Case 621D Wheel Loader Operator's Manual Brz 6-39500 NA - PDF DOWNLOAD

621D

Wheel Loader

Operator’s Manual

Brz 6-39500 NA 2nd Edition English 12/2014

A CNH INDUSTRIAL LATIN AMERICA LTDA. 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.

Wheel Loader 621D Brz 6-39500 NA 2nd Edition English 12/2014

READ, UNDERSTAND, AND FOLLOW ALL PRECAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL BEFORE OPERATING THE MACHINE.

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH INDUSTRIAL LATIN AMERICA LTDA. II

!

Attention: this warning symbol indicates an important safety message contained in this manual. When you see this symbol, read the followed message carefully and be aware to the possibility of personal injury or death.

The alert symbol indicated on this machine use the words Danger, Warning or Caution, which are defined in the following way •• DANGER: indicates an immediate danger situation which, if not avoided, will cause death of severe injuries. The color associated to the Danger is RED. •• WARNING: indicates a potential danger situation which, if not avoided, will cause severe injuries. The color associated to Warning is ORANGE. •• CAUTION: indicates a potential danger situation which, if not avoided, may cause a minor or moderate injury. It can also be used to warn against unsafe practices. The color associated to Caution is YELLOW. In case the Safety Decals of this machine are ISO two graphic panels type, the decals are defined as follows: •• The first plate indicates the nature of danger.

•• The second plate indicates the proper actions to prevent the danger.

•• The background color is YELLOW. •• Symbols of prohibition such as and PARE if used, are in RED.

!

WARNING

THE UNDUE OPERATION OF THIS MACHINE MAY CAUSE INJURY OR DEATH. BEFORE USING THIS MACHINE, MAKE SURE EACH OPERATOR: •• Has been instructed on the safety and proper use of the machine.

•• Has read and understood the manual(s) which is (are) related to the machine.

•• Has read and understood ALL alert symbol indicated on the machine.

•• Has emptied the area.

•• Learn and practice the safety information for this machine in an isolated area before operating it at a working place.

The operator is responsible for observing the corresponding laws and regulations, and following the instructions given by CASE CONSTRUCTION on the operation and maintenance of the machine.

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TABLE OF CONTENTS 1 3 4 6

SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 WHEEL AND TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . 16 READ OPERATORS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 INSTRUMENT/CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOOT PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDE CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 42 49 62 65

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

BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RUN - IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING THE ENGINE AND PARKING THE MACHINE . . . . . . . . . . . . .

STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADER FUNCTION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DECLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED) . . . . . . . . . . . . .

ROTATING BEACON (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RIDE CONTROL (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COUPLER PIN ENGAGEMENT (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . .

67 67 67 68 69 71 73 77 79 82 87 90 90 91 91 92 92 93

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TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS LOADER OPERATING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 WHEELS/TIRES/BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 TIRE PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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LUBRICATION/FILTERS/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . .

SUPPORT STRUT FOR LOADER LIFT ARMS . . . . . . . . . . . . . . . . . . . .

TRANSPORT/SERVICE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

THE ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

FLUIDS AND LUBRICANTS - 621D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GREASE FITTINGS - 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC/BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 109 110 111 112 112 113 114 115 116 119 120 121 122 123 124 125 129 134 138 141 146 151 154 157

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

STARTING FLUID CAN (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . .

CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

TORQUE SPECIFICATIONS FOR ROPS CAB AND ROPS CANOPY . . .

TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS . . . . . . . . . .

161 161 162 165 172 173 175

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TABLE OF CONTENTS ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT . 176 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . 176 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACEMENT FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE ELECTRICAL CONNECTOR (IF EQUIPPED) . . . . . . . . . . . . . .

AUXILIARY POWER OUTLET (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . .

AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION .

REPLACEMENT BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177 177 180 181 182 182 182 182

MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 185 185 186 193

AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

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SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE DATA 621D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL BOLT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

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BD01E110

621D Read this manual before you start the engine or operate the machine. If you need more information, see your dealer.

Your dealer can give you help with CNH approved service parts. Your dealer has specially trained technicians who know the best methods of repair and maintenance for your machine.

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

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TO THE OWNER

BD01E114

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

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

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

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

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

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

Call your dealer if you need any assistance or information.

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

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

Right-hand and left-hand, when used in this manual, indicate the right and left sides of the machine as seen from the operators seat.

RIGHT SIDE

FRONT

REAR

LEFT SIDE B891464J

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RIGHT, LEFT, FRONT AND REAR SIDES OF THE MACHINE

TO THE OWNER

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

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

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

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

Product Identification Number (P.I.N.) HOMOLOGAÇÃO

BR. CHASSIS VERSÃO MADE IN BRAZIL

MOTOR ENGINE Nº P/ REPOSIÇÃO Nº FOR SPARES

Nº DE PIECES DETACHEES ORD. Nº FUR ERSATZZWCKE

75320307 BD00M072

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Engine

Loader Bucket

BD00M015BR

RP95K195

ROPS Cab and Canopy TRIM THIS EDGE

Transmission

BD00M100

RD98K304

Axle

BD01E115BR

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MACHINE COMPONENTS 3

2

4

1

5

9 6 TRIM THIS EDGE

8

7

BD01F116

1.

2.

3.

4.

5.

6.

7.

8.

9.

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

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8 1

4 6

1.

2.

3.

4.

5.

6.

7.

8.

BD01F118

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

1

5

4 7

3

BD01F116

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2

3

TO THE OWNER

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

READ THIS MANUAL COMPLETELY and make sure you understand the controls.

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

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

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

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

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.

M171C

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

SAFETY/DECALS/HAND SIGNALS

BEFORE OPERATION ●

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

●

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

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Be prepared for emergencies.

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

●

Know the hand signals used on your job. Follow the instructions of the flagman, signs, etc. See Hand Signals starting on page 29.

●

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

●

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

1

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

Do not rush.

●

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

●

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

●

Make sure all persons are away from the machine before you start the engine.

●

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

●

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

●

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

●

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

●

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

1

2 BD00M065

1. HAND RAILS 2. STEPS

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SAFETY/DECALS/HAND SIGNALS

●

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

●

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

●

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

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

●

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

●

Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do. You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine at least 4.6 m (15 feet) away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

●

If a part of the machine touches high voltage power:

●

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

●

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

●

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

●

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

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

●

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

●

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

●

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

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

●

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

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

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MACHINE OPERATION

SAFETY/DECALS/HAND SIGNALS ●

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

●

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

● ●

Operate the machine controls from the operators seat only.

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

●

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

●

Stop operating the machine if a malfunction occurs. Watch the indicator and warning lamps in the machine.

Listen and smell for things that are not normal on your machine.

●

Drive around large objects such as large rocks or trees.

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PARKING THE MACHINE ●

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

●

If you must temporarily park the machine on a hillside, put the front of the machine toward the bottom of the hill. Make sure the machine is behind an object that will not move. Put blocks in front of each wheel on the downhill side.

●

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

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SAFETY/DECALS/HAND SIGNALS

●

Batteries contain sulfuric acid which can cause severe burns. Avoid contact with skin, eyes, or clothing. Antidote EXTERNAL - Flush with water.

INTERNAL - Drink large quantities of water or milk. DO NOT induce vomiting. Seek medical attention immediately. EYES - Flush with water for 15 minutes and seek medical attention immediately. BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area.

Always wear eye protection when working with new batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN.

●

When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

●

Hot coolant can spray out if the radiator cap is removed too quickly.

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

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

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

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BURN PREVENTION

SAFETY/DECALS/HAND SIGNALS

FIRE OR EXPLOSION PREVENTION ●

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

To prevent an explosion, do the following:

●

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

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

●

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

●

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

●

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

●

Starting fluid (ether) can explode and can cause injury or death. 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 the instructions in this manual.

●

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

●

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

●

Check the electrical system for loose connections or frayed insulation.

Repair or replace the loose or damaged parts.

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

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

TRIM THIS EDGE

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

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

●

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

●

DO NOT smoke while refueling the machine.

●

Use nonflammable cleaning solvent to clean parts.

●

A fire can cause injury or death.

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

●

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

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SAFETY/DECALS/HAND SIGNALS

MAINTENANCE ●

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

Additional tags are available from your CNH dealer.

●

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.

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

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

B9502062

●

●

●

●

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

●

Unauthorized modifications to this machine can cause injury or death. Do not make unauthorized modifications to this machine. Always see your CNH dealer before you weld, cut, or drill holes in your machine.

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

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

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

Disconnect the batteries before working on the electrical system.

●

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

●

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

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

SAFETY/DECALS/HAND SIGNALS ●

●

Lower the bucket or tool to the ground and block the machine securely.Before working on the machine, if you must service the machine with the loader raised, install the lift arm support shown on page 110. Follow the instructions in this manual when you service the machine.

●

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

●

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

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

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

WHEEL AND TIRE MAINTENANCE ●

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

●

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

ROLL-OVER PROTECTIVE STRUCTURE ●

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

Do not attempt to repair.

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SAFETY/DECALS/HAND SIGNALS

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

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

BC00G075

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“READ SERVICE MANUAL”

237187A1

“READ OPERATORS MANUAL”

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

SB002

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

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

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

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SAFETY/DECALS/HAND SIGNALS bd00n053/328904a1

1

2

1 2 TRIM THIS EDGE BD00B007/382622A1/364742A1/329051A1

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SAFETY/DECALS/HAND SIGNALS

3

BD01E142 / 323694A1

4

4

RD98K323/3217030

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3

SAFETY/DECALS/HAND SIGNALS

5

5

TRIM THIS EDGE

BD01E142 / 329047A1

6

6

BD00M041/328754A1

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SAFETY/DECALS/HAND SIGNALS

7

BD00M026/329049A1

8

8

BD01E117 / 328752A1

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7

SAFETY/DECALS/HAND SIGNALS

10

10 BD00M062/329044A1

11 TRIM THIS EDGE

11

BD00M005/332512A1

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SAFETY/DECALS/HAND SIGNALS

12

BD00M005/334456A1

13

13

13

BD00N056/BD00N055/335889A1

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12

SAFETY/DECALS/HAND SIGNALS

14

14

BD00N053/328904A1

TRIM THIS EDGE

15

15 388112A1/BD02N049

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SAFETY/DECALS/HAND SIGNALS

16

16

16

BD01E126BR/94F25/BD00M032

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MACHINE TIE DOWN

SAFETY/DECALS/HAND SIGNALS

17 TRIM THIS EDGE

17

BD01E142 / 407737A2

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SAFETY/DECALS/HAND SIGNALS

TRIM THIS EDGE

18

18 412477A1 / BD01E142

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SAFETY/DECALS/HAND SIGNALS

19 19 BDOON049

41247A1

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SAFETY/DECALS/HAND SIGNALS

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

BI97D059

BI97D025

STOP ENGINE

BP97D022

TRIM THIS EDGE

START ENGINE

BP97D023

COME TO ME

ALL STOP AND HOLD

Move hands forward and rearward (palms in)

Move hands forward and rearward (palms out).

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SAFETY/DECALS/HAND SIGNALS

BP97D030

BP97D060

GO THIS FAR

ALL STOP AND HOLD

TRIM THIS EDGE BI97D029

BI97D021

STOP

EMERGENCY STOP

Move one hand back and forth.

BI97D027

LOWER BUCKET

BI97D028

RAISE BUCKET

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SAFETY/DECALS/HAND SIGNALS

BI97D020

BI97D026

LOWER BUCKET SLOWLY

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RAISE BUCKET SLOWLY

BI97D034

BI97D033

TURN MACHINE LEFT SWING LOAD LEFT

TURN MACHINE RIGHT SWING LOAD RIGHT

To stop movement, stop moving hand and make a fist

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

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SAFETY/DECALS/HAND SIGNALS

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INSTRUMENT/CONTROLS FRONT CONSOLE 17

7

8

9

10

21

6

11

5

12

15 20

10

4 3

0

2

13

25

5 RPM x 100

14

30

electronic

15 16

18

19 20

22

PRESENTATION This machine has a multifunction panel for easy operator control of all machine functions during operation.

Any machine malfunctions will be shown on this panel with warning lights followed by a warning buzzer. Stop machine and remedy the concern. If necessary, call a CNH authorized serviceman.

Try to become familiar with the function of each indicator and gauge before operating the machine. For better familiarity, read gauges from the operator's seat position.

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1

INSTRUMENTS/CONTROLS 1. HYDRAULIC OIL FILTER RESTRICTION INDICATOR: The light will glow only if the hydraulic filter is clogged.

If so, replace the filter. The red indicator light will remain lit until the fault has been remedied.

2. HYDRAULIC OIL TEMPERATURE INDICATOR: The light will glow only if the hydraulic oil temperature rises above normal operating temperature.

NOTE: Increased hydraulic oil temperature will affect oil properties, resulting in hydraulic performance drop and likely hydraulic components overloads.

Some factors may be affecting oil temperature; stop the machine and remedy the fault.

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Check: Restricted return filter, low reservoir oil level, low coolant level in radiator this is responsible for oil cooling, and cooler restriction or clogging.

3. BRAKE FLUID PRESSURE INDICATOR: When switching on the machine this lamp will glow (if the brake accumulators aren‘t pressurized) and should go off when the engine is started. Check that the lamp is switching on indicating that the system is operating normally.

If the indicator comes on during machine operation, oil pressure is below required for brake engagement.

NOTE: Existing pressure is only sufficient to stop the machine DO NOT OPERATE UNDER THESE CONDITIONS. Usually, braking system pressure drop is caused by leakage. Check and remedty the fault.

WARNING: LIFE HAZARD. STOP MACHINE IMMEDIATELY.

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INSTRUMENTS/CONTROLS 4. TRANSMISSION OIL TEMPERATURE INDICATOR: This will light only if the transmission oil temperature rises above normal operating temperature.

If the machine has been operating in severe conditions for a long time there may be some increase in temperature. The system accommodates this slight increase for a short time, therefore when operating for long periods in severe conditions, stop frequently for a short time.

NOTE: Temperature increases will affect oil properties. If the machine operates for a long time at high transmission oil temperatures, this will cause early wear of transmission components.

The most frequent cause of temperature increases are: restricted transmission oil filter, low transmission oil level, or some other hydraulic system failure. Call a serviceman to remedy the concern.

This lamp will light only if the air cleaner element is restricted. If so, the filters need servicing. A restricted air cleaner will directly affect engine performance and consequently the hydraulic system as well.

Air cleaner element replacement intervals will depend on the working environment for the machine. See the maintenance chart.

6. COOLANT TEMPERATURE INDICATOR: The lamp will light only with engine coolant overheating.

The coolant is responsible for the heat exchange of both hydraulic fluid and engine coolant. Check for low coolant level and for a damaged or restricted radiator.

7. BATTERY CHARGE: The lamp will light when switching on the machine and will go out when the engine is started. Check that the lamp is on, indicating normal system operation.

If the indicator comes on during machine operation, there is something wrong with the battery charge system (alternator).

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5. AIR CLEANER RESTRICTION INDICATOR:

INSTRUMENTS/CONTROLS 8. TRANSMISSION OIL PRESSURE INDICATOR: The lamp will light when starting the engine and, after 5 seconds, will go out after the engine has started. Check that the lamp is on, indicating normal system operation, waiting more than 5 seconds without starting the engine.

If the indicator comes on during machine operation, transmission oil pressure is below needed operating temperature.

Check for low temperature oil level and if the oil being used is as specified in this Manual.

9. PARKING BRAKE INDICATOR: This indicator lamp will remain on for as long as the parking brake is engaged. With the parking brake engaged, transmission will be in neutral.

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10. ENGINE OIL PRESSURE INDICATOR: The lamp will light when starting the engine and will go out after the engine has started. Check that the lamp is on, indicating normal system operation.

If the indicator comes on during machine operation, engine oil pressure is below needed operating temperature.

Check for low engine oil level. If the oil used is as specified in this Manual, the relief valve setting may be incorrectly adjusted. Call an authorized CNH serviceman.

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

12. TURNING INDICATOR: This indicator lamp will be a flashing green for as long as the turn lever is engaged.

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INSTRUMENTS/CONTROLS 13. EMERGENCY FLASHER INDICATOR: This indicator lamp will light and the turning indicator (11) will be flashing for as long as the warning flasher is engaged.

14. HIGH BEAM INDICATOR: This indicator lamp will be a flashing blue for as long as the high been handle is engaged.

15. AUXILIARY ETHER COLD START

16. EMERGENCY TURNING INDICATOR: The lamp will come on only if there is a hydraulic system malfunction.

If the lamp glows, stop machine and call a serviceman.

This option will allow slight operation through an assist system sufficient to move the machine to a proper location for servicing. This should not be used as a substitute for the main system.

17. ENGINE OIL PRESSURE GAUGE: This indicator shows engine oil pressure variance during machine operation. Normal operating range is as shown by the green zone in the gauge. If the needle moves into the red zone, the warning light and buzzer will operate. The engine should not be operated outside normal oil operating pressure.

18. FUEL LEVEL GAUGE: This gauge shows fuel level variance in the fuel tank.

When the needle is in the red zone, reserve, this means only a few liters are left in the reservoir.

Do not allow the fuel tank to run completely empty. If so, air will enter the engine fuel system and will be necessary to bleed the system.

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This indicator lamp will flash when the ether cold start system operates.

INSTRUMENTS/CONTROLS

19. TACHOMETER: 15 20

10

25

5 0

RPM x 100

30

20

10

20. HOURMETER:

25

5 0

With engine running, this gauge shows engine speed variance in rpm.

electronic

RPM x 100 electronic

30

The gauge shows total engine operating hours.

21. TRANSMISSION OIL TEMPERATURTE GAUGE: This gauge shows transmission oil temperature variance during machine operation. Normal operating temperature range is in the green zone of the gauge.

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If the needle moves into the red zone, the warning light and buzzer will operate.

22. ENGINE COOLANT TEMPERATURE GAUGE: This gauge shows engine coolant temperature variance during machine operation. Normal operating range is in the green zone of the gauge. If the needle moves into the red zone the warning light and buzzer will operate. Do not operate the machine in this condition.

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INSTRUMENTS/CONTROLS

A

B

C RD98K322BR

BS00B351

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

A. Move the control lever away from you for FORWARD. position

is

C. Move the control lever toward you for REVERSE. 24. TRANSMISSION DISPLAY S T O P

NOTE: The F-N-R function of the Transmission Control Lever may be moved to the Loader Control Lever for operating efficiency. See page 79 and 81 of this manual.

The Transmission Display will show the status of the transmission control: gear selection (shift up or shift down in auto mode), error indication, error code in hexadecimal format (if an error is detected), F-N-R direction, gear, parking brake, calibration information, etc.

IMPORTANT: Consult an authorized CNH dealer if an error indicaton appears on the transmission display.

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B. The center NEUTRAL.

INSTRUMENTS/CONTROLS

BD00M085 RD98K313BR

TRIM THIS EDGE

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

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

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

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

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

IMPORTANT: Push down on the top of the parking brake switch, hold pressure on the brake pedal and put the transmission control lever either in FORWARD or REVERSE to DISENGAGE the parking brake

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INSTRUMENTS/CONTROLS 27. Key Switch The key switch has four positions:

RB98M031

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

RD98K312BR

RB99J178

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

START POSITION Turn the key to this position to engage the starter motor to star t the engine. The RB99J176 switch is spring loaded and will return to the ON position when released.

The Ether Start System (if equipped) can only be actuated when the key switch is in the ON or START position and the engine t e m p e ra t u r e i s b e l ow 5 0 ˚ F ( 1 0 ˚ C ) . T h e transmission control lever must be in the N E U T R A L p o s i t i o n fo r t h e s t a r t e r t o engage.

318764A

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

INSTRUMENTS/CONTROLS

FOOT PEDALS 2. BRAKE PEDAL: The pedal to the left of the steering column is the pedal to engage the s e r v i c e b r a ke s . T h e h e av i e r t h e pressure on the pedal, the heavier the brake engagement pressure.

When going down steep hills to not use just the ser vice brakes. With transmission in manual mode, select an appropriate gear; if on automatic mode, switch off the declutch switch, this will prevent transmission from disengaging as you press the brake pedal. With this care, overheating of the brake system i s p r eve n t e d , fo r l o n g b r a k e components life.

1 2

BD01A001BR

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1. FOOT THROTTLE The pedal to the right of the steering column of the machine governs engine speed. The heavier the pressure on the pedal, the higher the engine speed.

NOTE: Use the DECLUTCH SWITCH when you need maximum power (speed) for the loader lift arms and bucket. See page 52 and 90 in this manual for a detailed explanation.

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INSTRUMENTS/CONTROLS

LOADER CONTROL LEVERS TWO SPOOL VALVE - ONE CONTROL LEVER A

B

E

1 2 1 C

F

BS01E136 / BS00B353

1. LIFT ARM AND BUCKET CONTROL A. FLOAT (DETENT): This is a detent position. When in the FLOAT (Detent) position, the loader bucket can follow the l eve l o f t h e gr o u n d w i t h o u t movement of the control lever

3

BS01E142

2. AUXILIARY F-N-R Switch: This switch will allow the operator to put t h e Tra n s m i s s i o n i n Fo r wa r d , Neutral or Reverse. To activate this auxiliary F-N-R switch the proper sequence must be followed. Push the switch forward to place the Transmission in Forward, Place the switch in the middle position to place the transmission in Neutral and Pull the switch rearward to put the Transmission in Reverse.

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

D. RAISE E. DUMP

3. KICKDOWN BUTTON (DOWNSHIFT TRANSMISSION)

F. ROLLBACK

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D

INSTRUMENTS/CONTROLS

TWO SPOOL VALVE - TWO CONTROL LEVERS 2 1

E

D

F

3 2

4

G

A 1

C B BC01E133 / BS00B354

1. BUCKET CONTROL A. DUMP TRIM THIS EDGE

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

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

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

G. RAISE 3. KICKDOWN BUTTON (DOWNSHIFT TRANSMISSION) 4. AUXILIARY F-N-R Switch:This switch will allow the operator to put the Transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper sequence must be followed. Push the switch Forward to place the transmission in Forward, Place the switch in the middle position to place the transmission in Neutral and Pull the switch rearward to put the Transmission in Reverse.

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INSTRUMENTS/CONTROLS

THREE SPOOL VALVE - TWO CONTROL LEVERS

H

A

E

D

2

1

2

C

1

B

F

G 114/BS00B356

1. LIFT ARM AND BUCKET CONTROL

3

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

4

3. KICKDOWN BUTTON (DOWNSHIFT TRANSMISSION) 4. AUXILIARY F-N-R Switch:This switch will allow the operator to put t h e Tra n s m i s s i o n i n Fo r wa r d , Neutral or Reverse. To activate this auxiliary F-N-R switch the proper sequence must be followed. Push the switch Forward to place the transmission in Forward, Place the switch in the middle position to place the transmission in Neutral and Pull the switch rearward to put the Transmission in Reverse.

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

E. LOWER F. RAISE 2. AUXILARY CONTROL G. AUXILIARY FUNCTION H. AUXILIARY FUNCTION

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TRIM THIS EDGE

A. DUMP

INSTRUMENTS/CONTROLS

Three Spool - Three Levers A

2

H

1

D

1 E

3 C

3

F

2 I

B

G 412/376629A1

1. BUCKET CONTROL A. DUMP B. ROLLBACK TRIM THIS EDGE

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

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

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

G. RAISE 3. AUXILIARY CONTROL H. AUXILIARY FUNCTION I. AUXILIARY FUNCTION

46

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INSTRUMENTS/CONTROLS

4

A B

5

C

412

5. AUXILIARY F-N-R SWITCH: This switch will allow the operator to put the Transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper sequence must be followed. See page 79 and 81 in this manual. Push the switch Forward to place the Transmission in Forward, Place the switch in the middle position to place the Transmission in Neutral and Pull the switch rearward to put the Transmission in Reverse.

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

47

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TRIM THIS EDGE

4. KICKDOWN BUTTON (DOWNSHIFT TRANSMISSION.

INSTRUMENTS/CONTROLS

Four Spool Valve - Three Levers A

D 2

G

I

E 3 2

1

3

C

1 B

H

J

F 415/BS00N175

J. AUXILIARY FUNCTION

1. BUCKET AND LIFT ARM CONTROL A. DUMP TRIM THIS EDGE

5

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

4

BS01E142

4. KICKDOWN BUTTON (DOWNSHIFT TRANSMISSION) 5. AUXILIARY F-N-R SWITCH: This switch will allow the operator to put t h e Tra n s m i s s i o n i n Fo r wa r d , Neutral or Reverse. To activate this auxiliary F-N-R switch the proper sequence must be followed. Push the switch Forward to place the Transmission in Forward, Place the switch in the middle position to place the transmission in Neutral and Pull the switch rearward to put the Transmission in Reverse.

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

E. LOWER F. RAISE 2. AUXILIARY CONTROL G. AUXILIARY FUNCTION H. AUXILIARY FUNCTION 3. AUXILIARY CONTROL I. AUXILIARY FUNCTION 48

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

3

1

BS00M473

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

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

BC00B128

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

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

BC00B127

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

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TRIM THIS EDGE

4

2

INSTRUMENTS/CONTROLS

5

BS00M473

TRIM THIS EDGE

5. WIPER/WASHER SWITCH (IF EQUIPPED): T h e w i p e r / wa s h e r sw i t c h h a s fi ve positions.

D C

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

B

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

A

E BC00B131

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

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

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INSTRUMENTS/CONTROLS

6

A.OFF - Turn the switch completely counterclockwise for OFF.

E

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

D

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

C B

A BC00B133

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

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

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TRIM THIS EDGE

BS00M473

6. LAMP SWITCH: The lamp switch has five positions:

INSTRUMENTS/CONTROLS

9 8

10

7

BS00M473

TRIM THIS EDGE

BS98M034

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

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

75284720

75320861

87459001

8. DECLUTCH SWITCH: The declutch disengages the transmission when maximum power is needed for the loader. Push down on the top of the declutch switch and push on the brake pedal to operate the machine with the declutch.

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

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

Push down on the top of the Return-To-Travel switch to engage the return to travel detent. Push the bottom of the switch for the Float Detent position.

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INSTRUMENTS/CONTROLS

11 12

13

75284725

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

operation).

12. RIDE CONTROL SWITCH: (If equipped) Push on the top of the function switch for the ON position. Ride Control can be left ON at all times, whether loading or roading. In the on position ride control will automatically activate when ground speed 75326329 is above 5 km per hour (3.1 mph) and automatically shut off when ground speed is below 5 km per hour (3.1 mph). The indicator light on the lower half of the switch will illuminate when ride control is activated.To turn Ride Control OFF, push on the bottom of the function switch for the OFF position.

BC00B083

13. REAR WIPER/WASHER SWITCH (IF EQUIPPED): The rear wiper/washer switch has three positions. OFF - The switch is completely off when the bottom of the switch is pushed down.

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

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TRIM THIS EDGE

BS00M473

INSTRUMENTS/CONTROLS

14

BD01E113

14. ROTATING BEACON SWITCH (IF EQUIPPED): TRIM THIS EDGE

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

BS98M034

15

BD01E112

15. COUPLER PIN ENGAGE SWITCH: Slide the locking plate towards the center of the switch, push down on the top of the switch to RETRACT the pins. The switch lamp will illuminate when the pins are retracted. The switch will lock in the PIN 75324429 EXTENDED position after the bottom of the switch has been pressed and the PINS EXTENDED.

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INSTRUMENTS/CONTROLS

16

BS00M473

87453885

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

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TRIM THIS EDGE

16. FAN REVERSER SWITCH (IF equipped)

INSTRUMENTS/CONTROLS

17

TRIM THIS EDGE

BD01E113

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

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INSTRUMENTS/CONTROLS

MASTER DISCONNECT SWITCH

1

BD03A059

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

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

BS00A203

OFF - This position disconnects all power to the machine.

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

BS00A017

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TRIM THIS EDGE

BS00A018

INSTRUMENTS/CONTROLS

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

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

1

2

TRIM THIS EDGE

BD00B005

1. Loosen and slide knob as required to open or close louvers.

2. Recirculation louvers (behind filter)

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INSTRUMENTS/CONTROLS

MAIN AIR LOUVERS

1

3 3

3. LOWER FRONT MAIN LOUVERS

RD98K323

1. LEFT-HAND MAIN LOUVERS

TRIM THIS EDGE

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

2

2. RIGHT-HAND MAIN LOUVERS

BD01E137

RD98K303

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

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INSTRUMENTS/CONTROLS

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

6

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

TRIM THIS EDGE

4

6. LEFT-HAND DEFROST LOUVERS

4

4. LOWER DEFROST LOUVERS

BD01E137

5

RD98K303

5. RIGHT-HAND DEFROST LOUVERS

60

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RD98K323

INSTRUMENTS/CONTROLS

Radio (If Equipped)

Window Latch

1

RD97F215

RD98K301

TRIM THIS EDGE

1. LIFT TO OPEN

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

Door Latch 1

2 1 RD98K302

1. LATCH PIN 2. HOLD LATCH

The window can be kept partially open by lifting the Hold Latch and sliding it back on the Latch Pin until the Hold Latch locks in the Latch Pin.

RD97F218

1. PUSH TO OPEN DOOR

The window may be opened and locked against the side of the cab. To do this pull the hold latch toward the rear of the cab when the window is partially open.

This will unlatch the window and allow the window to swing back against the cab and lock.

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

61

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INSTRUMENTS/CONTROLS

Window Retainer Latch 1

RD97F173

1. PULL TO RELEASE WINDOW

OPERATORS SEAT TRIM THIS EDGE

Opcional Seat

1

3

2

2 RD98K266

3. RECLINER ADJUSTMENT HANDLE: L i f t u p o n t h e h a n d l e , m o ve t h e backrest to the desired position, release the handle to lock the backrest in position.

RD98K267

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

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

NOTE: Each armrest will pivot to the up position.

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INSTRUMENTS/CONTROLS

Optional Air Ride Seat 4

1 2

5

6 2 RD98K266

4. SLIDE ADJUSTMENT LEVER: Pull this lever up and adjust the seat forward or rearward as required.

Release the lever to lock the seat in position.

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

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

NOTE: Each armrest will pivot to the up position.

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

3

RD98K268

3. RECLINER ADJUSTMENT HANDLE: L i f t u p o n t h e h a n d l e , m o ve t h e backrest to the desired position, release the handle to lock the backrest in position.

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TRIM THIS EDGE

RD98K267

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

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

5 4 RD98K268

TRIM THIS EDGE

4. SLIDE ADJUSTMENT LEVER: Pull this lever up and adjust the seat forward or rearward as required.

Release the lever to lock the seat in position.

6 7

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

RD98K268

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

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

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

Lift the handle UP and release.

The seat will automatically adjust UP and then bleed off air pressure to the optimum air pressure for the weight of the operator.

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INSTRUMENTS/CONTROLS

5

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

The suspension can be adjusted to various operating conditions.

8

RD00B010

TRIM THIS EDGE

SEAT BELT

RD97F225

RD97F225

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

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

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

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

M437

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INSTRUMENTS/CONTROLS

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

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

3. Replace all parts that have damage or wear.

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

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

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

7. Keep seat belts clean and dry.

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

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

Emergency Exit TRIM THIS EDGE

1 1

2

RD98K301

1. PIN 2. LATCH

BD01E122

1. EMERGENCY EXIT

Lift and pull the latch out of the pin.

Push the Right hand window open.

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

Make any necessary corrections before operating the machine.

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

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

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

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

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

3. Monitor the engine instruments frequently during operation.

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

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

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TRIM THIS EDGE

CM112

OPERATING INSTRUCTIONS

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

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

SEAT BELT

TRIM THIS EDGE

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

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

SA121

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OPERATING INSTRUCTIONS

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

SC037

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

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

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

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

6. After the engine starts, check the instr uments to make sure the indications are correct. Run the engine at approximately 1200 RPM with the transmission in neutral until the engine coolant temperature is warm.

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

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

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TRIM THIS EDGE

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

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

OPERATING INSTRUCTIONS

Priming the Turbocharger Lines with Oil

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

BD01E139BR

TRIM THIS EDGE

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

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

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

4. Connect the connector to the injection pump solenoid and start the engine.

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OPERATING INSTRUCTIONS

STOPPING THE ENGINE AND PARKING THE MACHINE WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand rails and steps, and get on or off the machine slowly.

SA038

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

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

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

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.

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

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

TRIM THIS EDGE

2. Lower the loader to the ground.

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

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OPERATING INSTRUCTIONS

Ether Cold Start (If Equipped)

!

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. Use starting fluid according to instructions in this manual.

SB039

NOTE: If the weather is cold, if the machine has not been run for several weeks or if the engine oil filter has been replaced, see Priming the Turbocharger Lines with Oil in this manual.

NOTE: For cold weather starting and operating procedures see cold weather starting and operating in cold weather in this manual.

TRIM THIS EDGE

IMPORTANT: The ether injection system on this machine is designed to deliver a measured amount of ether directly into the engine to assist starting in cold temperatures. Manually spraying or using ether in any unmeasured way may cause damage to the engine and make a hazardous situation for the person assisting. This practice is not recommended and strongly discouraged.

Important Rules When Using Ether 1. Know the correct method for starting your engine with ether.

5. When the temperature is above 35˚ to 40˚F (0 to 5˚C), remove the starting fluid container from the machine.

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

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

Do not make a hole in the container and do not put the container in a fire.

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

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

7. Do not store ether containers in the operators area.

8. Always read the instructions on the ether container.

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OPERATING INSTRUCTIONS

STARTING THE ENGINE The ether cold start injects a measured amount of ether into the engine during cold weather starting.

1. See Starting the engine in this manual for the correct procedure to start the engine.

2. Turn the key switch to the ON position.

3. Push and release the cold start button to inject a measured amount of ether into the engine. The ether is only injected when the button is released. Only use ether to aid in starting the engine. Set the throttle position at 3/4 throttle to set the injection pump to cold start timing. Turn the key to the START position.

When the engine starts, quickly move the throttle to 1/3 to 1/2 throttle to prevent damage to the engine. If the engine does not start after two attempts, check the supply of ether in the container.

IMPORTANT: Before you replace the ether container, read the instructions and warnings on the container.

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TRIM THIS EDGE

NOTE: The ether cold start system will operate only when the engine temperature is below 50˚F (10˚C).

OPERATING INSTRUCTIONS

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

BD02N067

Engine Oil Heater (If Equipped)

TRIM THIS EDGE

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

B830662P

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OPERATING INSTRUCTIONS

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

SA006

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

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

M146B

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

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

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

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

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

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

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

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

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

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

OPERATING INSTRUCTIONS

1

BD01E125

1. STANDARD BATTERIES (1 EACH SIDE)

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OPERATING INSTRUCTIONS

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

SA040

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

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

3. Fasten and adjust the seat belt.

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

5. Check the loader controls for correct operation.

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

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

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

D. Raise the loader bucket above the ground.

E. Shift the transmission into first gear forward.

F. The warning buzzer will sound.

G. Take your foot off the brake pedal.

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

7. Test the parking brakes at a maximum of 250 hour intervals: A. Ensure that the declutch switch is in the off position.

B. Apply the parking brake by pushing down on the top of the switch.

C. Shift the transmission into 3rd gear NEUTRAL. D. Push down and hold your foot against the brake pedal.

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

OPERATING INSTRUCTIONS E. Enable the pilot control levers by pushing down on the right hand side of the pilot control switch.

F. Raise the loader bucket above the ground.

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

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

I. Shift the transmission to the NEUTRAL position.

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

CM112

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

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M142A

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

M122B

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

SB013

8. Release the parking brake.

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

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

B. Raise the loader bucket just above the ground.

C. Place the transmission in the manual mode.

D. Shift the transmission into 2nd gear forward.

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

F. Reset the parking brake.

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

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OPERATING INSTRUCTIONS

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

The transmission can be operated in Automatic or Manual mode.

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

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

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

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

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

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

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

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Up-Shifts Manual Mode

OPERATING INSTRUCTIONS

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

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

1

1 TRIM THIS EDGE

BS01E142

BC01E146

DOWN-SHIFT BUTTON, JOYSTICK CONTROL

DOWN-SHIFT BUTTON, THREE LEVER (SHOWN) AND TWO LEVER CONTROLS

Shuttle Shifting (Direction change) Manual or Automatic It is not necessary to bring the machine to a complete stop when changing directions from forward to reverse or reverse to forward. For smooth operation and operator comfort, reduce engine speed before direction changes.

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OPERATING INSTRUCTIONS

F-N-R Switch (If equipped)

1

1. Transmission controller is in neutral.

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

3. The engine must be running.

4. Vehicle is stationary.

Depressing the F-N-R enable switch allows the transmission to be controlled by the auxiliary F-N-R switch. The indicator light on the bottom of the enable switch will illuminate when activated.

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BD01E113

The F-N-R switch can be enabled after the following conditions have been met:

OPERATING INSTRUCTIONS

CONTROL LEVERS TWO SPOOL VALVE - ONE CONTROL LEVER 4

2

5

1

3

BS01E154

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

1

4

2

3

B1119A88

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

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

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OPERATING INSTRUCTIONS

TWO SPOOL VALVE - TWO CONTROL LEVERS

3 1

5

4

5

2

BC01E133

1

3

2

4

TRIM THIS EDGE

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

B1119A88J

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

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

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OPERATING INSTRUCTIONS

THREE SPOOL VALVE - TWO CONTROL LEVERS 3

2

1

5 4

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

6

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

7

BS01E143

TRIM THIS EDGE

1

3

2

4

B1119A88

1. DUMP BUCKET 3. LOWER LIFT ARMS 2. ROLLBACK BUCKET 4. RAISE LIFT ARMS 5. HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVERS ARE IN HOLD. WHEN RELEASED, THE CONTROL LEVERS WILL RETURN TO HOLD AUTOMATICALLY. 6. 7.) AUXILIARY FUNCTION

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OPERATING INSTRUCTIONS

THREE SPOOL VALVE - THREE CONTROL LEVERS NOTE: This page shows the basic loader control lever positions. The Detent Switch for the loader functions is in the OFF position.

3

1 6

5 5

5 7

2

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

4

1

3

2

4

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BC01E146

B1119A88

1. DUMP BUCKET 3. LOWER LIFT ARMS 2. ROLLBACK BUCKET 4. RAISE LIFT ARMS 5. HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVERS ARE IN HOLD. WHEN RELEASED, THE CONTROL LEVERS WILL RETURN TO HOLD AUTOMATICALLY. 6. 7.) AUXILIARY FUNCTION.

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OPERATING INSTRUCTIONS

FOUR SPOOL VALVE - THREE CONTROL LEVERS 3

2

5

1

6

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

8

4

7

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

9

BS01E145

TRIM THIS EDGE

1

3

2

3

B1119A88

1. DUMP BUCKET 3. LOWER LIFT ARMS 2. ROLLBACK BUCKET 4. RAISE LIFT ARMS 5. HOLD: THE LOADER ARMS AND BUCKET WILL NOT MOVE WHEN THE CONTROL LEVERS ARE IN HOLD. WHEN RELEASED, THE CONTROL LEVERS WILL RETURN TO HOLD AUTOMATICALLY. 6-7.) FIRST AUXILIARY FUNCTION 8-9.) SECOND AUXILIARY FUNCTION

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OPERATING INSTRUCTIONS

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

1

2 RD97F178

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

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

1

2 1

BS01E154

BC01E143

1. FLOAT AND ROLLBACK DETENT

1. FLOAT 2. ROLLBACK DETENT

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

B1125A88J

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Return-To-Dig

OPERATING INSTRUCTIONS

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

1

1

BS01E154

BC01E143

1. RAISE

1. RAISE

TRIM THIS EDGE

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

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

1

1 2

BC01E143

BS01E154

1. ROLLBACK DETENT 2. FLOAT

1. FLOAT AND ROLLBACK DETENT

To actuate, move the control lever(s) into the FLOAT and ROLLBACK detents. The control lever(s) will automatically return to the HOLD position when the loader reaches the Return-To-Travel position. See for Return-To-Travel Adjustment in this manual.

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OPERATING INSTRUCTIONS

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

B1128A88J

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To actuate, move the control lever into the FLOAT detent. The control lever will remain in this position until manually removed. To enable this function press the bottom of the Return-To-Dig/Float switch.

1 1

BC01E143

BS01E154

1. Float

1. Float

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OPERATING INSTRUCTIONS

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

Test the accumulators for correct operation every 100 hours.

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

1. Start the engine.

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

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

3. Stop the engine.

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

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

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

1

RD97F178

1. DECLUTCH SWITCH

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OPERATING INSTRUCTIONS

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

BD00N076

Your Wheel Loader is equipped with an Auxiliary Hydraulic System. A control lever on the console controls flow to the auxiliary hydraulic connection points on the lift arms.The auxiliary control lever (1) used with a joystick (2) is equipped with mechanical detents to lock it into full forward, full rearward and neutral positions.

Auxiliary control levers on non-joystick machines DO NOT have mechanical detents.

2

BD00N032

1

BS01E143

Auxiliary Hydraulic System Specifications 621D Wheel Loader (XT and Z-Bar Linkage) Maximum System Pressure ....................................................250 Bar (3 625 PSI) Maximum Capacity at 2 150 Engine RPM .......................... 184 L/min (48.6 GPM) NOTE: Maximum system pressure measured on the machine at the pump pressure port.

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AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED)

OPERATING INSTRUCTIONS

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

RD97K027

RIDE CONTROL (IF EQUIPPED) TRIM THIS EDGE

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

Ride Control will reduce Fore and Aft pitching motion during travel to allow faster speeds in load and carry applications for increased 75326329 productivity and operator comfort. It will also reduce shock loads to the Wheel Loader for reduced tire flex, structural fatigue and vibration, resulting in longer component life and reduced costs.

The machine is equipped with speed dependent ride control. Push on the function switch symbol to activate. With ride control active, the green indicator light will illuminate anytime the machine is traveling faster than 5 km/h (3.1 mph) indicating that the ride control is functioning. Ride control will disengage automatically at slower speeds for loading and unloading.

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

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

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

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OPERATING INSTRUCTIONS

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

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

To connect an attachment, slide the locking tab upward and press the top of the COUPLER switch to RETRACT the PINS. The amber light will illuminate and the PINS will remain in the retracted position. Position the front coupler into the attachment. Press the bottom of the switch until it fully locks into place to EXTEND the PINS. Make sure the coupler pins are fully engaged to the attachment and the amber light is off before using the machine.

BD00B028

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

M781

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To change attachments, lower the attachment to the ground, slide the locking tab upward and press the top of the COUPLER switch (PINS RETRACT).

Back out of the attachment.

OPERATING INSTRUCTIONS

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

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

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

163L96

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

Scraping Operation 164L96

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

163L96

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

M465

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OPERATING INSTRUCTIONS

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

165L96

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

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

SB013

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

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SA041

OPERATING INSTRUCTIONS

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

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

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

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

B. Remove the Parking brake cover (1).

1

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C. Loosen the lock nut (2).

D. Turn the adjusting screw c o u n t e r c l o ck w i s e u n t i l t h e parking brake is released (3).

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

2

3 300372A1

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

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OPERATING INSTRUCTIONS

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

SB042

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

46-76C

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

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

84-13A

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

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

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

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

10. Put a cover over the exhaust pipe.

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

11. Rotate the beacon (if equipped) to the TRANSPORT position. See beacon in this manual. (if equipped)

3. Lower the loader bucket onto the trailer.

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

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

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

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

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

OPERATING INSTRUCTIONS

Transporting the Machine on a Trailer Machine Tie Down Locations

BD00M030

BD01E126BR

TRANSPORT LOCK MUST BE SECURED.

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

TRIM THIS EDGE BD00B012

CHAINS MUST BE SECURELY FASTENED AROUND LOADER ARM.

BD00M032

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

FAR1069

CHAINS MUST BE SECURELY FASTENED AROUND LOADER ARM.

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OPERATING INSTRUCTIONS

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

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

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

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

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

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

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

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

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

2. LUBRICANTS - Make sure you follow the recommended oil and filter service for the engine and the hydraulic system as shown in this manual. Use the correct viscosity oil in each component for the ambient temperatures the machine is operated in (see Lubrication in this manual).

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Check for water in the fuel system.

Cold temperatures can cause condensation to form in the fuel tank. Check the fuel filter for water.

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

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

When the machine has been correctly warmed up, apply the foot brake and hold, shift the transmission to forward push the park brake to the Off position and release the foot brake. Operate the machine in a clear safe area.

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

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

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

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

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

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

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

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

8. The transmission is equipped with internal protection that does not allow the transmission to engage below -12˚C (10˚F). If the transmission does not engage below these temperatures, allow 2 to 4 minutes of running in neutral ( t h i s t i m e w i l l va r y w i t h temperature), then try again.

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OPERATING INSTRUCTIONS

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

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

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

5. Check the condition of the drive belts.

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

6. Use lubricants viscosity.

of

the

correct

7. Check Battery fluid levels monthly.

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

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OPERATING INSTRUCTIONS

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

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

SD020

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

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

SB134

BALLAST It is the recommendation of the CNH. NOT to add Ballast to the tires of your machine. Make sure tires are properly inflated. See the Tire Chart on page 107 of this manual.

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84-113

WHEELS/TIRES/BALLAST

TRIM THIS EDGE B910410J

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

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WHEELS/TIRES/BALLAST

Adding Air to the Tires

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

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

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

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

Tire Tread Direction B790490R

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

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

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

FORWARD

B770164R

B4039288T

105

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

WHEELS/TIRES/BALLAST

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

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

Bolts are M22 - 1.5, GR. 10.9

10

1

8 12

6

3

4 TRIM THIS EDGE

11

5 7

2

9

B0987A88

621D

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WHEELS/TIRES/BALLAST

TIRE PRESSURE CHART TREAD

SIZE 17.5 X 25

Front

17.5 X 25

Front

17.5R25

Front

17.5R25

Front

20.5 X 25

Front

20.5 X 25

Front

20.5 X 25

Front

20.5 X 25

Front

TIRE PRESSURE

TYPE

kPa

(PSI)

(bar)

L2

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

345

50

3.45

275

40

2.75

Rear L3

Rear XTLA TL*

Rear XHA TL

Rear L2

Rear L3

Rear XTLA TL*

Rear XHA TL*

Rear

107

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TIRE

WHEELS/TIRES/BALLAST

NOTES

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LUBRICATION/FILTERS/FLUIDS

LUBRICATION/FILTERS/FLUIDS GENERAL SAFETY BEFORE YOU SERVICE WARNING: Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your dealer or the service manual for this machine.

SC021

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

SA044

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

TRIM THIS EDGE

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

U n d e r s t a n d t h e o p e ra t i o n o f t h e machine before you start servicing.

B770996R

B801147T

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

321-4614

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LUBRICATION/FILTERS/FLUIDS

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

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

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

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

M824

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2 2

1

3

BD01E127

BD01E116

SUPPORT STRUT IN TRANSPORT POSITION

SUPPORT STRUT IN SERVICE POSITION

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LUBRICATION/FILTERS/FLUIDS

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

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

SA069

BD00M030

STRAIGHT AHEAD LOCKED POSITION

BD00M027

OPERATING POSITION

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

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

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

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

LUBRICATION/FILTERS/FLUIDS

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

TRIM THIS EDGE B830752T

PLASTIC AND RESIN PARTS Avoid using gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts.

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

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LUBRICATION/FILTERS/FLUIDS

THE ENGINE HOOD

2

3

1

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

2. ASSIST STRAP 3. STRUT RELEASE TAB

BD01A003

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

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BD01E128BR

1. HANDLE

LUBRICATION/FILTERS/FLUIDS

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

0

RPM x 100

30

electronic

C HORÍMETRO

TRIM THIS EDGE

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

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LUBRICATION/FILTERS/FLUIDS

FLUIDS AND LUBRICANTS - 621D

Fuel Additive

CAPACITY

SPECIFICATIONS

189,0 L (50.0 US gal)

Diesel nÀ 2 Additive CNH 1 liter (71104731) Additive CNH 5 liters (71104732)

1,9 L (0.5 US gal)

Engine oil With filter change 15,1 L (4.0 US gal) Without filter change 14,2 L (3.7 US gal) Engine cooling system System total capacity 36,0 L (9.5 US gal) Hydraulic and Break system System total capacity

113,6 L (29.8 US gal)

With filter change

56,8 L (15.0 US gal)

Without filter change

68,5 L (18.0 US gal)

Transmission System total capacity With filter change Front and Rear axles System total capacity Differential Hubs Grease fittings All Air conditioning

Akcela nÀ 1 Engine Oil SAE 15W-40 API CJ-4

50% Akcela Premium Anti-freeze + 50% water Up to serial HBZN621DKEAE06828 Akcela Hy-Tran Ultraction Starting with serial HBZN621DKEAE06829 Akcela Auto Supreme 10W-30

26,0 L (6.7 US gal) 18,9 L (5.0 US gal)

Akcela nÀ 1 Engine Oil SAE 15W-40 API CJ-4

20,3 L (5.3 US gal) 13,9 L (3.6 US gal) 3,6 L (0.9 US gal)

Akcela Gear 135H EP 85W-140 (SAE 85W 140 API-GL5) + Additive CASE 149175A1 (see NOTE)

As needed

Akcela Molygrease

Compressor lubricant

200 ml

Air conditioning refrigerant

1700 g

Polyol esters synthetic lubricant (POE) HFC-134a Required viscosity ISO VG 68 Ecological refrigerant hydrofluorocarbon HFC-134a

NOTE: Front axle - supply (13.9 liters of oil + 0.6 liters of additive 149175A1) NOTE: Rear axle - supply (13.9 liters of oil + 0.6 liters of additive 149175A1) WARNING: Only the differential require additive 149175A1.

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COMPONENTS Fuel tank System total capacity

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

TRIM THIS EDGE

134 Air Cleaner (See Note 1)

❉

148 Hydraulic Filter (See Note 2)

❉

176 Alternator Drive Belt

❉

176 Air Conditioning Compressor Belt (If Equipped)

❉

131 Engine Oil Level (See Note 3)

10

139 Radiator Coolant Level (See Note 4)

50

152 Transmission Oil Level (engine running oil warm)

50

147 Hydraulic Reservoir Fluid Level

50

120 Bucket Pivots

6

50

121 Front Drive Shaft Support Bearing

1

50

121 Steering Cylinder Pivots - Closed End

2

100

121 Steering Cylinder Pivots - Rod End

2

100

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

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

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

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

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DRAIN WATERS

LUBRICATE

CLEAN

SERVICE POINTS

CHECK

NUMBER OF POINTS

PAGE NUMBER

FREQUENCY IN HOURS

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

131 Engine Oil

DRAIN WATER

CLEAN

LUBRICATE

REPLACE

CHANGE

SERVICE POINTS

CHECK

NUMBER OF POINTS

250

132 Engine Oil Filter

250

176 Air Conditioning Compressor Belt (If Equipped)

250

178 Battery Fluid Level

250

107 Tire Condition and Air Pressure

250

157 Cab Air Filter (If Equipped)

250

144 Fuel Filter

500

143 Fuel Tank

500

172 ROPS and Seat Belt Mounting Bolts

500

148 Hydraulic Filter

1000

152 Transmission Filter (See Note 1)

1000

152 Transmission Oil (See Note 2)

1000

152 Transmission Breather

1000

122 Upper and Lower Chassis Pivots

2

1000

NOTE 1:Replace the transmission filter if the transmission filter restriction warning lamp illuminates.

NOTE 2:After the first 100 hours of operation and then every 1000 hours there after.

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PAGE NUMBER

FREQUENCY IN HOURS

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

155 Rear Axle Differential Oil and Planetary Oil (See Note 1) Turbocharger Mounting Bolt Torque

1000 2000

150 Hydraulic Oil (See Note 1)

2000

138 Engine Coolant

2000

134 Air Filter Elements

2000

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NOTE 1:Or when ambient operating temperatures require.

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CLEAN

ADJUST

REPLACE

CHANGE

SERVICE POINTS

CHECK

NUMBER OF POINTS

PAGE NUMBER

FREQUENCY IN HOURS

LUBRICATION/FILTERS/FLUIDS

ACCESS DOORS

BD00M066

BD00M063

RAISE COOLING UNITS TO EXPOSE HYDRAULIC FILL CAP

TRIM THIS EDGE

ENGINE ACCESS HOOD

BD00M059

RADIATOR AND HYDRAULIC FLUID ACCESS DOOR

BD00N055

HYDRAULIC FLUID

BD00M063

RADIATOR CAP

BD00M068

FUSE BOX AND CAB FILTER ACCESS DOOR

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 50 HOURS Z-Bar Linkage Use AKCELA Molygrease (1070173)

1

1

1

B890716J

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

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 100 HOURS Z-Bar Linkage

TRIM THIS EDGE

Use AKCELA Molygrease (1070173)

1.

2.

3.

4.

5.

6.

7.

8.

BC01A101

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

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 1000 HOURS Z-Bar and XT Linkage Use AKCELA Molygrease (1070173)

TRIM THIS EDGE

1

3

2 BC00N081

1. Lower Chassis Pivot ....................................................................................... 1 2. Upper Chassis Pivot ....................................................................................... 1 3. Center Drive Shaft Slip Joint .......................................................................... 1

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 50 HOURS XT Linkage Use AKCELA Molygrease (1070173)

1

1

123

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907L92

1. Bucket and Bell crank Pivot Points ............................................................. 10

LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 100 HOURS XT Linkage Use AKCELA Molygrease (1070173)

TRIM THIS EDGE

BC01A100

1. Loader Lift Arm Pivots ....................................................... 8 (Four Each Side) 2. Lift Cylinders (Closed End)................................................. 2 (One Each Side)

1

1

1

4

5

1 2

3.

4.

5.

6.

7.

8.

L917L92

Steering Cylinders (Closed End, Remote)........................... 2 (One Each Side) Bucket Cylinder (Closed End, Remote) ............................... 2 (One Each Side) Lift Cylinders (Rod End) ...................................................... 2 (One Each Side) Front Driveshaft Support Bearing (Remote) ................................................... 1 Steering Cylinder (Rod End)................................................ 2 (One Each Side) Bucket and Bell Crank Pivot Points ....................................10 (Five Each side) 124

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LUBRICATION/FILTERS/FLUIDS

FLUID LEVELS 10 Hours

1

BD00M015BR

TRIM THIS EDGE

1. ENGINE OIL RESERVOIR

2

3

1

B910922J

2 3

BD00M062

RD98K315

2. RADIATOR COOLANT LEVEL AKCELA PREMIUM ANTI FREEZE AND WATER

3. RADIATOR AKCELA PREMIUM ANTI FREEZE AND WATER

125

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LUBRICATION/FILTERS/FLUIDS

50 Hours 4

5

4

BD00N055

4. HYDRAULIC RESERVOIR

TRIM THIS EDGE

4

RD98A170

5. TRANSMISSION RESERVOIR

5

B910922J

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LUBRICATION/FILTERS/FLUIDS

250Hours

1

BD00N050

TRIM THIS EDGE

1.FILL BATTERIES WITH DRINKING OR DISTILLED WATER (BOTH SIDES)

1

1 BS00N080

NOTE: One battery on each rear side of machine.

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

127

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LUBRICATION/FILTERS/FLUIDS

1

BC00N081

1. One battery each side.

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LUBRICATION/FILTERS/FLUIDS

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

If AKCELA Multi-Viscosity Engine Oil is not available, use only oil meeting API engine oil service category CJ-4, CH-4 or CI-4.

RH99K130

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

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

LUBRICATION/FILTERS/FLUIDS

Oil Viscosity/Temperature Ranges

TRIM THIS EDGE BC02N250

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

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LUBRICATION/FILTERS/FLUIDS

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

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

Oil type ...................................................................... See “Fluids and Lubricants” Oil Capacity - with filter change ..................................... 15.1 liters (4 U.S. Quarts)

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

BD00M015BR

ENGINE OIL LEVEL DIPSTICK

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Engine Oil Level

LUBRICATION/FILTERS/FLUIDS

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

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

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

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

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

2. Remove the engine oil drain plug.

IMPORTANT: Do not use a filter strap wrench to install the oil filter. An oil filter strap wrench can cause a leak if the filter is dented.

3. Open the rear engine access doors.

8. Install the drain plug.

TRIM THIS EDGE

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

1 2

BD02N070

1. ENGINE OIL FILTER

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

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

2. ENGINE OIL DRAIN

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

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

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BD00M031

LUBRICATION/FILTERS/FLUIDS

1

BD01E139

BD00M015BR

10. Fill the tubocharger oil lines with oil.

A. Disconnect the wire from the injector pump solenoid. Fhis will prevent the engine from starting.

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

C. Connect the wire to the injection pump solenoid.

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

12. Close the engine access doors.

Systemgard Lubrication Analysis Program The normal engine oil change interval is every 500 hours of operation or once a year whichever occurs first. Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended to use the Systemgard Lubrication Analysis Program. See your dealer.

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

CM107

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

CM115

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1. ELECTRICAL CONNECTOR

1. ENGINE OIL FILLER PIPE

LUBRICATION/FILTERS/FLUIDS

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

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

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

134

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LUBRICATION/FILTERS/FLUIDS

Dust Valve

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

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

BD00M008

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

BD00M011

3. Carefully remove (outer) element.

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the

primary

TRIM THIS EDGE

BD02N053

2. Rotate the end cap counterclockwise to unlock.

LUBRICATION/FILTERS/FLUIDS

BD00M012

BD00M012

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

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

TRIM THIS EDGE

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

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

7. Close the engine hood.

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

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

RD007081

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

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

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LUBRICATION/FILTERS/FLUIDS

Cleaning the Element

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

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

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

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

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

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

777L94

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

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

779L94

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

780L94

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778L94

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

LUBRICATION/FILTERS/FLUIDS

ENGINE COOLING SYSTEM Service Specifications Cooling System Capacity ..............................................36 liters (9.5 U.S. Gallons) Cooling system drain, flush, and refill interval ....... Every 2000 hours of operation or each year, whichever occurs first.

Reservoir Coolant Fluid Level Check Interval ............. Every 10 hours of operation

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

Coolant Mixture TRIM THIS EDGE

A mixture of 50% Akcela Premium Anti-freeze and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37˚C (34˚F). If the ambient temperature is lower, adjust the mixture to 60% Akcela Premium Anti-freeze and 40% water. It is recommended that Akcela Premium Anti-freeze and water be used in your machine all year.

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

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

Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance instructions.

SA023

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LUBRICATION/FILTERS/FLUIDS

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

IMPORTANT: Cooling System is under pressure. Before adding coolant, allow radiator to cool and remove radiator cap SLOWLY. Check the coolant reservoir fluid level when the coolant is cold and the engine i s s t o p p e d . D O N OT r e m ove t h e radiator cap during this check. The coolant level must be between the FULL and ADD marks on the reservoir.

Add coolant as required to raise the coolant level to the FULL mark.

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BD00M020

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

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

IMPORTANT: Only add the correct mixture of Akcela Premium Anti-freeze and water to the radiator.

BD00M062

1. RADIATOR CAP

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

Check and service engine cooling system according to maintenance instructions.

SA023

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LUBRICATION/FILTERS/FLUIDS

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

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

DO NOT remove the radiator cap if the c o o l a n t i s h o t . H ave a c o n t a i n e r available that is capable of holding 34.1 liters (9.0 gal).

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

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

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

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

5. Put a 50% mixture of Akcela Premium Anti-freeze and water in the radiator. See Coolant Mixture in this manual.

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

7. Install the radiator cap.

BD00M031

1. RADIATOR DRAIN VALVE

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LUBRICATION/FILTERS/FLUIDS

DIESEL FUEL SYSTEM Service Specifications Fuel Tank Capacity ..................................................... 189 liters (50 U.S. Gallons) Interval for draining water from the fuel filter ....................... 50 hours of operation Fuel filter replacement interval .......................................... 500 hours of operation or once each year, whichever occurs first Adjust fuel injector .................................................................see your CNH dealer

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

The conditioner will:

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

3. Separate moisture from the fuel.

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

SA022

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

Never smoke while refueling.

M139C

Fuel Filler Cap

BD00M036

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4. Stabilize the fuel in storage.

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

LUBRICATION/FILTERS/FLUIDS

Diesel Fuel

Fuel Storage

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

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

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

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

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

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

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

When adding fuel to the machine, remove the fuel cap SLOWLY to reduce the air pressure build up.

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

Specifications for Acceptable No. 2 Diesel Fuel API Gravity, Minimum API Gravity, Minimum ..................................................... 34 Flash Point, Minimum ........................................................................ 60˚C (140˚F) Cloud Point (wax appearance point), Maximum ...... -20˚C (-5˚F) See Note Above Pour Point, Maximum ............................................ -26˚C (-15˚F) See Note Above Distillation Temperature, 90% Point ............................ 282 to 338˚C (540 to 640F) Viscosity, at 38˚C (100˚F) Centistokes .......................................................................................... 2.0 to 4.3 Cetane Number, Minimum ...................... 43 (45 to 55 for winter or high altitudes) Water and Sediment, by Volume, Maximum ............................................... 0.05% WARNING: Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame, welding, burning cigars, cigarettes, etc.

SA022

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

Never smoke while refueling.

M139C

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LUBRICATION/FILTERS/FLUIDS

Removing Water and Sediment from the Fuel System Drain the water for the fuel filters after every 250 hours of operation. Drain the water and sediment from the fuel tank after every 500 hours of operation.

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

2. Close the drain valves.

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

BD01E130

1. WATER DRAIN

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1

LUBRICATION/FILTERS/FLUIDS

Fuel Filter Replace the fuel filters after every 500 hours of operation.

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

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

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

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

1

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

BD01E130

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1. FUEL FILTERS

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LUBRICATION/FILTERS/FLUIDS

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

Remove the filter from the fuel line.

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

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

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

BD01E131

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5. See Removing Water Sediment on Page 143.

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LUBRICATION/FILTERS/FLUIDS

HYDRAULIC/BRAKE SYSTEM Service Specifications Hydraulic/Brake System Fluid Chart Hydraulic Reservoir Refill Capacity w/filter change............ 56.8 Liters (15 gallons) Total System Capacity ................................................... 113.6 Liters (29.8 gallons) Type of Fluid.................................................................See “Fluids and Lubricants” Hydraulic Reservoir Fluid Level Check Interval...............................Every 50 Hours Filter Replacement Interval ................................Every 1000 Hours of Operation or if the Hydraulic Filter Warning Lamp Illuminates Hydraulic Fluid Change Interval ..................................................Every 2000 Hours or once each year, whichever occurs first.

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

SA047

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LUBRICATION/FILTERS/FLUIDS

Hydraulic Oil Level

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

2. Open the access cover in the hood.

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

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

4. Clean the area around the filler cap.

To check the oil level in the hydraulic reservoir do the following:

5. Slowly loosen the filler cap on the hydraulic reservoir. This will release the air pressure in the hydraulic reser voir.Remove the filler cap from the hydraulic reservoir.

1. Park the machine on a level surface and lower the loader bucket to the ground. Apply the parking brake.

2. Stop the engine.

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

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

7. Install the filler cap and hand tighten.

8. Repeat steps 2-3 in reverse order.

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BD01E132

3. Pivot the air conditioning condensor or cover to the rear. Ensure that the cooler is locked open.

LUBRICATION/FILTERS/FLUIDS

Hydraulic Filters

2. Increase the engine speed to full throttle. If the LAMP for the hydraulic oil filters illuminates, replace both filters.

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

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

Apply the parking brake.

2. Slowly loosen the filler cap on the hydraulic reservoir. This will release the air pressure in the hydraulic reservoir.

BD00N081

Hydraulic Filter Test TRIM THIS EDGE

3. Remove the access cover. (If Equipped)

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

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

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

A. Dump the bucket and hold over relief while cycling the Lift arms up and down. It can take several minutes to bring the oil to operating temperature. Refer to instruction on the instrument cluster for using it to read hydraulic oil temperature.

5. Lubricate the gasket on the new filter with hydraulic fluid. Turn the new filter clockwise until the filter contacts the head of the filter assembly. Continue to tighten the filter 1/2 to 3/4 turn by hand.

IMPORTANT: DO NOT use a filter wrench to tighten the hydraulic filter.

B. After 15 seconds, move the control lever to the HOLD position.

6. Tighten the filler cap.

7. Start and run the engine at approximately 1000 rpm. Check for oil leaks around the filter.

C. Repeat steps a and b until the hydraulic oil temperature is 50 C (120 F).

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LUBRICATION/FILTERS/FLUIDS 8. Stop the engine and check the hy d ra u l i c o i l l eve l . A d d o i l a s required. See Hydraulic System in this manual fo r correct specifications.

9. Install the Equipped)

access

cover.(If

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

SA047

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

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SA047

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LUBRICATION/FILTERS/FLUIDS

HYDRAULIC/BRAKE OIL CHANGE

8. Remove and replace the hydraulic oil filter.

Change the hydraulic/brake oil every 2000 hours of operation or one time each year, or when ambient operating temperatures require, whichever occurs first. When changing the hydraulic oil also replace the hydraulic oil filter. Have a container available that is capable of holding 68.5 liters (18 gal).

9. See Hydraulic System in this manual for the correct type and quantity of hydraulic oil. Put new oil into the reservoir.

1. Make sure the hydraulic oil is at operating temperature.

2. Park the machine on a level surface. Lower the loader bucket to the ground and apply the parking brake.

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3. Stop the engine. Put a DO NOT OPERATE tag on the steering wheel.

4. Make sure the accumulators are completely discharged. Push down and release the brake pedal a minimum of 30 times.

5. With the key in the RUN position, cycle the pilot controller repeatedly for at least 30 seconds. Open the manual valve for the ride control and allow it to bleed for one minute or until the hiss of discharging oil cannot be heard. Close the manual valve for the ride control.

10. Install the reservoir filler cap.

11. Start the engine and run at 1000 rpm. Check for oil leaks around the filter and the drain plug.

12. Bleed the brake system to remove old oil from the system. Remove a minimum of 1 Liter of oil from each bleed screw to make sure all old oil is removed from the system (See Bleeding the brake system in this manual).

13. Operate the loader controls several times to remove any air in the lines.

14. Lower the loader bucket to the ground and stop the engine. Check the hydraulic oil level.

15. Add oil as required.

6. Open the hydraulic reservoir remote drain over the container. The remote drain is the rearmost of the three drains behind the left rear wheel.

7. Clean the area around the filler cap and access cover. Slowly remove the filler cap of the reservoir. This will remove the air pressure from the reservoir.

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LUBRICATION/FILTERS/FLUIDS

TRANSMISSION Service Specifications Transmission refill capacity with filters............................. 7.8 liters (2 U.S. Gallons) Total system capacity .................................................... 26 liters (6.7 U.S. Gallons) Type of oil .................................................................. See “Fluids and Lubricants” Oil level check interval ............................................................................. 50 hours Filter replacement interval ............................ After the first 100 hours of operation and then every 1000 hours there after.

Breather cleaning interval ................................................................... 1000 hours Oil change interval ....................................... After the first 100 hours of operation and then every 1000 hours there after.

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

CM107

IMPORTANT: Change the transmission oil and replace the filter after the first 100 hours of operation.

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IMPORTANT: If the machine is new or the transmission has been replaced or rebuilt, change the transmission oil and replace the filter after the first 100 hours of operation.

LUBRICATION/FILTERS/FLUIDS

Transmission Oil Level

Warm Oil Level Check

See this page for the two methods to check the transmission oil level.

Check the transmission oil level every 50 hours of operation when the oil is at operating temperature. Do the following.

Oil Change, Filter Replacement, and Breather Cleaning

BD01E133

1. Park the machine on a level surface.

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2. Apply the parking brake.

3. Shift the transmission to NEUTRAL.

C h a n g e t h e t ra n s m i s s i o n o i l a n d replace the filter after the first 100 hours of operation with a new machine or if the transmission has been replaced or rebuilt. Then, do the above service and clean the breather every 1000 hours or operation.

If possible, drain the oil when the oil is at operating temperature. More contamination is removed when the oil is at operating temperature.

4. Run the engine at idle speed.

5. If the oil level is at or below the bottom of the crosshatch region, put the transport/service link in the LOCKED position and add oil to raise the oil level up to the top of the crosshatch region. See Transmission Service Specifications in this manual for the correct oil.

1. Put the transport/service link in the LOCKED position, apply the parking brake, and stop the engine.

2. Clean the area around the filters, drain plug, breather, and filler tube.

3. Have a container that will hold approximately 30.3 liters (8 U.S. Gallons).

Cold Oil Level Check Before you start the engine, check the transmission oil level in the sight gauge. If the oil level is below the arrow, add oil to raise the oil level up to the arrow. See Transmission Ser vice Specifications in this manual for the correct type of oil.

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LUBRICATION/FILTERS/FLUIDS 4. Remove the filler tube plug.

7. Install the filter as shown. Make sure the filter is SEATED against the filter base.

8. Spin the breather cap a few times w i t h y o u r fi n g e r eve r y 1 0 0 0 hours.(It is located directly on top of the transmission.

9. If the breather cap does not spin easily perform lines 10 and 11.

11. Install the breather.

12. Install the drain plug. Put new oil into the transmission. See Transmission Service Specifications in this manual.

13. Check the oil level in the sight gauge.

14. Start the engine and check for oil leaks around the filters and drain plug.

RB97G074J

1. DRAIN PLUG

2. O-RING

6. Remove the transmission filter.

Discard the old transmission filter.

15. Increase the transmission oil temperature to 90˚ C (194˚ F) and check the oil level again.

16. Stop the engine and return the transpor t/ser vice link to the OPERATING position.

BD00N081

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BD00M028

5. Remove the drain plug and drain the oil from the transmission.

10. Remove the breather. Clean the breather with solvent and dry with compressed air. Be sure to wear fa c e p r o t e c t i o n w h e n u s i n g compressed air.

LUBRICATION/FILTERS/FLUIDS

AXLES Service Specifications Type of oil ................................................................... See “Fluids and Lubricants” Alternate oil ............................................................................................. See note Oil change interval ................................... After the first 100 hours of operation and then every 1000 hours there after.

Front Axle - Differential................................. 13.9 liters of oil + 0.6 liters of additive Front Axle - Hubs .............................................................................. 3.6 liters of oil Rear Axle - Differential ................................. 13.9 liters of oil + 0.6 liters of additive Rear Axle - Hubs............................................................................... 3.6 liters of oil Type of oil and additive................................................ See “Fluids and Lubricants” Oil change interval ................................... After the first 100 hours of operation and then every 1000 hours there after.

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NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil.

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LUBRICATION/FILTERS/FLUIDS

Axle Oil Level To check the oil level at the center bowl and each planetary end, do the following procedure.

NOTE: The oil level and filler plugs in the center bowl and planetary ends are magnetic. Remove and clean these plugs after the first 50 and 500 hours of operation with a new or rebuilt axle.

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Differencial

Bujão de nível M 22 x 1,5

Hubs

1. Park the machine on a level surface.

2. Remove all 3 plugs from axle planetary and center bowl. Oil level must be on the boundarie of each holes

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LUBRICATION/FILTERS/FLUIDS

Axle Oil Change Change the axle oil After the first 100 hours of operation and then every 1000 hours there after.

Drain 1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Remove all 3 drain plugs from axle planetary and center bowl . Drain.

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Fill 1. After removal of the oil, install the center bowl and planetary drain plugs.

2. Fill with new oil according specifications. See “Fluids and Lubricants”

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LUBRICATION/FILTERS/FLUIDS

CAB AIR FILTER Clean or replace the cab air filters (if equipped) every 250 hours of operation or if the air flow in the cab is reduced.

3. Install a filter that has been cleaned or a new filter.

NOTE: If your machine is new, make sure the plastic cover is removed from the filters.

4. Close the access door and turn the handle to the locked position.

Removal and Installation

BD00M070

BD00M070

2. Pull the air filter out.

BD00M067

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1. Turn the handle and open the access door.

LUBRICATION/FILTERS/FLUIDS

Circulation Cover

BD00N028

5. Remove the air circulation filter.

6. Install a filter that has been cleaned or a new filter.

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LUBRICATION/FILTERS/FLUIDS

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

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

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

1. Remove the loose dirt with compressed air, 30 psi (207 kPa, 2 bar) maximum. Hold the nozzle at least one inch (25 mm) from the element. Make sure you wear face protection when using compressed air.

786L94

2. Mix two tablespoons of D1400 d e t e r g e n t ( C a s e p a r t nu m b e r A40910) with two gallons (7.6 litres) of water, one cup for 16 gallons (60 litres) of water.

788L94

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

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787L94

4. Use a water hose without a nozzle with pressure less than 40 psi (275 kPa, 2.7 bar) to flush all soap from the element.

LUBRICATION/FILTERS/FLUIDS 6. Use a light and inspect the element for holes or splits in the pleats.

Check for damage to the metal parts and rubber gasket.

789L94

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

WINDSHIELD WASHER RESERVOIR (IF EQUIPPED) TRIM THIS EDGE BD00M024

The windshield washer reservoir is located in the right side of the engine compartment. To add washer fluid, pull the cap up.

IMPORTANT: When the ambient temperature decreases to 0˚C (32˚F) and below, always use an antifreeze type washer solution.

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MAINTENANCE/ADJUSTMENT STARTING FLUID CAN (If Equipped) Replacing Starting Fluid Can 1. Loosen the clamp.

2. Remove (turn counterclockwise) the starting fluid container.

3. Install (turn clockwise) a new container of starting fluid.

4. Tighten the clamp.

IMPORTANT: Read the warnings and information on the containers of starting fluid.

When you do not need the Cold Start System because of warm weather, do the following to protect the solenoid valve:

DO NOT store extra containers in the operators area.

If you weld, grind or use a cutting torch on the machine, always remove the s t a r t i n g fl u i d c o n t a i n e r f r o m t h e m a c h i n e. U s e c o m p r e s s e d a i r t o remove any ether fumes from the area.

!

1. Remove the starting fluid container.

2. Install the cap on the solenoid valve.

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. Use starting fluid according to instructions in this manual.

SB039

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Storage BD01A002

MAINTENANCE/ADJUSTMENT

CAB SERVICE Air Conditioning (If Equipped) The components of the operators cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

WARNING: Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions.

SA048

Lubrication of the Air Conditioning Compressor Seals TRIM THIS EDGE

Operate the air conditioning once every 250 hours to lubricate the compressor seals. Turn the air conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 32˚F (0˚C) put a c o ve r o ve r t h e a i r c o n d i t i o n i n g condenser. This will make sure the refrigerant and lubricants in the system will be at operating temperature.

Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the condenser. Also check and clean the grille screen.

IMPORTANT: Because the condenser fins bend easily, be careful when you clean the condenser.

BD00M063

1. CONDENSER

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MAINTENANCE/ADJUSTMENT

Cab Headliner

Door Hinges

T h e fo a m h e a d l i n e r i n y o u r c a b decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

Use graphite to lubricate all hinges. DO NOT use oil.

IMPORTANT: DO NOT wash the headliner with water because water can cause damage to the headliner and lower the noise control capacity of the headliner.

Check all hoses and wiring for damage.

If damage occurred, see your dealer for repair or replacement.

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Hoses and Wiring

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MAINTENANCE/ADJUSTMENT

Operators Seat Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct use of a material cleaner.

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

WARNING: Never use gasoline, naptha or any other volatile material for any cleaning purposes. These materials may be toxic and/or flammable.

SA049

CLEANER FLUID - This type of cleaner can be used for grease or oil stains.

Carefully remove the item that caused the stain with a scraper or a knife that is not sharp. Use very little cleaner, no pressure, and clean cloths. Move the cloth from the outside of the stain toward the center of the stain and constantly change to a clean section of cloth.

When the stain is removed from the material, immediately use a cloth to make dry the area and to prevent a cleaner circle pattern. If a circle pattern occurs, clean the complete area.

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NOTE: A difficult stain can need a second application of cleaner fluid followed immediately by the use of a soft brush to completely remove the stain.

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MAINTENANCE/ADJUSTMENT

LOADER ADJUSTMENTS Height Control and Return To Travel Adjustment Procedure 6 2

5

4

3

BS00N076

1. Proximity Switch

4. Height Control Target

2. Return to Travel Target

5. Lift Arm

3. Target Mounting Plate

6. Front Chassis (Top Left Hand Side)

1. To avoid damage to the proximity switch, it must be adjusted back, away from the lift arm, to clear everything on the lift arm as it sweeps past.

2. Start the engine. Position the bucket flat on the ground. Shut the machine off.

Locate the return to travel target opposite the proximity switch and then tighten it to the target mounting plate. Next adjust the proximity switch out toward the target until and air gap of 3.5 to 5.0 mm (1/8 to 3/16 inch) is obtained. Lock the proximity switch in position with its jam nut. Torque the jam nut to 5 ft.lbs.

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1

MAINTENANCE/ADJUSTMENT

A

2

B

4

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BX00N077

2.) Return to Travel Target 4.) Height Control Target

3. The Location of the height control target within its slot in the target mounting plate will determine the automatic stopping height of the lift arms as they are raised. The higher the target is positioned in its slot in the target mounting plate, the lower the lift arms will automatically stop as they are raised. Position the target per the table below. Tighten the target in this position.

MACHINE

A mm (in)

APPROXIMATE B mm (in) APPROXIMATE RERESULTING RESULTING HEIGHT CONTURN TO TRAVEL TROL HINGE PIN HINGE PIN HEIGHT mm (in) HEIGHT

621D Z-BAR

54 (2.13 in)

380 (14.96 in)

48 (1.89 in)

3302 (130 in)

621D XT

51 (2.01 in)

403 (15.87 in)

43 (1.69 in)

3302 (130 in)

4. The location of the return to travel target within its slot in the target mounting plate will determine where the lift arms will automatically stop while they are lowered. The higher this target is located in its slot in the target mounting plate the lower the lift arms will automatically stop as they are lowered. Position the target per the above table. Tighten the target in this position.

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MAINTENANCE/ADJUSTMENT 5. Make sure the proximity switch and all the mounting bolts are tight. Start the engine. Set the detent switch to the on position, and set the return to travel/ float detent switch to the return to travel position. Raise the lift arms to approximately the horizontal position. Put the loader control lever in the raise position, and verify that the electromagnet holds it in that position until the height control target passes in front of the proximity switch. Next, with the lift arms still raised, put the loader control lever in the lower position, and verify that the electromagnet holds it in that position until the return to travel target passes in front of the proximity switch. Position the bucket flat on the ground.

Shut the machine off.

XT Return To Dig Adjustment Procedure 1 2 TRIM THIS EDGE

6

5 3 4

BS00N078

1. Tilt Cylinder (Left Hand Side)

4. Target Bar

2. Proximity Switch Mounting Bracket

5. Proximity Switch

3. Proximity Switch Guard

6. Target Mounting Bracket

1. Start the engine. Raise the lift arms until they are approximately horizontal.

Roll the bucket all the way back. Lower the arms until they are on the ground.

Shut the machine off.

2. Loosen the bolts holding the target mounting bracket to the tilt cylinder clevis.

Align the target mounting bracket parallel to the tilt cylinder, and tighten the bolts.

3. Loosen the bolts holding the target bar to the target mounting bracket. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

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MAINTENANCE/ADJUSTMENT 4. Loosen the bolts holding the proximity switch mounting bracket to the cylinder.

Position the proximity switch face parallel to the target bar surface, and tighten the bolts. Next adjust the proximity switch out toward the target bar until and air gap of 3.5 - 5.0 mm (1/8 - 3/16 inch) is obtained. The proximity switch must not protrude past the proximity switch guard. Lock the proximity switch in position with its jam nut. Torque the jam nut to 5.0 ft. lbs.

5. Start the engine. Position the bucket flat on the ground. Shut the machine off.

Loosen the bolts holding the target bar to the target mounting bracket. Slide the target bar away from the proximity switch until the face of the proximity switch is completely uncovered. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

6. Turn the ignition switch to the on position (not accessory position). Do not start the engine. Position the bucket control lever to the full roll back position.

The electromagnetic detent should hold the control lever in this position.

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7. Loosen the bolts holding the target bar to the target mounting bracket. Slowly slide the target bar towards the proximity switch. When the proximity switch face is nearly covered by the target bar, the switch will be activated, and the control lever will return to the center position. Tighten the bolts maintaining this location of the target bar. Verify that the 3.5 to 5.0 mm (1/8-3/16 inch) gap is maintained between the target bar and the proximity switch.

8. Make sure the proximity switch and all the mounting bolts are tight. Start the engine. Set the detent switch to the on position, and set the return to travel/ float detent switch to the return to travel position. Raise the lift arms to approximately the horizontal position. Position the bucket to the fully dumped position. Put the loader control lever in the roll back position, and verify that the electromagnet holds it in that position until the end of the target bar passes in front of the proximity switch. Lower the lift arms to the ground, and verify the bucket is flat on the ground.

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MAINTENANCE/ADJUSTMENT

Z-Bar Return To Dig Adjustment Procedure

1 3

7 5 4

6 BS00N079

1. Bell Crank

4. Proximity Switch Guard

2. Target Mounting Bracket

5. Proximity Switch

3. Tilt Cylinder

6. Proximity Switch Mounting Bracket 7. Target Bar

1. Start the engine. Raise the lift arms until they are approximately horizontal.

Fully dump the bucket. Lower the arms until bucket edge is on the ground.

Shut the machine off.

2. Loosen the bolts holding the target mounting bracket to the tilt cylinder eye.

Align the target mounting bracket parallel to the tilt cylinder, and tighten the bolts.

3. Loosen the bolts holding the target bar to the target mounting bracket. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

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2

MAINTENANCE/ADJUSTMENT 4. Loosen the bolts holding the proximity switch mounting bracket to the tilt cylinder. Position the proximity switch face parallel to the target bar surface, and tighten the bolts. Next adjust the proximity switch face parallel to the target bar surface, and tighten the bolts. Next adjust the proximity switch out toward the target bar until an air gap of 3.5 to 5.0 mm (1/8 to 3/16 inch) is obtained. The proximity switch must not protrude past the proximity switch guard. Lock the proximity switch in position with its jam nuts. Torque the jam nut to 5.0 ft. lbs.

5. Start the engine. Position the bucket flat on the ground. Shut the machine off.

Loosen the bolts holding the target bar to the target mounting bracket. Slide the target bar towards the proximity switch until the face of the proximity switch is completely covered. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

6. Turn the ignition switch to the on position (not accessory position). Do not start the engine. Position the bucket control lever to the full roll back position.

The electromagnetic detent should hold the control lever in this position.

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7. Loosen the bolts holding the target bar to the target mounting bracket. Slowly slide the target bar away from the proximity switch. When the proximity switch face is nearly uncovered, the switch will be activated, and the control lever will return to the center position. Tighten the bolts maintaining this location of the target bar. Verify that the 3.5 to 5.0 mm (1/8 to 3/16 inch) gap is maintained between the target bar and the proximity switch.

8. Make sure the proximity switch and all the mounting bolts are tight. Start the engine. Set the detent switch to the on position, and set the return to travel/ float detent switch to the return to travel position. Raise the lift arms to approximately the horizontal position. Position the bucket to the fully dumped position. Put the loader control lever in the roll back position, and verify that the electromagnet holds it in that position until the end of the target bar passes in front of the proximity switch. Lower the lift arms to the ground, and verify the bucket is flat on the ground.

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MAINTENANCE/ADJUSTMENT

Bucket Height Control Minor Adjustment 1. Park the machine on a level surface. Lower the loader bucket to the floor.

2. Apply the parking brake and stop the engine.

3. Loosen the rear actuator.

4. To increase the dump height, move the actuator down in the slot. To decrease the dump height, move the actuator up.

5. Tighten the actuator.

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6. Start the engine and pull the lift control lever to the RAISE detent position.

When the loader arms stop moving, check the dump height.

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MAINTENANCE/ADJUSTMENT

ROLL-OVER PROTECTIVE STRUCTURE 4. Keep the seat belts clean. Wash the seat belts only in soap and water.

Yo u r m a c h i n e h a s a R o l l - O ve r Protective Structure (ROPS). A ROPS label shows the serial number of the R O P S , g r o s s w e i g h t , a p p r o va l , regulation, and model numbers of the machine. See Identification Numbers in this manual.

Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

5. Do not put the seat belts in bleach or dye. You will make the seat belts weak.

Maintenance and Inspection of ROPS After the first 20 hours of operation and after every 500 hours of operation, do the following:

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1. Check the torque of the ROPS m o u n t i n g b o l t s. I f n e c e s s a r y, tighten the bolts to the correct torque. See torque specifications on this page.

RD98K304

ROPS CANOPY LABEL

Seat Belt The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

2. Check the operators seat and the mounting parts for the seat belt.

Tighten the bolts to the correct torque. See Torque Specifications in this manual. Replace parts that have wear or damage.

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

1. Keep the seat belts away from objects that can damage the seat belts.

2. Check the seat belts for damage.

Replace all par ts that are damaged.

3. Make sure that the mounting bolts of the seat belts are tight. See Torque Specifications for Seat in this manual.

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MAINTENANCE/ADJUSTMENT

TORQUE SPECIFICATIONS FOR ROPS CAB AND ROPS CANOPY

BD00M101

NOTE: Torque specifications are for clean, dry threads.

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ROPS CAB AND ROPS CANOPY MOUNTING BOLTS (BOTH SIDES), TIGHTEN TO 772 TO 854 Nm (580 TO 630 POUND-FEET)

MAINTENANCE/ADJUSTMENT

Damage to the ROPS If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transpor t), you must replace the damaged ROPS components to get as much protection as you had originally.

After an accident, check the following for damage.

C. Seat belt mounting bolts and seat belt.

Before you operate the machine, replace all ROPS components that are damaged.

See the Parts Catalog or your dealer for components that are replaceable.

D O N OT T RY TO W E L D O R STRAIGHTEN THE ROPS.

A. ROPS canopy or cab.

B. Operators seat.

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WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this machine SA029

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

SB026

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label SA028

WARNING: Always fasten the seat belt securely before starting the engine SA036

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MAINTENANCE/ADJUSTMENT

TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS 1

2

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1

6397

1. 54-61 NM (40-45 FT LB) 2. 73-87 NM (54-64 FT LB)

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MAINTENANCE/ADJUSTMENT

ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT Service Interval Belt service interval.................................................................... Check as required Air conditioning compressor belt service interval................Check every 250 hours 4. Push the breaker bar forward just enough to release the tension on the drive belt. Remove the drive belt from the water pump pulley fi r s t a n d t h e n f r o m t h e o t h e r pulleys.

1. Park the machine on a level surface and apply the par king brake.

2. Turn the master disconnect to OFF. 3. Install a 1/2 inch breaker bar in the tension pulley bracket.

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) TRIM THIS EDGE

Type of Fire Extinguisher It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for C l a s s A , B a n d C t y p e fi r e s. T h e operating temperature is from -65˚ to 120˚F (-54˚ to 49˚C).

Inspection and Care EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to i n s u r e t h a t t h e g a u g e i s wo r k i n g correctly.

EVERY 6 MONTHS - Have the dry chemical removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

153L95

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS or FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

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ELECTRICAL SYSTEM Battery Safety

!

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

!

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

!

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

SA033

!

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (1) battery cable first.

2. When you connect the battery cables, always connect the negative (-) cable last.

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

4. Do not weld, grind, or smoke near a battery.

SB034

BATTERY SERVICE NOTE: The electrical system in this machine is 24 volts. Each battery is 12 volts.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Before you use an electric welder, d i s c o n n e c t t h e a l t e r n a t o r w i r e s, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

Do not run the engine with the battery c a bl e s d i s c o n n e c t e d o r w i t h t h e alternator wires disconnected.

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SB032

ELECTRICAL SYSTEM

Battery Fluid Level Check the fluid level of the batteries every 250 hours of operation. If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

IMPORTANT: If the temperature is 32˚F (0˚C) or below and you have added water to the batteries, do the following; Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

Battery Vents Keep the battery vents clean, make sure the vents are not restricted.

Cleaning the Batteries

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Check the batteries and battery compartment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries. Use one of the following methods to clean the batteries.

1. Use Case Battery Saver, Part Number M20376. Follow the instructions on the container. This cleaner does not need water.

2. Use baking soda or ammonia and flush the outside of the batteries with water.

If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

BS00N080

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ELECTRICAL SYSTEM

BD00N050

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IMPORTANT: Machine must be Jump Started from the LEFT side only!

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ELECTRICAL SYSTEM

FUSES The fuses in this machine are blade type. To replace, pull the old fuse straight out and push the new fuse straight in. The amperage for each fuse is stamped on the fuse. Refer to the fuse panel decal for correct location of each fuse.

RD97F154

TRIM THIS EDGE 75267433

NOTE: See the following page for detail of fuse information.

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ELECTRICAL SYSTEM

REPLACEMENT FUSES AMP

FUNCTION

A B

7.5 5

TRANSMISSION CONTROL FLASHER MODULE

C D E F G H J K L M N P R S T U V W X Y Z A’ B’ C’ D’ E’ F’ G’

5 5 10 5 15 5 10 10 7.5 7.5 10 7.5 7.5 5 7.5 7.5 7.5 15 7.5

RIDE/PILOT CONTROL PARKING BRAKE ETHER START ENGINE SHUTDOWN BLOWER SWITCH BACK UP ALARM FRONT WIPER/WASHER REAR WIPER/WASHER RADIO/CONVERTER SECONDARY STEERING COMPRESSOR (SEAT) COUPLER/FAN REVERSER SECONDARY STEERING INSTRUMENT CLUSTER TRANSMISSION CONTROL DOME LAMP-ENG COMP-HORN VOLTMETER CIGARETTE LIGHTER BEACON

10 10 5 5 5 5 5 5

FRONT FLOOD LIGHTS REAR FLOOD LIGHTS HIGH BEAM LEFT HIGH BEAM RIGHT LOW BEAM LEFT LOW BEAM RIGHT LEFT TAIL LIGHTS RIGHT TAIL LIGHTS

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FUSE

ELECTRICAL SYSTEM

SERVICE ELECTRICAL CONNECTOR (IF EQUIPPED) The cigar lighter socket (24 volt) can be used for the connection of a lighting device to help with service and maintenance procedures.

NOTE: This is a 24 volt outlet.

AUXILIARY POWER OUTLET (IF EQUIPPED) The Auxiliary Power Outlet socket (12 volt) can be used for the connection of a lighting device to help with service and maintenance procedures.

NOTE: This is a 12 volt outlet.

AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION TRIM THIS EDGE

The auxiliar y power equipment mounting brackets are located behind the right and left ROPS post covers.

These brackets are for mounting radios, phones, etc.

1

REPLACEMENT BULBS

HEADLAMP HIGH BEAM HEADLAMP LOW BEAM STOP/TURN/REVERSE TAIL LAMP POSITION DOME LAMP CONSOLE LAMP ROTATING BEACON *

CASE PART NUMBER

INDUSTRY NUMBER

410942A1 410941A1 410939A1 411085A1 410940A1 395185A1 --A187543 (Halogen)

H3 H7 S8 R10W T4W Osvam 6429 464 ----

* DO NOT touch the new halogen bulb with your fingers. Use gloves or use a tissue to hold the bulb.

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MACHINE STORAGE Storage Preparation

1. Wash the machine.

2. Lubricate the machine at all grease fittings.

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

4. Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

5. Drain the fuel tank.

6. Put approximately 8 liters (2 U.S. Gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue-white.

7. Drain the flushing oil from the fuel tank.

8. Put 15 ml (one tablespoon) of Shell Oil Company VPI crystals in the fuel tank.

10. Drain the cooling system. Leave the drain open and do not tighten the radiator cap. Put a Do Not Operate tag in the cab.

11. Clean or replace the element for the air filter.

primary

12. Cover the exposed steering cylinder rods, equipment valve spools with Case Rust and C o r r o s i o n P r eve n t a t i ve ( Pa r t Number B17510).

13. Charge the batteries. Remove the batteries from the machine and put the batteries on a wooden pallet in a cool dry area. If possible, keep the batteries in a building where the temperature is above freezing (0˚C [32˚F]). Make sure the batteries are clean.

NOTE: Always wear face protection when checking batteries. Check the batteries periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the batteries.

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If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

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

MACHINE STORAGE

Removal from Storage Do not start the engine until steps 1 through 10 have been done.

9. Use petroleum base solvent and r e m o ve t h e C a s e R u s t a n d Corrosion Preventive from the hydraulic cylinder rods.

1. Change the fuel filter.

2. Put coolant in the engine cooling system.

3. Check the condition of the drive belts. Replace if required.

10. See Battery Service in this manual and install the batteries.

11. Fill the fuel tank.

12. Prime the turbocharger with clean e n g i n e o i l . S e e yo u r S e r v i c e Manual or your dealer.

4. Check the engine oil level.

5. Check the hydraulic oil level.

6. Check the transmission oil level.

7. Check the oil level of both axles.

8. Lubricate the machine at all grease fittings.

13. Start the engine. It is important that you use the Starting the Engine procedure in this manual for priming the turbocharger lines with oil.

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SPECIFICATIONS

Make and model ....................................................................... Cummins 6T - 590 Air Induction ...................................................................................... Turbocharged Bore and stroke ........................................................ 102 x 120 mm (4.02” x 4.72”) Displacement .....................................................................5.9 Liters (359 cu inch) Compression ratio ..................................................................................... 17.5 to 1 Horsepower SAE gross ........................................ 102 kW at 2000 r/min (137 at 2000 rpm) SAE net ............................................... 93 kW at 2000 rpm (125 at 2000 rpm) Engine speeds Idle speed ................................................................................ 920 to 980 rpm Hydraulic Stall ...................................................................... 1980 to 2120 rpm Converter Stall ..................................................................... 1920 to 2120 rpm Combined Hydraulic and Converter Stall ............................ 1335 to 1570 rpm Valve Clearance (Engine Cold) Intake Valves ............................................................... 0.254 mm (0.010 inch) Exhaust Valves ............................................................. 0.508 mm (0.020 inch)

TRAVEL SPEEDS 621D with 17.5 x 25 Tires)

Forward Reverse

FIRST km/h (mph) 6.4 (4.0) 6.7 (4.2)

SECOND km/h (mph) 12.4 (7.7) 13.1 (8.1)

THIRD km/h (mph) 22.1 (13.7) 23.1 (14.4)

FOURTH km/h (mph) 35.7 (22.2) ---------

Buckets DESCRIPTION

WIDTH

CAPACITIES SAE Heaped

WEIGHT

Struck

m3

yd3

m3

yd3

kg

lbs

General Purpose

2602 mm (102.4 in)

1.91

(2.50)

1.66

(2.17)

705

(1 555)

General Purpose

2602 mm (102.4 in)

2.10

(2.75)

1.77

(2.32)

842

(1 856)

Material Handling

2602 mm (102.4 in)

2.29

(3.00)

1.96

(2.56)

884

(1 949)

XT Attachment

2602 mm (102.4 in)

1.91

(2.50)

1.64

(2.14)

*Weight includes coupler

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1 315* (2 900*)

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ENGINE DATA 621D

SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

A D B

E H

C

TRIM THIS EDGE

G

F

Machines with 1.91 m3 (2.5 yd3) General Purpose Bucket W/Bolt-On Edge A. B. C. D. E. F. G. H.

B0769A88

Tipping load, machine straight ....................................... 9 754 kg (21 503 lbs) Tipping load, 40 degree turn .......................................... 8 196 kg (18 070 lbs) Overall operating height, fully raised ............................... 4 925 mm (193.9 in) Height to bucket hinge pin, fully raised ........................... 3 829 mm (150.7 in) Dump height, 45 degree dump, full height ...................... 2 836 mm (111.7 in) Dump angle at full height ................................................................ 50 degree Bucket reach, 45 degree dump, full height .......................... 835 mm (32.9 in) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ....................................... 1 354 mm (53.3 in) Wheel Base ...................................................................... 2 900 mm (114.2 in) Overall Length .................................................................. 6 899 mm (271.6 in) Overall height to top of ROPS cab.................................... 3 259 mm (128.3 in)

Specifications taken with 20.5 R25 XTLA tires, ROPS cab with heater and air conditioning, 1 451 kg (3 3200 lb) rear counterweight, fenders, standard batteries, lamps, full fuel tank, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234,J695,J742 and J818.

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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

A D B

E H

G

F

Machines with 2.10 m3 (2.75 yd3) General Purpose Bucket W/Bolt-On Edge A. B. C. D. E. F. G. H.

B0769A88

Tipping load, machine straight ....................................... 9 634 kg (21 239 lbs) Tipping load, 40 degree turn .......................................... 8 089 kg (17 833 lbs) Overall operating height, fully raised ................................ 4 953 mm (195.0 in) Height to bucket hinge pin, fully raised ........................... 3 829 mm (150.7 in) Dump height, 45 degree dump, full height ...................... 2 782 mm (109.4 in) Dump angle at full height ................................................................ 50 degree Bucket reach, 45 degree dump, full height .......................... 880 mm (34.6 in) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ....................................... 1 371 mm (54.0 in) Wheel Base ...................................................................... 2 900 mm (114.2 in) Overall Length .................................................................. 6 974 mm (274.6 in) Overall height to top of ROPS cab.................................... 3 259 mm (128.3 in)

Specifications taken with 20.5 R25 XTLA tires, ROPS cab with heater and air conditioning, 1 451 kg (3 200 lb) rear counterweight, fenders, standard batteries, lamps, full fuel tank, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234, J695,J742 and J818.

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C

SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

A D B

E H

C

TRIM THIS EDGE

G

F

Machines with 2.29 m3 (3.0 yd3) Material Handling Bucket With Bolt-On Edge A. B. C. D. E. F. G. H.

Tipping load, machine straight ....................................... 9 537 kg (21 026 lbs) Tipping load, 40 degree turn .......................................... 7 997 kg (17 631 lbs) Overall operating height,(spillguard)................................. 5 030 mm (198.0 in) Height to bucket hinge pin, fully raised ........................... 3 826 mm (150.7 in) Dump height, 45 degree dump, full height ...................... 2 733 mm (107.6 in) Dump angle at full height ................................................................ 50 degree Bucket reach, 45 degree dump, full height ........................... 921 mm (36.2 in) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ....................................... 1 385 mm (54.5 in) Wheel Base ..................................................................... 2 900 mm (114.2 in) Overall Length ................................................................. 7 042 mm (277.2 in) Overall height to top of ROPS cab.................................... 3 259 mm (128.3 in)

Specifications taken with 20.5 R25 XTLA tires, ROPS cab with heater and air conditioning, 1 451 kg (3 200 lb) rear counterweight, fenders, standard batteries, lamps, full fuel tank, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234, J695, J742 and J818.

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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS

A D B

E H

G

F

XT Machines with 1.90 m3 (2.5 yd3) Bucket ACS Pro-Series 2000 Size 30 Coupler A. B. C. D. E. F. G. H.

B0769A88

Tipping load, machine straight ....................................... 8 107 kg (17 873 lbs) Tipping load, 40 degree turn .......................................... 6 690 kg (14 748 lbs) Overall operating height, (spillguard) ................................ 5 190 mm (204.4 in) Height to bucket hinge pin, fully raised ........................... 3 985 mm (156.9 in) Dump height, 45 degree dump, full height ...................... 2 943 mm (115.9 in) Dump angle at full height ................................................................ 50 degree Bucket reach, 45 degree dump, full height ........................ 1 150 mm (45.3 in) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ....................................... 1 695 mm (66.7 in) Wheel Base ..................................................................... 2 900 mm (114.2 in) Overall Length ................................................................. 7 202 mm (283.5 in) Overall height to top of ROPS cab.................................... 3 259 mm (128.3 in)

Specifications taken with 20.5 R25 XTLA tires, ROPS cab with heater and air conditioning, 1 451 kg (3 200 lb) rear counterweight, fenders, standard batteries, lamps, full fuel tank, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234, J695, J742 and J818.

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C

SPECIFICATIONS

Z-Bar Machines with 48” ACS Forks w/ Series 30 Coupler Fork Tine Size......................................... 64 x 152 x 1219 mm (2.5” x 6” x 48”) Maximum Fork Width.......................................................1 470 mm (57.9 inch) Maximum Fork Clearance....................................................... 3.7 m (12 ft 1 in) Fork Reach at Full Height - Vertical ....................................... 578 mm (22.8 in) Fork Clearance at Maximum Reach ....................................... 1.8 m (5 ft 10 in) Maximum Fork Reach ........................................................ 1 376 mm (54.2 in) Fork Reach at Ground - Vertical ........................................... 675 mm (26.6 in) Fork Load Center...................................................................... 610 mm (24 in) Weight (Fork Attachment, Forks and Coupler) .....................811 kg (1 789 lbs) Operating Load.................................................................. 3 072kg (6 774 lbs) Tipping Load (Straight) ................................................... 7 254 kg (15 992 lbs) Tipping Load (40 degree Turn) ........................................6 145 kg (13 547 lbs) Unit Operating Mass..................................................... 11 741 kg (25 885 lbs)

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SPECIFICATIONS

WEIGHTS - 621D Z-BAR Operating Weights with Machine Straight Bucket on Level Ground with 2.5 yd Bucket with edge

FRONT AXLE

REAR AXLE

TOTAL

4 391 kg (9 680 lbs)

7 352 kg (16 208 lbs)

4 445 kg (25 888 lbs)

WEIGHTS - 621D XT

with 2.5 yd Bucket with edge

FRONT AXLE

REAR AXLE

TOTAL

5 569 kg (12 227 lbs)

6 951 kg (15 325 lbs)

12 520 kg (27 602 lbs)

NOTE: Machine weights taken with 20.5 R25 XTLA Michelin tires; ROPS cab with heater and air conditioning; fenders; standard batteries; lamps; full fuel tank;1 451 kg (3 200 lb) standard counterweight; 79 kg (175 lb) operator and standard equipment.

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Operating Weights with Machine Straight

SPECIFICATIONS

Weight Adjustments for Optional Equipment 621D Z-Bar ITEM

POUNDS

(kg)

-1 156

-524

-948

-430

-1 016

-461

17.5 R 25, XHA

-792

-359

20.5 x 25, L2

-100

-45

228

104

380

173

-295

-134

17.5 x 25, L2 17.5 x 25, L3 17.5 R 25, XTLA

20.5 x 25, L3 20.5 R 25 XHA ROPS Canopy

Weight Adjustments for Optional Equipment 621D XT TRIM THIS EDGE

ITEM

POUNDS

(kg)

17.5 x 25, L2

-1 156

-524

17.5 x 25, L3

-948

-430

17.5 R 25, XTLA

-1 016

-461

17.5 R 25, XHA

-792

-359

20.5 x 25, L2

-100

-45

20.5 x 25, L3

228

104

20.5 R 25, XHA

380

173

IMPORTANT: The use of rear tire ballast is not permitted.

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SPECIFICATIONS

SPECIAL BOLT TORQUES

NOTE: All bolt torques are listed with dry threads. * See Wheel Nut Torque in this manual.

** No Impact Tools

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POUND-FOOT (44 to 51) (7.5 to 8.3)

(625 to 700) (185 to 205) (42 to 48) (52 to 58) (570 to 630) (73 to 94) (704 to 793) (510 to 575) (39 to 46) (42 to 48) (180 to 220) (28 to 31) (18 to 20) (52 to 58) (250 to 275) (175 to 225) (480 to 540) (17 to 20) (245 to 275) (25 to 32) (175 to 190) (480 to 540) (15 to 18)

(215 to 275) (30 to 35) (655 to 735) (185 to 235) (355 to 435) (4) (25 to 30) (45 to 60) (475 to 530)

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Nm Alternator Pulley ** ............................................................. 60 to 70 Air Cleaner Hose-Turbo Clamps ................................. 10.1 to 11.3 Articulation Mounting Pin Retainer Bolt .....................See ES-FA32 Articulation Pivot Pin Bolts ........................................See ES-FA32 Front Axle Mounting Bolts .............................................. 845 to 950 Rear Axle Trunnion Pin Bolts......................................... 251 to 280 Brake Pump to Engine Mounting ....................................... 57 to 65 Brake Pump Gear Nut ** .................................................... 70 to 79 Cab and Canopy Mounting Bolts (2) .............................. 773 to 854 CAC Hose Clamps ..................................................... See INF7888 Carrier Bearing Mounting Bolts ........................................ 99 to 128 Counterweight Bolts ................................................... 955 to 1 075 Counterweight Studs ...................................................... 693 to 780 Coupling to Flywheel ........................................................ 53 to 62 Drive Shaft to Coupling .................................................... 58 to 65 Engine (rubber ISO) Mounts (3) ..................................... 244 to 298 Exhaust Stack to Hood Bolts ............................................. 38 to 42 Fan to Fan Coupler .................................................................... 24 Fan Coupler to Shaft ** .............................................................. 74 Front Drive Shaft Yoke Nut ............................................. 339 to 373 Guide Link Nuts (XT Only) ............................................. 240 to 305 Guide Loader Linkage Bolts ......................................... 650 to 732 Hydraulic Oil Filter Mounting Bolts .................................... 23 to 27 Hydraulic Pump to Transmission Mounting ................... 335 to 375 Hydraulic Tank Cover Bolt .................................................. 34 to 44 Loader Linkage Pin Keeper ........................................... 325 to 373 Loader Linkage Bolts, Grade 8 (XT Only) ...................... 650 to 732 Muffler to Turbo Elbow Clamp ............................................ 20 to 25 Radiator Hose Clamp - Radiator Side ........................ See INF7888 Radiator Hose Clamp - Tube Side ............................ See INF7888 Steering Wheel Retaining Bolts .................................... 290 to 375 Steering Wheel Retaining Nut ............................................ 40 to 47 Transmission (rubber ISO) Mounts (3) ......................... 890 to 1000 Transmission Upper Mounting Bracket Bolts ................. 251 to 319 Transmission Left and Right Lower Mounting Bracket Bolts481 to 590 Turbo to Turbo Elbow Clamp ........................................................ 5 410R Universal Joints (Engine to Trans.............................. 34 to 41 480R Universal Joints (Trans. to Axles).............................. 61 to 81 Wheel Mounting Bolts ................................................... 640 to 720

SPECIFICATIONS

NOTES

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A Access Doors ................................ 119 Accumulators, Brake ....................... 90 After Delivery Check ............. 203, 205 Air Conditioning Compressor .............................. 162 Compressor Belt ....................... 176 Compressor Seal Lubrication .... 162 Condenser ................................ 162 Temperature Control ................... 52 Air Filter Cab ........................................... 157 Cleaning .................................... 137 Indicator ...................................... 35 Primary Element ....................... 136 Replacement ............................. 135 Secondary Element ................... 136 Service Specifications ............... 134 System ...................................... 134 Air Louvers, Cab ............................. 58 Alternator Belt ............................... 176 Autoshift Switch ............................... 53 Auxiliary F-N-R Switch .............. 43, 56 Auxiliary Hydraulic Connection .................................. 91 System Specifications ................. 91 Auxiliary Power Equipment Mounting Bracket .... 182 Outlet ........................................ 182 Axle Oil Change ................................ 156 Oil Level .................................... 154 Service Specifications ............... 154

B Battery Cleaning .................................... 178 Cold Weather Operations ........... 99 Connection, Booster ................... 75 Fluid Level ................................. 178 Safety ........................................ 177 Service ...................................... 177 Vents ......................................... 178

Before Operation Safety Message .. 10 Before Starting The Engine ............. 67 Belt Air Conditioning Compressor .... 176 Alternator .................................. 176 Fan ............................................ 176 Seat ............................... 65, 68, 172 Blower Fan Switch .......................... 49 Bolt Torques .................................. 193 Booster Battery Connection ............ 75 Brake Parking, Switch ........................... 40 Parking,Holding ........................... 77 Pedals ......................................... 42 Pressure Indicator ....................... 34 Service, Holding .......................... 77 Brake Accumulators ........................ 90 Bucket Height Control Function .................................. 88 Minor Adjustment .................. 171 Bucket Level Indicator ..................... 91 Bulbs, Replacement .............. 181, 182 Burn Prevention Safety Message .... 13

C Cab ................................................ 163 Air Filter ..................................... 157 Cleaning ............................... 159 Removal and Installation ...... 157 Cab Headliner ........................... 163 Door Hinges .............................. 163 Hoses and Wiring ...................... 163 Operators Seat .......................... 164 Service ...................................... 162 Charts Hydraulic System Fluid ............. 146 Lubrication ................ 116, 117, 118 Maintenance ............. 116, 117, 118 Clutch Cutout .................................. 90 Cold Starting Fluid ......................... 161 Cold Weather Operation ................. 99 Components, Machine ...................... 6 Conditioner, Fuel ........................... 141

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INDEX

INDEX Console Front ............................................33 Side ..............................................49 Controls Air Conditioning Temperature ......52 Blower Fan ...................................49 Hand ............................................33 Heat, Cab .....................................49 Lamp Switch ................................51 Steering Wheel Tilt ......................40 Wiper/Washer Switch ..................50 Coolant Fluid Level .................................139 Cooling System Cleaning .....................................140 Cold Weather Operations ............99 Coupler Pin Engagement Switch ..........................................54 TRIM THIS EDGE

D Declutch Switch .........................52, 90 Defrost Air Louvers ..........................60 Detent On/Off Switch .......................52 Diesel Fuel System ........................141 Disabled Machine Towing ................96 Do Not Operate Tag .........................15 Door Access .......................................119 Hinges ........................................163 Latch ............................................61 Dust Valve ......................................135

E Electrical System ...........................177 Emergency Exit ................................66 Engine Data ...................................185, 187 Ether Starting .........................72, 73 Hourmeter ..................................114 Lubrication .................................129 Service Specification .................131 Specifications .....................185, 187 Speed ..........................................70 Engine Coolant Cleaning the Cooling System ....140 Fluid Level .................................139 Gauge ..........................................35

Heater ......................................... 74 Mixture ...................................... 138 Engine Coolant Heater (If Equipped) ................................. 74 Engine Cooling System Coolant Mixture ......................... 138 Service Specifications ............... 138 Specifications ............................ 138 Thermostat ................................ 138 Engine Data .................................. 185 Engine Oil Change ..................................... 132 Filter .......................................... 132 Level ......................................... 131 Pressure Gauge ........................ 132 Selection ................................... 129 Engine Oil Heater (If Equipped) ...... 74 Ether Cold Start ............................... 72 Exit Emergency .................................. 66 Extinguisher Mounting, Fire .......... 176

F Fan Belt ......................................... 176 Fan Reverser (option) ..................... 55 Filter Air ............................................. 136 Cab Air ...................................... 157 Engine Oil ................................. 132 Fuel ........................................... 144 Hydraulic Oil ............................. 148 Transmission Oil ....................... 152 Filter Replacement Air ............................................. 135 Engine Oil ................................. 132 Hydraulic Oil ............................. 148 Transmission Oil ....................... 152 Filters Fuel, In-Line .............................. 145 Fire Extinguisher Mounting ........... 176 Fire Extinguisher Safety Message .. 13 Fire or Explosion Safety Message .. 14 First Service Intervals ...................... 68 Fittings, Grease 100 Hours XT Linkage ........................... 124

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INDEX

G Gauges

Engine Coolant ........................... 35 Fuel Level ................................... 37 HydraulicOil Temperature ........... 34 Transmission Oil Temperature .... 35 Volt Meter .................................... 35 General Safety .............................. 109 Grease Fittings 100 Hours XT Linkage ........................... 124 Z-Bar Linkage ....................... 121 1000 Hours Z-Bar Linkage ....................... 122 50 Hours XT Linkage ........................... 123 Z-Bar Linkage ....................... 120

H Hand Signals ................................... 29 Heat Control, Cab ........................... 49 Hoses and Wiring .......................... 163 Hot Weather Operation ................. 101 Hourmeter, Engine ........................ 114 Hydraulic Connection - Auxiliary ..... 91 Hydraulic Filter Test ...................... 148 Hydraulic Oil Filter .......................................... 148 Filter Indicator ............................. 34 Temperture Gauge ...................... 34 Hydraulic System Filter Replacement .................... 148 Fluid Chart ................................ 146 Hydraluic Filter Test .................. 148 Service Specifications ............... 146

I Identification Numbers ...................... 4 Indicator Air Filter ....................................... 35 Brake Pressure ........................... 34 Hydraulic Oil Filter ....................... 34 Lamp ........................................... 37 Parking Brake ............................. 36 Pilot Lockout ............................... 36 Transmission Oil Filter ................ 36 Instructions, General Safety .......... 109 Instrument Panel Indicator Gauges

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Z-Bar Linkage ....................... 121 1000 Hours Z-Bar Linkage ....................... 122 50 Hours XT Linkage ........................... 123 Z-Bar Linkage ....................... 120 Float ................................................ 89 Fluid and Lubricants....................... 115 Fluid Levels ................................... 125 10 Hours ................................... 125 250 Hours ................................. 127 50 Hours ................................... 126 Coolant ...................................... 139 Engine Coolant ......................... 139 Radiator .................................... 139 F-N-R Switch ............................. 43, 56 Foot Pedals Brake Pedals ............................... 42 Foot Throttle ................................ 42 Four-Way Flasher Lamp ........................................... 36 Switch ......................................... 37 Front Console .................................. 33 Four-Way Flasher ....................... 37 Key/Ignition Switch ...................... 41 Park Brake Switch ....................... 40 Steering Wheel Tilt Control ......... 40 Transmission Control Lever ........ 39 Fuel Conditioner ............................ 141 Fuel Filter ...................................... 144 Fuel Level Gauge ............................ 37 Fuel Storage .................................. 142 Fuel System Cold Weather Operations ........... 99 Diesel Fuel Specifications ......... 142 Filter, In-Line ............................. 145 Fuel Conditioner ........................ 141 Fuel Filter .................................. 144 Fuel Storage ............................. 142 Removing Water ....................... 143 Service Specifications ............... 141 Fuse Panel .................................... 180 Fuses ............................................ 180

INDEX Engine Coolant ........................35 Fuel Level ................................37 Hydraulic Oil Temperature ......34 Transmission Oil Temperature ..35 Volt Meter ................................35 Indicator Lamps Air Filter ...................................35 Brake Pressure ........................34 Four-Way Flasher ....................36 Hydraulic Oil Filter ...................34 Lamp Indicator .........................37 Parking Brake ..........................36 Pilot Lockout ............................36 Transmission Oil Filter .............36 Turn Signal ..............................36

J Jump Start ........................................75 TRIM THIS EDGE

K Key Switch, Ignition ..........................41

L Lamp Four-Way Flasher ........................36 Turn Signal ..................................36 Lamp Indicator .................................37 Lamp Switch, Cab ............................51 Latch Door .............................................61 Window ........................................61 Window Retainer .........................62 Levers Transmission Control ...................39 Link Safety .........................................111 Transport ...................................111 Loader Adjustments Return-To-Dig ............................165 Loader Function Switches ................87 Loader Operating Tips .....................94 Leveling Operation .......................94 Pushing Operation .......................94 Scraping Operation ......................94 Transport and Carry Operation ....95 Loader Operations Cold Weather ...............................99

Louvers, Air Defrost ........................................ 60 Recirculation ............................... 58 Lubrication Analysis, Systemgard . 133 Lubrication Chart ........... 116, 117, 118 Lubrication, Engine ....................... 129

M Machine Components ....................... 6 Machine Operation Before Operating ........................ 77 Transmission Operation .............. 79 Machine Operation Safety Message ..... 11, 12, 13, 14, 15, 16 Machine Storage ........................... 183 Removal .................................... 184 Storage Preparaton .................. 183 Machine Tie Down Locations .......... 98 Machines ....................................... 188 Maintenance and Inspection of ROPS ..................................... 172 Maintenance Chart ........ 116, 117, 118 Maintenance Safety Message ......... 15 Master Disconnect Switch ............... 57 Material Safety Data Sheets ........... 15 MSDS Sheets .................................. 15

O Oil Change .................................................. 156 Engine ....................................... 132 Oil Level Axle ........................................... 154 Engine ....................................... 131 Transmission ............................ 152 Oil Selection, Engine ..................... 129 Oil Viscosity/Temperature Ranges ... 130 Operating Data ...... 186, 187, 189, 188 Operating Dimensions .. 186, 187, 188, 189 Operating in Cold Weather .............. 99 Operating In Hot Weather ............. 101 Operating Instructions ..................... 67 Before Starting The Engine ........ 67 Operating The Machine ................... 77 Operating Tips - Loader .................. 94

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INDEX

P Parking Brake Holding Check ............................. 77 Indicator ...................................... 36 Switch ......................................... 40 Parking The Machine ...................... 71 Parking the Machine Safety Message ................................... 12 Pedals, Foot .................................... 42 Pilot Lockout Indicator ..................... 36 Plastic and Resin Parts ................. 112 Power Outlet, Auxiliary .................. 182 Pressure, Tire ................................ 103 Primary Element, Air Filter ............ 136 Product Identification Number ........... 4

R Radiator Fluid Level ................................. 139 Radio ............................................... 61 Read Operators Manual .................. 17 Rear Fog Lamp Switch .................... 54 Rear Wiper/Washer Switch ............. 53 Reservoir, Windshield Washer ...... 160 Return-To-Dig Adjustment ................................ 165 Function ...................................... 87 Return-To-Travel ............................. 88 Switch ......................................... 52 Ride Control .................................... 92 Switch ......................................... 53 Roll-Over Protective Structure ...... 172 Roll-Over Protective Structure Safety Message ........................ 16 ROPS ............................................ 172 Damage Information ................. 174 Maintenance and Inspection ..... 172 Seat Torque Specifications ........... 175 Seat Belt ................................... 172

Torque Specifications ........... 175 Specifications Canopy Torque ..................... 173 Cap Torque ........................... 173 Rotating Beacon .............................. 92 Switch ......................................... 54 Run-In Procedure ............................ 67

S Safety Decals .................................. 17 Safety Instructions, General .......... 109 Safety Link, Service ...................... 111 Safety Rules ...................................... 9 Hand Signals ............................... 29 Safety, Battery ............................... 177 Safety/Decals/Hand Signals .............. 9 Before Operation ......................... 10 Burn Prevention .......................... 13 Fire Extinguisher ......................... 13 Fire or Explosion ......................... 14 Machine Operation ... 11, 12, 13, 14, 15, 16 Maintenance ............................... 15 Parking the Machine ................... 12 Read Operators Manual .............. 17 Roll-Over Protective Structure .... 16 Safety Decals .............................. 17 Wheel and Tire Maintenance ...... 16 Seat Belts .............................. 65, 68, 172 Inspection and Care ............... 66 Opcional ...................................... 62 Operators ............................ 62, 164 Optional Air Ride ......................... 63 Torque Specifications ............... 175 Seat Belt Torque Specifications ............... 175 Secondary Element, Air Filter ....... 136 Sediment Removal, Fuel System .. 143 Serial Numbers ................................. 4 Service Connector ......................... 182 Service Intervals - First ................... 68 Service Safety Link ....................... 111 Service,Holding ............................... 77 Side Console ................................... 49 Air Conditioning Temperature ..... 52

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Operator Manual Storage Compartment .............................. 3 Operators Manual, Read ................. 17 Operators Seat ........................ 62, 164 Owner, To The .................................. 1

INDEX

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Autoshift Switch ...........................53 Storage, Fuel ................................. 142 Blower Fan Switch .......................49 Storage, Machine Coupler Pin Engage Switch .........54 Preparation ............................... 183 Declutch Switch .....................52, 90 Removal .................................... 184 Detent On/Off Switch ...................52 Switch Heat Control .................................49 Autoshift ...................................... 53 Lamp Switch ................................51 Blower Fan .................................. 49 Rear Fog Lamp Switch ................54 Coupler Pin Engage .................... 54 Rear Wiper/Washer Switch ..........53 Declutch ................................ 52, 90 Return-To-Travel Switch ..............52 Detent On/Off .............................. 52 Ride Control Switch .....................53 F-N-R .................................... 43, 56 Rotating Beacon Switch ...............54 Four-Way Flasher ....................... 37 Wiper/Washer Switch ..................50 Key/Ignition ................................. 41 Wrist Rest ....................................49 Lamp ........................................... 51 Wrist Rest, Adjustment ................49 Loader Function .......................... 87 Specifications .................................185 Bucket Height Control ............ 88 Air Filter .....................................134 Float ....................................... 89 Auxiliary Hydraulic System ..........91 Return-To-Travel .................... 88 Axle ............................................154 Master Disconnect ...................... 57 Cooling System, Engine ............138 Park Brake .................................. 40 Diesel Fuel System ....................141 Rear Fog Lamp ........................... 54 Dimensions .........186, 187, 188, 189 Rear Wiper/Washer .................... 53 Engine Cooling System .............138 Return-To-Travel ........................ 52 Engine Data .......................185, 187 Ride Control ................................ 53 Engine Service ...........................131 Rotating Beacon ......................... 54 Fuel System ...............................141 Wiper/Washer ............................. 50 Hydraulic System .......................146 Systemgard Analysis ..................... 133 Machines T ACS PRO 2000 Bucket .........187 Thermostat Specifications ............. 138 General Purpose Bucket 186, 187 Throttle, Foot ...................................

42 Operating Data ..187, 188, 186, 189 Tire Or Rim Service .......................

105 ROPS Torque ............................173 Seat Belt Torque ........................175 Tire Pressure ................................. 103 Seat Torque ...............................175 Tire Tread Direction ...................... 105 Thermostat .................................138 Tires, Adding Air ............................ 105 Transmission .............................151 Torque - Wheel Nut ....................... 106 Travel Speeds ............................185 Towing, Machine ............................. 96 Transmission XT Machines Breather Cleaning ..................... 152 ACS PRO 2000 Fork Option .190 Cold Oil Level Check ................ 152 Starting Fluid Can ..........................161 Control Lever .............................. 39 Starting The Engine .........................69 Filter Replacement .................... 152 Steering Wheel Tilt Control ..............40 Oil Change ................................ 152 Stopping The Engine .......................71 Oil Level .................................... 152 Storage Operation of ................................ 79 Starting Fluid Can ......................161 Service Specifications ............... 151 Storage Compartment Warm Oil Level Check .............. 152 Operator Manual ............................3 200

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Transmission Oil Filter .......................................... 152 Filter Indicator ............................. 36 Level ......................................... 152 Check ................................... 152 Temperature Gauge .................... 35 Transmission Operation Automatic Mode Operation ......... 79 Down-Shift Button, Manual Mode .. 79 Down-Shifts Manual Mode .......... 79 Manual Mode Operation ............. 79 Shifting, Automatic Mode ............ 79 Up-Shifts Manual Mode .............. 79 Transport Link ............................... 111 Transporting The Machine .............. 97 On A Trailer ................................. 98 Travel Speeds ................................ 185 Turbocharger Priming the Lines with Oil ........... 70 Turn Signal Lamp ........................................... 36

V Volt Meter Gauge ............................ 35

W Water Removal, Fuel System ....... 143 Weights Adjustments, Optional Equipment .192 Wheel and Tire Maintenance Safety Message ................................... 16 Wheel And Tires ............................ 103 Wheel Nut Torque ......................... 106 Window Latch ........................................... 61 Retainer Latch ............................. 62 Windshield Washer Reservoir ....... 160 Wiper/Washer Switch ...................... 50 Wrist Rest ........................................ 49 Adjustment Knob ......................... 49

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INDEX

INDEX

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TERM OF WARRANTY CASE CONSTRUCTION Products

CNH INDUSTRIAL LATIN AMERICA LTDA., manufacturer of CASE CONSTRUCTION equipments warrants all its new products against any defects of workmanship or material through its new work of authorized dealership.

The authorized dealer will repair in his own installation the equipment or any part of the equipment; which according to the technical analysis presents a failure or material defect, at not cost for the end user, including the labor for the installation of the part in reference for a period of 12 (twelve) months unlimited hours beginning from the date of delivery.

This warranty does not include, expenses such as transport of this equipment or its components to the installations of the Distributor, as well expenses such as stay and travel if the end users decides to get the work done outside the Dealer’s installation. In this case the Authorized Dealer must present by writing to the customer an estimated cost for his previous approval.

The contractual warranty of the equipment is subject to the execution of all scheduled service, as defined in the manual of operation and maintenance performed by authorized service personnel of CASE CONSTRUCTION, including the delivery of technical.

Parts installed as replacement will be covered under the remaining warranty period.

Original parts purchased through a CASE CONSTRUCTION Dearlership will also have a warranty of 90 (ninety) days from the invoiced date of purchase, under the same parameters of CASE CONSTRUCTION warranty policy. If applied by authorized dealer, original parts, will have a warranty of (180) days. This warranty is subject to the realization of the technical delivery.

THIS IS THE ONLY WARRANTY OFFERED AND REPLACES ANY OTHER EXPRESSED OR IMPLIED. THERE ARE NOT OTHER WARRANTY OF CNH WHICH WILL SURPASS THE HERE STATED­.

EXCLUSIONS AND LIMIT LIMITATIONS TIONS – This warranty would not apply in case of: •• Verify through the technician analysis, THE IMPROPER USE OR MAINTENACE, NEGLET, INCAPACITY OR ACCIDENT, IN ADDITION TO IMPLEMENTS AND/OR PARTS NOT CERTIFIED BY CNH, AND/ OR USE OF NONRECOMMENDED LUBRICANTS AND OILS; •• New products which are subjected to operations which exceed the recommended capacity or is used for applications no recommended; •• Equipments that have been altered or repaired in a way not authorized by CNH INDUSTRIAL LATIN AMERICA LTDA., the manufacturer of CASE CONSTRUCTION products; •• Equipment to which preventive maintenance or inspections have not been done according the specification established for CASE CONSTRUCTION equipment.

•• Components which are covered by their own manufacturer such as tires, electrical components, and fuel injection components.

•• Defects caused by modification or installation of parts or components no authorized by CNH INDUSTRIAL LATIN AMERICA LTDA.. Manufacturer or CASE CONSTRUCTION products.

•• Monetary Loss, inconvenience, commercial or consequent damaged caused by a failure or cost caused by rented equipment.

•• Normal wear items such as: brakes discs, clutches, cutting edges, cutting knife, bolt, lubricated joints(pins, bushing), parts wear due to ground contact, oils, lubricants, exhaust or associated parts, injectors, belts, lamps, glasses, light bulbs and fuses.

•• THE RESPONSABILITY OF CNH OR THE AUTHORIZED DEALER, be by civil contract or imply warranty, declaration, instructions or effects of any source, will be limited to the repair or delivery of the parts, new or reconditioned, under the conditions previously stated.­ CNH INDUSTRIAL LATIN AMERICA LTDA. CNH INDUSTRIAL LATIN AMERICA LTDA. reserves the right to revise, modify or discontinue any product at any time without implying to do the same to products already marketed.

G-1

G-2

BEFORE DELIVERY CHECK FIRST PAGE MAINTENANCE – CHECK AND ADJUST AS NECESSARY Number of O.S.

Number of Hours

Date

Owners Name Address Dealers Name Address Machine Model Number

Hourmeter Indication

Machine Product Identification Number (P.I.N.)

Items to be inspected COOLING SYSTEM Check for leaks.

Check the coolant levels.

FUEL SYSTEM Check for leaks.

Check that no water and sediment from the fuel tank.

ELECTRICAL SYSTEM Check battery fluid level and specific gravity.

Check operation of starter, alternator, and instruments and warning lamps.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

Check the oil level of the front and rear axles.

Check the oil level of the transmission.

#

MOTOR Check condition of drive belt.

Check engine oil level.

Check engine speed at idle and full throttle.

Check the air cleaner filter elements conditions.

HYDRAULIC SYSTEM Check for leaks.

Check the reservoir fluid level.

Change the hydraulic filter.

Check the main relief valve pressure.

GENERAL Check for leaks and loose parts.

Check the wheel nut and bolt torques.

Check the tire pressure.

Tighten all hoses clamps.

Check loader operation.

Check the service brakes and parking brake operation.

Check the control levers for correct operation.

Check the operator seat operation.

SAFETY Check the torque of ROPS and seat belt mounting bolts.

Check the safety and information decals and replace if necessary.

Make sure the Operators Manual and Safety Manual are in the Manual Storage Box. Check the saddle lock pin.

DEALER: Make sure the new owner/operator understands all the safety and information decals, the service information, and the service procedures in this operator’s manual.

Mechanic (signature) Dealer (signature) Owner (signature)

Dealer Copy

G-3

G-4

BEFORE DELIVERY CHECK FIRST PAGE MAINTENANCE – CHECK AND ADJUST AS NECESSARY Number of O.S.

Number of Hours

Date

Owners Name Address Dealers Name Address Machine Model Number

Hourmeter Indication

Machine Product Identification Number (P.I.N.)

Items to be inspected COOLING SYSTEM Check for leaks.

Check the coolant levels.

FUEL SYSTEM Check for leaks.

Check that no water and sediment from the fuel tank.

ELECTRICAL SYSTEM Check battery fluid level and specific gravity.

Check operation of starter, alternator, and instruments and warning lamps.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

Check the oil level of the front and rear axles.

Check the oil level of the transmission.

#

MOTOR Check condition of drive belt.

Check engine oil level.

Check engine speed at idle and full throttle.

Check the air cleaner filter elements conditions.

HYDRAULIC SYSTEM Check for leaks.

Check the reservoir fluid level.

Change the hydraulic filter.

Check the main relief valve pressure.

GENERAL Check for leaks and loose parts.

Check the wheel nut and bolt torques.

Check the tire pressure.

Tighten all hoses clamps.

Check loader operation.

Check the service brakes and parking brake operation.

Check the control levers for correct operation.

Check the operator seat operation.

SAFETY Check the torque of ROPS and seat belt mounting bolts.

Check the safety and information decals and replace if necessary.

Make sure the Operators Manual and Safety Manual are in the Manual Storage Box. Check the saddle lock pin.

DEALER: Make sure the new owner/operator understands all the safety and information decals, the service information, and the service procedures in this operator’s manual.

Mechanic (signature) Dealer (signature) Owner (signature)

Owner Copy

G-5

G-6

NOTES

G-7

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