Case 821 C Loader Operators Manual 6-3591EUR - PDF DOWNLOAD

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821 C Loader Operators Manual

Bur 6-3591EUR

TABLE OF CONTENTS 1 3 3 4 6

SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 WHEELS AND TIRES SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INFORMATIONAL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INTERNATIONAL SYMBOL DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 INSTRUMENT/CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 FRONT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 37 INSTRUMENT PANEL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . 38 - 53 INFORMATION CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 - 59 GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 - 66 TRANSMISSION DISPLAY CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . 67 - 69 FOOT PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 LOADER CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SIDECONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 - 83 MASTER DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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

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

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

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

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

TABLE OF CONTENTS

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OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 RUN - IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 STOPPING THE ENGINE AND PARKING THE MACHINE . . . . . . . . . . . . . 97 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 LOADER CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 LOADER FUNCTION SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 CLUTCH CUTOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED) . . . . . . . . . . . . 114 ROTATING BEACON (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 COUPLER PIN ENGAGEMENT (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . 116 LOADER OPERATING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 WHEELS/TIRES/BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 BALLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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LUBRICATION/FILTERS/FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . 129 SYSTEMGARD LUBRICATION ANALYSIS PROGRAM . . . . . . . . . . . . . . 130 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 TRANSPORT/SERVICE LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 LUBRICATION/MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . 134 - 136 ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 GREASE FITTINGS - 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 GREASE FITTINGS - 100 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 GREASE FITTINGS - 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 AIR FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 HYDRAULIC/BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 AXLES - EARLY PRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 AXLES - LATE PRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 CAB AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 182MAINTENANCE/ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

TRANSMISSION CLUTCH CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH CUTOUT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECONDARY STEERING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

FAN BELT, ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . .

SPARK ARRESTING MUFFLER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . .

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179 179 182 183 185 186 188 196 198 199 200 201

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TABLE OF CONTENTS

TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

203 203 205 205 206 206 207

MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING DATA AND DIMENSIONS 821C . . . . . . . . . . . . . . . . . . . . .

OPERATING DATA AND DIMENSIONS 821C XR . . . . . . . . . . . . . . . . . .

OPERATING WEIGHT ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . .

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

211 211 213 216 219 220

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INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231, 233

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RP98N347

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

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

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

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

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

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TO THE OWNER

TO THE OWNER DO NOT use this machine for any application or purpose other than those described in this manual. If the loader is to be used in a application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer or the Case Cor poration. Consult an authorized dealer or Case Corporation on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements.

Unauthorized modifications will cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

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

Call your dealer if you need any assistance or information.

Operator Manual Storage Compartment TRIM THIS EDGE

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit.

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

1

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

RD98K305

1. OPERATORS MANUAL STORAGE COMPARTMENT

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TO THE OWNER

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

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

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

FRONT

REAR

LEFT SIDE B891464J

CASE CORPORATION P.O. BOX 6006 FARGO, ND 58102

DEALERS STAMP

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RIGHT SIDE

TO THE OWNER

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

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

MACHINE MODEL NUMBER PRODUCT IDENTIFICATION NUMBER ENGINE SERIAL NUMBER TRANSMISSION MODEL AND SERIAL NUMBER

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

Product Identification Number (P.I.N.)

RD98K294

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TO THE OWNER

Engine

Loader Bucket

RD98D017

RP95K195

ROPS Cab and Canopy TRIM THIS EDGE

Transmission

RD98A238

RD98K304

Axle

BD00B025

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TO THE OWNER

MACHINE COMPONENTS 2 6 9

9

10

3 4 5

1 7

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11

8 RD98N341

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

ENGINE ACCESS DOOR) ROPS CAB BUCKET CYLINDER LOADER ARM STANDARD BUCKET LOADER CONTROLS CAB AIR FILTERS STEPS HAND RAILS REAR ACCESS DOOR DRAWBAR PIN

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TO THE OWNER

1 1 2 4

8 3 7

RP98N347

1.

2.

3.

4.

5.

6.

7.

8.

HAND RAILS AIR CONDITIONER CONDENSER STEP ENGINE ACCESS DOOR STEP TRANSPORT/SERVICE LINK HYDRAULIC FILTERS HYDRAULIC RESERVOIR SIGHT GAUGE

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TO THE OWNER

OFFICIAL JUSTIFYING DOCUMENTS Special Test Certificate (Copy) -Noise level (86/662/EEC with amendments 89/513/EEC and 95/27/EEC) -Special safety equipment (86/295/EEC and 86/296/EEC) EEC Declaration of conformity for an earth-moving machine -Safety (98/37/EC, was 89/392/EEC with amendments 91/368/EEC and 93/44/ EEC)

Vibration Level The level of vibration emitted by the wheel loader and transmitted to the operator’s seat (posterior) does not exceed 1.25 m/s2.when tested per ISO 7096, Class 3.

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SAFETY/DECALS/HAND SIGNALS !

SAFETY RULES

!

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

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit.

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

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

RD98K305

1. OPERATORS MANUAL STORAGE BOX

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

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

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

!

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B

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SAFETY/DECALS/HAND SIGNALS

!

UTILITY SAFETY

!

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

Electrical Power LIne

●

Gas Line

●

Water Line

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Communication LIne - Telephone or Cable Television

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Before beginning any excavating or other constr uction wor k it is your responsibility to be aware of all such utility lines buried in the area of your project and to avoid them.

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

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU EXCAVATE

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

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

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SAFETY/DECALS/HAND SIGNALS

!

PERSONAL SAFETY

!

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

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

●

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

●

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

●

CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

ISO two panel pictorial symbol decals are defined as follows: ●

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW.

●

Prohibition symbols such as

and

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STOP

if used, are RED.

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DANGER, WARNING or CAUTION are defined as follows:

SAFETY/DECALS/HAND SIGNALS

! ●

BEFORE OPERATION

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

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●

Be prepared for emergencies.

Always have a first aid kit and a fire extinguisher on the machine. Be sure that the extinguisher is properly maintained and be familiar with its proper use.

●

Know the hand signals used on your job. Follow the instructions of the flagman, signs, etc.

●

Know the rules, laws, and safety equipment necessary for transporting or driving this machine on a road or highway. Rotating beacon, backup alarm, SMV, and other items are available from your dealer.

●

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

●

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

●

Always use the hand rails when mounting or dismounting from the machine. Always face the machine when mounting or dismounting. This will provide more secure hand and foot mobility to help prevent slipping and possible injury.

!

●

Remove all loose objects from the operators area and from the machine. Loose objects can jam controls and cause accidents.

●

Operate controls only when seated in the Operators seat.

●

Before starting the engine, securely fasten your seat belt. Your machine is equipped with a ROPS cab or canopy for your protection. The seat belt can help insure your safety if it is used correctly and maintained.

Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

●

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

●

Before starting the engine, be sure all operating controls are in neutral and the parking brake is applied.

●

Sound horn to alert persons in the work area.

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SAFETY/DECALS/HAND SIGNALS

MACHINE OPERATION

●

Do not turn the steering wheel until everyone is clear of the machine and the center pivot area.

●

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

●

A frequent cause of personal injury or death is persons falling off and being runover. Do not permit other persons to ride on the machine.

Only one person - the operator should be on the machine when it is in operation.

●

●

●

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

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

Stop the machine or decrease the speed until you can see everything around you in the work area.

Contact with overhead power lines can cause severe electrical burns or death from electrocution. Make sure there is enough clearance between the machine and overhead power lines.

! ●

!

●

Electrical cables, gas pipes, water pipes, or other underground objects can cause injury or death. Learn the location of underground hazards before you operate your machine in a new area.

●

If this machine rolls over, you can be injured or killed. You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill ramp, or rough ground.

●

Stay away from natural hazards, such as ditches, overhangs, etc.

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

●

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

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

●

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

●

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

PARKING THE MACHINE

!

Park the machine on level ground and before you leave the operators area, always lower the loader bucket to the ground, apply the parking brake, and stop the engine.

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!

SAFETY/DECALS/HAND SIGNALS

!

MAINTENANCE

!

●

Before you service the machine, put a Do Not Operate tag on the steering wheel. A Do Not Operate tag is available from your dealer. The Do Not Operate tag is included with your new machine.

●

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

●

Unauthorized modifications to this machine can cause injury or death.

Do not make unauthorized modifications to this machine.

321-4614

TRIM THIS EDGE

●

●

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

Keep clear of the center pivot area of this machine when the engine is running unless the transport/service link is in the LOCKED position. After service, return the transport/service link to the OPERATING position.

●

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

●

Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. If the fluid is injected into your skin, see a doctor immediately and have the fluid removed.

●

If you must service the machine with the loader raised, always block the loader arms.

●

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

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SAFETY/DECALS/HAND SIGNALS

●

BURN PREVENTION

Battery acid causes severe burns.

Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing.

Antidote - EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a doctor immediately. EYES: Flush with water for 15 minutes and get prompt medical attention.

!

!

●

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

●

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

FIRE OR EXPLOSION PREVENTION

!

●

Engine fuel can cause an explosion or fire. Do not fill the fuel tank with the engine running, if you are near an open fire, or if you are welding, smoking, etc.

2. When connecting jumper cables to start the engine, use the procedure shown in this manual. See Booster Batter y Connections in this manual.

●

Use nonflammable cleaning solvent to clean parts.

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

●

Sparks or flame can cause the hydrogen gas in a battery to explode. To prevent an explosion, do the following:

4. Do not weld, grind, or smoke near a battery. ●

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

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

15

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!

SAFETY/DECALS/HAND SIGNALS ●

A fire can cause injury or death.

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

●

Remove all trash or debris from the machine. Make sure that oily rags or other flammable materials are not stored on the machine.

●

Check for fuel, oil, and hydraulic fluid leaks. Replace worn or damaged hoses or lines. After repairs are made, clean the machine before you operate.

●

TRIM THIS EDGE

Starting fluid (ether) can explode and can cause injury or death. Do not breathe starting fluid vapors. Wear face protection when you remove or install a starting fluid container. Use starting fluid according to the instructions in this manual. See Cold Weather Starting in this manual.

! !

●

Keep the starting fluid (ether) container out of the reach of children.

●

Before you discard an empty starting fluid (ether) container, use rubber gloves and push in on the valve in the end of the container to remove any pressure. Do not make a hole in the container and do not put the container in a fire.

●

Do not store starting fluid (ether) containers in the operators area.

●

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

WHEELS AND TIRES SAFETY

!

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

SB134

!

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

84-113

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SAFETY/DECALS/HAND SIGNALS

HAZARDOUS CHEMICALS

!

●

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

●

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

●

Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released.

MSDS are available from your dealer.

●

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

●

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

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

●

Before you service your machine, check the MSDS for each fluid lubricant, etc., used in this machine.

This information indicates what the risks are and how to service the machine safely.

Follow this information when servicing the machine.

R412

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!

SAFETY/DECALS/HAND SIGNALS

!

INFORMATIONAL DECALS

!

D e c a l s w h i c h d i s p l ay t h e “ R e a d Operators Manual” symbol are intended to direct the operator to the O p e r a t o r s M a n u a l fo r f u r t h e r information regarding maintenance, adjustments and/or procedures for particular areas of the Wheel Loader.

When a decal displays this symbol refer to the Operators Manual.

237187A1

“READ OPERATORS MANUAL”

! !

SAFETY DECALS

!

TRIM THIS EDGE

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

SC002

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

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

You must replace a decal if the decal is damaged, the decal is missing or the decal cannot be read.

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SAFETY/DECALS/HAND SIGNALS

2

2

3

1

3

RD00B007/256147A1/364817A1/329051A

3.EMERGENCY EXIT ●

READ OPERATORS MANUAL

●

Fasten Seat Belt

●

NO Riders

●

Keep Others Away 19

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1

SAFETY/DECALS/HAND SIGNALS

4 4

5

RD98K362

323695A1

TRIM THIS EDGE

CRUSH HAZARD

4

KEEP CLEAR

RD98M011

5

5

RD98K363

329048A1

CRUSH HAZARD ENGAGE LOCK LINK BEFORE SERVICE OR TRANSPORT

20

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SAFETY/DECALS/HAND SIGNALS

6

328755A1

CRUSH HAZARD

6

SUPPORT DURING MAINTENANCE OR REPAIR.

TRIM THIS EDGE

RD98K363

7

329045A11

HAZARD

7

HOT LIQUID UNDER PRESSURE SERVICE WHEN COOL. RD98K349

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SAFETY/DECALS/HAND SIGNALS

8

8 RD98K294

329050A1

RUNOVER HAZARD

TRIM THIS EDGE

BLOCK WHEELS TO PREVENT MACHINE MOVEMENT BEFORE DISENGAGING PARK BRAKE FOR TOWING.

9

328753A1

RUNOVER HAZARD KEEP CLEAR

9 RD98K283

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SAFETY/DECALS/HAND SIGNALS

9 9

10 RB97D043

10

328903A1

HAZARD PRESSURIZED SYSTEM RELIEVE PRESSURE BEFORE MAINTENANCE.

23

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RD97F151

SAFETY/DECALS/HAND SIGNALS

11

11

RD98K354

TRIM THIS EDGE

33269A1

HAZARD PRESSURIZED SYSTEM RELIEVE PRESSURE BEFORE MAINTENANCE.

11

RD98M010

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SAFETY/DECALS/HAND SIGNALS

15

15

RD98K357

334455A1

TRIM THIS EDGE

START ENGINE FROM OPERAOTRS SEAT ONLY, TRANSMISSION IN NEUTRAL..

16

16

BD00B008

386241A1

USE SEAT BELT. AVOID CRUSHING DO NOT JUMP IF MACHINE TIPS.

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SAFETY/DECALS/HAND SIGNALS

12

12

RD98K360

TRIM THIS EDGE

332511A1

HAZARD ENTANGLEMENT

12

KEEP CLEAR

RD98K346

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SAFETY/DECALS/HAND SIGNALS

INTERNATIONAL SYMBOL DECALS

139879A1

139879A1

TIE DOWN POINT

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DIESEL FUEL

318764A1

139879A1

KEY SWITCH POSITIONS

LIFT POINT

187863A1

HYDRAULIC OIL

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SAFETY/DECALS/HAND SIGNALS

BS00B355

E134402

LIFT ARM AND BUCKET CONTROL

NO STEP

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BC00F006

BS99K030

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

187864A1

REMOTE GREASE FITTING LOCATION

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SAFETY/DECALS/HAND SIGNALS

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

BI97D059

BI97D025

STOP ENGINE

BP97D022

TRIM THIS EDGE

START ENGINE

BP97D023

COME TO ME

ALL STOP AND HOLD

Move hands forward and rearward (palms in)

Move hands forward and rearward (palms out).

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SAFETY/DECALS/HAND SIGNALS

BP97D030

BP97D060

GO THIS FAR

ALL STOP AND HOLD

TRIM THIS EDGE BI97D029

BI97D021

STOP

EMERGENCY STOP

Move one hand back and forth.

BI97D027

LOWER BUCKET

BI97D028

RAISE BUCKET

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SAFETY/DECALS/HAND SIGNALS

BI97D020

BI97D026

LOWER BUCKET SLOWLY

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RAISE BUCKET SLOWLY

BI97D034

BI97D033

TURN MACHINE LEFT SWING LOAD LEFT

TURN MACHINE RIGHT SWING LOAD RIGHT

To stop movement, stop moving hand and make a fist

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

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SAFETY/DECALS/HAND SIGNALS

NOTES

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INSTRUMENT/CONTROLS FRONT CONSOLE 3

2

4

RD98K315

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

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

BC00B087

BC00B048

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

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

BC00B085

BS98M034

BC00B101

BS98M034

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

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1

INSTRUMENTS/CONTROLS

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

5

RD98K322

A

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

TRIM THIS EDGE

C. Move the control lever toward you for REVERSE.

B

C BS00B351

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INSTRUMENTS/CONTROLS

FRONT CONSOLE

8 7 9 RD97F213 RD98K311

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

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

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

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

10

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

RD98K313

9. PARKING BRAKE SWITCH:

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

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

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

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INSTRUMENTS/CONTROLS

FRONT CONSOLE

11 RB99J178

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

RD98K312

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

318764A

10. Key Switch The key switch has four positions:

RB98M031

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

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

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

INSTRUMENTS/CONTROLS

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

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

TRIM THIS EDGE

2

1

1

RD98K315

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

BS96H049

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

BC00B082

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

4

5

6

RD98K315

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

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

BC00B048

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

BC00B110

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

6. BRAKE PRESSURE INDICATOR:

BC00B108

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

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

NOTE: Stop the machine and correct the problem.

39

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3

INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

7

TRIM THIS EDGE

RD98K315

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

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

BC00B290

Display

Description

Corrective Action

ENGINE OIL PRESSURE

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

BRAKE PRESSURE

Low Brake Pressure

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

Low Steering Pressure.

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

STEERING PRESSURE (W/ AUX STEERING)

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INSTRUMENTS/CONTROLS

Low Coolant Level.

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

COOLANT TEMPERATURE

High Engine Coolant Temperature.

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

HYDRAULIC OIL TEMPERATURE

High Hydraulic Oil Temperature.

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

TRANSMISSION OIL TEMPERATURE

High Transmission Oil Temperature.

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

TRIM THIS EDGE

COOLANT LEVEL

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS 8

TRIM THIS EDGE

RD98K315

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

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

BC00B291

Display PARKING BRAKE

Description

Corrective Action

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

COOLANT TEMPERATURE

High engine coolant temperature

1. Idle machine and monitor temperature.

2. Clean radiator.

3. If condition persists, contact your dealer.

HYDRAULIC TEMPERATURE

High hydraulic temperature

1.Idle machine and monitor temperature.

2. Clean cooler.

3. If condition persists, contact your dealer.

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TRANSMISSION TEMPERATURE

ENGINE OIL PRESSURE (Early Production Only) AIR CONDITIONING

AIR FILTER

TRANSMISSION FILTER HYDRAULIC FILTER ALTERNATOR

FUEL

High transmission temperature

1. Idle machine and monitor temperature.

2. Clean the cooler.

3. Use a lower gear.

4. If condition persists, contact your dealer.

Low engine oil pressure.

1.Check low idle specifications 2. Change engine oil and filter.

3. Change operating procedures 4. If condition persists, contact your dealer.

High or Low air conditioning pressure.

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

3. Servicing required.

4. If condition persists, contact your dealer.

High air filter restriction

1. Clean air filter.

2. Replace primary and secondary filters.

3. If condition persists, contact your dealer.

Transmission filter restriction.

1. Replace transmission filter.

2. If condition persists, contact your dealer.

Hydraulic filter restriction.

1. Replace hydraulic filter.

2. If condition persists, contact your dealer.

Alternator malfunction.

1. Check electrical system.

2. Voltages are out of range.

3. Change operating procedure.

4. If condition persists, contact your dealer.

Low fuel.

1. Fill fuel tank within the next hour.

43

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INSTRUMENTS/CONTROLS

INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

9

10

11

TRIM THIS EDGE

RD98K315

9. SECONDARY STEERING INDICATOR (IF EQUIPPED):

BS00B111

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

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

10. PARKING BRAKE INDICATOR:

BS96H049

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

11. AIR CONDITIONING INDICATOR:

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

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

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

12 13

RD98K315

12. HYDRAULIC OIL FILTER INDICATOR:

BC00B113

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

13. AIR FILTER INDICATOR:

BS98M026

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

14. TRANSMISSION OIL FILTER INDICATOR (IF EQUIPPED):

BS99J182

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

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14

INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

15

TRIM THIS EDGE

RD98K315

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

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

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

TRANSMISSION OIL TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

20°C and below (68°F and below)

Oil temperature is very low

Caution (Yellow)

Flashes

3 Seconds

20 to 120°C (68 to 248°F)

Oil temperature is normal

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

Caution (Yellow)

Flashes

3 Seconds

125°C and above (257°F and above)

Stop (Red)

Flashes

Continuous

Oil temperature is very high

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

Correct the problem before continuing to operate the machine 46

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

RD98K315

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

HYDRAULIC OIL TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

20°C and below (68°F and below)

Hydraulic oil temperature is very low

Caution (Yellow)

Flashes

3 Seconds

20 to 105°C (68 to 221°F)

Hydraulic oil temperature is normal

105 to 110°C (221 to 230°F)

Hydraulic oil temperature is high

Caution (Yellow)

Flashes

3 Seconds

110°C and above (230°F and above)

Hydraulic oil temperature very high

Stop (Red)

Flashes

Continuous

NOTE: Stop the machine and correct the problem.

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

17 TRIM THIS EDGE

RD98K315

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

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

VOLTMETER GAUGE Gauge Indication 0 to 18 Volts

18 to 24 Volts

Engine Speed Condition o f Charging System

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

Stopped or low idle Above low idle

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

Alarm Status

Flashes

3 Seconds

3 Seconds

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

24 to 26 Volts

Gauge Status Flashes

Above low idle

Problem system

in

charging

Normal battery charge Problem system

in

charging

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

NOTE: Stop the machine and correct the problem.

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INSTRUMENTS/CONTROLS

18 RD98K315

BS98M034

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

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

FUEL LEVEL GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

5 percent and below

Fuel level low

Caution (Yellow)

Flashes

3 Seconds

5 percent and above

Fuel level normal

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

19 TRIM THIS EDGE

RD98K315

19. ENGINE OIL PRESSURE GAUGE - EARLY PRODUCTION: The engine oil pressure gauge indicates the oil pressure in the engine lubrication system. The engine oil pressure is shown with indicator bars. Normal operation is in the green zone. When the engine oil BS99D060 pressure decreases or increases the bars move into the yellow zone and begin to flash, the warning alarm sounds for three seconds. The caution master indicator turns yellow. When the oil pressure decreases below a safe operating pressure, the bars move into the red zone and continue to flash and the warning alarm sounds continuously. The stop master indicator turns red.

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

ENGINE OIL PRESSURE GAUGE - EARLY PRODUCTION Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

0 to 100 kPa Very low (Red zone) (0 to 15 psi) (See the (too low to run engine) note below.)

Stop (Red)

Flashes

Continuous

100 to 140 kPa (15 to 20 psi)

Low (Yellow zone) (above low idle)

Caution (Yellow)

Flashes

3 Seconds

140 kPa and above (20 psi and above)

Normal (Green zone) (above low idle)

NOTE: Stop the engine immediately and correct the problem.

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

RD98K315

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

ENGINE OIL PRESSURE GAUGE - LATE PRODUCTION Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

0 to 70 kPa (0 to 10 psi)

Very low (too low to run engine)

Stop (Red)

Flashes

Continuous

70 to 110 kPa (10 to 16 psi)

Low (above low idle)

110 kPa and above (16 psi and above)

Normal (above low idle)

NOTE: Stop the engine immediately and correct the problem.

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

20

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RD98K31

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

ENGINE COOLANT TEMPERATURE GAUGE Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

20°C and below (68°F and below)

Coolant temperature is very low

Caution (Yellow)

Flashes

3 Seconds

20 to 105°C (68 to 221°F)

Coolant temperature is normal

105 to 110°C (221 to 230°F)

Coolant temperature is high

Caution (Yellow)

Flashes

3 Seconds

Stop (Red)

Flashes

Continuous

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

NOTE: Stop the engine immediately and correct the problem.

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INSTRUMENTS/CONTROLS

INSTRUMENT PANEL INDICATORS

RD98K31

21. FOG LAMP INDICATOR (IF EQUIPPED): Indicator illuminates when fog lamps are ON.

BC00B080

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

1

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RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

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

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

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

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

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

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

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

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

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

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

NOTE: The program/reset (C, D) switch is a three position rocker switch. The center position is OFF or NEUTRAL. 55

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

1

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RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

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

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

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

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

To view the service hour interval locations: ●

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

●

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

●

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

●

Read the accumulated hours shown on the Display Center.

To reset the service interval hours: ●

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

●

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

●

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

●

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

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1

INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

1 TRIM THIS EDGE

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

●

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

●

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

●

Read any fault codes on the Display Center.

●

Press the program (C) switch again.

●

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

●

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

●

Read the hours at which the previous code occurred.

The hour location will always follow the fault code location.

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INSTRUMENTS/CONTROLS

INFORMATION CENTER

A B

C

D

RD98K316

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

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

Press the program (C) switch.

●

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

●

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

●

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

●

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A B

C

D

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A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

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

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

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

NOTE: 05 is the setting from the factory.

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A C

D

1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

●

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

●

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

●

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

●

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

●

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A B

C

D

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A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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

●

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

●

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

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

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A B

C

D

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A B

C

D

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1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

●

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

●

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

You will now see the function you’ve chosen.

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

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

●

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

●

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

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

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A C

D

1 RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

Press the program (C) switch.

●

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

●

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

●

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

●

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

●

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

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

●

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

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INSTRUMENTS/CONTROLS

GAUGE DISPLAY

A B

C

D

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A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

Press the program (C) switch.

●

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

●

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

●

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

●

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

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INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER B A

C D

E

RD97F206

C. GEAR D. BAR

E. AUTOMATIC MODE

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

N - Flashing set control lever to neutral position.

R - Flashing reverse not engaged.

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

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

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

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A. F - N - R B. DISPLAY CENTER

INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER

A B

C

D

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RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

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

Programming Minimum Gear Selection ●

Press the program (C) switch.

●

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

●

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

●

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

●

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

●

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

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INSTRUMENTS/CONTROLS

TRANSMISSION DISPLAY CENTER

A C

D

RD98K316

A. UP COUNT B. DOWN COUNT

C. PROGRAM D. RESET

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

Programming Maximum Gear Selection ●

Press the program (C) switch.

●

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

●

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

●

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

●

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

●

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

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INSTRUMENTS/CONTROLS

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

1

3 2 RD97F194

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

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RD97K027

2. BRAKE PEDALS: Push down on the bottom of the Declutch switch (3). This turns OFF the Declutch feature. When either pedal is pushed down, the brakes are actuated, the brake light is illuminated, and the transmission clutch will remain engaged. Push down on the top of the Declutch switch and this will turn on the Declutch feature. When either brake pedal is pushed down the brakes are actuated, the brake light is illuminated and the transmission clutch is disengaged.

3. DECLUTCH SWITCH

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INSTRUMENTS/CONTROLS

LOADER CONTROL LEVERS Two Spool - One Lever B

1

E

A

1 C D RB97F106/BS00B353

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

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

D. RAISE E. DUMP F. ROLLBACK

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F

INSTRUMENTS/CONTROLS

Two Spool - Two Levers D 3

3

E F

A

2

G 2 C B RB97F105/BS00B354

2. BUCKET CONTROL

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

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

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

G. RAISE

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INSTRUMENTS/CONTROLS

Three Spool - Three Levers D 4

5

E

F H

6 5 A

6

C G 4 I RB97F108/BS00B356

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

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

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

G. RAISE 6. CLAM CONTROL (IF EQUIPPED) H. CLAM OPEN I. CLAM CLOSED

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INSTRUMENTS/CONTROLS

Three Spool - Two Levers A

E

8

7

G D 8 C

7

B

F

H

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RB97F107/BS00B355

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

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

E. LOWER F. RAISE 8. CLAM CONTROL (IF EQUIPPED) G. CLAM OPEN H. CLAM CLOSED

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INSTRUMENTS/CONTROLS

Four Spool - Two Levers 10

9

E D

A

I

K

G

10

9 J B

F

C

H

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

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

E. LOWER F. RAISE 10. AUXILIARY CONTROL (IF EQUIPPED) IMPORTANT: If your machine is equipped with an auxiliary attachment, write the control lever positions next to the letters below.

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

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RB97F107/BS00B357

INSTRUMENTS/CONTROLS

SIDECONSOLE 1. DOWN SHIFT BUTTON: The down shift button is located on top of the loader control valve lever and is used to put the transmission in the down shift mode (see transmission Operation in this manual for complete operation).

1

RD97F185

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

4 2

5

RD98K306

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

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

BC00B128

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

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

BC00B127

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

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3

INSTRUMENTS/CONTROLS

SIDE CONSOLE 6

TRIM THIS EDGE

RD98K306

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

D C

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

B

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

A

E BC00B131

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

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

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

RD98K306

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

E

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

D

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

C B

A BC00B133

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

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

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7

INSTRUMENTS/CONTROLS

SIDE CONSOLE

9

10

11

8

TRIM THIS EDGE

RD98K273

BS98M034

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

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

BC00B098

9. DECLUTCH SWITCH: The clutch cutout disengages the transmission when maximum power is needed for the loader (the foot pressure required to disengage the transmission is adjustable, see Clutch Cutout Adjustment on page 183 of this manual). Push down on the top of the declutch switch and push on either brake pedal to operate the machine with the clutch cutout.

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

BC00B097

BC00B086

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

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

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INSTRUMENTS/CONTROLS

SIDE CONSOLE

12 13

RD98K273

BC00B081

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

operation).

13. RIDE CONTROL SWITCH: Push down on the top of the Ride Control switch and pull back on the Loader Lift Control Lever to raise the lift arms until the Green light in the Ride Control Switch intensifies for the ON position. Push the BC00B094 bottom of the switch for the OFF position. Ride Control is OFF when key switch is OFF. Ride Control Must be reset once the engine is started again. (see Ride Control Operation in this manual for operation).

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

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

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

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14

INSTRUMENTS/CONTROLS

SIDE CONSOLE

16 15

TRIM THIS EDGE

RD98K273

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

BS98M034

16. BACKUP ALARM CANCELLATION SWITCH (IF EQUIPPED):

BC00B079

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

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

!

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

M564

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INSTRUMENTS/CONTROLS

SIDE CONSOLE 17. REAR FOG LAMP SWITCH (IF EQUIPPED):

BC00B080

16

BD00B028

TRIM THIS EDGE

17 17

RD97K027

BD00B028

EARLY PRODUCTION MACHINES

LATE PRODUCTION MACHINES

18. COUPLER PIN ENGAGE SWITCH:

BC00B099

Early Production: Push down on the top of the coupler switch to RETRACT the PINS. Push down on the bottom of the coupler switch to EXTEND the PINS.

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

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INSTRUMENTS/CONTROLS

MASTER DISCONNECT SWITCH ON - This position energizes the entire electrical system. When th e ma s te r Di s c o nn e c t BS00A203 switch is ON and the key switch is OFF, the following electrical components have power : dome lamp, horn, stop lamps, four-way flashers and the rotary light switch.

1

OFF - This position disconnects all power to the machine.

BD00E001

TRIM THIS EDGE

BS00A018

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

BS00A017

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

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INSTRUMENTS/CONTROLS

Recirculation Air Louvers The recirculation air louvers are behind the operators seat next to the floor.

When open, air is recirculated in the cab. To open the louvers turn the knob clockwise. To close the louvers turn the knob counterclockwise.

1 2

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

3

Main Air Louvers

RD97F221

The louvers on the RH and LH side in front of the console direct air flow back to the operator.

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

TRIM THIS EDGE

1. EARLY PRODUCTION 2. KNOB - ROTATE KNOB AS REQUIRED TO OPEN OR CLOSE LOUVERS 3. RECIRCULATION LOUVERS

4 5

1

6

BD00B005

4. LATE PRODUCTION 5. KNOB- LOOSEN AND SLIDE KNOB AS REQUIRED TO OPEN OR CLOSE LOUVERS 6. RECIRCULATION LOUVERS (BEHIND FILTER)

RD98K323

1. MAIN LOUVERS

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INSTRUMENTS/CONTROLS

1 1

RD98K303

1

RD97F194

1. MAIN LOUVERS

1. DEFROST LOUVERS

1 TRIM THIS EDGE

1

RD98K303

RD97F194

1. DEFROST LOUVERS

1. MAIN LOUVERS

Defrost Air Louvers

1

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

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

RD98K323

1. DEFROST LOUVERS

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INSTRUMENTS/CONTROLS

Radio (If Equipped)

Window Latch

1

RD97F215

RD98K301

TRIM THIS EDGE

1. LIFT TO OPEN

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

Door Latch 1

2 1 RD98K302

1. LATCH PIN 2. HOLD LATCH

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

RD97F218

1. PUSH TO OPEN DOOR

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

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

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

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INSTRUMENTS/CONTROLS

Window Retainer Latch

1. PULL TO RELEASE WINDOW

1

RD97F173

OPERATORS SEAT TRIM THIS EDGE

Standard Seat

1

3

2

2 RD98K266

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

RD98K267

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

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

NOTE: Each armrest will pivot to the up position.

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INSTRUMENTS/CONTROLS

Optional Air Ride Seat

4 1 2

5

6 2 RD98K266

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

Release the lever to lock the seat in position.

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

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

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

NOTE: Each armrest will pivot to the up position.

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

3

RD98K268

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

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RD98K267

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

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

5 4 RD98K268

TRIM THIS EDGE

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

Release the lever to lock the seat in position.

6 7

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

RD98K268

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

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

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

Lift the handle UP and release.

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

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INSTRUMENTS/CONTROLS

5

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

8

RD00B010

TRIM THIS EDGE

SEAT BELT

RD97F225

RD97F225

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

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

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

!

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

M437

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INSTRUMENTS/CONTROLS

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

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

3. Replace all parts that have damage or wear.

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

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

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

7. Keep seat belts clean and dry.

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

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

Emergency Exit TRIM THIS EDGE

1

1

2

RD98K301

1. PIN 2. LATCH

RP98N341

1. EMERGENCY EXIT

Lift and pull the latch out of the pin.

Push the Right hand window open.

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

Make any necessary corrections before operating the machine.

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

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

CM112

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

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

3. Monitor the engine instruments frequently during operation.

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

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

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!

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

OPERATING INSTRUCTIONS

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

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

TRIM THIS EDGE

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

!

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

SA121

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OPERATING INSTRUCTIONS

STARTING THE ENGINE

!

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

SC037

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

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

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

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

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

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

NOTE: If the weather is cold, See Cold Weather Starting in this manual. If the engine has not been started for 3 or more days or if the engine oil filter has been replaced, See Priming the Turbocharger in this manual.

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

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

OPERATING INSTRUCTIONS

Priming the Turbocharger Lines with Oil

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

1

RD98D020

1. WIRE CONNECTOR

TRIM THIS EDGE

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

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

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

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

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OPERATING INSTRUCTIONS

STOPPING THE ENGINE AND PARKING THE MACHINE

!

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand rails and steps, and get on or off the machine slowly.

SA038

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

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

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

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

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

2. Lower the loader to the ground.

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

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

OPERATING INSTRUCTIONS

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

B830661M

Engine Oil Heater (If Equipped) TRIM THIS EDGE

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

B830662P

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OPERATING INSTRUCTIONS

Booster Battery Connections to Machine Batteries (Jump Start)

!

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

SA006

!

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

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

M146B

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

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

Standard Batteries

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

1

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

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

B1060A88

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

1. CONNECT POSITIVE JUMPER CABLE

Optional Batteries

1

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

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

B1061A88

1. CONNECT POSITIVE JUMPER CABLE

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

OPERATING INSTRUCTIONS

MACHINE OPERATION

!

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

SA040

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

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

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

TRIM THIS EDGE

3. Fasten and adjust the seat belt.

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

5. Check the loader controls for correct operation.

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

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

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

D. Raise the loader bucket above the ground.

E. Shift the transmission into first gear forward.

F. Take your foot off the brake pedal.

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

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

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

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

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

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

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

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

I. Raise the loader bucket above the ground.

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

L. Shift the transmission to the NEUTRAL position.

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

!

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

CM112

!

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

M142A

!

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

M122B

!

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

SB013

8. Release the parking brake.

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

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

B. Raise the loader bucket just above the ground.

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

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

D. Shift the transmission into 2nd gear forward.

E. Release the parking brake.

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

G. Reset the parking brake.

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

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

The transmission can be operated in Automatic or manual mode.

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

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

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

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

Down-Shift Button, Manual Mode The down-shift button is used to shift the transmission from 2nd gear to 1st. The transmission will shift back to 2nd gear if (1) the down-shift button is pressed again or (2) if the transmission control lever is moved to NEUTRAL and then to FORWARD or REVERSE. 102

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OPERATING INSTRUCTIONS

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

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

The down-shift button is used to shift down through the gears in single steps.

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

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Down-shift Button, Automatic Mode

OPERATING INSTRUCTIONS

LOADER CONTROL LEVERS Two Spool Valve - Two Control Levers 1 5

3

5

2

4

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

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

RB97F105

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1

3

2

4

B1119A88J

1. DUMP

2. ROLLBACK

3. LOWER

4. RAISE

5 HOLD: The loader arms and bucket will not move when the control levers are in HOLD. When released, the control levers will return to HOLD automatically.

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OPERATING INSTRUCTIONS

Two Spool Valve - One Control Lever 3 2

5

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

1 4

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

1

3

2

4

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RB97F106

B1119A88J

1. DUMP

2. ROLLBACK

3. LOWER

4. RAISE

5 HOLD: The loader arms and bucket will not move when the control lever is in HOLD. When released, the control lever will return to HOLD automatically.

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OPERATING INSTRUCTIONS

Three Spool Valve - Three Control Levers 1 7

3 2

5 7

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

7 6

4

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

RB97F108

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1

4

2

5

3

6

B1120A88J

1. DUMP 2. RAISE

3. ROLLBACK 4. CLAM OPEN (IF EQUIPPED)

5. LOWER 6. CLAM CLOSED (IF EQUIPPED)

7 HOLD: The loader arms, bucket, and clam will not move when the control levers are in HOLD. When released, the control levers will return to HOLD automatically.

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OPERATING INSTRUCTIONS

Three Spool Valve - Three Control Levers - Optional Forestry Configuration 1 7

3 2

5 7

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

7 6

4

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

1

4

2

5

3

6

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RB97F108

BS00C008

1. CLAM OPEN (IF EQUIPPED 2. CLAM CLOSED (IF EQUIPPED)

3. DUMP 4. ROLLBACK

5. LOWER 6. RAISE

7 HOLD: The loader arms, bucket, and clam will not move when the control levers are in HOLD. When released, the control levers will return to HOLD automatically.

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OPERATING INSTRUCTIONS

Three Spool Valve - Two Control Levers 3

7

2

5 1

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

7 6

4

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

RB97F107

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1

4

2

5

3

6

B1120A88J

1. DUMP 2. ROLLBACK

3. LOWER 4. RAISE

5. CLAM OPEN 6. CLAM CLOSED

7 HOLD: The loader arms, bucket, and clam will not move when the control levers are in HOLD. When released, the control levers will return to HOLD automatically.

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OPERATING INSTRUCTIONS

Four Spool Valve - Two Control Levers 3 2

9

7 1

6

9

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

5 8

See Next Page for RETURN-TO-DIG, BUCKET HEIGHT CONTRO L and R E T U R N - TO - T R AV E L / F L O AT switches.

4

4

RB97F107

B1121A88J

B1238A88J

IMPORTANT: If your machine is equipped with an auxiliary attachment, write the control lever positions next to the numbers below.

5

2

6 7 B1239A88J

8

3 9 HOLD: The loader arms, bucket,

B1239A88J

and auxiliary attachment will not move when the control levers are in HOLD. When released, the control l ev e r s w i l l r e t u r n t o H O L D automatically.

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1

OPERATING INSTRUCTIONS

LOADER FUNCTION SWITCHES Push down on the top of the detent switch to engage all detents. Push on th e bot tom o f swi tc h for t he O FF position.

The Return-To-Dig function is used to move the loader bucket for another dig cycle after you have dumped the load.

1

2 RD97F178

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

Return-To-Dig The Return-To-Dig function is used to automatically return the loader bucket to the dig position after you have dumped the loader bucket.

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1

2 1

RB97F106

RB97F105

1. FLOAT AND ROLLBACK DETENT

1. FLOAT 2. ROLLBACK DETENT

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

B1125A88J

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OPERATING INSTRUCTIONS

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

1

1

RB97F106

RB97F105

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

Return-To-Travel NOTE: The Return-To-Dig function must be selected to select the Return-ToTravel function.

The Return-To-Travel function is used to automatically stop the loader bucket at the carry height that you select.

1

1 2

RB97F105

1. ROLLBACK DETENT 2. FLOAT

RB97F106

1. FLOAT AND ROLLBACK DETENT

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

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1. RAISE

1. RAISE

OPERATING INSTRUCTIONS

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

B1128A88J

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

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1

1

RB97F105

RB97F106

1. FLOAT

1. FLOAT

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OPERATING INSTRUCTIONS

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

Periodicall test the accumulators for correct operation.

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

3. Stop the engine.

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

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

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

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

CLUTCH CUTOUT The Clutch Cutout function is used to allow the engine to increase speed and supply the loader with more hydraulic oil for greater loader power and faster control function. When the clutch cutout switch is in the ON position, and you push down on the brake pedal, the transmission is disengaged from the drive wheels. Realease the brake pedal to engage the transmission power. The machine can roll free when the clutch cutout switch is pushed. If required, use the brake to stop the machine. The Clutch Cutout Switch is adjustable. See Clutch Cutout Adjustment on page 183 of this manual.

1 RD97F178

1. CLUTCH CUTOUT SWITCH

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1. Start the engine.

OPERATING INSTRUCTIONS

BUCKET LEVEL INDICATOR The bottom of the bucket is parallel with the ground when the mar k on the bucket linkage is even with the mark on the cylinder rod eye.

B4065588

AUXILIARY HYDRAULIC CONNECTION (IF EQUIPPED) TRIM THIS EDGE

Your Wheel Loader is equipped with an Auxiliary Hydraulic System. A control lever on the console controls flow to the auxiliary hydraulic connection points on the lift arms.

RD97F185

FAR1048

Auxiliary Hydraulic System Specifications 821C Wheel Loader (Z-Bar Linkage) Maximum System Pressure ................................................... 2 810 PSI (194 bar) Maximum Capacity at 2 200 Engine RPM ............................ 78 GPM (356 L/Min) NOTE: Maximum system pressure measured on the machine at the pump pressure port.

IMPORTANT: Exceeding the Auxiliary Hydraulic System specifications can result in overheating and damaging the hydraulic system.

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OPERATING INSTRUCTIONS

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

RD97K027

Ride Control is a feature that i ncr eas es the r id e c o m fo r t o f t h e W h e e l Loader over all types of BC00B094 terrain with either an empty or load ed bucket. Rid e C o n t r o l w i l l r e d u c e Fo r e a n d A f t pitching motion during travel to allow fa s t e r s p e e d s i n l o a d a n d c a r r y applications for increased productivity and operator comfort. It will also reduce shock loads to the Wheel Loader for reduced tire flex, structural fatigue and vibration, resulting in longer component life and reduced costs.

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RIDE CONTROL

RD97K027

Push on the symbol of the function switch for the ON position. Pull back on the Loader Lift Control Lever to raise the lift arms until the Green light in the Ride Control Switch intensifies. Ride Control is OFF when key switch is OFF. Ride Control Must be reset once the engine is started again.

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

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

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

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OPERATING INSTRUCTIONS

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

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

To connect an attachment, position the front coupler into the attachment, push and hold on the top of the COUPLER switch to RETRACT the PINS and release the switch (PINS ENGAGED).

M a ke s u r e t h e C o u p l e r P i n s a r e engaged before you use the machine.

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RD97K027

EARLY PRODUCTION MACHINES

BD00B028

LATE PRODUCTION MACHINES

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

To change attachments, lower the attachment to the ground. For early production machines, push and hold the top of the COUPLER switch (PINS RETRACT).

Back out of the attachment, release the switch. For late production machines slide the locking plate toward the center of the switch, push down on the top of the switch (PINS RETRACT), back out of the attachment, push the bottom of the switch, (PINS EXTEND) switch is locked.

!

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

M781

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OPERATING INSTRUCTIONS

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

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

Pushing Operation 163L96

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

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

164L96

163L96

!

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

M465

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

OPERATING INSTRUCTIONS

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

165L96

!

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

SA041

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OPERATING INSTRUCTIONS

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

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

NEVER TOW MACHINE FROM THE FRONT. If you must tow the machine, read the following recommendations and use caution.

1. Attach a rigid drawbar to the retrieval hitch pin hole at the rear of the machine.

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

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

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

If you must tow the machine, read the following recommendations and use caution.

1. Attach a rigid drawbar to the machine.

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

B. Remove the Parking brake cover (1).

1

C. Loosen the lock nut (2).

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

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

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

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2

3 300372A1

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

OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE

!

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

SB042

!

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

46-76C

!

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

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

84-13A

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

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

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

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

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

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

3. Lower the loader bucket onto the trailer.

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

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

10. Put a cover over the exhaust pipe.

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

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

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

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OPERATING INSTRUCTIONS

Transporting the Machine on a Trailer Machine Tie Down Locations

BD00B013

CHAINS MUST BE SECURELY FASTENED TO THE TIE DOWN SLOT.

BK00D002

CHAINS MUST BE SECURELY FASTENED AROUND LOADER FRAME.

2

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1

2 BD00B012

BD00B014

CHAINS MUST BE SECURELY FASTENED TO TIE DOWN EYE (1) OR SLOTS (2).

CHAINS MUST BE SECURELY FASTENED TO THE TIE DOWN SLOT.

FAR1069

CHAINS MUST BE SECURELY FASTENED.

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OPERATING INSTRUCTIONS

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

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

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

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

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

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

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

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

Check for water in the fuel system.

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

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

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

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

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

The hydraulic steering can become s l o w i n s ev e r e c o l d w e a t h e r conditions. Cycle the steering from full right to left a minimum of 3 to 5 times before you dr ive the machine.

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

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

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

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

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

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

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

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

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

OPERATING INSTRUCTIONS

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

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

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

5. Check the condition of the drive belts.

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

6. Use lubricants viscosity.

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

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of

the

correct

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

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

WHEELS AND TIRES

!

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

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

!

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

84-113

!

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

SB134

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SD020

WHEELS/TIRES/BALLAST

TRIM THIS EDGE B910410J

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

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WHEELS/TIRES/BALLAST

Adding Air to the Tires

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

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

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

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

Tire Tread Direction

B790490R

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

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

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

FORWARD

B770164R

B4039288

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

WHEELS/TIRES/BALLAST

Wheel Nut Torque

1

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

13

10 8

6 11

If a wheel is removed from the machine and installed, tighten the nuts using the sequence shown. First tighten the nuts to 203 Nm (150 pound-feet), then to a final torque of 515 to 569 Nm (380 to 420 pound-feet) in the same sequence.

15

3

4 16

12 5

7 9

14

2

B890880J

Tire Pressure Chart TRIM THIS EDGE

TIRE

PLY

TREAD

SIZE

RATING

TYPE

kPa

(PSI)

(bar)

20.5 x 25

16

L2

379

55

3.7

20.5 x 25

16

TIRE PRESSURE

L3

345

50

3.4

XHA TL★

448

65

4.5

Rear

XHA TL★

276

40

2.8

Front

XTLA TL★

448

65

4.5

Rear

XTLA TL★

276

40

2.8

Front

VUT★

448

65

4.5

Rear

VUT★

379

55

3.8

Front

VMT★

448

65

4.5

VMT★

379

55

3.8

L2

310

45

3.1

20.5 R 25

Front

20.5 R 25

20.5 R 25

20.5 R 25

Rear 23.5 x 25

12

L3

276

40

2.7

23.5 R 25

23.5 x 25 Front

12

XHA TL★

448

65

4.5

Rear

XHA TL★

276

40

2.8

23.5 R 25

Front

VUT★

379

55

3.8

Rear

VUT★

310

45

2.8

23.5 R 25

Front

VMT★

379

55

3.8

Rear

VMT★

310

45

2.8

128

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LUBRICATION/FILTERS/FLUIDS GENERAL SAFETY BEFORE YOU SERVICE

!

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

SC021

!

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

SA044

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

TRIM THIS EDGE

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

Understand the operation of the machine before you start servicing

B770996R

B801147T

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

321-4614

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LUBRICATION/FILTERS/FLUIDS

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

TRIM THIS EDGE B830752T

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

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

130

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LUBRICATION/FILTERS/FLUIDS

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

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

TRANSPORT/SERVICE LINK

!

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

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

SA069

TRIM THIS EDGE

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

RD98K363

STRAIGHT AHEAD LOCKED POSITION

RD98M044

OPERATING POSITION

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LUBRICATION/FILTERS/FLUIDS

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

TRIM THIS EDGE

RD98K315

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

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LUBRICATION/FILTERS/FLUIDS

FLUIDS AND LUBRICANTS Engine Crankcase Oil Capacity - with filter change................................... 20.8 litres (22 U.S. Quarts) Specifications ............................................ See Engine Lubrication in this manual Cooling System Capacity ...................................................................33.5 litres (35.6 U.S. Quarts) Specifications .............................................. 50% water and 50% Ethylene Glycol Fuel Tank Capacity ....................................................................268 litres (70.8 U.S. Gallons Specifications ...........................................See Diesel Fuel System in this manual

Transmission Refill Capacity - with filter change .......................... 26.8 litres (7.25 U.S. Gallons) Total System Capacity............................................... 35 litres (9.25 U.S. Gallons) Specifications ............................................. Case No. 1 Engine Oil (SAE 15W-40) Axles Capacity Early Production Front Axle Capacity Center Bowl .............................................................21 litres (22 U.S. Quarts) Planetary End ...........................................................6 litres (6.5 U.S. Quarts) Rear Axle Capacity Center Bowl .............................................................15 litres (16 U.S. Quarts) Planetary End ...........................................................5.5 litres (6 U.S. Quarts) Late Production Total Front Axle Capacity ...........................................33 litres (35 U.S. Quarts) Limited Slip Front Addition .....................................2.1 litres (2.25 U.S. Quarts) Total Rear Axle Capacity ........................................26.5 litres (28 U.S. Quarts) Limited Slip Rear Addition .......................................1.9 litres (2.0 U.S. Quarts) Specifications ................................Case 135H EP gear lubricant (SAE 85W-140) Grease Fittings Quantity..............................................................................................As Required Specifications ............................................................. Case Molydisulfide Grease

133

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Hydraulic/Brake System Reservoir Refill Capacity.........................................150.2 litres (159 U.S. Quarts) Total System Capacity Early Production Machine .....................................174.2 litres (184 U.S. Quarts) Late Production Machine ......................................174.2 litres (184 U.S. Quarts) Specification..................................................................MS-1209, Hy-Tran Ultra

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

TRIM THIS EDGE

148 Air Precleaner (See Note 1)

❉

148 Air Cleaner (See Note 1)

❉

159 Hydraulic Filter (See Note 2)

❉

199 Fan Belt Condition

❉

199 Alternator Drive Belt

❉

199 Air Conditioning Compressor Belt (If Equipped)

❉

145 Engine Oil Level (See Note 3)

10

153 Radiator Coolant Level (See Note 4)

50

166 Transmission Oil Level (engine running oil warm)

50

159 Hydraulic Reservoir Fluid Level

50

138 Rear Axle Trunnion Pivots

2

50

138 Bucket Pivots

3

50

138 Center Drive Shaft Slip Joint

1

50

138 Front Drive Shaft Support Bearing

1

50

138 Rear Drive Shaft Slip Joint

1

50

139 Steering Cylinder Pivots - Closed End

2

100

139 Steering Cylinder Pivots - Rod End

2

100

139 Loader Lift Arm and Cylinder Pivots

10

100

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

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

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

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

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DRAIN WATERS

LUBRICATE

CLEAN

SERVICE POINTS

CHECK

NUMBER OF POINTS

PAGE NUMBER

FREQUENCY IN HOURS

LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

199 Fan Belt

DRAIN WATER

CLEAN

LUBRICATE

REPLACE

CHANGE

SERVICE POINTS

CHECK

NUMBER OF POINTS

250

146 Engine Oil (See Note 3 on Page 98)

250

146 Engine Oil Filter

250

199 Alternator Drive Belt

250

199 Air Conditioning Compressor Belt (If Equipped)

250

204 Battery Fluid Level

250

125 Tire Condition and Air Pressure

250

174 Cab Air Filter (If Equipped)

TRIM THIS EDGE

PAGE NUMBER

FREQUENCY IN HOURS

250

153 Engine Cooling System Filter (See Note 1)

250

157 Fuel Filter

250

157 Fuel Tank

500

196 ROPS and Seat Belt Mounting Bolts

500

159 Hydraulic Filters

1000

166 Transmission Filter (See Note 2)

1000

166 Transmission Oil (See Note 3 on Page 98)

1000

166 Transmission Breather

1000

139 Upper and Lower Chassis Pivots

2

172 Front Axle Differential and Planetary Oil - Early Production Front Axle Differential and Planetary Oil - Late Production

1000 1000 1000

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

135

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LUBRICATION/FILTERS/FLUIDS

LUBRICATION/MAINTENANCE CHART

173 Rear Axle Differential Oil and Planetary Oil - Early Production

CLEAN

ADJUST

REPLACE

1000

Rear Axle Differential Oil and Planetary Oil - Late Production SM Turbocharger Mounting Bolt Torque

CHANGE

SERVICE POINTS

CHECK

NUMBER OF POINTS

PAGE NUMBER

FREQUENCY IN HOURS

1000 2000

161 Hydraulic Oil (See Note 3)

2000

154 Engine Coolant (See Note 1)

2000

TRIM THIS EDGE

149 Air Filter Elements

2000

SM Engine Injectors (See Note 2)

6000 6000

SM Fuel Pump (See Note 2)

6000 6000

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

NOTE 2:Contact your dealer.

NOTE 3:Or when ambient operating temperatures require.

SM - See Service Manual.

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LUBRICATION/FILTERS/FLUIDS

ACCESS DOORS

RP98N345

RP98N342

RADIATOR ACCESS DOOR

TRIM THIS EDGE

LEFT SIDE ENGINE ACCESS DOOR

RD98N339

RIGHT SIDE ENGINE ACCESS DOOR

137

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 50 HOURS Use Case Molydisulfide Grease

1

2

1

2

1 B910922J

1. Bucket pivot points ........................................................................................ 3 2. Rear axle trunnion (remote fitting) ................................................................. 2

TRIM THIS EDGE

6

5

4

B910921J

3. Center drive shaft slip joint ........................................................................... 1 4. Front drive shaft support bearing .................................................................. 1 5. Rear drive shaft slip joint .............................................................................. 1

138

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LUBRICATION/FILTERS/FLUIDS

GREASE FITTINGS - 100 HOURS Use Case Molydisulfide Grease

3

3

1

1

2

2

3

3

3 B910922J

1. Steering cylinder - closed end and rod end ............................. 4 (2 each side) 2. Loader pivot points - remote grease fittings .................................................. 4 3. Loader pivot points ................................................................................................. 6

GREASE FITTINGS - 1000 HOURS Use Case Molydisulfide Grease

1

1 B910921J

1. Upper and lower chassis pivot ............................................ 2 (one each pivot)

139

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TRIM THIS EDGE

2

LUBRICATION/FILTERS/FLUIDS

FLUID LEVELS 10 Hours 2

1

RD98D019

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

RD98K317

2. RADIATOR COOLANT LEVEL ETHYLENE GLYCOL AND WATER

TRIM THIS EDGE

2

3

1 B910922J

3

RD98K328

3. RADIATOR ETHYLENE GLYCOL AND WATER

140

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LUBRICATION/FILTERS/FLUIDS

50 Hours 5

4

RD98K299

HYDRAULIC RESERVOIR CASE TRANS-XHD® FLUID

5 TRIM THIS EDGE

4

RD98A170

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

B910922J

141

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250 Hours 1

B1060A88

BATTERIES DRINKING OR DISTILLED WATER

TRIM THIS EDGE

1

B910921J

142

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LUBRICATION/FILTERS/FLUIDS

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

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

BP97H064

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

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

143

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RH99K130

LUBRICATION/FILTERS/FLUIDS

Oil Viscosity/Temperature Ranges

TRIM THIS EDGE BS99M162

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

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

144

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LUBRICATION/FILTERS/FLUIDS

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

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

Oil type ....................................................... Case No. 1 Engine Oil (SAE 15W-40) Oil Capacity - with filter change ................................... 20.8 litres (22 U.S. Quarts)

To check the engine oil level put the machine on a level surface and stop the engine. Remove engine oil dipstick and wi pe c l ea n wi th a cl ot h. R ep la c e dipstick in tube and push the engine oil dipstick completely DOWN and then remove. If the oil level is below the ADD mark, add oil to raise the oil level to the FULL mark.

RD98D019

145

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TRIM THIS EDGE

Engine Oil Level

LUBRICATION/FILTERS/FLUIDS

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

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

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

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

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

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

TRIM THIS EDGE

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

8. Install the drain plug.

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

1. Before draining the oil, have a container that will hold at least 36 litres (9.5 US gallons).

2. Remove the engine oil drain plug.

3. Open the rear engine access doors.

RD98D017

RD98D034

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

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

146

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

12. Close the engine access doors.

RD98D019

10. Fill the turbocharger oil lines with oil.

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

The normal engine oil change interval is every 250 hours of operation or once a year whichever occurs first. Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended to use the Systemgard Lubrication Analysis Program. See your dealer.

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

C. Connect the wire to the injection pump solenoid.

!

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

CM107

!

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

CM115

147

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TRIM THIS EDGE

Systemgard Lubrication Analysis Program

LUBRICATION/FILTERS/FLUIDS

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

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

TRIM THIS EDGE

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

Cap for the Air Cleaner

Dust Valve

This cap removes coarse particles from the air entering the air intake pipe.

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

RD98K330

Wear face protection and clean the dust and dir t from the cap with co mp re ss ed a ir. To c le an oi l an d grease from the cap, wash the cap in hot water wi th a smal l a mount of detergent.

148

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RD98D023

LUBRICATION/FILTERS/FLUIDS

Primary (Outer) Element

5. Install the end cover and push the spr i ng c lamps in to the l ocke d position.

1. Open the RIGHT engine access door. Lift the spring clamps and remove the end cover.

6. Close the access door.

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

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

Secondary (Inner) Element the

primary

(outer)

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

RD98D023

2. Carefully remove (outer) element.

the

primary

RD98D025

RD98D024

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

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

149

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TRIM THIS EDGE

1. Remove element.

LUBRICATION/FILTERS/FLUIDS 4. Install a new secondary (inner) element. Make sure the element has full gasket.

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

5. Install the primary (outer) element and end cover.

NOTE: Make sure the end cover is in place and each spring clamp is closed tight.

6. Close the access door.

RD97D081

TRIM THIS EDGE

!

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

CM115

150

TRIM THIS EDGE Bur 6-3591 LEFT PAGE

LUBRICATION/FILTERS/FLUIDS

Cleaning the Element

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

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

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

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

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

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

777L94

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

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

779L94

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

780L94

151

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TRIM THIS EDGE

778L94

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

LUBRICATION/FILTERS/FLUIDS

ENGINE COOLING SYSTEM Service Specifications Cooling System Capacity ...........................................33.5 litres (35.6 U.S. Quarts) Cooling system drain, flush, and refill interval ....... Every 2000 hours of operation or each year, whichever occurs first.

Cooling system filter replacement interval .............. Every 250 hours of operation with Case filter A77659, every time you drain, flush, and refill the cooling system.

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

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

TRIM THIS EDGE

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

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

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

!

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

Scalding can result from fast removal of radiator cap.

Check and service engine cooling system according to maintenance instructions.

SA023

152

TRIM THIS EDGE Bur 6-3591 LEFT PAGE

LUBRICATION/FILTERS/FLUIDS

Radiator Fluid Level

1. Rotate the shutoff valve 1/4 turn to the LEFT to the OFF position.

The coolant fluid level is monitored at the ins tr umen t cl us ter. Whe n th e coolant level indicator illuminates, add coolant to the radiator as required to raise the coolant level.

1

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

2

RD98D029

2. Turn the coolant filter counterclockwise to remove the old filter. Discard the filter.

3. Use a clean cloth and clean the coolant filter mounting area on the engine.

RD98K316

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

5. Turn the new coolant filter clockwise until the gasket comes in contact with the filter head. Tighten the coolant filter 1/2 to 3/4 of a turn by hand.

RD98K328

Replacing the Coolant Filter

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

When the coolant filter is too tight you can cause damage to the gasket and coolant filter.

Replace the Coolant Filter every 250 hours of operation. Drain and flush the Engine Cooling System every 2000 hours. Replace the Coolant Filter after ever y draining and flushing of the Engine Cooling System.

6. Rotate the shutoff valve 1/4 turn to the RIGHT to the ON position.

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1. SHUTOFF VALVE SHOWN IN THE ON POSITION 2. FILTER

LUBRICATION/FILTERS/FLUIDS

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

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

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

1. Open the radiator drain valve and remove the radiator cap. The drain valve is located at the lower left corner of the radiator.

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

TRIM THIS EDGE

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

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

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

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

See Coolant Mixture in this manual.

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

8. Install the radiator cap, if removed.

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LUBRICATION/FILTERS/FLUIDS

DIESEL FUEL SYSTEM Service Specifications Fuel Tank Capacity .................................................. 268 litres (70.8 U.S. Gallons) Interval for draining water from the fuel filter ....................... 50 hours of operation Fuel filter replacement interval .......................................... 250 hours of operation or once each year, whichever occurs first Adjust fuel injector ....................................................... 1500 hours of operation or or once each year, whichever occurs first Clean and calibrate fuel injectors and fuel pump ........ 6000 hours of operation or every 3 years, whichever occurs first.

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

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

The conditioner will:

3. Separate moisture from the fuel.

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

!

4. Stabilize the fuel in storage.

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

SA022

!

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

Never smoke while refueling.

M139C

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TRIM THIS EDGE

Fuel Conditioner

LUBRICATION/FILTERS/FLUIDS

Diesel Fuel

Fuel Storage

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

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

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

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

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

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

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

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

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

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

!

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

SA022

!

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

Never smoke while refueling.

M139C

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LUBRICATION/FILTERS/FLUIDS

Removing Water and Sediment from the Fuel System

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

Drain the water for the fuel filter after every 50 hours of operation. Drain the water and sediment from the fuel tank after every 500 hours of operation.

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

2

1

RD98D020

1. FIRST STAGE FUEL FILTER 2. SECOND STAGE FUEL FILTER

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

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

RD98D020

2. Close the drain valve.

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

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

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

B4029591T

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

LUBRICATION/FILTERS/FLUIDS

HYDRAULIC/BRAKE SYSTEM Service Specifications Hydraulic/Brake System Fluid Chart Hydraulic Reservoir Refill Capacity..........................150.2 Litres (159 U.S. Quarts) Total System Capacity..............................................174.2 Litres (184 U.S. Quarts) Type of Fluid.....................................................................MS-1209, Hy-Tran Ultra® Hydraulic Reservoir Fluid Level Check Interval...............................Every 50 Hours Filter Replacement Interval ................................Every 1000 Hours of Operation or if the Hydraulic Filter Warning Lamp Illuminates Suction Screen Cleaning Interval................................................Every 2000 Hours Hydraulic Fluid Change Interval ..................................................Every 2000 Hours or once each year, whichever occurs first.

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!

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

SA047

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LUBRICATION/FILTERS/FLUIDS

Hydraulic Oil Level

3. Check the oil level in the sight gauge. If the oil is cold, the level is correct when you see oil in the lower 1/4 of the sight gauge. If the oil is at operating temperature, 50°C (120°F), the oil level must be in the upper 1/4 of the sight gauge.

DO NOT over fill. See Hydraulic Sy stem i n this manual for th e correct oil.

To add oil to the hydraulic reservoir do the following:

RD98K299

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

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

To check the oil level in the hydraulic reservoir do the following: 1. Park the machine on a level surface and lower the loader bucket to the ground. Apply the parking brake.

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

2. Stop the engine.

4. Install the filler cap and hand tighten.

Hydraulic Filters Replace the two hydraulic filters every 100 0 hour s o f o pera tio n o r if th e hydraulic oil filter LAMP illuminates.

Hydraulic Filter Test To check the condition of the hydraulic filters do the following.

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

A. Hold the loader control lever in the ROLLBACK position until the loader bucket is against the s t op s, c o nt i nu e t o h ol d t h e control lever in the ROLLBACK position for 15 seconds.

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1. Clean the area around the filler cap.

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

C. Repeat steps a and b until the side of the hydraulic reservoir feels very warm.

2. Increase the engine speed to full t h r o t t l e . I f t h e L A M P fo r t h e hydraulic oil filters illuminates, replace both filters.

RD98K317

Hydraulic Filter Replacement IMPORTANT: Always replace both hydraulic filters at the same time.

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

TRIM THIS EDGE

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

Apply the parking brake.

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

3. Remove the access cover.

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

6. Tighten the filler cap.

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

8. Stop the engine and check the hy d ra ul i c oi l l evel . Ad d oi l as required. See Hydraulic System in this manual fo r correct specifications.

9. Install the access cover.

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

!

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

SA047

!

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

SA047

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LUBRICATION/FILTERS/FLUIDS

Hydraulic/Brake Oil Change

1 6 2

TRIM THIS EDGE

5 6

3 4

911L92

1. FILLER CAP 2. SUCTION SCREEN 3. PLUG

4. DRAIN VALVE 5. ACCESS COVER 6. SEAL

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LUBRICATION/FILTERS/FLUIDS Change the hydraulic/brake oil every 2000 hours of operation or one time each year, or when ambient operating temperatures require, whichever occurs first. When changing the hydraulic oil also replace both hydraulic oil filters and clean the suction screen.

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

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

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

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4. Make sure the accumulators are completely discharged. Push down a n d r e l ea s e o n e o f t h e b ra ke pedals a minimum of 30 times.

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

6. Remove the plug from the drain valve and install a hose on the drain valve.

7. Put the other end of the drain hose into a container that will hold 32 gallons (121 litres).

12. Clean the suction screen in solvent and dry the suction screen with compressed air. Install the suction screen.

13. Turn the reservoir drain valve to OFF. Remove the drain hose and install the plug in the drain valve.

14. Install the access cover with a new seal and tighten the mounting bolt.

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

16. Install the reservoir filler cap.

17. Start the engine and run at 1000 rpm. Check for oil leaks around the filters, access cover and the drain plug. When the balance pressure wa r n in g bu z zer s t op s m ak i n g noise, run the engine at 1500 rpm.

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

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

8. Open the drain valve.

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

9. Replace the hydraulic oil filters.

21. Add oil as required.

10. Remove the access cover from the hydraulic reservoir and remove the suction screen. Turn the suction screen counterclockwise to remove.

11. Clean the inside of the hydraulic reservoir with clean cloths.

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LUBRICATION/FILTERS/FLUIDS

Bleeding the Brake System NOTE: Oil will begin to flow from the bleed screw when engine is started.

2. Loosen the bleed screw on the accumulator charge valve a small amount. If possible attach a hose to the bleed screw to help prevent oil spillage.

4. When there are no air bubbles in the oil that is flowing from the bleed screw, close the bleed screw.

5. Continue to run the engine at idle until the low brake pressure lamp is no longer illuminated and both accumulators are fully charged.

6. Stop the engine.

7. Do procedure A or B to fully discharge the two accumulator pistons.

A. Push down and then release the brake pedal 15 to 20 times until there is no hydraulic pressure in the brake system.

1

BD00C005

1. BLEED SCREW ON ACCUMULATOR CHARGE VALVE

B. See Step 9 of this procedure for location of the bleed screw on t h e a x l e. L o o s e n t h e bl e e d screw on the front axle, push down on the brake pedal until there is no forced flow from the open bleed screw. Tighten the bleed screw.

8. Start and run the engine at idle.

Apply the parking brake.

3. Start and run the engine at idle.

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1. Park the machine on a level s u r fa c e . B l o c k t h e w h e e l s .

Completely raise the loader frame, connect acceptable lifting equipment to the loader arms that will hold the loader arms in place.

Apply the parking brake. Stop the engine. Put a DO NOT OPERATE tag on the steering wheel.

LUBRICATION/FILTERS/FLUIDS 9. Open the left bleed screw on the front axle.

NOTE: Early Production Axle not shown.

NOTE: DO NOT push the brake pedal farther than necessary to cause the oil to flow from the bleed screw. The farther you push the pedal the higher the pressure in the brake circuit. High pressure can cause injury or damage.

11. Open the right bleed screw on the front axle. Repeat Step 10

1

12. Start and run the engine at idle for 2 minute.

13. Stop the engine. Open the left blee d s c rew on the r ear a xl e.

Repeat Step 10.

14. Open the right bleed screw on the rear axle. Repeat Step 10.

BD00B027

TRIM THIS EDGE

1. BLEED SCREW ON FRONT AXLE - LATE PRODUCTION

10. Slowly push down on the brake pedal until oil begins to flow from the bleed screw. Hold the brake pedal in position until 1 liter of oil has been bled and/or there is no air bubbles in the oil flowing from the bleed screw. Close the bleed screw and release the brake pedal.

15. Check the brake system for correct operation. If the brake system is not operating proper ly see the S er v i c e M a nu a l o r yo u r Ca s e Dealer.

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LUBRICATION/FILTERS/FLUIDS

TRANSMISSION Service Specifications Transmission refill capacity with filters ..................... 26.8 litres (7.25 U.S. Gallons) Total system capacity ................................................. 35 litres (9.25 U.S. Gallons) Type of oil ................................................... Case No. 1 Engine Oil (SAE 15W-40) Oil lever check interval ............................................................................ 50 hours Filter replacement interval ............................ After the first 100 hours of operation and then every 1000 hours there after.

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

!

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

CM107

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

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IMPORTANT: If the machine is new or the transmission has been replaced or rebuilt, change the transmission oil and replace the filter after the first 100 hours of operation.

LUBRICATION/FILTERS/FLUIDS

Transmission Oil Level

2. Apply the parking brake.

See this page for the two methods to check the transmission oil level.

3. Shift the NEUTRAL.

transmission

to

4. Run the engine at idle speed.

5. If the oil level is at or below the A DD m ar k , p u t t he t ra ns p o r t / service link in the LOCKED position and add oil to raise the oil level up to the FULL mark. See Tr a n s m i s s i o n Service Specifications in this manual for the correct oil.

B910924J

Oil Change, Filter Replacement, and Breather Cleaning

TRIM THIS EDGE

Ch a n ge th e tra n s m i s s i on o il a n d replace the filter after the first 100 hours of operation with a new machine or if the transmission has been replaced or rebuilt. Then, do the above service and clean the breather every 1000 hours or operation.

RD97F167

Cold Oil Level Check

If possible, drain the oil when the oil is at operating temperature. More contamination is removed when the oil is at operating temperature.

Before you start the engine, check the transmission oil level in the sight gauge. If the oil level is below the arrow, add oil to raise the oil level up to the arrow. See Transmission Service Specifications in this manual for the correct type of oil.

Warm Oil Level Check

1. Put the transport/service link in the LOCKED position, apply the parking brake, and stop the engine.

2. Clean the area around the filters, drain plug, breather, and filler tube.

3. Have a container that will hold approximately 30.3 litres (8 U.S. Gallons).

Check the transmission oil level every 50 hours of operation when the oil is at operating temperature. Do the following.

1. Park the machine on a level surface.

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LUBRICATION/FILTERS/FLUIDS 7. Install the filter as shown. Make sure the filter is SEATED against the filter base.

4. Remove the filler tube plug.

B4028891T

5. Remove the drain plug and drain the oil from the transmission.

9. Install the breather.

10. Install the drain plug. Put new oil into the transmission. See Tr a n s m i s s i o n Service Specifications in this manual.

2 1

RB97G074J

1. DRAIN PLUG

2. O-RING

6. Remove the transmission filters.

Discard the old transmission filters.

11. Check the oil level in the sight gauge.

12. Start the engine and check for oil leaks around the filters and drain plug.

13. Increase the transmission oil temperature to operating temperature and check the oil level again.

14. Stop the engine and return the transpor t/ser vice link to the OPERATING position.

RD98K296

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RD98M046

8. Remove the breather. Clean the breather with solvent and dry with compressed air. Be sure to wear fa c e p r o t e c t i o n w h e n u s i n g compressed air.

LUBRICATION/FILTERS/FLUIDS

AXLES EARLY PRODUCTION Service Specifications Front Axle Capacity Center Bowl ...................................................................21 litres (22 U.S. Quarts) Planetary End .................................................................6 litres (6.5 U.S. Quarts) Rear Axle Capacity Center Bowl ...................................................................15 litres (16 U.S. Quarts) Planetary End .................................................................5.5 litres (6 U.S. Quarts) Total axle capacity Front.............................................................................. 33 litres (35 U.S. Quarts) Rear ........................................................................... 26.5 litres (28 U.S. Quarts) Type of oil ............................................. Case 135H EP gear lube (SAE 85W-140) Alternate oil ............................................................................................. See note

TRIM THIS EDGE

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

NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil.

Axle Oil Level To check the oil level at the center bowl and each planetary end, do the following procedure.

NOTE: The oil level and filler plugs in the center bowl and planetary ends are magnetic. Remove and clean these plugs after the first 50 and 100 hours of operation with a new or rebuilt axle.

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LUBRICATION/FILTERS/FLUIDS

Axle Planetary

Center Bowl

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Use acceptable lifting equipment and lift the axle until the tires are off the floor. Support axle with jack stands.

2. Remove the oil level plug from the center bowl. The oil level must be level with the bottom of the oil level plug hole.

3. Rotate the tires until the filler plug is in the three o’clock position shown.

2

A17932

3. Add oil as required. See Axle Service Specifications on 168 in this manual.

RP95K190

1. OIL LEVEL 2. FILLER PLUG

4. Clean and install the oil level plug.

4. Remove the oil level and filler plugs from the planetary ends. The oil level must be level with the bottom of the oil level and filler plug hole.

5. Add oil as required. See Axle Se r v i ce S pe c ifi c at io ns i n th is manual.

6. Clean and install the filler plugs.

7. Remove jack stands. Lower the axle until the tires are on the floor and remove the lifting equipment.

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1

LUBRICATION/FILTERS/FLUIDS

Axle Oil Change Change the axle oil every 1000 hours of operation. Each axle has a common oil level between the planetary ends and the center bowl. The oil flow is restricted between these areas so you must follow the oil fill instructions.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Have a container that will hold approximately 6 litres (6.5 U.S. Quarts) for each planetary end and a container that will hold approximately 21 litres (22 U.S. Gallons) for the center bowl.

TRIM THIS EDGE

3. With the oil warm from operation, remove the oil level and filler plug and the drain bolts from planetary ends and the oil level plug and oil drain bolt from the center bowl.

Drain the oil from the axles.

A17932

4. Clean the oil level and oil filler plugs.

5. After all oil has been removed, install and tighten the drain bolts.

6. Install the exact amount of oil in each planetar y end and in the center bowl. See Axle Ser vice Specifications in this manual.

7. Install the oil level and filler plug in the planetary ends and the oil level plugs in the center bowls.

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LUBRICATION/FILTERS/FLUIDS

AXLES LATE PRODUCTION Service Specifications Total front axle capacity .................................................. 33 litres (35 U.S. Quarts) Limited slip addition, front axle.....................................2.1 litres (2.25 U.S. Quarts) Total rear axle capacity ............................................... 26.5 litres (28 U.S. Quarts) Limited slip addition, rear axle........................................1.9 litres (2.0 U.S. Quarts) Type of oil ............................................. Case 135H EP gear lube (SAE 85W-140) Alternate oil ............................................................................................. See note Oil change interval ................................... After the first 100 hours of operation and then every 1000 hours there after.

Axle Oil Level To check the oil level, do the following procedure.

NOTE: The oil level and filler plugs in are magnetic. Remove and clean these plugs after the first 50 and 100 hours of operation with a new or rebuilt axle.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

3. Add oil as required. See Axle S er v i ce S pe c if ic at io ns i n th is manual.

2. Remove the oil level and filler plug from the center bowl of the axle.

The oil level must be level with the bottom of the oil level and filler plug hole.

4. Clean and install the filler plug.

1

BD00B002

1. OIL LEVEL AND FILLER PLUG

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NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an alternate oil.

LUBRICATION/FILTERS/FLUIDS

Front Axle Oil Change After the first 100 hours of operation and then every 1000 hours there after.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

1

2. Have a container that will hold approximately 38 litres (40 U.S. Quar ts) for the front axle and a container that will hold approximately 28.5 litres (30 U.S. Gallons) for the rear axle.

1 BD00C007

3. With the oil warm from operation, remove the oil level and filler plug and the drain plug from center bowl of the axle. Drain the oil from the axle.

1. DRAIN PLUG

TRIM THIS EDGE

1

1

BD00E002

1. DRAIN PLUG

2 BD00B026

1. OIL LEVEL AND FILLER PLUG 2. DRAIN PLUG

NOTE: Some machines may be equipped with two drain plugs, while other machines may only have one drain plug.

4. Remove the the drain plugs from the planetar y ends of the axle.

Drain the oil from both planetary ends of the axle. The drain plug can be located in either location, see the following photo.

5. Clean the oil level and oil filler plugs.

6. After all oil has been removed, install and tighten the drain plugs.

7. Install the exact amount of oil in the center bowl of the axle. See Axle Service Specifications on 171 in this manual.

8. Install the oil level and filler plug in the center bowl of the axle.

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LUBRICATION/FILTERS/FLUIDS

Rear Axle Oil Change

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Have a container that will hold approximately 38 litres (40 U.S. Quar ts) for the front axle and a container that will hold approximately 28.5 litres (30 U.S. Gallons) for the rear axle.

3. With the oil warm from operation, remove the oil level and filler plug from the beam of the axle and the drain plugs from the planetary ends of the axle. Drain the oil from the planetary ends of the axle.

4. Remove the drain plug from center section of the axle. Drain the oil from the center section of the axle.

1 BD00B002

3. DRAIN PLUG FOR AXLE CENTER SECTION

5. Clean the oil level and oil filler plug and the drain plugs.

6. After all oil has been removed, install and tighten the drain plugs.

7. Install the exact amount of oil in the axle.

See Axle Service Specifications on 171 in this manual.

1

1

BD00C010

2 BD00B002

1. OIL LEVEL AND FILLER PLUG

8. Install the oil level and filler plug in the beam of the axle.

2 BD00C007

1. OIL LEVEL AND FILLER PLUG 2. DRAIN PLUG FOR PLANETARY

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

LUBRICATION/FILTERS/FLUIDS

CAB AIR FILTER Clean or replace the cab air filters (if equipped) every 250 hours of operation or if the air flow in the cab is reduced.

3. Install a filter that has been cleaned or a new filter.

NOTE: If your machine is new, make sure the plastic cover is removed from the filters.

Removal and Installation 1. Turn the handle and open the access door.

RD98K285

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4. Close the access door and turn the handle to the locked position.

RD97F156

2. Pull the air filter out.

RD97F156

RD98K285

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LUBRICATION/FILTERS/FLUIDS

Circulation Cover - Early Production

4. Install the circulation cover.

1. Remove the air circulation cover.

RD97F223

RD97F223

2. Remove the air circulation filter.

Circulation Cover - Late Production TRIM THIS EDGE

1. Remove the air circulation filter.

RD97F222

3. Install a filter that has been cleaned or a new filter.

RD97F222

2. Install a filter that has been cleaned or a new filter.

RD97F222 RD97F222

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LUBRICATION/FILTERS/FLUIDS

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

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

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

1. Remove the loose dirt with compressed air, 30 psi (207 kPa, 2 bar) maximum. Hold the nozzle at least one inch (25 mm) from the element. Make sure you wear face protection when using compressed air.

787L94

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4. Use a water hose without a nozzle with pressure less than 40 psi (275 kPa, 2.7 bar) to flush all soap from the element.

786L94

2. Mix two tablespoons of D1400 d et e r g e n t ( Ca s e p a r t nu m be r A40910) with two gallons (7.6 litres) of water, one cup for 16 gallons (60 litres) of water.

788L94

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

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LUBRICATION/FILTERS/FLUIDS 6. Use a light and inspect the element for holes or splits in the pleats.

Check for damage to the metal parts and rubber gasket.

789L94

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

TRIM THIS EDGE

WINDSHIELD WASHER RESERVOIR (If Equipped)

RD98K286

The windshield washer reservoir is located on the frame below the cab on the Right Hand side. To add washer fluid, pull the cap up.

IMPORTANT: When the ambient temperature decreases to 0°C (32°F) and below, always use an antifreeze type washer solution.

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LUBRICATION/FILTERS/FLUIDS

NOTES

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182MAINTENANCE/ADJUSTMENT CAB SERVICE Air Conditioning The components of the operators cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

!

WARNING: Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning and the safety precautions which must be followed. Serious injury can result if you do not follow these instructions.

Lubrication of the Air Conditioning Compressor Seals Operate the air conditioning once every 250 hours to lubricate the compressor seals. Turn the air conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 32°F (0°C) put a c o v e r o ve r t h e a i r c o n d i t i o n i n g condenser. This will make sure the refrigerant and lubricants in the system will be at operating temperature.

Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the condenser. Also check and clean the grille screen.

IMPORTANT: Because the condenser fins bend easily, be careful when you clean the condenser.

10 Ampere Circuit Breakers for Condenser Blower Fans

Condenser 1

1

1

RD98A205

1. PLUGS

RD98A205

1. CONDENSER AND FANS

If one of the fans stop, remove the plug on that side and push the Reset Button on the circuit breaker. Install the plug. If fan still will not operate properly, see your dealer.

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SA048

MAINTENANCE/ADJUSTMENT

Cab Headliner

Door Hinges

T h e fo a m h e a d l i n e r i n y o u r c a b decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

Use graphite to lubricate the cab door hinges. DO NOT use oil.

IMPORTANT: DO NOT wash the headliner with water because water can cause damage to the headliner and lower the noise control capacity of the headliner.

Check all hoses and wiring for damage.

If damage occurred, see your dealer for repair or replacement.

Hoses and Wiring

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RD97F215

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MAINTENANCE/ADJUSTMENT

Operators Seat Remove dust and dirt from the seat with a vacuum cleaner or soft brush. Clean stains with the correct use of a material cleaner.

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

!

WARNING: Never use gasoline, naptha or any other volatile material for any cleaning purposes. These materials may be toxic and/or flammable.

SA049

CLEANER FLUID - This type of cleaner can be used for grease or oil stains.

Carefully remove the item that caused the stain with a scraper or a knife that is not sharp. Use very little cleaner, no pressure, and clean cloths. Move the cloth from the outside of the stain toward the center of the stain and constantly change to a clean section of cloth.

NOTE: A difficult stain can need a second application of cleaner fluid followed immediately by the use of a soft brush to completely remove the stain.

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When the stain is removed from the material, immediately use a cloth to make dry the area and to prevent a cleaner circle pattern. If a circle pattern occurs, clean the complete area.

MAINTENANCE/ADJUSTMENT

TRANSMISSION CLUTCH CALIBRATION Transmission clutch calibration ensures optimum shifting of the transmission.

Make sure of the following before proceeding with transmission clutch calibration.

●

The Modulation Cycle Number will be displayed in the 1st and 2nd spaces (2 00 XX - the XX represents the 1st and 2nd spaces).

●

During Clutch Calibration, the Clutch Calibration Main Code will change from 01 to 07 as the process is completed. The code 07 will indicate that the process is complete and the Information Center will return to normal working status.

●

If any of the Clutch Calibration parameters are incorrect, the display center will stop flashing and display the Clutch Calibration Main Code in the 1st, 2nd, 3rd, and 4th spaces.

A. The parking brake has been tested.

B. The transmission oil is warm.

C. The engine idle speed is correct.

D. The transmission is in neutral.

E. The parking brake is applied.

Do the following procedure to calibrate the transmission clutches:

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1. Put the transmission in the machine shift mode and the gear selector in 3rd gear neutral.

2. Press the program switch.

3. Press the up-count switch until the display reads 011.

4. Return the program switch to the center position.

5. Press the up-count switch twice so the display reads 02.

In the event, the code in the 3rd and 4th spaces will be 09 to 14 and will indicate the process that the calibration was in when it was aborted.

The 1st and 2nd spaces will produce the Clutch Calibration Sub-Code, which is the code that will inform the operator of the reason process was aborted.

6. After completing the clutch calibration procedure, tur n the engine off for 15 seconds to set the calibration in the controller.

At this time, 2 00 00 will begin flashing in the display center. ●

After one second, the Clutch Calibration Main Code status will be displayed in the 3rd and 4th spaces (2 XX 00 - the XX represents the 3rd and 4th spaces).

NOTE: See Clutch Calibration Main Code and Clutch Calibration Sub-Code on the following page.

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MAINTENANCE/ADJUSTMENT

Clutch Calibration Main Codes 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14

CLUTCH CALIBRATION SUB-CODE

MEANING Clutch Calibration Mode was not initiated because one of the requirements was not met.

Adjusting 1st gear Adjusting 2nd gear Adjusting 3rd gear Adjusting 4th gear Adjusting Forward gear Adjusting Reverse gear Clutch Calibration Completed Operator aborted calibration procedure.

Aborted while adjusting 1st gear Aborted while adjusting 2nd gear Aborted while adjusting 3rd gear Aborted while adjusting 4th gear Aborted while adjusting Forward gear Aborted while adjusting Reverse gear

MEANING Calibration in process

00 01 02 03 04 05 06 07 08

Fault present Shift lever not in neutral Park brake not applied Output speed not 0 kph/mph Adjusting Forward gear High transmission oil temperature Low engine RPM High engine RPM

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CLUTCH CALIBRATION MAIN CODE

Clutch Calibration SubCodes

CLUTCH CUTOUT ADJUSTMENT 1. Park the machine on a level surface.

2. Lower the loader bucket to the floor.

3. Apply the parking brake and stop the engine.

NOTE: The following photo shows the brake pedal/valve assembly removed for clarity. Do not remove the brake pedal/valve assembly from the machine.

2 1

BD00C006

1. PLUG 2. ADJUSTMENT SCREW

4. Remove the plug (1) from the base of the left hand brake pedal/valve assembly.

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MAINTENANCE/ADJUSTMENT 5. Turn the adjustment screw (2) in or out as required to adjust the clutch c u t o u t p o i n t . Tu r n i n g t h e adjustment screw clockw ise increases the brake force at the c l u t c h c u t o u t . Tu r n i n g t h e adjustment screw counterclockwise decreases the brake force at the clutch cutout.

6. Install the plug (1) in the base of the left hand brake pedal/valve assembly.

7. If the clutch cutout is not operating properly see the Service Manual or your Case Dealer

NOTE: On Late Production machines, the clutch cutout is set the at the factory at approximately 30 percent of full brake system pressure. Do not increase this setting more that 1 turn clockwise (approximately +325 psi) Do not reduce this setting more than 1/2 turn counterclockwise (approximately 75 psi).

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MAINTENANCE/ADJUSTMENT

SECONDARY STEERING CHECK NOTE: Test the secondary steering at a maximum of 250 hours.

RD98K316

1. Park the machine on a hard, level surface with enough clearance around the machine to allow you to completely steer from side to side.

2. Start the engine.

3. Raise the bucket approximately 500 mm (20 inches) above the ground.

4. With the machine at low idle and steering straight ahead, turn the steering wheel either left or right.

DO NOT TURN THE STEERING W H E E L TO T H E S T E E R I N G STOP. While steering, turn the key switch to the OFF position to stop the engine and then immediately back to the ON position (not the S TA RT p o s i t i o n . R e l e a s e t h e steering wheel. The secondar y steering pump/motor should start running immediately.

IMPORTANT: DO NOT turn the key switch to the OFF position if the machine is steered against either the right hand or left hand steering stop.

The steering wheel may kick back.

NOTE: The secondary steering system will only function as long as there is sufficient battery capacity. Replace weak or worn batteries.

5. Steer the machine left and right to confirm that the secondary steering pump is working. The secondary pump/motor should not be r un continuously for more than 20 seconds at a time without a 2 minute cool down.

NOTE: Operating the secondary pump/ motor for long periods of time can result in very hot conditions and shortened secondary pump/motor life.

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The secondary steering system is electrically powered which allows you to steer the machine if the primary steering system stops working. Always maintain the batteries.

MAINTENANCE/ADJUSTMENT 6. Look at the instrument cluster to verify that the secondary steering light comes on.

7. Turn the key switch to the OFF position. The secondary steering motor should stop.

8. If Steps 2 through 6 function properly, the secondary steering sy stem is operating cor rec tly.

Repair the secondar y steering system if the secondary steering system does not operate correctly.

9. Restart the engine and allow the b a t t e r i e s t o r e c h a r g e fo r a minimum of 10 minutes.

PARKING BRAKE CHECK NOTE: Test the parking brake at a maximum of 250 hours.

Before you operate the machine periodically test the parking brake functions.

TRIM THIS EDGE RD98K316

1. To release the park brake, all the following are required:

2. To engage the park brake, any of the following is required:

A. Push the Park Brake switch to the release position.

A. Loss of service brake pressure in both axles.

B. Service brake depressed indicating brake lights.

B. Loss of system electrical power (key OFF).

C. Transmission shifter positioned from N to F or R for a second, and back to N.

C. Park Brake switch in engaged position.

D. Adequate service brake pressure to stop the machine.

3. To test these functions: A. Start on a clear level surface.

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MAINTENANCE/ADJUSTMENT B. With Step 1, A through C c o m p l e t e, s t a r t t h e e n g i n e release the par k brake, r ed warning light out.

4. Put the park brake switch in the release position, attempt B and C in Step 1. The park brake light must turn OFF,

C. Shutdown the engine turn the key switch to the ON position, engine off the Park Brake light should come ON.

A. Allow the machine to roll slowly forward with the transmission in F put the park switch to engage.

The machine must come to a stop immediately. Park light ON. Transmission disengages.

E. Pump the service brakes, the red warning light should come ON first. Continue to pump the service brakes. Pump until the brake light comes ON, pump the brakes three more times, it could require as many as forty pumps total.

If all steps are working positive the system works correct. If there was a problem with the test contact you dealer.

F. Start the engine and allow the brake pressure to build until the warning light goes out.

G. Depress the service brake and release. The light must stay ON. H. Put the transmission in F or R and back to N the brake light must stay ON. I. Put the park brake switch in the engaged position, attempt B and C in Step 1. The park brake light must stay ON.

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D. Release the park Brake using B and C in Step 1. Make sure the park brake light is out.

MAINTENANCE/ADJUSTMENT

LOADER ADJUSTMENTS Return-To-Dig Adjustment 1. Park the machine on a level surface.

2. Lower the loader frame and adjust the position of the bucket so the cutting edge is flat on the floor.

1 2 B4037588T

1. SWITCH 2. SHIELD

5. Loosen the cap screws that fasten the actuator.

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RD98D004

3. Apply the parking brake and stop the engine.

1 2 A18090

1. SWITCH 2. ADJUSTING BOLTS

6. Move the actuator all the way to the rear.

RD98K313

4. Make sure the switch is even with the edge of the shield. Adjust the shield and actuator to get 1/8 to 3/ 16 inch (3.2 to 5.0 mm) clearance b e t w e e n t h e sw i t c h a n d t h e actuator. Make sure the actuator is parallel to the shield so that the 1/8 to 3/16 inch (3.2 to 5.0 mm) clearance is maintained through the full stroke of the cylinder.

1

A18091

1. ACTUATING ARM

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MAINTENANCE/ADJUSTMENT 7. Turn the key switch to the ON position but do not start the engine.

A18091

RD98K312

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8. Push down on the top side of the detent function switch.

10. Tighten the cap screws that fasten the actuator. Make sure the 1/8 to 3/16 inch (3.2 to 5.0 mm) clearance is mainta ined thr ough the full stroke of the cylinder.

1

RD97F177

1. DETENT OFF/ON SWITCH

A18090

9. Have another person help you at this time. Slowly move the actuator forward until the bucket control lever returns to NEUTRAL.

11. Start the engine. Raise the loader frame all the way and dump the bucket completely. Increase the engine speed to full throttle. Pull back the bucket control lever to the ROLLBACK position. The bucket will roll back automatically.

12. Lower the bucket to the floor and stop the engine.

13. If the bucket is not in the correct position, adjust the actuator as required.

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MAINTENANCE/ADJUSTMENT

Return-To-Travel Minor Adjustment

Return-To-Travel Adjustment

1. Lower the loader bucket to the ground.

2. Park the machine on a level surface and apply the par king brake.

3. Stop the engine.

4. Loosen the front actuator.

1. Park the machine on a level surface and apply the par king brake.

2. Raise the loader until the front actuator is even with the ReturnTo-Travel switch. Make sure the clearance is 1/8 to 3/16 inch (3.2 to 5.0 mm).

1

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2 A18144

5. To increase the carry height, move the actuator down in the slot. To decrease the carry height, move the actuator up in the slot.

6. Tighten the actuator and check the adjustment.

A18082

1. FRONT ACTUATOR 2. RETURN-TO-TRAVEL SWITCH

3. Stop the engine.

4. Loosen and remove the screws and hardened washers that fasten the cover.

A18083

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MAINTENANCE/ADJUSTMENT 5. Remove the cover.

8. Loosen the actuator.

6. Check the clearance between the ac t u at or a nd th e swi t c h. Thi s clearance is 1/8 to 3/16 inch (3.2 to 5.0 mm). If the clearance is not correct, loosen the nuts for the switch and adjust the nuts so there is 1/8 to 3/16 inch (3.2 to 5.0 mm) clearance between the switch and the actuator. Hold the switch in position and tighten the nuts.

A18144

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9. Move the actuator up in the slot and hand tighten the actuator.

A18084

7. Have another person help you at this time. Star t the engine and lower the loader frame until the bucket is at the desired height above the floor. Put a sufficient suppor t under each end of the bucket and stop the engine.

A18145

10. Turn the key switch to ON but do not start the engine.

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MAINTENANCE/ADJUSTMENT 11. Push down on the top of the Return-To-Travel detent switch.

Move the lift control lever from the HOLD position to the RAISE position several times to relieve all of the pressure in the accumulator.

Tur n the key switch to the ON position. Move the lift control lever to the FLOAT position. The lift control lever will remain in this position and the loader frame will not move.

13. Tighten the actuator. Move the lift control lever to the FLOAT position.

The loader frame will lower and stop at the adjusted height above the floor.

A18144

14. When the adjustment is correct, install the cover.

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15. Install the screws and hardened washers and tighten the screws.

1

RD97F177

1. RETURN-TO-TRAVEL SWITCH

12. Loosen the actuator and slowly move the actuator down the slot until the lift control lever returns to HOLD. A18083

16. Remove each support from under the bucket and lower the bucket to the floor.

A18146

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MAINTENANCE/ADJUSTMENT

Bucket Height Control Minor Adjustment

Bucket Height Control Adjustment

1. Park the machine on a level surface. Lower the loader bucket to the floor.

1. Park the machine on a level surface and lower the loader frame so the bucket is flat on the floor.

2. Apply the parking brake and stop the engine.

3. Loosen the rear actuator.

A18088

4. To increase the dump height, move the actuator down in the slot. To decrease the dump height, move the actuator up.

3. Loosen and remove the screws and hardened washers that fasten the cover.

5. Tighten the actuator.

6. Start the engine and pull the lift control lever to the RAISE detent position. When the loader arms s top m ovi ng , ch eck the d um p height.

A18083

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RD98D004

2. Stop the engine and apply the parking brake.

MAINTENANCE/ADJUSTMENT 4. Remove the cover.

5. Start the engine and raise the loader frame until the rear actuator is even with the Bucket Height Control switch. Stop the engine.

IMPORTANT: Connect acceptable lifting equipment to the loader arms that will hold the loader in place.

7. Disconnect the lifting equipment.

Start the engine. Dump the bucket completely and raise or lower the loader frame for the bucket height required. Stop the engine. Connect the lifting equipment to the crossmember of the loader.

8. Loosen the actuator.

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A18088 A18147

6. Loosen the nuts of the switch and adjust the nuts so there is 1/8 to 3/ 16 inch (3.2 to 5.0 mm) clearance b e t w e e n t h e sw i t c h a n d t h e actuator. Hold the switch in position and tighten the nuts.

A18148

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MAINTENANCE/ADJUSTMENT 9. Move the actuator down in the slot.

12. Slowly move the actuator up the slot until the lift control lever returns to HOLD. 13. Tighten the actuator.

A18086

10. Turn the key switch to ON but do not start the engine.

A18088

14. Disconnect the lifting equipment from the crossmember of the loader frame. Start the engine and lower the l oader frame so the bucket is flat on the floor.

15. Put the lift control lever in the RAISE position. The loader frame will raise and stop at the adjusted bucket height.

16. Lower the loader frame so that the bucket is flat on the floor. Stop the engine.

17. Install the cover.

18. Install the screws and hardened washers and tighten the screws.

A18085

!

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

CM115S

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11. Push in the left side of the Bucket H e i g h t C o n t r o l sw i t c h o n t h e instrument panel. Move the lift control lever to the RAISE position.

The lift control lever will remain in this position and the loader frame will not move.

MAINTENANCE/ADJUSTMENT

ROLL-OVER PROTECTIVE STRUCTURE Yo u r m a c h i n e h a s a R o l l - O v e r Protective Structure (ROPS). A ROPS label shows the serial number of the ROPS, gros s weight, appr oval, regulation, and model numbers of the machine. See Identification Numbers in this manual.

1. Check the torque of the ROPS m o u nt i n g b o l t s. I f n e c e s s a r y, tighten the bolts to the correct torque. See torque specifications on this page.

2. Check the operators seat and the mounting parts for the seat belt.

Tighten the bolts to the correct torque. See Torque Specifications in this manual. Replace parts that have wear or damage.

Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

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

Seat Belt

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The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

1. Keep the seat belts away from objects that can damage the seat belts.

2. Check the seat belts for damage.

Replace all par ts that are damaged.

Torque Specifications for ROPS Cab and ROPS Canopy

3. Make sure that the mounting bolts of the seat belts are tight. See Torque Specifications for Seat in this manual.

4. Keep the seat belts clean. Wash the seat belts only in soap and water.

5. Do not put the seat belts in bleach or dye. You will make the seat belts weak.

Maintenance and Inspection of ROPS

RD98D027

ROPS CAB AND ROPS CANOPY MOUNTING BOLTS (BOTH SIDES), TIGHTEN TO 772 TO 854 Nm (580 TO 630 POUND-FEET)

NOTE: Torque specifications are for clean, dry threads.

After the first 20 hours of operation and after every 500 hours of operation, do the following:

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MAINTENANCE/ADJUSTMENT

Damage to the ROPS If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transpor t), you must replace the damaged ROPS components to get as much protection as you had originally.

After an accident, check the following for damage.

C. Seat belt mounting bolts and seat belt.

Be for e you ope ra te t he mac hin e, replace all ROPS components that are damaged.

See the Parts Catalog or your dealer for components that are replaceable.

D O N OT T RY TO W E L D O R STRAIGHTEN THE ROPS.

A. ROPS canopy or cab.

!

WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this machine SA029

!

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

SB026

!

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

!

WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label SA028

!

WARNING: Always fasten the seat belt securely before starting the engine SA036

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B. Operators seat.

MAINTENANCE/ADJUSTMENT

TORQUE SPECIFICATIONS FOR SEAT AND SEAT BELTS 1

1 TRIM THIS EDGE 6397

1. 73 TO 87 Nm (54 TO 64 LB-FOOT)

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MAINTENANCE/ADJUSTMENT

FAN BELT, ALTERNATOR BELT AND AIR CONDITIONING COMPRESSOR BELT Service Interval Fan belt service interval ......................................................Check every 250 hours Alternator belt service interval.............................................Check every 250 hours Air conditioning compressor belt service interval ................Check every 250 hours 1. Park the machine on a level surface and apply the par king brake.

6. Remove the necessary.

fan

guards

as

7. If machine is equipped with air conditioning loosen the air compressor pivot bolts and remove air conditioning belt.

2. Stop the engine, remove the key, and open the hood.

3. Turn the master disconnect to OFF.

1

1

BD00E004

1. AIR COMPRESSOR PIVOT BOLT

8. Remove alternator belt.

BD00E003

9. Install the new alternator belt.

1. TENSION PULLEY BRACKET

5. Push the breaker bar forward just enough to release the tension on the drive belt. Remove the drive belt from the water pump pulley first and then from the other pulleys.

10. Replace the fan guards.

11. Replace the air conditioning belt.

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4. Install a 1/2 inch breaker bar in the tension pulley bracket.

MAINTENANCE/ADJUSTMENT

FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) Type of Fire Extinguisher It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Cl as s A , B and C ty pe fi r es. Th e operating temperature is from -65° to 120°F (-54° to 49°C).

Inspection and Care EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to i n s ur e t h at t he g a ug e i s wor k i n g correctly.

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EVERY 6 MONTHS - Have the dr y chemical removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

153L95

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS or FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

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MAINTENANCE/ADJUSTMENT

SPARK ARRESTING MUFFLER (IF EQUIPPED) Cleaning

3. Remove the brass plug from the bottom of the muffler.

The spark arresting muffler must be cleaned by removing the loose carbon in the muffler after every 250 hours of operation.

1. Place the transmission shift lever in the NEUTRAL position and engage the park brake.

2. Clean all debris from the machine.

5. Install the plug in the muffler.

6. Clean debris from the machine.

NOTE: Replacement plug (if required) must be of brass material.

WARNING: Exhaust surfaces may be HOT if the engine has been operatedrecently. Be careful not to touch the exhaust serfaces while cleanig the muffler.

M789

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!

4. Start the engine and run for 2 to 3 minutes while debris is ejected from the muffler.

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MAINTENANCE/ADJUSTMENT

NOTES

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ELECTRICAL SYSTEM Battery Safety

!

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046

!

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

!

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

SA033

!

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (1) battery cable first.

2. When you connect the battery cables, always connect the negative (-) cable last.

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

4. Do not weld, grind, or smoke near a battery.

SB034

BATTERY SERVICE NOTE: The electrical system in this machine is 24 volts. Each battery is 12 volts.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Before you use an electric welder, disconnect the alter nator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

Do not run the engine with the battery c a bl e s d i s c o n n e c t e d o r w i t h t h e alternator wires disconnected.

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SB032

ELECTRICAL SYSTEM

Battery Fluid Level Check the fluid level of the batteries every 250 hours of operation. If the fluid level is low, add clean or distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

IMPORTANT: If the temperature is 32°F (0°C) or below and you have added water to the batteries, do the following; Connect a battery charger to the batteries or operate the machine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

Battery Vents Keep the battery vents clean, make sure the vents are not restricted.

Cleaning the Batteries Check the batteries regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries. Use one of the following methods to clean the batteries.

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1. Use Case Battery Saver, Part Number M20376. Follow the instructions on the container. This cleaner does not need water.

2. Use baking soda or ammonia and flush the outside of the batteries with water.

If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

(-) (-)

(+) (-) (+) (+)

(+) (-)

B1060A88

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B1061A88

ELECTRICAL SYSTEM

FUSES The fuses in this machine are blade type. To replace, pull the old fuse straight out and push the new fuse straight in. The amperage for each fuse is stamped on the fuse. Refer to the fuse panel decal for correct location of each fuse.

315096A1

SERVICE ELECTRICAL CONNECTOR (IF EQUIPPED) The cigar lighter socket (24 volt) can be used for the connection of a lighting d ev i c e t o h e l p w i t h s e r v i c e a n d maintenance procedures.

NOTE: This is a 24 volt outlet.

BD00B030

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RD97F154

ELECTRICAL SYSTEM

AUXILIARY POWER OUTLET (IF EQUIPPED) The Auxiliary Power Outlet socket (12 volt) can be used for the connection of a lighting device to help with service and maintenance procedures.

NOTE: This is a 12 volt outlet.

BD00B003

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AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION The auxiliar y power equipment mounting brackets are located behind the right and left ROPS post covers.

Th es e b ra cke ts a r e fo r m o un ti n g radios, phones, etc.

To locate the bottom of the mounting bracket measure 300 mm (11.8 inches) from the bottom edge of the plastic panel. To locate the top of the mounting bracket measure 420 mm (16.5 inches) from the bottom edge of the plastic panel. The mounting bracket is approximately 70 mm (2.75 inches) wide.

1

BD00B009

1. RIGHT ROPS POST COVER

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ELECTRICAL SYSTEM

REPLACEMENT BULBS

Driving Lamp

103654A1

INDUSTRY NUMBER ----

Working Lamp

103653A1

----

Stop and Tail Lamp

24005R1

1662

Directional Lamp

446914

1683

Turn Signal

446914

1683

Dome Lamp (Early Production)

456602

Dome Lamp (Late Production)

395185A1

1692

Console Lamp

---

464

*Rotating Beacon

A187543 (Halogen)

----

Osvam 6429 Phillips 13866

* DO NOT touch the new halogen bulb with your fingers. Use gloves or use a tissue to hold the bulb.

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CASE PART NUMBER

ELECTRICAL SYSTEM

NOTES

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MACHINE STORAGE Storage Preparation

1. Wash the machine.

2. Lubricate the machine at all grease fittings.

3. Paint any areas where the paint has been damaged.

4. Move all hydraulic controls to relieve any pressur e in the hydraulic circuits.

5. Drain the fuel tank.

6. Put approximately 8 litres (2 U.S. Gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue-white.

7. Drain the flushing oil from the fuel tank.

8. Put 15 ml (one tablespoon) of Shell Oil Company VPI crystals in the fuel tank.

10. Drain the cooling system. Leave the drain open and do not tighten the radiator cap. Put a Do Not Operate tag in the cab.

11. Clean or replace the element for the air filter.

primary

12. Cover the exposed steering cylinder rods, equipment valve spools with Case Rust and C o r r o s i o n P r eve n t a t i ve ( Pa r t Number B17510).

13. Charge the batteries. Remove the batteries from the machine and put the batteries on a wooden pallet in a cool dry area. If possible, keep the batteries in a building where the temperature is above freezing (0°C [32°F]). Make sure the batteries are clean.

NOTE: Always wear face protection when checking batteries. Check the batteries periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the batteries.

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If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

9. Change the engine oil and replace the oil filter.

MACHINE STORAGE

Removal from Storage Do not start the engine until steps 1 through 10 have been done.

9. Use petroleum base solvent and remove the Case Rust and Corrosion Preventive from the hydraulic cylinder rods.

1. Change the fuel filter.

2. Put coolant in the engine cooling system.

3. Check the condition of the drive belts. Replace if required.

10. See Battery Service in this manual and install the batteries.

11. Fill the fuel tank.

12. Prime the turbocharger with clean e n g i n e o i l . S e e yo u r S e r v i c e Manual or your dealer.

4. Check the engine oil level.

5. Check the hydraulic oil level.

6. Check the transmission oil level.

7. Check the oil level of both axles.

8. Lubricate the machine at all grease fittings.

13. Start the engine. It is important that you use the Star ting the Engine p r o c e d u r e i n t h i s m a n u a l fo r priming the turbocharger lines with oil.

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SPECIFICATIONS ENGINE DATA Standards

or

Make and model ................................................................................ Case 6T-830 Firing order ........................................................................................... 1-5-3-6-2-4 Air Induction ...................................................................................... Turbocharged Bore and stroke .................................................. 114 x 135 mm (4.48 x 5.32 inch) Displacement ................................................................ 8269 cu. cm (504 cu inch) Compression ratio ..................................................................................... 17.3 to 1 Horsepower SAE gross ......................................... 149 kW at 2000 r/min (200 at 2000 rpm) 142 kW at 2200 r/min (190 at 2200 rpm) SAE net ........................................... 139 kW at 2000 r/min (187 at 2000 rpm) 129 kW at 2200 r/min (173 at 2200 rpm) Engine speeds Full throttle - no load ............................................................ 2375 to 2460 rpm Full throttle - full load ......................................................................... 2200 rpm Idle speed ................................................................................ 920 to 980 rpm Hydraulic stall ...................................................................... 2250 to 2310 rpm Converter stall ..................................................................... 1885 to 2065 rpm Combined hydraulic and converter stall .............................. 1600 to 1825 rpm Valve clearance - engine cold Intake valves ................................................................ 0.305 mm (0.012 inch) Exhaust valves ............................................................ 0.610 mm (0.024 inch) Lubrication System Oil pressure at idle speed (minimum) ...................................... 70 kPa (10 psi) Oil pressure at 1300 rpm .................................. 240 to 310 kPa (35 to 40 PSI) Type of system ............................................................ pressure and spray

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NOTE: All specifications are given according to SAE Recommmended Practices where the specification applies.

SPECIFICATIONS

BUCKET DESCRIPTION

WIDTH

CAPACITIES SAE Heaped m

3

yd

WEIGHT

Struck

3

m

3

yd

kg

pounds

3

General Purpose

2770 mm (109 in)

2.68

(3.50)

2.32

(3.03)

1247

(2750)

Material Handling

2770 mm (109 in)

3.00

(3.92)

2.61

(3.41)

1361

(3000)

4-in-1

2770 mm (109 in)

2.32

(3.04)

1.93

(2.52)

1994

(4396)

TRAVEL SPEEDS (with 20.5 x 25 L3 Tires) FIRST

SECOND

THIRD

FOURTH

km/h

(mph)

km/h

(mph)

km/h

(mph)

km/h

(mph)

Forward

7.2

(4.5)

12.8

(7.9)

23.6

(14.7)

35.5

(22.1)

Reverse

7.6

(4.7)

13.4

(8.4)

24.9

(15.5)

-----

-----

TRAVEL SPEEDS (with 23.5 x 25 L3 Tires) TRIM THIS EDGE

FIRST

SECOND

THIRD

FOURTH

km/h

(mph)

km/h

(mph)

km/h

(mph)

km/h

(mph)

Forward

7.8

(4.9)

13.8

(8.6)

25.4

(15.8)

37.9

(23.5)

Reverse

8.3

(5.1)

14.5

(9.0)

26.8

(16.6)

-----

-----

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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS 821C Specifications taken with 23.5 x 25, 12PR, L2 tires, ROPS cab with heater, 2449 kg (5400 lb) rear counterweight, fenders, standard battery, lights, full fuel, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234, J742, and J818.

D L K

E M

B 7 FT (2.13 m)

A C

H J

G

Machines with 2.67 m3 (3.50 yd3) General Purpose Bucket A. B. C. D. E. F. G. H. J. K. L. M.

B0769A88J

Tipping load, machine straight ............................. 13 645 kg (30 083 pounds) Tipping load, 40 degree turn ................................ 10 992 kg (24 234 pounds) Overall operating height, fully raised ................... 5 348 mm (17 foot 6.6 inch) Height to bucket hinge pin, fully raised ............. 3 952 mm (12 foot 11.6 inch) Dump height, 45 degree dump, full height ............... 2 972 mm (9 foot 9 inch) Dump angle at full height ................................................................ 50 degree Bucket reach, 45 degree dump, full height ............ 1106 mm (3 foot 7.6 inch) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ........................... 1 683 mm (5 foot 6.3 inch) Bucket rollback at ground line ......................................................... 40 degree Digging Depth, bucket edge ................................................. 79 mm (3.1 inch) Wheel Base ................................................................. 3 194 mm (125.8 inch) Tread width (23.5 x 25, 12PR, L2 tires) ............................ 2 083 mm (82 inch) Overall length (without bucket teeth or bolt on cutting edge) ... 7 470 mm (24 foot 6.1 inch) Overall height to top of ROPS cab .................... 3 329 mm (10 foot 11.1 inch) Height to top of exhaust pipe ................................. 3 048 mm (10 foot 0 inch) Height to top of steering wheel ................................ 2 616 mm (8 foot 7 inch) Turning angle from center ......................................................... 40 degree SAE operating weight .......................................... 16 951 kg (37 371 pounds) 213

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F

SPECIFICATIONS

D L K

E M

B 7 FT (2.13 m)

A C

F H J

G

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Machines with 2.29 m3 (3.0 yd3) 4-in-1 Bucket A. B. C.

D. E. F. G. H. J. K. L. M.

B0769A88J

Tipping load, machine straight .............................. 12 551 kg (27 671 pounds) Tipping load, 40 degree turn .................................. 9 988 kg (22 020 pounds) Overall operating height, fully raised ................... 5 265 mm (17 foot 3.3 inch) Height to bucket hinge pin, fully raised ...............3 949 mm (12 foot 11.5 inch) Dump height, 45 degree dump, full height ............. 2 984 mm (9 foot 9.5 inch) Dump height, using clam ..................................... 3 700 mm (12 foot 1.7 inch) Dump angle at full height ................................................................ 50 degree Bucket reach, 45 degree dump, full height ............... 949 mm (3 foot 1.4 inch) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ............................ 1 531 mm (5 foot 0.3 inch) Bucket rollback at ground line ......................................................... 42 degree Digging Depth, bucket edge ............................................... 183 mm (7.2 inch) Digging Depth, at blade ....................................................... 170 mm (6.7 inch) Wheel Base ..................................................................3 194 mm (125.8 inch) Tread width (23.5 x 25, 12PR, L2 tires) ............................. 2 083 mm (82 inch) Overall length (without bucket teeth) ................... 7 432 mm (24 foot 4.6 inch) Overall height to top of ROPS cab ..................... 3 329 mm (10 foot 11.1 inch) Height to top of exhaust pipe .................................. 3 048 mm (10 foot 0 inch) Height to top of steering wheel ................................. 2 616 mm (8 foot 7 inch) Turning angle from center ........................................................ 40 degree SAE operating weight .......................................... 17 698 kg (39 017 pounds)

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SPECIFICATIONS

D L K

E M

B 7 FT (2.13 m)

A C

F

J

G

Machines with 3.06 m3 (4.0 yd3 ) Loose Material Bucket A. B. C. D. E. F. G. H. J. K. L. M.

B0769A88J

Tipping load, machine straight .............................. 13 514 kg (29 794 pounds) Tipping load, 40 degree turn ................................. 10 861 kg (23 944 pounds) Overall operating height, fully raised ................... 5 400 mm (17 foot 8.6 inch) Height to bucket hinge pin, fully raised .............. 3 952 mm (12 foot 11.6 inch) Dump height, 45 degree dump, full height ............ 2 893 mm (9 foot 5.9 inch) Bucket reach, 45 degree dump, full height ......... 1 186 mm (3 foot 10.7 inch) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ........................... 1 724 mm (5 foot 7.9 inch) Bucket rollback at ground line ......................................................... 40 degree Digging Depth, bucket edge.................................................. 79 mm (3.1 inch) Wheel Base ................................................................. 3 194 mm (125.8 inch) Tread width (23.5 x 25, 12PR, L2 tires) ............................ 2 083 mm (82 inch) Overall length (without bucket teeth) ................. 7 584 mm (24 foot 10.6 inch) Overall height to top of ROPS cab ..................... 3 329 mm (10 foot 11.1inch) Height to top of exhaust pipe .................................. 3 048 mm (10 foot 0 inch) Height to top of steering wheel ................................ 2 590 mm (8 foot 6 inch) Turning angle from center ......................................................... 40 degree SAE operating weight .......................................... 17 065 kg (37 621 pounds)

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SPECIFICATIONS

OPERATING DATA AND DIMENSIONS 821C XR Specifications taken with 23.5 x 25, 12 PR, L2 tires, ROPS cab with heater, 2 449 kg (5 400 lb) rear counterweight, fenders, standard battery, lights, full fuel, and a 80 kg (175 lb) operator. Specifications per SAE J732, J1234, J695, J742, and J818.

D L K

E M

B 7 FT (2.13 m)

A C

F

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H J

G

XR Machines with 2.67 m3 (3.50 yd3) General Purpose Bucket A. B. C. D. E. F. G. H. J. K. L. M.

B0769A88J

Tipping load, machine straight .............................. 10 319 kg (22 749 pounds) Tipping load, 40 degree turn ................................... 8 313 kg (18 327 pounds) Overall operating height, fully raised ................... 5 656 mm (18 foot 6.7 inch) Height to bucket hinge pin, fully raised ...............4 259 mm (13 foot 11.7 inch) Dump height, 45 degree dump, full height ........... 3 279 mm (10 foot 9.1 inch) Dump angle at full height ................................................................ 51 degree Bucket reach, 45 degree dump, full height ............ 1 457 mm (4 foot 9.4 inch) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ............................ 2 186 mm (7 foot 2.1 inch) Bucket rollback at ground line ......................................................... 38 degree Digging Depth, bucket edge .............................................. 414 mm (16.3 inch) Wheel Base ..................................................................3 194 mm (125.8 inch) Tread width (23.5 x 25, 12PR, L2 tires) ............................. 2 083 mm (82 inch) Overall length (without bucket teeth or bolt on cutting edge) ........ 8 051mm (26 foot 5 inch) Overall height to top of ROPS cab ...................... 3 329 mm (10 foot 11.1inch) Height to top of exhaust pipe ...................................3 048 mm (10 foot 0 inch) Height to top of steering wheel ................................. 2 616 mm (8 foot 7 inch) Turning angle from center ........................................................ 40 degree SAE operating weight .......................................... 17 134 kg (37 774 pounds) 216

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SPECIFICATIONS

D L K

E M

B 7 FT (2.13 m)

A C

F

J

G

XR Machines with 2.29 m3 (3.0 yd3) 4-In-1 Bucket A. B. C.

D. E. F. G. H. J. K. L. M.

B0769A88J

Tipping load, machine straight ................................ 9 382 kg (20 683 pounds) Tipping load, 40 degree turn ................................... 7 430 kg (16 381pounds) Overall operating height, fully raised ................... 5 572 mm (18 foot 3.4 inch) Height to bucket hinge pin, fully raised .............. 4 257 mm (13 foot 11.6 inch) Dump height, 45 degree dump, full height ........... 3 291mm (10 foot 9.6 inch) Dump height, using clam .................................... 4 008 mm (13 foot 1.8 inch) Dump angle at full height ................................................................ 51 degree Bucket reach, 45 degree dump, full height ........... 1 300 mm (4 foot 3.2 inch) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ........................... 2 034 mm (6 foot 8.1 inch) Bucket rollback at ground line ......................................................... 39 degree Digging Depth, bucket edge.............................................. 518 mm (20.4 inch) Digging Depth, at blade .................................................... 505 mm (19.9 inch) Wheel Base ................................................................. 3 194 mm (125.8 inch) Tread width (23.5 x 25, 12PR, L2 tires) ............................ 2 083 mm (82 inch) Overall length (without bucket teeth) ................... 7 995 mm (26 foot 2.8 inch) Overall height to top of ROPS cab ..................... 3 329 mm (10 foot 11.1inch) Height to top of exhaust pipe .................................. 3 048 mm (10 foot 0 inch) Height to top of steering wheel ................................ 2 616 mm (8 foot 7 inch) Turning angle from center ......................................................... 40 degree SAE operating weight .......................................... 17 881 kg (39 420 pounds)

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H

SPECIFICATIONS

D L K

E M

B 7 FT (2.13 m)

A C

F H J

G

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XR Machines with 3.06 m3 (4.0 yd3) Loose Material Bucket A. B. C. D. E. F. G. H. J. K. L. M.

B0769A88J

Tipping load, machine straight .............................. 10 189 kg (22 463 pounds) Tipping load, 40 degree turn ................................... 8 183 kg (18 041 pounds) Overall operating height, fully raised ................... 5 709 mm (18 foot 8.8 inch) Height to bucket hinge pin, fully raised ...............4 259 mm (13 foot 11.7 inch) Dump height, 45 degree dump, full height .............. 3 200 mm (10 foot 6 inch) Bucket reach, 45 degree dump, full height ............ 1 536 mm (5 foot 0.5 inch) Bucket reach, 45 degree dump, 2134 mm (7 foot) dump height ............................ 2 235 mm (7 foot 4.0 inch) Bucket rollback at ground line ......................................................... 38 degree Digging Depth, bucket edge .............................................. 415 mm (16.3 inch) Wheel Base ..................................................................3 194 mm (125.8 inch) Tread width (23.5 x 25, 12PR, L2 tires) ............................. 2 083 mm (82 inch) Overall length (without bucket teeth) ................... 8 166 mm (26 foot 9.5 inch) Overall height to top of ROPS cab ...................... 3 329 mm (10 foot 11.1inch) Height to top of exhaust pipe ...................................3 048 mm (10 foot 0 inch) Height to top of steering wheel ................................. 2 616 mm (8 foot 7 inch) Turning angle from center ........................................................ 40 degree SAE operating weight .......................................... 17 247 kg (38 024 pounds)

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SPECIFICATIONS

OPERATING WEIGHT ADJUSTMENTS Optional Equipment Item Optional 2 449 kg (5 400 lb) Counterweight ROPS Canopy With Heavy Batteries

(kg) + 54 -134 + 54

Pounds - 120 - 295 - 120

Item 20.5 x 25, 16PR, L2 *+# 20.5 x 25, 16PR, L2 20.5 x 25, 16PR, L3 *+# 20.5 x 25, 16PR, L3 20.5 R 25, XHA TL★ *+# 20.5 R 25, XHA TL★ 20.5 R 25, XTLA TL★ *+# 20.5 R 25, XTLA TL★ 23.5 x 25, 12 PR, L2 23.5 x 25, 12 PR, L3 23.5 R 25, XHA TL★

(kg) - 608 - 184 - 459 - 35 - 415 -6 - 591 - 168 0 + 172 + 390

Pounds - 1340 - 406 - 1012 - 78 - 916 - 18 - 1304 - 370 0 + 380 + 860

* The use of rear tire ballast with the optional 2 449 kg (5 400 lb) rear counterweight is not approved + Rear tires 75% filled with calcuim chloride solution of 2.27 kg (5.0 lbs) calcuim chloride per gallon of water. # Equipped with 1 996 kg (4 400 lb) rear counterweight.

NOTE: It is Case Corporation’s recommendation NOT to add ballast to the tires of your machine. Keep tires inflated to the correct pressure. See Tire Pressure Chart in this manual.

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Tire Weight Adjustments

SPECIFICATIONS

SPECIAL BOLT TORQUES

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Nm Articulation mounting pin keeper.......................... 203 to 244 Articulation Pivot Mounting .................................. 204 to 235 Axle Mounting Bolts (Front and Rear) .................. 884 to 979 Brake Pump Bolts .................................................... 57 to 65 Brake Pump Gear Nut.............................................. 71 to 79 Cab and Canopy Mounting Bolts ......................... 772 to 854 Counterweight Bolt............................................... 814 to 881 Counterweight Stud Nuts (Inside) ........................ 237 to 305 Counterweight Stud Nuts (Outside) ..................... 745 to 881 Engine Mounting Bracket to Engine ....................... 89 to 122 Engine and Transmission Shock Mount Nuts....... 366 to 408 Exhaust Stack to Hood............................................. 27 to 31 Fan Mounting Bolts .................................................. 54 to 60 Flex Plate to Flywheel .............................................. 33 to 41 Front Drive Shaft Yoke Nut ................................... 646 to 714 Hitch Bolts (Class 3) ............................................ 260 to 464 Hydraulic Oil Filter Head to Mounting Bracket ......... 23 to 27 Hydraulic Pump to Transmission.......................... 238 to 258 Hydraulic Tank Cover Bolt ........................................ 20 to 30 Loader Linkage Pin Keeper 5/8 Inch Bolts ........... 203 to 244 Pin Hitch Bolts (Class 3) .................................... 564 to 1001 Oil Cooler Hose Connections................................. 95 to 115 Steering Wheel Nut.................................................. 40 to 47 Transmission to Flywheel Housing........................... 54 to 60 Transmission Mount to Transmission ................... 483 to 592 Trunnion Mounting Pin Bolts ................................ 354 to 422 Universal Joints........................................................ 75 to 82 *Wheel Nuts ......................................................... 515 to 569 NOTE: All bolt torques are listed with dry threads. * See Wheel Nut Torque in this manual.

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POUND-FOOT (150 to 180) (151 to 173) (650 to 720) (42 to 48) (52 to 58) (570 to 630) (600 to 650) (175 to 225) (550 to 650) (66 to 90) (270 to 300) (20 to 23) (40 to 44) (24 to 30) (475 to 525) (192 to 342) (17 to 20) (175 to 190) (15 to 20) 150 to 180) (416 to 738) (70 to 85) (30 to 35) (40 to 44) (355 to 435) (260 to 310) (55 to 60) (380 to 420)

A

B

Access Doors ................................ 137 Accumulators, Brake ..................... 113 After Delivery Check ............. 231, 233 Air Cleaner .................................... 148 Cap ........................................... 148 Air Conditioning Compressor .............................. 179 Compressor Belt ....................... 199 Compressor Seal Lubrication .... 179 Condenser ................................ 179 Condenser Blower Fans Circuit Breakers .................... 179 Indicator ...................................... 44 Temperature Control ................... 80 Air Filter Cab ........................................... 174 Cleaning .................................... 151 Indicator ...................................... 45 Primary Element ....................... 149 Replacement ............................. 149 Secondary Element ................... 149 Service Specifications ............... 148 System ...................................... 148 Air Louvers, Cab ............................. 85 Alternator Belt ............................... 199 Autoshift Switch ......................... 81, 82 Auxiliary Hydraulic Connection ..... 114 Auxiliary Hydraulic System Specifications .......................... 114 Auxiliary Power Equipment Mounting Bracket .... 206 Outlet ........................................ 206 Axle Early Production Oil Change ............................ 170 Oil Level ................................ 168 Service Specifications .......... 168 Late Production Oil Change Front ................................. 172 Rear ................................. 173 Oil Level ................................ 171 Service Specifications .......... 171

Backup Alarm Cancellation Switch ......................................... 82 Ballast, Wheel ............................... 125 Battery Cleaning .................................... 204 Cold Weather Operations ......... 122 Connection, Booster ................... 99 Fluid Level ................................. 204 Safety ........................................ 203 Service ...................................... 203 Vents ......................................... 204 Beacon Indicator ............................. 38 Before Starting The Engine ............. 93 Belt Air Conditioning Compressor .... 199 Alternator .................................. 199 Fan ............................................ 199 Seat ............................... 91, 94, 196 Bleeding the Brake System ........... 163 Blower Fan Switch .......................... 77 Bolt Torques, Special .................... 220 Booster Battery Connection ............ 99 Brake Parking, Check .......................... 186 Parking, Switch ........................... 36 Pedals ......................................... 70 Pressure Indicator ....................... 39 Brake Accumulators ...................... 113 Brake System Bleeding .................................... 163 Bucket Height Control Adjustment ............................ 193 Function ................................ 111 Minor Adjustment .................. 193 Specifications ............................ 212 Bucket Level Indicator ................... 114 Bulbs, Replacement ...................... 207 Button Down Shift ................................... 76

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INDEX

INDEX

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C

D

Cab Air Filter .....................................174 Circulation Cover Early Production ................175 Late Production .................175 Cleaning ................................176 Removal and Installation .......174 Cab Headliner ............................180 Door Hinges ...............................180 Hoses and Wiring ......................180 Operators Seat ..........................181 Service .......................................179 Cap, Air Cleaner ............................148 Caution Master Indicator ..................42 Charts Hydraulic System Fluid ..............158 Lubrication .................134, 135, 136 Maintenance ..............134, 135, 136 Tire Pressure .............................128 Chemicals, Hazardous .....................17 Clutch Calibration Main Codes ................................183 Sub-Codes .................................183 Transmission .............................182 Clutch Cutout .................................113 Components, Machine .......................6 Conditioner, Fuel ............................155 Console Front ..........................33, 34, 35, 37 Side ....76, 77, 78, 79, 80, 81, 82, 83 Controls Air Conditioning Temperature ......80 Blower Fan ...................................77 Hand ..........................33, 34, 35, 37 Heat, Cab .....................................77 Lamp Switch ................................79 Steering Wheel Tilt ......................35 Wiper/Washer Switch ..................78 Coolant Filter, Engine ....................153 Cooling System Cleaning .....................................154 Cold Weather Operations ..........122 Coupler Pin Engagement ...............116 Switch ..........................................83

Decals Informational ............................... 18 Safety .......................................... 18 Declutch Switch ............................... 80 Defrost Air Louvers ......................... 86 Detent On/Off Switch ...................... 80 Diesel Fuel System ....................... 155 Disabled Machine Towing ............. 119 Display Center Lamp, Setting .............................. 65 Transmission .................. 67, 68, 69 Displays, Warning Non - Critical Warning Displays .................................. 42 Door Access ...................................... 137 Hinges ....................................... 180 Latch ........................................... 87 Down Shift Button ........................... 76 Dust Valve ..................................... 148

E Electrical Service Connector .................... 205 Electrical System ........................... 203 Emergency Exit ............................... 92 Engine Data .......................................... 211 Hourmeter ................................. 132 Lubrication ................................ 143 Service Specification ................ 145 Specifications ............................ 211 Speed ......................................... 96 Engine Coolant Cleaning the Cooling System ... 154 Fluid Level ................................ 153 Gauge ......................................... 52 Heater ......................................... 98 Mixture ...................................... 152 Engine Cooling System Coolant Mixture ......................... 152 Service Specifications ............... 152 Specifications ............................ 152 Thermostat ................................ 152

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E

F

Engine Oil Change ..................................... 146 Filter .......................................... 146 Heater ......................................... 98 Level ......................................... 145 Pressure Gauge Early Production ..................... 50 Late Production ...................... 51 Selection ................................... 143 Environment .................................. 131 Exit Emergency .................................. 92 Extinguisher Mounting, Fire .......... 200

Fluid Levels ................................... 140 10 Hours ................................... 140 250 Hours ................................. 142 50 Hours ................................... 141 Engine Coolant ......................... 153 Radiator .................................... 153 Foot Pedals Brake Pedals ............................... 70 Foot Throttle ................................ 70 Four-Way Flasher Lamp ........................................... 38 Switch ......................................... 33 Front Console ................ 33, 34, 35, 37 Four-Way Flasher ....................... 33 Horn ............................................ 35 Key/Ignition Switch ...................... 37 Park Brake Switch ....................... 36 Pilot Control Switch ..................... 33 Program/Reset Switch ................ 33 Steering Wheel Tilt Control ......... 35 Transmission Control Lever ........ 34 Turn Signal .................................. 35 Up/Down Count Switch ............... 33 Fuel Conditioner ............................ 155 Fuel Filter ...................................... 157 Fuel Level Gauge ............................ 49 Fuel Storage .................................. 156 Fuel System Cold Weather Operations ......... 122 Diesel Fuel Specifications ......... 156 Fuel Conditioner ........................ 155 Fuel Filter .................................. 157 Fuel Storage ............................. 156 Removing Water ....................... 157 Service Specifications ............... 155 Fuse Panel .................................... 205 Fuses ............................................ 205

F Fact Attachment ............................ 116 Fan Belt ......................................... 199 Filter Air .............................................. 149 Cab Air ...................................... 174 Coolant ...................................... 153 Engine Coolant ......................... 153 Engine Oil ................................. 146 Fuel ........................................... 157 Hydraulic Oil .............................. 160 Transmission Oil ....................... 166 Filter Replacement Air .............................................. 149 Engine Coolant ......................... 153 Engine Oil ................................. 146 Hydraulic Oil .............................. 160 Transmission Oil ....................... 166 Fire Extinguisher Mounting ........... 200 Fire Prevention Information ............. 15 First Service Intervals ...................... 94 Fittings, Grease 100 Hours ................................. 139 1000 Hours ............................... 139 50 Hours ................................... 138 Float .............................................. 112 Fluid and Lubricants ...................... 133

G Gauge Displays ...................................

60, 61, 62, 63, 64, 65, 66 Programming .............................. 61

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INDEX

INDEX

G

I

Gauges Engine Coolant ............................52 Engine Oil Pressure Early Production ......................50 Late Production .......................51 Fuel Level ....................................49 HydraulicOil Temperature ............47 Transmission Oil Temperature ....46 Volt Meter ....................................48 General Safety ...............................129 Grease Fittings 100 Hours ..................................139 1000 Hours ................................139 50 Hours ....................................138

Indicator Air Conditioning .......................... 44 Air Filter ...................................... 45 Beacon ........................................ 38 Brake Pressure ........................... 39 Caution Master ........................... 42 Hydraulic Oil Filter ...................... 45 Lamp ........................................... 39 Low Coolant ................................ 39 Parking Brake ............................. 44 Pilot Lockout ............................... 39 Secondary Steering Master ........ 44 Stop Master ................................ 40 Transmission Oil Filter ................ 45 Indicator Lamps ...................................

38, 39, 40, 42, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53 Information Center ..............................

54, 55, 56, 57, 58, 59 Programming .............................. 55 Informational Decals ....................... 18 Instructions, General Safety .......... 129 Instrument Panel .................................

38, 39, 40, 42, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53 Indicator Gauges Engine Coolant ....................... 52 Engine Oil Pressure Early Production ................. 50 Late Production .................. 51 Fuel Level ............................... 49 Hydraulic Oil Temperature ...... 47 Transmission Oil Temperature ....................... 46 Volt Meter ............................... 48

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Hand Signals ....................................29 Heat Control, Cab ............................77 Horn .................................................35 Hoses and Wiring ...........................180 Hot Weather Operation ..................124 Hourmeter, Engine .........................132 Hydraulic Connection Auxiliary ...................................114 Hydraulic Filter Test .......................159 Hydraulic Oil Filter ...........................................160 Filter Indicator ..............................45 Temperture Gauge ......................47 Hydraulic System Filter Replacement .....................160 Fluid Chart .................................158 Hydraluic Filter Test ...................159 Hydraulic/Brake Oil Change ......161 Service Specifications ................158 Hydraulic/Brake Oil Change ...........161

I Identification Numbers .......................4

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Instrument Panel - continued Indicator Lamps Air Conditioning ...................... 44 Air Filter .................................. 45 Brake Pressure ....................... 39 Caution Master ....................... 42 Four-Way Flasher ................... 38 Hydraulic Oil Filter .................. 45 Lamp Indicator ........................ 39 Low Coolant ............................ 39 Parking Brake ......................... 44 Pilot Lockout ........................... 39 Rotating Beacon ..................... 38 Secondary Steering ................ 44 Stop Master ............................ 40 Transmission Oil Filter ............ 45 Turn Signal ............................. 38

Loader Control Levers Four Spool - Two Levers ............. 75 Four Spool Valve - Two Control Levers ...................... 109 Three Spool - Three Levers ........ 73 Three Spool - Two Levers ........... 74 Three Spool Valve - Three Control Levers ...................... 106 Three Spool Valve - Three Control Levers - Optional Forestry Configuration .......... 107 Three Spool Valve - Two Control Levers ...................... 108 Two Spool - One Lever ............... 71 Two Spool - Two Levers ............. 72 Two Spool Valve - One Control Lever ........................ 105 Two Spool Valve - Two Control Levers ...................... 104 Loader Function Switches ............. 110 Loader Operating Tips .................. 117 Leveling Operation .................... 117 Pushing Operation .................... 117 Scraping Operation ................... 117 Transport and Carry Operation .............................. 118 Loader Operations Cold Weather ............................ 122 Louvers, Air Defrost ........................................ 86 Main ............................................ 85 Recirculation ............................... 85 Low Coolant Indicator ..................... 39 Lubrication Analysis, Systemgard ..................... 130, 147 Lubrication Chart ........... 134, 135, 136 Lubrication, Engine ....................... 143

J Jump Start ....................................... 99

K Key Switch, Ignition ......................... 37

L Lamp Four-Way Flasher ....................... 38 Turn Signal .................................. 38 Lamp Indicator ................................ 39 Lamp Switch, Cab ........................... 79 Latch Door ............................................ 87 Window ....................................... 87 Window Retainer ......................... 88 Levers Loader Control ............................ 71 Transmission Control .................. 34 Turn Signal .................................. 35 Link Safety ........................................ 131 Transport ................................... 131 Loader Adjustments Return-To-Dig ........................... 188 Return-To-Travel ....................... 190

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INDEX

INDEX

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Machine Components ........................6 Machine Operation Before Operating .......................100 Transmission Operation .............102 Machine Storage ............................209 Removal .....................................210 Storage Preparaton ...................209 Machine Tie Down Locations .........121 Main Air Louvers ..............................85 Maintenance and Inspection of ROPS ..................................196 Maintenance Chart .........134, 135, 136 Master Disconnect Switch ................84 Muffler Cleaning .....................................201 Spark Arresting ..........................201

Operator Manual Storage Compartment .............................. 2 Operators Seat ........................ 88, 181 Optional Equipment ....................... 219 Owner, To The .................................. 1

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P Parking Brake Check ........................................ 186 Indicator ...................................... 44 Switch ......................................... 36 Parking The Machine ...................... 97 Pedals, Foot .................................... 70 Pilot Control Switch ......................... 33 Pilot Lockout Indicator ..................... 39 Plastic and Resin Parts ................. 130 Power Outlet, Auxiliary .................. 206 Pressure, Tire ................................ 125 Primary Element, Air Filter ............ 149 Product Identification Number ........... 4 Program/Reset Switch .................... 33 Programming Display Center Lamp, Setting ..... 65 Gauge Display ............................ 61 Information Center ...................... 55

Official Justifying Documents ..............8 Oil Change Axle Early Production ....................170 Late Production Front ..................................172 Rear ..................................173 Engine ........................................146 R Oil Level Radiator Axle ............................................168 Fluid Level ................................ 153 Late Production .....................171 Radio ............................................... 87 Engine ........................................145 Rear Fog Lamp Switch .................... 83 Transmission .............................166 Rear Wiper/Washer Switch ............. 81 Oil Selection, Engine ......................143 Reservoir, Windshield Washer ...... 177 Oil Viscosity/Temperature Return-To-Dig Ranges ....................................144 Adjustment ................................ 188 Operating Data Function .................................... 110 821C ..........................................213 Return-To-Travel ........................... 111 821CXR .....................................216 Adjustments ..............................

190 Operating Dimensions Minor Adjustments ....................

190 821C ..........................................213 Switch .........................................

80 821CXR .....................................216 Ride Control ..................................

115 Operating In Hot Weather ..............124 Switch ......................................... 81 Operating Instructions ......................93 Roll-Over Protective Structure ...... 196 Before Starting The Engine .........93 Operating The Machine .................100 Operating Tips - Loader .................117 Operating Weight Adjustments ......219 226

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ROPS ............................................ 196 Damage Information ................. 197 Maintenance and Inspection ..... 196 Seat Torque Specifications ........... 198 Seat Belt ................................... 196 Torque Specifications ........... 198 Specifications Canopy Torque ..................... 196 Cap Torque ........................... 196 Rotating Beacon ............................ 115 Switch ......................................... 82 Run-In Procedure ............................ 93

Sediment Removal, Fuel System .................................... 157 Serial Numbers ................................. 4 Service Electrical Connector ......... 205 Service Intervals - First .................... 94 Service Safety Link ....................... 131 Side Console .......................................

76, 77, 78, 79, 80, 81, 82, 83 Air Conditioning Temperature ..... 80 Autoshift Switch .......................... 81 Backup Alarm Cancellation Switch ..................................... 82 Blower Fan Switch ...................... 77 Coupler Pin Engage Switch ........ 83 Declutch Switch .......................... 80 Detent On/Off Switch .................. 80 Down Shift Button ....................... 76 Heat Control ................................ 77 Lamp Switch ............................... 79 Rear Fog Lamp Switch ............... 83 Rear Wiper/Washer Switch ......... 81 Return-To-Travel Switch ............. 80 Ride Control Switch .................... 81 Rotating Beacon Switch .............. 82 Wiper/Washer Switch .................. 78 Wrist Rest ................................... 77 Wrist Rest, Adjustment ............... 77 Spark Arresting Muffler .................. 201 Specifications 821C Machines 4-In-1 Bucket ........................ 214 General Purpose Bucket ...... 213 Loose Material Bucket .......... 215 821CXR Machines 4-In-1 .................................... 217 General Purpose Bucket ...... 216 Loose Material Bucket .......... 218 Air Filter ..................................... 148 Auxiliary Hydraulic System ....... 114 Axle ................................... 168, 171 Bolt Torques, Special ................ 220 Bucket ....................................... 212 Cooling System, Engine ............ 152 Diesel Fuel System ................... 155

S Safety Instructions, General .......... 129 Safety Link, Service ...................... 131 Safety Rules ...................................... 9 Before Operation ......................... 12 Burn Prevention .......................... 15 Fire/Explosion Prevention ........... 15 Hand Signals ............................... 29 Hazardous Chemicals ................. 17 Informational Decals ................... 18 Machine Operation ...................... 13 Maintenance ............................... 14 Parking the Machine ................... 13 Safety Decals .............................. 18 Utility ..................................... 10, 11 Wheels and Tires ........................ 16 Safety, Battery ............................... 203 Safety/Decals/Hand Signals .............. 9 Seat Belts .............................. 91, 94, 196 Inspection and Care ............... 92 Operators ............................ 88, 181 Optional Air Ride ......................... 89 Standard ..................................... 88 Torque Specifications ............... 198 Seat Belt Torque Specifications ............... 198 Secondary Element, Air Filter ....... 149 Secondary Steering Master Indicator .................................... 44

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INDEX

INDEX

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S

S

Specifications - continued Dimensions 821C ......................................213 821CXR .................................216 Engine Cooling System .............152 Engine Data ...............................211 Engine Service ...........................145 Fuel System ...............................155 Hydraulic System .......................158 Operating Data 821C ......................................213 821CXR .................................216 Operating Weight Adjustments ...........................219 Optional Equipment ...................219 ROPS Torque ............................196 Seat Belt Torque ........................198 Seat Torque ...............................198 Thermostat .................................152 Tire Weight ................................219 Transmission .............................165 Travel Speeds ............................212 Starting The Engine .........................95 Steering Wheel Tilt Control ..............35 Steering, Secondary ......................185 Stop Master Indicator .......................40 Stopping The Engine .......................97 Storage Compartment Operator Manual ............................2 Storage, Fuel .................................156 Storage, Machine Preparation ................................209 Removal .....................................210 Switch Autoshift .......................................81 Backup Alarm Cancellation ..........82 Blower Fan ...................................77 Coupler Pin Engage .....................83 Declutch .......................................80 Detent On/Off ...............................80 Four-Way Flasher ........................33 Key/Ignition ..................................37 Lamp ............................................79

Switch - continued Loader Function ........................ 110 Bucket Height Control ........... 111 Float ...................................... 112 Return-To-Travel .................. 111 Master Disconnect ...................... 84 Park Brake .................................. 36 Pilot Control ................................ 33 Program/Reset ............................ 33 Rear Fog Lamp ........................... 83 Rear Wiper/Washer .................... 81 Return-To-Travel ........................ 80 Ride Control ................................ 81 Rotating Beacon ......................... 82 Up/Down Count .......................... 33 Wiper/Washer ............................. 78 Systemgard Analysis ............. 130, 147

T Thermostat Specifications ............. 152 Throttle, Foot ................................... 70 Tire Or Rim Service ....................... 127 Tire Pressure ................................. 125 Chart ......................................... 128 Tire Tread Direction ...................... 127 Tire Weight Adjustments ............... 219 Tires, Adding Air ............................ 127 Torque - Wheel Nut ....................... 128 Towing, Machine ........................... 119 Transmission Breather Cleaning ..................... 166 Clutch Calibration ..................... 182 Main Codes .......................... 183 Sub-Codes ............................ 183 Cold Oil Level Check ................ 166 Control Lever .............................. 34 Display Center ................ 67, 68, 69 Filter Replacement .................... 166 Oil Change ................................ 166 Oil Level .................................... 166 Operation of .............................. 102 Service Specifications ............... 165 Warm Oil Level Check .............. 166

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Transmission Oil Filter .......................................... 166 Filter Indicator ............................. 45 Level ......................................... 166 Check ................................... 166 Temperture Gauge ...................... 46 Transmission Operation Automatic Mode Operation ....... 103 Down-Shift Button Automatic Mode .................... 103 Manual Mode ........................ 102 Down-Shifts Manual Mode ........ 102 Manual Mode Operation ........... 102 Shifting, Automatic Mode .......... 103 Up-Shifts Manual Mode ............ 102 Transport Link ............................... 131 Transporting The Machine ............ 120 On A Trailer ............................... 121 Travel Speeds ............................... 212 Turbocharger Priming the Lines with Oil ........... 96 Turn Signal Lamp ........................................... 38 Lever ........................................... 35

Warning Displays Non - Critical Warning Displays .................................. 42 Water Removal, Fuel System ........ 157 Weight Adjustments Operating .................................. 219 Optional Equipment .................. 219 Tire Weight ................................ 219 Wheel And Tires ............................ 125 Wheel Ballast ................................ 125 Wheel Nut Torque ......................... 128 Window Latch ........................................... 87 Retainer Latch ............................. 88 Windshield Washer Reservoir ....... 177 Wiper/Washer Switch ...................... 78 Wrist Rest ........................................ 77 Adjustment Knob ......................... 77

U Up/Down Count Switch ................... 33 Utility Safety .............................. 10, 11

V Volt Meter Gauge ............................ 48

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INDEX

INDEX

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AFTER DELIVERY CHECK AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Hourmeter Indication:

Machine Model Number: Machine Product Identification Number (P.I.N.): COOLING SYSTEM

HYDRAULIC SYSTEM

Check the coolant levels.

Check the oil level.

Check for leaks.

Check the pressure setting of the main relief valve.

Replace the hydraulic oil filter.

FUEL SYSTEM

GENERAL

Drain water and sediment from the fuel tanks.

Look for oil leaks and loose parts.

Check tire pressure.

ELECTRICAL SYSTEM Check battery.

Tighten all hose clamps.

Check operation of starter, alternator, and instruments.

Check drive chain tension..

Check operation of all lamps.

Check brake operation.

Check wheel nut torque.

LUBRICATION

Check the control levers for correct operation.

Check the operators seat bar for correct operation.

Lubricate all pivot points.

Engine SAFETY

Check condition of drive belt.

Check engine oil level.

Inspect the ROPS.

Check engine speed at idle and at full throttle.

Check the safety decals and replace if necessary.

Service air cleaner.

Check the operator restraint system.

Make sure the machine has the operators manual in the manual storage box.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature: Dealer Copy

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Check for leaks.

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AFTER DELIVERY CHECK AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Hourmeter Indication:

Machine Model Number: Machine Product Identification Number (P.I.N.): ENGINE

HYDRAULIC SYSTEM

Check the engine oil level.

Check for leaks.

Check air cleaner.

Tighten all hose clamps.

Check the reservoir oil level.

COOLING SYSTEM

GENERAL

Check the coolant level of radiator and coolant reservoir.

FUEL SYSTEM

Check the operation of the brakes.

Check the control levers for correct operation.

SAFETY

Check for leaks.

Check the safety and information decals.

Drain water and sediment from the fuel tanks.

Check the torque of ROPS and seat belt mounting bolts.

ELECTRICAL SYSTEM

Make sure the 550H Operator’s Manual and Safety Manual are in the Manual Storage Box.

Check operation of starter, alternator, and instruments.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

Check oil level of final drives.

Check transmission oil level.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature: Owner Copy

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Tighten all hose clamps.

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