Case 821E Wheel Loader Operator's Manual 75314524 - PDF DOWNLOAD

821E

Wheel Loader

Operator’s Manual

75314524 4th Edition English 12/2014

A CNH INDUSTRIAL LATIN AMERICA LTDA. Reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations.

Dimensions and weights are only approximate.

Illustrations do not necessarily show products in standard condition.

For exact information about any particular product, please consult your Dealer.

Wheel Loader 821E 75314524 4th Edition English 12/2014

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

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

!

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

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

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

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

!

WARNING

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

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

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

•• Has emptied the area.

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

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

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TABLE OF CONTENTS TO THE OWNER ............................................................................................... 1 WHEEL LOADERS ............................................................................................... 1 OPERATOR MANUAL STORAGE COMPARTMENT .................................................. 2 RIGHT, LEFT, FRONT AND REAR OF THE MACHINE ............................................... 3 IDENTIFICATION NUMBERS ................................................................................. 4 MACHINE COMPONENTS ..................................................................................... 6

INSTRUMENTS AND CONTROLS ................................................................. 33 FRONT CONSOLE ............................................................................................. 33 LCD MULTI-FUNCTION DISPLAY ......................................................................... 46 FOOT PEDALS .................................................................................................. 58 LOADER CONTROL LEVERS .............................................................................. 59 SIDE CONSOLE ................................................................................................. 63 OPERATORS SEAT ............................................................................................ 75 SEAT BELT ....................................................................................................... 78 OPERATING INSTRUCTIONS ....................................................................... 81 OPERATING THE MACHINE ................................................................................ 81 CONTROL LEVERS ............................................................................................ 92 LOADER FUNCTION SWITCHES ......................................................................... 96 BRAKE ACCUMULATORS ................................................................................... 99 LOADER OPERATING TIPS .............................................................................. 103 TRANSPORTING THE MACHINE ....................................................................... 106 LUBRICATION/FILTERS/FLUIDS ................................................................ 113 SERVICING INSTRUCTIONS ............................................................................. 113 SUPPORT STRUT FOR LOADER LIFT ARMS ...................................................... 115 FLUIDS AND LUBRICANTS ............................................................................... 116 ENGINE OIL VISCOSITY/TEMPERATURE RANGES ............................................. 117 DAILY INSPECTIONS ....................................................................................... 121 LUBRICATION AND MAINTENANCE CHART ....................................................... 122 ACCESS DOORS AND FILL LOCATIONS ............................................................ 124 MAINTENANCE AND ADJUSTMENTS ....................................................... 157 SECONDARY STEERING CHECK (IF EQUIPPED) ................................................ 163 PARKING BRAKE CHECK ................................................................................. 164 OPERATOR PROTECTIVE STRUCTURE ............................................................ 171 OPERATOR PROTECTIVE STRUCTURE ............................................................ 172

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SAFETY / DECALS / HAND SIGNALS ............................................................ 9 SAFETY RULES ................................................................................................... 9 PERSONAL SAFETY .......................................................................................... 10 UTILITY SAFETY ............................................................................................... 10 DECALS ........................................................................................................... 21

TABLE OF CONTENTS _____________________________________________

ELECTRICAL SYSTEM ................................................................................ 175 REPLACEMENT FUSES ................................................................................... 178 SERVICE ELECTRICAL CONNECTOR (IF EQUIPPED) ......................................... 179 AUXILIARY POWER OUTLET (IF EQUIPPED) ...................................................... 179 AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION ..................... 180 SPECIFICATIONS ......................................................................................... 181 821E .............................................................................................................. 181 OPTIONAL EQUIPAMENT ................................................................................. 194 INDEX ............................................................................................................. 195 AFTER DELIVERY CHECK ......................................................................... 201

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TO THE OWNER

BD06F007

821E

DO NOT use this machine for any application or purpose other than those described in this manual. If the loader is to be used in an application that involves special attachments or equipment, such as forestry, etc., consult an authorized dealer. Consult an authorized dealer on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications 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 your dealer to obtain additional manuals. Contact your dealer for any further information or assistance about your machine. Your dealer has Case approved service parts. Your dealer has technicians with special training that know best methods of repair and maintenance for your Wheel Loader.

Before permitting a new operator on this machine, make sure: • That the operator has received the necessary training on how to operate the machine correctly and safely.

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

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

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

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WHEEL LOADERS

TO THE OWNER _________________________________________________

OPERATOR MANUAL STORAGE COMPARTMENT When you see this symbol read your Operator’s Manual.

When you see this symbol refer to your Service Manual.

BD06F071

Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

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

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• The first panel indicates the nature of the hazard.

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

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

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

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

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and

_________________________________________________ TO THE OWNER

RIGHT, LEFT, FRONT AND REAR OF THE MACHINE The terms Right-hand, Left-hand, Front, and Rear are used in this manual to indicate the sides as they are seen from the operator's seat.

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B891464

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4.

LEFT-HAND FRONT RIGHT-HAND REAR

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TO THE OWNER _________________________________________________

IDENTIFICATION NUMBERS Write the Product Identification Number (P.I.N.) and the engine serial number on the lines provided below. If needed, give these numbers to your Case dealer when you need parts or information for your machine. Keep a record of these numbers and your Manufacturers 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_____________________________________________________ ROPS CAB _________________________________________________________________ TRANSMISSION _____________________________________________________________ FRONT AXLE _______________________________________________________________ REAR AXLE_________________________________________________________________ STANDARD LOADER BUCKET (Part Number) _____________________________________ TRIM THIS EDGE

Product Identification Number (P.I.N.)

Engine

BD06F092 BD06F166

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Transmission

Axle

BD02N124

BD02N126

Standard Axle- until serial HBZN821ELBAE00873

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Axle

Standard Axle - starting HBZN821ELBAE00874

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with

serial

TO THE OWNER _________________________________________________

MACHINE COMPONENTS 4

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1 1 2

8 4PA82100409

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CAB DOOR AND HAND HOLDS STEPS BUCKET BELLCRANK BUCKET CYLINDER ROPS CAB ENGINE HOOD LEFT BATTERY ACCESS

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4 5

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4PA82100401

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2.

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5.

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RIGHT SIDE BATTERY COMPARTMENT ENGINE HOOD CAB AIR FILTER ACCESS FRONT CONSOLE LOADER LIFT ARM LOADER LIFT CYLINDER

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TO THE OWNER _________________________________________________

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SAFETY / DECALS / HAND SIGNALS SAFETY RULES

!

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

M171C

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.

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.

BD06F071

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

OPERATOR’S MANUAL STORAGE SPACE

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

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

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

SAFETY/DECALS/HAND SIGNALS ___________________________________

PERSONAL SAFETY ISO two panel pictorial symbol decals are defined as follows:

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

• The first panel indicates the nature of the hazard.

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

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

• Background color is YELLOW.

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

Prohibition symbols such as , if used, are RED. STOP

and

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

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

Safety precaution MUST be followed when working near buried and overhead utility lines.

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

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

• Electrical Power Line

In U.S.A. and Canada call one of many “One Call System Director” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888258-0808.

• Gas Line • Water Line • Communication Line - Telephone or Cable Television

IMPORTANT: Check with local authori-

• Sewer Line

ties for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

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___________________________________ SAFETY/DECALS/HAND SIGNALS

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

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

• Certain protective equipment should be replaced and renewed upon age and wear.

Old hard hats may not afford the original users intention. Faded and soiled vest are no longer as highly visible as original intent.

See the manufacture’s recommendation.

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

• Do not rush. Walk, do not run.

Know the utility color code (U.S.A. and Canada): Electric...................................................Red Gas, Oil, or Petroleum........................Yellow Communication, Telephone, Television.... Orange Water .................................................... Blue Sewer ..................................... Green/Brown Proposed Excavation .......................... White Surveying.............................................. Pink Reclaimed Water and Slurry...............Purple

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

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

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• Know and use the protective equipment that is to be worn when operating this machine.

Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of type of equipment that may be required.

SAFETY/DECALS/HAND SIGNALS ___________________________________

General

Mounting and Dismounting Precautions

• It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• DO NOT OPERATE this machine or perform maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

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

BD06F163

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

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

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

• Do not jump off the machine.

• Make sure that all protective guards, canopies, doors, etc. are in place and secure.

• Do not dismount while the machine is in motion.

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

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

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

Starting and Stopping Precautions • Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting.

Do not start until all personnel are clearly away from the machine. Sound the horn, if equipped, before starting.

• Before leaving the operator’s station, lower the equipment to the ground, shut off the engine and place the function cancellation lever into the locked or up position.

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

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

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

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

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

• Do not bypass the machine’s neutral-start system. The neutral-start system must be repaired if it malfunctions.

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

• Use jumper cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion. Ventilate the battery area before using jumper cables. Make sure that using jumper cables will not interfere or harm electronic processing or computer devices.

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

• DO NOT OPERATE the engine in an enclosed area without adequate ventilation.

• Operate and drive the machine with care and at speeds compatible with conditions.

Use extra caution when operating over rough ground, on slopes, and when turning.

• Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

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Operating Precautions

• Check that the parking brake is applied, place the transmission in neutral or park as specified by the manufacturer, and disengage the PTO, if so equipped, before starting the machine.

SAFETY/DECALS/HAND SIGNALS ___________________________________ • Carry loads in recommended positions for maximum stability.

• Use the recommended transport devices when roading the machine.

• Never lift loads in excess of capacity.

• Use the approved drawbar and / or attachment point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Use the recommended machine ballast and counterweighting.

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

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

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

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

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

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• Watch for bystanders and never allow anyone to be under or to reach through the machine and its equipment while operating.

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

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

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

• When roading a machine, know and use the signaling devices required on the machine.

Provide and escort for roading where required.

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

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

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

• Keep machine and attachments a safe distance from electrical power lines as per the following instructions.

VOLTAGE (VOLTS) SAFETY DISTANCE 10 ft. (3,0 m)

50 k TO 200 kV

15 ft. (4,5 m)

200 k TO 350 kV

20 ft. (5,0 m)

350 k TO 500 kV

25 ft. (7,5 m)

500 k TO 750 kV

35 ft. (10,5 m)

750 k OR OVER

45 ft. (13,5 m)

• DO NOT OPERATE the machine if you do not feel well. This can be dangerous for you and for the people around you.

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

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

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

• 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.

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

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

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

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50 k OR LESS

SAFETY/DECALS/HAND SIGNALS ___________________________________ • Use extreme caution when removing radiator, reservoir, or tank caps, drain plugs, grease fittings or pressure taps. Park the machine and let it cool down before opening a pressurized tank.

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

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

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

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

• Wear protective glasses and other required safety equipment when servicing or repairing the machine.

• Wear gloves to protect hands when handling cable.

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

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

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a towbar must be used or two towing machines must be used - one in front pulling and one in the rear to act as a brake.

Avoid towing over long distances.

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

• Observe proper maintenance procedures.

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

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alt: Use a brass hammer, drift or suitable material on the pin, etc.

• To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges.

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

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

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

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___________________________________ SAFETY/DECALS/HAND SIGNALS

Fuel handling precautions

• Clean up spilled fuel immediately and dispose of contaminated material in an environmentally correct manner.

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

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

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

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

!

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

Antidote: EXTERNAL - Flush with water.

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

DO NOT induce vomiting. Seek medical attention immediately.

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

BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. M144B • 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.

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

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Burn prevention

SAFETY/DECALS/HAND SIGNALS ___________________________________

Hazardous chemical precautions

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

• 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.

Roll-over protective structure (if equipped)

• 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.

Do NOT modify the ROPS in any manner.

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

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• 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.

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

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

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

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___________________________________ SAFETY/DECALS/HAND SIGNALS 2. Tighten the seat belt by pulling on the loose end on the right-hand seat belt.

Seat belt precautions 1

2

BD06G176

BD06G176

1. RIGHT-HAND BELT STRAP 2. LATCH MECHANISM

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

!

!

WARNING: Before starting the engine ensure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system.

Never wear the belt in a twisted condition or pinched between the seat structural members.

M422A WARNING: Securely fasten your seat belt. Your machine is equipped with a ROPS cab 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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3. To unlatch the seat belt, press the red button on the left-hand side latch mechanism.

SAFETY/DECALS/HAND SIGNALS ___________________________________

Specific precautions to this machine • Keep the load or tool as low as possible while moving the machine around the jobsite.

• Never smoke while refuelling.

• Prior to any maintenance, service work or transportation, lock the articulation Transport Service link.

BD06G098

TRANSPORT / SERVICE LINK IN OPERATING POSITION

• Always use the loader arm support strut if service is necessary with the arms off the ground.

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BD06G099

TRANSPORT / SERVICE LINK LOCKED

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___________________________________ SAFETY/DECALS/HAND SIGNALS

DECALS

! !

WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary.

CE-NA000 WARNING: Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible, with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part.

CE-NA000

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

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

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

• Background color is YELLOW. • Prohibition symbols such as

and

STOP

if used, are RED.

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

SAFETY/DECALS/HAND SIGNALS ___________________________________

1 3

1 2

2

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3

DSC09555 / 323695A1 / 407741A1 / 187864A1

1. WARNING - CRUSH HAZARD - Keep clear.

2. DANGER - CRUSH HAZARD - Always install Lift Arm Support during maintenance or repair.

3. Lubrication points - grease

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___________________________________ SAFETY/DECALS/HAND SIGNALS

4 3 2

5 1

1

2

4

5

DSC09555 / DSC09557 / 329048A1 / 329050A1 / 328903A1 / 379186A1 / 333269A1

1. WARNING - CRUSH HAZARD - Engage lock link before service or transport 2. CAUTION - RUNOVER HAZARD - Block wheels to prevent machine movement before disengaging park brake for towing.

3. WARNING - PRESSURIZED SYSTEM HAZARD Relieve pressure before maintenance.

4. WARNING - PRESSURIZED SYSTEM HAZARD Relieve pressure before maintenance.

5. Transmission oil specification

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3

SAFETY/DECALS/HAND SIGNALS ___________________________________

1 1

DSC09588 / 332511A1

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1. WARNING - ENTANGLEMENT HAZARD - Keep clear or stop engine before servicing.

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___________________________________ SAFETY/DECALS/HAND SIGNALS

1

2

1

DSC09575 / 332511A1 / 334455A1

1. WARNING - ENTANGLEMENT HAZARD Keep clear or stop engine before servicing.

2. DANGER - Start engine from operator's seat. Transmission in NEUTRAL.

1

1

BD06G101 / 412476A1

ONE EACH SIDE 1. DANGER - EXPLOSION HAZARD - Read procedure in Operator's Manual before jump start or service to avoid injury.

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2

SAFETY/DECALS/HAND SIGNALS ___________________________________

1 1

3 TRIM THIS EDGE

2

2

3

BD06F001 / 329045A1 / 333269A1 / 332511A1

1. WARNING - HOT LIQUID UNDER PRESSURE HAZARD - Service when cool.

2. WARNING - PRESSURIZED SYSTEM HAZARD - Relieve pressure before maintenance.

3. WARNING - ENTANGLEMENT HAZARD - Keep clear or stop engine before servicing.

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___________________________________ SAFETY/DECALS/HAND SIGNALS

1

1

2

3

3

2

DSC09568 / 387149A1

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1. Engine oil drain 2. Engine cooling system water drain 3. Hydraulic system drain

1

1 2

DSC09569 / 87524649

1. Engine Hood - Open/Close 2. Master Switch

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SAFETY/DECALS/HAND SIGNALS ___________________________________

1

2

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1

2

BD06F149 / 412426A1 / 328903A1

1. DANGER - CRUSH HAZARD KEEP CLEAR - Always install Lift Arm Support during maintenance or repair.

2. WARNING - PRESSURIZED SYSTEM HAZARD - Relieve pressure before maintenance.

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___________________________________ SAFETY/DECALS/HAND SIGNALS

1 2

2 TRIM THIS EDGE

1

DSC09628 / 323695A1 / 333269A1 / 407741A1

1. WARNING - PRESSURIZED SYSTEM HAZARD - Relieve pressure before maintenance.

2. WARNING - CRUSH HAZARD - Keep clear.

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SAFETY/DECALS/HAND SIGNALS ___________________________________

1

4

3 2

1 2 3

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4

DSC09580 / 328753A1 / 139728A1 / 87688774 / 388113A1

1.

2.

3.

4.

DANGER - RUNOVER HAZARD - Keep clear of machine.

Tie hook Maintenance Schedule WARNING - ENTANGLEMENT HAZARD - Keep clear or stop engine before servicing.

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___________________________________ SAFETY/DECALS/HAND SIGNALS

1

DSC09661 / 386241A1

1. WARNING - AVOID CRUSHING DO NOT JUMP if machine tips USE SEAT BELT

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1

SAFETY/DECALS/HAND SIGNALS ___________________________________

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INSTRUMENTS AND CONTROLS FRONT CONSOLE

1

2

BD06F223

Push on the LH side of the switch to disable the pilot controls, the pilot control lamp will BC00B048 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.

Push the RH side of the of the flasher switch to actuate the BC00B087 flashers. Push the LH side of the flasher switch for the OFF position.

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2.PILOT CONTROL SWITCH:

1.FOUR-WAY FLASHER SWITCH:

INSTRUMENTS AND CONTROLS ____________________________________ 1. 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 FORWARD, NEUTRAL and REVERSE.

2

BD06F161

2. STEERING WHEEL TILT CONTROL:

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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.

1 BD06F160

NOTE: The F-N-R function of the transmission control lever may be moved to the loader control lever for operating efficiency.

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

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____________________________________ INSTRUMENTS AND CONTROLS

3

5 4 BD06F157

BD02N211

3. HORN:

5.PARKING BRAKE SWITCH: NOTE: Make sure the ma-

4. TURN SIGNAL LEVER: BC00B095

Push the control lever up to signal a left turn. Pull the control down to signal a right turn. You must move the control lever to the center position to stop the signal.

chine has come to a complete stop before applying the parking brake.

IMPORTANT: The parking brake is a

spring applied, hydraulic released brake, which is applied to the drive shaft. It is effective in holding the machine stopped when used correctly.

To engage the parking brake 1. Push down on the top of the park brake switch to ENGAGE the parking brake.

The parking brake will also engage whenever the key switch is moved to the OFF position.

NOTE: The service brake must be at

operating pressure before the parking brake can be released to move the machine. The brake pressure indicator lamp must not be illuminated when disengaging the parking brake. Attempting to move the machine before the service brake pressures are completely built up to operating pressure can result in premature park brake pad wear.

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Push the horn button to actuate the horn.

INSTRUMENTS AND CONTROLS ____________________________________ 3. Right side FNR switch must be in neutral.

Parking brake release

4. Machine speed is zero.

A. For transmission FNR control to be at the transmission control lever at the left side steering wheel.

5. Engine should be running.

6. Push down on the top of the transmission enable switch located in the side console.

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

All following steps are required: 1. Service brake pressure must be at operating pressure.

2. Transmission control lever must be in neutral.

7. Push down on the bottom of the parking brake switch to release the parking brake. (Must occur within 8 seconds of enable).

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

8. Place the right side FNR switch in either FORWARD or REVERSE to move the machine. (Must occur within 8 seconds of enable).

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

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B. For transmission FNR control to be at the right side of the steering wheel in the hydraulic controller area.

IMPORTANT: A failure in the operating

procedure or a failure in the electrical or hydraulic function can result in abrupt engagement of the paring brake. Always wear your seat belt.

All the following steps are required: 1. Service brake pressure must be at operating pressure.

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

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____________________________________ INSTRUMENTS AND CONTROLS

Instrument panel indicator 6

Instrument cluster The instrument cluster will check each monitored system when you turn the key switch to the ON position. All LED’s (light emitting diodes) will illuminate, and the warning alarm will sound for three seconds. At the end of this check all monitored systems will return to normal operation. If there is an open circuit between a sensor and the instrument cluster, the LED will flash and the warning alarm will sound for 5 seconds

BD06F155

6. KEY SWITCH: The key switch has four positions:

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

This position will energize the optional radio only. It will not energize the instruments or start the engine.

OFF POSITION All switch controlled current is OFF. Turn the key to OFF to stop the engine. Remove the key and turn the master disconnect switch to OFF. ON POSITION This position energizes all electrical systems.

The key will return to this position after you release the key from the START position.

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

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IMPORTANT: If during operation, the

ACCESSORY POSITION

INSTRUMENTS AND CONTROLS ____________________________________

6 4

2

5

3

1

1

BD06F096

1.INDICATOR LAMP FOR FOUR-WAY FLASHER AND TURN SIGNALS:

4.SECONDARY STEERING INDICATOR (IF EQUIPPED):

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This indicator illuminates when the primary steering system BS00B111 pressure is too low. The alarm sounds continuously and the stop master indicator turns red.

This green indicator lamp will BS96H049 flash when you signal a turn or when you actuate the four-way flashers.

2.LAMP INDICATOR:

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

This indicator illuminates when the lamps are ON.

5.PARKING BRAKE INDICATOR:

BS98M062

3.BRAKE PRESSURE INDICATOR:

This indicator illuminates when the parking brake is BS96H049 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.

This indicator illuminates when the brake system presBC00B108 sure is too low. The alarm sounds continuously and the stop master indicator will be red.

NOTE: Stop the machine and correct the

problem.

6.ENGINE GRID HEATER INDICATOR LAMP: To start the engine, turn the key switch to the ON position. The indicator (6) illuminates when the engine grid heater is operating. Wait until the indicator light goes OFF before moving the key switch to the START position to start the engine. The indicator light may come on again during cranking and shortly after the engine starts for post heating of the air. This allows for smooth running conditions during cold weather warm up.

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____________________________________ INSTRUMENTS AND CONTROLS 7.STOP MASTER INDICATOR (RED, CRITICAL): The stop master indicator is a critical warning display. See critical warning displays.

7

BC00B290

BD06F096

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 will be displayed in the message area.

Display ENGINE OIL PRESSURE

Description Low Engine Oil Pressure. Below 10 PSI

BRAKE PRESSURE

Low Brake Pressure

STEERING PRESSURE (W/AUX STEERING)

Low Steering Pressure.

COOLANT LEVEL

Low Coolant Level.

COOLANT TEMPERATURE

High Engine Coolant Temperature.

HYDRAULIC OIL TEMPERATURE

High Hydraulic Oil Temperature.

TRANSMISSION OIL TEMPERATURE

High Transmission Oil Temperature.

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

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

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

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.

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.

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

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

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Critical Warning Displays

INSTRUMENTS AND CONTROLS ____________________________________

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 will be displayed in the message area. When this occurs return the machine to a service position and shutdown the engine to help avoid expensive repairs.

8

BD06F096

8.CAUTION MASTER INDICATOR (YELLOW, NONCRITICAL): The caution master indicator is a non-critical warning display. See non-critical warning displays.

BC00B291

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____________________________________ INSTRUMENTS AND CONTROLS

Description

Corrective Action

PARKING BRAKE

Parking brake engaged and shifts to F or R.

Release the parking Brake.

COOLANT TEMPERATURE

High engine coolant temperature

1. Idle machine and monitor temperature.

2. Clean radiator or Operate fan reverser. (If equipped) 3. If condition persists, contact your dealer.

HYDRAULIC TEMPERATURE

1. Idle machine and monitor temperature.

2. Clean cooler or Operate fan reverser. (If High hydraulic temperature equipped) 3. If condition persists, contact your dealer.

TRANSMISSION TEMPERATURE

1. Idle machine and monitor temperature.

2. Clean cooler or Operate fan reverser. (If equipped) 3. Use a lower gear.

4. If condition persists, contact your dealer.

High transmission temperature

1. Turn air conditioning OFF. High or low air conditioning 2. Low outside temperature.

AIR CONDITIONING pressure.

3. Servicing required.

4. If condition persists, contact your dealer.

AIR FILTER

High air filter restriction

1. Clean air filter.

2. Replace primary and secondary filters.

3. If condition persists, contact your dealer.

TRANSMISSION FILTER

Transmission filter restriction.

1. Replace transmission filter.

2. If condition persists, contact your dealer.

HYDRAULIC FILTER

Hydraulic filter restriction.

1. Replace hydraulic filter.

2. If condition persists, contact your dealer.

ALTERNATOR

Alternator malfunction.

1. Check electrical system.

2. Voltages are out of range.

3. Change operating procedure.

4. If condition persists, contact your dealer.

FUEL

Low fuel.

1. Fill fuel tank as soon as possible.

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Display

INSTRUMENTS AND CONTROLS ____________________________________

9

BD06F096

9.TRANSMISSION OIL TEMPERATURE GAUGE:

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The transmission oil temperature gauge indicates the oil temperature of the transmission. Normal operating temperature is in the green zone. When the transmission oil temperature increases, the gauge will move into the yellow BS98M028 zone, the warning alarm sounds for three seconds, and the caution master indicator turns yellow. When the temperature continues to increase the gauge moves into the red zone, the warning alarm will sound continuously, and the stop master indicator turns red. The machine must not be operated when the temperature is in the red zone. .

Gauge Indication 20 °C and below (68 °F and below) 20 to 120 °C (68 to 248 °F) 120 to 125 °C (248 to 257 °F) (See the note below) 125 °C and above (257 °F and above)

TRANSMISSION OIL TEMPERATURE GAUGE Master Gauge Condition Indicator Status Oil temperature is Caution Flashes very low (Yellow) Oil temperature is normal

Alarm Status 3 Seconds

Oil temperature is high

Caution (Yellow)

Flashes

3 Seconds

Oil temperature is very high

Stop (Red)

Flashes

Continuous

NOTE: To prevent damage to the transmission, stop the machine, shift the transmission to

NEUTRAL, and run the engine at full throttle until the transmission cools. If the transmission oil temperature does not return to normal operating temperature, run the engine at idle speed and check the transmission oil level. Correct the problem before continuing to operate the machine.

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____________________________________ INSTRUMENTS AND CONTROLS

10

BD06F096

The hydraulic oil temperature gauge indicates the oil temperature of the hydraulic system. Normal operating temperature is in the green zone. When the hydraulic oil temperature increases the gauge will move into the yellow zone, BC00B123 the warning alarm sounds for three seconds, and the caution master indicator turns yellow. When the temperature continues to increase the gauge moves into the red zone and the warning alarm sounds continuously. The stop master indicator turns red. 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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10.HYDRAULIC OIL TEMPERATURE GAUGE:

INSTRUMENTS AND CONTROLS ____________________________________

11

BD06F096

11.FUEL LEVEL GAUGE:

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BS98M034

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

FUEL LEVEL GAUGE

Gauge Indication

Condition

Master Indicator

Gauge Status

Alarm Status

10 percent and below

Fuel level low

Caution (Yellow)

Flashes

3 Seconds

10 percent and above

Fuel level normal

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____________________________________ INSTRUMENTS AND CONTROLS

12

BD06F096

The engine coolant temperature gauge indicates the coolant temperature of the engine. Normal operating temperature is in the green zone. When the engine coolant temperature increases the gauge will move into the yellow zone, and BS98H053 the warning alarm sounds for three seconds. The caution master indicator turns yellow. When the temperature continues to increase the gauge moves into the red zone and the warning alarm sounds continuously. The stop master indicator turns red. 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

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

Coolant temperature is very high

Stop (Red)

Flashes

Continuous

NOTE: Stop the engine immediately and correct the problem.

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12.ENGINE COOLANT TEMPERATURE GAUGE:

INSTRUMENTS AND CONTROLS ____________________________________

LCD MULTI-FUNCTION DISPLAY 1. In the example, above, the machine hours are displayed. Machine hours will always be displayed briefly, on start up. After, the machine is started, the display will show engine rpm’s. After, beginning travel, the machine will display travel speed, if default settings were not changed by the operator.

(See options on page 56).

1

2. This example, shows that the transmission control lever is in neutral. The display will show forward, neutral, or reverse, depending on where the directional control lever is positioned.

BD06F096

1. LCD MULTI-FUNCTION DISPLAY

NOTE: Forward and reverse will blink if the

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The LCD multi-function display is located at the center of the modular dashboard. On start up the cluster will flash the instructional lamps and the LCD multi-display will flash, CASE, with the machine model.

transmission clutches are disconnected.

3. This example shows the maximum gear allowed when in automatic mode. If display is blank the manual mode has been selected.

1 2

4. This example shows the current transmission mode that has been selected.

4

3

A. If the transmission is operating normally it will display either: •A: Automatic

5

•M: Manual operation.

B. If the Transmission is not operating normally the display will show:

6

•C: Substitute Clutch.

7

•L: Limp Home.

BD06F185

•S: Transmission Shutdown.

LCD MULTI-FUNCTION DISPLAY

•U: TCU Shutdown.

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

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____________________________________ INSTRUMENTS AND CONTROLS A. Escape key: Use this key to exit and return to the driving screen. Use this key anytime you would like to start over and begin again, plus use to check active, acknowledge errors.

5. This example (not displayed) will show the transmission clutches disengaged, if the park brake is OFF. 6. This example shows the Power Boost Status. See page 53.

B. Enter key: Use this key to confirm, yes, this is the desired function.

•MAX: Maximum Power.

•STD: Standard Mode of Operation.

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

•AUTO: Switches automatically between Maximum and Standard Power.

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

•ECO: Limited Power for fuel efficiency.

7. This example will show the Time in either 12 hour or 24 hour.

NOTE: Arrows on the screen will indicate if

Navigating through the LCD multi-function display screens

NOTE: Display units can be changed by the operator (See page 55).

Using the arrow keys A

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

The following sequence is using the down key only.

C

B

D BD06F186

KEY PAD

Located on the steering column, just to the left of the Park Switch, is the key pad. Use this key pad to move from one screen to another, choose various selections, monitor the machine functions, and retrieve information. All functions can be accessed in the same basic manner.

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selections are up or down from the current selection.

INSTRUMENTS AND CONTROLS ____________________________________ NOTE: Pressing the escape key will return

the LCD back to the normal driving screen.

BD06F027

Info 2 will be displayed next. The Info 2 screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Farenheit or Celsius, as well as oil pressure PSI.

BD06F188

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

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BD06F184

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

Push the down button again and the Info 3 screen. This screen displays the temperature in Farenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and radiator coolant temperature.

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____________________________________ INSTRUMENTS AND CONTROLS

To reset the trip information

BD06F169

Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.

BD06F170

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Highlight the trip screen you wish to set.

BD06F187

Press the confirm button to reset the trip selection to zero.

BD06F170

By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.

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INSTRUMENTS AND CONTROLS ____________________________________ The trip screen will indicate a reset message.

At this screen, press confirm to clear the numbers and reset the trip information. The current date and time will display automatically.

The hours, fuel consumption, and fuel used per hour will reset and revert to zero.

BD06F172

Entering service screens NOTE: When all the selections have been

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After the machine has been started or the key switch has been turned to on the operator or service technican may use this service menu to adjust machine configurations to working conditions, test components, view faults that may have occurred, or select preferences.

made they will be stored in memory. If there is an abrupt battery disconnect you may loose all of your selections and need to reprogram the LCD multi-function display.

BD06F177 / BD06F188

1. Power mode menu

Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to scroll through the menu’s.

•Max: Maximum power possible •Standard: Standard operation •Auto: Will cycle between Max and Normal •Eco: Limited power for economy

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____________________________________ INSTRUMENTS AND CONTROLS 7. Cluster S/W

2. Preferences menu

•Part number

French,

•Loader version

•Units: Metric orEnglish

•ID

•Clock: 24 or 12 hour

•Version

3. Options menu

8. Config menu

•Fan Auto: manual or automatic

•Change model *

•Idle Auto: manual or automatic

•Select tires (select tire sizes)

•Show RPM

•Clutch calibration (calibrate gear box)*

•Show MPH/KPH

•Gear limits (choose maximum gear)

4. Display menu

•Park brake (park brake test)

•Day display

•Cold start (choose cold start system)

•Day LED

•FAN test (sound level)

•Night display

•Special

•Night LED

- Reset error

5. Clock menu

- Factory set

•Hour

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

•Minute •Day •Month •Year 6. Cluster H/W •Part number •Serial number •ID •Version

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•Language: English, Italian, Spanish, Portuguese, German

INSTRUMENTS AND CONTROLS ____________________________________

Select screen

Hardware screen

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

Scroll to the hardware selection and press confirm to display machine information.

BD106F193

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The cluster hardware selection will display the CNH part number, serial number, ID number and version of the Instrument cluster. This display is a convenient source of information when ordering parts or accessories. Press escape to exit from this field and return to the selection menu or use the up or down arrow key to toggle to the software information screen.

BD06F177

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____________________________________ INSTRUMENTS AND CONTROLS

Selecting power modes

Software screen

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

BD06H028

The cluster software selection will display the CNH part number, serial number, ID number and software version of the Instrument cluster. This display is a convenient source of information when ordering parts or accessories. Press escape to exit from this field and return to the selection menu or use the up or down arrow key to toggle to the software information screen.

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Press and hold the confirmation button for two seconds to arrive at the service screen.

BD06F177

At the screen shown above, highlight the power mode and press the confirmation button to move to the power mode selection menu.

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INSTRUMENTS AND CONTROLS ____________________________________

BD06F178

BD06F176

At the power mode menu press the confirmation button again to activate the selections. The highlighted section will flash to indicate a new selection can be made.

Should an error message display, press the confirmation button to acknowledge and begin again.

Preferences

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Press the up or down button to select the power mode, and then press the confirmation button again. This changes the mode and locks it into memory.

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

NOTE: Selecting options and navigating

through the screen menus are the same for all functions. The display will tell the operator if errors have occurred.

BD06F179

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____________________________________ INSTRUMENTS AND CONTROLS

Language screen, measurement units, and clock

Calibrating the gear box After warming the oil temperature: 1. Park the machine on a firm level surface.

The LCD screen can be set with language, units, and clock preferences. Use the arrow keys to scroll to the preferences menu.

Press confirm.

2. Place the transmission control lever in NEUTRAL.

Choose the preferences desired, language in (English, Italian, Spanish, Portuguese, German, French, measurement units in English or Metric and clock units in either 12 or 24 hour). Highlight the preference you wish to change and press the confirm key.

The preference will flash and allow you to scroll through the choices. When the correct preference is chosen, use the confirm key to lock in the preference for the display. The escape key will allow you to leave this application.

4. With the engine running, at idle, enter the service screen menu and scroll to config.

BD06F202

Use the confirm and arrow button to scroll to the screen shown above. At this screen push the confirm button again.

BD06F195

This screen will prompt the operator or technican to confirm or escape.

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3. Set the park brake.

INSTRUMENTS AND CONTROLS ____________________________________

BD06F196

BD06F174

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If, conditions are not correct, an error message will appear and guide the operator or technican.

Options menu

There are six, if conditions not met, screens: • Not in neutral • Park brake OFF • Machine moving • Oil temp too low • Oil temp too high • Engine RPM low • Engine RPM high

Fan auto

Use the arrow keys to choose the options menu. Press the confirm key, and the options sub-menu will appear. The options menu will allow the operator to choose options for the fan, idle.

The fan can be set to run in automatic or manual mode. In the manual mode the fan will run at maximum speed with no reversal.

Automatic is the more common or preferred setting. It will switch between high speed, low speed, or reverse as conditions require depending on actual temperature of the coolant, turbocharger air, transmission oil, and hydraulic oil.

If conditions are correct the operator or technican will see six calibration screens pass. They will display in this order: • Adjust K1 • Adjust K2 • Adjust K3 • Adjust K4 • Adjust KV • Adjust KR

The operator can choose fan speed or reversing capabilities. Highlight the fan auto selection by using the arrow keys, then press confirm. This will allow you scroll through the fan choices. When you have chosen the selection, lock the selection into memory by pressing the confirm key.

Once the process is completed this screen will direct the operator or technican to shut the engine OFF and then re-start.

If the process is not completed the operator or technican will be prompted to escape.

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____________________________________ INSTRUMENTS AND CONTROLS

Auto idle

RPM

Idling can be changed from automatic to a fixed rate. The fixed idle rate is defined as Standard Idle at 900 RPM. Highlight the auto idle selection by using the arrow keys, then press confirm. This will allow you scroll through the idle choices. When you have chosen the selection, lock the selection into memory by pressing the confirm key.

Engine speed in RPM will show on the display if the engine speed is greater than 550 RPM’s, and will disappear if the engine speed is lower than 300 RPM.

MPH / km/h Vehicle speed will show on the display if it is greater than 1.0 MPH / 1.5 km/h and will disappear if the vehicle speed is less than 0.6 MPH / 1.0 km/h.

Display menu

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The display menu can be used to change the background and brightness of the screen. Use the arrow keys to make your selection from the display menu and press the confirm key to lock the selection into memory. The screen display can be changed to suit working conditions for day and night separately.

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INSTRUMENTS AND CONTROLS ____________________________________

FOOT PEDALS 1

2

BD06F104

BD06F104

1. FOOT THROTTLE:

2. BRAKE PEDAL:

Push the foot throttle to increase the engine speed. Release the foot throttle to decrease the engine speed.

Pushing pedal will actuate the brakes.

NOTE: Use the DECLUTCH SWITCH (page

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68) when you need maximum power (speed) for the loader lift arms and bucket.

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____________________________________ INSTRUMENTS AND CONTROLS

LOADER CONTROL LEVERS Two spool valve - one control lever E

2

B A

C

1 D

1

BD06H024 / 87536095

1. LIFT ARM AND BUCKET CONTROL

3

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

BD06G091

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

2. AUXILIARY F-N-R SWITCH: This switch will allow the operator to put the Transmission in Forward, Neutral or Reverse.

To activate this auxiliary F-N-R switch the proper sequence must be followed. Push the switch forward to place the transmission in forward, place the switch in the middle position to place the transmission in neutral and pull the switch rearward to put the transmission in reverse.

NOTE: See transmission operation / initial

D. RAISE E. DUMP F. ROLLBACK

machine movement for moving machine after engine start up.

3. TRANSMISSION DOWN SHIFT (BUTTON)

59

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F

INSTRUMENTS AND CONTROLS ____________________________________

Three spool valve - two control levers 2

4

2 H

G E A

D

C

1

F

1 B TRIM THIS EDGE

87536094 / BD06F271

1. LIFT ARM AND BUCKET CONTROL A. DUMP

3

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

4

3. TRANSMISSION DOWN SHIFT (BUTTON) 4. AUXILIARY F-N-R Switch: This switch will allow the operator to put the Transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper sequence must be followed. Push the switch forward to place the transmission in forward, place the switch in the middle position to place the transmission in neutral and pull the switch rearward to put the transmission in reverse.

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

NOTE: See transmission operation / initial machine movement for moving the machine after engine start up.

2. AUXILARY CONTROL G. AUXILIARY FUNCTION H. AUXILIARY FUNCTION

60

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____________________________________ INSTRUMENTS AND CONTROLS

Three spool - three levers E 2

5

1

F

D 2

A

3

C

H

1

G B I

3 BD06F004 / 87536093

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.

4

5

A

B C

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

BD06F004

4. TRANSMISSION DOWN SHIFT (BUTTON) 5. FNR Switch: This switch will allow the operator to put the Transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper sequence must be followed. Push on the front of the switch to place the transmission in forward, place the switch in the middle position to place the transmission in neutral and push on the back of the switch to put the transmission in reverse.

A. Forward (Transmission)

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

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

61

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

1. BUCKET CONTROL

INSTRUMENTS AND CONTROLS ____________________________________

Four spool valve - three levers 3 2

I

J

G

H

3

A

2

E

C

D

1

1 B

F

87536096 / BD06H025

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J. AUXILIARY FUNCTION

1. BUCKET AND LIFT ARM CONTROL A. DUMP B. ROLLBACK

5

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

4 BD06G091

4. TRANSMISSION DOWN SHIFT (BUTTON) 5. AUXILIARY F-N-R SWITCH: This switch will allow the operator to put the transmission in Forward, Neutral or Reverse. To activate this auxiliary F-N-R switch the proper sequence must be followed. Push the switch forward to place the transmission in forward, place the switch in the middle position to place the transmission in neutral and pull the switch rearward to put the transmission in reverse.

NOTE: See transmission operation / initial

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

E. LOWER F. RAISE 2. AUXILIARY CONTROL

machine movement for moving the machine after engine start up.

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

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____________________________________ INSTRUMENTS AND CONTROLS

SIDE CONSOLE

1 2

BD06F094 / BD06F105

3. SIDE ADJUSTMENT KNOB:

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

To adjust wrist rest sideways, loosen the adjustment knob and move wrist rest from side to side. Tighten the knob.

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

3 BD06F156

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1. WRIST REST:

INSTRUMENTS AND CONTROLS ____________________________________

6

4

5 BD06F093

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4. HEAT / AIR CONDITIONER CONTROL (IF EQUIPPED) (Until serial NAAE13132):

5. BLOWER FAN SWITCH (IF EQUIPPED) (Until serial NAAE13132): The blower fan switch has four positions: OFF, 1, 2, 3, and 4. Turn the switch to 4 for maximum speed and to 1 for the slowest speed. Turn the switch completely counterclockwise for OFF.

Turn the control clockwise and, adjust the control to the needed temperature. Turn the control completely counterclockwise for OFF. Select the desired fan speed.

NOTE: Make sure the water inlet on the

To activate the air conditioner push down on the fan switch. The center of the switch will illuminate.

engine for the heater is in the full ON position.

6. FRESH AIR / RECIRCULATION (IF EQUIPPED) (Until serial NAAE13132): Turn knob to the left for recirculation and to the right for fresh air.

64

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____________________________________ INSTRUMENTS AND CONTROLS

6b

4

6a. AIR CONDITIONING CONTROL (IF EQUIPPED) (starting with serial NAAE13133):

4. CLIMATE CONTROL ADJUSTMENT (IF EQUIPPED) (starting with serial NAAE13133):

Push on the snowflake switch to turn the air conditioning function ON. When the air conditioner is ON, the snowflake will illuminate. Turn the control to adjust the control to the desired temperature. Blue markings indicate cooler temperatures.

Turn the control clockwise, and adjust the control to the desired temperature. Blue markings indicate cooler temperatures. Red markings indicate warmer temperatures when using the heater. Heater and air conditioning switches turn the functions on and off.

5. FAN (IF EQUIPPED) (starting with serial NAAE13133):

6b. RECIRCULATION SWITCH (IF EQUIPPED) (starting with serial NAAE13133):

Turn the control clockwise for higher fan speed. and adjust the control to the desired speed.

The blower fan switch has five positions: OFF, 1, 2, 3, and 4.

Press the recirculation switch to bring in fresh air or use in conjunction with the climate control to adjust air flow.

Turn the switch to 4 for maximum speed and to 1 for the lowest speed. Turn completely counterclockwise for OFF.

NOTE: Make sure the water inlet for the

heater is in the full ON position. This inlet is located in the left rear of the engine compartment.

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5

6a

INSTRUMENTS AND CONTROLS ____________________________________

8 7

BD06F102

8. REAR WIPER SWITCH:

7. FRONT WIPER/WASHER TOGGLE SWITCH (IF EQUIPPED): TRIM THIS EDGE

A. Push switch to middle position for on.

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

B. Push on front of switch for washer fluid.

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

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

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

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

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____________________________________ INSTRUMENTS AND CONTROLS

10 9

BD06F101

10. WORK LIGHT SWITCH:

A. Push on front of switch for roading machine.

B. Push on front of switch for working at night.

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9. DRIVING LIGHT SWITCH:

INSTRUMENTS AND CONTROLS ____________________________________

19

20

11 17

13

18

14

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15

21 16

12

BD06G089

11. DECLUTCH SWITCH:

13. AUTOSHIFT SWITCH:

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

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

12. RETURN-TO-TRAVEL, DETENT SWITCH: The Return-To-Travel switch is used to automatically return the loader bucket to the travel position after you have dumped the loader bucket. Push down on the back of the Return-To-Travel switch to engage the return to travel detent. Push the top of the switch for the float detent position.

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

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____________________________________ INSTRUMENTS AND CONTROLS 19. FAN REVERSER SWITCH (IF EQUIPPED):

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

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

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

Enable the auxiliary F-N-R switch by pushing down on the top of the enable switch. The indicator light on the bottom of the enable switch will illuminate when activated. By following the correct sequence and enabling the auxiliary F-N-R the operator may select FORWARD-NEUTRAL-REVERSE from the LOADER CONTROL LEVER or the AUXILIARY F-N-R SWITCH.

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. 21. BACKUP ALARM SWITCH (IF EQUIPPED):

18. ROTATING BEACON SWITCH (IF EQUIPPED):

To cancel the backup alarm depress the front of the switch.

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

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20. COUPLER PIN ENGAGE SWITCH (IF EQUIPPED):

17. F-N-R SWITCH:

INSTRUMENTS AND CONTROLS ____________________________________

Master disconnect switch

BD06F045

BD06F043

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2

1

BD06F042

The master disconnect switch has two positions: ON and OFF. (1) The panel, located at the right rear hood position, may be locked. See the decal located on the inside of the panel.

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

BS00A203

OFF: This position disconnects all power to the machine.

IMPORTANT: DO NOT use the master disconnect switch to stop the engine.

BS00A017

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____________________________________ INSTRUMENTS AND CONTROLS

Hood switch

If the machine has no power or the battery is too low for the hood switch to function

BD06F044

1. Push up on the switch to raise the hood.

The switch will remain in the up position for hands free opening.

!

WARNING: This procedure is not for starting the engine.

Attempting to jump start the engine from this location may cause electrical and harness damage.

1. Connect the positive jumper cable to the Cab B+ junction post, located behind the right side cab access door.

2. Connect the negative cable to a proper ground. The hood may now be operated at the switch.

BD06F042

2. To close the hood push down on the switch. The down position must be held to lower the hood.

!

WARNING: Keep hands clear of the hood as it closes to avoid injury.

Keep all tools, service equipment and personnel clear as the hood comes down.

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BD06G174

INSTRUMENTS AND CONTROLS ____________________________________

Recirculation air louvers

If the machine has power but the actuator is not functioning

The recirculation air louvers are behind the operators seat next to the floor. When open, air is recirculated in the cab. To open and close louvers see page 64 NOTE: Always have these louvers open for

maximum cooling with the air conditioning or maximum heat with the heater.

BD03A229

2

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1. Park the machine on level ground, lower the bucket. Put the transmission in neutral, apply the parking brake. Shut the engine off.

1

2. Remove the two actuator mounting bolts at the left rear of the machine just in front of the battery compartment.

BD06F095

1. Loosen knob and remove cover to access recirculation filter.

3. Lift and support the hood with suitable equipment.

2. Recirculation filter.

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____________________________________ INSTRUMENTS AND CONTROLS

Air louvers 1

3 3 BD06F159

3. LOWER FRONT MAIN LOUVERS

BD06G095

The lower front louvers direct air flow back to the operator, and air flow can be directed to the windshield.

1. LEFT-HAND LOUVER

The upper louvers under the front windshield and the louvers on the front of each ROPS post 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.

2

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

BD06G094

2. RIGHT-HAND LOUVER

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

4

4 BD06F159

4. LOWER DEFROST LOUVERS

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Defrost air louvers

INSTRUMENTS AND CONTROLS ____________________________________

Radio (If Equipped)

2

1

BD06G093 RD06F053

1. LATCH PIN 2. HOLD LATCH

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

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.

Door latch TRIM THIS EDGE

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.

1

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

BD06G103

Window retainer latch

1. PUSH DOWN TO OPEN DOOR

Window latch

1 1 BD06F158

1. PULL TO RELEASE WINDOW

BD06G177

1. LIFT TO OPEN

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____________________________________ INSTRUMENTS AND CONTROLS

OPERATORS SEAT Standard seat 3 1

BD06F046

1. LUMBAR ADJUSTMENT KNOB:

Lift up on the handle, move the backrest to the desired position, release the handle to lock the backrest in position.

Turn the knob clockwise to increase the lumbar support, turn the knob counterclockwise to decrease the lumbar support.

4 2

2

BD06F052

4. SLIDE ADJUSTMENT LEVER:

BD06F047

2. ARMREST HEIGHT CONTROL ADJUSTMENT:

Pull this lever up and adjust the seat forward or rearward as required. Release the lever to lock the seat in position.

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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3. RECLINER ADJUSTMENT HANDLE:

BD06F051

INSTRUMENTS AND CONTROLS ____________________________________

Optional air ride seat 1

5

2 BD06F048

5. WEIGHT ADJUSTMENT KNOB:

BD06G181

1. LUMBAR ADJUSTMENT KNOB:

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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. Turn the knob counterclockwise to decrease the weight resistance.

Turn the knob clockwise to increase the lumbar support, turn the knob counterclockwise to decrease the lumbar support.

2. ARMREST HEIGHT CONTROL ADJUSTMENT:

6. HEIGHT ADJUSTMENT, STANDARD SEAT:

Turn the knob to raise or lower the armrest to the desired position.

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.

NOTE: Each armrest will pivot to the up

position.

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____________________________________ INSTRUMENTS AND CONTROLS 5. HEIGHT ADJUSTMENT HANDLE: A. Automatic Adjustment: With the operator sitting in the seat. Lift the handle UP and release. The seat will automatically adjust UP and then bleed off air pressure to the optimum air pressure for the weight of the operator.

3

BD06F046

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

5

6

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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 DOWN to decrease the air pressure and lower the seat.

7 BD06G182

4

6. SEAT DEPTH HANDLE:

BD06G182

Lift handle up and move the cushion to the desired position. Release the handle to lock the cushion in position.

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

7. SEAT CUSHION ANGLE ADJUSTMENT HANDLE:

NOTE: When adjusting the seat height for the

Lift up on the handle. Move the seat to the desired angle. Release the handle to lock the cushion angle.

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.

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INSTRUMENTS AND CONTROLS ____________________________________ 8. DAMPENING ADJUSTMENT LEVER:

8

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

Each of the adjustments has a slight detent.

The suspension can be adjusted to various operating conditions.

5

BD06G183

SEAT BELT NOTE: Make sure the belt end and buckle are securely fastened. Do not pull out the righthand buckle.

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!

RD97F225

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

RD97F225

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

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WARNING: Securely fasten your seat belt. Your machine is equipped with a ROPS cab 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

____________________________________ INSTRUMENTS AND CONTROLS

Emergency exit

Inspection and care of seat belt 1. Keep sharp edges and items that can cause damage, away from the belts.

1

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.

BD06F166

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

1. EMERGENCY EXIT

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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.

1

2

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

BD06G177

1. PIN 2. LATCH

Lift and pull the latch out of the pin. Push the right hand window open.

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INSTRUMENTS AND CONTROLS ____________________________________

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OPERATING INSTRUCTIONS OPERATING THE MACHINE During this period:

Before starting the engine

Warm up the engine before using it under load.

DO NOT OPERATE the engine at maximum power for prolonged periods of time.

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.

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

Frequently check the instruments on the instrument panel.

During the run-in period, the following checks and servicing operations should be carried out in addition to those specified in the service schedule:

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

!

IMPORTANT: For turbocharged engines it

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

CM112

is necessary to shut the engine down from the low idle position only, to prevent damage to the turbocharger.

After the first 100 hours

Run-In Period

•Change the engine oil and filters.

Your machine will, last longer, give better and more economical performance, if you pay particular attention to the engine during the first 100 hours of operation.

•Replace the fuel filters.

•Replace the hydraulic oil return filter.

•Change the break-in oil in axles.

•Change transmission oil and filter.

After the first 250 hours •Calibrate the clutch.

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Check the oil levels and coolant solution level frequently.

2. See the maintenance chart in this manual and do the items in the 10 hour section.

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

Before operating machine

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

WARNING: Do not attempt to operate this machine unless you have first read and fully understand the safety messages and instructions appearing in this manual.

NA000

10. Remove any obstructions which hinder visibility. Clean the windshield, the windows and the rear view mirrors.

Before operating this machine, be sure to do the following:

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

1. Check the level of all fluids (engine oil, hydraulic fluid, and coolant) and make sure that the fluids and lubricants are suitable for prevailing conditions.

12. Make sure no one is on or under the machine. The operator must be alone on the machine.

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2. Carry out the daily maintenance operations.

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

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

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

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

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

5. Check the tires for air pressure and damage. Adjust tire pressure and repair or replace damaged tires.

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

6. Clean the steps and access handles.

Grease, oil, mud or ice (in winter) on the steps and access handles can causes accidents. Make sure they are kept clean at all times.

7. Clean or replace any decals which are illegible. See decals in chapter 2.

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_______________________________________ OPERATING INSTRUCTIONS

F. The warning buzzer will sound.

G. Take your foot off the brake pedal.

H. Increase the engine speed to 1/2 throttle. The machine must not move. If the machine moves, see the service manual or see your authorized dealer and correct the problem.

When the parking brake is applied, the transmission is automatically shifted into neutral.

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

!

18. Fasten and adjust the seat belt.

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

!

20. Check the loader controls for correct operation.

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

!

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

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

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

22. Release the parking brake.

D. Raise the loader bucket above the ground.

23. Test the foot brake for correct operation at a maximum of 250 hour intervals.

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!

E. Shift the transmission into first gear forward.

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

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

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

B. Raise the loader bucket just above the ground.

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

Monitor the engine grid heater indicator.

Do not turn the engine over until the grid heater indicator lamp is off.

C. Place the transmission in the manual mode.

D. Shift the transmission into 2nd gear forward.

NOTE: If the weather is cold see operating

the machine in cold weather on page 110.

E. Release the parking brake.

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

F. Increase the engine speed to full throttle. the machine must not move.

If the machine does move, decrease engine speed to low idle. See your Service manual or your dealer for repairs.

IMPORTANT: Do not hold the starter key in

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the START position for more than 15 seconds.

If the engine does not start, return the key switch to the OFF position, wait 30 seconds, and then try again.

G. Reset the parking brake.

24. Test the secondary steering (if equipped) at a maximum of 250 hour intervals.

(See secondary steering check in maintenance and adjustments in this manual.

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

Starting engine NOTE: If the machine has been out of use for some time, see starting up after storage in this some time, see starting up after storage in this

IMPORTANT: Operate the machine at reduced loads until all systems reach operating temperature. This is very important during extremely cold weather operation to protect both the engine and hydraulic systems. See operating the machine in cold climates on page 110.

NOTE: If you need to start the engine using a booster battery, see connecting a booster battery in chapter 7.

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

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

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_______________________________________ OPERATING INSTRUCTIONS 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.

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.

2. Lower the loader to the ground.

Run the engine at low idle for a minute at start up before picking up speed and load.

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

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

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

Always shut the engine down from the lowest idle to prevent damage to the turbocharger.

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

Stopping the engine and parking the machine after operations

!

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

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

SA038

NOTE: Slowly move the equipment levers through all rotations to ensure that residual pressures in the hydraulic system are released.

Turn the master disconnect switch to the OFF position.

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.

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NOTE: Do not turn the engine off at anything other than low idle to prevent damage to the turbocharger.

OPERATING INSTRUCTIONS _______________________________________

Engine coolant heater (if equipped)

Engine grid heater

BD06F096

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

BD06G097

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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 manufacturers instructions for installation.

Turn the ignition switch to ON and wait for the indicator lamp to go out. The engine should be turned over only after the lamp goes out.

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

!

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WARNING: Ether is not to be used.

_______________________________________ OPERATING INSTRUCTIONS

Booster battery connection to machine batteries for jump start

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!

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 in this manual. 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

1. Open the access panel. Sit in the operators seat and have the other person make the connections.

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

3. If using another machine for power, make sure the two machines, DO NOT TOUCH. 4. Connect the positive (+) jumper cable to the positive (+) battery terminals first.

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

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

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

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

OPERATING INSTRUCTIONS _______________________________________

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

1

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.

BD06F091

1. DOWN-SHIFT BUTTON, JOYSTICK CONTROL

NOTE: When the automatic mode has been

1

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chosen by the operator the automatic mode indicator will be shown in the multi-function display.

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

Each time the switch is pressed down the transmission will shift down one gear range until 1st gear is reached. Once the downshift button has been pressed down the transmission maximum gear allowed is lowered. It will return to the automatic mode when (1) the transmission control lever gear changes, or (2) the transmission control lever is moved to NEUTRAL and then to FORWARD or to REVERSE.

BD06F004

1. DOWN-SHIFT BUTTON, THREE LEVER CONTROLS

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

NOTE: When the automatic mode has been chosen by the operator the automatic mode indicator will be shown in the multi-function display.

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_______________________________________ OPERATING INSTRUCTIONS

Forward, Neutral, Reverse (F-N-R) Switch

1

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

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

3. The engine must be running.

NOTE: Within 8 seconds from depressing the

The F-N-R switch can be enabled after the following conditions have been met: 1. Transmission controller is in neutral (left side).

F-N-R enable switch the following 3 actions must take place or the F-N-R enable switch must be reactivated.

4. Machine is stationary.

5. Parking brake is released.

1. The parking brake switch must be released.

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

2. The service brake must be stepped on.

3. The F-N-R switch must select F or R from the neutral position.

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BD06F100

OPERATING INSTRUCTIONS _______________________________________

Auxiliary Forward, Neutral, Reverse (F-N-R) switch for joystick control lever aplications A 1 B 3 C BD06F065

BD06F099

5. The parking brake must be released (3).

1. AUXILIARY JOYSTICK F-N-R SWITCH TRIM THIS EDGE

A. FORWARD B. NEUTRAL C. REVERSE

4

To actuate the auxiliary F-N-R switch the following conditions MUST be met: 1. The machine must be stopped.

2. The engine must be running.

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

BD06F103

When steps 1 through 5 have been completed the auxiliary F-N-R Switch may be enabled by pushing down on the top of the switch (4). The indicator light on the bottom of the switch will illuminate.

The auxiliary F-N-R switch will be DEACTIVATED and F-N-R control will default back to the standard transmission control lever if:

2

1. The engine is stopped.

2. The parking brake is applied.

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

BD06F160

4. The standard transmission control lever (2) must be in neutral.

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_______________________________________ OPERATING INSTRUCTIONS

Auxiliary Forward, Neutral, Reverse (F-N-R) switch with three spool valve (three levers) A B

1

3

C

BD06F004

BD06F099

5. The parking brake must be released (3).

1. AUXILIARY THREE LEVER F-NR SWITCH

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A. FORWARD B. NEUTRAL C. REVERSE

4

To actuate the auxiliary F-N-R switch the following conditions MUST be met: 1. The machine must be stopped.

2. The engine must be running.

3. The auxiliary F-N-R switch (1) must be in Neutral (B).

BD06F103

When steps 1 through 5 have been completed the auxiliary F-N-R Switch may be enabled by pushing down on the top of the switch (4). The indicator light on the bottom of the switch will illuminate.

2

The auxiliary F-N-R control will default back to the standard transmission control lever if: 1. The engine is stopped.

2. The parking brake is applied.

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

BD06F160

4. The standard transmission control lever (2) must be in neutral.

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OPERATING INSTRUCTIONS _______________________________________

CONTROL LEVERS Two spool valve (one control lever) See loader function switches in this manual for RETURN-TO-DIG, BUCKET HEIGHT CONTROL and RETURN-TO-TRAVEL/ FLOAT switches.

6 3 2

1

5 4 BD06H024

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1

3

2

4

B1119A88

1. DUMP BUCKET

3. LOWER LIFT ARMS

2. ROLLBACK BUCKET

4. RAISE LIFT ARMS

5. HOLD: The loader arms and bucket will not move when the control 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.

6. 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.

NOTE: This page shows the basic loader control lever positions.

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_______________________________________ OPERATING INSTRUCTIONS

Three spool valve (two control levers) NOTE: This page shows the basic control

lever positions.

6

6 3

See loader function switches in this manual for RETURN-TO-DIG, BUCKET HEIGHT CONTROL and RETURN-TO-TRAVEL/ FLOAT switches.

1

5

7 2

4

1

3

2

4

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BD06F271

B1119A88

1. DUMP BUCKET

3. LOWER LIFT ARMS

2. ROLLBACK BUCKET

4. RAISE LIFT ARMS

5. HOLD: The loader arms and bucket will not move when the control 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.

6. 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.

(7. 8.) AUXILIARY FUNCTION

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OPERATING INSTRUCTIONS _______________________________________

Three spool valve (three control levers) NOTE: This page shows the basic loader control lever positions.

6 3

5

1 6

See loader function switches in this manual for RETURN-TO-DIG, BUCKET HEIGHT CONTROL and RETURN-TO-TRAVEL/ FLOAT switches.

5 4

5 2 7

BD06F004

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1

3

2

4

B1119A88

1. DUMP BUCKET

3. LOWER LIFT ARMS

2. ROLLBACK BUCKET

4. RAISE LIFT ARMS

5. HOLD: The loader arms and bucket will not move when the control 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.

6. 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.

(7. 8.) AUXILIARY FUNCTION

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_______________________________________ OPERATING INSTRUCTIONS

Four spool valve (three control levers) 6

7

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

9

See loader function switches in this manual for RETURN-TO-DIG, BUCKET HEIGHT CONTROL and RETURN-TO-TRAVEL/ FLOAT switches.

3 5

1 8

2

10

4 1

3

2

4

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BD06H025

B1119A88

1. DUMP BUCKET

3. LOWER LIFT ARMS

2. ROLLBACK BUCKET

4. RAISE LIFT ARMS

5. HOLD: The loader arms and bucket will not move when the control 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.

6. 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.

(7. 8.) FIRST AUXILIARY FUNCTION (9. 10.) SECOND AUXILIARY FUNCTION

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OPERATING INSTRUCTIONS _______________________________________

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

2

1 1

3 BD06F271

1. FLOAT AND ROLLBACK DETENT

To actuate, move the control lever(s) into the FLOAT and ROLLBACK detents. The bucket control lever will automatically return to the HOLD position and the loader arm will remain in float when the loader reaches the Return-To-Dig position. See loader adjustments in this manual for Return-To-Dig adjustments for Z Bar ( 168).

BD06F274

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

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

2 1

BD06F004

1. FLOAT 2. ROLLBACK DETENT

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_______________________________________ OPERATING INSTRUCTIONS

Bucket height control

Return-To-Travel function

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

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

1 1 2

1. RAISE

BD06F004

1. ROLLBACK DETENT 2. FLOAT

1

1 BD06F271

1. RAISE

To actuate, move the control lever into the RAISE to the HOLD position when the loader bucket reaches the height selected. See for bucket height control adjustments in this manual( 170).

BD06F271

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 ( 166).

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BD06F004

OPERATING INSTRUCTIONS _______________________________________

Float

Loader control

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

The loader control levers are connected to a hydraulic accumulator through a pressure reducing valve. The purpose of the reducing valve and accumulator combination is to: (1) allow the operator to lower the loader arms if the engine stops with the loader arms raised, or (2) give the control system hydraulic pressure assistance when operating the machine at low idle speed. To test accumulator performance, perform steps 1 through 5.

1. Start the engine.

B1128A88J

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

2. Raise the loader bucket.

3. Stop the engine.

4. Turn the key to RUN.

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5. Move the lift arm control to LOWER. The loader bucket must lower to the ground.

If the bucket does not lower to the ground, see the service manual for this machine or see your dealer.

1

BD06F004

1. FLOAT

1

BD06F271

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.

DeClutch function The declutch function is used to allow the engine to increase speed and supply the loader with more hydraulic oil for greater loader power and faster control function.

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

Test the accumulators for correct operation every 100 hours.

1. Start the engine.

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

3. Stop the engine.

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

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1

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.

RD06F100

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.

1. DECLUTCH SWITCH

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OPERATING INSTRUCTIONS _______________________________________

Bucket level indicator The bottom of the bucket is parallel with the ground when the flat portion of the bucket, (shown) is horizontal.

BD03A009

2 BD00N076

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Auxiliary hydraulic connection (if equipped) Your wheel loader is equipped with an auxiliary hydraulic system. A control lever on the console controls flow to the auxiliary hydraulic connection points on the lift arms.The auxiliary control lever (1) used with a joystick (2) is equipped with mechanical detents to lock it into full forward, full rearward and neutral positions. Auxiliary control levers on non-joystick machines DO NOT have mechanical detents.

1 BD06F165

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_______________________________________ OPERATING INSTRUCTIONS

Rotating beacon (if equipped)

Ride control (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.

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

BD06G089

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.

101

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Ride control is a feature that increases the ride comfort of the Wheel Loader over all types of terrain with either an BC00B094 empty or loaded bucket. Ride control will reduce fore and Aft pitching motion during travel to allow faster speeds in load and carry applications for increased productivity and operator comfort.

It will also reduce shock loads to the wheel loader for reduced tire flex, structural fatigue and vibration, resulting in longer component life and reduced costs.

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.

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

BD06G089

!

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

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

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

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

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

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

163L96

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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IMPORTANT: The bucket MUST NOT be in

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 12 to 18 inches (305 to 457 mm) 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 on a hill

!

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

SB013

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

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_______________________________________ OPERATING INSTRUCTIONS A. Put blocks in front of and behind each wheel.

Moving a disabled machine Engine stalls while traveling Brake System: The brakes can be applied by pressing the pedal for four or five applications until the accumulator is discharged.

The operator must limit use of the brakes in this situation. In the event the brakes cannot be applied by the pedal, apply the parking brake switch.

1

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

BD03A036

Engine or hydraulic failure

C. Remove the parking brake cover (1).

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

2

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

Never tow the machine from the front BD03A037

D. Loosen the lock nut (2).

E. Turn the adjusting screw counterclockwise until the parking brake is released.

F. Tighten the lock nut and replace the cover.

1. Attach a rigid drawbar to the machine.

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.

2. If the machine cannot be started to release the parking brake, do the following:

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

BD06F167

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B. Clean the area around the cover to eliminate contamination.

OPERATING INSTRUCTIONS _______________________________________

TRANSPORTING THE MACHINE

!

! !

WARNING: The machine can slip and fall from a trailer or ramp can cause injury or death. Make sure the trailer and ramp is not slippery.

Remove all oil, grease, ice, etc. Carefully move the machine off or onto the trailer with the machine centered on the trailer and ramp.

SB042 WARNING: Before you put the machine on a trailer, remove all snow, ice, oil or grease from the trailer and ramp.

46-76C WARNING: Know the rules, regulations, laws and safety equipment necessary for transporting or operating this machine on a road or highway. Rotating beacon, backup alarm, slow moving vehicle emblem and other safety equipment items are available from your dealer.

84-13A 7. Turn the battery master disconnect switch to the OFF position.

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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 equipped with the correct safety equipment.

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.

10. Put a cover over the exhaust pipe.

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

3. Lower the loader bucket onto the trailer.

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

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

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

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_______________________________________ OPERATING INSTRUCTIONS

Transporting the machine on a trailer Machine tie down locations

BD01E126

BD06G099

TRANSPORT LOCK MUST BE SECURED.

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

BD00B012 BD00M032

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

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

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OPERATING INSTRUCTIONS _______________________________________

Operating the machine on sloping ground

!

Machine storage Preparation for storage The following procedure applies when the machine is to be stored for a month or more.

Store the machine on flat, level ground, inside a building. If a building is not available, park the machine in a dry area on planks and use wheel chocks, front and rear. Cover the machine with a waterproof covering. Before storing the machine, carry out the following operations:

WARNING: Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc. modify terrain conditions. It is up to you to decide if the machine can be used safely.

CE-NA000

During hillside operations, be extra careful.

Make sure that the low speed travel is selected.

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Always travel in the same direction as the slope, to prevent the machine from turning over.

1. Clean the machine completely and lubricate all components equipped with grease fittings.

Operating the machine in water

2. Drain the water from the cooling system.

If the system is filled with an antifreeze mixture, this operation is not necessary.

3. To avoid rust, it is necessary to refill the fuel tank completely.

1. Make sure that the bottom of the stream, or water in which you will work, can support the weight of the machine.

4. Remove the injectors and inject, through the injector holes, some engine oil (the operation should be performed using a syringe, after moving each piston to B.D.C.).

2. Do not allow the water level to reach the top of the axles.

IMPORTANT: DO NOT OPERATE in a fast

flowing stream.

5. Crank the engine a few turns to spread a protective film on the cylinder walls.

Reinstall the injectors.

3. Before using the machine in water, inject large quantities of fresh grease into the appropriate grease fittings.

6. If possible, store the batteries in a place where there is no danger of freezing.

Recharge them monthly.

4. After completing the operation make sure to inject fresh quantities of grease into any fitting that was in water.

7. To ensure adequate protection of the transmission components, at least once a month, the machine should be moved for short distances, so that a film of oil is renewed on the parts.

8. Place a DO NOT OPERATE tag on the key switch or steering wheel.

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_______________________________________ OPERATING INSTRUCTIONS

Periodical checks

Start up after storage

Every month, check:

1. Close the drain valves and fill cooling system.

A. The battery charge. Recharge the batteries if necessary.

2. Drain the fuel tank and fill with clean diesel fuel.

B. The grease on the cylinder rods.

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

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

D. The condition of all lines, connectors, and clamps (rust). Lubricate if necessary.

5. Install the batteries.

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

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

4. Change the fuel filter.

8. Check the hydraulic fluid level and add more fluid if necessary.

9. Check the axle oil level and add more oil if necessary.

10. Clean the cylinder rods.

11. Remove the DO NOT OPERATE tag and start the engine, following the starting up procedure.

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

!

WARNING: Check the machine for leaks or for any parts that are broken, defective, or missing.

CE-NA000

!

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WARNING: Avoid running the engine in a confined place.

Make sure there is adequate ventilation at all times. CE-NA000

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6. Lubricate the machine thoroughly.

OPERATING INSTRUCTIONS _______________________________________

Operating in cold climate conditions Cold weather conditions require special operating procedures. During these conditions your machine will require special start up, warm up and maintenance procedures for the best performance. Proper cold weather maintenance will extend the service life of your machine.

4. Cooling System:

1. Batteries:

Check the coolant mixture before operating in cold temperatures. A mixture of 50% ethylene glycol and 50% water must be used.

This mixture is used if the lowest ambient temperature is -34° F (-37° C). If the ambient temperature is lower, adjust the mixture.

It is recommended that ethylene glycol and water be used in the machine all year long.

See Engine Cooling System in this manual.

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

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

5. Cold temperature starting aids:

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Inspect the battery cables and terminals.

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

.

!

2. Lubricants:

WARNING: Ether.

DO

NOT

USE

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

Follow the recommended oil and filter service for the engine and hydraulic system as shown in this manual. Use the correct viscosity oil in each component for the ambient temperatures the machine is operating in.

For extreme cold conditions, contact your dealer for alternative lubricants for the hydraulic and transmission systems.

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

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

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_______________________________________ OPERATING INSTRUCTIONS When the machine has been correctly warmed up, apply the foot brake and hold, shift the transmission to forward, push the park brake to OFF position and Release the foot brake. Operate the machine in a clear safe area. Check the full operation of the machine.

6. Machine warm up: Once the engine has started, run the engine at about half throttle (1100 to 1300 rpm) for a minimum of 4 minutes under no load. This will help stabilize the engine.

After engine warm up, enable the pilot control by pushing down on the control knob just to the rear of the loader control levers.

At this time, place the lift arm into float and the bucket into roll back to load the engine to heat the hydraulic oil, and hold for approximately 2 minutes. This will yield approximately 68° F (20° C). This might take several minutes. Apply and hold the foot brake, cycle the lift arm and bucket. Repeat the float/roll back heating procedure for several minutes. Raise the lift arms enough to steer the unit full left and right to warm the oil in the steering cylinders. In extreme cold conditions, hold the float/roll back condition for 5 minutes maximum.

IMPORTANT: DO NOT OPERATE the

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 should happen you MUST go through the complete warm up procedure.

8. The transmission is equipped with internal protection that does not allow the transmission to engage below 10° F (12° C). If the transmission does not engage below these temperatures, allow 2 to 4 minutes of running in neutral and try again. The warm up time needed will vary depending on the air temperature.

IMPORTANT: Make sure there is clearance

around the machine before steering the machine left and right.

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 pump the brake pedal a minimum of 8 to 10 times before the machine is moved to obtain proper heating. Actuating and releasing the brakes should occur in a cycle of 3 seconds full on and 3 seconds off to obtain exchange of the brake oil.

In extreme cold weather conditions, the brake response can be slow. The use of correct oil in the hydraulic/brake system is required in persistently severe applications.

Contact your dealer for the correct oil.

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machine on the road until the transmission oil and axle oil have been correctly warmed up.

Operate the machine in a clear safe area before road operation in first and second gear only.

OPERATING INSTRUCTIONS _______________________________________

Operating the machine in hot climates Follow the recommendations made below: 1. Keep the coolant at the correct level in the coolant reservoir and in the radiator.

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

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

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

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

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6. Check the dust valve in the air cleaner frequently during extreme dust conditions.

7. Use lubricants of the correct viscosity.

See fluids and lubricants in the lubrication, filters, and fluids chapter.

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LUBRICATION/FILTERS/FLUIDS

!

!

serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your dealer.

CE-NA000

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

Unless otherwise specified, all maintenance operations should be carried out with:

WARNING: Before attempting any service procedures on the machine it is your responsibility to know how many accumulators are on the machine and how to properly release pressure of each. Not releasing pressure properly can cause death or serious injury.

M959

• the engine stopped • the transport / service link locked into position to stop the machine from unexpected articulation • engage the parking brake • the key removed from the starter switch • place a DO NOT OPERATE tag on the starter switch

WARNING: Be sure all the service operations in this section are carried out punctually at the intervals given, in order to ensure optimum performance levels and maximum safety when using the machine. M959

• wheel chocks blocking the wheels • wait for all circuits to cool down before starting work • release all hydraulic pressure in lift arm and bucket/attachment circuits • be certain that any accumulator pressure is released for the appropriate circuit Clean the grease fittings before lubrication.

Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits. Wear suitable clothing and remember to use the necessary safety equipment.

When carrying out service work on the machine, place a DO NOT OPERATE, or Warning tag on the instrument panel or key switch. Never climb down from the operator's compartment leaving the engine running.

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!

SERVICING INSTRUCTIONS General information WARNING: There is a risk of

LUBRICATION/FILTERS/FLUIDS ____________________________________ Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization. Consult your dealer.

Hourmeter

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

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

BD06F097

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

IMPORTANT: Oils and fluids must be

disposed of properly.

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

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

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

SUPPORT STRUT FOR LOADER LIFT ARMS

!

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

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

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

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

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

2

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

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

M824

2

3

1 DSC09555

BD06G090

SUPPORT STRUT IN TRANSPORT POSITION

SUPPORT STRUT IN SERVICE POSITION

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LUBRICATION/FILTERS/FLUIDS ____________________________________

FLUIDS AND LUBRICANTS – 821E COMPONENTS Fuel tank System total capacity Reservoir capacity

CAPACITY

SPECIFICATIONS

253 L (66.83 US gal) 246 L (64.98 US gal)

Diesel nº 2

2,5 L (0.7 US gal)

Additive CNH 1 liter (71104731) Additive CNH 5 liters (71104732)

11,3 L (2.98 US gal) 12,3 L (3.24 US gal)

Akcela nº 1 Engine Oil SAE 15W-40 API CJ-4

56,0 L (14.80 US gal)

50% Akcela Premium Anti-freeze + 50% water

System total capacity

168,5 L (44.51 gal)

Reservoir capacity

105,7 L (27.92 gal)

Up to serial HBZN821EEEAE06829 Akcela Hy-Tran Ultraction Starting with serial HBZN821EEEAE06830 Akcela Auto Supreme 10W-30

36,9 L (9.75 US gal)

Akcela nº 1 Engine Oil SAE 15W-40 API CJ-4

40,0 L (10.70 US gal)

Akcela Transaxle Fluid SAE 80W-140

40,0 L (10.70 US gal)

Akcela Transaxle Fluid SAE 80W-140

Fuel Additive Engine oil Capacity With filter change Engine cooling system System total capacity Hydraulic and Break system

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Transmission With filter change Front axle Capacity axle STD Rear axle Capacity axle STD Eixos dianteiro e traseiro Front axle capacity STD (up to serial HBZN821ELBAE00873 Rear axle capacity STD (up to serial HBZN821ELBAE00873) Front axle capacity STD (starting with serial HBZN821ELBAE00874) Rear axle capacity STD (starting with serial HBZN821ELBAE00874) Grease fittings All Air conditioning

42,6 L (11.25 US gal) 34,5 L (9.11 US gal) Akcela Transaxle Fluid SAE 80W-140 40,0 L (10.57 US gal) 40,0 L (10.57 US gal) As needed

Compressor lubricant

200 ml

Air conditioning refrigerant

1700 g

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

_____________________________________ LUBRICATION/FILTERS/FLUIDS

ENGINE OIL VISCOSITY/TEMPERATURE RANGES TEMPERATURE FAHRENHEIT

TROPIC

SAE 15W-40

ALL SEASONS

AKCELA nº 1 ENGINE OIL (SAE15W40-CI-4) ALL SEASONS WINTER AKCELA nº 1 10W-30

WINTER

ARTIC

TEMPERATURE CELSIUS Indicate the use of an Engine Oil Heater or a Jacket Water Heater is required.

BC02N250

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when

operating temperatures are in Winter or Arctic conditions.

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

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ARTIC

LUBRICATION/FILTERS/FLUIDS ____________________________________

Transmission oil viscosity/Temperature ranges TEMPERATURE FAHRENHEIT

Akcela nº 1 Engine Oil SAE 15W-40 API CJ-4 AKCELA Hy-Tran Ultra (see note) AKCELA Hy-Tran Ultra SSL (see note)

TEMPERATURE CELSIUS BC04F193

Hydraulic/brake system/Temperature range TRIM THIS EDGE

TEMPERATURE FAHRENHEIT

AKCELA Hy-Tran Ultra (see note) AKCELA Hy-Tran Ultra SSL (see note)

TEMPERATURE CELSIUS BC04F192

NOTE: For fluids and lubricants specifications, see page 116.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

Coolant solution

Fuel

Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage. Do not use non-approved anti-rust additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

Contact your Dealer who will supply you with the suitable coolant solution.

In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

For areas where the ambient temperature is over -34°F (-36°C), use a blend of 50% water and 50% ethylene-glycol based anti-freeze.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

For areas where the temperature is below 34°F (-36°C), it is advisable to use a blend of 40% water and 60% ethylene-glycol based anti-freeze.

Hydraulic fluid Hydraulic fluid is specially designed for high pressure applications and for the hydraulic system and depends on ambient temperatures. See Chart on page 118.

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Fuel storage

LUBRICATION/FILTERS/FLUIDS ____________________________________

Transmission oil

Environment

Extreme pressure oil used for enclosed transmission components depends on ambient temperatures. See Chart on page 118.

Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

Grease

Contact your local Dealer to obtain information on the correct method of disposing of these lubricants.

The type of grease to use depends on ambient temperature.

Akcela Molydisulfide Grease

Engine oil Type of engine oil used depends on ambient temperature.

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Akcela engine oil is recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions.

If Akcela engine oil cannot be obtained, use only SAE 15W40 API CI-4 engine oil. See Chart on page 117.

NOTE: Do not put any performance additive or other additive in the sump.

Oil change intervals shown in this manual are based on tests carried out on case lubricants.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

DAILY INSPECTIONS Every day, before starting work, it is necessary to inspect the machine and service certain of its components.

Other

IMPORTANT: If the slightest defect is

Check that the hydraulic oil is clean.

Check the hydraulic reservoir level.

found, repair it immediately before using the machine or see your dealer.

Check the condition of all lines.

Check for electrical short-circuits.

General remarks

Check that all battery connections are properly tightened.

Check for water or oil leaks.

Check that all screws and nuts are correctly tightened.

Adjust the rear view mirrors.

Check for oil leaks on the cylinders.

Wipe off any dust or accumulated debris (engine, operator's compartment, etc.).

Check tires for proper inflation.

After starting the engine

Check for damage.

Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Engine

Check for abnormal noise on the hydraulic components.

Check the oil level and change the oil if necessary.

Check for water or oil leaks on the components.

Check the coolant level.

Check for clogging or damage to the radiator.

Check the audible alarm devices, working lights and windshield wipers.

Check the engine accessory drive belt tension.

Check that all hydraulic circuits are functioning correctly.

Check the air filter is clean and not restricted.

Check for water or oil leaks on the components.

Check the condition of all lines.

Check the fuel tank level.

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Check the condition of the bucket or forks.

LUBRICATION/FILTERS/FLUIDS ____________________________________

Variable periodic (*)

Every 10 hours

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Every 50 hours

First 100 hours (first change only)

Every 100 hours

Every 250 hours

Every 500 hours

154

Air cleaner

*

145

Hydraulic filter

*

138

Engine accessory drive belt

*

139

Radiator coolant level

*

165

Fire extinguisher

*

159

Tires

*

128

Check engine oil level

10

128

Check engine coolant level

50

129

Bleed fuel filter of condensation

*

50

130

Check transmission oil level

50

130

Check hydraulic oil level

50

131

Grease bucket mounting fittings

50

131

Grease the pivot pin of the rear axle

50

141

Change engine oil and filters

100

144

Replace fuel filters

100

145

Change hydraulic filter

100

147

Change oil in axles

100

137

Change transmission oil and filter

100

132

Grease front drive shaft support bearing

100

132

Grease machine fittings

138

Check cab air filter

250

138

Check engine accessory drive belt

250

139

Check radiator coolant level

250

140

Check tire pressure & wheel torque

4

SM

Transmission clutch calibration

250

141

Change engine oil and filter

250

142

Change crankcase filter

250

142

Check axle oil level

144

Replace fuel filter

145

Drain fuel tank condensation

100

250

500 500 500

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ADJUST

REPLACE

LUBRICATE

DRAIN

CLEAN

CHECK

SERVICE POINTS

CHANGE

FREQUENCY IN HOURS

INITIAL SERVICE

SERVICE INTERVAL

PAGE NUMBER

LUBRICATION AND MAINTENANCE CHART

Every 2000 hours

Every 6000 hours

145

Replace hydraulic oil filter

146

Grease articulation fittings

ADJUST

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

FREQUENCY IN HOURS

1000 1000

147

Change front & rear axle oil

149

Replace cab air filter

1000

150

Change transmission oil and filter

151

Replace drive belt

SM

Check injector calibration

1000

SM

Check valve adjustment

1000

SM

Transmission clutch calibration

1000

152

Change hydraulic oil

2000

153

Change coolant

2000

1000 1000 1000

154

Replace engine air cleaner

SM

Valve clearance

2000

SM

Engine injectors

6000

SM

Fuel pump

6000

2000

SM = See service manual or contact authorized dealer

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6000

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Every 1000 hours

SERVICE POINTS

INITIAL SERVICE

SERVICE INTERVAL

PAGE NUMBER

_____________________________________ LUBRICATION/FILTERS/FLUIDS

LUBRICATION/FILTERS/FLUIDS ____________________________________

ACCESS DOORS AND FILL LOCATIONS

BD06F068

BD06F166

HYDRAULIC ACCESS DOOR / RADIATOR ACCESS COVER LEFT SIDE

CAB FILTER / FUSE ACCESS RIGHT SIDE

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RADIATOR CAP RIGHT SIDE ENGINE COVER

BATTERY ACCESS ONE EACH SIDE

BD06F106

BD06F066

ENGINE HOOD / HYDRAULIC OIL COOLER PANEL RIGHT SIDE

TRANSMISSION / HYDRAULIC FILTER ACCESS RIGHT SIDE

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

BD06F091

BD06F014

ENGINE OIL DIPSTICK AND FILL LOCATION

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RAISE COOLING UNITS TO EXPOSE HYDRAULIC FILL CAP

DSC09557

TRANSMISSION CHECK AND FILL LEFT SIDE

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LUBRICATION/FILTERS/FLUIDS ____________________________________

Variable periodic maintenance Some working environments require that maintenance be performed more frequently. Dust, dirt, moisture, extreme hot or cold and many other factors should be taken into consideration when servicing the machine. Certain equipment or auxiliary tools may cause more stress on hydraulics, drivetrain, engines or filters. The following maintenance should be performed on regular schedules but often need special attention when conditions require.

2. 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.

Engine Air Filter Replace the primary and secondary element if the air filter restriction indicator lamp illuminates.

The primary element may be cleaned by using air, however a new element is recommended, if questionable.

The inner element must not be cleaned. It must be replaced by a new one.

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Cleaning Air Filter 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 its original shape, discard the element.

CA5003J

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

IMPORTANT: Do not clean the primary element for more than 3 times. Never clean the secondary element.

1. Remove the loose dirt with compressed air at 30 psi (207 kPa; 2kgf/cm 2 ) maximum. Hold the nozzle at least one inch (25 mm) from the element.

Tires and Wheels Adjust the inflation pressure of the tires every time that circumstances require. A daily visual inspection during the pre-start walk around and mechanical checks when environmental or work conditions require more.

Wheels should be checked for proper torque every twenty hours when new and until they remain tight. See the Wheel Bolt Torque on page 159 for pressures and torques.

CA5000J

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

Air conditioning condenser

Bleeding air from the fuel system

Raise Hydraulic access door. Air Conditioner condenser is located under the access door. Unlatch condenser and raise.

Use compressed air to remove debris and buildup on the condenser.

!

Prolonged period of inactivity or running out of fuel may allow air to get into the fuel system. If this should happen make sure the tank is full and then bleed the system.

WARNING: Wear full coverage safety glasses with side panels when using compressed air. Limit the pressure to 29 psi (2 bar).

Fuses Fuses may be reached by opening the access door located on the right side of the cab. If a fuse has blown the indicator light will illuminate.

Fuel Cooler

NOTE: If a fuse blows, replace it at once.

Locate the problem and if it re-occurs, have it checked by a service technican.

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To access the fuel cooler, raise the Hydraulic access door. Unlatch and raise the air conditioner condenser. Fuel cooler is located in the front of the hydraulic fill compartment. Use compressed air to remove debris and buildup on the cooler.

Fuel filter Raise the engine hood and drain water and sediment from the fuel pre filter, located on the right side of the chassis. Slowly loosen the drain valve located under the filter until clean fuel runs out.

Retighten the valve but do not overtighten.

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LUBRICATION/FILTERS/FLUIDS ____________________________________

10 Hour maintenance

50 Hour maintenance

Engine oil

Engine coolant

The engine oil level should be checked every 10 hours or each day, whichever occurs first.

Check the coolant reservoir fluid level when the coolant is cold and the engine is stopped. DO NOT remove the radiator cap during this check. The coolant level must be between the FULL and ADD marks on the reservoir. Add coolant as required to raise the coolant level to the FULL mark.

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BD06F014

With the machine on a level surface remove the dipstick and check the engine oil level.

This procedure is best performed at the beginning of the work day with the engine cool and all oil drained back down to the pan.

WARNING: Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap: Let the system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions.

SA023

Cleaning axle plugs (starting with serial HBZN821ELBAE00874) The oil level and filling plugs are magnetic.

Remove and clean the plugs in the first 50 and 100 hours of operation of a new axle or if the axle has been repaired.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

Drain fuel filter of condensation

DSC09585

Raise the engine compartment access hood and check the indicator on the side of the coolant bottle.

BD03A015

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

2. Close the drain valve.

NOTE: In certain geographic regions and climates it may be necessary to drain off condensation more frequently.

BD06F001

Radiator cap access and fill access.

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Drain the water and sediment from the fuel pre-filter located on the right-hand side of the engine.

In the event that the system needs topping off make sure to use the proper ratio of water and antifreeze/coolant.

LUBRICATION/FILTERS/FLUIDS ____________________________________

Transmission oil level

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Hydraulic oil level

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WARNING: This check must be performed with the engine running! Comply with the following: • Make sure the gear selector is in neutral and the parking brake is set.

• Make sure the bucket or equipment is on the ground and the pilot lock out is engaged to neutralize hydraulic flow.

• The transport/service link must be in place to prevent accidental articulation.

If this check must be performed in an enclosed area be sure to ventilate properly to reduce the deadly exhaust fumes.

BD06F031

Check the level of the hydraulic oil tank with the machine on hard, level ground.

Rest the bucket/attachment on the ground, turn-off the engine, and check the level on the indicator. Oil must appear at the center of the level sight gauge.

In the event oil is not visible, slowly loosen the tank cap and top-off until the proper level is reached.

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WARNING: The hydraulic oil tank is pressurized. If removal of the cap is required, loosen it slowly to relieve residual pressure in the tank. Do not overfill.

DSC09557

Check the transmission oil level at idle speed with the oil temperature of 176° to 194°F (80° to 90°C).

The correct level is within the mark HOT. Do not overfill.

BD06F002

The hydraulic oil fill cap is located under the condenser core behind the operator’s cab.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

Bucket pivot pins grease fittings Grease the bucket pivot pins every 50 hours of operation.

Specification ............................................................................................ Akcela Molydisulfide

Rear axle pivot pin grease fittings Grease the rear axle pivot pin every 50 hours of operation.

Specification ............................................................................................ Akcela Molydisulfide

BWL_BS_002_12_1

Clean around the area to be greased before service.

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WARNING: Prior to maintenance always have the machine on firm, level ground with the equipment on the ground, also. Make sure all residual pressure is relieved from circuits before beginning maintenance.

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WARNING: Do not work under or near the equipment of a machine or components which are not adequately supported or blocked.

IMPORTANT: In severe conditions, such as immersion in water, it may be necessary to increase

the greasing service intervals.

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BS06B144

LUBRICATION/FILTERS/FLUIDS ____________________________________

100 Hour maintenance Machine grease fittings Grease the steering cylinder, boom pivot, loader lift arm cylinder, and front driveshaft support bearing fittings every 100 hours of operation.

Specification ........................................................................................... Akcela Molydisulfide

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BS06B144

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Change front and rear axle oil (until serial HBZN821ELBAE00873) After the first 100 hours of operation on a new machine you must change the break-in oil.

Normal axle oil maintenance will be at the 1000 hour operation point.

BD01E136

3. Place a suitable container with sufficient capacity to capture the old oil under each axel end.

1. Clean the area around the drain and fill caps of both axles and all four axel ends.

4. Re-install the drain plugs of both axles and the four axel ends.

5. Follow the procedure on page 142 under axle oil level to fill the axles to the proper level.

NOTE: The oil will take some time to fill each axle. Allow time for the oil to circulate throughout the axle.

BD02N123

2. Place a suitable container with sufficient capacity to capture the old oil under the front and rear axles and drain.

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WARNING: Make sure that the bucket/attachment is resting on the ground and the transport/service link is installed to stop unexpected articulation.

LUBRICATION/FILTERS/FLUIDS ____________________________________

Change front and rear axle oil (starting with serial HBZN821ELBAE00874) After the first 100 hours of operation on a new machine you must change the break-in oil.

1

Normal axle oil maintenance will be at the 1000 hour operation point.

!

WARNING: Make sure that the bucket/attachment is resting on the ground and the transport/service link is installed to stop unexpected articulation.

2 RCPH10WHL082AAH

Rear axle 1. LEVEL PLUG 2. AXLE END PLUG AND DRAIN

1. Clean the area around the drain and filler caps of both axles and all four axel ends.

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1

WARNING: Do not dispose of used oil and waste in the environment, this oil should be packaged in appropriate containers and sent to a recycling company (check your area).

NOTE: The oil level and filling plugs are

2

magnetic. Remove and clean the plugs in the first 50 and 100 hours of operation of a new axle, if the axle has been repaired, or during the oil changes.

3

3. Reinstall drain plugs of both axles and the four axle ends. Take care not to damage the drain plug seal.

RCPH10WHL081AAH

Front axle 1. LEVEL PLUG 2. CENTRAL DRAIN PLUG 3. AXLE END PLUG AND DRAIN

4. Fill the axle with new axle oil at axle ends. Oil should reach the bottom of the axle end level plug (rear axle) and the bottom of the central level plug (front axle).

2. Place a suitable container with sufficient capacity to capture the old oil under the front and rear axles (central part and axle ends) and drain the oil. Remove drain plugs to allow oil to drain.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS NOTE: The oil will take some time to fill each axle. Allow time for the oil to circulate throughout the axle.

Replace hydraulic oil filter After the first 100 hours of operation on a new machine you must replace the hydraulic oil filter Normal hydraulic oil filter oil maintenance will be at the 1000 hour operation point.

1

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WARNING: Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground.

1. FILLER PLUG

Change engine oil and filter

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After the first 100 hours of operation on a new machine you must change engine oil and filter.

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

2. Slowly loosen the filler cap on the hydraulic reservoir to release pressure in the reservoir. Leave it loose during the procedure.

Normal engine oil and filter maintenance will be at the 250 hour operation point.

See page 135 for more details.

Specification ........ Akcela nº 1 Engine Oil

3. Remove the access cover, if equipped.

SAE 15W40 API CI-4

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1. Park the machine on a level surface.

Lower the loader bucket/attachment to the ground and stop the engine. Apply the parking brake.

LUBRICATION/FILTERS/FLUIDS ____________________________________

Replace fuel filter After the first 100 hours of operation on a new machine you must replace the fuell filter Normal fuel filter oil maintenance will be at the 500 hour operation point.

BD06F066

4. Turn the filter counterclockwise to remove.

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5. Lubricate the gasket of the new filter (s) with clean oil and install. After the filter makes contact with the filter head tighten 1/2 to 3/4 turns.

BD06F014

Clean the filter head area, the outside of the filter (s) and any dirt and debris around the area that might contaminate the system.

IMPORTANT: Never use a filter wrench to

tighten a new filter on install.

6. Tighten the cap on the hydraulic reservoir.

1. Turn the filter counterclockwise and remove. Be sure to capture any fuel remaining in the lines or the filter and discard properly.

7. Start the engine and run at 1000 rpm.

Have an assistant check for leaks around the filter area.

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

8. Stop the engine and check the hydraulic oil level. Top off if necessary.

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

IMPORTANT: Never use a filter wrench to

tighten a new filter on install.

!

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

_____________________________________ LUBRICATION/FILTERS/FLUIDS

Change transmission oil and filter After the first 100 hours of operation on a new machine you must change transmission oil and filter Normal transmission oil and filter maintenance will be at the 1000 hour operation point.

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WARNING: Avoid polluting the environment.

BD02N124

7. Remove the drain plug and drain the oil.

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

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2. Lower bucket/attachment to the ground and lock the pilot control lock lever.

3. Put the transport/service link into the locked service position to avoid unexpected articulation and stop the engine.

BD06F065

8. Remove the filter.

9. Apply a film of clean transmission oil to the gasket of the new filter and install.

Make sure that the proper contact is made with the base.

10. Check the oil level at the sight gauge.

BD06F065

11. Start the engine and check for oil leaks around the filter and drain plug.

4. Clean the area around the filter head and around the transmission drain and fill caps.

12. Bring the transmission oil up to working temperature and check the level again.

5. Remove the dipstick.

6. Have a suitable container that will hold the appropriate amount of fluid before draining.

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LUBRICATION/FILTERS/FLUIDS ____________________________________

250 Hour maintenance Cab air filters

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WARNING: Wear full coverage safety glasses with side panels when using compressed air to clean components.

Limit the pressure to 29 psi (2 bar).

4. Clean the main filter with compressed air or replace it with a new one.

5. Secure the access filter cover.

Check drive belt DSC09624

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The cab filter is located on the right side of the cab. Unlatch and remove cover to access the filter.

1. Remove the filter and check it for debris or tears.

BD06F167

The drive belt is located behind the rear grille.

BD06F095

2. Remove the retaining screw that holds the re-circulation air filter cover in place and remove the filter.

3. Clean the re-circulation filter with detergent and water or replace with a new one. Dry with compressed air.

BD06F033

Perform a visual inspection for cracks and damage. To replace the belt use a breaker bar and release the tension from the automatic tension device.

NOTE: Do not get too close to the filters with

the air nozzle or you may damage the filters.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS Raise the engine compartment hood and check the indicator on the side of the coolant bottle.

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

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions.

In the event that the system needs topping off make sure to use the proper ratio of water and antifreeze/coolant.

BD06F001

Radiator cap access and fill access.

DSC09585

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LUBRICATION/FILTERS/FLUIDS ____________________________________

Tire pressure

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WARNING: Explosive separation of the tire and / or rim parts can cause injury or death.

When tire service is necessary, have a qualified tire technican service the tire.

To add air to a tire: 1. Use an air hose with a remote shutoff valve and a self-locking air chuck.

2. Stand BEHIND the tread of the tire and make sure ALL personnel are away from the side of the tire before you start.

BD03A024

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3. Inflate the tire to the manufactures recommended air pressure.

WARNING: Wear full coverage safety glasses with side panels when using compressed air.

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.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

Change engine oil and filter Change the engine oil and filter after 500 hours of operation or once a year, whichever occurs first. Change the engine oil more frequently when the engine operating conditions are severe.

Specification ........ Akcela nº 1 Engine Oil SAE 15W40 API CI-4 1. Place the machine on level ground, in neutral with the parking brake applied.

BD06F042

2. Lower bucket/attachment to the ground and install the transport/service link into the lock position.

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4. Raise the engine hood.

BD06F041 BD06F008

5. Clean the area around the filter of dirt and debris.

3. Use a suitable container and drain the engine oil.

6. Turn the filter counterclockwise to remove. Remove and discard the filter following local environmental and waste regulations.

REMOTE ENGINE OIL DRAIN

NOTE: When changing engine oil the oil flow rate can be improved if the oil fill cap or dipstick is removed from the engine while draining.

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

IMPORTANT: Never use a filter wrench to

install a new filter.

8. Turn the new oil filter onto the base until the gasket makes contact with the base and then turn by hand for 3/4 more turn.

9. Close the remote drain.

10. Fill the engine with the proper amount of oil.

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LUBRICATION/FILTERS/FLUIDS ____________________________________ 11. Start the engine a run at idle speed.

Check the engine oil filter and remote drain for leaks.

500 Hour maintenance Axle oil level (until serial HBZN821ELBAE00873)

12. After two minutes stop the engine.

1. Park the machine on a level surface.

Lower bucket/attachment to the ground and apply the parking brake.

13. Wait for the engine oil to drain down for an accurate read on the dipstick.

14. Check the dipstick and if necessary add oil.

15. Lower the engine hood.

2. Lock the pilot control out and stop the engine.

Crankcase filters

3. Place the transport/service link into the position.

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BD01E134

4. Clean the area thoroughly and then remove the axle dipstick. One each wheel.

BD03A209

CRANKCASE BREATHER FILTER HOUSING

Remove the screws on the filter housing and replace the two filters.

BD02N131

5. Place the dipstick back into the fill hole but do not thread it down.

6. Remove and measure the oil level.

NOTE: Be careful to not damage the O-ring.

Replace it if necessary.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

Axle oil level (starting with serial HBZN821ELBAE00874) 1. Park the machine on a level surface.

Lower bucket/attachment to the ground and apply the parking brake.

2. Lock the pilot control out and stop the engine.

1

3. Place the transport/service link into the position.

2 RCPH10WHL082AAH

1

Rear axle

5. Oil should reach the bottom of the axle end level plug (rear axle) and the bottom of the central level plug (front axle).

2

3 RCPH10WHL081AAH

Front axle 1. LEVEL PLUG 2. CENTRAL DRAIN PLUG 3. AXLE END PLUG AND DRAIN

4. Clean the area around the drain and filler caps of both axles and all four axel ends.

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1. LEVEL PLUG 2. AXLE END PLUG AND DRAIN

LUBRICATION/FILTERS/FLUIDS ____________________________________

Battery electrolyte

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Replace fuel filter

WARNING: Batteries contain SULPHURIC ACID. Protect your eyes when working on batteries, to prevent possible splashes of acid. In the event acid contact the skin, eyes or clothing, WASH IMMEDIATELY WITH WATER FOR A MINIMUM OF FIFTEEN MINUTES. Seek immediate medical help.

BD06F014

Clean the filter head area, the outside of the filter (s) and any dirt and debris around the area that might contaminate the system.

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1. Turn the filter counterclockwise and remove. Be sure to capture any fuel remaining in the lines or the filter and discard properly.

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

3. 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.

BD06F013

Access the batteries by opening the respective compartment.

IMPORTANT: Never use a filter wrench to

tighten a new filter on install.

!

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

_____________________________________ LUBRICATION/FILTERS/FLUIDS

1000 Hour maintenance

Drain fuel tank condensation

Replace hydraulic oil filter Replace the hydraulic oil filter every 1000 hours or if the hydraulic filter warning lamp illuminates.

Every 500 hours of operation the condensation must be removed from the fuel tank.

1. Park the machine on a level surface.

Lower the loader bucket/attachment to the ground and stop the engine. Apply the parking brake.

1. Park the machine on level ground and follow the required safety procedures with the bucket/attachment on the ground.

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

BD06H026

!

2. Have a suitable container ready to capture the condensation and fuel. Dispose of the waste following local regulations.

2. Slowly loosen the filler cap on the hydraulic reservoir to release pressure in the reservoir. Leave it loose during the procedure.

3. Place hose over fuel tank petcock and open slowly and allow the condensation to flow until only fuel is discharged.

NOTE: The fuel petcock is located on the bottom left front corner of the fuel tank, behind the rear axle.

4. Tighten the fuel tank petcock.

NOTE: In certain geographic regions and climates it may be necessary to drain off condensation more frequently.

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WARNING: Fluid under pressure. Always rest the hydraulic bucket/attachment on the ground.

LUBRICATION/FILTERS/FLUIDS ____________________________________ 3. Remove the access cover, if equipped.

Grease articulation fittings

BD06F066

4. Turn the filter counterclockwise to remove.

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5. Lubricate the gasket of the new filter (s) with clean oil and install. After the filter makes contact with the filter head tighten 1/2 to 3/4 turns.

DSC09555

1. Park the machine on a level surface.

Lower the loader bucket/attachment to the ground and stop the engine. Apply the parking brake.

IMPORTANT: Never use a filter wrench to tighten a new filter on install.

6. Tighten the cap on the hydraulic reservoir.

2. Place the transport/service link into the lock position to stop unexpected articulation of the machine.

7. Start the engine and run at 1000 rpm.

Have an assistant check for leaks around the filter area.

3. Clean the area around each fitting and grease.

8. Stop the engine and check the hydraulic oil level. Top off if necessary.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

Change front and rear axle oil (until serial HBZN821ELBAE00873) Normal axle oil maintenance will be at the 1000 hour operation point.

!

WARNING: Make sure that the bucket/attachment is resting on the ground and the transport/service link is installed to stop unexpected articulation.

BD01E136

1. Clean the area around the drain and fill caps of both axles and all four axel ends.

3. Place a suitable container with sufficient capacity to capture the old oil under each axel end.

5. Follow the procedure on page 142 under axle oil level to fill the axles to the proper level.

NOTE: The oil will take some time to fill each axle. Allow time for the oil to circulate throughout the axle.

BD02N123

2. Place a suitable container with sufficient capacity to capture the old oil under the front and rear axles and drain.

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4. Re-install the drain plugs of both axles and the four axel ends.

LUBRICATION/FILTERS/FLUIDS ____________________________________

Change front and rear axle oil (starting with serial HBZN821ELBAE00874) After the first 100 hours of operation on a new machine you must change the break-in oil.

1

Normal axle oil maintenance will be at the 1000 hour operation point.

!

WARNING: Make sure that the bucket/attachment is resting on the ground and the transport/service link is installed to stop unexpected articulation.

2 RCPH10WHL082AAH

Rear axle 1. LEVEL PLUG 2. AXLE END PLUG AND DRAIN

1. Clean the area around the drain and filler caps of both axles and all four axel ends.

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1

WARNING: Do not dispose of used oil and waste in the environment, this oil should be packaged in appropriate containers and sent to a recycling company (check your area).

NOTE: The oil level and filling plugs are

2

magnetic. Remove and clean the plugs in the first 50 and 100 hours of operation of a new axle, if the axle has been repaired, or during the oil changes.

3

3. Reinstall drain plugs of both axles and the four axle ends. Take care not to damage the drain plug seal.

RCPH10WHL081AAH

Front axle 1. LEVEL PLUG 2. CENTRAL DRAIN PLUG 3. AXLE END PLUG AND DRAIN

4. Fill the axle with new axle oil at axle ends. Oil should reach the bottom of the axle end level plug (rear axle) and the bottom of the central level plug (front axle).

2. Place a suitable container with sufficient capacity to capture the old oil under the front and rear axles (central part and axle ends) and drain the oil. Remove drain plugs to allow oil to drain.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS NOTE: The oil will take some time to fill each axle. Allow time for the oil to circulate throughout the axle.

Replace Cab Air Filter

1

DSC09624

The cab filter is located on the right side of the cab. Remove 2 bolts and remove the cover to access the filter.

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1. FILLER PLUG

DSC09625

Pull the main filter out and replace it.

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LUBRICATION/FILTERS/FLUIDS ____________________________________

Change transmission oil and filter

!

WARNING: Avoid polluting the environment.

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

2. Lower bucket/attachment to the ground and lock the pilot control lock lever.

3. Put the transport/service link into the locked service position to avoid unexpected articulation and stop the engine.

BD02N124

7. Remove the drain plug and drain the oil.

TRIM THIS EDGE BD06F065

BD06F065

8. Remove the filter.

4. Clean the area around the filter head and around the transmission drain and fill caps.

9. Apply a film of clean transmission oil to the gasket of the new filter and install.

Make sure that the proper contact is made with the base.

5. Remove the dipstick.

6. Have a suitable container that will hold the appropriate amount of fluid before draining.

10. Spin the breather, located on the top of the transmission, a few times every 1000 hours.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS 11. If the breather is difficult to spin follow steps 12 and 13.

Replace drive belt

12. Remove the breather. Clean it with solvent and dry with compressed air.

!

WARNING: Wear full coverage safety glasses with side panels when using compressed air.

13. Install the breather.

14. Check the oil level at the sight gauge.

15. Start the engine and check for oil leaks around the filter and drain plug.

BD06F033

16. Bring the transmission oil up to working temperature and check the level again.

To install the new belt lay it over the alternator, crankshaft pulleys and complete the turn while lifting the tensioner with the breaker bar.

Check injector calibration This should be done by a qualified service technician. Contact your Dealer.

Check valve adjustment This should be done by a qualified service technican. Contact your dealer.

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Actuate the belt tensioner with a breaker bar and remove the belt.

LUBRICATION/FILTERS/FLUIDS ____________________________________ 7. Open the hydraulic reservoir remote drain and drain the oil into a suitable container.

2000 Hour maintenance Change hydraulic oil

8. Clean the area around the filler cap and slowly remove the cap.

1. Park the machine on a level surface, lower bucket/attachment to the ground and apply the parking brake.

2. Stop the engine. Put a DO NOT OPERATE tag on the steering wheel or key switch.

3. Place the transport/service link into the lock position to prevent unexpected articulation.

4. Make sure the brake accumulators are completely discharged by pushing down on the brake pedal a minimum of 30 times.

BD06F065

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5. Make sure ride control accumulators are completely disengaged, if equipped.

9. Remove and replace the hydraulic oil filter.

10. Fill the reservoir with new hydraulic oil.

6. With the key in the RUN position cycle the bucket/attachment control levers repeatedly through their complete range of motion for at least 30 seconds.

11. Install the reservoir filler cap.

12. Start the engine and run at 1000 rpm.

Check for leakage around the filter and drain.

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

14. Place the loader bucket/attachment on the ground and stop the engine. Check the hydraulic oil level.

15. If it is necessary to top off with more oil, remove the fill cap slowly to release pressure in the reservoir.

BD06F008

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

Change coolant Drain, flush and replace the engine coolant every 2000 hours of operation or each year, whichever occurs first. Clean the system and replace the coolant if it becomes dirty or has the color of rust.

WARNING: Hot coolant can spray out if radiator cap is removed. To remove the radiator cap: BD06F008

Let the system cool, turn cap counterclockwise to the first notch, then wait until all pressure is released.

2. With a suitable container of the proper capacity under the remote drain, open the cap by turning counterclockwise and drain the coolant from the system.

Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions.

3. After all the coolant is drained secure the drain cap.

4. Use a system cleaning product to clean and flush the system. Contact your dealer.

5. After, the system has been cleaned and flushed following the instructions of the manufacturer, replace and secure the drain cap.

6. Pour the proper mix of antifreeze/coolant and water into the system.

7. Start the engine and let it run at low idle until the engine reaches the operating temperature. Check the level the system.

8. Install the radiator cap.

BD06F001

1. After the engine has cooled so the temperature of the coolant is safe, remove the cap.

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LUBRICATION/FILTERS/FLUIDS ____________________________________

Precleaner (if equipped) Check the precleaner bowl and remove dust as required.

1 3

2

BD03J009

1. Access the engine air filters by raising the hood.

BD06F019

1. Loosen nut (1) and remove cap (2).

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2. Remove bowl (3) and clean with damp cloth. Install bowl and cap.

Replace engine air cleaner The air filter and dust valve should be checked periodically for dirt and debris build up. In extreme work conditions more often.

Replace the engine air filters every 2000 hours, if the filter restriction indicator lamp on the instrument cluster illuminates or each year, whichever occurs first.

BD06F018

1. Release the four clips that secure the end cap.

2. Remove the primary and secondary filters.

BD06F015

3. Wipe the inside of the filter body and clean of dirt and debris before installing the new filters.

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_____________________________________ LUBRICATION/FILTERS/FLUIDS

BD06F016

BD06F018

6. Install the end cap and lock the four clips to lock the cover on.

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4. Install the new secondary filter.

BD06F017 BD06F018

5. Install the new primary filter.

7. Push on both ends of dust valve to drain dust and debris from filter housing.

8. Close the engine hood.

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LUBRICATION/FILTERS/FLUIDS ____________________________________

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MAINTENANCE AND ADJUSTMENTS Wheels and tires

! !

!

WARNING: Explosive separation of the tire and / or rim parts will result in serious injury or death. When tire service is necessary, have a qualified tire technican service the tire.

84-113 WARNING: DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air / gas mixture that will be ignited with high temperatures. This can happen to tires inflated or deflated. Removing air or breaking the bead is not adequate. Tires MUST be completely removed from the rim prior to welding.

SB134 WARNING: Wear full coverage safety glasses with side panels when using compressed air.

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!

WARNING: Exploding tires and / or rim parts will result in serious injury or death. Keep yourself and others out of the DANGER AREA. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires.

SD020

MAINTENANCE AND ADJUSTMENTS ________________________________

Ballast It is the recommendation of CNH America LLC NOT to add Ballast to the tires of your wheel loader. Make sure tires are properly inflated.

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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________________________________ MAINTENANCE AND ADJUSTMENTS

Adding air to the tires

Tire or rim service

This procedure is only for adding air to the tire. If the tire has lost most or all of the air, do the following: • Before you add air, have the wheel correctly installed on the machine or put the wheel in a restraining device (tire inflation cage).

Always have a qualified tire technician service the tires and rims for this machine. It is recommended that you have this technician inflate the tires. To prevent accidents, use a restraining device (tire inflation cage), correct equipment, and correct procedure.

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

B790490R

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

B770164R

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

BD03A024

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

• Inflate the tire to the manufactures recommended air pressure.

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Tire tread direction

MAINTENANCE AND ADJUSTMENTS ________________________________

Wheel nuts torque

Wheel nuts torque 821E

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

1

15

11

8 4

10

13

5

6 9

14 2

3 16

7

12 87307434

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Tighten the wheel nuts using the sequence shown. First tighten the nuts to 220 poundfeet (298 Nm), then tighten to a final torque of 475-530 pound-feet (640 to 720 Nm), using the same sequence.

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________________________________ MAINTENANCE AND ADJUSTMENTS

Cab service Air conditioning (if equipped) The components of the operators cab, including the components of the air conditioning system, require service at different intervals.

Service the following items as required to maintain maximum operating efficiency.

!

WARNING: Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning and the safety precautions which must be followed.

SD048

BD06F040

1. CONDENSER

Keep the air conditioning condenser core clean. Use compressed air 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.

WARNING: Wear full coverage safety glasses with side panels when using compressed air.

Radiator/cooler access for cleaning

Lubrication of the air conditioning compressor seals

(Additional radiator access can be gained on both the LH & RH sides of the machine).

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 cover over the air conditioning condenser. This will make sure the refrigerant and lubricants in the system will be at operating temperature.

1. Remove bolt from end of the plastic fender insert.

2. Slide fender insert to the rear of the machine 1 inch (25mm) to disengage fender insert from rear frame side plate.

3. The lower areas and radiator/cooler in general can be cleaned using shopvacuum and or pressure washer.

IMPORTANT: Be careful not to bend or

damage radiator/cooler fins during cleaning. DO NOT exceed 1000 psi (6890 kPa) nozzle pressure when cleaning.

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MAINTENANCE AND ADJUSTMENTS ________________________________

Hoses and wiring

1

Check all hoses and wiring for damage. If damage occurred, see your dealer for repair or replacement.

Operator’s 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.

2

Before removing stains, try to find what type and how old the stains are. Some stains can be removed with water or soap solution.

BD06F038

1. INSERT 2. BOLT

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Cab headliner TRIM THIS EDGE

The foam headliner in your cab decreases noise. To keep the headliner in good operating condition, remove dust with a vacuum cleaner.

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.

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.

When the stain is removed from the material, immediately use a cloth to dry the area and to prevent a cleaner circle pattern. If a circle pattern occurs, clean the complete area.

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.

BD06F053

Door hinges Use graphite to lubricate all hinges. DO NOT use oil.

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________________________________ MAINTENANCE AND ADJUSTMENTS

SECONDARY STEERING CHECK (IF EQUIPPED) NOTE: Test the secondary steering a minimum of every 250 hours.

!

4. With the machine at low idle and steering straight ahead, turn the key switch to the OFF position to stop the engine and then immediately back to the ON position (not start position). The secondary steering pump/motor should start running immediately. Confirm the light is on and the motor is running.

WARNING: The secondary steering system is electrically powered. This system allows you to steer the machine if the primary steering system stops working.

Maintain the batteries to assure the system will function.

5. Steer the machine full left and then full right to confirm that the secondary steering pump is working. Confirm there is no lack of steering function.

IMPORTANT: Do not run the secondary pump/motor continuously for more than 20 seconds at a time without a 2 minute cool down.

7. Restart the engine. Confirm the secondary steering light stays on. The secondary steering motor should stop after about 3 seconds and the secondary steering light should go out.

BD06F096

1. Prior to checking the secondary steering system, park the machine on hard packed level ground with enough clearance around the machine to allow you to completely steer from side to side.

Raise the bucket approximately 20 inches (500 mm) above the ground.

8. If steps 2 through 7 function properly, the secondary steering is operating correctly. If not, repair and retest.

9. Let the engine run and allow the batteries to recharge for a minimum of 10 minutes.

2. With the key switch on and the engine off, confirm the secondary steering light within the cluster is on. This indicates the steering pressure is low.

!

3. Start the machine and let the engine run for a few seconds. Confirm the secondary steering light is out after the first second. This confirms the electrical function of the circuit is operating correctly and also confirms pressure has been built and the module has been armed.

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WARNING: Do not turn the key switch off if the machine is steered against either the right hand or left hand steering stop.

The steering wheel may kick back.

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6. Look at the instrument cluster to verify that the secondary steering light comes on.

MAINTENANCE AND ADJUSTMENTS ________________________________

PARKING BRAKE CHECK NOTE: Test the parking brake at a maximum of 250 hours.

C. Stop the engine turn the key switch to the ON position, engine off the park brake light should come ON.

Before you operate the machine periodically test the parking brake functions.

D. Release the park brake using B and C in step 1. Make sure the park brake light is out.

E. Pump the service brakes, the low brake pressure warning light should come ON first. Continue to pump the service brakes. Pump until the park brake light comes ON, pump the brakes three more times, it could require as many as forty pumps total.

F. Start the engine and allow the brake pressure to build until the warning light goes out.

BD06F096 / BD06F099

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1. To release the park brake, all the following are required:

G. Depress the service brake and release. The brake light must stay ON.

A. Push the park brake switch to the release position.

H. Put the transmission in F or R and back to N the brake light must stay ON.

B. Press on brake pedal noting function when brake lights come 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.

C. Transmission shifter positioned from N to F or R for a second, and back to N. D. Adequate service brake pressure to stop the machine.

4. Put the park brake switch in the release position, attempt B and C in step 1. The park brake light must turn OFF.

2. To engage the park brake, any of the following is required:

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 brake light ON. Transmission disengages.

A. Loss of service brake pressure in both axles.

B. Loss of system electrical power (key OFF).

C. Park brake switch in engaged position.

If all steps are working positive the system works correct. If there was a problem with the test contact your dealer.

3. To test these functions: A. Start on a clear level surface.

B. With step 1, A through C complete, start the engine release the park brake, red warning light out.

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________________________________ MAINTENANCE AND ADJUSTMENTS

Fire extinguisher (if equipped)

Plastic and resin parts When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

It is strongly recommended to have a fire extinguisher and to place it in the rear lefthand side compartment in the bracket designed for the purpose.

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

Maintenance specification Every month Examine the fire extinguisher and make sure it is not damaged.

Whenever carrying out a welding operation on the machine as authorized by the manufacturer and in accordance with their instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires. Disconnect electrical harness of engine and transmission control modules. Connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Every six months Have an approved specialist empty and refill the powder in the fire extinguisher.

Every year Have an approved specialist examine the fire extinguisher.

Always connect the welding apparatus to the same structure that is being welded.

Never connect the welding apparatus ground to a component of the hydraulic system.

!

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WARNING: Do not undertake any modifications to your machine.

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Welding on the machine

MAINTENANCE AND ADJUSTMENTS ________________________________ 3. The Location of the height control target within its slot in the target mounting plate will determine the automatic stopping height of the lift arms as they are raised.

The higher the target is positioned in its slot in the target mounting plate, the lower the lift arms will automatically stop as they are raised. Position the target per the table below. Tighten the target in this position.

Loader adjustments Height control and return to travel adjustment procedure 6

2

5

1 3

4

A

2

BS00N076

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1.

2.

3.

4.

5.

6.

PROXIMITY SWITCH RETURN TO TRAVEL TARGET TARGET MOUNTING PLATE HEIGHT CONTROL TARGET LIFT ARM FRONT CHASSIS (TOP LEFT HAND SIDE)

B

4

1. To avoid damage to the proximity switch, it must be adjusted back, away from the lift arm, to clear everything on the lift arm as it sweeps past.

2. Start the engine. Position the bucket flat on the ground. Shut the machine off.

Locate the return to travel target opposite the proximity switch and then tighten it to the target mounting plate. Next adjust the proximity switch out toward the target until and air gap of 1/8 to 3/16 inch (3.5 to 5.0 mm) is obtained. Lock the proximity switch in position with its jam nut. Torque the jam nut to 5 ft.lbs.

BS00N077

4. The location of the return to travel target within its slot in the target mounting plate will determine where the lift arms will automatically stop while they are lowered. The higher this target is located in its slot in the target mounting plate the lower the lift arms will automatically stop as they are lowered. Position the target per the table below. Tighten the target in this position.

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________________________________ MAINTENANCE AND ADJUSTMENTS

Machine

A in (mm)

Approximate resulting return to travel hinge pin height in (mm)

B in (mm)

Approximate resulting height control hinge pin height in (mm)

821E Z - Bar.

1.73 in (44 mm)

14.96 in (380 mm)

1.50 in (38 mm)

130 in (3302 mm)

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5. Make sure the proximity switch and all the mounting bolts are tight. Start the engine. Set the detent switch to the on position, and set the return to travel/float detent switch to the return to travel position. Raise the lift arms to approximately the horizontal position. Put the loader control lever in the raise position, and verify that the electromagnet holds it in that position until the height control target passes in front of the proximity switch. Next, with the lift arms still raised, put the loader control lever in the lower position, and verify that the electromagnet holds it in that position until the return to travel target passes in front of the proximity switch. Position the bucket flat on the ground. Shut the machine off.

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MAINTENANCE AND ADJUSTMENTS ________________________________

Z-bar Return to dig adjustment procedure 1

2 3

4

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5

7

6

BSOON079

1.

2.

3.

4.

5.

6.

7.

BELL CRANK TARGET MOUNTING BRACKET TILT CYLINDER PROXIMITY SWITCH GUARD PROXIMITY SWITCH PROXIMITY SWITCH MOUNTING BRACKET TARGET BAR

4. Loosen the bolts holding the proximity switch mounting bracket to the tilt cylinder. Position the proximity switch face parallel to the target bar surface, and tighten the bolts. Next adjust the proximity switch face parallel to the target bar surface, and tighten the bolts. Next adjust the proximity switch out toward the target bar until an air gap of 1/8 to 3/ 16 inch (3.5 to 5.0 mm) is obtained. The proximity switch must not protrude past the proximity switch guard. Lock the proximity switch in position with its jam nuts.

Torque the jam nut to 5.0 ft. lbs.

1. Start the engine. Raise the lift arms until they are approximately horizontal. Fully dump the bucket. Lower the arms until bucket edge is on the ground. Shut the machine off.

2. Loosen the bolts holding the target mounting bracket to the tilt cylinder eye.

Align the target mounting bracket parallel to the tilt cylinder, and tighten the bolts.

3. Loosen the bolts holding the target bar to the target mounting bracket. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

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________________________________ MAINTENANCE AND ADJUSTMENTS 8. Make sure the proximity switch and all the mounting bolts are tight. Start the engine. Set the detent switch to the on position, and set the return to travel/float detent switch to the return to travel position. Raise the lift arms to approximately the horizontal position. Position the bucket to the fully dumped position. Put the loader control lever in the roll back position, and verify that the electromagnet holds it in that position until the end of the target bar passes in front of the proximity switch. Lower the lift arms to the ground, and verify the bucket is flat on the ground.

5. Start the engine. Position the bucket flat on the ground. Shut the machine off.

Loosen the bolts holding the target bar to the target mounting bracket. Slide the target bar towards the proximity switch until the face of the proximity switch is completely covered. Align the target bar parallel to the tilt cylinder, and tighten the bolts.

6. Turn the key switch to the on position (not accessory position). Do not start the engine. Position the bucket control lever to the full roll back position. The electromagnetic detent should hold the control lever in this position.

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7. Loosen the bolts holding the target bar to the target mounting bracket. Slowly slide the target bar away from the proximity switch. When the proximity switch face is nearly uncovered, the switch will be activated, and the control lever will return to the center position. Tighten the bolts maintaining this location of the target bar. Verify that the 1/8 to 3/16 inch (3.5 to 5.0 mm) gap is maintained between the target bar and the proximity switch.

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MAINTENANCE AND ADJUSTMENTS ________________________________

Bucket height control minor adjustment

Seat belt The seat belt is an important part of your Rollover Protection Structure (ROPS). You must wear the seat belt at all times when you operate the machine.

1. Park the machine on a level surface.

Lower the loader bucket to the ground.

2. Apply the parking brake and stop the engine.

1. Keep the seat belts away from objects that can damage the seat belts.

3. Loosen the rear actuator.

2. Check the seat belts for damage.

Replace all parts that are damaged.

4. To increase the dump height, move the actuator down in the slot. To decrease the dump height, move the actuator up.

3. Make sure that the mounting bolts of the seat belts are tight. See torque specifications for seat in this manual.

5. Tighten the actuator.

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6. Start the engine and pull the lift control lever to the RAISE detent position. When the loader arms stop moving, check the dump height.

4. Keep the seat belts clean. Wash the seat belts only in soap and water.

Do not put the seat belts in bleach or dye.

This will make the seat belts weak.

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________________________________ MAINTENANCE AND ADJUSTMENTS

OPERATOR PROTECTIVE STRUCTURE Torque specifications for ROPS cab and ROPS canopy

BD06F070

ROPS CANOPY LABEL

Maintenance and inspection of ROPS

ROPS CAB AND ROPS CANOPY MOUNTINGBOLTS (BOTH SIDES), TIGHTEN TO 580 TO 630 POUND-FEET (772 TO 854 NM)

After the first 20 hours of operation and after every 500 hours of operation, do the following:

NOTE: Torque specifications are for clean, dry threads.

1. Check the torque of the ROPS mounting bolts. If necessary, 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.

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.

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BD00M101

MAINTENANCE AND ADJUSTMENTS ________________________________

OPERATOR PROTECTIVE STRUCTURE

!

WARNING: Your machine is equipped with an operator protective structure, such as: Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS) or cab with ROPS. A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. The Protective Structure is a special safety component of your machine.

DO NOT attach any device to the protective structure for pulling purposes.

DO NOT drill holes in the protective structure.

The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the protective structure MUST be replaced so that it will provide the same protection as a new protective structure. Contact your dealer for protective structure inspection and replacement.

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After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: • The Protective Structure MUST be replaced.

• The mounting or suspension for the protective structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT.

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________________________________ MAINTENANCE AND ADJUSTMENTS

Torque specifications for seat and seat belts

Engine accessory belt Service interval

1

Belt service interval. Check as required or every 250 hours.

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

2. Open the hood.

3. Turn the master disconnect switch off.

6397

BD06G096

2 SCREWS ON EACH SIDE

1. 54-64 FT LB (73-87 NM)

4. Remove the 4 screws that hold the protective cover.

BD06F033

5. Install a 3/8 inch breaker bar in the tension pulley bracket.

6. Push the breaker bar forward just enough to release the tension on the drive belt.

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1

MAINTENANCE AND ADJUSTMENTS ________________________________

Fire extinguisher mounting (if equipped)

Inspection and care EVERY MONTH: It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

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.

EVERY 6 MONTHS: Have the dry chemical removed and refilled by a fire equipment technician.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Class A, B and C type fires. The operating temperature is from -65° to 120°F (-54° to 49°C).

ONCE EACH YEAR: Have the fire equipment technician inspect the fire extinguisher.

TRIM THIS EDGE 153L95

IMPORTANT: DO NOT mount the Fire

Extinguisher on any part of the ROPS or FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

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ELECTRICAL SYSTEM Battery safety

!

! !

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

SA046 WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately. EYES: flush with water for 15 minutes and get prompt medical attention.

SB032 WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge.

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

Battery vents

NOTE: The electrical system in this machine is 24 volts. Each battery is 12 volts.

Keep the battery vents clean, make sure the vents are not restricted.

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Do not run the engine with the battery cables disconnected or with the alternator wires disconnected.

Do not use a steam cleaner or cleaning solvent to clean the alternator.

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!

ELECTRICAL SYSTEM ____________________________________________

Cleaning the Batteries Check the batteries and battery compartment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries. Use one of the following methods to clean the batteries.

1

Use baking soda or ammonia and flush the outside of the batteries with water.

DSC02161

To access the batteries, right or left side, remove the three bolts that secure the cover. Handles are provided for easy removal and installation (1). (one ea. side).

IMPORTANT: Booster batteries must be conTRIM THIS EDGE

nected on the LEFT side only!

BD06G102

BATTERY COVER

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____________________________________________ ELECTRICAL SYSTEM

Fuses

DSC09626

The fuse decal is located inside the access door.

NOTE: See the following page for detail of fuse information.

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BD06G175

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.

ELECTRICAL SYSTEM ____________________________________________

REPLACEMENT FUSES ECC Fuse panel

ECD Fuse panel

FUSE

AMP

FUNCTION

FUSE

AMP

FUNCTION

F1

7,5

DOME LAMP - BEACON

F1

7,5

TRANSMISSION CONTROL

F2

15

WORK LIGHTS

F2

30

ENGINE STARTER

F3

15

ROAD LIGHTS

F3

10

INSTRUMENT CLUSTER

F4

10

BRAKE LIGHTS - FLASHER

F4

10

12 VOLT AUX. PLUG

F5

10

ENGINE START

F5

10

12 VOLT AUX. PLUG

F6

7,5

HORN

F6

10

RADIO

F7

7,5

HOOD RAISE - LOWER

F7

15

12 VOLT AUX. PLUG

F8

15

CIGARETTE LIGHTER

F8

F9

10

ECB Fuse panel

F10

ECA Fuse panel TRIM THIS EDGE

FUSE

AMP

FUNCTION

F1

7,5

TRANSMISSION CONTROL

F2

5

STEERING

F3

7,5

INSTRUMENT CLUSTER

F4

7,5

SECONDARY STEERING

F5

5

RIDE CONTROL

F6

5

PARKING BRAKE

F7

7,5

COUPLER/FAN REVERSER

F8

5

TURN SIGNAL/FLASHER

F9

10

ENGINE STOP

F11

25

BLOWER SWITCH

F12

10

FRONT WIPER

F13

10

REAR WIPER

F14

5

BACK-UP ALARM

F15

7,5

AIR CONDITIONING

F16

10

COMPRESSOR (SEAT)

F17

7,5

SECONDARY STEERING

FUSE

AMP

FUNCTION

F1

10

FRONT FLOOD LIGHTS

F2

10

REAR FLOOD LIGHTS

F3

5

HIGH BEAM LEFT

F4

5

HIGH BEAM RIGHT

F5

5

LOW BEAM LEFT

F6

5

LOW BEAM RIGHT

F7

5

LEFT TAIL LIGHTS

F8

5

RIGHT TAIL LIGHTS

F10

F18 F19 F20

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____________________________________________ ELECTRICAL SYSTEM

SERVICE ELECTRICAL CONNECTOR (IF EQUIPPED) The cigar lighter socket (24 volt) can be used for the connection of a lighting device to help with service and maintenance procedures.

NOTE: This is a 24 volt outlet.

BD06F056

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: These are 12 volt outlets.

BD06F060 / BD06F055

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AUXILIARY POWER OUTLET (IF EQUIPPED)

ELECTRICAL SYSTEM ____________________________________________

AUXILIARY POWER EQUIPMENT MOUNTING BRACKET LOCATION The auxiliary power equipment mounting brackets are located behind the right and left ROPS post covers. These brackets are for mounting radios, phones, etc.

To locate the bottom of the mounting bracket measure 11.8 inches (300 mm) from the bottom edge of the plastic panel. To locate the top of the mounting bracket measure 16.5 inches (420 mm) from the bottom edge of the plastic panel. The mounting bracket is approximately 2.75 inches (70 mm) wide.

BD00B009

RIGHT ROPS POST COVER

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SPECIFICATIONS 821E Model.....................................................................................Case 667TA/EBD Tier 3 certified Type ...........................................................................4-stroke, turbocharged, air-to-air cooled Cylinders................................................................................................................................ 6 Bore/stroke ................................................................... 4.09” in x 5.20” in (104 mm x 132 mm) Displacement .................................................................................................. 411 cu in (6.7 L) Fuel Injection ............................................................................................................Electronic Horsepower - Peak Max Power Gross (SAE J1995) ...................................................... 227 hp (169 kW) @ 2000 rpm Net (SAE J1349) ......................................................... 213 hp (159 kW) @ 2000 rpm Standard Power Gross (SAE J1995) ....................................................... 210 hp (157 kW) @1800 rpm Net (SAE J1349) ........................................................... 198 hp (148 kW) @1800 rpm Economy Power Gross (SAE J1995) ....................................................... 190 hp (142 kW) @1500 rpm Net (SAE J1349) .......................................................... 181 hp (135 kW) @1500 rpm Torque - Peak Max Power Gross (SAE J1995) .................................................. 739 lb.ft (1002 Nm) @ 1400 rpm Net (SAE J1349) ........................................................ 712 lb.ft (966 Nm) @ 1400 rpm Standard Power Gross (SAE J1995) .................................................... 724 lb.ft (982 Nm) @ 1400 rpm Net (SAE J1349) ........................................................ 701 lb.ft (950 Nm) @ 1300 rpm Economy Power Gross (SAE J1995) .................................................... 712 lb.ft (966 Nm) @ 1200 rpm Net (SAE J1349) ........................................................ 693 lb.ft (940 Nm) @ 1200 rpm Torque rise @ 2000 rpm ....................................................................................... 32,2% Engine Speeds Rated speed, full load ...................................................................................... 2000 rpm Low idle .................................................................................................... 875 - 925 rpm High idle, no load ................................................................................. 2120 to 2200 rpm Batteries ..................................................................................................................... 2 x 12 V Alternator ..................................................................................................................... 65 Amp Voltage .................................................................................................. 24 V, negative ground

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Engine

SPECIFICATIONS ________________________________________________ Drivetrain Transmission ......................................4F/3R Proportional w/ Electronic Control Module torque sensing autoshift/manual shift and modulation Gears...................................................................................................................... Helical Cut Until serial HBZN821ELBAE00873 Gear ratios 1st 2nd 3rd 4th

Forward 3,745 2,089 1,072 0,636

Reverse 3,551 1,981 1,017 -----

Torque converter stall ratio............................................................................................. 2,28:1 Differential .............................................. limited slip with 45% transfer on front and rear axles Rear axle oscillation .................................................................................................... 24° total Until serial HBZN821ELBAE00873 TRIM THIS EDGE

Axles Differential ratio Planetary ratio Final axle ratio

Front And Rear 4,11 6,000 24,67

Planetaries.................................................................................................................Outboard Service brakes ...................................... hydraulically actuated, maintenance-free, multiple wet disc w/accumulator to all four wheels Parking brakes .................... spring-applied hydraulic release disc on transmission output shaft Until serial HBZN821ELBAE00873 Travel speeds 1st 2nd 3rd 4th

Forward, mph (km/h) 4.4 (7.1) 7.8 (12.6) 14.5 (23.3) 23.0 (37.0)

Reverse, mph (km/h) 4.9 (7.9) 8.6 (13.8) 15.7 (25.3) -----

NOTE: Travel speeds @ full engine throttle with 23.5x25 L3 tires.

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________________________________________________ SPECIFICATIONS Starting with serial HBZN821ELBAE00874 Gear ratios 1st 2nd 3rd 4th

Forward 3,745 2,184 1,072 0,636

Reverse 3,551 2,071 1,017 -----

Torque converter stall ratio ............................................................................................ 2,28:1 Differential .............................................. limited slip with 45% transfer on front and rear axles Rear axle oscillation .................................................................................................... 24° total Starting with serial HBZN821ELBAE00874 Front And Rear 4,11 6,000 24,67

Planetaries.................................................................................................................Outboard Service brakes ...................................... hydraulically actuated, maintenance-free, multiple wet disc w/accumulator to all four wheels Parking brakes .................... spring-applied hydraulic release disc on transmission output shaft Starting with serial HBZN821ELBAE00874 Travel speeds 1st 2nd 3rd 4th

Forward, mph (km/h) 4.4 (7.1) 7.6 (12.2) 14.5 (23.6) 22.9 (36.8)

Reverse, mph (km/h) 4.7 (7.6) 8.0 (12.8) 15.6 (25.1) -----

NOTE: Travel speeds @ full engine throttle with 23.5x25 L3 tires.

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Axles Differential ratio Planetary ratio Final axle ratio

SPECIFICATIONS ________________________________________________

Hydraulics Pump-1 ................................................................................................dual, vane-type tandem Variable displacement ....................................................... (120 L/min @ 2000 rpm @ 248 bar) 3.84 in3/rev (63 cm 3/rev) 31.6 gpm @ 2000 rpm @ 3600 psi Pump-2 ................................................................ closed centered pressure/flow compensated Variable displacement ....................................................... (120 L/min @ 2000 rpm @ 248 bar) 3.84 in3/rev (63 cm 3/rev) 31.6 gpm @ 2000 rpm @ 3600 psi Loader control valve............................................. open-center, sectional 2,3,or 4-spool w/pilot control for lift, tilt and auxiliary hydraulics, electromagnetic detentes in float, raise and rollback Loader auxiliary hydraulics ..................................................25.3 to 63.2 gpm (96 to 239 L/min) Loader auxiliary steering ...........hydraulic orbital center-pivot articulating w/on-demand oil flow High pressure standby ............................................................................... 3 600 psi (248 Bar) NOTE: Filtration10-micron, full flow replaceable cartridges on return line, condition

indicator light for filter.

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Lift capacity 821E Z-Bar 3.5 yd3 (2.6 m3) 3.5 yd3 (2.6 m3) Bucket w/boltBucket w/teeth on edge 20 615 lb Full Height 20 495 lb (9 296 kg) (9 351 kg) Maximum 27 893 lb 28 014 lb Reach (12 652 kg) (12 707 kg) 37 257 lb 37 388 lb Ground (16 899 kg) (16 959 kg)

4.25 yd3 (3.2 m3) 4.25 yd3 (3.2 m3) Bucket w/boltBucket w/teeth on edge 20 155 lb 20 275 lb (9 142 kg) (9 196 kg) 27 536 lb 27 658 lb (12 490 kg) (12 545 kg) 36 731 lb 36 864 lb (16 661 kg) (16 721 kg)

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4.50 yd3 (3.4 m3) Bucket w/bolton edge 20 204 lb (9 164 kg) 27 571 lb (12 506 kg) 36 608 lb (16 605 kg)

________________________________________________ SPECIFICATIONS

BS06C560

SAE bucket capacity Struck .................................................................................................. 2.90 yd3 (2.22 m3) Heaped ................................................................................................ 3.44 yd3 (2.63 m3) A. Height to top of cab........................................................................ 135.8 in (3 450 mm) B. Wheelbase..................................................................................... 131.5 in (3 340 mm) C. Ground clearance ............................................................................ 16.4 in (415.8 mm) D. Angle of departure .......................................................................................33 degrees Width Overall w/o bucket and 23.5-25 XHATL tires.......................................113.6 in (2.89 m) Centerline tread ....................................................................................87.8 in (2.23 m) Turning radius - outside w/ 23.5-25 XHATL tires......................................237.5 in (6.03 m) Turning angle From center .................................................................................................40 degrees Total angle ..................................................................................................80 degrees E. Operating height - fully raised w/spillguard...........................................210.1 in (5.34 m) F. Hinge pin height - fully raised ..............................................................162.3 in (4.12 m) G. Overall length - bucket level on ground ...............................................308.4 in (7.83 m) H. Dump height - fully raised, 45 degree dump ........................................118.1 in (3.00 m) J. Bucket reach - fully raised, 45 degree dump ..........................................42.8 in (1.09 m) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .......................66.6 in (1.69 m) L. Dig depth ................................................................................................2.9 in (74 mm) Tipping load - ISO Machine straight .......................................................................... 32 025 lb (14 526 kg) 40 degree turn ............................................................................. 27 711 lb (12 570 kg) Operating load - ISO ................................................................................. 13 856 lb (6 285 kg) 185

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821E Z-BAR DIMENSIONS WITH 3.5 YD3 (2.6 M3) BUCKET WITH TEETH

SPECIFICATIONS ________________________________________________

821E Z-BAR DIMENSIONS WITH 3.5 YD3 (2.6 M3) BUCKET WITH BOLT-ON EDGE

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BS06C560

SAE bucket capacity Struck .................................................................................................. 2.90 yd3 (2.22 m3) Heaped ................................................................................................ 3.44 yd3 (2.63 m3) A. Height to top of cab........................................................................ 135.8 in (3 450 mm) B. Wheelbase..................................................................................... 131.5 in (3.340 mm) C. Ground clearance ............................................................................ 16.4 in (415.8 mm) D. Angle of departure .......................................................................................33 degrees Width Overall w/o bucket and 23.5-25 XHATL tires .......................................113.6 in (2.89 m) Centerline tread ....................................................................................87.8 in (2.23 m) Turning radius - outside w/ 23.5-25 XHATL tires......................................237.5 in (6.03 m) Turning angle From center .................................................................................................40 degrees Total angle ..................................................................................................80 degrees E. Operating height - fully raised w/spillguard...........................................210.1 in (5.34 m) F. Hinge pin height - fully raised ..............................................................162.3 in (4.12 m) G. Overall length - bucket level on ground ...............................................303.1 in (7.70 m) H. Dump height - fully raised, 45 degree dump ........................................121.5 in (3.09 m) J. Bucket reach - fully raised, 45 degree dump ............................................38.8 in (.98 m) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .......................64.0 in (1.63 m) L. Dig depth ................................................................................................2.9 in (74 mm) Tipping load - ISO Machine straight .......................................................................... 32 178 lb (14 596 kg) 40 degree turn ............................................................................. 27 864 lb (12 639 kg) Operating load - ISO ................................................................................. 13 932 lb (6 320 kg) 186

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________________________________________________ SPECIFICATIONS

BS06C560

SAE bucket capacity Struck .................................................................................................. 3.54 yd3 (2.71 m3) Heaped .................................................................................................4.15 yd3 (3.17 m3) A. Height to top of cab........................................................................ 135.8 in (3 450 mm) B. Wheelbase..................................................................................... 131.5 in (3 340 mm) C. Ground clearance ............................................................................ 16.4 in (415.8 mm) D. Angle of departure .......................................................................................33 degrees Width Overall w/o bucket and 23.5-25 XHATL tires.......................................113.6 in (2.89 m) Centerline tread ....................................................................................87.8 in (2.23 m) Turning radius - outside w/ 23.5-25 XHATL tires......................................237.5 in (6.03 m) Turning angle From center .................................................................................................40 degrees Total angle ..................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..........................................216.4 in (5.50 m) F. Hinge pin height - fully raised ..............................................................162.3 in (4.12 m) G. Overall length - bucket level on ground ...............................................314.7 in (7.99 m) H. Dump height - fully raised, 45 degree dump ........................................114.1 in (2.90 m) J. Bucket reach - fully raised, 45 degree dump ..........................................47.6 in (1.21 m) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump.......................69.5 in (1.76 m) L. Dig depth ................................................................................................2.9 in (74 mm) Tipping load - ISO Machine straight .......................................................................... 31 482 lb (14 280 kg) 40 degree turn ............................................................................. 27 190 lb (12 333 kg) Operating load - ISO ................................................................................. 13 595 lb (6 167 kg) 187

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821E Z-BAR DIMENSIONS WITH 4.25 YD3 (3.2 M3) BUCKET WITH TEETH

SPECIFICATIONS ________________________________________________

821E Z-BAR DIMENSIONS WITH 4.25 YD3 (3.2 M3) BUCKET WITH BOLT-ON-EDGE

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BS06C560

SAE bucket capacity Struck .................................................................................................. 3.54 yd3 (2.71 m3) Heaped .................................................................................................4.15 yd3 (3.17 m3) A. Height to top of cab........................................................................ 135.8 in (3 450 mm) B. Wheelbase..................................................................................... 131.5 in (3 340 mm) C. Ground clearance ............................................................................ 16.4 in (415.8 mm) D. Angle of departure .......................................................................................33 degrees Width Overall w/o bucket and 23.5-25 XHATL tires .......................................113.6 in (2.89 m) Centerline tread ....................................................................................87.8 in (2.23 m) Turning radius - outside w/ 23.5-25 XHATL tires......................................237.5 in (6.03 m) Turning angle From center .................................................................................................40 degrees Total angle ..................................................................................................80 degrees E. Operating height - fully raised w/spillguard ..........................................216.4 in (5.50 m) F. Hinge pin height - fully raised ..............................................................162.3 in (4.12 m) G. Overall length - bucket level on ground ...............................................309.4 in (7.86 m) H. Dump height - fully raised, 45 degree dump ........................................117.5 in (2.98 m) J. Bucket reach - fully raised, 45 degree dump ..........................................43.6 in (1.11 m) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .......................67.0 in (1.70 m) L. Dig depth ................................................................................................2.9 in (74 mm) Tipping load - ISO Machine straight .......................................................................... 31 639 lb (14 351 kg) 40 degree turn ............................................................................. 27 348 lb (12 405 kg) Operating load - ISO ................................................................................. 13 674 lb (6 202 kg) 188

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________________________________________________ SPECIFICATIONS

BS06C560

SAE bucket capacity Struck ...................................................................................................3.78 yd3 (2.89 m3) Heaped ................................................................................................ 4.43 yd3 (3.39 m3) A. Height to top of cab........................................................................ 135.8 in (3 450 mm) B. Wheelbase..................................................................................... 131.5 in (3 340 mm) C. Ground clearance ............................................................................ 16.4 in (415.8 mm) D. Angle of departure .......................................................................................33 degrees Width Overall w/o bucket and 23.5-25 XHATL tires.......................................113.6 in (2.89 m) Centerline tread ....................................................................................87.8 in (2.23 m) Turning radius - outside w/ 23.5-25 XHATL tires......................................237.5 in (6.03 m) Turning angle From center .................................................................................................40 degrees Total angle ..................................................................................................80 degrees E. Operating height - fully raised w/spillguard...........................................217.7 in (5.53 m) F. Hinge pin height - fully raised ..............................................................162.3 in (4.12 m) G. Overall length - bucket level on ground ...............................................310.8 in (7.89 m) H. Dump height - fully raised, 45 degree dump ........................................116.6 in (2.96 m) J. Bucket reach - fully raised, 45 degree dump ..........................................44.6 in (1.13 m) K. Bucket reach - 7 ft 0 in (2.13 m) height, 45 degree dump .......................67.7 in (1.72 m) L. Dig depth ................................................................................................2.9 in (74 mm) Tipping load - ISO Machine straight .......................................................................... 31 376 lb (14 351 kg) 40 degree turn ............................................................................. 27 110 lb (12 297 kg) Operating load - ISO ................................................................................. 13 555 lb (6 148 kg) 189

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821E Z-BAR DIMENSIONS WITH 4.50 YD3 (3.4 M3) BUCKET WITH BOLT-ON-EDGE

SPECIFICATIONS ________________________________________________

Weight adjustments 821E Select options

Weight adjustment

Base counterweight L2BIAS Tires L3CIAS Tires

-1 499 lb. (-680 kg) -1 116 lb. (-506 kg) -480 lb. (-218 kg)

Tipping load adjustment Tipping load adjustment straight 40° turn -3 608 lb (-1 637 kg) -3 045 lb. (- 1 381 kg) -895 lb. (-406 kg) -790 lb. (-358 kg) -385 lb. (-175 kg) -340 lb. (-154 kg)

NOTE: Unit equipped with Z-Bar loader arms, 4.25 yd 3 (3.2 m 3 ) general purpose pin on

bucket w/bolt-on edge, 23.5-25 XHATL tires, ROPS cab with heater/AC, full counterweight, heavy-duty batteries, front and rear fenders, full fuel and 175 lb (79 kg) operator.

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________________________________________________ SPECIFICATIONS

MATERIAL

MATERIAL

kg/m3

lb/ft3

Alum-Lump.

881

55

Pulverized

769

48

Ashes

561-833

35-52

Bauxite

1202-1922 75-120

Beans

769

48

Charcoal

368

23

Chips

288

18

Coal

1282

80

Coke - Lump - Loose

849-1009

53-63

Clay

368-513

23-32

Concrete

1378-1778 86-111

Copper Ore

1666

104

Corn - Shelled

673

42

Cottonseed

401

25

Earth - Dry Loam

929-1089

58-68

Wet

1602-1666 100-104

Earth - Sand Gravel

1570

98

Ensilage

577

36

Granite

1490-1778 93-111

Gravel - Dry

1522

95

Wet

1906

119

593

37

Iron Ore

2323

145

Limestone - Loose - Crushed

1538-1602 96-100

Ice - Crushed

kg/m3

lb/ft3

Oats

416

26

Peanuts - Shelled

280

17

Peas

769

48

Peat - solid

753

47

Phosphate - Granular

1442

90

Potash

1089

68

Potatoes

769

48

Quartz - Granular

1762

110

Rice

769

48

Rye

705

44

Salt - Rock - Solid

2163

135

Sand & Gravel - Dry

1730

108

Wet

2003

125

Sand - Foundry

1522

95

Shale

1410

88

Slag - Crushed

1121

70

Slate

2243

130

Snow

240-801

15-50

Soybeans

743

46

Sugar Beet Pulp - Wet

561

35

Sugar - Raw

961

60

Sulphur - Lumpy

1330

83

Taconite

1714

107

Wheat

769

48

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Material weights

SPECIFICATIONS ________________________________________________

Torque charts Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil.

Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

Grade 8 Bolts, Nuts, and Studs

Size

Pound-Inches

Newton-metres

Size

Pound-Inches

1/4 inch

108 to 132

12 to 15

1/4 inch

44 to 180

Newton-metres 16 to 20

5/16 inch

204 to 252

23 to 28

5/16 inch

288 to 348

33 to 39

3/8 inch

420 to 504

48 to 57

3/8 inch

540 to 648

61 to 73

7/16 inch

54 to 64

73 to 87

7/16 inch

70 to 84

95 to 114

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1/2 inch

80 to 96

109 to 130

1/2 inch

110 to 132

149 to 179

9/16 inch

110 to 132

149 to 179

9/16 inch

160 to 192

217 to 260

5/8 inch

150 to 180

203 to 244

5/8 inch

220 to 264

298 to 358

3/4 inch

270 to 324

366 to 439

3/4 inch

380 to 456

515 to 618

7/8 inch

400 to 480

542 to 651

7/8 inch

600 to 720

814 to 976

1,0 inch

580 to 696

787 to 944

1,0 inch

900 to 1080

1220 to 1465

1-1/8 inch

800 to 880

1085 to 1193

1-1/8 inch

1280 to 1440

1736 to 1953

1-1/4 inch

1120 to 1240

1519 to 1681

1-1/4 inch

1820 to 2000

2468 to 2712

1-3/8 inch

1460 to 1680

1980 to 2278

1-3/8 inch

2380 to 2720

3227 to 3688

1-1/2 inch

1940 to 2200

2631 to 2983

1-1/2 inch

3160 to 3560

4285 to 4827

NOTE: Use thick nuts with Grade 8 bolts.

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________________________________________________ SPECIFICATIONS

Grade 8.8 Bolts, Nuts, and Studs

Grade 10.9 Bolts, Nuts, and Studs 10.9

Size

Pound-Inches

Newton-metres

Size

Pound-Inches

M4

24 to 36

3 to 4

M4

36 to 48

Newton-metres 4 to 5

M5

60 to 72

7 to 8

M5

84 to 96

9 to 11

M6

96 to 108

11 to 12

M6

132 to 156

15 to 18

M8

228 to 276

26 to 31

M8

324 to 384

37 to 43

M10

456 to 540

52 to 61

M10

54 to 64

73 to 87

M12

66 to 79

90 to 107

M12

93 to 112

125 to 150

M14

106 to 127

144 to 172

M14

149 to 179

200 to 245

M16

160 to 200

217 to 271

M16

230 to 280

310 to 380

M20

320 to 380

434 to 515

M20

450 to 540

610 to 730

M24

500 to 600

675 to 815

M24

780 to 940

1050 to 1275

M30

920 to 1100

1250 to 1500

M30

1470 to 1770

2000 to 2400

M36

1600 to 1950

2175 to 2600

M36

2580 to 3090

3500 to 4200

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

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8.8

SPECIFICATIONS ________________________________________________

OPTIONAL EQUIPAMENT Cab group:

Hydraulics:

Air conditioning w/heater

Auxiliary hydraulics

Cab heater

Ride control

Radio

Secondary steering

Radio-ready (12 or 24 volt)

3 or 4-spool loader valves with 2 or 3 lever loader control

Cloth mechanical suspension seat

Hydraulic reversing fan

Cloth air suspension seat

Hydraulic cooler

12 volt aux power Lighter 24 volt

Tires:

Fire extinguisher

821E

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Rotating beacon

23.5 x 25 12PR L3 Bias (Rock)

Engine group:

23.5R25 Radial (Dirt/Traction)

Cold weather starting aid, block heater

23.5R25 Radial (Rock)

Pre-cleaner, full view

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INDEX

Brake Parking, Check . . . . . . . . . . . . . . . . . . . . . . . . . 164 Parking, Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Pressure indicator . . . . . . . . . . . . . . . . . . . . . . . 38 Brake accumulators . . . . . . . . . . . . . . . . . . . . . . . . . 99 Bucket Height control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Minor adjustment . . . . . . . . . . . . . . . . . . . . 170 Level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Bucket pivot pins grease fittings . . . . . . . . . . . . . 131 Burn prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C Cab service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Caution master indicator . . . . . . . . . . . . . . . . . . . . 40 Climate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Console Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Controls Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . 65 Blower fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Heat, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Recirculation switch . . . . . . . . . . . . . . . . . . . . . . 65 Steering wheel tilt . . . . . . . . . . . . . . . . . . . . . . . 34 Wiper/Washer switch . . . . . . . . . . . . . . . . . . . . . 66 Coupler pin engagement Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

D Daily inspections . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DeClutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Declutch switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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B Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Battery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Before operating machine . . . . . . . . . . . . . . . . . . . 82 Belt Air conditioning compressor . . . . . . . . . . . . . 173 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Blower fan switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Booster battery connections . . . . . . . . . . . . . . . . . 87

Template Name: OM_1_col Template Date: 1994_05_26

Alternator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Autoshift switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Auxiliary hydraulic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 System specifications . . . . . . . . . . . . . . . . . . . 100 Auxiliary power Equipment mounting bracket . . . . . . . . . . . . . 180 Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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A Access doors and fill locations . . . . . . . . . . . . . . 124 Accumulators, Brake . . . . . . . . . . . . . . . . . . . . . . . . 99 After Delivery Check . . . . . . . . . . . . . . . . . . .201, 203 Air conditioning Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Compressor belt . . . . . . . . . . . . . . . . . . . . . . . . 173 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Air conditioning control . . . . . . . . . . . . . . . . . . . . . . 65 Air Louvers, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

INDEX __________________________________________________________

E Engine oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . 4 Entering service screens . . . . . . . . . . . . . . . . . . . . .50 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Template Name: OM_1_col Template Date: 1994_05_26

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Engine coolant Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Engine grid heater . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Engine grid heater indicator lamp . . . . . . . . . . . . . 38

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Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Key ignition switch . . . . . . . . . . . . . . . . . . . . . . .37 Park brake switch . . . . . . . . . . . . . . . . . . . . . . . .35 Pilot control switch . . . . . . . . . . . . . . . . . . . . . . .33 Steering wheel tilt control . . . . . . . . . . . . . . . . .34 Transmission control lever . . . . . . . . . . . . . . . .34 Turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Fuel Handling precautions . . . . . . . . . . . . . . . . . . . . .17 Level gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Fuse panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 Fuses, Replacement . . . . . . . . . . . . . . . . . . . . . . .178

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Fan Reverser (option) . . . . . . . . . . . . . . . . . . . . . . . 69 Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Fluid capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Fluids and capacities . . . . . . . . . . . . . . . . . . . . . . . 116 F-N-R Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Foot pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Foot throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Four-way flasher Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Four-way flasher . . . . . . . . . . . . . . . . . . . . . . . . . 33

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G Hydraulic oil temperature . . . . . . . . . . . . . . . . .43 Transmission oil temperature . . . . . . . . . . . . .42

Gauges Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

H Hazardous chemical precautions . . . . . . . . . . . . . 18 Heat control, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Hood switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Hydraulic connection - auxiliary . . . . . . . . . . . . . 100 Hydraulic oil Temperture gauge . . . . . . . . . . . . . . . . . . . . . . . 43 Hydraulic/brake system temperature range . . . 118

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__________________________________________________________ INDEX

L Lamp Four-way flasher . . . . . . . . . . . . . . . . . . . . . . . . 38 indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Latch Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 LCD Multi-function display . . . . . . . . . . . . . . . . . . . 46 Levers Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Transmission control . . . . . . . . . . . . . . . . . . . . . 34 Turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Lift capacity 821E . . . . . . . . . . . . . . . . . . . . . . . . . 184

Loader adjustments . . . . . . . . . . . . . . . . . . . . . . . . 166 Loader control levers . . . . . . . . . . . . . . . . . . . . . . . . 59 Loader function switches . . . . . . . . . . . . . . . . . . . . 96 Loader operating tips . . . . . . . . . . . . . . . . . . . . . . . 103 Leveling operation . . . . . . . . . . . . . . . . . . . . . . 103 Pushing operation . . . . . . . . . . . . . . . . . . . . . . 103 Scraping operation . . . . . . . . . . . . . . . . . . . . . . 103 Transport and carry operation . . . . . . . . . . . . 104 Louvers, Air Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Lubrication and maintenance chart . . . . . . . . . . 122 Lubrication/Filters/Fluids . . . . . . . . . . . . . . . . . . . . 113

M Machine components . . . . . . . . . . . . . . . . . . . . . . . . 6 Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Machine tie down locations . . . . . . . . . . . . . . . . . 107 Maintenance and adjustments . . . . . . . . . . . . . . 157 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . 16 Maintenance, 10 Hour . . . . . . . . . . . . . . . . . . . . . . 128 Maintenance, 100 Hour . . . . . . . . . . . . . . . . . . . . 132

Maintenance, 1000 Hour . . . . . . . . . . . . . . . . . . . . 145 Maintenance, 2000 Hour . . . . . . . . . . . . . . . . . . . . 152 Maintenance, 250 Hour . . . . . . . . . . . . . . . . . . . . . 138 Maintenance, 50 Hour . . . . . . . . . . . . . . . . . . . . . . 128 Maintenance, 500 Hour . . . . . . . . . . . . . . . . . . . . . 142 Master disconnect switch . . . . . . . . . . . . . . . . . . . . 70 Moving a disabled machine . . . . . . . . . . . . . . . . . 105

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Template Name: OM_1_col Template Date: 1994_05_26

K Key switch ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Hydraulic oil temperature . . . . . . . . . . . . . . 43 Transmission oil temperature . . . . . . . . . . 42 Indicator lamps Brake pressure . . . . . . . . . . . . . . . . . . . . . . . 38 Caution master . . . . . . . . . . . . . . . . . . . . . . . 40 Four-way flasher . . . . . . . . . . . . . . . . . . . . . 38 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . 38 Secondary steering . . . . . . . . . . . . . . . . . . . 38 Stop master . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Turn signal . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Instruments and controls . . . . . . . . . . . . . . . . . . . . 33

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I Identification numbers . . . . . . . . . . . . . . . . . . . . . . . . 4 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Indicator Brake pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Caution master . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Secondary steering master . . . . . . . . . . . . . . . 38 Stop master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Indicator gauges Engine coolant . . . . . . . . . . . . . . . . . . . . . . . 45

INDEX __________________________________________________________

O Template Name: OM_1_col Template Date: 1994_05_26

Operating in cold climate conditions . . . . . . . . . 110 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . 81 Operating precautions . . . . . . . . . . . . . . . . . . . . . . . 13 Operating the machine . . . . . . . . . . . . . . . . . . . . . . 82 Operating the machine in hot climates . . . . . . . 112 Operating the machine in water . . . . . . . . . . . . . 108

Operating the machine on sloping ground . . . .108 Operating tips loader . . . . . . . . . . . . . . . . . . . . . . .103 Operator Manual Storage Compartment . . . . . . . . 2 Operator protective structure . . . . . . . . . . . . . . . .171 Operators seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Optional air ride seat . . . . . . . . . . . . . . . . . . . . . . . .76

P Pilot control switch . . . . . . . . . . . . . . . . . . . . . . . . . .33 Plastic and resin parts . . . . . . . . . . . . . . . . . . . . . .165 Power outlet, auxiliary . . . . . . . . . . . . . . . . . . . . . .179 Product Identification Number (P.I.N.) . . . . . . . . . . 4

Parking brake Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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R

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Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Rear axle pivot pin grease fittings . . . . . . . . . . . 131 Recirculation switch . . . . . . . . . . . . . . . . . . . . . . . . . 65 Return-To-Dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Return-To-Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Right, left, front and rear of the machine . . . . . . . . 3 ROPS Seat Torque specifications . . . . . . . . . . . . . . . .173 Seat belt Torque specifications . . . . . . . . . . . . . . . .173 Rotating beacon . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Run-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

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T Temperature range, Oil viscosity engine . . . . . 117 Temperature range, Transmission oil viscosity . 118 Throttle, Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 To th owner Right, left, front and rear of the machine . . . . 3 To the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Identification numbers . . . . . . . . . . . . . . . . . . . . 4 Machine components . . . . . . . . . . . . . . . . . . . . . 6 Wheel loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . 105

Transmission Control lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Transmission oil Temperture gauge . . . . . . . . . . . . . . . . . . . . . . . 42 Transmission operation Automatic mode operation . . . . . . . . . . . . . . . . 88 Shifting, automatic mode . . . . . . . . . . . . . . . . . 88 Transporting the machine . . . . . . . . . . . . . . . . . . . 106 Transporting the machine on a trailer . . . . . . . . 107 Turn signal Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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Alt= to hide template information Alt+ to display template information Template Name: OM_1_col Template Date: 1994_05_26

Specific precautions to this machine . . . . . . . . . . 20 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Auxiliary hydraulic system . . . . . . . . . . . . . . . 100 Seat belt torque . . . . . . . . . . . . . . . . . . . . . . . . 173 Seat torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Specifications and capacities, 821E . . . . . . . . . 116 Start up after storage . . . . . . . . . . . . . . . . . . . . . . . 109 Starting and stopping precautions . . . . . . . . . . . . 13 Starting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Steering wheel tilt control . . . . . . . . . . . . . . . . . . . . 34 Stop master indicator . . . . . . . . . . . . . . . . . . . . . . . . 39 Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . 85 Storage Compartment Operator Manual . . . . . . . . . . . . . . . . . . . . . . . . . 2 Storing the machine . . . . . . . . . . . . . . . . . . . . . . . . 108 Support strut for loader lift arms . . . . . . . . . . . . . 115 Switch Autoshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Blower fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Coupler pin engage . . . . . . . . . . . . . . . . . . . . . . 69 Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Four-way flasher . . . . . . . . . . . . . . . . . . . . . . . . 33 Key ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Loader function . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Bucket height control . . . . . . . . . . . . . . . . . 97 Return-To-Travel . . . . . . . . . . . . . . . . . . . . . 97 Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Pilot control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Return-To-Travel . . . . . . . . . . . . . . . . . . . . . . . . 68 Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Rotating beacon . . . . . . . . . . . . . . . . . . . . . . . . . 69 Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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S Safety and decals Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Safety, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Safety/Decals/Hand signals . . . . . . . . . . . . . . . . . . . 9 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Inspection and care . . . . . . . . . . . . . . . . . . 79 Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Torque Specifications . . . . . . . . . . . . . . . . . . . 173 Seat Belt Torque Specifications . . . . . . . . . . . . . . . . . . . 173 Seat belt precautions . . . . . . . . . . . . . . . . . . . . . . . 19 Secondary steering check . . . . . . . . . . . . . . . . . . 163 Secondary steering master indicator . . . . . . . . . . 38 Service connector . . . . . . . . . . . . . . . . . . . . . . . . . 179 Servicing instructions . . . . . . . . . . . . . . . . . . . . . . 113 Side console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Air conditioning control . . . . . . . . . . . . . . . . . . . 65 Autoshift switch . . . . . . . . . . . . . . . . . . . . . . . . . 68 Blower fan switch . . . . . . . . . . . . . . . . . . . . . . . . 64 Climate control . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Coupler pin engage switch . . . . . . . . . . . . . . . 69 Declutch switch . . . . . . . . . . . . . . . . . . . . . . . . . 68 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Heat control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Recirculation switch . . . . . . . . . . . . . . . . . . . . . 65 Return-To-Travel switch . . . . . . . . . . . . . . . . . . 68 Ride control switch . . . . . . . . . . . . . . . . . . . . . . 68 Rotating beacon switch . . . . . . . . . . . . . . . . . . 69 Wiper/Washer switch . . . . . . . . . . . . . . . . . . . . 66 Wrist rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Wrist rest, Adjustment . . . . . . . . . . . . . . . . . . . 63

INDEX __________________________________________________________

U Utility safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Template Name: OM_1_col Template Date: 1994_05_26

V Variable periodic maintenance . . . . . . . . . . . . . . 126

W Warning displays Non-critical warning displays . . . . . . . . . . . . . . 40 Welding on the machine . . . . . . . . . . . . . . . . . . . . 165 Wheel loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Wheel nuts torque . . . . . . . . . . . . . . . . . . . . . . . . . 160

Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . .157 Wiper/Washer switch . . . . . . . . . . . . . . . . . . . . . . . .66 Wrist rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Adjustment knob . . . . . . . . . . . . . . . . . . . . . . . . .63

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Z Z-bar Return to dig adjustment procedure . . . . 168

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TERM OF WARRANTY CASE CONSTRUCTION Products

CNH INDUSTRIAL LATIN AMERICA LTDA., manufacturer of CASE CONSTRUCTION equipments warrants all its new products against any defects of workmanship or material through its new work of authorized dealership.

The authorized dealer will repair in his own installation the equipment or any part of the equipment; which according to the technical analysis presents a failure or material defect, at not cost for the end user, including the labor for the installation of the part in reference for a period of 12 (twelve) months unlimited hours beginning from the date of delivery.

This warranty does not include, expenses such as transport of this equipment or its components to the installations of the Distributor, as well expenses such as stay and travel if the end users decides to get the work done outside the Dealer’s installation. In this case the Authorized Dealer must present by writing to the customer an estimated cost for his previous approval.

The contractual warranty of the equipment is subject to the execution of all scheduled service, as defined in the manual of operation and maintenance performed by authorized service personnel of CASE CONSTRUCTION, including the delivery of technical.

Parts installed as replacement will be covered under the remaining warranty period.

Original parts purchased through a CASE CONSTRUCTION Dearlership will also have a warranty of 90 (ninety) days from the invoiced date of purchase, under the same parameters of CASE CONSTRUCTION warranty policy. If applied by authorized dealer, original parts, will have a warranty of (180) days. This warranty is subject to the realization of the technical delivery.

THIS IS THE ONLY WARRANTY OFFERED AND REPLACES ANY OTHER EXPRESSED OR IMPLIED. THERE ARE NOT OTHER WARRANTY OF CNH WHICH WILL SURPASS THE HERE STATED­.

EXCLUSIONS AND LIMIT LIMITATIONS TIONS – This warranty would not apply in case of: •• Verify through the technician analysis, THE IMPROPER USE OR MAINTENACE, NEGLET, INCAPACITY OR ACCIDENT, IN ADDITION TO IMPLEMENTS AND/OR PARTS NOT CERTIFIED BY CNH, AND/ OR USE OF NONRECOMMENDED LUBRICANTS AND OILS; •• New products which are subjected to operations which exceed the recommended capacity or is used for applications no recommended; •• Equipments that have been altered or repaired in a way not authorized by CNH INDUSTRIAL LATIN AMERICA LTDA., the manufacturer of CASE CONSTRUCTION products; •• Equipment to which preventive maintenance or inspections have not been done according the specification established for CASE CONSTRUCTION equipment.

•• Components which are covered by their own manufacturer such as tires, electrical components, and fuel injection components.

•• Defects caused by modification or installation of parts or components no authorized by CNH INDUSTRIAL LATIN AMERICA LTDA.. Manufacturer or CASE CONSTRUCTION products.

•• Monetary Loss, inconvenience, commercial or consequent damaged caused by a failure or cost caused by rented equipment.

•• Normal wear items such as: brakes discs, clutches, cutting edges, cutting knife, bolt, lubricated joints(pins, bushing), parts wear due to ground contact, oils, lubricants, exhaust or associated parts, injectors, belts, lamps, glasses, light bulbs and fuses.

•• THE RESPONSABILITY OF CNH OR THE AUTHORIZED DEALER, be by civil contract or imply warranty, declaration, instructions or effects of any source, will be limited to the repair or delivery of the parts, new or reconditioned, under the conditions previously stated.­ CNH INDUSTRIAL LATIN AMERICA LTDA. CNH INDUSTRIAL LATIN AMERICA LTDA. reserves the right to revise, modify or discontinue any product at any time without implying to do the same to products already marketed.

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BEFORE DELIVERY CHECK FIRST PAGE MAINTENANCE – CHECK AND ADJUST AS NECESSARY Number of O.S.

Number of Hours

Date

Owners Name Address Dealers Name Address Machine Model Number

Hourmeter Indication

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

Items to be inspected COOLING SYSTEM Check for leaks.

Check the coolant levels.

FUEL SYSTEM Check for leaks.

Check that no water and sediment from the fuel tank.

ELECTRICAL SYSTEM Check battery fluid level and specific gravity.

Check operation of starter, alternator, and instruments and warning lamps.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

Check the oil level of the front and rear axles.

Check the oil level of the transmission.

#

MOTOR Check condition of drive belt.

Check engine oil level.

Check engine speed at idle and full throttle.

Check the air cleaner filter elements conditions.

HYDRAULIC SYSTEM Check for leaks.

Check the reservoir fluid level.

Change the hydraulic filter.

Check the main relief valve pressure.

GENERAL Check for leaks and loose parts.

Check the wheel nut and bolt torques.

Check the tire pressure.

Tighten all hoses clamps.

Check loader operation.

Check the service brakes and parking brake operation.

Check the control levers for correct operation.

Check the operator seat operation.

SAFETY Check the torque of ROPS and seat belt mounting bolts.

Check the safety and information decals and replace if necessary.

Make sure the Operators Manual and Safety Manual are in the Manual Storage Box. Check the saddle lock pin.

DEALER: Make sure the new owner/operator understands all the safety and information decals, the service information, and the service procedures in this operator’s manual.

Mechanic (signature) Dealer (signature) Owner (signature)

Dealer Copy

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BEFORE DELIVERY CHECK FIRST PAGE MAINTENANCE – CHECK AND ADJUST AS NECESSARY Number of O.S.

Number of Hours

Date

Owners Name Address Dealers Name Address Machine Model Number

Hourmeter Indication

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

Items to be inspected COOLING SYSTEM Check for leaks.

Check the coolant levels.

FUEL SYSTEM Check for leaks.

Check that no water and sediment from the fuel tank.

ELECTRICAL SYSTEM Check battery fluid level and specific gravity.

Check operation of starter, alternator, and instruments and warning lamps.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

Check the oil level of the front and rear axles.

Check the oil level of the transmission.

#

MOTOR Check condition of drive belt.

Check engine oil level.

Check engine speed at idle and full throttle.

Check the air cleaner filter elements conditions.

HYDRAULIC SYSTEM Check for leaks.

Check the reservoir fluid level.

Change the hydraulic filter.

Check the main relief valve pressure.

GENERAL Check for leaks and loose parts.

Check the wheel nut and bolt torques.

Check the tire pressure.

Tighten all hoses clamps.

Check loader operation.

Check the service brakes and parking brake operation.

Check the control levers for correct operation.

Check the operator seat operation.

SAFETY Check the torque of ROPS and seat belt mounting bolts.

Check the safety and information decals and replace if necessary.

Make sure the Operators Manual and Safety Manual are in the Manual Storage Box. Check the saddle lock pin.

DEALER: Make sure the new owner/operator understands all the safety and information decals, the service information, and the service procedures in this operator’s manual.

Mechanic (signature) Dealer (signature) Owner (signature)

Owner Copy

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NOTES

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