the area, release the differential lock button or de-activate the switch.

IMPORTANT: You can cause damage to the rear axle if you try to engage the differential lock when the machine is turning or if one rear wheel is rotating faster than the other rear wheel.

SE056

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CHAPTER 4 - OPERATING INSTRUCTIONS FOUR WHEEL DRIVE OPERATION

RIDE CONTROL

IMPORTANT: Drive the machine in first or second gear only when the front drive axle is engaged.

Figure 12

BI01H088

RIDE CONTROL SWITCH Figure 11

BD06A099

FRONT WHEEL DRIVE FRONT AXLE SWITCH

The front drive axle is engaged and disengaged by the four wheel drive front axle switch.

To engage the front drive axle, push the upper end of the rocker switch down. The icon will illuminate when the axle is engaged.

To disengage the front drive axle, push the lower end of the rocker switch down.

Ride Control is a feature that increases the ride comfort of the machine over all types of terrain with either an empty or loaded bucket. Ride Control will reduce fore and aft pitching motion during travel to allow faster speeds in load and carry applications for increased productivity and operator comfort. It will also reduce shock loads for reduced tire flex, structural fatigue and vibrations.

To engage Ride Control, lower the loader bucket to or near the ground line.

Push the Ride Control rocker switch emblem, the switch lamp will illuminate. There can be a slight loader arm drop when the Ride Control is activated.

To disengage, push the opposite end of the Ride Control rocker switch, the lamp will go out.

Ride Control should not be used for fine grading with the loader bucket or when precise placement of the loader is required.

WARNING: DO NOT attempt to lift or hold the front of the machine off the ground with the loader when Ride Control is engaged. DO NOT engage Ride Control while using the loader to lift or hold the front of the machine off the ground. Failure to comply could result in injury or death.

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4-11

CHAPTER 4 - OPERATING INSTRUCTIONS LOADER OPERATION This information for loader operation does not include all possible conditions. This is basic information that is needed to operate the machine.

STANDARD BUCKET LEVEL INDICATOR

WARNING: When you lower a loaded bucket, material can spill out if you do not manually roll back the bucket. The self-leveling feature does not roll back the bucket automatically when the loader is lowered. Other persons in the area can be injured if material spills from the bucket when the loader is lowered. Failure to comply could result in injury or death.

CM101

Figure 14

BD06A098

Transmission Disconnect Button

STANDARD BUCKET LEVEL INDICATOR

The bucket level indicator has two pointers on the bucket links. The bucket is level on the ground when the two pointers are opposite each other.

MULTI PURPOSE BUCKET INDICATORS

Figure 13

BI01H083

TRANSMISSION DISCONNECT BUTTON

Push the transmission disconnect button to give maximum power to the loader hydraulics. When you push the transmission disconnect button, the transmission is disengaged from the drive wheels.

Release the transmission disconnect button to engage the transmission power. The machine can roll free when the transmission disconnect button is pushed. Use the brakes to stop the machine.

4-12

Figure 15

BD05E506

MULTI PURPOSE BUCKET POSITION INDICATOR

The bucket position indicator is located on the bucket links. This shows the correct bucket angle when the bucket is used as a clam, loader, scraper, or dozer.

Put the loader bucket 12 in (0.3 m) above the ground, and tilt the bucket to the desired position.

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CHAPTER 4 - OPERATING INSTRUCTIONS MULTI PURPOSE BUCKET CLAM DEPTH INDICATOR Dozer

Figure 16

BD05E507

AS173

CLAM INDICATOR

The clam indicator is located on the right side of the bucket. This indicator is used when the bucket is in the scraper position. The bucket opening or depth of cut is shown on this indicator. The multi purpose bucket can make a cut up to 4 in (102 mm) in depth.

Figure 19

Open the clam completely and place the bucket in the position shown for dozer operations.

Clamshell

MULTI PURPOSE BUCKET OPERATION Scraper

AS174

Figure 20

Position the bucket over the material to be moved and close the clam on the material.

Figure 17

AS172

Tilt the bucket to the scraper position on the indicator and open the clam to the desired depth of cut.

Standard Bucket

Figure 18

AS171

Close the clam for Standard Bucket operation.

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CHAPTER 4 - OPERATING INSTRUCTIONS JOB LAYOUT

RETURN-TO-DIG

1

Figure 21

BI01H083

(1) MOVE THE CONTROL LEVER TO THE FLOAT AND ROLLBACK POSITIONS FOR RETURN-TO-DIG.

After dumping the bucket, use the return-to-dig to place the bucket in position for another dig cycle.

Figure 24

BC01G146

Set up the work cycle to be as short as possible.

Truck positioning is very important for fast cycles.

2

Spend a few minutes leveling off the work area, if necessary. Smooth runways for the machine and a level parking area for trucks will speed up the job.

WARNING: Operating a loader with a full bucket on a hillside can cause the machine to roll over. If possible, avoid turning the machine, and always move forward up the hill and back down. Always keep the load low.

Failure to comply could result in injury or death.

Figure 22

BC01G172

The return-to-dig uses both the FLOAT and the ROLLBACK positions. To operate, put the lift arm control in the ROLLBACK position and the FLOAT position. The bucket will roll backward (2) until the bottom of the bucket is level. The bucket will stop automatically.

SA058

WARNING: When you operate the machine, keep the loader bucket as low as possible.

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

Failure to comply could result in injury or death.

3 SA041

BC01G171

Figure 23

The loader arms will continue to lower until (3) the bucket reaches the ground or you manually pull the lift arm control back to HOLD (NEUTRAL).

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CHAPTER 4 - OPERATING INSTRUCTIONS LIFTING WITH THE LOADER If you lift a suspended load with the loader, be very careful. This machine is NOT a crane.

Keep all unauthorized personnel clear of the area.

Lift only in a firm, level area.

1

Figure 25

BD06A100

1. LIFTING POINTS

Use the lifting points (1) supplied with the bucket.

IMPORTANT: Make sure that you use rigging material that has the capacity to lift the required loads. Always check the rigging material each time it is used for damaged or missing parts.

WARNING: Do not move the load over personnel or bystanders. Always keep the load low as possible. Failure to comply could result in injury or death.

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CHAPTER 4 - OPERATING INSTRUCTIONS LOADER HYDRAULIC COUPLER

Figure 26

BI01H155

The loader hydraulic coupler allows the operator to change front end attachments without the use of special tools or additional manpower.

Figure 29

BI01H154

When the hydraulic quick coupler switch is pressed and held the pins will retract as shown.

Installing An Attachment:

2 1

Figure 30

BI01H153

Figure 27

3. Lift the loader arms and rotate the coupler rearward until the coupler lock pins are aligned with the attachment lower mounting bores.

Release the coupler switch allowing the coupler lock pins to engage in the attachment mounting bores.

1. Tilt the loader hydraulic coupler forward and engage the top coupler pins in the attachment upper mounting hooks.

4. Visually confirm the coupler lock pins have secured the attachment.

BI01H157

1. COUPLER PIN (ONE EACH SIDE) 2. UPPER MOUNTING HOOK (ONE EACH SIDE)

Removing An Attachment: 1. With the attachment resting on the ground press and hold the loader hydraulic coupler switch to disengage the coupler lock pins.

2. Raise the attachment off the ground and slowly rotate the top of the attachment outward until the lock pins are clear of the attachment mounting bores. Release the loader hydraulic coupler switch.

3

3. Carefully lower the attachment to the ground while rotating the top of the coupler outward.

BIO1H145

Figure 28

3. HYDRAULIC QUICK COUPLER SWITCH

4. When the upper coupler mounting pins are free, back away from the attachment.

2. Press and hold the loader hydraulic quick coupler switch located on the instrument panel.

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CHAPTER 4 - OPERATING INSTRUCTIONS THREE-POINT HITCH OPERATION THREE-POINT HITCH MODE CONTROL

Figure 31

BI01H043

Connect compatible equipment to the three point hitch using pins and lock pins as required.

BD05H049 / BD06A102

Figure 34

THREE-POINT HITCH MODE CONTROL SWITCH

The three-point hitch lock valve is engaged and disengaged by a rocker switch. The rocker switch hitch has three positions.

Normal Mode: With the rocker switch in this position, the lock valve is closed. When the three point hitch lift spool is in NEUTRAL or the key switch is turned to the OFF position a load/attachment cannot be lowered.

1

Float Up Mode:

Figure 32

BD01D135

1. AUXILIARY HYDRAULIC CONNECTIONS

FLOW CONTROL REGULATOR

With the rocker switch in the center position, the lock valve remains closed no matter what position the lift spool is moved to and a load/attachment cannot be lowered. By moving the lift control lever to the FLOAT position, the load/attachment cannot be lowered but will float up as required and then return to the original position.

Laser Mode: Push the rear of the rocker switch to put the three point hitch lift circuit in the laser mode. In this mode the lock valve remains open and the optional laser valve that is mounted to the lock valve controls the lift circuit. Use of the lift control lever will over ride the laser mode.

Figure 33

BD05H011

Loosen the set screw and adjust the flow as required.

Counterclockwise (MIN) . . . . . . . . . . . . . . . . . 3 gpm Clockwise (MAX) . . . . . . . . . . . . . . . . . . . . . . . 8 gpm

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IMPORTANT: It is recommended when operating the three point hitch lift circuit in the laser mode that the Flow Control Regulator be at the 3 gpm setting. The Flow Control Regulator is turned completely counterclockwise for 3 gpm.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS ANTI-SWAY CALIPER

REAR COUNTERWEIGHT

Figure 37

BD07C007

Figure 35

BD07C007

Connect compatible equipment to the three point hitch using pins and lock pins as required.

A rear 525 lb (238 kg) counterweight is available for use with the machine when the rear attachment is r e m o v e d . S e e y o u r C a s e d e a l e r fo r m o r e information.

OPTIONAL REAR COUNTERWEIGHT A rear 3000 lb (1361 kg) counterweight is available for use when the rear attachment is removed. See your dealer for more information.

1

BD07C005

Figure 36

T h e a n t i - sw ay c a l i p e r i s d e s i g n e d t o a l l o w attachments to be used with a minimum of sway.

When installing a compatible attachment, tighten the three caliper bolts in accordance with the type of attachment and work conditions.

WARNING: The braking ability of the machine is greatly reduced when the rear mounted equipment or rear counterweight is removed. After you remove the rear mounted equipment and before you operate the machine, always install the correct rear equipment or counterweight for this machine.

Failure to comply could result in injury or death.

Adjust the three bolts by tightening until an increased resistance is felt, then back off one full turn and tighten the lock nut.

4-18

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87612257NA

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

BY TRUCK OR 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. Keep all unauthorized personnel clear of the area.

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

3. Fasten your seat belt and raise the rear attachment, shift the transmission to first gear and slowly drive the machine onto the trailer.

4. Carefully move the machine SLOWLY onto the trailer.

12. Measure the distance between the ground and the highest point of the machine. You must know t h e o ve r a l l h e i g h t . S e e M a c h i n e o ve r a l l dimensions in the Chapter 8 (Specifications).

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

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

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

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

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

5. Lower the loader bucket onto the trailer.

6. Shift the direction control lever to Neutral, and apply the parking brake.

7. Lower the rear attachment to the floor of the trailer if possible.

8. Stop the engine and remove the key.

9. Shift the transmission control to neutral.

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

11. Use chains and binders to fasten the machine to the trailer.

87612257NA

Issued 04-07

Bur

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE ON A TRAILER Machine Tie Down Locations

BD07A032

Figure 38

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

Figure 39

BD07A176

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

Tie down location - rear chassis, both sides Tie down location if equipped with optional rear weights, rear chassis both sides.

TRANSPORTING THE MACHINE BY RAIL Transport by rail is subject to special regulations, consult an approved organization.

4-20

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87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS LUBRICATION, FILTERS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Before You Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Systemgard® Lubrication Analysis Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plastic and Resin Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Loader Lift Arm Support Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relieving Hydraulic Pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 5-3 5-4 5-4 5-4 5-4 5-5 5-5

FLUIDS AND LUBRICANT CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lubrication and Maintenance Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 10 Hour or Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 20 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 50 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

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5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Lubrication, Filters and Fluids GENERAL SAFETY BEFORE YOU SERVICE WARNING: Before you begin any service or repair work you must know and understand how to relieve hydraulic pressure properly. Always have tools and attachments lowered in safe positions. Failure to comply could result in injury or death.

Figure 1

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.

1

SC021

WARNING: Do not allow equipment to remain raised when exiting the cab. Before you leave the operator’s compartment, always support or lower all equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine. Failure to comply could result in injury or death.

SA044

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

1. DO NOT OPERATE TAG

Before you ser vice the machine, put a Do Not Operate or mark out tag on the instrument panel or ignition key.

WARNING: Never loosen any hydraulic lines or fittings without first having the boom in the completely lowered position (on the ground) or resting solidly on the support strut. Any attachment must be in the completely lowered position to relieve all pressure in the circuit. Failure to comply could result in injury or death.

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

Maintenance and Lubrication schedules are defined for normal working environments and conditions.

Extreme working conditions and environments require more frequent service and care. Contact your Dealer if you have any questions about service intervals or requirements.

Figure 2

BD06A082

M1150

WARNING: Do not attempt any service procedure or check until components involved and surrounding components have cooled. Failure to comply could result in injury or death.

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Issued 04-07

Bur

5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS SYSTEMGARD® LUBRICATION ANALYSIS PROGRAM

PLASTIC AND RESIN PARTS Do not use gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts. Do not allow any liquid to leak into the console or gauges, as moisture can damage machine electronics.

Using gasoline, kerosene, thinners, etc., will cause discoloration, cracking or deformation of the part being cleaned.

ENVIRONMENT

A27274

Figure 3

Ask your dealer about our lubr icant analysis program, Systemgard®. Through this service, your lubricants are tested in an independent laboratory.

Remove a sample of lubricant from your machine and send the sample to the independent System gard ® lab orator y. After the sam ple is processed, the laboratory will report back to you and g u i d e yo u w i t h m a i n t e n a n c e r e q u i r e m e n t s .

Systemgard® can help support your equipment up time and provide you with a service that can pay back dividends when you trade for another piece of equipment.

Before you service this machine and dispose of oil, f l u i d s a n d l u b r i c a n t s, a l way s r e m e m b e r t h e environment. Do not drain oil or fluids onto the ground or into containers that can leak. Check with your local environmental, recycling center, or your dealer for correct disposal information.

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

The normal engine oil change interval is every 250 hours of operation. Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended that you use the Systemgard® Lubricant Analysis program. See your dealer.

HYDRAULIC AND ENGINE AIR FILTERS Always replace hydraulic and engine filters if the respective warning lamps illuminate.

Figure 4

BD05D010RX

The engine hourmeter shows the amount of actual hours the engine has run. The first number to the right displays tenths of an hour (6 minutes) and the remaining numbers to the left display hours. Use the engine hourmeter along with the Quick Reference Lubrication and Maintenance Chart to service your machine at the correct time periods.

Engine hours are displayed with the key switch off or with the engine running.

5-4

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Bur

87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS INSTALLING THE LOADER LIFT ARM SUPPORT STRUT

3 1 2

Figure 5

BD04G019

LOADER LIFT ARM

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

2. Raise the loader lift arms (1) to maximum height and stop the engine.

Figure 7

BD06A086

4. Install the support strut pin (2) to lock the strut (3) onto the cylinder, as shown. Slowly lower the lift arms until the support strut makes contact with the cylinder, as shown.

LOWERING THE LOADER LIFT ARMS 1. Raise the loader lift arms and remove the pin from the support strut.

2. Raise the support strut up to the storage position and install the pin.

3

3. Lower the loader to the ground.

WARNING: If you service the machine with the loader lift arms raised, always use the support strut. Failure to comply could result in injury or death.

2 SA068

RELIEVING HYDRAULIC PRESSURE: Figure 6

BD06A084

3. Remove the support strut pin (2), and lower the support strut (3) onto the cylinder rod.

1. Lower the boom and attachment to the ground.

2. Lower the three point hitch controls to the lowest position.

3. Turn off the key switch and stop the engine.

4. Move the bucket and auxiliary controls through several cycles to relieve all pressure in these circuits.

5. In some situations the hydraulic reservoir fill cap may need to be opened slightly.

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.

87612257NA

Issued 04-07

Bur

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANT CAPACITIES FUEL TANK Capacity ..........................................................................................................................................31.4 gal (119.0 L) Optional Tank.........................................................................................................................................40 gal (151 L) Specifications ............................................................................................................................................... #2 Diesel ENGINE CRANKCASE OIL Capacity - with filter change .............................................................................................................11.6 qts (11.0 L) Specifications .......................................................................................... Case Akcela 15W-40 or 10W-30 engine oil COOLING SYSTEM Capacity with heater ........................................................................................................................... 17.4 qt (16.5 L) Capacity without heater ...................................................................................................................... 16.7 qt (15.8 L) Specifications ..................................................................................................... 50% water and 50% ethylene glycol HYDRAULIC SYSTEM Capacity - Total System ........................................................................................................................ 81 qt (77.0 L) Reservoir - with filter change ................................................................................................................. 58 qt (55.0 L) Reservoir - without filter change ............................................................................................................ 56 qt (53.0 L) Specifications ..................................................................................................................................... Hy-Tran® Ultra TRANSMISSION 2 WHEEL DRIVE Total system capacity ........................................................................................................................ 19.5 qt (18.5 L) Refill capacity with or without filter change......................................................................................... 12.6 qt (11.9 L) Specifications ..................................................................................................................................... Hy-Tran® Ultra 4 WHEEL DRIVE Total system capacity ............................................................................................................................ 22 qt (21.0 L) Refill capacity with or without filter change......................................................................................... 15.2 qt (14.4 L) Specifications ..................................................................................................................................... Hy-Tran® Ultra FRONT DRIVE AXLE - 4 WHEEL DRIVE Capacity - center bowl ........................................................................................................................... 5.8 qt. (5.5 L) Capacity - each wheel end ..................................................................................................................0.75 qts (0.7 L) Specifications ..................................................................................................................................... Hy-Tran® Ultra REAR AXLE Capacity - center bowl ........................................................................................................................... 15 qt (14.2 L) Capacity - wheel ends ...........................................................................................................................1.6 qts (1.5 L) Specifications ..................................................................................................................................... Hy-Tran® Ultra AOA ..................................................................................................................................................Brake oil additive GREASE FITTINGS Specifications ...................................................................................................................Case Molydisulfide grease

NOTE: Engine oil to be used should be based on the ambient temperature the machine will be operating in. See the Oil Viscosity/Temperature Chart on page 5-9.

5-6

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87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

As Required 10 Hours or Daily

5-8

5-31

Air Filter Pre-Cleaner Engine Oil Level Loader and Machine Grease Fittings Front Axle Pivot Pins 2WD Wheel Torque Check Until Stable Three-Point-Hitch Transmission Fluid Hydraulic Filter Rear Axle Oil Level Front Four Wheel Drive Axle Hydraulic Coupler and Clam Bucket Fittings Front Axle Pivot Pins 4WD Rear Axle Drive Shaft Hydraulic Reservoir Fluid Coolant Reservoir Fluid Level Check Fuel Filter for Water and Sediment Foot Brake and Parking Brake Tire Pressure and Condition Spark Arresting Muffler Battery Radiator Coolant Level Engine Oil and Filter Front Axle Oil Level- Breather 4WD Rear Axle Oil Level- Breather Fuel Tank Transmission Fluid Level Driveshaft Slip Splines Inspect and Lubricate Seat ROPS Canopy and Seat Restraint System Fuel Filters Hydraulic Fluid and Filter Transmission Fluid and Filter Rear Axle Oil Front Axle Oil Check Engine Valve Clearances Air Filter Elements Cab Air Filter

5-32

Drain and Flush the Radiator

5-10 5-11 5-13 6-10 5-14 5-15

20 Hours

5-15

(Initial)

5-16 5-16 5-17 5-17

50 Hours

5-17 5-18 5-18 5-19 6-13

100 Hours

6-8 6-11 7-5 5-20 5-21 5-22

250 Hours

5-23 5-23 5-24 5-24 5-24

500 Hours

1000 Hours or Annually

2000 Hours or Annually

6-3 5-25 5-26 5-27 5-28 5-29 Dealer 5-30

LUBRICATE

DRAIN

CHANGE

CLEAN

FREQUENCY IN HOURS

CHECK

SERVICE POINTS

PAGE NUMBER

SERVICE INTERVAL

INITIAL OR NEW

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

AR 10 10 10 Run-in

10 10

Run-in

20

Run-in

20

Run-in

20

Run-in

20 50 50 50 50 50 50

Run-in

100 100 100 250 250 250 250

250

250 250 250

250

250 250 500 500 1000 1000 1000 1000 1000 1000 1000 2000

NOTE: Recommended intervals are for normal operating conditions. More frequent maintenance may be required for severe or specific operating conditions.

87612257NA

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5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS LUBRICATION AND MAINTENANCE ACCESS BATTERY ACCESS

ENGINE ACCESS

1

Figure 8

BD01053

ENGINE HOOD HANDLE

To open the engine hood, turn the handle located on the hood counterclockwise to release.

Figure 11

BD05H077

Remove the bolts (1) that secure the battery access cover and remove the cover.

Figure 12

BD07C008 BD01D086

Figure 9

Check the pre-cleaner and remove the dust and debris as necessary. To check the bowl, remove the wing nut on top cover. Wipe clean, replace cover and wingnut.

Lift the hood and rotate forward.

BD01D053

PRE-CLEANER SERVICE

Figure 10

To close, lower the hood, and tur n the handle clockwise to lock.

Do not move the machine without the hood firmly locked in place, as damage to the machine can result.

5-8

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Bur

87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ENGINE OIL Case Akcela 15W-40 or 10W-30 API Service CI-4 Engine Oil is recommended.

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

NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase.

Oil Viscosity/Temperature Ranges

Figure 13

BC04F170

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Issued 04-07

Bur

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR OR DAILY MAINTENANCE ENGINE OIL Service Specifications Capacity (with filter change) . . . . . . . . 11.6 qt. (11 L) Type of oil . . . . . . . . . . . . . . . . . . . . . . . Case Akcela Check the engine oil level daily before beginning operation and/or every 10 hours of operation. Always check the oil with the engine stopped and when the machine is on level ground.

2

1

Figure 14

BD04E107

1. ENGINE OIL LEVEL DIPSTICK 2. ENGINE OIL FILL LOCATION

Keep all unauthorized personnel clear of the area.

Par k the machine on fir m, level ground. This procedure is best performed at the beginning of the work day with the engine cool and all oil drained to the pan.

Make sure the engine level dipstick is pushed completely down. Remove the dipstick to check the oil level.

2

BD04E107

Figure 15

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

5-10

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Bur

87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

1 3 4 5

6

2 6 Figure 16

BC01G174X

LOADER AND MACHINE GREASE FITTINGS Lubricate the loader pivot pins every 10 hours of operation or each day. If you operate in severe conditions, lubricate more often. Clean the fittings before lubricating.

Specification ................................................................................................................................Case Molydisulfide

1

2

Figure 17

BD01D028

1. Lift Arm Pivot. . . . . . . . . . . . . . . . . . . . . 2 fittings

BI01H013

Figure 19

2. Lift Cylinder Closed End . . . . . . . . . . . . 2 fittings

1

3 Figure 18

BD01D028

Lift Arm Pivot . . . . . . . . . . . . . . . . . . . . . . . . 2 fittings

87612257NA

Issued 04-07

Bur

BD01D030

Figure 20

3. Lift Cylinder Rod End . . . . . . . . . . . . . . . 2 fittings

5-11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

6

5

4 6

Figure 23

BP9410036

Figure 21

BD01D037

Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . 2 fittings

Bucket Cylinder Rod End . . . . . . . . . . . . . . 2 fittings Bucket Pivots. . . . . . . . . . . . . . . . . . . . . . . . 4 fittings

4

BD01D031

Figure 22

Bucket Cylinder Trunnion . . . . . . . . . . . . . . . 2 fittings

5-12

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87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

1

2

3

Figure 24

BC01G174X

3 2

1

Figure 25

BP9410043

Tie Rod End - Outer . . . . . . . . . . . . . . . . . . 2 fittings King Pins - Upper and Lower. . . . . . . . . . . . 4 fittings

87612257NA

Issued 04-07

Bur

BI01H017

Figure 26

Tie Rod End - Inside. . . . . . . . . . . . . . . . . . . . 1 fitting

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

Figure 27

BD05J011

THREE POINT HITCH Lubricate the three point hitch grease fittings every 10 hours of operation. If operating in severe conditions, lubricate more frequently. Remove all dirt from the fittings prior to lubricating.

5-14

Issued 04-07

Bur

87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 20 HOUR MAINTENANCE (INITIAL) TRANSMISSION FLUID CHECK

REPLACE HYDRAULIC FILTER

Check the fluid level of the transmission after the first 20 hours of operation on a new machine.

I f t h e m a c h i n e i s n e w o r a m a j o r hy d r a u l i c component has been replaced, replace the hydraulic filter after the first 20 hours of operation.

Service Specifications 2 Wheel Drive . . . . . . . . . . . . . . . . . . 19.5 qt (18.5 L) 4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . 22 qt (21 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hy-Tran Ultra Keep all unauthorized personnel clear of the area.

Park the machine on firm, level ground with the engine running.

NOTE: Always replace the filter if the hydraulic filter warning lamp illuminates.

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

2. Release all pressure in the hydraulic system.

Lower the loader bucket to the ground and apply the parking brake. Stop the engine.

WARNING: Contact with rotating fan and belts will cause injury. Keep clear! Failure to comply could cause severe injury or death

BD07DXXX

Figure 29

3. Use a filter wrench and remove the old hydraulic filter from the machine.

Figure 28

4. Lubricate the gasket on the new filter with clean oil.

The fluid level must be between the ADD and FULL marks on the transmission dipstick. If the fluid level is at the ADD mark, add fluid as required until the fluid level is at the FULL mark on the dipstick.

5. Install the new filter and turn clockwise until the gasket contacts the head of the filter assembly.

Continue to tighten the filter for an additional 1/3 turn.

BD05H028

TRANSMISSION FLUID DIPSTICK

VD01D019

Figure 30

6. Start the engine and check for leaks at the hydraulic filter. Check the reservoir level. Oil should appear at the center of the sight gauge.

Top off with fluid, if necessary.

87612257NA

Issued 04-07

Bur

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 20 HOUR MAINTENANCE (INITIAL)

4-WD FRONT AXLE OIL LEVEL

REAR AXLE OIL LEVEL

Service Specifications Center bowl capacity . . . . . . . . . . . . . . . 5.8 qt (5.5 L) Each wheel end. . . . . . . . . . . . . . . . . .0.75 qt (0.7 L) Type. . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra

Check the level of the axle oil after the first 20 hours of operation on a new machine.

Service Specifications Center bowl capacity . . . . . . . . . . . . . . 15 qt (14.2 L) Each wheel end . . . . . . . . . . . . . . . . . . .1.6 qt (1.5 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra

Figure 33

861835J

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface.

BD05J008

Figure 31

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface with the oil level plug in the position shown.

2. Remove the plug. The oil level must be even with the plug hole. Add oil, if necessary.

2. Place blocks in front of and behind the rear tires.

Make certain the direction control lever is in the neutral position and the gear shift control lever is in the neutral position.

3. Use the loader and raise the front wheels about one inch (25 mm) above the ground.

4. Rotate the wheel so the oil level plug is in the position shown.

3. Replace the plug.

4. Repeat the procedure for the other side.

5. Remove the plug. The oil level must be even with the plug hole. If necessary, add oil.

6. Replace the plug and repeat the procedure for the other side.

7. Lower the wheels to the ground.

BI01H124

Figure 32

5. Remove the oil level plug for the center bowl.

The oil level must be even with the plug hole.

Add oil if necessary.

6. Replace the oil level plug.

Figure 34

BI01H127

8. Remove the plug for the center bowl. The oil must be even with the plug hole. Add oil if necessary.

5-16

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Bur

87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE HYDRAULIC COUPLER AND CLAM BUCKET FITTINGS Lubricate the following fittings at every 50 hours of operation. If you operate in severe conditions, lubricate more often. Clean the fittings before lubricating.

Service Specifications Grease Type ..................................................................................................................................Case Molydisulfide

Figure 35

BI01H156

Hydraulic Coupler Lock Pins . . . . . . . . . . . . 2 fittings

Figure 36

BI01H010

Clam Cylinder . . . . . . . . . . . . . . . . . . . . . . . 2 fittings

BI01H184

Figure 38

Clam Cylinder Closed End . . . . . . . . . . . . . . 2 fittings

BI01H034

Figure 39

4-WD Front Axle King Pins- Upper and Lower. . . . . . . . . . . . . 4 fittings

Figure 37

BI01H183

Clam Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . 2 fittings

BI01H123

Figure 40

Rear Axle Drive Shaft Rear Slip Spline . . . . . . . . . . . . . . . . . . . . . . . 1 fitting

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE

COOLANT RESERVOIR FLUID LEVEL

HYDRAULIC RESERVOIR OIL LEVEL CHECK

Service Specifications

Service Specifications Total system capacity . . . . . . . . . . . . . 81 qt. (77.0 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra

Coolant Capacity with heater . . . . . . 17.4 qt (16.5 L) Coolant Capacity without heater . . . . 16.7 qt (15.8 L) Specification . . . . . 50% ethylene glycol - 50% water

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

Check the coolant reservoir fluid every 50 hours of operation.

Keep all unauthorized personnel clear of the area.

Park the machine on firm, level ground with the attachments on the ground and the engine stopped.

NOTE: Check when the fluid is cold or the same temperature as the outside air.

Figure 43

BD05H005

COOLANT RESERVOIR

Check the coolant level when the coolant is cold and the engine is stopped. DO NOT remove the radiator cap during this check.

Figure 41

BD05H076

HYDRAULIC OIL LEVEL SIGHT GAUGE

The hydraulic reservoir is full when hydraulic fluid covers half of the sight gauge window.

IMPORTANT: When the hydraulic fluid level is low, a small amount of hydraulic fluid will remain on the lower part of the sight gauge window. This condition does not show a correct fluid level.

Figure 44

BD05H024

The coolant level should be between the FULL and ADD mark on the reservoir. Add a 50% mixture of water and ethylene glycol as required.

BD01D019

Figure 42

If it is necessary to top off the hydraulic fluid, make certain all pressure is relieved from the hydraulic system. Open tank cap slowly.

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87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE FUEL FILTER (PRIMARY) Check the primary fuel filter for water or sediment every 50 hours of operation.

Figure 45

BD01049

FUEL FILTER DRAIN VALVE

1. Hold a small glass container under the main filter and loosen the drain valve.

Figure 46

BD05H026

HAND PRIMER

2. Use the hand primer to drain fuel from the filter.

NOTE: If there is no fuel when you operate the hand primer rotate, the engine 1/3 turn and operate the hand primer again.

3. Tighten the valve and check the container for water or sediment.

4. If water or sediment is found, the fuel tank should be checked, also.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE RADIATOR COOLANT LEVEL WARNING: Hot coolant can spray out if radiator cap is loosened or removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released.

Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance instructions.

Failure to comply could result in injury or death.

Figure 48

BD05H024

Every 250 hours check the radiator coolant level when the engine is stopped and the coolant is cold.

Service Specifications

The coolant level should be between the FULL and ADD mark on the reservoir. Add a 50% mixture of water and ethylene glycol as required.

Coolant Capacity with heater . . . . . . 17.4 qt (16.5 L) Coolant Capacity without heater. . . . 16.7 qt (15.8 L) Specification . . . . .50% ethylene glycol 2- 50% water

Figure 49

BD05H024

Check coolant level in the radiator. The coolant level must be up to the radiator top just under the overflow tube.

Figure 47

BD05H005

COOLANT RESERVOIR

Keep all unauthorized personnel clear of the area.

Park the machine on firm, level ground for the most accurate reading.

5-20

Turn cap slowly to the first notch to allow pressure to release.

If additional coolant is required, make certain to add the correct mixture of 50% ethylene glycol and 50% water to the radiator.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE ENGINE OIL AND FILTER Service Specifications Capacity (with filter change) . . . . . . . . 11.6 qt. (11 L) Type of oil . . . . . . . . . . . . . . . . . . . . . . . Case Akcela NOTE: For more complete removal of foreign material, change the engine oil while the engine is still warm, but not hot from operation.

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

Figure 52

BD06A103

ENGINE OIL FILTER

3. Turn the filter counterclockwise to remove.

Dispose of the filter properly.

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

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

6. Put new oil into the engine oil filter.

Figure 50

BD01D047

ENGINE OIL FILL LOCATION

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground with attachments on the ground.

7. Turn the new oil filter clockwise onto the base until the gasket makes contact with the base.

Continue to tighten the filter with your hand until tight.

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

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

9. Fill with the correct type and quantity of oil.

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

11. Install the engine oil drain plug access cover.

Dispose of the oil in accordance with the local regulations. DO NOT drain onto the ground or into a drain. Be environmentally responsible.

Figure 51

BI01H186

ENGINE OIL DRAIN PLUG ACCESS COVER

2. Remove access cover to access engine oil drain plug. Remove the engine oil drain plug and drain the oil into a suitable container.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE 4-WHEEL DRIVE FRONT AXLE OIL LEVEL Service Specifications Center bowl capacity . . . . . . . . . . . . . . 5.8 qt (5.5 L) Each wheel end . . . . . . . . . . . . . . . . . 0.75 qt (0.7 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra Check the oil level of the front drive axle after every 250 hours of operation. Check the center bowl and each wheel end.

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface, and place blocks behind and in front of the rear wheels.

Figure 54

BI01H127

2. Place the Direction Control and the Gear Shift Control Levers in NEUTRAL.

8. Remove the plug for the center bowl. The oil must be even with the plug hole. Add oil if necessary.

3. Use the loader and raise the front wheels about 1 inch (25mm) above the ground.

9. Replace the plug.

BREATHER Clean the breather for the front axle every 250 hours of operation. Clean the breather more frequently if you operate in severe conditions.

BD05J006

Figure 53

4. Rotate the wheel so that the oil plug is in the position shown.

Figure 55

BP410085

5. Remove the plug. The oil level must be even with the plug hole. In necessary add oil.

6. Replace the plug and repeat the procedure for the other side.

7. Lower the wheels to the ground.

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BREATHER

1. Remove the dirt and debris from around the breather with solvent.

2. Wear face protection compressed air.

Issued 04-07

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and

blow

dry

with

87612257NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE

BREATHER

REAR AXLE OIL LEVEL

Clean the rear axle breather every 250 hours of operation. Clean the breather more frequently if operating in severe conditions.

Service Specifications Center bowl capacity . . . . . . . . . . . . . . 15 qt (14.2 L) Each wheel end . . . . . . . . . . . . . . . . . . . 1.6 qt (1.5 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra Check the oil level of the rear axle every 250 hours of operation. Check the oil level in the center bowl and each wheel.

Figure 58

BP07DXXX

BREATHER

1. Remove the dirt and debris from around the breather with solvent.

2. Wear face protection compressed air.

Figure 56

BD05J008

OIL LEVEL AND DRAIN PLUG

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

Make certain the oil drain plug and oil level line are in the position shown.

2. Remove the plug. The oil level must be even with the plug hole. Add oil if necessary.

and

blow

dry

with

OIL TEMPERATURE LAMP The rear axle oil temperature warning lamp will illuminate when the temperature reaches 305° F (152° C). If the lamp illuminates, select a lower transmission gear. If the lamp continues to illuminate stop the machine and allow the axle oil to cool.

Continuous hard braking can cause the axle oil temperature to rise, illuminating the lamp.

3. Replace the plug.

FUEL TANK

4. Repeat the procedure for the other side.

Check the fuel tank for water and sediment every 250 hours of operation. Fill the fuel tank at the end of e a c h d a y, a s a f u l l t a n k w i l l p r e ve n t w a t e r condensation.

Figure 57

BI01H124

5. Remove the oil level plug for the center bowl.

The oil level must be even with the plug hole.

Add oil if necessary.

Figure 59

BD06A104

6. Replace the oil level plug.

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FUEL TANK DRAIN PLUG Bur

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE

DRIVESHAFT SLIP SPLINES

TRANSMISSION FLUID CHECK

Lubricate the driveshaft slip splines every 250 hours of operation or each week. If you operate in severe conditions, lubricate more often. Clean the fittings before lubricating.

Specification . . . . . . . . . . . . . . . Case Molydisulfide

Check the fluid level of the transmission every 250 hours of operation.

Service Specifications 2 Wheel Drive . . . . . . . . . . . . . . . . . . 19.5 qt (18.5 L) 4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . 22 qt (21 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran Ultra Keep all unauthorized personnel clear of the area.

Park the machine on firm, level ground with the engine running.

WARNING: Contact with rotating fan and belts will cause injury. Keep clear! Failure to comply could cause serious injury or death

2

1 Figure 61

1

Figure 60

BD05H028

TRANSMISSION FLUID DIPSTICK

The fluid level must be between the ADD and FULL marks on the transmission dipstick. If the fluid level is at the ADD mark, add fluid as required until the fluid level is at the FULL mark on the dipstick.

Figure 62

BD05H031

4WD FRONT SLIP SPINE GREASE FITTING

Slip Spline . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 fitting

2

SEAT RAILS Every 250 hours of operation apply a small amount of grease to the last 3 inches (76 mm) of each seat rail. Move the seat forward and rearward completely to disburse the grease as evenly as possible.

Specification . . . . . . . . . . . . . . . Case Molydisulfide

Figure 63

BD05H031

REAR SLIP SPINE GREASE FITTING

Slip Spline . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 fitting

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE REPLACE THE FUEL FILTERS

REMOVING AIR FROM THE FUEL SYSTEM

Replace the in-line and primary fuel filters every 500 hours or operation or if you have a loss of engine power.

Air must be removed from the fuel system if one or more of the following conditions occur:

IN-LINE FILTER REPLACEMENT

• The engine stops because of no fuel.

• The fuel filters are replaced.

• The fuel system has been serviced.

• The machine has been in storage three months or more.

Figure 1

BD05H029

IN-LINE FUEL FILTER

1. Clean the area around the in-line filter before proceeding.

3. Secure the lower hose to prevent it from falling down and draining fuel from the tank.

4. Remove the old filter.

Figure 2

BD05H027

2. Loosen the hose clamps for the in-line fuel filter.

AIR REMOVAL SCREW

1. Fill the fuel tank.

2. Loosen the air removal screw on the top of the fuel filter head two or three turns.

5. Install the new filter with the arrow on the filter pointing in the correct direction.

6. Tighten the hose clamps.

PRIMARY FUEL FILTER REPLACEMENT 1. Clean the area around the filter.

2. Use a filter wrench and counterclockwise to remove.

turn

the

filter

3. Remove the rubber seal from the filter head.

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

Figure 3

BD05H029

HAND PRIMER PUMP

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

6. Install the rubber seal on the filter head.

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

8. Turn the main filter clockwise onto the filter body until the filter gasket makes contact with the filter body. Continue to tighten the filter with your hand for an additional 1/2 to 3/4 turn.

3. Actuate the hand primer pump.

4. When fuel with no air flows from the air removal screw, tighten the air removal screw.

NOTE: If there is no fuel when you operate the hand primer pump, rotate the engine 1/3 turn and operate the pump again.

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

9. Fill the fuel tank and remove air from the system.

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5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE HYDRAULIC RESERVOIR FLUID AND HYDRAULIC FILTER CHANGE Service Specifications Total system capacity . . . . . . . . . . . . . 81 qt. (77.0 L) Reservoir with filter change . . . . . . . . . . 58 qt. (55 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra Change the hydraulic fluid and filter every 1000 hours of operation or more often if conditions so warrant.

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

Make certain all pressure is released from the hydraulic system. The system will drain best if the hydraulic system is just under operating temperature.

Figure 5

BD07DXXX

7. Remove the hydraulic filter and clean the area around the filter head.

2. Lower the loader bucket to the ground. Lower the rear attachment, if equipped, to the ground.

8. Lubricate the gasket on the new filter with clean oil.

3. Stop the engine and put a Do Not Operate tag on the key switch.

9. Install the new filter and turn clockwise until the gasket makes contact with the filter head assembly. Continue to tighten for 1/3 turn.

4. Place a suitable container under the drain plug.

10. Install the reservoir drain plug.

11. Put new fluid into the reservoir.

12. Start the engine and operate the loader controls for three to four minutes. Stop the engine and check for leaks.

1

13. Check the fluid level in the reservoir.

PUMP CHARGE PROCEDURE If the hydraulic fluid supply to the pump has been interrupted due to hydraulic fluid change, pump replacement, or a broken line, you MUST fill the hydraulic pump with oil.

2

Figure 4

BD05H071

5. Remove the fill cap (1).

6. Remove the drain plug (2) from the hydraulic reservoir tank and drain into the container.

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.

1. Make sure the oil level in the hydraulic reservoir is correct.

2. Remove the cap from the hydraulic reservoir.

3. Use a regulated air supply to pressurize the hydraulic reservoir. 5 to 10 psi (34.5 to 69.0 kPa) is all that is required to move the oil.

IMPORTANT: Pressure above 10 psi (69.0 kPa) can damage the hydraulic reservoir.

4. Have another person start and run the engine at low idle while the air pressure is being applied to the hydraulic reservoir.

ENGINE VALVE CLEARANCE CHECK Have your Dealer Technician check the valves for proper adjustment when the machine hour meter registers 1000 hours or annually.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE TRANSMISSION FLUID - FILTER - BREATHER Service Specifications 2 Wheel Drive . . . . . . . . . . . . . . . . . . 19.5 qt (18.5 L) 4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . 22 qt (21 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hy-Tran Ultra Change the transmission fluid, replace the transmission filter, and clean the breather every 1000 hours of operation.

Specification . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra 1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground, with the parking brake applied and a Do Not Operate tag on the key switch.

Figure 8

BI01H129

TRANSMISSION FILTER

4. Remove the old filter and clean the area around the mounting area.

5. Lubricate the gasket of the new filter with clean oil.

6. Install the new filter and turn clockwise until the gasket contacts the head of the filter assembly.

Continue to tighten the filter for and additional 1/3 turn.

7. Install the reservoir tank drain plug and fill with new fluid.

Figure 6

BD05H028

TRANSMISSION FLUID DIPSTICK

2. Have a suitable container ready to drain the fluid.

Figure 9

BI01H130

TRANSMISSION BREATHER

8. Clean the area around the transmission breather.

9. Remove and clean the breather with solvent.

Wear full face protection and blow dry with compressed air.

Figure 7

BI01H160

10. Install the breather.

TRANSMISSION DRAIN PLUG

3. Remove the dipstick and drain plug. Allow the fluid to drain.

11. Start the engine and check for leaks around the filter.

12. Operate the machine in first and second gear for a few minutes.

13. Park the machine on a firm and level surface and apply the parking brake.

14. Check the fluid and add more fluid if necessary.

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5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE REAR AXLE OIL CHANGE Service Specifications Center bowl capacity . . . . . . . . . . . . . . 15 qt (14.2 L) Each wheel end . . . . . . . . . . . . . . . . . . 1.6 qt (1.5 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra Change the rear axle oil when the hour meter registers 1000 and every 1000 hours thereafter. The oil will drain more completely when near operating temperature.

Figure 12

BI01H124

CENTER BOWL PLUG

4. Add the specified amount of new oil to the center bowl.

BD05H065

Figure 10

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface, with the drain plug as shown, and place a Do Not Operate on the key switch.

Figure 13

BD05H064

5. Rotate the plug into the fill/check position shown and add new oil until it just begins to run out of the orifice.

BI01H121

Figure 11

2. Place suitable containers under the drain plug and center bowl plugs and drain the old oil.

3. After the oil is drained, install the plugs.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE 4-WHEEL DRIVE FRONT AXLE OIL LEVEL Service Specifications Center bowl capacity . . . . . . . . . . . . . . . 5.8 qt (5.5 L) Each wheel end . . . . . . . . . . . . . . . . . .0.75 qt (0.7 L) Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran® Ultra Change the oil in the front drive axle after every 1000 hours of operation.

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface, and place blocks behind and in front of the rear wheels.

2. Place the Direction Control and the Gear Shift Control Levers in NEUTRAL. 3. Use the loader and raise the front wheels about 1 inch (25mm) above the ground.

BI01H127

Figure 15

7. Place a suitable container under the center bowl plug. Remove the plug for the center bowl and allow oil to drain.

8. Replace the plugs and fill both the axle ends and center both with the specified amount of oil.

Figure 14

BD05J006

4. Rotate the wheel so that the oil level plug is in the correct position to drain the oil.

5. Place a suitable container under the plug, and remove the plug.

6. Replace the planetary plug and repeat the procedure for the other side.

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5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE CHANGE AIR CLEANER ELEMENTS Both air cleaner elements should be changed when the hour meter registers 1000 hours or if the air restriction indicator is illuminated with the engine running.

Raise the hood for access to the air filter.

Figure 19

BI01H070

SECONDARY ELEMENT

3. Remove the secondary element.

4. Clean the inside of the filter housing before replacing the elements.

Figure 16

BI01H065

PRIMARY AIR CLEANER COVER

IMPORTANT: The inner end of the canister must be free of dirt and debris to insure that the element will seal properly. A faulty or incorrect seal between the filter and canister may cause major engine damage.

5. Reinstall the new elements in reverse order.

6. Reinstall the cover, and tighten the bolt to secure in place.

Figure 17

BI01H066

1. Turn the I-bolt out of the mounting to remove the air cleaner cover.

Figure 18

BI01H069

PRIMARY ELEMENT

2. Remove the primary element.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE

CLEANING FILTERS

CAB AIR FILTER

When cleaning filters, check the rubber seal on the end. If the rubber seal is hard and does not move back to its original shape when pressed, discard the element and replace with a new filter.

Check the cab air filters ever y 1000 hours of o p e ra t i o n o r m o re o f te n i n s eve r e o p e ra t i n g conditions.

Wear face protection. Remove the loose dirt with compressed air 30 psi (2 bar) maximum. Hold the nozzle at least one inch (25 mm) from the element.

The filter can also be cleaned with Case detergent and water. Follow directions on the container for use and soak the element for 15 to 20 minutes. Shake the element to loosen as much dirt as possible while soaking.

Flush all detergent from the element with a hose.

Allow to air dry before reinstallation. If using a dryer, do not exceed 160° F (71° C) and make certain air is circulating in the dryer.

Figure 20

BD07C141A

The filters are located behind the screen in the top rear portion of the cab.

Figure 21

BP9410094

1. To clean filters, remove rear screen. Remove the recessed hex cap screw. Filters are held in place on the outer end with a clip. Slide the left hand filter to the center and remove. Remove the right hand filter out of the left side as well.

2. Wipe the filter area clean. Install a new or cleaned filter, making certain the arrows on the filter point toward the cab.

3. Install the cover, slide each locking plate inward, and tighten the cap screw. Install the rear screen and tighten the mounting bolt.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE DRAIN AND FLUSH THE RADIATOR Service Specifications Capacity with heater . . . . . . . . . . . . . 17.4 qt (16.5 L) Capacity without heater . . . . . . . . . . 16.7 qt. (15.8 L) Specification . . . 50% water and 50% ethylene glycol Drain and flush the cooling system every 2000 hours or every year. Clean the system and replace the coolant if the coolant has becomes dirty or has the color of rust.

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

This procedure is to be performed only when the engine components and coolant are cool to the touch.

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

Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to maintenance instructions. Failure to comply could cause injury or death.

5. Add a cleaning solution to the cooling system and fill the system with clean water. Follow the directions included with the cleaning solution.

Replace the radiator cap.

6. After draining the cleaning solution, flush with clean water.

7. Check hoses, elbows, and water pump for leaks.

Make cer tain the outside of the engine and radiator is clean.

8. Refill radiator with a mixture of 50% ethylene glycol and 50% water. Completely fill the radiator and coolant reservoir slowly. Replace radiator cap.

9. Start the engine and increase the temperature.

Stop the engine and allow to cool. Check coolant level at the coolant reservoir only. DO NOT remove the radiator cap.

10. Fill the coolant reservoir to the full mark as required.

11. Dispose of old coolant in an environmentally correct manner. Ethylene glycol is toxic, keep away from children and animals. Do not leave in open containers.

SA023

Figure 22

BD06A105

RADIATOR DRAIN VALVE

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

Have a suitable container ready.

2. Remove the radiator cap.

3. Open the radiator drain valve and drain into the container.

4. After all coolant is removed, close the radiator drain valve.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS MAINTENANCE AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Roll-over Protective Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Operator Protective Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Tires and Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Wheel Nut and Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Spark Arresting Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Loader Return-to-dig Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Air Precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Foot Brake Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Ether Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Windshield Washer Fluid (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 CAb Air Conditioning (If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Fan Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Machine Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE AND ADJUSTMENTS ROLL-OVER PROTECTIVE STRUCTURE

OPERATOR PROTECTIVE STRUCTURE

Your machine has a Roll-Over Protective Structure (ROPS). A ROPS label shows the certification of the ROPS, gross weight, approval, regulation, and model numbers of the machine.

Check and inspect the ROPS structure and the seat restraint system every 500 hours of operation.

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 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.

Figure 1

BK97K220

ROPS CANOPY LABEL

The Protective Structure and interconnecting components are a cer tified system. Any damage, fire, corrosion or modification will weaken the str ucture 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 Str ucture inspection and replacement.

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.

Figure 2

BD06A078

ROPS CAB LABEL

MAINTENANCE AND INSPECTION OF ROPS 1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

2. Check the operator’s seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. Replace parts that have wear or damage.

3. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, contact your dealer.

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T h e m o u n t i n g o r s u s p e n s i o n fo r t h e Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s p r o t e c t ive s y s t e m M U S T b e c a r e f u l l y inspected for damage.

All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO S T R A I G H T E N O R R E PA I R T H E P R OT E C T I V E STRUCTURE. M O D I F I C AT I O N I N A N Y WAY C A N REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SEAT BELT The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed. Make sure all hardware that secures the seat to the cab are torqued. Make sure all seat belt hardware is secure and torqued.

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine. Failure to comply could result in injury or death.

SA080

WARNING: Adding additional weight (attachments, etc). to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label. Failure to comply could result in injury or death.

SA028

WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the parts catalog for this machine. Failure to comply could result in injury or death.

SA029

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MOUNTING BOLTS FOR ROPS CANOPY, ROPS CAB AND LOWER FRAME

2

2

2

1

Figure 3

BS01H200/ BS07181A

TORQUE SPECIFICATIONS Mounting bolts are the same for the ROPS canopy and the ROPS cab.

(1) ....................................................................................................................93 to 112 pound-feet (125 to 150 Nm) (2) ..................................................................................................................220 to 264 pound-feet (298 to 358 Nm)

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS MOUNTING BOLTS FOR ROPS CANOPY TO LOWER FRAME

1

Figure 4

B9412190S

Torque Value: (1) 251 to 329 NM (185 to 235 LB FT)

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELT MOUNTING BOLTS

3

4

2

1

Figure 5

615L93

Torque Values: 1. 90 to 107 NM (66 to 79 LB FT) 2. 73 to 87 NM (54 to 64 LB FT) 3. 51 mm (2 inch) Seat Belt 4. 76 mm (3 inch) Seat Belt

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TIRES AND RIMS Check the air pressure and condition of the tires every 100 hours of operation.

WARNING: Exploding tires and / or rim parts can cause death or serious injury. 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 to the tires. Failure to comply could result in injury or death.

SD020

.

FRONT TIRES Ply Rating

Size

11L x 16 (2WD)

10

F3

358, 3.6 (52)

12 x 16.5 (4WD)

8

Lug

345, 3.5 (50) Figure 8

REAR TIRES Ply Rating

Size

IMPORTANT: Tire pressure gauges should be checked at regular intervals for calibration and accuracy.

Air Pressure kPa, bar (psi)

Figure 6

ADDING AIR TO THE TIRES

Type Tread

Type Tread

Air Pressure kPa, bar (psi)

17.5L x 24

10

R4

220, 2.2 (32)

19.5L x 24

10

R4

193, 1.9 (28)

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface.

Figure 9

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

Failure to comply could result in injury or death.

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

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

84-113

BD06B277

Figure 7

4. Wear face protection and stand BEHIND the tread of the tire and make sure ALL persons are away from the side of the tire before you start to add air.

5. Inflate the tire to the recommended air pressure.

D O N OT i n f l a t e t h e t i r e m o r e t h a n t h e recommended maximum pressure given.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TIRE OR RIM SERVICE WARNING: DO NOT weld to wheel or rim until the tire is completely removed. Inflated tires can generate a gas mixture with the air that can be ignited by high temperatures from welding procedures performed on the wheel or rim. This condition can exist whether tires are inflated or deflated. Removing the air or loosening the tire on the rim (breaking the bead) will NOT eliminate the hazard. The tire MUST be completely removed from the wheel or rim prior to welding the wheel or rim.

Always have a qualified tire technician service the tires and rims on this machine. It is recommended that you have the technician inflate the tires. To prevent accidents, always use a restraining device (tire inflation cage), correct equipment, and correct procedure. Explosive separation of the tire can cause death or serious injury.

DIRECTION OF INSTALLATION When the tire is installed on a wheel, make sure to have the tread of the tire in the direction shown.

SC134

Figure 10

B770164R

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

BD01D001A

Figure 11

The front wheels can be tur ned around (tread direction reversed) if more traction is required in reverse.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WHEEL NUT AND BOLT TORQUES When the machine is new or when a front wheel is removed for service, check the wheel nut or bolt torques every 10 hours of operation until the wheel nuts or bolts remain tight.

REAR WHEEL MOUNTING NUTS

FRONT WHEEL MOUNTING BOLTS 2 WHEEL DRIVE NOTE: This procedure is for the front wheels only.

Do not follow this procedure on the rear wheels.

IMPORTANT: The rear wheel mounting nuts on this machine are metric. Use only the mounting nuts shown in the parts catalog for this machine.

TORQUE VALUES

Torque Values

Two wheel drive machines 156 to 203 Nm (115 to 150 pound-feet)

Rear wheel mounting nut 305 Nm (225 pound-feet)

FRONT WHEEL MOUNTING NUTS 4 WHEEL DRIVE

R E A R W H E E L M O U N T I N G N U T TO R Q U E PROCEDURE

Front Wheel Mounting Nuts 251 Nm (185 pound-feet)

1

FRONT WHEEL MOUNTING NUT TORQUE PROCEDURE

1

5

8

9

4

3

10

8

5 4

7 2

3 6 7 BD00F102

Figure 13

BP98J086

REAR WHEEL MOUNTING NUT TORQUE SEQUENCE

2 Figure 12

FRONT WHEEL MOUNTING NUT TORQUE SEQUENCE

1. Install all eight (8) mounting nuts. Tighten all mounting nuts, in the sequence shown, until the wheel is snug against the axle hub.

2. Tighten the mounting nuts, in the sequence shown, to a torque of 122 Nm (90 pound-feet).

3. Then turn each nut in the tightening direction, in the sequence shown, an additional 90 degrees to set the required pre-load on the front wheel mounting nuts.

6-10

6

1. Install all ten (10) wheel mounting nuts. Tighten all mounting nuts, in the sequence shown, until the wheel is snug against the axle hub.

2. Tighten the mounting nuts, in the sequence shown, to a torque of 136 Nm (100 pound-feet).

3. Then tighten the mounting nuts again, in the sequence shown, to a torque of 271 Nm (200 pound-feet).

4. Then turn each mounting nut in the tightening direction, in the sequence shown, an additional 30 degrees to set the required pre-load on the rear wheel mounting nuts.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS SPARK ARRESTING MUFFLER WARNING: Explosion Hazard: All maintenance personnel should wear full face protection when performing this procedure. Failure to comply could result in injury or death.

Clean the spark arrester muffler every 100 hours of operation. This is a two-person procedure. Wear full face coverage when performing this procedure.

WARNING: Explosion Hazard: The spark arrester muffler will not prevent explosions if used in closed areas where there is dust or vapor that can cause an explosion. Failure to comply could result in injury or death.

M724

Figure 14

BD01D050

INJECTION PUMP SOLENOID WIRE CONNECTOR

5. Disconnect the wire to the injection pump solenoid.

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

2. Stop the engine and make sure the loader bucket and attachments are on the ground in safe positions.

3. Apply the parking brake.

4. Open the hood.

Figure 15

B861829J

SPARK ARRESTER PLUG

6. Remove the plug from the side of the muffler.

IMPORTANT: Wear full coverage face protection for the next step.

7. Hold a block of wood over the muffler outlet while another person turns the key switch to START for approximately 30 seconds.

8. Turn the key switch to OFF. 9. Connect the wire to the injection pump solenoid and install the muffler plug.

10. Close the engine side panels.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS LOADER RETURN-TO-DIG ADJUSTMENT

AIR PRECLEANER

1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface and apply the parking brake.

2. Lower the rear attachment, if equipped, to the ground.

Service the pre-cleaner periodically. If the warning lamp for the air filter restriction illuminates, stop the machine and clean immediately. If the lamp remains i l l u m i n a t e d , c h e ck c o n d i t i o n o f p r i m a r y a n d secondar y filter. See Chapter 5 - Filters and Lubricants.

3. Lower the loader bucket to the ground and make sure the bottom of the bucket is at the desired angle.

4. Stop the engine.

Figure 17

BD01D060

1. Check the precleaner bowl and remove the dust as required.

2. Loosen the nut and remove the cap.

Figure 16

BD06A106

RETURN TO DIG ADJUSTING BOLTS

3. Remove the bowl and clean with a damp cloth.

Install the bowl and cap.

5. Loosen the adjusting bolts for the return-to-dig switch and move the switch in the slot so that the roller on the switch is resting on the edge of the cam on the loader arm.

6. Tighten the bolts.

7. Start the engine, raise the loader bucket to full height, and dump the bucket.

8. Put the loader control lever in the RETURN-TO-DIG position. The loader bucket will lower to the ground.

9. Check the position of the loader bucket. If the bucket is not in the correct position, see steps 10 and 11.

10. Move the return-to-dig switch rearward if the bucket did not roll back far enough.

11. Move the return-to-dig switch forward if the bucket rolled back too far.

NOTE: When moving the switch bracket forward or backward for adjustment, be sure the bracket is pushed in toward the machine as the bolts are tightened. This will assure full contact of the switch with the actuating cam.

12. Repeat steps 6 through 10 until the bucket returns to the correct position.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FOOT BRAKE CHECK

PARKING BRAKE

Pa r k i n g a n d f o o t b r a k e s s h o u l d b e t e s t e d periodically. If you doubt your ability to perform these procedures correctly, call your dealer.

Check the operation of the parking brake after the first 100 hours of operation.

Keep all non-authorized personnel clear of the area when performing the parking brake test.

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

12

WARNING: Brake tests should only be performed by a skilled, qualified operator or technician. This test requires running the engine at above idle RPM’s. Failure to comply could result in machine damage, injury, or death.

Check the operation of the foot brakes on a hard level surface after the first 100 hours of operation.

Make sure the area is clear of other persons. Lock both pedals together with the brake pedal lock.

Shift the transmission to second gear. Drive the machine forward at full throttle. When the machine is moving at full speed, stop the machine. The machine must stop smoothly in a straight line and the brake pedal effort must feel firm.

IMPORTANT: If the machine does not stop in a straight line or if the brake pedal effort feels soft, see the repair manual or contact your dealer.

Figure 18

BD01D110

PARKING BRAKE ENGAGED

2. Pull the parking brake control lever back to apply the parking brake.

3. Shift the transmission direction control to forward and increase the engine speed to 1500 rpm. The machine should not move.

4. Shift the transmission direction control to reverse and increase the engine speed to 1500 rpm. The machine should not move.

Figure 19

BD01D110

PARKING BRAKE ADJUSTMENT

If the parking brake does not hold, release the parking brake and turn the end of the lever clockwise two or three turns. If this adjustment does not make the parking brake hold, consult your dealer.

NOTE: A warning alarm will sound when you shift the direction control lever into FORWARD or REVERSE while the parking brake is engaged. You can damage the parking brake if you move the machine while the brake is applied.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 2. Turn the ether container counterclockwise to remove the container.

ETHER STARTING AID REPLACING THE CONTAINER Before you discard an empty ether container, use rubber gloves and push the valve in the end of the container to remove any pressure. Do not puncture o r o t h e r w i s e d a m a g e t h e c o n t a i n e r. D o n o t incinerate the container. Dispose of properly in an environmentally correct manner.

If welding, grinding, or using a cutting torch on the machine, always remove the ether container from the machine. Use compressed air to remove any ether fumes from the area.

WARNING: Starting fluid (ether) can cause injury or death. An explosion can result if sparks, flame, or extreme heat contact the ether in the starting fluid container. Do not breathe starting fluid vapors. Wear face protection when you remove or install a starting fluid container or when you use an aerosol spray starting fluid. Use starting fluid according to instructions in this manual.

Failure to comply could result in injury or death.

3. Install the new ether container by inverting on the valve and turning clockwise in the bracket.

4. Tighten the clamp to secure the ether container in place.

5. Discard old container properly.

Remove the ether container when temperatures are above 35° F to 40° F (0 to 5° C). Install the cap on the solenoid valve.

WARNING: Do Not store ether containers in the operator’s compartment. Wear rubber gloves when handling ether containers.

Failure to comply could result in injury or death.

WINDSHIELD WASHER FLUID (IF EQUIPPED) When required, fill the windshield washer reservoir with windshield washer fluid.

SA039

Figure 21

BK97K213

The windshield washer reservoir is located under the engine hood beside the air cleaner.

Figure 20

BD01D110

ETHER STARTING AID

1. Clean the ether starting aid container and base.

To remove the container, loosen the clamp on the ether bracket securing the ether container in place.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CAB AIR CONDITIONING (IF EQUIPPED) Lubrication of the Air Conditioning Compressor Seals Operate the air conditioning once every 250 hours to lub r icat e th e co m pr ess or s ea ls. Tu r n th e a ir 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.

AIR CONDITIONING COMPRESSOR BELT TENSION Check the tension of a new drive belt after the first 10 hours of operation. Then, check the tension of the drive belt every 250 hours of operation.

Check the belt with a belt tension gauge, and adjust the belt to 20 to 25 kg (45 to 55 pounds).

BELT ADJUSTMENT 1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

Lower the loader bucket to the ground and stop the engine.

2. Open the hood.

3. Loosen the pivot bolt of the air conditioner compressor.

4. Loosen the adjusting bolts.

1

2 Figure 22

BD01D052

1. ADJUSTING BOLTS 2. PIVOT BOLT

5. Move the compressor out to tighten the belt.

Tighten the adjusting bolts when the tension is correct.

6. Tighten the pivot bolt.

7. Close the hood.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FAN DRIVE BELT REPLACEMENT 1. Keep all unauthorized personnel clear of the area. Park the machine on a firm, level surface and apply the parking brake.

15. Use the breaker bar to move the tension pulley bracket just far enough to install the drive belt on the alternator pulley.

16. Remove the breaker bar and close the hood.

2. Lower the rear attachment, if equipped, to the ground.

17. Lower the loader bucket to the ground.

3. Raise the loader lift arms to full height and install the loader lift arm support strut on the cylinder rod.

PLASTIC AND RESIN PARTS

4. Stop the engine, remove the key, and open the hood.

5. Install a 1/2 inch breaker bar in the tension pulley bracket.

Avoid using gasoline, paint thinner, etc., when cleaning plastic parts, console, instrument cluster, etc. Use only water, mild soap, and a soft cloth when you clean these parts.

Using gasoline, thinners, etc., can cause discoloration, cracking, or deformation of the part being cleaned.

MACHINE CLEANING It is recommended that the complete machine be kept clean. Machine operation in water, mud, dust, landfill, land clearing or forestry will require complete machine clean up. Cleaning includes periodic removal of inspection covers and guards to gain access for cleaning and removal of dirt or debris.

Clean all dirt and foreign material from the front engine guard. Dirt will cause rust on the engine oil pan and the loss of engine oil.

BP9410096

Figure 23

6. Push the breaker bar forward just enough to release the tension on the drive belt. Remove the drive belt from the water pump pulley first and then from the other pulleys.

7. If equipped with air conditioning, see Adjusting the Air Compressor Belt. Move the air conditioning compressor belt out of the way.

8. Remove the four cap screws, flat washers, and lock washers that fasten the pump drive coupling to the crankshaft pulley.

After cleaning is complete, install ALL covers and guards.

DO NOT operate machine with covers or guards removed.

WARNING: Replace all covers or guards after servicing or cleaning the machine.

NEVER operate the machine with covers or guards removed. Failure to comply could result in injury or death.

9. Move the pump drive coupling toward the hydraulic pump.

10. Remove the old drive belt.

11. Install the new drive belt on the water pump pulley and crankshaft pulley.

12. If equipped with air conditioning, see Adjusting the Air Compressor Belt. Install the air conditioning compressor belt.

13. Align the coupling with the crankshaft pulley.

14. Install the cap screws, flat washers, and lock w a s h e r s t h a t fa s t e n t h e c o u p l i n g t o t h e crankshaft pulley. Tighten the cap screws from 95 to 114 Nm (70 to 85 pound-feet).

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FIRE EXTINGUISHER MOUNTING TYPE OF FIRE EXTINGUISHER A fire extinguisher is recommended on board every machine. Your Dealer will assist you in the mounting and installation of the proper fire extinguisher.

The fire extinguisher will mount on the right rear of the cab, behind the operator.

FIRE EXTINGUISHER INSPECTION AND CARE EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

E V E RY 6 M O N T H S - H ave t h e d r y c h e m i c a l removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS or FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MACHINE STORAGE LONG TERM STORAGE PREPARATION

REMOVAL FROM STORAGE

Geographic, environmental and actual storage conditions make it difficult to follow a set storage procedure. The following procedure is for a storage period of 6 months or longer. This procedure is a good starting point but may not be all inclusive. If you have questions about storing your machine, contact your Dealer.

Do not start the engine until steps 1 through 13 have been done.

1. Wash the machine.

2. Replace any worn or damaged parts and components.

3. Park the machine inside a building. If a building is not available, park the machine in a dry area on planks, and cover the machine with a waterproof cover.

4. Lubricate the machine grease fittings.

5. Paint areas that may have been scuffed or deteriorated due to operating environments.

6. Move all hydraulic controls through their com ple te ran ge s s evera l tim es to r elieve pressure in the circuits.

1. If the machine was blocked, lower it to the ground.

2. Change the fuel filters.

3. Fill the engine cooling system.

4. Check the condition of the drive belts. Replace if necessary.

5. Check the engine oil level.

6. Check the hydraulic oil level.

7. Check the transmission oil level.

8. Replace the engine air filters. Replace cab air filters, if equipped.

9. Check the oil level of the rear axle. Check the front of the 4WD axle, if equipped.

10. Lubricate the machine grease fittings.

11. Use a petroleum based solvent, and remove the rust and corrosion preventative.

7. Drain the fuel tank.

12. Install the battery(ies).

8. Put approximately 2 gal. (8 L) of diesel flushing oil in the fuel tank. Run the engine until exhaust smoke is blue/white.

13. Lubricate the turbocharger by priming the lines with oil before starting.

9. Drain the flushing oil from the fuel tank.

NOTE: Follow starting instructions for starting machines equipped with turbocharger. See Chapter 4 - Operating Instructions.

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

14. Start the engine.

11. Change the engine oil, and replace the oil filter.

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

13. Place a Do Not Operate tag on the steering wheel.

14. Cover the exposed cylinder rods, equipment va l ve s p o o l s , w i t h a r u s t a n d c o r r o s i o n preventive.

15. Clean and charge the battery or batteries. If necessary, move the battery(ies) to a wooden pallet in a temperature controlled environment.

16. Check the battery(ies) periodically for the correct electrolyte level. Wear face protection and test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the battery (ies).

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

IMPORTANT: Extreme precautions must be taken when blocking a machine up for long periods. Block the machine with the tires just off the surface. No more than 1 in (25.4 mm) above the surface.

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CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

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CHAPTER 7 - ELECTRICAL

NOTES

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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 booster battery cables incorrectly or short- circuiting battery terminals can cause an accident. Connect auxiliary starting cables as per the following instructions. Failure to comply can cause injury or death.

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

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

4. Do not weld, grind, or smoke near a battery.

Failure to comply can cause injury or death.

SB034

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-). Failure to comply can cause machine damage, injury or death.

SAFETY_ID_1C02

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the off position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last. Failure to comply can cause machine damage, injury or death.

SAFETY_ID_1C02

WARNING: Whenever carrying out a welding operation on the machine (authorized by the manufacturer and in accordance with manufacturer’s instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator. When reconnecting, check the markings on the wires. Failure to comply with the following warnings could result in machine damage, serious injury, or death.

SAFETY_ID_1C02

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CHAPTER 7 - 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 250 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.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

In extreme heat conditions check battery fluid more frequently.

IMPORTANT: If the temperature is 0°C (32°F) or below and you have added water to the batteries, perform the following: Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver. Follow the instructions on the container. This cleaner does not need water.

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

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CHAPTER 7 - ELECTRICAL BATTERY SERVICE

TWO BATTERY SYSTEM

Check the fluid level and condition of the batteries every 250 hours of operation. If the fluid level is low, add clean or distilled water to each cell until the level is 1/8 inch below the split ring at the bottom of each cell opening.

3

1

ONE BATTERY SYSTEM

1

2

BD00F076

Figure 2

1. POSITIVE TERMINAL 2. NEGATIVE TERMINAL 3. NEGATIVE TERMINAL AND GROUND

2

NOTE: The electrical system in this machine is 12 volts negative ground.

Figure 1

BD05H078

1. NEGATIVE BATTERY CABLE 2. POSITIVE BATTERY CABLE

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Check the battery or batteries for dirt, corrosion or damage. Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with a Battery Saver and Cleaner. See your Dealer for battery products.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

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CHAPTER 7 - ELECTRICAL BOOSTER BATTERY CONNECTION TO MACHINE 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 could result in injury or death.

4. Connect the other end of the negative cable to the 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 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.

SA033

WARNING: Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. Failure to comply could result in injury or death.

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.

SA031

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

2

1 BD00F078

Figure 3

1. POSITIVE TERMINAL 2. FRAME

Make sure that the voltage of the booster batteries is the same as that of the machine system.

1. Turn off the ignition and all accessories on the machine(s). Remove the door cover from the hood switch on the r ight hand side of the machine. Remove the right battery terminal cover.

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 (+) ter minal of the discharged battery.

3. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

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CHAPTER 7 - ELECTRICAL ACCESSORY OUTLETS (IF EQUIPPED)

FUSES

There are two 12 volt accessory outlets on the rear back side of the right console.

1

BD05H080

Figure 5

1. FUSE AND RELAY COVER Figure 4

BD04H089

1. ACCESSORY OUTLETS

BD05H081

Figure 6

Remove the two screws to expose the fuses and relays.

BD05H082

Figure 7

The fuse decal is located on the inside of the cover.

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CHAPTER 7 - ELECTRICAL LAMP REPLACEMENT FLASHER, TURN SIGNAL, AND STOP AND TAIL LAMPS

DOME LAMP

Figure 9

BP9410067

Remove lens cover to replace the dome lamp cover.

BP9410108

Remove the screws holding the lens in place being careful not to damage the lens.

BP9410109

Figure 8

Replace the bulb. Replace lens cover.

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CHAPTER 7 - ELECTRICAL DRIVING AND FLOOD LAMPS

2

Front of Machine

1

1 2

Top of ROPS Cab or ROPS Canopy

Figure 10

B9412114T

1. DRIVING LAMP 2. FLOOD LAMP

REPLACING LAMP

BD05H082

Figure 11

BD05H082

Remove the two screws holding the lamp assembly in place.

Figure 12

Disconnect lamp and replace.

VERTICAL ADJUSTMENT OF DRIVING AND WORK LAMPS The cross bolt in the lamp mounting bracket must be loosened before the lamp is moved. Moving the lamp without loosening the cross bolt can cause damage to the plastic housing.

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7-9

CHAPTER 7 - ELECTRICAL INSTRUMENT CLUSTER Bulbs in the instrument cluster may be replaced as necessary.

Part number for Warning and Instrument Lamps....................................................................................... 388053A2.

1

1 1

1 3

3

2

2 Figure 13

BS00F083

1. WARNING LAMPS 2. BACKLIGHT LAMPS 3. MOUNTING SCREWS

5

1. Disconnect the negative (-) battery cable or cables prior to replacing Instrument Cluster Lamps.

2. Remove the two mounting screws that fasten the instrument cluster in the console.

3. Disconnect the electrical connector from the rear of the instrument cluster and remove the cluster.

Figure 15

BI01H167

5. Remove the rear cover.

NOTE: Make sure the O-ring (5) is in position on the rear cover when it is re-installed.

BI01H168

Figure 14

4. Remove the two screws that fasten the rear cover to the frame.

Figure 16

BI01H166

6. Turn the bulb holder counterclockwise to remove.

The bulb and bulb holder are serviced together.

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CHAPTER 7 - ELECTRICAL Protec ting The Elec trica l Sy st ems Duri ng Charging Or Welding To avoid damage to the electronic and electrical systems, always observe the following: 1. Never make or break any of the charging circuit connections, including the battery connections, when the engine is running.

2. Never short any of the charging components to ground.

3. Do not use a booster battery of higher than 12 volts nominal voltage.

4. Always observe correct polarity when installing the batteries or using a booster battery to jump start the engine. Follow the instructions in the operator’s manual when jump star ting the machine. Connect positive to positive and negative to negative.

5. Always disconnect the negative cable from the batteries before carrying out arc welding on the machine or on any implement attached to the machine.

6. Position the welder ground clamp as close to the welding area as possible.

7. Never allow welding cables to lay on, near or across any electr ical wir ing or electronic component while welding is in progress.

8. Always disconnect the negative cable(s) from the battery(ies) when charging the batteries in the machine with a battery charger.

IMPORTANT: Failure to disconnect the ground cable connection(s) at the battery(ies) prior to charging the batteries or welding on the machine or attachment will result in damage to the electrical system.

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CHAPTER 7 - ELECTRICAL

NOTES

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 570MXT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 570MXT Turbocharged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Lightest Configuration with Normally Aspirated Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Heaviest Configuration with Turbocharged Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

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CHAPTER 8 - SPECIFICATIONS

NOTES

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CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

570MXT (NATURALLY ASPIRATED) Case ................................................................................................................... CDC 4-390 Emissions Compliant Aspiration ................................................................................................................................................ Natural Firing Order..............................................................................................................................................1,3,4,2 Fuel Type..................................................................................................................................................#2 Diesel Bore and Stroke ..................................................................................................... 4.02 in x 4.72 in (102 x 120 mm) Displacement ................................................................................................................................239 cu in³ (3.92 L) Compression Ratio......................................................................................................................................17.0 to 1 Horsepower - rated SAE Net .............................................................................................73 hp @ 2200 rpm (54.3 kW @ 2200 r/min) SAE Gross ........................................................................................ 75 hp @ 2200 rpm (57.5 kW @ 2200 r/min) Maximum torque Gross................................................................................................................... 201 lb.-ft. (273 Nm) @ 1200 rpm Net....................................................................................................................... 200 lb.-ft. (271 Nm) @ 1200 rpm Torque rise @ rated speed.....................................................................................................................12 percent Engine Speeds High Idle- No Load ......................................................................................................................2350 to 2500 rpm Rated Speed- Full Load ...........................................................................................................................2200 rpm Low Idle .........................................................................................................................................900 to 1100 rpm Loader Hydraulic Stall .................................................................................................................2100 to 2350 rpm Torque Converter Stall.................................................................................................................1850 to 2350 rpm Valve Clearance - Engine cold Intake valves........................................................................................................................0.010 inch (0.254 mm) Exhaust valves ....................................................................................................................0.020 inch (0.508 mm)

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CHAPTER 8 - SPECIFICATIONS 570MXT TURBOCHARGED Case..................................................................................................................CDC 4T-390 Emissions Compliant Aspiration ...................................................................................................................................... Turbocharged Firing Order.............................................................................................................................................. 1,3,4,2 Fuel Type.................................................................................................................................................. #2 Diesel Bore and Stroke..................................................................................................... 4.02 in x 4.72 in (102 x 120 mm) Displacement ................................................................................................................................239³ cu in (3.92 L) Compression Ratio...................................................................................................................................... 17.0 to 1 Horsepower - rated SAE Net .............................................................................................80 hp @ 2200 rpm (60.0 kW @ 2200 r/min) SAE Gross ........................................................................................ 85 hp @ 2200 rpm (63.4 kW @ 2200 r/min) Maximum torque Gross................................................................................................................... 254 lb.-ft. (344 Nm) @ 1500 rpm Net....................................................................................................................... 249 lb.-ft. (338 Nm) @ 1500 rpm Torque rise @ rated speed..................................................................................................................... 25 percent Engine Speeds High Idle - No Load .....................................................................................................................2350 to 2500 rpm Rated Speed - Full Load ..........................................................................................................................2200 rpm Low Idle ........................................................................................................................................900 to 1100 rpm Loader Hydraulic Stall .................................................................................................................2100 to 2350 rpm Torque Converter Stall ................................................................................................................2100 to 2350 rpm Valve Clearance - Engine cold Intake valves ....................................................................................................................... 0.010 inch (0.254 mm) Exhaust valves .................................................................................................................... 0.020 inch (0.508 mm)

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CHAPTER 8 - SPECIFICATIONS TRAVEL SPEEDS Measured with 17.5L x 24 Tires

km/h

1st (mph)

2nd km/h (mph)

Forward

5.4

(3.4)

9.8

Reverse

6.6

(4.1)

11.8

km/h

3rd (mph)

km/h

4th (mph)

(6.1)

18.8

(11.7)

37.6

(23.4)

(7.4)

22.7

(14.1)

45.4

(28.2)

NOTE: Travel speeds measured at 2334 engine rpm.

Figure 1

Measured with 19.5L x 24 Tires

km/h

1st (mph)

2nd km/h (mph)

Forward

5.8

(3.6)

10.5

Reverse

7.0

(4.4)

12.6

km/h

3rd (mph)

km/h

4th (mph)

(6.5)

20.1

(12.5)

40.2

(25.0)

(7.9)

24.3

(15.1)

48.6

(30.2)

NOTE: Travel speeds measured at 2334 engine rpm.

Figure 2

ELECTRICAL Battery ............................................................................................................................................................. 12-volt Alternator .....................................................................................65 amp (2.5 kW), solid-state rectifier and regulator System protection.................................................................................................................... 30 amp circuit breaker HYDRAULICS Pump ..........................................................................................Gear-type, front mounted, direct drive to crankshaft Loader flow @ rated engine rpm ..........................................................28.5 gpm @ 3000 psi (108 L/min @ 207 bar) Loader control valve2 or 3 - spool monoblock with single lever control for lift, dump and tilt and auxiliary hydraulics, positive hold float and return-to-dig.

3-pt hitch flow @ rated engine rpm................................................0 to 8 gpm @ 2000 psi (0 to 30 L/min @ 137 bar) 3-pt hitch control valve....................................................................... Sectional 4-spool, open-center parallel circuits with variable control for lift, pitch, tilt and 1 auxiliary.

Loader auxiliary hydraulics ...................................................................................12 to 28.5 gpm (45.4 to 108 L/min) Main relief pressure ................................................................ 3050 ±50 psi @ 28.5 gpm (210 ± 3 bar @ 108 L/min) Filtration.............................................7 micron full flow replaceable cartridge on return line, condition indicator light Oil cooler ................................................................................................................................................. Heavy Duty

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CHAPTER 8 - SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

Figure 3

BS07C021

A. Height to top of ROPS canopy 2WD w/19.5L x 24 tires.......................................................................................................8 ft 11 in (2722 mm) 4WD w/19.5L x 24 tires.......................................................................................................8 ft 11 in (2725 mm) 2WD w/17.5L x 24 tires.........................................................................................................8 ft 8 in (2662 mm) 4WD w/17.5L x 24 tires.........................................................................................................8 ft 8 in (2665 mm) A. Height to top of ROPS cab 2WD w/19.5L x 24 tires.........................................................................................................9 ft 0 in (2739 mm) 4WD w/19.5L x 24 tires.........................................................................................................9 ft 0 in (2741 mm) 2WD w/17.5L x 24 tires.........................................................................................................8 ft 9 in (2682 mm) 4WD w/17.5L x 24 tires.........................................................................................................8 ft 9 in (2682 mm) B. Height to top of exhaust stack 2WD w/19.5L x 24 tires.........................................................................................................8 ft 5 in (2571 mm) 4WD w/19.5L x 24 tires.........................................................................................................8 ft 6 in (2577 mm) 2WD w/17.5L x 24 tires.........................................................................................................8 ft 5 in (2576 mm) 4WD w/17.5L x 24 tires.........................................................................................................8 ft 6 in (2582 mm) C. Overall length w/82 in (2083 mm) standard bucket..................................................................................16 ft 11 in (5154 mm) w/82 in (2083 mm) multi-purpose bucket .........................................................................16 ft 8.3 in (5088 mm) D. Wheelbase 2WD w/19.5L x 24 tires.........................................................................................................7 ft 0 in (2134 mm) 4WD w/19.5L x 24 tires.........................................................................................................7 ft 1 in (2146 mm) 2WD w/17.5L x 24 tires.........................................................................................................7 ft 0 in (2134 mm) 4WD w/17.5L x 24 tires.........................................................................................................7 ft 1 in (2146 mm) Width over tires 11L x 16 tires .........................................................................................................................79.3 in (2015 mm) 12 x 16.5 tires ........................................................................................................................81.1 in (2060 mm) 19.5L x 24 tires ......................................................................................................................81.4 in (2067 mm) 17.5L x 24 tires ......................................................................................................................81.7 in (2074 mm) Ground clearance at front axle .....................................................................................................10.9 in (276 mm)

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CHAPTER 8 - SPECIFICATIONS

Figure 4

BS07C022

Operating Data and Dimensions with standard 82 inch (2083 mm) bucket Lift capacity to full height ............................................................................................................. 6 503 lbs (2 950 kg) A. Height to bucket hinge pin - raised 2WD ........................................................................................................................................11 ft 2 in (3413 mm) 4WD ........................................................................................................................................11 ft 2 in (3405 mm) B. Bucket rollback at ground line ............................................................................................................ 40 degrees C. Dump Angle at full height ................................................................................................................... 46 degrees D. Rollback at full height is adjustable ...................................................................................................... Adjustable Maximum grading angle ................................................................................................................. 116 degrees E. Dump clearance at full height - 45 degree 2WD ......................................................................................................................................8 ft 8 in (2642 mm) 4WD ......................................................................................................................................9 ft 8 in (2934 mm) F. Dump reach at full height - 45 degree 2WD ............................................................................................................................................26 in (660 mm) 4WD ............................................................................................................................................26 in (657 mm) G. Digging depth below ground line with bucket flat 2WD ...........................................................................................................................................7.5 in (191 mm) 4WD ...........................................................................................................................................7.8 in (199 mm) H. Overall operating height 2WD ....................................................................................................................................13 ft 8 in (4167 mm) 4WD ....................................................................................................................................13 ft 8 in (4170 mm)

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CHAPTER 8 - SPECIFICATIONS

Figure 5

BS07C022

Operating Data and Dimensions with 82 inch 4-in-1 (2083 mm) Bucket Lift Capacity to full height ................................................................................................................6537 lb (2965 kg) A. Height to bucket hinge pin - raised 2WD ....................................................................................................................................11 ft 2 in (3413 mm) 4WD ....................................................................................................................................11 ft 2 in (3405 mm) B. Bucket rollback at groundline ................................................................................................................40 degree C. Dump angle at full height ......................................................................................................................45 degree D. Rollback at full height ........................................................................................................................... Adjustable Maximum grading angle....................................................................................................................116 degree E. Dump clearance at full height................................................................................................................45 degree 2WD Clam open ........................................................................................................................9 ft 8 in (2942 mm) Clam closed....................................................................................................................8 ft 11 in (2720 mm) 4WD Clam open ........................................................................................................................8 ft 8 in (2634 mm) Clam closed....................................................................................................................8 ft 11 in (2712 mm) F. Dump reach at full height ......................................................................................................................45 degree 2WD Clam open ..............................................................................................................................12 in (299 mm) Clam closed............................................................................................................................25 in (644 mm) 4WD Clam open ..............................................................................................................................12 in (302 mm) Clam closed............................................................................................................................26 in (647 mm) G. Digging depth below ground line with bucket flat 2WD ..............................................................................................................................................7 in (172 mm) 4WD ..............................................................................................................................................7 in (180 mm) Dozing depth, clam open, pads parallel to ground 2WD ..............................................................................................................................................4 in (103 mm) 4WD ..............................................................................................................................................4 in (111 mm) H. Overall height 2WD ....................................................................................................................................14 ft 3 in (4350 mm) 4WD ....................................................................................................................................14 ft 3 in (4353 mm) 8-8

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CHAPTER 8 - SPECIFICATIONS

WEIGHTS LIGHTEST CONFIGURATION WITH NATURALLY ASPIRATED ENGINE 2WD, non-suspension seat, 82 in (2083 mm general purpose bucket, 525 lb (238 kg) counterweight, 3-point hitch, 17.5L x 24 rear tires, 11L x 16SL front tires, single battery and no operator.

10 367 lbs (4 702 kg) HEAVIEST CONFIGURATION WITH TURBOCHARGED ENGINE 4WD, suspension seat, 82 in (2083 mm) multi purpose bucket with clam, 3-point hitch, 600 lb (272 kg) counterweight, box scraper, 19.5L x 24 rear tires, 12L x 16.5 front tires, dual batteries, and no operator.

12 942 lbs (5 870 kg) Additional Weights 4-in-1 Bucket, 82 in (2083 mm) ................................................................................................... 1451 lbs (658 kg) General Purpose Bucket, 82 in (2083 mm) ................................................................................... 683 lbs (310 kg) Cab (over canopy) ......................................................................................................................... 454 lbs (206 kg) 4WD with dirveshaft guard (over 2WD)......................................................................................... 283 lbs (128 kg) Optional counterweight.............................................................................................................. 3000 lbs (1361 kg) Optional plug in cast counterweight .............................................................................................. 480 lbs (219 kg) Loader Buckets Width mm (Inch)

Type

Capacities SAE Heaped m3 (cu yd)

Capacities Struck m3 (cu yd)

Weight kg (lbs)

2083 (82)

Standard

0.79 (1.03)

0.67 (.87)

311 (686)

2083 (82)

Multi Purpose with Clam

0.80 (1.04)

0.65 (.85)

663 (1462) Figure 6

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CHAPTER 8 - SPECIFICATIONS

Material Weights MATERIAL

kg/m3

lbs/ft3

MATERIAL

kg/m3

lbs/ft3

Alum-Lump.

881

55

Oats

416

26

Pulverized

769

48

Peanuts - Shelled

280

17

Ashes

561-833

35-52

Peas

769

48

Bauxite

1202-1922

75-120

Peat - solid

753

47

Beans

769

48

Charcoal

368

23

Phosphate Granular

1442

90

Chips

288

18

Potash

1089

68

Coal

1282

80

Potatoes

769

48

Coke - Lump Loose

849-1009

53-63

Clay

368-513

Concrete

Quartz - Granular

1762

110

Rice

769

48

23-32

Rye

705

44

1378-1778

86-111

Salt - Rock - Solid

2163

135

Copper Ore

1666

104

Corn - Shelled

673

42

Sand & Gravel Dry

1730

108

Cottonseed

401

25

2003

125

Earth - Dry Loam

929-1089

58-68

Sand - Foundry

1522

95

1602-1666

100-104

Shale

1410

88

Earth - Sand Gravel

1570

98

Ensilage

577

Granite

1490-1778

Wet

Wet

Slag - Crushed

1121

70

Slate

2243

130

36

Snow

240-801

15-50

93-111

Soybeans

743

46

1522

95

1906

119

Sugar Beet Pulp Wet

561

35

Ice - Crushed

593

37

Sugar - Raw

961

60

Iron Ore

2323

145

Sulphur - Lumpy

1330

83

Limestone - Loose - Crushed

1538-1602

96-100

Taconite

1714

107

Wheat

769

48

Gravel - Dry Wet

Figure 7

8-10

Figure 8

Issued 04-07

Bur

87612257NA

CHAPTER 8 - SPECIFICATIONS

TORQUE CHARTS Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

PoundInches

Newton meters

1/4 inch

108 to 132

12 to 15

5/16 inch

204 to 252

23 to 28

3/8 inch

420 to 504

48 to 57

7/16 inch

54 to 64

73 to 87

1/2 inch

80 to 96

109 to 130

9/16 inch

110 to 132

149 to 179

5/8 inch

150 to 180

203 to 244

3/4 inch

270 to 324

366 to 439

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

PoundInches

Newton meters

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

7/16 inch

70 to 84

95 to 114

1/2 inch

110 to 132

149 to 179

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

3/4 inch

380 to 456

515 to 618

7/8 inch

600 to 720

814 to 976

1.0 inch

900 to 1080

1220 to 1465

1-1/8 inch

1280 to 1440

1736 to 1953

1-1/4 inch

1820 to 2000

2468 to 2712

1-3/8 inch

2380 to 2720

3227 to 3688

1-1/2 inch

3160 to 3560

4285 to 4827

Size

NOTE: Use thick nuts with Grade 8 bolts.

Figure 9 Figure 10

87612257NA

Issued 04-07

Bur

8-11

CHAPTER 8 - SPECIFICATIONS

Grade 10.9 Bolts, Nuts, and Studs

Grade 8.8 Bolts, Nuts, and Studs

10.9

8.8

Size

PoundInches

Newton meters

M4

24 to 36

3 to 4

M5

60 to 72

7 to 8

M6

96 to 108

11 to 12

M8

228 to 276

26 to 31

M10

456 to 540

52 to 61

M12

66 to 79

90 to 107

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

Size

PoundInches

Newton meters

M4

36 to 48

4 to 5

M5

84 to 96

9 to 11

M6

132 to 156

15 to 18

M8

324 to 384

37 to 43

M10

54 to 64

73 to 87

M12

93 to 112

125 to 150

M14

149 to 179

200 to 245

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

M24

780 to 940

1050 to 1275

M30

1470 to 1770

2000 to 2400

M36

2580 to 3090

3500 to 4200 Figure 12

Figure 11

Grade 12.9 Bolts, Nuts, and Studs 12.9 Figure 13

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

8-12

Issued 04-07

Bur

87612257NA

CHAPTER 9 - INDEX

Chapter 9

INDEX A Accessory Outlet ................................................. 7-7 Air Conditioning Compressor ............................. 6-15

B

C Cab Air Conditioning Air Conditioning Compressor ........................ 6-15 Lubricating the Air Conditioning Compressor Seals 6-15 Cab and Canopy Options Radio Ready Package .................................. 3-27 Clam Control and Lockout (If Equipped) ............. 3-9

D Decals ................................................................ 2-11 Direction Control Lever ........................................ 3-5

E Electrical Service Accessory Outlet ............................................. 7-7 Electrical System ................................................. 7-3 Engine Hourmeter ....................................................... 5-4 Specifications .................................................. 8-3 Environment ........................................................ 5-4 Ether Cold Start Aid Starting the Engine with Ether ......................... 4-7 Ether Starting Aid .............................................. 6-14 Extinguisher Mounting, Fire ............................... 6-17

F Fan Drive Belt Replacement .............................. 6-16 Fire Extinguisher Mounting ................................ 6-17 Fluid and Lubricant Capacities ............................ 5-6 Foot Pedals Brake Pedal Lock ............................................ 3-6 Foot Throttle .................................................... 3-6 Left Brake Pedal .............................................. 3-6 Right Brake Pedal ........................................... 3-6 Issued 04-07

G General Safety .....................................................5-3

Battery Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Brake Pedal Lock ................................................ 3-6 Button Transmission Disconnect ................................ 3-5

87612257NA

Foot Throttle .........................................................3-6 Fuel Handling Precautions ...................................2-8

Bur

H Hazardous Chemical Precautions ........................2-9 Horn ......................................................................3-4 Hourmeter, Engine ...............................................5-4 Hydraulic Pump Charge Procedure ....................5-26

I Identification Numbers Engine ..............................................................1-4 Product Identification Number (P.I.N.) .............1-3 Instructions, General Safety .................................5-3 Instrument Panel ..................................................3-3

L Left Brake Pedal ...................................................3-6 Lever Direction Control ..............................................3-5 Transmission Shift ............................................3-5 Lift Arm and Bucket Controls ................................3-8 Loader Controls Clam Control and Lockout (If Equipped) ..........3-9 Lift Arm and Bucket ..........................................3-8 Lubricating the Air Conditioning Compressor Seals ..

6-15

M Machine Cleaning ...............................................6-16 Machine Components ..........................................1-5 Machine Storage ................................................6-18 Maintenance and Adjustments Fan Drive Belt Replacement ..........................6-16 Plastic and Resin Parts ..................................6-16 Maintenance Precautions .....................................2-8 Maintenance/Adjustments Machine Cleaning ..........................................6-16 Roll-Over Protective Structure .........................6-3 Seat Belt ..........................................................6-4 Torque Specifications for Seat and Seat Belt Mounting Bolts .........................................6-5

O Oil Temperature .....................................................5-9 Viscosity ...........................................................5-9 9-1

CHAPTER 9 - INDEX Operating Precautions ......................................... 2-6

Starting the Engine With Ether .............................4-7 Storage of machine ............................................6-18

P Pedals Foot Throttle .................................................... 3-6 Left Brake ........................................................ 3-6 Right Brake ..................................................... 3-6 Plastic and Resin Parts .............................. 5-4, 6-16 Priming the turbocharger ..................................... 4-4

R Radiator Coolant Level ...................................... 5-20 Radio Ready Package ....................................... 3-27 Rear Axle Oil Temperature ................................ 5-23 Rear Wheel Mounting Nut Torque Procedure ... 6-10 Relieving Hydraulic Pressure .............................. 5-5 Right Brake Pedal ................................................ 3-6 Right Side Instrument Console .......................... 3-30 Right Side Instrument Console Lockup Kit ........ 3-30 Roll-Over Protective Structure ............................. 6-3 ROPS Maintenance and Inspection ........................... 6-3 Run In Period ....................................................... 4-3

S Safety Instructions, General ................................ 5-3 Safety, Battery ..................................................... 7-3 Seat and Shoulder Belt ...................................... 3-29 Seat Backrest Tilt Adjustment Control ............... 3-26 Seat Belt .............................................................. 6-4 Torque Specifications ...................................... 6-5 Seat Belt Precautions .......................................... 2-9 Seat Cushion Tilt Adjustment ............................ 3-25 Seat Forward/Rearward and Swivel Control ..... 3-26 Seat Height Adjustment Control ........................ 3-26 Seat Lumbar Adjustment Control ...................... 3-26 Seat Weight Adjustment Control ....................... 3-26 Sides of the machine Right-hand, left-hand, front, and rear .............. 1-2 Specific machine precautions ............................ 2-10 Specifications Engine Specifications ...................................... 8-3 Weights ........................................................... 8-9 Standard Suspension Seat Backrest Tilt Adjustment Control ................... 3-26 Forward/Rearward and Swivel Seat Control . 3-26 Height Adjustment Control ............................ 3-26 Lumbar Adjustment Control .......................... 3-26 Seat Cushion Tilt Adjustment ........................ 3-25 Weight Adjustment Control ........................... 3-26 Standard Transmission Controls Transmission Disconnect Button ..................... 3-5 Starting and Stopping Precautions ...................... 2-6 9-2

T Tires, Inflation and Service ...................................6-8 Torque Specifications Seat Belt Mounting Bolts ..................................6-5 Transmission Disconnect Button ..........................3-5 Transmission Disconnect Button (Standard) ........3-5 Transmission Shift Lever ......................................3-5 Transporting the machine ...................................4-20 Turbocharger priming ...........................................4-4

U Utility Safety .........................................................2-4 Utility Safety Rules Message ................................2-4

V Vandal Lockup Kits .............................................3-30

W Weights ................................................................8-9 Welding on or Charging the Machine .................7-11 Wheel Nut and Bolt Torques Front Wheel Mounting Bolts - 2 Wheel Drive .6-10 Rear Wheel Mounting Nut Torque Procedure 6-10 Rear Wheel Mounting Nuts ............................6-10 Wheel Nut and Bolts Torques Front Wheel Mounting Nut Torque Procedure ......

6-10

Issued 04-07

Bur

87612257NA