Case 750B Wheel Loader Operator's Manual 9-6701 - PDF DOWNLOAD

750B Wheel Loader Operator's Manual 9-6701

THIS IS A SAFETY WARNING NOTICE THAT SHOWS YOU IMPORTANT INFORMATION FOR h MACHINE OPERATION. WHEN YOU SEE THIS . . TYPE OF NOTICE READ IT CAREFULLY TO PREVENT POSSIBLE INJURY TO PERSONS OR DEATH.

BEFORE ANY PERSON OPERATES THIS MACHINE, MAKE SURE TMAT THIS PERSON: 1. - GETS INSTRUCTION ON THE SAFE AND CORRECT USE OF THE MACHINE 2. -

READS AND UNDERSTANDS THE MANUAL FOR THIS MACHINE.

PRINTED IN SPAIN

JUNE 78

IN D EX SAFETY RULES . . . . . . . . . .

Before you start the machine .. .

Loader operation. . . . . . . . . .

Maintenance . . . .

INTRODUCTION . . . . . . . .

1-ACCESSORIES . . . . . . .

2-VIEWS OF THE MACHINE 3-SERIAL NUMBER LOCATION 4-GENERAL SPECIFICATIONS. -Engine. . . . . . . . . . • . . . . .

-Torque converter and transmission -Speeds. . . . . . . . . . . . .

-Hydraulic circuits . . . . . . . . . . .

-Automatic hydraulic system . -Capacities . . . . . . . . . . . . .

-Tires. . . .. . . . . . . . . . .

5-0PERATING DIMENSIONS 6-0PERATING DATA -General specifications . . . .

-Dimensions . . . . . . . . . .

-Hydraulic cylinders . . . . . . . . . .

-Buckets . . . . . . . . . . . . . . . ..

-Optional equipment. . . . . . . . ..

7-INSTRUMENTS AND CONTROLS. -Instrument gauges . . . . . .

-Indicators and switches . . .

-Heating (switch) .. . . . . .

-Control panel levers .'. . . .

-Accelerator and brake pedals . . .

-Driver's seat. . . . . . . . . . . .

-Arm and bucket driving levers -Dump/Rollback . . . . . . . . .

-Parking brake. . . . . . . . . . .

-Emergency steering . . . . . . .

8-0PERATING INSTRUCTIONS .

-Running-in period . . . . . . . . .

-Checks to be made before starting -Instructions to start .

-Aids to cold starting . . . . . . . .

-Stopping instructions . . . . . . .

-Instructions for towing the machine.

-On-the-road traveling . . . . . . .

9-LOADER OPERATING INFORMATION . . . . .

-Work preparation . . .

-Filling the bucket . . . . . . . . . . .

-Transport of materials . . . . . . . . , -Unloading the bucket into a truck -Volume increase in earth-moving. "

IV XII 1 2 3 4 5 5 6 6 6 7 7 7 8 9 9 9 10 10 10 11 12 14 17 20 21 22 23 26 28 29 30 30 30 31 32 34 35 35 37 37 37 39 39 40

-Weight of the most common materials 10-FUEL AND LUBRICANTS. .

-Fuel storage . . . . . . . . . . '. . . ..

-Filling of fuel tanks . . . . . . . . . .

11-TYPESOF LUBRICANTS. . . . ..

12-MAiNTENANCE AND LUBRICATION GUIDE. . . . . . . . . . . . . .

13-LUBRICATION POINTS . . . . . ..

-Every 10 hours of operation . . . . .

-Every 50 hours of operation -Every 100 hours of operation .

14-ENGINE MAINTENANCE . .

-Engine oil and filter . . . . . .

-Air compressor . . . . . . . . . . . .

-Fuel system . . . . . . . . . . . . . ..

-Valve adjustment and cylinder head tightening . . . . . .

-Fan belt adjustment . . , -Engine air intake . . . . .

-Cooling system . . . . . .

-Turbo . . . . . . . . . . . .

15-ELECTRICALSYSTEM. .

-Parts and location of lights -Road lights adjustment -Starter . . . . . . . . . . . . . . . .

-Alternator . . . . . . . . . . .

-Batteries .. . . . . . . .

-Electrical installations . .

16-HYDRAULIC SYSTEM -Oil level .. . . . . . . . .

-Oil change and replacement of filter element . . . . . . . . . . . . . . . .

17-TRANSMISSION AND TORQUE CONVERTER . . . . . . . . .

-Regular inspections. Cleaning -Oil.change . . . . . . . . .

-Clutch main pressure. .

-Oil cooling. . . . . . .

18-AXLES AND TIRES. .

-Axle maintenance -Tire maintenance.

1~BRAKESYSTEM

-Left pedal . . . . .

-Right pedal . . . . . .

-Bleeding the brake hydraulic system -Brake air reservoir . . . . .

-Adjustment of brake pads . . . . . ..

-Ai r cI eaner. .

-Parking brake . . . . . . . . . . . . ..

40 41 41 41 42 43 46 46 47 47 48 48 50 51 57 59 59 61 66 68 68 69 69 70 71 73 78 7878 81 81 83 84 84 85 85 86 89 89 89 90 92 93 93 93

A

SAFETY RULES

A

If you carefully operate this equipment, you will be safe and the persons around you will be safe. Before you operate any equipment, make sure you know the position and operation of all the controls.

BEFORE YOU START YOUR WORK, PUT THE MACHINE IN A SAFE AND OPEN AREA. THEN CHECK ALL THE CONTROLS. READ EVERY PAGE OF THIS MANUAL. Make sure you understand the instructions. Do not operate this machine before you know the specifications for speed, braking, steering, stability and load.

The safety codes, insurance rules, country and local laws, are not in this manual. Know the rules and laws for you area. Make sure your machine is correctly fitted according to these laws and rules.

It is our recommendation that the following safety rules be put in a place where they can be seen clearly.

BEFORE YOU START THE MACHINE

-;-Q

~ --. !'

...... ...... w_ --

y

,"

o

o

740.90.059

CAUTION - If you cannot clearly read any of the safety decals, clean or replace it.

CAUTION - Before you start the machine, give a warning to all maintenance personnel, if any, or other persons in the work area.

"

CAUTION - Use the correct safety equipment. Do not wear loose clothing h that can fall into the machine. If necessary, get other safety equipment, a . . hard hat, safety shoes, ear protectors, reflecting clothing, safety goggles and heavy gloves are examples.

740.90.060

CAUTION - Check the outside of the machine; check for leaks, loose or broken parts, before operating the machine. Tighten all plugs, dip sticks, . . battery covers, etc. The failure of a part during the machine operation can cause injury.

h

h CAUTION - Always have a fire extinguisher available, as well as a first aid . . kit. Keep them in perfect condition. Know how to use them. h CAUTION - Check the local regulations before traveling with this machine . . on any road.

II

740.90 no;,;

WARNING - Before you start the engine, carefully read the information about Safety in the Operators Manual. Read all notices about safety on the machine. Make sure there are not other persons in the work area.' Before you operate .,the machin,e, learn to safely use the controls. Understand "the instructions about the operation and service of the machine. Understand all rules and regulations that have 1m application to this machine. Operator's and Service Manuals are available at your authorized Dealership.

h CAUTION - Be sure that the operator's area, steps, handles, the floor inside . . the cab, etc., are free from oil, loose objects, grease or ice. If you do not keep these areas clean, it may cause an accident.

740.90.056

III

h

WARNING - Know the location of electric cables, water and gas, etc., under . . the grou~d: If you break a gas pipe or cut an electric cable, the result can cause an InJU ry.

740.90.057

WARNING - Before starting the machine, be sure there is no-one performing some maintenance operation on the machine. When performing some main. . tenance operation or checks on the machine, do not allow anyone to handle any control or switch.

h

LOADER OPERATION

A

A

WARNING CORRECT HANDLING IS THE BEST INSURANCE AGAINST ACCIDENTS

A

CAUTION - Check and know the work area.

WARNING - Be careful if this machine is not the one you know how to operate.

IV

h CAUTION - Adjust the operator's seat to your size and be sure it is correct. . Iy fastened in position. If the seat moves during the operation~ this can cause a bad injury.

74u.90.052

A

WARNING - Should you need to start the engine through auxiliary batteries, connect the positive cable to the battery terminal at the starting motor solenoid. Connect the negative cable to the chassis of the machine. Before starting the engine, the operator should be on his seat with belt fastened.

Before stepping down. from the machine, stop the engine and check the parking brake is on. Disconnect the cables. If you do not follow these instructions, the machine may move out of control.

h WARNING - Do not try to start the machine by towing it. You could cause . . serious damage to the machine.

WARNING - Do not move the machine until the air pressure in brake system reaches 4.5 kg/cm 2 , and the pilot light indicator is out. ,

WARNING - Before you get out of the machine, lower equipment to the ground, apply parking brake, stop the engine and remove the key.

v

740.90.053

·

-

h. WARNING· Before moving the machine, be sure that the steering operates . . correctly. h. CAUTION· Do not permit any other person to be on the machine, except . . the operator.

740.90.054

h. CAUTION· Before you operate the machine at night, check that all lights . . and indicators work correctly. . h. CAUTION· Keep the windshield and windows clean to make sure you can . . see clearly. If the windows are dirty, the result can be an accident.

740.90.049

VI

h

o

CAUTION - Operate the "machine and accessories from the seat position . . only.

h DA~G~R - Exhaust gases can cause deat~. If it is necessary to start the . . engine In an enclosed area, make sure there IS a good flow of air.

740.90.050

h CAUTION - Operate the machine at a speed that is correct for the condi. . tions of the work area. On rough ground do not go too fast. h ~

CAUTION - Know and understand the movement of vehicles in your work area. Understand the instructions of the flagman. Understand the road signs and/or signals.

740.90.051

DANGER - Do not permit any part of the machine to be in contact with electricity cables. If it is necessary to work close to electric cables, make sure the power is disconnected. It is not necessary for the machine to contact a cable for the electricity to go through the machine. If electricity is going through the machine, do not get out of the machine and DO NOT COME IN CONTACT WITH ANY METAL PART OF THE" MACHINE.

740.90.046

A

CAUTION - Do not work against the wind. Keep it behind you.

740.90.047

VIII

·

h

CAUTION - Be careful when working in dust and/or smoke. When you can. . not see clearly, slow down, stop if necessary.

740.90.048

h

CAUTION - Should you use the machine as a crane, do not lift weights . . more than the operating load. Secure the load in such a manner that the machine does not lose stability. See work specifications in the manual.

740.90.070

h

WARNING - Use extra caution when working on very steep slopes or on . . ground that may move under the weight of the machine.

IX

h WARNING - When going up a slope with the bucket full, drive up with the . . machine facing forward. When going down a slope with the bucket full, use reverse and drive slowly. These precautions depend on the degree of slope.

h

WARNING - When going down a slope, drive slowly. Never use neutral . . position always keep machine in gear.

h CAUTION - When dumping the bucket into a truck, use the brake"s care. . fully, If not you can cause damage. "

WARNING - Never travel the machine with a full bucket at full height. Keep the bucket as low as possible. This gives better balance and permits you to ~ see more clearly. If you use the machine with a full bucket over ground that is rough, operate at a speed that is safe.

h

x

740.90.065

h. ~

CAUTION - During the operation of the machine, do not use the bucket as a bulldozer blade. See regulations in section "Recommendations for the work cycle".

740.90.066

A

CAUTION - Do not go into the work too fast.

740.90.043

h. ~

CAUTION - Stop and look before you use a road. When you do, keep to the side so that the vehicles behind can get pass. Watch all road signs. Use correct procedure when driving on the road.

XI

h ~

CAUTION - Do not park the machine on the road, leave the roadway as free as possible. Should you need to park, put the emergency flashing lights on to give good warning to other drivers.

h

WARNING - Do not make any repair you do not understand. Check with ~ your official Dealer.

h

WARNING - Be ~aref~l. when near the fan, belts or other moving parts that . . can cause you sertous InJury.

h

WARNING - Use safety glasses when performing maintenance or repair . . work to the machine or when using tools.

h

WARNING - Use a rigid bar when you have to pull the machine or when . . being pulled.

740.90.067 XII

h.

WARNING - Should you need to pull another vehicle, or when moving with . . the bucket loaded, keep in mind, on using the brakes, that the bigger the pulled vehicle or the load carried, the longer the braking distance will be.

h.

CAUTION - At all times, lower all attachments to the ground or block them . . before you do any maintenance or adjustments.

740.90.069

h.

CAUTION - Before you make or break a connection make sure you "-now . . the circuit. A wrong connection can cause an injury.

h.

WARNING - Do not add fuel to the machine with the engine running, close . . to a fire, or if you are smoking.

740.90.062

XIII

I

• /\. CAUTION - There is pressure in the cooling system. Only when the engine is . . cool should you remove the radiator cap. If not, the result can be bad burns.

/ 740.21.092

WARNING - Be very careful when you disconnect hydraulic connections. /\.

There is HIGH pressure in the system. Release all pressure in the system . . before you disconnect the hydraulic hose, etc. If not, an injury can be the result.

/\.

WARNING - Extra caution is to be used when working on the fuel system . . . There is HIGH pressure in the system. If you have been in body contact with high pressure fuel, ask for a doctor immediately.

740.90.063

XIV

h CAUTION - When working on the electrical system, never wear a ring or a . . . metal watch band. These can cause injury.

A

CAUTION - The place for the storage of batteries should be ventilated.

DANGER - Batteries discharge gasses. Any sparks, flames or cigarettes must be kept away from the batteries. Be sure that there is air current in the place . . . where the batteries are kept. Wear safety glasses to handle de batteries.

h

740.90.040

h CAUTION - When taking a battery off, first disconnect the negative (-) . . . cable. When'installing a battery, connect the negative (-) cable last.

h WARNING - When you check the battery charge, be careful not to place . . . any metal object across the battery terminals. The sparks can cause a fire.

Use a voltmeter or a hydrometer.

xv

I I

DANGER - Batteries have acid in them, which can cause bad burns. If acid comes in contact with your skin, eyes or clothes, wash with water. Flush . . eyes with water for 15 minutes. GET A DOCTOR IMMEDIATELY. KEEP CHILDREN AWAY FROM BATTERIES.

h.

740.90.074

WARNING - Never do any maintenance with the engine running unless the Operator's Manual or Service Manual shows you how to do it. If it is neces. . sary to lift any accessory to do this maintenance, make sure that part is secure.

h.

h. CAUTION - Do not disassemble a tire if you do not know the method to . . follow. It can cause an injury. h. CAUTION - When checking the tire pressure or when inflating them, place . . yourself to one side, beyond the reach of the locking ring between the rim and the tire.

XVI

INTRODUCTION

If you read this MANUAL carefully, you will have safety and efficiency in your operations. There will be fewer errors made when personnel do maintenance work. It will also reduce any damage and loss of operating time because of wrong maintenance.

If you need more information, we are ready to give you assistance.

The guarantee of good service from the machine requires the full backing of spare parts and the repair\ facil ities of an Authorized Case Dealer.

NOTE: When "Right hand side" and "Left hand side" are used in this Manual, understand that this is the right and left side positions of the machine when you look from the seat for the operator.

LEFT SIDE

740.90.041 RIGHT SIDE CASE reserves the right to make improvem~nts in the design or make changes in specifications at any time, and has no obligation as a result.

This Manual may show pictures and drawings not corresponding to the standard equipment.

-1-

1. ACCESSORIES 1.

2.

3.

4.

5.

6.

Tool box OPTIONAL) NAL) Wheel blocks (. c linder (OPTIO Safety bar for 11ft d ~OPTIONAL) Bucket teeth guarls lever lock Hydrau I·I~ contrak bar Articulation lac

fj) ,/ 6 750B.46.001

Figure 1

·2 -

2. VIEWS OF THE MACHINE

750B.90. 001

Figure

2

3/4 REAR VIEW

Figure

3

750B. 90.002

3/4 FRONT VIEW -3 -

3. SERIAL NUMBER LOCATION

When you order parts or make any inquiry on the components of the machine, it is recommended to quote the serial numbers. The location of the serial numbers may be seen in figures 4, 5,6 and 7.

Figure 5 (Engine)

Figure 4 (Chassis)

Figure 7 (Axles)

Figure 6 (Transmission)

For your use, fill in the following space with the serial numbers of your machine.

(4) (5) (6) (7) (7)

Machine number . . . . . . . . . . . . . . .

Engine number . . . . . . . . . . . . . . . .

Transmission number . . . . . . . . . . .

Front axle . . . . . . . . . . . . . . . . . . .

Rear axle . . . . . . . . . . . . . . . . . . .

. . . . .

-4 -

4. GENERAL SPECIFICATIONS 4.1

ENGINE . . . . . . . . . . .

PERKINS T6.354.3 (Turbo) Diesel, 6 cylinders 1.5.3.6.2.4 98.5 X 127 5800 c.c.

16: 1 94 KW (126HP) DIN-70020 42.3 M.K.G. 2350 R.P.M. 1800 R.P.M. 750/800 R.P.M.

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forced circulation by water pump through radiator.

82 0 C (180 0 F) 97 0 C (205 0 F) 0.490 kg/cm 2

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

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Firing order . . . . . . . . . . . . . . . . . . . . . . . . .

Bore and stroke . . . . . . . . . . . . . . . . . . . . . .

Piston displacement . . . . . . . . . . . . . . . . . . .

Compression ratio . . . . . . . . . . . . . . . . . . . . .

Net horsepower . . . . . . . . . . . . . . . . . . . . -..

Maximum torque . . . . . . . . . . . . . . . . . . . . .

Maximum revolutions-rated load . . . . . . . . . . .

Maximum torque speed . . . . . . . . . . . . . . . . .

Low idle revolutions . . . . . . . . . . . . . . . . . . .

Cooling system

The thermostat begins to open at . . . . . . . . . . . .

Total opening at . . . . . . . . . . . . . . . . . . . . . . .

Pressure in the system . . . . . . . . . . . . . . . . . . .

Electric system Type of system . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Road lights . . . . . . . . . . . . ; . . . . . . . . . . . . .

Front flashers/position . . . . . . . . . . . . . . . . . .

Rear work lights . . . . . . . . . . . . • . . . . . . . . . .

Reverse lights . . . . . . . . . . . . . . . . . . . . . . . . .

Park/brake lights . . . . . . . . . . . . . . . . . . . . . .

Rear flashers . . . . . . . . . . . . . . . . . . . . . . . . .

- 5-

24 volts, negative earth 2 X 12 volts and 92 Amp. 24 v. - 50/50 w.

24 v. - 21/5 w.

24v.-50w.

24 v. - 21 w.

24 v. - 21/5 w.

24 v. - 21 w.

Lubrication circuit Type . . . . . . . . . . . . . . . .

Lubrication system pressure .

Filter . . . . . . . . . . . . . . . .

4.2

Forced circulation by eccentric rotor pump.

Built-in check valve: 2.1/4.2 kg/cm 2 (30/60 psi.)

Exchangeable cartridge.

TORQUE CONVERTER AND TRANSMISSION

Torque converter .... . . ..

Single stage, oil cooling through heat exchanger.

Transmission: Full Power Shift, 4 gears forward and 4 reverse, with safety switch so that starter only operates in neutral. 4 wheel drive, with mechanical disconnect to the rear axle.

4.3

SPEEDS (KM/H)

Forward. . . . . . . . . . . . . .

Reverse. . . . . . . . . . . . . . .

4.4

2nd.

12.5 12.5

1st.

6 6

3rd.

21 21

4th.

36 36

HYDRAULIC CIRCUIT (STEERING)

Both the hydraulic steering circuit and the general hydraulic circuit are fed bya common double-body gear pump. The assembly is directly attached to the transmission.

Type . . . . . . . . . . . . . . . .

Hydrostatic system with gear pump and Orbitrol control valve. Regulating valve block coupled to Orbitrol.

Pump Power intake . . . . . . . . . . .

Flow at max. r.p.m. '" _ ..

Pressure . . . . . . . . . . . . . .

4.5

Direct from the transmission.

85 Its/min. at 2350 r.p.m. (18.6 imp. gals.)

120 kg/cm 2 . (1706 psi)

-GENERAL HYDRAULIC CIRCUIT

Pump Type . . . . . . . . . . . . . . .

Power intake . . . . . . . . . .

Maximum flow . . . . . . . . .

Pressure . . . . . . . . . . . . .

. . . .

Gear pump.

Direct from the transmission.

265 Its/min. at 2350 r.p.m. (58 imp. gals.)

150 kg/cm 2 (2133 psi)

- 6 -.

Control valve

Type . . . . . . . . . . . . . . . .

Two spool open centre valve. With optional equipment such as scarifier, log bucket, etc., will require a three spool valve.

Filter

Type

4.6

Replaceable element with magnetic column and bY'pass valve. (10 micronL

AUTOMATIC HYDRAULIC SYSTEM Through an electromagnetic system built in the hydraulic control valve, the following positions may be automatically selected: - Arm lift.

- Bucket release.

- Operating position to the ground level.

- Floating position.

4.7

CAPACITIES Crankcase . . . . . . . . . . . . . . . . . .

Fuel tanks . . . . . . . . . . . . . . . . . .

Cooling system, complete ........

Hydraulic oil tank . . . . . . . . . . . . .

Hydraulic system, complete ......

Converter and transmission .......

Front axle . . . . . . . . . . . . . . . . . .

Rear axle . . . . . . . . . . . . . . . . . .

4.8

. 15 Its. (3.3 imp. gals.) . 300 Its. (66 imp. gals.) . 26 Its. (5.7 imp. gals.) . 200 Its. (44 imp. gals.) . 250 Its. (55 imp. gals.) . 23.5 Its. (5.1 imp. gals.) . 25 Its. (5.5 imp. gals.) . 25 Its. (5.5 imp. gals.)

TIRES Standard

Size· . . . . . . . . . . . . . . . . . . . . . . .

Front tire ppressure . . . . . . . . . . . .

Rear. tire pressure . . . . . . . . . . . . . .

-7 -

17.5 X 25 X B, Michelin B type.

3.5 kg/cm2 (50 psi) 2 kg/cm 2 (28 psi)

5. OPERATING DIMENSIONS

Figure 8

Figure 9

- 8-

750B. 90.003

T

U

40·

2500

6. OPERATING DATA 6.1

GENERAL SPECIFICATIONS Operating weight of the machine (cab, full tanks, heating, cooling and operator. . . . . . . . . . . . . . ..

11.700 kgs. (25794Ibs)

Efforts Lift capacity at ground level . . . . . . . . . . . . . . . .

Lift capacity to maximum height . . . . . . . . . . . . .

Breakout force at the bucket . . . . . . . . . . . . . . .

Max. tipping load with the machine straight ......

Tipping load, full turn . . . . . . . . . . . . . . . . . . . .

. . . . .

14.800 7.690 11,775 7,680 6,560

kgs. kgs. kgs. kgs. kgs.

(32628 Ibs) (16953 Ibs) (25959Ibs) (16931 Ibs) (14462 Ibs)

To calculate the operating load of the machine, take half of the tipping load in any of the several positions.

Cycle times Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 sec.

2.5 sec.

4 sec.

Angles H Dump angle at maximum height . . . . . . . . . . . .

I Roll back at the ground level . . . . . . . . . . . . . .

J Excavation angle . . . . . . . . . . . . . . . . . . . . . .

6.2

45 0 41 0 56 0

DIMENSIONS A B C E F G K L M N P Q R S T U

Maximum height to the top of the cab .......

Maximum height without cab (steering wheel) ..

Rear hook height . . . . . . . . . . . . . . . . . . . . .

G.round clearance . . . . . . . . . . . . . . . . . . . . .

Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . .

Total length, bucket on ground . . . . . . . . . . . .

Dump reach . . . . . . . . . . . . . . . . . . . . . . . . .

Dump clearance maximum height . . . . . . . . . .

Height to hinge pin . . . . . . . . . . . . . . . . . . . .

Maximum height to bucket . . . . . . . . . . . . . . .

Width to outside of tires . . . . . . . . . . . . . . . .

Track width . . . . . . . . . . . . . . . . . . . . . . . . .

Turning radius to the outside of tires . . . . . . . .

Turning radius to bucket outside . . . . . . . . . . .

Pivot angle . . . . . . . . . . . . . . . . . . . . . . . . .

Standard bucket width . . . . . . . . . . . . . . . . .

-9 -

. . . . . . . . . . . . . . . .

3260 mm. (128.3 2540 mm. (100 1000 mm. (39.3 340 mm. (13.3 2900 mm. (114.1 6642 mm. (261.5 1100 mm. (43.3 2800 mm. (110.2 3645 mm. (143.5 4610 mm. (181.5 2358 mm. (92.8 1912 mm. (]5.2 5055 mm. (199 5475 mm. (215.5 40 0 to both sides 2500 mm. (98.4

inch) inch) inch) inch) inch) inch) inch) inch) inch) inch) inch) inch) inch) inch) inch)

6.3

HYDRAULIC CYLINDERS Arm lift

Piston diameter and stroke. . . . . . . . . . . . . . . . ..

135/70 f/J X 893 mm.

(5.35/2.15 X 53.15 inch)

Tilt cylinders

Piston diameter and stroke. . . . . . . . . . . . . .. . ..

125/65 tfJ X 475 mm.

(4.92/2.55 X 18.7 inch),

Steering

Piston diameter and stroke . . . . . . . . . . . . . . . . ..

6.4

85/45 (/J X 425 mm.

(3.34/1.77 X 16.73 inch)

BUCKETS Excavation

Capacity, heaped (m 3 ) . . . . . .

1.5 Total width (mm.) . . . . . . . . 2500 Blade. type. . . . . . . . . . . . .. Straight Bucket type

Excavation . . . . . . . .

General purpose .....

Rock . . . . . . . . . . . .

Light duty . . . . . . . . .

. . . .

General Purpose 1.8 2800 Straight

Rock 1.5 2500 "V" shaped

Light Duty 2.3 2500 Straight

Density of acceptable material 2 Ton. m 3 1.8 Ton. m 3 2 Ton. m 3 1.5 Ton. m 3

Specifications according to SAE standards.

All specifications are given with standard bucket, 1.8 m 3 and tires 17.5 X 25.

Without .the cab, decrease the operating weight by 315 kg. (694 Ibsl.

6.5

OPTIONAL EQUIPMENT

Tree shears, lift forks and advance bucket. Cab heater, speedometer, radio, cigarette lighter, air conditioning, emergency steering, safety belt.

-10 -

7. INSTRUMENTS AND CONTROLS

7506.26.001

Figure 10 The controls and instrumentation of this Wheel Loader, are strategically located in the cab, close to the driver, for easy handling of the machine. The arrangement is shown in figure 10.

" 11 "

7.1

INSTRUMENT GAUGES (LEFT SIDE)

Instrument gauges are located to the driver's left, on a detachable panel. See location iri figure 11.

Figure 11

1.

Brake air pressure gauge This double gauge, on one needle shows the constant pressure in the brake system and the other needle shows the effective pressure obtained when applying the brake.

WARNING - Do not move the machine until the needle showing the brake circuit pressure reaches 4.5 kg/cm2 (64 psi). The pilot light indicator showing low brake pressure should be off.

2.

Transmission and torque converter oil temperature gauge.

Thi~ gauge shows the oil temperature in the transmission and torque converter. The maximum oil operating temperature is 1200 C. STOP the machine. Place transmission in neutral gear and run the engine at maximum revolutions. If the needle does not return to normal, contact your local distributor.

- 12 -

3.

Water Temperature gauge Shows the water temperature in the engine cooling circuit. This temperature should not exceed 1040 C. (Pressurized system) . . Any increase above this temperature can cause serious damage to the engine.

4.

Ampere gauge Shows the amount of charge to the battery. Its operation is correct when the needle points to the area from 0 to . Should the needle move outside this area, it means that there is a failure in the electrical system, or an excessive dischar· ge.

5.

Transmission clutch pressure gauge The clutch pressure should be between 15.5 and 17.2 bar at maximum engine revolutions. If the needle does not indicate these pressures, stop the machine and check to find the failure.

6.

Engine oil pressure gauge Shows the pressure of engine lubrication circuit. This pressure should not be less than 2.1 bar. With the engine running and with the oil hot, if it does not reach this pressure, stop and check the reasons. Do not start the engine till having located the failure.

- 13 -

7.

Fuel gauge Shows the amounnt of fuel available. Refill the tanks upon finishing the work shift to prevent water condensation.

8.

Hour meter This machine is equipped with an electric hourmeter, with a minute hand. This instrument is very useful as an indication for periodic maintenance.

9.

Battery isolation switch By turning this key, the batteries are connected to the electrical circuit of the machine. .

It is recommended that, when the machine is not going to be used for a long time (at the end of the shift), disconnect the batteries with this switch.

7.2 INDICATORS AND SWITCHES (RIGHT HAND SIDE)

Indicators and switches are located to the driver's right, on a detachable panel. See figure 12.

Figure 12

- 14 -

1. Stop control Pulling this control outwards, stops the engine. Once the engine is stopped, return the control to its normal position, and place the key switch in the «off» position .

2. Engine oil pressure indicator

•

This light comes on when the oil pressure in the engine is low.

When this happens, check the reason and do not start the engin'e until the fault has been corrected. See 7.1-6. '

3. Alternator charge indicator This light should go out with the engine running. If not, check the electric installation, since it usually means the battery is not being charged correctly. See 7.1-4.

4. Parking brake indicator This light is on when the parking brake is applied.

5. Brake low pressure indicator This light comes on when the air pressure in the brake circuit below4.5kg/cm 2 . See7.1-1.

h ..

I]

•

~pes

WARNING - YOU SHOULD NEVER OPERATE THE MACHINE WITH THIS LIGHT ON. YOU CAN CAUSE AN ACCIDENT.

6. Air cleaner indicator This light comes on when there is excessive dirt or a restriction in the air cleaner. If this happens (see instructions), clean or replace the filter element .

7. Road lights indicator This light comes on when using the main beam lights.

- 15 -

•

8.· Hazard warning light This light comes on when connecting the emergency or warning lights.

9.

Direction indicator The light flashes when operating the .direction indiccltor lever, showing the operation of the left or right hand flashing lights.

10.

Lift arm position switch This switch ·operates the electrical circuit which governs lift arm height control and float position.

Bucket rollback control switch This switch controls bucket rollback, and can be used in conjunction with No.1 0 above.

Front windshield-wiper switch

Rear windshield-wiper switch

Parking lights switch

Front working lights and parking lights switch

Rear working lights and parking lights switch

Rotating light switch (optional)

- 16 -

18.

Hazard warning lights switch On operating this switch, all flashing lights are operated at the same time.

19. Key switch Connects the starter electric circui~ when turning the key clockwise or counter-clockwise. Figure 13 shows the different key positions.

o 1 2 3 4

Off Contact and control operation Start Pre-heater Start

740.21.004

Figure 13 ATTENTION - ONCE THE ENGINE STARTS, EITHER IN POSITION 2 OR IN POSITION 4, THE KEY SHOULD ALWAYS BE RETURNED TO POSITION 1.

The key returns to position 1 if you start the machine by turning it clockwise, but if you I,lse the pre-heater for cold weather start (anti-clockwise), the key returns to position O. THEREFORE, WHEN USING THE START COUNTER-CLOCKWISE, THE KEY SHOULD BE MAN~ALLY RETURNED TO CONTACT POSITION 1.

20. Switch (cab heater-optional) Operation The heater electrical circuit is directly energised by means of the battery switch, independently of the starter key position.

The heater switch has two operating positions, the first actuating the fan only for ventilation.

I n the second position the switch actuates the heater fuel feed, initiates combustion simultaneously by energising the glow plug coil and lights the heater indicator lamp, which remains lit until the heater is switched off.

- 17 -

Fully pressing in the switch stops the heating cycle. The red light will go out but the fans will continue turning until the heat chamber has been cooled and the combustion chamber is free of gases (2 to 3 minutes). Then the fans automatically stop, after which the heater can btl switched on again.

CAUTION - DO NOT SWITCH THE HEATER ON AGAIN UNTIL THE HEATER MOTOR STOPS, NOR SWITCH OFF THE BATTERY-SUPPLIED CURRENT UNTIL THE HEATER FANS HAVE STOPPED.

Figure 14

Possible faults a)

If the heater fails to light up (e.g. for lack of fuel) it will automatically cut itself out after a maximum of two minutes from having been switched on. It can be switched on again after first pressing in the safety switch on the control unit (figure .14), but this must not be attempted more than twice. If the heater fails to light up, repair or correct the fault.

b)

If the flame goes out while the heater is in operation, the heater will cut itself out automatically after 4 minutes.

c)

In the event of overheating (e.g. due to obstruction of the hot air channels) the safety switch will cut out the electric fuel feed pump. The heater will automatically stop.

Having rectified the fault which caused overheating, replace the safety fuse and again press in the safety switch on the control unit.

- 18 -

h CAUTION - Do not operate the cab heat.er system inside buildings or other enclos~d . . spaces.

Description and maintenance .. Fuel tank (1) Filter (2) - Electric suction pump (3) - fuel feed pump (4) and flow damper (5) - Heating element (6) If the heater is not to be used for long periods it should be operated for a few minutes once a month.

750B.46.002 Figure 15

21. Electrical power point As an option, it may have speedometer, cigarette lighter (22) and radio (23).

- 19 -

73

CONTROLPANELLEVERS

1. Gear selector and forward-reverse lever

Located to the left hand side of the driver, the following positions may be obtained through the two movements shown in figures 16 and 17.

740.26.006

740.26.005 Figure 16

Figure 17

Figure 16 shows the forward-reverse movement. Move the lever upwards for forward and down for reverse. The centre position (N) is in neutral.

Figure 17 shows the gear range movement. The lever moves horizontally through any of the three positions of forward, neutral, reverse. First gear is when the lever is closest to the steering column. Each higher gear is obtained by moving the lever progressively to the left as shown in the figure.

2. Light switch

Located to the left of the steering column (Figure 18). It has three positions, and is actio ned by the parking light switch on the right hand control panel.

- Lower position .. . . ..

Parking lights, connecting the switch (7.2-14)

- Centre position

Dipped beam.

_. Upper position

Main beam

Pulling this lever towards the driver, operates the head lamp flasher.

3. Turn indicator lever Located to the right hanc! side of the steering column. See figure 18.

By moving this lever up or down, the left or right flashing lights are operated.

- 20-

Figure 18 To operate the horn, press on the end of the turn indicator lever.

The windshield-wiper water circuit operates by pulling this lever towards the driver.

7.4

OTHER CONTROLS INSIDE THE CAB 1. Interior cab light

I nstalled on the roof, with its own switch.

2. Windshield washer reservoir

This reservoir is located to the left of the driver on the front of the control panel.

The level should be regularly checked.

3. Brake pedals

This machine has two brake pedals. Using the left pedal disconnects the drive to the transmission at the same time as applying the brakes. This use allows full engine power to be diverted from the transmission to the hydraulic circuit if required.

- 21 .

The right pedal is for normal braking and should be used when negotiating steep slopes or other rough ground.

Figure 19 4. Accelerator pedal

Located 'to the right of the brake pedals.

5. Driver's seat

This seat is of the absorption, regulable type.

OPTIONALLY, it may have a safety belt.

The seat may be adjusted for height, fordwards/backwards, angle the back of the seat also a load regulator to absorb shocks.

·22·

Figure 20 1. Height control.

2. Load adjustment control.

3. Forward and reverse control.

4. Seat back angle control.

5. Safety belt.

6. Hydraulic system manual operation lever

This lever, located to the driver's right side, operates the lift arm and bucket hydraulic systems.

®

~~@ 740.90.004

Figure 21

-23 -

The various positions are shown in figure 21.

o

Neutral position. With the electrical ci rcuit disengaged (see items 10 and 11, page 16) ie: manual operation, the control lever always returns to this position.

1

Lower. With the lever held in this position, the arm bucket assembly is lowered under power.

2 - Float. In this position, when the bucket reaches the ground the bucket and arm assembly "floats" over the contours of the ground.

3 - Lift. Pulling the lever rearwards, the lift arm assembly is raised.

4 - Bucket rollback. With the lever held towards the driver, the bucket is rolled back.

5 - Bucket dumping. By pushing the lever away from the driver, the bucket is dumped.

The operation of the lift arm and bucket is made through a single lever.

Figure 22 The lever is provided with a safety lock as shown in figure 22.

It is advisable to have this safety lock in position when the hydraulics are not being used.

- 24-

Lift-lower The positions of this lever, are as shown in the figures below:

o -I n

any position, when releasing the operating lever, the hydraulic circuits are blocked_

1 - When moving the lever to position 1, the arm lowers the descent speed depending on the engine speed.

2 - When moving the lever to position 2, and hold ing in this position, a floating position of the arm-bucket assembly is attained (see figure 23), By using the hydraulic control valve electric system, the lever automatically remains in this position.

740.QO.004

Figure 23

3 - Moving the lever to position 3, the arm lifts. This position may be manual or automatic if the control valve electric circuit switch is connected. The lift height, on automatic, is adjustable.

Dump/Rollback

Figure 24

- 25-

740.90.004

o

In this position, the bucket hydraulic circuit is blocked.

4

By moving the lever to the left, the bucket rolls back. This position may be manual or automatic with the control valve electric circuit connected.

5 - The bucket dump position is attained by moving the lever to the right. This is a manual position only.

Automatic system The positions that may be automatically attained through the electromagnetic system built-in to the control valve are: - Arm lift (height adjustable).

- Float position at ground level.

- Bucket rollback.

Automatic position of the arm At the location marked on figure 25, is an "end of stroke" adjustable contactor, to obtain different unloading heights, as required.

This only operates if the appropriate switch located on the control panel is connected.

Figure 25

- 26-

Bucket automatic rollback

As in the arm system, the bucket system is fitted with an "end of stroke" adjust· ment to obtain different angles of bucket rollback. See figure 26.

For automatic operation, use the appropriate switch.

Figure 26

7. Rear axle disconnect control To travel on the road or when the machine is to be towed, it is advisable to discon· nect the rear axle drive. The control is located behind and to the right of the driver.

To disconnect the drive push the lever forwards and connect the drive by pulling it backwards. Both operations must be performed with the machine at a standstill.

Should you find any difficulty with this operation, move the machine slightly for· wards and backwards.

Figure 27 ·27·

8. Parking brake The brake lever is at the operator's left hand on a bracket fixed to the cab floor· see Figure 28. Pulling the lever upwards applies the parking brake.

The brake indicator light glows when the parking brake is applied and the starter key is in the contact position.

Before setting the machine in motion push the hand lever forward to its neutral position. The indicator light will go· out.

This is a mechanical brake acting on a disc coupled to tne transmission output shaft - see Figure 29.

The efficiency of this parking brake permits using it to supplement or in substitution of the foot brakes but only in an emergency.

To adjust the parking brake proceed as follows: 1)

2)

Turn the lever handle anti-clockwise to the fully slack position.

Adjust the clearance between the brake pads and the disc so that a 1 mm.

-(0.04 in) metal strip can be inserted between the disc and one of the pads. The other pad should remain pressed against the disc.

To adjust the clearance release the locknut and turn the centre screw, No.2 in Figure 29.

Having obtained the correct clearance, tighten the locknut.

Figure 28 3)

Then give the parking brake lever handle four full turns clockwise see figure 28.

- 28 -

To check the adjustment proceed as follows: a)

Start the engine.

b)

With the hand brake applied, select forward and second gear and accelerate to maximum rev/min. .

With the parking brake adjusted correctly the machine should not move forward. If it does, repeat the adjustment procedure.

Figure 29

h

~

CAUTION - DO NOT TIGHTEN THE HAND GRIP MORE THAN INDICATED AS EXCESSIVE TAUTNESS COULD SNAP THE HAND BRAKE CABLE.

Every 1000 hours the parking brake pads are to be checked for wear and if necessary adjusted by the procedure detailed above.

The parking brake pads must be replaced when worn down to 4 mm. (0.16 in) thickness.

9. Auxiliary steering (OPTIONAL EQUIPMENT) The auxiliary steering consists of a hydraulic circuit combined with the standard equipment, operated through an electropump, preventing loss of steering should the engine fail or through a failure of the steering hydraulic pump.

To operate the auxiliary steering electrical circuit, the battery isolator switch must be on and the key switch in contact position 1.

NOTE: The application of the parking brake cuts-out the auxiliary steering system.

- 29 -

8. OPERATING INSTRUCTIONS

8.1

RUNNING·IN

Special attention should be paid to the engine running-in.

The pistons, rings, rods, etc., may be damaged if the running-in instructions are not carried out correctly.

The following procedure is recommended: - During the first 50 hours of operation, use normally but do not overload the engine.

- Try not to operate the machine with the engine at low revolutions.

- Keep the engine temperature within the recommended range. Working at low temperature helps the formation of destructive acids and carbon in the engine.

- Drain the oil from the crankcase and change the oil filter after the first 20 hours of operation. Refill the crankcase with oil as recommended in the lubrication chart.

- If the engine has been working under load, "idle" the engine for a while before stopping it, so that the engine parts can cool evenly.

8.2

CHECKS TO BE MADE BEFORE STARTING

Before starting the engine, and before every work shift, check the following: 1.

2.

3.

4.

5.

All the points suggested in the Maintenance Guide.

That there is sufficient fuel in the tank.

That the fan belts are correctly adjusted.

That there are no oil leaks.

Check the tyres to see that they do not have deep cuts, stones and that they are at the recommended pressure.

6. The exterior condition of the machine.

-30-

8.3

INSTRUCTIONS TO START Before starting the engine, check that the parking brake is applied, check that the gear lever is in neutral (N) and that the engine stop control is pushed in.

To start the engine: - Connect the battery isolator switch.

- Fully depress accelerator pedal.

- Turn the key switch to start the engine. The indicators for: alternator, engine oil pressure and parking brake will be on.

NOTE: If the engine does not start immediately, do not keep the start key operated for more than 30 seconds. Release it and wait for at least 30 seconds to allow the batteries to recover and then try again .

•

- Immediately the engine starts,check that the oil pressure indicator light goes out. Otherwise, stop and check the reason.

- Check that the light for the alternator circuit goes out, showing that the battery charging system is operating.

Checks before moving off Upon starting the engine, allow it to warm up for a few minutes, so that the lubri· cating oil has enough time to circulate.

IMPORTANT: Watch the engine oil pressure indicator. Should the pressure fall below the recommended pressure, stop immediately and do not start again until the problem isdiagnosed.

h

~

WARNING· Do not move the machine while the pneumatic brake circuit pressure is below 4.5 kg/cm 2 . The warning light for low brake pressure should be off.

- 31 .

Operating in high temperatures

Use the following checks to ensure efficient operation when the machine works in high temperatures.

- Check the radiator water level frequently.

- Ensure the radiator cap is fitted correctly (pressurized).

- Keep the radiator clean.

- Frequently check the fan belt adjustment ..

- Carefully follow the maintenance and lubrication schedule of the machir.le.

- Frequently check the engine air cleaner indicator.

- Check the battery level.

8.4 Aids to cold starting To start the engine in cold weather, proceed as follows: - Be sure that the engine "stop" control is pushed in.

- Turn the key switch to the preheater position (3), for 15-20 seconds (see figure 30).

740.90.005

Figure 30 - Turn the key to the start position (4). If the engine does not start turn the key back to position 3 for 10 seconds and then again to engine start position (4). See also Note under Instructions to start.

- Once the engine starts, return the key to position (1).

- 32-

Figure 31 In case of starting problems, check that the fuel reaches the cold starting aid on the intake manifold, by unscrewing the fuel intake connection. If the fuel is satisfactorily reaching there, and the engine still does not start, check by removing the heater element (see location in figure 31), then operating the key switch to see ifthe element is getting hot.

8.5 COLD WEATHER OPERATION Precautions Batteries

- Keep the batteries fully charged.

Lubrication - Use oil of correct viscosity for the engine and transmission. See lubri-

cant section.

Cooling system

Protect the cooling system with a good brand of high boiling point, permanent type, ethylene glycol anti-freeze.

Fuel tank

- Drain the fuel tank water trap daily.

- Fill the tank daily, to prevent water condensation and its possible freezing.

- 33-

8.6 EXTREMELY COLD WEATHER

Under extreme circumstances, follow the indications below:

Batteries Remove the batteries and store them in a warm place. Always place the batteries on wood. Refit the batteries when required.

Engine oil Drain. the crankcase oil while it is hot after work, and store it in a warm place. If possible, heat the oil to approximately 35 0 C before replacing it in the engine.

Engine water Be sure you are using correct antifreeze mixture for very cold temperatures; otherwise, drain the water from the radiator and engine to prevent freezing.

Engine operation without load If the engine should run at "idle" for long periods of time, the engine coolant will not reach its correct operating temperature. This causes incomplete combustion and in turn creates excessive carbon deposits in the engine. .

If the engine has to run without load for a long period of time, keep the engine speed· at approximately 2/3 throttle open.

8.7 STOPPING INSTRUCTIONS

1. Stop the machine and place the forward/reverse lever in neutral (N). Apply the parking brake.

2. If the machine has been working under extremely heavy conditions or heavy loads, decrease the engine speed to 1/2 rate for 5 minutes. This will. permit the engine to cool evenly.

- 34 -

3. Run the engine at "idle" and pull out the stop control. Once the engine is stopped, return the stop control to its normal position.

4. Turn the key switch to position O.

8.8 INSTRUCTIONS FOR TOWING THE MACHINE ATTENTION:

The machine may be towed at a slow speed, for a distance not exceeding 1 km. For longer distances, lift the front axle off the ground and disconnect the rear axle drive.

If the machine has to be towed and no lifting facilities are available, then the front axle drive shaft must be removed and the rear axle drive disengaged. Failure to observe these instructions will cause serious damage in the transmission and hydraul ic pumps.

A

WARNING -

Alwa~s

use a rigid bar when towing or bein'g towed.'

740.90.067 8.9 TYRES Due to their large dimensions, the tyres of your Wheel Loader require special care when travelling on the road, or when the machine is towed.

- 35-

- Check the tyre pressure before travelling on the road. Correct pressures are 3.75 kg/cm 2 (53 psi).

- Travell ing on a road causes the tyres to get warm with an increase in pressure. This is normal. Do not readjust pressures.

- Every two hours of travel, stop for 30 minutes to allow the tyres to cool off. Do not pour water on a hot tyre.

h ~

CAUTION - Stop and look before you use a road. When you do, keep to the right so that the vehicles behind can get past. Use correct procedure when driving on the road.

740.90.044

h ~

CAUTION - Do not park the machine on the road, leave the roadway as free as possible. Should you need to park,yut the emergency lights on and give good warning to other drivers.

740.90.045

- 36-

9. LOADER OPERATING INFORMATION 9.1 STANDARD BUCKET The following recommendations regarding operational procedures will help you to obtain a higher performance with less wear to your machine and less effort for you.

9.2 WORK PREPARATION

Make the work cycle as short as possible. Correct positioning of the truck is essential, for efficient operation. See figure 32.

Take some minutes to level the working area if necessary. A smooth level area for the machine and trucks, will increase operating speed and operator comfort.

Figure 32

9.3 FILLING THE BUCKET To fill the bucket, the bucket should be horizontal for loading or with a slight downward angle if you are going to dig. The chassis should be straight to get the highest penetration force. Be sure that the bucket is in the horizontal position and not slightly rolled back, since this will cause the bucket to be underfilled.

- 37-

Engine speed and transmission range

Place the transmission range selector lever in low range during loading operations and when transporting a load.

Penetrate the pile smoothly and firmly. Do not use the loader like a ramrod; it is hard on both man and machine.

Methods are generally of two types: the arc penetration method, in which the loader bucket is penetrated into the bank in a continuous upward arc until filled; and the step penetration method, in which the loader bucket is penetrated horizontally into the bank with intermittent and successively higher levels, or steps, until the bucket is filled.

Step penetration

7508.90.00 Lf

Figure 33 Step penetration

Approach bank slowly with bucket horizontal at ground level. With engine running at full throttle, penetrate bucket straight into pile as far as possible during initial thrust.

When engine speed starts to drop, depress left brake pedal. Keep bucket horizontal and raise approximately one foot. Resume forward motion of machine, and drive bucket further into the pile. Repeat the cycle as many times as necessary until the bucket is full.

Use the left brake pedal so that the lift cylinders will have maximum hydraulic power when raising the bucket after each thrust into the pile.

Arc penetration

\ o ~ / ~ +------ ---0

)

-'-"'"

Figure 34

-38 -

7508.90.005

Arc penetration

Approach bank or stockpile with bucket horizontal at ground level. With engine running at full throttle keep machine in forward motion until bucket is full. Penetrate bucket straight into pile about 6 or 8 inches (152 or 203 mm.). Then coordinate loader arm lift motion and bucket rollback motion so that the rear of the bucket is filled as the machine moves forward. Too much rollback will underfill the bucket; too little rollback will overload the bucket.

/\.. ..

CAUTION - Do not go into the work face too fast. Use low gear and maximum engine speed.

/\.. ..

CAUTION - During the o~ration of the machine, '0"0 not use the bucket as a bulldozer blade.

740.90.066

9.4 TRANSPORT OF MATERIALS

/\.. ..

WARNING - Never travel the machine with a full bucket at full height.

Keep the bucket as low as possible. This gives better balance and permits you to see more clearly. If you use the machine with a full bucket over ground that is rough operate at a speed that is safe.

740.90.065

- 39 -

9.5 UNLOADING THE BUCKET INTO A TRUCK When you dump a load into a truck, make sure the wind is behind you. Inthis way, dust and loose material will not go into your face and prevent you from seeing.

This also makes reduction in the need for maintenance on the engine air cleaner.

Start to lift the bucket so it is at the correct height when you come to the truck side area.

If one side of the truck is lower than the other, you can put the truck in a position that will permit you to dump over the low side. In this way, you can make a better distribution of the load in the truck.

Dump into the far side of the truck first. Fill the truck gradually from the far side to the near side. This will give a better distribution of the load in the truck.

·40·

10. FUELS AND LUBRICANTS

10.1 FUEL STORAGE Storing fuel for a long period of time causes accumulation of sediment, dirt, scale, water and other foreign material in the fuel. Many engine difficulties can be traced to dirty fuel and long storage periods.

10.2 FILLING OF FUEL TANK The Wheel Loader tanks are located on both sides of the machine and to the rear, with the filler cap in the right hand side tank. The capacity of the tanks is 200 Its. Always clean the outside of the cap before removing it to refill with fuel.

10.3 LUBRICANTS It is extremely important to use high quality oils for your machine. It is also important that the oil is of the correct viscosity.

- 41 -

11. TYPES OF LUBRICANTS

LUBRICATION POINTS

ENGINE OILS

CAP. LlTRES

15

TRANSMISSION AND CONVERTER

RECOMMENDED LUBRICANTS

SAE STANDARD

FROM OOF (-180C) *MIL-L-2104C OILS TO 30°F (--1°C) MOBIL OIL DELVAC 1310 SAE10 FROM 30°F (-1°C) TO 800F (27°C) SAE 20 MOBIL OIL DELVAC 1320

23.5

MOBIL OIL 1310

SAE 10 W2Q-C.2

250

MOBIL OIL 1310

SAE 10 W20-C.2

FRONT AXLE

25

MOBIL OIL EP-90

SAE 90.6.E.P.

REAR AXLE

25

MOBIL OIL EP-90

SAE 90.6.E.P.

GREASING POINTS

-

MOBIL OIL SPECIAL AUTO-GREASE

-

BRAKE FLUID

-

KRAFFT SUPER 3

--

HYDRAULIC SYSTEM COMPLETE

ATTENTION:

IN ALL GREASING POINTS USE LITHIUM BASE GREASE WITH MOLYBDENUM DISULPHIDE.

• Lubricating oils for normally aspirated engines should meet the requirements of the U.S. Ordnance Specification MI L-L-46152 or MI L-L-21 04C. Lubricating oils for engines installed in Heavy Duty Earthmoving Equipment should meet the U.S. Ordnance Specificat ion MI L-L-21 04C. Some of these oils are listed above. Any other oils which meet these specifications are aho suitabl(~.

Lubricating oils for use in Perkins Diesel engines should have a minimum viscosity index of HO.

- 42-

12. MAINTENANCE AND LUBRICATION GUIDE

12.1 The maintenance of the machine only takes a few minutes daily.

To ensure maximum service, two factors should be observed: 1. Establish a regular maintenance and lubrication schedule. All periods given in the lubrication and maintenance chart are based on the readings of the hour meter.

2. Use Qnly high quality oils and greases, as given in the section LUBRICANTS. The different grease points, oil changes, levels, filter replacements and service to the equipment are summarized in the maintenance guide.

This guide shows: -_. Periodic servicing, operations to be performed, type of lubricant used and location of the various points.

1.2

MAINTENANCE GUIDE INTERVAL

After the first 20 hours of operation

OPERATION TO BE PERFORMED Change: - Engine oil - Engine oil filter - Fuel fi Iters - Transmission and converter oil - Transmission filter - Hydraulic filter Check levels of: - Brake fluid . - Front and rear axles (oil) Clean: - The fuel water and sediment trap - The filter in the fuel lift pump - The filter in the converter intake Miscellaneous: - Drain the water from the fuel and hyd raul ic oil tanks - Tighten fan belts - Set the rocker clearance - Tighten nuts on engine cylinder head - Tighten the wheel nuts, axle bolts, planetary covers and differential housing bolts.

-43-

TYPE OF LUBR ICANT

See page 42' See page 42

See page 42 See page 42

INSTH UCT IONS

See See See See See See

page page page page page page

48 49 53 83 81 78

See page 92 See page 85 See page 53 See page 53 See page 83

See pages 52-80 See page 59 See page 58 See page 58 See page 86

INTERVAL

Every 10 hours of operation or daily

OPERATION TO BE PERFORMED

Grease: - All the loader and bucket linkage pivot points

TYPE OF LUBRICANT

See page 42

Check levels of: - Engine oil - Transmission and converter oil - Hydraulic oil - Radiator - Fuel

Lubrication of: - Rear axle trunnion pivot bolts - Steering cylinders - Chassis pivot bearings - Accelerator and brake pedals, hinges, levers, etc.

-

See See See See See

-

See page 87

-

See page 57

-

See page 61

-

See page 21

See page 42 See page 42 See page 42

See page 47 See page 47 See page 47

See page 42

Check: - Brake fluid level - Battery acid level and terminal condition - Drain the water from the fuel tank - Drain the water from hydraulic oil tank Every 100 hou rs of operation

Change OT: - Engine oil - Engine oil filter - Fuel filters

Miscellaneous: - Oil level in axles - Clean fuel sediment water trap - Check tyre pressu res - Tighten chassis pivot pin nuts 78/81 M.K .G.

- 44-

page page page page page

48 83 78 62 14

-

-

See page 91

-

See page 72 See page 52

-

See page 80

See page 42

See page 48 See page 48 See page 53

-

Lubrication of: - Front cardan drive shaft - Centre bearing - Centre cardan drive shaft - Rear cardan drive shaft

See page 46

-

MisceUaneous: - Check the condition of tyres - Clean and chek the engine air intake installation. Clean the filter cartridge and the filter bowl. Check its condition - If necessary, clean the radiator core - Refill the windshield wiper fluid reservoir Every 50 hours of operation or weekly

INSTRUCTIONS

See See See See

page page page page

-

-

42 42 42 42

See See See See

page page page page

47 47 47 47

See page 85 See page 53 See page 87

INTERVAL

Every 200 hours of operation

Every 500 hours of operation

OPERATION TO BE PERFORMED

Check: - The brake and hydraulic installation - The bra.ke pad wear - Change the transmission filter (250 hours) Change of: - Transmission and converter oil - Hydraulic oil - Hyd~aulic oil filter - Engine air intake filter element - Front and rear axle oil Check and clean: - The engine outside - Mesh filter of the fuel lift pump - Engine air intake installation - Cooling installation - Outside of transmission and converter - Transmission mesh filter - Transmission breather - Hydraulic oil tank - Hydraulic filter magnetic column - Tighten fan belts

Every 1000 hours of operation

Change of: - Brake fluid - Radiator coolant

See page 89 See page 93

-

See page 81

See page 42 See page 42

See page 83 See page 78 See page 78 See page 60 See page 86

-

See page 42

-

-45 -

-

-

See page 53 See page 60 See page 61

-

See page See page See page See page See page

-

Check: - Engine: Lubrication circuit. cooling circuit. fuel circuit and air intake installation.

- Hydraulic installation: Brake and hydraulic circuits. electrical circuit

INSTRUCTIONS

-

See page 42

Check and clean: - Hie compressor head - General hydraulic circuit - Steering circuit - Park ing brake pads - Clean the air filter in the brake system Whenever required

TYPE OF LUBRICANT

-

83 78 79 59 81

See page 91 See page 61 See page 51 See page 28

See page 70 See page 93

-

-

-

-

13. LUBRICATION POINTS

If the machine is working under severe or abnormal conditions, halve the lubrication intervals shown in the figures.

Every 10 hours of operation or daily

Figure 35 1.

2.

3.

4.

5.

Lift arm pivots . . . . . . . . . . . . . .

Lift cylinder pivots . . . . . . . . . . .

Dump link pivots . . . . . . . . . . . .

Bucket pivot pins . . . . . . . . . . . .

Bucket cylinder pivots ..; .......

. . . . .

(2) (6) (4) (4) (4)

one on each side three on each side two on each side two on each side two on each side

IMPORTANT - IF YOU SUSPECT THAT THE GREASE, DUE TO ANY REASON, DOES NOT ENTER ANY OF THE GREASE POINTS, DISASSEMBLE IT, THOROUGHLY CLEAN AND GREASE THEM PRIOR TO REASSEMBLY ON THE MACHINE.

- 46-

Every 50 hours of operation or weekly

Figure 36 6. Rear axle trunnion pivot bolts .... .

7. Steering cylinder pivot points .... .

8. Chassis pivot pins . . . . . . . . . . . . .

(2) (4) two on each side

(2)

Every 100 hours of operation

Figure 37 9.

10.

11.

12.

Rear cardan drive shaft . . . . . . . . .

Central card an drive shaft. . . . . . ..

Centre bearing . . . . . . . . . . . . . ..

Front cardan drive shaft. . . . . . . ..

-47 -

(3) (3) (1) (3)

14. ENGINE MAINTENANCE 14.1 ENGINE OIL AND FILTER Engine oil level check Check the engine oil level daily, using the dipstick. It is located on the left side of the engine, see figure 38. Check the oil level before starting the engine or 5 to 10 minutes after stopping the engine. .

Should you note some discolouration in the oil, check with yoOr official Case dealer.

Figure 38 Engine oil change The engine oil should be changed after the first 20 hours of operation and after, at every 100 hours. Should the work conditions be extremely hard, the engine oil should be changed more often.

It is advisable to change the oil when hot. See the location of the drain plug in figure 39.

Figure 39

·48·

To refill the crankcase

1. Use a good quality oil to specifications shown in the lubrication chart. Refill the crankcase with the correct quantity. Filler cap shown in Fig. 40.

2. Start the engine and check for leaks. l'hen, stop the engine, wait a moment and then recheck the engine oil level with the dipstick.

Figure 40 Engine oil filter cleaning

The engine oil filter is located to the right rear part of the Loader. See location in figure 41.

~

Figure 41

·49·

750B.21.005

This filter is of the disposable type.

To replace it: 1. Remove the used filter, turning it to the left, and throw it away.

2. Lubricate the "0" ring of the new filter with oil or grease.

3. Fit the new filter and tighten it by hand.

The filter should be replaced with every oil change.

When the new filter is installed, check the engine oil level and see if there are any leaks once the engine is started.

Engine oil pressure gauge and indicator

The pressure should not be less than 2.1 Kg/cm 2 .

Should the pressure fall below these figures, stop the engine and check the cause.

If the oil pressure warning indicator lights during the regular operation of the Loader, stop the engine and check the reason. Do not start the engine until you know the cause .

14.2 AIR COMPRESSOR

•

The compressor is directly coupled to the engine block, being lubricated and cooled directly by engine oil. See figure 42.

Figure 42

- 50 -

The only service needed by the compressor is: - Check the air connections.

- Exterior cleaning.

- Remove the head and clean every 1000 hours of operation.

14.3 FUEL SYSTEM

Fuel is taken from the tank by a diaphragm lift pump, which is mounted on the cylinder block and driven by the camshaft. Fuel goes through sediment/water trap to the lift pump, through two filters, to the fuel pump.

- Fuel tank - Sediment/water trap - Lift pump - Filters - Injection pump - Injectors - Tank return line To prevent any foreign matter in the fuel, first, use a good fuel, and clean the system regularly.

General scheme Figure 43 shows the fuel system.

- 51 -

1. Tanks 2. SedimentlWater trap 3. Lift pump 4. Filters 5. Injection pump 6. Injectors 740.90.009

Figure 43

1. Tanks The fuel tanks together have a capacity of 200 Iitres. Both tanks are connected to each other as shown in figure. 44. The filler cap is located in the right hand tank, to the rear of the machine. Each tank has a drain plug to drain any water.

This operation should be made everv 50 hours or weekly.

1.

2.

3.

4.

5.

6.

7.

Fuel intake Breather Return Gauge (level) Filler cap Inter·tank connection Inspection covers and water drains.

Figure 44 . It is ad~isable to fill the tanks at the end of each day, to prevent water condensa. tlon ?ve~nlght. Thoroughly clean the outside of the filler cap to the tank, before opening It.

·52·

h. ..

WARNING - Do not put fuel in the machine with the engine running, close to a fire or if you are smoking.

2. Sediment/water trap

740.90.U62

The fuel sediment/water trap is bolted to the side of the hydraulic oil tank. Its position may be seen between the left rear wheel and the fuel tank on the same side. See location in figure 45.

It should be drained after the first 20 hours and then, every 100 hours of operation.

3. Lift pump Of the diaphragm type, driven by the camshaft and can be operated manually.

This pump lifts the fuel from the tank to the injection pump through the main filters.

The mesh filter located in the upper part of the lift pump, should be cleaned after the first 20 hours of operation, and then, every 500 hours.

4. Fuel filters Of the replaceable type. In the upper part it has two plugs to bleed the air from the system.

The filter elements should be replaced after the first 20 hours, and then, every 100 hours of operation.

5. Injection pump This pump takes the fuel from the main filters, delivering it under high pressure to the injectors. Excess fuel is returned to the tank.

6. Injectors They supply the fuel to the engine combustion chambers in spray form, under high pressure. Their lubrication is by the fuel itself.

- 53-

Service to the fuel sediment/water trap Clean the sediment bowl regularly (100 hours) of any sediment and water that may be in it.

Figure 45 To replace the filter elements, proceed as follows: a.- Before disassembly, thoroughly clean the filter assy on the outside. Figure 46. b.- Remove the used filter elements. c.- Clean the inside of the filter bases. d.- Fit the new filter elements, using the new seals supplied.

Figure 46

- 54-

e.- Lubricate the gaskets and fit the filter elements. f.- Open the bleed screws in the filters and injection pump and prime the circuit using the manually operated plunger of the lift pump. When the fuel flows through, without showing any air bubbles, tighten the bleed screws on the injection pump and filters.

Injection pump

This pump is directly lubricated by the fuel system.

Servicing the pump only requires: 1.- Exterior cleaning.

2.- Check for leaks.

DISASSEMBLY OR REPAIR WORK OR ADJUSTMENTS SHOULD BE MADE

BY YOUR OFFICIAL CASE DEALER.

Figure 47

Defective injection may be due to: a) Carbon deposits on the nozzles or looseness of the nuts.

- 55-

b) c) d) e) f) g)

The spray holes of the nozzle are blocked.

Dirt on the seal between the nozzle and the cyl inder head.

Dirt in the needle seat.

Seizing of the needle to the nozzle.

Defective adjustment or breakage of the needle spring.

Cracks in the injector body.

To locate a defective injector, loosen the injector pipe nut two or three turns, while the engine is running slowly. Fuel to the injector is stopped and if there is no change in the engine performance, it may be assumed that the injector is defective and should be removed to be checked.

ATTENTION:

It is most important not to bend the fuel return pipes when removing a single injector. Remove the whole assembly to prevent damage.

Bleeding of the fuel system

The fuel system should be bled if air enters the circuit, as a consequence of: Fuel tank is empty.

The engine has not been used for a long period of time.

Some repairs or part replacements have been made.

To bleed the system, open the bleed screws in the main filters, manually operate the lift pump till clean fuel with no air bubbles flows through. Close the filter bleed screws and open the injection pump bleed screws (figure 46). repeating the same operation.

To bleed the injectors, loosen each injector pipe nut in turn with the el'!gine running allowing the fuel to flow till there is no air bubbles. Tighten the nuts following the ignition order of the engine 1.5.3.6.2.4, number one closest to the fan.

- 56-

A

WARNING - Extra caution is to be used when working on the fuel system.

There is HIGH pressure in the syst~m. If you have been in body contact with high pressure fuel, ask for a doctor Immediately.

740.90.063

If, after the above operations, the engine will not start, repeat the bleeding procedure.

14.4 VALVE ADJUSTMENT AND HEAD TIGHTENING

After the first 20 hours, check the valve clearances: Cold engine 0.30 mms. (0.012").

Hot engine 0.25 mms. (O.OOg").

To adjust the clearance'of the valves, proceed as follows: (see fig. 48)_ a)

With the valves of number 6 cylinder rocking (both valves open), adjust the clearance of the valves in cyl inder number 1.

b)

With the valves of cylinder number 5 rocking, adjust the clearance of the valves of cylinder number 2.

c)

With the valves of cylinder number 4 rocking, adjust the clearance of the valves of cylinder number 3.

- 57-

d)

With the valves of cylinder number 3 rocking, adjust the clearance of the valves of cyl inder number 4.

e)

With the valves of cylinder number 2 rocking, adjust the clearance of the valves of cylinder number 5.

f)

With the valves of cylinder number 1 rocking, adjust the clearance of the valves of cylinder number 6.

With the engine running at "idle", check that the oil is reaching the rocker assembly.

0.30 mm. (cold) (0.012") 0.25 mm. (hot) (0.009")

Figure 48

Cylinder head tightening After the first 20 hours of operation, retighten the head nuts in the order shown in figure 49 to the following values:

13.8 MKG (100 Ibs.ft.)

740.21.109

Figure 49

- 58 -

14.5 BELT TIGHTENING After the first 20 hours of ·operation, check the fan belts, then every 500 hours.

The belt adjustment should be an approximate deflection of 10 mm. (3/8") on the longest run. See figure 50.

Figure 50

The correct tightening of the fan belts is essential to prevent premature wear of the alternator and water pump bearings, or to prevent the fan belts from slipping.

A new belt should be retightened after the first 50 hours of operation.

14.6 ENGINE AIR INTAKE

I]

When the air cleaner dirt indicator is showing, the filter element requires immediate cleaning or replacement.

1. Filter bowl 2. Indicator pressure switch Figure 51

- 59-

Maintenance and service to the engine air intake system Check the installation daily (possible dust) and clean every 500 hours.

For the correct use of the filter, it is necessary: - To clean the dust collector daily.

- Check the filter cartridge daily or before if the indicator comes on. Clean or replace if necessary.

Figure 52 - Replace the element if excessive dirt or wear is noted.

- The cartridge should be replaced every 500 hours of operation, or before if the environmental conditions are excessively dirty.

1.

2.

3.

4.

5.

6.

Dustcap and collector Filter cartridge Filter support Intake element Pipe Indicator pressure switch 7. Hose Figure 53

- 60-

2-F--

52

51 \

50 /'

,i 11 .

==ti=(~- 40

53 : , I

I"

(

)

"':

54

:::: II "

I

55 11

57

[J

D

31 JJ

'

11_____.

750B. 3'-1. 002

---l1 I QQQ /'

52 Figure 68

I

\

51

50

Auxiliary

~11!I!r

i"'1ldl!etrieal diagram (OPTIONAL EQUIPMENT)

n

5

-f 1. Electropump 2.

3.

4.

5.

6.

7.

AD

If- 1 J..

Relay Pressure switch Audible warning device End of stroke relay Starter Battery

1

7

l--

6

d'

L}

740.4('.00/,

F igurl! G!)

Cab tWatl!r 1!ll!etr ieal dia'llalll (OPTIONAL EQUIPMENT)

1. Motor 2. Resistance 3. Heating element 4. Fuse holder 6 Amp. -5. Automatic switch 6. Switch 7. Thermal switch 8. Metering pump 9. Lift pump 10. Start switch 11. Fuse 16 Amp. 12. Battery 13. Electronic control unit.

r.

730.46.001

Figure 70

·76 -

ATTENTION: Keep in mind the following precautions: - Extreme care should be applied when handling the filter cartridge, not to puncture the paper.

- Always use clean and dry low pressure air for cleaning.

- Check the air intake installation for leaks.

All these precautions will help to prevent excessive wear in the engine.

14.7 COOLING SYSTEM System capacity . . . . . . . . . . . . . ~ystem pressurization· . . . . . . . . .

4

261itres 0.490 kg/cm 2 (7 psi)

WATER OIL

740.22.001

1. Radiator 2. Engine 3. Torque converter and transmission 4. Oil cooler

Figure 54 The engine water pump delivers a constant water flow to the radiator. This is cooled with air delivered by the fan, When leaving the radiator the water returns to the engine through the oil heat exchanger of the torque converter, as shown in the diagram of figure 54.

Water pump The water pump installed on the engine does not require any kind of lubrication.

Check the cooling installation every 500 hours.

Radiator

The radiator is located at the rear of the machine. The radiator is fitted with a cap to pressurize the cooling system, increasing the boiling point and reducing losses in the circuit from evaporation. It also serves as the system safety valve. See location in figure 55.

- 61 -

The efficiency of a pressurized cooling system shows the advantage to quickly locate the fluid losses.

Figure 55

The efficiency of the radiator is impaired if it gets blocked with foreign materials.

Check the condition of the assembly and clean when necessary. Do not use metal objects inside for cleaning purposes.

1\. ..

CAUTION - There is pressure in the cooling system. Only when the engine is cool should you remove the radiator cap.

If not the result can be bad burns.

I 740.21.092

Coolant

Water - cooling fluid.

Do not mix different types of antifreeze in the engine. Should you only use water, ddd an antirust additive. Use soft water only, this will help prevent lime scaling in

the engine block.

·62 -

ATTENTION: . NEVER PUT COLD WATER IN A HOT ENGINE. YOU COULD CRACK THE CYLINDER BLOCK.

Antifreeze proportions for different temperatures

Temperature

-5°C

-10°C

-16°C --20°C

Amount of antifreeze

10%

20%

30%

35%

-23°C -34°C 40%

50%

Thermostat

The cool ing system has two thermostats that begin opening at 820C (180°F) and fully open at 97 0 C (205°F).

The cooling temperature depends on the mao chine work load.

A radiator working at the appropriate pressure will allow temperatures of up to 104°C with· out damage and without loss of coolant.

To check the thermostat A suspected faulty thermostat may be checked as follows: (Thermostat location in figure 56). .

Figure 56

·63·

Remove the thermostat (see figure 56).

Suspending it in water that is being heated.

Check the opening temperature with a thermometer.

Beginning of opening at 820 C. Total opening at 97 0 C. Should it prove to be defective, replace the thermostat.

Replacement of thermostats a.' Drain the radiator below the thermostat level. See location in figure 56. b.· Remove the water outlet hose. c.' Remove the bolts securing the thermostat housing. d.· Take the thermostats out and replace them if defective. e.' F it a new gasket and reassemble the hose and thermostat housing. f.' Refill the radiator, start the engine and check for leaks. g.- Check the cooling fluid level.

Figure 57

740.21.112

To clean the cooling system Thoroughly clean the cooling system, at least once a year. In case of hard water, that is, with a high content in salts, clean the system more often.

To clean the system, proceed as follows: 1. Stop the engine and while the cooling fluid is still hot, drain the radiator and t!ngine block through the drain cocks. See figures 58 and 59.

- 64-

2. Add a radiator cleaner to the system and refill with clean water. Use a commercial cleaner well guaranteed. Follow the instructions of the cleaner. Start the engine and keep it at.idle for 15 minutes.

3. Stop the engine and upon draining the cleaning solution, check the housing of the water pump, for possible leaks, etc. Once checked, flush the system with clean water, keeping the engine at idle for 5 minutes. Stop the engine and drain the system_

Figure 58 4. Clean all dirt and grease that may have accummulated on the engine and radiator.

5. Refill the system to the correct level, with clean water.

6. Start the engine for 5 minutes to expel the air from the system and recheck the level.

Figure 59 65

14.8. Turbocharger The turbocharger, Figure 60, is installed at the outlet of the exhaust manifold and lubricated by the engine oil system.

It is important not to speed up the engine suddenly when starting the machine, and before the engine is shut off it should be allowed to idle for a few minutes. Thus the turbocharger assembly will cool evenly and the turbine will not rotate on unlu· bricated bearings.

Figure 60 Turbocharger maintenance Every 1000 hours carry out or ensure proper cleaning of the turbocharger oil drain pipe and turbines. This operation must only be undertaken by dealers authorised to service the high precision turhocharger assembly. The procedure is as follows: . Detach the lubrication oil fI!ed and drain pipes.

- Remove the exhaust outll!t clamps from the turbocharger (the following numbers in brackets correspono with thoSI! in F igulI! (1).

- Mark the relative positions of ttll! turbine housinq (1), compressor housing (4) and housing clamp (2).

- Remove the housing bolts (3) and dt!tach till! complI!SSOI housing (4).

- Remove the housing clamp and spring (2) and detach ttll! inside assembly from the housing.

Wash the impeller and compressor turbines in a non·corrosive cleaning solvent, using a non-metal brush or a plastic scraper.

After cleaning reassemble in the opposite order of removal.

- 66-

CAUTION - Do not run the engine whilst any of the air inlet or exhaust pipes are disconnected, This could not only cause damage to the turbocharger by . . drawing in dirt; personal injuries 'could also result, from side emission of exhaust gases and of burning carbon deposits,

h.

Figure 61 IMPORTAi<JT: When removing the lubrication oil feed and drain pipes, plug the connections to prevent any dirt from entering the system, On leassembly, before attaching the oil feed pipe, turn the engine with the throttle and fuel knob closed, until oil flows through the pipe, 11wn tighten the connection and start the engine by the normal Ploc(!riurp..

III Ih,' ,'v"111 of II,sldllinq i1 IWW turbocharger, the engine should not be run to its "'.1""1111"' Ipll' III'liI .I IWI iod of 25 hours has been completed.

67 -

15. ELECTRIC SYSTEM Type of system . . . . . . . . . . . . . . . . . . . . . . . .

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Road lights . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear working lights . . . . . . . . . . . . . . . . . . . . . .

Flashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Park/brake lights . . . . . . . . . . . . . . . . . . . . . . .

Reverse light . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

24 Volts (negative earth) 2 X 12 Volt and 92 Amp. 24 V. 50/50 w.

24 V. - 50 w.

24V.-21w.

24V.21/5w.

24 V. - 21 w.

15.1 PARTS AND LOCATION OF LIGHTS (See Figure 62) Every bulb shows its voltage and wattage.

When replacing any of these bulbs, be sure it is of the right voltage and watts.

Should you use lower voltage bulbs, they will immediately blow-out. Do not touch inside of the reflector with your fingers.

7hOll. Jlo.OOi

Figure 62 - 68

15.2 ROAD LIGHTS REGULATION To maintain the correct lighting when travelling on the road, you should adjust the beams periodically. The wear of tyres or the installation of new tyres of different manufacturers and sizes affect the beam heights.

To adjust the beams, proceed as follows: · Plilce the machine on a leve.l surface, facing a wall, as shown in figure 63 ..

12m.

740.90.010

Beam height Distance between beams

Figure 63 · Mark three vertical parallel lines on the wall, as shown in the figure (reference A is the distance between the beam centers). On the two outside lines make a mark that corresponds to half the height of the light-unit from the ground.

- Place the machine 12 metres from the wall, as shown in the figure. The center of th~ machine should correspond to the central line on the wall.

- With the machine in this position, switch on the dipped beam and move the regulating screw of each light unit until the beam center corresponds to the marks made on the wall (H/2).

NOTE: Some countries may have more rigid laws regarding front light regulations for on-the-road travel. If there is any doubt, check with the local authority.

15.3 STARTER Service to the starter (see location i[1 figure 64) · Make sure that all connections are tight. · If, when using the starter, the cranking speed of the engine is low, check the batteries and the battery terminals.

·69

- It the starter opetates correctly, probably the starter clutch is slipping.

Figure 64

15.4 ALTERNATOR Maintenance precautions

. Make sure that the batteries are correctly connected (negative (-) to earth)' - Do not short-circuit or ground, any of the alternator or regulator terminals.

- Make sure that all wires and terminals are properly connected.

- Always disconnect the battery negative-cable before working on the alternator or regulator circuits.

Figure 65

- 70

- Never operate the alternator in open circuit.

- Be sure that all wires are connected and the terminals are tight . . When electric welding, disconnect the battery and the alternator and regulator terminals.

15.5 BATTERIES I t is most important, specially with diesel engines, to keep the batteries fully charged. Starting largely depends on the cranking speed of the engine. (See location in figure 66).

To check the battery charge - Use a hydrometer to check the specific gravity of the electrolyte. The density of the electrolyte shows the approximate condition of the battery. The.hydrometer gives a correct indication when the electrolyte temperature is about 25 to 26 0 c.

Figure 66

71

Clwck the level of the electrolyte in the battery every 50 hours of operation. If tlw TTlachine is working in a warm environment, check it more often. The level should be 1 cm. above the spacer plates. If the level is low, add distilled water to I~dch battery cell till the fluid level is correct. If water is added with room tempe· r alllle of 0 0 C and the battery is not charged, the water will stay on the top and t rl~I~/e; therefore, add water just before using the machine or with the battery charged enough to mix the water to the electrolyte.

Nl!ver add any acid to the batteries. Acid should only be handed by a battery I!Xpert.

DANGER· Batteries have acid in them, which can comes in contact with your skin, eyes or clothing, . . eyes with water for 15 minutes. GET A DOCTOR CHILDREN AWAY FROM BATTERIES.

A

cause bad burns. If acid wash with water. Flush IMMEDIATELY. KEEP .

740.90.074

A WARNING - When you check the battery charge, be careful not to place any . . metal object across the battery terminals. The sparks can cause a fire. Use a voltmeter or a hydrometer.

- Excessive water consumption in a battery may be due to an incorrect adjustment of the regulator or to an increase in temperature. If it uses no water for a long period of tine, it may be that there is an insufficient charge. This may be due to bad connections or to a low adjustment of the voltage regulator.

A CAUTION - When working on the electrical system never wear a ring, a metal . . watch band or any other metal object. These can cause injury.

72

h DANG E R Batteries discharge gases. Any sparks, flames or cigarettes must . . tH: kept iJway from the batteries. Be sure that there is air current in the place whel e the batteries are kept. Wear safety glasses to handle the batteries.

h CAUTION - When removing a battery, first disconnect the negative cable (-). . . When installing a battery, connect the negative cable (-) last.

15.6 ELECTRICAL INSTALLATION Fuse box

Figure 63 shows the location of the box containing the fuses.

To gain access to the box, remove the lower right plate in the control panel.

FUSE POSITIONS 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Figure 67

·73

Alternator Starter relay Horns Stop and reverse lights Control panel lights Rear work lights Left flashers Right flashers Left parking lights Right parking lights Left dipped beam Right dipped beam Left main beam Right main beam Cab light Rotating light Rear windshield-wiper Front windshield-wiper

General Wiring Diagram Item 1 2 3 4

5 6

7 8 9

10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 <;4

Description Front sidelamp Headlamps and Tail lamps End·ol·stroke relay switch Horns Horn push button F lasher indicator Set 01 warning lights (for main beam, oil filter, brake pressure) Set of warning lights (for hand brake, alternator charge, engine oil pressure) Switch for flashers, windscreen washer pump and horn.

Front lighting switch Connector Hourmeter Fuel gauge sender Engine oil pressure switch Transmission oil pressure switch Socket Starter key Windscreen washer pump Hazard warning switch Rotating beacon switch Rear main lamps switch Switch for lamps on cab roof Switch for sidelights Switch for rear windscreen wiper Switch for front windscreen wiper Autoswitch, return-to-dig, bucket Autoswitch, return-to-dig, boom (arms) Ammeter Water temperature gauge Transmission oil temperature gauge Dual gauge, brake system Fuse box Reversing light switch Warning lights switch Horn switch Flasher switch Hand brake light switch Assembly, return-to-dig autoswitches Boom return-to-dig electromagnet Bucket return-to-dig electromagnet Starter solenoid Neutral position (starter isolating) switch Air filter indicator Pressure/vacuum switch Batteries Batteries cut-out switch Alternator Temperature sender, torque converter Stop lamp contact switch Reversing lamp Rear side and stop lamps Rear flasher Fuel gauge F upl heater

Item

Description

Starter motor 55 56 - Lighting switch 57 - Water temperature sender Item

Fuses

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 .17 18

Alternator, 70 A Starter switch, 30 A Horns, 15 A Stop and reversing lights, 6 A Instrument panel, 15 A Rear working lamps, 6 A Left hand flasher, 6 A Right hand flasher, 6 A Left side lamps, 6 A Right sidelamps, 6 A Main beam, left hand, 6 A Main beam, right hand, 6 A Low light, left hand, 6 A Low light, right hand, 6 A Cab light, 6 A Rotating beacon, 6 A Rear windscreen wiper, 15 A Front windscreen wiper, 15 A

Colour Coding of Cables A B C D E F G H I

J K L M N

I'iI 0 P Q

R S T

U V W

X Y Z AA AS AC AD

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Blue, 1.5 mm2 Blue & Yellow, 1.5 mm2 Blue & Red, 2.5 mm2 Red & Green, 2 mm2 Green, 2 mm2 Grey, ·1.5 mm2 Red, 1.5 mm2 Brown, 2 mm2 Grey & Blue, 1.5 mm2 Pink, 1 mm2 Black, 1.5 mm2 White & Red, 1.5 mm2 White,2 mm2 Purple, 1 mm2 Brown, 1.5 mm2 White & Blue, 1 mm2 Yellow, 2.5 mm2 Recj & Blue, 1 mm2 Blue,1 mm2 Yellow & Blue, 1.5 mm2 Blue,4 mm2 Red,4 mm2 Blue, 2.5 mm2 Grey & Red, 1.5 mm2 Orange & Black, 1.5 mm2 Purple, 1.5 mm2 Pink, 1.5 mm2 GreY,2.5mm2 Green & Blue, 1 mm2 Transparent, 1.5 mm2 Blue, 50 mm2 (0.08 in2)

Cab electrical diagram

1. Parking lights 2, 3.

4.

5.

Work lights Rotating light Cab inside light Front windshield wiper motor 6. Rear windshield wiper motor.

11. Connector to the panel

'6

740.34.006

Figure 71

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16. HYDRAULIC SYSTEM

Tank capacity . . . . . . . . . . . . . . . . . . . . . .

T utal capacity of the system . . . . . . . . . . . . .

Pressure of the main valve . . . . . . . . . . . . . .

200 litres (44 imp.gals.)

250 litres (55 imp.gals.)

150 kgs./cm2 (2133 p.s.i.)

Tank pressurized at . . . . . . . . . . . . . . . . . . .

0.290 kg/cm2 (4 p.s.i.)

16.1 HYDRAULIC OIL LEVEL

Check the oil level, located at the rear of the machine, before starting work. See location in figure 72.

To correctly check the level, place the machine on flat ground. Lower the lift arm to the ground, bucket flat. Apply the parking brake and stop the engine. Check the level, top up if necessary.

HYDRAULIC LEVEL

Figure 72 If some repairs have been carried out in the general or steering hydraulic circuits, make several work cycles without load to eliminate the air from the system before checking the level.

16.2 OIL CHANGE AND REPLACEMENT OF THE OIL FILTER

After the first 20 hours of operation drain the oil into a clean container and remove the old filter. Fit a new filter and replace the original oil.

Atterwards, change the oil and the filter every 500 hours.

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h. ..

WARNING· BLOCK THE WHEELS AND APPLY THE PAHKING BRAKE. LOWER LIFT ARMS TO GROUND LEVEL WITH BUCKET FLAT. STOP THE ENGINE BEFORE PERFORMING ANY REPAIRS TO THE SYSTEM.

To change oil, follow the instructions below: . Place a container under the lower cover of the tank. The container should hav(! an approximate capacity of 250 litres. Remove the plug . . Clean the lower cover plate and remove.

5-

7508.15. 002

Steering circuit Figure 73

_

General circuit

4. Lower drain cover and plug 5. Filter (section)

1. Oil filter assembly 2. Filler cap (pressurized) 3. Oil level dipstick

- Clean the inside of the tank-of all dirt and sediment that may have settled on the bottom.

- When it is thoroughly clean. replace the "0" Ring seal and the cover.

-79·

Remove the rear cover giving access to the upper part of the hydraulic oil tank.

Clean the top of the tank, the filter and the filter cap.

Remove the filter cover. Take the spring and filter assembly out. See filter location in figure 74.

Remove the pin and the locknut of the assembly, and discard filter element.

Clean the magnetic column and fit a new filter element with nut and pin. Be sure that the "0" ring seals are in perfect condition and their position correct. See the section for filter assembly in figure 73.

.; 750B.)0.001

Figure 74 - Fit the filter assembly, the upper spring and the cover. Do not overtighten.

- Refill with new oil up to the level.

- Start th~ engine and make several cycles with the hydraulics. Check the level again and check for leaks.

Any condensation in the tank should be drained every 50 hours.

A

WARNING - Be very careful when you disconnect hydraulic 'connections. There is HIGH pressure in the 'system. Release all pressure in the system before you disconnect the hydraulic hose, etc. If not an injury can be the result. .

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17. TRANSMISSION AND TORQUE CONVERTER

17.1 REGULAR INSPECTIONS. CLEANING

The outside of the transmission should be cleaned and checked at regular intervals.

The breather should also be removed and cleaned every 500 hours.

Figure 75

Replacement of the filter The transmission oil filter is located in the top of the transmission. See figure 76.

To reach it, remove the footrest plate in the cab floor.

Figure 76

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'hI!

a~~I!IT1bly

is held by the filter bowl itself.

'() lI!place it, proceed as follows: Turn the filter bowl counterclockwise.

Remove the filter element and throw it away.

F it a new "0" ring seal. . Fit a new filter element and tighten by hand only.

Once the assembly is installed, start the engine and check for leaks.

This filter should be replaced after the first 20 hours of operation, and afterwards, every 250 hours.

To check the oil level Check the oil level daily.

To check the transmission oil level figure 77, follow the steps below: 1. Run the engine until the oil reaches working temperature (80-90 0 C).

2. Once the above temperature is reached, make sure the oil level is to the upper level (FULL level), keeping the engine at "idle".

NEVER CHECK THE LEVEL WITH THE OIL COLD, SINCE IT GIVES A FALSE READING.

Figure 77

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17.2 OIL CHANGE

Intervals between changes The interval between oil changes is 500 hours. The oil and filter el(~n1l!nts should he replaced more frequently when the oil is contaminated or overheat(~d. Ttw pJ(~sence of dirt, water or foreign matter in the oil may damage the transmission or lJiv(~ un satisfactory performance.

To change the oil The transmission oil should be hot, to get a better flow. Remove the drain plug, S(!(! figure 78, and the mesh filter and oil filter assembly. Allow the system to thorou~lh Iy drain before replacing the plug. Clean the mesh filter. Replace the oil filter eft! ment according to the instructions on page 81.

1. Mesh filter 2. Drain plug 3. Oil level 750B.23.003

Figure 78 With the mesh filter and the filter element correctly installed, replace the drain plug and fill up to 23.5 litres of oil (5.2 imp. gals.! through the filler plug located inside the cab. See location in figure 79.

Figure 79

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IllI'o .:h.IIHI'! h"l II "

~h()llid

ile made altel tilt; lirst 20 hours, alit I altl!lwalds CVCIY

~)()lJ

Oil temperature The gauge installed on the control panel, gives a continuous reading of the converter and transmission oil temperature.

With normal operation of the machine, temperature needle will point between 90 and 100o C, and may reach up to 120o C.

17.3 CLUTCH MAIN PRESSURE

The gauge installed on the control panel of the machine, shows the oil pressure in the transmission clutches. This pressure should be between 15.5 and 17.2 bar.

17.4 OIL COOLING The oil cooling is performed in closed circuit through a heat exchanger, located under the radiator. See cooling diagram in figure 80.

WATER OIL

1. Radiator 2. Engine 3. Torque COnVI!Iit!1 .IIHI 11.111'.1111'."1'"1 4. Oil cooll!1 740.22.001

Figure SO

18. AXLLS AND TYHlS

18.1 AXLE MAINTENANCE

Oil capacity per axle ...

25 I itres (55 imp. gals).

To check the levels Check the oil level in the differential after the first 20 hours of operation, and then every 100 hours.

To check level, place the machine on a level surface. Wait for some minutes (it is advisable to perform this operation at the beginning of the work shift), then remove the oil level plug and check.

The oil chambers in the planetaries and the differential are common, therefore there is only one level for both planetaries and differential.

Figure 81

Figure 82

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011 chnnnA

I" <1'''111 tlrll oil from the axles, remove the drain plugs and level plugs in each pla'If1ta,y and the differential. Thoroughly drain every section of the axle.

OliCII

plllll

tlrt! assembly is drained, replace the drain plugs and refill thorough the level tiro contral differential. Check for leaks.

III

I Irt! axlo lubricating oil should be changed after the first 20 hours of operation, :,,,,t tlron, every 500 hours.

Axle security Aftor the first 20 hours of operation, retighten the following: (see figure 83).

1. Wheelnuts -----------------------------------2. Nuts securing both axles to the chassis (front) or the trunnion (rear axle) ----3. Bolts on the planetary cover -----------4. Differential nuts -----------------------------

45/50 M.K.G. 45/50 M.K.G. 13/15 M.K.G. 12/14 M.K.G.

740.19.004 Figure 83

18.2 TIRE MAINTENANCE Tire inflation The correct air pressure in the assures its correct deflection, that in turn, warrants: the traction, flotation and support of the respective loads put on them.

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740.42.001 Figure 84

1. Overpressure 2. Underpressure 3. Correct pressure Check the tyres daily for cuts, etc. Check the pressure every 100 hours of operation, otherwise tyre Iife can be reduced.

The inflation pressures shown below are "cold" pressures. With the mach ine operating, the air inside the tyre heats up, increasing in volume and therefore, the pressure. It is advisable to check the pressure after a week-end, so that the temperature inside the tyres is similar to the ambient temperature.

If you cannot perform this operation, i.e.: cold condition, an increase of 0.75 kg/cm 2 on the recommended pressures is allowed.

Recommended pressures Operating pressure: Front wheels/rear wheels Front wheels/rear wheels On the road:

3.5/2 kg/cm 2 (49.8/28 psi) 2.25/2 kg/cm 2 (32/28 psi)

Travelling on a road causes the tyres to get warm with an increase in pressure. This is normal. Do not readjust the pressures.

Water ballasting the tyres

Usually, it is not necessary to increase the weight of the machine through water ballast in the rear tyres, since the performance decreases due to the extra weight and running resistance. However, under some operating conditions or on specific soils, it may be necessary.

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II Villi "'II""I~ 10

watl!r ballast the wheels, your Official Case Dealer should carry will know the precautions required.

,,"I Ill,'

WIII!.- ,11111

{JlltllH III

considerations

1\11

111111

~illlHlld ,1111111111

IYII!S should be identical regarding: the manufacturer, design, size, etc. you note on checking the tyres, some cuts or grooves on the outside, cut till! unsound area up to the base of the cut, with a sharp knife. See figure

1\ "

Figure 85 This operation should be performed in such a maimer so that nothing can be caught in the cut made.

Prevent the tyres getting in touch with solvents, oils or greases, since they shorten the tyre life.

h ..

h ..

WARNING· Do not disassemble a tyre if you do not know the method to follow. It can cause an injury.

CAUTION· When checking the tyre pressure or when inflating them, place yourself to one side, beyond the reach of the locking ring between the rim and the tyre.

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I~I

IIIII\KI

~;y~;

11M

111111'II'IIll\I lJ',1111J

ttll'

I"ft pl'ILII (h-,coIJlll'!:!', till' dIIV,· II) 1111' 11.111 .. 1111 .. ·.11111 .11

.,,,,,Iy,,,,, II,,· i>,.ok,~·. 111I~ .. IIows 11111 '~IHJlI\" '011111 III 11,,·I,ytll.ollliC CIICllll II lI~qlllll~d.

POW"I

1I1I

III I,,· cI,v," "''' I" ,'"

.. 11111

II"

11'11,' .1",

"."".""'.

I!U IUGHT PEDAL 1111:

pedal is for normal braking and should be used wllI:l\ or other rough ground.

light

sl()~ws

Ilt~ql)ll.oIII'"

'.1,·1'

Figure 86

ATTENTION - When working in difficult conditions or on step gradients never use the left brake pedal because the engine cannot be used as a brake through its retarding effect. To prevent this always use the right brake pedal so that full retardation can be used.

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WARNING - Should you need to tow another vehicle, 01 wht!11 movll1g with the bucket loaded, keep in mind, on using the bl,lkos, thilt thl!

11I!l!Iel the towed vehicle or the load carried, the greiltCl tho hi ilklllQ distance.

CAUTION - When dumping the bucket into a truck, use the brakes carefully, if not you can cause damage_

740.90.064

19.3 BLEEDING THE BRAKE HYDRAULIC SYSTEM Should you note a decrease in the braking efficiency without the air service pressure having decreased, you should bleed the brake hydraulic installation to eliminate any air that may have accumulated inside_ This operation should also be performed after having repaired any part of the brake fluid circuit.

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Figure 87

1. Brake fluid reservoir 2. Bleed screw (brake cylinder) 3. Hydraulic cylinder To perform this operation, two persons are required. Milk!! SUI!! tlil' Iioilid III ,rI,,' I', applied, and start the engine until the brake pressure is at 7.3 k!l/clTI/ Stop till' engine. Loosen the bleed screw (see figure 87) on the left hilnd illakl! Cylllld"1 Apply pressure to the brake pedal and, when brake fluid flows from till' illl!l!d SClI'W free of air bubbles, tighten the screw. Do the same operation to the right hand cy linder. Both bleed screws are to be tightened while the brake pedal is dep,,!ssed making sure no air enters the system again.

Repeat this same operation with each of the four wheel cylinders in turn. S!!!! figure 88.

Figure 88

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II" 1.1I1·1t1l

III

nllllOllqhly cil!,111 around the bleed screws IwIIHI!

1t)()~I'IlIII'l

1111'111

111'1"1 '11111t! 11'~\llls II IS II!COlTllllellded that you use the method shown III 11'11111,1\'1 11t.11 I',. COl 11 !pc I d hlt!l!d tube to a container with brake fluid ill il. 10 PII'V"III .," II' 1'1111'11I1'Ilhl! sySIt!Ill, should the pl!dal not be held correctly.

7506.25.005

Figure 89 19.4 BRAKE AIR RESERVOIR

The brake air reservoir does not need to be bled by hand to extract condensation, since this is automatically made by a valve located in the lower part. See figure 90.

However, it is advisable to regularly check its efficiency.

Figure 90

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111.11 ADJUSTMENT OF BRAKE PADS With d'\1:

IlIak(~5. 110

adjustment is necessary.

Chl'd, cOl1ditiol1 of the pads every 200 hours. They must be replaced when their tlllt:kl1"~'s is down to 4 mm. When replacing the pads, check the brake fluid level.

19.6 AIH CLEANER I h .. all cleaner in the brake circuit is built-in to ti:le pressure regulation valve in the .. y .. t(!IT1. See location in figure 91.

CI'!'lIl (!very 1000 hours of operation. Remove the lower part of the cle!mer and clt!an with fuel oil. After re-assembly, start the engine and make sure that there arc no leaks.

NOTE:

Remove this cleaner by using the large hexagon on the body. DO NOT TOUCH THE ADJUSTING SCREW IN THE BODY.

Figure 91

19.7 PARKING BRAKE See operating and adjustment instructions on page 28.

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I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I